6000-TG100B-EN-P PowerFlex 6000T Drives Hardware Service Manual Troubleshooting Guide

PowerFlex 6000T, PF6000T, 6000T

"PowerFlex 6000T, PF6000T, 6000T"

Rockwell Automation

PowerFlex 6000T Drives Hardware Service Manual

themselves with installation and wiring instructions in addition to requirements ... Smart Fiber Interface Circuit Board Replacement . ... static wristband.

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6000-tg100 -en-p

PowerFlex 6000T Drives Hardware Service Manual
Bulletin Number 6000T

Troubleshooting Guide

Original Instructions

PowerFlex 6000T Drives Hardware Service Manual Troubleshooting Guide
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).

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Table of Contents

Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 7 Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Required Supplemental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Before You Begin Tests, Maintenance, or Repairs

Chapter 1
Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Qualified Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove Power from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Commonly Used Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Preventative and Predictive Maintenance

Chapter 2
Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 17 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Maintenance of Industrial Control Equipment. . . . . . . . . . . . . . . . . . . . . 20
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Clean the Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Regular Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Physical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Power Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Medium Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . 23 General Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Review Firmware and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspect/Review Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Professional Maintenance Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Miscellaneous Preventive Maintenance Work . . . . . . . . . . . . . . . . . . 25 Replacement Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Locate Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Acknowledge Maintenance Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Upgrade Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Prepare Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Table of Contents

Predictive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Upgrade Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Component Inspection and Test Procedures

Chapter 3
Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replace/Clean Door-mounted Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Recommended Cleaning Method of Filters . . . . . . . . . . . . . . . . . . . . . 38 Replace Filter for A-frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Replace Filter for B-frame Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Inspect Top Mounted Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Replace Top Mounted Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Replace EC400 Fan Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Replace EC500 Fan Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Replace Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Inspect/Replace Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . 47 Component Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

LV Control Cabinet

Chapter 4
Control Pod Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Fiber Transceiver Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . 52 Main Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Set Jumpers on MCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Set the IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Backplane Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Power I/O Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Set Jumpers on PIOB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Smart Fiber Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . 60 I/O Option Cards Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Control Pod Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Replace Upper Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 63 Replace Lower Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 64 Control Pod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Inspect the Integrated Touch Screen Display . . . . . . . . . . . . . . . . . . . . . . 68 Replace the Integrated Touch Screen Display . . . . . . . . . . . . . . . . . . . . . . 68 Remove Existing Integrated Touch Screen Display from the Panel . 68 Mount the Integrated Touch Screen Display in the Panel . . . . . . . . 68 Remove the Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Ground the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Isolation Transformer Cabinet

Chapter 5
Inspect Isolation Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Inspect/Replace Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replace Voltage Sensing Board (A-frame) . . . . . . . . . . . . . . . . . . . . . . 71 Inspect/Replace HECS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Power Cell Cabinet Inspect Connections

Table of Contents
Chapter 6
Inspect Power Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Replace Power Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Install the Power Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Using the Lift Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Replace Power Cell Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chapter 7
Inspect LV Component Terminal and Plug-in Connections . . . . . . . . . 83 Inspect Medium Voltage Cable Connections . . . . . . . . . . . . . . . . . . . . . . . 83 Inspect Power Cable and Control Wire Terminals . . . . . . . . . . . . . . . . . . 83 Inspect Transformer Secondary Windings . . . . . . . . . . . . . . . . . . . . . . . . 83 Inspect Power Cell Input and Output Power Connections . . . . . . . . . . . 84
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Table of Contents
Notes:

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Preface

About This Publication

This manual provides a recommended preventative maintenance schedule, major component test, and hardware replacement procedures for PowerFlex® 6000T medium voltage drives.

Download Firmware, AOP, EDS, and Other Files

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

Who Should Use This Manual

This manual is intended for use by personnel familiar with operating medium voltage and solid-state variable speed drive equipment. The manual contains material that enables operation and regular maintenance of the drive system.

What Is Not in This Manual

This manual provides information specific to maintaining the PowerFlex 6000T medium voltage variable-frequency drive. It excludes 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 9.

Required Supplemental 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. Contact the local Rockwell Automation office to obtain digital copies, if necessary.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Preface
General Precautions
Summary of Changes

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 80004.5.2, "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 highvoltage detector that is properly rated for the line and motor voltages. All status indicator 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.

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

Topic Updated Inrush current spec in Table 1 - Line-to-Ground Short-circuit Specification Updated Periodic Preventative Maintenance Schedule Updated section Regular Maintenance Intervals Added topic Replacement Schedule to Chapter 2 Updated topic Final Report Added topic Predictive Maintenance to Chapter 2 Updated section Replace Top Mounted Cooling Fans Added topic Replace Sensors to Chapter 3 Added topic Control Pod Overview to Chapter 4 Updated drawing of MCB for step 7 of topic Main Control Board Replacement Added sections Set Jumpers on MCB and Set IP Address to topic Main Control Board Replacement Added section Set Jumpers on PIOB to topic Power I/O Board Replacement Added topic I/O Option Card Settings to Chapter 4 Added section Replace Upper Control Pod Fan Assembly to topic Control Pod Fan Assembly Replacement

Page 13 19 21
26...31 32
33...35 41...44 45...46
50 54
56
60 63
63

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Preface

Additional Resources

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

Resource

Description

PowerFlex 6000T Drives Shipping and Handling Manual, publication 6000-PC100

Provides instructions for shipping and handling PowerFlex 6000T drives and related equipment.

PowerFlex 6000T Drives Installation Instructions, publication 6000-IN100

Provides instructions for installing PowerFlex 6000T drives and related equipment.

PowerFlex 6000T Drives Programming Manual, publication 6000-PM100

Provides detailed information on drive features, programming parameters, and troubleshooting faults and alarms.

Enhanced HIM Integrated Touch Screen Display, publication EHIM-QS001

Provides detailed information on the integrated touch screen display and how to use it to configure, program, and monitor the status of PowerFlex 6000T drives.

PowerFlex 20-HIM-A6 and 20-HIM-C6S HIM (Human Interface Module), publication 20HIM-UM001

Provides detailed instructions on how to use the Human Interface Module (HIM) capabilities for configuring PowerFlex 6000T drives.

PowerFlex Drives with TotalFORCE Control Built-in EtherNet/IP Adapter, publication 750COM-UM009

Provides information about the dual-port, built-in EtherNet/IPTM adapter in PowerFlex 6000T drives and how to use the adapter for network communication.

EtherNet/IP Network Devices User Manual, ENET-UM006

Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP network.

Ethernet Reference Manual, ENET-RM002

Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

System Security Design Guidelines Reference Manual, SECURE-RM001

Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and dispose of equipment.

Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Specifications, publication IC-TD002

Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.

Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides

Safety Guidelines for the Application, Installation, and Maintenance of Solid- general guidelines for the application, installation, and maintenance of solid-state control in

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 6000 product line. Contact your local Rockwell Automation sales representative to arrange commissioning.
Rockwell Automation support includes, but is not limited to: · quoting and managing product on-site startups · quoting and managing field modification projects · quoting and managing product training at Rockwell Automation facilities and on-site

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Preface
Notes:

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

1 Chapter
Before You Begin Tests, Maintenance, or Repairs

Product Advisories

Topic

Page

Product Advisories

Safety Considerations

Remove Power from the System

Commonly Used Tools

Fastener Torque Sequences

Torque Requirements

Read the information in this chapter before you begin tests, maintenance, or repairs on drive components.

IMPORTANT

Once the product is connected to a power supply, always verify that system power is not present before performing any work on the product. See safety-related practices that are contained in publication NFPA 70E, Standard for Electrical Safety in the Work Place.

Read the following precautions before you begin to test components, perform maintenance, or repair the drive.
Qualified Personnel
ATTENTION: Only qualified personnel familiar with PowerFlex 6000T products and associated machinery should plan or implement the installation, startup, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. ATTENTION: These tasks require persons skilled in this type of detailed work. Read and understand this manual thoroughly before commencing. Contact Rockwell Automation with any questions or for clarification.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 1 Before You Begin Tests, Maintenance, or Repairs
Personal Safety
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before servicing. ATTENTION: Potentially fatal voltages can result from improper usage of an oscilloscope and other test equipment. The oscilloscope chassis can be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high-voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope is used in the A minus B Quasi-differential mode and the oscilloscope chassis is grounded to an earth ground. ATTENTION: Always perform Power Lockout procedure before servicing equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury, or death. ATTENTION: Servicing energized Medium Voltage Motor Control Equipment can be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present.For countries following NEMA standards, refer to National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (Lockout/Tagout) and OSHA Electrical Safety Related Work Practices safety related work practices, including procedural requirements for lockout/tagout, and appropriate work practices, personnel qualifications and training requirements, where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.For countries following IEC standards, refer to local codes and regulations. 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 highvoltage detector that is properly rated for the line and motor voltages. All status indicator 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. ATTENTION: Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury, or death.
Product Safety
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when you install, test, service, or repair this assembly. Component damage can result if ESD control procedures are not followed.
Class 1 Light-emitting Diode Product
ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Safety Considerations

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

SHOCK HAZARD: Energized industrial control equipment can be dangerous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment. Hazardous voltages may exist in the drive cabinet even with the input circuit breaker in the off position. If it is necessary to work in the vicinity of energized equipment, the safety-related work practices that are outlined in Electrical Safety requirements for Employee Work places must be followed. Before attempting any work, verify that the system has been locked out and tested to have no potential.

Lockout and tagout the device feeding power to the input of the drive before performing any drive maintenance or component replacements. After the input device cabinet doors are opened, immediately test the outgoing power cables feeding the drive with a live-line tool (hot stick) while wearing highvoltage gloves. Repeat the live-line tool (hot stick) testing at the drive incoming line power cable connections to verify that medium voltage is not present. Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time. Only after the drive equipment has been verified as isolated and de-energized can subsequent work be performed. Even though the input to the drive may be open, it is still possible for hazardous voltage to be present.

Table 1 - Line-to-Ground Short-circuit Specifications

Attribute Line-to-Ground short-circuit current Incoming circuit breaker withstand current short time Ik Opening time Breaking time Inrush current

Value 31.5 kA 4 s 31.5 kA 40...60 ms 50...75 ms up to 12.5 p.u.

See national and local safety guidelines for detailed procedures on how to isolate the equipment from hazards safely.
ATTENTION: The national and local electrical codes outline provisions for safely installing and working on electrical equipment. Installation must comply with specifications regarding wire type, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

Remove Power from the System

Follow the appropriate procedures to remove power from the drive system.
WARNING: Remove power before you remove or make cable connections. When you remove or insert a cable connector with power applied, an electric arc can occur. An electric arc can cause personal injury or property damage in theses ways: · An electric arc can send an erroneous signal to system field devices, which
can cause unintended machine motion · An electric arc can cause an explosion in a hazardous environment Electric arcs cause excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance.
1. Turn off and lockout all input power, including any external power sources.
2. Wait 15 minutes.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 1 Before You Begin Tests, Maintenance, or Repairs
3. Measure the AC input and DC bus voltage to verify that there is no voltage present.

Commonly Used Tools

The tools that are listed in this section are required to maintain the PowerFlex 6000T drives. Only a subset of the tools is required for specific drive preventive maintenance work.

IMPORTANT

Care must be taken to be sure that tools and/or hardware components do not fall into open drive assemblies. Do not energize the drive unless all loose tools and/or hardware components have been removed from the drive assemblies and enclosure.

Tools required:
· 5 kV DC insulation resistance tester · Digital multimeter · Torque wrench · Portable computer and related software, data connectivity · Tool set (screwdriver, metric open-end wrench, metric socket wrench,
and so on) · Fast wrench · 10 kV electroscope (up to and including 10 kV) and ground protection
line (greater than 25 square feet) · Safety gloves that can withstand at least 17 kV · Vacuum cleaner with anti-static hose (provided by customers) · Anti-static cleaning cloth · Power cell lift cart (required for pull-out power cells)
Materials required:
· Torque seal (yellow), part number RU6048, or equivalent · Electrical joint compound, Alcoa EJC number 2, or equivalent · Shell number 7 aviation grease, part number 40025-198-01, or equivalent
Documents required:
· PowerFlex 6000T Drives Installation Instructions, publication 6000-IN100
· PowerFlex 6000T Drives Programming Manual, publication 6000-PM100
· Electrical and mechanical drawings of specific drive · List of spare parts for specific drive

Software Tools
Connected Components WorkbenchTM software is an application that can be used to upload and download parameter configuration and monitor system parameters.

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Chapter 1 Before You Begin Tests, Maintenance, or Repairs
Connected Components Workbench software version 12 or later, and the latest version of the PowerFlex drives device database files for Connected Components Workbench software, are required for use with PowerFlex 6000T products. For DeviceLogixTM, the profile in Connected Components Workbench software can be used to set up programs.
You can also use Studio 5000 Logix Designer® application version 21 or later, with Add-on Profile (AOP) for PowerFlex drives and SMCs (all Logix versions) version 5.07 or later.

Fastener Torque Sequences

ATTENTION: When mounting components to a drive heatsink, component fastener torque sequences and tolerances are crucial to component-to-heat sink heat dissipation. Components can be damaged if initial tightening procedure is not performed to specification.

The following illustrates initial and final tightening sequences for components that are fastened to a heatsink by using two, four, and six screws. Initial torque is 1/3 (33%) of final torque, except six-point mountings, which require 0.7 N·m (6 lb·in) initial torque. The numeric illustration labels are for your assistance. Drive components do not contain these labels.
Figure 1 - Two-point Mounting

Initial Sequence

Final Sequence

Figure 2 - Four-point Mounting

Initial Sequence

Final Sequence

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4 1
15

Chapter 1 Before You Begin Tests, Maintenance, or Repairs Figure 3 - Six-point Mounting

Torque Requirements

Initial Sequence Do not exceed 0.7 N·m (6 lb·in) on initial torque of all six screws.

Final Sequence

Proper tightening torque must be used for installation and wiring.

Table 2 - Torque Requirements

Thread Size
M4 M5 M6 M8 M10 M12 M14 M16 M20

Torque

Class 8.8

N·m

lb·ft

3.0

2.2

5.9

4.4

10.5

7.7

26.0

19.2

51.0

37.6

89.0

65.7

141.0

104.1

215.0

158.7

420.0

310.0

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

2 Chapter
Preventative and Predictive Maintenance

Topic

Page

Recommended Preventative Maintenance

Maintenance Schedule

Maintenance of Industrial Control Equipment

Physical Checks

General Tasks

Replacement Schedule

Upgrade Plan

Final Report

Predictive Maintenance

This chapter provides information on preventative maintenance for components that can affect the life and operational characteristics of PowerFlex 6000T drives.

Recommended Preventative Maintenance

The drive can experience reduced service life if operated outside of its design parameters. Verify that the operating environment is within specifications. Daily inspection and regular maintenance helps maximize the service life of the equipment.
This periodic preventative maintenance program includes the following primary tasks:
· A visual inspection of all drive components accessible from the front of the unit.
· Power supply voltage level checks · General cleaning and maintenance · Tightness checks on all accessible power connections

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Chapter 2 Preventative and Predictive Maintenance

Maintenance Schedule

The codes that are listed in Table 3 are used to identify the task that is associated with the components that are identified in the preventative maintenance schedule in Table 4.

Table 3 - Schedule Codes Explanation

Code I C M R
Rv RFB/R

Task Inspect Clean Maintain Replace
Review Refurbishment/Replacement

Description Inspect the component for signs of excessive accumulation of dust, dirt, or external damage. For example, inspect the filters/fan inlet screens for debris that can block the airflow path. Clean the components that can be reused, specifically the door-mounted air filters and fan inlet screens. This type of maintenance task can include an inductance test of line reactors/DC links, or a full test of an isolation transformer, and so on. This component has reached its mean operational life. Replace the component to decrease the chance of failure. It is likely that components can exceed the designed life in the drive, but component life is dependent on many factors such as usage and heat. A discussion with Rockwell Automation personnel is recommended to help determine whether any of the enhancements/changes made to the drive hardware and control could benefit the application. The parts can be refurbished at lower cost OR the parts can be replaced with new ones.

ATTENTION: Customers can replace components for the PowerFlex 6000T drives. However repairs must only be performed by qualified Rockwell Automation personnel.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Table 4 - Periodic Preventative Maintenance Schedule

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Drive Runtime (in hours from first operation commissioning date)

Maintenance Run Time (hours)

7,680 16,440 25,200 33,960 42,720 51,480 60,240 69,000 77,760 86,520 95,280 104,040 112,800 121,560 130,320 139,080 147,840 156,600 165,360 174,120

Maintenance Number 0 1

10 11

Component Component

Location

Category

Component/Item

Door-mounted Air Filters C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R

Isolation Transformer Cabinet

Air-cooling system Top-mounted Cooling Fans
Integral Magnetics Isolation Transformer

Power Cell Cabinet

LV Control

Voltage Sensing Board

Door-mounted Air Filters C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R C / R

Air-cooling system Top-mounted Cooling Exhaust Fans

Power Cell

Electrolytic Capacitors(1)

Misc.

HECS

Misc.

AC/DC Power Supplies

UPS

UPS(2)

Control Pod Printed Air-cooling system Circuit Board Fans

Door Fans

Control Cabinet

Control Pod

LV Control

Enhanced HIM LV Control Relays

LV Control Circuit Breakers

Temperature Sensing

Temperature Sensors

LV Component Terminal & Plug-in Connections

Medium Voltage Cable

All

Connections

Transformer Secondary Winding Connections

Power Cell Input and Output Power Connections

Enhancements

General

Operational Conditions Spare Parts

Filter Cabinet Fans

Firmware Hardware
Parameters / Variables
Inventory Needs Top-mounted Cooling Fans

Rv --

Rv Rv --

Rv --

Rv I

(1) Based on full load/full speed operation at 8700 hours per year at 30 °C (86 °F) ambient temperature. For higher ambient temperatures the replacement should be done sooner, contact factory for details. (2) Fully discharge and recharge the UPS batteries every 6 months, to extend battery life.

Chapter 2 Preventative and Predictive Maintenance

Chapter 2 Preventative and Predictive Maintenance
Maintenance of Industrial Control Equipment

ATTENTION: Performing service on energized Industrial Control Equipment can be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present. See National Fire Protection Association Standard No. NFPA 70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (lockout/tagout) and OSHA Electrical Safety Related Work Practices for safety-related work practices. These publications include procedural requirements for lockout/tagout, and appropriate work practices, personnel qualifications, and required training where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.

Daily Inspection
Check the following items during normal operation of the drive: · abnormal noise or vibration in the drive or motor · abnormal temperature in the drive or motor · ambient temperature in the control room above nominal · accumulation of dust or particulate on control room floor or surfaces · abnormal load current above nominal

Clean the Air Filters
PowerFlex 6000T drives require a continuous, smooth airflow to cool the power components and the isolation transformer to deliver stable and reliable operation of the equipment. Obstruction of the air filters is the main cause of poor cooling airflow.
The drive uses a number of cooling fans that are installed at the top of the cabinet to deliver sufficient airflow to cool the power components and isolation transformer. When the equipment is running for some time, the air filters accumulate dust and obstructs the airflow. Failure to clean the air filters regularly may result in insufficient cooling airflow, which may cause some parts of the drive to send an overtemperature alarm or even trip(a):
· Transformer overtemperature alarm / trip · Power cell overtemperature trip
Immediately after receiving the overtemperature warning, you should plan to replace or clean the air filters. At this point there should be a few days or weeks before the air filters fail, but this depends on the amount of dust in the environment.

(a) Obstruction of the air filters is not the only cause of over temperature alarm and trip.

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Chapter 2 Preventative and Predictive Maintenance
Regular Maintenance Intervals
The periodic maintenance requirements are summarized in the preventative maintenance schedule on page 19 as a guideline. Detailed procedures referred to in that table are described the following chapters:
· Chapter 3, Component Inspection and Test Procedures on page 37 · Chapter 4, LV Control Cabinet on page 49 · Chapter 5, Isolation Transformer Cabinet on page 71 · Chapter 6, Power Cell Cabinet on page 77 · Chapter 7, Inspect Connections on page 83
Medium Voltage Motor control equipment should be inspected periodically. Inspection intervals should be based on environmental and operating conditions and adjusted as indicated by experience. An initial comprehensive inspection, within three to four months after installation, is suggested. See the following standards for general guidelines for setting-up a periodic maintenance program. For countries following NEMA standards, refer to National Electrical Manufacturers Association (NEMA) Standard No. ICS 1.1 (Safety Guidelines for the Application, Installation, and Maintenance of SolidSate Control) for MV Drives and ICS 1.3 (Preventive Maintenance of Industrial Control and Systems Equipment) for MV Controllers. For countries following IEC standards, refer to IEC 61800-5-1 Sec. 6.5 for MV Drives and IEC 60470 Sec. 10, IEC 62271-1 Sec. 10.4 for MV Controllers.
The maintenance work for PowerFlex 6000T drives should normally be performed every time the drive completes one year of runtime operation. This work is carried out by Rockwell Automation medium voltage drive customers. The customer may extend the maintenance interval appropriately according to the installation conditions and operating conditions of the drive. Determine the maintenance cycle and component/items according to the Preventative Maintenance alerts (page 26) for the drive. Check parameter 0:1064 [Maint Run Time] to verify the drive runtime hours and follow the guideline for that respective period of maintenance (Table 4). After maintenance is performed, acknowledge the relevant maintenance alerts.
Figure 4 - Maintenance Acknowledgment Parameters

The purpose of performing regular maintenance is to locate potential failures and take preventive measures before a real failure occurs. Therefore it is recommended to spend about 16 hours to perform maintenance to verify that the drive is functioning reliably. This can greatly reduce the risk of unplanned downtime.

Before starting preventative maintenance, you should record some important information, including:
· Report of the previous preventive maintenance (if any) · Get motor parameters and applications

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Chapter 2 Preventative and Predictive Maintenance
· Check the current settings of the drive · Check the fault/warning queue · Save parameters to a recipe file(a) or parameter record · Record the board part number, serial number, and edition(b)
IMPORTANT The parameter values are tied to the Nonvolatile Memory (NVM) of the Motor Control Board (MCB), and hence constrained by the lifespan of the MCB.
If inspection reveals that dust, dirt, moisture, or other contamination has reached the control equipment, the cause must be eliminated. This could indicate unsealed enclosure openings (conduit or other) or incorrect operating procedures. Replace any damaged or embrittled seals, and repair or replace any other damaged or malfunctioning parts. Replace dirty, wet, or contaminated control devices unless they can be cleaned effectively by vacuuming or wiping.
IMPORTANT Compressed air is not recommended for cleaning because it may displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.

Physical Checks

Power Connection Inspection
· Inspect PowerFlex 6000T drive, input/output/bypass sections, and all associated drive components for loose power cable connections and ground cable connections: torque them based on the required torque specifications.
· Inspect the bus bars and check for any signs of overheating / discoloration and tighten the bus connections to the required torque specifications.
· Clean all cables and bus bars that exhibit dust build-up.
· The torques of incoming / outgoing cable screws of the power unit shall be check if they are in the specified range.
· Use torque sealer on all connections. Conduct integrity checks on the signal ground and safety grounds.

(a) For devices with recipe function options. (b) Records are required only if spare parts replacement is replaced after preventive
maintenance activities.

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Chapter 2 Preventative and Predictive Maintenance
Physical Inspection
· Check for any visual/physical evidence of damage or degradation of components in the low voltage compartments.
- This includes relays, contactors, timers, terminal connectors, circuit breakers, ribbon cables, control wires, optional UPS, AC/DC power supplies, and so on. Causes could be corrosion, excessive temperature, or contamination.
· Check for any visual/physical evidence of damage or degradation of components in the medium voltage compartments (cables, contactors, circuit breakers, isolation disconnecting blades, power units, and so on).
- This includes main cooling fan, power devices, heatsinks, circuit boards, insulators, cables, capacitors, current transformers, potential transformers, fuses, wiring, and so on; Causes could be corrosion, excessive temperature, or contamination.
· Clean all contaminated components using a vacuum cleaner (DO NOT use a blower), and wipe clean components where appropriate.
· Conduct the physical inspection and verification for the proper operation of the contactor/isolator interlocks, and door interlocks.
· Conduct the physical inspection and verification for the proper operation of the key interlocks.
· Conduct the cleaning of the fans and verify that the ventilation passages are not blocked and the impellers are freely rotating without any obstruction.
· Conduct the insulation resistance (IR) test on the transformer, motor, and associated cabling.
· Check all bolts for fastening and adjust them as necessary.
· Check all labels for readability. If any labels are unreadable, damaged, or missing, contact Rockwell Automation for replacements.

Medium Voltage Testing
Medium voltage insulation resistance (IR) or dielectric withstanding voltage tests should not be used to check solid-state control equipment. When performing IR tests on electrical equipment, such as transformers or motors, solid-state devices must be bypassed before performing the test. Even though no damage may be readily apparent after an IR test, the solid-state devices are degraded and repeated application of high voltage can lead to failure.

Maintenance after a Fault Condition

Opening of the short circuit protective device (such as fuses or circuit breakers) in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload. Such conditions can cause damage to medium voltage motor control equipment. Before restoring power, the fault condition must be corrected and any necessary repairs or replacements must be made to restore the medium voltage motor control equipment to good working order. See NEMA Standards Publication No. ICS2, Part ICS2-302 for procedures. Use only replacement parts and devices that are recommended by Rockwell Automation to maintain the integrity of the equipment. Verify that the parts are properly matched to the model, series, and revision level of the equipment. After maintenance or repair of the equipment,

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 2 Preventative and Predictive Maintenance
always test the control system for proper functioning under controlled conditions (that avoid hazards in the event of a control malfunction). For additional information, see NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT, published by the National Electrical Manufacturers Association, and NFPA70B, ELECTRICAL EQUIPMENT MAINTENANCE, published by the National Fire Protection Association.

General Tasks

Review Firmware and Hardware
Verify the firmware revision in the device definition page on the integrated touch screen display (eHIM), and in the device info page or with parameters in Connected Components Workbench software.
Contact Rockwell Automation to determine whether there are any enhancements or changes that are made to the Drive Hardware and Control that would be valuable to the application.
Verify that the integrated touch screen display is operational. Check the status indicators on the control unit in the LV Control cabinet register as normal.
ATTENTION: Verify that there is no power to the drive and wear an antistatic wristband.
Remove any dirt or foreign material. Wipe components with an anti-static cloth, where applicable.

Inspect/Review Spare Parts
Inspect and review the spare parts that are shipped with the drive (see the packing list if applicable). Check for signs of damage, dirt, or foreign material.
ATTENTION: Some circuit boards can be destroyed by static charges. Use of damaged circuit boards may also damage related components. Use a grounding wriststrap when handling sensitive circuit boards. ATTENTION: Due to the characteristics of DC capacitors, rejuvenation is necessary on power cell DC capacitors if the power cell has not been energized in the last one year. Therefore the spare power cells must be energized annually.

Professional Maintenance Service
Rockwell Automation also offers professional maintenance service that is provided by the Rockwell Automation field support engineer, contact your local Rockwell Automation sales person for more information.

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Chapter 2 Preventative and Predictive Maintenance

Miscellaneous Preventive Maintenance Work
· Communicate with the customer regarding problems found during the preventive maintenance process.
· Raise the problems found during the maintenance process.
· Provide relevant solutions and record them in the final report.
· Provide advice on operation and maintenance of the drive to the customer's maintenance personnel.
· Provide information about requirements for safe operation of the drive and safety instructions.
· Provide information about operating conditions (environment, temperature, and so on) required for stable operation of the drive.
· Obtain spare parts information from the customer to determine whether they have sufficient stock. Recommend the customer to purchase additional spare parts if necessary.

For more information, contact PF6000TechnicalSupport@ra.rockwell.com.

Table 5 - Estimated Time Required for Maintenance Work

Activity
Daily maintenance Annual maintenance Initial collection of information Visual inspection and cleaning · Electrical connection · Ground · Control cabinet · Transformer cabinet · Power cabinet · Inside the power cell · Fan · Door and mechanical parts · Insulation Low voltage check · Control system · Cooling fan · Parameters Final inspection before commissioning · Final inspection · Medium voltage test · Run to maximum load Miscellaneous work · Survey · Informal training · Spare parts analysis Final report

Time Required(1) 0.5 hours for each air filter 0.5 hours
6.0 hours
2.0 hours 2.0 hours 2.0 hours 4.0 hours

(1) These inspection items and time are only estimated. Depends on the situation when conducting preventive maintenance and the operation of the drive.

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Chapter 2 Preventative and Predictive Maintenance

Replacement Schedule

PowerFlex 6000T drives require periodic replacement of the cooling fans and power cells. "Replacement counters" provide regular alerts for the replacement of the components, depending on the operation runtime hours of the component.

There are four replacement counters: · Power Cells · Cooling Exhaust Fans · Control Pod Printed Circuit Board Fans · Door Fans
Once you receive the alert for the replacement of a component, follow this process to act on the alert and acknowledge that you have performed the required maintenance action.
1. Check the alert and locate the component on the drive. For information on how to locate and identify the component, see page 27.

2. Check the replacement schedule (Table 6) to replace the component. 3. Acknowledge the alert for the component.
· For door fans and control pod fans, see page 28. · For cooling fans, see page 29. · For power cells, see page 30.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Locate Components

Chapter 2 Preventative and Predictive Maintenance

Check the label inside the power cell door panel for a location map of the power cells, as shown in the following example. The power cell layout depends on the drive frame type.
Figure 5 - Power Cell Identification Label Example, A-frame

Figure 6 - Power Cell Identification Label Example, B-frame

The fans are also labeled with their number for easy identification as shown in the following example.
Figure 7 - Fan Number Label Example

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Chapter 2 Preventative and Predictive Maintenance
Acknowledge Maintenance Alerts
After maintenance is performed, acknowledge the relevant maintenance alerts.
Door Fans and Control Pod Fans
Locate the respective parameters for the door fans or control pod fans.
Figure 8 - Door Fans and Control Pod Fans Parameters

Acknowledge the alert and that you have replaced the component.
Figure 9 - Acknowledge Door Fans and Control Pod Fans Alert

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Cooling Fans

Chapter 2 Preventative and Predictive Maintenance

Locate the respective parameters for the cooling fans.
Figure 10 - Cooling Fans Parameters

Select the cabinet according to the component number of the fan. For example, if the component is Fan 32, select the Isolation Transformer cabinet.
Figure 11 - Select Fan Location

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Chapter 2 Preventative and Predictive Maintenance
Acknowledge the alert and that you have replaced the component.
Figure 12 - Acknowledge Cooling Fans Alert
Power Cells
Locate the respective parameters for the power cells.
Figure 13 - Power Cell Fans Parameters
Acknowledge the alert and that you have replaced the component.
Figure 14 - Acknowledge Power Cell Fans Alert

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Table 6 - Component Replacement Schedule

Component Location Isolation Transformer Cabinet

Component Category Fans

Power Cell

Power Cell Cabinet
Fans

Filter Cabinet Fans

Component Run Time (hours)

Component/Item

Top-mounted Cooling Exhaust Fans · Electrolytic
Capacitors · IGBT, IGBT (Bypass) · Diode Top-mounted Cooling Exhaust Fans

Control Pod Printed Circuit Board Fans

Door Fans

Top-mounted Cooling Fans

Number of Runtime Hours Since Component Replacement
8,759 17,519 26,279 35,039 43,799 52,559 61,319 70,079 78,839 87,599 96,359 105,119 113,879 122,639 131,399 140,159 148,919 157,679 166,439 175,199

Rplc Fanxx 90d
Rplc Fanxx 90d Rplc Fanxx 90d Rplc Fanxx 90d Rplc Fanxx 90d

Rplc PCxx 90d

Chapter 2 Preventative and Predictive Maintenance

Upgrade Plan

If the drive firmware is upgraded from an earlier revision to 8.001 or later, the maintenance and replacement counters are available upon upgrade. The values in the earlier counters for the drive and components are used to set the initial values in the new counters.

If the counters were reset prior to the firmware upgrade, the periodicity of the
alerts will not be accurate. In this scenario, use the following guidelines:
· For drive maintenance alerts when referencing the Periodic Preventative Maintenance schedule (Table 4), consider the "maintenance number" as the approximate number of years from drive commissioning for the first alert and so forth.
· For replacement of critical parts when referencing the Component Replacement schedule (Table 6), consider the alerts only after a new component is installed and the runtime counter for that component is reset.

Final Report

Record a complete and detailed report on all steps in the Preventative Maintenance procedures to identify changes.
Record a detailed description of all adjustments and measurements that were taken during the process (interlock adjustments, loose connections, voltage readings, insulation resistance (IR) test results, parameters, and so on).
Acknowledge the maintenance alert in Connected Components Workbench software or Studio 5000 Logix Designer application.
Figure 15 - Maintenance Alert

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Predictive Maintenance

Prepare Final Report

Chapter 2 Preventative and Predictive Maintenance

The Rockwell Automation service engineer will provide a maintenance report to the customer based on the outcome of the maintenance work. All steps in the preventative maintenance process are recorded in detail in the report and identifies changes that are made.
The final report includes:
· A complete copy of the Preventative Maintenance checklist. · Problems that are found during the investigation process and
rectification recommendations. · Adjustments and measurements during maintenance (including
mechanical adjustment, connection status, voltage reading, vibration test results, parameters, and so on).
This information will be sent to the PowerFlex 6000 Technical Support and Product Support for the latest on-site information for future maintenance and technical support.

PowerFlex 6000T drives with TotalFORCE® technology include patented algorithms developed from extensive component life testing. They measure actual operating conditions, characterize how the drive is running, and make a prediction of remaining usable life.
90 days advance alarms are set to alert when a drive should be serviced and components replaced, before it leads to a downtime event.
These onboard models assess conditions that impact the longevity of critical drive and system fans to help ensure the timely service or replacement.
If the drive comes with firmware revision 8.001 or later, a predictive maintenance model is built-in to the firmware (as standard design, unless modified) to monitor the following components:
· Cooling Exhaust Fans · Control Pod Printed Circuit Board Fans · Door Fans
The remaining life of the fans can be viewed in the Predictive Maintenance page in the Connected Components Workbench software and Studio 5000 Logix Designer application. You can view the different fans based on type and location.
The life of the fans decreases with increased usage. An alert is generated when a fan reaches the equivalent of 90 runtime days of life remaining, at the prescribed ambient temperature.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 2 Preventative and Predictive Maintenance Figure 16 - View Fan Alarms
When you receive an alert, perform the following procedure to replace the component:
1. Check the alert and locate the components on the drive.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 2 Preventative and Predictive Maintenance
Record the location of the fans that need to be replaced.

You can also see the Hardware Drawings for the location of the fans.
2. Contact Rockwell Automation Customer Support and Maintenance. Provide your Rockwell Automation Drive Sales Order/Serial Number to verify the type of fans to purchase for replacement.
3. Procure and replace the fans. 4. Reset the counter for the component to start the counter for the
remaining life of the new fan.
If the drive firmware is upgraded from an earlier revision to 8.001 or later, there is an option available to upgrade the Predictive Maintenance offering. See Upgrade Kit on page 35 for instructions on how to purchase the upgrade.
Upgrade Kit
To purchase an upgrade kit for your drive, see the following procedure:
1. Verify your Rockwell Automation Drive Order or Serial Number. 2. Contact your Sales or Customer Support Representative to provide order
information and obtain pricing. 3. Once confirmed by a Rockwell Automation Expert, a Field Support
Engineer from Rockwell Automation installs the upgrade bundle for your drive, which includes the following: · New fans (Exhaust, Door, Control Pod) Quantity and details as per
drive configuration · Temperature sensor assembly Sensor housing and mounting · Component labels To identify exhaust fans · Other accessories POINT I/OTM modules, power supplies, and so on · Update drive hardware configuration file (DHCF) with Predictive
Maintenance enabled

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 2 Preventative and Predictive Maintenance
Notes:

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

3 Chapter
Component Inspection and Test Procedures

Topic

Page

Component Inspection and Maintenance

Replace/Clean Door-mounted Air Filters

Inspect Top Mounted Cooling Fans

Replace Sensors

Inspect/Replace Door Position Limit Switch

Component Fuse Tests

This chapter provides details on how to inspect and test the major components of the drive and includes recommendations for repairs. Review the Troubleshooting chapter in the PowerFlex 6000T Drives Programming Manual, publication 6000-PM100, for information on conditions that can cause a fault or alarm and how to troubleshoot these conditions.

Component Inspection and Maintenance

Visually inspect the door filters and major components on the control pod, power cells, and components for dirt and damage. Dirt build-up on some components can lead to component damage or failure. Avoid damage to the product by replacing components and/or circuit boards with burn marks, breakage, or foil delamination. Follow these inspection and maintenance instructions along with the Recommended Preventative Maintenance information on page 17.
1. Review the Product Advisories on page 11.
2. Remove power from the system. See Remove Power from the System on page 13.
3. Remove the filters from the enclosure doors and inspect for dirt buildup or blockage. Clean or replace all filters as necessary.

See the procedures on page 38 for removal instructions.
4. Inspect the enclosure fan assemblies for blockage and verify free rotation. Clean or replace as necessary.

See the procedures on page 40 for removal instructions:
5. Inspect the door position limit switches for obvious signs of damage, dust, or foreign material. Remove any dirt or foreign material. Wipe components with an anti-static cloth, where applicable. Check that the aviation plug has a hand-tight connection.

See the procedures on page 47 for removal instructions:

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Chapter 3 Component Inspection and Test Procedures
6. Remove the cover from the control pod and inspect all visible major components, including: circuit boards, wire harnesses, fiber-optic cables, and connectors. If any components show evidence of burn marks or breakage, replace the damaged components without further testing.
7. Visibly inspect all visible circuit boards, wire harnesses, fiber-optic cables, and connectors through-out the system. Replace any of these circuit boards, wire harnesses, or fiber-optic cables without further testing if they show evidence of burn marks, breakage, or foil delamination. See the appropriate removal and replacement procedures for the affected module/component.

Replace/Clean Doormounted Air Filters

Periodically remove and clean, or remove and replace, the air filters according to the Periodic Preventative Maintenance schedule (Table 4). The frequency with which you renew the filters depends on the cleanliness of the available cooling air.
There are two types of design for the air filters. The quantity of air filters on the cabinet door are different, depending on the drive ratings. However, the method to remove or clean the air filters is the same. The screens may be replaced while the drive is operating, but the procedure is easier to perform while the drive is shut down.
If the drive is running, you must replace the filter as soon as possible to prevent foreign material from entering into the drive.

Recommended Cleaning Method of Filters
· Vacuum Cleaner A vacuum cleaner on the inlet side of the filter will remove accumulated dust and dirt.
· Blow with Compressed Air point compressed air nozzle in opposite direction of operating airflow (Blow from exhaust side toward intake side)
· Cold Water Rinse Under normal conditions the foam media used in the filters, require no oily adhesives. Collected dirt is washed away quickly and easily using just a standard hose nozzle with plain water.
ATTENTION: The filter must be completely dry before reinstalling.
· Immersion in Warm Soapy Water Where stubborn air-borne dirt is present, the filter may be dipped in a solution of warm water and mild detergent. Rinse in clear clean water, let stand until completely dry and free of moisture.
Use only Rockwell Automation-supplied or -approved replacement filters. Replace the filters in the reverse order of its removal. Check that there are no openings to allow foreign matter to enter the drive.

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Chapter 3 Component Inspection and Test Procedures
Replace Filter for A-frame Drives
1. Unlatch the thumbscrews and remove the air filter frame. 2. Remove and clean the cotton filter, or replace with a new cotton filter. IMPORTANT When removing the filter, prevent accumulated dirt on the inlet side of
the filter from being sucked into the drive. It may be difficult to remove the filter material without tearing due to the suction at the air inlet. 3. Close the air filter frame and tighten thumbscrews.
Figure 17 - Replace the Filter, A-frame

Thumbscrew

Air inlet frame

Cotton filter

Replace Filter for B-frame Drives
1. Unlatch and open the cabinet filter door more than 90°.
Figure 18 - Replace the Filter, B-frame

Screw Air inlet frame

Cotton filter
2. Remove the screens by pulling up out of the door. IMPORTANT When removing the filter, prevent accumulated dirt on the inlet side of
the filter from being sucked into the drive. It may be difficult to remove the filter material without tearing due to the suction at the air inlet. 3. Reinstall the cleaned or new air filter using reverse order of removal. Verify that the door is fully closed and locked.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 3 Component Inspection and Test Procedures

Inspect Top Mounted Cooling Fans

Inspect fans that are used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely.

The fans are supplied with 380/460V AC power, which is fed by the low voltage taps of the Isolation Transformer. The control voltage is 220V. The voltage of the fan can be measured through a small door on the Isolation Transformer.

ATTENTION: Exercise caution when measuring the voltage of the fans.

Apply power momentarily to check operation.
· A-frame Fans rotate when medium voltage is applied. · B-frame Transformer fans rotate when medium voltage is applied.
Power cell fans do not rotate until you run the drive.
If unit does not operate, check and replace wiring, fuse, or fan motor as appropriate. Clean or change air filters as recommended in this manual. Verify that the aviation plug has a proper hand-tight connection. Verify that the ventilation passages are not blocked and the impellers can rotate freely without any obstruction.

Replace Top Mounted Cooling Fans
There are two types of top fan housings. The top fan housing consists of a motor and impeller assembly. To replace the fan, it is necessary to remove the fan housing lid.
ATTENTION: Fan replacement requires working at a significant height from the floor. Complete this procedure on a safe, stable platform.
ATTENTION: Always perform Power Lockout procedure before servicing equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury, or death.
ATTENTION: Medium Voltage must be turned off when replacing the main cooling fans.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Replace EC400 Fan Unit

Chapter 3 Component Inspection and Test Procedures

To replace an EC400 fan unit follow these instructions: 1. Remove and retain nine M6 x 16 hexagon socket screws around the front side of the fan unit.
Mesh screen frame for IP32 or louver for IP42
M6 x 16 socket screw (9)

2. Remove and retain the mesh screen frame for IP31, or louver for IP42. 3. Disconnect the two cables from the fan connectors.

Fan connectors

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Chapter 3 Component Inspection and Test Procedures
4. Remove and retain eight M6 x 16 hexagon socket screws from the top plate and replace the fan unit.
M6 x 16 socket screw (8)

5. Install hardware in reverse order of removal.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Replace EC500 Fan Unit

Chapter 3 Component Inspection and Test Procedures

To replace an EC500 fan, follow these instructions: 1. Remove and retain nine M6 x 16 hexagon socket screws around the front side of the fan unit.
Mesh screen frame for IP32 or louver for IP42 M6 x 16 socket screw (9)
Noise barrier hood

2. Remove and retain the noise barrier hood (if present) and mesh screen frame for IP31, or louver for IP42.
3. Disconnect the two cables from the fan connectors.
Fan connectors

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Chapter 3 Component Inspection and Test Procedures
4. Remove and retain eight M6 x 16 hexagon socket screws from the top plate and replace the fan unit.
M6 x 16 socket screw (8)

5. Install hardware in reverse order of removal.
Fan Balance
Fan impellers are statically and dynamically balanced within acceptable tolerances at the factory. Damage in shipping or from incorrect handling or installation may upset the balance. An improperly balanced impeller can lead to excessive vibration causing undue wear on the entire unit.
If vibration is excessive, shut down the fan and determine the cause. Common causes of excessive vibration include:
· Drive support structure not sufficiently rigid or level · Loose mounting bolts · Loose impeller or bushing

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Replace Sensors

Chapter 3 Component Inspection and Test Procedures
Follow these steps to replace the sensors in the LV Control cabinet. 1. Observe the routing of the wires in the cabinet and the connection points in the LV Control cabinet.
Figure 19 - Sensor Connection Point Example

Consider taking pictures of the connection points and wire routes before removing the existing sensors. Electrical connections in the LV tub are also presented in the electrical diagrams.
2. Disconnect the existing sensor from the cabinet structure by removing the three screws.

Screw mounting point

Sensor wire

3. Disconnect the sensor wire along the path.

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Chapter 3 Component Inspection and Test Procedures
A-frame drives have the sensor wired directly into the LV Control cabinet section while B-frame drives that require a shipping split have a shipping split connector. Rockwell Automation supplies the connector for the shipping split in the replacement kit.
Figure 20 - Shipping Split Connector Example

4. Install the new sensor in the same position following the same wire routing and connection points like the original installation.
WARNING: It is important to follow the original wire routing in the MV sections to preserve the electrical clearances from the MV components. Wire ties are needed to secure the wire properly along the path.
Figure 21 - Example of a Wire Exit Point in the Power Cell Cabinet, A-frame

Opening for sensor wire exit point

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Inspect/Replace Door Position Limit Switch

Chapter 3 Component Inspection and Test Procedures
ATTENTION: Verify that the input circuit breaker feeding the drive is open. Lockout and tagout the input circuit breaker before performing any work on the drive or bypass units.
Follow these steps to replace the door position limit switch. 1. Open the drive cabinet door. 2. Disconnect the aviation plug from the back of the limit switch. 3. For A-frame drives remove two M4 x 30 bolts from the mounting bracket. For B-frame drives remove two M4 x 35 bolts and hardware from the mounting bracket. 4. Install the new limit switch in reverse order of removal.
Figure 22 - Replace Door Position Limit Switch, A-frame

Mounting bracket Limit Switch Aviation plug
Figure 23 - Replace Door Position Limit Switch, B-frame

M4 x 30 bolt

Mounting bracket

M4 x 35 bolt Limit Switch

Aviation plug

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 3 Component Inspection and Test Procedures

Component Fuse Tests

Follow these steps to check the fuses for other components/modules.
1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on
page 13. 3. Continuity test the fuse or fuses. 4. Replace a fuse as necessary.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

LV Control Cabinet

4 Chapter

Topic

Page

Control Pod Overview

Control Pod Cover Removal

Fiber Transceiver Circuit Board Replacement

Main Control Board Replacement

Backplane Circuit Board Replacement

Power I/O Board Replacement

Smart Fiber Interface Circuit Board Replacement

I/O Option Cards Settings

Control Pod Fan Assembly Replacement

Control Pod Replacement

Inspect the Integrated Touch Screen Display

Replace the Integrated Touch Screen Display

This chapter provides detailed instructions for how to remove and replace control cabinet and control pod components.

For more information about:
· features of the control pod, see the PowerFlex Drives with TotalFORCE Control Built-in EtherNet/IP Adapter User Manual, publication 750COM-UM009.
· configuring the control pod, see the PowerFlex 750-series AC Drives with TotalFORCE Control Quick Start, publication 750-QS100.

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Control Pod Overview

The following graphic shows the components inside the control pod.
Figure 24 - Control Pod Components

Bucket Transceiver card

I/O option module (2 modules)

Power I/O Board (PIOB) Transceiver cards (8)

Main Control Board (MCB)
Spare option slots (3) POD MV Smart Fiber Interface Board (SFIB)

Control Pod Cover Removal You must remove the control pod cover to access other components inside
the pod.
Follow these steps to remove the control pod cover.
1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on
page 13. 3. Open the control bay enclosure door. 4. Loosen, but do not remove, the bottom two M4 x 8 mm slotted-torx
screws that secure the cover to the assembly.

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Chapter 4 LV Control Cabinet

5. Remove the top two M4 x 8 mm slotted-torx screws that secure the cover to the assembly and remove the cover.

M4 x 8 mm

4, 5

T20 or F - 6.4 mm (0.25 in.)

2.6 N·m (23 lb·in)

The Control Pod is shown separated from the Control/Input Bay to clarify the instructions only.
6. To install the control pod cover, perform the operation in the reverse order of removal.

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Chapter 4 LV Control Cabinet
Fiber Transceiver Circuit Board Replacement

Replace a fiber transceiver circuit board with kit part number PN-579788.

Follow these steps to replace the fiber transceiver circuit board.

1. Review the Product Advisories on page 11.

2. Remove power from the system. See Remove Power from the System on page 13.

3. Open the control bay enclosure door.

4. Remove the control pod cover. See Control Pod Cover Removal on page 50.

5. Remove the fiber-optic cables for the corresponding fiber transceiver circuit board from the cable management devices in the control pod.

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50

mm (2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases as inside bend radius is decreased.

50 mm (2 in.)

When all or many of the fiber-optic ports are used, it is easier to remove the fiber transceiver circuit boards from the pod before removing the fiberoptic cables. However, it is possible to remove the fiber-optic cables without removing the boards. This procedure assumes that all fiber-optic ports are used.
PCx8

PCx0 PCx1 PCx2 PCx3 PCx4 PCx5 PCx6 PCx7

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6. Loosen the two captive thumbscrews that secure the board and fiberoptic cables to the chassis and remove the board and cables.

T15 or F - 5 mm (0.19 in.)

0.45 N·m (4 lb·in)

Main Control Board Replacement

7. For each fiber-optic cable, remove the cable from the transceiver. 8. To install the fiber transceiver circuit board, perform the operation in the
reverse order of removal.
Replace a main control board (MCB) with kit part number PN-579785.
Follow these steps to replace the main control board. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on page 50.

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Chapter 4 LV Control Cabinet

5. Remove the DPITM cable from the port on the main control board if present.
5

6. Disconnect any Ethernet cables from the ports on the bottom of the main control board.
7. Disconnect the plug-in terminal block (TB 1) on the bottom of the main control board.

8. Disconnect the plug-in terminal block P9 on the bottom of the main control board.
9. Disconnect the pod fan connector from the main control board.

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10. Loosen the three captive thumbscrews that secure the main control board to the pod chassis and remove the board.
10

HIM bezel not shown for clarity only.

T15 or F - 5 mm (0.19 in.)

0.45 N·m (4 lb·in)

11. To install the main control board, perform the operation in the reverse order of removal. Check that the jumpers and switches are set the same as the board removed.

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Chapter 4 LV Control Cabinet

Set Jumpers on MCB

Verify that the jumpers on the new main control board are set according to the following:
· Jumper P7 (MCB Input Disable) Removed · Jumper P8 (MCB Safety Enable) Installed
Figure 25 - Set MCB Jumpers

IP address DIP switches

Jumper P8

Jumper P7

Set the IP Address

Set the IP address for the drive using the DIP switches on the main control board. (Figure 25). The main control board provides dual Ethernet ports and supports the Device Level Ring (DLR) network topology. For more information on how to configure the drive to use in a DLR network, see the PowerFlex Drives with TotalFORCE Control Built-in EtherNet/IP Adapter User Manual, publication 750COM-UM009.

Table 7 - IP Address DIP Switches

Possible Settings 000, 255...887, 889...999 (1) 001...254 888

Description Use the value of parameter 0:300 [Net Addr Sel]: · 1 = Parameters
0:302...0:305 [IP Addr Cfg 1...4] 0:306...0:309 [Subnet Cfg 1...4] 0:310...0:313 [Gateway Cfg 1...4] · 2 = BOOTP · 3 = DHCP Use the value set by the DIP switches (192.168.1.xxx, where xxx = DIP switch settings). Reset the IP address function to factory defaults. This setting also resets most parameters to factory defaults on the drive. Afterwards, the drive must be powered down, the switches set to a value other than 888, and then the drive must be powered up again to accept the new IP address.

(1) 999 is the default setting and disables the DIP switches.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Backplane Circuit Board Replacement

Chapter 4 LV Control Cabinet

Replace a control pod backplane circuit board with kit catalog number SK-RM-PODBP1.

Follow these steps to replace the backplane circuit board.

1. Review the Product Advisories on page 11.
2. Remove power from the system. See Remove Power from the System on page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page 50.
5. Remove the main control circuit board. See Main Control Board Replacement on page 53.
6. Remove the power cable from the backplane that goes to the Power I/O Board.
7. Disconnect and remove any option modules from the backplane circuit boards.
8. Remove the two M4 x 8 mm torx screws that secure the backplane circuit board to the pod chassis and remove the board.

M4 x 8 mm

T20 or F - 5 mm (0.19 in.)

2.6 N·m (23 lb·in)

9. To install the backplane circuit board, perform the operation in the reverse order of removal.

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Chapter 4 LV Control Cabinet
Power I/O Board Replacement

Replace a Power I/O board (PIOB) with kit part number PN-579786.
Follow these steps to replace the power I/O board. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on page 50. 5. Disconnect all connectors from the power I/O board.
=

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Chapter 4 LV Control Cabinet

6. Loosen the three captive thumbscrews and remove the two loose screws that secure the power I/O board to the smart fiber interface circuit board.

M4 x 8 mm

T20 or F - 5 mm (0.19 in.)

2.6 N·m (23 lb·in)

7. To install the power I/O board, perform the operation in the reverse order of removal.

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Chapter 4 LV Control Cabinet

Set Jumpers on PIOB
Verify that the jumpers on the new power I/O board are set according to the following:
· Jumper P9 Installed · HECS Jumpers Follow the setting on the previous power I/O board. If
you encounter any issues, contact Rockwell Automation Customer Support and Maintenance for assistance.
Figure 26 - Set PIOB Jumpers

HECS jumpers

Jumper P9

Smart Fiber Interface Circuit Board Replacement

Replace a Smart Fiber interface circuit board with kit part number PN-579787.
Follow these steps to replace the Smart Fiber interface circuit board.
1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on
page 13. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on
page 50. 5. Disconnect connector P14 from connector J14 on the Smart Fiber
interface circuit board.

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Chapter 4 LV Control Cabinet
6. Disconnect the two fan power supply connectors from connectors J18 and J25 on the Smart Fiber interface circuit board.
=

J14 J13

J25

J18

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50

mm (2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases as inside bend radius is decreased.

50 mm (2 in.)

7. Remove the fiber-optic cables from the cable management devices in the control pod.
8. Remove the power I/O board. See Remove the Power I/O Board on page 58.
9. Remove the fiber transceiver circuit board. See Remove the Fiber Transceiver Circuit Board on page 52.
10. Remove the main control circuit board. See Main Control Board Replacement on page 53.
11. Remove the four M4 x 8 mm screws that secure the control pod chassis to the standoffs on the control panel, then remove control pod chassis.
IMPORTANT The four M4 x 8 mm screws that secure the control pod chassis to the control panel are not retentive. Take steps to be sure that the screws do not fall into the drive below.
12. Remove the three M4 x 8 mm long screws that secure the Smart Fiber interface circuit board to the control pod.
13. Move the Smart Fiber interface circuit board slightly upward toward top of the control pod, so that keyholes on board clear the mounting posts and lift off the board.

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Chapter 4 LV Control Cabinet

14. Rotate the left side of Smart Fiber interface circuit board away from the control pod so that the board clears the mounting tab on right sidewall of the control pod. Remove the board from the control pod.

M4 x 8 mm

T20 or F - 6.4 mm (0.25 in.)

2.6 N·m (23 lb·in)

15. To install the Smart Fiber interface circuit board, perform the operation in the reverse order of removal.

When installing the fiber-optic cables:

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50

mm (2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases as inside bend radius is decreased.

50 mm (2 in.)

1. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver.
2. Insert the transceiver and fiber-optic cable into the connector on the board, until you hear an audible `click.'

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

I/O Option Cards Settings

Chapter 4 LV Control Cabinet

If you have installed an I/O option card (20-750-2262C-2R) in port 7 or 8, set the jumpers on the option card as follows:

· Port 7 as needed · Port 8 Verify with the Electrical Drawings to determine the correct
mode. - AI0 = Voltage Mode (Potentiometer) - AI1 = Current Mode (based on DCS speed reference selection)

Table 8 - Input Mode Jumpers

Jumper Position

Voltage Mode

Current Mode

Ai1

Ai0

For more information on the I/O option card, see the PowerFlex 750-Series I/O, Feedback, and Power Option Modules Installation Instructions, publication 750-IN111.

Control Pod Fan Assembly Replacement

Replace Upper Control Pod Fan Assembly
Replace the upper control pod fan assembly with kit part number PN-535604-R.
Follow these steps to replace the control pod fan assembly. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on page 50. 5. Disconnect the fan power supply connector from the main control board.

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Chapter 4 LV Control Cabinet

6. Push the flexible tab at both sides of the fan assembly to unlock and remove it from the control pod.
Flexible tab

7. To install the control pod fan assembly, perform the operation in the reverse order of removal.
Replace Lower Control Pod Fan Assembly
Replace the lower control pod fan assembly with kit catalog number SK-RM-PODFAN1-F8.
Follow these steps to replace the control pod fan assembly. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on page 50. 5. Disconnect the two fan power supply connectors from connectors J18 and J25 on the fiber-optic interface board.

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Chapter 4 LV Control Cabinet
6. Remove the harness from the cable supports on the side of the pod chassis. =
J25 J18

7. Loosen the two captive thumbscrews on the fan assembly and pull the assembly out and off the pod chassis.

T20 or F - 6.4 mm (0.25 in.)

2.6 N·m (23 lb·in)

8. To install the control pod fan assembly, perform the operation in the reverse order of removal.

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Chapter 4 LV Control Cabinet
Control Pod Replacement

Replace the control pod assembly with kit part number PN-579789.

Follow these steps to replace the control pod.

1. Review the Product Advisories on page 11.

2. Remove power from the system. See Remove Power from the System on page 13.

3. Open the control bay enclosure door.

4. Remove the control pod cover. See Control Pod Cover Removal on page 50.

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50

mm (2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases as inside bend radius is decreased.

50 mm (2 in.)

5. Remove the fiber-optic cables from the cable management devices in the control pod.
6. Remove the fiber transceiver circuit board. See Remove the Fiber Transceiver Circuit Board on page 52.
7. Unplug all cable harnesses to the main control board, control pod option cards, power I/O board, and smart fiber interface board.
8. Loosen the six M4 x 8 mm torx screws that secure the pod chassis to the back panel.

M4 x 8 mm

T20 or F - 5 mm (0.19 in.)

2.6 N·m (23 lb·in)

Rear view of screw locations

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Chapter 4 LV Control Cabinet

9. Slide the pod up, so that the keyholes on the pod clear the mounting screws, and remove the control pod.

M4 x 8 mm

T20 or F - 5 mm (0.19 in.)

2.6 N·m (23 lb·in)

10. To install the control pod, perform the operation in the reverse order of removal.

When installing the fiber-optic cables:

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50

mm (2 in.). Any bends with a shorter inside radius can

permanently damage the fiber-optic cable. Signal

attenuation increases as inside bend radius is decreased.

50 mm (2 in.)

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Chapter 4 LV Control Cabinet
Inspect the Integrated Touch Screen Display
Replace the Integrated Touch Screen Display

1. Verify the input and output cables and communication cables are handtight.
2. Power up the integrated touch screen display. 3. Verify that the integrated touch screen display is operating normally.
ATTENTION: Always perform Power Lockout procedure before servicing equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury, or death.
Remove Existing Integrated Touch Screen Display from the Panel
Follow these steps to remove the display from the panel. 1. Disconnect power to the display. 2. Disconnect network cable from the display. 3. Release the mounting levers by rotating them in the direction indicated, slide them to the bottom of the mounting slot, and remove.

4. Grip the sides of the display and gently pull the display out of the panel opening.

Mount the Integrated Touch Screen Display in the Panel
1. Make sure that the sealing gasket is properly positioned on the integrated touch screen display.

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Chapter 4 LV Control Cabinet
This gasket forms a compression type seal. Do not use sealing compounds.

Sealing gasket
2. Place the integrated touch screen display in the panel opening. 3. Install all mounting levers in the mounting slots on the integrated touch
screen display.
Slide each level until the short, flat side of the lever touches the surface of the panel.
Mounting slots

Short, flat side of mounting lever

Mounting levers

4. When all levers are in place, slide each lever and additional notch or tow until you hear a click.
5. Rotate each lever in the direction indicated until it is in the final latch position.

Follow the latching sequence for the optimum fit.

Rotate until notch in lever aligns with proper alignment mark. Notch

Latching sequence

1 5

4 7

Six alignment marks

8 3

6 2

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Chapter 4 LV Control Cabinet

6. Reconnect all cables in reverse order of removal.
Remove the Power Terminal Block
The integrated touch screen display ships with a power terminal block installed. You can remove the power terminal block for ease of installation, wiring, and maintenance.
Follow these steps to remove the terminal block. 1. Insert the tip of a small, flat-blade, screwdriver into the terminal block access slot. 2. Gently pry the terminal block away from the display to release the locking mechanism.

Power Terminal Block

Follow these steps to replace the terminal block. 1. Press the terminal block base in first with the block leaning outward. 2. Gently push the top of the terminal block back to a vertical position to snap in the locking tab.
Connect Power
Follow these steps to connect power. 1. Verify that the display is not connected to a power source. 2. Secure the 24V DC power wires to the terminal block. 3. Secure the functional earth ground wire to the functional earth ground terminal screw on the terminal block. 4. Apply 24V DC power to the terminal.
Ground the Display
Integrated touch screen displays have a functional earth terminal that you must connect to a low-impedance earth ground. The functional earth connection is on the power input terminal block. The negative power terminal is not internally connected to earth ground.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Isolation Transformer Cabinet

5 Chapter

Topic

Page

Inspect Isolation Transformer

Inspect/Replace Voltage Sensing Board

Inspect/Replace HECS

ATTENTION: Wait at least 15 minutes for the stored energy to discharge fully before performing maintenance on the Isolation Transformer cabinet. Failure to do so may result in severe burns, injury, or death.

Inspect Isolation Transformer

1. Verify that the fan is rotating in the proper direction.
2. Verify the incoming and outgoing power cable connections are torqued to specifications. See Torque Requirements on page 16.
3. Check the cabinet interior and Isolation Transformer windings and remove any foreign material. Vacuum dust or debris from the Isolation Transformer cabinet.
4. Check for any physical evidence of damage or degradation of components.

Inspect/Replace Voltage Sensing Board

Replace a voltage sensing board with kit part number PN-569153.
The VSB cable connections and wire connectors must be firmly fastened and show no signs of damage or accumulation of dirt, dust, or debris.
ATTENTION: To prevent electrical shock, disconnect the main power before working on the Voltage Sensing Board. Verify that all circuits are voltagefree, using a hot stick or appropriate high voltage-measuring device. Failure to do so may result in injury or death.

Replace Voltage Sensing Board (A-frame)
1. Open the front door of the Junction cabinet.

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Chapter 5 Isolation Transformer Cabinet

2. Remove and retain the nine M6 nuts, D6 washers, and D6 lock washers that secure the VSB PC cover, and remove the cover.

Junction cabinet front door

VSB signal wires
M6 nuts, washers, and lock washers (9)

VSB PC cover

VSB cables

3. Remove the six medium voltage cables, one ribbon cable, and two grounds.
4. Remove and retain the four M8 x 30 bolts and washers that secure the VSB, and remove the VSB.

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Chapter 5 Isolation Transformer Cabinet
5. Install the new VSB in the reverse order of removal.
Junction cabinet front door VSB
M8 x 30 bolts and washers (4)
VSB PC cover

Inspect/Replace HECS

There are three current sensors that are located inside the Isolation Transformer cabinet. Verify that the current sensor wire connector is properly seated. Check for obvious signs of damage.
ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free, using a hot stick or appropriate high voltage-measuring device. Failure to do so may result in injury or death. 1. Unplug the Current Sensor Connector from the HECS.
Figure 27 - HECS for A-frame
Mounting insulation bracket
Current Sensor connection

HECS

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Chapter 5 Isolation Transformer Cabinet

Figure 28 - HECS for B-frame

Mounting bracket
HECS Current Sensor connection

2. Disconnect one end of the power cable that goes through the HECS from the power cell.
3. Remove the Mounting Bracket with the HECS still attached. 4. Remove and retain hardware connecting the HECS to the Mounting
Bracket. IMPORTANT Note the orientation of the HECS on the bracket. The new HECS must be
installed facing the same direction.
Figure 29 - Exploded view of the HECS and Mounting Bracket for A-frame
Ø6 washer (4) Ø6 lock washer (4) M6 nut (4)
M4 nut (4) Ø4 lock washer (4) Ø4 washer (4)
M4 x 16 cross pan head combination screw (4)

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 5 Isolation Transformer Cabinet Figure 30 - Exploded view of the HECS and Mounting Bracket for B-frame
M5 x 16 cross pan head screw Ø5 washer M5 nut
M6 nut Ø6 washer
5. Install the HECS on the Mounting Bracket using the existing hardware. ATTENTION: Verify that the current sampling direction is correct. This is indicated by an arrow symbol on the top of the HECS.
6. Install the Mounting Bracket to the cabinet using existing hardware. 7. Reroute the power cable through the HECS and reattach to the power
cell.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 5 Isolation Transformer Cabinet
Notes:

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Power Cell Cabinet

6 Chapter

Inspect Power Cells Replace Power Cell

Topic

Page

Inspect Power Cells

Replace Power Cell

Replace Power Cell Fuses

1. Inspect the power connections for loose connections or any evidence of discoloration of connections from heating.
2. Remove dust or debris from all ventilation openings on the power cell.
3. Inspect the electrolytic capacitors, which are located in the ventilation openings of the power cell.
a. Inspect for signs of discoloration, odor, or leakage.
b. Replace power cells if the capacitors have discoloration, odor, or leakage.

Some power cell output ratings may come with either two or three fuses. When replacing a power cell, always replace with a similar power cell for your specific configuration.

Table 9 - Power Cell Specifications

Frame A-frame B-frame

Output Rating (Amps) 36...70 A 71...140 A 141...215 A 201...305 A 351...680 A

Dimensions (HxWxD) approx 210 x 110 x 569 mm (8.3 x 4.3 x 22.4 in.) 210 x 190 x 624.5 mm (8.3 x 7.5 x 24.6 in) 210 x 215 x 674 mm (8.3 x 8.5 x 26.5 in) 552.5 x 244.5 x 663 mm (21.8 x 9.6 x 26.1 in.) 471 x 354 x 746 mm (18.5 x 13.9 x 29.4 in.)

Weight approx 13 kg (28.6 lb) 25 kg (55 lb) 35 kg (77 lb) 70 kg (154 lb) 95 kg (209 lb)

ATTENTION: At least two people are required to handle the power cells.

ATTENTION: The high-voltage power source must be switched off before replacing a power cell. Wait at least 15 minutes before opening the cabinet doors. Verify that all circuits are voltage-free, using a hot stick or appropriate high voltage-measuring device. Failure to do so may result in injury or death.
1. Remove the mounting bolts (M6 x 20) from both sides of the power cell. 2. Disconnect the three-phase input power cables.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 6 Power Cell Cabinet

Figure 31 - Power Cell Component Location
30/50 A rating power cells with three fuses shown

Fiber-optic cables connection point
Output copper bar connection location

Fuse
M6 x 16 hexagon combination screws (2) Three-phase input cables from isolation transformer
3. Remove the output copper bars that connect adjacent power cells (Figure 32).
If the power cell is at the end of a row, remove the VSB and motor cable instead of an output copper bus. 4. Disconnect the fiber-optic cables.
ATTENTION: When removing the fiber-optic cables, be careful to prevent the cables from straining or crimping as the resulting loss in light transmission will impact performance. ATTENTION: Minimum bend radius that is permitted for the fiber-optic cables is 50 mm (2.0 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable.
Figure 32 - Close up of Fiber-optic Cable Location and Power Cables
30/50 A rating power cell with three fuses shown

Motor cable to Junction cabinet Fiber-optic cables
VSB cable Output copper bar

5. Carefully withdraw the power cell.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 6 Power Cell Cabinet
Install the Power Cell
ATTENTION: Do not use the front-mounted positioning handles for lifting the power cells. They are designed to position or withdraw the power cell when on the tray assembly.
ATTENTION: The power cell finger assemblies must be fully seated on the cabinet stab assemblies.
IMPORTANT The power cell should be handled carefully. After removing the packaging, inspect the power cell to confirm that there is no damage and moisture.
For A-frame Drives
For A-frame drives, install the new power cell in reverse order of removal.
100/140/180/215 A rating power cell with two fuses shown

For B-frame Drives

Mounting points

For B-frame drives, follow these steps to install the power cell.
1. You can use the lift cart to move and position the power cell to the appropriate location in the cabinet. For more information on how to use the lift cart, see page 80.
2. Push the power cell slowly along the guide rails until it cannot be pushed in further.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 6 Power Cell Cabinet

3. After installing the power cell in place, use the mounting brackets and the M6 × 16 large flat pad galvanized nickel screws to fix the four corners, as shown in the following illustration.
438/560/680 A rating power cell with two fuses shown
Mounting points

Using the Lift Cart

Mounting points
Power cells 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 for power cell replacement.
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. The lift cart's hydraulic cylinder can be operated by either a hand or foot crank. The lifting capacity is 400 kg (882 lb).

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 6 Power Cell Cabinet

Figure 33 - Lift Cart Procedure

Hand Crank Pressure Release Knob

Release pressure in cylinder
Lift tray
Foot Crank

Seal pressure in cylinder

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 lowest position.
3. Move the power cell on the tray and lift the module to the appropriate height using the Foot Crank and complete the installation.
The Foot Crank raises the lift tray faster than the Hand Crank. Use this to raise the power cell 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 original position.
5. Repeat steps 1...4 to complete the installation for all power cells.

Replace Power Cell Fuses

Follow these steps to replace the fuses on a power cell.
ATTENTION: Verify that the input circuit breaker feeding the drive is open. Lockout and tagout the input circuit breaker before performing any work on the drive or bypass units.
1. Remove the nut, lock washer, and washer from the top and bottom of the fuse.
2. Remove the cables from the top and bottom of the fuse, and remove another washer.
3. Install the new fuse, and replace cables and hardware in reverse order of removal.
4. Torque all hardware to specifications. See Torque Requirements on page 16.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 6 Power Cell Cabinet

Figure 34 - Replace Power Cell Fuse Example
Washer Lock washer
Nut Fuse

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Inspect Connections

7 Chapter

Topic

Page

Inspect LV Component Terminal and Plug-in Connections

Inspect Medium Voltage Cable Connections

Inspect Power Cable and Control Wire Terminals

Inspect Transformer Secondary Windings

Inspect Power Cell Input and Output Power Connections

Inspect LV Component Terminal and Plug-in Connections

All LV control connections must be secure. Check for dirt, debris, or foreign material, and clean with anti-static cloth if necessary.
Check relays, contactors, timers, terminal connectors, circuit breakers, ribbon cables, control wires, and so on. Check for corrosion, excessive temperature, or contamination. Clean all components with a vacuum cleaner.

Inspect Medium Voltage Cable Connections

Verify that all MV power cable connections and grounding cables are torqued to specification. Apply torque sealer where necessary. Check for corrosion, excessive temperature, or contamination.

Inspect Power Cable and Control Wire Terminals

Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure. Loose connections in control circuits can cause control malfunctions. Loose bonding or grounding connections can increase hazards of electrical shock and contribute to electromagnetic interference (EMI). Check the tightness of all terminals and busbar connections and tighten securely any loose connections. Replace any parts or wiring that is damaged by overheating, and any broken wires or bonding straps. See the User Manual for torque values that are required for power cable and bus hardware connections.

Inspect Transformer Secondary Windings

Check the Incoming Line Power Cable connections (L1, L2, and L3), the Outgoing Motor Power Cable connections (U, V, W), and the Isolation Transformer Power Cable connections are torqued to specifications.
Inspect the busbars and cable connections. Check for any signs of overheating / discoloration and tighten the bus connections to the required torque specifications. Clean all cables and busbars that exhibit dust build-up. Check for corrosion, excessive temperature, or contamination.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Chapter 7 Inspect Connections
Inspect Power Cell Input and Output Power Connections

Verify that all power cell input line cables and output bus connections are properly torqued. Verify that the output cables, VSB Cables, and star connection cables are properly torqued. Apply torque sealer if necessary. Check for corrosion, excessive temperature, or contamination.

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

A
AC/DC Power Supplies Inspect 23 Maintenance Schedule 19
Air Filters
Clean 20, 38
Replace 38 apply power 13
B
backplane circuit board install 57 remove 57
C
Commissioning Support 9 component
inspection 37 Connections
Inspect 23 Maintenance Schedule 19 Control Pod Maintenance Schedule 19 control pod inspect 38 install 67 remove 66 control pod cover install 51 remove 50 control pod fan assembly
irnesmtaolvle646,36, 564
D
Door Mounted Air Filters Clean/Replace 38 Maintenance Schedule 19
E
E-HIM Maintenance Schedule 19
equipment maintenance 20
F
fan inspection 37
fiber transceiver circuit board install 53 remove 52

Index
filter inspect 37
Firmware Maintenance Schedule 19
Fuse Replace 81
G
General Precautions 8
H
HECS Hardware 73 Inspect 73 Maintenance Schedule 19 Mounting Bracket 74 Replace 73
HMI Firmware 24 Inspect/Replace 68
I
inspect components 37 control pod 38 filter 37
inspection fan 37
Install Power Cell 79 Isolation Transformer
Clean/Replace Air Filters 38 Fan Balance 44 Inspect 71
IMnasipnetecnt aSnecceonSdcahreydWuliend19in,g3s1 83
Replace HECS 73 Replace Voltage Sensing Board 71 Top-mounted Cooling Fans 40 Isolation Transformer Cabinet Replace Top-mounted Cooling Fans 40
L
Lift Cart Operation 80
Lockout and tagout 13 LV Control Cabinet
HMI Firmware 24 Maintenance Schedule 19 Replace HMI 68 LV Control Circuit Breakers Inspect 23 Maintenance Schedule 19 LV Control Relays Inspect 23 Maintenance Schedule 19

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Index

main control circuit board (frame 8...15)

install 55

remove 53

Maintenance

Estimated Time Required 25

Final Report 32

Inspect Inspect

Components Connections

8833,

Inspect Power Connection 22

Inspect Terminals 83

Inspect/Review Spare Parts 24

Miscellaneous Work 25

PSchhyseidcualleIn18s,p2e0ct,io2n1 23

Services 24

maintenance

equipment 20

Physical Maintenance Checks

Inspect Power Connections 22 Physical Inspection 23 power

apply 13 remove 13

Power Cell

CHoEmCSpo7n3e, n74ts 78

Inspect 77

Inspect Input and Output Connections 84 Install 79 Lift Cart 79 Replace 77 Replace Fuse 81 Specifications 77 Power Cell Cabinet

Clean/Replace Air Filters 38

Fan Balance 44 Maintenance Schedule

19,

Replace HECS 73

Replace Top-mounted Cooling Fans 40

Top-mounted Cooling Fans 40 power I/O board

remove 58

PowerFlex 6000 Torque Requirements 16
precautions 11

R
remove power 13

S
Safety Considerations Lockout and tagout 13
Smart Fiber circuit board remove 60
Smart Fiber interface circuit board install 62
software tools 14 Spare Parts
Inspect/Review 24 Maintenance Schedule 19

Top-mounted Cooling Fans

FHaanrdBwaalarenc4e1,4443

Inspect 40 Maintenance

Schedule

19,

Replace 40

Torque Requirements 16

U
UPS Inspect 23 Maintenance Schedule 19

V
visual inspection 37 Voltage Sensing Board
Inspect 71 Maintenance Schedule 19 Replace 71

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

PowerFlex 6000T Drives Hardware Service Manual Troubleshooting Guide

Rockwell Automation Publication 6000-TG100B-EN-P - July 2021

Rockwell Automation Support

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