Allen-Bradley PowerFlex 6000 User manual

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:

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 11
Chapter 1
Introduction
Around the world, Allen-Bradley® PowerFlex® medium voltage drives from
Rockwell Automation have built a reputation for providing efficient and reliable
motor control for industry's most demanding applications. From the hardware
designed to help optimize production to the power of networked control
platforms, users can quickly and easily gain access to valuable information from
their systems. Better information leads to higher asset availability, reduced energy
and maintenance costs, and asset and personnel protection - all resulting in an
increased return on your investment and real bottom-line savings. No matter
where your applications are located - and whether your requirements are simple
or complex, count on PowerFlex medium voltage drives for the optimal solution.
Safety Considerations
Lockout and tagout the device feeding power to the input of the drive before
performing any drive maintenance or component replacements. After the input
device cabinet doors are opened, immediately test the outgoing power cables
feeding the drive with a live-line tool (hot stick) while wearing high voltage
gloves. Repeat the live-line tool (hot stick) testing at the drive incoming line
power cable connections to verify that medium voltage is not present. Pay special
attention to any capacitors connected to medium voltage that can retain a charge
for a period of time. Only after the drive 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.
Table 1 - Line-to-Ground Short-circuit Specifications
SHOCK HAZARD: 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 drive
cabinet even with the input circuit breaker in the off position. 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.
Attribute Value
Line-to-Ground short-circuit current 31.5 kA
Incoming circuit breaker withstand current short time 4 s
Ik ≥ 31.5 kA

12 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018
Chapter 1 Introduction
Refer to national and local safety guidelines for detailed procedures on how to
safely isolate the equipment from hazards.
Environmental Conditions •Elevation above sea level must be less than 1000 m (3250 ft)(1).
•Ambient air temperature must be between 0...40 °C (32...104 °F)(2).
•Relative humidity must be less than 95%, non-condensing.
•Operation Vibration limited to 3M3(a) per IEC60721-3-3.
•The drive must be installed indoors; there must be no dripping water or
other fluids in the room.
•Cooling air must be clean without significant concentrations of sand,
corrosive or conductive dust, or explosive gas.
•Free from significant vibration.
•The drive must be anchored on a level floor. Please refer to the dimension
drawing for the anchor point sizes and locations.
For the equipment to operate in conditions other than those specified, consult
the local Rockwell Automation Sales Office.
How it Works Cascaded “H” Bridge (CHB) Topology
The proven CHB topology combines an integrally mounted phase shifting
isolation transformer and series-connected power modules for each phase. In
addition to stepping down the input voltage, the isolation transformer also
provides two other principal functions:
•Mitigate common mode voltage stress so motors with standard insulation
levels can be used.
•Reduce Total Harmonic Distortion (THD), due to the phase shifting of
its secondary windings, so input side harmonics don’t negatively impact
the plant or utility power grid.
Opening time 40...60 ms
Breaking time 50...75 ms
Inrush current Inverter input current x 4 or Inverter input current x 5
ATTENTION: The national and local electrical codes outline provisions for safely
installing and working on electrical equipment. Installation must comply with
specifications regarding wire type, conductor sizes, branch circuit protection
and disconnect devices. Failure to do so may result in personal injury and/or
equipment damage.
(1) Options are available for operation up to 5000 m.a.s.l. However, these must be stated at the time of order and cannot be retrofitted
in the field.
(2) Options are available for ambient temperatures up to 50 ºC. However, these must be stated at the time of order and cannot be
retrofitted in the field.

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 13
Introduction Chapter 1
A number of identical low voltage power modules are series-connected
(cascaded) together to produce the medium voltage levels required to operate the
motor.
The voltage step for each module is relatively small and a Pulse Width
Modulation (PWM) switching pattern is used so output harmonics and torque
pulsations at the motor are minimal, even at lower speeds. This technology is
very motor friendly so standard motors can be used for new applications and it
also is ideal for retrofitting existing motors. This also allows for the motor cable
lengths required for most applications, without the requirement for output
filtering.
This power module concept makes maintenance quick and easy. Each module has
powerful built in diagnostics to identify and isolate a module needing
replacement, in the unlikely event of a failure. This minimizes power module
replacement time, so process uptime is maximized.
Figure 1 - 6.6 kV Example Power Structure
Input power
3-phase AC Power Modules
Isolation
Transformer

14 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018
Chapter 1 Introduction
Simplified Electrical
Diagrams Figure 2 - 2300V / 2400V / 3300V(18 Pulse - 9 Power Modules)
Figure 3 - 4000V / 4160V (24 Pulse - 12 Power Modules)
Figure 4 - 6000V (30 Pulse - 15 Power Modules)
Figure 5 - 6300V / 6600V /6900V (36 Pulse - 18 Power Modules)
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 15
Introduction Chapter 1
Figure 6 - 10000V (48 Pulse - 24 Power Modules)
Figure 7 - 11000V (54 Pulse - 27 Power Modules)
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W

16 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018
Chapter 1 Introduction
Figure 8 - Connectivity Overview
Reset
Start
Stop
Current output
4-20 mA
Frequency output
4-20 mA
Speed input 4-20 mA
Analog spare 4-20 mA
Analog spare 4-20 mA
110/120/220/240V AC
Control Power
MV Closed
Permit Close MV Indicator
MV Closed Indicator
Warning Indicator
Fault Indicator
Running Indicator
Stop Indicator
Ready Indicator
Remote Control Indicator
Permit to Close Customer Breaker (CB)
Emergency/Fault Trip
Emergency Stop status
MV Pre-Closed
MV Closed
Warning
Fault
Running
Stop
Ready
Remote Control
Permit Close CB
Trip
Three-phase
Induction
Motor
Emergency/Fault Trip
(Reserved)
MV Close
Emergency Stop status
(Reserved)
Emergency Stop
Emergency Stop
Trip
MV Close
E-Stop
E-Stop

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 17
Introduction Chapter 1
Figure 9 - PowerFlex 6000 Principal Components
Generous space for terminating incoming line
cables
Generous space for terminating outgoing load
cables
Integrally mounted Multi-pulse Isolation
Transformer (3 wires in & 3 wires out) ensures
low line side harmonics and high input power
factor
Cabinet ships in two sections to minimize
shipping and handling issues
All Power Modules are identical to minimize
spare parts
All Power Modules are designed for easy
removal and replacement to minimize MTTR
Power Module has a PWM pattern to reduce
output harmonics
Optional Power Module bypass feature ensure
critical process reliability
All MV doors are electrically interlocked with
input switching device
All MV doors are interlocked with mechanical
interlocking device (for UL rating)
Isolation Transformer Temperature Monitor
All door filters can be changed while the drive
is running
All cooling fans are internally powered by a
dedicated winding in the Isolation Transformer
– no separate fan power supply is needed from
customer
All MV doors are lockable
Intuitive, easy-to-use, color touchscreen HMI
Many communication modules are available,
such as EtherNet I/P and Profibus DP
Automatic switchover (no trip) to internally
supplied control power if customer-supplied
single phase control power is lost
On-line UPS supplied as standard to support
ultra long control power loss ride-through
capability
Isolation Transformer Power Modules
Door Filters
Cooling Fans
HMI

18 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018
Chapter 1 Introduction
Standards Compliance Technical specifications and relevant standards in the manufacture, testing, and
acceptance of equipment include:
Standard Number Standard Description
UL 347A Medium Voltage Power Conversion Equipment Preliminary Standard
CSA C22.2 No. 274-13 Adjustable Speed Drives
ANSI Instrument Transformers C57.13
NEC National Electric Code
OSHA Occupational Safety & Health Act
IEC 60034-17 Rotating Electrical Machines Part 17, Cage Induction Motors When Fed from Converters
IEC 60146 Semiconductor Converters General Requirements
IEC 60204-11 Safety of machinery Electrical Equipment of machines-Part 11: requirements of HV equipment
for voltages above 1000V AC or 1500V DC and not exceeding 36 kV
IEC 60529 Degrees of Protection provided by enclosures
IEC 61800-3 Adjustable speed electric power drive systems - Part 3 EMC requirements and specific test
methods
IEC 61800-4 Adjustable speed electric power drive systems - Part 4 Rating specification for AC power drive
systems above 1000V AC and not exceeding 35 kV
IEC 61800-5-1 Adjustable speed electric power drive systems - Part 5-1: Safety requirements - Electrical,
thermal and energy
IEC 60076 Electric Power Transformer
IEC 60038:1983 IEC Standard Voltages
IEEC C57.18.10-1998 IEEE Standard Practices and Requirements for Semiconductor Power Rectifier Transformers
IEEC C57.12.01-1998 IEEE Standard General Requirements for Dry-Type Distribution and Power Transformers
IEEE C57.12.91-1995 IEEE Standard Test Code for Dry-Type Distribution and Power Transformers
IEEE 519-1992 IEEE Practices and Requirements for Harmonic Control in Electrical Power Systems

Rockwell Automation Publication 6000-UM002E-EN-P - April 2018 19
Chapter 2
Drive System Layout
All PowerFlex 6000 power modules designed as front connection. For a drive
amperage rating ≤350 A (304 A for heavy duty), a fixed-mounted power module
design is supplied. Fixed-mounted modules are shipped installed in the drive.
For a drive amperage rating of >350 A (304 A for heavy duty), power modules are
shipped separately, therefore site installation and cable connection is needed. In
this case, a lifting cart is supplied for power cell replacement.
The PowerFlex 6000 drive is shipped in two sections, the Isolation Transformer
cabinet and the Power Module/LV Control cabinet. See the PowerFlex 6000
Medium Voltage Variable Frequency Drive Shipping, Handling, and Installation
Instructions, publication 6000-IN006.
Elevation Drawings Depending on the drive rating, the system layout may be different.
Figure 10 - Drive Configurations
Isolation Transformer Cabinet 20
Power Module Cabinet 30
LV Control Cabinet 34
Isolation Transformer cabinet Power Module cabinet LV Control
cabinet

20 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018
Chapter 2 Drive System Layout
Isolation Transformer
Cabinet
Isolation Transformer cabinetPower Module cabinetLV Control
cabinet
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
Voltage Sensing Board 29