Rockwell Automation Allen-Bradley PowerFlex 6000 Kurzanleitung

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Commissioning Manual

Publication 6000-IN007B-EN-P

Commissioning Manual

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-IN007B-EN-P - March 2016 3

Table of Contents

Preface

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

Introduction

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

Preparation and Inspection (For IEC)

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

Chapter 3

Preparation and Inspection (For UL)

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

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

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

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

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

Table of Contents

Appendix B

Single Line Diagrams

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

Appendix C

Special Function Parameter Settings

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

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

Table of Contents

Notes:

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

Preface

Introduction This document provides procedural information for commissioning

PowerFlex® 6000 medium voltage drives with version 4.001 firmware.

Who Should Use This Manual 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.

What Is Not in This Manual 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.

WARNING: This document is for internal use only (for Rockwell CSM/field

support Engineers). DO NOT disclose this document to customers or any non-

Rockwell Automation employee. Disclosure of sensitive information in this

document may cause dire consequences to the drive.

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)

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

Preface

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.

Table 2 - Dimensional Drawings

Control and Medium Voltage Power Ratings

Drive Options

Motor Ratings

Drive Power Component Selection Ratings

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

Preface

General Precautions

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

ATTENTION: 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.

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

Industrial Automation Wiring and 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.

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

Preface

Notes:

Andere Handbücher für Allen-Bradley PowerFlex 6000

Inhaltsverzeichnis

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