Allen-Bradley PowerFlex 753 User manual

PowerFlex 750-Series AC Drives

Quick Start

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, PowerFlex, Rockwell Software, and Rockwell Automation 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 750-QS001A-EN-P - March 2015 3

Table of Contents

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

Introduction

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supported Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

For More Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 1: Gather Required Information

Record Motor Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 2: Validate the Drive Installation

Identify Which Drive You Have. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Verify Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Verify Power Jumper Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Verify I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Where are Signal Sources Connected? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 3: Power Up, Configure the Drive, and Spin the Motor Shaft

Power the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Drive Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 4: Set Up Speed Reference and Start/Stop

Input/Output Configuration Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 5: Special Considerations

Step 6: Verify Drive Operation

Configuration Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Reference Section

Determine Drive Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Identify Option Modules and Compatible Ports . . . . . . . . . . . . . . . . . . . . 32

Drive Device Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

HIM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Resetting Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Typical Speed Reference Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

EtherNet/IP Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2-Wire and 3-Wire Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4Rockwell Automation Publication 750-QS001A-EN-P - March 2015

Table of Contents

Dynamic Brake Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Acceleration and Deceleration Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Direction Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Analog Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Digital Output Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Relay Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Disable the HIM Start Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

HIM CopyCat Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

If You Have to Contact Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . 83

Rockwell Automation Publication 750-QS001A-EN-P - March 2015 5

Introduction

This Quick Start publication is designed to guide you through the 6 BASIC STEPS that are required to start up your

PowerFlex 750-Series AC drive for the first time for simple applications.

Who Should Use This Manual

This manual is intended for qualified personnel.

• You must understand the hazards that are associated with electromechanical equipment installations.

• You must understand and follow all applicable local, national, and/or international electrical codes.

• You must be able to program and operate Adjustable Frequency AC Drive devices.

• You must have an understanding of the parameter settings and functions.

Equipment

The following equipment requirements apply to the use of this publication.

• The drive is a PowerFlex 750-Series in a standalone installation.

• No load sharing or multiple motors on a single drive.

• The drive is equipped with either a PowerFlex 20-HIM-A6 or a 20-HIM-C6S Human Interface Module (HIM).

• The drive is used with an induction motor type only.

Supported Applications

This publication is intended for use on typical applications such as fans, pumps, compressors, and conveyors.

Installation

The content of this manual assumes that the drive is installed according to Rockwell Automation guidelines and includes

the following.

• The drive installation meets mechanical requirements for drive orientation, cooling airflow, and mounting hardware.

• The drive installation meets environmental requirements for surrounding air temperature, ambient atmosphere, and

the enclosure rating.

• The drive installation meets electrical requirements for AC supply, motor sizing, wiring and grounding, and

overload and short circuit protection.

• The drive installation is compliant with all applicable local, national, and international codes, standards, and

requirements.

IMPORTANT

PowerFlex 750-Series drives handle multiple types of motors and applications globally that are not covered in this manual.

6Rockwell Automation Publication 750-QS001A-EN-P - March 2015

Introduction

For More Information

The following table lists publications that provide general drive-related information.

Resource Description

PowerFlex 750-Series AC Drives Technical Data,

publication 750-TD001

Provides detailed information on:

• Drive specifications

• Option specifications

• Fuse and circuit breaker ratings

PowerFlex 750-Series AC Drives Installation Instructions,

publication 750-IN001

Provides detailed information on:

• Drive installation

•Powerwiring

•I/Owiring

PowerFlex 750-Series AC Drives Programming Manual,

publication 750-PM001

Provides detailed information on:

• I/O, control, and feedback options

• Parameters and programming

• Faults, alarms, and troubleshooting

PowerFlex 750-Series AC Drives Reference Manual,

publication 750-RM002

Provides detailed information on utilizing specific drive

features in common applications.

Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

Provides the basic information needed to properly install,

protect, wire, and ground pulse width modulated (PWM)

AC drives.

PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface

Module) User Manual, publication 20HIM-UM001

Provides detailed information on HIM components,

operation, and features.

PowerFlex Dynamic Braking Resistor Calculator

Application Technique, publication PFLEX-AT001

Provides detailed information on dynamic braking

components, operation, and features.

PowerFlex 20-750-ENETR Dual-Port EtherNet/IP Option

Module User Manual, publication 750COM-UM008

Provides detailed information on installing, configuring,

using, and troubleshooting the dual-port EtherNet/IP

option module.

PowerFlex 755 Drive Embedded EtherNet/IP Adapter User

Manual, publication 750COM-UM001

Provides detailed information on installing, configuring,

using, and troubleshooting the embedded EtherNet/IP

adapter.

Rockwell Automation Publication 750-QS001A-EN-P - March 2015 7

Step 1: Gather Required Information

When you apply power to your drive for the first time, you need to enter specific information about your application. You

need to enter motor nameplate data and set up your I/O.

Step 1: Gather Required Information helps you to verify that you have the needed information prior to drive powerup.

Record Motor Nameplate Data

Record the motor nameplate data to be entered into the Motor Data parameters during powerup. You can also record data

for up to five drive/motor combinations. Use this table to record a descriptive name for each drive/motor combination and

their respective parameters.

Drive/Motor Name

(example, Main Exhaust Fan)

Drive/Motor 1: Drive/Motor 2: Drive/Motor 3: Drive/Motor 4: Drive/Motor 5:

Parameter

No.

Parameter

Name

Drive/Motor 1: Drive/Motor 2: Drive/Motor 3: Drive/Motor 4: Drive/Motor 5:

25 Motor NP Volts

26 Motor NP Amps

27 Motor NP Hertz

28 (1)

(1) Use the Slip RPM rather than the Synchronous RPM.

Example: Use 1750 RPM rather than 1800 RPM for a 60 Hz motor.

Motor NP RPM

29 (2)

(2) The default units for parameter 29 [Motor NP Pwr Units] is horsepower (Hp).

Mtr NP Pwr Units ❑kW ❑Hp ❑kW ❑Hp ❑kW ❑Hp ❑kW ❑Hp ❑kW ❑Hp

30 Motor NP Power

31 (3)

(3) To calculate: Number of poles = 120 x parameter 27 [Motor NP Hertz] / parameter 28 [Motor NP RPM]. Round the result to the nearest even whole number.

Example: 120 x 60 Hz / 1800 RPM = 4 poles

Motor Poles

8Rockwell Automation Publication 750-QS001A-EN-P - March 2015

Step 2: Validate the Drive Installation

It is important that you thoroughly inspect each of your drive installations before applying power for the first time. This is

especially important if you did not personally perform the installation tasks. Satisfy yourself now that each drive is ready to

be energized when you get to Step 3: Power Up, Configure the Drive, and Spin the Motor Shaft.

Identify Which Drive You Have

There are two types of PowerFlex 750-Series drives, the PowerFlex 753 and the PowerFlex 755. There are some important

differences between the drives that need to be considered in subsequent steps. If you don’t know how to determine what

type of drive you have, see Determine Drive Type on page 22.

Verify Power Wiring

Visually inspect the power wiring connections to each drive. Be sure you are satisfied that the correct wires are connected to

the input terminals and to the output terminals. See Power Wiring on page 23 for more information on where these

connections are made.

ATTENTION: To avoid an electric shock hazard, the drive must be locked and tagged before continuing Step 2: Validate the Drive

Installation. Failure to comply can result in personal injury and/or equipment damage.

Drive/Motor Name

(example, Main Exhaust Fan)

Drive/Motor 1: Drive/Motor 2: Drive/Motor 3: Drive/Motor 4: Drive/Motor 5:

Installed Drive ❑753 ❑755 ❑753 ❑755 ❑753 ❑755 ❑753 ❑755 ❑753 ❑755

Verify Wiring Drive 1

Wiring is Correct

Drive 2

Wiring is Correct

Drive 3

Wiring is Correct

Drive 4

Wiring is Correct

Drive 5

Wiring is Correct

AC input power is on L1, L2, L3 / R, S, T. ❑❑❑❑❑

Output motor connection is on T1, T2, T3 / U, V, W. ❑❑❑❑❑

Proper ground wire terminations at PE ground studs. ❑❑❑❑❑

If equipped, dynamic brake resistor connection is on BR1 and BR2.

If wires are present, go to Dynamic Brake Resistor on page 66 to record

dynamic brake resistor nameplate information.

❑❑❑❑❑

IMPORTANT

Rockwell Automation recommends that XLPE-type cabling be used on output of the drive.

Rockwell Automation Publication 750-QS001A-EN-P - March 2015 9

Step 2: Validate the Drive Installation

Verify Power Jumper Configuration

PowerFlex 750-Series drives contain protective MOVs and common mode capacitors that are referenced to ground. To

guard against drive damage and/or operation problems, these devices must be properly configured.

Record that the power jumper configuration for each drive is correct.

Verify I/O Wiring

To properly configure a drive, you need to know the source of the speed reference and the start/stop commands. There are

three places where signal sources (such as push buttons and potentiometers) are connected to the drive.

1. The drive’s main control board.

• Terminal block TB1 on a PowerFlex 753

• Embedded EtherNet/IP port on a PowerFlex 755

• Terminal block TB1 on a PowerFlex 755 Di0

2. An expansion I/O module.

3. A communication network module.

IMPORTANT

A properly configured drive has all jumpers connected or all jumpers disconnected, depending on whether the power source is

solid grounded or non-solid grounded. If jumpers are not all connected or all disconnected, the power jumpers are not properly

configured. The drive power source type must be accurately determined and the jumpers must be configured for the power source.

See Power Jumpers on page 27 for more information on common power source types and where power jumpers are in the drive.

Valid Power Jumper Configurations

Power Source Jumper Positions (1)

(1) See Power Jumper Locations on page 28.

Solid Ground All Connected

Non-solid Ground, including High-resistance Grounding All Disconnected

Drive 1

Power jumpers are

configured correctly.

Drive 2

Power jumpers are

configured correctly.

Drive 3

Power jumpers are

configured correctly.

Drive 4

Power jumpers are

configured correctly.

Drive 5

Power jumpers are

configured correctly.

❑❑❑❑❑

IMPORTANT

The drive can always be controlled by the HIM for speed, start, and stop control. If that is the case for operating conditions, proceed

to Step 3: Power Up, Configure the Drive, and Spin the Motor Shaft on page 12.

10 Rockwell Automation Publication 750-QS001A-EN-P - March 2015

Step 2: Validate the Drive Installation

Where are Signal Sources Connected?

Use this diagram to help determine where signal sources are connected in each of your drives.

You will need this information when you get to Step 4: Set Up Speed Reference and Start/Stop on page 17.

IMPORTANT

The 750-Series drive uses the term ‘Port’ to designate (in software) the physical location where hardware is located for ease of

selecting hardware or functions to program. For more information on port locations, see Drive Device Ports on page 33.

Item Description

(1) Terminal block TB1, PowerFlex 753 drives.

(2) Embedded EtherNet/IP, PowerFlex 755 drives.

(3) Expansion I/O module, PowerFlex 753 and 755 drives.

(Port 4 installation shown.)

(4) Communication network module, PowerFlex 753 drives.

(Port 6 installation shown.)

(5) Terminal block TB1 on PowerFlex 755 drive is located behind

the Ethernet port.

Ao0-

Ao0+

10VC

+10V

Ai0-

Ai0+

Ptc-

Ptc+

To0

24VC

+24V

Di C

Di 1

Di 2

PTC–

PTC+

Ao0–

Ao0+

Ao1–

Ao1+

–10V

10VC

+10V

Ai0–

Ai0+

Ai1–

Ai1+

24VC

+24V

DiC

Di0

Di1

Di2

Di3

Di4

Di5

PTC–

PTC+

Ao0–

Ao0+

Ao1–

Ao1+

–10V

10VC

+10V

Ai0–

Ai0+

Ai1–

Ai1+

24VC

+24V

DiC

Di0

Di1

Di2

Di3

Di4

Di5

PowerFlex 753 PowerFlex 755

(1)

(3)

(4)

(2)

(3)

Port Location

Examples Port Location

Examples

(5)

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