Rockwell Automation Allen-Bradley PowerFlex 750 Series User manual

PowerFlex 750-Series Products with TotalFORCE Control
Catalog Numbers 20G, 20J
Reference Manual
Original Instructions

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 3
Table of Contents
Preface
Overview Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Adaptive Control Load Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adaptive Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Position and Velocity Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bus Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Feed Forward Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reference Notch Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
AC Line Tuning Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AC Source Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
External Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bus Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AC Line Source Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3
Precharge Sequence Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frames 7…15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 4
Secondary Motor Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Secondary Motor Control Configuration . . . . . . . . . . . . . . . . . . . . . . . 27
Application Use Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 5
Energy Pause Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Monitor Status with Energy Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Activate Energy Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4Rockwell Automation Publication 750-RM100A-EN-P - August 2019
Table of Contents
Chapter 6
Predictive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Setting the Event Levels and Event Actions. . . . . . . . . . . . . . . . . . . . . . 40
Monitor Elapsed Life and Remaining Life . . . . . . . . . . . . . . . . . . . . . . . 41
Predictive Maintenance Function Details . . . . . . . . . . . . . . . . . . . . . . . 42
Resetting the Meters After Component Replacement . . . . . . . . . . . . 47
Reset Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Monitoring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 7
DeviceLogix Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DeviceLogix Configuration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DeviceLogix Tag Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Download and Enable the Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chapter 8
Emergency Override Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Activate the Emergency Override Feature . . . . . . . . . . . . . . . . . . . . . . . 65
Decide Which Protections to Override. . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 9
Reference Motion Planners New Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Position Reference Motion Planner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Velocity Reference Motion Planner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chapter 10
Droop Control for Parallel
Operation of PowerFlex 755TM
AFE Bus Supplies
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Derating for Voltage Boost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Chapter 11
Application References PowerFlex 755T Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . 101
Anti-Sway Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 5
Preface
Overview
The purpose of this manual is to provide detailed information about configuring
PowerFlex® 750-Series products with TotalFORCE® control for common
applications.
Who Should Use This
Manual
This manual is intended for qualified personnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must have
an understanding of the parameter settings and functions.
Manual Conventions 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.
• PowerFlex 755TR drive when referring to the regenerative drive product.
• PowerFlex 755TM drive system when referring to regenerative bus supply
and common bus inverter products.
Additional Resources The following table lists publications that provide general drive-related
information.
Resource Description
PowerFlex 750-Series Products with TotalFORCE Control
Technical Data, publication 750-TD100
Provides detailed information about:
• Drive and bus supply specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 755TM IP00 Open Type Kits Technical Data,
publication 750-TD101
Provides detailed information about:
• Kit selection
• Kit ratings and specifications
• Option specifications
PowerFlex 755TM IP00 Open Type Kits Installation
Instructions, publication 750-IN101
Provides instructions to install IP00 Open Type kits in
user-supplied enclosures.
PowerFlex 750-Series I/O, Feedback, and Power Option
Modules Installation, publication 750-IN111
Provides instructions to install and wire 750-Series
option modules.
PowerFlex Drives with TotalFORCE Control Programming
Manual, publication 750-PM100
Provides detailed information about:
• I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
Drives in Common Bus Configurations with PowerFlex
755TM Bus Supplies Application Techniques, publication
DRIVES-AT005
Provides basic information to wire and ground the
following products in common bus applications:
• PowerFlex 755TM drive system for common bus
solutions
• PowerFlex 750-Series AC and DC input drive
• Kinetix® 5700 servo drives

6Rockwell Automation Publication 750-RM100A-EN-P - August 2019
Preface
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
PowerFlex 755T Flux Vector Tuning, publication 750-AT006 Provides guidance about how to tune Flux Vector
position and velocity loops, filters, and other features
to achieve the level of performance that is required
for a given application. This publication is intended
for novice drives users and users with advanced skills.
PowerFlex Drives with TotalFORCE Control Built-in
EtherNet/IP Adapter User Manual, publication 750COM-
UM009
Provides information about how to install, configure,
and troubleshoot applications for the PowerFlex
drives with the built-in EtherNet/IP™ adapter.
PowerFlex 750-Series Products with TotalFORCE Control
Hardware Service Manual, publication 750-TG100
Provides detailed information about:
• Preventive maintenance
•Component testing
• Hardware replacement procedures
PowerFlex 750-Series Safe Speed Monitor Option Module
Safety Reference Manual, publication 750-RM001
These publications provide detailed information
about installation, setup, and operation of the 750-
Series safety option modules.
PowerFlex 750-Series Safe Torque Off Option Module User
Manual, publication 750-UM002
PowerFlex 750-Series ATEX Option Module User Manual,
publication 750-UM003
PowerFlex 755 Integrated Safety - Safe Torque Off Option
Module User Manual, publication 750-UM004
PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface
Module) User Manual, 20HIM-UM001
Provides detailed information about HIM
components, operation, and features.
PowerFlex 755TM AC Precharge Modules Unpacking and
Lifting Instructions, publication 750-IN102
These publications provide detailed information
about:
• Component weights
• Precautions and recommendations
• Hardware attachment points
• Lifting the component out of the packaging
PowerFlex 755TM DC Precharge Modules Unpacking and
Lifting Instructions, publication 750-IN103
PowerFlex 755TM Power and Filter Modules Unpacking
and Lifting Instructions, publication 750-IN104
PowerFlex 750-Series Service Cart Instructions, publication
750-IN105
Provides detailed setup and operating instructions for
the module service cart and DC precharge module lift.
PowerFlex 755TM Power and Filter Module Storage
Hardware Instructions, publication 750-IN106
Provides detailed installation and usage instructions
for this hardware accessory.
PowerFlex 755T Module Service Ramp Instructions,
publication 750-IN108
Provides detailed usage instructions for the module
service ramp.
Industry Installation Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-AT003
Provides basic information about enclosure systems,
considerations to help protect against environmental
contaminants, and power and grounding
considerations for installing Pulse Width Modulated
(PWM) AC drives.
Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives, publication DRIVES-IN001
Provides basic information to properly wire and
ground PWM AC drives.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and
other certification details.
Rockwell Automation Knowledge Base The Rockwell Automation Support Forum
Resource Description

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 7
Chapter 1
Adaptive Control
A brief overview of Load Observer, Adaptive Tuning, and Autotune is provided
in this section. For detailed information about how to use each of these features,
see the PowerFlex® 755T Flux Vector Tuning Application Technique, publication
750-AT006.
Load Observer The load observer feature is a control loop inside the drive that estimates the
mechanical load on the motor and compensates for it while the drive is running.
This feature allows high performance and control loop tuning simplicity similar
to that of a mechanically disconnected motor. Its primary function is to:
• Automatically compensate for unknown inertia, compliance, and low
frequency resonance
• Automatically compensate for disturbances and changes in inertia
• Force consistent dynamic behavior, which makes the drive easier to tune
Benefits
You can use load observer with out-of-box control loop gains, where the load is
unknown or compliant and thus 10/11:901 [Load Ratio] = 0. You can also use
load observer with autotuned control loop gains where 10/11:901 [Load
Ratio] > 0. This value can be a known positive value or one that is calculated by
performing an autotune procedure.
When load observer is enabled with the recommended out-of-box control loop
gains:
• A tuning expert is not needed
• Commissioning time is reduced, especially for high drive count
• Relatively high performance control is provided without tuning
• Changes in inertia, compliance, and low frequency resonances are
compensated for automatically
• Periodic retuning to account for machine wear over time is not needed
When load observer is enabled with autotuned control loop gains:
• Load disturbances are compensated for automatically
• Tracking errors, machine vibration, and power consumption are
minimized
• Bandwidth and line speeds can be increased
• Tighter control of moving parts reduces wear and saves material costs

8Rockwell Automation Publication 750-RM100A-EN-P - August 2019
Chapter 1 Adaptive Control
Adaptive Tuning The adaptive tuning feature is an algorithm that continuously monitors and, if
necessary, adjusts filter parameters and control loop gains to compensate for
unknown and changing load conditions. Adaptive tuning performs the following
functions:
• Monitors motor-side resonances
• Automatically adjusts torque loop notch and low pass filter parameters to
suppress resonances
• Automatically tunes control loop gains to avoid instability
Benefits
When you enable adaptive tuning with the recommended out-of-box control
loop settings, you do not need a tuning expert. You also gain the following
benefits:
• Reduced commissioning time, especially for high drive count
• Automatically suppressed continuously changing resonances
• Periodic identification of resonances and retuning is not needed
• Periodic retuning of filters is not needed
• Minimized tracking errors, machine vibration, and power consumption
• Increased bandwidth and line speeds
• Tighter control of moving parts reduces wear and saves material costs
Autotune The Autotune function is used to measure motor characteristics. It is composed
of several individual tests, each of which is intended to adjust one or more motor
parameters. These tests require you to enter motor nameplate information into
the drive parameters. Although you can change some of the parameter values
manually, measured values can provide improved performance.
Autotuning is often unnecessary when you apply Load Observer with the
recommended default settings.

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 9
Adaptive Control Chapter 1
Position and Velocity
Regulators
The PowerFlex 755T utilizes a series form of a Proportional-Integral (PI)
controller for the Position Regulator (PReg) and the Velocity Regulator (VReg).
The proportional and integral gains are expressed in units of Hz. The
proportional gains have been normalized by removing inertia and represent
bandwidth which is a readily understood and measureable value. Relating the
proportional gains to bandwidth makes the tuning experience more intuitive.
Figure 1 - Regulator Schemes
The recommended method for tuning the position and velocity regulators is
adjusting the System Bandwidth parameter 10/11:906 [System BW]. By
adjusting the System bandwidth, the proportional and integral gains for the
position and velocity regulators are automatically calculated, which eliminates
the need to adjust each gain individually. For more information on the Position
and Velocity regulators and how to tune them, refer to the PowerFlex 755T Flux
Vector Tuning Application Technique, publication 750-AT006.
Bus Observer The bus observer feature is available in the PowerFlex 755T regenerative and low
harmonic AFE products. Bus observer was added to compensate for unknown
capacity changes in the system demand. Enhanced DC bus voltage regulation and
repeatability of control loop performance in the presence of unknown AC line
conditions are the main goals of the bus observer, rather than command tracking,
which allows for lower gain settings. Bus observer performs the following
functions:
• Enhances the regulation of the DC bus voltage control.
• Compensates for unknown capacity changes in the system demand.
• Compensates for the external connected capacitance that is less than three
times the bus supply.
• Uses current feedback to feed forward the bus voltage regulator.
PowerFlex 755TL/TR drives use power feed forward to enhance the DC bus
regulation. The inverter load is fed forward into the converter to improve DC
bus voltage regulation.
When the bus observer is not used, higher gain settings are required for a
sufficiently robust system. Higher gain settings cause heating of the inductors and
capacitor resonance trips. The accuracy of the total bus capacitance that is
entered directly affects overall performance.
[Hz]
[Hz]
1
s2K
PI
2K
PP
[Hz]
[Hz]
1
s2K
VI
2K
VP
Position Regulator Velocity Regulator

10 Rockwell Automation Publication 750-RM100A-EN-P - August 2019
Chapter 1 Adaptive Control
Example: The bandwidth = 400 Hz with bus observer disabled. However, the
bandwidth = 150 Hz with bus observer enabled for equivalent DC bus voltage
regulation with lower inductor temperatures.
Bus Observer Limitations
• If the external capacitance is greater than three times the supply, DC bus
regulation can become unstable.
• Do not enter an external capacitance value greater than what is connected
or stability can be affected. It is recommended to use the lowest estimated
value. Bus observer can compensate for increased line capacitance, but it
cannot reduce line capacitance.
• Cannot be enabled or disabled while the converter is active (running).
Figure 2 and Figure 3 show the Bus Observer function.
Figure 2 - Voltage Control (VoltCtrl) Block Diagram
Auto Gain
Calculation
PI Regulator
55
56
Volt Reg BW
Volt Reg Damping
0
1
54
Volt Reg C/U Sel
0
1
59
u Volt Reg Ki
57
u Volt Reg Kp
c Volt Reg Ki 60
c Volt Reg Kp 58
DC Bus Command
50
VoltRefGen [G3]
Internal Bus Cap
acitance
Metering [D5]
DC Bus Ob
s
A[2]
52
Ext Bus Cap
VbusErr
VbusRegKi
VbusRegKp
IqRefVbusReg
Volt Reg C/U Sel Selector:
0- Calculated
1- User Entered
Total Sys Cap
DcBusObs [C1]
BusRegIntegTerm
BusRegPropTerm
BusObsMode
BusObsMode (320):
0- BusObs Only
1- BusObsVltEst 320
3
Port 0,DC Bus Volts
0
1
DC Bus Obs
[H5]
BusObs Volt Est
1
0,2
BusDistRejMode(300):
0- Disabled
1-BusObserver.
2- FF Power.
300
BusCompMode