PowerFlex 6000T Drives

Bulletin Number 6000T

Installation Instructions Original Instructions

PowerFlex 6000T Drives Installation Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

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).

The following icon may appear in the text of this document.

Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in
alignment with the movement toward inclusive language in technology. We are proactively collaborating with industry peers to
find alternatives to such terms and making changes to our products and content. Please excuse the use of such terms in our
content while we implement these changes.
2 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022
 Table of Contents

Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 5
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contractor Scope of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1
Drive Mechanical Installation Mechanical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connect Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Affix Cabinets to Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Seismic Rated Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install Main Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install Power Modules (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
External Ducting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Conditioning Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chapter 2
Drive Electrical Installation Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grounding System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Cable Insulation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Cable Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor Cable Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control Signal Wiring Design Considerations . . . . . . . . . . . . . . . . . . . . . 43
Electrical Installation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connect the System Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Insulation Resistance (IR) Test of Power Cables . . . . . . . . . . . . . . . . . . . . 46
Connect Incoming Line and Outgoing Motor Power Cables . . . . . . . . . 46
Connect Control Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Connect External Control Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 54

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Table of Contents

Chapter 3
Drive Electrical Interconnection Electrical Interconnection Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Power Cable Interconnection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connect Isolation Transformer Secondary Power Cables . . . . . . . . . . . 59
Connect Motor and Voltage Sensing Board Cables . . . . . . . . . . . . . . . . . 60
Connect LV Control and Fan Wiring Bundles . . . . . . . . . . . . . . . . . . . . . . 62
Connect Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Complete the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Appendix A
Pre-Commissioning Pre-Commissioning Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pre-Commissioning Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Appendix B
Torque Requirements Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appendix C
General Wire Categories General Wire Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix D
Power Cabling and Control Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Signal Wiring Details Standard Input/Output Connection Points . . . . . . . . . . . . . . . . . . . . . . . . 74

Appendix E
Line and Load Cable Sizes Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Preface

About This Publication This manual provides procedural information for installing PowerFlex® 6000T
medium voltage drives.

Rockwell Automation recognizes that some of the terms that are currently
used in our industry and in this publication are not in alignment with the
movement toward inclusive language in technology. We are proactively
collaborating with industry peers to find alternatives to such terms and
making changes to our products and content. Please excuse the use of such
terms in our content while we implement these changes.

Download Firmware, AOP, Download firmware, associated files (such as AOP, EDS, and DTM), and access
EDS, and Other Files product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.

Who Should Use This This manual is intended for use by professional riggers, general contractors,
Manual electrical contractors, or plant operations personnel familiar with moving and
siting heavy equipment. Specific experience with solid-state variable speed
drive equipment is NOT required for this part of the installation process, but is
mandatory for subsequent processes.

What Is Not in this Manual This manual provides information specific for installing a PowerFlex 6000T
drive. It excludes project-specific, or drive-specific topics such as:
• Dimensional Drawings (DD) and Electrical Drawings (ED) that are
generated for each customer’s order.
• Spare parts lists compiled for each customer’s order.
• Drive-specific technical specifications.

For additional product detail or information relating to PowerFlex 6000T

drives, see the publications that are listed in Additional Resources on page 7.

Required Supplemental This manual includes generic information about the drive cabinet layout
Information orientation and generic electrical connection information.

Review the project-specific Dimensional Drawings (DDs) and Electrical

Drawings (EDs) to better understand the specific drive system cabinet
orientation and wiring requirements before performing any mechanical or
electrical work. Paper copies of the DDs and EDs are placed in the document/
hardware box in the Isolation Transformer Cabinet before shipment. Contact
the local Rockwell Automation office to obtain digital copies, if necessary.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 5

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 6000T Adjustable

Speed Drive (ASD) and associated machinery should plan or implement the
installation, startup, and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.

ATTENTION: Only qualified personnel with the correct PPE (Personal

Protective Equipment) should service the equipment. Be sure to follow the
safety procedures and local regulations to disconnect the high voltage. After
waiting for 15 minutes, open the cabinet door and verify the absence of
medium voltage on the input, output, and power cell terminals with a high-
voltage detector that is properly rated for the line and motor voltages. All
LED lights on the power cells must be off and the drive be grounded with
portable grounding cables on the input and output before servicing. Failure
to follow the safety procedures can result in severe injury or death.

Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.

Topic Page
Typical floor drawing A-frame (2.4…4.16 kV, UL and IEC)
• Added 70 A Non-Seismic/Seismic 15
• Added 140 A Non-Seismic/Seismic 16
• Updated 215 A Non-Seismic/Seismic 17
Updated drive ratings for A-frame drives (IEC) 23, 30, 31, 48, 52
Updated table Line and Load Cable Sizes for A-frame Drives (IEC) 77

6 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Preface

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description
PowerFlex 6000T Drives Shipping and Handling Manual, Provides instructions for shipping and handling PowerFlex6000T drives and related
publication 6000-PC100 equipment.
Provides instructions for daily recurring drive usage, HMI, and maintenance tasks for the
PowerFlex 6000T Drives Hardware Service Manual, publication 6000-TG100 product’s end user.
Provides detailed information on drive features, programming parameters, and
PowerFlex 6000T Drives Programming Manual, publication 6000-PM100 troubleshooting faults and alarms.
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
EtherNet/IP Network Devices User Manual, ENET-UM006 network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Provides guidance on how to conduct security assessments, implement Rockwell
System Security Design Guidelines Reference Manual, SECURE-RM001 Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Industrial Components Preventive Maintenance, Enclosures, and Contact Provides a quick reference tool for Allen-Bradley industrial automation controls and
Ratings Specifications, publication IC-TD002 assemblies.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
Safety Guidelines for the Application, Installation, and Maintenance of general guidelines for the application, installation, and maintenance of solid-state control in
Solid-state Control, publication SGI-1.1 the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature.

Commissioning Support After installation, Rockwell Automation is responsible for commissioning

activities for the PowerFlex 6000T product line. Contact your local Rockwell
Automation sales representative to arrange commissioning.

Rockwell Automation support includes, but is not limited to:

• quoting and managing product on-site startups
• quoting and managing field modification projects
• quoting and managing product training at Rockwell Automation
facilities and on-site

Contractor Scope of Work Typical scope of work by the freight company, third-party contractor and/or
customer (based on ex-works Incoterms)(a):
• Load equipment on truck at a Rockwell Automation manufacturing
facility and transport equipment to site
• Offload equipment from truck on-site
• Perform initial inspection(b)
• Move equipment to the final installation location
• Position the cabinet sections together as shown in Dimensional Drawing
and level the cabinet lineup
• Mechanically join cabinets together
• Affix the cabinets to the floor
• Install assemblies shipped loose (fan assemblies).

(a) All or part of these activities could be provided by Rockwell Automation or its
representatives, based on contract Incoterms and negotiated scope of supply/services
agreement. Contact the local Rockwell Automation office for further information.
(b) Customer should lead the initial inspection process.
Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 7
Preface

• Install external ductwork to exhaust heated air from control room (if
required)
• Install power and control cabling and terminate cable connections to
drive system:
- Connect system ground cable
- Insulation Resistance (IR) testing of incoming line and outgoing
motor power cables
- Connect incoming line and outgoing motor power cables
- Connect control power wiring
- Connect all external customer required control signal wiring
- Connect electrical safety interlock control signal wiring circuit to
input circuit breaker
• Connecting the power cables and control wiring between cabinets that
are shipped separately(a)
• Complete Pre-commissioning Checklist

Environmental Conditions • Elevation above sea level must be less than 1000 m (3250 ft)(b).
• Ambient air temperature must be between 0…40 °C (32…104 °F)(c).
• Relative humidity must be less than 95%, noncondensing.
• Operation Vibration limited to 3M11 per IEC 60721-3-3.
• G2 rating with 60% humidity – Storage, Transport, and Operation – as
per ISA 71.04-2013.
• The drive must be installed indoors; there must be no dripping water or
other fluids in the room.
• Cooling air must be clean without significant concentrations of sand,
corrosive or conductive dust, or explosive gas. The drive must be installed
in a Pollution Degree 2 environment as per IEC 61800-5.
• Free from significant vibration.
• The drive must be anchored on a level floor. See the dimension drawing
for the anchor point sizes and locations.

For the equipment to operate in conditions other than those specified, consult
the local Rockwell Automation Sales Office.

(a) Interconnection of power cables and low voltage control wiring bundles, between separately
shipped cabinets, can be done by the contractor or Rockwell Automation. The
commissioning quote from Rockwell Automation reflects this and will contain two options:
a) the base quote, reflecting the power cable and control wiring interconnection work being done by the contractor
b) the optional quote adder, reflecting the additional time and cost for Rockwell Automation to perform the power cable and
control wiring interconnection work immediately before the commissioning process.
(b) Options are available for operation up to 5000 m.a.s.l. However, these must be stated at the
time of order and cannot be retrofitted in the field.
(c) Options are available for ambient temperatures up to 50 ºC. However, these must be stated
at the time of order and cannot be retrofitted in the field.
8 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022
 Chapter 1

Drive Mechanical Installation

The installation process is divided into three principal activities. The

mechanical installation process described in this chapter, the electrical
installation process described in Drive Electrical Installation on page 39, and
the electrical interconnection process described in Drive Electrical
Interconnection on page 57.

Mechanical Installation The cabinets must be arranged as shown in the Dimensional Drawing (DD).
Summary Topic Page
Connect Shipping Splits 9
Affix Cabinets to Floor 13
Install Seismic Rated Enclosures 19
Install Main Cooling Fans 27
Install Power Modules (if applicable) 31
External Ducting 35

Follow all applicable guidelines for siting the components before continuing
with these installation instructions.

There may be some variation in the process depending on the type and number
of drive components in your particular installation.

Connect Shipping Splits

ATTENTION: Install the drive on a level surface (+/- 1 mm per meter
[+/- 0.036 in. per 36 in.] of drive length in all directions). If necessary, use
metal shims to level the cabinets before joining them; attempting to level
after joining may twist or misalign the cabinets.

Connect DV/DT Filter Cabinet for A-frame Drives (All ratings)

The standard A-frame for PowerFlex 6000T drives comes fully assembled and
does not require any shipping splits. However, if a DV/DT filter is included
with the drive then there is one shipping split, and the drive and filter must be
connected as follows:
1. Remove the M16x16 countersunk screw that secures the LV covers and
grounding cover at the right side of the main drive, and the left side of
the filer cabinet. Then remove the covers.
2. Arrange the sections as described in the Dimensional Drawings and
move the sections together.

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Chapter 1 Drive Mechanical Installation

3. Align the cabinet side sheets together at the holes for the hardware.
Figure 1 - Align the Cabinets, A-frame

Isolation Transformer Cabinet DV/DT Filter Cabinet

A B
Front Front
Side View

4. Secure the cabinets together with two L-shaped brackets and four M12
hexagon socket bolts, D12 washers, and D12 lock washers at the front and
rear side.
5. Verify that the front of the SIL channels at A and B (Figure 1) are aligned.

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 Chapter 1 Drive Mechanical Installation

Figure 2 - Secure the Cabinets, A-frame

LV cover

M16x16 countersunk
head screw (x4)

Grounding cover

M16x16 countersunk
head screw (x2)

M12 hexagon socket screw

(x4)
D12 lock washers (x4)
D12 washers (x4)

L-shaped bracket (x2)

Connect Cabinets for B-frame Drives

The B-frame for PowerFlex 6000T drives are shipped in two sections, the
Isolation Transformer Cabinet and Power Module/LV Control Cabinet. These
two cabinets must be connected after located in its final position. The cabinets
are connected together in 8 or 10 places (depending on the drive rating), half
along the front edge of the cabinet and half along the rear edge of the cabinet.
Access to the interior of the cabinet is required to make these connections.
Access for the front connections requires only opening the doors. Access for
the rear connections requires removing the back plates of the cabinet.
1. Arrange the sections as directed in the Dimensional Drawings and move
the sections together.

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Chapter 1 Drive Mechanical Installation

2. Align the cabinet side sheets together at the holes for the hardware
(see Figure 3).
Figure 3 - Align the Cabinets, B-frame (6 kV shown)

Power Module/LV Control Cabinet Isolation Transformer Cabinet

Table 1 - Sidesheet Openings ❶

❶ Front Wireway
❷
❷ U Phase Motor Cable
❸ V Phase Motor Cable
❹ W Phase Motor Cable ❼
❺ Ground Bus Connection
❻ Voltage Sensing Board Cables
Isolation Transformer Secondary
❼
Cables(1)(2) ❻
❸

(1) The number of Isolation Transformer secondary

cables is dependent on motor voltage class. ❼
• 9 cables per motor phase (27 total) for 3/3.3 kV
•12 cables per motor phase (36 total) for 4.16 kV
• 15 cables per motor phase (45 total) for 6 kV
•18 cables per motor phase (54 total) of 6.6 kV
•24 cables per motor phase (72 total) for 10 kV
• 27 cables per motor phase (81 total) for 11 kV
(2) 6/6.6 kV configurations only require 18 cable ❹
hole locations per phase. Extra cable hole
locations allow for added installation flexibility. ❼

Front Front
Side View

3. Secure the cabinets together using M6 or M8 hardware. See Torque

Requirements on page 67 for proper torque requirements.

Open the doors to access front edge joining holes (four or five places).

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 Chapter 1 Drive Mechanical Installation

Figure 4 - Secure the Cabinets, B-frame

Secure with M6
hardware (8 places)

2-socket screw M6x16

Combination pillar

Affix Cabinets to Floor Typical floor drawings show minimum clearance distance, conduit openings,
and mounting holes for anchor bolts, as shown in Figure 5. See customer-
specific dimensional drawing for outgoing motor and incoming line cable
openings.

Figure 5 - Typical Floor Drawing, B-frame

Dimensions are in mm.
Power Module/LV Control Cabinet Isolation Transformer Cabinet

Input cable

Control signal

Bottom View Output cable

Secure the cabinet to the channel steel base using M12 bolt (recommended),
lock washer, two flat washers, and a nut.

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Chapter 1 Drive Mechanical Installation

Figure 6 - Bolt Cabinet to Steel Base, B-frame

Lock washer M16 bolt

Flat washer

Optional: The cabinet can also be welded to the steel base once it is securely
bolted, if desired.

Each weld location should be 100 mm (3.9 in.) for every 1000 mm (39.4 in.). See
Mounting Requirements in the PowerFlex 6000T Drives Shipping and
Handling Manual, publication 6000-PC100 for further information on the
steel base and desired trench and mounting customer-specifications.

ATTENTION: Failure to correctly anchor the cabinet may result in damage to

the equipment or injury to personnel.

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 Chapter 1 Drive Mechanical Installation

Figure 7 - Typical Floor Drawing, A-frame, 70 A (2.4…4.16 kV, UL and IEC)

Dimensions are in mm.

70 A, Non-seismic

70 A, Seismic

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Chapter 1 Drive Mechanical Installation

Figure 8 - Typical Floor Drawing, A-frame, 140 A (2.4…4.16 kV, UL and IEC)
Dimensions are in mm.

140 A, Non-seismic

140 A, Seismic

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 Chapter 1 Drive Mechanical Installation

Figure 9 - Typical Floor Drawing, A-frame, 215 A (2.4…4.16 kV, UL and IEC)

Dimensions are in mm.

215 A, Non-seismic

215 A, Seismic

Secure the cabinet to the channel steel base using M12 bolt (recommended),
lock washer, two flat washers, and a nut.

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Chapter 1 Drive Mechanical Installation

Figure 10 - Typical Floor Drawing, A-frame (6…6.6 kV, IEC only)

Dimensions are in mm.

70 A, Non-seismic/Seismic

140 A, Non-seismic/Seismic

215 A, Non-seismic/Seismic

Secure the cabinet to the channel steel base using M16 bolt (recommended),
lock washer, two flat washers, and a nut.

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 Chapter 1 Drive Mechanical Installation

Install Seismic Rated This section describes how to install the drive for seismic conditions.
Enclosures Figure 11 - Guidance for Seismic Installation

12.7 mm (1/2 in.) Anchor bolt

12.7 mm (1/2 in.) Anchor bolt

effective embedded depth 127 mm (5 in.)

Condition 1 Condition 2
Anchors braced at front Anchors braced at front
and rear side and wall-mounted angle

Install A-frame Drives (2.4…4.16 kV, UL and IEC)

For condition 1, 70 A seismic installation, follow these instructions:
1. Open MV front door and back door.
2. Remove the JC front barrier.
3. Remove two thermostats from the DIN rail in PC and TC at the right-
hand side of the cabinet.

Step 1 Step 2 Step 3

4. Remove the HECS insulation bracket.

5. Remove the grounding terminal of the right side plate at the back side.

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Chapter 1 Drive Mechanical Installation

6. Remove the right side plate, put the secondary cables close to Tx winding,
and disassemble three horizontal baffles.

Step 4 Step 5 Step 6

7. Remove the seismic cover at the front and back side of the JC, and the
right side of the drive.
8. Drill anchor holes at the left-hand side of the cabinet.
9. Drill anchor holes at the right-hand side of the cabinet, then install the
anchors.

Step 7 Step 8 Step 9

10. Install all parts in reverse order of removal.

Step 10

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 Chapter 1 Drive Mechanical Installation

For condition 1, 140 A seismic installation, follow these instructions:

1. Open MV front door and back door.
2. Remove the JC front barrier.
3. Remove the back horizontal baffles, cable bracket, and all seismic covers.

Step 1 Step 2 Step 3

4. Drill anchor holes at the back of the cabinet.

5. Drill anchor holes at the front of the cabinet.

Step 4 Step 5

6. Install all removed parts in reverse order of removal.

Step 6

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Chapter 1 Drive Mechanical Installation

For condition 1, 215 A seismic installation, follow these instructions:

1. Open MV front door and back door.
2. Remove the JC front barrier.
3. Remove the back horizontal baffles and all seismic covers.

Step 1 Step 2 Step 3

4. Drill anchor holes at the front of the cabinet.

5. Drill anchor holes at the back of the cabinet.

Step 4 Step 5

6. Install all removed parts in reverse order of removal.

Step 6

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 Chapter 1 Drive Mechanical Installation

For condition 2 seismic installation, if there is no rear access available, the top
of the drive can be mounted to the wall rather than mounted to the floor at the
back of the cabinet. If there is a fan redundancy condition for frame 1 and
frame 2, then wall bracket B is not needed.

Figure 12 - Condition 2 Seismic Installation, A-frame Drives (2.4…4.16 kV, UL and IEC)
Wall bracket B Wall bracket A
Wall bracket B

M12xL35
Based on bracket thickness
of 11 mm (0.43 in.)

Frame 1

Wall bracket B Wall bracket A

Wall bracket A

Frame 2

Frame 3

Install A-frame Drives

(11 kV in/3.3 kV out, 13.8 kV in/4.16 kV out, or all 6…6.6 kV out, IEC only)

For condition 1 seismic installation, install the cabinet using the anchoring
locations that are shown in Figure 12.

For condition 2 seismic installation, follow these instructions to secure the

cabinet:

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Chapter 1 Drive Mechanical Installation

1. Install a seismic end bracket to the cabinet with M16 hardware.

2. Remove the connecting bracket and associated M16 and M6 hardware.

Replace the M6 hardware into the top plate of the Junction cabinet to fill
the hole.

3. Install a seismic end bracket to the Junction cabinet with M16 hardware.

Install B-frame Drives

For condition 1, installation of power cell cabinets, follow these instructions:

1. Disassemble the grounding busbar at the front of the cabinet.
2. Disassemble the anchor cover at the front of the cabinet.

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 Chapter 1 Drive Mechanical Installation

3. Drill an anchor hole.

Grounding busbar Anchor cover

Left cabinet Step 1 Step 2 Step 3

Grounding busbar Anchor cover

Middle cabinet Step 1 Step 2 Step 3

For condition 1, installation of transformer cabinets, follow these instructions:

1. Disassemble the grounding busbar, wire duct, and barrier bracket at the
front of the cabinet.
2. Disassemble the anchor cover at the front of the cabinet.
3. Drill an anchor hole.

Barrier bracket
Grounding busbar Anchor cover
Wire duct
Left cabinet Step 1 Step 2 Step 3

Barrier bracket

Grounding
busbar
Anchor cover
Wire duct

Right cabinet Step 1 Step 2 Step 3

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Chapter 1 Drive Mechanical Installation

For condition 1, installation of standard cabinets and filter cabinets, follow

these instructions:
1. Disassemble the grounding busbar at the front of the cabinet.
2. Disassemble the anchor cover at the front of the cabinet.
3. Drill an anchor hole.

Grounding busbar Anchor cover

Standard or filter cabinet Step 1 Step 2 Step 3

For condition 2 seismic installation, if there is no rear access available, the top
of the drive can be mounted to the wall rather than mounted to the floor at the
back of the cabinet.

Wall bracket B Wall bracket A

M12xL35
Based on bracket thickness
of 11 mm (0.43 in.)

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 Chapter 1 Drive Mechanical Installation

Figure 13 - ASTM A36 Angle Bracket Dimensions

Min T = 11.1 [7/16]

Ø13 [0.51] Ø13 [0.51]

101.6…177.8 [4.00…7.00]
Min 76.2 [3.00]

25.4 [1.00] 15 [0.59] 15 [0.59]

101.6 [4.00] 74 [2.91] 64.0 [2.52]
Based on against the wall 40 [1.57]
130.0 [5.11]
Dimensions are in mm [in.] Wall bracket A Wall bracket B

Install Main Cooling Fans Main cooling fans are shipped in separate crates. The fans are shipped
assembled in the fan housing, but must be installed after siting the drive.

IMPORTANT See Mounting Clearance Distance in the PowerFlex 6000T Drives

Shipping and Handling Manual, publication 6000-PC100 to verify that the
fans have the appropriate clearance distance on top of the cabinet.

Table 2 - Fan Housing Specifications

Model Dimensions (HxWxD), approx. Weight, approx.
EC400 428 x 480 x 672 mm (16.9 x 18.9 x 26.5 in.) 30 kg (66 lb)
520 x 580 x 783 mm (20.5 x 22.8 x 30.8 in.) 45 kg (99 lb)
EC500
520 x 580 x 1125 mm (20.5 x 22.8 x 44.3 in.) 60 kg (132 lb)
RH50V 547 x 739 x 1200 mm (21.53 x 29.1 x 47.24 in.) 82 kg (180 lb)
RH50C 607 x 739 x 1200 mm (23.9 x 29.1 x 47.24 in.) 86 kg (189 lb)
RH40V 547 x 532 x 1100 mm (21.53 x 20.94 x 43.3 in.) 60 kg (132 lb)
RH35C 547 x 532 x 1100 mm (21.53 x 20.94 x 43.3 in.) 64 kg (141 lb)
1. Place the fan housing on the top plate of the drive, making sure that the
socket is on the same side as the aviation plug.
2. Secure the fan housing using M6 hardware (six places).
See Torque Requirements on page 67.
3. Connect the aviation plug on top of the cabinet with the socket on the fan
housing.

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Chapter 1 Drive Mechanical Installation

Figure 14 - Main Cooling Fan Housing, B-frame

Main Cooling Fan housing

Socket

Aviation plug

Rear View

Install the Cooling Fan and Noise Reduction Barrier for A-frame
Drives (2.4…4.16 kV, UL and IEC)

To install the cooling fan for A-frame 2.4…4.16 kV drives, follow these
instructions.
1. Place the fan housing on the top plate of the drive. Verify that the socket
is on the same side as the aviation plug.
2. Secure the fan housing using M6 hardware (six places).
3. Connect the aviation plug on the top of the cabinet with the socket on the
fan housing.
Figure 15 - Main Cooling Fan Housing, A-frame (2.4…4.16 kV, UL and IEC)

Main Cooling Fan housing

Socket

Noise reduction barrier

Aviation plug

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 Chapter 1 Drive Mechanical Installation

If your application uses noise reduction barriers for the fans, follow these
instructions.
1. Remove the four M6 screws on the left and right sides of the front fan
housing.
2. Place the noise reduction barrier in front of the fan housing.
3. Secure the noise reduction barrier wit h the four M6 screws.
Figure 16 - Install the Noise Reduction Barrier

Install the Mixing Hood for A-frame Drives (2.4…4.16 kV, UL and IEC)

If your application uses a mixing hood with redundant fan, follow these
instructions.
1. Remove the air hood from the skid.
2. Install the four eyebolts at each corner of the air hood.
3. Life the air hood by the four eyebolts and align with the provisions on the
top plate.
4. Secure the air hood with 12 M16x16 hexagon combination screws.
5. Put the fan modules onto the air hood and align with the provisions on
the air hood.
6. Secure the fan modules with 16 M16x16 hexagon combination screws.

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Chapter 1 Drive Mechanical Installation

Figure 17 - Install a Mixing Hood with Redundant Fan

M16x16 hexagon
combination screw (16)

Eyebolt (4)

M16x16 hexagon
combination screw (12)

Install the Cooling Fan for A-frame Drives

(11 kV in/3.3 kV out, 13.8 kV in/4.16 kV out, or all 6…6.6 kV out, IEC only)

To install the cooling fan for A-frame drives, follow these instructions.
1. Place the fan housing on the top plate of the drive and slide the fan
housing back. Verify that the back flange of the fan housing slides under
the top plate fan bracket assembly.
2. Secure the fan housing using M6 hardware across the front of the fan
assembly.
3. Connect fan wiring to fan terminals located behind the cover on the front
of the fan housing.

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Figure 18 - Main Cooling Fan Housing, A-frame

(11 kV in/3.3 kV out, 13.8 kV in/4.16 kV out, or all 6…6.6 kV out, IEC only)

Fan wiring terminals

located behind this cover

Mount fan assembly with

M6 hardware across the
front of the fan assembly

Front View

Back flange of fan

Top plate bracket

assembly

Back View

Install Power Modules Power Modules are available in a wide variety of amperage ratings relating to
(if applicable) the required motor current. Power Modules that are rated up to and including
350 A are mounted in the drive and ship already installed.

Power Modules that are rated above 350 A are shipped separately, therefore site
installation and cable connection is needed. In this case, a lift cart is supplied
and shipped together with the other components.

Power Module Lift Cart

ATTENTION: Only authorized personnel should operate the lift cart. Keep
hands and feet away from the lifting mechanism. Do not stand under the lift
tray when in use. Store the lift cart with the tray fully lowered.

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Chapter 1 Drive Mechanical Installation

The lift cart’s hydraulic cylinder can be operated by either a hand or foot crank.
The lifting capacity is 400 kg (882 lb).

Figure 19 - Lift Cart Procedure

1. Check the lift tray before use to verify that the

tray can be raised and lowered smoothly.
2. Rotate the Pressure Release Knob
counterclockwise to verify that the tray is in the
Hand Crank
lowest position.
3. Move the Power Module on the tray and lift the
module to the appropriate height using the Foot
Pressure Release Knob Crank and complete the installation.
The Foot Crank raises the lift tray faster
than the Hand Crank. Use this to raise the
Power Module to just below the tray
assembly in the drive. Use the Hand Crank
for final precise positioning.
4. Rotate the Pressure Release Knob
counterclockwise to lower the tray to its
Release Seal original position.
pressure in pressure in
cylinder cylinder
5. Repeat steps 1…4 to complete the installation
for all Power Modules.

Lift tray

Foot Crank

Table 3 - Power Module Specifications

Frame Output Rating (Amps) Dimensions (HxWxD), approx. Weight, approx.
36…70 A 210 x 110 x 569 mm (8.3 x 4.3 x 22.4 in.) 13 kg (28.6 lb)
A-frame 71…140 A 210 x 190 x 624.5 mm (8.3 x 7.5 x 24.6 in) 25 kg (55 lb)
(all ratings)
141…215 A 210 x 215 x 674 mm (8.3 x 8.5 x 26.5 in) 35 kg (77 lb)
201…350 A 552.5 x 244.5 x 663 mm (21.8 x 9.6 x 26.1 in.) 70 kg (154 lb)
B-frame
351…680 A 471 x 354 x 746 mm (18.5 x 13.9 x 29.4 in.) 95 kg (209 lb)

ATTENTION: Two people are required to handle the Power Modules.

Install Power Modules

IMPORTANT The Power Module should be handled carefully. After removing the
packaging, inspect the Power Module to confirm that there is no damage
and moisture.
1. You can use the lift cart to move and position the Power Module to the
appropriate location in the cabinet.
2. Push the Power Module slowly along the guide rails until it cannot be
pushed in further.

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 Chapter 1 Drive Mechanical Installation

3. After installing the Power Module in place, use the mounting brackets
and the M6 × 16 large flat pad galvanized nickel screws to fix the four
corners, as shown below.

Mounting brackets

Power Module

Guide rail

Mounting brackets

Install Power Modules for A-frame Drives (All ratings)

IMPORTANT The Power Module should be handled carefully. After removing the
packaging, inspect the Power Module to confirm that there is no
damage and moisture.
1. Push the Power Module slowly along the guide rails until it cannot be
pushed in further.
2. After installing the Power Module in place:

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Chapter 1 Drive Mechanical Installation

a. For 140/215 A rating – use the mounting brackets and M6x16 large flat
pad galvanized nickel screws to secure the two bottom corners.

Power Module

Guide rail

Mounting brackets

b. For 70 A rating – use M16x16 large flat pad galvanized nickel screws to
secure the two bottom corners directly.

Power Module

Guide rail

Secure points

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External Ducting The PowerFlex 6000T design can accommodate ducting exhaust air outside of
the control room.

ATTENTION: The Isolation Transformer Cabinet and the Power Module/LV

Control Cabinet must be ducted separately.

The following requirements are mandatory design requirements for systems

that will externally duct the exhaust air and draw cleansed outside air:
• External ducting including an external filtering system must not add
more than 50 Pa (0.2 in. of water) pressure drop to the PowerFlex 6000T
drive airflow system. Ensure a minimum top clearance of 1500 mm (39.4
in.) above the drive top plate.
• The control room must provide slightly more make-up air, creating a
pressurized room. This slight pressurization helps prevent unfiltered air
drawing into the room.
• The drive is intended to operate in conditions with no special
precautions to minimize the presence of sand or dust, but not in close
proximity to sand or dust sources. IEC 721-1 defines this as being less
than 0.2 mg/m3 of dust.
• If outside air does not meet this condition, filter the air to EU EN779
Class F6 or ASHRAE Standard 52.2 MERV 11. These ratings address a high
percentage of the 1.0...3.0 μm particle size. Clean or change filters
regularly to achieve proper flow.
• The make-up air must be between 0...40 °C (32...104°F).
• Relative humidity must be less than 95% noncondensing.
• If the ducting length is greater than 4 m (13 ft), an axial fan must be
installed at the air outlet. The exhaust flow of the axial fan must be
greater than the total flow amount of all centrifugal fans in this air duct.
• The ducting can be shared by multiple cabinets.
• Do not cover any medium voltage or control power wires that enter or
exit from the top of the cabinet.
• The air duct outlet must slope downward to help prevent water damage.
• Screens must be installed in the air duct outlet.
• An air inlet must be added to the drive room. The cross-sectional area of
this inlet must meet the ventilation requirements of all drives. Screens
must be installed in the air inlet.
• The air inlet and outlet must not be at the same side of the drive room.

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Chapter 1 Drive Mechanical Installation

Cabinet Airflow, A-frame (All ratings) (a)

Cabinet Airflow, B-frame (a)

(a) Top ducting shown by contractor.

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Air Conditioning Sizing If the drive is located in an enclosed space, install air conditioners for each
drive. A general formula to calculate air conditioner power required:

DriveRating  kW    1 – DriveEfficiency 
--------------------------------------------------------------------------------------------------------= Air Conditioning Size (tons)
3.5

EXAMPLE For a 1000 kW drive with 96.5% efficiency:

·
1000   1 – 0.965 
------------------------------------------- = 10 tons of AC required
3.5

This is for a general estimate. See the actual heat loss data to calculate air
conditioning sizing. Contact the local Rockwell Automation office for actual
data.

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Notes:

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 Chapter 2

Drive Electrical Installation

The installation of all external power cables and control signal wiring is
covered in this chapter. General electrical safety and installation guideline
topics are also included. The basic activities include connecting the system
ground cable, line and motor cables, control power, and all control signal
wiring from the sources to the drive. See Figure 40, Figure 41 and Figure 42 for
an overview of these connections.

Electrical interconnections are also required between cabinets that have

shipped separately. These are described in Drive Electrical Interconnection on
page 57.

Safety and Codes

SHOCK HAZARD: Connecting to potentially 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 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 that are outlined in Electrical Safety
requirements for Employee Work places must be followed. Before
attempting any work, verify that the system has been locked out and tested
to have no potential.

Lockout and tagout the input circuit breaker before performing any electrical
connection work. After the input circuit breaker cabinet doors are opened,
immediately test the outgoing connections and any components that are
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.

See national and local safety guidelines for detailed procedures on how to
safely isolate the equipment from hazards.

ATTENTION: The national and local electrical codes outline provisions for
safely installing electrical equipment. Installation must comply with
specifications regarding wire type, conductor sizes, branch circuit
protection, and disconnect devices. Failure to do so may result in personal
injury and/or equipment damage.

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Electrical Drawings Before connecting any power cables or control signal wiring, review and
understand the information that is contained in the project-specific Electrical
Drawings (ED).

They contain critical information such as:

• Minimum power cable insulation ratings and sizes
• Power terminal locations and designations
• Terminal block designations for all connections to external customer
control signal wiring and control power supply cables.

The practice that is used within the PowerFlex 6000T electrical drawing is
based on the IEC or NEMA standard depending on the requirements. The
symbols used to identify components on the drawings are international.

Device designations that are used on the drawings and labeling are explained
on each drawing set.

Wiring identification uses a source/destination wire number convention on

point-to-point multi-conductor wiring and in situations where the system is
warranted. The wire-numbering system of unique, single numbers for multi-
drop and point-to-point wiring continues to be used for general control and
power wiring.

Wiring that connects between the sheets or that ends at one point and starts at
another point on a drawing has an arrow and drawing reference to indicate
the ongoing connection. The drawing reference indicates the sheet and the X/
Y coordinates of the continuation point. The reference system is explained on a
sheet in each drawing set. The unique wire numbering system serves as
confirmation that the correct wire is being traced from sheet-to-sheet or
across a drawing. Wires in multi-conductor cables are typically identified by
color rather than by number. Abbreviations used to identify the colors on the
drawings are fully identified on a sheet in the drawing set.

Grounding System As a general guideline, the ground path must be of sufficiently low impedance
Requirements and capacity that:
• the rise in potential of the drive ground point when subjected to a
current of twice the rating of the supply should be no higher than 4V over
ground potential
• the current flowing into a ground fault is of sufficient magnitude to
cause the protection to operate.

The general grounding point must be reliably connected with the grounding
network.

Attach an external ground cable to the main ground bus, in compliance with
applicable national and local electrical codes.

IMPORTANT The primary grounding cable must have a diameter of at least 50 mm2
and meet all applicable national and local electrical codes.

Run the system ground cable separately from power and signal wiring so that
faults:

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 Chapter 2 Drive Electrical Installation

• do not damage the grounding circuit

• will not interfere with or damage the protection or metering systems, or
cause undue disturbance on power lines.

See the following diagram for ground connections. This ground bus is the
common ground point for all grounds internal to the drive.

Bond each AC motor frame to the buildings steel that is grounded and within
6 m (20 ft) of this location. Tie it to the ground bus of the drive using ground
wires within the power cables or conduit.

IMPORTANT Do not connect the main ground bus of the drive to the system ground.
The conduit or cable armor must bond to ground at both ends.

Isolation Transformer
U
Inverter
V

Rectifier
W

Ground Bus

PowerFlex 6000T drives do not have any restrictions to be used on direct

grounded, high impedance or ungrounded electrical systems. Since the
neutral point of the isolation transformer for PowerFlex 6000T drives is not
grounded, a PowerFlex 6000T drive will not affect the upstream system
grounding current distribution/measurement, and it is operation will not be
affected by the upstream grounding. For more details on proper grounding
practices, see Wiring and Grounding for Pulse Width Modulated (PWM) AC
Drives Installation Instructions, publication DRIVES-IN001.

Power Cable Insulation Incoming line power cable ratings are shown on the Electrical Drawings and
Requirements reflect what would typically be supplied, based on line voltage rating.

All voltage ratings for outgoing motor cables that are shown are line-to-ground
rated power-frequency voltages and line-to-line power-frequency voltages.

Table 4 - Cable Insulation Requirements for Outgoing Motor Cables

Minimum Insulation Rating (kV) - Motor Side
System Voltage
(V, RMS) Line-to-Ground Rated Power Line-to-Line Rated Power
Frequency Voltage Uo Frequency Voltage U
2300 ≥1.7 ≥2.8
2400 ≥1.7 ≥2.8
3000 ≥2.3 ≥3.9
3300 ≥2.3 ≥3.9
4000 ≥2.8 ≥4.8
4160 ≥2.8 ≥4.8
6000 ≥4.0 ≥6.9
6300 ≥4.5 ≥7.8

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Chapter 2 Drive Electrical Installation

Table 4 - Cable Insulation Requirements for Outgoing Motor Cables (Continued)

Minimum Insulation Rating (kV) - Motor Side
System Voltage
(V, RMS) Line-to-Ground Rated Power Line-to-Line Rated Power
Frequency Voltage Uo Frequency Voltage U
6600 ≥4.5 ≥7.8
6900 ≥4.8 ≥8.3
10,000 ≥6.4 ≥11.1
11,000 ≥7.2 ≥12.5

Select cables of appropriate voltage classes when the incoming line grid-side
voltage class differs from the outgoing line motor-side voltage class.

Standard power cable ratings commercially available can vary in different

regions around the world. Cable must meet the minimum line-to-ground and
line-to-line requirements.

IMPORTANT Follow the recommended field power cabling insulation levels to help
achieve trouble-free startup and operation. The cable insulation level
must be increased over that which would be supplied for an across-the-
line application with the same rated line-to-line voltage.

Power Cable Design Use fire retardant cables for the drive input/output connections.
Considerations
Shielded or unshielded cable can be used based on the criteria that are
considered by the distribution system designer and national and local
electrical codes.

If shielded power cables are used, connect the shield of the main input/output
power cables with the general grounding point of the drive. Ground the drive
output protective grounding connection separately, and only at the drive side.

Comply with the maximum tensile stress and the minimum curvature radius
that is recommended by the cable manufacturer.

Do not bundle the input/output cables of the drive together.

The power cable tray must not be less than 300 mm (12 in.).

There must be no gaps where the conduit connects to the cabinet and the
ground bond must be less than 0.1 ohms. Spacing between wire groups is the
recommended minimum for parallel runs of approximately 61 m (200 ft) or
less.

IMPORTANT PowerFlex 6000T drives are able to operate motors if the cable length is
less than 800 m (2624 ft). Contact the factory when cable lengths at the
drive output exceed 800 m (2624 ft).
When the cable length is longer than 800 m (2624 ft), an assessment is
required. It does not necessarily mean that an output filter is required.
Configurations can be provided for longer cable distances, but must be
specified at the time of order.

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 Chapter 2 Drive Electrical Installation

All input and output power wiring, control wiring, or conduit must be brought
through the conduit entrance holes of the cabinet. Use appropriate connectors
to maintain the environmental rating of the cabinet.

Motor Cable Sizing Voltage drop in motor leads may adversely affect motor starting and running
performance. Installation and application requirements may dictate that
larger wire sizes than indicated in national and local electrical codes are used.

Wire sizes must be selected individually, observing all applicable safety and
national and local electrical codes. The minimum permissible wire size does
not necessarily result in the best operating economy. The minimum
recommended size for the wires between the drive and the motor is the same
as that used if a main voltage source connection to the motor was used. The
distance between the drive and motor can affect the size of the conductors
used.

Consult the Electrical Drawings and appropriate national and local electrical
codes to determine correct power wiring. If assistance is needed, contact your
local Rockwell Automation Sales Office.

Control Signal Wiring Use shielded cables for all analog and digital control cables.
Design Considerations
Steel conduit or a cable tray can be used for all PowerFlex 6000T drive power or
control wiring; however, use only steel conduit for all signal wiring.

ATTENTION: Steel conduit is required for all control and signal circuits
when the drive is installed in European Union countries.

Wires for digital and analog signals must be routed separately.

Control cables and power cables must be routed separately; the distance
between the control cable tray and the power cable tray must not be less than
300 mm (11.8 in.).

If the control cable must pass through the power cable tray, the angle between
the cable trays must be as close to 90° as possible.

Do not mix AC and DC wires in the same cable bundle.

General Wire Categories on page 69 identifies general wire categories for

installing the PowerFlex 6000T drive. Each category has an associated wire
group number that is used to identify the required wire. Application and signal
examples, along with the recommended type of cable for each group, are
provided. A matrix providing the recommended minimum spacing between
different wire groups that run in the same tray or in a separate conduit is also
provided.

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Chapter 2 Drive Electrical Installation

Control Signal Wire Shield Grounding

Guidelines for Drive Signal and Safety Grounds: when using interface cables
carrying signals, where the frequency does not exceed 1 MHz, for
communications with the drive, follow these general guidelines:
• Ground screen mesh around the entire circumference, rather than
forming a pigtail grounded only at one point.
• For coaxial cables with one conductor surrounded by a mesh screen,
ground the screen at both ends.
• When using a multi-layer screened cable (that is, a cable with both a
mesh screen and a metal sheath or some form of foil), there are two
alternative methods:
- Ground the mesh screen at both ends to the metal sheath. The metal
sheath or foil (known as the drain) should, unless otherwise specified,
be grounded at one end only, again, as specified above, at the receiver
end or the end that is physically closest to the main equipment ground
bus
- Leave the metal sheath or foil insulated from ground, and ground the
other conductors and the mesh cable screen at one end only, as stated
above.

Grounding provisions for control signal wiring is shown in Figure 20.

Figure 20 - Vertical Ground Bus in LV Cabinet

A-frame (All ratings) B-frame

Ground Bus

Provisions for grounding

Control Signal Wiring shields,
Ground Bus and so on.
Provisions for grounding
Control Signal Wiring shields,
and so on.

Electrical Installation
Summary Topic Page
Connect the System Ground Cable 45
Insulation Resistance (IR) Test of Power Cables 46
Connect Incoming Line and Outgoing Motor Power Cables 46
Connect Control Power Wiring 51
Connect External Control Signal Wiring 54
Connect Electrical Safety Interlock Circuit to Input Circuit Breaker 54

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Connect the System Ground The drive ground bus runs along the bottom of the drive at the front. The
Cable ground bus is accessible at the bottom of the front of each drive cabinet when
the cabinet door is opened. Connect the system ground cable to the drive
ground bus (Figure 21, Figure 22, and Figure 23).

Figure 21 - Ground Cable Connection in the Isolation Transformer Cabinet, A-frame (2.4…4.16 kV, UL
and IEC)

Customer/Contractor supplied
System Ground cable

Ground Bus

M8x25 bolt Flat washer Lock washer

Figure 22 - Ground Cable Connection in the Isolation Transformer Cabinet, A-frame (6…6.6 kV, IEC
only)

Transformer Cabinet Junction/LV Cabinet Top View of Surge Arrestor Ground Bus

Ground Bus Ground Lug Ground Bus Ground Lug Ground Bus Ground Lug

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 45

Chapter 2 Drive Electrical Installation

Figure 23 - Ground Cable Connection in the Isolation Transformer Cabinet, B-frame

Customer/Contractor supplied
System Ground cable

Ground Bus

Lock washer
Flat washer
M8x25 bolt

IMPORTANT If an optional cabinet is supplied, the system ground cable connection is

in the optional cabinet. See the PowerFlex 6000T Drives Hardware
Service Manual, publication 6000-TG100.

Insulation Resistance (IR) Before connecting the incoming line and outgoing motor power cables, follow
Test of Power Cables standard industry practice to verify the integrity of the power cable insulation
from the input breaker to the drive and from the drive to the motor.

Connect Incoming Line and The installer must ensure that all power connections are in accordance with
Outgoing Motor Power national and local electrical codes.
Cables Each drive is equipped with provisions for bottom power cable entry as
standard. Provisions for top power cable entry can also be provided. This must
be specified at the time of order.

For the location of incoming line and outgoing motor power cable
connections, refer to the customer-specific Dimension Drawing.

The drive is supplied with the following provisions for power cable lugs.

Table 5 - Power Terminals

Incoming Line Cable Connections L1 L2 L3
Outgoing Motor Cable Connections U V W

46 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 2 Drive Electrical Installation

Connect Cables for A-frame Drives (All ratings)

For A-frame drives, Figure 24 and Figure 25 show typical connection points for
the primary entrance/exit cable.

IMPORTANT If a filter cabinet is supplied, the incoming line cables are from Junction
cabinet and outgoing motor cable connections are in the filter cabinet
(see Figure 26). See the PowerFlex 6000T Drives Hardware Service
Manual, publication 6000-TG100.
1. Connect the three-phase medium voltage inputs L1, L2, and L3 for top or
bottom entry to the user-provided input three-phase AC power.

IMPORTANT Cable entry and exit cable holes should be sealed.

2. Connect three-phase medium voltage inputs U, V, and W for top or
bottom entry to the user-provided three-phase asynchronous motor.
3. Cable clamps are provided in the cabinet to aid in routing and
supporting the incoming line and outgoing motor power cables.
Figure 24 - Isolation Transformer Cabinet, A-frame (2.4…4.16 kV, UL and IEC) (DV/DT cabinet not
applied)

Top entry

Top entry
Incoming line power
cable connections
Outgoing motor power
cable connections

Bottom entry
Incoming line power
cable connections

Outgoing motor power

cable connections

Cable clamp

Bottom entry

Front View Side View

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 47

Chapter 2 Drive Electrical Installation

Figure 25 - Isolation Transformer Cabinet, A-frame (DV/DT cabinet not applied)

(11 kV in/3.3 kV out, 13.8 kV in/4.16 kV out, or all 6…6.6 kV out, IEC only)

Top entry

Cable clamp

Outgoing motor power

cable connections
Incoming line power
cable connections

Bottom entry

B-B A-A Front View

Cable clamp Cable clamp

U L1
V L2
W L3

Front Front
Junction cabinet Junction cabinet
Section View A-A Section View B-B

48 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 2 Drive Electrical Installation

Figure 26 - Isolation Transformer Cabinet, A-frame (All ratings) (DV/DT filter cabinet applied)

Input Output
Shielded cable

Non-shielded cable
Input Output
Top entry Bottom entry

Remove Barrier for Bottom Entry Connections (2.4…4.16 kV, UL and IEC)

If you choose to connect the cables through the bottom entry of the A-frame
drive, you have to remove the insulation barrier before you proceed.
1. Remove the three plastic M6x25 bolts that secure the removable
insulation barrier.

Removable barrier

Plastic M6x25 bolt, plastic nut,

and plastic washer (3)

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 49

Chapter 2 Drive Electrical Installation

2. Pull out the removable barrier.

3. Connect the cables.

4. Install the removable barrier in the reverse order of removal.

Connect Cables for B-frame Drives

For B-frame drives, Figure 27 show typical connection points for the primary
entrance/exit cable.

IMPORTANT If an optional cabinet is supplied, the incoming line and outgoing motor
cable connections are in the Bypass cabinet. See the PowerFlex 6000T
Drives Hardware Service Manual, publication 6000-TG100.
1. Connect the three-phase medium voltage inputs L1, L2, and L3 to the
user-provided input three-phase AC power.
2. Connect three-phase medium voltage inputs U, V, and W to the user-
provided three-phase asynchronous motor.
3. Cable clamps are provided in the cabinet to aid in routing and
supporting the incoming line and outgoing motor power cables.

50 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 2 Drive Electrical Installation

Figure 27 - Isolation Transformer Cabinet, B-frame (Junction cabinet applied for cable connection)
)

Junction
cabinet
L3 L2 L1
Incoming line
power cable
connections

Outgoing motor
W V U
power cable
connections

Isolation
Transformer

Front View Side View

Connect Control Power Externally supplied control power is required to operate the drive. The
Wiring standard voltage that is supported is 220V AC/50 Hz. The other typical phase
voltages of 230V AC, 240V AC, 110V AC, and 120V AC are also supported (50/60
Hz), but must be specified at the time of order. A minimum of 1.5 kVA is
required to supply the control circuit.

Wiring Routing and Connection

The opening for the control power wiring must be specified during the
quotation stage. See the customer-specific Dimension Drawing for the
location of the opening.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 51

Chapter 2 Drive Electrical Installation

Figure 28 - Control Power Wiring Opening, A-frame (2.4…4.16 kV, UL and IEC)

Cable entrance in top

of LV Control Cabinet
Wire duct for
bundling cable

Bracket for
bundling cable

Cable entrance in bottom

of LV Control Cabinet

Figure 29 - Control Power Wiring Opening, A-frame

(11 kV in/3.3 kV out, 13.8 kV in/4.16 kV out, or all 6…6.6 kV out, IEC only)

Cable entrance in top

of LV Control Cabinet

Wire duct for

bundling cable

Cable entrance in bottom

of LV Control Cabinet

52 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 2 Drive Electrical Installation

Figure 30 - Control Power Wiring Opening, B-frame

Cable entrance in
top or bottom front
of LV Control Cabinet

The control power wiring terminates to the VFD1 terminal block strip on the
left side of the LV Control cabinet (Figure 31).

Figure 31 - Terminal Block Strip locations

VFD1 Terminal
Block strip

-A-

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 53

Chapter 2 Drive Electrical Installation

Connect External Control This section summarizes the control signal wiring from the remote DCS/PLC
Signal Wiring or discrete control to the drive. General connections are detailed in Power
Cabling and Control Signal Wiring Details on page 71. Refer to the Electrical
Drawings for connection information specific See the drive being installed.

Analog and Digital I/O Overview

Four 4…20 mA analog input signals. One may be used for DCS with rotating
speed setting and three for backup. For detailed information, see Table 14 and
Table 15 on page 74.

Up to four 4…20 mA analog output signals for indication signals such as output
motor current and frequency. See Table 14 and Table 15 on page 74.

Twelve passive dry contact inputs (internal 24V DC power supply) start/stop
and reset controls. For detailed information, see Table 14 and Table 15 on
page 74. These inputs are scalable depending on user requirements.

Four dry contact outputs from the POD option cards are standard with a
capacity of 20 W for indication. Interposing relays are provided to interfacing
to power switching devices and fault status information. The quantity is based
on the options that are ordered with the drive. The rating of these contacts is
220V AC/5 A. For detailed information, see Table 14 and Table 15 on page 74.
These outputs are scalable depending on user requirements.

EtherNet/IP™ interface is supplied as standard (other communication

interfaces including Modbus TCP, Modbus Plus, Modbus RTU, and PROFIBUS
are provided as options).

Wiring Routing and Connection

The control signal wiring enters the drive through the same opening as the
control power wiring in the LV Control Cabinet (Figure 30).

The wiring terminates to the VFD1 terminal block strips on the sides of the LV
Control cabinet (Figure 31).

Connect Electrical Safety The electrical safety interlock circuit is part of the overall control signal wiring
Interlock Circuit to Input activity. However, it is mentioned separately in this document due to its
critical importance related to the safe operation of the drive and personnel
Circuit Breaker safety.

The circuits that are connected between the drive and the input circuit
breaker:
• allow the drive to trip the input circuit breaker if a drive cabinet door is
opened. This applies to the cabinet doors where medium voltage is
present. The LV Control cabinet door can be opened while the drive is
energized.

54 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 2 Drive Electrical Installation

• allow the drive to prevent the input circuit breaker from closing when
required.
• indicate to the drive when the input circuit breaker is closed.

MV Door Safety Interlock

If the MV cabinet door is opened, the Allen-Bradley Guardmaster® Limit
Switch (440P-CRPS11D4B) on the cabinet door actuates. The drive sends a trip
signal to the input circuit breaker to disconnect the medium voltage power
supply to the drive.

ATTENTION: The door position interlock is a safety feature. It must not be

used solely as a part of the plant operation process to ensure that the drive
has been disconnected from input medium voltage. Keep the medium
voltage doors locked as standard practice. Always go to the input circuit
breaker feeding the drive to verify if it is open. Lock out and tagout the
input circuit breaker before performing any work on the drive or bypass
units.
Figure 32 - Interlock for Cabinet Doors

Door Position Limit Switch

When the doors of the Power Module/LV Control Cabinet or Isolation

Transformer Cabinet are not closed, when the drive is being maintained or
when the control power switch is not closed, the drive will not send a signal
allowing the input circuit breaker to close; this is wired as a permissive contact
in the input circuit breaker’s closing circuit so that the input circuit breaker
cannot close.

Wire Routing and Connection

The electrical safety interlock control signal wiring enters the drive through
the same opening as the control power wiring in the bottom of the LV Control
Cabinet (Figure 30).

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 55

Chapter 2 Drive Electrical Installation

Notes:

56 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 3

Drive Electrical Interconnection

The drive is shipped in two sections, the Isolation Transformer cabinet and the
Power Module/LV Control cabinet. An optional cabinet may also be supplied.
Drive Mechanical Installation on page 9 describes mechanically joining these
cabinets together. This chapter describes the activities that are required to
electrically connect these drive cabinets’ components together.

Electrical Interconnection
Summary Topic Page
Connect Isolation Transformer Secondary Power Cables 59
Connect Motor and Voltage Sensing Board Cables 60
Connect LV Control and Fan Wiring Bundles 62
Connect Ground Bus 62

Power Cable Figure 33 provides a three-line drawing overview of the power cable
Interconnection Overview interconnections between the power modules (PC XX) in the Power Module/
LV Control cabinet and the secondary windings of the isolation transformer in
the Isolation Transformer cabinet. The number of power modules is
dependent solely on output (motor) voltage:
• 9 power modules for 2.3/2.4/3.0/3.3 kV
• 12 power modules for 4.0/4.16 kV
• 15 power modules for 6.0 kV
• 18 power modules for 6.6/6.9 kV
• 24 power modules for 10 kV
• 27 power modules for 11 kV

It also shows the connection point from the U, V, and W motor output phases
from the power module array to the voltage sensing board cables and the
motor cables.

The isolation transformer secondary windings as shown do reflect the actual

orientation on the isolation transformer.

The Power Module/LV Cabinet orientation is optimized for drawing clarity. To

better understand the physical orientation, the components and connections
that are shown in the Power Module/LV Control Cabinet would be rotated 90º
counter clockwise. The U phase is the top horizontal row, the V phase is the
middle horizontal row, and the W phase is the bottom horizontal row.

See the Electrical Drawing (ED) for actual wire number designations.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 57

Chapter 3 Drive Electrical Interconnection

Figure 33 - Power Cabling Overview (3.3 kV shown), A-frame

\

U U
Motor V
V
W W
Isolation Transformer
Voltage Sensing
Board

1U
1V
1W
PC A0
2U
2V
2W
PC A1
3U
3V
3W
PC A2

4U
L1 4V PC B0
Input power 4W

3-phase AC L2
5U
5V PC B1
5W
any voltage
L3 6U
6V PC B2
6W

7U
7V
7W
PC C0
8U
8V
8W
PC C1
9U
9V
9W
PC C2

Isolation Transformer Cabinet Power Module/LV Control Cabinet

Figure 34 - Power Cabling Overview (3.3 kV shown), B-frame

Isolation Transformer

9W
9V PC C2
9U

8W
8V
8U
PC C1
7W
7V
7U
PC C0

6W
6V PC B2
Input power
L3 6U

5W
3-phase AC L2 5V
5U
PC B1
any voltage
L1 4W
4V
4U
PC B0

3W
3V PC A2
3U

2W
2V
2U
PC A1
1W
1V
1U
PC A0

Voltage Sensing
Board
W W
V V
Motor
U U

Isolation Transformer Cabinet Power Module/LV Control Cabinet

58 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Chapter 3 Drive Electrical Interconnection

Connect Isolation The isolation transformer’s three-phase primary coils are oriented A, B, and C
Transformer Secondary from left to right, as viewed from the front. The secondary windings are also
divided into three principal sections from top to bottom. The upper third are to
Power Cables feed the power modules in the U output phase. The middle third are to feed the
power modules in the V output phase. The bottom third are to feed the power
modules in the W output phase (Figure 35).

Figure 35 - Isolation Transformer Primary and Secondary Winding Orientation

PRIMARY WINDING INPUT

A (L1) B (L2) C (L3)

U U
SECONDARY WINDING OUTPUT

SECONDARY WINDING OUTPUT

V V

W W

The secondary windings are brought out to corresponding vertical isolated

stand-offs on the body of the transformer (orientated U, V, and W from left to
right as viewed from the front). See Figure 36.

Each secondary winding set has a designated U, V, and W terminal

connection. For example, (from top to bottom and left to right) the terminals
from the first winding set are 1W, 1V, and 1U, the terminals from the next
winding set are 2W, 2V, and 2U, and so on.

As shown in Figure 33, the first winding set (1U, 1V, and 1W) connects to the
three-phase input power connection of the first power module in the U motor
phase array (PCA1), the second winding set connects to the second power
module in the U motor phase array (PCA2), and the third winding set connects
to the third power module in the U motor phase array (PCA3). The next three
winding sets connect to the power modules in the V motor phase array. The
remaining three winding sets connect to the power modules in the W motor
phase array.

Figure 33 shows 3.0/3.3 kV configuration. The 6.0/6.6 kV and 10 kV

configuration have more power modules and therefore have more
corresponding isolation transformer secondary windings. The concept is the
same—the top third of the winding sets feeds the power modules in the U

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 59

Chapter 3 Drive Electrical Interconnection

phase, the middle third feeds the power modules in the V phase, and the
bottom third feeds the power modules in the W phase.

Each three-phase secondary winding set of the isolation transformer has three
individual single-phase power cables connecting its output to the three-phase
power input of its corresponding power module.

Drives are shipped split with an Isolation Transformer cabinet and a Power
Module cabinet, and connection at the site is needed. The power cables
connect to the secondary winding termination in the Isolation Transformer.
All cables can be connected from the front of the cabinet.

Cable Routing and Connection

Figure 36 - 6.0/6.6 kV Power Module Configuration

(1-n) U (1-n) V (1-n) W

Secondary Winding Connections Secondary Winding Connections Secondary Winding Connections

Power Cable to Power Module

1U

2U
3U

4U
5U

6U

A-frame – M8 Hex Nut

M8 Flange Nut
B-frame – M10 Hex Nut

Front View

Connect Motor and Voltage The Voltage Sensing Board cables and the motor cables both connect to the
Sensing Board Cables same output point of each motor phase array (Figure 33). The voltage sensing
cables must be connected on site.

For drive ratings with power modules ≥250 A, the connection points are always
on the right side of the power module cabinet. For drive ratings with power
modules ≤200 A, the connection points are on the left side of the power module
cabinet.
60 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022
 Chapter 3 Drive Electrical Interconnection

A typical connection with connection points on the left side of the power
module cabinet are shown in the following diagrams (Figure 37, Figure 38).

Figure 37 - 4.16 kV Power Module Configuration – A-frame

U Phase

M6x16 bolt V Phase

Motor cable
to Junction
cabinet

W Phase

VSB cable

Front View

Figure 38 - 6.6/6.9 kV Power Module Configuration – B-frame

VSB cable Hex bolt

Motor cable

Hex nut Flat washer U Phase

Lock washer
V Phase

W Phase
Front View

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 61

Chapter 3 Drive Electrical Interconnection

Connect LV Control and Fan There are control wiring bundles that must be reconnected after the drive
Wiring Bundles cabinets are connected together. These control wiring bundles are connected
for the factory test and then disconnected and bundled at the shipping splits
before shipment.

For exact wire numbers and terminal block designations, see the Electrical
Drawings.

Connect Ground Bus A solid ground bus is located at the bottom front of each cabinet. When a
shipping split is required, ground bus connectors are supplied. One is attached
above the solid ground bus and one below (Figure 39).

Ground bus connection openings are provided in the cabinet sidesheets for
this connection.

Figure 39 - Interconnection Ground

M8 Hex Nut
Lock Washer
Grounding Bus
Connector
Flat Washer
Grounding
Bus
M8x30 Hex Bolt

Complete the Installation 1. Inspect the interior of all cabinets carefully for hardware or tools that
may have been misplaced.
2. Check and verify that no hardware or foreign material has fallen in the
secondary windings in the Isolation Transformer cabinet.
3. Check that all mechanical work has been completed properly. All barriers
and guards that may have been removed must be reinstalled.
4. Check that all electrical connections have been made and torqued as
specified.
5. Verify that the safety circuit is working properly (see page 54).
6. Reinstall all cabinet back plates.

62 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix A

Pre-Commissioning

Pre-Commissioning Rockwell Automation manages the startup service for each installed drive at
Responsibilities the customer’s site, but there are a number of tasks the customer or its
representatives must complete before scheduling Rockwell Automation
personnel for drive commissioning.

Review this information before commissioning the drive as a reference for

drive line-up commissioning. Record the information in the data sheets
provided; these are useful during future maintenance and troubleshooting
exercises.

ATTENTION: Perform the pre-commissioning tasks in the order listed in this

chapter. Failure to do so may result in equipment failure or personal injury.

IMPORTANT Rockwell Automation requests a minimum of four weeks’ notice to

schedule each startup.

Inspection and Verification

Before the drive commissioning occurs, Rockwell Automation recommends
that the customer arranges a pre-installation meeting to review:
1. the startup plan
2. the startup schedule
3. the drives installation requirements
4. the pre-commissioning checklist

Customer personnel must be on-site to participate in the system startup

procedures.

See Safety and Codes on page 39.

ATTENTION: The CMOS devices that are used on the control circuit boards
are susceptible to damage or destruction by static charges. Personnel
working near static sensitive devices must be appropriately grounded.

Pre-Commissioning Once all points of the checklist are complete, initial each checkbox and provide
Checklist the date. Photocopy the checklist and fax the copy to the Rockwell Automation
Start-up Manager, along with the planned startup date. Upon receiving this
checklist, the Project Manager contacts the site to finalize arrangements for a
startup engineer to travel to the site at your convenience.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 63

Appendix A Pre-Commissioning

Print the following information:

Name: Date:
Company:
Phone: Pages:
Fax:

Drive Serial Number:

Rockwell Automation Service Engineer Requested (YES/
NO):
Scheduled Commissioning Date:

Table 6 - Receiving and Unpacking

Initials Date Check
The drives have been checked for shipping damage upon receiving.
After unpacking, the items received are verified against the bill of materials.
Any claims for breakage or damage, whether concealed or obvious, are made
to the carrier by the customer as soon as possible after receipt of shipment.
All packing material, wedges, or braces are removed from the drive.

Table 7 - Installation and Mounting

Initials Date Check
The drive is securely fastened in an upright position, on a level surface.
The Isolation Transformer Cabinet, Power Module Cabinet, and Bypass Cabinet
(if applicable) are correctly installed.
Lifting Angles have been removed.
Bolts are inserted into original location on top of drive (help prevent leakage of
cooling air).
All contactors and relays have been operated manually to verify free
movement.
The back plates to the cabinets have been reinstalled.

Table 8 - Safety
Initials Date Check
The grounding of the drive should be in accordance with national and local
electrical codes.

Table 9 - Control Wiring

Initials Date Check
All low voltage wiring entering the drive is labeled, appropriate wiring diagrams
are available, and all customer interconnections are complete.
All AC and DC circuits are run in separate conduits.
All wire sizes that are used are selected by observing all applicable safety and
national and local electrical codes.
Remote I/O is correctly installed and configured (if applicable).
All 3-phase control wiring is within specified levels and has been verified for
proper rotation, UVW.
All single-phase control wiring is within specified levels and has grounded
neutrals.
Control lines must be shielded and grounded. Control and Power lines must run
in separate conduits.
The electrical safety interlock wiring to input circuit breaker is correctly
installed.

64 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix A Pre-Commissioning

Table 10 - Power Wiring

Initials Date Check
The power cable connections to the drive, motor, and isolation transformer
adhere to national and local electrical codes.
The cable terminations, if stress cones are used, adhere to the appropriate
standards.
Appropriate cable insulation levels are adhered to, as per Rockwell Automation
specifications.
All shields for shielded cables must be grounded at the source end only.
If shielded cables are spliced, the shield must remain continuous and insulated
from ground.
All wire sizes that are used are selected by observing all applicable safety and
national and local electrical codes.
All power connections are torqued as per Rockwell Automation specifications.
Refer to Torque Requirements on page 67.
All customer power cabling has been insulation resistance (IR) tested or hi-pot
tested before connecting to drive system.
Power wiring phase rotation has been verified per the specific electrical
diagrams that are supplied by Rockwell Automation.

Table 11 - Interconnection Wiring

Initials Date Check
The power cable connection between the Isolation Transformer and Power
Modules.
The motor cable connection to the three output buses.
The Voltage Sensing Board connections to the three output buses and input
buses.
All low voltage connections to the Isolation Transformer Low Voltage panel for
B-frame drives.

Table 12 - Drive Line-up Status

Initials Date Check
The medium voltage and low voltage power is available for startup activities.
The motor is uncoupled from the driven load.
The load is available for full load testing.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 65

Appendix A Pre-Commissioning

Notes:

66 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix B

Torque Requirements

Torque Requirements Proper tightening torque must be used for installation and wiring.
Table 13 - Torque Requirements
Torque
Thread Size Class 8.8
N•m lb•ft
M4 3.0 2.2
M5 5.9 4.4
M6 10.5 7.7
M8 26.0 19.2
M10 51.0 37.6
M12 89.0 65.7
M14 141.0 104.1
M16 215.0 158.7
M20 420.0 310.0

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 67

Appendix B Torque Requirements

Notes:

68 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix C

General Wire Categories

General Wire Categories

Conductors Category Voltage Class Signal Examples Recommended Cable Conductors Group Notes
Per IEC / NEC, Local Should only be run with 120 or 240 digital
Customers Control Power <240V AC 120V or 220V, 1Ø codes and application Tray or Conduit control
requirements
Per IEC / NEC, Local
Dry Contact Relay Logic
<240V AC codes and application Tray or Conduit Should only be run with Control Power
Outputs requirements
Digital I/O
Per IEC / NEC, Local
POD I/O or Dry Contact Relay
24V DC codes and application Tray or Conduit Can be run with Small Signal
Logic Output requirements
Belden 8760(1)
Analog Signals 4…20 mA, ±10V Belden 8770(2) Tray or Conduit
Small Signal Can be run with 24V DC digital I/O
Belden 9460(3)
Communications Ethernet, Internal Drive Link(4) CAT 5E Tray or Conduit
(1) 18 AWG, twisted-pair, shielded
(2) 18 AWG, 3 conductor, shielded
(3) 18 AWG, twisted-pair, shielded
(4) Internal Drive Link Communication — The recommended cable to use is AB 1485C-P1Cxxx, where xxx is the length of the cable on the spool (Belden type YR 39660).

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 69

Appendix C General Wire Categories

Notes:

70 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 110/120/220/230/240V AC, 1 phase, 50/60 Hz.
Control Signal with Branch Circuit Protection
(Minimum 3 kVA Capacity is needed)

Schematic Diagrams
Control Signal

MFN1

that are provided with the drive.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022
To Motor

4.16 kV, 3 phase, 60 Hz

Upstream Circuit Breaker
(Customer scope of supply)

Customer Supplied
Figure 40 - Schematic Diagram of the Drive System without a Bypass Cabinet, A-frame(a)

Ground
DANGER:
Appendix

The medium voltage drive is one component in this system, which includes an input device that is supplied by others.
Power Cabling and Control Signal Wiring Details

The supplier of the input device is responsible for confirming that there is safe access to the input/output drive (if used) and safe access to the drive.
D

(a) Wiring locations are for design reference only; actual wiring must comply with the drawings

71
72
Appendix D

13.8 kV, 3 phase, 60 Hz

110/120/220/230/240V AC, 1 phase, 50/60 Hz.
Upstream Circuit Breaker
Control Signal with Branch Circuit Protection
(Customer scope of supply)
(Minimum 3 kVA Capacity is needed)

To Motor Control Signal

Customer Supplied
Ground

Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan
29 28 27 26 25 24 23 22 21 35 34 33 32 71
Power Cabling and Control Signal Wiring Details

31(1) 72(1)
Transformer(a)

$ $ $ $

3(*5'

Fan
Control
/ / / 8 9 : Cabinet
9)' 9)'
T1
/
1

that are provided with the drive.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022
Control Cabinet Power Cell Cabinet Transformer Cabinet 1 Filter Cabinet /
Junction Cabinet

(1) Redundant fan number shown in red box

DANGER:
Figure 41 - Schematic Diagram of the Drive System without a Bypass Cabinet, B-frame with one

The medium voltage drive is one component in this system, which includes an input device that is supplied by others.
The supplier of the input device is responsible for confirming that there is safe access to the input/output drive (if used) and safe access to the drive.

(a) Wiring locations are for design reference only; actual wiring must comply with the drawings
 13.8 kV, 3 phase, 60 Hz
110/120/220/230/240V AC, 1 phase, 50/60 Hz.
Upstream Circuit Breaker
Control Signal with Branch Circuit Protection
(Customer scope of supply)
(Minimum 3 kVA Capacity is needed)

To Motor Control Signal

Customer Supplied
Ground

Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan Fan
40(1) 39 38 37 36 29(1) 28 27 26 25 24 23 22 21 35 34 33 32 31(1) 72(1) 71
Transformers(a)

$ $ $ $ $

3(*5'

Fan Fan
Control Control
Cabinet / / / 8 9 : Cabinet
9)' 9)'
T2 T1
/

that are provided with the drive.

1

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

Appendix D

Control Cabinet Transformer Cabinet 2 Power Cell Cabinet Transformer Cabinet 1 Filter Cabinet /
Junction Cabinet

(1) Redundant fan number shown in red box

DANGER:
The medium voltage drive is one component in this system, which includes an input device that is supplied by others.
Figure 42 - Schematic Diagram of the Drive System without a Bypass Cabinet, B-frame with two

The supplier of the input device is responsible for confirming that there is safe access to the input/output drive (if used) and safe access to the drive.

(a) Wiring locations are for design reference only; actual wiring must comply with the drawings

73
Power Cabling and Control Signal Wiring Details
Appendix D Power Cabling and Control Signal Wiring Details

Standard Input/Output
Connection Points
Table 14 - Standard I/O Connections Points
Signal Name DI DO Wire Numbers Signal Usage Signal Logic
MV Close Permissive (NO) X 2535, 2538 Allows MV device to close when closed PIOB - DO1 (NO) + Estop (NO) + MV Doors Closed (NO)
PIOB - DO1 (NC) parallel with Estop (NC) parallel with MV Doors
MV Close Permissive (NC) X 2544, 2545 Allows MV device to close when open Closed (NC)
PIOB - DO0 (NO) parallel with EStop (NC) parallel with MV
MV Open Command (NO) X 2539, 2540 Commands MV device to open when closed Doors Closed (NC)
MV Open Command (NC) X 2546, 2549 Commands MV device to open when open PIOB - DO0 (NC) + Estop (NO) + MV Doors Closed (NO)
Estop Status (NO) X 2541, 2542 Estop active when closed Estop (NC)
Estop Status (NC) X 2541, 2543 Estop active when open Estop (NO)
MV Device Status X D-1035A, D-1036A MV device is closed when closed Goes to interposing relay whose contacts go to PIOB DI0.

Standard I/O Connections Points for Option -24TAOP

Signal Name DI DO Wire Numbers Signal Usage Signal Logic
Output Device Close (NO) X 2550, 2553 Commands output device to close when PIOB - DO3 (NO) + Estop (NO) + MV Doors Closed (NO)
closed
Commands output device to open when PIOB - DO2 (NO) parallel with EStop (NC) parallel with MV
Output Device Open (NO) X 2554, 2555 closed Doors Closed (NC)
Output Device Status X D-1052A, D-1236 Output device is closed when closed Goes to PIOB DI1.

Table 15 - I/O Connections related to Remote Distributed Control System

Standard Option
Signal Name AI AO DI DO Wire Numbers Signal Usage Signal Logic
Drive Code
Remote speed reference
Remote Speed Reference X 931/931A -14TS1 programmed for 4…20 mA as Direct to POD Option Card Port 8 - AI1
standard
Spare Analog Input X 932/932A CMOD Direct to POD Option Card Port 7 - AI0
Spare Analog Input X 934/934A CMOD Direct to POD Option Card Port 7 - AI1
Isolated analog output POD Option Card Port 8 - AO0 to 931H
Speed Feedback X User provided -14TS2 programmed for 4…20 mA as Isolator
standard
Isolated analog output POD Option Card Port 7 - AO0 to 931H
Motor Current Feedback X User provided -14TS4 programmed for 4…20 mA as Isolator
standard
Remote Start Command X 1442/1442A -3LL/-3LB Start command from Remote Hardwired to POD Option Card Port 8
source (Edge Triggered) - DI1, Enabled with switch in 'Remote '
Start command from DCS Hardwired to POD Option Card Port 8
DCS Start Command X 1442/!442C -3LB source (Edge Triggered) - DI1, Enabled with switch in 'DCS'
Stop command from Remote Hardwired in series with local stop to
Remote Stop Command X 1438/1439 -3LL/-3LB source (Maintained) POD option Card Port 8 - DI0
Stop command from DCS Hardwired in series with local stop to
DCS Stop Command X 1438/1439 -3LB source (Maintained) POD option Card Port 8 - DI0
Remote Speed Up / for Hardwired to POD Option Card Port 7
Remote Speed Up X 1535/1442A -3LL/-3LB Customers use based on - DI0
selections available in POD I/O
Remote Slow Down / for Hardwired to POD Option Card Port 7
Remote Slow Down X 1536/1442A -3LL/-3LB Customers use based on - DI1
selections available in POD I/O
Remote Preset Speed 3/7 / for Hardwired to POD Option Card Port 7
Remote Preset Speed 3/7 X 1537/1442A -3LL/-3LB Customers use based on - DI2
selections available in POD I/O
Remote Preset Speed 6/7 / for Hardwired to POD Option Card Port 7
Remote Preset Speed 6/7 X 1538/1442A -3LL/-3LB Customers use based on - DI3
selections available in POD I/O
Hardwired to POD Option Card Port 8
Fault Reset X 1444/1052A -3LL/-3LB Fault Reset - DI3

74 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix D Power Cabling and Control Signal Wiring Details

Table 15 - I/O Connections related to Remote Distributed Control System (Continued)

Standard Option
Signal Name AI AO DI DO Wire Numbers Signal Usage Signal Logic
Drive Code
2436/2437 Hardwired in series with Emergency
Emergency Stop X X Emergency Stop Interlock
2439/2440 Stop PB on Door
Status of permission to close NO Relay contacts from interposing
MV permissive to close (NO) X D-758/D758A X MV (NO) - permission when relay driven by PIOB - DO1
closed
Status of permission to close NC Relay contacts from interposing
MV permissive to close (NC) X D-759/D759A X MV (NC) - permission when relay driven by PIOB - DO1
open
NO Relay contacts from interposing
Status of MV device feedback
MV device closed (NO) X D-760/D760A X relay driven by MV Device Status
(NO) - closed when closed from customer
NC Relay contacts from interposing
Status of MV device feedback
MV device closed (NC) X D-761/D761A X relay driven by MV Device Status
(NC) - open when closed from customer
Drive Warning Status (NO) - NO Relay contacts from interposing
Drive Alarm (NO) X D-752/D752A -89D6 warning when closed relay driven by POD Port 7 - RO0
Drive No Warning Status (NO) - NC Relay contacts from interposing
Drive Alarm (NC) X D-753/D753A -89D6 no warning when closed relay driven by POD Port 7 - RO0
Drive Fault Status (NO) - faulted NO Relay contacts from interposing
Drive Fault (NO) X D-748/D748A -89D6 when closed relay driven by POD Port 7 - RO1
Drive Not Faulted Status (NO) - NC Relay contacts from interposing
Drive Fault (NC) X D-749/D749A -89D6 not faulted when closed relay driven by POD Port 7 - RO1
Drive Running Status (NO) - NO Relay contacts from interposing
Drive Running (NO) X D-744/D744A -89D6 running when closed relay driven by POD Port 8 - RO1
Drive Not Running Status (NO) - NC Relay contacts from interposing
Drive Running (NC) X D-745/D745A -89D6 not running when closed relay driven by POD Port 8 - RO1
Drive Ready Status (NO) - ready NO Relay contacts from interposing
Drive Ready (NO) X D-740/D740A -89D6 when closed relay driven by POD Port 8 - RO0
Drive Not Ready Status (NO) - NC Relay contacts from interposing
Drive Ready (NC) X D-741/D741A -89D6 not ready when closed relay driven by POD Port 8 - RO0
Remote is selected for control NO Relay contacts from interposing
Remote Selected (NO) X D-762/D762A -3LL/-3LB source (NO) - remote selected relay driven by Local/Remote
when closed Selector switch
Remote is selected for control NC Relay contacts from interposing
Remote Selected (NC) X D-763/D763A -3LL/-3LB source (NC) - remote selected relay driven by Local/Remote
when open Selector switch
DCS is selected for control NO Relay contacts from interposing
DCS Selected (NO) X D-764/D764A -3LB source (NO) - DCS selected relay driven by Local/Remote/DCS
when closed Selector switch
DCS is selected for control NC Relay contacts from interposing
DCS Selected (NC) X D-765/D765A -3LB source (NC) - DCS selected relay driven by Local/Remote/DCS
when open Selector switch

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 75

Appendix D Power Cabling and Control Signal Wiring Details

Notes:

76 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix E

Line and Load Cable Sizes

Cable Sizes The data in the following tables are informative only; do not base final design
criteria solely on this data. Follow national and local installation codes,
industry best practices, and cable manufacturer recommendations. As cabling
methods can vary widely, maximum cables sizes do not account for the size of
the conduit hub.

Table 16 - Line and Load Cable Sizes for A-frame Drives (IEC)
Description Drive Enclosure Max Size and No.
Motor V Frequency Entry Opening mm (in.) Incoming Cables: IEC(1) (2) (3)
Top 435 x 300 (17.1 x 11.8) 203 mm² 6.6 kV/phase or
3000V 50 Hz
Bottom 220 x 143 (8.7 x 5.6) 240 mm² (500 AWG) 15 kV/phase
Top 435 x 300 (17.1 x 11.8) 203 mm² 6.6 kV/phase or
3300V 50 Hz
Bottom 220 x 143 (8.7 x 5.6) 240 mm² (500 AWG) 15 kV/phase
Maximum Line Top 435 x 300 (17.1 x 11.8) 203 mm² 6.6 kV/phase or
Cable Sizes 4000/4160V 50/60 Hz
Bottom 220 x 143 (8.7 x 5.6) 240 mm² (500 AWG) 15 kV/phase

200 x 250 (7.87 x 9.84) 240 mm² (500 AWG) 8 kV or

6000V 50 Hz Top 240 mm² (500 AWG) 15 kV/phase
170 x 400 (6.69 x 15.74) 240 mm² (500 AWG) 8 kV or
6300/6600V 50 Hz Bottom 240 mm² (500 AWG) 15 kV/phase
Top 435 x 300 (17.1 x 11.8)
3000V 50/60 Hz 203 mm² 6.6 kV/phase
Bottom 220 x 143 (8.7 x 5.6)
Top 435 x 300 (17.1 x 11.8)
3300V 50/60 Hz 203 mm² 6.6 kV/phase
Maximum Load Bottom 220 x 143 (8.7 x 5.6)
Cable Sizes Top 435 x 300 (17.1 x 11.8)
4000/4160V 50/60 Hz 203 mm² 6.6 kV/phase
Bottom 220 x 143 (8.7 x 5.6)
6000V 50 Hz Top 200 x 250 (7.87 x 9.84) 240 mm² (500 AWG) 8 kV
6300/6600V 50 Hz Bottom 170 x 400 (6.69 x 15.74) 240 mm² (500 AWG) 8 kV
(1) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial
cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next
higher-rated cable (that is, 8 kV is not commercially available in many areas of the world, therefore Rockwell Automation
provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker
insulation on the higher-rated cable. IEC ratings show the equivalent to the NEMA sizes. The exact cable mm2 size that is
shown is not commercially available in many cases; use the next smaller standard size.
(2) Minimum cable bend radius recommendations vary by national codes, cable type, and cable size. Consult local codes for
guidelines and requirements. General relationship of cable diameter to bend radius is typically between 7x…12x (for example,
if the cable diameter is 1 in. [2.54 cm] the minimum bend radius could range between 7…12 in. [18.8…30.48 cm]).
(3) As cabling methods can vary widely, maximum cable sizes that are shown do not account for the size of the conduit hub.
Verify size of conduit hubs against the “Drive enclosure openings” shown.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 77

Appendix E Line and Load Cable Sizes

Table 17 - Line and Load Cable Sizes for A-frame Drives (UL)
Description Drive Enclosure Max Size and No.
Motor V Frequency Entry Opening mm (in.) Incoming Cables: IEC(1) (2) (3)
Top 435 x 300 (17.1 x 11.8)
2300/2400V 60 Hz 203 mm² (400 AWG) 6.6 kV/phase
Maximum Line Bottom 220 x 143 (8.7 x 5.6)
Cable Sizes Top 435 x 300 (17.1 x 11.8)
4000/4160V 50/60 Hz 203 mm² (400 AWG) 6.6 kV/phase
Bottom 220 x 143 (8.7 x 5.6)
Top 435 x 300 (17.1 x 11.8)
2300/2400V 60 Hz 203 mm² (400 AWG) 6.6 kV/phase
Maximum Load Bottom 220 x 143 (8.7 x 5.6)
Cable Sizes Top 435 x 300 (17.1 x 11.8)
4000/4160V 50/60 Hz 203 mm² (400 AWG) 6.6 kV/phase
Bottom 220 x 143 (8.7 x 5.6)
(1) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial
cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next
higher-rated cable (that is, 8 kV is not commercially available in many areas of the world, therefore Rockwell Automation
provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker
insulation on the higher-rated cable. IEC ratings show the equivalent to the NEMA sizes. The exact cable mm2 size that is
shown is not commercially available in many cases; use the next smaller standard size.
(2) Minimum cable bend radius recommendations vary by national codes, cable type, and cable size. Consult local codes for
guidelines and requirements. General relationship of cable diameter to bend radius is typically between 7x...12x (for example,
if the cable diameter is 1 in. [2.54 cm] the minimum bend radius could range between 7...12 in. [18.8...30.48 cm]).
(3) As cabling methods can vary widely, maximum cable sizes that are shown do not account for the size of the conduit hub.
Verify size of conduit hubs against the “Drive enclosure openings” shown.

Line and Load Cable Sizes for B-frame Drives (IEC and UL)
Description Drive Enclosure Max Size and No.
Motor V Frequency Opening mm (in.) Incoming Cables(1) (2) (3)
608 mm² (1200 kcmil) 5 kV or
2400V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
3000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
3300V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
4160V 50/60 Hz 138 x 138 (5.4 x 5.4)
Maximum Line 608 mm² (1200 kcmil) 8 kV/phase
Cable Sizes 608 mm² (1200 kcmil) 8 kV or
6000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
608 mm² (1200 kcmil) 8 kV or
6600V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
608 mm² (1200 kcmil) 8 kV or
7200V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
10,000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
11,000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
608 mm² (1200 kcmil) 5 kV or
2300/2400V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
3000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
3300V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 8 kV/phase
608 mm² (1200 kcmil) 5 kV or
4000/4160V 50/60 Hz 138 x 138 (5.4 x 5.4)
Maximum Load 608 mm² (1200 kcmil) 8 kV/phase
Cable Sizes 608 mm² (1200 kcmil) 8 kV or
6000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
608 mm² (1200 kcmil) 8 kV or
6300/6600V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
608 mm² (1200 kcmil) 8 kV or
6900V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
10,000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase
11,000V 50/60 Hz 138 x 138 (5.4 x 5.4) 608 mm² (1200 kcmil) 15 kV/phase

78 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Appendix E Line and Load Cable Sizes

(1) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial
cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next
higher-rated cable (that is, 8 kV is not commercially available in many areas of the world, therefore Rockwell Automation
provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker
insulation on the higher-rated cable. IEC ratings show the equivalent to the NEMA sizes. The exact cable mm2 size that is
shown is not commercially available in many cases; use the next smaller standard size.
(2) Minimum cable bend radius recommendations vary by national codes, cable type, and cable size. Consult local codes for
guidelines and requirements. General relationship of cable diameter to bend radius is typically between 7x…12x (for example,
if the cable diameter is 1 in. [2.54 cm] the minimum bend radius could range between 7…12 in. [18.8…30.48 cm]).
(3) As cabling methods can vary widely, maximum cable sizes that are shown do not account for the size of the conduit hub.
Verify size of conduit hubs against the “Drive enclosure openings” shown.

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 79

Appendix E Line and Load Cable Sizes

Notes:

80 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Index

A Drive Electrical Installation 39

Cable Connections 60
Air Conditioning Cable Insulation Rating 41
Calculation 37 Cable Routing 60
Sizing 37 Control Power Wiring 51
Ambient Air Temperature 8 Control Power Wiring Installation 51
Anchor bolts 13 Control Signal Wiring Design 43
ASHRAE Standard 52.2 MERV 11 35 Control Signal Wiring Shield Grounding 44
Aviation Plug 27 Electrical Drawings 40
External Control Signal Wiring 54
Grounding System Requirements 40
C Incoming Line Cables 46
Isolation Transformer Secondary Power
Cables Cables 59
Control Power Wiring Location 51 Motor Cables 43
Electrical Safety Interlock Wire routing 55 Outgoing Motor Power Cables 46
Fan Wiring Bundles 62 Power Terminals 46
General Wire Categories 69 Summary 44
Ground Bus 62 Torque Requirements 67
Incoming Line Cables 46 Drive Electrical Interconnection
Insulation Resistance (IR) Test of Power Fan Wiring Bundles 62
Cables 46 Ground Bus 62
Isolation Transformer Secondary Power Isolation Transformer Secondary Power
Cables 59 Cables 59
Isolation Transformer Secondary Winding Motor cables 60
60 Power Cable Interconnection 57
Line Cable Sizes 77 Summary 57
Load Cable Sizes 77 Torque Requirements 67
Motor Cables 60 Voltage Sensing Board 60
Outgoing Motor Power Cables 46 Drive Mechanical Installation 9
Power Cable Interconnection Overview 57 Affix Cabinet to Floor 13
Shielded cables 42 Air Conditioning Sizing 37
System Ground Cable 45 Connect Shipping Splits 9
Torque Requirements 67 External Ducting 35
Voltage Sensing Board 60 Install Cooling Fans 27
Commissioning Support 7 Install Power Modules 31
Conduit Openings 13 Power Module Lift Cart 31
Contractor Scope of Work 7 Summary 9
Control Power Wiring
Installation 51 E
Routing 51
Torque Requirements 67 Electrial Safety Interlock 54
Control Signal Wiring 43 Electrical Drawings 40
Routing 43 Contents 40
Shield Grounding 44 Electrical Safety Interlock
Shielded cables 43 Location 55
Torque Requirements 67 Wire Routing 55
Control Signal Wiring Details Elevation 8
Schematic (No Bypass) 71, 72, 73 Environmental Conditions
Cooling Fans
Ambient Air Temperature 8
Hardware 27 Elevation 8
Installation 28 IEC721-1 8
Orientation 28 Relative Humidity 8
Wiring Bundles 62 Vibration 8
EU EN779 Class F6 35
D External Control Signal Wiring 54
Analog I/O 54
Design Considerations 43 Digital I/O 54
Documentation box Torque Requirements 67
Electrical Drawings 40 Wiring Routing 54
External Ducting
Specifications 35

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 81

Index

G Load Cable Sizes 77

Drive Enclosure Opening 77
General Precautions 6
Maximum Size 77
Safety and Codes 39 Motor Voltage/Frequency 77
General Wire Categories 69 Lockout 39
Ground Bus
LV Cabinet 44
System Ground Cable Installation 45 M
Grounding System
Motor Cables
Requirements 40
Sizing 43
Torque Requirements 67
H U Phase Sidesheet opening 12
V Phase Sidesheet opening 12
Hardware W Phase Sidesheet opening 12
Fan Housing 27
Ground Bus 62
Power Module Power Cables 60 O
Secondary Winding Connections 60 Outgoing Motor Power Cable Connections
Shipping Splits 12
System Ground Cable 45 Location 47, 48, 51
Output Connection Points 74
Torque Requirements 67

I P
IEC721-1 8, 35 Power Cables
Incoming Line Power Cable Connections Desing Considerations 42
Location 47, 48, 51 Insulation Requirements 41
Interconnection Overview 57
Input Connection Points 74
Maximum Distance 42
Input/Output Connections Schematic (No Bypass) 71, 72, 73
Remote Distributed Control System 74 Torque Requirements 67
Standard I/O Connection Points 74 Power Module Lift Cart 31
Insulation Resistance (IR) Test Lifting Capacity 31
Power Cables 46 Operating Procedure 31
Isolation Transformer Precautions 31
Location 51 Power Module/LV Control Cabinet
Isolation Transformer Cabinet Control Power Wiring Location 51
Ground Bus 62 Electrical Safety Interlock Wire Entry 55
Layout 47, 49, 51 Ground Bus 62
Secondary Power Cables 59 Motor cables 61
Secondary Winding Connections 60 Power Module Installation 31
Power Module Interconnections 60
Power Module Lift Cart 31
J Terminal Block Strip location 53
Voltage Sensing Board cables 61
Junction Cabinet
Power Modules
Location 51
Air Flow 37
Cable Routing and Connection 60
L Fan Wiring Bundles 62
Installation 31
Lift Cart 31 Lift Cart 32
Lifting capacity 31 Lift cart 31
Operation 31 Motor Cable connection 61
Lifting Angles Voltage Sensing Board connection 61
Torque Requirements 67 Power Terminals 46
Line Cable Sizes 77 PowerFlex 6000T
Drive Enclosure Opening 77 Electrical Installation 39
Maximum Size 77 External Ducting Specifications 35
Motor Voltage/Frequency 77 Isolation Transformer Cabinet Layout 47,
Line-to-Ground Rated Power Frequency 49, 51
Voltage 41 Line Cable Sizes 77
Load Cable Sizes 77
Line-to-Line Power Frequency Maximum
Mechanical Installation 9
Voltage 41 Power Module Lift Cart 31
Pre-Commissioning 63
Schematic (No Bypass) 71, 72, 73

82 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 Index

Pre-commissioning System Ground Cable

Checklist 63 Installation 45
Inspection 63 Location 45
Verification 63 Torque Requirements 67
Pre-commissioning Checklist 63
T
R Tagout 39
Required Supplemental Information 5 Terminal Block Strip
Location 53
Torque Requirements 67
S
Safety and Codes 39
ASHRAE Standard 52.2 MERV 11 35 V
EU EN779 Class F6 35 Vibration 8
IEC721-1 35 Voltage Sensing Board
Lockout and tagout 39 Cable Installation 60
Shielded Cables 42
Shipping Splits 9
Align the Cabinets 12 W
Connection 9 Weld locations 14
Hardware 12
Specifications Wiring
Cable Insulation Rating 41 External Control Signal Wiring 54
External Ducting 35 LV Control Bundles 62
Standard Input/Output Connection Points 74

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 83

Index

Notes:

84 Rockwell Automation Publication 6000-IN100D-EN-P - July 2022

 PowerFlex 6000T Drives Installation Instructions

Rockwell Automation Publication 6000-IN100D-EN-P - July 2022 85

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Publication 6000-IN100D-EN-P - July 2022

Supersedes Publication 6000-IN100C-EN-P - September 2021 Copyright © 2022 Rockwell Automation, Inc. All rights reserved.