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Powerflex 755 installation manual

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This document provides instructions for the installation of an IP00, Open Type PowerFlex® drive (Frames 8 10) in a user supplied enclosure. PowerFlex Drive Embedded EtherNet/IP Adapter User. Manual, publication COM-UM These publications provide detailed information on to.


Drive Modernization Part V PowerFlex To PowerFlex | Horizon Solutions


The PowerFlex 4-Class of drives consists of two. The cost and performance of a DeviceNet , Select units for which you would like to see manuals, wiring diagrams or spare parts Monitor View , other important MCC information. Shaded areas are applicable to PowerFlex 40 only. Rockwell , are applicable to PowerFlex 40 only. DriveExplorer ,.

Remove the cassette. Allows for wiring space. Available in power ratings from 0. In no event will Rockwell Automation, Inc. The , added to the PowerFlex with a communication module. Contact your local Rockwell Automation Drive Systems representative. These enclosures are intended for indoor use primarily to provide a degree of protection against contact with enclosed equipment. These enclosures offer no protection against airborne contaminants.

Refer to Table 6 and Table 7 for an explanation of enclosure options. Operating Conditions and Temperatures PowerFlex Series drives are designed to operate at the following air temperatures without derating. Environmental Specifications Description m ft maximum without derating C F Important: Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust.

If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere. Pollution Degree Description 1 No pollution or only dry, non-conductive pollution occurs.

The pollution has no influence. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the drive is out of operation. Minimum Mounting Clearances Specified vertical clearance requirements indicated in Figure 1 are intended to be from drive to drive. Other objects can occupy this space; however, reduced airflow may cause protection circuits to fault the drive. The drive must be mounted in a vertical orientation as shown. In addition, inlet air temperature must not exceed the product specification.

Dimensions are in millimeters and inches. Weights are in kilograms and pounds. Frame A 2 Frame A 6 Frame 2 Important: Must use mounting hardware supplied to meet enclosure rating. Lifting the Drive The dimensions and weights specified must be taken into consideration when mounting the drive. All lifting equipment and lifting components hooks, bolts, lifts, slings, chains, etc.

Do not allow any part of the drive or lifting mechanism to make contact with electrically charged conductors or components.

Do not subject the drive to high rates of acceleration or deceleration while transporting to the mounting location or when lifting. Do not allow personnel or their limbs directly underneath the drive when it is being lifted and mounted. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. To guard against drive damage, these devices must be configured according to the recommendations in Table 21 on page See pages for jumper locations.

Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions are divided into 2 basic categories: 1. All drives The power system has power factor correction capacitors switch in and out of the system, either by the user or by the power company. The power source has intermittent voltage spikes in excess of volts.

These spikes could be caused by other equipment on the line or by events such as lightning strikes. The power source has frequent interruptions. The impedance on the input side of the drive is less than 0. If any of these conditions exist, additional source impedance is required. The total input impedance is a function of all transformers, cabling, and reactors if used that supply power to the drive. Guidelines must be followed when using non-inverter grade motors to avoid premature motor failures.

Hp Motor Drive Output 5 Hp 3. PVC jacket. Power 0. Signal 0. Combined 0. Control and signal wires should be separated from power wires by at least 0. The use of shielded wire for AC input power may not be necessary but is always recommended. If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

Grounding these terminals can cause signal noise. Recommended Torque 0. Flat Screwdriver 2 Pozidrive C Phillips 0. Recommended Torque Table 12 Frames 25 No. Terminating point to chassis ground for incoming AC line, motor shields, and control wire shields. Table 13 Frames 67 No. Dynamic Brake Resistor Terminals are optional on Frame 6 and 7 drives: catalog number position Refer to Catalog Number Explanation on page 4.

Table 14 Frame 5 Common Bus No. Table 15 Frames 67 Common Bus No. Refer to page 53 for information on removing common mode capacitors. Regenerative Unit to Drive Connections. Sizes listed are the recommended sizes based on 40 degree C and the U. Other country, state or local codes may require different ratings.

Refer to Table 18 which describes input device requirements based on physical installation choice. Heat sink is inside or acceptable. UL Certification Not Required. Installed inside or outside of any cabinet. Installed in any cabinet. Heat sink is inside or outside IP00 of cabinet. Devices in Table 19 excluding time delay fuses and maximum value for non-time delay fuses. All devices in Table 19 are All devices in Table 19 are acceptable.

All devices in Table 19 are acceptable. For optimum protection, semiconductor type fusing is recommended. For general purpose fusing, refer to the recommended types listed below. For example, a C drive can be used in Normal Duty mode on a 7. The drive can be programmed for either mode. Wiring and fuses can be sized based on the programmed mode. For any given drive catalog number, Normal Duty mode provides higher continuous current but smaller overload current with respect to Heavy Duty mode.

See parameter [Duty Rating]. See Table 8 for frame sizes of other enclosure types. Ratings shown are maximum. The trip setting should be set to the input current of the drive and should be sized for the continuous current of the system. UL compliance, Reduced electrical noise, Most stable operation, EMC compliance, Reduced voltage stress on components and motor bearings Helps avoid severe equipment damage when ground fault occurs.

To connect or disconnect these devices, refer to the jumper locations shown in Figure 32, Figure 33 and Figure Frames 25 use jumper screws to complete an electrical connection when installed. Install or remove jumper screws according to the recommendations in Table For Frames 25, completely remove the jumper screw from the circuit board. When power jumper screws are not used, they are stored on the left interior chassis wall as shown.

Frames 67 use jumper wires to complete an electrical connection when installed. Install or remove jumper wires according to the recommendations in Table For Frames 67, secure the disconnected jumper wire to the standoff provided.

Wire with an insulation rating of V or greater is recommended. Squeeze locking tabs and pull out bottom of cover. Pull cover down and away from the chassis.

Frames Loosen door screws. Gently pry the door open to remove. Hardware enable jumper. Removed when a hardware enable configuration is utilized. Safety enable jumper. Removed when safety option is installed. Input mode jumper. Select voltage mode or current mode. Cable connection for handheld and remote HIM options. Digital input power terminal block. Relay terminal block. Motor protection device Positive Temperature Coefficient.

Open drain output, 48V DC, mA maximum load. Drive supplied logic input power. Input provides high common mode immunity. Relay 0 Common Relay 0 N. Description Output Relay 0 normally closed contact. Output Relay 0 common Output Relay 0 normally open contact. Digital input common Connections for AC power supply. Table 28 Control Board Details No. Rotary switches for setting lowest octet of EtherNet address forces address to Network cable connection. Description Connections for AC power supply.

Digital input common Connections for DC power supply. Connections for drive supplied 24V power. Hardware Enable Circuitry The main control module has one digital input that can be used as a general purpose programmable input, or by removal of a jumper, configured as a dedicated hardware enable, which is unaffected by parameter settings.

To configure the input as a dedicated hardware enable, complete the following steps. Access the control pod as described beginning on page PowerFlex – J1 Jumper Location. This jumper must be removed when using the safe torque off or speed monitoring safety options. Important: Failure to remove the jumper will cause the drive to fault when a start command is issued. PowerFlex – J2 Jumper Location.

Option Module Installation Compatible port locations may be restricted for each module. An icon with position number s is provided to indicate which option module ports are compatible. For example, the icon to the right indicates that the option module is only compatible with port 4.

To avoid damaging the drive, verify that the voltage on the bus capacitors has discharged completely and all control power is removed before performing any work on the drive. To install an option module: 1. Firmly press the module edge connector into the desired port.

Tighten the top and bottom retaining screws. Related Param. Name Relay 0 N. Refer to Select A Device on page 96 for instructions on how to access parameters on an option module. Controller DiC Di0 Di1. Safe Torque Off Option Module The safe torque off option is just one component in a safety control system.

Components in the system must be chosen and applied appropriately to achieve the desired level of operational safety. Description User-supplied 24 volt power. Installation Notes 1. If not installed, the drive will fault when a start command is issued.

Enables pulse testing. Safe Limited Speed Output. Safe Stop Output. Module is not functional without these connections. Related Param 74 73 72 60 58 52 54 Important: When the Safe Speed Monitor option is used with the Dual Incremental Encoder option, both modules must be installed on the same backplane ports 6, 5, 4. Description Terminating point for wire shields when an EMC plate or conduit box is not installed. Power supply for encoder mA. Single channel or quadrature A input.

Quadrature B input. Pulse, marker or registration input. Power source for homing input. Captures the AB edge counter. Refer to Select A Device on page 96 for instructions on how to access an option parameter set. Enabled Position Storage Position. P4 – 12V Jumper Enables use with 12 volt supply in Enabled position and 5 volt supply in Storage position.

Terminating point for wire shields when an EMC plate or conduit box is not installed. Power supply for Encoder 1, mA. Initializing, not active. Communication lost, attempting to reconnect. Operational, no faults are present. Module error. Check P1 [Module Sts] Normal operation. Module is booting. Fatal module error.

Cycle power Flash update module firmware Replace module A type 2 alarm condition exists. Check P1 [Module Sts] A type 1 alarm condition exists. Check P1 [Module Sts] Module is flash updating. Flashing Alternately Off Not powered.

Not communicating. Flashing Module is attempting to communicate with the DPI host. Steady Properly connected and communicating. Module is flash updating. Flashing Module is not communicating with the DPI host. Steady DPI communication failure such as invalid port. Flashing Normal operation. Quadrature B input or encoder output.

Pulse, marker or registration input or encoder output. Important: Only one linear feedback device can be connected to the option module. Important: The Auxiliary Power Supply option module may be installed in any option port. Due to its size, the module will extend over and block an adjacent port.

Therefore, installation in Port 8 is recommended. A connector cable is provided with Auxiliary Power Supply option modules for use in PowerFlex drives. The cable is used to connect the module to the backplane when installed on the upper control pod brackets. The connector cable is not used with PowerFlex drives.

Sets the node address of the option module. Channel B redundant BNC connection to the network. See Table Only works in the Modbus RTU mode. Requires this adapter firmware version or higher. Requires firmware version v1. Chinese, Japanese, and Korean languages are supported at the time of publication. Some of the voltages present are at incoming line potential.

To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. Confirm that all inputs are connected to the correct terminals and are secure. Verify that AC line power at the disconnect device is within the rated value of the drive. Verify that control power voltage is correct. Figure 36 DPI Ports and. Apply AC power and control voltages to the drive.

If any digital inputs are configured to Stop CF, Run, or Enable, verify that signals are present or the drive will not start. Refer to Troubleshooting Drive Fault and Alarm Descriptions on page 98 for a list of potential digital input conflicts. When prompted, select a display language. The Start-Up Screen will automatically display for drives that have not been previously configured. If the Start-Up screen is not displayed press the Enter key.

Press the Enter key to display the Start-Up Menu. Press the Enter key. Follow the menu using the Enter key which will step you through the Start-Up routine. The Start-Up routine asks simple questions and prompts you to input required information.

General Startup. To access the Start-Up menu after the initial drive power-up, apply power to the drive. Upon a subsequent power up, the Status screen for Port 00 Host Drive is shown by default. LCD Display Elements. The Status Bar provides information about the operating condition of the Host Drive. Figure 41 Status Bar on the Display Screen. Indicates current Host Drive operating status.

Text flashes when a fault is present. Indicates drive output feedback for example, Hz, RPM, amps, etc. Bell icon indicates that an alarm is present. Indicates direction of Host Drive operation. Up to five dynamic soft keys shown shaded in Figure 42 may be available. Figure 42 Soft Keys. The five gray number keys 0, 1, 3, 7, and 9 are used only to enter their respective numeric value. Figure 43 Navigation and Number Keys. Description Enters the numeric value 2.

Scrolls down to select an item. Enters the numeric value 4. Scrolls left to select an item. Enters the numeric value 5. Displays the next level of a selected menu item. Enters new values. Performs intended actions. Enters the numeric value 6.

Scrolls right to select an item. Enters the numeric value 8. Scrolls up to select an item. Each of the four single-function keys shown in Figure 44 always performs only its dedicated function. Figure 44 Single Function Keys. Description Start the drive. Access parameters, diagnostics, memory functions, preferences, and other tasks such as Start-Up. Used to stop the drive or clear a fault. This key is always active. Controlled by parameter [Stop Mode A]. Connectors and embedded devices have fixed port numbers that cannot be changed.

Option modules are assigned a port number when installed. Figure 45 Drive Device Ports 00 07 08 01 14 04 05 06 13 Description Fixed port for the drive. Fixed port at HIM cradle connector. Splitter cable connector provides Port 01 when HIM cradle connector is unused. Splitter cable connection. Provides Port 02 and Port Option Modules Available ports for option modules. Ports 07 and 08 PowerFlex drives only. Reserved for future use. Access the Status Screen. When the drive is powered up, the Status screen for Port 00 Host Drive is shown by default.

Drive running, no faults are present. Yellow Drive is not running, a type 2 non-configurable alarm condition exists and the drive cannot be started. Steady Drive is not running, a type 1 alarm condition exists. The drive can be started. Red Flashing A major fault has occurred. Drive will stop. Drive cannot be started until fault condition is cleared. Steady A non-resettable fault has occurred.

When running, the drive continues to run. Yellow Alternately System is brought to a stop under system control. Fault must be cleared to continue. Use parameter [Minor Flt Config] to enable. If not enabled, acts like a major fault. Steady Adapter failed the duplicate IP address detection test. Green Alternately Green Flashing Adapter is properly connected but is not communicating with any devices on the network.

Steady Adapter is properly connected and communicating on the network. Unlit Off Adapter is not powered or is not transmitting on the network. Green Flashing Adapter is properly connected and transmitting data packets on the network. Steady Adapter is properly connected but is not transmitting on the network. If a Communication Adapter is installed, refer to that options user manual for a description of LED location and indication.

Port 00 Host Drive displays the event number only. Troubleshooting Drive Fault and Alarm Descriptions The table below contains a list of drive faults and alarms, the type of fault or alarm, the action taken when the drive faults, the parameter used to configure the fault or alarm if applicable , and a description and action where applicable.

Important: See the User Manual, publication UM, for descriptions of faults and alarms generated by installed option modules. The DC bus voltage exceeded the maximum value. An internal electronic overload trip has occurred. The output transistors have exceeded the maximum operating temperature. The dynamic brake resistor has exceeded its maximum operating temperature. The drive output current has exceeded the hardware current limit.

The output torque current is below the value programmed in P [Load Loss Level] for a time period greater than the time programmed in P [Load Loss Time]. The DC bus ripple has exceeded a preset level.

The current in one or more phases has been lost or remains below a preset level. The drive is not following a commanded deceleration because it is attempting to limit the bus voltage. The motor operating speed exceeds the limit set by the maximum speed setting P [Overspeed Limit]. For all other non-flux vector control modes, the motor operating speed is determined by P1 [Output Frequency]. The encoder movement has exceeded the level in P [Brk Slip Count] after the brake was set and the brake slip maneuver is controlling the drive.

Drive is active. The encoder movement has exceeded the level in P [Brk Slip Count] after the brake was set and the brake slip maneuver is finished.

Drive is stopped. If these parameters point to a feedback module, the module parameters must also be properly set. Encoderless TorqProve has been enabled but user has not read and understood application concerns of encoderless operation. Analog input has a lost signal.

The drive unsuccessfully attempted to reset a fault and resume running for the programmed number of tries.