Allen-Bradley The PowerFlex 755 On-Machine User Manual Download Page 145 | Manualshive

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Rockwell Automation Publication 750-UM006C-EN-P - March 2022

145

Chapter

5

Drive Maintenance

Repair and Replacement
Procedures

The following table displays which maintenance topics are covered in this
manual. When a component has specific instructions on repair or replacement,
a link to that component instructions is provided.

ATTENTION:

If any component is removed, replaced, or adjusted, the On-

Machine Drive must

go through the entire startup procedure

to verify

proper configurations and settings. Failure to do so could cause equipment
damage or failure.

IMPORTANT

Only open the front cover of the enclosure if you suspect the components
inside are damaged.

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Summary of Contents for The PowerFlex 755 On-Machine

Page 1: ...User Manual Original Instructions PowerFlex 755 On Machine Drive Bulletin Number 26G...

Page 2: ...you aware of safety considerations These labels may also be on or inside the equipment to provide specific precautions The following icon may appear in the text of this document Rockwell Automation r...

Page 3: ...onment 20 Wiring and Workmanship Guidelines 20 Electromagnetic Compatibility EMC 21 General Notes 21 Wiring 22 Power Requirements 22 Circuit Protection 23 Short circuit current rating SCCR 24 Circuit...

Page 4: ...Update the Module Properties 63 Verify Drive Data 66 Choose Integrated or Hard wired Safety 67 Safety Configuration for SSM and S4 69 Configure the Drive Parameters 72 Setup the Datalinks 85 Create Sa...

Page 5: ...e 2 Heatsink Fan 160 Replace Option Modules 160 Replace the Auxiliary Circuit Breakers 5CB070 and 1CB250 or 5CB130 161 Replace the Drive HIM 1HIM320 162 Replace the EMC Kit 1CH030 163 Replace the ETAP...

Page 6: ...190 Updating the Drive Firmware 191 Chapter7 Periodic and Preventive Maintenance Recommended Preventive Maintenance 195 Schedule Codes Explanations 196 Maintenance of Industrial Control Equipment 197...

Page 7: ...Manual These conventions are used throughout this manual Where a parameter is referenced it is referenced as Port Parameter parameter name Example 00 301 Net Addr Scr or 10 350 Vref Source Where grou...

Page 8: ...dpersonnelwhoplanand design installations of PWM AC drives Integrated Motion on the EtherNet IP Network Reference Manual publication MOTION RM003 Use this manual to review descriptions of the AXIS_CIP...

Page 9: ...BASICSTEPSthatarerequiredtostartupyourPowerFlex 750 Series AC drive for the first time for simple applications PowerFlex 750 Series AC DrivesTechnical Data publication 750 TD001 Provides detailed info...

Page 10: ...ublication 750 IN007 Provides instructions on replacing EMC Cores in PowerFlex 750 Series frame 1 5 drives PowerFlex 750 Series EMC Plate and Cores Frames 1 7 Installation Instructions publication 750...

Page 11: ...ptions available for the drive Safe Torque Off 20 750 S3 Safe torque off for safety related applications that require the removal of rotational power to the motor without shutting down the drive Netwo...

Page 12: ...on the front cover near the data nameplate The UL listing on the data nameplate relates to the enclosure rating See System Overview on page 11 for the location of the data nameplate that is on the fr...

Page 13: ...power and control terminals CatNo OriginalFirmware 13 001 Nameplatelabelsample Servomotor HDshown UL Type 12 IP66 Specifications andCustom Catalog Number representingoptions installed at factory Name...

Page 14: ...ceptacles Female male receptacles are a panel mount connector with flying leads 9 889N F4 Control Auxiliary Power Media Patchcords Patchcord cable with integral female or male connector on each end 10...

Page 15: ...o the drive and motor by providing a plug and play environment that also avoids system mis wiring Details of ArmorConnect power media are described in the ArmorConnect Power and Control Media Selectio...

Page 16: ...ating 022 configures the drive for Heavy Duty HD rating 2 M2 and M3 are only available in 480V AC 60 Hz Allen Bradley MPL MPM servo motor for use with 14 AWG or 16 AWG motor cable M3 2 3 3 Option M3 f...

Page 17: ...On Machine Drive A hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION To avoid electrical shock open the appropriate upstream protection discon...

Page 18: ...lid ground neutral to maintain the CE UL certification If the user supplied input power distribution exceeds 20 times the drive rating kVa additional impedance must be supplied in the form of an input...

Page 19: ...It should not require an additional system enclosure when used in locations consistent with the enclosure type ratings stated in theEnvironment on page 20 section of this publication Subsequent secti...

Page 20: ...Electrical Code NEC and NFPA 79 outline the following guidance for installations in the United States and Canada The electrical standard for industrial machinery states that cable tray use and install...

Page 21: ...ling must be kept at least 150 mm 6 in away from EtherNet IP network cables to avoid noise issues EtherNet IP is an unpowered network If the device status is important when the power distribution disc...

Page 22: ...explosionmayexist whichmay lead to personal injury or death property damage or economic loss Incoming power requirements must be a delta Wye solid ground neutral to maintain the CE UL certification If...

Page 23: ...system Failure to do so may lead to personal injury or death property damage or economic loss IMPORTANT The drive requires a solidly grounded delta wye power source for example 480 277V AC or 400 230...

Page 24: ...fuses for this circuit must be capable of delivering not more than 65 000 RMS symmetrical amperes at 480V AC maximum when protected by CC J and T class Circuit Breakers The drive has three circuit bre...

Page 25: ...and Open Auxiliary Circuit Breaker Door on page 176 1 400 480V AC rotary power for main circuit breaker 140G G6C3 C30 AJ 2 24V DC mechanical brake circuit breaker 1489 M2D040 is shown on the enclosure...

Page 26: ...on around the drive For best air movement do not mount drives directly above each other Drives should be mounted with a minimum of 152 4 mm 6 in of clearance from the top bottom left and right sides A...

Page 27: ...shown in millimeters inches Dimensions are not intended to be used for installation purposes All dimensions are approximate B C A E F D I H G LeftView FrontView BottomView BackView Drive Dimensions A...

Page 28: ...able shipping cleats and is covered an anti corrosion type of plastic wrap Protection is for horizontal shipping and some water resistant protection but it is not waterproof For ease of handling Rockw...

Page 29: ...09 6 mm x 274 4 mm 24 in x 24 in x 11 in Product Dimensions H xW x D 711 2 mm x 649 8 mm x 391 9 mm 28 in x 25 58 in x 15 43 in Packaging Dimensions H XW x D with product inside 475 mm x 800 mm x 800...

Page 30: ...See Remove the Front Cover on page 148 for instructions on how to open the front cover 7 If damage to the enclosure exists a Note on the delivery receipt that the equipment is damaged b Contact the ca...

Page 31: ...ifting holes as shown in the illustration ATTENTION All equipment and hardware that is used to lift the drive must be properly sized and rated to lift and hold the weight of the drive safely To guard...

Page 32: ...is greater than 60 610 24 00 305 12 00 60 Dimensions are in millimeters and inches Hand hold Lifting Handle one left one right Mechanical Lifting Handle one left one right ATTENTION When approaching...

Page 33: ...been secured and stabilized Two Person Lifting The drive weighs more than 45 36 kg 100 lb As a result two people are required to hand lift the drive ATTENTION Risk of equipment damage exists Intercon...

Page 34: ...guage labels should not be removed or covered up Any additional labels must be added on a bare surface A B C D E F G H I J Data nameplate label Arch Flash label French Arch Flash label English MCBTrip...

Page 35: ...uide for proper installation Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive...

Page 36: ...nding system Grounding Safety Grounds The object of a safety ground is to verify that all metal work is at the same power distribution earth grounding system potential at power frequencies Impedance b...

Page 37: ...e PE connection with a separate ground conductor We recommend that each motor frame is grounded to building steel at the motor Refer to Table 4 on page 39 for motor cable information Keep the motor ca...

Page 38: ...transfer impedance from the shield or armor of the cable to the conduit entry plate at both the motor and the drive for electrical bonding Themotorcableshouldbekeptasshortaspossibletoavoidelectromagn...

Page 39: ...Shielded Motor patch cable assemblyWith straight Male Female receptacle with leads 29 mm Shell 4 pin 12 AWG T123 for drive rating 22 A OutputPowerReceptacle M35 4 pin 280 PWRM35G M 3 ArmorConnect Pow...

Page 40: ...Female Right Angle 4 Pin PVC Cable Yellow Unshielded 22 AWG DC Micro M12 Straight Male 889D M4AC DC micro M12 Male Straight 4 Pin PVC Cable Yellow Unshielded IEC Color coded No Connector P1 P1 Digital...

Page 41: ...C ColorCoded DC Mic Male Straight 879D F4ACDM V Cable DC Micro M12 Female Straight 4 Pin PVC Cable Yellow Unshielded 22 AWG DC Micro M12 Straight Male 879D R4ACDM V Cable DC Micro M12 Female Right Ang...

Page 42: ...DC Mic Male Straight 889D F5ACDE Patchcord DC Micro M12 Female Straight 5 Pin PVC Cable Yellow Unshielded IEC ColorCoded DC Mic Male R Angle CFBM HIP SC Encoder Receptacle Servo BulkH E52 E55 2090 CFB...

Page 43: ...Rated 1585D M4TB 1585 Ethernet Cables 4 Conductors M12 Straight Male Standard Flying Leads Teal RoboticTPE 100BASE TX 100 Mbit s 4 Conductor TealTPE Flex Rated 1 Use M23 12 Pin 20 coded connector cabl...

Page 44: ...ordered This section provides detail about the different gland plate options the receptacle pin out information and how to make connections The power I O and EtherNet IP network connections are made w...

Page 45: ...the Drive Chapter 3 Figure 3 Maximum Possible Receptacle Details Induction Motor 24V DC Brake 15 4 amps Figure 4 Maximum Possible Receptacle Details Induction Motor 24V DC Brake 22 amps Figure 5 Maxim...

Page 46: ...apter 3 Install the Drive Figure 6 Maximum Possible Receptacle Details Induction Motor Source Brake 22 amps Figure 7 Maximum Possible Receptacle Details Servo Motor 24V DC Brake 14 amps Figure 8 Maxim...

Page 47: ...SISC DENC0 and DENC1 5 Source brake EMB1 6 Dynamic brake DBR 7 Output power T123 and CPBM 8 Input power 400 480V AC L123 Table 5 Drive Gland Plate Abbreviation Definitions Terminal Designations Descri...

Page 48: ...4 2 SI1 10 Not used Pin Function 3 SC 11 Common 2 L1 4 Not used 12 12V DC power 3 L2 5 TO0 DENC1 Dual Incremental Encoder 1 M23 1 Ground S1 Network Safety S4 M12 DC micro Pin Function Pin Function 1 S...

Page 49: ...e Startup Gather the following information before proceeding to startup We recommend that you print this page and keep it available during the startup process See Startup Information on page 207 in Ap...

Page 50: ...Polarity Voltage 24V DC or 400 480V AC Universal Feedback Port Forward Direction Ethernet IP address Reverse Direction Firmware Revision 3 4 Drive Catalog Number 4 Drive Rating 4 Add on ProfileVersion...

Page 51: ...page 44 for more information After the information is gathered for Prepare for Initial Drive Startup on page 49 follow these steps to use the HIM 1 Open the door for the auxiliary circuit breaker refe...

Page 52: ...o next step For information on how to use the HIM see publication 20HIM UM001 When powering up a new drive for the first time the HIM runs through an initial operating routine that Prompts you to sele...

Page 53: ...ublication 20HIM UM001 Set the Adapter IP Address The drive ships with its EtherNet IP adapter rotary switches factory set to a value of 999 Based on this setting 13 36 BOOTP determines the source of...

Page 54: ...et Device function of the HIM in the DIAGNOSTIC folder for the drive The ENET status indicator is steady green or updates green if the IP address is correctly configured 4 Review 13 37 Net Addr Src to...

Page 55: ...data rate and duplex setting that the adapter uses to communicate 1 Set the value of 13 50 Net Rate Cfg to the data rate at which your network is operating 2 Cycle power to the drive to reset the adap...

Page 56: ...and Download Center PCDC can help you find product related downloads including firmware release notes associated software drivers tools and utilities The PCDC can be accessed using this link https com...

Page 57: ...werFlex 755 firmware ControlFLASH files to update your unit go to the product compatibility download center PCDC to download the required PowerFlex 755 files See the information you collected in the t...

Page 58: ...e It provides a similar user experience as the Rockwell Automation AC drives that are used with Logix controllers on an EtherNet IP network such as PowerFlex 523 525 70 700 and 753 Applications such a...

Page 59: ...e to configure program servos and drives the same way Drive applications that could benefit from motion instructions servo performance is not needed but it is advantageous to use the Studio 5000 motio...

Page 60: ...ty Tab set the Safety Level to SIL3 PLe This populates the I O tree with the safety processor and it s partner TIP The procedure is written for the Network Integrated SafeTorque Off S3 option module T...

Page 61: ...network in the Controller Organizer and select New Module to add the PowerFlex 755 drive to the EtherNet IP network 4 In the Select Module Type dialog box type PowerFlex 755 5 Scroll through the list...

Page 62: ...Start Up the Drive 6 On the Identity page of the Device Definition dialog box type a Name Description optional and the IP address of the drive In this example we use PowerFlex 755_PTP_Turntable and an...

Page 63: ...ur EtherNet IP network Enter the Information Manually on page 64 ImportaTemplateFile 1 From the Overview page click Device Definition 2 On the Device Definition dialog box click Import to open File Ex...

Page 64: ...t shows a status bar which indicates the progress 3 Review the uploaded information on the status dialog box and make any necessary changes 4 Click Continue to finish the upload 5 See Verify Drive Dat...

Page 65: ...age 16 for more information The slots are auto assigned but can be reassigned for configuration compatibility TIP For this example the SSM and S4 drive has HIM 20 HIM C6S is in slot 2 Universal feedba...

Page 66: ...that the data matches the drive being commissioned 2 Check the PowerFlex 755 drive part number to confirm which option modules are included and in which port they are stored to verify that they match...

Page 67: ...odule I O connection that is shown on the electrical schematics must be wired to an appropriate safety I O device or safety relay via the receptacle that is labeled SO to provide the safety function S...

Page 68: ...twork the connection type must be Standard and Safety If you want to use Network Integrated Safety Function SSM or Network Integrated Safety Function with Brake Control S4 the connection type must be...

Page 69: ...55 755T Integrated Safety Functions Option Module publication 750 UM005 for additional information IMPORTANT Only reset ownership if your drive safety card was previously owned by a different controll...

Page 70: ...tion Publication 750 UM006C EN P March 2022 Chapter 4 Configure and Start Up the Drive 1 Review and verify that information on the drive overview page 2 On the Overview page select Safety Configuratio...

Page 71: ...Select the SS1 tab the information here can be setup in the drive or in the PLC 7 If using Time Safe Speed in Guard Logix change Stop Delay to 1000 ms 8 Select the Primary Feedback tab If you plan to...

Page 72: ...ou plan to use the SXF command enter the value 4096 into the Position Scaling field 10 Click Create or Apply Configure the Drive Parameters Use the PowerFlex 755 Startup Wizard to create and configure...

Page 73: ...ep 1 On the Overview page choose the Wizards page 2 Click Start to run the PowerFlex 755 Startup Wizard 3 Click Next until you advance to the Ethernet Port step 4 On the Ethernet Port step change Idle...

Page 74: ...Control Mode Speed Units RPM is standard and Feedback Encoders that are used for the Speed and Position feedback these typically match Click Next A Universal Feedback device is used in this example wh...

Page 75: ...mation is found in the Prepare for Initial Drive Startup on page 49 table 7 On the Stop Mode step enter the desired stop brake mode along with the dynamic brake resistor data collected before startup...

Page 76: ...formed offline Click Next 9 On the Ramp Rates Speed Limits step set the Max Forward and Reverse speed limits for the motor Click Next TIP InthePowerFlex750 SeriesProgrammingmanual publication750 PM001...

Page 77: ...peed Accel Time 1 and Decel Time 1 to the desired rates Click Next Decel 1 time is the rate that is used on a ramp stop regardless of what mode the drive is configured for Speed or Position mode It is...

Page 78: ...speed and position based drives Click Next If your application requires different values click the ellipsis and use the pull down menus to select the Port and Parameter for the source of Speed referen...

Page 79: ...ve is used as a Position and point to point PTP regulated drive set the parameters for the desired performance on the Position PTP Reference step Click Next 15 On the Start Stop step configure the dig...

Page 80: ...mostat is wired to the drive Digital Input 0 on the PowerFlex 755 If desired assign this input to Enable or Aux Fault input as shown to cause the drive to shut down if this thermostat opens If you are...

Page 81: ...shut down and so on See the On Machine electrical schematics for more information 17 Click Next 18 On the Digital Output steps click the ellipsis and use the pull down menus to configure the output AT...

Page 82: ...tput 0 are wired in parallel to the brake coil This lets the drive sequence the brake when running or lets the Logix controller release the brake when not running typically used during testing As a re...

Page 83: ...via Datalink or leave it unconfigured When selecting 00 935 Drive Status 1 bit 1 Active is selected in the Digital Output step the transistor closes anytime the drive is ON running with its transistor...

Page 84: ...cation 750 UM006C EN P March 2022 Chapter 4 Configure and Start Up the Drive 21 Review the changes to the drive configuration Click Finish to return to the Wizards dialog box 22 Click OK to close the...

Page 85: ...Use the pull down menus to select the drive Input Parameters that you want the Logix Controller to read from the drive You can select up to 16 parameters from any port in the drive Examples include sp...

Page 86: ...ck Yes Create Safety Logic to Control the Safety Module The Safe Torque Off function is in the PowerFlex 755 drive and requires safety logic for control When the connection type is configured as Stand...

Page 87: ...output tag is PowerFlex 755_PTP_Turntable SO SafeTorqueOff is used in a Logix controller safety task to control the Safe Torque Off module in the PowerFlex 755 drive For SSM and S4 the output is calle...

Page 88: ...nd in the Logix Designer application to trend performance of the system that is controlled by the PowerFlex 755 On Machine Drive To create a trend follow these steps 1 In the Controller Organizer righ...

Page 89: ...dialog box to configure the chart pen colors scaling and so on The trend captures the data when online with the Logix Designer application later in this procedure See How to Use Trend Settings on page...

Page 90: ...t to access Chart Properties 2 After configuration click Run to start the trend and issue a run or jog command to the PowerFlex 755 from the Logix controller Trend captures the data You may save it de...

Page 91: ...display the difference in the values of these two times 4 After creating a trend click Log on the Trend Control Bar to save the file if desired 5 If you save the Logix Designer application project aft...

Page 92: ...lication project 2 From the Communications menu select Who s Active to load the program to your Logix controller 3 From the Who s Active dialogue box choose your controller then select Download 4 When...

Page 93: ...drive If a yellow triangle appears next to the EtherNet IP network entry it indicates an issue with that device This is likely because the project drive parameters and I O configurations do not match...

Page 94: ...the physical drive 2 Check Use Project for all applicable items Click Continue The Logix Designer application loads the drive parameters from the project to the drive 3 When notified that a reset is...

Page 95: ...Notice in the example that the yellow triangle has disappeared Put the Logix Controller Into Run Mode 1 Use the Controller Status pull down menu to put the Logix controller into Run mode 2 Click Yes...

Page 96: ...r 00 11 DC Bus Volt With the main input energized the voltage should be 515V DC with 400V AC input 650V DC with 480V AC input If circuit breakers 1 and 2 are both energized properly 07 01 Dig In Sts b...

Page 97: ...ublication 750 AT004 and PowerFlex 750 Series AC Drives Quick Start publication 750 QS001 Autotune StaticTune The Autotune test identifies the correct motor flux and stator electrical properties inclu...

Page 98: ...dback to the drive The value used was 05 137 Open Loop Fdbk 00 128 Alt Vel Fdbk Sel has also been chosen to provide alternate velocity feedback and display the speed The value used was 05 05 FB0 Posit...

Page 99: ...137 Open Loop Fdbk 5 Change 00 128 Alt Vel Fdbk Sel to 05 05 FB0 Position to observe the encoder velocity and direction when the motor is jogged 6 On the Parameters page change the Parameter selectio...

Page 100: ...torleakageinductancetestforthebestpossibleautomaticsettingofP74 IxoVoltageDrop inaFluxVector FV mode Astart command is required following initiation of this setting Used when motor cannot be rotated R...

Page 101: ...h 2022 101 Configure and Start Up the Drive Chapter 4 10 After the Static Tune 2 completes 00 70 Autotune changes back to Ready 0 and 00 71 Autotune Torque 00 73 IR Voltage Drop and 00 74 Ixo Voltage...

Page 102: ...ation InertiaTune After the Autotune and Rotate Tune are complete perform an Inertia Tune The motor should be uncoupled During the test the drive motor is accelerated using the entered Autotune Torque...

Page 103: ...Inertia is updated This number represents how long it takes to accelerate the Motor being used from 0 RPM to Motor Nameplate RPM speed at 100 motor torque This test can be redone after coupling to the...

Page 104: ...oder direction can be observed 2 Use a Logix controller or HIM to jog the drive and observe the direction of the motor in 00 131 Active Vel Fdbk 3 Compare the direction to the encoder direction in 00...

Page 105: ...ey don t match as shown you have to change the electrical direction of the encoder to forward a To change the encoder rotation to the forward direction view the port that contains the encoder feedback...

Page 106: ...s to invert the direction from the present status to rotate in a forward direction d Return the drop downs on the Parameters page to 0 PowerFlex Feedback Show Non Defaults e Jog the unit again and ver...

Page 107: ...Vel Fdbk Sel back to the original configuration so it is used by 00 131 Active Vel Fdbk velocity loop for the drive as desired 7 Next run or jog the drive from the Logix controller and verify the per...

Page 108: ...ing If the performance Speed Position regulation is not adequate refer to PowerFlex 700S and PowerFlex 755 Drives Tuning publication DRIVES AT004 for guidance on setting the various parameters associa...

Page 109: ...and repeat the Jog to observe performance 2 Adjust parameters to obtain machine performance as required 3 Use the RS Trend function to observe the performance For more information on using trend see...

Page 110: ...755 drive parameters Because we adjusted numerous parameters in the previous steps to tune the drive and the motor the adjusted parameters in the drive appear 2 Choose Use Physical and click OK to im...

Page 111: ...Enc 0 FB or 04 14 Enc 1 FB for the dual encoder feedback device and the linear position feedback device 05 05 FB0 Position Y1 1000 Y2 3000 X1 10 000 X2 85 000 Y2 Y1 2000 delta linear feedback counts X...

Page 112: ...gure an integrated motion on theEtherNet IPnetworkapplicationandtostartupyour motion solution with a Logix controller based system Motion SystemTuning ApplicationTechniques publication MOTION AT005 Th...

Page 113: ...rFlex 755 EENET CM S4 for the Network Integrated Safety Function S4 option B or option C Choose PowerFlex 755 EENET CM if no safety option module is used Refer to the Catalog Number Explanation on pag...

Page 114: ...slots 4 5 and 7 See Prepare for Initial Drive Startup on page 49 and Catalog Number Explanation on page 16 for more information 1 From the Module Definition dialog box right click on the Drive shown...

Page 115: ...encoder or dual feedback monitoring for multiple encoders 6 From the Power Structure pull down list select the appropriate power structure Youcan locate the power structure reference numbers in these...

Page 116: ...though a feedback device has been selected the drive is not configured You must associate the axis first and then you have the option to configure a feedback module 10 On the General page click OK to...

Page 117: ...In the Module Properties dialog box under the Motion tree choose Associated Axis 2 Click Ok in the dialogue box to open Select Module Type 3 Close the Select Module Type dialogue box 4 Double click o...

Page 118: ...els that you can select are related to which hardware you have installed You must manually establish the motor feedback option module Port Channel assignment for the PowerFlex 755 drive Follow these i...

Page 119: ...ction select shunt resistor type and configure limits Configure the drive dynamic brake DB values if used and wired to DBR receptacle 1 On the Module Properties dialog box choose the Power page 2 Type...

Page 120: ...per the following table 1 From the Module Properties dialog box choose Digital Input 2 Change the value of the inputs 3 Click Apply to save changes TIP Under axis properties you may also elect to hav...

Page 121: ...in slot 7 of the drive See the electric drawings to observe that Digital Output 1 is wired in parallel to Digital Output 2 From the 20 750 2263C 1R2T option module relay 0 and transistor 0 are wired...

Page 122: ...dditional information about which I O configurations are acceptable for your environment 1 From the Module Properties dialogue box choose Actions 2 Change Connection Loss and Connection Idle to the op...

Page 123: ...ety tree choose Scaling 8 Change Scaling to Revs 9 Click Apply to save changes CreateaMotionGroup All axes must be configured properly and added to the Motion Group in your project If the axes remain...

Page 124: ...oup Motion_Group Table 7 Safety Controller System Requirements Safety Option Module 20 750 S3 Integrated Safe Torque Off Module 20 750 S4 Integrated Safety Functions Module Mode of Operation I O mode...

Page 125: ...ated into the motion group that you created follow these steps 1 In the Controller Organizer select the axis 2 Drag and drop the axis into the motion group folder 3 Expand the drop down next to the mo...

Page 126: ...box choose the Attribute tab 2 Set the Base Update period to an interval between 4 0 32 0 ms For the PowerFlex 755 drive the minimum Base Update Rate is 4 0 ms 3 Click on Axis Schedule to open the sch...

Page 127: ...RM003 for complete information on Axis Attributes and how to apply Control Modes At this point the configuration is still offline and has not been downloaded into the controller 1 Double click on the...

Page 128: ...y Control F See Application Notes on page 111 for more information related to position loop setup 3 Choose a Feedback Configuration type the table compares feedback type and loop type 4 Choose and App...

Page 129: ...s tab are also mapped to the drive when you associate an axis and a drive 8 Click Apply to save changes ApplicationType Kpi Kvi ihold Kvff Kaff torqLPF Custom 1 1 If you set the type to Custom you can...

Page 130: ...ate or nonvolatile memory The nameplate option requires that you enter the motor specification information Youcan find the information on the hardware nameplate or product data sheets 1 Double click o...

Page 131: ...the encoder mounted and wired to the drive In our example we use a Hiperface encoder with 4096 Turns 7 Click Apply 8 Choose the Scaling page 9 Choose the Load Type In our example we use a turntable wi...

Page 132: ...changes The following dialog box appears 12 Click Yes 13 Choose the Planner page to enter system limits 14 Set the values as desired for the application See information from Prepare for Initial Drive...

Page 133: ...Configure and Start Up the Drive Chapter 4 In our example we use Passive which means the PLC will take the present position and log it as 0 degrees 18 Click Apply 19 Choose the Actions page 20 For the...

Page 134: ...on 750 UM005 for recommendations on specific applications 21 Click Apply 22 Choose the Drive Parameters page for S3 or Cyclic Parameters for SSM and S4 23 Select the drive parameters for controller ma...

Page 135: ...der programming language This manual is one of a set of related manuals that show common procedures for programming and operating Logix 5000 controllers For a complete list of common procedure manuals...

Page 136: ...open RSLinx 3 On the Who Active dialog box expand the tree under the appropriate EtherNet IP driver to show the available controllers 4 Select your target controller 5 Click Download The controller s...

Page 137: ...ex 755 drive You can observe connecting configuring and syncing from the HIM mounted on the front cover of the drive After the synchronization is complete the yellow triangle next to the drive should...

Page 138: ...he Motion Group in the project tree double click the axis to commission to open the Axis Properties dialog box 2 From the Axis Properties dialog box expand the Motor tree and choose the Analyzer page...

Page 139: ...rt to initiate the Static Motor Test 3 After the Static Motor Test is complete click OK 4 Click Accept Test Results to move the results into the Logix controller properties ATTENTION Because the drive...

Page 140: ...Motor Flux Current required to rotate the motor with no load attached 1 From the Analyzer page choose the Dynamic Motor Test tab 2 Click Start to run the test 3 After the Dynamic Motor Test is comple...

Page 141: ...4 4 After the test is complete click OK 5 If the motor rotated in the proper direction click Yes 6 If the answer is No see Motor Polarity on page 141 MotorPolarity If the motor did not rotate in the a...

Page 142: ...ation Notes on page 111 for more information related to position loop setup 1 From the Axis Properties dialog box choose the Autotune page 2 Enter the allowable Travel Speed Torque and Direction limit...

Page 143: ...PowerFlex 755 and adjust tuning parameters until a desirable response is obtained 1 From the Axis Properties dialog box choose the Autotune page 2 Click Manual Tune from the lower left corner of the...

Page 144: ...o allow the drive to run 1 Save the project 2 Click Yes 3 The project uploads automatically to the location that was mapped in Save and Download the Project on page 135 4 Write and test your Logix app...

Page 145: ...ructions on repair or replacement a link to that component instructions is provided ATTENTION If any component is removed replaced or adjusted the On Machine Drive must go through the entire startup p...

Page 146: ...Brake 2 Yes Replace the DC Brake Surge Suppressor 1BD0270 on page 151 7 Brake Contactor upper left Yes Replace the Brake Contactor 5BC130 on page 152 8 Common Mode Core No 9 Receptacles bottom Yes Rep...

Page 147: ...ion see the Circuit Breakers on page 24 ATTENTION Failure to observe this warning can result in machine damage or personnel injury Remove power from the drive system and wait for the voltageonthebusto...

Page 148: ...om the front cover 5 Lift the cover up approximately 2 inches and turn the cover over this motion is similar to how you would turn a page a Use a 10 mm wrench to disconnect the ground nut on the back...

Page 149: ...ce Chapter 5 b To remove the front cover on the drive squeeze the sides as indicated on the drive and lift c Disconnect the HIM cable from the drive and free the HIM cable to allow the front cover of...

Page 150: ...hold the surge suppressor in place 5 Remove the surge suppressor 6 Unpack and inspect the new surge suppressor AC source brake 7 Connect the wires to terminals T1 and T2 on the brake contactor Torque...

Page 151: ...brake contactor 5 Unpack and inspect the new surge suppressor DC brake 6 Insert the surge suppressor into the brake contactor with the text upright 7 Use a flathead screwdriver to connect the wires in...

Page 152: ...ontactor to the enclosure 5 Use a screwdriver to dislodge the brake contactor from the DIN rail 6 Remove the brake contactor from the cabinet Location Wire Description Terminal Number Top 5BC130 L1 L1...

Page 153: ...he procedure to Remove Power on page 146 2 Follow the instructions to Remove the Front Cover on page 148 3 Use a 5 hex key to remove the wires from the input and output side of the main circuit breake...

Page 154: ...er from the internal rotary mechanism of the main circuit breaker 7 Use a T20 torque bit to remove the two screws that connect the rotary disconnect switch to the front cover 8 Unpack and inspect the...

Page 155: ...breaker to the enclosure Torque screws to 25 lb in 12 Use the 5 hex key to attach the wires terminals listed in step 3 to the main circuit breaker Torque screws to 62 lb in 13 Follow the instructions...

Page 156: ...structions to Remove the Front Cover on page 148 3 Remove the front cover from the drive a Squeeze the locking tabs and pull out the bottom of cover b Pull the cover down and away from the chassis c L...

Page 157: ...ed to rewire the terminal blocks verify terminal screws and wires are secure Terminal wiring does not need to be removed to replace the PowerFlex 755 drive ATTENTION Notewhichsloteachoftheoptionmodule...

Page 158: ...or additional information 12 Use a T20 torque bit to remove the 14 screws that hold the drive to the enclosure TIP To avoid the need to rewire the terminal blocks verify terminal screws and wires are...

Page 159: ...n modules 19 Use a 2 Pozidriv M3 x 7 tool to connect all power wires listed in step 9 Refer to the electrical schematics for more information Torque terminal screws to 5 lb in 20 Use a 7 mm hex deep s...

Page 160: ...themajorityofcablesandwiresroutedintotheFrame2drive can remain connected while replacing the heatsink fan TIP To avoid the need to rewire the terminal blocks verify terminal screws and wires are secur...

Page 161: ...breakers to the DIN rail Circuit Breaker Description Catalog Number 400 480V AC source mechanical brake 140M C2E B25 140MT C3E B25 Auxiliary Contactfor Sourcebrake CB 140M C AFA10 140MT C AFA10 24V D...

Page 162: ...ver on page 169 Replace the Drive HIM 1HIM320 Follow the procedure to Remove Power on page 146 and follow the instructions to Remove the Front Cover on page 148 For information on how to replace the H...

Page 163: ...ove Power on page 146 2 Follow the instructions to Remove the Front Cover on page 148 3 Use a flathead screwdriver to disconnect the wires listed in the following table 4 Disconnect the Ethernet cable...

Page 164: ...urn to these instructions IMPORTANT Many of the receptacles could appear to be interchangeable because they have the same mounting hole pattern Verify your pin out and connectors before attaching to t...

Page 165: ...10 CPBR 24V DC Brake Power 45 10 DBRT Brake ResistorThermostatTemperature 45 10 SO S0 Safety S3 45 10 S0 S0 Network Safety S4 45 10 S0 S0 Network Safety S4 with brake 45 10 S1 S1 Network Safety S4 45...

Page 166: ...eptacles are installed with the receptacle and bulkhead adapter inside the enclosure The sealing washer and screws are installed from the bottom side of the gland plate Receptacle Abbreviation Recepta...

Page 167: ...ceptacle Replacement Type 4 The table below describes the receptacles that fall under type 4 Type 4 receptacles are installed from inside the enclosure and the washer and lock nut are installed from t...

Page 168: ...nside the enclosure Receptacle Replacement Type 6 The table below describes the receptacles that fall under type 6 Type 6 receptacles are installed from the bottom side of the gland plate and the flat...

Page 169: ...covers 6 To align the drive cover align the main circuit breaker shaft with the rotary disconnect switch and allow them to fully mate 7 Rotate the cover counter clockwise to expose the grounding stud...

Page 170: ...sconnecting cables To avoid an electric shock hazard verify that the voltage on the bus capacitors has entirely discharged before servicing IMPORTANT Many of the receptacles could appear to be interch...

Page 171: ...n Machine Drive has multiple grounding locations Refer to the electrical schematics for specific information about the grounding for your specific configuration See the Catalog Number Explanation on p...

Page 172: ...0G G6C3 C30 AJ 2 24V DC mechanical brake circuit breaker 1489 M2D040 is shown on the enclosure The 400 480V AC source mechanical brake circuit breaker 140M C2E B25 140MT C3E B25 is shown on the left 3...

Page 173: ...Checklist of Industrial Control and Drive System Equipment publication DRIVES TD001 for bus capacitor reforming requirements and Maintenance of Industrial Control Equipment on page 197 for more inform...

Page 174: ...unciated on the HIM and the drive status is transmitted to the PLC via EtherNet IP SeetheHIMmanualfoundintheAdditionalResourceson page 8fordetails onusingthe20 HIM C6Sto viewFaults and alarm details S...

Page 175: ...erFlex 755 faults and alarms 1 Circuit Breaker A visual inspection can verify that the breakers are individuallyopenedorclosed orthattheconnectionsare loose The400 480VACincomingpowerisprovidedtothema...

Page 176: ...ositions ATTENTION Toavoidanelectricshockhazard verifythatthevoltageonthe bus has entirely discharged before servicing ATTENTION The drive contains high voltage that takes time to discharge after remo...

Page 177: ...The 400 480V AC source mechanical brake circuit breaker 140M C2E B25 140MT C3E B25 is shown on the left 3 24V DC control power circuit breaker 1489 M2D2040 In addition to visual inspection two of the...

Page 178: ...no power present at the L123 receptacle go to the customer Power Distribution Panel PDP and verify the power source to the M35 trunk line is energized 400 480V AC 6 If 24V DC CP control power circuit...

Page 179: ...ot all inclusive and will vary based on the design of your mechanical system Refer to the PowerFlex 750 Series AC Drives Programming Manual publication 750 PM001 for encoder faults and corrective acti...

Page 180: ...lex 750 Series AC Drives Programming Manual publication 750 PM001 for encoder faults and corrective actions Main control module Option Module backplane connector Encoder feedback device slots 4 and 5...

Page 181: ...M001 for encoder faults and corrective actions Loose coupling Missed positioning Erratic motion Hardwire over current faults Broken coupling Speed position errors Mechanical bind than normal current a...

Page 182: ...widthModulated PWM ACDrives publication DRIVES IN001 for more information Power Is 400 480V AC at the line input terminals Faults Present on Drive Are there faults present that do not reset Drive Rea...

Page 183: ...and use Note 2 Label 2 Label 1 Change Feedback Change 00 125 PriVel Fdbk Sel to the original value use drive parameter backup Example Port 5 Fdbk 0 50005 Label 2 Change Feedback Change 00 126 PriVel F...

Page 184: ...rtia a If 00 76 Total Inertia is too high then the gains might be too high 00 76 Total Inertia and 00 636 Speed Reg BW create 00 645 Speed Reg Kp 00 647 Speed Reg Ki of the speed loop Values that are...

Page 185: ...parameter settings device status and diagnostics from multiple tab views Adapter Parameter Description 34 DLs From Net Act The number of controller to drive datalinks that are included in the network...

Page 186: ...leared The adapter takes a communication or idle fault action Bit 0 of 13 53 Web Features is used to help protect the configured settings for email messaging By default settings are not protected and...

Page 187: ...re the new settings take effect You can reset the adapter by cycling power to the drive or by using the Reset Device function of the HIM in the DIAGNOSTIC folder for the drive TIP Changes to this para...

Page 188: ...ller is idle peer I O is disrupted or MSG instruction for drive control is disrupted To determine the action of the adapter and drive use the Port 13 embedded adapter parameters 54 Comm Flt Action 55...

Page 189: ...u must set these Port 13 parameters to values required by your application Table 8 Fault Configuration Parameter Values Changes to these parameters take effect immediately A reset is not required TIP...

Page 190: ...ateway Cfg 1 4 50 Net Rate Cfg Follow these steps to restore adapter parameters to their default configuration values 1 Access the Status screen which is displayed on HIM power up 2 Use the or key to...

Page 191: ...l firmware update files and associated Release Notes that describe the following items Firmware update enhancements and anomalies How to determine the existing firmware revision How to update the firm...

Page 192: ...e current version and the upgrade version 3 Verify that 24V DC auxiliary control power is ON 4 Verify the EtherNet IP is connected and transmitting 5 Go to the PCDC and search for PowerFlex 755 6 From...

Page 193: ...Choose Managed Download or Direct Download Follow the prompts to complete the download 12 Open ControlFLASH 13 Click Next 14 In the Catalog Number dialog box select your drive from the list LP stands...

Page 194: ...firmware 20 In the ControlFLASH dialog box select Yes to confirm update The drive flashes and a status window indicates the progress The drive reboots after the firmware download is complete 21 After...

Page 195: ...m includes the following primary tasks A visual inspection of all drive components General cleaning and maintenance Tightness checks on all power connections Tightness checks on all bottom plate conne...

Page 196: ...IMPORTANT Review product manuals for detailed maintenance information relevant for a particular model Code Task Description I Inspect Inspect the component for signs of excessive accumulation of dust...

Page 197: ...if the shaft does not turn freely if blades are missing or if the fan is not functioning properly Apply power momentarily to check operation If unit does not operate replace fan as appropriate Predic...

Page 198: ...fe of the component Elapsed Life is the amount of life that has been expended Remaining Life is the Total Life minus Elapsed Life Event Level is the amount of Elapsed Time in percent of Total Life whe...

Page 199: ...maged by overheating Also check ground connection integrity Coils If a coil exhibits evidence of overheating cracked melted or burned insulation it must be replaced In that event check for and correct...

Page 200: ...tom Table 9 Drive Storage Duration and Reforming Recommendations Duration Reforming Guideline Under 2 years Noreforming required 2 3 years Apply rated voltage per the normal method for 30 minutes unde...

Page 201: ...0 T123 Output Power 60 10 DRB Dynamic Brake 60 10 EMB1 400 480V AC Source Mechanical Brake 45 10 EMB2 24V DC Mechanical Brake 45 10 CP 24V DC Control Power 45 10 CPBR 24V DC Brake Power 45 10 DBRT Bra...

Page 202: ...ting Table 11 Recommended Drives Maintenance Tasks and Schedule IMPORTANT Duty cycle load profile temperature altitude incoming line conditions and other operating environmental conditions greatly aff...

Page 203: ...3 1EA030_SSM PowerFlex750IntegratedNetworkSafetyFunctions Module 20 750 S4 1EA030_I O PowerFlex 750 24V DC 1R2T I O Module 20 750 2263C 1R2T 1EA030_APS PowerFlex 750 Auxiliary Power Supply Module 20 7...

Page 204: ...STO PowerFlex 750 Network SafeTorque Off Module 20 750 S3 1EA030_SSM PowerFlex750IntegratedNetworkSafetyFunctions Module 20 750 S4 1EA030_I O PowerFlex 750 24V DC 1R2T I O Module 20 750 2263C 1R2T 1EA...

Page 205: ...030_SSM PowerFlex 750 Network Integrated Network Safety Functions Module 20 750 S4 1EA030_I O PowerFlex 750 24V DC 1R2T I O Module 20 750 2263C 1R2T 1EA030_APS PowerFlex 750 Auxiliary Power Supply Mod...

Page 206: ...5D D4TBJM 0M3 ENC0 INC Encoder Receptacle M23 12 Pin E41 SK 26G RCPT ENC0 E41 M23 12 HIPSC HIPSC Encoder Receptacle M23 12 Pin E42 SK 26G RCPT HIPSC E42 M23 12 SSISC SSI SC Rotary Encoder Recp M23 12...

Page 207: ...Rating 4 Add on ProfileVersion Option Module Port Assignment 5 Port 4 Port 5 Port 6 Port 7 Port 8 20 750 2263C 1R2T 20 750 APS 1 The motor data must be entered in kW when doing installation for integ...

Page 208: ...208 Rockwell Automation Publication 750 UM006C EN P March 2022 Appendix B Startup Information Notes...

Page 209: ...BOOTP 50 53 disabling 54 brake 25 151 176 contactor 152 troubleshooting 175 mechanical brake 96 source brake 25 161 176 branch circuit protection 23 176 202 requirement 25 bus capacitor discharge 17 r...

Page 210: ...e 21 wiring 22 electrostatic discharge ESD 20 embedded EtherNet IP 51 EMC kit 163 EMI filter 21 encoder mechanical checks 180 181 system components 180 encoder feedback troubleshooting 175 179 end of...

Page 211: ...e 35 overview 17 precaution 17 receive unpack inspect 28 30 receptacle pinout 48 integrated motion 112 130 add axis to motion group 125 add drive 112 axis association 116 base update period 125 go onl...

Page 212: ...25 51 96 circuit breaker DC 161 minimum mounting clearance 28 module properties I O mode 63 drive parameter 72 import template file 63 manual entry 63 safety 67 verify data 66 integrated motion add dr...

Page 213: ...51 Net Rate Act 185 13 52 Web Enable 186 13 53 Web Features 186 13 54 Comm Flt Action 188 13 55 Idle Flt Action 188 13 56 Peer Flt Action 188 13 57 Msg Flt Action 188 13 58 Flt Cfg Logic 188 13 59 Flt...

Page 214: ...ooting 175 safety product manuals 9 save and download project I O mode 92 integrated motion 135 save project 92 135 144 schedule maintenance 202 scheduling axis 126 servo motor 24V DC 14 amps 46 24V D...

Page 215: ...system configuration 13 T three phase power Seepower trend properties 89 troubleshooting 173 brake contactor 174 175 circuit breakers 178 encoder feedback 179 fault 174 188 fault action 187 grounding...

Page 216: ...216 Rockwell Automation Publication 750 UM006C EN P March 2022 Index Notes...

Page 217: ...Rockwell Automation Publication 750 UM006C EN P March 2022 217 PowerFlex 755 On Machine Drive User Manual...

Page 218: ...e Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Pro...

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