Rockwell Automation Allen-Bradley 24G Installation Instructions Manual Download Page 6

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Rockwell Automation Publication 750-IN118A-EN-P - May 2021

Notes:

Summary of Contents for Allen-Bradley 24G

Page 1: ...PowerFlex 755T Drives Configured to Order Program Catalog Numbers 24G 24J Installation Instructions Original Instructions ...

Page 2: ...d 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 provi...

Page 3: ... Option Modules 21 Intermittent Overload Duty Rating 22 Configured Input Bay 22 Configured Output Bay 24 Control and Power Options and Publication Language 25 Commonly Used Installation Tools 26 Installation Tools 26 Configuration Tool Options 27 Approximate Dimensions 29 Frame 8 29 Frame 9 30 Approximate Weights 31 Chapter 2 Prepare for Installation CE Conformity 33 Location Planning 34 Environme...

Page 4: ...s the Drive Control Pod 60 Electrical Connections Made to Each Configured Bay During Installation 61 Frame 8 Electrical Connections 61 Frame 9 Electrical Connections 62 Component and Connection Locations 64 Frame 8 Component and Connection Locations 65 Frame 9 Component and Connection Locations 74 Bay to Bay Connection Hardware 84 PE Ground Bar Splice Connection Hardware 84 AC Busbar Splice Connec...

Page 5: ...tent Overload 108 Motor Overload Protection 108 Short circuit Current Rating 108 Applying and Removing Power 108 Contactor Precautions 108 Input Contactor Precautions 108 Output Contactor Precaution 109 Bypass Contactor Precaution 110 Install Components that were Removed During Installation 110 Chapter 5 Service and Maintenance Replacement Parts 111 Commonly Used Tools 116 Remove Power from the Sy...

Page 6: ...6 Rockwell Automation Publication 750 IN118A EN P May 2021 Notes ...

Page 7: ...ected 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 on page 8 section is a directory of Rockwell Automation resources that provide detailed drive information from wiring and ground...

Page 8: ... Fuse and circuit breaker ratings PowerFlex 750 Series Products with TotalFORCE Control Hardware Service Manual publication 750 TG100 Provides detailed information on Preventive maintenance Component testing Hardware replacement procedures PowerFlex Drives with TotalFORCE Control Programming Manual firmware revision 10 xxx and later publication 750 PM101 Provides detailed information on I O contro...

Page 9: ...strial automation controls and assemblies Safety Guidelines for the Application Installation and Maintenance of Solid state Control publication SGI 1 1 Designed to harmonize with NEMA Standards Publication No ICS 1 1 1987 and provides general guidelines for the application installation and maintenance of solid state control in the form of individual devices or packaged assemblies incorporating sol...

Page 10: ...10 Rockwell Automation Publication 750 IN118A EN P May 2021 Notes ...

Page 11: ...d potentiometer infrared IR window and voltage indicator Output contactor output sine wave filter or output sine wave filter with contactor For a full list of features available on the configured input and output bays see the Catalog Number Explanation on page 15 Product Advisories Read the following precautions before you begin installation of the product Qualified Personnel IMPORTANT New configu...

Page 12: ... is open and the power is OFF If both the line side and load side have power the circuit breaker is closed and the power is ON If the line side and load side both have no power then measure resistance across line and load to see if the breaker is open or closed Circuit breaker locations are shown in Component and Connection Locations on page 64 ATTENTION To avoid an electric shock hazard the confi...

Page 13: ...PowerFlex 755T drives bus supplies and common bus inverters are exempt from the efficiency requirements of Commission Regulation EU 2019 1781 on the basis of Article 2 3c and 3d EMC In conformity with EMC Directive 2014 30 EU C3 Directive for Conducted and Radiated Emissions All PowerFlex 755T drives bus supplies and common bus inverters Functional safety TÜV and Rheinland Certification applies to...

Page 14: ...0 Each data nameplate includes the catalog number of the entire PowerFlex 755T Drives Configured to Order Program product and other specifications of the product The configured output bays do not have a nameplate For information about the catalog number see Catalog Number Explanation on page 15 For information about drive characteristics that are indicated in the catalog number see the Product Rat...

Page 15: ...rmittent Overload Duty Rating of the Entire PowerFlex 755T Drives Configured to Order Program Product Catalog Number Positions 19 20 Figure 6 Configured Input Bay Codes Catalog Number Positions 21 31 Figure 7 Configured Output Bay Codes Catalog Number Positions 32 35 Figure 8 Drive Common Bus Inverter Bus Supply Power and Control Option Codes and Publication Language Catalog Number Positions After...

Page 16: ...d PowerFlex 755TR Drives 8 9 Configured PowerFlex 755TM Common Bus Inverters 8 9 24J Configured PowerFlex 755TM Bus Supplies 8 9 B Corrosive Gas Protection and Cooling Type Code Description Frames E Corrosive Gas Protection XT Forced Air 8 9 C Input Type Code Description Frames D Common Bus with DC Precharge 8 9 E Common Bus without DC Precharge 8 9 F Regenerative and Low Harmonic Active Front End...

Page 17: ...erFlex 755T Drive Normal Duty Ratings Catalog Number Positions 8 10 1 4 5 6 7 8 11 12 13 _ _ _ _ _ _ _ 2 3 _ _ _ 9 10 _ _ _ F1 F4 F1 F2 PowerFlex 755T ND Drive Ratings PowerFlex 755T ND Drive Ratings 400V 50 Hz Input 480V 60 Hz Input Code Amps kW Frame Code Amps Hp Frame 302 302 160 8 302 302 250 8 367 367 200 361 361 300 460 460 250 430 430 350 540 540 315 505 505 400 585 585 315 545 545 450 650 ...

Page 18: ...0V 60 Hz Input Code Amps kW Frame Code Amps kW Frame 302 324 188 8 302 311 216 8 367 394 228 361 371 258 460 494 286 430 442 307 540 579 336 505 519 361 585 628 364 545 560 390 650 698 405 617 635 442 750 805 467 710 730 508 770 826 479 740 761 529 920 987 572 9 800 823 573 9 1K0 1116 647 960 987 687 1K1 1193 692 1K0 1075 748 1K2 1261 731 1K1 1167 812 1K4 1570 910 1K3 1404 977 G3 G4 PowerFlex 755T...

Page 19: ...0 540 315 505 505 400 585 585 315 545 545 450 650 650 355 617 617 500 750 750 400 710 710 600 770 770 400 740 740 650 920 920 500 9 800 800 700 9 1K0 1040 560 960 960 800 1K1 1112 630 1K0 1045 900 1K2 1175 710 1K1 1135 1000 1K4 1463 800 1K3 1365 1100 H3 H4 PowerFlex 755T Normal Duty Common Bus Inverter Ratings PowerFlex 755T Normal Duty Common Bus Inverter Ratings 600V 60 Hz Input 690V 50 Hz Input...

Page 20: ...or marine applications P51 is selected PE B ReflectiveWave Filtering Frames J 3 3 Does not provide a C2 solution C3 compliant but does include some filtering Yes Installed Removed No 8 9 K 3 Yes Installed Removed Yes 8 9 L 4 4 C3 compliant without additional filtering No Installed Removed No 8 9 M 4 No Installed Removed Yes 8 9 J Dynamic Braking 1 1 Not available on Frames 8 9 Code Internal Resist...

Page 21: ...on Module Code Option Frames N No Port 6 I O Option module 8 9 A Hardwired Safe Torque Off 8 9 B Hardwired Safe Speed Monitor 8 9 C Networked Safe Torque Off 8 9 D Integrated Safety Functions Networked 8 O Port 7 I O Option Module Code Option Frames N No Port 7 I O Option Module 8 9 A 24V DC 2262C 2R for internal controls 8 9 B 115V AC 2262D 2R for internal controls 8 9 P Port 8 I O Option Module ...

Page 22: ...atalog Number Positions 19 20 Configured Input Bay The options in this section apply to an optional configured input bay that is connected to the drive A dash precedes each code in this section R Intermittent Overload Duty Rating Code Duty Rating 1 min 1 1 Overload capability for up to 1 minute out of 10 minutes 3 s 2 2 Overload capability for up to 3 seconds out of 60 seconds Frames LD Light Duty...

Page 23: ...rol Power Code Option Frames N Customer Provided 120V AC 8 9 A Rockwell Automation Provided 120V AC 8 9 B RA provided 120VAC Additional Va 8 9 X 24V DC Auxiliary Power Code Option Frames N Customer Provided 24V DC Aux Power 8 9 A 24V DC Aux Power Supply 8 9 B 24V DC Aux Power Supply and UPS 8 9 Y Door Mounted Operator Station Control Set Code Option Frames N No Operator Devices 8 9 A Bus Supply ON...

Page 24: ...tput Line Reactor 8 9 C DV DT Output 1 1 Available in frame 8 9 via internal drive option D Sine wave Output Filter 2 3 2 Sine wave output filters are not CE rated If your product includes a sine wave filter refer to the product data nameplate for CE certification information 3 Sine wave output filters are only required when motor cables are longer than 305 m 1000 ft 8 9 AE Output Contactor Code O...

Page 25: ...ion 5 C0 Torque Accuracy Module 8 9 D E F G 6 7 C11 Single Control Pod with Control Bay 1 1 When the Door mounted HIM code in position 13 is set to D code C11 includes one door mounted HIM and code C12 includes two door mounted Human Interface Modules HIMs 8 9 D E C12 Dual Control Pods with Control Bay 1 8 9 D E Q4 Q5 24G Power Options Selection Code Option Frames Input Type position 5 P15 1 1 Onl...

Page 26: ...amp 1000 A AC rms signal output ESD protected place of work Work surface floor cover seat and ground connections ESD protective clothing Wrist wrap shoes overall clothing coat Flashlight Flat nose screwdriver 3 mm 0 12 in 5 mm 0 19 in 6 4 mm 0 25 in Fuse puller Hexalobular star or Torx screw driver bit 15 20 25 30 40 45 Hexagonal socket wrench 2 5 mm 7 mm 8 mm 10 mm 12 mm 13 mm 17 mm 18 mm Insulat...

Page 27: ...the automatic download of configuration data The download occurs after the Logix controller establishes an EtherNet IP network connection to a PowerFlex 755TL 755TR or 755TM product and its associated peripherals A computer connection to the EtherNet IP network Hardware Installation Diagrams Illustrations throughout this manual contain diagrams as shown here These diagrams identify the correspondi...

Page 28: ... 6 lb in initial torque The numeric illustration labels are for explanation Drive components do not contain these labels Figure 19 Two point Mounting Figure 20 Four point Mounting Figure 21 Six point Mounting ATTENTION Components can be damaged if initial tightening procedure is not performed to specification 1 2 1 2 2 1 Initial Sequence Final Sequence 1 2 4 3 4 3 1 2 1 3 4 2 Initial Sequence Fina...

Page 29: ...h Input Protection The approximate dimensions for Frame 8 configured input bays with input protection apply to the following bays Configured input bay with fuses top entry bay that is shown in Figure 23 Configured input bay with fuses bottom entry Configured input bay with circuit breaker top entry Configured input bay with circuit breaker bottom entry Figure 24 Frame 8 ConfiguredOutputBay with Co...

Page 30: ...it Breaker Top Entry 647 2 mm 25 48 in 600 0 mm 23 62 in 400 0 mm 15 75 in 2000 0 mm 78 74 in 800 0 mm 31 50 in 642 0 mm 25 28 in 2288 5 mm 90 09 in 2000 0 mm 78 74 in 600 0 mm 23 62 in 2210 0 mm 87 01 in 600 0 mm 23 62 in 600 0 mm 23 62 in 642 0 mm 25 28 in Figure 29 Frame 9 Configured Output Bays Top Exit The Frame 9 configured output bays with top entry are a section of two bays that are connec...

Page 31: ...ng the weights of all the bays Frame Size Configured Bay Size Approximate Maximum Weight kg lb 8 Configured input bay control only 93 205 Configured input bay with fuses top entry 114 252 Configured input bay with fuses bottom entry 116 255 Configured input bay with circuit breaker top entry 113 249 Configured input bay with circuit breaker bottom entry 114 252 Configured output bay with contactor...

Page 32: ...32 Rockwell Automation Publication 750 IN118A EN P May 2021 Chapter 1 Product Overview Notes ...

Page 33: ...ean Norm EN standards which are referenced by the Official Journal of the European Union PowerFlex 755T Drives Configured to Order Program products comply with the EN standards that are listed in this section when installed according to these installation instructions EU Declarations of Conformity are available online at http www rockwellautomation com global certification overview page For detail...

Page 34: ...wing when choosing the installation location for your product Ventilation and air conditioning concerns beyond meeting the ambient temperature requirements Input power cable entry points Motor cable exit points Alignment with other equipment Future needs Environmental Specifications The installation site must be compatible with the degree of protection that is provided by the bay PowerFlex 755T pr...

Page 35: ... moisture and direct sunlight Make sure that filters and debris screens are installed Mounting Considerations The mounting surface for floor mount bays must be a flat and level surface If necessary use metal shims to level the bays before joining them Make sure that the mounting surface and installation location allow the product to be mounted in an upright orientation square vertical and stable F...

Page 36: ...le Bottom Entry and Exit Figure 33 shows a drive power bay as an example but is applicable to all bottom entry or bottom exit bays Front Rear Conduit Mounting screws see page 44 Mounting surface see page 35 Bottom view Recommended gland or conduit hole pattern Use the locations marked on the plate Side view Floor mounting hardware ...

Page 37: ...hat air temperature around the bays does not exceed the ambient temperature specification in the Environmental Specifications on page 34 Some airflow examples are provided in Figure 36 and Figure 37 on page 38 The vents below the center of the bay are air intake locations white arrows and the vents above the center of the bay are air exhaust locations black arrows Regularly inspect and replace the...

Page 38: ... Examples of Frame 8 Lineups Including Configured Input Bay Drive Bays and Configured Output Bay Configured input bay with input circuit breaker top entry Configured input bay with input circuit breaker top entry Configured output bay with contactor only top Configured output bay with sine wave filter and Configured input bay with input fuses top entry Configured output bays top exit Configured in...

Page 39: ...ing hardware For the PowerFlex 750 Series service cart 20 750 MCART1 to be able to access the power bay of a drive the following requirements must be met Floor mounting hardware height The maximum height of the floor mounting hardware is 254 mm 10 in This measurement is also an installation limit per NEC requirements for the circuit breaker disconnect handle Enclosure setback If the bay is mounted...

Page 40: ...ng mounting hardware that must pass through the mounting hole Figure 39 Typical Bay Mounting Holes Recommended Mounting Fasteners IMPORTANT Bays must be mounted to the floor using one of these floor mounting options between the bays and the floor Bays cannot be mounted directly to the floor Four bay mounting holes Debris plug Frame Size Fastener Size Usage Notes Frames 8 9 M12 0 5 in Secure the ba...

Page 41: ...tion Optional trim panels can be used along the perimeter of the lineup Each corner base attaches to a corner of the enclosure using an M12 screw that is included with the system Hardware for attaching the corner base to the mounting surface is not included The recommended hardware for attaching a corner base to the mounting surface is an M12 anchor bolt like the one shown in Figure 42 on page 44 ...

Page 42: ...es of the bay are not the full length of the side of the bay they are used for because part of that length can be covered by corner panels over the corner bases Corner base required for base plinth system 100 4 0 200 8 0 Trim panels for between adjacent corner bases where bays are joined optional 100 4 0 200 8 0 Trim panels to cover the corner bases optional 100 4 0 200 8 0 Trim panels for front b...

Page 43: ... page 29 Consider the height of the mounting hardware for Overhead Clearance on page 37 To allow for service cart access the mounting hardware must be no more than 254 mm 10 in tall Table 3 Steel Beam Minimum Dimensions Style Depth d mm in Width b mm in Thickness tw mm in Flange tf mm in Length 1 l mm in 1 The minimum length of beam under each corner of the bay Using the minimum length of beam pro...

Page 44: ...sing M12 nuts and lock washers Secure the steel beam to the concrete floor by using M12 0 5 in anchor bolts It is recommended that you orient the beams so that the I shape of the I beam or the C shape of the C beam is visible when viewing the beam from the side of the bay not the front of the bay This orientation allows for the addition of the bay into the lineup or removal of the bay from the lin...

Page 45: ...sted Remove Side and Top Packaging If there is any packaging on the sides and top of the shipping section remove it Packaging may include plastic wrapping and a wood crate Save any documentation packaged in the plastic wrapping Topic Page Remove Side and Top Packaging 45 Remove Detached Installation Hardware 46 Remove Shipping Skid and Cleats 47 Prepare Bay Interiors for Installation 48 Attach Flo...

Page 46: ...trical connection hardware Detached Roof Vent Some configured bays come with a roof vent Some roof vents ship detached from the bay and must be attached later in the installation Table 4 Configured Bays that Come with Detached Electrical Connection Hardware Frame Configured Bay Connection Hardware Location of Hardware 9 Configured input bay fuses top entry Flexibar flexible busbar On the skid with...

Page 47: ...Bay Cleats from the Shipping Skid 2 For this step see the Transport by Crane or Hoist procedure in the PowerFlex 755T Drives Configured to Order Program Receiving Handling and Storage Installation Instructions publication 750 IN110 Place the bay on supports that provide enough space under the cleats to remove the cleats from the bay Wooden beams can be used as supports 3 Remove the cleats from the...

Page 48: ...cedure 1 Use the double bit key that is provided to open the bay doors 2 Remove the protective touch guards from the bays To remove the guards from configured bays see Remove or Install Protective Touch Guards on page 49 To remove the guards from the drive bays see the PowerFlex 750 Series Products with TotalFORCE Control Installation Instructions publication 750 IN100 3 Remove any components from...

Page 49: ... procedure to install a protective touch guard in a configured bay 1 Open the bay door 2 Position the touch guard on the M5 5 screws that secure the touch guard See Example Touch Guard Locations 3 Tighten the screws to the torque listed in Figure 46 on page 50 Example Touch Guard Locations The locations of touch guards vary for different bays For some example locations see Figure 46 on page 50 whi...

Page 50: ...more configured output bays optional 1 Position the first bay or section of bays in the lineup using the Transport by Crane or Hoist procedure in the PowerFlex 755T Drives Configured to Order Program Receiving Handling and Storage Installation Instructions publication 750 IN110 The first bay is the first bay on the input or wire entry side of the lineup 2 If your product includes any other bays pr...

Page 51: ...Table 6 1 remove the side panel Use the panel and hardware in step 2 Figure 47 Removing or Installing a Bay Side Panel 2 Install the side panel on the side of the configured bay that will not be joined to the drive You should not need a new gasket to install this side panel because it includes a factory installed gasket Table 6 Bay Joinings that Require Moving a Side Panel Frame Side 1 of Joining ...

Page 52: ...t at the Joining Location 1 At the end of the bay lineup where you are adding a bay apply the gasket in one continuous strip around the mating surface of the section Seam the gasket at the approximate middle of the bottom of the mating surface Figure 48 Applying the Gasket to the Mating Surface Gasket Gasket Seam location ...

Page 53: ...ical Connections Made to Each Configured Bay During Installation on page 61 2 Align the new bay to the existing lineup of bays at a distance of approximately 20 cm 8 in using the Transport by Crane or Hoist procedure in the PowerFlex 755T Drives Configured to Order Program Receiving Handling and Storage Installation Instructions publication 750 IN110 3 Move the new bay into contact with the existi...

Page 54: ... installed at the factory If your product has IP54 UL Type 12 bays you must place each roof exhaust vent assembly that came with a configured bay using one of the following procedures Roof Panel with Roof Vents Assembly 1 Remove the shipping roof panel from the bay 2 Lower the IP54 UL Type 12 roof assembly onto the bay Do not secure the roof assembly to the bay during this step Wait until after in...

Page 55: ...mation Publication 750 IN118A EN P May 2021 55 Chapter 3 Mechanical and Electrical Installation Three front vents Exhaust Hood 1 Remove the shipping roof panel from the bay Figure 52 Removing the Shipping Roof Panel ...

Page 56: ...o the bay 4 Connect the rings of the two part eye bolts to the rods of the two part eye bolts 5 Use the two part eye bolts and washers to attach the exhaust hood to the bay Figure 53 Installing the Three front vent Exhaust Hood 1 2 3 4 6 5 Item Description 1 Ring of a two part eye bolt 2 Washer 3 Rod of a two part eye bolt 4 Gasket 5 Base structure view side walls panels and bay doors not shown 6 ...

Page 57: ...m or move them in any way Table 7 Standard Installation Joining Hardware Frame Side 1 of Joining Side 2 of Joining Type of Joining Hardware 8 Section including configured input bay and drive bays Configured output bay Top Brackets and Frame Clamps on page 58 9 Configured input bay with control only fuses with top or bottom entry circuit breaker with bottom entry Drive bays section Top Brackets and...

Page 58: ...ackets on top of the bays as shown in Figure 54 3 Install the bolts that join each pair of angle brackets and tighten 4 Place and tighten the frame clamps clamping the side frames of the bays together Figure 54 Joining Bays with Top Brackets and Frame Clamps IMPORTANT The paint piercing rubber washers are required for both grounding purposes and to meet the enclosure rating ATTENTION Do not attemp...

Page 59: ... be used as spare parts To install the bay joining hardware use the following procedure 1 Make sure that the two sides of the joining are aligned level and pushed together tightly 2 Attach the interior corner brackets to the four interior corners of the mating surface as shown in Figure 55 3 Place and tighten the frame clamps clamping the side frames of the bays together Figure 55 Joining Bays wit...

Page 60: ...connections not connections to the customer power source or motor See the following sections to make the bay to bay electrical connections Electrical Connections Made to Each Configured Bay During Installation on page 61 This section provides references to the hardware used to make the connections Component and Connection Locations on page 64 Bay to Bay Connection Hardware on page 84 The drawings ...

Page 61: ...undle of 16 AWG control cables with connectors on both ends See Configured Bay Control Connection Hardware on page 88 Inside the configured input bay and drive bays Connected to the configured input bay Must be connected to configured output bay during installation Contactor input terminals Drive power bay AC power output busbar Power cables with barrel lugs connect to drive output busbar See Barr...

Page 62: ...N100 Control cable 16 AWG PB3 drive disable push button terminals 21 and 22 In drive input bay control pod main control board TB1 I O terminal block See the Main Control Board section in 750 IN100 Control cables 16 AWG connected to one plug connector that connects to the TB1 socket connector on the main control board See Drive Main Control Board Connection Hardware on page 87 Multiple connection l...

Page 63: ...ontrol connector in the configured output bay The connection hardware for each of these connections is a bundle of 16 AWG control cables with connectors on both ends See Configured Bay Control Connection Hardware on page 88 Inside the drive bays Must be connected to the configured input bay and configured output bay during installation PE ground bar Drive PE ground bar PE Ground Bar Splice Connect...

Page 64: ... Entry Internal Components and Installation Connection Locations 70 Frame 8 Configured Input Bay Top Entry Control Panel 71 Frame 8 Configured Input Bay Bottom Entry Control Panels 71 Frame 8 Configured Output Bay with Contactor Only Top or Bottom Exit Internal Components and Installation Connection Locations 72 Frame 8 Configured Output Bay with Sine wave Filter and Contactor Top or Bottom Exit I...

Page 65: ...switch selects between Hand mode Off mode and Auto mode In Hand mode the drive is controlled using only the push buttons on the configured input bay In Off mode the drive does not operate In Auto mode an external control system controls the drive 9 Local start push button green for starting the drive 10 Local stop push button red for stopping the drive using a programed stop profile 11 Drive disab...

Page 66: ...re 58 Frame 8 Configured Input Bay Control only Internal Components Item Description 1 Terminal blocks 2 Fuse blocks 3 Control relays 4 Control power supply 24V DC 5 Uninterruptible power supply and battery behind control power supply 6 Control transformer 7 PE ground bar with ground clamps included 5 6 4 1 2 3 7 ...

Page 67: ...ed Terminating point to chassis ground for incoming AC line and shield Ground connections must be made during installation 3 Terminal lugs for customer AC line input power These power connections must be made during installation 4 Thermostat 5 AC line input protection fuses 6 Terminal lugs to supply power to the drive input bay 7 Terminal blocks 8 Fuse blocks 9 Control relays 10 Control power supp...

Page 68: ...rmostat located behind bay frame 6 Terminal block 7 AC line input protection fuses 8 Control relay 9 Terminal lugs for customer AC line input power Connections must be made during installation 10 Control power supply 24V DC 11 Uninterruptible power supply behind control power supply 12 Battery 13 PE ground bar with ground clamps included Terminating point to chassis ground for incoming AC line and...

Page 69: ...included Terminating point to chassis ground for incoming AC line and shield Ground connections must be made during installation 3 Terminal lugs for customer AC line input power Connections must be made during installation 4 Thermostat 5 AC line input protection circuit breaker 6 Terminal lugs to supply power to the drive input bay 7 Terminal blocks 8 Fuse blocks 9 Control relays 10 Control power ...

Page 70: ... Terminal lugs to supply power to the drive input bay 8 AC line input protection circuit breaker 9 Terminal lugs for customer AC line input power Connections must be made during installation 10 Control power supply 24V DC 11 Uninterruptible power supply behind control power supply 12 Battery 13 PE ground bar with ground clamps included Terminating point to chassis ground for incoming AC line and s...

Page 71: ...rol Panel Figure 64 Frame 8 Configured Input Bay Bottom Entry Control Panels Item Description for top and bottom entry control panels 1 Terminal blocks 2 Fuse blocks 3 Control relays 4 Control power supply 24V DC 5 Uninterruptible power supply 6 Battery 7 Control transformer on bottom entry control panel but not top entry control panel 1 2 3 4 5 6 1 2 6 7 3 4 5 ...

Page 72: ...allation In this area there is also a thermostat 2 Contactor output terminal lugs for power to customer motor Connections must be made during installation 3 Contactor 4 Contactor input terminal lugs for power from the drive Connections are made on the contactor at the factory Connections must be made to the drive during installation 5 PE ground bar with ground clamps included Terminating point to ...

Page 73: ...allation 4 Contactor output terminal lugs for power connection to customer motor Connections must be made during installation 5 Contactor 6 Sine wave filter reactor input power connections for power from the drive Braided busbar connections are made to the sine wave filter reactor at the factory 7 Sine wave filter reactor 8 PE ground bar with ground clamps included Terminating point to chassis gro...

Page 74: ...roduct including catalog number and agency certifications 13 Infrared IR window allows you to measure the temperature of the customer power input connection using an infrared measuring device aimed through the window 14 Drive disable push button red for stopping and disabling the drive without using a programed stop profile Causes the drive to cease output and execute a coast to stop 15 Circuit br...

Page 75: ...als are made at the factory 2 Fan with internal air filter This fan is present on the interior of the door for every configured input bay with input protection Figure 69 shows a frame 9 configured input bay with fuses top entry The labeled door components are the basic door internal components common to all frame 8 and frame 9 configured input bays with input protection To identify additional inte...

Page 76: ...tions to configured output bay not visible in this view located behind bay frame Connections must be made during installation 2 Control relays 3 Control terminal blocks 4 Fuse blocks 5 Control power supply 24V DC 6 Uninterruptible power supply and battery behind control power supply 7 Control transformer 8 PE ground bar with ground clamps included 9 PE ground bar splice connection hardware Ground ...

Page 77: ...d control power supply 9 PE ground bar 10 Control transformer 11 Battery 12 PE ground bar splice connection hardware Ground splice connection to drive PE ground bar must be made during installation 13 Flexibar connections to configured input bay power output Connections must be made during installation 14 Flexibar connections to drive input bay power input Connections must be made during installat...

Page 78: ...former 11 PE ground bar with ground clamps included Terminating point to chassis ground for incoming AC line and shield Ground connections must be made during installation 12 PE ground bar splice connection hardware Ground splice connection to drive PE ground bar must be made during installation 13 AC line input protection fuses 14 Cable support brackets support and guide power cables that connect...

Page 79: ...ntrol power supply 9 Battery 10 Control transformer 11 PE ground bar 12 PE ground bar splice connection hardware Ground splice connection to drive PE ground bar must be made during installation 13 Cable support brackets support and guide power cables that connect to the drive input bay 14 Terminal lugs to supply power to the drive input bay Cables are connected to these terminals at the factory Ca...

Page 80: ...coming AC line and shield Ground connections must be made during installation 12 PE ground bar splice connection hardware Ground splice connection to drive PE ground bar must be made during installation 13 Cable support bracket support and guide customer AC line input power cables 14 Cable support brackets support and guide power cables that connect to the drive input bay 15 Terminal lugs for cust...

Page 81: ...Control Panel for Frame 9 Configured Input Bay with Fuses Bottom Entry Figure 77 Control Panel for Frame 9 Configured Input Bay with Circuit Breaker Top or Bottom Entry Item Description for Figure 75 Figure 76 and Figure 77 1 Control relays 2 Terminal blocks 3 Fuse blocks 4 Control power supply 24V DC 5 Uninterruptible power supply 6 Battery only in Figure 76 and Figure 77 1 2 3 4 5 1 2 3 5 6 4 1 ...

Page 82: ...hole L bracket In the left bay the top extruded busbar has two 2 hole L brackets In the right side bay the top extruded busbar has one 2 hole L bracket Connections must be made during installation 3 AC busbar splice connection hardware for power from the drive 4 PE ground bar splice connection hardware Ground splice connection to drive PE ground bar must be made during installation 5 Thermostat no...

Page 83: ...und bar must be made during installation 4 Thermostat not visible in this view located behind sine wave filter capacitor bank 5 Sine wave filter capacitor bank 6 Fan for airflow upward through the bay 7 Sine wave filter reactor 8 Connections for power output to customer motor Connected via lug to L bracket to extruded busbar connection Each extruded busbar in the wire exit bay has two 4 hole L bra...

Page 84: ...have a PE ground bar are joined together during installation use this hardware to connect the PE ground bars Figure 80 PE Ground Bar Splice Connection Hardware AC Busbar Splice Connection Hardware To determine if you must make a connection using this hardware during installation see Electrical Connections Made to Each Configured Bay During Installation on page 61 This hardware is used to make the ...

Page 85: ...ion from the drive power bay to some types of configured output bay Figure 82 Barrel Lug Connections to Drive Output Busbars Braided Busbar to Drive Output Busbar Connection Hardware To determine if you must make a connection using this hardware during installation see Electrical Connections Made to Each Configured Bay During Installation on page 61 This hardware is used to make the power connecti...

Page 86: ...xibar Connection Hardware dimensions in mm in Barrel Lug to Drive Input Busbar Connection Hardware To determine if you must make a connection using this hardware during installation see Electrical Connections Made to Each Configured Bay During Installation on page 61 This hardware is used in the drive input bay to make the power connection from some types of configured input bay to the drive input...

Page 87: ...ections Made to Each Configured Bay During Installation on page 61 This hardware is used to connect various devices in the configured input bay to the 22 Series I O Option Module in the control pod in the drive input bay For a full list of all devices that are connected to the module with these connections see the electrical schematic that came with your product 2 1 Item Name Description 1 TB1 Dri...

Page 88: ...l connector in the configured output bay The connection hardware for each of these connections is a bundle of 16 AWG control cables with connectors on both ends The following figures show configured bay control connectors in various types of bays Configured bay control connectors are located inside the bay on the side that contacts the drive near the top of the bay When the bays arrive to the cust...

Page 89: ...at on the Frame 8 Configured Output Bay Control Panel 1 2 3 4 5 Item Identification Description 1 PLUG1 Four pole socket connector 24V DC 2 PLUG1 Four pole plug connector 24V DC Must connect to item 1 during installation 3 PLUG2 Eight pole socket connector 120V AC 4 PLUG2 Eight pole plug connector 120V AC Must connect to item 3 during installation 5 TAS2 Thermostat ...

Page 90: ...Item Identification Description 1 PLUG2 Four pole socket connector 120V AC 2 PLUG2 Four pole plug connector 120V AC Must connect to item 1 during installation 3 Cutout for configured bay control connector wires to route between the configured input bay and the drive input bay 4 PLUG1 Four pole plug connector 24V DC Must connect to item 5 during installation 5 PLUG1 Four pole socket connector 24V D...

Page 91: ...l Connections on the Frame 9 Configured Output Bay 2 3 1 4 Item Identification Description 1 PLUG3 Four pole socket connector 24V DC 2 PLUG3 Four pole plug connector 24V DC Must connect to item 1 during installation 3 PLUG4 Four pole socket connector 120V AC 4 PLUG4 Four pole plug connector 120V AC Must connect to item 3 during installation ...

Page 92: ...nstallation Figure 91 Frame 9 Configured Bay Control Connector Wire Route from Drive Power Bay to Configured Output Bay 1 2 Item Description 1 Cutout for routing configured bay control wires out of the drive power bay 2 Cutout for routing configured bay control wires into the configured output bay ...

Page 93: ...supply systems The supply system kVA must be equal to or greater than the product related kW and the system impedance must be less than 10 Operation outside these limits can cause instability and product shutdown System Impedance PowerFlex 755T kVA Transformer kVA x Transformer Impedance You must account for the kVA of all PowerFlex 755T Drives Configured to Order Program products on the distribut...

Page 94: ...Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Recommended Grounding Scheme A single point PE only grounding scheme should be used Some applications may require alternate grounding schemes For information on alternate grounding schemes see the Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 The drawing package that came with your order...

Page 95: ...cally checked See the instructions supplied with the filter Power Cable Specifications Various cable types can be used as input power cables and motor cables for PowerFlex 755T Drives Configured to Order Program installations For an in depth discussion of cable types including a table of maximum motor cable lengths see the Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives pub...

Page 96: ...s per phase wires must be arranged so that each conduit bundle or cable contains equal numbers of conductors from all three phases Make sure that there is a clearance of at least 5 1 mm 2 0 in between each end of the busbar and any conductor Figure 93 Conductor Spacing Example ATTENTION National codes and standards NEC BSI and so forth and local codes outline provisions for safely installing elect...

Page 97: ...put Power and Motor Connection Hardware on page 97 If your product does not include a configured input bay with input protection connect the input power cables to the drive input bay See the PowerFlex 750 Series Products with TotalFORCE Control Installation Instructions publication 750 IN100 If your product does not include a configured output bay connect the motor power cables to the drive power ...

Page 98: ...cket and a two lug L bracket The four lug L bracket can connect to up to four lugs two on each side of the L bracket The two lug L bracket can connect to up to two lugs one on each side of the L bracket Figure 95 on page 99 shows the four lug L bracket To attach the conductors to the L brackets use M12 or 0 5 in diameter bolts nuts and washers Bellville spring washers or equivalent are recommended...

Page 99: ... kit contains three L brackets and mounting hardware When using mechanical barrel lugs be sure to maintain adequate spacing to adjacent wires terminals and other parts 51 mm 2 in 51 mm 2 in M12 19 mm 38 0 N m 336 lb in M10 15 mm 38 0 N m 336 lb in Figure 96 L Bracket Approximate Dimensions Figure 97 Typical Barrel Lug Connection to L Bracket Options 46 0 mm 1 81 in 25 5 mm 1 04 in 85 1 mm 3 35 in ...

Page 100: ...erminal to the torque listed in one of the following tables securing the cable Figure 98 Example Terminal Lug Item Description 1 Back row of cable terminals secured by bottom row of cable set screws 2 Front row of cable terminals secured by top row of cable set screws 3 Top row of cable set screws 4 Bottom row of cable set screws 1 2 3 4 Table 13 Frame 8 Terminal Lug Locations and Torques Location...

Page 101: ...configured input bay has no input protection devices then see the fuses and circuit breaker recommendations for the standard drive Those recommendations are provided in the PowerFlex 750 Series Products with TotalFORCE Control Installation Instructions publication 750 IN100 Branch circuit short circuit protection must meet the following requirements Branch circuit protection must be provided in ac...

Page 102: ...igured Input Bay with Control Only or Circuit Breaker Input Protection 8 9 Input Power Fuses FU1 FU2 FU3 Voltage Vision Fuses FU4 FU5 FU6 FU4 FU5 FU6 Control Transformer Primary Fuse FU7 FU8 FU7 FU8 Control Transformer Secondary Fuse 1 FU9 FU9 Control Transformer Secondary Fuse 2 FU10 FU10 Frame Fuse Schematic Symbol Input Voltage V Specification Quantity Included in Configured Input Bay Manufactu...

Page 103: ... 650 Normal 624 170M6466 CLASS aR 690V 1250 A 540 Heavy 518 170M6466 CLASS aR 690V 1250 A 400 kW 796 Light 764 170M6466 CLASS aR 690V 1250 A 750 Normal 720 170M6466 CLASS aR 690V 1250 A 585 Heavy 562 170M6466 CLASS aR 690V 1250 A 400 kW 832 Light 799 170M6466 CLASS aR 690V 1250 A 770 Normal 739 170M6466 CLASS aR 690V 1250 A 650 Heavy 624 170M6466 CLASS aR 690V 1250 A 480V 250 Hp 361 Light 332 Mers...

Page 104: ...0V 500 A 355 Heavy 327 CLASS J 600V 500 A 450 Hp 51 Light 469 Cooper Bussmann 170M6463 CLASS aR 690V 900 A 435 Normal 400 LPJ 600SP CLASS J 600V 600 A 395 Heavy 363 Mersen AJT500 CLASS J 600V 500 A 500 Hp 580 Light 534 Cooper Bussmann 170M6463 CLASS aR 690V 900 A 545 Normal 501 170M6463 CLASS aR 690V 900 A 450 Heavy 141 LPJ 600SP CLASS J 600V 600 A 690V 200 kW 265 Light 243 170M6461 CLASS aR 690V ...

Page 105: ...5 Normal 1128 170M6471 CLASS aR 690V 2000 A 565 Normal 519 170M6466 CLASS aR 690V 1250 A 1090 Heavy 1046 170M6471 CLASS aR 690V 2000 A 505 Heavy 464 170M6466 CLASS aR 690V 1250 A 800 kW 1581 Light 1518 170M6471 CLASS aR 690V 2000 A 630 kW 735 Light 675 170M6466 CLASS aR 690V 1250 A 1463 Normal 1406 170M6471 CLASS aR 690V 2000 A 650 Normal 597 170M6466 CLASS aR 690V 1250 A 1175 Heavy 1128 170M6471 ...

Page 106: ...kA 395 Normal 363 140G M0H3 D60 42 kA 540 Heavy 518 140G M0H3 D80 100 kA 355 Heavy 327 140G M0H3 D60 42 kA 400 kW 796 Light 764 140G N0I3 E12 120 kA 450 Hp 51 Light 469 140G M0H3 D80 42 kA 750 Normal 720 140G N0I3 E12 120 kA 435 Normal 400 140G M0H3 D60 42 kA 585 Heavy 562 140G M0H3 D80 100 kA 395 Heavy 363 140G M0H3 D60 42 kA 400 kW 832 Light 799 140G N0I3 E12 120 kA 500 Hp 580 Light 534 140G M0H...

Page 107: ...50 kA 1090 Heavy 1046 140G R12K3 E20 W1 130 kA 650 Heavy 597 140G N0I3 E12 50 kA 800 kW 1581 Light 1518 140G R12K3 E20 W1 130 kA 800 kW 920 Light 845 140G N0I3 E12 50 kA 1463 Normal 1406 140G R12K3 E20 W1 130 kA 820 Normal 753 140G N0I3 E12 50 kA 1175 Heavy 1128 140G R12K3 E20 W1 130 kA 735 Heavy 675 140G N0I3 E12 50 kA 480V 700 Hp 960 Light 883 140G R12K3 E20 W1 125 kA 900 kW 1074 Light 986 140G ...

Page 108: ...m from a configured input bay the following precautions apply Electronic motor overload protection Class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL61800 5 1 File E59272 Maximum short circuit current rating Suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes up t...

Page 109: ... remove the AC line to the drive An auxiliary braking method may be required ATTENTION An auxiliary contact on the output contactor is wired to a drive digital input that is programmed as Enable This causes the drive to execute a coast to stop cease output whenever the output contactor is opened This is a safety measure to guard against damage to the drive ATTENTION To guard against drive damage w...

Page 110: ...e 117 3 Use the double bit key that is provided to open the bay doors Figure 99 Unlocking the Bay Door 4 Install the protective touch guards To install the guards in the configured bays See Remove or Install Protective Touch Guards on page 49 To install the guards in the drive bays see the PowerFlex 750 Series Products with TotalFORCE Control Installation Instructions publication 750 IN100 5 Insta...

Page 111: ...anual publication 750 TG100 Replacement Parts The following tables list the replaceable parts in the configured bays information for ordering replacement parts and links to any relevant information to use to perform the part replacement Frame 8 Configured Input Bay and Configured Output Bay Replaceable Parts on page 112 Frame 9 Configured Input Bay and Configured Output Bay Replaceable Parts on pa...

Page 112: ...al 3241110 IP21 IP54 Door Fan Vent Assembly on page 117 FAN3 Input Bay Door Fan Filter Media Rittal 3172100 IP21 IP54 Door Vent Filter Media on page 122 FAN4 FAN5 Output Bay Door Fan 115VAC 529CFM W FLTR Rittal 3245510 IP21 IP54 Door Fan Vent Assembly on page 117 FAN4 FAN5 Output Bay Door Fan Filter Media Rittal 3173100 IP21 IP54 Door Vent Filter Media on page 122 1 Roof Vent Filter for Input Bay ...

Page 113: ...Plug In Rockwell Automation 1492 CJLJ6 2 Terminal Block Specifications Technical Data publication 1492 TD015 IEC Center Jumper 3 PL 6 mm Plug In Rockwell Automation 1492 CJLJ6 3 IEC Center Jumper 4 PL 6 mm Plug In Rockwell Automation 1492 CJLJ6 4 IEC 35 mm x 7 5 mm x 1 m DIN Rail Rockwell Automation 199 DR1 DIN Mounting Rail Zinc plated Chromated Steel product summary IEC 6 x 5 mm Marker Card Rock...

Page 114: ...C 529 CFM W FLTR Rittal 3245510 IP21 IP54 Door Fan Vent Assembly on page 117 Input Bay Door Fan Filter Media Rittal 3173100 IP21 IP54 Door Vent Filter Media on page 122 FAN4 FAN5 FAN6 FAN7 FAN8 FAN9 FAN10 FAN11 Output Bay Sine wave Filter Reactor Cooling Fan Mechatronics UF16FC12 BTHR Sine wave Filter Reactor Cooling Fan on page 125 Fingersafe Guard for Sine wave Filter Reactor Cooling Fan Mechatr...

Page 115: ...015 IEC End Barrier 1 5 x 53 9 x 60 mm Rockwell Automation 1492 EBJD4 1492 Terminal Block Accessories End Barrier product summary IEC Terminal Block 3 x 80 x 63 mm Partition Plate Rockwell Automation 1492 PPJD3 Terminal Block Specifications Technical Data publication 1492 TD015 IEC End Anchor 8 x 56 x 47 mm Rockwell Automation 1492 EAJ35 1492 Terminal Block Accessories End Anchor product summary I...

Page 116: ...nections ESD protective clothing Wrist wrap shoes overall clothing coat Flashlight Flat nose screwdriver 3 mm 0 12 in 5 mm 0 19 in 6 4 mm 0 25 in Torx star or hexalobular screw driver bit 15 20 25 30 40 45 Hexagonal socket wrench 2 5 mm 7 mm 8 mm 10 mm 12 mm 13 mm 17 mm 18 mm Insulation tester 1000V DC Level Lift strap 5 16 in J hook style 24 in long 1000 lb Minimum Multi meter Digital multi meter...

Page 117: ...de the following IP21 IP54 Door Fan Vent Assembly To replace the IP21 IP54 door fan vent assembly Figure 100 use the following procedure This procedure applies to multiple types door fan vent assemblies For the catalog number of the replacement part for your product see Replacement Parts on page 111 IMPORTANT It is recommended that you wait 5 minutes before cycling power disconnect switches This r...

Page 118: ... 6 Remove the fan vent assembly through the cutout in the bay door Figure 103 Removing the Fan Vent Assembly 7 Insert the new fan vent assembly making sure that the airflow direction is into the bay The direction of airflow and the direction of rotation are each marked on the fan housing with an arrow 8 Install the screws that secure the vent to the bay door Figure 101 Lifting the Vent Cover Tab F...

Page 119: ...on and rotate the fan 90 in the direction you want Once it reaches the corner position it snaps into position Figure 104 Rotating the Fan Housing to Reposition the Power Connection 10 Remove the cover from the power connection Figure 105 Power Connection Cover ATTENTION Do not rotate the fan to a position where the power connection is 180 from its original position that is shown in Figure 100 on p...

Page 120: ...ic for your type of fan Figure 106 Fan Wiring Schematics 12 Attach the power connection cover 13 To achieve EMC protection the make sure the four contact foils at the corners of the fan housing are protruded helping prevent EMC contact between the fan components and other components in the bay Figure 107 EMC Contact Foil in Protruded Position M 1 Rittal part 3245510 Rittal part 3241110 L N PE M 1 ...

Page 121: ...age 111 1 Review Product Advisories on page 11 2 Remove power from the system See Remove Power from the System on page 117 3 Lift the tab on the top center of the vent cover and open the vent cover Figure 108 Lifting the Vent Cover Release Tab and Opening the Vent Cover 4 Remove the screws that secure the vent to the bay door These screws are at the corners of the vent 5 Remove the vent from the b...

Page 122: ...on page 111 1 Review Product Advisories on page 11 2 Remove power from the system See Remove Power from the System on page 117 3 Lift the tab on the top center of the vent cover and open the vent cover allowing access to the filter media Figure 110 Lifting the Door Vent Cover Tab Figure 111 Accessing the Door Vent Filter Media 4 Remove the old filter media from the vent cover 5 Install the new fil...

Page 123: ...ystem See Remove Power from the System on page 117 3 Slide the vent cover up to release the tabs from the slots in the vent Remove the vent cover Figure 112 Removing the IP21 IP54 Small Roof Vent Cover 4 Remove the filter media from the vent cover Figure 113 Removing the IP21 IP54 Small Roof Vent Filter Media from the Vent Cover 5 Place the new filter media into the vent cover making sure that the...

Page 124: ...y two filter medias The procedure is the same for all four filter medias 1 Review Product Advisories on page 11 2 Remove power from the system See Remove Power from the System on page 117 3 Slide the vent cover up to release the tabs from the slots in the vent assembly and remove the vent cover 4 Remove the filter media from the vent cover Figure 114 Removing the IP54 Large Roof Vent Filter Media ...

Page 125: ...the tray out further 4 Disconnect the fan you want to replace in the Figure 115 example item 3 from the tray mounted fan connection item 2 5 Remove the fasteners that attach the fan and lower fan guard to the fan tray 6 Remove the fasteners that attach the upper fan guard to the fan 7 Install the new fan oriented so that the airflow indication arrow on the fan item 4 points upward To install the f...

Page 126: ... the configured input bay to ON If your configured input bay does not use a form of input protection that includes a power ON OFF disconnect control skip to the next step 2 To start up the drive bays perform the appropriate start up after repair procedure for your drive size found in the Start Up After Repairs chapter in the PowerFlex 750 Series Products with TotalFORCE Control Hardware Service Ma...

Page 127: ...Electrical Manufacturers Association NEMA Standard No ICS 1 3 Preventive Maintenance of Industrial Control and Systems Equipment for general guidelines for defining a periodic maintenance program Also see the Maintenance of Industrial Control Equipment section in the PowerFlex 750 Series Products with TotalFORCE Control Hardware Service Manual publication 750 TG100 Task Code Explanations The follo...

Page 128: ... 18 19 20 Air cooling System Door mounted Ventilation Air Filters C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R Roof mounted Ventilation Air Filters C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R C R Door mounted Fans Input Bay Output Bay I I I I I I I I I I I I I I I I I I I I Sine wave Filter Reactor Tray Fans Frame 9 Output Bay I I ...

Page 129: ...Rockwell Automation Publication 750 IN118A EN P May 2021 129 PowerFlex 755T Drives Configured to Order Program Installation Instructions ...

Page 130: ...to knowledgebase Local Technical Support Phone 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 Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and access product release notes rok auto pcdc At th...

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