Rockwell Automation Allen-Bradley PowerFlex 755TS Series User manual

PowerFlex 755TS Products
with TotalFORCE Control
Catalog Numbers 20G2, 20GE
Installation Instructions Original Instructions

2Rockwell Automation Publication 750-IN119A-EN-P - April 2022
PowerFlex 755TS Products with TotalFORCE Control 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-IN119A-EN-P - April 2022 3
Preface
Commonly Used Installation Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Line to Load Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Product Overview Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Rating Cross-reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hardware Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Configuration Tool Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 2
Receiving, Handling, and
Storage
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Approximate Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3
Prepare for Installation CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Location Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 4
Mechanical and Electrical
Installation
Installation of Products with Corrosive Gas Protection (XT). . . . . . . . . 51
Access Panels, Covers, and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Hardware Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Safety Enable Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Drive Device Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Chapter 5
Power Wiring AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
RF Emission Category C3 Compliant Wiring. . . . . . . . . . . . . . . . . . . . . . . 61
Power Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Terminal Block Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Three-phase Power Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frames 1…7 AC Input Power Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Frames 5…7 Common DC Input Terminal Locations . . . . . . . . . . . . . . . . 68
Frames 5…7 Common DC Input Power Terminals . . . . . . . . . . . . . . . . . . 70
Fuse and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Intermittent Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4Rockwell Automation Publication 750-IN119A-EN-P - April 2022
Motor Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Short-circuit Current Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Apply and Remove Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Input Contactor Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Output Contactor Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Bypass Contactor Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drive Power Jumper Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Chapter 6
Service and Maintenance Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 85
Shock Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Maintenance of Industrial Control Equipment. . . . . . . . . . . . . . . . . . . . . 89
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Commonly Used Installation and Service Tools . . . . . . . . . . . . . . . . . . . . 95
Remove Power from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Start Up After Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
No-load DC Bus Voltage and Output Current Measurements. . . . . . . . 97

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 5
Preface
This manual provides procedures for the mechanical and electrical installation
of PowerFlex® 755TS products with TotalFORCE® control.
This manual provides instructions for an initial product installation. Assembly
procedures in chapters 1...4 assume that supply power is not connected. 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 safety-related
practices that are contained in publication NFPA 70E, Standard for Electrical
Safety in the Work Place.
This manual is intended for two types of personnel:
• Qualified personnel familiar with handling mechanical electrical
equipment.
• Qualified electricians or other personnel who have experience with
electrical terminology, equipment, methods, and safety precautions.
The Additional Resources section is a directory of Rockwell Automation
publications that provide detailed drive information from wiring and
grounding recommendations to troubleshooting and repair.
Commonly Used Installation
Tools
See Chapter 6 on page 85 for a list of common tools used for installing
PowerFlex 755TS products.

6Rockwell Automation Publication 750-IN119A-EN-P - April 2022
Preface
Line to Load Installation
Guidelines
This section provides direction for how and where to find information from
line to load on the successful installation and implementation of PowerFlex
755TS drives.
Topic PowerFlex 750-Series Drives
AC supply source Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Chapter 2 – System Configurations.
Input power
conditioning Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001
See Chapter 2 – AC Line Impedance.
1321 Power Conditioning Products Technical Data, publication 1321-TD001
See this publication for line reactors and isolation transformers.
Input fusing and
circuit breakers See Fuse and Circuit Breaker Ratings on page 71.
Input power wire
and cable Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001
See Chapter 1 – Input Power Cables.
EMC filters See Installation Requirements Related to EN 61800-3 and the EMC Directive on page 27.
Electrical
interference Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001
See Chapter 6 – How Electromechanical Switches Cause Transient Interference.
Grounding Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Chapter 3 – Grounding.
See Grounding Requirements on page 60.
GND

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 7
Preface
Jumpers See Drive Power Jumper Configuration on page 77.
Mounting
considerations See Mounting Surface on page 29 and Minimum Clearances on page 30.
Environment Industry Installation Guidelines for Pulse-width Modulated (PWM) AC Drives Application Technique,
publication DRIVES-AT003
See this publication for information for different enclosure systems and environmental/location
considerations (to help protect against environmental contaminants), and power and grounding
considerations.
See Environment on page 29.
Control and signal
cabling Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001
See Chapter 4 – Wire Routing.
PowerFlex 750-Series I/O, Feedback, and Power Option Modules Installation Instructions, publication
750-IN111
Output power
cabling Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions, publication DRIVES-IN001
See Chapter 1 – Motor Cables.
Output devices Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Chapter 6 – Shielded or Armored Power Cable.
1321 Power Conditioning Products Technical Data, publication 1321-TD001
See this publication for load reactors, RWRs, and common mode chokes/cores.
1204 Terminator Instructions, publication 1204-IN002
See this publication for motor terminators.
See Output Contactor Precaution on page 77.
Cable length Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Chapter 5 – Length Restrictions for Motor Protection.
Encoder Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Chapter 1 – Analog Signal and Encoder Cable.
Motor Wiring and Grounding Guidelines for Pulse-width Modulated (PWM) AC Drives Installation Instructions,
publication DRIVES-IN001
See Appendix A – Overview.
Topic PowerFlex 750-Series Drives
PowerFlex 755TS Drive
WVUGND
PE (T1) (T2) (T3)
(L3)(L2)(L1)GND
PE R S T

8Rockwell Automation Publication 750-IN119A-EN-P - April 2022
Preface
Additional Resources The following table lists publications that provide general drive-related
information.
You can view or download publications at rok.auto/literature.
Resource Description
PowerFlex 750-Series Products with TotalFORCE Control
Reference Manual, publication 750-RM100 Provides detailed setup and programming instructions for common applications.
PowerFlex TotalFORCE Firmware Documentation Set:
• PowerFlex Drives with TotalFORCE Control
Programming Manual, publication 750-PM101
• PowerFlex Drives with TotalFORCE Control Parameters
Reference Data, publication 750-RD101
• PowerFlex Drives with TotalFORCE Control Conditions
Reference Data, publication 750-RD102
Provides detailed information on:
• Startup, control algorithms, and status indicators
• Parameters and programming
• Faults, alarms, events, and troubleshooting
PowerFlex 755TS Products with TotalFORCE Control
Technical Data, publication 750-TD104 Provides detailed information on:
• Drive specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 755T Products with TotalFORCE Control
Hardware Service Manual, publication 750-TG101 Provides detailed information on:
• Preventive maintenance
• Component testing
• Hardware replacement procedures
Drives in Common Bus Configurations with PowerFlex
755TM Bus Supplies Application Techniques, publication
DRIVES-AT005
Provides basic information to properly 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 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. This publication is
intended for novice drives users and users with
advanced skills.
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 Built-in
EtherNet/IP Adapter User Manual, publication
750COM-UM009
Provides information on how to install, configure,
and troubleshoot applications for the PowerFlex
drives with the built-in EtherNet/IP™ adapter.
PowerFlex 750-Series Safe Speed Monitor Option Module
Safety Reference Manual, publication 750-RM001 These publications provide detailed information on installation, set-up, 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 on HIM components, operation, and features.
Industry Installation Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-AT003 Provides basic information on 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

Rockwell Automation Publication 750-IN119A-EN-P - April 2022 9
Chapter 1
Product Overview
PowerFlex® 755TS Products with TotalFORCE® control are Architecture Class
AC drives. These products provide a broad set of features and application-
specific parameters, and they are ideal for high-performance applications.
Product Advisories Read the following precautions before you begin installation of the product.
Qualified Personnel
Personal Safety
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
startup, and subsequent maintenance of the system. Failure to comply can
result in personal injury and/or equipment damage.
ATTENTION: Measure the DC bus voltage at the power terminal block by
measuring between the +DC and -DC terminals (see Figure 41 and Figure 42
for location) or between the +DC and -DC test point sockets if equipped. Also
measure between the +DC terminal or test point and the chassis, and
between the -DC terminal or testpoint and the chassis. The voltage must be
zero for all three measurements.
ATTENTION: Hazard of personal injury or equipment damage exists when
using bipolar input sources. Noise and drift in sensitive input circuits can
cause unpredictable changes in motor speed and direction. Use speed
command parameters to help reduce input source sensitivity.
ATTENTION: Risk of injury or equipment damage exists. DPI™ or SCANport™
host products must not be directly connected together via 1202 cables.
Unpredictable behavior can result if two or more devices are connected in
this manner.
ATTENTION: The drive start/stop/enable control circuitry includes solid
state components. If hazards due to accidental contact with moving
machinery or unintentional flow of liquid, gas or solids exists, an additional
hardwired stop circuit may be required to remove the AC line to the drive. An
auxiliary braking method may be required.

10 Rockwell Automation Publication 750-IN119A-EN-P - April 2022
Chapter 1 Product Overview
Product Safety
Waste Electrical and Electronic Equipment
ATTENTION: Hazard of personal injury or equipment damage due to
unexpected machine operation exists if the drive is configured to
automatically issue a Start or Run command. Do not use these functions
without considering applicable local, national and international codes,
standards, regulations or industry guidelines.
ATTENTION: A possible hazard of personal injury due to prolonged exposure
to high sound levels. Follow applicable local, national, and international
codes, standards, regulations, or industry guidelines for hearing protection
when exposed to potentially damaging noise hazards.
ATTENTION: An incorrectly applied or installed drive system can result in
component damage or a reduction in product life. Wiring or application errors
such as an under-sized motor, incorrect or inadequate AC supply, a corrosive
environment, or excessive surrounding air temperatures can result in
malfunction of the system.
ATTENTION: This product contains Electrostatic Discharge (ESD) sensitive
parts and assemblies. Static control precautions are required when you install
these assemblies. Component damage can result if ESD control procedures
are not followed. If you are not familiar with static control procedures,
reference any applicable ESD protection handbook.
ATTENTION: If you configure an analog input for 0…20 mA operation and
driving it from a voltage source could cause component damage. Verify
proper configuration prior to applying input signals.
At the end of its life, this equipment should be collected separately from any
unsorted municipal waste.