Configurable Communication Loss Fault for Option Modules

System Feature First Identified as of PowerFlex 755 Firmware Revision 16.002

System Feature First Identified as of PowerFlex 753 Firmware Revision 16.002

This feature allows you to configure the drive’s response to a communication loss fault (224…228 ‘Port n Comm Loss’) for an option module that is installed in slots 4…8 in the control pod of a PowerFlex® 753 or PowerFlex 755 drive.

New parameters 965 [Option Loss Actn] and 966 [Option Loss Dly] have been added to support the configuration of this new feature.

Configurable Programmable Logic Controller Outputs when in Program Mode

System Feature First Identified as of PowerFlex 755 Firmware Revision 16.002

This feature allows configuration of programmable logic controller outputs for integrated motion on the EtherNet/IP™ network (CIP) mode when the controller is set to program (IDLE mode).

See the “Integrated Motion on EtherNet/IP Application” appendix in the PowerFlex® 750-Series AC Drives Programming Manual, publication
750-PM001, for details on the attributes that have been added to support this feature.

Reduced Pulse Width Modulation to Help Improve Insulated Gate Bipolar Transistor Life

System Feature First Identified as of PowerFlex 755 Firmware Revision 16.002

System Feature First Identified as of PowerFlex 753 Firmware Revision 16.002

This feature allows you to configure a reduced Pulse Width Modulation (PM) carrier frequency when the carrier frequency reaches a specific threshold. Reduced PWM carrier frequency can help improve the life of the drive’s insulated gate bipolar transistors (IGBTs).

New parameters 39 [PWM Trans Freq] and 40 [Mtr Options Cfg] have been added to support this new feature.

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.

Product Updates and Replacements

PowerFlex® 755 firmware revision 14.004 or later is installed by using a *.dmk file. Firmware updates for PowerFlex 755 drives can be performed using the following software:

Before You Begin a Firmware Update

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

• ControlFLASH Firmware Upgrade Kit User Manual, publication 1756-UM105
• ControlFLASH Plus Quick Start Guide, publication CFP-QS001

For information on connecting the 1203-USB or 1203-SSS converter to your drive, see these publications:

• 1203-USB USB Converter User Manual, publication DRIVES-UM001
• 1203-SSS Smart Self-powered Serial Converter User Manual, publication 20COMM-UM001

Use ControlFLASH Plus to Update the Firmware

See “Use ControlFLASH Plus to update firmware” in the ControlFLASH Plus Quick Start Guide, publication CFP-QS001

Use ControlFLASH to Update the Firmware

Follow these steps to update your PowerFlex 755 drive firmware.

1. Download the applicable firmware revision from the Product Compatibility and Download Center.
2. Place the *.dmk file in one of the following directories on your computer:

• C:\Program Files (x86)\ControlFLASH
• C:\Users\Public\Documents\Rockwell Automation\Firmware Kit
• C:\Users\USER NAME\Downloads\RA
• C:\Users\USER NAME\Desktop\cfkits

Note: In this example, the file name is PF755_App_v14_004_230_Secure.dmk.

3. Verify that the drive is stopped and not communicating with a controller, by inhibiting the drive in the software.
4. Open ControlFLASH on your computer.
5. In the Welcome dialog box, choose RSLinx Classic or FactoryTalk Linx. RSLinx Classic is used in this example.

6. Click Next.
7. In the Catalog Number dialog box, select the appropriate drive family.

Important: Choose the appropriate “PowerFlex 755 xx” catalog number selection for your application. Do not choose an option that includes the “via…” option.

8. Click Next.
9. In the RSWho browser dialog box, select your drive.

10. Click OK.
11. In the Multiple Assemblies Found dialog box, select Port 0 – PowerFlex 755.

12. Click OK.
13. In the Firmware Revision dialog box, click Show all revisions.
14. Below Revision, select the applicable firmware revision.

15. Click Next.
16. In the Summary dialog box, click Finish.

17. In the ControlFLASH message box, click Yes.

18. The firmware update begins and a Progress dialog box appears.

19. When the firmware update is complete, the Update Status dialog box appears.

20. Click OK.
21. Exit ControlFLASH.

The drive firmware update has been completed.

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.