
Allen-Bradley 20G1AND156JA0NNNNN
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The Allen-Bradley 20G1AND156JA0NNNNN is a PowerFlex 755 series AC variable frequency drive manufactured by Allen-Bradley, a brand of Rockwell Automation. This unit belongs to the PowerFlex 750-Series product family, which is designed for demanding industrial motor control applications requiring high performance and flexibility. The SKU 20G1AND156JA0NNNNN identifies a specific configuration within the PowerFlex 755 line, indicating a 200V AC input class drive rated at 156 amperes output current with a standard enclosure and no embedded safety option.
The PowerFlex 755 features an embedded EtherNet/IP communication port as standard, enabling seamless integration into Logix-based control architectures without the need for an additional communication module. The drive supports a wide range of optional plug-in option cards including additional fieldbus adapters (DeviceNet, Profibus, ControlNet), encoder feedback modules, and safety option cards such as the Safe Torque Off (STO) and Safe Speed Monitor (SSM) functions. The architecture uses a modular option bay system that allows field installation of up to five option modules simultaneously. The drive employs advanced motor control algorithms including Sensorless Vector Control and Closed Loop Vector Control, delivering precise speed and torque regulation across a broad speed range.
The PowerFlex 755 is widely deployed in industries such as oil and gas, mining, metals, pulp and paper, water and wastewater, and material handling. It is suitable for driving pumps, fans, compressors, conveyors, extruders, and hoists where variable speed control and high dynamic performance are required. The drive's scalable power range, robust thermal management, and compatibility with the Rockwell Automation Integrated Architecture make it a practical choice for both standalone machine applications and large distributed control system installations.
Technical Specifications
| Series/Product Family | PowerFlex 755 |
|---|---|
| Input Voltage | 200–240 V AC, 3-phase |
| Output Current (Continuous) | 156 A |
| Power Rating | Approximately 45 kW (60 HP) at 240 V AC |
| Input Frequency | 47–63 Hz |
| Control Type | V/Hz, Sensorless Vector Control, Closed Loop Vector Control |
| Communication Interface | Embedded EtherNet/IP; optional DeviceNet, ControlNet, Profibus DP |
| Feedback Interface | Optional encoder feedback via plug-in option card (incremental, absolute) |
| Safety Features | Optional Safe Torque Off (STO) SIL 2 / PLd, Safe Speed Monitor (SSM) |
| Operating Temperature | 0 to 50 degrees C (derating required above 40 degrees C) |
| Storage Temperature | -40 to 70 degrees C |
| Relative Humidity | 5–95% non-condensing |
| IP/Protection Rating | IP20 (open type enclosure) |
| Mounting | Panel mount (bookshelf or flat) |
| Certifications | UL, cUL, CE, RCM |
| Number of Axes | 1 |
Common Fault Codes
- Fault Code 2
- Auxiliary Input fault. A digital input configured as an auxiliary input has opened, indicating an external fault condition.
Check the external device or circuit connected to the auxiliary input. Verify wiring continuity and confirm the external device is operating correctly before clearing the fault. - Fault Code 3
- Power Loss fault. The drive detected a loss of input AC power or a significant voltage sag below the minimum threshold.
Check incoming AC supply voltage at all three phases. Inspect fuses, contactors, and supply cabling. Verify that supply voltage is within the rated input range of the drive. - Fault Code 4
- UnderVoltage fault. DC bus voltage has dropped below the minimum operating level during run.
Measure incoming line voltage. Check for loose connections or phase loss. Verify that the supply transformer is adequately sized for the load. - Fault Code 5
- OverVoltage fault. DC bus voltage has exceeded the maximum allowable level, typically caused by regenerative energy from a decelerating load.
Increase deceleration time to reduce regenerative energy. Consider adding a dynamic braking resistor or an active front end. Check for overhauling load conditions. - Fault Code 7
- Motor Overload fault. The drive's electronic overload protection has detected sustained overcurrent conditions indicating the motor is thermally overloaded.
Reduce load on the motor or increase the motor overload parameter setting if the motor is rated for higher current. Check for mechanical binding or excessive load inertia. - Fault Code 12
- HW OverCurrent fault. Hardware overcurrent protection has tripped due to output current exceeding the instantaneous hardware current limit.
Check for a short circuit or ground fault on the output wiring or motor windings. Verify motor insulation resistance. Reduce acceleration rate or increase current limit settings if appropriate. - Fault Code 29
- Analog Input Loss fault. An analog input signal has fallen below the configured loss-of-signal threshold (e.g., 4 mA signal lost on a 4–20 mA input).
Check the analog signal source and wiring to the drive's analog input terminals. Verify the signal source is powered and functioning. Inspect for broken wires or loose terminal connections. - Fault Code 71
- Adapter Communication Loss fault. The drive has lost communication with an installed option card or external communication adapter.
Check that the option card is fully seated in the option bay. Inspect the network cable and connections. Verify the network scanner or controller is active and the communication parameters match.
Frequently Asked Questions
What is the input voltage class for the 20G1AND156JA0NNNNN?
The '2' in the catalog number prefix indicates this drive is rated for a 200–240 V AC three-phase input supply. It is not suitable for 400 V or 480 V applications without selecting the appropriate voltage class variant.
Does this drive include a built-in safety function?
The base unit 20G1AND156JA0NNNNN does not include an embedded safety option as indicated by the 'N' safety option code in the catalog string. Safety functions such as Safe Torque Off (STO) can be added by installing a compatible safety option card in one of the drive's option bays.
What communication protocols does the PowerFlex 755 support?
The PowerFlex 755 includes an embedded EtherNet/IP port as standard. Additional protocols including DeviceNet, ControlNet, Profibus DP, and Modbus TCP can be supported by installing the appropriate plug-in communication option card.
Can the PowerFlex 755 be used with an encoder for closed-loop speed control?
Yes, closed-loop vector control with encoder feedback is supported. An encoder feedback option card must be installed in one of the drive's option bays, and the drive must be configured for the appropriate control mode in the parameter settings.
How many option cards can be installed simultaneously in the PowerFlex 755?
The PowerFlex 755 provides up to five option bays, allowing simultaneous installation of multiple option cards for communication, feedback, I/O expansion, and safety functions, subject to compatibility and power budget constraints.
Troubleshooting
Drive powers up but immediately faults on Fault Code 5 (OverVoltage) during deceleration
Monitor the DC bus voltage parameter during deceleration using DriveExecutive or Studio 5000. If DC bus voltage rises above the overvoltage trip threshold, the load is regenerating energy back into the drive faster than it can be dissipated.
Increase the deceleration time in the drive parameters to reduce regenerative energy. If fast deceleration is required, install a dynamic braking resistor kit and enable the braking IGBT function, or consider an active front end regenerative unit.
Drive displays Fault Code 71 (Adapter Communication Loss) after option card installation
Remove and reseat the option card to confirm it is fully engaged in the option bay connector. Check the option card type against the drive firmware version for compatibility. Use the drive's HIM or parameter list to verify the option card is recognized in the correct bay.
Ensure the option card is correctly seated and the bay cover is secured. Update drive firmware if the card requires a newer firmware version. Verify network cable integrity and that the controlling device (PLC or scanner) is actively communicating on the network.
Motor runs but speed does not match the commanded reference
Check the speed reference source parameter to confirm the correct input (analog, network, or preset) is selected. Measure the analog input signal voltage or current at the drive terminals if using an analog reference. Verify scaling parameters for minimum and maximum speed and reference signal range.
Correct the speed reference source selection parameter. Adjust the analog input scaling parameters to match the signal range from the controller. If using EtherNet/IP, verify the reference data is being written correctly to the drive's output assembly.
Drive runs hot and thermal fault or derating occurs at rated load
Check ambient temperature at the drive installation location. Inspect the drive's internal cooling fan for operation and airflow obstruction. Verify that the minimum clearances above and below the drive are maintained per the installation manual.
Improve ventilation in the enclosure or reduce ambient temperature. Clean any dust or debris from the heatsink fins and fan blades. If ambient temperature exceeds 40 degrees C, apply the published derating curves and reduce load accordingly or select a higher-rated drive.
Drive will not enable and displays a Safe Torque Off (STO) active status even though no safety option card is installed
Check the hardware enable input wiring at the drive's control terminal block. The PowerFlex 755 requires the hardware enable input to be energized before the drive will accept a run command. Verify the enable input terminal is jumpered or connected to a 24 V DC source.
Install a jumper between the 24 V DC supply terminal and the hardware enable input terminal on the control terminal block if no external enable circuit is used. If an external safety relay or PLC output is controlling the enable, verify the output is active and the wiring is intact.
| Condition | Repair, Used, Refurbished, New in box (sealed) |
|---|
Common defects
Common defects on a Allen-Bradley 20G1AND156JA0NNNNN are:
Power Supply Related Issues
- No power / drive not turning on
- Blown fuses
- Defective rectifier bridge
- Damaged DC bus capacitors
- IGBT / MOSFET module failure
- Overvoltage / undervoltage errors
Control & Electronics Failures
- Faulty control board or PCB damage
- Firmware or memory corruption
- Fieldbus communication errors (Profibus, Modbus, EtherCAT, CANopen)
- Input / output circuit damage
- Gate driver module failure
Motor Control Problems
- Motor not starting or no output
- Unstable speed control
- No torque output
- Trip during acceleration or deceleration
- Encoder feedback errors
Thermal & Cooling Defects
- Overheating due to failed cooling fans
- Defective temperature sensors
- Poor heatsink performance
Mechanical & Environmental Damage
- Burnt or loose connectors
- PCB track damage
- Corrosion or moisture ingress
- Oil, dust or contamination damage
- Cracked solder joints
Error Codes & Drive Trips
- Overcurrent faults (OC)
- Ground fault / earth leakage error
- Short-circuit fault
- Motor or drive overload
- Overvoltage or undervoltage error
- Undervoltage trip when starting or stopping
- Phase loss / imbalance
- Synchronization issues with multiple drives
Other
- Display defect
- Control keys or keypad not working
- Parameters no longer readable or lost
- Brake resistor problems (brake chopper defect)
- Internal relays/contactors defective
- EMI/RFI interference due to defective filters
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