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PowerFlex 750 Series AC Drive User Guide

PowerFlex 750 Series AC Drive User Guide

1. Operation Panel (Keypad) Usage

The operation panel (keypad) of the PowerFlex 750 series AC drive serves as the primary interface for user interaction. It allows users to navigate menus, set parameters, and view status information.

Navigation and Selection: Use the arrow keys to navigate through menus and the “Select” button to enter specific settings or parameter editing mode.

Parameter Editing: In edit mode, enter or adjust parameter values using the numeric keys or arrow keys.

Saving and Exiting: After making changes, use the “Save” button to save modifications and the “Exit” button to return to the previous menu or the main interface.

Status Viewing: Select the appropriate option from the menu to view the drive’s output frequency, current, voltage, fault codes, and other status information.

Rockwell Powerflex 755 Series VFD Status Indicator Light Description

2. Open-Loop V/F Control Parameter Settings

In open-loop V/F (Volts per Hertz) control mode, the drive regulates the motor speed by adjusting the ratio between the output voltage and frequency. Here are guidelines for setting key parameters:

  • P35 (Motor Control Mode): Set to “V/Hz” mode to enable open-loop V/F control.
  • P25 (Motor Nameplate Voltage): Enter the motor’s rated voltage.
  • P27 (Motor Nameplate Frequency): Input the motor’s rated frequency.
  • P60 (V/F Curve Settings): Adjust the V/F curve as needed to optimize motor performance.
  • P520/P521 (Maximum Forward/Reverse Speed): Set the maximum operating frequency limits for the motor.
I/O Wiring Diagram for Rockwell Powerflex 755 Series VFD

3. Terminal Start and Potentiometer Speed Adjustment Wiring and Parameter Settings

Wiring Instructions:

  • Main Power and Control Power Connection: Connect the three-phase main power and (if required) control power as specified in the manual.
  • Motor Connection: Wire the motor’s three-phase leads to the U, V, W output terminals.
  • Start/Stop Terminal Connection: Connect the contacts of the external start/stop buttons to the drive’s DI (Digital Input) terminals and configure the related parameters.
  • Potentiometer Speed Adjustment Connection: Connect the potentiometer’s wiper to the AI (Analog Input) terminal for speed regulation.

Parameter Settings:

  • Digital Input Configuration: Configure relevant parameters to assign DI terminals for start/stop functions.
  • Analog Input Configuration: Ensure AI terminals are set as the speed reference source and adjust the input range to match the potentiometer’s output range.
  • Speed Reference Selection: Specify the analog input as the source for speed references in the parameters.

4. Fault Code Analysis and Troubleshooting Summary

According to the fault code list provided in the manual (pages 316-323, fault numbers 0-155), here are summaries of a few common faults, their possible causes, and troubleshooting methods:

  • F001: Overcurrent Protection. Check for motor overload, stable power supply voltage, and short circuits in the output circuit.
  • F002: Overvoltage Protection. Verify that the input voltage is within the allowed range and consider installing a voltage stabilizer or adjusting the input filter.
  • F003: Undervoltage Protection. Check if the power supply voltage is too low and confirm correct power line connections.
  • F004: Overheat Protection. Inspect the drive and motor cooling, clean dust from the heat sink, and ensure proper ventilation.
  • F005: Communication Failure. Check communication line connections, verify correct communication parameter settings (including baud rate, data bits, etc.).

Please note, the above fault codes are examples, and specific fault codes and their solutions should be referenced directly from the manual.

5. General Troubleshooting Steps

  • Check Fault Code: Read and record the fault code on the operation panel.
  • Consult the Manual: Look up the corresponding fault description, possible causes, and solutions in the manual.
  • Perform Preliminary Checks: Examine power sources, motors, communication lines, etc.
  • Reset the Drive: If initial checks reveal no issues, attempt to reset the drive to clear temporary faults.
  • Advanced Diagnostics: If problems persist, professional tools may be
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JACT AT500 Inverter Operation Guide and Fault Handling Summary

AT500 Inverter Operation Guide and Fault Handling Summary

I. AT500 Inverter Operation Panel Usage

  1. Operation Panel Layout and Indicator Description:
    • Introduces the display, buttons (RUN, STOP/RES, MK, Λ, V, >>, etc.) on the operation panel and their functions.
    • Explains the meanings of various indicators (Run, Alm, Hz, A, V, %, rpm, F/R, etc.).
  2. Menu and Parameter Settings:
    • Describes the three-level menu mode (function parameter group, function code, function code modification) and its operation method.
    • Elaborates on how to view and modify various inverter parameters through the operation panel.
  3. Operation Mode Control:
    • Introduces starting the inverter via the RUN button and stopping it via the STOP/RES button.
    • Explains the jog operation function and its debugging applications.
Function diagram of AT500 inverter operation panel buttons

II. Terminal Control and External Potentiometer Debugging Mode Setup

  1. Terminal Control Setup:
    • Guides users to enter the F0 parameter group and set F0.02 to 1 to enable terminal control.
    • Demonstrates how to assign functions to each input terminal through the F2 parameter group and explains wiring requirements.
  2. External Potentiometer Debugging Mode:
    • Teaches users to set F0.03 or F0.04 to AI3 (keyboard potentiometer) to adjust the output frequency by rotating the potentiometer knob.
JACT AT500 inverter wiring diagram

III. Inverter Fault Code Classification and Troubleshooting Methods

  1. Overcurrent Faults (Err02-Err04):
    • Lists possible causes (output circuit short circuit, too short acceleration/deceleration time, etc.).
    • Provides solutions (check output circuit, adjust acceleration/deceleration time, etc.).
  2. Overvoltage Faults (Err05-Err07):
    • Analyzes fault causes (excessively high input voltage, external force during deceleration, etc.).
    • Offers remedies (adjust input voltage, eliminate external force during deceleration, etc.).
  3. Undervoltage Fault (Err09):
    • Describes fault causes (instantaneous power failure, low input voltage, etc.).
    • Suggests solutions (check input power supply, adjust voltage range, etc.).
  4. Overload Faults (Err10-Err11):
    • Indicates faults may be caused by excessive load, motor stall, etc.
    • Proposes reducing the load, checking the motor and mechanical conditions, etc.
  5. Input/Output Phase Loss Faults (Err12-Err13):
    • Analyzes fault causes (input power phase loss, faulty output wires or motor, etc.).
    • Offers advice on checking power and motor, troubleshooting peripheral faults, etc.
  6. Module Overheating Fault (Err14):
    • Explains fault causes (high ambient temperature, blocked air ducts, etc.).
    • Emphasizes the importance of reducing ambient temperature, cleaning air ducts, replacing fans, etc.
  7. Communication Fault (Err16):
    • Mentions possible causes (incorrect communication parameter settings, faulty communication cables, etc.).
    • Suggests checking communication parameters, cables, and the host computer.