Rockwell Automation Allen-Bradley PowerFlex 755TS Series Bedienungsanleitung

PowerFlex 755TS Products

with TotalFORCE Control

Catalog Numbers 20G2, 20GE

Installation Instructions Original Instructions

2Rockwell Automation Publication 750-IN119A-EN-P - April 2022

PowerFlex 755TS Products with TotalFORCE Control Installation Instructions

Important User Information

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

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

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

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

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

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

impaired.

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

or application of this equipment.

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

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

actual use based on the examples and diagrams.

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

described in this manual.

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

prohibited.

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

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

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-IN119A-EN-P - April 2022 3

Preface

Commonly Used Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Line to Load Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

Product Overview Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Product Rating Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hardware Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Configuration Tool Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 2

Receiving, Handling, and

Storage

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Approximate Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 3

Prepare for Installation CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Location Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 4

Mechanical and Electrical

Installation

Installation of Products with Corrosive Gas Protection (XT). . . . . . . . . 51

Access Panels, Covers, and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Hardware Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Safety Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Drive Device Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Chapter 5

Power Wiring AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Motor Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

RF Emission Category C3 Compliant Wiring. . . . . . . . . . . . . . . . . . . . . . . 61

Power Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Terminal Block Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Three-phase Power Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Frames 1…7 AC Input Power Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Frames 5…7 Common DC Input Terminal Locations . . . . . . . . . . . . . . . . 68

Frames 5…7 Common DC Input Power Terminals . . . . . . . . . . . . . . . . . . 70

Fuse and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Intermittent Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4Rockwell Automation Publication 750-IN119A-EN-P - April 2022

Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Short-circuit Current Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Apply and Remove Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Input Contactor Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Output Contactor Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Bypass Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drive Power Jumper Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Chapter 6

Service and Maintenance Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 85

Shock Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Maintenance of Industrial Control Equipment. . . . . . . . . . . . . . . . . . . . . 89

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Commonly Used Installation and Service Tools . . . . . . . . . . . . . . . . . . . . 95

Remove Power from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Start Up After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

No-load DC Bus Voltage and Output Current Measurements. . . . . . . . 97

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 5

Preface

This manual provides procedures for the mechanical and electrical installation

of PowerFlex® 755TS products with TotalFORCE® control.

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 mechanical electrical

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.

Commonly Used Installation

Tools

See Chapter 6 on page 85 for a list of common tools used for installing

PowerFlex 755TS products.

6Rockwell Automation Publication 750-IN119A-EN-P - April 2022

Preface

Line to Load Installation

Guidelines

This section provides direction for how and where to find information from

line to load on the successful installation and implementation of PowerFlex

755TS drives.

Topic PowerFlex 750-Series Drives

AC supply source Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 2 – System Configurations.

Input power

conditioning Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 2 – AC Line Impedance.

1321 Power Conditioning Products Technical Data, publication 1321-TD001

See this publication for line reactors and isolation transformers.

Input fusing and

circuit breakers See Fuse and Circuit Breaker Ratings on page 71.

Input power wire

and cable Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 1 – Input Power Cables.

EMC filters See Installation Requirements Related to EN 61800-3 and the EMC Directive on page 27.

Electrical

interference Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 6 – How Electromechanical Switches Cause Transient Interference.

Grounding Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 3 – Grounding.

See Grounding Requirements on page 60.

GND

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 7

Preface

Jumpers See Drive Power Jumper Configuration on page 77.

Mounting

considerations See Mounting Surface on page 29 and Minimum Clearances on page 30.

Environment Industry Installation Guidelines for Pulse-width Modulated (PWM) AC Drives Application Technique,

publication DRIVES-AT003

See this publication for information for different enclosure systems and environmental/location

considerations (to help protect against environmental contaminants), and power and grounding

considerations.

See Environment on page 29.

Control and signal

cabling Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 4 – Wire Routing.

PowerFlex 750-Series I/O, Feedback, and Power Option Modules Installation Instructions, publication

750-IN111

Output power

cabling Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 1 – Motor Cables.

Output devices Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 6 – Shielded or Armored Power Cable.

1321 Power Conditioning Products Technical Data, publication 1321-TD001

See this publication for load reactors, RWRs, and common mode chokes/cores.

1204 Terminator Instructions, publication 1204-IN002

See this publication for motor terminators.

See Output Contactor Precaution on page 77.

Cable length Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 5 – Length Restrictions for Motor Protection.

Encoder Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Chapter 1 – Analog Signal and Encoder Cable.

Motor Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

See Appendix A – Overview.

Topic PowerFlex 750-Series Drives

PowerFlex 755TS Drive

WVUGND

PE (T1) (T2) (T3)

(L3)(L2)(L1)GND

PE R S T

8Rockwell Automation Publication 750-IN119A-EN-P - April 2022

Preface

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

information.

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

Resource Description

PowerFlex 750-Series Products with TotalFORCE Control

Reference Manual, publication 750-RM100 Provides detailed setup and programming

instructions for common applications.

PowerFlex TotalFORCE Firmware Documentation Set:

• PowerFlex Drives with TotalFORCE Control

Programming Manual, publication 750-PM101

• PowerFlex Drives with TotalFORCE Control Parameters

Reference Data, publication 750-RD101

• PowerFlex Drives with TotalFORCE Control Conditions

Reference Data, publication 750-RD102

Provides detailed information on:

• Startup, control algorithms, and status indicators

• Parameters and programming

• Faults, alarms, events, and troubleshooting

PowerFlex 755TS Products with TotalFORCE Control

Technical Data, publication 750-TD104 Provides detailed information on:

• Drive specifications

• Option specifications

• Fuse and circuit breaker ratings

PowerFlex 755T Products with TotalFORCE Control

Hardware Service Manual, publication 750-TG101 Provides detailed information on:

• Preventive maintenance

• Component testing

• Hardware replacement procedures

Drives in Common Bus Configurations with PowerFlex

755TM Bus Supplies 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.

PowerFlex 750-Series I/O, Feedback, and Power Option

Modules Installation, publication 750-IN111 Provides instructions to install and wire 750-Series

option modules.

PowerFlex Drives with TotalFORCE Control Built-in

EtherNet/IP Adapter User Manual, publication

750COM-UM009

Provides information on how to install, configure,

and troubleshoot applications for the PowerFlex

drives with the built-in EtherNet/IP™ adapter.

PowerFlex 750-Series Safe Speed Monitor Option Module

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

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.

Industry Installation Guidelines for Pulse Width Modulated

(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, rok.auto/certifications Provides declarations of conformity, certificates,

and other certification details.

Rockwell Automation Knowledge Base The Rockwell Automation Support Forum

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 9

Chapter 1

Product Overview

PowerFlex® 755TS Products with TotalFORCE® control are Architecture Class

AC drives. These products provide a broad set of features and application-

specific parameters, and they are ideal for high-performance applications.

Product Advisories Read the following precautions before you begin installation of the product.

Qualified Personnel

Personal Safety

ATTENTION: Only qualified personnel familiar with adjustable frequency AC

drives 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: Measure the DC bus voltage at the power terminal block by

measuring between the +DC and -DC terminals (see Figure 41 and Figure 42

for location) or between the +DC and -DC test point sockets if equipped. Also

measure between the +DC terminal or test point and the chassis, and

between the -DC terminal or testpoint and the chassis. The voltage must be

zero for all three measurements.

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: The drive start/stop/enable control circuitry includes solid

state components. If hazards due to accidental contact with moving

machinery or unintentional flow of liquid, gas or solids exists, an additional

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

auxiliary braking method may be required.

10 Rockwell Automation Publication 750-IN119A-EN-P - April 2022

Chapter 1 Product Overview

Product Safety

Waste Electrical and Electronic Equipment

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 international codes,

standards, regulations or industry guidelines.

ATTENTION: A possible hazard of personal injury due to prolonged exposure

to high sound levels. Follow applicable local, national, and international

codes, standards, regulations, or industry guidelines for hearing protection

when exposed to potentially damaging noise hazards.

ATTENTION: An incorrectly applied or installed drive system can result in

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

such as an under-sized motor, incorrect or inadequate AC supply, a corrosive

environment, or excessive surrounding air temperatures can result in

malfunction of the system.

ATTENTION: This product contains Electrostatic Discharge (ESD) sensitive

parts and assemblies. Static control precautions are required when you install

these assemblies. Component damage can result if ESD control procedures

are not followed. If you are not familiar with static control procedures,

reference any applicable ESD protection handbook.

ATTENTION: If you configure an analog 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.

At the end of its life, this equipment should be collected separately from any

unsorted municipal waste.

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