Allen-Bradley PowerFlex 6000 Firmware, Parameters, And Troubleshooting Manual

PowerFlex 6000 Medium Voltage Variable Frequency Drive

Firmware, Parameters, and Troubleshooting Manual

Firmware Revision 6.xxx

Technical Data

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required

to be carried out by suitably trained personnel in accordance with applicable code of practice.

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

impaired.

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

use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

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

software described in this manual.

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

Inc., is prohibited.

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

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc.

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

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 3

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Preface

About this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1

Functional Descriptions

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

HMI Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Stop Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Motor Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Switch Frequency Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VF Curve Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Digital Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pre-charge Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cell Information Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Customized Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Over Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Line Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Voltage Sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Low Voltage Ride Through (LVRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Power Loss Auto Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motor Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Current Stability Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Load Loss Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Motor Auto-tune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Restart Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Skip Frequency Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Start and Stop Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Process Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Deceleration and Acceleration Process User Define . . . . . . . . . . . . . 39

PID Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Table of Contents

Deceleration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 2

Parameter Descriptions

PowerFlex 6000 Medium Voltage AC Drive

Database Revision # 6.xxx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Interpreting Bit-Encoded Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Control Owner Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Nameplate Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Other Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

HMI Display Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Ramp Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Frequency Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Stop Mode Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Motor Direction Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Switch Frequency Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

VF Curve Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Analog Input Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Digital Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Analog Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Version Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Fan Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Pre-charge Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Customized Trip Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Over Speed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Voltage Sag Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Voltage Loop Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Low Voltage Ride Through Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Power Loss Auto Restart Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Cell Bypass Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Bypass Mode Switch Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Fault Automatic Switch to Bypass Parameters. . . . . . . . . . . . . . . . . . . . . . 107

Current Limit Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Current Stability Loop Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Flying Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Load Loss Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Motor Auto-tune Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Restart Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Skip Frequency Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Start and Stop Sequence Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Deceleration and Acceleration Process Parameters . . . . . . . . . . . . . . . . . 128

PID Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Deceleration Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Parameters Listed by Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Control Owner Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 5

Table of Contents

Nameplate Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Other Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

HMI Display Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Ramp Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Frequency Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Stop Mode Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Motor Direction Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 155

Switch Frequency Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 155

VF Curve Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Analog Input Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Digital Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Analog Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Version Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Fan Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Pre-charge Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Customized Trip Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Over Speed Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Voltage Sag Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Voltage Loop Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Low Voltage Ride Through Parameters. . . . . . . . . . . . . . . . . . . . . . . . 162

Power Loss Auto Restart Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Cell Bypass Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Bypass Mode Switch Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Fault Automatic Switch to Bypass Parameters. . . . . . . . . . . . . . . . . . 164

Current Limit Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Current Stability Loop Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Flying Start Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Load Loss Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Motor Auto-tune Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Restart Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Skip Frequency Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Start and Stop Sequence Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Deceleration and Acceleration Parameters. . . . . . . . . . . . . . . . . . . . . 168

PID Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Deceleration Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Parameters Listed by Linear Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Alphabetical Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Linear Number Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Chapter 3

Fault Messages

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Logic Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Power Cell Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

6 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Table of Contents

Chapter 4

Warning Messages

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Warning Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

System Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Logic Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Power Cell Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 7

Preface

About this Publication

This manual provides details regarding functions, parameters and

troubleshooting information for medium voltage PowerFlex® 6000 drives.

Who Should Use This Manual

This manual is intended for qualified service personnel responsible for

troubleshooting and repairing medium voltage PowerFlex 6000 drives. You

should have previous experience with, and basic understanding of, electrical

terminology, procedures, required troubleshooting equipment, equipment

protection procedures and methods, and safety precautions.

Additional Resources

These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http:/www.rockwellautomation.com/literature/

. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

Acronyms and Abbreviations

Resource Description

PowerFlex 6000 Medium Voltage Variable

Frequency Drive Installation Manual,

publication 6000-IN006

Provides instructions for installing the drive, dimensions,

requirements, and wiring information.

PowerFlex 6000 Medium Voltage Variable

Frequency Drive Shipping and Handling

Manual, publication 6000-IN008

Provides instructions for shipping and handling a Medium Voltage

variable frequency drive and related equipment.

PowerFlex 6000 Medium Voltage Variable

Frequency Drive User Manual, publication

6000-UM002

Provides instructions for daily recurring drive usage, HMI interface and

maintenance tasks for the product’s end-user.

Acronym/

Abbreviation

Description Acronym/

Abbreviation

Description

A2D Analog to Digital FPGA Field-Programmable Gate Array

A/D Analog/Digital Freq Frequency

AC Alternating Current GND Ground

ACB Analog Control Board Gnrl General

Accel Acceleration HECS Hall Effect Current Sensor

ADC Analog to Digital Converter Hi High

Anlg Analog HP Horse Power

BW Bandwidth HW Hardware

Cap Capacitor I Current

Ch Channel IGDPS Isolated Gate Driver Power Supply

Chn Channel Init Initialize

8 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Preface

CIB Customer Interface Board Inv Inverter

CMC Common Mode Choke IO Input/Output

Cmd Command Isoltn Sw Isolation Switch

Conv Converter L Inductance

CT Current Transformer L Line

Ctctr Contactor LED Light-emitting diode

Cur Current Liq Liquid

DAC Digital to Analog Converter LR Line Reactor

DB Dynamic Braking Lo Low

DC Direct Current LV Low Voltage

DCB Drive Control Board M Machine

DCSL Drive Control and Synchronization Link Magntz Magnetizing

DD Dimensional Drawings Max Maximum

Decel Deceleration Min Minimum

DIM Drive Identity Module Mstr Master

Dly Delay MTR Motor

DO Drive Output NVRAM Non-Volatile Random Access Memory

DPI Drive Peripheral Interface OC Overcurrent

DPM Drive Processor Module OL Overload

DrvIn Drive Input OP Output

ED Electrical Drawings PF Power Factor

ESP Electric Submersible Pump PFC Power Factor Correction

Fbk Feedback PID Proportional, Integral, Derivative (process control)

Flt Fault PLC Programmable Logic Control

Fltr Filter Sync Synchronous

FO Fiber-Optic Tach Tachometer

FOB Fiber-Optic Interface Board

FOI Fiber-Optic Interface TFB Temperature Feedback Board

PWM Pulse-Width Modulation TFB3 Temperature Feedback Board, 3

rd

generation

Rect Rectifier Trp Trip

Rot’n Rotation Trq Torque

SCB Signal Conditioning Board TSN Transient Suppression Network

SCR Silicon-Controlled Rectifier UB Unbalance

SGCT Symmetrical-Gate Commutated Thyristor UPS Uninterrupted Power Supply

Slv Slave USART Universal Synchronous/Asynchronous Transmitter/Receiver

Spd Speed V Volt

SPGD Self-Powered Gate Driver VSB Volt Sensing Board

SW Software Wrn Warning

OT Overtemperature Xfer Transfer

OV Overvoltage XIO External Input/Output

PD Parallel Drive

Acronym/

Abbreviation

Description Acronym/

Abbreviation

Description

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 9

Chapter 1

Functional Descriptions

Introduction

The PowerFlex 6000 is an adjustable speed AC drive that is particularly suitable

for new and retrofit centrifugal fan and pump applications. Air-cooled PowerFlex

6000 drives are designed to maximize energy efficiency by enabling soft-starting

and variable-speed control in medium voltage, normal duty applications.

To achieve the low input harmonics and near-unity power factor that make this

an ideal solution for standard motors, the drives utilize Cascaded “H’” Bridge

(CHB) topology. This proven CHB topology combines an integrally mounted

phase-shifting isolation transformer with series-connected power modules for

each phase. In addition to stepping down the input voltage, the isolation

transformer also provides two other principal functions:

• Mitigate common mode voltage stress so motors with standard insulation

levels can be used.

• Reduce Total Harmonic Distortion (THD), due to the phase shifting of

its secondary windings, so input side harmonics don’t negatively impact

the plant or utility power grid.

System Settings

The system settings include the following functions:

• Control Owner

on page 10

• HMI Display on page 12

• Nameplate on page 13

• Ramp on page 14

• Rated Frequency on page 15

• Stop Mode on page 15

• Motor Direction Control on page 16

• Switch Frequency Settings on page 16

• Tre n d s on page 17

• VF Curve Setting on page 17

10 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

Control Owner

This function is used to switch the control source between Local, DCS, and

Remote Box. The switch can be performed while the drive is online.

Three parameters are used to determine the control method and given frequency

reference. The value range of Owner #1 Selection (P475) is “0 or 1”, the value

range of Owner #2 Selection (P476) is “2...23”, and the value range of Owner #3

Selection (P477) is “18...23”. The default values for the parameters are “0, 8, and

23” respectively. The combinations are shown in the following table.

Table 1 - Frequency Reference and Control Command Source Matrix

The control command selections are:

1. Drive HMI or control panel buttons

2. Remote hardwired

3. Remote communications

4. Remote box buttons

The frequency reference selections are:

1. Local touchscreen

2. Potentiometer on the control panel

3. Remote control analog 4-20 mA

4. Remote communications

5. 4-speed governor

(Four frequency values are stored in parameters: 4-Step Variable Speed -

Speed1 (P480), 4-Step Variable Speed - Speed2 (P481), 4- Step Variable

Speed - Speed3 (P482), and 4-Step Variable Speed - Speed4 (P483))

6. Remote box buttons

Frequency Owner

Control Owner

HMI Comm /

Local Button

DCS I/O DCS Comm Remote Box

(Option)

HMI 061218

Potentiometer

0-10V (Option)

171319

Analog 4-20 mA 281420

Comm 391521

4-Speed 4 101622

Remote Box 5 111723

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 11

Functional Descriptions Chapter 1

Take note of the following:

• When HMI is selected, the HMI converts the frequency reference to a

value from 0...100 and sends it to the controller. The controller converts

the received value to a unified data value from 0...10000 for internal

calculations within the controller and computes the given frequency to be

sent to the DSP.

• When the potentiometer is selected, the 0-10V signal sent to the controller

is adjusted using the potentiometer. The controller processes the signal and

computes the given frequency to be sent to the DSP (If the wiring is

disconnected, the frequency reference value changes to zero and there will

be no message prompt).

• When analog 4-20 mA is selected, the controller processes the signal and

computes the given frequency to be sent to the DSP.

• When 4-speed governor is selected, the four frequency values stored in

parameters 4-Step Variable Speed - Speed1, 4-Step Variable Speed - Speed2,

4-Step Variable Speed - Speed3, and 4-Step Variable Speed - Speed4 are used.

These parameters correspond to the controller input points I-24, I-25, I-

26, and I-27.

When the controller receives an input at a high level from an input point

that corresponds to a frequency reference stored in one of the 4-Step

Variable Speed parameters, the drive frequency reference is set to that

value. For example, when the input I-24 is at a high level, the value of 4-

Step Variable Speed - Speed1 is read as the frequency reference of the drive

and so on.

• When remote communication is selected, the frequency reference value is

provided by the remove communication with a range from 0...1000

(1000 = maximum frequency reference).

When there is a fault between the host computer and remote

communications, the drive response is determine by the value set in

parameter When Disconnected Between DCS and PLC (P485) and

described as follows:

– P485= 0; The drive stops immediately.

– P485 = 1; The drive continues running at current frequency.

– P485 = 2; The drive continues running at frequency set in

4-step Variable peed - Speed1.

– P485 = 3; The drive continues running at frequency set in

4-step Variable Speed - Speed2.

– P485 = 4; The drive continues running at frequency set in

4-step Variable Speed - Speed3.

– P485 = 5; The drive continues running at frequency set in

4-step Variable Speed - Speed4.

• When Remote box is selected, the frequency reference is set by using the

acceleration/deceleration button on the HMI, or the acceleration/

deceleration button on the remote control box. The frequency step size is

determined by the value of Frequency Step For Acceleration Or Deceleration

(P493).

12 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

Switching between Local, DCS, or Remote box can be performed on the HMI,

or using a selector switch mounted on the control panel. When Local/Remote

Owner Selection (P478) is set to “1”, the selector switch is used. When Local/

Remote Owner Selection is set to “0”, the HMI is used. When Local control

method is selected, Owner #1 Selection is active. When DCS control method is

selected, Owner #2 Selection is active. When Remote box control method is

selected, Owner #3 Selection is active.

HMI Display

This function is used to set the display parameters of some analog output signals

such as setting-frequency, actual-frequency, stator-voltage, and stator-current.

Each signal is made up of four display parameters, such as memory address, filter

parameter, HMI display integer part, and HMI display decimal part. See the

following table for the different display signals and their respective parameters.

Table 2 - Analog Output Signals and Corresponding Parameters

For example, if we want to output the “given frequency” with the settings –

memory address is 221, the filter time is 100 ms, the maximum integer part is 60,

and the maximum decimal part is 0 – then we can set the following:

• Rated Frequency HMI Display Filter Time (P351) = 100

• Rated Frequency HMI Display Integer Part (P352) = 60

• Rated Frequency HMI Display Decimal Part (P353) =0

• Rated Frequency HMI Display Address (P371) = 221

IMPORTANT

Remote box control method is only applicable to manual bypass, one-drive-

one-motor, and automatic bypass, one-drive-one-motor.

Analog Output Signals Parameters

Setting frequency display Rated Frequency HMI Display Filter Time (P351)

Rated Frequency HMI Display Integer Part (P352)

Rated Frequency HMI Display Decimal Part (P353)

Rated Frequency HMI Display Address (P371)

Stator voltage display Motor Voltage HMI Display Filter Time (P354)

Motor Voltage HMI Display Integer Part (P355)

Motor Voltage HMI Display Decimal Part (P356)

Motor Voltage HMI Display Address (P372)

Output frequency display Actual Frequency HMI Display Filter Time (P357)

Actual Frequency HMI Display Integer Part (P358)

Actual Frequency HMI Display Decimal Part (P359)

Actual Frequency HMI Display Address (P373)

Stator current display Motor Current HMI Display Filter Time (P360)

Motor Current HMI Display Integer Part P(361)

Motor Current HMI Display Decimal Part (P362)

Motor Current HMI Display Address (P374)

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 13

Functional Descriptions Chapter 1

The values of the four parameters Rated Frequency HMI Display Address (P371),

Motor Voltage HMI Display Address (P372), Actual Frequency HMI Display

Address (P373), and Motor Current HMI Display Address (P374) need not be

changed and can be left at their default values. The field support engineer can

change them according to the specific case.

Nameplate

This function is used to set the basic parameters of motor, drive, transformer, and

HECS. They are rated current, rated power, rated speed, rated power factor,

number of motor pole pairs, and so on.

Number of Power Cells Per Phase (P007) is the amount of power cells in one

phase.

For example, if the amount of power cells in one phase is five, then Number of

Power Cells Per Phase must be set to five. The number of power cell’s fault

information and warning information is based on Number of Power Cells Per

Phase. If Number of Power Cells Per Phase is set to zero, then all power cell’s fault

information and warning information is ignored. This allows the drive to be run

in low voltage. This function can be used for checking of low voltage components

and the control box.

Power Cell DC Bus Rated Voltage (P011) is the DC bus rated voltage of the

power cell. Motor Rated Current (P199) is used for the fault judgment related

motor current. The parameters Motor Rated Voltage (P012), Motor Rated Power

(P013), Motor Rated Speed (P014), Motor Rated Power Factor (P015), and

Number of Motor Pole Pairs (P017) are used for calculating the motor stator's

parameters.

Encoder Resolution (P019), Line CT Ratio (P195), and Line CT Burden Resistor

(P196). Motor HECS Ratio (P197) and Motor HECS Burden Resistor (P198) are

used to calculate the Hall current sensor's rated current, which is used for the

sampling of the drive's current (Line CT Ratio, Line CT Burden Resistor, Motor

HECS Ratio, and Motor HECS Burden Resistor are set based on the AT board

configuration).

IMPORTANT

The value of this parameter must be set to the actual amount used in each

phase.

14 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

Ramp

This function includes the S curve setting, frequency dead zone setting, and

frequency amplitude limit.

The S curve setting means integral setting on frequency signal, also known as the

ramp setting. In PowerFlex 6000 drives, the curve is used to set the motor’s speed.

The ramp curve in S curve can avoid the over current and over voltage faults by

reducing the increasing or decreasing speed. Also, the rounded corners in S curve

can reduce the impact on mechanical components.

• Deceleration-time “Td” is determined by the formula:

Deceleration Time (P399) * Deceleration Time Unit (P406)

This value should be adjusted according to the actual case. An

inappropriate setting will result in an input voltage over-voltage fault in the

power cell.

• Deceleration-rounded-corner-time “Trd” is determined by the formula:

Deceleration Ramp Transition Time (P405) * Deceleration Time Unit

(P406)

In most cases, the default value need not be changed.

• Acceleration-time “Tu” is determined by the formula:

Acceleration Time (P401) * Acceleration Time Unit (P403)

This value should be adjusted according to the actual case. An

inappropriate setting will result in an over-current fault.

• Acceleration-rounded-corner-time “Tru” is determined by the formula:

Acceleration Ramp Transition Time (P402) * Acceleration Time Unit

(P403)

In most cases, the default value need not be changed.

• Amplification Coefficient Of Error Terms (P409) is also used.

See the following diagram for the explanation of the different time settings.

Figure 1 - S Curve Diagram

Frequency

Tru

Tu

Td

Tru

Trd

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 15

Functional Descriptions Chapter 1

Rated Frequency

This function is used to the set the drive's rated frequency parameters and also

the frequency limit. Frequency dead zone setting is used to limit the low

frequency starting range, and prevent output fluctuations when the drive is in

analog input mode and the frequency is around zero Hz. Frequency amplitude

limit is used to limit the amplitude of set frequency, thus it prevents the set

frequency from exceeding the drive's maximum output frequency.

Parameter Rated Output Frequency (P460) is the drive’s rated output frequency.

The frequency value ranges from 0...75 Hz and should be set equal to the motor’s

rated frequency. If Rated Output Frequency is not set correctly it may cause

damage to the motor.

Parameter Maximum Output Frequency (P466) is the drive’s maximum output

frequency. Rated Output Frequency cannot be set higher than Maximum Output

Frequency. Any attempt to do so will fail.

If the original setting-frequency is lower than parameter Frequency Command

Deadband Upper Limit (P414), frequency dead zone setting can change the

setting- frequency to equal Frequency Command Deadband Upper Limit.

Frequency amplitude limit can limit the setting-frequency between parameters

Frequency Command Lower Limit (P413) and Frequency Command Upper Limit

(P415). Following the rule:

Frequency Command Upper Limit > Frequency Command Lower Limit > 0

This function is used to limit the amplitude for setting-frequency. This prevents

the setting-frequency from becoming bigger than the drive’s maximum output

frequency.

Stop Mode

There are two methods in which a PowerFlex 6000 drive can use to stop – ramp

down and coast stop.

The stop mode can be selected by setting Stop Method (P024) to “1” for coast

stop and “0” for ramp down.

If coast stop was selected, you must wait for a certain time to elapse before

restarting the drive. The time is determined by the formula:

Time = Motor Coast Stop Time (P253) * frequency before stop / max frequency

If ramp down was selected, the motor will ramp down.

Parameters Frequency Command-Low Frequency Region Boundary (P251) and

Delayed Lockout Time of Stop Operation (P270) are also used in this function.

16 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

Motor Direction Control

This function is designed to work with other functions such as command source,

motor rotation direction, switch frequency, and frequency command source

selection.

The command source function is used to select the command source for starting,

stopping, and resetting the drive.

The motor rotation direction function is used to change the motor's rotating

direction without any hardware changing. There are two methods available in

PowerFlex 6000. The offline method is performed locally and cannot be done

when the motor is running. The online method is performed remotely and can be

done using the DCS while the motor is running.

When Motor Rotation Direction Command Selection (P009) is set to “0”, it means

offline local control, and the user can only change the motor’s rotating direction

using the HMI when the drive is stopped. DCS control is disabled. To change the

motor’s rotating direction, set parameter Motor Rotation Direction Under Local

Control (P008) to “0” for reverse rotating or “1” for forward rotating.

When Motor Rotation Direction Command Selection (P009) is set to “1”, it means

online remote control, and the user can change the motor’s rotating direction

using the DCS while the drive is running. HMI control is disabled.

Switch Frequency Settings

The switch frequency function is used to set the switch frequency of the power

semiconductor. The frequency command source selection function is used the

select the given frequency mode.

Set parameter Switch Frequency Setting Enable Code (P087) to “0” to disable or

“1” to enable the function.

Set parameter Switch Frequency Setting (P088) to “0” to set the switch frequency

at 600 Hz or “1” to set the switch frequency at 1200 Hz.

IMPORTANT

Set the Switch Frequency Setting Enable Code parameter back to zero after

changing the Switch Frequency Setting parameter. The Switch Frequency

Setting parameter can only be changed when offline.

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 17

Functional Descriptions Chapter 1

Trends

There are two kinds of dynamic trends available for PowerFlex 6000. The first

type of trend cannot be changed but can save history data. It can only show the

output voltage, output current and output frequency. The second type of trend

can be configured but cannot save the history data. It can show output frequency,

output voltage, motor estimated speed, output current, average DC voltage,

maximum DC voltage and minimum DC voltage by drawing curves of this status

data.

For the first type of trend, no configuration is required. For the second type of

trend, you can configure the parameter to display. Trends curves are showed by

the percentage value. For more details, see the PowerFlex 6000 Medium Voltage

Variable Frequency Drive User Manual(6000-UM002

).

VF Curve Setting

This function is designed to calculate the drive's output voltage according to the

set frequency. There are six kinds of V/F curves available – linear, curve, straight-

curve, parabolic-curve, 5 point VF, and SVC. Compensation voltage can be set to

improve the lower frequency start torque.

When a linear, curve, straight-curve, parabolic-curve, or SVC is selected, set the

parameters Low Speed Voltage Compensation (P451) and Low Speed Voltage

Compensation Frequency Threshold (P452). If the output frequency is lower than

the value of Low Speed Voltage Compensation Frequency Threshold, the output

voltage will be improved by the percentage value set in Low Speed Voltage

Compensation to enhance the output torque. If SVC is selected, the above

parameters need to be set based on the field conditions.

When VF curve is selected, the five points are defined based on their load curve.

These five points are Point 1 (f1, V1), Point 2 (f2, V2), Point 3 (f3, V3), Point 4

(f4, V4), and Point 5 (f5, V5).

The following parameters are used to define the five points:

• f1 = Frequency At First Point For 5 Point VF (P375)

• V1 = Amplitude At First Point For 5 Point VF (P376)

• f2 = Frequency At Second Point For 5 Point VF (P377)

• V2 = Amplitude At Second Point For 5 Point VF (P378)

• f3 = Frequency At Third Point For 5 Point VF (P379)

• V3 = Amplitude At Third Point For 5 Point VF (P380)

• f4 = Frequency At Fourth Point For 5 Point VF (P381)

• V4 = Amplitude At Fourth Point For 5 Point VF (P382)

• f5 = Frequency At Fifth Point For 5 Point VF (P383)

• V5 = Amplitude At Fifth Point For 5 Point VF (P384)

18 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

The voltage value for each of the five points should be set as follows:

V1 < V2 < V3 < V4 < V5

The voltage and frequency values for each of the five points should be set as

follows:

V1 < f1; V2 < f2; V3 < f3; V4 < f4; V5 < f5.

The relationship between the five points is shown in the diagram below.

Figure 2 - 5 Point VF Diagram

Digital Output

This function is used to set the digital output channel parameters. There are eight

digital output channels available in PowerFlex 6000 drives. The address, polarity,

and output delay time parameters can be adjusted according to the user’s

requirements.

For example, a user wants to configure a warning bell that is controlled through

the digital channel. This warning bell will go off when the digital channel output

voltage reaches a high level. Follow these steps below to configure the settings for

this example:

1. Set the address of the “warning bell” with parameter Digital Output #5

Memory Address (P320). The default value is “99”.

2. Enable this function by setting parameter Digital Output #5 Bit Selection

(P322) to “5” because this function corresponds to the position of Bit 5 of

K99.

3. Set the polarity with parameter Digital Output #5 Logic (P321). If you

want a high voltage level, set the value to “0”, else set the value to “1”.

4. If a one second signal delay is needed, set Digital Output #5 Delay (P323)

to “1000 ms”.

f1

V1

V2

V3

V4

V5

1

Voltage

Frequency

f2 f3 f4 f5 1

Rockwell Automation Publication 6000-TD004D-EN-P - November 2017 19

Functional Descriptions Chapter 1

Table 3 - Digital Output Signal Parameter Setting Group

Analog Output

This function is used to set the analog output channel. The analog signal can be

output into 0-5V voltage or 4-20 mA current. There are four analog output

channels available in PowerFlex 6000 drives – one for actual frequency variant,

one for stator current variant, and the rest are reserved.

The selected variant will undergo a Low-Pass Filter, Amplitude-correction, and

Amplitude-limitation process before the final result is output as a 0-5V and 4-20

mA analog signal. See the following diagram for the process.

Figure 3 - Analog Output Function Diagram

The actual frequency was filtered through the Low-Pass Filter with the filter time

set to one second, amplitude scaling factor to 50%, offset to zero, and the output

channel number is one.

Analog Output #1 Memory Address (P332) = 252

Analog Output #1 Filter Time (P333) = 1000 ms

Analog Output #1 Offset (P334) = 0

Analog Output #1 Scaling Factor (P335) = 50.00%

Hardwired I/O Interface Description Related Parameters

I/O0 High voltage can be closed P300, P301, P302, P303

I/O1 System running P304, P305, P306, P307

I/O2 System fault P308, P309, P310, P311

I/O3 System trip P312, P313, P314, P315

I/O4 Warning P316, P317, P318, P319

I/O5 Warning bell P320, P321, P322, P323

I/O6 Customized trip P324, P325, P326, P327

I/O7 Pre-charge complete P328, P329, P330, P331

Low-pass Filter

Y = x / (P333 * s + 1)

Linear Transformation

Y = P335 * (x +P334)

Limit Amplitude

Digital/Analog

Transformation

0-5V

4-20 mA

20 Rockwell Automation Publication 6000-TD004D-EN-P - November 2017

Chapter 1 Functional Descriptions

Table 4 - Analog Output Display Parameter Setting Group

Drive Configuration

The drive configuration include the following functions:

• Fan Control

on page 20

• Pre-charge Control on page 23

• Customized Trip on page 25

• Over Speed on page 26

Fan Control

This function is used to manage heat dissipation in the transformer cabinet, filter

cabinet, and power module cabinet when the drive is running. If the additional

heat generated is not dissipated in time, the drive will trip, or the transformer,

power module, or filter device may be damaged. There are three fan control

modes – non-redundant fan, one fan as redundant fan, all fans work in cycle

mode. Configuring a redundant fan can help to improve reliability of the drive

and reduce downtime.

Table 5 - PLC I/O and K Register Definition

Analog Output Data Storage Parameters Hardwired I/O

Interface (current)

Hardwired I/O

Interface (voltage)

Actual frequency K252 P332, P333,

P334, P335

IoutA equals P11.5

Signal ground equals P11.1

UoutA equals P10.5

Signal ground equals P10.1

System current K206 P336, P337,

P338, P339

IoutB equals P11.6

Signal ground equals P11.2

UoutB equals P10.6

Signal ground equals P10.2

Channel 3 Reserved P340, P341,

P342, P343

IoutC equals P11.7

Signal ground equals P11.3

UoutC equals P10.7

Signal ground equals P10.3

Channel 4 Reserved P344, P345,

P346, P347

IoutD equals P11.8

Signal ground equals P11.4

UoutD equals P10.8

Signal ground equals P10.4

Fan Control I/O Assign

TX Cabinet Fan Control Power Cabinet Filter Cabinet

PLC Module PLC8 PLC9

Fan CMD I/O O-8 O-9 O-10 O-11 O-12 O-13 O-14 O-15 O-0 O-1 O-2 O-3 O-4 O-5 O-6 O-7 O-8 O-9 O-10 O-11 O-12

Register Mapping K201...K202 K203 K204

PLC Module PLC7

Fan Fdb I/O I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11 I-12 I-13 I-14 I-15 I-16 I-17 I-18 I-19 I-20 I-21

Register Mapping K66 and K67 K68 K69

Fan Type Definition TX1 Main Cooling Fan I/O TX2 Main Cooling Fan I/O R-Fan

I/O

Main

Cooling

Fan

R-Fan

I/O

R-Fan

I/O

R-Fan

I/O

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Allen-Bradley PowerFlex 6000 Firmware, Parameters, And Troubleshooting Manual

Allen-Bradley PowerFlex 6000 Firmware, Parameters, And Troubleshooting Manual

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