Allen-Bradley PowerFlex 755T User manual

PowerFlex 750-Series Products with TotalFORCE Control

Catalog Numbers 20G , 20J

Installation Instructions

Original Instructions

Important User Information

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

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

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

and standards.

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

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

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

be impaired.

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

the use or application of this equipment.

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

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

liability for actual use based on the examples and diagrams.

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

software described in this manual.

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

Inc., is prohibited

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

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

WARNING: Identifies information aboutpractices 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 iscritical 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.

BURNHAZARD:Labels may be onor inside theequipment, for example, adriveormotor,toalert peoplethatsurfacesmay

reach dangerous temperatures.

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

potentialArcFlash.ArcFlashwillcausesevereinjury or death. WearproperPersonalProtectiveEquipment(PPE).FollowALL

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

Rockwell Automation Publication 750-IN100B-EN-P - July 2017 3

TableofContents

Preface

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 1

Product Overview General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Product Rating Cross-references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hardware Installation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2

Receiving, Handling, and Storage Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shipment Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 3

Prepare for Installation CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Location Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Minimum Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Recommended Cabinet Mounting Hardware. . . . . . . . . . . . . . . . . . . . 39

Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installation Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 4

Mechanical and Electrical

Installation Prepare Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Component Removal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Remove Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Remove Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Remove LCL Filter Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Place the Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Join Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Affix the Enclosures to the Floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Electrical Interconnections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Fiber-optic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Chapter 5

Power Wiring Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Power Cable Types Acceptable for 400…690 Volt Installations. . . 101

Motor Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4Rockwell Automation Publication 750-IN100B-EN-P - July 2017

Table of Contents

Field Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Recommended Cable Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Short Circuit Current Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Input Contactor Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Output Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Bypass Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Applying and Removing Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Drive Power Jumper Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Chapter 6

I/O Wiring I/O Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Access Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Main Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Hardware Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Safety Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Fiber Optic Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Option Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

11-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

11-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

22-Series I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

22-Series I/O Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Safe Torque Off Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Safe Speed Monitor Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Integrated Safety - Safe Torque Off Option Module. . . . . . . . . . . . . 165

DeviceNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

ControlNet Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Dual-Port EtherNet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . 168

Profibus Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

BACnet/IP Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Single Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . 171

Dual Incremental Encoder Option Module. . . . . . . . . . . . . . . . . . . . . 173

Universal Feedback Option Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Motor Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Feedback Device Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Motor Feedback Wiring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Rockwell Automation Publication 750-IN100B-EN-P - July 2017 5

Preface

This manual provides procedures for the mechanical and electrical installation

of PowerFlex® 750-Series products with TotalFORCE™ control. This manual

includes the basic steps to transport, position, and join the product enclosures,

to make internal electrical connections, to connect power and the motor, and

to wire basic I/O.

This manual provides instructions for an initial product installation. Assembly

procedures in chapters 1...4 assume that supply power is not connected. 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.

This manual is intended for two types of personnel:

• Qualified personnel familiar with handling heavy equipment.

• Qualified electricians or other personnel who have experience with

electrical terminology, equipment, methods, and safety precautions.

The Additional Resources section is a directory of Rockwell Automation

publications that provide detailed drive information from wiring and

grounding recommendations to troubleshooting and repair.

Additional Resources The following table lists publications that provide general drive-related

information.

Resource Description

PowerFlex 750-Series Products with TotalFORCE Control

Technical Data, publication 750-TD100 Provides detailed information on:

• Drive and bus supply specifications

• Option specifications

• Fuse and circuit breaker ratings

PowerFlex 755TM IP00 Open Type Kits Technical Data,

publication 750-TD101 Provides detailed information on:

• Kit selection

• Kit ratings and specifications

• Option specifications

PowerFlex 755TM IP00 Open Type Kits Installation

Instructions, publication 750-IN101 Provides instructions to install IP00 Open Type kits in

user-supplied enclosures.

PowerFlex Drives with TotalFORCE Control Programming

Manual, publication 750-PM100 Provides detailed information on:

• I/O, control, and feedback options

• Parameters and programming

• Faults, alarms, and troubleshooting

Drives in Common Bus Configurationswith PowerFlex

755TM BusSupplies Application Techniques, publication

DRIVES-AT005

Provides basic information to properly wire and

ground the following products in common bus

applications:

• PowerFlex 755TM drive system for common bus

solutions

• PowerFlex 750-Series AC and DC input drives

• Kinetix 5700 servo drives

PowerFlex 755T Flux Vector Tuning, publication 750-AT006 Provides guidance on how to tune Flux Vector

position and velocity loops, filters, and other features

to achieve the level of performance that is required

for a given application. This publication is intended

for novice drives users and users with advanced skills.

6Rockwell Automation Publication 750-IN100B-EN-P - July 2017

Preface

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page.

To order paper copies of technical documentation, contact your local Allen-

Bradley distributor or Rockwell Automation sales representative.

PowerFlex Drives with TotalFORCE Control Built-in

EtherNet/IP Adapter User Manual, publication 750COM-

UM009

Providesinformationonhow toinstall,configure,and

troubleshoot applications for the PowerFlex drives

with the built-in EtherNet/IP adapter.

PowerFlex 750-Series Products with TotalFORCE Control

Hardware Service Manual, publication 750-TG100 Provides detailed information on:

• Preventive maintenance

•Componenttesting

• Hardware replacement procedures

PowerFlex 750-Series Safe Speed Monitor Option Module

Safety Reference Manual, publication 750-RM001 These publications provide detailed informationon

installation, set-up, and operation of the 750-Series

safety option modules.

PowerFlex 750-Series Safe Torque Off Option Module User

Manual, publication 750-UM002

PowerFlex 750-Series ATEX Option Module User Manual,

publication 750-UM003

PowerFlex 755 Integrated Safety - Safe Torque Off Option

Module User Manual, publication 750-UM004

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

Module) User Manual, 20HIM-UM001 Provides detailed information on HIM components,

operation, and features.

PowerFlex 755TM AC Precharge Modules Unpacking and

Lifting Instructions, publication 750-IN102 These publications provide detailed information on:

• Component weights

• Precautions and recommendations

• Hardware attachment points

• Lifting the component out of the packaging

PowerFlex 755TM DC Precharge Modules Unpacking and

Lifting Instructions, publication 750-IN103

PowerFlex 755TM Power and Filter Modules Unpacking

and Lifting Instructions, publication 750-IN104

PowerFlex750-SeriesServiceCart Instructions,publication

750-IN105 Provides detailed set-up and operating instructions

for the module service cart and DC precharge module

lift.

PowerFlex 755TM Power and Filter Module Storage

Hardware Instructions, publication 750-IN106 Provides detailed installation and usage instructions

for this hardware accessory.

PowerFlex 755T Module Service Ramp Instructions,

publication 750-IN108 Provides detailed usage instructions for the module

service ramp.

Industry InstallationGuidelinesforPulseWidthModulated

(PWM) AC Drives, publication DRIVES-AT003 Provides basic information on enclosure systems,

considerations to help protect against environmental

contaminants, and power and grounding

considerations for installing Pulse Width Modulated

(PWM) AC drives.

Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives, publication DRIVES-IN001 Provides basic information to properly wire and

ground PWM AC drives.

Product Certifications website, http://

www.rockwellautomation.com/global/certification/

overview.page

Provides declarations of conformity, certificates, and

other certification details.

Rockwell Automation Knowledge Base The Rockwell Automation Support Forum

Resource Description

Rockwell Automation Publication 750-IN100B-EN-P - July 2017 7

Chapter 1

Product Overview

PowerFlex 750-Series products with TotalFORCE control are Architecture

Class AC drives, bus supplies, and common bus inverters. These products are

designed for applications that require harmonic mitigation, regeneration, or

common-bus system configurations. These products provide a broad set of

features and application-specific parameters, and they are ideal for high-

performance applications.

In this manual we refer to the PowerFlex 750-Series products with

To ta l FO RCE c ontrol a s :

• PowerFlex 755T products when referring to the group of drives, bus

supplies, and common bus inverters.

• PowerFlex 755TL drive when referring to the low harmonic drive

product.

• PowerFlex 755TR drive when referring to the regenerative drive

product.

• PowerFlex 755TM drive system when referring to regenerative bus

supply and common bus inverter products.

General Precautions Read the following precautions before you begin installation of the product.

Qualified Personnel

ATTENTION: Only qualified personnel familiar withadjustable frequency AC

drives and associated machinery should plan or implement the installation,

start-up and subsequent maintenance of the system.Failure to comply may

result in personal injury and/or equipment damage.

8Rockwell Automation Publication 750-IN100B-EN-P - July 2017

Chapter 1 Product Overview

Personal Safety

Product Safety

ATTENTION: To avoidan electric shock hazard, verify that the voltage on the

bus capacitors has discharged completely beforeservicing. Remove power

and wait five minutes beforeyou open theenclosure door.Measure theDC

bus voltage at the -DC and +DC TESTPOINT socketson the front ofthe power

module (see Remove Power from the Drive System on page 102for location).

ATTENTION: Hazard of personal injury or equipment damage exists when

using bipolar input sources. Noise and drift in sensitive input circuits can

cause unpredictable changes in motor speed and direction. Use speed

command parameters to help reduce input source sensitivity.

ATTENTION: Risk of injury or equipment damage exists. DPI™ or SCANport™

host products must not be directly connected together via 1202 cables.

Unpredictable behavior can result if two or more devices are connected in

this manner.

ATTENTION: Thedrivestart/stop/enablecontrolcircuitry includessolidstate

components. If hazards due to accidental contact with moving machinery or

unintentionalflowofliquid,gasorsolidsexists,anadditionalhardwiredstop

circuit may be required to remove the AC line to the drive. An auxiliary

braking method may be required.

ATTENTION: Hazard of personal injury or equipment damage due to

unexpected machine operation exists if the drive is configured to

automatically issue a Start or Run command. Do not use these functions

without considering applicable local, national and internationalcodes,

standards, regulations or industry guidelines.

ATTENTION: An incorrectly applied or installed drive can result in

component damage or a reduction in product life. Wiring or application

errors such as under sizing the motor, incorrect or inadequate AC supply, a

corrosiveenvironment,orexcessive surroundingair temperaturesmayresult

in malfunction of the system.

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 any applicableESD protection handbook.

ATTENTION: Configuring ananalog input for 0…20 mA operation and

driving it from a voltage source could cause component damage. Verify

proper configuration prior to applying input signals.

Rockwell Automation Publication 750-IN100B-EN-P - July 2017 9

Product Overview Chapter 1

Class 1 LED 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.

ATTENTION: To avoid an electric shock hazard, the installer must provide

guarding to shield exposed electrical equipment against accidental contact.

Exposed electrical components that carry potentially hazardous voltages are

identified in the PowerFlex 750-Series Product with TotalFORCE Control

Hardware Service Manual, publication 750-TG100. When installingthis

equipment, consider the design and placement of guarding to help prevent

personal injury of equipment damage.

10 Rockwell Automation Publication 750-IN100B-EN-P - July 2017

Chapter 1 Product Overview

Catalog Number Explanation

Drive

Code Type Frames

20G PowerFlex 755 8…12

20J PowerFlex 755TM Bus Supplies 8…12

Cooling Type

Code Description Frames

1 Forced Air 8…12

Input

Type

Code Description Frames

D Common Bus with DC Precharge 8…12

E Common Bus without DC Precharge 8…12

F Regenerative and Low Harmonic AFE 8…12

GLowHarmonicAFE

(1)

(1) Applies to 755TL products.

8…10

Enclosure

Code Description Frames

3 IP21, UL Type 1; Floor Mount 8…12

4 IP54, UL Type 12; Floor Mount 8…12

Voltage Rating

Code Voltage

C 400V AC; 3 PH

D 480V AC; 3 PH

E 600V AC; 3 PH

F 690V AC; 3 PH

PowerFlex 755TL/TR ND Rating

400V, 50 Hz Input

Code Amps kW Frame

302 302 160

367 367 200

460 460 250

540 540 315

585 585 315

650 650 355

750 750 400

770 770 400

920 920 500

1K0 1040 560

1K1 1112 630

1K2 1175 710

1K4 1465 800

1K6 1590 850

101K7 1715 1000

2K1 2156 1250

2K8 2849 1650 11

3K5 3542 2000 12

PowerFlex 755TL/TR ND Rating

600V, 60 Hz Input

Code Amps Hp Frame

242 242 250

295 295 300

355 355 350

395 395 400

435 435 450

545 545 550

595 580 600

690 690 700

760 760 800

825 825 900

980 980 1000

1K1 1045 1100

101K2 1220 1250

1K5 1430 1500

2K0 1946 2000 11

2K4 2420 2500 12

PowerFlex 755TL/TR ND Rating

480V, 60 Hz Input

Code Amps Hp Frame

302 302 250

361 361 300

430 430 350

505 505 400

545 545 450

617 617 500

710 710 600

740 740 650

800 800 700

960 960 800

1K0 1045 900

1K1 1135 1000

1K3 1365 1100

1K4 1420 1250

101K6 1655 1500

2K0 2072 1800

2K6 2738 2400 11

3K4 3404 3000 12

PowerFlex 755TL/TR ND Rating

690V, 50 Hz Input

Code Amps kW Frame

215 215 200

265 265 250

330 330 315

370 370 355

415 415 400

505 505 500

565 565 560

650 650 630

735 735 710

820 820 800

920 920 900

1K0 1030 1000

101K1 1150 1100

1K4 1419 1400

1K8 1865 1800 11

2K3 2318 2300 12

1…3 4 5 6 7 8…10 11 12 13 14 15 16 17 18

20G

1 G 3 D 740 L N A N N N N N -C0-P15…

abcde ghif1…f4

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