Rockwell Automation Allen-Bradley PowerFlex 6000 Commissioning Manual

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Page 1

Commissioning Manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual

Publication 6000-IN007B-EN-P

Page 2

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, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Page 3

Preface

Introduction

Preparation and Inspection (For IEC)

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensional Drawings and Electrical Drawings. . . . . . . . . . . . . . . . . . . 7

Shipping, Handling, and Installation Manual . . . . . . . . . . . . . . . . . . . . . 8

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Documentation and Application Review. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Review all Rockwell Automation Supplied Documentation . . . . . . 12

Pre-commissioning Customer Meeting. . . . . . . . . . . . . . . . . . . . . . . . . 13

Review Drive Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2

Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 15

Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Drive Megger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Isolate the Power and Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 23

Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 29

Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Preparation and Inspection (For UL)

Chapter 3

Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 31

Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Table of Contents

Drive Megger Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Isolate the Power and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 39

Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 46

Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 4

Commissioning

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Control System Check Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Simulate Closed Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . 48

Energize Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Control System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Verify Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Set P Parameters to Enable Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Verify Settings for Low-Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . 58

Verify Operation of Frequency Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Verify Operation to Set Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Simulate Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Verify E-Stop Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Verify Switching from Local Control to Remote Control . . . . . . . . 73

Verify Operation of Input/Output and Bypass Isolation Switches

(Manual Bypass). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Verify Operation of Input/Output and Bypass Contactors

(Automatic Bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Verify Operation of DCS Input and Output Signals . . . . . . . . . . . . . 83

Restore P Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Set Date and Time Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Access T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Change Time/Date/Regional Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 5

No-load Test

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

No-load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Energize Drive Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Configure P and T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Change Parameters T11...T13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Close Isolation Switches in Bypass Cabinet . . . . . . . . . . . . . . . . . . . . 102

Close Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Check Cooling Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Operate Motor by HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Load Test of Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Appendix A

Torque Requirements

4 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Page 5

Appendix B

Table of Contents

Single Line Diagrams

Special Function Parameter Settings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Appendix C

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

System Setting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Number of Power Modules Per Phase . . . . . . . . . . . . . . . . . . . . . . . . . 117

Switch Control Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Rated/Maximum Output Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . 118

Motor Parameter Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Hall Effect Current Sensor Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Analog Output Display Parameter Setting . . . . . . . . . . . . . . . . . . . . . 119

Restore Factory Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Speed Command Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Set Frequency Command Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Set Frequency Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Frequency Command Deadband Upper Limit . . . . . . . . . . . . . . . . . 120

Frequency Amplitude Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Frequency Skip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Speed Reference Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

V/F Curve Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Set Maximum Modulation Index and Limit Output Voltage

Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Set Flux Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Flying Start Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Restart the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Index

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 5

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Table of Contents

Notes:

6 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 7

Preface

Introduction

Who Should Use This Manual

What Is Not in This Manual

This document provides procedural information for commissioning PowerFlex® 6000 medium voltage drives with version 4.001 firmware.

This manual is intended for Rockwell Automation Field Service Engineers with Medium Voltage Drive factory training and field experience commissioning medium voltage solid-state variable speed drive equipment.

WARNING: This document is for internal use only (for Rockwell CSM/field support Engineers). DO NOT disclose this document to customers or any nonRockwell Automation employee. Disclosure of sensitive information in this document may cause dire consequences to the drive.

This manual is generic and does not include project-specific or drive-specific information. Contact the Start-up Project Manager for required project-specific or drive-specific information such as:

• Dimensional Drawings and Electrical Drawings generated for the customer’s order.

• Spare parts lists compiled for the customer’s order.

• Drive-specific technical specifications.

• Pre-commissioning Checklist

• PLC program for standard, integral PLC

Required Supplemental Information

Dimensional Drawings and Electrical Drawings

Thoroughly review the project-specific Dimensional Drawings (DDs) and Electrical Drawings (EDs) to understand the specific drive system being commissioned, before performing any mechanical or electrical work.

Within these drawings is detailed information which is important to understand for the commissioning and installation of the equipment.

Table 1 - Electrical Drawings

Contactor Locations (electrically)

Drive Topology

General Notes

Minimum Power Cable Insulation Ratings

Component Designations

Customer Power and Control Wiring Locations (electrically)

Control and Medium Voltage Power Ratings

Fuse Locations (electrically)

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 7

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Preface

Table 2 - Dimensional Drawings

Control and Medium Voltage Power Ratings

Drive Options

Motor Ratings

Drive Power Component Selection Ratings

If the drawings require changes to suit the installation and application of the system, fax or e-mail the marked up drawings to the Start-up Project Manager.

Shipping, Handling, and Installation Manual

Review publication 6000-IN006_-EN-P, PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping, Handling, and Installation manual.

The customer/contractor has the option to perform the electrical interconnection work between cabinet shipping splits, as shown in this manual, or contract Rockwell Automation to perform this work. This will be reflected in the Services Purchase Order and the pre-commissioning checklist. Verify that the documentation matches the actual scope of work done by the customer/ contractor. You will be required to either perform this interconnection work immediately prior to the commissioning process or to verify the work was done correctly by the contractor. It is very important to confirm the alignment of the paperwork with the actual scope of work.

It is also extremely important to understand the contractor’s basic scope of work, preceding the commissioning process. Part of the overall commissioning process is to ensure this work has been done correctly. If this work has not been done properly, this must be brought to the attention of the customer immediately. Do not proceed with commissioning until this issue is resolved.

Additional required information about the PowerFlex 6000 can be downloaded from http:/www.rockwellautomation.com/literature/

• 6000-IN006_-EN-P

: PowerFlex 6000 Medium Voltage Variable

Frequency Drive Shipping, Handling, and Installation Instructions

• 6000-UM002_-EN-P

: PowerFlex 6000 Medium Voltage Variable

Frequency Drive User Manual (operating the HMI, full parameter listing)

You must review these publications thoroughly before beginning the commissioning process. They contain supplemental information that will aid in the commissioning process.

8 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preface

General Precautions

Additional Resources

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.

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 general guidelines for installing a Rockwell Automation industrial system.

Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 9

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Preface

Notes:

10 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Introduction

Chapter 1

Overview

Information contained in this chapter will assist in commissioning a PowerFlex 6000 medium voltage AC drive.

Review the information contained in this chapter prior to commissioning the drive and use it as a reference while the drive commissioning is performed.

WARNING: Perform the commissioning checks illustrated in the sequence that they have been presented. Failure to do so may result in equipment failure, personal injury, or death.

Prior to commissioning, the following work will have been performed by the customer or the customer’s electrical contractor:

Connect External Cabling and Wiring

Connect System Ground Cable

Megger Test of Power Cables

Connect Incoming Line and Outgoing Motor Power Cables

Connec t Control Powe r Wiring

Connec t Extern al Control S ignal Wiri ng

Connect Electrical Safety Interlock Control Signal Wiring Circuit to Input Circuit Breaker

Connect Internal Cabling and Wiring

Connect Isolation Transformer Secondar y Power Cables to Power Modules

Connect Motor Cables and Voltage Sensing Board Cables to U, V, and W Output Phase Buses

Connect LV Control and Fan Wiring Bundles

Connect Ground Bus Splices

(1)

(2)

(1) If an optional bypass unit is supplied, the system ground cable, incoming line power cables, and outgoing motor power cables are

connected to the bypass unit.

(2) Interconnection of power cables and low voltage control wiring bundles, between separately shipped cabinets, can be done by the

contractor or Rockwell Automation. The commissioning quote from Rockwell Automation reflects this and will contain two options: a) the base quote, reflecting the power cable and control wiring interconnection work being done by the contractor b) the optional quote adder, reflecting the additional time and cost for Rockwell Automation to perform the power cable and control wiring interconnection work immediately prior to the commissioning process.

This work will be reviewed during the pre-commissioning customer meeting and validated during the commissioning process; see Installaion Review on page 21

page 37

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Chapter 1 Introduction

Lockout

and Tagout

Functio nal

Assessment

Interconnection

Review

Installation

Review

Control

System Ch eck

(LV Only)

No-load Test

of Drive System

(MV)

Load Test o f

Drive System

(MV)

Documentation and Application Review

Preparation and Inspection

Review

Rockwell

Automation

Supplied

Documentation

Pre-commissioning

Customer Meeting

Gather

Required Tools

and Test

Equipme nt

Review Drive

Application

Commissioning

Inspect Drive Components

Meggering

Final Review

and Preparation

Process Flowcharts

Documentation and Application Review

Review all Rockwell Automation Supplied Documentation

Each drive is shipped with the technical publications required to assist in commissioning and troubleshooting the drive. Request copies or revisions of these documents from the Start-up Project Manager. However, you will have received e-copies of this information prior to commissioning by the Start-up Project Manager.

Before commissioning the drive, ensure you have the following resources:

• Project-specific Electrical Drawings and Dimensional Drawings

• PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping,

): provides

Handling, and Installation Manual 6000-IN006_-EN-P procedural information for physically unloading, moving, and installing equipment

• PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual (6000-IN007_-EN-P

): required procedures and

checklists for Rockwell Automation Field Service Engineers.

• PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual (6000-UM002_-EN-P interface, and maintenance tasks

): instructions for daily recurring drive usage, HMI

12 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Introduction Chapter 1

• PLC Program: The PLC I/O processes control signals within the drive and I/O signals to and from the customer’s control system and input circuit breaker. The PLC program is standardized. However, it may be customized to address specific customer requirements by Rockwell Automation during the Application Engineering phase of order execution.

Pre-commissioning Customer Meeting

Before commissioning the drive, it is recommended to schedule a meeting with the customer.

1. Discuss the activities and documentation needed to review the drive application

2. Review the start-up activities and timelines

3. Review the Pre-commissioning Checklist (see 6000-IN006_-EN-P)

4. Review the drive application

Review Drive Application

To ensure trouble-free commissioning , it is necessary for all personnel involved in the start-up to familiarize themselves with the drive and actual application. Service on the equipment should not be performed without a clear understanding of how the equipment has been designed to function and how the equipment has been applied.

Before commissioning the drive, inspect the process that the drive is intended to control. This identifies how the equipment is designed to suit the application, and any potential hazards. Determine what measures must be taken to ensure that commissioning the equipment does not expose anyone to hazardous situations or damage to the equipment. Verify that the load is not turning due to the process, as a freewheeling motor can generate voltage that will be back-fed to the equipment being serviced. Take all actions necessary to ensure that motor regeneration into the drive does not occur while the equipment is being started up or being serviced.

Review Electrical System One-line Diagram

Identify all relevant equipment Tag Identification names and numbers. Study the system for sources of power and parallel paths of medium voltage power. Retain a copy of the one-line diagram for commissioning the drive. If applicable, send a copy of the one-line diagram to the Start-up Project Manager to be archived and used for future customer assistance.

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Chapter 1 Introduction

On-site Verification of Electrical System One-line Diagram

ATT EN TI ON : Make sure the medium voltage input circuit breaker feeding the drive is locked out and tagged out. Make sure the LV circuit breaker feeding control power to the drive is locked out and tagged out. Make sure the drive is de-energized before conducting the drive inspection process.

Once all documentation has been reviewed, an on-site inspection of the drive is required. Identify the physical locations of the connections to the drive using Tag Identification names or numbers from the one-line diagram and Rockwell Automation Electrical Drawings.

All customer power and control wiring required for the drive line-up installation has been identified on the Rockwell Automation Electrical Drawings by a dashed line.

Installation of all external power cabling and control wiring interfacing with the drive is completed by the customer or their electrical contractor. Verify that this wiring is installed correctly and meets electrical voltage and current capacity requirements. Trace the power cables point-to-point from the input circuit breaker to the drive, and from the drive to the motor using the Electrical Drawings as a reference for proper drive power cable termination locations. Any discrepancy between the physical installation and the Electrical Drawings of the following items should be reviewed prior to commissioning the drive:

• Medium voltage power cabling in from the input circuit breaker to drive

• Medium voltage power cabling out from drive to motor

• Low Voltage control power cables from LV MCC or circuit breaker to

drive

• Ground connection from system ground to drive

• Control signal wires and communication cables from remote DCS/PLC

or other remote device to drive

• Electrical safety interlock/control wiring from the drive to the input

circuit breaker

ATT EN TI ON : Do not change wiring or remove terminal wiring.

14 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 15

Preparation and Inspection (For IEC)

Chapter 2

Gather Required Tools and Test Equipment

Hand Tools

• Metric wrenches and sockets

• To r qu e w re nc h

• Assortment of screw drivers

• Wire stripper/cutter

Electrical Equipment

• High voltage gloves – 17 kV insulation rating (minimum)

• Anti-static strap

• Live-line tool (Hot stick)

• 5 kV Insulation Tester

Test Equipment

• 600V (1000V rating) digital multimeter with assorted clip leads

Computer Requirements and Software

• Laptop computer

• USB cable

• PLC program

• CCW software

Lockout and Tagout

SHOCK HAZARD: Servicing 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 cabinet even with the input circuit breaker in the off position. Required practice is to disconnect and lock out control equipment from power sources, and confirm discharge of stored energy in capacitors. 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.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 15

Page 16

Chapter 2 Preparation and Inspection (For IEC)

IMPORTANT

Lockout and tagout the input circuit breaker before opening the doors to the drive system cabinets. After the cabinet doors are opened, immediately test the incoming and outgoing power cables and any components connected to medium voltage with a live-line tool (hot stick) while wearing high voltage gloves. Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time. Only after the 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.

Refer to local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards.

Safety Test

Complete every point included in this section prior to continuing with the drive commissioning, to ensure that the commissioning continues in an environment safe to all those involved in servicing the drive. Ensure that commissioning of this drive is performed in accordance with local safety standards.

Inspect Drive Components

After performing the lockout and tagout procedure (see page 15), open all of the cabinet doors. Inspect each component for signs of shipping damage (see Ta b l e 3

on page 18). An initial inspection would have been done by the customer when

the equipment was received. However, this would have been done from the front only and was just looking for obvious signs of damage (see publication 6000-

IN006_-EN-P). Record the part number and description of any damaged

components and immediately contact the Start-up Project Manager to order replacement components, if required.

ATT EN TI ON : Verify the equipment against any damage. Do not install a damaged drive.

Verify that all components are securely affixed to the cabinet.

Most components will be easily visible on the doors or from the front of the cabinets after the doors are opened. Some components are best viewed from the rear of the cabinet.

For rear inspection, remove top and bottom rear access plates from the drive and bypass cabinet (if supplied). See publication 6000-IN006_-EN-P.

The Inspect Drive Components Checklist (see page 18) mentions the principal base components supplied in the drive and bypass units. It is not comprehensive, as customer-required options may be supplied and three different bypass configurations are available.

Perform the shipping damage inspection for all components mounted in the drive cabinets and specific bypass unit cabinet (if supplied).

16 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 17

Preparation and Inspection (For IEC) Chapter 2

Functional Assessment

After the components are visually inspected to identify any shipping damage, a thorough functional assessment should be performed (see Table 4 on page 19 The main purpose of this assessment is to ensure that all movable parts and assemblies operate properly, connect properly, and components are wired properly and securely.

The Functional Assessment procedure can be combined with the “Inspect Drive Components” checklist on page 18

Descriptions of the Power Cable Connections to be inspected and torqued to specifications are in the Interconnection Review and Installation Review sections.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 17

Page 18

Chapter 2 Preparation and Inspection (For IEC)

Door:

Pilot lights

Push buttons

Selector switches

HMI

Interface board (on the back of the LV door)

Panel:

DIN rail mounted components

UPS

Fiber optic cables

PLC

Control U nit

UPS connections

Fixed Mounted Power Module Configuration:

Door:

Power Module retaining tabs

Transformer Temperature monitor

Check for debris

Output Bus Supports

Fuse Mounting Supports

Drawout Power Module Configuration:

– Fan control c ircuit breaker s

LV Cabinet components

Cabinet:

Transformer Plastic Baffle

Support frame

Power Modules

(1)

Outgoing Motor Power Cable standoffs on

Cabinet Sidesheet

– Verify orientation relative to barrier plates

Fixed Mounted Power Module:

Heat sink

Drawout Power Module:

Power In/Power Out connections

(1)

– Inspect nomex wrap

– Verify windings from core are undamaged

Outgoing Motor Power Cable Terminal

– Check for debris in top of core

Insulators on transformer

Voltage Sensing Board

Incoming Line Power Cable Terminal Insulators

on transformer

Motor Cable Braces

Fixed Mounted Power Module Configuration:

Transformer Secondary Windings (2 sets)

Fixed Mounted Power Module Configuration:

Transformer Secondary Windings (1)

– Inspect nomex wrap

– Verify windings from core are undamaged

– Check for debris in top of core

– Inspect nomex wrap

– Verify windings from core are undamaged

Drawout Power Module Configuration:

Transformer Secondary Windings (3)

– Check for debris in top of core

Door:

Pilot Lights

Voltage Indicator Relay

Cabinet:

Insulators

Switch assemblies

Vacuum contactors

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltag e Control Cabinet

Table 3 - Inspect Drive Components Checklist (IEC)

Mechanical linkages

Front

Rear

18 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

(1) Motor Cable terminations could be on the transformer structure or cabinet sidesheet, depending on the power rating.

Page 19

Preparation and Inspection (For IEC) Chapter 2

– Check connec tion of all fiber optic cables

– Check connec tion of HMI interface board

Control Unit

HECS (2)

– HMI

– Check plug connectors

– Test switch contacts wired back to terminal

Door Interlock Limit Switches (2)

and terminal blocks

– Tug test all wires on door, panel, and relays

Low Voltage wires

blocks in LV panel with ohmmeter

Power Modules fiber optic cables

– Check all connections

– Verify operation

Circuit Breakers and Contactors

– Test each fuse with multimeter

Power Modules Fuses

components

– Check connec tions from all attached

Vertical Ground Bus

Door Grounding Straps

Low Voltage Door



devices

– Verify operation of all operator interface

– Check connections

AC/DC Power Sup plies

Door Grounding Straps

– Check connection

UPS

– Check electrical connection

Top Mounted Cooling Fans

Table 4 - Functional Assessment Checklist (IEC)

Transformer Secondary Cables

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet

Electrical Door Interlock

– Verify cables are properly fed through the

– Verify proper operation of auxiliary contacts

glanding plate and are undamaged

with an ohmmeter

to the board are secure

– Verify the primar y and secondary connections

Voltage Sensing Board cables

– Verify proper operation with an ohmmeter

Isolation switch auxiliary contacts

Isolation switches

terminal blocks in LV panel with ohmmeter

– Test auxiliary switch contacts wired back to

Door Interlock Limit Switches

– Verify proper operation

– Outer jaws must securely contact the center

– Verify wires are intact and properly inserted

Temperature Sensing Wires (3 places)

stab in the closed position

– Check all connections per Electrical Drawings

Secondary Wiring and Low Voltage Fuses

Front

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 19

Bottom-mounted Auxiliary Fan power from

Isolation Transformer Auxiliary Winding

Door Grounding Straps

– Check connections

Door Grounding Straps

– Tug test on all cable connections

Transformer Temperature Protection Relay

– Check electrical connection

Auxiliary Cooling Fans (3)

glanding plate are undamaged

– Verify cables are properly fed through the

Transformer Secondary Cables

– Check braided copper connections

Surge Arrestors

– Verify connection

Tap Changer

– Pe rform tug tes t

Voltage Sensing Relay Cables

– Check electrical connection

Top Mounted Cooling Fans

– Verify phasing and torque

Line and Load side power cables

Top Ground Bus

Rear

structure

– Assembly must be affixed properly to

Fan H ousi ngs

– Verify braided connections

– Check electrical connection

Auxiliary Cooling Fans (3)

Page 20

Chapter 2 Preparation and Inspection (For IEC)

IMPORTANT

Interconnection Review

Table 5 - Interconnection Review Checklist (IEC)

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Review the braided ground connection to adjacent cabinet

Verify line and load power cables from Isolation Transformer

Front Inspection

Rear Inspection

Cabinet are properly connected Verify all control wires per

Electrical Drawing

The interconnection checklist summarizes the required items to review to validate the reconnection of power, ground, and control cables between cabinets within the drive system, that were disconnected for shipment. Power and control cables that pass from one cabinet to another are bundled in the appropriate cabinet. These cables are connected for system test at the factory but disconnected and coiled up for shipment. If this interconnection work was done by the contractor, use this checklist to review and ensure the work was done correctly. If the interconnection work was not done by the contractor, the scope of work required to be performed is described in 6000-IN006_-EN-P

Check torque on all power and ground cable connections per specifications listed in Torque Requirements

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Review all isolation transformer secondary wiring from Power Module cabinet (2 sets)

Verify that the shields of all of the system’s connecting wires are properly grounded

Verify all control wires per Electrical Drawing

– Cables are run in LV cable

sections along front and back of cabinet

Fixed Mounted Power Module:

Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected (1 set)

Drawout Power Module:

Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected (3 sets)

Verify all power supply cables for main cooling fans for Isolation Transformer Cabinet are properly connected(3 sets)

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Verify that the shields of all of the system’s connecting wires are properly grounded

Review load power cable connection from Isolation Tra nsf orm er C abi net

Verify Voltage Sensing Board power cables from Isolation Transformer Cabinet are properly installed

on page 109.

Verify control signal wiring bundles from LV Control cabinet to LV panel in Isolation Transformer cabinet and LV panel in the Bypass Cabinet (if supplied) are routed correctly

20 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preparation and Inspection (For IEC) Chapter 2

Installation Review

Prior to commencing the commissioning of the drive, verify the equipment was properly installed. Identifying errors in the drive installation prior to commencing the commissioning as opposed to mid-way through the commissioning process will greatly reduce the amount of time required to commission the drive. Verify the drive and all associated equipment have the system power grounding cable installed. Refer to 6000-IN006_-EN-P

to review the contractor’s drive installation responsibilities and understand the scope of the work you will be reviewing.

Mechanical Installation Inspection

Sequence Task Reference Document

1 Verify line up positioning Dimensional Drawings

2 Verify cabinets are bolted together correctly 6000-IN006_-EN-P

3 Verify cabinets are affixed to the floor properly Dimensional Drawings,

6000-IN006_-EN-P

4 Verify fans are installed correctly 6000-IN006_-EN-P

5 Verify power modules are installed correctly 6000-IN006_-EN-P

6 Review duct installation (if applicable) 6000-IN006_-EN-P

7 Verify the cable trenches meet design requirements 6000-IN006_-EN-P

8 Verify required cabinet clearances 6000-IN006_-EN-P

9 Verify there are no scratches or damage to the cabinet body N/A

10 Verify the top cover of the isolation transformer cabinet is securely

mounted

6000-IN006_-EN-P

Refer to project-specific EDs to review all electrical connections to external input and output devices.

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Chapter 2 Preparation and Inspection (For IEC)

Electrical Installation Inspection

Sequence Task Reference

Document

1 Verify that medium voltage cables are separated at least 30 cm from the control cables

2 Verify that all secondary control wiring use shielded cables

3 Verify that input and output medium voltage cables specifications meet the stated

insulation requirements

4 Verify that input and output medium voltage cables have attached nameplates

5 Verify the diameter of control power cables comply with the drawings Electrical

6 Verify that the electrical safety circuit wiring between the input circuit breaker and the drive

7 Verify the wiring between the DCS and the drive is shielded and only the end the drive side is

8 Verify that the user-provided ground cable is ≥50 mm

9 Verify the isolation transformer’s primary input voltage matches the system primary voltage

10 Verify that the customer motor specifications match the drive voltage and current

11 Verify that the isolation transformer’s input si de wiring is correct Electrical

12 Verify that the motor output side wiring is correct Electrical

13 Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical

14 Verify torque on incoming line power cable and outgoing motor powe r cable terminations Electrical

is shielded and only the end at the drive side is grounded

grounded

capabilities

Electrical Drawings

Drawings

Power Cabling

Trace the power cabling from termination point to termination point while examining the cable and its routing for mechanical damage, sharp bend radiuses and sources of induced noise and heat. The power cabling must be is sufficiently braced to contain the cabling in the event of a ground fault. Color coding is used to indicate the phase orientation of the drive.

Table 6 - Color Coding

Color Incoming Line Side Outgoing Motor Side

Black L11 (A Phase) Line Cable Terminal U Phase:

Brown L12 (B Phase) Line Cable Terminal V Phase:

Grey L13 (C Phase) Line Cable Terminal W Phase:

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

22 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preparation and Inspection (For IEC) Chapter 2

Incoming Line and Outgoing Motor cables must be routed separately to prevent cable insulation damage.

All cables must be terminated on each end and sufficiently torqued.

All customer power cables must be Hi-Potted or Meggered and read a sufficient insulation value. Review Hi-Pot or megger test report from the customer.

Control Wiring

Identify all customer-required control wiring detailed on the Electrical Drawings and locate it within the terminal blocks. Verify the cable insulation is not tightened in a terminal connection. All connections must have proper continuity.

Inspect the control cable routing to ensure that DC control wiring and AC control wiring are separated from each other. Routing them together in the same bundle or cabling product may result in unwanted noise being induced in the drive control. In the overhead cable tray provided at the front of the drive, the AC control, DC control and fiber optic cables must be separate. These cables may also be from the bottom.

Drive Megger Check

Control wiring must be routed separately from power cabling.

Inspect for additional control not shown on the Electrical Drawings. Determine its purpose, mark the changes on the electrical diagram and send the prints to the Start-up Project Manager for future reference.

Perform a tug test on all control cables to ensure that they are securely fastened, and check each plug and connector to ensure it is properly seated in its socket.

Isolate the Power and Control Circuits

ATT EN TI ON : Verify the grounding cable connection is secure.

Disconnect the low voltage power before the megger test. Short circuit the 3 input cables and 3 output cables on one point.

1. Isolate and lock out the drive system from any high voltage source.

Disconnect any incoming power sources, medium voltage sources should be isolated and locked out and all control power sources should be turned off at their respective circuit breaker(s).

Verify with a potential indicator that power sources have been disconnected, and that the control power in the drive is de-energized.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 23

Page 24

Chapter 2 Preparation and Inspection (For IEC)

VSB Board Cable connected to Transformer Cabinet

Keep the plug at least

100 mm away from

Temperature Monitor plug

2. Disconnect four 380V AC cables (a, b, c, and o cables) from the bottom of the Isolation Transformer.

Figure 1 - 380V AC Bottom-mounted Auxiliary Fan Input Cables (IEC)

3. Disconnect the Voltage Sensing Board Output Cable. Keep the plug at least 100 mm away from the Voltage Sensing Board.

Figure 2 - Voltage Sensing Board Output Connection Cable (IEC)

4. Disconnect the Isolation Transformer Temperature Monitor. Keep the plug at least 100 mm away from the connection point on the Monitor.

Figure 3 - Isolation Transformer Temperature Monitor (IEC)

24 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preparation and Inspection (For IEC) Chapter 2

Miniature Circuit Breakers

Top Main Cooling Fan Cir cuit Brea kers

Miniature Circuit Breakers

5. Switch the miniature circuit breakers in the LV Cabinet off.

Figure 4 - Control Switches (IEC)

6. Switch the miniature circuit breakers in the Isolation Transformer Cabinet LV Control panel off. Switch the Top Main Cooling Fan circuit breakers off.

Figure 5 - Control Switches (IEC)

7. Remove two star connection cables (the cabling that goes through the HECS) and connect them to the output connections of any two power modules within a phase.

Figure 6 - Star Connection Cable

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 25

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Chapter 2 Preparation and Inspection (For IEC)

Control Cable

HECS

(located at the top of the

power unit cabinet)

Control Board Power Cables

HMI Power Cable

8. Disconnect the control cable of HECS.

Figure 7 - Hall Effect Current Sensor

9. Disconnect the HMI and Control Board power cables.

Figure 8 - Back of HMI

26 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preparation and Inspection (For IEC) Chapter 2

Analog Interface Board location on Control Unit

Control Unit terminals

10. Remove the Analog Interface board and disconnect all of the terminals from the Control Unit.

Figure 9 - Back of Control Unit

Connect the Insulation Meter

1. Connect the red wire from the insulation meter to the U Phase and the black wire to the grounding bus.

ATTENTION: Verify the drive and any connected equipment is clear of personnel and tools prior to commencing the Megger test. Barricade off any open or exposed conductors. Conduct a walk-around inspection before commencing the test.

2. Use jumper wires to make the connections as shown in Figure 10

The jumper wires must be rated for greater than 5 kV or must maintain sufficient clearance to any metal surface.

3. If the Megger has a lower voltage setting (normally 500V or 1000V), apply that voltage for 5 seconds as a precursor for the higher voltage rating. This may limit the damage if there is a problem. If the reading is very high, apply the test voltage per Figure 10

4. Perform a Megger test with the insulation meter voltage set according to the voltages shown in Ta b l e 7

for 1 minute and record the result.

The test should produce a reading greater than the minimum values listed below. If the test results produced a value lower than these values start segmenting the drive system down into smaller components and repeat the test on each segment to identify the source of the ground fault.

ATTENTION: Discharge the Megger prior to disconnecting it from the equipment.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 27

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Chapter 2 Preparation and Inspection (For IEC)

Ground Bus Bar

Insulation Meter

Outgoing Motor Power

Cable Connections

Incoming Line Power Cable Connections

5. Disconnect the Insulation Meter and jumpers installed in steps 1 and 2.

6. Reconnect all wires, cables, and connections in reverse order of removal.

Figure 10 - Connected Insulation Meter (IEC)

Table 7 - Insulation Test Voltage Values

Drive Rated Voltage U1 Insulation Resistance Test Direct Voltage (V)

1000<U1≤5000 2500

5000<U1 5000

Typical of Drive Minimum Megger Value

Entire Drive 1 kM Ohm

28 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 29

Preparation and Inspection (For IEC) Chapter 2

IMPORTANT

Apply silicone as

shown by bold lines

Apply silicone as

shown by bold lines

Final Steps before Equipment is Ready for Energization

1. Review interior of all cabinets for foreign material that might have been left behind during the installation process. Ensure no tools, hardware, or wiring debris remain in the drive system cabinets. Clear any metal shavings that may result from any drilling activities.

2. If any internal barriers were removed during the commissioning process, ensure they are reinstalled.

Seal the Cabinet Plates

Once the back plates have been reattached, the seams along the plates must be sealed with silicone. Where the silicone is applied is dependent on the cabinet configuration (Fixed-mounted or Drawout Power Module).

Use the approved silicone that is shipped with the drive.

Figure 11 - Silicone Locations on Fixed-mounted Power Module Configuration

Figure 12 - Silicone Locations on Drawout Power Module Configuration

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 29

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Chapter 2 Preparation and Inspection (For IEC)

Notes:

30 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 31

Preparation and Inspection (For UL)

Chapter 3

Gather Required Tools and Test Equipment

Hand Tools

• Metric wrenches and sockets

• To r qu e w re nc h

• Assortment of screw drivers

• Wire stripper/cutter

Electrical Equipment

• High voltage gloves – 17 kV insulation rating (minimum)

• Anti-static strap

• Live-line tool (Hot stick)

• 5 kV Insulation Tester

Test Equipment

• 600V (1000V rating) digital multimeter with assorted clip leads

Computer Requirements and Software

• Laptop computer

• USB cable

• PLC program

• CCW software

Lockout and Tagout

SHOCK HAZARD: Servicing energized industrial control equipment can be

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 31

Page 32

Chapter 3 Preparation and Inspection (For UL)

IMPORTANT

Refer to local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards.

Safety Test

Inspect Drive Components

After performing the lockout and tagout procedure (see page 31), open all of the cabinet doors. Inspect each component for signs of shipping damage (see Ta b l e 8

on page 34). An initial inspection would have been done by the customer when

the equipment was received. However, this would have been done from the front only and was just looking for obvious signs of damage (see publication 6000-

IN006_-EN-P). Record the part number and description of any damaged

components and immediately contact the Start-up Project Manager to order replacement components, if required.

ATT EN TI ON : Verify the equipment against any damage. Do not install a damaged drive.

Verify that all components are securely affixed to the cabinet.

Most components will be easily visible on the doors or from the front of the cabinets after the doors are opened. Some components are best viewed from the rear of the cabinet.

For rear inspection, remove top and bottom rear access plates from the drive and bypass cabinet (if supplied). See publication 6000-IN006_-EN-P.

The Inspect Drive Components Checklist (see page 34) mentions the principal base components supplied in the drive and bypass units. It is not comprehensive, as customer-required options may be supplied and three different bypass configurations are available.

Perform the shipping damage inspection for all components mounted in the drive cabinets and specific bypass unit cabinet (if supplied).

32 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 33

Preparation and Inspection (For UL) Chapter 3

Functional Assessment

After the components are visually inspected to identify any shipping damage, a thorough functional assessment should be performed (see Table 9 on page 35 The main purpose of this assessment is to ensure that all movable parts and assemblies operate properly, connect properly, and components are wired properly and securely.

The Functional Assessment procedure can be combined with the “Inspect Drive Components” checklist on page 34

Descriptions of the Power Cable Connections to be inspected and torqued to specifications are in the Interconnection Review and Installation Review sections.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 33

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Chapter 3 Preparation and Inspection (For UL)

Door:

Fixed Mounted Power Module Configuration:

Pilot lights

Power Module retaining tabs

Push buttons

Selector switches

HMI

Interface board (on the back of the LV door)

Check for debris

Output Bus Supports

Fuse Mounting Supports

Voltage Sensing Board

Panel:

DIN rail mounted components

UPS

Fiber optic cables

PLC

Control U nit

UPS connections

– Verify orientation relative to barrier plates

Drawout Power Module Configuration:

Support frame

Power Modules

(1)

Fixed Mounted Power Module:

Heat sink

Table 8 - Inspect Drive Components Checklist (UL)

Door:

Transformer Temperature monitor

LV Cabinet components

Cabinet:

Transformer Plastic Baffle

Outgoing Motor Power Cable standoffs on

Cabinet Sidesheet

Outgoing Motor Power Cable Terminal

Insulators on transformer

Incoming Line Power Cable Terminal Insulators

on transformer

Motor Cable Braces

Door:

Pilot Lights

Voltage Indicator Relay

Cabinet:

Insulators

Switch assemblies

Vacuum contactors

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltag e Control Cabinet

Mechanical linkages

Front

– Fan control c ircuit breaker s

Fixed Mounted Power Module Configuration:

– Inspect nomex wrap

– Verify windings from core are undamaged

Transformer Secondary Windings (2 sets)

– Check for debris in top of core

Fixed Mounted Power Module Configuration:

Transformer Secondary Windings (1)

– Inspect nomex wrap

Rear

– Verify windings from core are undamaged

– Check for debris in top of core

(1) Motor Cable terminations could be on the transformer structure or cabinet sidesheet, depending on the power rating.

34 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

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Preparation and Inspection (For UL) Chapter 3

– Check connec tion of all fiber optic cables

– Check connec tion of HMI interface board

– Check plug connectors

– HMI

– Test switch contacts wired back to terminal

Mechanical Interlock (2)

Control Unit

HECS (2)

and terminal blocks

– Tug test all wires on door, panel, and relays

Low Voltage wires

blocks in LV panel with ohmmeter

Power Modules fiber optic cables

– Check all connections

– Verify operation

Circuit Breakers and Contactors

– Test each fuse with multimeter

Power Modules Fuses

components

– Check connec tions from all attached

Vertical Ground Bus

– Verify the primary and secon dary connections

Door Grounding Straps

Voltage Sensing Board cables

devices

– Verify operation of all operator interface

Low Volta ge Door

to the board are secure

Door Grounding Straps



– Check connection

UPS

– Check electrical connection

Top Mounted Cooling Fans

– Check connections

AC/DC Power Sup plies

Table 9 - Functional Assessment Checklist (UL)

Transformer Secondary Cables

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet

Electrical Door Interlock

– Verify cables are properly fed through the

– Verify proper operation of auxiliary contacts

glanding plate and are undamaged

with an ohmmeter

terminal blocks in LV panel with ohmmeter

– Test auxiliary switch contacts wired back to

Mechanical Interlock

– Verify proper operation with an ohmmeter

Isolation switch auxiliary contacts

– Verify wires are intact and properly inserted

Temperature Sensing Wires (3 places)

– Verify proper operation

– Outer jaws must securely contact the center

Isolation switches

– Tug test on all cable connections

Door Grounding Straps

Transformer Temperature Protection Relay

stab in the closed position

– Check all connections per Electrical Drawings

Secondary Wiring and Low Voltage Fuses

Door Grounding Straps

Front

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 35

glanding plate are undamaged

– Verify cables are properly fed through the

Transformer Secondary Cables

– Check braided copper connections

Surge Arrestors

– Verify connection

Line and Load side power cables

– Check electrical connection

Top Mounted Cooling Fans

– Verify phasing and torque

Top Ground Bus

Rear

Tap Changer

– Pe rform tug tes t

Voltage Sensing Relay Cables

structure

– Assembly must be affixed properly to

Fan H ousi ngs

– Verify braided connections

Page 36

Chapter 3 Preparation and Inspection (For UL)

IMPORTANT

Interconnection Review

Table 10 - Interconnection Review Checklist (UL)

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Review the braided ground connection to adjacent cabinet

Verify line and load power cables from Isolation Transformer Cabinet are properly connected

Front Inspection

Verify all control wires per Electrical Drawing

Check torque on all power and ground cable connections per specifications listed in Torque Requirements

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Review all isolation transformer secondary wiring from Power Module cabinet (2 sets)

Verify that the shields of all of the system’s connecting wires are properly grounded

Verify all control wires per Electrical Drawing

– Cables are run in LV cable

sections along front and back of cabinet

Verify the braided ground connection to adjacent cabinet(s) is properly installed

Verify that the shields of all of the system’s connecting wires are properly grounded

Review load power cable connection from Isolation Tra nsf orm er C abi net

Verify Voltage Sensing Board power cables from Power Module Cabinet are properly installed

Verify that the two plugs from the LV Control Cabinet and Isolation Transformer Cabinet are properly installed

on page 109.

Verify control signal wiring bundles from LV Control cabinet to LV panel in Isolation Transformer cabinet and LV panel in the Bypass Cabinet (if supplied) are routed correctly

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Preparation and Inspection (For UL) Chapter 3

Installation Review

to review the contractor’s drive installation responsibilities and understand the scope of the work you will be reviewing.

Mechanical Installation Inspection

Sequence Task Reference Document

1 Verify line up positioning Dimensional Drawings

2 Verify cabinets are bolted together correctly 6000-IN006_-EN-P

3 Verify cabinets are affixed to the floor properly Dimensional Drawings,

6000-IN006_-EN-P

4 Verify fans are installed correctly 6000-IN006_-EN-P

5 Verify power modules are installed correctly 6000-IN006_-EN-P

6 Review duct installation (if applicable) 6000-IN006_-EN-P

7 Verify the cable trenches meet design requirements 6000-IN006_-EN-P

8 Verify required cabinet clearances 6000-IN006_-EN-P

9 Verify there are no scratches or damage to the cabinet body N/A

10 Verify the top cover of the isolation transformer cabinet is securely

mounted

6000-IN006_-EN-P

Refer to project-specific EDs to review all electrical connections to external input and output devices.

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Chapter 3 Preparation and Inspection (For UL)

Electrical Installation Inspection

Sequence Task Reference

Document

1 Verify that medium voltage cables are separated at least 30 cm from the control cables

2 Verify that all secondary control wiring use shielded cables

3 Verify that input and output medium voltage cables specifications meet the stated

insulation requirements

4 Verify that input and output medium voltage cables have attached nameplates

5 Verify the diameter of control power cables comply with the drawings Electrical

6 Verify that the electrical safety circuit wiring between the input circuit breaker and the drive

7 Verify the wiring between the DCS and the drive is shielded and only the end the drive side is

8 Verify that the user-provided ground cable is ≥50 mm

9 Verify the isolation transformer’s primary input voltage matches the system primary voltage

10 Verify that the customer motor specifications match the drive voltage and current

11 Verify that the isolation transformer’s input si de wiring is correct Electrical

12 Verify that the motor output side wiring is correct Electrical

13 Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical

14 Verify torque on incoming line power cable and outgoing motor powe r cable terminations Electrical

is shielded and only the end at the drive side is grounded

grounded

capabilities

Electrical Drawings

Drawings

Power Cabling

Table 11 - Color Coding (UL)

Color Incoming Line Side Outgoing Motor Side

Black L1 (A Phase) Line Cable Terminal U Phase:

Red L2 (B Phase) Line Cable Terminal V Phase:

Blue L3 (C Phase) Line Cable Terminal W Phase:

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

• Power Module Bus

• VSB Input Cable

• Motor Cable Termination

• Motor Cable Connection to Power Module Bus

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Preparation and Inspection (For UL) Chapter 3

Incoming Line and Outgoing Motor cables must be routed separately to prevent cable insulation damage.

All cables must be terminated on each end and sufficiently torqued.

All customer power cables must be Hi-Potted or Meggered and read a sufficient insulation value. Review Hi-Pot or megger test report from the customer.

Control Wiring

Drive Megger Check

Control wiring must be routed separately from power cabling.

Perform a tug test on all control cables to ensure that they are securely fastened, and check each plug and connector to ensure it is properly seated in its socket.

Isolate the Power and Control Circuits

ATT EN TI ON : Verify the grounding cable connection is secure.

Disconnect the low voltage power before the megger test. Short circuit the 3 input cables and 3 output cables on one point.

1. Isolate and lock out the drive system from any high voltage source.

Disconnect any incoming power sources, medium voltage sources should be isolated and locked out and all control power sources should be turned off at their respective circuit breaker(s).

Verify with a potential indicator that power sources have been disconnected, and that the control power in the drive is de-energized.

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Chapter 3 Preparation and Inspection (For UL)

VSB Board Cable connected to

Transformer Cabinet

2. Disconnect four 380V AC cables (a, b, c, and o cables) from the bottom of the Isolation Transformer.

Figure 13 - 380V AC Bottom-mounted Auxiliary Fan Input Cables (UL)

3. Disconnect the Voltage Sensing Board Output Cable. Keep the plug at least 100 mm away from the Voltage Sensing Board.

Figure 14 - Voltage Sensing Board Output Connection Cable (UL)

4. Disconnect the Isolation Transformer Temperature Monitor. Keep the plug at least 100 mm away from the connection point on the Monitor.

Figure 15 - Isolation Transformer Temperature Monitor (UL)

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Preparation and Inspection (For UL) Chapter 3

Miniature Circuit Breakers

Top Main Cooling

Fan Cir cuit Bre akers

5. Switch the miniature circuit breakers in the LV Cabinet off.

Figure 16 - Control Switches (UL)

6. Switch the miniature circuit breakers in the Isolation Transformer Cabinet LV Control panel off. Switch the Top Main Cooling Fan circuit breakers off.

Figure 17 - Control Switches (UL)

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Chapter 3 Preparation and Inspection (For UL)

Control Cable

HECS (located on the right side of the power unit cabinet

7. Remove two star connection cables (the cabling that goes through the HECS) and connect them to the output connections of any two power modules within a phase.

Figure 18 - Star Connection Cable (UL)

8. Disconnect the control cable of HECS.

Figure 19 - Hall Effect Current Sensor (UL)

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Preparation and Inspection (For UL) Chapter 3

Control Board Power Cables

HMI Power Cable

Analog Interface Board location on Control Unit

Control Unit terminals

9. Disconnect the HMI and Control Board power cables.

Figure 20 - Back of HMI

10. Remove the Analog Interface board and disconnect all of the terminals from the Control Unit.

Figure 21 - Back of Control Unit

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Chapter 3 Preparation and Inspection (For UL)

Connect the Insulation Meter

1. Connect the red wire from the insulation meter to the U Phase and the black wire to the grounding bus.

2. Use jumper wires to make the connections as shown in Figure 22

The jumper wires must be rated for greater than 5 kV or must maintain sufficient clearance to any metal surface.

4. Perform a Megger test with the insulation meter voltage set according to the voltages shown in Ta b l e 1 2

for 1 minute and record the result.

ATTENTION: Discharge the Megger prior to disconnecting it from the equipment.

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Preparation and Inspection (For UL) Chapter 3

Ground Bus Bar

Insulation Meter

Incoming Line Power

Cable Connections

5. Disconnect the Insulation Meter and jumpers installed in steps 1 and 2.

6. Reconnect all wires, cables, and connections in reverse order of removal.

Figure 22 - Connected Insulation Meter (UL)

Table 12 - Insulation Test Voltage Values

Drive Rated Voltage U1 Insulation Resistance Test Direct Voltage (V)

1000<U1≤5000 2500

5000<U1 5000

Typical of Drive Minimum Megger Value

Entire Drive 1 kM Ohm

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Chapter 3 Preparation and Inspection (For UL)

IMPORTANT

Apply silicone as

shown by bold lines

Final Steps before Equipment is Ready for Energization

2. If any internal barriers were removed during the commissioning process, ensure they are reinstalled.

Seal the Cabinet Plates

Use the approved silicone that is shipped with the drive.

Figure 23 - Silicone Locations on Fixed-mounted Power Module Configuration

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Commissioning

Chapter 4

Introduction

ATT EN TI ON : The Control System Check requires LV Control power only. The

Input Circuit Breaker must remain locked out and tagged out for this procedure.

A number of activities are required before the Control System Check can be performed.

Procedure Page

Simulate Closed Input Circuit Breaker

Energize Control Ci rcuit 48

The complete Control System Check requires the following procedures to be performed.

Procedure Page

Verify Factory Default Settings 52

Set P Parameters to Enable Testing 55

Verify Settings for Low-Voltage Testing 58

Verify Operation of Frequency Steps 63

Verify Operation to Set Frequency 65

Simulate Warnings and Faults 65

Verify E-Stop Functionality 72

Verify Switching from Local Control to Remote Control 73

Verify Operation of Input/Output and Bypass Isolation Switches (Manual Bypass)

Verify Operation of Input/Output and Bypass Contactors (Automatic Bypass)

Verify Operation of DCS Input and Output Signals 83

Restore P Parameter Settings 84

(1)

(1) Only required if a bypass configuration is supplied.

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Chapter 4 Commissioning

IMPORTANT

Control Power Transformer

UPS

REAR

FRONT

Control System Check Setup

Simulate Closed Input Circuit Breaker

The “normal” operating mode is for the input circuit breaker to be closed. Install a temporary jumper (X1-117, X1-119) in the LV Control Cabinet to simulate operating the system in “normal” mode (input circuit breaker closed) to allow the Control System Check process to proceed.

Refer to Electrical Drawings.

Energize Control Circuit

Before beginning this process, ensure that the customer's control power supply breaker is closed and control power is available.

Control power voltage used in the control circuit is nominally 220V and referred to in the example. The control circuit can directly accommodate other widely used voltages of 230V and 240V also. If 110V or 120V is the control power voltage supplied by the customer, a control power transformer is supplied in the LV control cabinet to step up the customer supplied control power to 220V (Figure 24

Q1 (CB1), Q2 (CB2), Q3 (CB3), Q5 (CB5), and Q6 (CB6) miniature circuit breaker designations are located in the LV Control Cabinet (Figure 25 (CB4) and Q7 (CB7) miniature circuit breaker designations are located in the LV Control panel of the Isolation Transformer Cabinet (Figure 26 Electrical Drawings.

). This must be specified at time of order.

). The Q4

). Refer to the

Test points indicated in the instructions are at the circuit breaker terminals, not at the terminal blocks.

Circuit breaker device designation labels (Q1 (CB1), Q2 (CB2), etc.) are affixed to the device mounting surfaces.

Figure 24 - UPS and CPT Mounting Plate (Top View)

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Page 49

Figure 25 - LV Control Cabinet

135

246

(CB1)Q2(CB2)

(CB3)

(CB6)

(CB5)

Q7Q4

For IE C For UL

Commissioning Chapter 4

Figure 26 - LV Panel in the Isolation Transformer Cabinet

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Chapter 4 Commissioning

Table 13 - Energize Control Circuit Sequence (For IEC)

Item Before Closing Breaker After Closing Breaker Comments

Close Breaker Q1

Verify that the input voltage at the Q1 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). Verify OPEN state (5 and 6).

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6).

Q1 connects customer-supplied control power to the control circuit (UPS).

Start UPS (Press ON button)

Close Breaker Q2

Close Breaker Q3

Close Breaker Q4

Close Breaker Q5

Close Breaker Q6

Close Breaker Q7

Before pressing the ON button, withdraw the Type I UPS power plug from the power receptacle (XS2). Verify that the input voltage of the XS2 receptacle is AC220V. Verify that the PE connection of the XS2 receptacle is properly grounded. Plug the UPS into the receptacle. Press and hold the ON button for 3 seconds to turn on the UPS (all status lights on the UPS will be green).

Verify that the input voltage at the Q2 circuit breaker is AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. Verify output is not shorted (2 and 4).

Verify that the input voltage at the Q3 circuit breaker is AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. Verify output is not shorted (2 and 4). Verify OPEN state (5 and 6).

Control power is fed from the isolation transformer tertiary winding for the Q4 circuit breaker, therefore not present for this test. A two pole breaker is supplied for lower power drives (220V powered auxiliary fans). A three pole breaker is supplied for higher power drives (380V power auxiliary fans). Verify open status (1 and 2) and output not shorted (2 and 4).

Control power is fed from the isolation transformer tertiary winding for the Q5 circuit breaker, therefore not present for this test. Verify open status (1 and 2) and output not shorted (2 and 4).

Verify that the input voltage at the Q6 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).

Verify that the input voltage at the Q7 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).

Verify that UPS operates normally and that the UPS output is AC220V. The output of the UPS is connected to the input of Q2 and Q3. The UPS output voltage can be checked at the input of Q2 or Q3 (1 is L, 3 is N).

Verify that the input voltage of power supplies is AC220V (L-N). Refer to Figure 27 PLC, HMI, and Control Unit power up.

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6). Verify that the PLC I/O status lights and control relay red indicating lights illuminate.

Verify closed status (1 and 2). Q4 connects control power from isolation

Verify closed status (1 and 2). Q5 connects back-up control power from

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the LV Door pilot lights illuminate.

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the Isolation Transformer temperature monitor powers up.

. Verify that the

UPS feeds control power to the circuits supplied by the Q2 and Q3 circuit breakers.

Q2 connects control power directly to AC/DC power supplies (G1, G2, and G3), PLC, HMI, and Control Unit

Q3 connects control power to PLC I/O and control relays.

transformer tertiary winding to bottommounted auxiliary fans (6).

isolation transformer tertiary winding to switch to the control circuit (UPS) if the main (customersupplied) control power is lost.

Q6 connects control power to door mounted pilot lights and spare relays for DCS.

Q7 connects control power to isolation transformer temperature monitor

ATT EN TI ON : The following should be opened successively when the control power is switched off: Q5, Q4, Q3, Q2 and UPS; opening Q1 is not necessary when the control power is not disconnected.

Table 14 - Energize Control Circuit Sequence (For UL)

Item Before Closing Breaker After Closing Breaker Comments

Close Breaker CB1

Start UPS (Press ON button)

Close Breaker CB2

50 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Verify that the input voltage at the CB1 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). Verify OPEN state (5 and 6).

Verify that the input voltage at the CB2 circuit breaker is AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. Verify output is not shorted (2 and 4).

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6).

Verify that UPS operates normally and that the UPS output is AC220V. The output of the UPS is connected to the input of CB2 and CB3. The UPS output voltage can be checked at the input of CB2 or Q3 (1 is L, 3 is N).

Verify that the input voltage of power supplies is AC220V (L-N). Refer to Figure 27 PLC, HMI, and Control Unit power up.

. Verify that the

CB1 connects customer-supplied control power to the control circuit (U PS).

UPS feeds control power to the circuits supplied by the CB2 and CB3 circuit breakers.

CB2 connects control power directly to AC/DC power supplies (G1, G2, and G3), PLC, HMI, and Control Unit

Page 51

Table 14 - Energize Control Circuit Sequence (For UL)

Close Breaker CB3

Close Breaker CB5

Verify that the input voltage at the CB3 circuit breaker is AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. Verify output is not shorted (2 and 4). Verify OPEN state (5 and 6).

Control power is fed from the isolation transformer tertiary winding for the CB5 circuit breaker, therefore not present for this test. Verify open status (1 and 2) and output not shorted (2 and 4).

Commissioning Chapter 4

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6). Verify that the PLC I/O status lights and control relay red indicating lights illuminate.

Verify closed status (1 and 2). CB5 connects back-up control power from

CB3 connects control power to PLC I/O and control re lays.

isolation transformer tertiary winding to switch to the control circuit (UPS) if the main (customersupplied) control power is lost.

Close Breaker CB6

Close Breaker CB7

Verify that the input voltage at the CB6 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).

Verify that the input voltage at the CB7 circuit breaker is AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).

Figure 27 - AC/DC Power Supplies

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the LV Door pilot lights illuminate.

Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the Isolation Transformer temperature monitor powers up.

CB6 connects control power to door mounted pilot lights and spare relays for DCS.

CB7 connects control power to isolation transformer temperature monitor

ATT EN TI ON : The following should be opened successively when the control power is switched off: CB5, CB3, CB2 and UPS; opening CB1 is not necessary when the control power is not disconnected.

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Chapter 4 Commissioning

IMPORTANT

TIP

Control System Check

Verify Factory Default Settings

Confirm Language, Bypass Mode, and Local Operation

The default Language setting and bypass mode are set before shipment.

You can change the language but cannot change the bypass mode, as this is set at the factory to match the shipped drive configuration.

1. Press in the System Parameter Settings

interface screen.

2. In the Languages

3. Press to accept and proceed to the Main Interface

Screen.

Detailed information about the HMI screens is included in publication

6000-UM002_-EN-P,

Drive User Manual.

dialog box, select the language you want and press

PowerFlex 6000 Medium Voltage Variable Frequency

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Commissioning Chapter 4

No Bypass Cabinet

Manual Bypass Cabinet

4. Press and confirm the Bypass Configuration matches one of the five Input Supply graphics.

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Chapter 4 Commissioning

Automatic Bypass Cabinet

Note the Contactor Operation selection appears when Automatic Bypass is selected

Manual Bypass Two Cabinets

Automatic Bypass Two Cabinets

Note the Contactor Operation selection appears when Automatic Bypass is selected

5. Und er Control Owner Selection, press .

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Commissioning Chapter 4

The Select Local Control? dialog box appears.

6. Select to confirm Local Control, and press to

return to the Main Interface Screen.

Set P Parameters to Enable Testing

There are two specific “P” parameters that must be changed to allow the Control System Check to proceed.

This section is password protected and the setup login process must be completed before making any changes.

Access Setup Settings

1. Press from the Main Interface Screen.

2. Press under Parameter Access Level

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Chapter 4 Commissioning

TIP

IMPORTANT

The Setup Login dialog box appears. Press .

3. Enter the User and Password details.

Press and enter “setup”. Press when finished.

Press to enter the password. Press when finished.

The password will be sent by the Project Start-up Manager.

4. Press to login.

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

5. Once logged in, press to proceed.

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

Set P Parameters

Once the appropriate access has been granted, you can now select and change parameters.

For the simulation tests, you only need to change two parameters: P007 and P224.

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Commissioning Chapter 4

TIP

1. Press in the Setup Parameter Type.

2. Press the P007 parameter input field.

WARNING: Do NOT press . This will reset all factory-set parameters.

When the “P” Parameter number is pressed (e.g. P007), the description appears in the information box at the bottom of the screen.

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Chapter 4 Commissioning

IMPORTANT

3. Press “0” on the keypad dialog and press .

Parameter 007 will now show a value of “0”.

4. Repeat steps 2 and 3 to change Parameter 224 to “120”.

Verify Settings for Low-Voltage Testing

The following settings are for low-voltage testing only.

Before performing high-voltage testing, the “Power Loss” setting must be restored to the unshielded state.

1. Press from the Main Interface Screen.

2. Press under Parameter Access Level

The R&D Login dialog box appears. Press .

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Commissioning Chapter 4

IMPORTANT

3. Enter the User and Password details.

Press and enter “RD”. Press when finished.

Press and enter “668”. Press when finished.

4. Press to login.

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

5. Once logged in, press to proceed.

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

Set P Parameters

Once the appropriate access has been granted, you can now select and change parameters.

1. Press under P Parameter Settings

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Chapter 4 Commissioning

2. Press “499” on the keypad dialog and press .

will now show a value of “499”.

3. Press and enter “1”. Press when finished.

4. Press . The should display “1.00”.

5. Press to view the Fault Masks screen.

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Commissioning Chapter 4

For IEC Standard

6. Press and . The buttons should change

to and respectively.

WARNING: Before performing the high-voltage test, press

to change back to and keep current blocked because there is no hardware detection in IEC)

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Chapter 4 Commissioning

IMPORTANT

For UL Standard

7. Press to change the button to .

8. Press to return to P Parameter Settings and continue with low-voltage testing.

After the end of the simulation tests, the “Power Loss” setting must be restored to the unshielded state.

9. Press to exit P Parameter Settings, and . Press

to confirm Setup has logged out.

10. Press to return to the Main Interface Screen.

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Commissioning Chapter 4

TIP

Verify Operation of Frequency Steps

There are two parts to this procedure, increasing the frequency in set increments and increasing the frequency to a specific rated frequency.

During the Control System Check procedure, an “Abnormal Output Voltage Warning” will appear, as the procedure is done without MV and the Control System is expecting an output voltage. Ignore this warning for this procedure.

Increase Frequency by Step

1. From the Main Interface Screen, press the Set Frequency: input field.

2. In the Set Freq: dialog box, enter a value of “10” and press .

Press to confirm.

The Set Frequency and Actual Frequency occasionally will not show the exact integral value selected, due to internal data conversion in the HMI program.

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Chapter 4 Commissioning

IMPORTANT

TIP

3. Press , and press in the Start Drive? dialog box to confirm operation.

When the drive is ≥0.5 Hz, the “Connect” light will be illuminated. When the speed of the drive surpasses 0.5 Hz, the “Connect” and “Running” lights will be red. The “Warning” light will illuminate when the Actual Frequency increases above 10.00 Hz. This is an internal function for testing purposes only.

4. When the Actual Frequency reaches 10 Hz, press .

Press in the Accel Speed by Step? dialog box.

T Parameter T09 determines the value of the frequency step change. The default is 1. Refer to Access T Parameters

on page 86.

The Set Frequency and Actual Frequency are now 11 Hz.

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Commissioning Chapter 4

5. Press and press in the Decel Speed by Step? dialog box.

The actual frequency will decrease by 1 Hz.

Verify Operation to Set Frequency

1. Press the Set Frequency: input field and enter “50” in the Set Freq: dialog

box and press .

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Chapter 4 Commissioning

2. Press to accept and begin the simulation.

Actual Frequency: will show the frequency increasing to 50 Hz.

3. Once the actual frequency has reached the set frequency, press

and press in the Stop Drive? dialog to confirm

action.

The actual frequency will decrease to 0 Hz.

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Simulate Warnings and Faults

This section describes how to simulate warnings and faults, and how to clear or reset the alarm. Warning codes begin with a W prefix, and fault codes begin with a F prefix.

Alarm Self-clearing Requires Reset

Transformer Overtemperature Warning YES

Transformer Overtemperature Trip YES

Transformer Cabinet Main Cooling Fan Fault YES

Power Module Cabinet Main Cooling Fan Fault YES

Cabinet Door Open Warning

– Left Isolation Transformer Cabinet Door – Right Isolation Transformer Cabinet Door – Left Power Module/LV Cabinet Door – Right Power Module/LV Cabinet Door – Bypass Cabinet Door (if applicable)

The Set Frequency: field will already have 50 Hz shown from the previous exercise in the Set Freq: dialog box.

YES

1. Press , and press in the Start Drive? dialog box.

Simulate the Transformer Overtemperature Warning

1. Start the drive, then open the door of the Control cabinet.

2. In the control cabinet, remove the wire from terminal block 419. This

triggers the transformer overtemperature warning alarm.

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Chapter 4 Commissioning

3. Press to view alarm record.

4. Replace the wire for terminal block 419 and tighten properly to remove the warning.

Simulate Transformer Overtemperature Trip

1. Start the drive, then open the door of the Control cabinet.

2. In the Control cabinet, remove the wire from terminal block 418. This

triggers the transformer overtemperature trip alarm.

3. Press to view the alarm record.

4. Replace the wire for terminal block 418 and tighten properly to remove the

trip message.

5. Press to return to the Main Interface Screen.

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Commissioning Chapter 4

TIP

6. Press , and press to confirm the operation in the Reset Drive? dialog box.

Wait until the Ready status indicator is red before starting another simulation.

Simulate a Transformer Cabinet Main Cooling Fan Fault

1. Set the frequency to 10 Hz and start the drive.

2. Open the LV door of the Isolation Transformer cabinet.

The circuit breakers for the main cooling fans for the entire drive are located here.

3. Turn the first motor control circuit breaker (Q10 for IEC and CB10 for UL), controlling the Isolation Transformer Cabinet Main Cooling Fans (one per fan), to the OFF position.

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Chapter 4 Commissioning

TIP

4. Press to confirm the Transformer Cabinet Main Cooling Fan Fault.

5. After the fault is reported, the drive is in a fault stop state.

6. Turn the first (Q10 for IEC and CB10 for UL) circuit breaker to the ON

position, to remove the fault.

7. Press to return to the Main Interface Screen.

Simulate a Power Module Cabinet Main Cooling Fan Fault

1. Set the frequency to 10 Hz and start the drive.

2. Open the LV door of the Isolation Transformer cabinet.

From left to right on the DIN rail in the LV cabinet, the main cooling fan circuit breakers are located first for the Isolation Transformer cabinet then the Power Module cabinet.

Almost all drive configurations will have a maximum of three main cooling fans for the Isolation Transformer Cabinet. Therefore, the main cooling fan circuit breaker designations of Q10, Q11, and Q12 are reserved for the Isolation Transformer Main Cooling Fans. Power Module Cabinet Main Cooling Fan circuit breaker designations begin at Q13.

Refer to the appendix in 6000-IN006_-EN-P cabinet location, or look at the fans on the top plate of the drive.

3. Turn the applicable motor control circuit breaker (Q13 for IEC and CB13 for UL), controlling the Power Module Main Cooling Fans (one per fan), to the OFF position.

to determine the number of main cooling fans in each

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Commissioning Chapter 4

4. Press and confirm the Power Module Cabinet Fan Fault.

5. After the fault is reported, the drive is in a fault stop state.

6. Turn the (Q13 for IEC and CB13 for UL) circuit breaker to the ON

position, to remove the fault.

7. Press to return to the Main Interface Screen.

Simulate Cabinet Door Open Warning

1. Open the left Isolation Transformer Cabinet door.

2. Press to confirm the Cabinet Door Open Warning.

The drive will shut off.

3. Close the left Isolation Transformer Cabinet to remove the warning.

4. Repeat this procedure using the:

• Right Isolation Transformer Cabinet door

• Left Power Module/LV Cabinet door

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Chapter 4 Commissioning

• Right Power Module/LV Cabinet door

• Bypass Cabinet door (if applicable)

5. Press to return to the Main Interface Screen.

6. Press to remove the fault. Press to confirm operation in the Reset Drive? dialog.

Verify E-Stop Functionality

1. Press on the Main Interface Screen to start the drive.

2. Push the E-stop button on the front of the LV Control cabinet.

3. Press and confirm the E-stop Trip fault.

4. Twist to pull out the E-stop button on the front of the LV Control cabinet.

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Commissioning Chapter 4

5. Press to return to the Main Interface Screen.

6. Press to remove the fault. Press to confirm operation in the Reset Drive? dialog.

Verify Switching from Local Control to Remote Control

Depending on whether the drive has an automatic or manual Bypass or no Bypass configuration, the Operation Interface screen will be different.

1. Press from the Main Interface Screen.

2. Press in the Control Owner Selection

3. Press in the Select Remote Control? dialog.

4. Press to return to the Main Interface Screen and confirm Remote status indicator light is on.

5. Press from the Main Interface Screen.

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Chapter 4 Commissioning

6. Und er Control Owner Selection, press .

7. Select to confirm selection in the Select Local Control? dialog,

and press to return to the Main Interface Screen and confirm the Local status indicator is on.

Verify Operation of Input/Output and Bypass Isolation Switches (Manual Bypass)

Input/Output Isolation Switches

1. Press from the Main Interface screen.

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Commissioning Chapter 4

2. Open the Bypass cabinet door, and close QS2 and QS3.

Verify the Input and Output contactors are closed on the HMI.

3. Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).

Verify the input circuit breaker is closed.

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Chapter 4 Commissioning

Bypass Isolation Switches

1. Press from the Main Interface screen.

2. Open the Bypass cabinet door, and close QS1.

Verify the bypass isolation switch is closed on the HMI.

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Commissioning Chapter 4

IMPORTANT

3. Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).

Verify the input circuit breaker is closed.

Verify Operation of Input/Output and Bypass Contactors (Automatic Bypass)

Input/Output Drive Contactors

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

1. Press from the Main Interface screen.

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Chapter 4 Commissioning

2. Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).

Verify the input circuit breaker is closed.

3. Press under Contactor Operation confirm.

, and press to

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Verify the input and output drive contactors are closed.

Commissioning Chapter 4

4. Press under Contactor Operation confirm.

, and press to

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Chapter 4 Commissioning

IMPORTANT

5. Verify the input and output drive contactors are open.

Bypass Contactors

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

1. Press from the Main Interface screen.

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Commissioning Chapter 4

2. Press under Contactor Operation, and press to confirm.

Verify the bypass contactor is closed.

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Chapter 4 Commissioning

3. Press under Contactor Operation, and press to confirm.

Verify the bypass contactor is open.

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Commissioning Chapter 4

Verify Operation of DCS Input and Output Signals

Figure 28 - Status Indicators

Table 15 - Drive to DCS

Signal Name Terminal Number HMI Status Terminal Open Terminal Closed

MVPRE-Closed CB 901-902 Allowed Red Grey

MV CLOSING 903-904 MVClosd Red Grey

Warning 905-906 Warning Red Grey

Fault 907-908 Warning Red Grey

Drive running 909-910 Running/Connect Red Grey

Drive STOP 911-912 Running/Connect Red Grey

READY 913-914 Ready Red Grey

DCS control 915-916 Remote Red Grey

Local Grey Red

Table 16 - 4-20 mA

Output Current 925-926 Motor Cu rrent 0-Rated Current

Output Frequency 927-928 Actual Frequency 0-Rated Frequency

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Chapter 4 Commissioning

When the two terminals specified are shorted, verify the result shown in the third column occurs.

Table 17 - DCS to Drive

Signal Name Terminal Number Function

Fault Reset 412-401 Reset System

DCS Start 449-401 Start Drive

DCS Stop 450-401 Stop Drive

E-stop 1101-1101 E-stop Drive

Frequency Set 931-402 Set Drive Frequency

Restore P Parameter Settings

1. Press , and press under Parameter Access Level.

The Setup Login dialog box appears. Press .

2. Enter the User and Password details.

Press to enter user details. Press when finished.

Press to enter password details. Press when finished.

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Commissioning Chapter 4

3. Press to login.

4. Press , and press .

WARNING: Do NOT press Reset. This will reset all factory-set parameters.

5. Press the P007 parameter field to enter the number of power cells per

phase, and press .

6. Press the P224 parameter field .

7. Change the value from 120 to 80. Press , and press .

8. Press to exit P Parameter Settings

, to confirm

Setup has logged out, and to return to the Main Interface Screen.

WARNING: Remove the temporary jumper (X1-117, X1-119) in the LV Control Cabinet, which was installed to enable the Control System Test.

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Chapter 4 Commissioning

TIP

Set Date and Time Zone

To access the Date and Time Zone settings, you must exit the PowerFlex 6000 HMI to Windows CE.

Access T Parameters

1. Press from the Main Interface Screen.

2. Press under Parameter Access Level.

The Setup Login dialog box appears. Press .

3. Enter the User and Password details.

4. Press to login.

5. Once logged in, press .

6. Press in the Setup Parameter Type

7. Press the T10 parameter input field. Enter “555” and press .

8. Press and to confirm.

It will take 3...5 minutes to shutdown.

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Commissioning Chapter 4

IMPORTANT

Change Time/Date/Regional Settings

Enter the Time Zone settings before changing the date and time.

1. In Windows ME, press Ter mi na l S et tin gs [F 4] .

2. Press the Down Arrow to choose Time/Date/Regional Settings, and press Enter.

3. Choose Time zone and press Enter.

4. Scroll up or down and select the desired time zone.

a. Press Daylight Savings [F1] b. Select the Ye s radio button, and press Close [F8].

5. Press OK [F7].

6. Choose Date and press Enter.

a. Press Yea r [ F1 ], Month [F2], and Day [F3] to set the correct date. b. Press OK [F7].

7. Choose Time and press Enter. a. Press Hour [F1], Minute [F2], and Seconds [F3] to set the correct

time.

b. Press OK [F7].

8. Press Close [F8] twice, Reset [F7], and Yes [ F7 ] to restart the HMI.

9. Select language and bypass mode in the System Parameters Settings

interface.

10. Press to accept and proceed to the Main Interface Screen.

Verify the date and time is updated under Version Info.

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Chapter 4 Commissioning

Notes:

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No-load Test

Chapter 5

Introduction

No-load Test

ATT EN TI ON : Medium Voltage is required for parts of this test. Close and lock all

medium voltage doors on the PowerFlex 6000 and Bypass Cabinet (if supplied) prior to removing Lockout and Tagout provisions and closing the input circuit breaker. All safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed when removing the input circuit breaker from the locked out, tagged out state.

The No-load Test consists of the following procedures and must be performed in the sequence shown.

Sequence Procedure Page

1 Energize Drive Control Circuit 90

2 Configure P and T Parameters 90

Only

3 Close Isolation Switches in Bypass Cabinet

4 Close Input Circuit Breaker

5 Check Cooling Fan Operation 103

6 Operate Motor by HMI 104

(1) This procedure is performed only if an optional bypass configuration is supplied.

(1)

102

103

WARNING: These procedures must be performed in the order they are listed here. Failure to do so may result in personal injury or death, property damage, or economic loss.

ATT EN TI ON : Isolation switches in bypass cabinets can only be opened or closed when the Input Circuit Breaker is in the open position. Isolation Switches must not be operated when the Input Circuit Breaker is closed.

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Chapter 5 No-load Test

TIP

Energize Drive Control Circuit

The “Energize Control Circuit” process is already described on page 48. For the “Energize Drive Control Circuit” procedure, repeat the process in the same sequence, without the requirements of taking voltage measurements.

1. Close circuit breaker Q1 (CB1).

2. Start UPS. Press and hold the ON button for approximately 3 seconds.

3. Close circuit breakers Q2 (CB2), Q3 (CB3), Q5 (CB5), and Q6 (CB6) in

the LV Control Panel.

4. Close circuit breakers Q4 (CB4) and Q7 (CB7) in the Isolation Tra ns fo rm er Ca bi ne t LV P an e l .

Configure P and T Parameters

See Set P Parameters to Enable Testing on page 55 for information on how to access and change parameters.

Set the P parameters as shown in Ta b l e 1 8 , and T parameters as shown in

Ta b l e 1 9

This table outlines the specific parameters that must be checked and/or modified. Parameters that must be modified are outlined in the Instruction column. All other parameters listed must be verified. For special functions or actions which are not listed here, but are commonly performed while commissioning a drive, see Special Function Parameter Settings

Table 18 - Setup and R&D P Parameters

Parameter Number

P004 Command Source

P005 Restore Factory Settings

P007 Nu mber of Power Cells Per P hase 0 9 9 ON

P008 Motor Rotation Direction Under Local Control

P009 Motor Rotation Direction Command Selection:

P010 Power Cell Fault Mask 0 32767 32767 ON

P017 Number Of Motor Pole Pairs 0 100 2 OFF

P019 Encoder Resolution 0 4096 1024 OFF

Description Min. Max. Default Modify

020OFF

0 = Communication Port 1 = Digital Input 2 = EtherNet/IP

0500OFF

30 = Restore Setup Level 40 = Restore User Level 50 = Restore R&D Level

011OFF

0 = Reverse 1 = Forward

010OFF

0 = Local Control 1 = DCS

on page 117.

Root

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Table 18 - Setup and R&D P Parameters (Continued)

No-load Test Chapter 5

Parameter Number

P020 Mask Bit For System Fault 0 32767 32767 ON

P021 Mask Bit For System Warning 0 32767 32767 ON

P022 Mask Bit For Logic Fault A 0 32767 32767 ON

P023 Mask Bit For Logic Fault B 0 32767 32767 ON

P024 Stop Method

P025 Flux Reduction Enable

P026 Power Angle Threshold For Flux Reduction 0 180 0 ON

P027 Time For Flux Reducing 0 32767 5000 ON

P028 Flux Reduction Ratio 0 100 70 ON

P029 Power Angle Threshold For Flux Restore 0 180 0 ON

P030 Powercell Fault Trip Signal Mask Register 0 32767 32767 OFF

P031 System Fault Trip Signal Mask Register 0 32767 32767 OFF

P032 Logic Fault A Trip Signal Mask Register 0 32767 32767 OFF

P033 Logic Fault B Trip Signal Mask Register 0 32767 32767 OFF

P034 Current Stability Loop Filter Time 0 32767 63 ON

P035 Current Stability Loop Output Scaling Factor 0 100 20 ON

P036 Current Stability Loop Output Upper Limit 0 100 10 ON

P037 Current Stability Loop Output Lower Limit -100 100 -10 ON

P038 Current Stability Loop Enable

P039 Current Stability Loop Enable Frequency Range Upper

P040 Safe Start Condition

P087 Switch Frequency Setting Enable Code

P088 Switch Frequency Setting

P089 Skip Frequency Enable

P090 Skip Frequency 1 Lower Limit 0 75 0 ON

P091 Skip Frequency 1 Upper Limit 0 75 0 ON

P092 Skip Frequency 2 Lower Limit 0 75 0 ON

P093 Skip Frequency 2 Upper Limit 0 75 0 ON

P113 Flying Start-Initial Output Voltage 0 100 5 ON

Description Min. Max. Default Modify

Root

010ON

0 = Ramp Dow 1 = Coast Stop

010ON

0 = Disable 1 = Enable

011ON

0 = Disable 1 = Enable

0 100 40 ON

Limit

011OFF

0 = Zero Frequency Command Required 1 = Frequency Command Allowed

010OFF

0 = Disable 1 = Enable

010OFF

0 = 600 Hz 1 = 1200 Hz

010ON

0 = Disable 1 = Enable

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Chapter 5 No-load Test

Table 18 - Setup and R&D P Parameters (Continued)

Parameter Number

P114 Flying Start-Current Comparison Delay For Motor Speed

P115 Flying Start-Current Threshold For Successful Motor

P198 HECS Rated Current 0 5000 0 ON

P199 Motor Rated Current 0 5000 0 ON

P200 Ia Motor Current Memory Address 0 500 13 ON

P201 Motor Ia Scaling Correction Factor 0.00 199.99 100.00 ON

P202 Ib Motor Current Memory Address 0 500 14 ON

P203 Motor Ib Scaling Correction Factor 0.00 199.99 100.00 ON

P204 Motor Uab Voltage Address 0 500 11 ON

P205 Motor Uab Voltage Scaling Factor Correction 0.00 199.99 199.99 ON

P206 Motor Uac Voltage Scaling Factor Correction 0.00 199.99 199.99 ON

P208 Phase Over Current Enable Frequency Range Upper Limit 0 100 10 ON

P209 Phase Over Current Filter Time 0 32767 5 ON

P210 Phase Over Current Threshold 0 199.99 180 ON

P211 Filter Time For Abnormal Output Voltage 0 32767 1000 ON

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

P213 Output Short-Circuit Fault Threshold 0 199.99 180 ON

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

P215 Filter Time For Output Over Current 0.0 3276.7 20.0 ON

P216 High-Frequency Output Over Current Threshold 0.00 199.99 120.00 ON

P217 Low-Frequency Output Over Current Threshold 0.00 199.99 70.00 ON

P218 Filter Time For Motor Over Temperature 0.0 3276.7 600.0 ON

P219 Motor Over Temperature Warning Threshold 0.00 199.99 110.00 ON

P220 Motor Over Temperature Fault Threshold 0.00 199.99 120.00 ON

P221 Filter Time For Output Over Voltage 0 32767 100 ON

P222 Output Over Voltage Fault Threshold 0.00 199.99 130.00 ON

P223 Output Voltage Deviation Warning Threshold 0.00 199.99 60.00 ON

P224 Output Voltage Deviation Fault Threshold 0.00 199.99 80.00 ON

P225 Motor Over Temperature Warning Cancellation

P226 Output Voltage Abnormality Warning Cancellation

P227 Ground Fault Detection Scaling Correction Factor 0.00 199.99 100.00 ON

P228 Filter Time For Ground Fault 0 32767 1000 ON

P229 Ground Fault Warning Threshold 0.00 199.99 20.00 ON

P230 Ground Fault Trip Threshold 0.00 199.99 60.00 ON

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

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

Description Min. Max. Default Modify

0 5000 1000 ON

01005ON

Speed Search

0.00 199.99 100.00 ON

Temperature

0.00 199.99 50.00 ON

Threshol d

Root

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Table 18 - Setup and R&D P Parameters (Continued)

No-load Test Chapter 5

Parameter Number

P233 Threshold Of Over-Speed Fault At Lower Frequency Limit 0.00 199.99 20.00 ON

P234 Threshold Of Over-Speed Fault At Upper Frequency Limit 0.00 199.99 20.00 ON

P235 Frequency Deviation Warning Cancellation Threshold 0.00 199.99 0.99 ON

P236 Frequency Deviation Warning Threshold 0.00 199.99 6.00 ON

P237 Frequency Deviation Warning Delay 0 32767 8 ON

P238 Motor Stall Fault Threshold 0.00 199.99 10.00 ON

P239 Motor Stall Fault Delay 0 32767 6000 ON

P240 Transformer Over Temperature Fault Delay 0 32767 5000 ON

P241 Transformer Over Temperature Warning Delay 0 32767 5000 ON

P247 Software Interlock

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

P251 Frequency Command-Low Frequenc y Region Boundary 0.0 100.0 0.5 ON

P252 Motor In Stopping Condition Threshold 0 100 1 ON

P253 Motor Coast Stop Time 0 10000 10 ON

P256 Ground Fault Warning Cancellation Threshold 0.00 199.99 10.00 ON

P257 Motor Stall Warning Cancellation Threshold 0.00 199.99 2.98 ON

P259 Frequency Command Analog Offset -100.00 199.99 0.00 ON

P260 Frequency Command Analog Scaling Factor 0.00 199.99 100.00 ON

P261 Frequency Command Analog Minimum 0.00 199.99 0.49 ON

P262 Frequency Command Source Selection

P263 Power Loss Restart Enable

P264 Power Loss Allowable Time 0.00 3599.96 59.63 OFF

P265 Power Loss Time Max Limit 0.00 3599.96 299.82 OFF

P268 Flux Control Signal Filter Time 0.00 13499.96999.97 ON

Description Min. Max. Default Modify

Root

011ON

0 = Enable 1 = Disable

010OFF

0 = Digital 1 = Analog

010OFF

0 = Disable 1 = Enable

P269 System Derating Control Signal Filter Time 0.00 13499.96999.97 ON

P270 Delayed Lockout Time Of Stop Operation 0 5000 2000 ON

P271 Flux Delay 0 5000 50 ON

P272 Flux Control Regulation Time 0.96 999.97 0.96 ON

P273 Flux Control Regulation Control Enable

0 = Disable 1 = Enable

P275 Flux Control Regulation Acceleration Threshold 100.00 199.99 100.00 ON

P276 Derating Control No-Load Modulation Index 50 100 80 ON

P277 Derating Control Full-Load Modulation Index 50.00 199.99 81.99 ON

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Page 94

Chapter 5 No-load Test

Table 18 - Setup and R&D P Parameters (Continued)

Parameter Number

P278 Derating Control Enable Threshold 50.00 199.99 100.00 ON

P279 Derating Control Output Filter Time 9.95 1999.94 9.95 ON

P280 Low Voltage Ride Through Recovery Voltage Boost

P281 Low Voltage Ride Through Min Time Interval 0.00 1000.00 9.97 ON

P282 Low Voltage Ride Through Min Frequenc y Limit 5 100 20 OFF

P283 Low Voltage Ride Through Enable

P284 Low Voltage Ride Through Min Time Limit 20.02 13663.0139.62 OFF

P285 Low Voltage Ride Through Max Time Limit 20.02 13663.0199.66 OFF

P286 Low Voltage Ride Through Recovery Frequency

P287 Low Voltage Ride Through Recovery Time 145.95 13663.011499.95 OFF

P288 Low Voltage Ride Through System Delay Correction

P289 Low Voltage Ride Through Motor Speed Estimation Filter

P290 Voltage Loop Enable

P291 Voltage Loop Enable Min Frequency 0 100 20 OFF

P292 Voltage Loop Proportional Coefficient 99.98 1999.94 899.96 ON

P293 Voltage Loop Integral Coefficient 0.00 99.98 19.96 ON

P294 Voltage Loop Positive Incremental Error Limit 20.02 1000.00 49.99 ON

P295 Voltage Loop Negative Incremental Error Limit 20.02 1000.00 99.98 ON

P296 Reserved 49.99 1000.00 0.00 ON

P297 Voltage Loop Voltage Reference 125.00 1200.12 1000.00 ON

P298 Voltage Loop Current Filter Time 0.00 1999.94 9.95 ON

P299 Voltage Loop Voltage Filter Time 0.00 1999.94 2.99 ON

P300 Digital Output #0 Memory Address 0 500 99 ON

P301 Digital Output #0 Logic

P302 Digital Output #0 Bit Selection 0 15 0 ON

P303 Digital Output #0 Delay 0 32767 0 ON

P304 Digital Output #1 Memory Address 0 500 99 ON

P305 Digital Output #1 Logic

P306 Digital Output #1 Bit Selection 0 15 1 ON

P307 Digital Output #1 Delay 0 32767 0 ON

Description Min. Max. Default Modify

Root

0 100 10 ON

Coefficient

010ON

0 = Disable 1 = Enable

-200.00 199.99 0.00 OFF

Compensation Factor

0.00 10000.002199.97 ON

Fac tor

0.98 1000.00 9.95 OFF

Time

010OFF

0 = Disable 1 = Enable

010ON

0 = Non-Inverting 1 = Inverting

010ON

0 = Non-Inverting 1 = Inverting

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Table 18 - Setup and R&D P Parameters (Continued)

No-load Test Chapter 5

Parameter Number

P308 Digital Output #2 Memory Address 0 500 99 ON

P309 Digital Output #2 Logic

P310 Digital Output #2 Bit Selection 0 15 2 ON

P311 Digital Output #2 Delay 0 32767 0 ON

P312 Digital Output #3 Memory Address 0 500 99 ON

P313 Digital Output #3 Logic

P314 Digital Output #3 Bit Selection 0 15 3 ON

P315 Digital Output #3 Delay 0 32767 0 ON

P316 Digital Output #4 Memory Address 0 500 99 ON

P317 Digital Output #4 Logic

P318 Digital Output #4 Bit Selection 0 15 4 ON

P319 Digital Output #4 Delay 0 32767 0 ON

P320 Digital Output #5 Memory Address 0 500 99 ON

P321 Digital Output #5 Logic

P322 Digital Output #5 Bit Selection 0 15 5 ON

P323 Digital Output #5 Delay 0 32767 0 ON

P324 Digital Output #6 Memory Address 0 500 99 ON

P325 Digital Output #6 Logic

P326 Digital Output #6 Bit Selection 0 15 6 ON

P327 Digital Output #6 Delay 0 32767 0 ON

P328 Digital Output #7 Memory Address 0 500 99 ON

P329 Digital Output #7 Logic

P330 Digital Output #7 Bit Selection 0 15 7 ON

P331 Digital Output #7 Delay 0 32767 0 ON

P332 Analog Output #1 Memory Address 0 500 252 ON

P333 Analog Output #1 Filter Time 0 32767 1000 ON

P334 Analog Output #1 Offset -100 100 0 ON

P335 Analog Output #1 Scaling Factor 0.00 199.99 100.00 ON

P336 Analog Output #2 Memory Address 0 500 206 ON

P337 Analog Output #2 Filter Time 0 32767 1000 ON

P338 Analog Output #2 Offset -100 100 0 ON

Description Min. Max. Default Modify

Root

010ON

0 = Non-Inverting 1 = Inverting

010ON

0 = Non-Inverting 1 = Inverting\

010ON

0 = Non-Inverting 1 = Inverting

010ON

0 = Non-Inverting 1 = Inverting

010ON

0 = Non-Inverting 1 = Inverting

010ON

0 = Non-Inverting 1 = Inverting

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Chapter 5 No-load Test

Table 18 - Setup and R&D P Parameters (Continued)

Parameter Number

P339 Analog Output #2 Scaling Factor 0.00 199.99 100.00 ON

P340 Analog Output #3 Memory Address 0 500 0 ON

P341 Analog Output #3 Filter Time 0 32767 1000 ON

P342 Analog Output #3 Offset -100 100 0 ON

P343 Analog Output #3 Scaling Factor 0.00 199.99 100.00 ON

P344 Analog Output #4 Memory Address 0 500 0 ON

P345 Analog Output #4 Filter Time 0 32767 1000 ON

P346 Analog Output #4 Offset -100 100 0 ON

P347 Analog Output #4 Scaling Factor 0.00 199.99 100.00 ON

P351 Rated Frequency HMI Display Filter Time 0 32767 100 ON

P352 Rated Frequency HMI Display Integer Part 0 75 50 ON

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

P354 Motor Voltage HMI Display Filter Time 0 32767 2000 ON

P355 Motor Voltage HMI Display Integer Part 0 16384 10000 ON

P356 Motor Voltage HMI Display Decimal Part 0 1000 0 ON

P357 Actual Frequency HMI Display Filter Time 0 32767 100 ON

P358 Actual Frequency HMI Display Integer Part 0 75 50 ON

P359 Actual Frequency HMI Display Decimal Part 0 1000 0 ON

P360 Motor Current HMI Display Filter Time 0 32767 2000 ON

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

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

P371 Rated Frequency HMI Display Address 0 500 221 ON

P372 Motor Voltage HMI Display Address 0 500 119 ON

P373 Actual Frequency HMI Display Address 0 500 252 ON

P374 Motor Current HMI Display Address 0 500 118 ON

P375 Frequency At First Point for 5 Point VF 0 10 1 OFF

P376 Amplitude At First Point for 5 Point VF 0 3 1 OFF

P377 Frequency At Second Point for 5 Point VF 0 100 20 OFF

P378 Amplitude At Second Point for 5 Point VF 0 100 10 OFF

P379 Frequency At Third Point for 5 Point VF 0 100 40 OFF

P380 Amplitude At Third Point for 5 Point VF 0 100 27 OFF

P381 Frequency At Fourth Point for 5 Point VF 0 100 60 OFF

P382 Amplitude At Fourth Point for 5 Point VF 0 100 45 OFF

P383 Frequency At Fifth Point for 5 Point VF 0 100 80 OFF

P384 Amplitude At Fifth Point for 5 Point VF 0 100 70 OFF

P385 Deceleration Process Enable

P386 Deceleration Time 1 0 3276 150 ON

Description Min. Max. Default Modify

Root

010OFF

0 = Disable 1 = Enable

96 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 97

Table 18 - Setup and R&D P Parameters (Continued)

No-load Test Chapter 5

Parameter Number

P387 Deceleration Frequency 1 0 75 30 ON

P388 Deceleration Time 2 0 3276 80 ON

P389 Deceleration Frequency 2 0 75 20 ON

P390 Deceleration Time 3 0 3276 80 ON

P391 Deceleration Frequency 3 0 75 10 ON

P392 Deceleration Time 4 0 3276 100 ON

P399 Deceleration Time 0 3276 400 ON

P401 Acceleration Time 0 3276 200 ON

P402 Acceleration Ramp Transition Time 0 3276 3 ON

P403 Acceleration Time Unit

P405 Deceleration Ramp Transition Time 0 3276 3 ON

P406 Deceleration Time Unit

P409 Amplification Coefficient Of Error Terms 0.00 199.99 100.00 ON

P411 Over Speed Upper Limit Reference 0 100 100 ON

P412 Over Speed Lower Limit Reference 0 100 0 ON

P413 Frequency Command Lower Limit -16384 16384 0 ON

P414 Frequency Command Deadband Upper Limit 0.00 100.00 0.49 ON

P415 Frequency Command Upper Limit -16384 16384 16384 ON

P416 Flying Start Mode

P417 Flying Start Motor Speed Search Timeout 0 1000 50 ON

P438 Current Limitation Enable Frequency Range Lower Limit 0 100 10 ON

P439 Current Limitation Upper Offset 0 10 3 ON

P440 Current Limitation Lower Offset 0 10 3 ON

P441 Current Limitation Threshold 0 130 100 ON

P451 Low Speed Voltage Compensation 0.00 3.00 0.99 OFF

P452 Low Speed Voltage Compensation Frequency Threshold 0 100 20 ON

P453 V/F Curve

P454 Flux Time (s) 0.0 10.0 0.5 OFF

P455 Modulation Index 0.00 110.00 87.99 ON

P456 Motor Voltage Upper Limit 0.00 110.00 87.99 ON

P457 Flying Start Voltage Recovery Time (Low Speed Region) 0.00 163.84 5.00 ON

Description Min. Max. Default Modify

00.10.1ON

1000 = 0.01 s 10000 = 0.1s

00.10.1ON

1000 = 0.01 s 10000 = 0.1s

030ON

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

0 = Linear 1 = Parabolic Curve 2 = Predefined Cur ve #1 3 = Predefined Cur ve #2 4 = 5 Point VF

04 (R&D)

3 (Setup)

1OFF

Root

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 97

Page 98

Chapter 5 No-load Test

Table 18 - Setup and R&D P Parameters (Continued)

Parameter Number

Description Min. Max. Default Modify

Root

P458 Coefficient A 0 100 40 OFF

P459 Flying Star t Voltage Recovery Time (High Spe ed Region) 0 163.84 5 ON

P460 Rated Output Frequency 0 75 50 OFF

P461 Restart Enable

010ON

0 = Disable 1 = Enable

P462 Fault Reset Timeout 0 120 120 ON

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

P465 Power Cell Fault Auto Reset Delay 0 10 4 ON

P466 Maximum Output Frequency 0 75 50 OFF

P467 Over Speed Enable

010OFF

0 = Disable 1 = Enable

P470 Version Compatibility Enable

011OFF

0 = Disable 1 = Enable

P497 Major Rev # Of DSP Main Firmware —— —— 0 Cannot

Modify

P498 Minor Rev # Of DSP Main Firmware —— —— 2 Cannot

Modify

P499 Display Fault Masks Button

010ON

0 = Disable 1 = Enable

P500 Display DSP Variables 0 1 0 ON

There are no specific T parameters to modify when commissioning a drive. Verify the values and only modify per customer specifications.

Table 19 - Setup and R&D T Parameters

Parameter Number

T01 Fault-To-Bypass

T02 Fault-To-Bypass Delay (0...5s) 3 Yes 16-bit Unsigned Integer

T03 Fault-To-Bypass Delay When Starting the Motor

T04 Fault-To-Bypass Minimum Frequency

T07 Local Frequency Command Selection

T08 Remote Frequency Command Selection

T09 Frequency Step For Accel or Decel 1 Yes 16-bit Unsigned Integer

Description Default

Value

0 Yes B oolean 0 = Disable 1 = Enable

60 Yes 16-bit Unsigned Integer (0...60s)

5 Yes 32-bit Float

0...Rated Frequency (Hz)

0 Yes B oolean 0 = Digital 1 = Analog

1 Yes 16-bit Unsigned Integer 1 = Analog 2 = 4-Step Speed 4 = Communication Port

Modify Root

Data Type

98 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Page 99

Table 19 - Setup and R&D T Parameters (Continued)

No-load Test Chapter 5

Parameter Number

T10 Exit To Configuration Mode Password 555 No 16-bit Unsigned Integer

T11 Automatic Bypass-To-Drive or

T12 PID Parameter Settings

T13 4-Step Variable Speed (available only when T8 = 2)

T14 One-Drive-Two-Motor Mode, QS Enable

T15 Bypass Mode Selection (0...4) 0 Operation Button

T16 When Disconnected between

Description Default

Value

0 Operation Button

Drive-To-Bypass Selection

Bypass-To -Drive Yes

Drive-To-Bypass Yes

P 0.01 Yes 32-bit Float

I 0.01 Yes 32-bit Float

D 0 Yes 32-bit Float

D Gain 0 Yes 32-bit Float

Speed 1 10 Yes 32-bit Float

Speed 2 20 Yes 32-bit Float

Speed 3 30 Yes 32-bit Float

Speed 4 40 Yes 32-bit Float

1 Yes B oolean 0 = No 1 = Yes

No Bypass Yes

Manual Bypass, One-Drive-One-Motor Yes

Auto Bypass, One-Drive-One-Motor Yes

Manual Bypass, One-Drive-Two-Motor Yes

Auto Bypass, One-Drive-Two-Motor Yes

1 Yes 16-bit Unsigned Integer 0 = Stop 1 = Keep Current Frequency 2 = Keep T13, Speed 1 3 = Keep T13, Speed 2 4 = Keep T13, Speed 3 5 = Keep T13, Speed 4

Modify Root

Data Type

ATT EN TI ON : If you enter a value that is greater than the allowed range for the

parameter, the input field will turn red.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 99

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Chapter 5 No-load Test

Change Parameters T11...T13

Parameter T11

To change Parameter T11:

1. Press the T11 Parameter input field.

2. In the Operation Mode dialog, press or .

3. If you select , the:

• drive must be set to Local Control

• position switch must be set to Drive

• bypass contactor must be ON

• drive must not be running.

4. If you select , the:

• drive must be set to Local Control

100 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Rockwell Automation Allen-Bradley PowerFlex 6000 Commissioning Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual

Important User Information

Table of Contents

Preface

Introduction

Who Should Use This Manual

What Is Not in This Manual

Required Supplemental Information

Dimensional Drawings and Electrical Drawings

Shipping, Handling, and Installation Manual

General Precautions

Additional Resources

Overview

Documentation and Application Review

Review all Rockwell Automation Supplied Documentation

Pre-commissioning Customer Meeting

Review Drive Application

Gather Required Tools and Test Equipment

Lockout and Tagout

Inspect Drive Components

Functional Assessment

Interconnection Review

Installation Review

Mechanical Installation Inspection

Electrical Installation Inspection

Power Cabling

Control Wiring

Drive Megger Check

Isolate the Power and Control Circuits

Connect the Insulation Meter

Final Steps before Equipment is Ready for Energization

Seal the Cabinet Plates

Gather Required Tools and Test Equipment

Lockout and Tagout

Inspect Drive Components

Functional Assessment

Interconnection Review

Installation Review

Mechanical Installation Inspection

Electrical Installation Inspection

Power Cabling

Control Wiring

Drive Megger Check

Isolate the Power and Control Circuits

Connect the Insulation Meter

Final Steps before Equipment is Ready for Energization

Seal the Cabinet Plates

Introduction

Control System Check Setup

Simulate Closed Input Circuit Breaker

Energize Control Circuit

Control System Check

Verify Factory Default Settings

Set P Parameters to Enable Testing

Verify Settings for Low-Voltage Testing

Verify Operation of Frequency Steps

Verify Operation to Set Frequency

Simulate Warnings and Faults

Verify E-Stop Functionality

Verify Switching from Local Control to Remote Control

Verify Operation of Input/Output and Bypass Isolation Switches (Manual Bypass)

Verify Operation of Input/Output and Bypass Contactors (Automatic Bypass)

Verify Operation of DCS Input and Output Signals

Restore P Parameter Settings

Set Date and Time Zone

Access T Parameters

Change Time/Date/Regional Settings

No-load Test

Introduction

Energize Drive Control Circuit

Configure P and T Parameters

Change Parameters T11...T13