Allen-Bradley PowerFlex 755T Installation Instructions Manual

Powerflex 750-series products with totalforce control

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Page 1 Installation Instructions Original Instructions PowerFlex 750-Series Products with TotalFORCE Control Catalog Numbers 20G , 20J...
Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Page 3: Table Of Contents
Table of Contents Preface Additional Resources ......... . . 5 Chapter 1 Product Overview General Precautions .
Page 4 Table of Contents Field Connections..........106 Recommended Cable Spacing .
Page 5: Additional Resources
• PowerFlex 755TM drive system for common bus solutions • PowerFlex 750-Series AC and DC input drives • Kinetix 5700 servo drives PowerFlex 755T Flux Vector Tuning, publication 750-AT006 Provides guidance on how to tune Flux Vector position and velocity loops, filters, and other features to achieve the level of performance that is required for a given application.
Page 6 PowerFlex 755TM Power and Filter Module Storage Provides detailed installation and usage instructions Hardware Instructions, publication 750-IN106 for this hardware accessory. PowerFlex 755T Module Service Ramp Instructions, Provides detailed usage instructions for the module publication 750-IN108 service ramp. Industry Installation Guidelines for Pulse Width Modulated...
Page 7: General Precautions
In this manual we refer to the PowerFlex 750-Series products with TotalFORCE control as: • PowerFlex 755T products when referring to the group of drives, bus supplies, and common bus inverters. • PowerFlex 755TL drive when referring to the low harmonic drive product.
Page 8 Chapter 1 Product Overview Personal Safety ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Remove power and wait five minutes before you open the enclosure door. Measure the DC bus voltage at the -DC and +DC TESTPOINT sockets on the front of the power module (see Remove Power from the Drive System on page for location).
Page 9 Product Overview Chapter 1 Class 1 LED Product ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber optic cable connectors. ATTENTION: To avoid an electric shock hazard, the installer must provide guarding to shield exposed electrical equipment against accidental contact.
Page 10: Catalog Number Explanation
Chapter 1 Product Overview Catalog Number Explanation 1…3 8…10 -C0-P15… Control and Power Options f1…f4 Drive PowerFlex 755TL/TR ND Rating PowerFlex 755TL/TR ND Rating Code Type Frames 400V, 50 Hz Input 480V, 60 Hz Input PowerFlex 755 8…12 Code Amps Frame Code Amps...
Page 11 Product Overview Chapter 1 Catalog Number Explanation (continued) 1…3 8…10 -C1-P16… f5…f8 Control and Power Options PowerFlex 755TM Bus Supplies ND Rating PowerFlex 755TM Bus Supplies ND Rating 400V, 50 Hz Input 480V, 60 Hz Input Code Amps Frame Code Amps Frame 1116...
Page 12 Chapter 1 Product Overview Catalog Number Explanation (continued) 1…3 8…10 -C0-C11-P15… Control and Power Options f9…f12 PowerFlex 755TM Common Bus Inverter ND Rating PowerFlex 755TM Common Bus Inverter ND Rating Filtering and CM Cap Configuration 400V, 50 Hz Input 480V, 60 Hz Input CM Cap Default Reflected Wave Code...
Page 13: Product Rating Cross-References
Product Overview Chapter 1 Product Rating Cross- PowerFlex 755TL and 755TR Drives references Table 1 - PowerFlex 755TL and 755TR Drive Ratings to Frame Size Cross-references Drive Code 1 – Cat. No. Position 6 2 – Cat. No. Positions 7…10 Enclosure Code Input Voltage and ND Amp Rating Nameplate 1:...
Page 14 Chapter 1 Product Overview PowerFlex 755TM Bus Supplies Table 2 - Modular AFE Bus Supply Ratings to Frame Size Cross-references Drive Code 1 – Cat. No. Position 6 2 – Cat. No. Positions 7…10 Enclosure Code Input Voltage and ND Amp Rating Nameplate 1: Specifications and Custom Catalog Number representing options installed at factory.
Page 15 Product Overview Chapter 1 PowerFlex 755TM Common Bus Inverters Table 3 - Modular CBI Ratings to Frame Size Cross-references Drive Code 1 – Cat. No. Position 6 2 – Cat. No. Positions 7…10 Enclosure Code Input Voltage and ND Amp Rating Nameplate 1: Specifications and Custom Catalog Number representing options installed at factory.
Page 16: Commonly Used Tools
Chapter 1 Product Overview Commonly Used Tools Installation Tools This list includes the tools that are needed for installation and test measurements. IMPORTANT Care must be taken to be sure that tools and/or hardware components do not fall into open drive assemblies. Do not energize the drive unless all loose tools and/or hardware components have been removed from the drive assemblies and enclosure.
Page 17: Hardware Installation Diagrams
Product Overview Chapter 1 Configuration Tool Options Any of the following configuration tools can be used: • PowerFlex® 20-HIM-A6 or 20-HIM-C6S HIM See the PowerFlex 20-HIM-A6 or 20-HIM-C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001. • Connected Components Workbench™ (CCW) software R10.00 or later •...
Page 18: Fastener Torque Sequences
Chapter 1 Product Overview Fastener Torque Sequences ATTENTION: Components can be damaged if initial tightening procedure is not performed to specification. The following illustrates initial and final tightening sequences for components that are fastened to a heat sink by using two, four, and six screws. Initial torque is 1/3 (33%) of final torque, except six-point mountings, which require 0.7 N m (6 lb...
Page 19: Receiving
Heavy duty/export packaging is not waterproof, watertight, or intended for long-term storage. Upon delivery of the PowerFlex 755T product, refer to the packing slip for sizes and exact shipping weights. The packing slip will also list the items that are included in the shipment.
Page 20: Shipment Configurations
For further assistance, contact your Rockwell Automation representative. Shipment Configurations Some PowerFlex 755T products are divided into sections for shipment. The approximate weight of each section and the approximate total weight of the product is listed in the following tables.
Page 21 Receiving, Handling, and Storage Chapter 2 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 22: Handling
ATTENTION: Follow local codes and guidelines in addition to your company safety procedures when you handle PowerFlex 755T products. To avoid personal injury and structural damage to the PowerFlex 755T product, never attempt to lift or move the equipment by any means other than those listed in this publication.
Page 23 PowerFlex 755T products are top- and front-heavy. 2. Keep the load against the load backrest of the lift truck. Use a belt to secure the PowerFlex 755T product to the lift truck. Tilt the load a few degrees backward toward the lift truck mast.
Page 24 Use slings with load-rated hooks or shackles. 3. Adjust the rigging lengths to compensate for any unequal weight distribution of the load and support the PowerFlex 755T product in an upright position. 4. To reduce tension on the rigging and compression on the structural angle, verify that the angle between the straps or cables and horizontal plane is greater than 60°.
Page 25: Storage
Ø 40 mm (1.4 in.) Storage PowerFlex 755T products are shipped from the factory wrapped in plastic to help prevent dirt and dust from entering the enclosure. If you must store the equipment after you receive it, take the following precautions.
Page 26 Chapter 2 Receiving, Handling, and Storage Notes: Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 27: Ce Conformity
• PowerFlex 755T products are not intended to be used on public low- voltage networks that supply domestic premises. Without additional mitigation, radio frequency interference is expected if used on such a network.
Page 28 Installation Requirements Related to EN 61800-5-1 and the Low Voltage Directive • Voltage classes up to 690V PowerFlex 755T products are compliant with the CE LVD when used on a ‘corner-earthed’ supply system and all other common grounded supply systems for altitudes up to and including 2000 m (6562 ft).
Page 29 Prepare for Installation Chapter 3 ATTENTION: PowerFlex 755T products produce DC current in the protective earthing conductor which can reduce the ability of RCDs (residual current-operated protective devices) or RCMs (residual current-operated monitoring devices) of type A or AC to provide protection for other equipment in the installation.
Page 30 Chapter 3 Prepare for Installation Table 4 - PowerFlex 755T Input Product RF Emission Compliance and Installation Requirements Drive Frame and Catalog Number EN61800-3 Category C3, I > 100 A Frame 8 - AC input product 150 m (492 ft) motor cable limit.
Page 31: Location Planning
Prepare for Installation Chapter 3 Location Planning Consider the following when planning the location for your PowerFlex 755T product. • Environment - temperature, humidity, and vibration or shock • Ventilation and air conditioning • Input power cable entry points • Motor cable exit points •...
Page 32: Minimum Clearances
Chapter 3 Prepare for Installation Minimum Clearances The product must be mounted in a vertical orientation. Observe the clearance requirements that are shown in the following figures. The overhead clearance requirements that are indicated in Figure 7 allow access to the exhaust hoods and cooling fan housings. Figure 7 - Minimum Overhead Clearances 250 mm (9.8 in.)
Page 33 Prepare for Installation Chapter 3 PowerFlex 755T products can be mounted on a service pad or platform. The platform height and enclosure setback measurements that are indicated in Figure 8 are the maximum that is allowed for by the PowerFlex 750-Series service cart (20-750-MCART1).
Page 34 Chapter 3 Prepare for Installation Airflow through the enclosure must not be impeded. Regular inspection and replacement of the filter media is required to maintain proper cooling. Refer to the PowerFlex 750-Series Products with TotalFORCE Control Hardware Service Manual, publication 750-TG100 for filter media maintenance schedules.
Page 35: Mounting Options
Prepare for Installation Chapter 3 Mounting Options Several mounting options are covered in this section. In all instances, each enclosure has a mounting hole in each corner. All mounting holes must be used to secure the enclosure properly. Remove the debris plug when using mounting hardware that must pass through the mounting hole.
Page 36 Chapter 3 Prepare for Installation Rittal Corner Base/Plinth System Rittal Flex-Block base/plinth systems are available from Rittal Corporation in 100 mm (4.0 in.) and 200 mm (8.0 in.) heights. Systems provide a base/plinth for each corner of a Rittal TS 8 enclosure and are secured by using an M12 screw in each corner.
Page 37 Prepare for Installation Chapter 3 Structural Steel System Enclosures can be mounted to structural steel that is anchored to concrete and meet the following specifications and minimum dimensions. • Material: ASTM A-36 / ASME SA36, or equivalent Figure 12 - Structural Steel Beam Cross-sections Wide Flange Beam Channel Beam Table 6 - Steel Beam Dimensions...
Page 38 Chapter 3 Prepare for Installation Anchor Bolt System Enclosures can be mounted directly to a level concrete surface by using M10 (0.375 in.) anchor bolts. The enclosures must be secured to the anchor bolts in all four corners by using M10 nuts and lock washers.
Page 39: Recommended Cabinet Mounting Hardware
Prepare for Installation Chapter 3 Recommended Cabinet Frame Size Fastener Size Usage Notes Mounting Hardware Frames 8 and Threads into the cabinet mounting hole. larger M12 (0.5 in.) • Corner base/plinth system • Structural steel system Property Class 8.8 or better (Grade 5 or better) Frames 8 and Passes through the cabinet mounting hole.
Page 40 Chapter 3 Prepare for Installation PowerFlex 755TL and 755TR Drives Approximate Dimensions Frame 8 Drives Top, Front, and Bottom Views - Dimensions are mm (in.) page 45 for optional exit wire bay dimensions. Input Power Cables - Top Entry (12.3) (5.0) (11.9) IP54, UL Type 12...
Page 41 Prepare for Installation Chapter 3 Frame 9 Drives Top, Front, and Bottom Views - Dimensions are mm (in.) page 45 for optional exit wire bay dimensions. Input Power Cables - Top Entry (20.2) (5.0) (11.9) IP54, UL Type 12 (28.4) IP21, UL Type 1 (3.5) (26.6)
Page 42 Chapter 3 Prepare for Installation Frame 10 Drives Top, Front, and Bottom Views - Dimensions are mm (in.) page 45 for optional entry and exit wire bay dimensions. IP54, UL Type 12 (18.6) (28.4) IP21, UL Type 1 (26.6) (1.8) Control Cables - Top Entry (28.6) (7.9)
Page 43: Frame 11 Drives Top, Front, And Bottom Views
Prepare for Installation Chapter 3 Frame 11 Drives Top, Front, and Bottom Views - Dimensions are mm (in.) page 45 for optional exit wire bay dimensions. IP54, UL Type 12 (18.6) (28.4) IP21, UL Type 1 (26.6) (1.8) Signal Cables - Top Entry (28.6) (7.9) Input Bay...
Page 44: Frame 12 Drives Top, Front, And Bottom Views
Chapter 3 Prepare for Installation Frame 12 Drives Top, Front, and Bottom Views - Dimensions are mm (in.) page 45 for optional entry and exit wire bay dimensions. Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 45: Drives Optional Entry And Exit Wire Bays Top, Front, And Bottom Views
Prepare for Installation Chapter 3 Drives Optional Entry and Exit Wire Bays Top, Front, and Bottom Views - Dimensions are mm (in.) Input Power Cables - Top Entry (12.0) (12.0) (12.0) Motor Cables - Top Exit (7.2) (7.2) Input Power Cables - Top Entry Motor Cables - Top Exit (26.6) (26.6)
Page 46 Chapter 3 Prepare for Installation PowerFlex 755TM Bus Supplies Approximate Dimensions Frame 8 Bus Supplies Top, Front, Bottom, and Side Views - Dimensions are mm (in.) page 51 for optional entry wire bay dimensions. Input Power Cables - Top Entry (12.3) (5.0) (11.9)
Page 47 Prepare for Installation Chapter 3 Frame 9 Bus Supplies Top, Front, Bottom, and Side Views - Dimensions are mm (in.) page 51 for optional entry wire bay dimensions. Input Power Cables - Top Entry (20.2) (5.0) (11.9) IP54, UL Type 12 (28.4) IP21, UL Type 1 (3.5)
Page 48 Chapter 3 Prepare for Installation Frame 10 Bus Supplies Top, Front, and Bottom Views - Dimensions are mm (in.) page 51 for optional entry wire bay dimensions. IP54, UL Type 12 (18.6) (28.4) IP21, UL Type 1 (26.6) (1.8) Signal Cables - Top Entry (28.6) (7.9) Power Bay...
Page 49 Prepare for Installation Chapter 3 Frame 11 Bus Supplies Top, Front, and Bottom Views - Dimensions are mm (in.) page 51 for optional entry wire bay dimensions. IP54, UL Type 12 (18.6) (28.4) IP21, UL Type 1 (26.6) (1.8) Signal Cables - Top Entry (28.6) (7.9) Input Bay...
Page 50 Chapter 3 Prepare for Installation Frame 12 Bus Supplies Top, Front, and Bottom Views - Dimensions are mm (in.) page 51 for optional entry wire bay dimensions. IP54, UL Type 12 (18.6) (28.4) IP21, UL Type 1 (26.6) (1.8) Signal Cables - Top Entry (28.6) (7.9) Input Bay...
Page 51: Optional Entry Wire Bays Top, Front, And Bottom Views
Prepare for Installation Chapter 3 Optional Entry Wire Bays Top, Front, and Bottom Views - Dimensions are mm (in.) Power Cables - Top Entry (12.0) (12.0) (12.0) (7.2) (7.2) Power Cables - Top Entry (26.6) (26.6) (12.2) (12.2) (15.7) (31.5) 2132 2132 (83.9)
Page 52 Chapter 3 Prepare for Installation PowerFlex 755TM Common Bus Inverters Approximate Dimensions Frame 8 Top, Front, and Bottom Views - Dimensions are mm (in.) page 57 for optional exit wire bay dimensions. IP54, UL Type 12 (28.4) IP21, UL Type 1 (26.6) Control Bay Power Bay...
Page 53: Frame 9 Top, Front, And Bottom Views
Prepare for Installation Chapter 3 Frame 9 Top, Front, and Bottom Views - Dimensions are mm (in.) page 57 for optional exit wire bay dimensions. IP54, UL Type 12 (28.4) IP21, UL Type 1 (26.6) Control Bay Power Bay IP54, UL Type 12 2291 (90.2) IP21, UL Type 1...
Page 54: Frame 10 Top, Front, And Bottom Views
Chapter 3 Prepare for Installation Frame 10 Top, Front, and Bottom Views - Dimensions are mm (in.) page 57 for optional exit wire bay dimensions. IP54, UL Type 12 (28.4) IP21, UL Type 1 (26.6) Control Bay Power Bay IP54, UL Type 12 2291 (90.2) IP21, UL Type 1...
Page 55: Frame 11 Top, Front, And Bottom Views
Prepare for Installation Chapter 3 Frame 11 Top, Front, and Bottom Views - Dimensions are mm (in.) page 57 for optional exit wire bay dimensions. IP54, UL Type 12 (28.4) IP21, UL Type 1 (26.6) Power Bay Power Bay IP54, UL Type 12 2291 (90.2) IP21, UL Type 1...
Page 56: Frame 12 Top, Front, And Bottom Views
Chapter 3 Prepare for Installation Frame 12 Top, Front, and Bottom Views - Dimensions are mm (in.) page 57 for optional exit wire bay dimensions. IP54, UL Type 12 (28.4) IP21, UL Type 1 (26.6) Power Bay Power Bay IP54, UL Type 12 2291 (90.2) IP21, UL Type 1...
Page 57 Prepare for Installation Chapter 3 Common Bus Inverters Control Bay and Optional Exit Wire Bays Top, Front, and Bottom Views - Dimensions are mm (in.) Motor Cables - (12.0) (12.0) (12.0) Top Exit (7.2) (7.2) Motor Cables - (26.6) Top Exit (26.6) (26.6) (7.9)
Page 58: Installation Site Requirements
Chapter 3 Prepare for Installation Installation Site Figure 16 - Cross-section View of Cable Bottom Entry and Exit Requirements Front Rear Mounting Hardware (See page 39) Mounting Surface (See page 31) Conduit Bottom Recommended Cable Pattern, Power Bay Use the locations marked on the plate. See Approximate Dimensions on page 39.
Page 59: Prepare Enclosures
Chapter Mechanical and Electrical Installation The PowerFlex 755T installation process is divided into three principal activities: • Mechanically install the enclosures • Make the electrical interconnections between enclosures • Make power supply and motor connections (Chapter Prepare Enclosures Access to the enclosure interior is required during product installation to complete the following tasks: •...
Page 60: Component Removal Requirements
Mechanical and Electrical Installation Component Removal This section outlines which components must be removed to install each PowerFlex 755T product. Each figure illustrates the minimum requirement to Requirements allow adequate access to join and anchor the enclosures, and to interconnect bus bars.
Page 61 Mechanical and Electrical Installation Chapter 4 PowerFlex 755TL and 755TR Drives This section lists the LCL filter modules, line side converters, and motor side inverters that you must remove to install the product. Removal of these components facilitates access to join and anchor cabinets, and for making electrical interconnections between the cabinets.
Page 62 Chapter 4 Mechanical and Electrical Installation Figure 19 - Frame 8 Drives LCL0 Module Type Remove Position No. Shipping Split Section LCL filter module LCL0 Section 1 of 1 Line side converter Motor side inverter Figure 20 - Frame 9 Drives Module Type Remove Position No.
Page 63 Mechanical and Electrical Installation Chapter 4 Figure 21 - Frame 10 Drives Shipping Split LCL1 Module Type Remove Position No. Shipping Split Section Line side converter L0, L1 Section 1 of 2 (left section) Section 2 of 2 (right section) LCL filter module LCL1 Motor side inverter...
Page 64: L0 L1
Chapter 4 Mechanical and Electrical Installation Figure 23 - Frame 12 Drives Shipping Splits LCL2 Module Type Remove Position No. Shipping Split Section Line side converter L0, L1 Section 1 of 3 (left section) L2, L3 Section 2 of 3 (center section) LCL filter LCL2 Motor side inverter...
Page 65: Line Side Converter
Mechanical and Electrical Installation Chapter 4 PowerFlex 755TM Bus Supplies This section lists the LCL filter modules and line side converters that you must remove to install the product. For instructions on how to remove these components from the enclosure, see Remove Power Module on page Remove LCL Filter Module on page 79.
Page 66: L2 L3
Chapter 4 Mechanical and Electrical Installation Figure 26 - Frame 10 Bus Supply LCL1 Module Type Remove Position No. Shipping Split Section Line side converter L0, L1, L2 Section 1 of 1 LCL filter LCL1 Figure 27 - Frame 11 Bus Supply Shipping Split Module Type Remove Position No.
Page 67 Mechanical and Electrical Installation Chapter 4 Figure 28 - Frame 12 Bus Supply Shipping Split LCL2 Module Type Remove Position No. Shipping Split Section Line side converter L0, L1 Section 1 of 2 (left section) L2, L4 Section 2 of 2 (right section) LCL filter LCL2 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 68: Motor Side Inverter
Chapter 4 Mechanical and Electrical Installation PowerFlex 755TM Common Bus Inverters This section lists the motor side inverters that you must remove to install the product. For instructions on how to remove this component from the enclosure, see Remove Power Module on page 73. Figure 29 - Frame 8 Common Bus Inverter Module Type Remove Position No.
Page 69 Mechanical and Electrical Installation Chapter 4 Figure 31 - Frame 10 Common Bus Inverter Module Type Remove Position No. Shipping Split Section Motor side inverter M0, M1, M2 Section 1 of 1 Figure 32 - Frame 11 Common Bus Inverter Module Type Remove Position No.
Page 70: Remove Protective Guards
Guards can also provide electrical insulation between components. Remove guards only when access is required. Replace guards promptly. Never operate PowerFlex 755T products without all guards in place. Follow these steps to remove and replace the input bay protective touch guards.
Page 71 Mechanical and Electrical Installation Chapter 4 Figure 34 - Input Bay Touch Guards M5.5 4.8 N•m (42 lb•in) M5.5 2.6 N•m (23 lb•in) Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 72 Chapter 4 Mechanical and Electrical Installation Figure 35 - Control and Power Bay Touch Guards M5.5 Control Bay Power Bay Power Bay 2.6 N•m (23 lb•in) without DC Precharge Modules with DC Precharge Modules Figure 36 - Wire Bay Touch Guards M5.5 2.6 N•m (23 lb•in) Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 73: Remove Power Module
Mechanical and Electrical Installation Chapter 4 Remove Power Module Follow these steps to remove a power module from the enclosure. 1. Review the General Precautions on page 7. 2. Open the enclosure door. 3. If present, remove the protective touch guards from the enclosure. See Remove Protective Guards on page 70.
Page 74 Chapter 4 Mechanical and Electrical Installation 6. Disconnect the PDI and CTL fiber-optic cables, if present, from the power layer interface circuit board. See Figure 7. Without bending the cables to a radius less than 50 mm (2 in.), carefully remove the cables from the power module chassis.
Page 75 Mechanical and Electrical Installation Chapter 4 Figure 39 - Power Module I/O Panel Connections 12. Loosen the two M10 x 10 mm hex nuts (See 1 in Figure 40) that secure the power input/output terminals to the DC precharge module or DC link fuse terminals.
Page 76 PowerFlex 750-Series Service Cart and DCPC Module Lift Instructions, publication 750-IN105. To remove the module using PowerFlex 755TM service ramp, follow the procedures detailed in the PowerFlex 755T Module Service Ramp Instructions, publication 750-IN108. Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 77 Mechanical and Electrical Installation Chapter 4 15. Remove the two remaining M10 screws to release the power module (see Figure 40). 16. Remove the power modules from the enclosure. Center of gravity label. ATTENTION: LCL filter modules and power modules have a high center of gravity and a tip-over hazard exists.
Page 78 Chapter 4 Mechanical and Electrical Installation Install Power Modules in the Enclosure Install the power modules into the enclosure in the reverse order of removal. When you install the fiber-optic cables: 1. Remove the transceiver from the fiber-optic connector port on the power layer interface circuit board.
Page 79: Remove Lcl Filter Module
Mechanical and Electrical Installation Chapter 4 Remove LCL Filter Module Follow these steps to remove the LCL filter module from an enclosure. Power Module Connections If power modules have already been removed, skip this section and go to Module Connections on page 1.
Page 80 Chapter 4 Mechanical and Electrical Installation 6. Disconnect the PDI and CTL fiber-optic cables, if present, from the power layer interface circuit board. Figure 42 - Power Module PDI and CTL Fiber-optic Cable Connections LCL filter with one line side converter. LCL filter with two line side converters.
Page 81 Mechanical and Electrical Installation Chapter 4 LCL Module Connections 1. Disconnect the AC input fuse wire harness connector P5 and the 240 volt connector P4 on the LCL filter module. See Figure Figure 44 - LCL Filter Wiring Harnesses Power Control Bus AC Fuse Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 82 Chapter 4 Mechanical and Electrical Installation 2. Remove the three M12 x 13 mm hex nuts that secure the flex bus cables to the AC input fuse terminals and remove the flex bus cables. See Figure Figure 45 - Chassis and AC Bus Connections 17 mm 38 N•m (336 lb•in) M10 x 20mm...
Page 83 Mechanical and Electrical Installation Chapter 4 Center of gravity label. ATTENTION: LCL filter modules and power modules have a high center of gravity and a tip-over hazard exists. To guard against death, serious personal injury, or equipment damage, do not subject the module to high rates of acceleration or deceleration while transporting.
Page 84 Chapter 4 Mechanical and Electrical Installation IMPORTANT Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm attenuation increases as inside bend radius is (2 in.) decreased.
Page 85: Place The Enclosures
If your PowerFlex 755T product consists of multiple enclosures, the enclosures must be arranged as shown in the dimensional drawings starting on page 39.
Page 86 Chapter 4 Mechanical and Electrical Installation Position the Enclosure 1. Release the enclosure from the shipping skid. For multiple enclosures, start with input bay. 19 mm 2. Place the enclosure on supports, such as wooden beams, that provide enough space to remove the bolts that secure the cleats to the enclosure. 19 mm 3.
Page 87: Join Enclosures
Mechanical and Electrical Installation Chapter 4 Join Enclosures PowerFlex 755T products that ship in multiple sections must be connected after they are located in their final positions. The enclosures are connected together using the joining hardware provided. Each of the three types of enclosure connections are made in the same way.
Page 88 Chapter 4 Mechanical and Electrical Installation 2. Apply the gasket in one continuous strip around the mating surface of the enclosure. Seam the gasket at the approximate middle of the bottom of the enclosure. Seam Location 3. Align the right enclosure assembly (section 2 of n) with the input bay assembly (section 1 of n) and bring together with the placed input bay.
Page 89 Mechanical and Electrical Installation Chapter 4 5. Remove the structural angles. IMPORTANT Make any final position adjustments before this step. 19 mm 38 N•m (336 lb•in) Install IP54, UL Type 12 Roof Assemblies 1. Remove the shipping roof panels. Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 90 Chapter 4 Mechanical and Electrical Installation 2. Lower the IP54, UL Type 12 roof assemblies on to the enclosures. IMPORTANT Use care not to damage the roof assembly gasket material. 3. Connect the fan wiring harnesses. 13 mm 4.8 N•m (42 lb•in) 4.
Page 91 Mechanical and Electrical Installation Chapter 4 Install Joining Hardware Use the joining hardware provided to mechanically connect the enclosures together. Nine frame clamps and two top bracket sets are provided. 1. Install the top bracket sets to the cabinets. Ensure that the cabinets are aligned, level, and pushed together tightly. 2.
Page 92 Chapter 4 Mechanical and Electrical Installation Figure 47 - Bracket Spacing Top Bracket Sets Install top clamp on door side of the enclosure only. 1869 mm Frame Clamps Enclosure Back Side (73.6 in.) 1368 mm (53.9 in.) 918 mm (36.1 in.) 243 mm (9.6 in.) 43 mm...
Page 93: Affix The Enclosures To The Floor
Mechanical and Electrical Installation Chapter 4 Secure and Seal Roof Panels and Side Sheet 1. Use the M12 screws with integral paint-piercing rubber washers to secure and seal the roof panels. 19 mm M12 Screw 20 N•m (177 lb•in) Paint-piercing Washer 4.8 N•m (42 lb•in) 2.
Page 94: Electrical Interconnections
Chapter 4 Mechanical and Electrical Installation Electrical Interconnections After the product enclosures are mechanically joined and properly anchored to the mounting surface, electrically connect the enclosures together. There are five electrical interconnections that are required: • AC bus • DC bus •...
Page 95 Mechanical and Electrical Installation Chapter 4 Figure 49 - Splicing Hardware 85 mm 15 mm (3.3 in.) 38 N•m (336 lb•in) 268.5 mm (10.6 in.) AC Bus Bar Splicing Hardware 15 mm 38 N•m (336 lb•in) 85 mm (3.3 in.) 186 mm (7.3 in.) DC Bus Bar Splicing Hardware...
Page 96: Fiber-Optic Connections
Chapter 4 Mechanical and Electrical Installation Fiber-optic Connections Fiber-optic cables are stored on the right interior panel of the first power bay. These cables connect the fiber interface board to the line side converters and motor side inverters in the adjacent enclosures. See Figure 42 on page Fiber-optic cables are stored in a coil inside...
Page 97 Mechanical and Electrical Installation Chapter 4 2. Route the cables through the control power channel cable guides. Reverse Angle View Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 98 Chapter 4 Mechanical and Electrical Installation 3. Connect the each fiber-optic cable to its designated CTL port on the power module power layer interface circuit board. See Figure 38 on page Figure 50 - Fiber Interface to CTL Port Connections Shipping Splits L0-CTL and L1-CTL connections L2-CTL…L4-CTL Connections...
Page 99: Grounding Requirements
Chapter Power Wiring Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins. ATTENTION: The following information is merely a guide for proper installation.
Page 100 Chapter 5 Power Wiring Figure 51 - Typical Grounding Example Input Bay Power Bay To Line PE (Input Bay) U (T1) V (T2) W (T3) R (L1) To PE (Power Bay) SHLD S (L2) T (L3) Shield Termination - SHLD The shield terminal provides a grounding point for the motor cable shield.
Page 101: Power Cable Types Acceptable For 400
Power Wiring Chapter 5 Power Cable Types A variety of cable types are acceptable for drive installations. For an in-depth discussion of cable types, including a table of maximum motor cable lengths, Acceptable for 400…690 refer to the Wiring and Grounding Guidelines for Pulse Width Modulated Volt Installations (PWM) AC Drives, publication DRIVES-IN001.
Page 102: Bus Bar Locations
Chapter 5 Power Wiring Bus Bar Locations Figure 52 - Frame 8 and 9 Drives Frame 8 drive shown. Item Name Description AC Link Connects AC circuit breaker to LCL fuse assembly Testpoints DC+, DC- and R/L1, S/L2, T/L3 voltage testpoint sockets Control Bus 120/240V and 24V AC control power supply connections Input Power Bus...
Page 103 Power Wiring Chapter 5 Figure 53 - Frames 10…12 Drives Frame 10 drive shown. Layout is typical for Frames 10…12. Item Name Description Item Name Description AC Bus AC power supply Control Bus 120/240V and 24V AC control power supply connections DC Bus DC+, DC- Power Bus...
Page 104 Chapter 5 Power Wiring Figure 54 - Frames 8…12 Bus Supplies Frame 8 bus supply shown. Frame 10 bus supply shown. Layout is typical for Frames 10 through 12. Item Name Description Item Name Description AC Link Connects AC circuit breaker to LCL fuse assembly Power Bus R/L1, S/L2, T/L3 AC line input power connections AC Bus...
Page 105 Power Wiring Chapter 5 Figure 55 - Frames 8…12 Common Bus Inverters Frame 8 Frame 10 (Layout is typical for Frames 9…12) Item Name Description DC bus DC power supply Control bus Control power supply Power bus U/T1, V/T2, W/T3 motor connections PE grounding bar Terminating point to chassis ground for incoming AC line and motor shield.
Page 106: Field Connections
Chapter 5 Power Wiring Figure 56 - Optional Entry and Exit Wire Bays 400 mm (15.7 in.) 800 mm (31.5 in.) Item Name Description DC bus DC power supply Control bus Control power supply Power bus R/L1, S/L2, T/L3 AC line input power connections (entry wire bay) U/T1, V/T2, W/T3 motor connections (exit wire bay) PE grounding bar Terminating point to chassis ground for incoming AC line and motor shield.
Page 107 Power Wiring Chapter 5 Bus Bar Connections AC line input power and output motor cables with appropriate barrel lugs are connected directly to bus bars and use the fastening hardware provided. Keep the wire connections at least 51 mm (2 in.) away from the ends of the slotted bus bar.
Page 108 Chapter 5 Power Wiring PE Ground Connections The clamp kits listed in this table can be used to secure round copper ground conductors to 9.5 mm (0.37 in.) thick ground bus bars. Kit Catalog Number Conductor Cross-sections ISO (mm AWG/MCM Tightening Torque N•m (lb•in) SK-RM-GRNDCLMP-16 2.5…16...
Page 109 19 mm 38 N•m (336 lb•in) Additional Power Terminal L-Brackets PowerFlex 755T entry and exit wire bays come equipped with L-brackets. If an application requires additional L-brackets, kit number 20-750-MLBRKT- F8M is available. Each kit contains three L-brackets and mounting hardware.
Page 110: Recommended Cable Spacing
Both Sides - Up to four lugs. Recommended Cable Spacing PowerFlex 755T products require multiple conductors in parallel. Wire size and number of conductors must be determined by the customer based on drive rated current, local codes, operating conditions, and specific application needs.
Page 111 Power Wiring Chapter 5 Figure 61 - Recommended Cable Spacing Example - 1000 mm (39.4 in.) Wire Input Bay Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 112 Chapter 5 Power Wiring Figure 62 - Recommended L-bracket Spacing Example - 800 mm (31.5 in.) Wire Bay One phase of input power connections shown for clarity. Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 113: Fuses And Circuit Breakers
Power Wiring Chapter 5 Fuses and Circuit Breakers The tables on the following pages provide recommended AC line input fuse and circuit breaker information. Sizes listed are the recommended sizes based on 40 °C (104 °F) and the U.S. NEC. Other country, state, or local codes can require different ratings.
Page 114 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 115 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 116 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 117 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 118 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 119 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 120 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 121 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 122 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 123 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 124 Chapter 5 Power Wiring Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 125 Power Wiring Chapter 5 Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 126: Motor Overload Protection
Chapter 5 Power Wiring Motor Overload Protection 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. Short Circuit Current Rating Maximum Short Circuit Rating Suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes, up to 600V maximum and 65 kA rms symmetrical amperes at 690V maximum.
Page 127: Bypass Contactor Precaution
• Wiring AC line to drive output or control terminals. • Improper bypass or output circuits not approved by Allen-Bradley. • Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring.
Page 128 Jumpers PE-A, PE-A1, PE-A2, and PE-B1 must be configured for the power source type according to the recommendations in the PowerFlex 755T Input Product RF Emission Compliance and Installation Requirements table on page 30. Table 12 - PowerFlex 755TL/TR Drive Jumpers...
Page 129 Power Wiring Chapter 5 Table 14 - PowerFlex 755TM Common Bus Inverter Jumpers Supply Source Grounding Scheme PE-A PE-A1 PE-A2 PE-B1 Type Option (MOV on the AC (MOV in the TVSS (Common Mode (Y-Caps on Line (Y-Caps on Motor Precharge Module) Caps on All AC Side Converter...
Page 130 Chapter 5 Power Wiring ATTENTION: Hazard of equipment damage exists if jumpers are not properly disconnected or are set differently between power and LCL filter modules. Secure a disconnected jumper in the socket or on the insulated spacer that is provided and verify that all modules are configured identically.
Page 131 Power Wiring Chapter 5 Recommended PE-A1 Jumper Configuration The PE-A1 power jumper is connected to the TVSS module (cat. no. 20-750- MACP-xx-TVSS). The Frame 8 and 9 AC precharge modules include an insulated spacer and hardware for the jumper PE-A1 OUT position and hardware for the jumper PE-A1 IN position.
Page 132 Chapter 5 Power Wiring Recommended PE-A2 Jumper Configuration The PE-A2 power jumper is connected to the AC common mode filter circuit board in the LCL filter modules. Figure 65 - Recommended PE-A2 Jumper Configuration M6 x 20 mm 5.2 N•m (46 lb•in) Jumper PE-A2 IN Jumper PE-A2 OUT LCL Filter Module...
Page 133 Power Wiring Chapter 5 Recommended PE-B1 Jumper Configuration The PE-B1 power jumper is connected to the power interface circuit board in the power modules. Figure 66 - Recommended PE-B1 Jumper Configuration Jumper Shown in the Default Installation Location. J5 (PE-B1 IN) J6 (PE-B1 OUT) Power Module Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 134 Chapter 5 Power Wiring Notes: Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 135: I/O Wiring
Chapter I/O Wiring Important points to remember about I/O wiring: • Always use copper wire. • Wire with an insulation rating of 600V or greater is recommended. • Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
Page 136: I/O Terminal Blocks
Chapter 6 I/O Wiring I/O Terminal Blocks Table 15 - Main Control Board I/O Terminal Block Specifications Name Wire Size Range Torque Strip Length Maximum Minimum Maximum Recommended 755T Control Module TB1 2.5 mm 0.3 mm 0.25 N•m 0.2 N•m 6 mm (14 AWG) (28 AWG)
Page 137 I/O Wiring Chapter 6 Table 18 - Common DC Input Drive Assembly I/O Terminal Block and Connector Specifications Name Wire Size Range Torque Strip Length Maximum Minimum Maximum Recommended Common DC Input TB1…TB5 4.0 mm 0.25 mm 0.5 N•m 0.4 N•m 7 mm (12 AWG) (24 AWG)
Page 138: Access Control Pod
Chapter 6 I/O Wiring Access Control Pod The control pod is located in the input bay of 755TL and 755TR drives and the control bay of a common bus inverter, if equipped. Input Bay Control Bay 755TL and 755TR Drives and 755TM Bus Supplies 755TM Common Bus Inverters 1.
Page 139 I/O Wiring Chapter 6 2. Lift the HIM cradle. – Loosen the retention screw. – Lift the cradle until the latch engages. Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 140: Main Control Board
Chapter 6 I/O Wiring Main Control Board Table 20 - Main Control Board Details Item Name Description HIM Connector DPI Port 01 (HIM Cradle) connection. Fan Connector Power supply for internal cooling fan. Control Selector Rotary switch for setting the programming mode. Embedded EtherNet/IP Address Rotary switches for setting lowest octet of EtherNet address (forces...
Page 141: Hardware Enable Circuitry
• PowerFlex 755T - Digital Input 0 is found on TB1 To configure Digital Input 0 as a dedicated hardware enable, complete the following steps.
Page 142: Safety Enable Circuitry
Chapter 6 I/O Wiring Safety Enable Circuitry The drive ships with the safety enable jumper (SAFETY) installed. This jumper must be removed when using the safe torque off or speed monitoring safety options. IMPORTANT Failure to remove the jumper when using either safety option will cause the drive to fault when a start command is issued.
Page 143: Fiber Optic Interface Board
I/O Wiring Chapter 6 Fiber Optic Interface Board The fiber-optic interface board holds the fiber transceiver circuit boards. ACP0 ACP1 / TAM Table 22 - Fiber Transceiver Circuit Board Connections Port Name Description ACP0 Fiber transceiver port for the fiber-optic connection from ACP on the AC precharge control board. ACP1 TAM Fiber transceiver port for the fiber-optic connection from TAM on the torque accuracy module.
Page 144: Option Module Installation
Chapter 6 I/O Wiring Option Module Installation Compatible port locations may be restricted for each module. An icon with position number(s) is provided to indicate which option module slots (ports) are compatible. For example, the icon to the right indicates that the option module is only compatible with slot 04.
Page 145: 11-Series I/O Module
I/O Wiring Chapter 6 11-Series I/O Module Table 23 - Analog Input Mode Jumpers 20-750-1132C-2R (24 Volts DC) 20-750-1133C-1R2T (24 Volts DC) Voltage Mode Current Mode 20-750-1132D-2R (120 Volts AC) Table 24 - TB1 Terminal Designations Terminal Name Description Related Param –10V –10 Volt Reference Negative 10V DC for analog inputs.
Page 146 Chapter 6 I/O Wiring ATTENTION: Risk of equipment damage exists. Ensure that the correct voltage is applied to the I/O Module digital inputs. Refer to the I/O Module catalog number to determine the voltage rating. • 20-750-1132C-2R is rated 24 Volts DC •...
Page 147 I/O Wiring Chapter 6 Table 27 - 24 Volt DC Power Supply Source for Digital Inputs Jumpers Internal External Important: 24 Volt DC supply is only used with modules 20-750-1132C-2R and 20-750-1133C-1R2T. 11-Series I/O with ATEX Module The 11-Series I/O option module can be used with the ATEX option module, catalog number 20-750-ATEX.
Page 148: 11-Series I/O Wiring Examples
Chapter 6 I/O Wiring 11-Series I/O Wiring Examples Table 28 - 11-Series I/O Module TB1 Wiring Examples Input/Output Connection Example Required Parameter Changes Potentiometer Unipolar • Set Direction Mode Speed Reference Port 10/11:930 [Direction Mode] = 0 ‘Unipolar’ • Set Selection 10k Ohm Pot.
Page 149 I/O Wiring Chapter 6 Table 28 - 11-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes Analog Voltage Input • Set Direction Mode Unipolar Speed Reference Port 10/11:930 [Direction Mode] = 0 ‘Unipolar’ • Set Selection 0 to +10V Input Common Ai0–...
Page 150 Chapter 6 I/O Wiring Table 28 - 11-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes 2-Wire Control Non- • Set Direction Mode Reversing Port 10/11:930 [Direction Mode] = 2 ‘Rev Disable’ Stop-Run • Set Selection 24V DC internal supply Port 00:120 [DI M Run] = Port nn:1 [Dig In Sts], bit 0 = Input 0 (11-Series I/O Module) Di0P...
Page 151 I/O Wiring Chapter 6 Table 28 - 11-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes 3-Wire Control • Set Selection Port 00:108 [DI M Stop] = Port nn:1 [Dig In Sts], bit 0 = Input 0 (11-Series I/O Module) External 24 volt supply Stop Port 00:117 [DI M Start] = Port nn:1 [Dig In Sts], bit 1 = Input 1 (11-Series I/O Module)
Page 152 Chapter 6 I/O Wiring Table 28 - 11-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes Digital Input • Set Selection Port 00:108 [DI M Stop] = Port nn:1 [Dig In Sts], bit 0 = Input 0 (11-Series I/O Module) PLC Output Module Port 00:117 [DI M Start] = Port nn:1 [Dig In Sts], bit 1 = Input 1 (11-Series I/O Module) External supply...
Page 153 I/O Wiring Chapter 6 Table 28 - 11-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes Digital Output • Set Selection Port nn:20 [TO0 Sel] (11-Series I/O Module) = Port 10/11:354 [Motor Side Sts 1], bit 7 = Internal supply Faulted +24V...
Page 154: 22-Series I/O Module
Chapter 6 I/O Wiring Table 29 - 11-Series I/O Relay Wiring Examples Input/Output Connection Example Required Parameter Changes Relay Output 11-Series I/O Module • Set Selection Port nn:10 [RO0 Sel] (11-Series I/O Module) = Port 10/11:354 [Motor Side Sts 1], bit 7 = External supply Faulted •...
Page 155 I/O Wiring Chapter 6 Table 31 - TB1 Terminal Designations Terminal Name Description Related Param Shield Terminating point for wire shields when an EMC plate or conduit box is not installed. Ptc– Motor PTC (–) Motor protection device (Positive Temperature Coefficient).
Page 156 Chapter 6 I/O Wiring Table 32 - TB2 Terminal Designations (2 Relay Outputs: 2R) Relay Out Terminal Name Description Related Param R0NO Relay 0 N.O. Relay Normally Open contact output: 10, 100, 101, 240V AC, 24V DC, 2 A max. R0NO Relay 0 Common 105, 106...
Page 157: 22-Series I/O Wiring Examples
I/O Wiring Chapter 6 22-Series I/O Wiring Examples Table 34 - 22-Series I/O Module TB1 Wiring Examples Input/Output Connection Example Required Parameter Changes Potentiometer Unipolar • Set Direction Mode Speed Reference Port 10/11:930 [Direction Mode] = 0 ‘Unipolar’ • Set Selection 10k Ohm Pot.
Page 158 Chapter 6 I/O Wiring Table 34 - 22-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes Analog Current Input • Set Direction Mode Unipolar Speed Reference Port 10/11:930 [Direction Mode] = 0 ‘Unipolar’ Common • Set Selection Ai0–...
Page 159 I/O Wiring Chapter 6 Table 34 - 22-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes 3-Wire Control • Set Selection Port 00:108 [DI M Stop] = Port nn:1 [Dig In Sts], bit 0 = Input 0 (22-Series I/O Module) Internal supply Port 00:117 [DI M Start] = Port nn:1 [Dig In Sts], bit 1 = Input 1 (22-Series I/O Module) 24VC...
Page 160 Chapter 6 I/O Wiring Table 34 - 22-Series I/O Module TB1 Wiring Examples (continued) Input/Output Connection Example Required Parameter Changes Digital Input • Set Selection Neutral/ Port 00:108 [DI M Stop] = Port nn:1 [Dig In Sts], bit 0 = Input 0 (22-Series I/O Module) PLC Output Module Common Port 00:117 [DI M Start] = Port nn: 1 [Dig In Sts], bit 1 = Input 1 (22-Series I/O Module)
Page 161: Safe Torque Off Option Module
I/O Wiring Chapter 6 Safe Torque Off Option The safe torque off option is just one component in a safety control system. Components in the system must be chosen and applied appropriately to Module achieve the desired level of operational safety. For detailed information on applying this option, refer to the PowerFlex 750-Series Safe Torque Off User Manual, publication 750-UM002.
Page 162 Chapter 6 I/O Wiring Port Assignment When used in an Integrated Motion application, the Safe Torque Off option must be installed in Port 06. Only one safety option module can be installed at a time. Multiple safety options or duplicate safety option installations are not supported. Jumper Settings Ensure the hardware enable jumper (ENABLE) on the main control board is installed.
Page 163: Safe Speed Monitor Option Module
I/O Wiring Chapter 6 Safe Speed Monitor Option The Safe Speed Monitor option is just one component in a safety control system. Components in the system must be chosen and applied appropriately Module to achieve the desired level of operational safety. For detailed information on applying this option, refer to the Safe Speed Monitor Option Module for PowerFlex 750-Series AC Drives Safety Reference Manual, publication 750-...
Page 164 Chapter 6 I/O Wiring Cabling 20-750-S1 20-750-DENC-1 Safety input wiring must be protected against external damage by cable ducting, conduit, armored cable or other means. Shielded cable is required. When installed in a Frame 8 or larger drive, an EMC Core Kit, catalog number 20-750-EMCSSM1-F8, is required.
Page 165: Integrated Safety - Safe Torque Off Option Module
I/O Wiring Chapter 6 Integrated Safety - Safe The integrated safety - safe torque off option module is just one component in a safety control system. Components in the system must be chosen and applied Torque Off Option Module appropriately to achieve the desired level of operational safety. For detailed information on applying this option, refer to the PowerFlex 755 Integrated Safety - Safe Torque Off User Manual, publication 750-UM004.
Page 166: Devicenet Option Module
Chapter 6 I/O Wiring • 24V DC ±10% must be supplied by a power supply that complies with IEC/EN 61558-1. For planning information, refer to the guidelines in Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. DeviceNet Option Module For complete information on the DeviceNet Option Module, refer to the PowerFlex 750-Series Drive DeviceNet Option Module User Manual, publication 750COM-UM002.
Page 167: Controlnet Option Module
I/O Wiring Chapter 6 ControlNet Option Module For complete information on the ControlNet Option Module, refer to the PowerFlex 20-750-CNETC Coaxial ControlNet Option Module User Manual, publication 750COM-UM003. Table 43 - ControlNet Option Module LED Indication 20-750-CNETC Name Description PORT DPI Connection Status Option Module Status NET A...
Page 168: Dual-Port Ethernet/Ip Option Module
Chapter 6 I/O Wiring Dual-Port EtherNet/IP Option For complete information on the Dual-Port EtherNet/IP Option Module, refer to the PowerFlex 20-750-ENETR Dual-Port EtherNet/IP Option Module Module User Manual, publication 750COM-UM008. Table 46 - EtherNet Option Module LED Indication 20-750-ENETR Name Description PORT DPI Connection Status...
Page 169: Profibus Option Module
I/O Wiring Chapter 6 Profibus Option Module For complete information on the Profibus Option Module, refer to the PowerFlex 20-750-PBUS Profibus DPV1 Option Module User Manual, publication 750COM-UM004. Table 50 - Profibus Option Module LED Indication 20-750-PBUS Name Description PORT DPI Connection Status Option Module Status NET A...
Page 170: Bacnet/Ip Option Module
Chapter 6 I/O Wiring BACnet/IP Option Module For complete information on the BACnet/IP Option Module, refer to the PowerFlex 20-750-BNETIP BACnet/IP Option Module User Manual, publication 750COM-UM005. Table 54 - BACnet/IP Option Module LED Indication 20-750-BNETIP Name Description PORT DPI Connection Status Option Module Status NET A BACnet Status...
Page 171: Single Incremental Encoder Option Module
I/O Wiring Chapter 6 Single Incremental Encoder Option Module Table 57 - Single Incremental Encoder Specifications 20-750-ENC-1 Consideration Description Input Differential or Single Ended operation, Constant Current Sink operation ~10 mA, 5V DC minimum to 15V DC maximum sourcing 10 mA minimum high state voltage of 3.5V DC maximum low state voltage of 0.4V DC Maximum Cable Length...
Page 172 Chapter 6 I/O Wiring Table 59 - Single Incremental Encoder Sample Wiring Connection Example Encoder Power by Drive 12V DC, 250 mA 5V DC, 250 mA Separately Powered Encoder – Encoder Signal – Single-Ended, Dual Channel Encoder Signal – Differential, Dual Channel Homing Signal –...
Page 173: Dual Incremental Encoder Option Module
I/O Wiring Chapter 6 Dual Incremental Encoder Option Module Table 60 - Dual Incremental Encoder Jumper Settings 20-750-DENC-1 Jumper Enabled Position Storage Position P3 - Safety Jumper Enables use with speed monitoring safety option (20-750-S1). P4 - 12V Jumper Enables use with 12 volt supply in “Enabled”...
Page 174 Chapter 6 I/O Wiring Table 62 - Dual Incremental Encoder Terminal Designations Terminal Name Description +12 or +5 Volt DC Power Power supply for Encoder 0, 250 mA. Common +12V and +5V Encoder 0, common Encoder 0: A Single channel or quadrature A input. Encoder 0: A (NOT) Encoder 0: B Quadrature B input.
Page 175 I/O Wiring Chapter 6 Figure 70 - Differential Dual Channel with Z Channel Single Incremental Encoder Encoder TB Option Module TB Shield Enc +12V Enc Ret Enc +5V Enc A /Enc A Enc B /Enc B Enc Z /Enc Z +24V 24VC Figure 71 - Differential Dual Channel without Z Channel...
Page 176 Chapter 6 I/O Wiring Figure 73 - Single-Ended, Dual Channel Single Incremental Encoder Encoder TB Option Module TB Shield Enc +12V Enc Ret Enc +5V Enc A /Enc A Enc B /Enc B Enc Z /Enc Z +24V 24VC Wiring Examples - Dual Incremental Encoder Option Module Connections Figure 74 - Differential Dual Channel with Z Channel Dual Incremental Encoder Primary...
Page 177: Universal Feedback Option Module
I/O Wiring Chapter 6 Universal Feedback Option Module Table 63 - Universal Feedback Option Module LED Indication 20-750-UFB-1 Name Color State Description Board Unlit Not powered. Green Flashing Initializing, not active. Communication lost, attempting to reconnect. Steady Operational, no faults are present. Flashing Module error.
Page 178 Chapter 6 I/O Wiring Table 64 - Universal Feedback Option Module DIP Switch Settings - Safety Application Safety Channel Selection DIP Switch Settings Primary Safety Channel S1 S2 S3 To connect feedback signals to the Primary Safety Channel, set: S1 sliders to ON S2 sliders to OFF S3 slider to ON Secondary Safety Channel...
Page 179 I/O Wiring Chapter 6 Table 65 - TB1 Terminal Designations Terminal Name Description Sine (–) Positive and negative terminals for Sine and Cosine signals. Sine (+) For use with 5V incremental encoders only. Cosine (–) Cosine (+) Inner Shield Heidenhain inner shield terminal Outer Shield Cable shield terminal Channel X Clock (–)
Page 180: Motor Power Cables
Chapter 6 I/O Wiring IMPORTANT Only one linear feedback device can be connected to the option module. Wire the device to either Channel X on TB1 or Channel Y on TB2. Table 67 - Universal Feedback Incremental AquadB Encoder Consideration Description Input Differential or Single Ended operation, Constant Current Sink operation ~10 mA...
Page 181: Rockwell Automation Publication 750-In100B-En-P - July
MP-Series (460V) motor and Stegmann rotary or Rotary encoder 2090-CFBM7DF-CEAAXX Figure 80 - on page 184 HPK series motor and Stegmann rotary or Rotary encoder Allen-Bradley 1326AB-Series motor and Stegmann rotary or Rotary encoder Stegmann rotary encoder 1326-CECU-XXL-XXX Figure 81 - on page 185...
Page 182 Chapter 6 I/O Wiring Figure 76 - Heidenhain EnDat Angle Encoder with External Power Supply Universal Feedback Option Heidenhain EnDat Module TB1 Encoder TB RD/BK RD/BK 13 B- BL/BK BL/BK 12 B+ YL/BK YL/BK 16 A- GN/BK GN/BK 15 A+ 11 Inner Shld Outer Shld 9 CLK/...
Page 183 I/O Wiring Chapter 6 Figure 78 - Heidenhain EnDat Rotary Encoder (ECN 412 EnDat01) with Internal Power Supply Universal Feedback Option Heidenhain EnDat Module TB1 Encoder TB RD/BK RD/BK 13 B- BL/BK BL/BK 12 B+ YL/BK YL/BK 16 A- GN/BK GN/BK 15 A+ 11 Inner Shld...
Page 184 Chapter 6 I/O Wiring Figure 80 - 460V MP-Series, HPK-Series, or Allen-Bradley 1326AB-Series Motor and a Stegmann Rotary or Rotary Encoder connected via a 2090-CFBM7DF-CEAAXX (Non-Flex) or -CEAFXX (Flex) Universal Feedback Option Stegmann Module TB1 Encoder TB BK/WH BK/WH REFSIN...
Page 185 I/O Wiring Chapter 6 Figure 81 - Stegmann Rotary Encoder connected via a 1326-CECU-XXL-XXX Cable Universal Feedback Option Stegmann Module TB1 Encoder TB REFSIN +SIN REFCOS +COS DATA- (RS485) DATA+ (RS485) SHIELD OVERALL SHIELD POWER COMMON POWER Set Universal Feedback parameter 6 [FB0 Device Sel] or 36 [FB1 Device Sel] to 2 ‘Hiperface SC.’...
Page 186 Chapter 6 I/O Wiring Figure 83 - Stegmann Rotary Encoder Connected via a Shielded, Twisted Pair Cable with an 8- pin Berg Style Connector Universal Feedback Option Stegmann Module TB1 Encoder TB REFSIN +SIN REFCOS +COS DATA- (RS485) DATA+ (RS485) POWER COMMON POWER Set Universal Feedback parameter 6 [FB0 Device Sel] or 36 [FB1 Device Sel]...
Page 187 I/O Wiring Chapter 6 Figure 85 - Stegmann Rotary Encoder Connected via a Shielded, Twisted Pair Cable with a 12- pin DIN Style Connector Universal Feedback Option Stegmann Module TB1 Encoder TB REFSIN +SIN REFCOS +COS DATA- (RS485) DATA+ (RS485) OVERALL SHIELD POWER COMMON POWER...
Page 188 Chapter 6 I/O Wiring Figure 87 - Registration Sensor Universal Feedback Option Rotary Registration Module TB2 Sensor Power Common Line Registration Sensor Power Common Universal Feedback Option Module TB1 Power Common External Power Supply 12 or 24V DC See Universal Feedback parameters 90 through 129. Figure 88 - Simulated Incremental Encoder Output Universal Feedback Option Module TB1...
Page 189 I/O Wiring Chapter 6 Figure 89 - Differential Dual Channel with Z Channel with 5V Internal Supply Universal Feedback Option Incremental Module TB1 Encoder TB Shield DC Return DC+ Input /Enc A Enc A /Enc B Enc B /Enc Z Enc Z Set Universal Feedback parameter 6 [FB0 Device Sel] or 36 [FB1 Device Sel] to 12 “Inc A B Z.”...
Page 190 Chapter 6 I/O Wiring Notes: Rockwell Automation Publication 750-IN100B-EN-P - July 2017...
Page 192 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, CompactLogix, Connected Components Workbench, ControlLogix, DeviceLogix, DPI, Kinetix, PowerFlex, StudioLogix 5000 Logix Designer, TorqProve, TotalFORCE, Rockwell Automation, Rockwell Software, SCANport, Stratix, and TorqProve are trademarks of Rockwell Automation, Inc.

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