Rockwell Automation Allen-Bradley PowerFlex 755T Series User manual

PowerFlex 755T Drives
Configured to Order Program
Catalog Numbers 24G, 24J
Installation Instructions Original Instructions

2Rockwell Automation Publication 750-IN118A-EN-P - May 2021
PowerFlex 755T Drives Configured to Order Program Installation 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-IN118A-EN-P - May 2021 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shipped with the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Product Overview Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Qualified Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product Certifications and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 13
Data Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Product Type and Voltage Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Product Normal Duty Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Additional Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drive Input/Output 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
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Minimum Clearances and Access Requirements . . . . . . . . . . . . . . . . 37
Floor Mounting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Recommended Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Rittal Base/Plinth System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Structural Steel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chapter 3
Mechanical and Electrical
Installation
Remove Side and Top Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove Detached Installation Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . 46

4Rockwell Automation Publication 750-IN118A-EN-P - May 2021
Detached Electrical Connection Hardware . . . . . . . . . . . . . . . . . . . . . 46
Detached Roof Vent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Remove Shipping Skid and Cleats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prepare Bay Interiors for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Remove or Install Protective Touch Guards . . . . . . . . . . . . . . . . . . . . 49
Attach Floor Mounting Hardware to the Bays . . . . . . . . . . . . . . . . . . . . . . 50
Position the First Bay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Place an Additional Bay Into the Lineup . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Move the Drive Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Apply a Gasket at the Joining Location . . . . . . . . . . . . . . . . . . . . . . . . . 52
Place the New Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Remove Lifting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Place the IP54, UL Type 12 Roof Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 54
Roof Panel with Roof Vents Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 54
Three-front-vents Exhaust Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Install Bay Joining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Top Brackets and Frame Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Internal Corner Brackets and Frame Clamps . . . . . . . . . . . . . . . . . . . 59
Secure Roof Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Secure Floor Mounting Hardware to the Floor . . . . . . . . . . . . . . . . . . . . . 60
Make Bay-to-Bay Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Access 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 Connection Hardware . . . . . . . . . . . . . . . . . . . . . . . 84
Terminal Lug Connection Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Barrel Lug to Drive Output Busbar Connection Hardware . . . . . . . 85
Braided Busbar to Drive Output Busbar Connection Hardware . . 85
Flexibar Flexible Busbar Connection Hardware. . . . . . . . . . . . . . . . . 86
Barrel Lug to Drive Input Busbar Connection Hardware . . . . . . . . 86
Drive Main Control Board Connection Hardware. . . . . . . . . . . . . . . 87
22-Series I/O Option Module Connection Hardware . . . . . . . . . . . . 87
Configured Bay Control Connection Hardware. . . . . . . . . . . . . . . . . 88
Chapter 4
Power Wiring AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Motor Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Recommended Grounding Scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Grounding Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
RFI Filter Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Rockwell Automation Publication 750-IN118A-EN-P - May 2021 5
Power Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Power Cable Types Acceptable for 400…690 Volt Installations . . . . 96
Recommended Cable Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Make Connections for Customer Input Power and Motor . . . . . . . . . . . 97
Customer Input Power and Motor Connection Hardware. . . . . . . . . . . 97
UL Listed Barrel Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Barrel Lug to L-Bracket to Busbar Connections . . . . . . . . . . . . . . . . . 98
Additional Power Terminal L-Brackets. . . . . . . . . . . . . . . . . . . . . . . . . 99
Terminal Lug Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
I/O, Feedback, and Safety Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Branch Circuit Short-circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Control Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Input Power Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Input Power Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Intermittent 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 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Part Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
IP21/IP54 Door Fan/Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
IP21/IP54 Door Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
IP21/IP54 Door Vent Filter Media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
IP21/IP54 Small Roof Vent Filter Media . . . . . . . . . . . . . . . . . . . . . . . 123
IP54 Large Roof Vent Filter Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Sine-wave Filter Reactor Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . 125
Start Up After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Task Code Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Recommended Maintenance Tasks and Schedule . . . . . . . . . . . . . . 128

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

Rockwell Automation Publication 750-IN118A-EN-P - May 2021 7
Preface
About This Publication The PowerFlex® 755T Drives Configured to Order Program combines standard
PowerFlex 750-Series Drives with configured input bay and configured output
bay options. This manual (750-IN118) provides procedures for the mechanical
and electrical installation of the configured input bays and configured output
bays of the PowerFlex 755T Drives Configured to Order Program.
For mechanical and electrical installation information about the standard
drive bays (or non-configured bays) of the PowerFlex 755T Drives Configured
to Order Program, see the PowerFlex 750-Series Products with TotalFORCE®
Control Installation Instructions, publication 750-IN100.
See the following table for a summary of which bays are covered in each
publication.
This manual includes the basic steps to position and join the product bays, to
make internal electrical connections, to connect power and the motor, and to
wire basic I/O.
This manual provides instructions for an initial product installation.
Installation procedures in Chapter 1...Chapter 3 assume that supply power is
not connected.
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 grounding recommendations to troubleshooting and repair.
Download Firmware, AOP,
EDS, and Other Files
Access the Product Compatibility and Download Center at rok.auto/pcdc to
download firmware and associated files (such as AOP, EDS, and DTM), and
access product release notes.
Categories of Bays in the
PowerFlex 755T Drives
Configured to Order Program
Bays Relevant Publications
Standard drive bays
(non-configured bays)
Drive input bay
750-PC100, 750-IN100
Drive power bay
Optional wire entry bay
Optional wire exit bay
Configured bays Optional configured input bay 750-PC108, 750-IN118
Optional configured output bay
ATTENTION: Once the product is connected to a power supply, always verify
that system power is not present before performing any work on the product.
See the safety-related practices that are contained in the National Fire
Protection Association publication NFPA 70E, Standard for Electrical Safety in
the Work Place, available on nfpa.org.

8Rockwell Automation Publication 750-IN118A-EN-P - May 2021
Additional Resources These documents and resources contain additional information that is related
to PowerFlex 755T configured products.
Shipped with the Product
A documentation package is shipped with your product. It contains the
following:
Read and understand this documentation before you install and operate the
drive. Keep the documentation package for future reference.
Online
These documents and resources are not shipped with the product, but are
available online.
Resource Description
Product schematics and drawings Wiring schematics, elevation drawings
PowerFlex 755T Drives Configured to Order Program Product Information,
publication 750-PC108 Provides product information about the configured input bays and configured output bays in
the PowerFlex 755T Drives Configured to Order Program.
PowerFlex 750-Series Products with TotalFORCE Control Product
Information, publication 750-PC100 Provides product information about the PowerFlex 755TL drive, PowerFlex 755TR drive, and
PowerFlex 755TM bus supply.
PowerFlex 755T Drives Configured to Order Program Receiving, Handling, and
Storage Installation Instructions, publication 750-IN110 Provides the basic steps to transport and store the shipping sections of the PowerFlex 755T Drives Configured to Order Program.
Resource Description
PowerFlex 750-Series Products with TotalFORCE Control Installation
Instructions, publication 750-IN100 Provides the basic steps to install PowerFlex 755TL drives, PowerFlex 755TR drives, and PowerFlex 755TM bus supplies.
PowerFlex 750-Series Products with TotalFORCE Control Technical Data,
publication 750-TD100
Provides detailed information on:
• Drive and bus supply specifications
• Option specifications
• 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, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series Products with TotalFORCE Control Reference Manual,
publication 750-RM100 Provides detailed setup and programming instructions for common applications.
PowerFlex 750-Series Service Cart Instructions, publication 750-IN105 Provides detailed set-up 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.
Switched Mode Power Supply Specifications Technical Data, publication
1606-TD002 Provides specifications for Bulletin 1606 products and applications. This includes the
optional uninterruptible power supply in the 750-Series configured output option.
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.
EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, SECURE-RM001 Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.

Rockwell Automation Publication 750-IN118A-EN-P - May 2021 9
To view or download publications, go to rok.auto/literature.
To access declarations of conformity, certificates, and other certification
details, go to rok.auto/certifications.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley® industrial 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 solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Resource Description

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