Secure Erase

System Feature First Identified as of PowerFlex 755T and PowerFlex 755TS Firmware Revision 11.001

Secure erase provides a way for users to remove the drive configuration and secondary indications of the configuration securely. Secure erase is a more complete method to remove drive configuration than a reset to defaults. This method protects from commercial data recovery mechanisms. The benefit is confidentiality of intellectual property. We expect customers to use this functionality when a drive is decommissioned for a sale or repair.

Power Module Fault and Alarm Indication

System Feature First Identified as of PowerFlex 755T Firmware Revision 11.001

This release of firmware provides fault and alarm indication for the specific line side and motor side power modules. This feature is useful on PowerFlex® 755TL/TR/TM products that have multiple power modules operating in parallel (frames 9…15). For the motor-side inverters, see parameters 12:8 [M Side Fault], and 12:9 [M Side Alarm]. For the line-side converters, see parameters 14:8 [L Side Fault], and 14:9 [L Side Alarm]. The benefit is to reduce troubleshooting time.

Flying Start Counter EMF using Open-Loop Permanent Magnet Control

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

PowerFlex® 755TL/TR frames 5 and 6 drives and PowerFlex 755TM frame 6 bus supplies now support the ‘CounterEMF’ option in parameter 10/11:70 [FlyingStart Mode] for interior permanent magnet (IPM) motors.

‘CounterEMF’ (1) – This mode analyzes the motor Counter EMF to determine the motor frequency. This mode is usually the fastest and most effective mode.

Loss of Torque During Power Loss Ride-Through

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

A loss of torque no longer occurs during a power loss when parameter 10/11:271 [Power Loss Mode A] or 10/11:275 [Power Loss Mode B] is set to 1 'Decel' while under loaded conditions.

Option Module Analog Output Data High Parameters do not Reset to Default

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

The following I/O option module parameters did not correctly reset to the default value after a factory reset:

• nn:78 [Anlg Out0 DataHi]
• nn:88 [Anlg Out1 DataHi]
• nn:78 [Anlg Out0 DataHi]
• nn:88 [Anlg Out1 DataHi]

nn = port at which the I/O option module resides

Predictive Maintenance Lifetime Consumption for Converter Power Semiconductor Bondwire Fatigue

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

For PowerFlex® 755T frame 5 and 6 products, the lifetime consumption models for bondwire fatigue in the converter power semiconductors now accrue at the correct rate.

Significant Drop in Phase Current can Cause Erroneous Fault

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

After a sudden drop in load current, faults 13003 'Phase Loss Det' and 13004 'Phase Loss RTExp' no longer occur.

Velocity Reference Scaled Values Update Delay

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

The velocity reference now appropriately updates scaled values when the Feedforward Velocity Rate Reference, parameter 10/11:1931 [FF Vel Rate Ref], or Velocity Reference Scale, parameter 10/11:1932 [VRef Scale], are configured.

Digital Input Configured for Power Loss Action

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

A digital input can now be configured to initiate a power loss action for the power loss ride-through feature.

Invalid Port Configuration Alarm with Multiple Safety Option Modules

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

The product now correctly provides an invalid port configuration (Alarm 104…108 ‘Port n Cfg’) alarm when multiple safety option modules are installed in the control pod.

Motor Side Regeneration Status Bit Set to ‘1’

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

After a stop command is issued, the ‘Regen’ bit (31) in parameter 10/11:354 [Motor Side Sts 1], is no longer set incorrectly.

Purge Frequency does not Retain Value after Firmware Update

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

Parameter 0:457 [Purge Frequency] now correctly retains its value when the firmware is upgraded to revision 11.xxx or later.

PWM Frequency Change without Power Cycle Followed by Rotate Motor ID Test Can Run Motor to Full Speed

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

If a power cycle was not performed after updating the Pulse Width Modulation (PWM) Frequency in parameter 10/11:425 [PWM Frequency], a Rotate Motor ID autotune test could ramp to the nameplate motor speed.

Torque Transients Occur when Slip Regulator Turns On or Off

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

Torque transients no longer occur when the slip regulator turns on or off.

Velocity Can Exceed Maximum Limit with Multiple Consecutive Rotate Motor ID Autotune Tests

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 11.001

If the Rotate Motor ID autotune test was run multiple times consecutively, the velocity could exceed the expected limit denoted in parameter 10/11:912 [Autotune Vel Lim]. This issue applied to PowerFlex® Frame 5 and 6 products only.

Permanent Damage to Predictive Maintenance Data for Frames 5 and 6 When Firmware is Upgraded or Downgraded

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 13.001

A structural difference in the EEPROM memory map between firmware revisions 12 or earlier and revisions 13 or later led to the loss of predictive maintenance data during firmware updates or downgrades.

Permanent data loss occurred under the following conditions:

• Firmware update from revision 12 or earlier to revision 13 or 14
• Firmware downgrade from revision 13 or 14 to revision 12 or earlier

This issue affected PowerFlex® 755TL, 755TR, and 755TM products with frame sizes 5 and 6. Other frame sizes were not impacted. PowerFlex 755TS products were also unaffected.

To resolve this issue, you can update from revision 12 or earlier directly to revision 14.002, which restructures the data to align with the newer memory map.

Note: Once a drive is at revision 14.002, downgrading to revision 12 or earlier results in data loss.

Line Synch Loss Fault Can Occur on Auxiliary Power During Mains Power Cycle

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 11.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

The line side converter may trigger a “LnSyncLoss Det” fault (F13001) under the following sequence:

1. Power up using only auxiliary power.

2. Energize three-phase mains power and allow precharge to complete.

3. Deenergize three-phase mains power.

4. Reenergize three-phase mains power after DC bus voltage drops below 50V.

ControlFlash does not Prevent Incompatible Firmware Updates to Frame 5 and 6 PowerFlex 755T Products

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 12.001

Corrected Anomaly with PowerFlex 755TS Firmware Revision 12.001

With this firmware revision, ControlFLASH™ software now prevents an incompatible firmware update for PowerFlex 755T frame 5 and 6 drives and bus supplies at firmware revisions from 1.xxx…3.xxx.

Incremental Encoder and Dual Incremental Encoder Feedback Option Modules Allowed in Control Pod Slot 7/8

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

No fault occurs when an Integrated Safety Functions option module (cat. no. 20-750-S4) in CIP safety mode is installed and one of these feedback option modules is incorrectly installed in slot 7 or 8 in the control pod:

• Incremental Encoder (cat. no. 20-750-ENC-1)
• Dual Incremental Encoder (cat. no. 20-750-DENC-1)

When a safety option module 20-750-S4 is installed, feedback option cards 20-750-DENC-1 and 20-750-ENC-1 must be installed in Slot 4 or Slot 5 to function properly.

IPM Flux Vector Flying Start with Low Accel Time Causes Fault

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

Fault 10073/11073 'IPMSpdEstEr' (internal permanent magnet speed estimate error) can occur when an interior permanent magnet (IPM) motor under flux vector control attempts a flying start with very low acceleration times.

IPM Open Loop Inertia Tune Results in 10073 ‘IPMSpdEstErr’ Fault

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

During an Inertia Tune of an Interior-Mounted Permanent Magnet (IPM) motor in open loop flux vector control mode, fault 10073 ‘IPMSpdEstErr’ can occur in cases where the motor rated power is less than one half of the drive rated power.

Process PID does not Support Secondary Motor Control

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

The Process PID function does not support motors operating from the Secondary Motor Control port.

Transition Time from Primary to Secondary Motor Control

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

Approximately 1 second can elapse while transitioning from primary to secondary motor control mode.

20-750-ENETR Option Module Firmware Update on Option Module Ethernet Network Fails

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 11.001

Attempting to update a Dual-port EtherNet/IP (20-750-ENETR) option module’s firmware by using ControlFLASH™ software and the option module’s communication port fails. To update the option module’s firmware by using ControlFLASH software, you must use the built-in EtherNet/IP™ adapter on the PowerFlex® 755T main control circuit board.

Acceleration and Deceleration Bits Turn off Early when Using Reference Notch Filter

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

When using a reference notch filter, bits 4 ‘Acceleration’ and 5 ‘Deceleration’ in parameter 10/11:354 [Motor Side Sts 1] now function as expected.

Autotune Inertia Test Fails when Travel Position Differs from Zero

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

An Autotune Travel fault (F10046) no longer erroneously occurs during an Inertia test when parameter 10/11:911 [Autotune Psn Lim] is set to a non-zero value.

Band Pass Filter Remains at Last Value when Energy Pause Begins

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 13.002

With this firmware revision, the Band Pass Filter currents go to zero when entering energy pause.

DCHP IP Address Does Not Release after Lease Time Expires

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

With this firmware revision, when an IP address is assigned by using DCHP and the IP address lease time expires, the PowerFlex® product no longer use the IP address.

Digital Input Motor Side Run Signal in Level Mode Requires New Signal to Wake the Product

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

Parameter 0:101 [Digital In Cfg] set to ‘Run Level’ functions properly.

Previously, when these conditions were set, a new signal was required to wake the product:

• Parameter 0:101 [Digital In Cfg] is set to ‘Run Level’

• A digital input is assigned to parameter 0:120 [DI M Run]

• The product is in sleep wake mode

This condition applied to emergency override for purge frequency as well.

Fault/Alarm Timestamp Appears on HIM without Fault/Alarm Data

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 11.001

When a fault or alarm occurs, the timestamp only appears on the Human Interface Module (HIM), without the fault or alarm data, respectively.

Heatsink Under Temperature Alarm Triggers at -20 °C Instead of -25 °C

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 11.001

A heatsink under temperature alarm triggers at -20 °C instead of -25 °C.

Human Interface Module (HIM) Connects to Port 6 with Option Module Installed in Same Port

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

A Human Interface Module (20-HIM-C6S) would connect to Port 6 of the product when an option module is already installed in that port. This firmware revision corrects this anomaly.

IPM Open Loop Faults Occur During Transitions Between Low and High Speed

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 11.001

Operating an Interior Permanent Magnet (IPM) motor in open loop can cause faults to occur during transitions between low and high speed.

Motor ID Test Fails when Autotune Travel Position Differs from Zero

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

An Autotune Current Regulator fault (F10045) no longer erroneously occurs during the Motor ID test when parameter 10/11:911 [Autotune Psn Lim] is set to a non-zero value.

New Parameters Added During Firmware Update Initialize with Random Value

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 12.001

With this firmware revision, new parameters that are added to the device during a firmware update no longer initialize with a random value.

Port 10/11 Current or Power Parameter Values Sent as DataLinks Provide Unfiltered Values

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

When parameters 10/11:3 [Output Current], 10/11:4 [Output Power], or 10/11:8 [Torque Cur Fb] are sent by using a Datalink, the data is correctly received by the programmable controller as a filtered value.

Port 10/11 Offline Parameters Default Unit Set to RPM Instead of Hertz

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 12.001

The offline default unit was set to RPM instead of Hertz for parameters 10/11:1392 [Max Speed Fwd] and 10/11:1393 [Max Speed Rev]. The default unit for these parameters is now Hertz.

Port 13 Parameters Default Configurations Differ when Online Versus Offline

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

With this firmware revision, the default configuration for the following port 13 parameters is now the same when online with the drive and when offline with the drive.

• 42 [ManDCBus AnIgLo]

• 62 [DBC V Thresh Lo]

• 63 [DBC V Thresh Hi]

• 64 [DBC V Thresh Nom]

PowerFlex Bus Supplies and Drives can Crash During a Soft Reset

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 10.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 11.001

PowerFlex® 755TM bus supplies and 755TL and 755TR drives can crash during a soft reset. This anomaly is observed in less than one percent of successive soft reset cycles. If a crash occurs after a soft reset, cycle power to the drive or bus supply.

Predictive Maintenance Displays Two Capacitor Catalog Numbers for Frame 5 Drive

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 12.001

The Predictive Maintenance page no longer displays two LCL filter capacitor catalog numbers for a frame 5 drive. The Predictive Maintenance page now correctly displays only one LCL filter capacitor.

Predictive Maintenance Lists Components Not Present in the Product

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 14.001

The Predictive Maintenance page in Connected Components Workbench® software lists components that are not present in the product. For example, the drive cannot detect a fan in a wire entry bay and therefore always lists a fan whether it is present or not. This anomaly has been corrected with this firmware release.

PWM Frequency Can Change Unexpectedly in Open Loop Mode

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

When in an Open Loop motor control mode, pulse-width modulation (PWM) frequency could change unexpectedly. This firmware revision corrects this anomaly.

Reverse End Limit Can Fail to Produce an Alarm

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 13.002

With this firmware revision, when a digital input is assigned in parameter 0:182 [DI RevEndLimit], and the end limit is reached, the product produces an alarm.

Safe Torque Off Option Module Issues Incorrect Fault when Jumper is ‘IN’

Corrected Anomaly with PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 12.001

When a Safe Torque Off (20-750-S) option module is installed with the Safety jumper in the ‘IN’ position on the main control board, the incorrect ‘Safety Brd Fault’ (nn087) displayed instead of the expected ‘Safety Jumper In’ fault (nn089). Firmware revision 12.001 corrects this anomaly. The correct fault, ‘Safety Jumper In’ fault (nn089) now displays when the safety jumper is in the ‘IN’ position when a Safe Torque Off option module is installed.

The safety jumper must be removed from the main control board when a safety option module is installed in the system. See the appropriate manual for details on safety option module safety jumper information.

PowerFlex® Drives with TotalFORCE® Control Installation Instructions, publication 750-IN100

PowerFlex 755TS Products with TotalFORCE Control Installation Instructions, publication 750-IN119

PowerFlex 750-Series Safe Torque Off Option Module User Manual, publication 750-UM002

Torque Reference can Exceed 800% when Writing to Load Ratio Parameter

Corrected Anomaly with PowerFlex 755TL/TR/TM Firmware Revision 12.001

Corrected Anomaly with PowerFlex 755TS Firmware Revision 12.001

With previous firmware revisions, the resulting Torque Reference could exceed 800% when writing to the Load Ratio parameter (10/11:901 [Load Ratio]). The load ratio can be correctly configured by using parameter 10/11:901 [Load Ratio] with firmware revision 12.001.

Update to PowerFlex Firmware Revision 11.001 Causes Parameters to Reset to Defaults and Voltage Class Change

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM and PowerFlex 755TS Firmware Revision 11.001

An update from PowerFlex firmware revision 10.001 to PowerFlex firmware revision 11.001 causes these issues:

• All parameters are reset to default values, including the IP address parameters, unless the IP address rotary switches on the main control board are used.

• 480V products are changed to 400V.

• 690V products are changed to 600V.

IMPORTANT: To avoid these issues, before completing the firmware update, save the product parameter configuration for all ports (to a HIM set or an offline file). Once the firmware update is complete, download the parameter configuration to the product.

For instructions on using the Human Interface Module (HIM) to save the parameter configuration, see the PowerFlex 20-HIM-A6/-C6S HIM (Human Interface Module) User Manual, 20HIM-UM001.

For instruction for saving an offline file, see the appropriate online help available with the drive configuration software.

Digital Output Momentarily Energizes During Drive Power-up

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 14.001

Known Anomaly First Identified as of PowerFlex 755TS Firmware Revision 14.001

A digital output will momentarily energize during power-up if it is configured to follow a bit that is normally on (one) and is set to invert the logic of that bit.

For example, consider the configuration where the first relay output on an IO card in slot 5 is set to follow the Brake Set bit in the Torque Prove Status parameter, and the logic is inverted:

• Parameter 5:10 [RO0 Sel] is mapped to parameter 9:52 [Trq Prove Status] bit 4 'Brake Set', which is normally on (one).

• Bit 0 'Relay Out 0' is set (one) in parameter 5:6 [Dig Out Invert].

• When the drive powers up, it momentarily energizes the relay output.

If the signal from this digital output is used to release a brake in a torque-proving application, such as within a crane or hoist, the brake will momentarily release during the drive's power-up.

To avoid this undesirable behavior in the above torque-proving example, configure the digital output to follow the Brake Release bit instead of the Brake Set bit in the Torque Prove Status parameter without inverting the logic:

• Map parameter 5:10 [RO0 Sel] to parameter 9:52 [Trq Prove Status] bit 8 'BrakeRelease', which is normally off (zero).

• Reset bit 0 'Relay Out 0' in parameter 5:6 [Dig Out Invert] to a value of zero.

PowerFlex Drives Power-up with No Faults but Lists Multiple Faults and Alarms in Queue

Known Anomaly First Identified as of PowerFlex 755TL/TR/TM Firmware Revision 11.001

PowerFlex® 755TL and 755TM drives can power-up without active faults or alarms but contain multiple faults and alarms in the queues.

Application Notes for PowerFlex® 755TL/TR/TM and PowerFlex 755TS Firmware Revision 11.001 and Later

Before You Begin a Firmware Update

PowerFlex 755TL/TR/TM and PowerFlex 755TS products (PowerFlex 755T products) revision 11.001 and later firmware is provided as a *.dmk file. ControlFLASH™ Plus software is the recommended application for upgrading your firmware when using a *.dmk file. You can use ControlFLASH™ software to upgrade your firmware, with exceptions.

If necessary, download and install the preferred software from the Product Compatibility and Download Center.

Use ControlFLASH Plus to Update PowerFlex 755T Product Firmware

• For instructions on how to install ControlFLASH Plus software, see the ControlFLASH Plus Quick Start Guide, publication CFP-QS001.
• For instructions on how to upgrade your PowerFlex 755T product firmware by using ControlFLASH Plus, see “Use ControlFLASH Plus to update firmware” in the ControlFLASH Plus Quick Start Guide.

Use ControlFLASH to Update PowerFlex 755T Product Firmware

• For instructions on how to install ControlFLASH software, see the ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-UM105.
• For instructions on how to upgrade your PowerFlex 755T product firmware by using ControlFLASH, see Knowledgebase Answer ID BF25100.