Allen-Bradley PowerFlex 6000 User manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive
Installation Manual
Publication 6000-IN006F-EN-P
Installation Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Rockwell Software, Rockwell Automation, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Contractor Scope of Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
Drive Mechanical Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Affix Cabinets to Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Power Modules (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Module Lift Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 2
Drive Electrical Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grounding System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor Cable Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Signal Wiring Design Considerations. . . . . . . . . . . . . . . . . . . . . . 27
Control Signal Wire Shield Grounding. . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connect the System Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 29
Connect Incoming Line and Outgoing Motor Power Cables. . . . . . . . . 29
Connect Control Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connect External Control Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Analog and Digital I/O Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 35

4Rockwell Automation Publication 6000-IN006F-EN-P -March 2018
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MV Door Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 3
Drive Electrical Interconnection
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Interconnection Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . . 38
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cable Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . . 41
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Connect LV Control and Fan Wiring Bundles. . . . . . . . . . . . . . . . . . . . . . 42
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix A
Pre-Commissioning
Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection and Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pre-Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Appendix B
Torque Requirements
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Appendix C
General Wire Categories
General Wire Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Appendix D
Power Cabling and Control Signal
Wiring Details
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix E
Line and Load Cable Sizes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 5
Preface
Introduction This document provides procedural information for physically unloading,
moving, and installing PowerFlex® 6000 medium voltage drives.
Who Should Use This Manual This manual is intended for use by professional riggers, general contractors,
electrical contractors, or plant operations personnel familiar with moving and
siting heavy equipment. Specific experience with solid-state variable speed drive
equipment is NOT required for this part of the installation process, but is
mandatory for subsequent processes.
What Is Not in this Manual This manual provides information specific for physically unloading and situating
a PowerFlex 6000 drive. It does not include project-specific, or drive-specific
topics such as:
•Dimensional Drawings and Electrical Drawings generated for each
customer’s order.
•Spare parts lists compiled for each customer’s order.
•Drive-specific technical specifications.
Refer to the following documents for additional product detail or instruction
relating to PowerFlex 6000 drives:
•PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping and
Handling Manual, publication 6000-IN008: instructions for shipping and
handling a Medium Voltage variable frequency drive and related
equipment.
•PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual,
publication 6000-UM002: instructions for daily recurring drive usage,
HMI interface and maintenance tasks for the product’s end-user.
•PowerFlex 6000 Medium Voltage Variable Frequency Drive Parameter
Manual, publication 6000-TD004: detailed information on drive features,
parameters, and troubleshooting faults.
Required Supplemental
Information
This manual includes generic information about the drive cabinet layout
orientation and generic electrical connection information.
Review the project-specific Dimensional Drawings (DDs) and Electrical
Drawings (EDs) to better understand the specific drive system cabinet
orientation and wiring requirements before performing any mechanical or
electrical work. Paper copies of the DDs and EDs are placed in the document/
hardware box in the Isolation Transformer Cabinet before shipment. Contact the
local Rockwell Automation office to obtain digital copies, if required.

6Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Preface
General Precautions
Commissioning Support After installation, Rockwell Automation is responsible for commissioning
activities for the PowerFlex 6000 product line. Contact your local Rockwell
Automation sales representative to arrange commissioning.
Rockwell Automation support includes, but is not limited to:
•quoting and managing product on-site start-ups
•quoting and managing field modification projects
•quoting and managing product training at Rockwell Automation facilities
and on-site
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Staticcontrol precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference Allen-Bradley publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as,
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
ATTENTION: Only personnel familiar with the PowerFlex 6000 Adjustable
Speed Drive (ASD) and associated machinery should plan or implement the
installation, start-up and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.
Resource Description
PowerFlex 6000 Medium Voltage Variable Frequency Drive
Shipping and Handling Manual, publication 6000-IN008 Provides instructions for shipping and handling a
Medium Voltage variable frequency drive and related
equipment.
PowerFlex 6000 Medium Voltage Variable Frequency Drive
User Manual, publication 6000-UM002 Provides instructions for daily recurring drive usage,
HMI interface and maintenance tasks for the product’s
end-user.
PowerFlex 6000 Medium Voltage Variable Frequency Drive
Parameter Manual, publication 6000-TD004 Provides detailed information on drive features,
parameters, and troubleshooting faults.
Industrial Automation Wiringand Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 7
Preface
You can view or download publications at
http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Contractor Scope of Work Typical scope of work by the freight company, third-party contractor and/or
customer (based on ex-works INCO terms)(1):
•Load equipment on truck at a Rockwell Automation manufacturing
facility and transport equipment to site
•Offload equipment from truck on-site
•Perform initial inspection(2)
•Move equipment to the final installation location
•Position the cabinet sections together as shown in Dimensional Drawing
and level the cabinet lineup
•Mechanically join cabinets together
•Affix the cabinets to the floor
•Install assemblies shipped loose (fan assemblies).
•Install external ductwork to exhaust heated air from control room (if
required)
•Install power and control cabling and terminate cable connections to drive
system:
•Connect system ground cable
•Insulation Resistance (IR) testing of incoming line and outgoing motor
power cables
•Connect incoming line and outgoing motor power cables
•Connect control power wiring
•Connect all external customer required control signal wiring
•Connect electrical safety interlock control signal wiring circuit to input
circuit breaker
•Connecting the power cables and control wiring between cabinets that are
shipped separately(3)
•Complete Pre-commissioning Checklist
(1) All or part of these activities could be provided by Rockwell Automation or its representatives, based on contract INCO terms and
negotiated scope of supply/services agreement. Contact the local Rockwell Automation office for further information.
(2) Customer should lead the initial inspection process.
(3) Interconnection of power cables and low voltage control wiring bundles, between separately shipped cabinets,can be done by the
contractor or Rockwell Automation. The commissioning quote from Rockwell Automation reflects this and will contain two options:
a) the base quote, reflecting the power cable and control wiring interconnection work being done by the contractor
b) the optional quote adder,reflecting the additional timeand cost for Rockwell Automation to perform the power cable and
control wiring interconnection work immediately prior to the commissioning process.

8Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Preface
Notes:

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 9
Chapter 1
Drive Mechanical Installation
Introduction The installation process is divided into three principal activities. The mechanical
installation process described in this chapter, the electrical installation process
described in Drive Electrical Installation on page 23, and the electrical
interconnection process described in Drive Electrical Interconnection on
page 37.
Mechanical Installation
Summary
The cabinets must be arranged as shown in the Dimensional Drawing.
Follow all applicable guidelines for siting the components before continuing with
these installation instructions.
There may be some variation in the process depending on the type and number of
drive components in your particular installation.
Connect Shipping Splits
The PowerFlex 6000 drive is shipped in two sections, the Isolation Transformer
Cabinet and Power Module/LV Control Cabinet. These two cabinets must be
connected after located in its final position. The cabinets are connected together
in 8 or 10 places (depending on the drive rating), half along the front edge of the
cabinet and half along the rear edge of the cabinet. Access to the interior of the
cabinet is required to make these connections. Access for the front connections
requires only opening the doors. Access for the rear connections requires
removing the back plates of the cabinet.
Connect Shipping Splits 9
Affix Cabinets to Floor 13
Install Main Cooling Fans 16
Install Power Modules (if applicable) 17
External Ducting 20
ATTENTION: Install the drive on a level surface (+/- 1 mm per meter
[+/- 0.036 in. per 36 in.] of drive length in all directions). If necessary, use
metal shims to level the cabinets before joining them; attempting to level after
joining may twist or misalign the cabinets.
IMPORTANT
Rear access to all cabinets is required for subsequent processes. Do not reinstall
back plates until after the conclusion of the Drive Electrical Interconnection
process.

10 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
1. Arrange the sections as directed in the Dimensional Drawings and move
the sections together.
2. Align the cabinet side sheets together at the holes for the hardware
(see step 3).
Figure 1 - Aligning Cabinets, Type A (6/6.6 kV shown)
Isolation Transformer Cabinet Power Module/LV Control Cabinet
Optional Cabinets
1. Start-up cabinet (Pre-charge cabinet)
2. Output filter cabinet
3. Bypass cabinet
4. and others
Table 1 - Sidesheet Openings
❶Front Wireway
❷U Phase Motor Cable
❸V Phase Motor Cable
❹W Phase Motor Cable
❺Ground Bus Connection
❻Voltage Sensing Board Cables
❼Isolation Transformer Secondary Cables(1)
(1) The number of Isolation Transformer secondary cables is
dependent on motor voltage class.
• 9 cables per motor phase (27 total) for 3/3.3 kV
•12 cables per motor phase (36 total) for 4.16 kV
• 15 cables per motor phase (45 total) for 6 kV
•18 cables per motor phase (54 total) of 6.6 kV
•24 cables per motor phase (72 total) for 10kV
• 27 cables per motor phase (81 total) for 11 kV
❶
❷
❸❼
❹
❺
❻
❶
❸
❼
❹
❺
❻
Front Front
❷
Side View

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 11
Drive Mechanical Installation Chapter 1
Figure 2 - Aligning Cabinets, Type B (6 kV shown)
Isolation Transformer CabinetPower Module/LV Control Cabinet
Table 2 - Sidesheet Openings
❶Front Wireway
❷U Phase Motor Cable
❸V Phase Motor Cable
❹W Phase Motor Cable
❺Ground Bus Connection
❻Voltage Sensing Board Cables
❼Isolation Transformer Secondary
Cables(1)(2)
(1) The number of Isolation Transformer secondary
cables is dependent on motor voltageclass.
• 9 cables per motor phase (27 total) for 3/3.3 kV
•12 cables per motor phase (36 total) for 4.16 kV
• 15 cables per motor phase (45 total) for 6 kV
•18 cables per motor phase (54 total) of 6.6 kV
•24 cables per motor phase (72 total) for 10kV
• 27 cables per motor phase (81 total) for 11 kV
(2) 6/6.6 kV configurations only require 18 cable hole
locations per phase. Extra cable hole locations allow
for added installation flexibility.
❶
❸
❹
❺
❻
❷
Front Front
❼
Side View
❼
❼

12 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
3. Secure the cabinets together using M6 or M8 hardware. See To r q u e
Requirements on page 49 for proper torque requirements.
Open the doors to access front edge joining holes (four or five places).
Figure 3 - Secure the Cabinets, Type A
Figure 4 - Secure the Cabinets, Type B
Secure with M8 (or M10)
hardware (10 places)
M10x25 hex bolt
Lock washer
M10 hex nut
Flat washer (x2)
Cabinet sidesheets
Secure with M6
hardware (8 places)
2-socket screw M6x16
Combination pillar

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 13
Drive Mechanical Installation Chapter 1
4. Remove all back plates to access rear edge joining holes (five places).
Affix Cabinets to Floor Typical floor drawings show minimum clearance distance, conduit openings, and
mounting holes for anchor bolts(1), as shown in Figure 5. Refer to customer
specific dimensional drawing for outgoing motor and incoming line cable
openings.
Figure 5 - Typical Floor Drawing, Type A
Secure the cabinet to the channel steel base using M16 bolt, lock washer, two flat
washers and a nut.
TIP
Each back plate will have two keyhole screw holes on either side. Remove all of
the other screws first. Loosen the two screws in the keyhole screw holes last
and lift the back plate to remove. Do not remove these screws.
Do not replace the back plates until the Drive Electrical Interconnection Process
is complete (See Drive Electrical Interconnection on page 37).
To replace the back plates, the two remaining screws orient and hold the back
plate in place while fastening the other screws holding the back plates to the
frame of the cabinet. Tighten these screws last to complete the process.
(1) Mounting holes are represented as + in Figure 5.
Isolation Transformer Cabinet Power Module/LV Control Cabinet
Bottom View

14 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
Figure 6 - Typical Floor Drawing, Type B
Secure the cabinet to the channel steel base using M12 bolt (recommended), lock
washer, two flat washers and a nut.
Figure 7 - Bolt Cabinet to Steel Base, Type A
Figure 8 - Bolt Cabinet to Steel Base, Type B
Isolation Transformer CabinetPower Module/LV Control Cabinet
Bottom View
Control signal
Output cable
Input cable
M16 bolt
Flat washer
Lock washer
M16 bolt
Flat washer
Lock washer

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 15
Drive Mechanical Installation Chapter 1
Optional: The cabinet can also be welded to the steel base once it is securely
bolted, if desired.
Each weld location should be 100 mm (3.9 in.) for every 1000 mm (39.4 in.). See
Mounting Requirements in the PowerFlex 6000 Medium Voltage Variable
Frequency Drive Shipping and Handling Manual, publication 6000-IN008) for
further information on the steel base and desired trench and mounting
specifications.
Figure 9 - Welding locations
Channel steel baseRecommended weld locations
ATTENTION: Failure to correctly anchor the cabinet may result in damage to the
equipment or injury to personnel.

16 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
Install Main Cooling Fans Main cooling fans are shipped in separate crates. The fans are shipped assembled
in the fan housing, but must be installed after siting the drive.
Table 3 - Fan Housing Specifications
1. Place the fan housing on the top plate of the drive, making sure the socket
is on the same side as the aviation plug.
2. Secure the fan housing using M6 hardware (six places).
See Torque Requirements on page 49.
3. Connect the aviation plug located on top of the cabinet with the socket on
the fan housing.
Figure 10 - Main Cooling Fan Housing, Type A
IMPORTANT
See Mounting Clearance Distance in the PowerFlex 6000 Medium Voltage
Variable Frequency Drive Shipping and Handling Manual, publication 6000-
IN008) to verify that the fans have the appropriate clearance distance ontop of
the cabinet.
Model Dimensions (HxWxD), approx. Weight, approx.
RH40 340 x 440 x 500 mm (13.0 x 17.3 x 19.7 in.) 20 kg (44.1 lb)
RH45 380 x 490 x 550 mm (14.6 x 19.3 x 21.7 in.) 25 kg (55.1 lb)
EC400 358 x 480 x 670 mm (14.1 x 18.9 x 26.4 in.) 30 kg (66 lb)
Main Cooling Fan housing
Aviation plug
Socket
Rear View
M6 tapping screws or bolts

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 17
Drive Mechanical Installation Chapter 1
Figure 11 - Main Cooling Fan Housing, Type B
Install Power Modules (if
applicable)
Power Modules are available in a wide variety of amperage ratings relating to the
required motor current. Power Modules rated up to and including 350 A are
mounted in the drive and ship already installed.
Power Modules rated above 350 A are shipped separately, therefore site
installation and cable connection is needed. In this case, a lift cart is supplied and
shipped together with the other components.
Power Module Lift Cart
The lift cart’s hydraulic cylinder can be operated by either a hand or foot crank.
The lifting capacity is 400 kg (882 lb).
Main Cooling Fan housing
Aviation plug
Socket
Rear View
ATTENTION: Only authorized personnel should operate thelift cart. Keep hands
and feet away from the lifting mechanism. Do not stand under the lift tray
when in use. Store the lift cart with the tray fully lowered.

18 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
Figure 12 - Lift Cart Procedure
Table 4 - Power Module Specifications
Hand Crank
Foot Crank
Pressure Release Knob
1. Check the lift tray before use to ensure the tray
can be raised and lowered smoothly.
2. Rotate the Pressure Release Knob
counterclockwise to ensure that the tray is in
the lowest position.
3. Move the Power Module on the tray and lift
the module to the appropriate height using the
Foot Crank and complete the installation.
4. Rotate the Pressure Release Knob
counterclockwise to lower the tray to its
original position.
5. Repeat steps 1...4 to complete the installation
for all the Power Modules.
TIP
The Foot Crank raises the lift tray faster than
the Hand Crank. Use this to raise the Power
Module to just below the tray assembly in
the drive. Use the Hand Crank for final
precise positioning.
Lift tray
Release
pressure in
cylinder
Seal
pressure in
sylinder
Output Rating (Amps) Dimensions (HxWxD), approx. Weight, approx.
≤150 A 420 x 180 x 615 mm (16.5 x 7.1 x 24.2 in.) 20 kg (44.1 lb)
151...200 A 420 x 260 x 615 mm (16.5 x 10.2 x 24.2 in.) 25 kg (55.1 lb)
201...350 A 552.5 x 244.5 x 663 mm (21.8 x 9.6 x 26.1 in.) 70 kg (154 lb)
351...680 A 471 x 354 x 746 mm (18.5 x 13.9 x 29.4 in.) 95 kg (209 lb)
ATTENTION: Two people are required to handle the Power Modules.

Rockwell Automation Publication 6000-IN006F-EN-P - March 2018 19
Drive Mechanical Installation Chapter 1
Install Power Modules
1. You can use the lift cart to move and position the Power Module to the
appropriate location in the cabinet.
2. Push the Power Module slowly along the guide rails until it cannot be
pushed in further.
3. After installing the Power Module in place, use the mounting brackets and
the M6 × 16 large flat pad galvanized nickel screws to fix the four corners,
as shown below.
IMPORTANT
The Power Module should be handled carefully. After removing the packaging,
inspect the Power Module to confirm there is no damage and moisture.
Mounting brackets
Power Module
Guide rail
Mounting brackets

20 Rockwell Automation Publication 6000-IN006F-EN-P - March 2018
Chapter 1 Drive Mechanical Installation
External Ducting The PowerFlex 6000 design can accommodate ducting exhaust air outside of the
control room.
The following requirements are mandatory design requirements for systems that
will externally duct the exhaust air and draw cleansed outside air:
•External ducting including an external filtering system must not add more
than 50 Pa (0.2 in. of water) pressure drop to the PowerFlex 6000 drive air
flow system. Ensure a minimum top clearance of 1500 mm (39.4 in.) above
the drive top plate.
•The control room must provide slightly more make-up air, creating a
pressurized room. This slight pressurization prevents unfiltered air
drawing into the room.
•The drive is intended to operate in conditions with no special precautions
to minimize the presence of sand or dust, but not in close proximity to
sand or dust sources. IEC 721-1 defines this as being less than 0.2 mg/m3
of dust.
•If outside air does not meet this condition, filter the air to EU EN779
Class F6 or ASHRAE Standard 52.2 MERV 11. These ratings address a
high percentage of the 1.0...3.0 μm particle size. Clean or change filters
regularly to ensure proper flow.
•The make-up air must be between 0...40 °C (32...104°F).
•Relative humidity must be less than 95% non-condensing.
•If the ducting length is greater than 4 m, an axial fan must be installed at
the air outlet. The exhaust flow of the axial fan must be greater than the
total flow amount of all the centrifugal fans in this air duct.
•The ducting can be shared by more than one cabinet.
•Do not cover any medium voltage or control power wires which enter or
exit from the top of the cabinet.
•The air duct outlet must slope downward to prevent water damage.
•Screens must be installed in the air duct outlet.
•An air inlet must be added to the drive room. The cross-sectional area of
this inlet must meet the ventilation requirements of all drives. Screens
must be installed in the air inlet.
•The air inlet and outlet must not be at the same side of the drive room.
ATTENTION: The Isolation Transformer Cabinet and the Power Module/LV
Control Cabinet must be ducted separately.