Rockwell Automation 6000G Bedienungsanleitung

PowerFlex 6000 Medium

Voltage Variable Frequency

Drive

Catalog Number 6000G

Installation Instructions Original Instructions

2Rockwell Automation Publication 6000-IN006H-EN-P - October 2020

PowerFlex 6000 Medium Voltage Variable Frequency Drive 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.

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-IN006H-EN-P - October 2020 3

Table of Contents

Preface

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

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

What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Contractor Scope of Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 1

Drive Mechanical Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Connect DV/DT Filter Cabinet for A-Frame Drives . . . . . . . . . . . . 11

Connect Cabinets for H-Frame and B-Frame Drives . . . . . . . . . . . . 13

Affix Cabinets to Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Install Seismic Rated Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Install A-Frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Install B-Frame Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Install Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Install the Cooling Fan and Noise Reduction Barrier for A-Frame

Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Install the Mixing Hood for A-Frame Drives. . . . . . . . . . . . . . . . . . . . 31

Install Power Modules (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Power Module Lift Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Install Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Install Power Modules for A-Frame Drives . . . . . . . . . . . . . . . . . . . . . 34

External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 2

Drive Electrical Installation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Grounding System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Motor Cable Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Control Signal Wiring Design Considerations. . . . . . . . . . . . . . . . . . . . . . 43

Control Signal Wire Shield Grounding. . . . . . . . . . . . . . . . . . . . . . . . . 43

Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Connect the System Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 46

4Rockwell Automation Publication 6000-IN006H-EN-P - October 2020

Table of Contents

Connect Incoming Line and Outgoing Motor Power Cables . . . . . . . . . 46

Connect Cables for A-Frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connect Cables for H-Frame and B-Frame Drives. . . . . . . . . . . . . . . 49

Connect Control Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Wiring Routing and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Connect External Control Signal Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Analog and Digital I/O Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Wiring Routing and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 54

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

MV Door Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 3

Drive Electrical Interconnection

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Electrical Interconnection Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . . 58

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Cable Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . . 61

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Connect LV Control and Fan Wiring Bundles. . . . . . . . . . . . . . . . . . . . . . 62

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Appendix A

Pre-Commissioning

Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Inspection and Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Pre-Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Appendix B

Torque Requirements

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix C

General Wire Categories

General Wire Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Appendix D

Power Cabling and Control Signal

Wiring Details

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 76

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 5

Table of Contents

Appendix E

Line and Load Cable Sizes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6Rockwell Automation Publication 6000-IN006H-EN-P - October 2020

Table of Contents

Notes:

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 7

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 that are generated for each

customer’s order.

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

•Drive-specific technical specifications.

See 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, and maintenance tasks for the product’s end user.

•PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware,

Parameters, and Troubleshooting 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 necessary.

8Rockwell Automation Publication 6000-IN006H-EN-P - October 2020

Preface

General Precautions

Summary of Changes This publication contains the following new or updated information. This list

includes substantive updates only and is not intended to reflect all changes.

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, startup, and subsequent maintenance of the system. Failure to

comply may result in personal injury and/or equipment damage.

ATTENTION: Only qualified personnel with the correct PPE (Personal Protective

Equipment) should service the equipment. Be sure to follow the safety

procedures and local regulations to disconnect the high voltage. After waiting

for 15 minutes, open the cabinet door and verify the absence of medium

voltage on the input, output, and power cell terminals with a high-voltage

detector that is properly rated for the line and motor voltages. All LED lights on

the power cells must be off and the drive be grounded with portable grounding

cables on the input and output before servicing. Failure to follow the safety

procedures can result in severe injury or death.

Topic Page

Updated table Cable Insulation Requirements for Outgoing Motor Cables 41

Updated Important information under Power Cable Design Considerations 42

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 9

Preface

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at rok.auto/literature. To order paper

copies of technical documentation, contact your local Allen-Bradley distributor

or Rockwell Automation sales representative.

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 startups

•quoting and managing field modification projects

•quoting and managing product training at Rockwell Automation facilities

and on-site

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

customer (based on ex-works Incoterms)(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

Resource Description

PowerFlex 6000 MediumVoltageVariable Frequency Drive

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

MediumVoltage variable frequency drive and related

equipment.

PowerFlex 6000 MediumVoltageVariable Frequency Drive

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

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

PowerFlex 6000 MediumVoltageVariable Frequency Drive

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

parameters, and troubleshooting faults.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1 Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and

other certification details.

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

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

(2) Customer should lead the initial inspection process.

10 Rockwell Automation Publication 6000-IN006H-EN-P - October 2020

Preface

•Install assemblies shipped loose (fan assemblies).

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

necessary)

•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(1)

•Complete Pre-commissioning Checklist

(1) 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 before the commissioning process.

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