System Requirements Identified as of PowerFlex 755 Drive Firmware Revision 3.004

The new Auto/Manual HIM Preload feature requires firmware in the HIM that is newer than 1.007.

System Requirements Identified as of PowerFlex 755 Drive Firmware Revision 3.004

System Requirements Identified as of PowerFlex 753 Drive Firmware Revision 5.001

The Customer Configurable Response to HIM Communications Loss feature requires a new enhanced style HIM (20-HIM-A6, 20-HIM-C6S). This feature will not work with older contemporary 7-Class HIM’ s (20-HIM-A3, 20-HIM-A5, 20-HIM-C3S, 20-HIM-C5S).

System Requirement Identified as of PowerFlex 755 Drives Firmware Revision 8.001

System Requirement Identified as of PowerFlex 753 Drives Firmware Revision 9.001

PowerFlex 755 Firmware Revision 12.001 CIP Features Compatible Only with Studio 5000 Logix Designer 28.00.01

System Requirement Identified as of PowerFlex 755 Drives Firmware Revision 12.001

When using PowerFlex 755 drive firmware revision 12.001, any of the new or existing Integrated Motion on EtherNet/IP (CIP) features are compatible only with Studio 5000 Logix Designer version 28.00.01. The firmware revision 12.001 PowerFlex 755 drive AOP is installed with Studio 5000 Logix Designer version 28.00.01.

EtherNet/IP Port and 20-750-ENETR Require Quality of Service (QoS)

System Requirements Identified as of PowerFlex 755 Drive Firmware Revision 9.001

System Requirements Identified as of PowerFlex 753 Drive Firmware Revision 9.001

With this firmware revision, the EtherNet/IP port and 20-750-ENETR require the EtherNet/IP scanner to use a compatible method of specifying Quality of Service (QoS). The following table details the compatible products and firmware revisions.

Drive Firmware, Series, and Frame Size Compatibility Requirements

System Requirement Identified as of PowerFlex 755 Drive Firmware Revision 3.004

The following table identifies firmware revisions and the PowerFlex 755 drive series and frame sizes with which they are compatible:

1756-L85E Controller is Compatible with PowerFlex Firmware Revision 12.001 or Later

System Requirement Identified as of PowerFlex 755 Drives Firmware Revision 12.001

The 1756-L85E controller will only work with PowerFlex 755 drives firmware revision 12.001 or later due to the 2-cycle timing update.

Emergency Override in Standard I/O Mode

System Feature Identified as of PowerFlex 755 Drive Firmware Revision 14.002

System Feature Identified as of PowerFlex 753 Drive Firmware Revision 14.002

Home to Torque in Standard I/O Mode

System Feature Identified as of PowerFlex 755 Drive Firmware Revision 14.002

System Feature Identified as of PowerFlex 753 Drive Firmware Revision 14.002

Auto Clear Faults When Stopped in Standard I/O Mode

System Feature Identified as of PowerFlex 755 Drive Firmware Revision 14.002

System Feature Identified as of PowerFlex 753 Drive Firmware Revision 14.002

Top of Frame in Standard I/O Mode

System Feature Identified as of PowerFlex 755 Drive Firmware Revision 14.002

System Feature Identified as of PowerFlex 753 Drive Firmware Revision 14.002

Unfiltered Feedback

System Feature Identified as of PowerFlex 755 Drive Firmware Revision 14.002

System Feature Identified as of PowerFlex 753 Drive Firmware Revision 14.002

Preloaded Values when using TorqProve Features with Integrated Motion 

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

Preloaded values could not be used when TorqProve™ functionality was used with Integrated Motion. 

Initial Torque Command after a Power Cycle was Zero  

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

After a power cycle, the initial torque command was zero when used with TorqProve™ functionality. 

Brake Slip Fault  

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

An E-stop generated a brake slip fault when TorqProve functionality was used.  

Brake Slip Alarms   

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

The drive could cause brake slip alarms when TorqProve™ functionality was used.  

TrqProveSpd Band Fault   

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

TrqProveSpd Band faults did not work consistently when encoderless TorqProve™ functionality was used. 

Brake was not Released When Recovering From Low DC Bus Condition   

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

When recovering from a low DC bus condition, the brake did not release when TorqProve™ functionality was used. 

TorqProve Features and Integrated Motion Mode  

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

Added an option to enable/disable the TrqProve FW Load Limit function. 

New ‘Sweep 2’ Flying Start Mode

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Added a new ‘Sweep 2’ mode to the Flying Start function. It is similar to the ‘Sweep’ mode. The ‘Sweep 2’ mode works better for motor frequencies above 120 Hz.   

Pump Off Timer Reset

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

A Pump Off, Change Speed action caused the timer to reset.   

Pump Off Minimum and Maximum Torque Settings

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Added minimum and maximum torque settings to the Pump Off function.    

Pump Off Disable Baselining on Start

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Added the ability to disable baselining on start to the Pump Off function.

Profile Position Blend

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Profile position blend function did not work properly.

Voltage Spike in Sensorless Vector Control

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

The drive produced a voltage spike when it completed flux-up in Sensorless Vector Control mode. 

IPM Flux Vector 318.3 Hz

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

IPM Flux Vector encoderless mode did not run above 318.3 Hz. 

IPM Integrator Hold Function

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Added Integrator Hold function to the Current Regulator for IPM flux vector control. This helps to prevent over modulation of the drive for low impedance motors. Overmodulation may cause Instantaneous Over Current (IOC) faults. 

IPM Field Weakening

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Improved IPM field weakening control by changing the Vqs regulator. 

High-speed IPM Encoderless Control

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Improved IPM encoderless control by adding a new proportional gain for high speed. For more information, see the description of parameter 1662 [IPM SpdEst Kp Hi] in the PowerFlex 750-Series AC Drives Programming Manual, 750-PM001.

Autotune

CORRECTED Anomaly with PowerFlex 755 Drives Firmware Revision 14.002

CORRECTED Anomaly with PowerFlex 753 Drives Firmware Revision 14.002

Improved Autotuning function on low inductive (IM) motors.

Safety Board Faults

CORRECTED Anomaly with PowerFlex™ 755 Drives Firmware Revision 14.002

High power (frame 8…10) PowerFlex™ 755 drives produced safety board faults when used with the 20-750-S3 option module.

Known Anomaly First Identified as of PowerFlex 755 Drives Firmware Revision 3.004

Known Anomaly First Identified as of PowerFlex 753 Drives Firmware Revision 5.001

The HIM startup on the PowerFlex 755 drive includes a feedback device selection step. Depending on the option modules installed, that step may first ask the user to choose a port, then a parameter. In some situations, the list of ports incorrectly shows multiple copies of 'Port 0 - PowerFlex 755' followed by the feedback port/module.

The incorrect behavior happens only under the following conditions:

• It is the first time that startup feedback selection has been run since flashing the drive.
• The feedback module is a dual encoder or UFB and no other option modules are installed.
• A reset to defaults of the drive NVS parameters has not been performed since the drive was last flashed.

When the incorrect port list appears, it is still possible to successfully select the feedback module port by following one of these methods.

• Scroll past the multiple copies of Port 0 to reach the desired feedback module.
• Press the Esc soft key to back up one screen, then select Feedback and press the Enter soft key to display the port selection screen a second time. This time the correct list will be shown.

Known Anomaly First Identified as of PowerFlex 755 Drives Firmware Revision 8.001

Known Anomaly First Identified as of PowerFlex 753 Drives Firmware Revision 8.001

In an application with the use of a PowerFlex 755 or PowerFlex 753 along with the 20-750-ENETR dual port Ethernet/IP module, a persistent stop command may appear in some cases. The action of disconnecting the Ethernet cable from the 20-750-ENETR module, which will result in the drive stopping, may follow with a nuisance fault action. This fault action previously noted is persistent communication of stop commands.

Known Anomaly First Identified as of PowerFlex 755 Drives Firmware Revision 8.001

Known Anomaly First Identified as of PowerFlex 753 Drives Firmware Revision 8.001

In an application with the use of a PowerFlex 755 or PowerFlex 753 along with the 20-750-ENETR dual port Ethernet/IP module, in which a user attempts to save all parameters using DriveExplorer® in some causes the save execution does not complete. When attempting to execute the save all parameters in DriveExplorer the software tool enters an infinite loop and does not progress through the save in some instances. To exit the loop, press the cancel button and check if the text file has been saved.

Known Anomaly First Identified as of PowerFlex 755 Drive Firmware Revision 2.011

Known Anomaly First Identified as of PowerFlex 753 Drive Firmware Revision 7.001

You cannot change the level of current used during the direction test on a permanent magnet motor while in Integrated Motion on EtherNet/IP (CIP Motion) mode. It is set at 10%. If the system requires more than 10% to turn the motor, it will fail to perform the test.

Known Anomaly First as of PowerFlex 755 Drive Firmware Revision 2.011

The protection algorithms in frame 8 drives create false 168 “PWM Freq Reduced” exception events when running at zero speed. These can occur when the drive is first energizing the motor and establishing motor flux.

Known Anomaly First Identified as of PowerFlex 755 Drive Firmware Revision 3.004

Known Anomaly First Identified as of PowerFlex 753 Drive Firmware Revision 5.001

The following internal diagnostic items may contain incorrect data after upgrading a PowerFlex 755 from revision 1 to revision 6 firmware: 2 [PBLT Pwrup Time], 3 [PBLT GatesOnTime], 4 [PBLT Mtr MW Hrs], 5 [PBLT Rgn MW Hrs] and 67 [PwrBd Pwr Cycles].

The following parameters may contain incorrect data after upgrading a PowerFlex 755 from revision 1 to revision 6 firmware: 13[Elapsed MWH], 14 [Elapsed kWH], 15 [Elapsed Run Time], 16 [Elpsd Mtr MWHrs], 17 [Elpsd Rgn MWHrs], 18 [Elpsd Mtr kWHrs], 19 [Elpsd Rgn kWHrs], 490 [HSFan ElpsdLife], 497 [InFan ElpsdLife], 503 [MtrBrngElpsdLife], 508 [MtrLubeElpsdHrs], 512 [MchBrngElpsdLife] and 517 [MchLubeElpsdHrs].

These values will affect the associated calculated “ remaining life ” parameter values and predictive maintenance events.

Known Anomaly First Identified As of PowerFlex 755 Drive Firmware Revision 3.004

This anomaly affected customers using Integrated Motion on EtherNet/IP (CIP Motion). If you attempted to use Drive NV when configuring the motor on a motion axis with a PowerFlex 755, the drive would not return the appropriate error. This feature is not currently supported in the PowerFlex 755.

Known Anomaly First Identified as of PowerFlex 755 Drive Firmware Revision 8.001

The drive may throw an F927 fault when an axis is inhibited. If this occurs, the drive will shut down allowing the motor to coast. The status LED will blink 27 times, pause, then repeat. If this occurs, cycle power to the drive to clear the fault.

Known Anomaly First Identified as of PowerFlex 755 Drive Firmware Revision 6.004

Known Anomaly First Identified as of PowerFlex 753 Drive Firmware Revision 6.004

When running in Flux Vector open loop mode for induction motor or Interior Permanent Magnet (IPM) motor mode, the drive may experience an F918 exception event when the motor accelerates through a 7 Hz operating frequency due to the simultaneous transition from a 2 to 4 KHz carrier frequency. This exception can be avoided by setting parameter 40 [Mtr Options Cfg] bit 9 – PWM FreqLock], which will keep the carrier frequency at 4 KHz.

Universal Feedback Board Module Does Not Annunciate Fault

Known Anomaly First Identified as of:

• PowerFlex 755 Drive Firmware Revision 12.001
• PowerFlex 753 Drive Firmware Revision 12.001

When the UFB is configured to use the SSI Full Digital Feedback Device, the UFB does not annunciate a fault when the SSI Full Digital is the signal is lost. For full details on possible workarounds to this anomaly, see Technical Support Knowledgebase Article #463171. To determine if this notice affects you and for additional information, please refer to Knowledgebase Document Number #745654.

Application Notes

Use the Drive LCD HIM

1. Access the Status screen, which is displayed on HIM power up.

2. Use the or key to scroll to Port 00 for the Host Drive.
3. Press the key to display its last-viewed folder.
4. Use the or key to scroll to the DIAGNOSTIC folder.
5. Use the or key to select Device Version.
6. Press the (Enter) key to display device version information.

FW Revision is listed under – Main Control Board.

Use DriveExplorer Lite/Full

Important: You need DriveExplorer version 6.01 or later to interface with the PowerFlex 755 drive. To obtain the latest version, visit the Allen-Bradley Web Updates site located at http://www.ab.com/support/abdrives/webupdate

1. Launch DriveExplorer and go online with the PowerFlex 755 drive. To connect to the drive, use a 1203-USB converter, a 1203-SSS converter, or an EtherNet/IP network connection.
2. In the Devices hardware view, select the PowerFlex 755 drive.

Once selected, information regarding the PowerFlex 755 drive is shown in the right panel including the current firmware revision number.

Use DriveExecutive

Important: You need DriveExecutive version 5.01 or later to interface with the PowerFlex 755 drive. To obtain the latest version, visit the Allen- Bradley Web Updates site located at http://www.ab.com/support/abdrives/webupdate

1. Launch DriveExecutive and go online with the PowerFlex 755 drive. To connect to the drive, use a 1203-USB converter, a 1203-SSS converter, or an EtherNet/IP network connection.
2. In the Drives hardware view, select the PowerFlex 755 drive ().
3. Click the information icon () to display the drive’ s Properties dialog box.

In the Properties dialog box the “ Revision:” field ( ) will show the drive ’s current firmware revision number.

Product Updates and Replacements

Flashing can be performed using a 1203-USB or 1203-SSS converter. For information on connecting either converter to your drive, refer to the 1203-USB USB Converter User Manual, publication DRIVES-UM001, or 1203-SSS Smart Self-powered Serial Converter User Manual, publication 20COMM-UM001.

Note: Images are shown for example only. They are not intended to identify the exact firmware version to which you are updating. Therefore, do not use the data in the images as input or selections for your update.

Frame 8 and Larger Drives

When a Frame 8 or larger drive is flashed with firmware earlier than V4, a F361 “Rerate See Manual” fault will result.

1. Confirm the drive's current configuration by viewing Port 10, P21 [Effctv I Rating].
2. Save the current parameter settings using the Human Interface Module (HIM), DriveExecutive, or DriveExplorer.
3. Perform the flash update.

When concluded, an F361 “Rerate See Manual” fault is indicated.

4. Set Port 10, P20 [Recfg Acknowledg] to 1 “Acknowledge” to accept the reconfiguration.

Important: Drive parameters are set to factory defaults when the reconfiguration is acknowledged. If a condition exists that does not allow the drive parameters to be set to factory defaults, setting P20 to 1 “Acknowledge” will not be accepted. Such conditions include the drive is currently running, DeviceLogix is currently running, or the drive is communicating with a PLC.

5. Download the saved drive configuration.
6. Confirm the motor and drive ratings before running the drive.

Install the Flash Kit

1. Install the flash kit utility for the PowerFlex 755 drive, which includes the latest version of the ControlFLASH utility.
2. You are now ready to use DriveExplorer, DriveExecutive, ControlFLASH to update the drive.

Use DriveExplorer Lite/Full to Flash Update

1. With the Flash Kit installed (see “Install the Flash Kit”), launch DriveExplorer and go online (via a 1203-USB or 1203-SSS converter) with the PowerFlex 755 drive.
2. In the Devices hardware view, select the PowerFlex 755 drive ().
3. Click the information icon () to display the drive’s Properties dialog box.
4. In the Properties dialog box, click the Component Details tab ().

5. With the Main Control Board selected, click Flash Update.

Important: Flash updating the device firmware may cause the device to load defaults. It is recommended that you save the setting to your PC before proceeding.

6. From the list of available updates, select the desired firmware revision and click Next >.

7. Follow the remaining prompts until the flash update procedure completes and displays the new firmware revision.

Use DriveExecutive to Flash Update

1. With the Flash Kit installed, launch DriveExecutive and go online (via a 1203-USB or 1203-SSS converter) with the PowerFlex 755 drive.
2. In the Drives hardware view, select the PowerFlex 755 drive ().
3. Click the information icon () to display the drive’s Properties dialog box.
4. In the Properties dialog box, click the Component Details tab ().

5. With the PowerFlex 755 drive selected, click Flash Update.

6. From the list of available devices, select the PowerFlex 755 drive and click Next >.

Important: Flash updating the device firmware may cause the device to load defaults. It is recommended that you save the setting to your PC before proceeding.

7. From the list of available updates, select the desired firmware revision and click Next >.

8. Follow the remaining screen prompts until the flash update procedure completes and displays the new firmware revision.

Use ControlFLASH to Flash Update

1. With the Flash Kit installed, launch ControlFLASH by selecting Start > (All) Programs > Flash Programming Tools > ControlFLASH.
2. On the ControlFLASH Welcome screen, click Next >.

3. The Catalog Number dialog box appears. From the list, choose the communication device you will use to update the PowerFlex 755 drive. In the figure below, the embedded EtherNet device is selected.

Once the appropriate communication device is selected, click Next >.

4. Now that the correct communication device has been selected, you must select which device is being updated. With the Select the PowerFlex… dialog box displayed, follow these steps.
   1. Expand the hardware view for the communication path you are using ().
   2. Select the drive icon that represents the PowerFlex 755 drive you are updating ().
   3. Click OK ().

5. If the Multiple Assemblies Found dialog box opens, select “Port x-PowerFlex 755” from the list and click OK.

6. In the Firmware Revision dialog box, select the desired firmware revision from the list of available updates and click Next >.

7. Follow the remaining prompts until the flash procedure completes and displays the new firmware revision.

Important: When you update firmware from an unsigned revision 10.002 and earlier to the signed firmware revision 12.001 or later, error message dialog boxes, similar to the following examples, will appear during the update. Click OK in each dialog box to proceed. The firmware revision will be updated successfully.