Rockwell Automation Allen-Bradley PowerFlex 6000T User manual

PowerFlex 6000T Drives
Catalog Number 6000T
Installation Instructions Original Instructions

2Rockwell Automation Publication 6000-IN100B-EN-P - October 2020
PowerFlex 6000T Drives 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-IN100B-EN-P - October 2020 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 5
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contractor Scope of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Drive Mechanical Installation Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Affix Cabinets to Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Seismic Rated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Main Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install Power Modules (if applicable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 2
Drive Electrical Installation Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Grounding System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Motor Cable Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control Signal Wiring Design Considerations . . . . . . . . . . . . . . . . . . . . . 36
Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connect the System Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 39
Connect Incoming Line and Outgoing Motor Power Cables . . . . . . . . . 39
Connect Control Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connect External Control Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 45

4Rockwell Automation Publication 6000-IN100B-EN-P - October 2020
Table of Contents
Chapter 3
Drive Electrical Interconnection Electrical Interconnection Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . 49
Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . 50
Connect LV Control and Fan Wiring Bundles . . . . . . . . . . . . . . . . . . . . . . 52
Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Appendix A
Pre-Commissioning Pre-Commissioning Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pre-Commissioning Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix B
Torque Requirements Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Appendix C
General Wire Categories General Wire Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Appendix D
Power Cabling and Control
Signal Wiring Details
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 66
Appendix E
Line and Load Cable Sizes Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Rockwell Automation Publication 6000-IN100B-EN-P - October 2020 5
Preface
About This Publication This manual provides procedural information for installing PowerFlex® 6000T
medium voltage drives.
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.
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 installing a PowerFlex 6000T
drive. It does not include project-specific, or drive-specific topics such as:
• Dimensional Drawings (DD) and Electrical Drawings (ED) that are
generated for each customer’s order.
• Spare parts lists compiled for each customer’s order.
• Drive-specific technical specifications.
For additional product detail or information relating to PowerFlex 6000T
drives, see the publications listed in Additional Resources on page 6.
Required Supplemental
Information
This manual includes generic information about the drive cabinet layout
orientation and generic electrical connection information.
Review the project-specific Dimensional Drawings (DDs) and Electrical
Drawings (EDs) to better understand the specific drive system cabinet
orientation and wiring requirements before performing any mechanical or
electrical work. Paper copies of the DDs and EDs are placed in the document/
hardware box in the Isolation Transformer Cabinet before shipment. Contact
the local Rockwell Automation office to obtain digital copies, if required.

6Rockwell Automation Publication 6000-IN100B-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.
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 6000T 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 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 35
Updated Important information under Power Cable Design Considerations 36
Resource Description
PowerFlex 6000T Drives Shipping and Handling Manual,
publication 6000-PC100 Provides instructions for shipping and handling PowerFlex6000T drives and related
equipment.
PowerFlex 6000T Drives Hardware Service Manual, publication 6000-TG100 Provides instructions for daily recurring drive usage, HMI interface, and maintenance tasks
for the product’s end user.
PowerFlex 6000T Drives Programming Manual, publication 6000-PM100 Provides detailed information on drive features, programming parameters, and
troubleshooting faults and alarms.
EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, 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.
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.

Rockwell Automation Publication 6000-IN100B-EN-P - October 2020 7
Preface
You can view or download publications at rok.auto/literature.
Commissioning Support After installation, Rockwell Automation is responsible for commissioning
activities for the PowerFlex 6000T 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 INCO terms)(a):
• Load equipment on truck at a Rockwell Automation manufacturing
facility and transport equipment to site
• Offload equipment from truck on-site
• Perform initial inspection(b)
• Move equipment to the final installation location
• Position the cabinet sections together as shown in Dimensional Drawing
and level the cabinet lineup
• Mechanically join cabinets together
• Affix the cabinets to the floor
• Install assemblies shipped loose (fan assemblies).
• Install external ductwork to exhaust heated air from control room (if
required)
• Install power and control cabling and terminate cable connections to
drive system:
- Connect system ground cable
- Insulation Resistance (IR) testing of incoming line and outgoing
motor power cables
- Connect incoming line and outgoing motor power cables
- Connect control power wiring
- Connect all external customer required control signal wiring
- Connect electrical safety interlock control signal wiring circuit to
input circuit breaker
• Connecting the power cables and control wiring between cabinets that
are shipped separately(c)
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.
Resource Description
(a) All or part of these activities could be provided by Rockwell Automation or its
representatives, based on contract INCO terms and negotiated scope of supply/services
agreement. Contact the local Rockwell Automation office for further information.
(b) Customer should lead the initial inspection process.

8Rockwell Automation Publication 6000-IN100B-EN-P - October 2020
Preface
• Complete Pre-commissioning Checklist
Environmental Conditions • Elevation above sea level must be less than 1000 m (3250 ft)(a).
• Ambient air temperature must be between 0…40 °C (32…104 °F)(b).
• 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.
(c) 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.
(a) 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.
(b) 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-IN100B-EN-P - October 2020 9
Chapter 1
Drive Mechanical Installation
The installation process is divided into three principal activities. The
mechanical installation process described in this chapter, the electrical
installation process described in Drive Electrical Installation on page 33, and
the electrical interconnection process described in Drive Electrical
Interconnection on page 47.
Mechanical Installation
Summary
The cabinets must be arranged as shown in the Dimensional Drawing (DD).
Follow all applicable guidelines for siting the components before continuing
with these installation instructions.
There may be some variation in the process depending on the type and number
of drive components in your particular installation.
Connect Shipping Splits
Connect DV/DT Filter Cabinet for A-Frame Drives
The standard A-Frame for PowerFlex 6000T drives comes fully assembled and
does not require any shipping splits. However, if a DV/DT filter is included
with the drive then there is one shipping split, and the drive and filter needs to
be connected as follows:
1. Remove the M16x16 countersunk screw that secures the LV covers and
grounding cover at the right side of the main drive, and the left side of
the filer cabinet. Then remove the covers.
2. Arrange the sections as described in the Dimensional Drawings and
move the sections together.
3. Align the cabinet side sheets together at the holes for the hardware.
Connect Shipping Splits 9
Affix Cabinets to Floor 13
Install Seismic Rated Enclosures 16
Install Main Cooling Fans 23
Install Power Modules (if applicable) 26
External Ducting 30
ATTENTION: Install the drive on a level surface (+/- 1 mm per meter
[+/- 0.036 in. per 36 in.] of drive length in all directions). If necessary, use
metal shims to level the cabinets before joining them; attempting to level
after joining may twist or misalign the cabinets.

10 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020
Chapter 1 Drive Mechanical Installation
Figure 1 - Align the Cabinets, A-Frame
4. Secure the cabinets together using two L-shaped brackets and four M12
hexagon socket bolts, D12 washers, and D12 lock washers at the front and
rear side.
DV/DT Filter Cabinet
Side View
Front Front
Isolation Transformer Cabinet