Allen-Bradley PowerFlex 6000 User manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Installation Manual

Publication 6000-IN006F-EN-P

Installation Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

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.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

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).

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 3

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Preface

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Contractor Scope of Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1

Drive Mechanical Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Affix Cabinets to Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Install Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Install Power Modules (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power Module Lift Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Install Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 2

Drive Electrical Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Grounding System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Motor Cable Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Control Signal Wiring Design Considerations. . . . . . . . . . . . . . . . . . . . . . 27

Control Signal Wire Shield Grounding. . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Connect the System Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 29

Connect Incoming Line and Outgoing Motor Power Cables. . . . . . . . . 29

Connect Control Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wiring Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Connect External Control Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Analog and Digital I/O Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Wiring Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 35

4Rockwell Automation Publication 6000-IN006F-EN-P -March 2018

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MV Door Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Chapter 3

Drive Electrical Interconnection

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Electrical Interconnection Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . . 38

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cable Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . . 41

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Connect LV Control and Fan Wiring Bundles. . . . . . . . . . . . . . . . . . . . . . 42

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Appendix A

Pre-Commissioning

Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Inspection and Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Pre-Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Appendix B

Torque Requirements

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix C

General Wire Categories

General Wire Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Appendix D

Power Cabling and Control Signal

Wiring Details

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 55

Appendix E

Line and Load Cable Sizes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 5

Preface

Introduction This document provides procedural information for physically unloading,

moving, and installing PowerFlex® 6000 medium voltage drives.

Who Should Use This Manual This manual is intended for use by professional riggers, general contractors,

electrical contractors, or plant operations personnel familiar with moving and

siting heavy equipment. Specific experience with solid-state variable speed drive

equipment is NOT required for this part of the installation process, but is

mandatory for subsequent processes.

What Is Not in this Manual This manual provides information specific for physically unloading and situating

a PowerFlex 6000 drive. It does not include project-specific, or drive-specific

topics such as:

•Dimensional Drawings and Electrical Drawings generated for each

customer’s order.

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

•Drive-specific technical specifications.

Refer to the following documents for additional product detail or instruction

relating to PowerFlex 6000 drives:

•PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping and

Handling Manual, publication 6000-IN008: instructions for shipping and

handling a Medium Voltage variable frequency drive and related

equipment.

•PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual,

publication 6000-UM002: instructions for daily recurring drive usage,

HMI interface and maintenance tasks for the product’s end-user.

•PowerFlex 6000 Medium Voltage Variable Frequency Drive Parameter

Manual, publication 6000-TD004: detailed information on drive features,

parameters, and troubleshooting faults.

Required Supplemental

Information

This manual includes generic information about the drive cabinet layout

orientation and generic electrical connection information.

Review the project-specific Dimensional Drawings (DDs) and Electrical

Drawings (EDs) to better understand the specific drive system cabinet

orientation and wiring requirements before performing any mechanical or

electrical work. Paper copies of the DDs and EDs are placed in the document/

hardware box in the Isolation Transformer Cabinet before shipment. Contact the

local Rockwell Automation office to obtain digital copies, if required.

6Rockwell Automation Publication 6000-IN006F-EN-P - March 2018

Preface

General Precautions

Commissioning Support After installation, Rockwell Automation is responsible for commissioning

activities for the PowerFlex 6000 product line. Contact your local Rockwell

Automation sales representative to arrange commissioning.

Rockwell Automation support includes, but is not limited to:

•quoting and managing product on-site start-ups

•quoting and managing field modification projects

•quoting and managing product training at Rockwell Automation facilities

and on-site

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts

and assemblies. Staticcontrol 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.

ATTENTION: 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.

ATTENTION: 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.

Resource Description

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Shipping and Handling Manual, publication 6000-IN008 Provides instructions for shipping and handling a

Medium Voltage variable frequency drive and related

equipment.

PowerFlex 6000 Medium Voltage Variable Frequency Drive

User Manual, publication 6000-UM002 Provides instructions for daily recurring drive usage,

HMI interface and maintenance tasks for the product’s

end-user.

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Parameter Manual, publication 6000-TD004 Provides detailed information on drive features,

parameters, and troubleshooting faults.

Industrial Automation Wiringand Grounding Guidelines,

publication 1770-4.1 Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and

other certification details.

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 7

Preface

You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

Contractor Scope of Work Typical scope of work by the freight company, third-party contractor and/or

customer (based on ex-works INCO terms)(1):

•Load equipment on truck at a Rockwell Automation manufacturing

facility and transport equipment to site

•Offload equipment from truck on-site

•Perform initial inspection(2)

•Move equipment to the final installation location

•Position the cabinet sections together as shown in Dimensional Drawing

and level the cabinet lineup

•Mechanically join cabinets together

•Affix the cabinets to the floor

•Install assemblies shipped loose (fan assemblies).

•Install external ductwork to exhaust heated air from control room (if

required)

•Install power and control cabling and terminate cable connections to drive

system:

•Connect system ground cable

•Insulation Resistance (IR) testing of incoming line and outgoing motor

power cables

•Connect incoming line and outgoing motor power cables

•Connect control power wiring

•Connect all external customer required control signal wiring

•Connect electrical safety interlock control signal wiring circuit to input

circuit breaker

•Connecting the power cables and control wiring between cabinets that are

shipped separately(3)

•Complete Pre-commissioning Checklist

(1) All or part of these activities could be provided by Rockwell Automation or its representatives, based on contract INCO terms and

negotiated scope of supply/services agreement. Contact the local Rockwell Automation office for further information.

(2) Customer should lead the initial inspection process.

(3) 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 timeand cost for Rockwell Automation to perform the power cable and

control wiring interconnection work immediately prior to the commissioning process.

8Rockwell Automation Publication 6000-IN006F-EN-P - March 2018

Preface

Notes:

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 9

Chapter 1

Drive Mechanical Installation

Introduction The installation process is divided into three principal activities. The mechanical

installation process described in this chapter, the electrical installation process

described in Drive Electrical Installation on page 23, and the electrical

interconnection process described in Drive Electrical Interconnection on

page 37.

Mechanical Installation

Summary

The cabinets must be arranged as shown in the Dimensional Drawing.

Follow all applicable guidelines for siting the components before continuing with

these installation instructions.

There may be some variation in the process depending on the type and number of

drive components in your particular installation.

Connect Shipping Splits

The PowerFlex 6000 drive is shipped in two sections, the Isolation Transformer

Cabinet and Power Module/LV Control Cabinet. These two cabinets must be

connected after located in its final position. The cabinets are connected together

in 8 or 10 places (depending on the drive rating), half along the front edge of the

cabinet and half along the rear edge of the cabinet. Access to the interior of the

cabinet is required to make these connections. Access for the front connections

requires only opening the doors. Access for the rear connections requires

removing the back plates of the cabinet.

Connect Shipping Splits 9

Affix Cabinets to Floor 13

Install Main Cooling Fans 16

Install Power Modules (if applicable) 17

External Ducting 20

ATTENTION: Install the drive on a level surface (+/- 1 mm per meter

[+/- 0.036 in. per 36 in.] of drive length in all directions). If necessary, use

metal shims to level the cabinets before joining them; attempting to level after

joining may twist or misalign the cabinets.

IMPORTANT

Rear access to all cabinets is required for subsequent processes. Do not reinstall

back plates until after the conclusion of the Drive Electrical Interconnection

process.

10 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018

Chapter 1 Drive Mechanical Installation

1. Arrange the sections as directed in the Dimensional Drawings and move

the sections together.

2. Align the cabinet side sheets together at the holes for the hardware

(see step 3).

Figure 1 - Aligning Cabinets, Type A (6/6.6 kV shown)

Isolation Transformer Cabinet Power Module/LV Control Cabinet

Optional Cabinets

1. Start-up cabinet (Pre-charge cabinet)

2. Output filter cabinet

3. Bypass cabinet

4. and others

Table 1 - Sidesheet Openings

❶Front Wireway

❷U Phase Motor Cable

❸V Phase Motor Cable

❹W Phase Motor Cable

❺Ground Bus Connection

❻Voltage Sensing Board Cables

❼Isolation Transformer Secondary Cables(1)

(1) The number of Isolation Transformer secondary cables is

dependent on motor voltage class.

• 9 cables per motor phase (27 total) for 3/3.3 kV

•12 cables per motor phase (36 total) for 4.16 kV

• 15 cables per motor phase (45 total) for 6 kV

•18 cables per motor phase (54 total) of 6.6 kV

•24 cables per motor phase (72 total) for 10kV

• 27 cables per motor phase (81 total) for 11 kV

❶

❷

❸❼

❹

❺

❻

❶

❸

❼

❹

❺

❻

Front Front

❷

Side View

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