Rockwell Automation Allen-Bradley PowerFlex 6000 Quick start guide

PowerFlex 6000 Medium Voltage Variable Frequency Drive
Commissioning Manual
Publication 6000-IN007B-EN-P
Commissioning 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, 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-IN007B-EN-P - March 2016 3
Table of Contents
Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensional Drawings and Electrical Drawings. . . . . . . . . . . . . . . . . . . 7
Shipping, Handling, and Installation Manual . . . . . . . . . . . . . . . . . . . . . 8
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Introduction
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Documentation and Application Review. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Review all Rockwell Automation Supplied Documentation . . . . . . 12
Pre-commissioning Customer Meeting. . . . . . . . . . . . . . . . . . . . . . . . . 13
Review Drive Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2
Preparation and Inspection (For IEC)
Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 15
Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drive Megger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Isolate the Power and Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 29
Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 3
Preparation and Inspection (For UL)
Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 31
Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Table of Contents
Drive Megger Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Isolate the Power and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 46
Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 4
Commissioning
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Control System Check Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Simulate Closed Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . 48
Energize Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Verify Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Set P Parameters to Enable Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Verify Settings for Low-Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . 58
Verify Operation of Frequency Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Verify Operation to Set Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Simulate Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Verify E-Stop Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Verify Switching from Local Control to Remote Control . . . . . . . . 73
Verify Operation of Input/Output and Bypass Isolation Switches
(Manual Bypass). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Verify Operation of Input/Output and Bypass Contactors
(Automatic Bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Verify Operation of DCS Input and Output Signals . . . . . . . . . . . . . 83
Restore P Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Set Date and Time Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Access T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Change Time/Date/Regional Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 87
Chapter 5
No-load Test
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
No-load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Energize Drive Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Configure P and T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Change Parameters T11...T13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Close Isolation Switches in Bypass Cabinet . . . . . . . . . . . . . . . . . . . . 102
Close Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check Cooling Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Operate Motor by HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Load Test of Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix A
Torque Requirements
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 5
Table of Contents
Appendix B
Single Line Diagrams
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix C
Special Function Parameter Settings
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
System Setting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Number of Power Modules Per Phase . . . . . . . . . . . . . . . . . . . . . . . . . 117
Switch Control Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Rated/Maximum Output Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . 118
Motor Parameter Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Hall Effect Current Sensor Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Analog Output Display Parameter Setting . . . . . . . . . . . . . . . . . . . . . 119
Restore Factory Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Speed Command Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Set Frequency Command Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Set Frequency Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Frequency Command Deadband Upper Limit . . . . . . . . . . . . . . . . . 120
Frequency Amplitude Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Frequency Skip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Speed Reference Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
V/F Curve Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Set Maximum Modulation Index and Limit Output Voltage
Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Set Flux Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Flying Start Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Restart the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Index

6Rockwell Automation Publication 6000-IN007B-EN-P - March 2016
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Notes:

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 7
Preface
Introduction This document provides procedural information for commissioning
PowerFlex® 6000 medium voltage drives with version 4.001 firmware.
Who Should Use This Manual This manual is intended for Rockwell Automation Field Service Engineers with
Medium Voltage Drive factory training and field experience commissioning
medium voltage solid-state variable speed drive equipment.
What Is Not in This Manual This manual is generic and does not include project-specific or drive-specific
information. Contact the Start-up Project Manager for required project-specific
or drive-specific information such as:
•Dimensional Drawings and Electrical Drawings generated for the
customer’s order.
•Spare parts lists compiled for the customer’s order.
•Drive-specific technical specifications.
•Pre-commissioning Checklist
•PLC program for standard, integral PLC
Required Supplemental
Information
Dimensional Drawings and Electrical Drawings
Thoroughly review the project-specific Dimensional Drawings (DDs) and
Electrical Drawings (EDs) to understand the specific drive system being
commissioned, before performing any mechanical or electrical work.
Within these drawings is detailed information which is important to understand
for the commissioning and installation of the equipment.
WARNING: This document is for internal use only (for Rockwell CSM/field
support Engineers). DO NOT disclose this document to customers or any non-
Rockwell Automation employee. Disclosure of sensitive information in this
document may cause dire consequences to the drive.
Table 1 - Electrical Drawings
Contactor Locations (electrically)
Drive Topology
General Notes
Minimum Power Cable Insulation Ratings
Component Designations
Customer Power and Control Wiring Locations (electrically)
Control and Medium Voltage Power Ratings
Fuse Locations (electrically)

8Rockwell Automation Publication 6000-IN007B-EN-P - March 2016
Preface
If the drawings require changes to suit the installation and application of the
system, fax or e-mail the marked up drawings to the Start-up Project Manager.
Shipping, Handling, and Installation Manual
Review publication 6000-IN006_-EN-P, PowerFlex 6000 Medium Voltage
Variable Frequency Drive Shipping, Handling, and Installation manual.
The customer/contractor has the option to perform the electrical
interconnection work between cabinet shipping splits, as shown in this manual,
or contract Rockwell Automation to perform this work. This will be reflected in
the Services Purchase Order and the pre-commissioning checklist. Verify that the
documentation matches the actual scope of work done by the customer/
contractor. You will be required to either perform this interconnection work
immediately prior to the commissioning process or to verify the work was done
correctly by the contractor. It is very important to confirm the alignment of the
paperwork with the actual scope of work.
It is also extremely important to understand the contractor’s basic scope of work,
preceding the commissioning process. Part of the overall commissioning process
is to ensure this work has been done correctly. If this work has not been done
properly, this must be brought to the attention of the customer immediately. Do
not proceed with commissioning until this issue is resolved.
Additional required information about the PowerFlex 6000 can be downloaded
from http:/www.rockwellautomation.com/literature/.
•6000-IN006_-EN-P: PowerFlex 6000 Medium Voltage Variable
Frequency Drive Shipping, Handling, and Installation Instructions
•6000-UM002_-EN-P: PowerFlex 6000 Medium Voltage Variable
Frequency Drive User Manual (operating the HMI, full parameter listing)
You must review these publications thoroughly before beginning the
commissioning process. They contain supplemental information that will aid in
the commissioning process.
Table 2 - Dimensional Drawings
Control and Medium Voltage Power Ratings
Drive Options
Motor Ratings
Drive Power Component Selection Ratings

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 9
Preface
General Precautions
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
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.
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.

10 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016
Preface
Notes: