Allen-Bradley PowerFlex 6000 User manual

PowerFlex® 6000 Medium Voltage Variable Frequency Drive
Publication 6000-UM001B-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 Software, Rockwell Automation, 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-UM001B-EN-P - October 2014 3
Table of Contents
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
Chapter 1
Introduction
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cascaded “H” Bridge (CHB) Topology . . . . . . . . . . . . . . . . . . . . . . . . 10
Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standards Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2
Drive System Layout
Elevation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Isolation Transformer Temperature Monitor . . . . . . . . . . . . . . . . . . . 21
Isolation Transformer Auxiliary Cooling Fans . . . . . . . . . . . . . . . . . . 22
Top-mounted Main Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Incoming Line Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . 22
Outgoing Motor Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hall Effect Current Sensors (HECs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Top-mounted Main Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Unit (all modules). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 3
Setup and Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Main Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive Setup and Configuration Controls . . . . . . . . . . . . . . . . . . . . . . . 34
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Setup and Monitor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Table of Contents
Main Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Set Frequency (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drive Operation Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
View Version Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Alarm History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
View Voltage, Current or Frequency Trends . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Confirm Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Choose Local/Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Open/Close Drive Input and Output Contactors . . . . . . . . . . . . . . . 46
Open/Close Bypass Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Change User Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setup Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
View/Change P or T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Restore “P” or “T” Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 4
Parameters and Function Codes
P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
T Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chapter 5
Preventative Maintenance and
Component Replacement
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Regular Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Physical Checks (No Medium Voltage or Control Power) . . . . . . . . . . . 79
Power Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Medium Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Replace/Clean Door Mounted Air Filters. . . . . . . . . . . . . . . . . . . . . . . 81
Inspect Top Mounted Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . 82
Replace Top Mounted Main Cooling Fans. . . . . . . . . . . . . . . . . . . . . . 83
Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Inspect Isolation Transformer Auxiliary Cooling Fans . . . . . . . . . . . 85
Replace Isolation Transformer Auxiliary Cooling Fans. . . . . . . . . . . 86
Inspect Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspect Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 5
Table of Contents
Replace Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspect Door Position Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Replace Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Inspect, Clean, or Replace Door Mounted Air Filters. . . . . . . . . . . . 90
Inspect or Replace Top Mounted Main Cooling Fans . . . . . . . . . . . 90
Inspect Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Replace Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replace Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect or Replace HECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Inspect or Replace Door Position Limit Switch . . . . . . . . . . . . . . . . 100
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Inspect AC/DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replace AC/DC Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Inspect UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replace UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replace UPS Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspect PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Inspect/Replace Control Unit or Control Boards . . . . . . . . . . . . . . 108
Inspect the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace LV Control Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replace LV Control Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inspect Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . 116
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Inspect LV Component Terminal and Plug-in Connections . . . . 117
Inspect Medium Voltage Cable Connections . . . . . . . . . . . . . . . . . . 117
Inspect Power Cable and Control Wire Terminals . . . . . . . . . . . . . 117
Inspect Transformer Secondary Windings. . . . . . . . . . . . . . . . . . . . . 117
Inspect Power Module Input and Output Power Connections . . 118
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Review Firmware and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Inspect/Review Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Appendix A
Technical Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix B
Catalog Number Explanation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Appendix C
Preventative Maintenance Schedule
PowerFlex 6000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Table of Contents
Appendix D
Spare Parts
Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Appendix E
Torque Requirements
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Index

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 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 Shipping,
Handling, and Installation Instructions (6000-IN006_-EN-P). This
document provides procedural information for physically unloading,
moving, and installing PowerFlex 6000 medium voltage drives.
•PowerFlex 6000 Medium Voltage Variable Frequency Drive
Commissioning Manual (6000-IN007_-EN-P). This document provides
information for commissioning PowerFlex 6000 medium voltage drives.
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.
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.
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.

8Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Preface
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
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. Please refer to the
Pre-commissioning Checklist in the PowerFlex 6000 Medium Voltage Variable
Frequency Drive Shipping, Handling, and Installation Instructions
(6000-IN006_-EN-P).
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-UM001B-EN-P - October 2014 9
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.
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.

10 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
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 90%, non-condensing.
•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 (defined by IEC 721-1 as being less than
0.2 mg/mof 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.
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 3000 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-UM001B-EN-P - October 2014 11
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 - 6/6.6 kV Example Power Structure
Input Power
3 Phase AC
Power Modules
Isolation
Transformer

12 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 1 Introduction
Simplified Electrical
Diagrams
Figure 2 - 3000V / 3300V (18 Pulse - 9 Power Modules)
Figure 3 - 6000V /6600V (36 Pulse - 18 Power Modules)
Figure 4 - 10,000V (54 Pulse - 27 Power Modules)
Isolation Transformer Secondary Windings
U
V
W
Isolation Transformer Secondary Windings
U
V
W
Isolation Transformer Secondary Windings
U
V
W

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 13
Introduction Chapter 1
Figure 5 - Connectivity Overview
Reset
Start
Stop
Analog Output Current
4-20 mA
Analog Output Frequency
4-20 mA
Analog set 4-20 mA
Analog spare 4-20 mA
Analog spare 4-20 mA
AC220V Control Power
MV Closed
Customer Input Contact
Permit Close MV
MV Closed Indicator
Warning Indicator
Fault Indicator
Running Indicator
Stop Indicator
Ready Indicator
Remote Control Indicator
Permit to Close Customer
Emergency/Fault Trip
Emergency Stop
MV Pre-Closed
MV Closed
Warning
Fault
Running
Stop
Ready
Control
Permit Close CB
Trip
Three-phase
Induction
Motor

14 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 1 Introduction
Figure 6 - 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
All MV doors are electrically interlocked with
input switching device
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
Incoming Line Cables
Outgoing Load Cables
Isolation Transformer Power Modules
Door
Filters
Transformer
Temperature
Monitor Cooling Fans
HMI

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 15
Introduction Chapter 1
Standards Compliance Technical specifications and relevant standards in the manufacture, testing, and
acceptance of equipment include:
Standard Number Standard Description
IEEE 519 Electrical and Electronics Engineers Institute Harmonics Control Requirements
IEC 60146 Semiconductor Converters–Specification of Basic Requirements
IEC 60038:1983 IEC Standard Voltages
IEC 60050-151:2001 International Electrotechnical Vocabulary, Chapter 151: Electrical and Magnetic Devices
IEC 60050-551:1999 International Electrotechnical Vocabulary, Chapter 551: Power Electronics
IEC 60076 Electric Power Transformer
IEC 60721-3-1:1997 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities. Section 1: Storage
IEC 60721-3-2:1997 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities
IEC 60721-3-3:2008 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities. Stationary Use at Weather-protected Locations
IEC 61000-2-4:2002 Electromagnetic Compatibility (EMC), Part 2, Environment, Chapter 4: Compatibility Levels in
Industrial Plants for Low Frequency Conducted Disturbances
IEC 61000-4-7:2002 Electromagnetic Compatibility (EMC) Part 4: Testing and Measurement Techniques, Chapter 7:
General Guide on Harmonics and Inter-harmonics Measurements and Instrumentation, for
Power Supply Systems and Equipment Connected Thereto
IEC 61800-3:2004 Adjustable Speed Electrical Power Drive Systems, Part 3: EMC Requirements and Specific Test
Methods
IEC 61800-4:2004 Adjustable Speed Electrical Power Drive Systems, Part 4: General Requirement—Rating
Specifications for AC Power Drive Systems above 1000V AC and not Exceeding 35 kV
IEC 60757-1983 Code for Designation of Colors
IEC 106:1989 Environment Condition Guides for Specifying Performance Rating of Equipment
IEC 61508.1-7 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
GB/T 2900.18-2008 Electrotechnical terminology—Low Voltage Apparatus (IEC60050-441:1984)
GB/T 3859.1-2013 Semiconductor Converters. Specification of Basic Requirements (IEC60146-1-1:1991)
GB/T 3859.2-2013 Semiconductor Converters. Application Guide (IEC60146-1-2:1991)
GB/T 3859.3-2013 Semiconductor Converters. Transformers and Reactors (IEC 60146-1-3,1991)
GB 7678-87 Semiconductor Self-commutated Converters
GB 3797-2005 Electric-driving Control Gear, Part 2: Electric-driving Control Gear Incorporating Electronic
Devices
GB/T 14549-93 Quality of Electric Energy Supply Harmonics in Public Supply Network
GB 4208-2008 Degrees of Protection Provided by Enclosures (IP Code) (IEC 60529:1989)
GB/T 16935.1-2008 Insulation Coordination for Equipment within Low Voltage Systems, Part 1: Principles,
Requirements, and Tests (IEC 60664-1:1992)
GB 156-2007 Standard Voltages
GB/T 1980-2005 Standard Frequencies
GB/T 2423.10 Electric and Electronic Products—Basic Environmental Test Regulations for Electricians—
Guidelines for Vibration (sine)
GB/T 2681 Colors of Insulated Conductors Used in Electrical Assembly Devices
GB 2682 Colors of Indicator Lights and Push Buttons Used in Electrical Assembly Devices
GB/T 4588.1-1996 Specification for Single and Double-sided Printed Boards with Plain Holes
GB/T 4588.2-1996 Sectional Specification: Single and Double-sided Printed Boards with Plated-through Holes

16 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 1 Introduction
GB 10233.2005 Basic Test Method for Low Voltage Switchgear and Controlgear
GB 12668.4-2006 Adjustable Speed Drive Electrical System, Part 4: General Requirement for Voltage up to 35 kV
GB 12668.3-2006 Adjustable Speed Drive Electrical System, Part 3: EMC Requirement and Testing Method
GB 12668.701-2013 Adjustable Speed Drive Electrical System, Part 701: Communication
GB/T 15139-94 General Technical Standard for Electrical Equipment Structure
GB/ 13422-2013 Semiconductor Converters—Electrical Test Methods
IEEE 519-1992 Practices and Requirements for Harmonic Control in Electrical Power Systems
GB/T 12668.4-2006 Adjustable Speed Electrical Power Drive Systems, Part 4: General Requirements. Rating
Specifications for AC Power
GB1094.11-2007 Power Transformer, Part 11: Dry-type Transformer
Standard Number Standard Description

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 17
Chapter 2
Drive System Layout
There are two basic power cell configurations offered in the PowerFlex 6000
product line. For a drive amperage rating ≤200 A, a fixed-mounted power module
design is supplied. Fixed-mounted modules are shipped installed in the drive. For
a drive amperage rating of >200 A, a drawout power module design is supplied.
The PowerFlex 6000 drive is shipped in two sections, the Isolation Transformer
Cabinet and the Power Module/LV Control Cabinet. Refer to PowerFlex 6000
Medium Voltage Variable Frequency Drive Shipping, Handling, and Installation
Instructions (6000-IN006_-EN-P).
Elevation Drawings Figure 7 - Fixed-mounted Power Module Drive Configuration
Isolation Transformer Cabinet 18
Power Module Cabinet 25
LV Control Cabinet 29
Isolation Transformer Cabinet Power Module Cabinet LV Control
Cabinet

18 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 2 Drive System Layout
Figure 8 - Drawout Power Module Drive Configuration
Isolation Transformer
Cabinet
Isolation Transformer Cabinet Power Module CabinetLV Control Cabinet
Isolation Transformer 20
Isolation Transformer Temperature Monitor 21
Isolation Transformer Auxiliary Cooling Fans 22
Top-mounted Main Cooling Fan(s) 22
Incoming Line Power Cable Connections 22
Outgoing Motor Cable Connections 22
Door Position Limit Switch 23
Voltage Sensing Board 24

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 19
Drive System Layout Chapter 2
Figure 9 - Isolation Transformer Cabinet (Fixed-mounted Power Module Drive Configuration)
Figure 10 - Isolation Transformer Cabinet (Drawout Power Module Drive Configuration)
Isolation Transformer
Cable Clamp
Voltage Sensing
Board
Door Position
Limit Switches
L11
L12
L13
UV
W
Isolation Transformer
Auxiliary Cooling Fans
PowerCableConnections
to Power Modules
Incoming Line Power
Cable Connections
Outgoing Motor Power
Cable Connections
Top-mounted Main
Cooling Fan(s)
Cable Clamp
Voltage Sensing
Board
Isolation Transformer
Door Position
Limit Switches
L13 L12 L11 WV U
Incoming Line Power
Cable Connections
Outgoing Motor Power
Cable Connections
Isolation Transformer
Auxiliary Cooling Fans
Top-mounted Main
Cooling Fans

20 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 2 Drive System Layout
Isolation Transformer
The primary winding of the isolation transformer is rated for the voltage of the
distribution system. It is connected to the distribution system by the incoming
line power cables. The secondary windings of the isolation transformer are
connected to the inputs of the power modules. The secondary winding voltage is
typically 690V, to feed the low voltage power modules.
There are between 9 and 27 three-phase secondary side windings, dependent on
the motor voltage requirements. The phase relationship between the secondary
windings are optimized to provide the highest reduction of line side harmonics.
The isolation transformer’s three-phase primary coils are oriented C, B, and A
from left to right, as viewed from the front. The secondary windings are also
divided into three principal sections from top to bottom. The upper third are to
feed the power modules in the U output phase. The middle third are to feed the
power modules in the V output phase. The bottom third are to feed the power
modules in the W output phase (Figure 11).
Figure 11 - Isolation Transformer Primary and Secondary Winding Orientation
The secondary windings are brought out to corresponding vertical isolated stand-
offs on the body of the transformer (orientated C, B, and A from left to right as
viewed from the front).
PRIMARY WINDING INPUT
SECONDARY WINDING OUTPUT
C (L3) B (L2) A (L1)
U
V
W