Commissioning Manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Commissioning Manual
Publication 6000-IN007B-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, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.
 Table of Contents

Preface Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensional Drawings and Electrical Drawings. . . . . . . . . . . . . . . . . . . 7
Shipping, Handling, and Installation Manual . . . . . . . . . . . . . . . . . . . . . 8
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1
Introduction Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Documentation and Application Review . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Review all Rockwell Automation Supplied Documentation . . . . . . 12
Pre-commissioning Customer Meeting . . . . . . . . . . . . . . . . . . . . . . . . . 13
Review Drive Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2
Preparation and Inspection (For IEC) Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 15
Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drive Megger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Isolate the Power and Control Circuits. . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 29
Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Chapter 3
Preparation and Inspection (For UL) Gather Required Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . 31
Lockout and Tagout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspect Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Functional Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Interconnection Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mechanical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Electrical Installation Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Table of Contents

Drive Megger Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Isolate the Power and Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connect the Insulation Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Final Steps before Equipment is Ready for Energization . . . . . . . . . . . . . 46
Seal the Cabinet Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 4
Commissioning Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Control System Check Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Simulate Closed Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . 48
Energize Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Verify Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Set P Parameters to Enable Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Verify Settings for Low-Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . 58
Verify Operation of Frequency Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Verify Operation to Set Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Simulate Warnings and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Verify E-Stop Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Verify Switching from Local Control to Remote Control . . . . . . . . 73
Verify Operation of Input/Output and Bypass Isolation Switches
(Manual Bypass). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Verify Operation of Input/Output and Bypass Contactors
(Automatic Bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Verify Operation of DCS Input and Output Signals . . . . . . . . . . . . . 83
Restore P Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Set Date and Time Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Access T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Change Time/Date/Regional Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 5
No-load Test Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
No-load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Energize Drive Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Configure P and T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Change Parameters T11...T13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Close Isolation Switches in Bypass Cabinet . . . . . . . . . . . . . . . . . . . . 102
Close Input Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check Cooling Fan Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Operate Motor by HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Load Test of Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Appendix A
Torque Requirements Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Table of Contents

Appendix B
Single Line Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Appendix C
Special Function Parameter Settings Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
System Setting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Number of Power Modules Per Phase . . . . . . . . . . . . . . . . . . . . . . . . . 117
Switch Control Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Rated/Maximum Output Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Motor Parameter Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Hall Effect Current Sensor Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Analog Output Display Parameter Setting . . . . . . . . . . . . . . . . . . . . . 119
Restore Factory Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Speed Command Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Set Frequency Command Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Set Frequency Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Frequency Command Deadband Upper Limit . . . . . . . . . . . . . . . . . 120
Frequency Amplitude Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Frequency Skip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Speed Reference Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
V/F Curve Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Set Maximum Modulation Index and Limit Output Voltage
Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Set Flux Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Flying Start Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Restart the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Index

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Notes:

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

 Preface

Introduction This document provides procedural information for commissioning

PowerFlex® 6000 medium voltage drives with version 4.001 firmware.

Who Should Use This Manual This manual is intended for Rockwell Automation Field Service Engineers with
Medium Voltage Drive factory training and field experience commissioning
medium voltage solid-state variable speed drive equipment.

WARNING: This document is for internal use only (for Rockwell CSM/field
support Engineers). DO NOT disclose this document to customers or any non-
Rockwell Automation employee. Disclosure of sensitive information in this
document may cause dire consequences to the drive.

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 Dimensional Drawings and Electrical Drawings

Information
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)

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 7

Preface

Table 2 - Dimensional Drawings

Control and Medium Voltage Power Ratings
Drive Options
Motor Ratings
Drive Power Component Selection Ratings

If the drawings require changes to suit the installation and application of the
system, fax or e-mail the marked up drawings to the Start-up Project Manager.

Shipping, Handling, and Installation Manual

Review publication 6000-IN006_-EN-P, PowerFlex 6000 Medium Voltage

Variable Frequency Drive Shipping, Handling, and Installation manual.

The customer/contractor has the option to perform the electrical

interconnection work between cabinet shipping splits, as shown in this manual,
or contract Rockwell Automation to perform this work. This will be reflected in
the Services Purchase Order and the pre-commissioning checklist. Verify that the
documentation matches the actual scope of work done by the customer/
contractor. You will be required to either perform this interconnection work
immediately prior to the commissioning process or to verify the work was done
correctly by the contractor. It is very important to confirm the alignment of the
paperwork with the actual scope of work.

It is also extremely important to understand the contractor’s basic scope of work,

preceding the commissioning process. Part of the overall commissioning process
is to ensure this work has been done correctly. If this work has not been done
properly, this must be brought to the attention of the customer immediately. Do
not proceed with commissioning until this issue is resolved.

Additional required information about the PowerFlex 6000 can be downloaded

from http:/www.rockwellautomation.com/literature/.
• 6000-IN006_-EN-P: PowerFlex 6000 Medium Voltage Variable
Frequency Drive Shipping, Handling, and Installation Instructions
• 6000-UM002_-EN-P: PowerFlex 6000 Medium Voltage Variable
Frequency Drive User Manual (operating the HMI, full parameter listing)

You must review these publications thoroughly before beginning the

commissioning process. They contain supplemental information that will aid in
the commissioning process.

8 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preface

General Precautions 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.

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 9

Preface

Notes:

10 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Chapter 1

Introduction

Overview 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 Installaion Review on page 21 or
page 37.

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Chapter 1 Introduction

Process Flowcharts
Documentation and Application Review
Review
Rockwell
Pre-commissioning Review Drive
Automation
Customer Meeting Application
Supplied
Documentation

Preparation and Inspection

Gather
Required Tools Lockout Inspect Drive Functional Interconnection Installation Final Review
Meggering
and Test and Tagout Components Assessment Review Review and Preparation
Equipment

Commissioning

No-load Test
Control Load Test of
of Drive
System Check Drive System
System
(LV Only) (MV)
(MV)

Documentation and Review all Rockwell Automation Supplied Documentation

Application Review 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-UM002_-EN-P): instructions for daily recurring drive usage, HMI
interface, and maintenance tasks

12 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 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.

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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.

14 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Chapter 2

Preparation and Inspection (For IEC)

Gather Required Tools and Hand Tools

Test Equipment • 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-IN007B-EN-P - March 2016 15

Chapter 2 Preparation and Inspection (For IEC)

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 page 15), open all of the
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).

16 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) Chapter 2

Functional Assessment After the components are visually inspected to identify any shipping damage, a
thorough functional assessment should be performed (see Table 4 on page 19).
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-IN007B-EN-P - March 2016 17

18
Table 3 - Inspect Drive Components Checklist (IEC)
Chapter 2

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Door: Door: Fixed Mounted Power Module Configuration: Door:
Pilot Lights Transformer Temperature monitor Power Module retaining tabs Pilot lights
Voltage Indicator Relay LV Cabinet components Check for debris Push buttons
Cabinet: – Fan control circuit breakers Output Bus Supports Selector switches
Insulators Cabinet: Fuse Mounting Supports HMI
Switch assemblies Transformer Plastic Baffle Drawout Power Module Configuration: Interface board (on the back of the LV door)
Vacuum contactors Outgoing Motor Power Cable standoffs on Support frame Panel:
Mechanical linkages Cabinet Sidesheet(1) Power Modules DIN rail mounted components
Outgoing Motor Power Cable Terminal UPS
Preparation and Inspection (For IEC)

Front Insulators on transformer (1) Fiber optic cables

Voltage Sensing Board PLC
Incoming Line Power Cable Terminal Insulators Control Unit
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: Fixed Mounted Power Module: UPS connections
Transformer Secondary Windings (1) Heat sink
– Inspect nomex wrap – Verify orientation relative to barrier plates
– Verify windings from core are undamaged Drawout Power Module:
– Check for debris in top of core Power In/Power Out connections
Rear
Drawout Power Module Configuration:
Transformer Secondary Windings (3)
– Inspect nomex wrap

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

– Verify windings from core are undamaged
– Check for debris in top of core
(1) Motor Cable terminations could be on the transformer structure or cabinet sidesheet, depending on the power rating.
 Table 4 - Functional Assessment Checklist (IEC)
Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Electrical Door Interlock Transformer Secondary Cables HECS (2) Control Unit
– Verify proper operation of auxiliary contacts – Verify cables are properly fed through the – Check plug connectors – Check connection of all fiber optic cables
with an ohmmeter glanding plate and are undamaged Door Interlock Limit Switches (2) – Check connection of HMI interface board
Isolation switch auxiliary contacts Voltage Sensing Board cables – Test switch contacts wired back to terminal – HMI
– Verify proper operation with an ohmmeter – Verify the primary and secondary connections blocks in LV panel with ohmmeter Low Voltage wires
Isolation switches to the board are secure Power Modules fiber optic cables – Tug test all wires on door, panel, and relays
– Verify proper operation Door Interlock Limit Switches – Check all connections and terminal blocks
– Outer jaws must securely contact the center – Test auxiliary switch contacts wired back to Power Modules Fuses Circuit Breakers and Contactors
stab in the closed position terminal blocks in LV panel with ohmmeter – Test each fuse with multimeter – Verify operation
Front Secondary Wiring and Low Voltage Fuses Temperature Sensing Wires (3 places) Door Grounding Straps Vertical Ground Bus
– Check all connections per Electrical Drawings – Verify wires are intact and properly inserted – Check connections from all attached
Door Grounding Straps Bottom-mounted Auxiliary Fan power from components
Isolation Transformer Auxiliary Winding Low Voltage Door
– Check connections – Verify operation of all operator interface
Door Grounding Straps devices
Transformer Temperature Protection Relay AC/DC Power Supplies
– Tug test on all cable connections – Check connections
Auxiliary Cooling Fans (3) Door Grounding Straps
– Check electrical connection
Surge Arrestors Transformer Secondary Cables Top Mounted Cooling Fans UPS
– Check braided copper connections – Verify cables are properly fed through the – Check electrical connection – Check connection
Voltage Sensing Relay Cables glanding plate are undamaged
– Perform tug test Tap Changer
Line and Load side power cables – Verify connection
– Verify phasing and torque Top Mounted Cooling Fans
Rear
Top Ground Bus – Check electrical connection
– Verify braided connections Fan Housings

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

– Assembly must be affixed properly to
structure
Auxiliary Cooling Fans (3)
– Check electrical connection
Preparation and Inspection (For IEC)

19
Chapter 2
Chapter 2 Preparation and Inspection (For IEC)

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 109.

Table 5 - Interconnection Review Checklist (IEC)

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Verify the braided ground Verify the braided ground Verify the braided ground Verify control signal wiring
connection to adjacent cabinet(s) connection to adjacent cabinet(s) connection to adjacent cabinet(s) bundles from LV Control cabinet
is properly installed is properly installed is properly installed to LV panel in Isolation
Review the braided ground Review all isolation Verify that the shields of all Transformer cabinet and LV panel
connection to adjacent cabinet transformer secondary wiring of the system’s connecting wires in the Bypass Cabinet (if supplied)
Verify line and load power from Power Module cabinet are properly grounded are routed correctly
cables from Isolation Transformer (2 sets) Review load power cable
Cabinet are properly connected
Front Inspection Verify that the shields of all connection from Isolation
Verify all control wires per of the system’s connecting wires Transformer Cabinet
Electrical Drawing are properly grounded Verify Voltage Sensing
Verify all control wires per Board power cables from Isolation
Electrical Drawing Transformer Cabinet are properly
– Cables are run in LV cable installed
sections along front and
back of cabinet
Fixed Mounted Power
Module:
Verify all isolation
transformer secondary windings
from Power Module Cabinet are
properly connected (1 set)
Drawout Power Module:
Rear Inspection 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)

20 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) Chapter 2

Installation Review 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

Sequence Task Reference Document

1 Verify line up positioning Dimensional Drawings
2 Verify cabinets are bolted together correctly 6000-IN006_-EN-P
3 Verify cabinets are affixed to the floor properly Dimensional Drawings,
6000-IN006_-EN-P
4 Verify fans are installed correctly 6000-IN006_-EN-P
5 Verify power modules are installed correctly 6000-IN006_-EN-P
6 Review duct installation (if applicable) 6000-IN006_-EN-P
7 Verify the cable trenches meet design requirements 6000-IN006_-EN-P
8 Verify required cabinet clearances 6000-IN006_-EN-P
9 Verify there are no scratches or damage to the cabinet body N/A
10 Verify the top cover of the isolation transformer cabinet is securely 6000-IN006_-EN-P
mounted

Refer to project-specific EDs to review all electrical connections to external input

and output devices.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 21

Chapter 2 Preparation and Inspection (For IEC)

Electrical Installation Inspection

Sequence Task Reference

Document
1 Verify that medium voltage cables are separated at least 30 cm from the control cables
2 Verify that all secondary control wiring use shielded cables
3 Verify that input and output medium voltage cables specifications meet the stated Electrical
insulation requirements Drawings
4 Verify that input and output medium voltage cables have attached nameplates
5 Verify the diameter of control power cables comply with the drawings Electrical
Drawings
6 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
7 Verify the wiring between the DCS and the drive is shielded and only the end the drive side is
grounded
8 Verify that the user-provided ground cable is ≥50 mm2
9 Verify the isolation transformer’s primary input voltage matches the system primary voltage
10 Verify that the customer motor specifications match the drive voltage and current
capabilities
11 Verify that the isolation transformer’s input side wiring is correct Electrical
Drawings
12 Verify that the motor output side wiring is correct Electrical
Drawings
13 Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical
Drawings
14 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 Incoming Line Side Outgoing Motor Side
Black L11 (A Phase) Line Cable Terminal U Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
Brown L12 (B Phase) Line Cable Terminal V Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
Grey L13 (C Phase) Line Cable Terminal W Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus

22 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) 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.

Drive Megger Check 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-IN007B-EN-P - March 2016 23

Chapter 2 Preparation and Inspection (For IEC)

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 (IEC)

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 (IEC)

VSB Board Cable connected

to Transformer Cabinet

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 (IEC)

Keep the plug at least

100 mm away from
Temperature Monitor plug

24 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) Chapter 2

5. Switch the miniature circuit breakers in the LV Cabinet off.

Figure 4 - Control Switches (IEC)

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 (IEC)

Miniature Circuit Breakers 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

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 25

Chapter 2 Preparation and Inspection (For IEC)

8. Disconnect the control cable of HECS.

Figure 7 - Hall Effect Current Sensor

HECS
(located at the top of the
power unit cabinet)

Control Cable

9. Disconnect the HMI and Control Board power cables.

Figure 8 - Back of HMI

Control Board Power Cables

HMI Power Cable

26 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) 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.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 27

Chapter 2 Preparation and Inspection (For IEC)

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 (IEC)

Incoming Line Power
Outgoing Motor Power Cable Connections
Cable Connections

Insulation Meter

Ground Bus Bar

Table 7 - Insulation Test Voltage Values

Drive Rated Voltage U1 Insulation Resistance Test Direct Voltage (V)
1000<U1≤5000 2500
5000<U1 5000

Typical of Drive Minimum Megger Value

Entire Drive 1 kM Ohm

28 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For IEC) Chapter 2

Final Steps before 1. Review interior of all cabinets for foreign material that might have been
left behind during the installation process. Ensure no tools, hardware, or
Equipment is Ready for wiring debris remain in the drive system cabinets. Clear any metal shavings
Energization 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.

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

Apply silicone as
shown by bold lines

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 29

Chapter 2 Preparation and Inspection (For IEC)

Notes:

30 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Chapter 3

Preparation and Inspection (For UL)

Gather Required Tools and Hand Tools

Test Equipment • 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-IN007B-EN-P - March 2016 31

Chapter 3 Preparation and Inspection (For UL)

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 page 31), open all of the
cabinet doors. Inspect each component for signs of shipping damage (see Table 8
on page 34). 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 34) 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).

32 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For UL) Chapter 3

Functional Assessment After the components are visually inspected to identify any shipping damage, a
thorough functional assessment should be performed (see Table 9 on page 35).
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 34.

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-IN007B-EN-P - March 2016 33

34
Table 8 - Inspect Drive Components Checklist (UL)
Chapter 3

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Door: Door: Fixed Mounted Power Module Configuration: Door:
Pilot Lights Transformer Temperature monitor Power Module retaining tabs Pilot lights
Voltage Indicator Relay LV Cabinet components Check for debris Push buttons
Cabinet: – Fan control circuit breakers Output Bus Supports Selector switches
Insulators Cabinet: Fuse Mounting Supports HMI
Switch assemblies Transformer Plastic Baffle Voltage Sensing Board Interface board (on the back of the LV door)
Vacuum contactors Outgoing Motor Power Cable standoffs on Drawout Power Module Configuration: Panel:
Mechanical linkages Cabinet Sidesheet(1) Support frame DIN rail mounted components
Outgoing Motor Power Cable Terminal Power Modules UPS
Preparation and Inspection (For UL)

Front
Insulators on transformer (1) Fiber optic cables
Incoming Line Power Cable Terminal Insulators PLC
on transformer Control Unit
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: Fixed Mounted Power Module: UPS connections
Transformer Secondary Windings (1) Heat sink
Rear – Inspect nomex wrap – Verify orientation relative to barrier plates
– Verify windings from core are undamaged
– Check for debris in top of core
(1) Motor Cable terminations could be on the transformer structure or cabinet sidesheet, depending on the power rating.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Table 9 - Functional Assessment Checklist (UL)
Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Electrical Door Interlock Transformer Secondary Cables HECS (2) Control Unit
– Verify proper operation of auxiliary contacts – Verify cables are properly fed through the – Check plug connectors – Check connection of all fiber optic cables
with an ohmmeter glanding plate and are undamaged Mechanical Interlock (2) – Check connection of HMI interface board
Isolation switch auxiliary contacts Mechanical Interlock – Test switch contacts wired back to terminal – HMI
– Verify proper operation with an ohmmeter – Test auxiliary switch contacts wired back to blocks in LV panel with ohmmeter Low Voltage wires
Isolation switches terminal blocks in LV panel with ohmmeter Power Modules fiber optic cables – Tug test all wires on door, panel, and relays
– Verify proper operation Temperature Sensing Wires (3 places) – Check all connections and terminal blocks
– Outer jaws must securely contact the center – Verify wires are intact and properly inserted Power Modules Fuses Circuit Breakers and Contactors
stab in the closed position Door Grounding Straps – Test each fuse with multimeter – Verify operation
Front
Secondary Wiring and Low Voltage Fuses Transformer Temperature Protection Relay Door Grounding Straps Vertical Ground Bus
– Check all connections per Electrical Drawings – Tug test on all cable connections Voltage Sensing Board cables – Check connections from all attached
Door Grounding Straps – Verify the primary and secondary connections components
to the board are secure Low Voltage Door
– Verify operation of all operator interface
devices
AC/DC Power Supplies
– Check connections
Door Grounding Straps
Surge Arrestors Transformer Secondary Cables Top Mounted Cooling Fans UPS
– Check braided copper connections – Verify cables are properly fed through the – Check electrical connection – Check connection
Voltage Sensing Relay Cables glanding plate are undamaged
– Perform tug test Tap Changer
Line and Load side power cables – Verify connection
Rear
– Verify phasing and torque Top Mounted Cooling Fans
Top Ground Bus – Check electrical connection
– Verify braided connections Fan Housings
– Assembly must be affixed properly to

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

structure
Preparation and Inspection (For UL)

35
Chapter 3
Chapter 3 Preparation and Inspection (For UL)

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 109.

Table 10 - Interconnection Review Checklist (UL)

Bypass Cabinet (if supplied) Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet
Verify the braided ground Verify the braided ground Verify the braided ground Verify control signal wiring
connection to adjacent cabinet(s) connection to adjacent cabinet(s) connection to adjacent cabinet(s) bundles from LV Control cabinet
is properly installed is properly installed is properly installed to LV panel in Isolation
Review the braided ground Review all isolation Verify that the shields of all Transformer cabinet and LV panel
connection to adjacent cabinet transformer secondary wiring of the system’s connecting wires in the Bypass Cabinet (if supplied)
Verify line and load power from Power Module cabinet are properly grounded are routed correctly
cables from Isolation Transformer (2 sets) Review load power cable
Cabinet are properly connected
Verify that the shields of all connection from Isolation
Front Inspection Verify all control wires per of the system’s connecting wires Transformer Cabinet
Electrical Drawing are properly grounded Verify Voltage Sensing
Verify all control wires per Board power cables from Power
Electrical Drawing Module Cabinet are properly
– Cables are run in LV cable installed
sections along front and Verify that the two plugs
back of cabinet from the LV Control Cabinet and
Isolation Transformer Cabinet are
properly installed

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 Preparation and Inspection (For UL) Chapter 3

Installation Review 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

Sequence Task Reference Document

1 Verify line up positioning Dimensional Drawings
2 Verify cabinets are bolted together correctly 6000-IN006_-EN-P
3 Verify cabinets are affixed to the floor properly Dimensional Drawings,
6000-IN006_-EN-P
4 Verify fans are installed correctly 6000-IN006_-EN-P
5 Verify power modules are installed correctly 6000-IN006_-EN-P
6 Review duct installation (if applicable) 6000-IN006_-EN-P
7 Verify the cable trenches meet design requirements 6000-IN006_-EN-P
8 Verify required cabinet clearances 6000-IN006_-EN-P
9 Verify there are no scratches or damage to the cabinet body N/A
10 Verify the top cover of the isolation transformer cabinet is securely 6000-IN006_-EN-P
mounted

Refer to project-specific EDs to review all electrical connections to external input

and output devices.

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Chapter 3 Preparation and Inspection (For UL)

Electrical Installation Inspection

Sequence Task Reference

Document
1 Verify that medium voltage cables are separated at least 30 cm from the control cables
2 Verify that all secondary control wiring use shielded cables
3 Verify that input and output medium voltage cables specifications meet the stated Electrical
insulation requirements Drawings
4 Verify that input and output medium voltage cables have attached nameplates
5 Verify the diameter of control power cables comply with the drawings Electrical
Drawings
6 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
7 Verify the wiring between the DCS and the drive is shielded and only the end the drive side is
grounded
8 Verify that the user-provided ground cable is ≥50 mm2
9 Verify the isolation transformer’s primary input voltage matches the system primary voltage
10 Verify that the customer motor specifications match the drive voltage and current
capabilities
11 Verify that the isolation transformer’s input side wiring is correct Electrical
Drawings
12 Verify that the motor output side wiring is correct Electrical
Drawings
13 Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical
Drawings
14 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 11 - Color Coding (UL)
Color Incoming Line Side Outgoing Motor Side
Black L1 (A Phase) Line Cable Terminal U Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
Red L2 (B Phase) Line Cable Terminal V Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus
Blue L3 (C Phase) Line Cable Terminal W Phase:
• Power Module Bus
• VSB Input Cable
• Motor Cable Termination
• Motor Cable Connection to Power Module Bus

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 Preparation and Inspection (For UL) Chapter 3

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.

Drive Megger Check 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.

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Chapter 3 Preparation and Inspection (For UL)

2. Disconnect four 380V AC cables (a, b, c, and o cables) from the bottom of
the Isolation Transformer.

Figure 13 - 380V AC Bottom-mounted Auxiliary Fan Input Cables (UL)

3. Disconnect the Voltage Sensing Board Output Cable. Keep the plug at
least 100 mm away from the Voltage Sensing Board.

Figure 14 - Voltage Sensing Board Output Connection Cable (UL)

VSB Board Cable connected to

Transformer Cabinet

4. Disconnect the Isolation Transformer Temperature Monitor. Keep the

plug at least 100 mm away from the connection point on the Monitor.

Figure 15 - Isolation Transformer Temperature Monitor (UL)

40 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Preparation and Inspection (For UL) Chapter 3

5. Switch the miniature circuit breakers in the LV Cabinet off.

Figure 16 - Control Switches (UL)

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 17 - Control Switches (UL)

Top Main Cooling
Fan Circuit Breakers

Miniature Circuit Breakers

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Chapter 3 Preparation and Inspection (For UL)

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 18 - Star Connection Cable (UL)

8. Disconnect the control cable of HECS.

Figure 19 - Hall Effect Current Sensor (UL)

Control Cable

HECS
(located on the right side
of the power unit cabinet

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 Preparation and Inspection (For UL) Chapter 3

9. Disconnect the HMI and Control Board power cables.

Figure 20 - Back of HMI

Control Board Power Cables

HMI Power Cable

10. Remove the Analog Interface board and disconnect all of the terminals
from the Control Unit.

Figure 21 - Back of Control Unit

Analog Interface Board

location on Control Unit

Control Unit terminals

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Chapter 3 Preparation and Inspection (For UL)

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 22.

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 22.
4. Perform a Megger test with the insulation meter voltage set according to
the voltages shown in Table 12 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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 Preparation and Inspection (For UL) Chapter 3

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 22 - Connected Insulation Meter (UL)

Incoming Line Power

Cable Connections

Insulation Meter

Ground Bus Bar

Table 12 - Insulation Test Voltage Values

Drive Rated Voltage U1 Insulation Resistance Test Direct Voltage (V)
1000<U1≤5000 2500
5000<U1 5000

Typical of Drive Minimum Megger Value

Entire Drive 1 kM Ohm

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Chapter 3 Preparation and Inspection (For UL)

Final Steps before 1. Review interior of all cabinets for foreign material that might have been
left behind during the installation process. Ensure no tools, hardware, or
Equipment is Ready for wiring debris remain in the drive system cabinets. Clear any metal shavings
Energization 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.

Figure 23 - Silicone Locations on Fixed-mounted Power Module Configuration

Apply silicone as
shown by bold lines

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 Chapter 4

Commissioning

Introduction
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 Page
Simulate Closed Input Circuit Breaker 48
Energize Control Circuit 48

The complete Control System Check requires the following procedures to be

performed.

Procedure Page
Verify Factory Default Settings 52
Set P Parameters to Enable Testing 55
Verify Settings for Low-Voltage Testing 58
Verify Operation of Frequency Steps 63
Verify Operation to Set Frequency 65
Simulate Warnings and Faults 65
Verify E-Stop Functionality 72
Verify Switching from Local Control to Remote Control 73
Verify Operation of Input/Output and Bypass Isolation Switches (Manual Bypass)(1) 74
(1)
Verify Operation of Input/Output and Bypass Contactors (Automatic Bypass) 77
Verify Operation of DCS Input and Output Signals 83
Restore P Parameter Settings 84
(1) Only required if a bypass configuration is supplied.

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Chapter 4 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
(Figure 24). This must be specified at time of order.

Q1 (CB1), Q2 (CB2), Q3 (CB3), Q5 (CB5), and Q6 (CB6) miniature circuit

breaker designations are located in the LV Control Cabinet (Figure 25). The Q4
(CB4) and Q7 (CB7) miniature circuit breaker designations are located in the
LV Control panel of the Isolation Transformer Cabinet (Figure 26). 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 (CB1), Q2 (CB2), etc.) are affixed
to the device mounting surfaces.

Figure 24 - UPS and CPT Mounting Plate (Top View)

REAR

Control Power
Transformer

UPS
FRONT

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 Commissioning Chapter 4

Figure 25 - LV Control Cabinet

1 3 5

Q1 Q2 Q3 Q5 Q6
(CB1) (CB2) (CB3) (CB5) (CB6)

2 4 6

Figure 26 - LV Panel in the Isolation Transformer Cabinet

For IEC For UL

Q4 Q7

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Chapter 4 Commissioning

Table 13 - Energize Control Circuit Sequence (For IEC)

Item Before Closing Breaker After Closing Breaker Comments
Close Verify that the input voltage at the Q1 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 Q1 connects customer-supplied control power to
Breaker Q1 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify CLOSED state (5 and 6). the control circuit (UPS).
Verify OPEN state (5 and 6).

Start UPS Before pressing the ON button, withdraw the Type I UPS Verify that UPS operates normally and that the UPS feeds control power to the circuits supplied
(Press ON power plug from the power receptacle (XS2). Verify that the UPS output is AC220V. The output of the UPS is by the Q2 and Q3 circuit breakers.
button) input voltage of the XS2 receptacle is AC220V. Verify that the connected to the input of Q2 and Q3. The UPS
PE connection of the XS2 receptacle is properly grounded. output voltage can be checked at the input of Q2
Plug the UPS into the receptacle. Press and hold the ON or Q3 (1 is L, 3 is N).
button for 3 seconds to turn on the UPS (all status lights on
the UPS will be green).
Close Verify that the input voltage at the Q2 circuit breaker is Verify that the input voltage of power supplies is Q2 connects control power directly to AC/DC
Breaker Q2 AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. AC220V (L-N). Refer to Figure 27. Verify that the power supplies (G1, G2, and G3), PLC, HMI, and
Verify output is not shorted (2 and 4). PLC, HMI, and Control Unit power up. Control Unit
Close Verify that the input voltage at the Q3 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 Q3 connects control power to PLC I/O and control
Breaker Q3 AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. is N). Verify CLOSED state (5 and 6). Verify that relays.
Verify output is not shorted (2 and 4). Verify OPEN state (5 the PLC I/O status lights and control relay red
and 6). indicating lights illuminate.
Close Control power is fed from the isolation transformer tertiary Verify closed status (1 and 2). Q4 connects control power from isolation
Breaker Q4 winding for the Q4 circuit breaker, therefore not present for transformer tertiary winding to bottom-
this test. A two pole breaker is supplied for lower power mounted auxiliary fans (6).
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).
Close Control power is fed from the isolation transformer tertiary Verify closed status (1 and 2). Q5 connects back-up control power from
Breaker Q5 winding for the Q5 circuit breaker, therefore not present for isolation transformer tertiary winding to switch
this test. Verify open status (1 and 2) and output not shorted to the control circuit (UPS) if the main (customer-
(2 and 4). supplied) control power is lost.

Close Verify that the input voltage at the Q6 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 Q6 connects control power to door mounted pilot
Breaker Q6 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify that the LV Door pilot lights lights and spare relays for DCS.
illuminate.
Close Verify that the input voltage at the Q7 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 Q7 connects control power to isolation
Breaker Q7 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify that the Isolation Transformer transformer temperature monitor
temperature monitor powers up.

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.

Table 14 - Energize Control Circuit Sequence (For UL)

Item Before Closing Breaker After Closing Breaker Comments
Close Verify that the input voltage at the CB1 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 CB1 connects customer-supplied control power
Breaker CB1 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify CLOSED state (5 and 6). to the control circuit (UPS).
Verify OPEN state (5 and 6).

Start UPS Before pressing the ON button, withdraw the Type I UPS Verify that UPS operates normally and that the UPS feeds control power to the circuits supplied
(Press ON power plug from the power receptacle (XS2). Verify that the UPS output is AC220V. The output of the UPS is by the CB2 and CB3 circuit breakers.
button) input voltage of the XS2 receptacle is AC220V. Verify that the connected to the input of CB2 and CB3. The UPS
PE connection of the XS2 receptacle is properly grounded. output voltage can be checked at the input of
Plug the UPS into the receptacle. Press and hold the ON CB2 or Q3 (1 is L, 3 is N).
button for 3 seconds to turn on the UPS (all status lights on
the UPS will be green).
Close Verify that the input voltage at the CB2 circuit breaker is Verify that the input voltage of power supplies is CB2 connects control power directly to AC/DC
Breaker CB2 AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. AC220V (L-N). Refer to Figure 27. Verify that the power supplies (G1, G2, and G3), PLC, HMI, and
Verify output is not shorted (2 and 4). PLC, HMI, and Control Unit power up. Control Unit

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 Commissioning Chapter 4

Table 14 - Energize Control Circuit Sequence (For UL)

Close Verify that the input voltage at the CB3 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 CB3 connects control power to PLC I/O and
Breaker CB3 AC220V (1 is L, 3 is N). Ignore if done in “Start UPS” step. is N). Verify CLOSED state (5 and 6). Verify that control relays.
Verify output is not shorted (2 and 4). Verify OPEN state (5 the PLC I/O status lights and control relay red
and 6). indicating lights illuminate.
Close Control power is fed from the isolation transformer tertiary Verify closed status (1 and 2). CB5 connects back-up control power from
Breaker CB5 winding for the CB5 circuit breaker, therefore not present for isolation transformer tertiary winding to switch
this test. Verify open status (1 and 2) and output not shorted to the control circuit (UPS) if the main (customer-
(2 and 4). supplied) control power is lost.

Close Verify that the input voltage at the CB6 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 CB6 connects control power to door mounted
Breaker CB6 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify that the LV Door pilot lights pilot lights and spare relays for DCS.
illuminate.
Close Verify that the input voltage at the CB7 circuit breaker is Verify that the output voltage is AC220V (2 is L, 4 CB7 connects control power to isolation
Breaker CB7 AC220V (1 is L, 3 is N). Verify output is not shorted (2 and 4). is N). Verify that the Isolation Transformer transformer temperature monitor
temperature monitor powers up.

ATTENTION: The following should be opened successively when the control

power is switched off: CB5, CB3, CB2 and UPS; opening CB1 is not necessary
when the control power is not disconnected.

Figure 27 - AC/DC Power Supplies

NL NL

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Chapter 4 Commissioning

Control System Check 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. Press in the System Parameter Settings interface screen.

2. In the Languages dialog box, select the language you want and press
.

3. Press to accept and proceed to the Main Interface

Screen.

TIP Detailed information about the HMI screens is included in publication

6000-UM002_-EN-P, PowerFlex 6000 Medium Voltage Variable Frequency
Drive User Manual.

52 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Commissioning Chapter 4

4. Press and confirm the Bypass Configuration matches one of

the five Input Supply graphics.
No Bypass Cabinet

Manual Bypass Cabinet

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Chapter 4 Commissioning

Automatic Bypass Cabinet

Note the Contactor

Operation selection
appears when Automatic
Bypass is selected

Manual Bypass
Two Cabinets

Automatic Bypass
Two Cabinets

Note the Contactor

Operation selection
appears when Automatic
Bypass is selected

5. Under Control Owner Selection, press .

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 Commissioning Chapter 4

The Select Local Control? dialog box appears.

6. Select to confirm Local Control, and press to

return to the Main Interface Screen.

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. Press under Parameter Access Level.

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Chapter 4 Commissioning

The Setup Login dialog box appears. Press .

3. Enter the User and Password details.

Press and enter “setup”. Press when finished.

Press to enter the password. Press when finished.

TIP The password will be sent by the Project Start-up Manager.

4. Press to 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.

For the simulation tests, you only need to change two parameters: P007 and
P224.

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1. Press in the Setup Parameter Type.

2. Press the P007 parameter input field.

WARNING: Do NOT press . This will reset all factory-set

parameters.

TIP When the “P” Parameter number is pressed (e.g. P007), the description
appears in the information box at the bottom of the screen.
.

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Chapter 4 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”.

Verify Settings for Low-Voltage Testing

The following settings are for low-voltage testing only.

IMPORTANT Before performing high-voltage testing, the “Power Loss” setting must be
restored to the unshielded state.

1. Press from the Main Interface Screen.

2. Press under Parameter Access Level.

The R&D Login dialog box appears. Press .

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3. Enter the User and Password details.

Press and enter “RD”. Press when finished.

Press and enter “668”. Press when finished.

4. Press to login.
The Current User will now display RD, 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.

1. Press under P Parameter Settings.

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Chapter 4 Commissioning

2. Press “499” on the keypad dialog and press .

will now show a value of “499”.

3. Press and enter “1”. Press when finished.

4. Press . The should display “1.00”.

5. Press to view the Fault Masks screen.

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For IEC Standard

6. Press and . The buttons should change
to and respectively.
.

WARNING: Before performing the high-voltage test, press

to change back to and keep current blocked because there is
no hardware detection in IEC)

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Chapter 4 Commissioning

For UL Standard
7. Press to change the button to .
.

8. Press to return to P Parameter Settings and continue

with low-voltage testing.

IMPORTANT After the end of the simulation tests, the “Power Loss” setting must be restored
to the unshielded state.

9. Press to exit P Parameter Settings, and . Press

to confirm Setup has logged out.

10. Press to return to the Main Interface Screen.

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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.

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.

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Chapter 4 Commissioning

3. Press , and press in the Start Drive? dialog box to

confirm operation.

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 in the Accel Speed by Step? 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 86.

The Set Frequency and Actual Frequency are now 11 Hz.

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5. Press and press in the Decel Speed by Step? dialog

box.
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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Chapter 4 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.

The actual frequency will decrease to 0 Hz.

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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 Self-clearing Requires Reset

Transformer Overtemperature Warning YES
Transformer Overtemperature Trip YES
Transformer Cabinet Main Cooling Fan Fault YES
Power Module Cabinet Main Cooling Fan Fault YES
Cabinet Door Open Warning YES
– 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)

The Set Frequency: field will already have 50 Hz shown from the previous
exercise in the Set Freq: dialog box.

1. Press , and press in the Start Drive? dialog box.

Simulate the Transformer Overtemperature Warning

1. Start the drive, then open the door of the Control cabinet.
2. In the control cabinet, remove the wire from terminal block 419. This
triggers the transformer overtemperature warning alarm.

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Chapter 4 Commissioning

3. Press to view alarm record.

.

4. Replace the wire for terminal block 419 and tighten properly to remove the
warning.

Simulate Transformer Overtemperature Trip

1. Start the drive, then open the door of the Control cabinet.
2. In the Control cabinet, remove the wire from terminal block 418. This
triggers the transformer overtemperature trip alarm.

3. Press to view the alarm record.

4. Replace the wire for terminal block 418 and tighten properly to remove the
trip message.

5. Press to return to the Main Interface Screen.

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6. Press , and press to confirm the operation in the Reset

Drive? dialog box.

Wait until the Ready status indicator is red before starting another
simulation.

Simulate a Transformer Cabinet Main Cooling Fan Fault

1. Set the frequency to 10 Hz and start the drive.

2. 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.

3. Turn the first motor control circuit breaker (Q10 for IEC and CB10 for
UL), controlling the Isolation Transformer Cabinet Main Cooling Fans
(one per fan), to the OFF position.

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Chapter 4 Commissioning

4. Press to confirm the Transformer Cabinet Main Cooling Fan

Fault.

5. After the fault is reported, the drive is in a fault stop state.

6. Turn the first (Q10 for IEC and CB10 for UL) circuit breaker to the ON
position, to remove the fault.

7. Press to return to the Main Interface Screen.

Simulate a Power Module Cabinet Main Cooling Fan Fault

1. Set the frequency to 10 Hz and start the drive.

2. 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.

3. Turn the applicable motor control circuit breaker (Q13 for IEC and CB13
for UL), controlling the Power Module Main Cooling Fans (one per fan),
to the OFF position.

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4. Press and confirm the Power Module Cabinet Fan Fault.

5. After the fault is reported, the drive is in a fault stop state.

6. Turn the (Q13 for IEC and CB13 for UL) circuit breaker to the ON
position, to remove the fault.

7. 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

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Chapter 4 Commissioning

• Right Power Module/LV Cabinet door

• Bypass Cabinet door (if applicable)

5. Press to return to the Main Interface Screen.

6. Press to remove the fault. Press to confirm

operation in the Reset Drive? dialog.

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.

4. Twist to pull out the E-stop button on the front of the LV Control cabinet.

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5. Press to return to the Main Interface Screen.

6. Press to remove the fault. Press to confirm

operation in the Reset Drive? dialog.

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 in the Control Owner Selection.

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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Chapter 4 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.

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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.

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Chapter 4 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 4

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.

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Chapter 4 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. Press under Contactor Operation, and press to

confirm.

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 Commissioning Chapter 4

Verify the input and output drive contactors are closed.

4. Press under Contactor Operation, and press to

confirm.
.

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Chapter 4 Commissioning

5. Verify the input and output drive contactors are open.

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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2. Press under Contactor Operation, and press to

confirm.
.

Verify the bypass contactor is closed.

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Chapter 4 Commissioning

3. Press under Contactor Operation, and press to

confirm.
.

Verify the bypass contactor is open.

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Verify Operation of DCS Input and Output Signals

Figure 28 - Status Indicators

Table 15 - Drive to DCS

Signal Name Terminal Number HMI Status Terminal Open Terminal Closed
MVPRE-Closed CB 901-902 Allowed Red Grey

MV CLOSING 903-904 MVClosd Red Grey

Warning 905-906 Warning Red Grey

Fault 907-908 Warning Red Grey

Drive running 909-910 Running/Connect Red Grey

Drive STOP 911-912 Running/Connect Red Grey

READY 913-914 Ready Red Grey

DCS control 915-916 Remote Red Grey

Local Grey Red

Table 16 - 4-20 mA
Output Current 925-926 Motor Current 0-Rated Current
Output Frequency 927-928 Actual Frequency 0-Rated Frequency

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Chapter 4 Commissioning

When the two terminals specified are shorted, verify the result shown in the third
column occurs.
Table 17 - DCS to Drive
Signal Name Terminal Number Function
Fault Reset 412-401 Reset System
DCS Start 449-401 Start Drive
DCS Stop 450-401 Stop Drive
E-stop 1101-1101 E-stop Drive
Frequency Set 931-402 Set Drive Frequency

Restore P Parameter Settings

1. Press , and press under Parameter

Access Level.

The Setup Login dialog box appears. Press .

2. Enter the User and Password details.

Press to enter user details. Press when finished.

Press to enter password details. Press when finished.

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3. Press to login.

4. Press , and 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 to exit P Parameter Settings, to confirm

Setup has logged out, and to return to the Main Interface

Screen.

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 4 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. Press under Parameter Access Level.

The Setup Login dialog box appears. Press .

3. Enter the User and Password details.

4. Press to login.

5. Once logged in, press .

6. Press in the Setup Parameter Type.

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.

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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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Notes:

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 Chapter 5

No-load Test

Introduction 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.

No-load Test The No-load Test consists of the following procedures and must be performed in
the sequence shown.
Sequence Procedure Page
1 Energize Drive Control Circuit 90
LV
Only 2 Configure P and T Parameters 90
3 Close Isolation Switches in Bypass Cabinet(1) 102
4 Close Input Circuit Breaker 103
MV 5 Check Cooling Fan Operation 103
6 Operate Motor by HMI 104
(1) This procedure is performed only if an optional bypass configuration is supplied.

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 5 No-load Test

Energize Drive Control Circuit

The “Energize Control Circuit” process is already described on page 48. 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 (CB1).

2. Start UPS. Press and hold the ON button for approximately 3 seconds.
3. Close circuit breakers Q2 (CB2), Q3 (CB3), Q5 (CB5), and Q6 (CB6) in
the LV Control Panel.
4. Close circuit breakers Q4 (CB4) and Q7 (CB7) in the Isolation
Transformer Cabinet LV Panel.

Configure P and T Parameters

TIP See Set P Parameters to Enable Testing on page 55 for information on how to
access and change parameters.

Set the P parameters as shown in Table 18, and T parameters as shown in

Table 19.

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 117.
Table 18 - Setup and R&D P Parameters
Parameter Description Min. Max. Default Modify
Number Root
P004 Command Source 0 2 0 OFF
0 = Communication Port
1 = Digital Input
2 = EtherNet/IP
P005 Restore Factory Settings 0 50 0 OFF
30 = Restore Setup Level
40 = Restore User Level
50 = Restore R&D Level
P007 Number of Power Cells Per Phase 0 9 9 ON
P008 Motor Rotation Direction Under Local Control 0 1 1 OFF
0 = Reverse
1 = Forward
P009 Motor Rotation Direction Command Selection: 0 1 0 OFF
0 = Local Control
1 = DCS
P010 Power Cell Fault Mask 0 32767 32767 ON
P017 Number Of Motor Pole Pairs 0 100 2 OFF
P019 Encoder Resolution 0 4096 1024 OFF

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 No-load Test Chapter 5

Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P020 Mask Bit For System Fault 0 32767 32767 ON
P021 Mask Bit For System Warning 0 32767 32767 ON
P022 Mask Bit For Logic Fault A 0 32767 32767 ON
P023 Mask Bit For Logic Fault B 0 32767 32767 ON
P024 Stop Method 0 1 0 ON
0 = Ramp Dow
1 = Coast Stop
P025 Flux Reduction Enable 0 1 0 ON
0 = Disable
1 = Enable
P026 Power Angle Threshold For Flux Reduction 0 180 0 ON
P027 Time For Flux Reducing 0 32767 5000 ON
P028 Flux Reduction Ratio 0 100 70 ON
P029 Power Angle Threshold For Flux Restore 0 180 0 ON
P030 Powercell Fault Trip Signal Mask Register 0 32767 32767 OFF
P031 System Fault Trip Signal Mask Register 0 32767 32767 OFF
P032 Logic Fault A Trip Signal Mask Register 0 32767 32767 OFF
P033 Logic Fault B Trip Signal Mask Register 0 32767 32767 OFF
P034 Current Stability Loop Filter Time 0 32767 63 ON
P035 Current Stability Loop Output Scaling Factor 0 100 20 ON
P036 Current Stability Loop Output Upper Limit 0 100 10 ON
P037 Current Stability Loop Output Lower Limit -100 100 -10 ON
P038 Current Stability Loop Enable 0 1 1 ON
0 = Disable
1 = Enable
P039 Current Stability Loop Enable Frequency Range Upper 0 100 40 ON
Limit
P040 Safe Start Condition 0 1 1 OFF
0 = Zero Frequency Command Required
1 = Frequency Command Allowed
P087 Switch Frequency Setting Enable Code 0 1 0 OFF
0 = Disable
1 = Enable
P088 Switch Frequency Setting 0 1 0 OFF
0 = 600 Hz
1 = 1200 Hz
P089 Skip Frequency Enable 0 1 0 ON
0 = Disable
1 = Enable
P090 Skip Frequency 1 Lower Limit 0 75 0 ON
P091 Skip Frequency 1 Upper Limit 0 75 0 ON
P092 Skip Frequency 2 Lower Limit 0 75 0 ON
P093 Skip Frequency 2 Upper Limit 0 75 0 ON
P113 Flying Start-Initial Output Voltage 0 100 5 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P114 Flying Start-Current Comparison Delay For Motor Speed 0 5000 1000 ON
Search
P115 Flying Start-Current Threshold For Successful Motor 0 100 5 ON
Speed Search
P198 HECS Rated Current 0 5000 0 ON
P199 Motor Rated Current 0 5000 0 ON
P200 Ia Motor Current Memory Address 0 500 13 ON
P201 Motor Ia Scaling Correction Factor 0.00 199.99 100.00 ON
P202 Ib Motor Current Memory Address 0 500 14 ON
P203 Motor Ib Scaling Correction Factor 0.00 199.99 100.00 ON
P204 Motor Uab Voltage Address 0 500 11 ON
P205 Motor Uab Voltage Scaling Factor Correction 0.00 199.99 199.99 ON
P206 Motor Uac Voltage Scaling Factor Correction 0.00 199.99 199.99 ON
P208 Phase Over Current Enable Frequency Range Upper Limit 0 100 10 ON
P209 Phase Over Current Filter Time 0 32767 5 ON
P210 Phase Over Current Threshold 0 199.99 180 ON
P211 Filter Time For Abnormal Output Voltage 0 32767 1000 ON
P212 Filter Time For Output Short-Circuit 0 32767 10 ON
P213 Output Short-Circuit Fault Threshold 0 199.99 180 ON
P214 Over Current Low/High Speed Region Boundary 0 100 5 ON
P215 Filter Time For Output Over Current 0.0 3276.7 20.0 ON
P216 High-Frequency Output Over Current Threshold 0.00 199.99 120.00 ON
P217 Low-Frequency Output Over Current Threshold 0.00 199.99 70.00 ON
P218 Filter Time For Motor Over Temperature 0.0 3276.7 600.0 ON
P219 Motor Over Temperature Warning Threshold 0.00 199.99 110.00 ON
P220 Motor Over Temperature Fault Threshold 0.00 199.99 120.00 ON
P221 Filter Time For Output Over Voltage 0 32767 100 ON
P222 Output Over Voltage Fault Threshold 0.00 199.99 130.00 ON
P223 Output Voltage Deviation Warning Threshold 0.00 199.99 60.00 ON
P224 Output Voltage Deviation Fault Threshold 0.00 199.99 80.00 ON
P225 Motor Over Temperature Warning Cancellation 0.00 199.99 100.00 ON
Temperature
P226 Output Voltage Abnormality Warning Cancellation 0.00 199.99 50.00 ON
Threshold
P227 Ground Fault Detection Scaling Correction Factor 0.00 199.99 100.00 ON
P228 Filter Time For Ground Fault 0 32767 1000 ON
P229 Ground Fault Warning Threshold 0.00 199.99 20.00 ON
P230 Ground Fault Trip Threshold 0.00 199.99 60.00 ON
P231 Filter Time For Overspeed Fault (Upper Limit) 0 32767 100 ON
P232 Filter Time For Overspeed Fault (Lower Limit) 0 32767 100 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P233 Threshold Of Over-Speed Fault At Lower Frequency Limit 0.00 199.99 20.00 ON
P234 Threshold Of Over-Speed Fault At Upper Frequency Limit 0.00 199.99 20.00 ON
P235 Frequency Deviation Warning Cancellation Threshold 0.00 199.99 0.99 ON
P236 Frequency Deviation Warning Threshold 0.00 199.99 6.00 ON
P237 Frequency Deviation Warning Delay 0 32767 8 ON
P238 Motor Stall Fault Threshold 0.00 199.99 10.00 ON
P239 Motor Stall Fault Delay 0 32767 6000 ON
P240 Transformer Over Temperature Fault Delay 0 32767 5000 ON
P241 Transformer Over Temperature Warning Delay 0 32767 5000 ON
P247 Software Interlock 0 1 1 ON
0 = Enable
1 = Disable
P250 Input Contactor/Circuit Breaker Close Delay 0 10000 5000 ON
P251 Frequency Command-Low Frequency Region Boundary 0.0 100.0 0.5 ON
P252 Motor In Stopping Condition Threshold 0 100 1 ON
P253 Motor Coast Stop Time 0 10000 10 ON
P256 Ground Fault Warning Cancellation Threshold 0.00 199.99 10.00 ON
P257 Motor Stall Warning Cancellation Threshold 0.00 199.99 2.98 ON
P259 Frequency Command Analog Offset -100.00 199.99 0.00 ON
P260 Frequency Command Analog Scaling Factor 0.00 199.99 100.00 ON
P261 Frequency Command Analog Minimum 0.00 199.99 0.49 ON
P262 Frequency Command Source Selection 0 1 0 OFF
0 = Digital
1 = Analog
P263 Power Loss Restart Enable 0 1 0 OFF
0 = Disable
1 = Enable
P264 Power Loss Allowable Time 0.00 3599.96 59.63 OFF
P265 Power Loss Time Max Limit 0.00 3599.96 299.82 OFF
P268 Flux Control Signal Filter Time 0.00 13499.9 999.97 ON
6
P269 System Derating Control Signal Filter Time 0.00 13499.9 999.97 ON
6
P270 Delayed Lockout Time Of Stop Operation 0 5000 2000 ON
P271 Flux Delay 0 5000 50 ON
P272 Flux Control Regulation Time 0.96 999.97 0.96 ON
P273 Flux Control Regulation Control Enable 0 1 1 ON
0 = Disable
1 = Enable
P275 Flux Control Regulation Acceleration Threshold 100.00 199.99 100.00 ON
P276 Derating Control No-Load Modulation Index 50 100 80 ON
P277 Derating Control Full-Load Modulation Index 50.00 199.99 81.99 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P278 Derating Control Enable Threshold 50.00 199.99 100.00 ON
P279 Derating Control Output Filter Time 9.95 1999.94 9.95 ON
P280 Low Voltage Ride Through Recovery Voltage Boost 0 100 10 ON
Coefficient
P281 Low Voltage Ride Through Min Time Interval 0.00 1000.00 9.97 ON
P282 Low Voltage Ride Through Min Frequency Limit 5 100 20 OFF
P283 Low Voltage Ride Through Enable 0 1 0 ON
0 = Disable
1 = Enable
P284 Low Voltage Ride Through Min Time Limit 20.02 13663.0 39.62 OFF
1
P285 Low Voltage Ride Through Max Time Limit 20.02 13663.0 99.66 OFF
1
P286 Low Voltage Ride Through Recovery Frequency -200.00 199.99 0.00 OFF
Compensation Factor
P287 Low Voltage Ride Through Recovery Time 145.95 13663.0 1499.95 OFF
1
P288 Low Voltage Ride Through System Delay Correction 0.00 10000.0 2199.97 ON
Factor 0
P289 Low Voltage Ride Through Motor Speed Estimation Filter 0.98 1000.00 9.95 OFF
Time
P290 Voltage Loop Enable 0 1 0 OFF
0 = Disable
1 = Enable
P291 Voltage Loop Enable Min Frequency 0 100 20 OFF
P292 Voltage Loop Proportional Coefficient 99.98 1999.94 899.96 ON
P293 Voltage Loop Integral Coefficient 0.00 99.98 19.96 ON
P294 Voltage Loop Positive Incremental Error Limit 20.02 1000.00 49.99 ON
P295 Voltage Loop Negative Incremental Error Limit 20.02 1000.00 99.98 ON
P296 Reserved 49.99 1000.00 0.00 ON
P297 Voltage Loop Voltage Reference 125.00 1200.12 1000.00 ON
P298 Voltage Loop Current Filter Time 0.00 1999.94 9.95 ON
P299 Voltage Loop Voltage Filter Time 0.00 1999.94 2.99 ON
P300 Digital Output #0 Memory Address 0 500 99 ON
P301 Digital Output #0 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P302 Digital Output #0 Bit Selection 0 15 0 ON
P303 Digital Output #0 Delay 0 32767 0 ON
P304 Digital Output #1 Memory Address 0 500 99 ON
P305 Digital Output #1 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P306 Digital Output #1 Bit Selection 0 15 1 ON
P307 Digital Output #1 Delay 0 32767 0 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P308 Digital Output #2 Memory Address 0 500 99 ON
P309 Digital Output #2 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P310 Digital Output #2 Bit Selection 0 15 2 ON
P311 Digital Output #2 Delay 0 32767 0 ON
P312 Digital Output #3 Memory Address 0 500 99 ON
P313 Digital Output #3 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting\
P314 Digital Output #3 Bit Selection 0 15 3 ON
P315 Digital Output #3 Delay 0 32767 0 ON
P316 Digital Output #4 Memory Address 0 500 99 ON
P317 Digital Output #4 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P318 Digital Output #4 Bit Selection 0 15 4 ON
P319 Digital Output #4 Delay 0 32767 0 ON
P320 Digital Output #5 Memory Address 0 500 99 ON
P321 Digital Output #5 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P322 Digital Output #5 Bit Selection 0 15 5 ON
P323 Digital Output #5 Delay 0 32767 0 ON
P324 Digital Output #6 Memory Address 0 500 99 ON
P325 Digital Output #6 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P326 Digital Output #6 Bit Selection 0 15 6 ON
P327 Digital Output #6 Delay 0 32767 0 ON
P328 Digital Output #7 Memory Address 0 500 99 ON
P329 Digital Output #7 Logic 0 1 0 ON
0 = Non-Inverting
1 = Inverting
P330 Digital Output #7 Bit Selection 0 15 7 ON
P331 Digital Output #7 Delay 0 32767 0 ON
P332 Analog Output #1 Memory Address 0 500 252 ON
P333 Analog Output #1 Filter Time 0 32767 1000 ON
P334 Analog Output #1 Offset -100 100 0 ON
P335 Analog Output #1 Scaling Factor 0.00 199.99 100.00 ON
P336 Analog Output #2 Memory Address 0 500 206 ON
P337 Analog Output #2 Filter Time 0 32767 1000 ON
P338 Analog Output #2 Offset -100 100 0 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P339 Analog Output #2 Scaling Factor 0.00 199.99 100.00 ON
P340 Analog Output #3 Memory Address 0 500 0 ON
P341 Analog Output #3 Filter Time 0 32767 1000 ON
P342 Analog Output #3 Offset -100 100 0 ON
P343 Analog Output #3 Scaling Factor 0.00 199.99 100.00 ON
P344 Analog Output #4 Memory Address 0 500 0 ON
P345 Analog Output #4 Filter Time 0 32767 1000 ON
P346 Analog Output #4 Offset -100 100 0 ON
P347 Analog Output #4 Scaling Factor 0.00 199.99 100.00 ON
P351 Rated Frequency HMI Display Filter Time 0 32767 100 ON
P352 Rated Frequency HMI Display Integer Part 0 75 50 ON
P353 Rated Frequency HMI Display Decimal Part 0 1000 0 ON
P354 Motor Voltage HMI Display Filter Time 0 32767 2000 ON
P355 Motor Voltage HMI Display Integer Part 0 16384 10000 ON
P356 Motor Voltage HMI Display Decimal Part 0 1000 0 ON
P357 Actual Frequency HMI Display Filter Time 0 32767 100 ON
P358 Actual Frequency HMI Display Integer Part 0 75 50 ON
P359 Actual Frequency HMI Display Decimal Part 0 1000 0 ON
P360 Motor Current HMI Display Filter Time 0 32767 2000 ON
P361 Motor Current HMI Display Integer Part 0 5000 0 ON
P362 Motor Current HMI Display Decimal Part 0 1000 0 ON
P371 Rated Frequency HMI Display Address 0 500 221 ON
P372 Motor Voltage HMI Display Address 0 500 119 ON
P373 Actual Frequency HMI Display Address 0 500 252 ON
P374 Motor Current HMI Display Address 0 500 118 ON
P375 Frequency At First Point for 5 Point VF 0 10 1 OFF
P376 Amplitude At First Point for 5 Point VF 0 3 1 OFF
P377 Frequency At Second Point for 5 Point VF 0 100 20 OFF
P378 Amplitude At Second Point for 5 Point VF 0 100 10 OFF
P379 Frequency At Third Point for 5 Point VF 0 100 40 OFF
P380 Amplitude At Third Point for 5 Point VF 0 100 27 OFF
P381 Frequency At Fourth Point for 5 Point VF 0 100 60 OFF
P382 Amplitude At Fourth Point for 5 Point VF 0 100 45 OFF
P383 Frequency At Fifth Point for 5 Point VF 0 100 80 OFF
P384 Amplitude At Fifth Point for 5 Point VF 0 100 70 OFF
P385 Deceleration Process Enable 0 1 0 OFF
0 = Disable
1 = Enable
P386 Deceleration Time 1 0 3276 150 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P387 Deceleration Frequency 1 0 75 30 ON
P388 Deceleration Time 2 0 3276 80 ON
P389 Deceleration Frequency 2 0 75 20 ON
P390 Deceleration Time 3 0 3276 80 ON
P391 Deceleration Frequency 3 0 75 10 ON
P392 Deceleration Time 4 0 3276 100 ON
P399 Deceleration Time 0 3276 400 ON
P401 Acceleration Time 0 3276 200 ON
P402 Acceleration Ramp Transition Time 0 3276 3 ON
P403 Acceleration Time Unit 0 0.1 0.1 ON
1000 = 0.01 s
10000 = 0.1s
P405 Deceleration Ramp Transition Time 0 3276 3 ON
P406 Deceleration Time Unit 0 0.1 0.1 ON
1000 = 0.01 s
10000 = 0.1s
P409 Amplification Coefficient Of Error Terms 0.00 199.99 100.00 ON
P411 Over Speed Upper Limit Reference 0 100 100 ON
P412 Over Speed Lower Limit Reference 0 100 0 ON
P413 Frequency Command Lower Limit -16384 16384 0 ON
P414 Frequency Command Deadband Upper Limit 0.00 100.00 0.49 ON
P415 Frequency Command Upper Limit -16384 16384 16384 ON
P416 Flying Start Mode 0 3 0 ON
0 = Disable
1 = Set Frequency
2 = Stop Frequency Plus 5 Hz
3 = Rated Frequency
P417 Flying Start Motor Speed Search Timeout 0 1000 50 ON
P438 Current Limitation Enable Frequency Range Lower Limit 0 100 10 ON
P439 Current Limitation Upper Offset 0 10 3 ON
P440 Current Limitation Lower Offset 0 10 3 ON
P441 Current Limitation Threshold 0 130 100 ON
P451 Low Speed Voltage Compensation 0.00 3.00 0.99 OFF
P452 Low Speed Voltage Compensation Frequency Threshold 0 100 20 ON
P453 V/F Curve 0 4 (R&D) 1 OFF
0 = Linear 3
1 = Parabolic Curve (Setup)
2 = Predefined Curve #1
3 = Predefined Curve #2
4 = 5 Point VF
P454 Flux Time (s) 0.0 10.0 0.5 OFF
P455 Modulation Index 0.00 110.00 87.99 ON
P456 Motor Voltage Upper Limit 0.00 110.00 87.99 ON
P457 Flying Start Voltage Recovery Time (Low Speed Region) 0.00 163.84 5.00 ON

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Table 18 - Setup and R&D P Parameters (Continued)

Parameter Description Min. Max. Default Modify
Number Root
P458 Coefficient A 0 100 40 OFF
P459 Flying Start Voltage Recovery Time (High Speed Region) 0 163.84 5 ON
P460 Rated Output Frequency 0 75 50 OFF
P461 Restart Enable 0 1 0 ON
0 = Disable
1 = Enable
P462 Fault Reset Timeout 0 120 120 ON
P463 Flying Start Low/High Speed Regions Boundary 0 100 16 ON
P465 Power Cell Fault Auto Reset Delay 0 10 4 ON
P466 Maximum Output Frequency 0 75 50 OFF
P467 Over Speed Enable 0 1 0 OFF
0 = Disable
1 = Enable
P470 Version Compatibility Enable 0 1 1 OFF
0 = Disable
1 = Enable
P497 Major Rev # Of DSP Main Firmware —— —— 0 Cannot
Modify
P498 Minor Rev # Of DSP Main Firmware —— —— 2 Cannot
Modify
P499 Display Fault Masks Button 0 1 0 ON
0 = Disable
1 = Enable
P500 Display DSP Variables 0 1 0 ON

There are no specific T parameters to modify when commissioning a drive. Verify

the values and only modify per customer specifications.
Table 19 - Setup and R&D T Parameters
Parameter Description Default Modify Data Type
Number Value Root
T01 Fault-To-Bypass 0 Yes Boolean
0 = Disable
1 = Enable
T02 Fault-To-Bypass Delay (0...5s) 3 Yes 16-bit Unsigned Integer
T03 Fault-To-Bypass Delay When Starting the Motor 60 Yes 16-bit Unsigned Integer
(0...60s)
T04 Fault-To-Bypass Minimum Frequency 5 Yes 32-bit Float
0...Rated Frequency (Hz)
T07 Local Frequency Command Selection 0 Yes Boolean
0 = Digital
1 = Analog
T08 Remote Frequency Command Selection 1 Yes 16-bit Unsigned Integer
1 = Analog
2 = 4-Step Speed
4 = Communication Port
T09 Frequency Step For Accel or Decel 1 Yes 16-bit Unsigned Integer

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 No-load Test Chapter 5

Table 19 - Setup and R&D T Parameters (Continued)

Parameter Description Default Modify Data Type
Number Value Root
T10 Exit To Configuration Mode Password 555 No 16-bit Unsigned Integer
T11 Automatic Bypass-To-Drive or 0 Operation Button
Drive-To-Bypass Selection
Bypass-To-Drive Yes
Drive-To-Bypass Yes
T12 PID Parameter Settings
P 0.01 Yes 32-bit Float
I 0.01 Yes 32-bit Float
D 0 Yes 32-bit Float
D Gain 0 Yes 32-bit Float
T13 4-Step Variable Speed (available only when T8 = 2)
Speed 1 10 Yes 32-bit Float
Speed 2 20 Yes 32-bit Float
Speed 3 30 Yes 32-bit Float
Speed 4 40 Yes 32-bit Float
T14 One-Drive-Two-Motor Mode, QS Enable 1 Yes Boolean
0 = No
1 = Yes
T15 Bypass Mode Selection (0...4) 0 Operation Button
No Bypass Yes
Manual Bypass, One-Drive-One-Motor Yes
Auto Bypass, One-Drive-One-Motor Yes
Manual Bypass, One-Drive-Two-Motor Yes
Auto Bypass, One-Drive-Two-Motor Yes
T16 When Disconnected between 1 Yes 16-bit Unsigned Integer
0 = Stop
1 = Keep Current Frequency
2 = Keep T13, Speed 1
3 = Keep T13, Speed 2
4 = Keep T13, Speed 3
5 = Keep T13, Speed 4

ATTENTION: If you enter a value that is greater than the allowed range for the
parameter, the input field will turn red.

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Chapter 5 No-load Test

Change Parameters T11...T13

Parameter T11

To change Parameter T11:

1. Press the T11 Parameter input field.

2. In the Operation Mode 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

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 No-load Test Chapter 5

• 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.

Parameter T12

Parameter T12 is a reserved parameter for R&D and hand-off operation.

Parameter T13

To change Parameter T13:

1. Press the T13 Parameter input field.

2. Enter desired speed values in the Enter Four Steps dialog box.

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Chapter 5 No-load Test

Press the input field to enter a value.

IMPORTANT Parameter T08 must be set to 2.

3. Press to 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.

Close Isolation Switches in Bypass Cabinet

1. Manual bypass (see Figure 32)

a. Open QS1 (direct line operation) isolation switch
b. Close QS2 and QS3 (drive operation) isolation switches
2. Automatic Bypass (with isolating switches) (see Figure 31)
a. Close QS1 and QS2 (drive operation) isolation switches

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 No-load Test Chapter 5

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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Chapter 5 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 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.

3. Press , and press in the Start Drive? dialog box to

confirm operation.

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 No-load Test Chapter 5

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 103.
If the motor rotating direction is correct, continue to step 5.
5. From the Main Interface Screen, press the Set Frequency: input field.

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Chapter 5 No-load Test

6. In the Set Freq: dialog box, enter a value of “10” and press .

Press to confirm.

7. Press , and press in the Start Drive? dialog box to

confirm operation.

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 10 Hz 20 Hz 30 Hz 40 Hz 50 Hz
3 kV 310 770 1370 2110 3000
3.3 kV 340 850 1500 2320 3300
4.16 kV 430 1060 1900 2930 4160
6 kV 620 1540 2740 4220 6000
6.6 kV 690 1690 3010 4650 6600
10 kV (Not applicable for UL) 1040 2560 4560 7040 10,000

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 No-load Test Chapter 5

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.
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 Table on page 89.

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Chapter 5 No-load Test

Notes:

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 Appendix A

Torque Requirements

Torque Requirements Proper tightening torque must be used for installation and wiring.
Table 20 - Torque Requirements
Torque
Thread Size
N•m lb•ft
M4 1.4 1.0
M5 2.8 2.1
M6 4.6 3.4
M8 11 8.1
M10 22 16.2
M12 39 28.8
M14 62 45.7
M16 95 70.1
M20 184 135.7

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Appendix A Torque Requirements

Notes:

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 Appendix B

Single Line Diagrams

Figure 29 - PowerFlex 6000 without Bypass

Input Circuit Breaker

QF
(by Customer)

PowerFlex 6000

M Circuit
Breaker

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Appendix B Single Line Diagrams

Figure 30 - 6012M Automatic Bypass Version 1 (without Isolation Switches)

Input Circuit Breaker

QF
(by Customer)

KM2

KM1 PowerFlex 6000

KM3

M Circuit Vacuum
Breaker Contactor

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 Single Line Diagrams Appendix B

Figure 31 - 6012M Automatic Bypass Version 2 (with Isolation Switches)

Input Circuit Breaker

QF (by Customer)

QS1 Bypass Unit

KM2

KM1 PowerFlex 6000

KM3

QS2

M
Circuit Vacuum Isolation
Breaker Contactor Switch

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Appendix B Single Line Diagrams

Figure 32 - 6012M Manual Bypass

QF Input Circuit Breaker

(by Customer)

Bypass Unit

QS2

QS1 PowerFlex 6000

QS3

M Circuit Vacuum Isolation

Breaker Contactor Switch

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 Single Line Diagrams Appendix B

Figure 33 - PowerFlex 6000 Manual Bypass for Two Cabinets

Figure 34 - PowerFlex 6000 Automatic Bypass for Two Cabinets (with Isolation Switches)

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Appendix B Single Line Diagrams

Notes:

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 Appendix C

Special Function Parameter Settings

Overview Table 18 on page 90 and Table 19 on page 98 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: P007

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, P007=6. Power Module fault and
warning information is based on P007. If P007=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 56.

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Appendix C Special Function Parameter Settings

Switch Control Sources

Relevant parameter: P004

Description: P004 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: P017, 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. P017
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 Parameter

Set Frequency P351, P352, P353, P371
Motor Voltage P354, P355, P356, P372
Output Frequency P357, P358, P359, P373
Motor Current 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: P005

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.

Setup (P005 = 30) P004, P007, P008, P009, P024, P030, P031, P032, P033, P040, P087, P088, P089, P090, P091,
P092, P093, P113, P114, P115, P198, P199, P205, P206, P210, P212, P213, P215, P216, P222,
P223, P224, P238, P252, P253, P259, P260, P262, P263, P264, P278, P281, P282, P283, P285,
P335, P339, P352, P355, P358, P361, P385, P386, P387, P388, P389, P390, P391, P392, P399,
P401, P416, P417, P438, P441, P442, P451, P452, P453, P455, P456, P457, P459, P460, P463,
P466, P467
User (P005 = 40) P004, P198, P199, P262, P352, P355, P358, P361, P399, P401
R&D (P005 = 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 P262=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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 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: P089, P090, P091, P092, P093

Description: this function is designed to avoid a trip at certain output

frequencies.

Instruction: this function is enabled by P089. There are two bands, one is
between P090 and P091, the other is between P092 and P093. 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 (Figure 35). The recommended width of these intervals is 1 Hz.

Figure 35 - Principle diagram of Frequency Skip Function

fB2
Drive Recognize Frequency

fB1

fA2

fA1

P090 P091 P092 P093

User Set Frequency

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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 parabolic-
curve. 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.

122 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Special Function Parameter Settings Appendix C

Analog Input 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

.

Voltage Level (kV) VSB Output Line-to-Line Voltage (RMS V) P205, P206
3 3.62 195.20
3.3 3.98 177.46
4.16 3.77 187.64
6 3.63 195.09
6.6 3.98 177.35
10 (Not applicable for UL) 4.02 175.54

Stop Mode Relevant parameter: P024, P252, P253

Description: the drive has two ways to stop the drive, ramp down or coast stop.

Instruction: P024=1 to select coast stop, P024=0 to select ramp down.

If P024=1, the output will stop immediately, so the motor will stop by inertance.
If P024=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:

FrequencyBeforeStop
P253 × ----------------------------------------------------------
MaximumFrequency

Flying Start Function 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.

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 123

Appendix C Special Function Parameter Settings

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.

Restart the Drive 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.

124 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

 Index

A E
Analog Input 123 Electrical Installation Inspection 22, 38

C F
Cabinet Plates Flying Start Function 123
Pre-Commissioning Sealing 29, 46 Functional Assessment 17, 33
Commissioning 47 Checklist 19, 35
Control System Check 52
Procedure List 47
Setup 48 I
Process Flowcharts 12 Installation Review 21, 37
Set Date 86
Set Regional Settings 87 Electrical Inspection 22, 38
Set Time Zone 86 Mechanical Inspection 21, 37
Commissioning Requirements Interconnection Review 20, 36
Computer Requirements 15, 31 Checklist 20, 36
Electrical Equipment 15, 31
Hand Tools 15, 31
Software 15, 31 L
Test Equipment 15, 31 Lockout 15, 31
Control System Check 52 Safety Test 16, 32
P Parameters
Restore Settings 84
Set to Enable Testing 55 M
Procedure List 47 Mechanical Installation Inspection 21, 37
Setup 48
Energize Control Circuit 48
Simulate Closed Input Circuit Breaker 48
Simulate Warnings and Faults 67 N
Verify No-Load Test
E-Stop Functionality 72 Check Cooling Fan Operation 103
Factory Default Settings 52 Close Input Circuit Breaker 103
Operation to Set Frequency 65 Close Isolation Switches in Bypass Cabinet 102
Switching, Local to Remote Control 73 Configure P and T Parameters 90
Verify Operation of Energize Drive Control Circuit 90
Bypass Contactors 77 Operate Motor by HMI 104
Bypass Isolation Switches 74
DCS Input 83
Frequency Steps 63 O
Input/Output 74, 77
Output Signals 83 Overviews
Control Wiring 23, 39 Commissioning 47
Documentation and Application Review 12
Load Test 107
D No-load Test 89
Special Function Parameter Settings 117
Diagrams
6012M Automatic Bypass Version 1 112
6012M Automatic Bypass Version 2 113 P
6012M Manual Bypass 114, 115 Power Cabling 22, 38
PowerFlex 6000 without Bypass 111
Documentation and Application Review Color Coding 22, 38
Pre-Commissioning
Process Flowcharts 12
Documentation, Rockwell Automation 12 Cabinet Plates 29, 46
Computer Requirements 15, 31
Drive Application Drive Megger Check 23, 39
Review 13 Electrical Equipment 15, 31
Drive Components Final Steps 29, 46
Inspection 16, 32 Functional Assessment 17, 33
Checklist 18, 34 Checklist 19, 35
Drive Megger Check 23, 39 Installation Review 21, 37
Electrical Inspection 22, 38

Rockwell Automation Publication 6000-IN007B-EN-P - March 2016 125

Index

Mechanical Inspection 21, 37

Interconnection Review 20, 36
Checklist 20, 36
Software 15, 31
Test Equipment 15, 31
Tools
Hand Tools 15, 31
Preparation and Inspection
Process Flowcharts 12
Commissioning 12
Documentation and Application Review
12
Process Flowcharts
Commissioning 12
Documentation and Application Review 12
Preparation and Inspection 12

R
Restart the Drive 124

S
Safety Test (Lockout) 16, 32
Special Function Parameter Settings 117
Analog Input 123
Flying Start Function 123
Restart the Drive 124
Speed Command Function
Frequency Amplitude Limit 121
Frequency Command Deadband Upper
Limit 120
Frequency Skip 121
Set Frequency Command Source 120
Set Frequency Correction 120
Speed Command Functions 120
Speed Reference Functions 122
Limit Output Voltage Amplitude 122
Set Flux Time 122
Set Maximum Modulation Index 122
V/F Curve Setting 122
Stop Mode 123
System Setting Functions 117
Analog Output Display Parameter Set-
ting 119
Hall Effect Current Sensor Setting 118
Motor Parameter Setting 118
Number of Power Modules Per Phase
117
Rated/Maximum Output Frequency 118
Restore Factory Setting 119
Switch Control Sources 118
Speed Command Functions 120
Speed Reference Functions 122
Stop Mode 123

T
Tagout 15, 31
Torque Requirements 109

126 Rockwell Automation Publication 6000-IN007B-EN-P - March 2016

Rockwell Automation Support
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Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this
manual. You can contact Customer Support for initial help in getting your product up and running.
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Publication 6000-IN007B-EN-P - March 2016

Supersedes Publication 6000-IN007A-EN-P - October 2014 Copyright © 2016 Rockwell Automation, Inc. All rights reserved. Printed in Canada.