Allen-Bradley PowerFlex 6000 Manuel utilisateur

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Publication 6000-UM002E-EN-P

User 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 Automation, Rockwell Software, PanelView Plus, 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-UM002E-EN-P - April 2018 3

Table of Contents

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

Preface

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

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

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

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Product Environmental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Introduction

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cascaded “H” Bridge (CHB) Topology . . . . . . . . . . . . . . . . . . . . . . . . 12

Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Standards Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2

Drive System Layout

Elevation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Isolation Transformer Temperature Monitor . . . . . . . . . . . . . . . . . . . 23

Top-mounted Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Incoming Line Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . 25

Outgoing Motor Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Power Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Hall Effect Current Sensors (HECs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Top-mounted Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Control Unit (all modules). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4Rockwell Automation Publication 6000-UM002E-EN-P - April 2018

Table of Contents

Chapter 3

Setup and Operation

Main Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Drive Setup and Configuration Controls . . . . . . . . . . . . . . . . . . . . . . . 39

Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Operation Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Setup and Monitor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Main Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Set Frequency (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Drive Operation Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

View Version Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Alarm History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

View Voltage, Current or Frequency Trends . . . . . . . . . . . . . . . . . . . . 50

Customize a Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Confirm Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Choose Local/Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Open/Close Drive Input and Output Contactors . . . . . . . . . . . . . . . 57

Open/Close Bypass Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

User Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Change User Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 4

Parameters and Function Codes

P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Chapter 5

Preventative Maintenance and

Component Replacement

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Clean the Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Regular Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Physical Checks (No Medium Voltage or Control Power) . . . . . . . . . . . 90

Power Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Medium Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Replace/Clean Door Mounted Air Filters. . . . . . . . . . . . . . . . . . . . . . . 92

Inspect Top Mounted Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Replace Top Mounted Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Inspect Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Inspect Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 5

Table of Contents

Replace Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Inspect Door Position Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Replace Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Inspect, Clean, or Replace Door Mounted Air Filters. . . . . . . . . . . 101

Inspect or Replace Top Mounted Cooling Fans . . . . . . . . . . . . . . . . 101

Inspect Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Replace Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Replace Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Inspect or Replace HECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Inspect or Replace Door Position Limit Switch . . . . . . . . . . . . . . . . 109

LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Inspect AC/DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replace AC/DC Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Inspect UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Replace UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Inspect PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Inspect/Replace Control Unit or Control Boards . . . . . . . . . . . . . . 115

Inspect the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Replace the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Replace LV Control Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Replace LV Control Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 122

Inspect Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Inspect Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Inspect Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Inspect Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . 124

Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Inspect LV Component Terminal and Plug-in Connections . . . . 125

Inspect Medium Voltage Cable Connections . . . . . . . . . . . . . . . . . . 125

Inspect Power Cable and Control Wire Terminals . . . . . . . . . . . . . 125

Inspect Transformer Secondary Windings. . . . . . . . . . . . . . . . . . . . . 125

Inspect Power Module Input and Output Power Connections . . 126

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Review Firmware and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Inspect/Review Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Professional Maintenance Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Miscellaneous Preventive Maintenance Work. . . . . . . . . . . . . . . . . . 127

Tools/Materials/Documentation Requirements . . . . . . . . . . . . . . . 128

Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Prepare Final Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6Rockwell Automation Publication 6000-UM002E-EN-P - April 2018

Table of Contents

Appendix A

Technical Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Appendix B

Catalog Number Explanation

PowerFlex 6000 Medium Voltage Variable Frequency Drives . . . . . . . 133

Appendix C

Preventative Maintenance Schedule

PowerFlex 6000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Appendix D

Torque Requirements

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 7

Preface

Introduction This document provides procedural information for managing daily or recurring

tasks involving PowerFlex® 6000 medium voltage variable frequency drives.

Who Should Use This Manual This manual is intended for use by personnel familiar with operating medium

voltage and solid-state variable speed drive equipment. The manual contains

material that enables operation and regular maintenance of the drive system.

What Is Not in This Manual This manual provides information specific to maintaining the PowerFlex 6000

medium voltage variable frequency drive. It does not include topics such as:

•Dimensional and electrical drawings generated for each customer’s order

•Spare parts lists compiled for each customer’s order

Please refer to the following documents for additional product detail or

instruction relating to PowerFlex 6000 drives:

•PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation

Manual, publication 6000-IN006; instructions for installing the drive,

dimensions, requirements, and wiring information.

•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 Firmware,

Parameter, and Troubleshooting Manual, publication 6000-TD004. This

document provides detailed information on drive features, parameters, and

troubleshooting faults.

Rockwell Automation provides the site- and installation-specific electrical and

design information for each drive during the order process cycle. If they are not

available on site with the drive, contact Rockwell Automation.

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

Resource Description

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Installation Manual, publication 6000-IN006

Provides instructions for installing the drive,

dimensions, requirements, and wiring information.

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.

8Rockwell Automation Publication 6000-UM002E-EN-P - April 2018

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.

General Precautions

Service and Support Commissioning Support

After installation, Rockwell Automation is responsible for commissioning

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

Automation sales representative to arrange commissioning.

Rockwell Automation support includes, but is not limited to:

•quoting and managing product on-site start-ups

•quoting and managing field modification projects

•quoting and managing customer in-house and on-site product training

PowerFlex 6000 Medium Voltage Variable 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, http://www.ab.com Provides declarations of conformity, certificates, and

other certification details.

Resource Description

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.

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 9

Preface

The user or its representatives are responsible for pre-commissioning activities to

prepare the drive for commissioning. Failure to complete these activities prior to

the commissioning process will delay the start-up of the drive. Refer to the

Pre-commissioning Checklist in the PowerFlex 6000 Medium Voltage Variable

Frequency Drive Installation Manual, publication 6000-IN006.

Product Environmental

Information

Rockwell Automation maintains current product environmental information on

its website at:

http://www.rockwellautomation.com/rockwellautomation/about-us/

sustainability-ethics/product-environmental-compliance.page

10 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018

Preface

Notes:

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