Allen-Bradley PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual
PowerFlex 6000 are designed to provide reliable, efficient, and flexible control of large industrial motors. This drive is a powerful and versatile tool that offers a wide range of capabilities, making it ideal for use in various industries including mining, oil and gas, and manufacturing.
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Commissioning Manual
PowerFlex® 6000 Medium Voltage Variable Frequency Drive
Commissioning Manual
Publication 6000-IN007A-EN-P
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.
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.
Labels may also be on or inside the equipment to provide specific precautions.
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).
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Preface
Introduction
Preparation and Inspection
Commissioning
Table of Contents
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensional Drawings and Electrical Drawings. . . . . . . . . . . . . . . . . . . 7
Shipping, Handling, and Installation Manual . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Documentation and Application Review . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Review all Rockwell Automation Supplied Documentation . . . . . . 12
Pre-commissioning Customer Meeting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2
Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Isolate the Power and Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 29
Chapter 3
Simulate Closed Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . 32
Verify Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Set P Parameters to Enable Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Verify Operation of Frequency Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Verify Operation to Set Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Simulate Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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4
Table of Contents
No-load Test
Verify E-Stop Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Verify Switching from Local Control to Remote Control . . . . . . . . 51
Verify Operation of Input/Output and Bypass Isolation Switches
Verify Operation of Input/Output and Bypass Contactors
Verify Operation of DCS Input and Output Signals . . . . . . . . . . . . . 61
Restore P Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Change Time/Date/Regional Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter 4
Energize Drive Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Configure P and T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Close Isolation Switches in Bypass Cabinet . . . . . . . . . . . . . . . . . . . . . 75
Close Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Check Cooling Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Torque Requirements
Single Line Diagrams
Appendix A
Appendix B
Appendix C
Special Function Parameter Settings
Number of Power Modules Per Phase . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Rated/Maximum Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Hall Effect Current Sensor Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Analog Output Display Parameter Setting . . . . . . . . . . . . . . . . . . . . . . 89
Set Frequency Command Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Frequency Command Deadband Upper Limit . . . . . . . . . . . . . . . . . . 90
Frequency Amplitude Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Index
Table of Contents
Set Maximum Modulation Index and Limit Output Voltage
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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Table of Contents
Notes:
6
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Preface
Introduction
This document provides procedural information for commissioning
PowerFlex 6000 medium voltage drives.
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.
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)
Table 2 - Dimensional Drawings
Control and Medium Voltage Power Ratings
Drive Options
Motor Ratings
Drive Power Component Selection Ratings
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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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-UM001_-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.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
General Precautions
Additional Resources
Preface
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.
These documents contain additional information concerning related products from Rockwell Automation.
Resource
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, http://www.ab.com
Description
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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Preface
Notes:
10
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Overview
Chapter
1
Introduction
Information contained in this chapter will assist in commissioning a
PowerFlex 6000 medium voltage AC drive.
Review the information contained in this chapter prior to commissioning the drive and use it as a reference while the drive commissioning is performed.
WARNING: Perform the commissioning checks illustrated in the sequence that they have been presented. Failure to do so may result in equipment failure, personal injury, or death.
Prior to commissioning, the following work will have been performed by the customer or the customer’s electrical contractor:
Connect External Cabling and Wiring
Connect System Ground Cable
(1)
Megger Test of Power Cables
Connect Incoming Line and Outgoing Motor Power Cables
(1)
Connect Control Power Wiring
Connect External Control Signal Wiring
Connect Electrical Safety Interlock Control Signal Wiring Circuit to Input Circuit Breaker
Connect Internal Cabling and Wiring
(2)
Connect Isolation Transformer Secondary Power Cables to Power Modules
Connect Motor Cables and Voltage Sensing Board Cables to U, V, and W Output Phase Buses
Connect LV Control and Fan Wiring Bundles
Connect Ground Bus Splices
(1) If an optional bypass unit is supplied, the system ground cable, incoming line power cables, and outgoing motor power cables are connected to the bypass unit.
(2) 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 prior to the commissioning process.
This work will be reviewed during the pre-commissioning customer meeting and validated during the commissioning process; see
Installation Review on page 21
.
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Chapter 1
Introduction
Process Flowcharts
Documentation and Application Review
Review
Rockwell
Automation
Supplied
Documentation
Pre-commissioning
Customer Meeting
Preparation and Inspection
Gather
Required Tools and Test
Equipment
Lockout and Tagout
Inspect Drive
Components
Review Drive
Application
Functional
Assessment
Interconnection
Review
Installation
Review
Commissioning
Control
System Check
(LV Only)
No-load Test of Drive
System
(MV)
Load Test of
Drive System
(MV)
Meggering
Final Review and Preparation
Documentation and
Application Review
Review all Rockwell Automation Supplied Documentation
Each drive is shipped with the technical publications required to assist in commissioning and troubleshooting the drive. Request copies or revisions of these documents from the Start-up Project Manager. However, you will have received e-copies of this information prior to commissioning by the Start-up
Project Manager.
Before commissioning the drive, ensure you have the following resources:
•
Project-specific Electrical Drawings and Dimensional Drawings
•
PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping,
Handling, and Installation Manual 6000-IN006_-EN-P ): provides procedural information for physically unloading, moving, and installing equipment
•
PowerFlex 6000 Medium Voltage Variable Frequency Drive
Commissioning Manual ( 6000-IN007_-EN-P ): required procedures and checklists for Rockwell Automation Field Service Engineers.
•
PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual
( 6000-UM001_-EN-P ): instructions for daily recurring drive usage, HMI interface, and maintenance tasks
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Introduction
Chapter 1
•
PLC Program: The PLC I/O processes control signals within the drive and I/O signals to and from the customer’s control system and input circuit breaker. The PLC program is standardized. However, it may be customized to address specific customer requirements by Rockwell
Automation during the Application Engineering phase of order execution.
Pre-commissioning Customer Meeting
Before commissioning the drive, it is recommended to schedule a meeting with the customer.
1.
Discuss the activities and documentation needed to review the drive application
2.
Review the start-up activities and timelines
3.
Review the Pre-commissioning Checklist (see 6000-IN006_-EN-P)
4.
Review the drive application
Review Drive Application
To ensure trouble-free commissioning, it is necessary for all personnel involved in the start-up to familiarize themselves with the drive and actual application.
Service on the equipment should not be performed without a clear understanding of how the equipment has been designed to function and how the equipment has been applied.
Before commissioning the drive, inspect the process that the drive is intended to control. This identifies how the equipment is designed to suit the application, and any potential hazards. Determine what measures must be taken to ensure that commissioning the equipment does not expose anyone to hazardous situations or damage to the equipment. Verify that the load is not turning due to the process, as a freewheeling motor can generate voltage that will be back-fed to the equipment being serviced. Take all actions necessary to ensure that motor regeneration into the drive does not occur while the equipment is being started up or being serviced.
Review Electrical System One-line Diagram
Identify all relevant equipment Tag Identification names and numbers. Study the system for sources of power and parallel paths of medium voltage power. Retain a copy of the one-line diagram for commissioning the drive. If applicable, send a copy of the one-line diagram to the Start-up Project Manager to be archived and used for future customer assistance.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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Chapter 1
Introduction
On-site Verification of Electrical System One-line Diagram
ATTENTION: Make sure the medium voltage input circuit breaker feeding the drive is locked out and tagged out. Make sure the LV circuit breaker feeding control power to the drive is locked out and tagged out. Make sure the drive is de-energized before conducting the drive inspection process.
Once all documentation has been reviewed, an on-site inspection of the drive is required. Identify the physical locations of the connections to the drive using Tag
Identification names or numbers from the one-line diagram and Rockwell
Automation Electrical Drawings.
All customer power and control wiring required for the drive line-up installation has been identified on the Rockwell Automation Electrical Drawings by a dashed line.
Installation of all external power cabling and control wiring interfacing with the drive is completed by the customer or their electrical contractor. Verify that this wiring is installed correctly and meets electrical voltage and current capacity requirements. Trace the power cables point-to-point from the input circuit breaker to the drive, and from the drive to the motor using the Electrical
Drawings as a reference for proper drive power cable termination locations. Any discrepancy between the physical installation and the Electrical Drawings of the following items should be reviewed prior to commissioning the drive:
•
Medium voltage power cabling in from the input circuit breaker to drive
•
Medium voltage power cabling out from drive to motor
•
Low Voltage control power cables from LV MCC or circuit breaker to drive
•
Ground connection from system ground to drive
•
Control signal wires and communication cables from remote DCS/PLC or other remote device to drive
•
Electrical safety interlock/control wiring from the drive to the input circuit breaker
ATTENTION: Do not change wiring or remove terminal wiring.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Chapter
2
Preparation and Inspection
Gather Required Tools and
Test Equipment
Hand Tools
•
Metric wrenches and sockets
•
Torque wrench
•
Assortment of screw drivers
•
Wire stripper/cutter
Electrical Equipment
•
High voltage gloves – 17 kV insulation rating (minimum)
•
Anti-static strap
•
Live-line tool (Hot stick)
•
5 kV Insulation Tester
Test Equipment
•
600V (1000V rating) digital multimeter with assorted clip leads
Computer Requirements and Software
•
Laptop computer
•
USB cable
•
PLC program
•
CCW software
Lockout and Tagout
SHOCK HAZARD: Servicing 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 cabinet even with the input circuit breaker in the off position. Required practice is to disconnect and lock out control equipment from power sources, and confirm discharge of stored energy in capacitors. If it is necessary to work in the vicinity of energized equipment, the safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed.
Before attempting any work, verify the system has been locked out and tested to have no potential.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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Chapter 2
Preparation and Inspection
Lockout and tagout the input circuit breaker before opening the doors to the drive system cabinets. After the cabinet doors are opened, immediately test the incoming and outgoing power cables and any components connected to medium voltage with a live-line tool (hot stick) while wearing high voltage gloves. Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time. Only after the 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.
Refer to local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards.
Safety Test
Complete every point included in this section prior to continuing with the drive commissioning, to ensure that the commissioning continues in an environment safe to all those involved in servicing the drive. Ensure that commissioning of this drive is performed in accordance with local safety standards.
Inspect Drive Components
After performing the lockout and tagout procedure (see
cabinet doors. Inspect each component for signs of shipping damage (see Table 3 on page 18
). An initial inspection would have been done by the customer when the equipment was received. However, this would have been done from the front only and was just looking for obvious signs of damage (see publication 6000-
IN006_-EN-P ). Record the part number and description of any damaged components and immediately contact the Start-up Project Manager to order replacement components, if required.
ATTENTION: Verify the equipment against any damage. Do not install a damaged drive.
Verify that all components are securely affixed to the cabinet.
Most components will be easily visible on the doors or from the front of the cabinets after the doors are opened. Some components are best viewed from the rear of the cabinet.
For rear inspection, remove top and bottom rear access plates from the drive and bypass cabinet (if supplied). See publication 6000-IN006_-EN-P.
IMPORTANT
The Inspect Drive Components Checklist (see page 18
) mentions the principal base components supplied in the drive and bypass units. It is not comprehensive, as customer-required options may be supplied and three different bypass configurations are available.
Perform the shipping damage inspection for all components mounted in the drive cabinets and specific bypass unit cabinet (if supplied).
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Functional Assessment
Preparation and Inspection
Chapter 2
After the components are visually inspected to identify any shipping damage, a thorough functional assessment should be performed (see
).
The main purpose of this assessment is to ensure that all movable parts and assemblies operate properly, connect properly, and components are wired properly and securely.
The Functional Assessment procedure can be combined with the “Inspect Drive
Components” checklist on page 18
.
Descriptions of the Power Cable Connections to be inspected and torqued to specifications are in the Interconnection Review and Installation Review sections.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
17
Table 3 - Inspect Drive Components Checklist
Front
Rear
Bypass Cabinet (if supplied)
Door:
Pilot Lights
Voltage Indicator Relay
Cabinet:
Insulators
Switch assemblies
Vacuum contactors
Mechanical linkages
Isolation Transformer Cabinet
Door:
Transformer Temperature monitor
LV Cabinet components
– Fan control circuit breakers
Cabinet:
Transformer Plastic Baffle
Outgoing Motor Power Cable standoffs on
Cabinet Sidesheet
(1)
Outgoing Motor Power Cable Terminal
Insulators on transformer
(1)
Voltage Sensing Board
Incoming Line Power Cable Terminal Insulators on transformer
Motor Cable Braces
Fixed Mounted Power Module Configuration:
Transformer Secondary Windings (2 sets)
– Inspect nomex wrap
– Verify windings from core are undamaged
– Check for debris in top of core
Fixed Mounted Power Module Configuration:
Transformer Secondary Windings (1)
– Inspect nomex wrap
– Verify windings from core are undamaged
– Check for debris in top of core
Drawout Power Module Configuration:
Transformer Secondary Windings (3)
– Inspect nomex wrap
– Verify windings from core are undamaged
– Check for debris in top of core
Power Module Cabinet
Fixed Mounted Power Module Configuration:
Power Module retaining tabs
Check for debris
Output Bus Supports
Fuse Mounting Supports
Drawout Power Module Configuration:
Support frame
Power Modules
Fixed Mounted Power Module:
Heat sink
– Verify orientation relative to barrier plates
Drawout Power Module:
Power In/Power Out connections
(1) Motor Cable terminations could be on the transformer structure or cabinet sidesheet, depending on the power rating.
Low Voltage Control Cabinet
Door:
Pilot lights
Push buttons
Selector switches
HMI
Interface board (on the back of the LV door)
Panel:
DIN rail mounted components
UPS
Fiber optic cables
PLC
Control Unit
UPS connections
Table 4 - Functional Assessment Checklist
Front
Rear
Bypass Cabinet (if supplied)
Electrical Door Interlock
– Verify proper operation of auxiliary contacts with an ohmmeter
Isolation switch auxiliary contacts
– Verify proper operation with an ohmmeter
Isolation switches
– Verify proper operation
– Outer jaws must securely contact the center stab in the closed position
Secondary Wiring and Low Voltage Fuses
– Check all connections per Electrical Drawings
Door Grounding Straps
Surge Arrestors
– Check braided copper connections
Voltage Sensing Relay Cables
– Perform tug test
Line and Load side power cables
– Verify phasing and torque
Top Ground Bus
– Verify braided connections
Isolation Transformer Cabinet
Transformer Secondary Cables
– Verify cables are properly fed through the glanding plate and are undamaged
Voltage Sensing Board cables
– Verify the primary and secondary connections to the board are secure
Door Interlock Limit Switches
– Test auxiliary switch contacts wired back to terminal blocks in LV panel with ohmmeter
Temperature Sensing Wires (3 places)
– Verify wires are intact and properly inserted
Bottom-mounted Auxiliary Fan power from
Isolation Transformer Auxiliary Winding
– Check connections
Door Grounding Straps
Transformer Temperature Protection Relay
– Tug test on all cable connections
Auxiliary Cooling Fans (3)
– Check electrical connection
Transformer Secondary Cables
– Verify cables are properly fed through the glanding plate are undamaged
Tap Changer
– Verify connection
Top Mounted Cooling Fans
– Check electrical connection
Fan Housings
– Assembly must be affixed properly to structure
Auxiliary Cooling Fans (3)
– Check electrical connection
Power Module Cabinet
HECS (2)
– Check plug connectors
Door Interlock Limit Switches (2)
– Test switch contacts wired back to terminal blocks in LV panel with ohmmeter
Power Modules fiber optic cables
– Check all connections
Power Modules Fuses
– Test each fuse with multimeter
Door Grounding Straps
Top Mounted Cooling Fans
– Check electrical connection
Low Voltage Control Cabinet
Control Unit
– Check connection of all fiber optic cables
– Check connection of HMI interface board
– HMI
Low Voltage wires
– Tug test all wires on door, panel, and relays and terminal blocks
Circuit Breakers and Contactors
– Verify operation
Vertical Ground Bus
– Check connections from all attached components
Low Voltage Door
– Verify operation of all operator interface devices
AC/DC Power Supplies
– Check connections
Door Grounding Straps
UPS
– Check connection
Chapter 2
Preparation and Inspection
Interconnection Review
The interconnection checklist summarizes the required items to review to validate the reconnection of power, ground, and control cables between cabinets within the drive system, that were disconnected for shipment. Power and control cables that pass from one cabinet to another are bundled in the appropriate cabinet. These cables are connected for system test at the factory but disconnected and coiled up for shipment. If this interconnection work was done by the contractor, use this checklist to review and ensure the work was done
.
correctly. If the interconnection work was not done by the contractor, the scope of work required to be performed is described in 6000-IN006_-EN-P .
IMPORTANT
Check torque on all power and ground cable connections per specifications listed in
Torque Requirements on page 81 .
Table 5 - Interconnection Review Checklist
Front Inspection
Rear Inspection
Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet
Verify the braided ground connection to adjacent cabinet(s) is properly installed
Review the braided ground connection to adjacent cabinet
Verify line and load power cables from Isolation Transformer
Cabinet are properly connected
Verify all control wires per
Electrical Drawing
Verify the braided ground connection to adjacent cabinet(s) is properly installed
Review all isolation transformer secondary wiring from Power Module cabinet
(2 sets)
Verify that the shields of all of the system’s connecting wires are properly grounded
Verify all control wires per
Electrical Drawing
– Cables are run in LV cable sections along front and back of cabinet
Verify the braided ground connection to adjacent cabinet(s) is properly installed
Verify that the shields of all of the system’s connecting wires are properly grounded
Review load power cable connection from Isolation
Transformer Cabinet
Verify Voltage Sensing
Board power cables from Isolation
Transformer Cabinet are properly installed
Fixed Mounted Power
Module:
Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected (1 set)
Drawout Power Module:
Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected (3 sets)
Verify all power supply cables for main cooling fans for
Isolation Transformer Cabinet are properly connected(3 sets)
Low Voltage Control Cabinet
Verify control signal wiring bundles from LV Control cabinet to LV panel in Isolation
Transformer cabinet and LV panel in the Bypass Cabinet (if supplied) are routed correctly
20
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Installation Review
Preparation and Inspection
Chapter 2
Prior to commencing the commissioning of the drive, verify the equipment was properly installed. Identifying errors in the drive installation prior to commencing the commissioning as opposed to mid-way through the commissioning process will greatly reduce the amount of time required to commission the drive. Verify the drive and all associated equipment have the system power grounding cable installed. Refer to 6000-IN006_-EN-P to review the contractor’s drive installation responsibilities and understand the scope of the work you will be reviewing.
Mechanical Installation Inspection
8
9
10
6
7
4
5
2
3
Sequence Task
1 Verify line up positioning
Verify cabinets are bolted together correctly
Verify cabinets are affixed to the floor properly
Verify fans are installed correctly
Verify power modules are installed correctly
Review duct installation (if applicable)
Verify the cable trenches meet design requirements
Verify required cabinet clearances
Verify there are no scratches or damage to the cabinet body
Verify the top cover of the isolation transformer cabinet is securely mounted
Reference Document
Dimensional Drawings
6000-IN006_-EN-P
Dimensional Drawings,
6000-IN006_-EN-P
6000-IN006_-EN-P
6000-IN006_-EN-P
6000-IN006_-EN-P
6000-IN006_-EN-P
6000-IN006_-EN-P
N/A
6000-IN006_-EN-P
Refer to project-specific EDs to review all electrical connections to external input and output devices.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
21
Chapter 2
Preparation and Inspection
22
Electrical Installation Inspection
4
5
1
2
3
8
9
10
Sequence Task
6
7
11
12
13
14
Reference
Document
Verify that medium voltage cables are separated at least 30 cm from the control cables
Verify that all secondary control wiring use shielded cables
Verify that input and output medium voltage cables specifications meet the stated insulation requirements
Verify that input and output medium voltage cables have attached nameplates
Verify the diameter of control power cables comply with the drawings
Electrical
Drawings
Electrical
Drawings
Verify that the electrical safety circuit wiring between the input circuit breaker and the drive is shielded and only the end at the drive side is grounded
Verify the wiring between the DCS and the drive is shielded and only the end the drive side is grounded
Verify that the user-provided ground cable is ≥50 mm
2
Verify the isolation transformer’s primary input voltage matches the system primary voltage
Verify that the customer motor specifications match the drive voltage and current capabilities
Verify that the isolation transformer’s input side wiring is correct Electrical
Drawings
Verify that the motor output side wiring is correct Electrical
Drawings
Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical
Drawings
Verify torque on incoming line power cable and outgoing motor power cable terminations Electrical
Drawings
Power Cabling
Trace the power cabling from termination point to termination point while examining the cable and its routing for mechanical damage, sharp bend radiuses and sources of induced noise and heat. The power cabling must be is sufficiently braced to contain the cabling in the event of a ground fault. Color coding is used to indicate the phase orientation of the drive.
Table 6 - Color Coding
Color
Yellow
Incoming Line Side
L11 (A Phase) Line Cable Terminal
Green
Red
L12 (B Phase) Line Cable Terminal
L13 (C Phase) Line Cable Terminal
Outgoing Motor Side
U Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
V Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
W Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Drive Megger Check
Preparation and Inspection
Chapter 2
Incoming Line and Outgoing Motor cables must be routed separately to prevent cable insulation damage.
All cables must be terminated on each end and sufficiently torqued.
All customer power cables must be Hi-Potted or Meggered and read a sufficient insulation value. Review Hi-Pot or megger test report from the customer.
Control Wiring
Identify all customer-required control wiring detailed on the Electrical Drawings and locate it within the terminal blocks. Verify the cable insulation is not tightened in a terminal connection. All connections must have proper continuity.
Inspect the control cable routing to ensure that DC control wiring and AC control wiring are separated from each other. Routing them together in the same bundle or cabling product may result in unwanted noise being induced in the drive control. In the overhead cable tray provided at the front of the drive, the AC control, DC control and fiber optic cables must be separate. These cables may also be from the bottom.
Control wiring must be routed separately from power cabling.
Inspect for additional control not shown on the Electrical Drawings. Determine its purpose, mark the changes on the electrical diagram and send the prints to the
Start-up Project Manager for future reference.
Perform a tug test on all control cables to ensure that they are securely fastened, and check each plug and connector to ensure it is properly seated in its socket.
Isolate the Power and Control Circuits
ATTENTION: Verify the grounding cable connection is secure.
Disconnect the low voltage power before the megger test.
Short circuit the 3 input cables and 3 output cables on one point.
1.
Isolate and lock out the drive system from any high voltage source.
Disconnect any incoming power sources, medium voltage sources should be isolated and locked out and all control power sources should be turned off at their respective circuit breaker(s).
Verify with a potential indicator that power sources have been disconnected, and that the control power in the drive is de-energized.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
23
Chapter 2
Preparation and Inspection
2.
Disconnect four 380V AC cables (a, b, c, and o cables) from the bottom of the Isolation Transformer.
Figure 1 - 380V AC Bottom-mounted Auxiliary Fan Input Cables
VSB Output Cable
3.
Disconnect the Voltage Sensing Board Output Cable. Keep the plug at least 100 mm away from the Voltage Sensing Board.
Figure 2 - Voltage Sensing Board Output Connection Cable
4.
Disconnect the Isolation Transformer Temperature Monitor. Keep the plug at least 100 mm away from the connection point on the Monitor.
Figure 3 - Isolation Transformer Temperature Monitor
24
Keep the plug at least
100 mm away from
Temperature Monitor plug
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Preparation and Inspection
Chapter 2
5.
Switch the miniature circuit breakers in the LV Cabinet off.
Figure 4 - Control Switches
Miniature Circuit Breakers
Miniature Circuit Breakers
6.
Switch the miniature circuit breakers in the Isolation Transformer Cabinet
LV Control panel off. Switch the Top Main Cooling Fan circuit breakers off.
Figure 5 - Control Switches
Top Main Cooling
Fan Circuit Breakers
7.
Remove two star connection cables (the cabling that goes through the
HECS) and connect them to the output connections of any two power modules within a phase.
Figure 6 - Star Connection Cable
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25
Chapter 2
Preparation and Inspection
8.
Disconnect the control cable of HECS.
Figure 7 - Hall Effect Current Sensor
Control Cable
9.
Disconnect the HMI and Control Board power cables.
Figure 8 - Back of HMI
HECS
Control Board Power Cables
HMI Power Cable
26
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Preparation and Inspection
Chapter 2
10.
Remove the Analog Interface board and disconnect all of the terminals from the Control Unit.
Figure 9 - Back of Control Unit
Analog Interface Board location on Control Unit
Control Unit terminals
Connect the Insulation Meter
1.
Connect the red wire from the insulation meter to the U Phase and the black wire to the grounding bus.
ATTENTION: Verify the drive and any connected equipment is clear of personnel and tools prior to commencing the Megger test. Barricade off any open or exposed conductors. Conduct a walk-around inspection before commencing the test.
2.
Use jumper wires to make the connections as shown in Figure 10 .
The jumper wires must be rated for greater than 5 kV or must maintain sufficient clearance to any metal surface.
3.
If the Megger has a lower voltage setting (normally 500V or 1000V), apply that voltage for 5 seconds as a precursor for the higher voltage rating. This may limit the damage if there is a problem. If the reading is very high, apply
the test voltage per Figure 10
.
4.
Perform a Megger test with the insulation meter voltage set according to
the voltages shown in Table 7 for 1 minute and record the result.
The test should produce a reading greater than the minimum values listed below. If the test results produced a value lower than these values start segmenting the drive system down into smaller components and repeat the test on each segment to identify the source of the ground fault.
ATTENTION: Discharge the Megger prior to disconnecting it from the equipment.
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27
Chapter 2
Preparation and Inspection
Outgoing Motor Power
Cable Connections
5.
Disconnect the Insulation Meter and jumpers installed in steps 1 and 2.
6.
Reconnect all wires, cables, and connections in reverse order of removal.
Figure 10 - Connected Insulation Meter
Incoming Line Power
Cable Connections
Insulation Meter
28
Ground Bus Bar
Table 7 - Insulation Test Voltage Values
Drive Rated Voltage U1
1000<U1≤5000
5000<U1
Typical of Drive
Entire Drive
Insulation Resistance Test Direct Voltage (V)
2500
5000
Minimum Megger Value
1 kM Ohm
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Final Steps before
Equipment is Ready for
Energization
Preparation and Inspection
Chapter 2
1.
Review interior of all cabinets for foreign material that might have been left behind during the installation process. Ensure no tools, hardware, or wiring debris remain in the drive system cabinets. Clear any metal shavings that may result from any drilling activities.
2.
If any internal barriers were removed during the commissioning process, ensure they are reinstalled.
Seal the Cabinet Plates
Once the back plates have been reattached, the seams along the plates must be sealed with silicone. Where the silicone is applied is dependent on the cabinet configuration (Fixed-mounted or Drawout Power Module).
IMPORTANT
Use the approved silicone that is shipped with the drive.
Apply silicone as shown by bold lines
Figure 11 - Silicone Locations on Fixed-mounted Power Module Configuration
Apply silicone as shown by bold lines
Figure 12 - Silicone Locations on Drawout Power Module Configuration
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
29
Chapter 2
Preparation and Inspection
Notes:
30
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Introduction
Chapter
3
Commissioning
ATTENTION: The Control System Check requires LV Control power only. The
Input Circuit Breaker must remain locked out and tagged out for this procedure.
A number of activities are required before the Control System Check can be performed.
Procedure
Simulate Closed Input Circuit Breaker
Page
The complete Control System Check requires the following procedures to be performed.
Procedure
Verify Factory Default Settings
Set P Parameters to Enable Testing
Verify Operation of Frequency Steps
Verify Operation to Set Frequency
Verify Switching from Local Control to Remote Control
Verify Operation of Input/Output and Bypass Isolation Switches (Manual Bypass)
(1)
Verify Operation of Input/Output and Bypass Contactors (Automatic Bypass)
(1)
Verify Operation of DCS Input and Output Signals
(1) Only required if a bypass configuration is supplied.
Page
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
31
Chapter 3
Commissioning
Control System Check Setup
Simulate Closed Input Circuit Breaker
IMPORTANT
The “normal” operating mode is for the input circuit breaker to be closed.
Install a temporary jumper (X1-117, X1-119) in the LV Control Cabinet to simulate operating the system in “normal” mode (input circuit breaker closed) to allow the Control System Check process to proceed.
Refer to Electrical Drawings.
Energize Control Circuit
Before beginning this process, ensure that the customer's control power supply breaker is closed and control power is available.
Control power voltage used in the control circuit is nominally 220V and referred to in the example. The control circuit can directly accommodate other widely used voltages of 230V and 240V also. If 110V or 120V is the control power voltage supplied by the customer, a control power transformer is supplied in the
LV control cabinet to step up the customer supplied control power to 220V
). This must be specified at time of order.
Q1, Q2, Q3, Q5, and Q6 miniature circuit breaker designations are located in
the LV Control Cabinet ( Figure 14
). The Q4 and Q7 miniature circuit breaker designations are located in the LV Control panel of the Isolation Transformer
Cabinet (
Figure 15 ). Refer to the Electrical Drawings.
Test points indicated in the instructions are at the circuit breaker terminals, not at the terminal blocks.
Circuit breaker device designation labels (Q1, Q2, etc.) are affixed to the device mounting surfaces.
Figure 13 - UPS and CPT Mounting Plate (Top View)
REAR
XS2 Receptacle
32
FRONT
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
UPS
Optional
Control Power
Transformer
1 3 5
Figure 14 - LV Control Cabinet
Q1 Q2 Q3 Q5 Q6
Commissioning
Chapter 3
2 4 6
Figure 15 - LV Panel in the Isolation Transformer Cabinet
Q4 Q7
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
33
Chapter 3
Commissioning
Table 8 - Energize Control Circuit Sequence
Item
Close
Breaker Q1
Before Closing Breaker
Verify that the input voltage at the Q1 circuit breaker is
AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).
Verify OPEN state (5 and 6).
After Closing Breaker
Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6).
Comments
Q1 connects customer-supplied control power to the control circuit (UPS).
Start UPS
(Press ON button)
Close
Breaker Q2
Close
Breaker Q3
Close
Breaker Q4
Close
Breaker Q5
Before pressing the ON button, withdraw the Type I UPS power plug from the power receptacle (XS2). Verify that the input voltage of the XS2 receptacle is AC220V. Verify that the
PE connection of the XS2 receptacle is properly grounded.
Plug the UPS into the receptacle. Press and hold the ON button for 3 seconds to turn on the UPS (all status lights on the UPS will be green).
Verify that the input voltage at the Q2 circuit breaker is
AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step.
Verify output is not shorted (2 and 4).
Verify that the input voltage at the Q3 circuit breaker is
AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step.
Verify output is not shorted (2 and 4). Verify OPEN state (5 and 6).
Control power is fed from the isolation transformer tertiary winding for the Q4 circuit breaker, therefore not present for this test. A two pole breaker is supplied for lower power drives (220V powered auxiliary fans). A three pole breaker is supplied for higher power drives (380V power auxiliary fans). Verify open status (1 and 2) and output not shorted (2 and 4).
Control power is fed from the isolation transformer tertiary winding for the Q5 circuit breaker, therefore not present for this test. Verify open status (1 and 2) and output not shorted
(2 and 4).
Verify that UPS operates normally and that the
UPS output is AC220V. The output of the UPS is connected to the input of Q2 and Q3. The UPS output voltage can be checked at the input of Q2 or Q3 (1 is L, 3 is N).
Verify that the input voltage of power supplies is
AC220V (L-N). Refer to
. Verify that the
PLC, HMI, and Control Unit power up.
Verify that the output voltage is AC220V (2 is L, 4 is N). Verify CLOSED state (5 and 6). Verify that the PLC I/O status lights and control relay red indicating lights illuminate.
Verify closed status (1 and 2).
Verify closed status (1 and 2).
UPS feeds control power to the circuits supplied by the Q2 and Q3 circuit breakers.
Q2 connects control power directly to AC/DC power supplies (G1, G2, and G3), PLC, HMI, and
Control Unit
Q3 connects control power to PLC I/O and control relays.
Q4 connects control power from isolation transformer tertiary winding to bottommounted auxiliary fans (6).
Q5 connects back-up control power from isolation transformer tertiary winding to switch to the control circuit (UPS) if the main (customersupplied) control power is lost.
Close
Breaker Q6
Close
Breaker Q7
Verify that the input voltage at the Q6 circuit breaker is
AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).
Verify that the input voltage at the Q7 circuit breaker is
AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4).
Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the LV Door pilot lights illuminate.
Verify that the output voltage is AC220V (2 is L, 4 is N). Verify that the Isolation Transformer temperature monitor powers up.
Q6 connects control power to door mounted pilot lights and spare relays for DCS.
Q7 connects control power to isolation transformer temperature monitor
ATTENTION: The following should be opened successively when the control power is switched off: Q5, Q4, Q3, Q2 and UPS; opening Q1 is not necessary when the control power is not disconnected.
Figure 16 - AC/DC Power Supplies
34
N L
N L
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Control System Check
Commissioning
Chapter 3
Verify Factory Default Settings
Confirm Language, Bypass Mode, and Local Operation
The default Language setting and bypass mode are set before shipment.
IMPORTANT
You can change the language but cannot change the bypass mode, as this is set at the factory to match the shipped drive configuration.
1.
Select language in the System Parameter Settings interface screen.
2.
Press
TIP
to accept and proceed to the Main Interface Screen.
Detailed information about the HMI screens is included in publication
6000-UM001_-EN-P, PowerFlex 6000 Medium Voltage Variable Frequency
Drive User Manual.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
35
Chapter 3
Commissioning
3.
Press and confirm the Bypass Configuration matches one of the three Input Supply graphics.
No Bypass Cabinet
Manual Bypass Cabinet
36
Automatic Bypass Cabinet
4.
Under Control Owner Selection, press .
Note the Contactor
Operation selection appears when Automatic
Bypass is selected
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
The Select Local Control? dialog box appears.
Commissioning
Chapter 3
5.
Select to confirm Local Control, and press return to the Main Interface Screen.
to
Set P Parameters to Enable Testing
There are two specific “P” parameters that must be changed to allow the Control
System Check to proceed.
This section is password protected and the setup login process must be completed before making any changes.
Access Setup Settings
1.
Press from the Main Interface Screen.
2.
Parameter Access Level
.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
37
Chapter 3
Commissioning
The Setup Login dialog box appears. Press .
38
3.
Enter the User and Password details.
Press and enter “setup”. Press when finished.
Press
TIP
to enter the password. Press when finished.
The password will be sent by the Project Start-up Manager.
4.
login.
The Current User will now display Setup, indicating appropriate access has been granted.
5.
Once logged in, press to proceed.
IMPORTANT
If the login information was incorrect, you will be prompted to login again.
Set P Parameters
Once the appropriate access has been granted, you can now select and change parameters.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
For the simulation tests, you only need to change two parameters: P007 and
P224.
1.
the
.
2.
Press the P007 parameter input field.
TIP
WARNING: Do NOT press parameters.
. This will reset all factory-set
When the “P” Parameter number is pressed (e.g. P007), the description appears in the information box at the bottom of the screen.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
39
Chapter 3
Commissioning
3.
Press “0” on the keypad dialog and press
Parameter 007 will now show a value of “0”.
.
4.
Repeat steps 2 and 3 to change Parameter 224 to “120”.
5.
Press to exit P Parameter Settings, and
to confirm Setup has logged out.
. Press
6.
Press to return to the Main Interface Screen.
40
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
Verify Operation of Frequency Steps
There are two parts to this procedure, increasing the frequency in set increments and increasing the frequency to a specific rated frequency.
Durh
TIP
During the Control System Check procedure, an “Abnormal Output Voltage
Warning” will appear, as the procedure is done without MV and the Control
System is expecting an output voltage. Ignore this warning for this procedure.
Increase Frequency by Step
1.
From the Main Interface Screen, press the Set Frequency: input field.
2.
In the Set Freq: dialog box, enter a value of “10” and press
Press to confirm.
TIP
.
The Set Frequency and Actual Frequency occasionally will not show the exact integral value selected, due to internal data conversion in the HMI program.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
41
Chapter 3
Commissioning
3.
Press , and press confirm operation.
in the Start Drive? dialog box to
IMPORTANT
When the drive is
≥
0.5 Hz, the “Connect” light will be illuminated. When the speed of the drive surpasses 0.5 Hz, the “Connect” and “Running” lights will be red. The “Warning” light will illuminate when the Actual Frequency increases above 10.00 Hz. This is an internal function for testing purposes only.
4.
When the Actual Frequency reaches 10 Hz, press .
Press dialog box.
TIP
T Parameter T09 determines the value of the frequency step change. The
default is 1. Refer to Access T Parameters on page 64 .
42
The Set Frequency and Actual Frequency are now 11 Hz.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
5.
Press dialog box.
and press in the Decel Speed by Step?
The actual frequency will decrease by 1 Hz.
Verify Operation to Set Frequency
1.
Press the Set Frequency: input field and enter “50” in the Set Freq: dialog box and press .
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43
Chapter 3
Commissioning
2.
Press to accept and begin the simulation.
Actual Frequency:
will show the frequency increasing to 50 Hz.
3.
Once the actual frequency has reached the set frequency, press
and press in the Stop Drive? dialog to confirm action.
44
The actual frequency will decrease to 0 Hz.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
Simulate Warnings and Faults
This section describes how to simulate warnings and faults, and how to clear or reset the alarm. Warning codes begin with a W prefix, and fault codes begin with a F prefix.
Alarm
Transformer Overtemperature Warning
Transformer Overtemperature Trip
Transformer Cabinet Main Cooling Fan Fault
Power Module Cabinet Main Cooling Fan Fault
Cabinet Door Open Warning
– Left Isolation Transformer Cabinet Door
– Right Isolation Transformer Cabinet Door
– Left Power Module/LV Cabinet Door
– Right Power Module/LV Cabinet Door
– Bypass Cabinet Door (if applicable)
Self-clearing
YES
YES
YES
Requires Reset
YES
YES
The Set Frequency: field will already have 50 Hz shown from the previous exercise in the Set Freq: dialog box.
1.
Press , dialog box.
Simulate the Transformer Overtemperature Warning
1.
Open the LV door of the Isolation Transformer cabinet.
2.
Using a jumper wire, connect terminal blocks 401 and 419 on the transformer protection relay.
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45
Chapter 3
Commissioning
.
3.
Press to view alarm record.
4.
Remove the jumper wires to remove the warning.
Simulate Transformer Overtemperature Trip
1.
Open the LV door of the Isolation Transformer cabinet.
2.
Using a jumper wire, connect terminal blocks 401 and 418 on the transformer protection relay.
3.
Press to view the alarm record.
46
4.
Remove the jumper wires to remove the Trip message.
5.
Press to return to the Main Interface Screen.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
6.
Press , and press
Reset Drive?
dialog box.
Commissioning
Chapter 3
to confirm the operation in the
Wait until the Ready status indicator is red before starting another simulation.
Simulate a Transformer Cabinet Main Cooling Fan Fault
1.
Open the LV door of the Isolation Transformer cabinet.
TIP
The circuit breakers for the main cooling fans for the entire drive are located here.
2.
Turn the first motor control circuit breaker (Q10), controlling the
Isolation Transformer Cabinet Main Cooling Fans (one per fan), to the
OFF position.
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47
Chapter 3
Commissioning
3.
Press
Fault.
to confirm the Transformer Cabinet Main Cooling Fan
4.
Turn the first (Q10) circuit breaker to the ON position, to remove the fault.
5.
Press to return to the Main Interface Screen.
Simulate a Power Module Cabinet Main Cooling Fan Fault
1.
Open the LV door of the Isolation Transformer cabinet.
TIP
From left to right on the DIN rail in the LV cabinet, the main cooling fan circuit breakers are located first for the Isolation Transformer cabinet then the Power Module cabinet.
Almost all drive configurations will have a maximum of three main cooling fans for the Isolation
Transformer Cabinet. Therefore, the main cooling fan circuit breaker designations of Q10, Q11, and
Q12 are reserved for the Isolation Transformer Main Cooling Fans. Power Module Cabinet Main
Cooling Fan circuit breaker designations begin at Q13.
Refer to the appendix in 6000-IN006_-EN-P to determine the number of main cooling fans in each cabinet location, or look at the fans on the top plate of the drive.
2.
Turn the applicable motor control circuit breaker (Q13), controlling the
Power Module Main Cooling Fans (one per fan), to the OFF position.
48
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
3.
Press
Commissioning
Chapter 3
and confirm the Power Module Cabinet Fan Fault.
4.
Turn the (Q13) circuit breaker to the ON position, to remove the fault.
5.
Press to return to the Main Interface Screen.
Simulate Cabinet Door Open Warning
1.
Open the left Isolation Transformer Cabinet door.
2.
Press to confirm the Cabinet Door Open Warning.
The drive will shut off.
3.
Close the left Isolation Transformer Cabinet to remove the warning.
4.
Repeat this procedure using the:
•
Right Isolation Transformer Cabinet door
•
Left Power Module/LV Cabinet door
•
Right Power Module/LV Cabinet door
•
Bypass Cabinet door (if applicable)
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49
Chapter 3
Commissioning
5.
Press to return to the Main Interface Screen.
6.
Press
to remove the fault. Press operation in the Reset Drive? dialog.
to confirm
Verify E-Stop Functionality
1.
Press on the Main Interface Screen to start the drive.
2.
Push the E-stop button on the front of the LV Control cabinet.
3.
Press and confirm the E-stop Trip fault.
50
4.
Twist to pull out the E-stop button on the front of the LV Control cabinet.
5.
Press to return to the Main Interface Screen.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
6.
Press
to remove the fault. Press operation in the Reset Drive? dialog.
to confirm
Verify Switching from Local Control to Remote Control
Depending on whether the drive has an automatic or manual Bypass or no Bypass configuration, the Operation Interface screen will be different.
1.
Press from the Main Interface Screen.
2.
Press .
3.
Press in the Select Remote Control? dialog.
4.
Press to return to the Main Interface Screen and confirm
Remote
status indicator light is on.
5.
Press from the Main Interface Screen.
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51
Chapter 3
Commissioning
6.
Under Control Owner Selection, press .
7.
Select to confirm selection in the Select Local Control? dialog, and press to return to the Main Interface Screen and confirm the Local status indicator is on.
Verify Operation of Input/Output and Bypass Isolation Switches
(Manual Bypass)
Input/Output Isolation Switches
1.
Press from the Main Interface screen.
52
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
2.
Open the Bypass cabinet door, and close QS2 and QS3.
Verify the Input and Output contactors are closed on the HMI.
3.
Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).
Verify the input circuit breaker is closed.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
53
Chapter 3
Commissioning
Bypass Isolation Switches
1.
Press from the Main Interface screen.
2.
Open the Bypass cabinet door, and close QS1.
Verify the bypass isolation switch is closed on the HMI.
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Commissioning
Chapter 3
3.
Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).
Verify the input circuit breaker is closed.
Verify Operation of Input/Output and Bypass Contactors
(Automatic Bypass)
Input/Output Drive Contactors
IMPORTANT
Turn the 3-position on the selector switch on the front of the LV Cabinet to the
Drive position.
1.
Press from the Main Interface screen.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
55
Chapter 3
Commissioning
2.
Close the customer-supplied input circuit breaker by installing a temporary jumper wire (X-117, X-119).
Verify the input circuit breaker is closed.
3.
Contactor Operation
, and press to confirm.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
Verify the input and output drive contactors are closed.
.
4.
Contactor Operation
, and press to confirm.
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57
Chapter 3
Commissioning
5.
Verify the input and output drive contactors are closed.
Bypass Contactors
IMPORTANT
Turn the 3-position on the selector switch on the front of the LV Cabinet to the
Bypass position.
.
1.
Press from the Main Interface screen.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
.
2.
Contactor Operation
, and press to confirm.
Verify the bypass contactor is closed.
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59
Chapter 3
Commissioning
.
3.
Contactor Operation
, and press to confirm.
Verify the bypass contactor is open.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Verify Operation of DCS Input and Output Signals
Figure 17 - Status Indicators
Commissioning
Chapter 3
Table 9 - Drive to DCS
Signal Name
MVPRE-Closed CB
MV CLOSING
Warning
Fault 907-908
Drive running 909-910
Drive STOP
READY
DCS control
Terminal Number HMI Status
901-902 Allowed
903-904
905-906
911-912
913-914
915-916
MVClosd
Warning
Warning Red
Running/Connect Red
Running/Connect
Ready
Remote
Local
Terminal Open
Red
Terminal Closed
Grey
Red
Red
Grey
Grey
Red
Red
Red
Grey
Grey
Grey
Grey
Grey
Grey
Red
Table 10 - 4-20 mA
Output Current
Output Frequency
925-926
927-928
Motor Current
Actual Frequency
0-Rated Current
0-Rated Frequency
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Chapter 3
Commissioning
When the two terminals specified are shorted, verify the result shown in the third column occurs.
Table 11 - DCS to Drive
Signal Name
Fault Reset
DCS Start
DCS Stop
E-stop
Frequency Set
Terminal Number
412-401
449-401
450-401
1101-1101
931-402
Function
Reset System
Start Drive
Stop Drive
E-stop Drive
Set Drive Frequency
Restore P Parameter Settings
1.
Press
Access Level
.
, and press
The Setup Login dialog box appears. Press
under Parameter
.
62
2.
Enter the User and Password details.
Press to enter user details. Press when finished.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
Press to enter password details. Press when finished.
3.
login.
4.
press .
WARNING: Do NOT press Reset. This will reset all factory-set parameters.
5.
Press the P007 parameter field to enter the number of power cells per phase, and press .
6.
Press the P224 parameter field.
7.
Change the value from 120 to 80. Press , and press .
8.
Press ,
Setup has logged out, and
Screen.
to return to the Main Interface
WARNING: Remove the temporary jumper (X1-117, X1-119) in the LV Control
Cabinet, which was installed to enable the Control System Test.
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Chapter 3
Commissioning
Set Date and Time Zone
To access the Date and Time Zone settings, you must exit the PowerFlex 6000
HMI to Windows CE.
Access T Parameters
1.
Press from the Main Interface Screen.
2.
Parameter Access Level.
.
The Setup Login dialog box appears. Press
3.
Enter the User and Password details.
4.
login.
5.
Once logged in, press .
6.
Press in the Setup Parameter Type.
64
7.
Press the T10 parameter input field. Enter “555” and press
8.
Press and to confirm.
TIP
It will take 3...5 minutes to shutdown.
.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Commissioning
Chapter 3
Change Time/Date/Regional Settings
IMPORTANT
Enter the Time Zone settings before changing the date and time.
1.
In Windows ME, press Terminal Settings [F4].
2.
Press the Down Arrow to choose Time/Date/Regional Settings, and press
Enter
.
3.
Choose Time zone and press Enter.
4.
Scroll up or down and select the desired time zone.
a. Press Daylight Savings [F1] b. Select the Yes radio button, and press Close [F8].
5.
Press OK [F7].
6.
Choose Date and press Enter. a. Press Year [F1], Month [F2], and Day [F3] to set the correct date.
b. Press OK [F7].
7.
Choose Time and press Enter. a. Press Hour [F1], Minute [F2], and Seconds [F3] to set the correct time.
b. Press OK [F7].
8.
Press Close [F8] twice, Reset [F7], and Yes [F7] to restart the HMI.
9.
Select language and bypass mode in the System Parameters Settings interface.
10.
Press to accept and proceed to the Main Interface Screen.
Verify the date and time is updated under Version Info.
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Chapter 3
Commissioning
Notes:
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Introduction
No-load Test
Chapter
4
No-load Test
ATTENTION: Medium Voltage is required for parts of this test. Close and lock all medium voltage doors on the PowerFlex 6000 and Bypass Cabinet (if supplied) prior to removing Lockout and Tagout provisions and closing the input circuit breaker. All safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed when removing the input circuit breaker from the locked out, tagged out state.
The No-load Test consists of the following procedures and must be performed in the sequence shown.
Sequence Procedure
1
Energize Drive Control Circuit
LV
Only
2
3
Close Isolation Switches in Bypass Cabinet
MV
4
5
6
(1) This procedure is performed only if an optional bypass configuration is supplied.
Page
WARNING: These procedures must be performed in the order they are listed here. Failure to do so may result in personal injury or death, property damage, or economic loss.
ATTENTION: Isolation switches in bypass cabinets can only be opened or closed when the Input Circuit Breaker is in the open position. Isolation Switches must not be operated when the Input Circuit Breaker is closed.
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Chapter 4
No-load Test
Energize Drive Control Circuit
The “Energize Control Circuit” process is already described on
. For the
“Energize Drive Control Circuit” procedure, repeat the process in the same sequence, without the requirements of taking voltage measurements.
1.
Close circuit breaker Q1.
2.
Start UPS. Press and hold the ON button for approximately 3 seconds.
3.
Close circuit breakers Q2, Q3, Q5, and Q6 in the LV Control Panel.
4.
Close circuit breakers Q4 and Q7 in the Isolation Transformer Cabinet LV
Panel.
Configure P and T Parameters
TIP
See Set P Parameters to Enable Testing on page 37 for information on how to
access and change parameters.
Set the P parameters and T parameters as shown in Table 12 .
This table outlines the specific parameters that must be checked and/or modified. Parameters that must be modified are outlined in the Instruction column. All other parameters listed must be verified. For special functions or actions which are not listed here, but are commonly performed while
commissioning a drive, see Special Function Parameter Settings on page 87 .
Table 12 - Setup and R&D Parameters
P
Parameter
P004
Description
P007
Command Source
0: Communication Port
1: Other Sources
Number Of Power Cells Per Phase
P008
P009
P024
P040
P089
P090
9
Motor Rotation Direction Under Local Control
1: Forward
0: Reverse
1
0 Motor Rotation Direction Command
Selection
0: Local
1: DCS
Stop Method
0: Ramp Down
1: Coast Stop
0
Safe Start Condition
0: Zero Frequency Command Required
1: Frequency Command Allowed
Skip Frequency Enable
0: Disable
1: Enable
Skip Frequency 1 Lower Limit
1
0
0
Default Modify
Root
(1)
Min.
Value
0 OFF 0
Max.
Value
1
Login
Level
Instruction
Setup
ON
OFF
OFF
ON
OFF
ON
ON
0
0
0
0
0
0
0
9
1
1
1
1
1
75
Setup Set to 0 for Control System Check. Afterwards, set to actual value according to Electrical Drawings
Setup
Setup
R&D
Setup
R&D
R&D
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No-load Test
Chapter 4
P224
P252
P253
P259
P260
P262
P198
P199
P205
P206
P213
P216
Table 12 - Setup and R&D Parameters (Continued)
P
Parameter
P091
P092
P093
P113
P114
Description
Skip Frequency 1 Upper Limit
Skip Frequency 2 Lower Limit
Skip Frequency 2 Upper Limit
Flying Start-Initial Output Voltage
Percentage (%)
Flying Start-Current Comparison Delay For
Motor Speed Search (ms)
0
5
0
0
Default Modify
Root
(1)
Min.
Value
ON
ON
ON
ON
0
0
0
0
1000 ON 0
Max.
Value
75
75
75
100
5000 R&D
Login
Level
Instruction
R&D
R&D
R&D
R&D
P115 0 100 R&D
P335
Flying Start-Current Threshold For Successful
Motor Speed Search
5 ON
HECS Rated Current (A)
Motor Rated Current (A)
0
0
ON
ON
Motor Uab Voltage Scaling Factor Correction 199.99
ON
Motor Uac Voltage Scaling Factor Correction 199.99
ON
Output Short-Circuit Fault Threshold
High-Frequency Output Over Current
Threshold
180
120
ON
ON
Output Voltage Deviation Fault Threshold
Motor In Stopping Condition Threshold
Motor Coast Stop Time
Frequency Command Analog Offset
Frequency Command Analog Scaling Factor
Frequency Command Source Selection
0: Digital
1: Analog
Analog Output #1 Scaling Factor
80
1
10
0
100
0
100
ON
ON
ON
ON
ON
OFF
ON
0
0
0
0
0
0
5000 Setup Set value according to the Electrical Drawings
5000 Setup Set value according to the customer motor nameplate data
199.99
R&D
199.99
R&D
199.99
Setup
199.99
Setup
0
0
0
0
199.99
Setup Set to 120 for Control System Check. Set to 80 afterwards
100 R&D
0 10000 R&D
-100 199.99
R&D
199.99
Setup
1 Setup
P339
P352
P355
P358
P361
P399
P401
P413
P414
P415
Analog Output #2 Scaling Factor
Rated Frequency HMI Display Integer Part
Motor Voltage HMI Display Integer Part
100
50 ON
10000 ON
Actual Frequency HMI Display Integer Part 50
Motor Current HMI Display Integer Part
Deceleration Time (s)
0
300
Acceleration Time (s) 200
ON
ON
ON
ON
ON
Frequency Command Lower Limit 0
Frequency Command Deadband Upper Limit 0.49
Frequency Command Upper Limit
ON
ON
16384 ON
0
0
0
0
0
199.99
Setup DCS display the output voltage proportion coefficient and can be changed as the customer operation request from 0...200%
(2)
199.99
Setup DCS display the output current proportion coefficient and can be changed as the customer operation request from 0...200%
(2)
75 Setup
16384 Setup Local display voltage correction coefficient, the value must be done according to the rating of the inverter output voltage setting.
For example: if the output is 3 kV, then set P355 = 3000
75 Setup
0
0
0
5000 Setup Normally P361 = P199
3276 Setup Default value is 300 s. Set according to customer specification
The time from 50...0 Hz after stopping the motor
3276 Setup Default value is 200 s. Set according to customer specification
The time from 0...50 Hz after starting the motor
-16384 16384 R&D
0 100 R&D
-16384 16384 R&D
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Chapter 4
No-load Test
Table 12 - Setup and R&D Parameters (Continued)
P
Parameter
P416
P417
P438
P451
P452
P455
Description Default Modify
Root
(1)
Min.
Value
0 ON 0 Flying Start Mode
0: Disable
1: Set Frequency
2: Stop Frequency Plus 5 Hz
3: Rated Frequency
Flying Start Motor Speed Search Timeout (s) 50
Flying Start Current Compensation Threshold 100
ON
ON
0
0
Low Speed Voltage Compensation (%)
Low Speed Voltage Compensation Frequency
Threshold
Modulation Index
0.99
20
OFF
ON
87.99
ON
0
0
0
P456
P457
Motor Voltage Upper Limit
Flying Start Voltage Recovery Time (s)
(Low Speed Region)
87.99
ON
5 ON 0
0
Max.
Value
3
Login
Level
Instruction
Setup
1000 R&D
199.99
R&D
10
100
Setup
R&D
199.99
Setup Improve the real output of inverter voltage value. For example: rated voltage of the inverter for 10 kV, if the actual output is
9700V, the need to improve the actual output voltage to 10 kV, need to change this value
199.99
R&D
163.84
R&D
P459 Flying Start Voltage Recovery Time (s)
(High Speed Region)
5 ON 0 163.84
R&D
P460 Rated Output Frequency
(1) ON: Can be modified at any time. OFF: Drive must be off to modify.
(2) With Remote DCS only.
50 OFF 0 75 R&D
There are no specific T parameters to modify when commissioning a drive. Verify the values and only modify per customer specifications.
T
Parameter
T01
Description
T02
T03
T04
T05
T06
T07
Fault-To-Bypass
0: Disable
1: Enable
Fault-To-Bypass Delay
Fault-To-Bypass Delay When Starting the Motor (0...60s)
Fault-To-Bypass Minimum Frequency
0...Rated Frequency (Hz)
Auto Restart After Input Supply Power Loss
0: Disable
1: Enable
Input Supply Power Loss Time for
Auto Restart (0...20s)
Local Frequency Command Selection
0: Digital
1: Analog
3
60
5
0
20
0
Default Modify
Root
(1)
Min.
Value
0 ON 0
Max.
Value
1
ON
ON
ON
ON
ON
ON
0
0
0
0
0
0
60
60
Rated
Frequency
1
20
1
Login
Level
Setup
Setup
Setup
Instruction
While T1=1 valid
While T1=1 valid
Setup While T1=1 valid
Setup
Setup
Setup If T7=0, enter the frequency on the HMI. If T7=1, use a potentiometer to set the frequency on the LV Control
Cabinet. Confirm P262=1.
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No-load Test
Chapter 4
T
Parameter
T08
T09
T10
T11
T12
T13
Description
Remote Frequency Command Selection
1: Analog
2: 4-Step Speed
4: Communication Port
Frequency Step For Accel or Decel
Exit Config Environment Password
Automatic Bypass-To-Drive or
Drive-To-Bypass Selection
I
D
PID Parameter Settings
P
D Gain
4-Step Variable Speed
(available only when T8=2)
Speed 1
Speed 2
Speed 3
Speed 4
(1) ON: Can be modified at any time. OFF: Drive must be off to modify.
0
0
0.01
0.01
Default Modify
Root
(1)
1 ON
Min.
Value
1
1
555
ON
OFF
1
Max.
Value
4
Rated
Frequency
Login
Level
Instruction
Setup Confirm P262=1
If T8=1, then the analog quantity 4...20 mA from Remote,
4 mA corresponds to 0 Hz, 20 mA corresponds to the rated frequency.
If T8=2, use T13 to set step speed
If T8=4, communication mode with remote
Setup Changes the step frequency when Accel or Decel is pressed
Setup This function will not work if the drive is running.
Setup
Setup
ON
ON
ON
ON
0
0
0
0
32767
32767
32767
32767
Setup
10
20
30
40
ON
ON
ON
ON
0
0
0
0
Rated
Frequency
Rated
Frequency
Rated
Frequency
Rated
Frequency
Parameters T11...T13
To change Parameter T11:
1.
Press the T11 Parameter input field.
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Chapter 4
No-load Test
2.
In the Switch Method Selection dialog, press or .
3.
If you select , the:
•
drive must be set to Local Control
•
position switch must be set to Drive
•
bypass contactor must be ON
•
drive must not be running.
4.
If you select , the:
•
drive must be set to Local Control
•
position switch must be set to Drive
•
drive must be running.
5.
Press to confirm selection.
ATTENTION: If the conditions are incorrect, the following dialog appears.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Change Parameter T12:
1.
Press the T12 Parameter input field.
No-load Test
Chapter 4
2.
Enter desired PID values in the PID Parameter Settings dialog box.
Press the input field to enter a value.
3.
accept.
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73
Chapter 4
No-load Test
Change Parameter T13:
1.
Press the T13 Parameter input field.
2.
Enter desired speed values in the Enter Four Steps dialog box.
Press the input field to enter a value.
74
IMPORTANT
Parameter T08 must be set to 2.
3.
accept.
IMPORTANT
Refer to publication 6012-UM001_-EN-P, PowerFlex 6000 Drive Bypass Units
User Manual or detailed information about operating the switches in bypass cabinets.
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
No-load Test
Chapter 4
Close Isolation Switches in Bypass Cabinet
1.
Manual bypass (see Figure 21 )
a. Open QS1 (direct line operation) isolation switch b. Close QS2 and QS3 (drive operation) isolation switches
2.
Automatic Bypass (with isolating switches) (see
a. Close QS1 and QS2 (drive operation) isolation switches
Close Input Circuit Breaker
ATTENTION: Medium Voltage is required for this test. Close and lock all medium voltage doors on the PowerFlex 6000 and Bypass Cabinet (if supplied) prior to closing the input circuit breaker. All safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed when removing the input circuit breaker from the locked out, tagged out state.
1.
Remove tags and locks on the input circuit breaker.
2.
Close input circuit breaker.
3.
Verify that there are no faults or warnings on the HMI screen.
Check Cooling Fan Operation
1.
Open the Low Voltage panel door on the Isolation Transformer Cabinet door.
2.
Close all of the Drive Main Cooling Fan circuit breakers (Q10, ...) in the
Isolation Transformer Cabinet LV Panel.
3.
Verify that all cooling fans are operating.
4.
Turn off the first Main Cooling Fan Circuit Breaker (Q10) and record the direction of the fan.
Viewed from the rear, the blades will rotate left to right (counter-clockwise when viewed from the top). If the fan is rotating in the wrong direction, turn off the specific Main Cooling Fan breaker. Verify the output voltage is
0. Switch two wires on the output of the circuit breaker.
5.
Turn the circuit breaker back on, and repeat for the remaining Main
Cooling Fan circuit breakers.
6.
Verify that there are no faults or warnings on the HMI screen.
IMPORTANT
All fans must turn in the same direction.
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75
Chapter 4
No-load Test
Operate Motor by HMI
IMPORTANT
Before completing this procedure, verify there are no warnings or failure messages on the HMI. The “Ready” status indicator must be red.
1.
From the Main Interface Screen, press the Set Frequency: input field.
2.
In the Set Freq: dialog box, enter a value of “5” and press
Press
TIP
.
to confirm.
The Set Frequency and Actual Frequency occasionally will not show the exact integral value selected, due to internal data conversion in the HMI program.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
3.
Press , and press confirm operation.
No-load Test
Chapter 4
in the Start Drive? dialog box to
IMPORTANT
When the drive is
≤
0.5 Hz, the “Connect” light will be illuminated. When the speed of the drive surpasses 0.5 Hz, the “Connect” and “Running” lights will be red.
4.
Observe the direction of motor rotation.
If motor rotating direction is incorrect: a. Press . b. Open the Input Circuit Breaker. c. Perform the Lockout and Tagout procedures. d. Verify that medium voltage is not present in the drive and in the motor’s cable connection box by using a hot stick.
e. Swap any two cables in the motor’s cable connection box. f. Repeat
Close Input Circuit Breaker on page 75 .
If the motor rotating direction is correct, continue to step 5.
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Chapter 4
No-load Test
5.
From the Main Interface Screen, press the Set Frequency: input field.
6.
In the Set Freq: dialog box, enter a value of “10” and press
Press to confirm.
.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
7.
Press , and press confirm operation.
No-load Test
Chapter 4
in the Start Drive? dialog box to
8.
Record the output voltage in the HMI screen.
The value must not by more than ±10% of output voltage based on the drive configuration.
Drive Voltage
3 kV
3.3 kV
4.16 kV
6 kV
6.6 kV
10 kV
10 Hz
310
340
430
620
690
1040
20 Hz
770
850
1060
1540
1690
2560
30 Hz
1370
1500
1900
2740
3010
4560
40 Hz
2110
2320
2930
4220
4650
7040
50 Hz
3000
3300
4160
6000
6600
10,000
9.
Press the Set Frequency: input field. In the Set Freq: dialog box, enter a value of “20” and press . Press to confirm.
10.
Record the output voltage in the HMI screen.
Repeat this process for 30, 40, and 50 Hz (or 60 Hz).
11.
Run the drive for 30 minutes at 50 Hz or 60 Hz (dependent on system frequency).
12.
Switch off customer-supplied control power.
The Control Power Supply Loss warning appears in the HMI.
The K8 relay will automatically switch-off and the K9 relay will switch on to supply control power from the isolation transformer tertiary winding.
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Chapter 4
No-load Test
13.
Switch on the customer-supplied control power, and push the Power Reset button in control cabinet panel.
This clears the Control Power Supply Loss warning.
14.
Press .
ATTENTION: The following should be opened successively when the control power is switched off: Q5, Q4, Q3, Q2 and UPS; opening Q1 is not necessary when the control power is not disconnected.
Load Test of Drive System
This process is essentially a repeat of the No Load test procedure.
The Input Circuit Breaker should be off and locked out and tagged out to prevent any possibility of energization of the motor circuit while the application is reconfigured to apply load.
Repeat steps 1, 4, and 6 listed in the
.
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Appendix
A
Torque Requirements
Torque Requirements
Proper tightening torque must be used for installation and wiring.
Table 13 - Torque Requirements
Torque
Thread Size
M10
M12
M14
M16
M20
M4
M5
M6
M8
39
62
11
22
N•m
1.4
2.8
4.6
95
184
8.1
16.2
28.8
45.7
lb•ft
1.0
2.1
3.4
70.1
135.7
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81
Appendix A
Torque Requirements
Notes:
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Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Single Line Diagrams
Figure 18 - PowerFlex 6000 without Bypass
QF
Input Circuit Breaker
(by Customer)
Appendix
B
PowerFlex 6000
M
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Circuit
Breaker
83
Appendix B
Single Line Diagrams
Figure 19 - 6012M Automatic Bypass Version 1 (without Isolation Switches)
QF
Input Circuit Breaker
(by Customer)
KM1
KM2
PowerFlex 6000
KM3
84
M
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Circuit
Breaker
Vacuum
Contactor
Single Line Diagrams
Appendix B
Figure 20 - 6012M Automatic Bypass Version 2 (with Isolation Switches)
QF
Input Circuit Breaker
(by Customer)
M
KM1
QS1
Bypass Unit
KM2
KM3
QS2
PowerFlex 6000
Circuit
Breaker
Vacuum
Contactor
Isolation
Switch
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
85
Appendix B
Single Line Diagrams
Figure 21 - 6012M Manual Bypass
QF
Input Circuit Breaker
(by Customer)
Bypass Unit
QS2
QS1
PowerFlex 6000
QS3
86
M Circuit
Breaker
Vacuum
Contactor
Isolation
Switch
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
Appendix
C
Special Function Parameter Settings
Overview
outlines specific parameters that must be checked and/or modified when commissioning a drive. Listed below are specific parameters, a brief description and their function to execute optional special functions which, while not essential to commissioning a drive and will not be done every time, are frequently performed.
System Setting Functions
The system setting includes the amount of power modules in one phase, the command source, the drive rated parameter setting, the motor parameter setting, the sensor parameter setting, the restoring of factory default parameter setting, analog output parameter setting.
Number of Power Modules Per Phase
Relevant parameter: P7
Description: sets the amount of power modules per phase.
IMPORTANT
This number MUST match the actual amount of power cells in one phase.
P7 is equal to the amount of power modules in one phase; for example, if the amount of power cells in one phase is 6, P7=6. Power Module fault and warning information is based on P7. If P7=0, this is ignored and the user can run the drive using low voltage.
Use this parameter to check low voltage components and the control box.
See Set P Parameters on page 38 .
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Appendix C
Special Function Parameter Settings
Switch Control Sources
Relevant parameter: P4
Description: P4 selects the control source to start, stop, or reset the drive.
There are two Control Sources, the HMI and the hard-wired I/O interface
(DCS). They cannot be enabled at the same time.
Rated/Maximum Output Frequency
Relevant parameter: P460, P466
Description: sets the rated output frequency.
Instruction: P460 is drive’s rated output frequency, which should be the same as the motor’s rated frequency (0…75 Hz). P466 is the drive’s Maximum Output
Frequency; P460 cannot exceed P466.
Motor Parameter Setting
Relevant parameter: P17, P199
Description: set basic motor parameters, such as rated current and the number of pole pairs.
Instruction: P199 is motor rated current, which is used to determine faults. P17 sets the number of motor pole pairs.
Hall Effect Current Sensor Setting
Relevant parameter: P198
Instruction: Set the HECS rated current (A) used for the drive current sampling.
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Special Function Parameter Settings
Appendix C
Analog Output Display Parameter Setting
Relevant parameters:
Analog Output Display
Set Frequency
Motor Voltage
Output Frequency
Motor Current
Parameter
P351, P352, P353, P371
P354, P355, P356, P372
P357, P358, P359, P373
P360, P361, P362, P374
Description: sets the display parameters for the following analog output signals:
Set Frequency, Actual Frequency, Motor Voltage and Motor Current.
Instruction: each signal has four display parameters: memory address, filter parameter, HMI display integer part and HMI display decimal part.
EXAMPLE
To output the “given frequency” when the memory address is 221, the filter time is 100 ms, the maximum integer part is 60, the maximum decimal part is
0, set P351=100, P352=60, P353=0, P371=221.
The value of P371, P372, P373, P374 are default values and do not generally need to be changed. Field Support Engineers can change them according to the specific configuration.
Restore Factory Setting
Relevant parameter: P5
Description: restore factory setting parameters.
Instruction: this function includes the three different access levels: User Level,
Setup Level, and R&D Level. The amount of parameters restored is dependent on the access level. Press Reset to restore parameters.
The following table shows the parameters which can be restored in the different access levels.
User (P5 = 40) P4, P262, P198, P199, P352, P355, P358, P361, P399, P401
Setup (P5 = 30) P4, P262, P198, P199, P352, P355, P358, P361, P399, P401, P7, P8, P9, P40, P260, P213, P216,
P220, P222, P224, P230, P238, P335, P339, P343, P347, P451, P416, P442, P455, P461
R&D (P5 = 50) All P parameters
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Appendix C
Special Function Parameter Settings
Speed Command Functions
Set Frequency Command Source
Relevant parameter: P262
Description: this function selects the frequency command source (analog or digital).
Instruction: If P262=0, digital setting is selected, if P212=1, analog setting is selected. Digital mode is setting the frequency from HMI, analog mode is setting the frequency from hard-wired analog I/O. These two modes cannot be enabled at the same time.
Set Frequency Correction
Relevant parameters: P259, P260
Description: this improves the sampling accuracy.
IMPORTANT
It can only be enabled when the setting frequency source is set to analog.
Instruction: Set Frequency=P260*Original Set Frequency+P259.
Frequency Command Deadband Upper Limit
Relevant parameter: P414
Description: this function limits the low frequency starting range, reduce the low frequency output error for analog input mode. This parameter avoids the drive’s output fluctuation when the frequency is around 0 Hz.
Instruction: if the original set frequency is lower than P414, the set frequency will be changed to P414.
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fB2 fB1 fA2 fA1
Special Function Parameter Settings
Appendix C
Frequency Amplitude Limit
Relevant parameter: P413, P415
Description: this function limits the amplitude of the Set Frequency. The Set
Frequency must not exceed the maximum output frequency of the drive.
Instruction: this function can limit the Set Frequency between P413 and P415,
P415>P413>0.
Frequency Skip
Relevant parameter: P89, P90, P91, P92, P93
Description: this function is designed to avoid a trip at certain output frequencies.
Instruction: this function is enabled by P89. There are two bands, one is between
P90 and P91, the other is between P92 and P93. The Set Frequency can skip out from these two bands if it is within them. The Set Frequency will be changed automatically into the upper limit of the bands while the speed increases, or changed into the lower limit of the band while the speed decreases (
The recommended width of these intervals is 1 Hz.
Figure 22 - Principle diagram of Frequency Skip Function
P90
P91 P92
User Set Frequency
P93
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Appendix C
Special Function Parameter Settings
Speed Reference Functions
V/F Curve Setting
Relevant parameters: P451, P452, P453
Description: calculates the drive’s output voltage according to set frequency.
There are four available V/F curves: linear, curve, straight-curve and paraboliccurve. Set the compensation voltage to improve the lower frequency start torque.
Instruction: P451 is low speed voltage compensation (%), P452 is low speed voltage compensation frequency threshold. If the output frequency is lower than
P452, the output voltage will be improved per P451 (Low Speed Voltage
Compensation).
Set Maximum Modulation Index and Limit Output Voltage Amplitude
Relevant parameters: P455, P456
Description: this function sets the maximum modulation index and limit the output voltage amplitude, so the drive can run above rated frequency.
Instruction: change the output voltage without changing the output frequency by adjusting P455. Adjust this value according to the field conditions to ensure the output voltage/frequency is consistent with standard V/F curve.
P456 is the output voltage amplitude limit; the amplitude of output voltage cannot exceed this value.
Set Flux Time
Relevant parameters: P454
Description: this function is designed to build a steady rotating magnetic field before the rotor operates.
Instruction: P454 is the time to build the rotating magnetic field. This value will not generally be changed.
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Analog Input
Stop Mode
Flying Start Function
Special Function Parameter Settings
Appendix C
Relevant parameter: P205, P206
3/3.3 kV and 6/6.6 kV drives use the same VSB board.
.
Set P205 and P206 according to the following table
6
6.6
10
Voltage Level (kV)
3
3.3
4.16
6:5
6:5
10:5
VSB proportion (kV:V)
3:5
3:5
3:5
P205, P206
199.99
181.82
144.23
199.99
181.82
199.99
Relevant parameter: P24, P252, P253
Description: the drive has two ways to stop the drive, ramp down or coast stop.
Instruction: P24=1 to select coast stop, P24=0 to select ramp down.
If P24=1, the output will stop immediately, so the motor will stop by inertance. If
P24=0, the output will stop the from the set frequency to 0 Hz. When the frequency=P252*rated frequency (P252 is a percentage value), the system will be locked.
To restart the drive if coast stop was selected, wait until it stops before restarting.
The time needed is:
P253
MaximumFrequency
Relevant parameter: P113, P114, P115, P416, P417, P438, P457, P459,
P463, K5
Description: The PowerFlex 6000 has three flying start modes:
•
search the frequency from set frequency
•
search the frequency from the last stop frequency added 5 Hz
•
search from the maximum frequency.
Instruction: the flying start feature identifies the motor speed based on the output current.
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Appendix C
Special Function Parameter Settings
Restart the Drive
Some parameters must be changed based on the field application.
•
P113: Flying Start - Initial Output Voltage Percentage (%)
•
P114: Flying Start - Current Comparison Delay For Motor Speed Search
•
P115: Flying Start - Current Threshold For Successful Motor Speed
Search
•
P416: Enable Flying Start mode
•
P417: Flying Start Motor Speed Search Timeout (s)
•
P438: Flying Start Current Compensation Threshold
•
P457: Flying Start Voltage Recovery Time (s) (Low Speed Region)
•
P459: Flying Start Voltage Recovery Time (s) (High Speed Region)
•
P463: Flying Start Low/High Speed Regions Boundary (%)
IMPORTANT
P416 enables Flying Start Selection. If the Flying Start is not successful, change the other parameters listed accordingly. Otherwise, these parameters do not normally need to be changed.
If the drive cannot search the speed in the field, increase P417 to decrease the search step and improve the accuracy; or increase P113 and decrease P115 to improve the accuracy. If there was any noise during the restore stage, increase
P457 or P459. P463 does not need to be changed.
Search from Maximum Frequency to implement AC mode to VF mode.
Relevant parameter: P461, P462, P465
Description: these parameters use the auto-restart feature after a system fault.
Instruction: if P461 is enabled (P461=1), the drive will restart at once when system fault occurs.
If there is something wrong with a Power Module, it will wait for P465 before restarting. If a fault happens twice during the Fault Reset Timeout (P462), the drive will trip.
IMPORTANT
If restart feature was enabled, the second mode of flying start feature must be enabled.
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Index
A
Analog Input
E
Electrical Installation Inspection
C
Cabinet Plates
Pre-Commissioning Sealing
Commissioning
Control System Check
Procedure List
Setup
Process Flowcharts
Set Date
Set Regional Settings
Set Time Zone
Commissioning Requirements
Computer Requirements
Electrical Equipment
Hand Tools
Software
Test Equipment
Control System Check
P Parameters
Restore Settings
Set to Enable Testing
Procedure List
Setup
Energize Control Circuit
Simulate Closed Input Circuit Breaker
Simulate Warnings and Faults
Verify
E-Stop Functionality
Factory Default Settings
Operation to Set Frequency
Switching, Local to Remote Control
Verify Operation of
Bypass Contactors
Bypass Isolation Switches
DCS Input
Frequency Steps
Input/Output
,
Output Signals
Control Wiring
Flying Start Function
Functional Assessment
Checklist
I
F
Installation Review
Electrical Inspection
Mechanical Inspection
Interconnection Review
Checklist
L
Lockout
Safety Test
M
Mechanical Installation Inspection
N
No-Load Test
Check Cooling Fan Operation
Close Input Circuit Breaker
Close Isolation Switches in Bypass Cabinet
Configure P and T Parameters
Energize Drive Control Circuit
Operate Motor by HMI
D
Diagrams
6012M Automatic Bypass Version 1
6012M Automatic Bypass Version 2
6012M Manual Bypass
PowerFlex 6000 without Bypass
Documentation and Application Review
Process Flowcharts
Documentation, Rockwell Automation
Drive Application
Review
Drive Components
Inspection
Checklist
Drive Megger Check
O
Overviews
Commissioning
Documentation and Application Review
Load Test
No-load Test
Special Function Parameter Settings
P
Power Cabling
Color Coding
Pre-Commissioning
Cabinet Plates
Computer Requirements
Drive Megger Check
Electrical Equipment
Final Steps
Functional Assessment
Checklist
Installation Review
Electrical Inspection
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Index
96
Mechanical Inspection
Interconnection Review
Checklist
Software
Test Equipment
Tools
Hand Tools
Preparation and Inspection
Process Flowcharts
Commissioning
Documentation and Application Review
Process Flowcharts
Commissioning
Documentation and Application Review
Preparation and Inspection
R
Restart the Drive
S
Safety Test (Lockout)
Special Function Parameter Settings
Analog Input
Flying Start Function
Restart the Drive
Speed Command Function
Frequency Amplitude Limit
Frequency Command Deadband Upper
Limit
Frequency Skip
Set Frequency Command Source
Set Frequency Correction
Speed Command Functions
Speed Reference Functions
Limit Output Voltage Amplitude
Set Flux Time
Set Maximum Modulation Index
V/F Curve Setting
Stop Mode
System Setting Functions
Analog Output Display Parameter Setting
Hall Effect Current Sensor Setting
Motor Parameter Setting
Number of Power Modules Per Phase
Rated/Maximum Output Frequency
Restore Factory Setting
Switch Control Sources
Speed Command Functions
Speed Reference Functions
Stop Mode
T
Tagout
Torque Requirements
Rockwell Automation Publication 6000-IN007A-EN-P - October 2014
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, or contact your local
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Publication 6000-IN007A-EN-P - October 2014
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Key features
- Adjustable speed control
- Energy efficiency
- Precise torque control
- Advanced protection features
- Remote monitoring capabilities