Rockwell Automation 6000G User manual

PowerFlex 6000 Medium
Voltage Variable Frequency
Drive
Catalog Number 6000G
Installation Instructions Original Instructions

2Rockwell Automation Publication 6000-IN006H-EN-P - October 2020
PowerFlex 6000 Medium Voltage Variable Frequency Drive 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.
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-IN006H-EN-P - October 2020 3
Table of Contents
Preface
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Contractor Scope of Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Drive Mechanical Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connect DV/DT Filter Cabinet for A-Frame Drives . . . . . . . . . . . . 11
Connect Cabinets for H-Frame and B-Frame Drives . . . . . . . . . . . . 13
Affix Cabinets to Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install Seismic Rated Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install A-Frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install B-Frame Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install the Cooling Fan and Noise Reduction Barrier for A-Frame
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install the Mixing Hood for A-Frame Drives. . . . . . . . . . . . . . . . . . . . 31
Install Power Modules (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power Module Lift Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install Power Modules for A-Frame Drives . . . . . . . . . . . . . . . . . . . . . 34
External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 2
Drive Electrical Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grounding System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor Cable Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Control Signal Wiring Design Considerations. . . . . . . . . . . . . . . . . . . . . . 43
Control Signal Wire Shield Grounding. . . . . . . . . . . . . . . . . . . . . . . . . 43
Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connect the System Ground Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 46

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Table of Contents
Connect Incoming Line and Outgoing Motor Power Cables . . . . . . . . . 46
Connect Cables for A-Frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connect Cables for H-Frame and B-Frame Drives. . . . . . . . . . . . . . . 49
Connect Control Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Wiring Routing and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connect External Control Signal Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Analog and Digital I/O Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Wiring Routing and Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 54
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
MV Door Safety Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 3
Drive Electrical Interconnection
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical Interconnection Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . . 58
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cable Routing and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . . 61
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connect LV Control and Fan Wiring Bundles. . . . . . . . . . . . . . . . . . . . . . 62
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A
Pre-Commissioning
Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Inspection and Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Pre-Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Appendix B
Torque Requirements
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Appendix C
General Wire Categories
General Wire Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix D
Power Cabling and Control Signal
Wiring Details
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 76

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 5
Table of Contents
Appendix E
Line and Load Cable Sizes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

6Rockwell Automation Publication 6000-IN006H-EN-P - October 2020
Table of Contents
Notes:

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 7
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 that are generated for each
customer’s order.
•Spare parts lists compiled for each customer’s order.
•Drive-specific technical specifications.
See 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, and maintenance tasks for the product’s end user.
•PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware,
Parameters, and Troubleshooting 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 necessary.

8Rockwell Automation Publication 6000-IN006H-EN-P - October 2020
Preface
General Precautions
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
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, startup, and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.
ATTENTION: Only qualified personnel with the correct PPE (Personal Protective
Equipment) should service the equipment. Be sure to follow the safety
procedures and local regulations to disconnect the high voltage. After waiting
for 15 minutes, open the cabinet door and verify the absence of medium
voltage on the input, output, and power cell terminals with a high-voltage
detector that is properly rated for the line and motor voltages. All LED lights on
the power cells must be off and the drive be grounded with portable grounding
cables on the input and output before servicing. Failure to follow the safety
procedures can result in severe injury or death.
Topic Page
Updated table Cable Insulation Requirements for Outgoing Motor Cables 41
Updated Important information under Power Cable Design Considerations 42

Rockwell Automation Publication 6000-IN006H-EN-P - October 2020 9
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature. To order paper
copies of technical documentation, contact your local Allen-Bradley distributor
or Rockwell Automation sales representative.
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 startups
•quoting and managing field modification projects
•quoting and managing product training at Rockwell Automation facilities
and on-site
Contractor Scope of Work Typical scope of work by the freight company, third-party contractor and/or
customer (based on ex-works Incoterms)(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
Resource Description
PowerFlex 6000 MediumVoltageVariable Frequency Drive
Shipping and Handling Manual, publication 6000-IN008 Provides instructions for shipping and handling a MediumVoltage variable frequency drive and related
equipment.
PowerFlex 6000 MediumVoltageVariable Frequency Drive
User Manual, publication 6000-UM002 Provides instructions for daily recurring drive usage, HMI, and maintenance tasks for the product’s end user.
PowerFlex 6000 MediumVoltageVariable 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, rok.auto/certifications Provides declarations of conformity, certificates, and
other certification details.
(1) All or part of these activities could be provided by Rockwell Automation or its representatives, based on contract Incoterms and
negotiated scope of supply/services agreement. Contact the local Rockwell Automation office for further information.
(2) Customer should lead the initial inspection process.

10 Rockwell Automation Publication 6000-IN006H-EN-P - October 2020
Preface
•Install assemblies shipped loose (fan assemblies).
•Install external ductwork to exhaust heated air from control room (if
necessary)
•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(1)
•Complete Pre-commissioning Checklist
(1) 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 time and cost for Rockwell Automation to perform the power cable and
control wiring interconnection work immediately before the commissioning process.