Rockwell Automation Allen-Bradley PowerFlex 6000 User manual

User Manual Original Instructions
PowerFlex 6000 Medium
Voltage Variable Frequency
Drive
Bulletin Number 6000G

2Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
PowerFlex 6000 Medium Voltage Variable Frequency Drive 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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commissioning Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Introduction Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How it Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cascaded “H” Bridge (CHB) Topology. . . . . . . . . . . . . . . . . . . . . . . . . . 12
Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2
Drive System Layout Elevation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Isolation Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Isolation Transformer Temperature Monitor. . . . . . . . . . . . . . . . . . . 24
Top-mounted Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Incoming Line Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . 25
Outgoing Motor Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hall Effect Current Sensors (HECs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Top-mounted Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Unit (all modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Synchronous Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 3
Setup and Operation Main Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Drive Setup and Configuration Controls . . . . . . . . . . . . . . . . . . . . . . . 41
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Setup and Monitor Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Set Frequency (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drive Operation Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
View Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
View Voltage, Current, or Frequency Trends . . . . . . . . . . . . . . . . . . . 52
Customize a Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Confirm Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Choose Local/Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Open/Close Drive Input and Output Contactors . . . . . . . . . . . . . . . . 58
Open/Close Bypass Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
User Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Change User Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chapter 4
Parameters and Function Codes P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 5
Preventative Maintenance and
Component Replacement
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Clean the Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Regular Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Physical Checks (No Medium Voltage or Control Power) . . . . . . . . . . . . 85
Power Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Medium Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Replace/Clean Door-mounted Air Filters . . . . . . . . . . . . . . . . . . . . . . . 87
Inspect Top Mounted Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Replace Top Mounted Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Inspect Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Inspect Voltage Sensing Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Replace Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Inspect Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 5
Replace Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Inspect, Clean, or Replace Door Mounted Air Filters . . . . . . . . . . . . 98
Inspect or Replace Top Mounted Cooling Fans . . . . . . . . . . . . . . . . . 98
Inspect Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replace Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replace Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Inspect or Replace HECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Inspect or Replace Door Position Limit Switch . . . . . . . . . . . . . . . . 107
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Inspect AC/DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Replace AC/DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Inspect UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Inspect PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inspect/Replace Control Unit or Control Boards . . . . . . . . . . . . . . . 114
Inspect the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Replace the HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Replace LV Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Replace LV Control Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . 120
Inspect Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspect Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspect Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspect Locking and Interlocking Devices. . . . . . . . . . . . . . . . . . . . . 122
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Inspect LV Component Terminal and Plug-in Connections . . . . . 122
Inspect Medium Voltage Cable Connections . . . . . . . . . . . . . . . . . . 122
Inspect Power Cable and Control Wire Terminals. . . . . . . . . . . . . . 122
Inspect Transformer Secondary Windings . . . . . . . . . . . . . . . . . . . . 122
Inspect Power Module Input and Output Power Connections . . . 123
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Review Firmware and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Inspect/Review Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Professional Maintenance Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Miscellaneous Preventive Maintenance Work . . . . . . . . . . . . . . . . . 123
Tools/Materials/Documentation Requirements. . . . . . . . . . . . . . . . 124
Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Prepare Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Appendix A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Appendix B
Catalog Number Explanation PowerFlex 6000 Medium Voltage Variable Frequency Drives . . . . . . . 129
Appendix C
Preventative Maintenance
Schedule
PowerFlex 6000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Appendix D
Torque Requirements Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Appendix E
Spare Parts Storage Requirements and Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Power Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Signal Conditioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Control Equipment and Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
EC Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Spare Parts Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Spare Parts Connection Matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Power Supply Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1606 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Control Equipment and Boards Connection Guidelines. . . . . . . . . . . . 140
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Power Components Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . 142
Power Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Cooling System Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 144
EC Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Connection Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Guidelines for Extended Shutdown or Storage. . . . . . . . . . . . . . . . . . . . 146
Medium Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Storage Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Power Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Guidelines for Inspection After Extended Shutdown or Storage . . . . 147
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 7
Preface
About This Publication This document provides procedural information for managing daily or
recurring tasks involving PowerFlex® 6000 medium voltage variable frequency
drives.
Rockwell Automation recognizes that some of the terms that are currently
used in our industry and in this publication are not in alignment with the
movement toward inclusive language in technology. We are proactively
collaborating with industry peers to find alternatives to such terms and
making changes to our products and content. Please excuse the use of such
terms in our content while we implement these changes.
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 that are generated for each
customer’s order
• Spare parts lists compiled for each customer’s order
See the following documents for additional product detail or instruction
relating to PowerFlex 6000 drives:
• PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation
Manual, publication 6000-IN006; instructions for installing the drive,
dimensions, requirements, and wiring information.
• PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping
and Handling Manual, publication 6000-IN008: instructions for
shipping and handling a Medium Voltage variable frequency drive and
related equipment.
• PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware,
Parameter, and Troubleshooting Manual, publication 6000-TD004.
This document provides detailed information on drive features,
parameters, and troubleshooting faults.
Rockwell Automation provides the site- and installation-specific electrical and
design information for each drive during the order process cycle. If they are
not available on site with the drive, contact Rockwell Automation.
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.

8Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Preface
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.
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 startups
• 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 before the commissioning process will delay the startup of the drive.
Topic Page
Updated template Throughout
Added inclusive language acknowledgment 7
Updated Figure 17 - Isolation Transformer Temperature Monitors 25
Updated section HMI 38
Added section Operator Interface 39-40
Updated section Replace the eHIM 118
Added appendix Spare Parts Storage 137
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, 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.

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 9
Preface
See the Pre-commissioning Checklist in the PowerFlex 6000 Medium Voltage
Variable Frequency Drive Installation Manual, publication 6000-IN006.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation
Manual, publication 6000-IN006 Provides instructions for installing the drive, dimensions, requirements, and wiring
information.
PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping and
Handling Manual, publication 6000-IN008 Provides instructions for shipping and handling a Medium Voltage variable frequency drive
and related equipment.
PowerFlex 6000 Medium Voltage Variable Frequency Drive Parameter
Manual, publication 6000-TD004 Provides detailed information on drive features, parameters, and troubleshooting faults.
EtherNet/IP Network Devices User Manual, publication ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, publication ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual,
publication SECURE-RM001
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
publication CMPNTS-SR002 Assists original equipment manufacturers (OEMs) with construction of panels, to help ensure
that they conform to the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to Motor
Circuit Design, publication IC-AT001 Provides an overview of American motor circuit design based on methods that are outlined
in the NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
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.

10 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Preface
Notes:

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 11
Chapter 1
Introduction
Around the world, Allen-Bradley® PowerFlex® medium voltage drives from
Rockwell Automation have built a reputation for providing efficient and
reliable motor control for industry's most demanding applications. From the
hardware designed to help optimize production to the power of networked
control platforms, users can quickly and easily gain access to valuable
information from their systems. Better information leads to higher asset
availability, reduced energy and maintenance costs, and asset and personnel
protection - all resulting in an increased return on your investment and real
bottom-line savings. No matter where your applications are located - and
whether your requirements are simple or complex, count on PowerFlex
medium voltage drives for the optimal solution.
Safety Considerations
Lockout and tagout the device feeding power to the input of the drive before
performing any drive maintenance or component replacements. After the
input device cabinet doors are opened, immediately test the outgoing power
cables feeding the drive with a live-line tool (hot stick) while wearing high-
voltage gloves. Repeat the live-line tool (hot stick) testing at the drive incoming
line power cable connections to verify that medium voltage is not present. Pay
special attention to any capacitors connected to medium voltage that can
retain a charge for a period of time. Only after the drive equipment has been
verified as isolated and de-energized can subsequent work be performed. Even
though the input to the drive may be open, it is still possible for hazardous
voltage to be present.
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 that are outlined in Electrical Safety requirements for
Employee Work places must be followed. Before attempting any work, verify
that the system has been locked out and tested to have no potential.
Table 1 - Line-to-Ground Short-circuit Specifications
Attribute Value
Line-to-Ground short-circuit current 31.5 kA
Incoming circuit breaker withstand current short time 4 s
Ik ≥31.5 kA
Opening time 40...60 ms
Breaking time 50...75 ms
Inrush current Inverter input current x 4 or Inverter input current x 5

12 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 1 Introduction
See national and local safety guidelines for detailed procedures on how to
isolate the equipment from hazards safely.
Environmental Conditions • Elevation above sea level must be less than 1000 m (3250 ft)(1).
• Ambient air temperature must be between 0...40 °C (32...104 °F)(2).
• Relative humidity must be less than 95%, noncondensing.
• Operation Vibration limited to 3M3(a) per IEC60721-3-3.
• G2 rating with 60% humidity – Storage, Transport, and Operation – as
per ISA 71.04-2013.
• The drive must be installed indoors; there must be no dripping water or
other fluids in the room.
• Cooling air must be clean without significant concentrations of sand,
corrosive or conductive dust, or explosive gas. The drive must be installed
in a Pollution Degree 2 environment as per IEC 61800-5.
• 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.
A number of identical low voltage power modules are series-connected
(cascaded) together to produce the medium voltage levels that are 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 that are required for most applications, without the requirement
for output filtering.
ATTENTION: The national and local electrical codes outline provisions for
safely installing and working on electrical equipment. Installation must
comply with specifications regarding wire type, conductor sizes, branch
circuit protection, and disconnect devices. Failure to do so may result in
personal injury and/or equipment damage.
(1) Options are available for operation up to 5000 m.a.s.l. However, these must be stated at the time of order and cannot be retrofitted in the
field.
(2) Options are available for ambient temperatures up to 50 °C. However, these must be stated at the time of order and cannot be retrofitted in
the field.

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 13
Chapter 1 Introduction
This power module concept makes maintenance quick and easy. Each module
has powerful built-in diagnostics to identify and isolate a module needing
replacement, in the unlikely event of a failure. This minimizes power module
replacement time, so process uptime is maximized.
Figure 1 - 6.6 kV Example Power Structure
Simplified Electrical
Diagrams Figure 2 - 2300V / 2400V / 3300V (18 Pulse - 9 Power Modules)
Figure 3 - 4000V / 4160V (24 Pulse - 12 Power Modules)
Input power
3-phase AC Power Modules
Isolation
Transformer
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W

14 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 1 Introduction
Figure 4 - 6000V (30 Pulse - 15 Power Modules)
Figure 5 - 6300V / 6600V /6900V (36 Pulse - 18 Power Modules)
Figure 6 - 10000V (48 Pulse - 24 Power Modules)
Figure 7 - 11000V (54 Pulse - 27 Power Modules)
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W
M
Isolation Transformer Secondary Windings
U
V
W

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 15
Chapter 1 Introduction
Figure 8 - Connectivity Overview
Reset
Start
Stop
Current output
4-20 mA
Frequency output
4-20 mA
Speed input 4-20 mA
Analog spare 4-20 mA
Analog spare 4-20 mA
110/120/220/240V AC
Control Power
MV Closed
Permit Close MV Indicator
MV Closed Indicator
Warning Indicator
Fault Indicator
Running Indicator
Stop Indicator
Ready Indicator
Remote Control Indicator
Permit to Close Customer Breaker (CB)
Emergency/Fault Trip
Emergency Stop status
MV Pre-Closed
MV Closed
Warning
Fault
Running
Stop
Ready
Remote Control
Permit Close CB
Trip
Three-phase
Induction
Motor
Emergency/Fault Trip
(Reserved)
MV Close
Emergency Stop status
(Reserved)
Emergency Stop
Emergency Stop
Trip
MV Close
E-Stop
E-Stop

16 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 1 Introduction
Figure 9 - PowerFlex 6000 Principal Components
All-in-One Design (A-Frame)
Power Modules
HMI
Cooling Fan
Door Filters

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 17
Chapter 1 Introduction
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 (for H-Frame
and B-Frame drives only)
All Power Modules are identical to minimize
spare parts
All Power Modules are designed for easy
removal and replacement to minimize
MTTR
Power Module has a PWM pattern to reduce
output harmonics
Optional Power Module bypass feature
ensures critical process reliability
All MV doors are electrically interlocked
with input switching device
All MV doors are interlocked with
mechanical interlocking device (optional)
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 touch screen
HMI
Many communication modules are
available, such as EtherNet/IP and
PROFIBUS DP
Automatic switchover (no trip) to internally
supplied control power if customer-
supplied single-phase control power is lost
Online UPS supplied as standard to support
ultra long control power loss ride-through
capability
Available with redundant fan with
automatic switchover for increased uptime
Available with NEMA Type 1/IP31 or IP42
enclosure.
Isolation Transformer Power Modules
Door Filters
Cooling Fans
HMI
In-Line Design (B-Frame and H-Frame)
H-Frame
H-Frame
See Elevation Drawings on page 19 for details.

18 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 1 Introduction
Standards Compliance Technical specifications and relevant standards in the manufacture, testing,
and acceptance of equipment are included below. The AC drive has been tested
per applicable requirements of the following standards:
Standard Number Standard Description
UL 347A Medium Voltage Power Conversion Equipment Preliminary Standard
CSA C22.2 No. 274-13 Adjustable Speed Drives
ANSI Instrument Transformers C57.13
NEC National Electric Code
OSHA Occupational Safety & Health Act
IEC 60034-17 Rotating Electrical Machines Part 17, Cage Induction Motors When Fed from Converters
IEC 60146 Semiconductor Converters General Requirements
IEC 60204-11 Safety of machinery Electrical Equipment of machines-Part 11: requirements of HV
equipment for voltages above 1000V AC or 1500V DC and not exceeding 36 kV
IEC 60529 Degrees of Protection provided by enclosures
IEC 61800-3 Adjustable speed electric power drive systems - Part 3 EMC requirements and specific test
methods
IEC 61800-4 Adjustable speed electric power drive systems - Part 4 Rating specification for AC power
drive systems above 1000V AC and not exceeding 35 kV
IEC 61800-5-1 Adjustable speed electric power drive systems - Part 5-1: Safety requirements - Electrical,
thermal and energy
IEC 60076 Electric Power Transformer
IEC 60038:1983 IEC Standard Voltages
IEEC C57.18.10-1998 IEEE Standard Practices and Requirements for Semiconductor Power Rectifier
Transformers
IEEC C57.12.01-1998 IEEE Standard General Requirements for Dry-Type Distribution and Power Transformers
IEEE C57.12.91-1995 IEEE Standard Test Code for Dry-Type Distribution and Power Transformers
IEEE 519-1992 IEEE Practices and Requirements for Harmonic Control in Electrical Power Systems

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022 19
Chapter 2
Drive System Layout
All PowerFlex 6000 power modules that are designed as front connection. For a
drive amperage rating ≤350 A (304 A for heavy duty), a fixed-mounted power
module design is supplied. Fixed-mounted modules are shipped installed in
the drive.
For a drive amperage rating of >350 A (304 A for heavy duty), power modules
are shipped separately, therefore site installation and cable connection is
needed. In this case, a lifting cart is supplied for power cell replacement.
The PowerFlex 6000 drive is shipped in two sections, the Isolation
Transformer cabinet and the Power Module/LV Control cabinet, unless it is an
A-Frame drive, which is shipped in one single cabinet. See the PowerFlex 6000
Medium Voltage Variable Frequency Drive Shipping and Handling Manual,
publication 6000-IN008.
Elevation Drawings Depending on the drive rating, the system layout may be different.
Figure 10 - Drive Configurations
Topic Page
Isolation Transformer Cabinet 20
Power Module Cabinet 30
LV Control Cabinet 34
Power Module cabinetLV Control
cabinet
A-Frame

20 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022
Chapter 2 Drive System Layout
Isolation Transformer
Cabinet
Isolation Transformer cabinet Power Module cabinet LV Control
cabinet
H-Frame
Isolation Transformer cabinetPower Module cabinetLV Control
cabinet
B-Frame
Isolation Transformer 23
Isolation Transformer Temperature Monitor 24
Top-mounted Cooling Fans 25
Incoming Line Power Cable Connections 25
Outgoing Motor Cable Connections 26
Door Position Limit Switch 26
Voltage Sensing Board 29