Rockwell Automation Allen-Bradley PowerFlex 750 Series, PowerFlex 755TL, PowerFlex 755TM, PowerFlex 755TR Service Manual

Download

Hardware Service Manual

Original Instructions

PowerFlex 750-Series Products with TotalFORCE Control

Catalog Numbers 20G, 20J

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Before You Begin Tests, Maintenance, or Repairs

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 1

Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Class 1 Light-emitting Diode Product . . . . . . . . . . . . . . . . . . . . . . 14

Remove Power from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Frames 7…15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Hardware Installation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 2

Preventative Maintenance Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . 27

Predictive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Schedule Codes Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Shock Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance of Industrial Control Equipment . . . . . . . . . . . . . . . . . . 42

Solid-state Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chapter 3

Component Inspection and Test Procedures

Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 45

Forward and Reverse Biased IGBT/Diode Tests . . . . . . . . . . . . . . . . . 47

AC Input Link Fuses Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

DC Link Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Component Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 4

Frame 5 Components Frame 5 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remove the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Remove the Cover from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . 56

Install the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 57

Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . . 57

Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . 60

Stirring Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Remove the Stirring Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Install the Stirring Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 3

Table of Contents

Heatsink Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Remove the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . 62

Install the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fan Power Supply Circuit Board Replacement. . . . . . . . . . . . . . . . . . . 64

Remove the Fan Power Supply Circuit Board . . . . . . . . . . . . . . . . 64

Install the Fan Power Supply Circuit Board. . . . . . . . . . . . . . . . . . 65

Potential Earth (PE) Jumper Replacement . . . . . . . . . . . . . . . . . . . . . . 66

Remove the PE Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Install the PE Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Power Feedback Circuit Board and Bracket Replacement. . . . . . . . . 67

Remove the Power Feedback Circuit Board and Bracket . . . . . . 67

Install the Power Feedback Circuit Board and Bracket. . . . . . . . 70

LCL Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Remove the LCL Filter Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Install the LCL Filter Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Chapter 5

Frame 6 Components Frame 6 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Remove the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Remove the Cover from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . 76

Install the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 77

Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . . 77

Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . 80

Stirring Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Remove the Stirring Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Install the Stirring Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Heatsink Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Remove the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . 82

Install the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 83

DR and PE-A (EMC & MOV) Jumper Replacement. . . . . . . . . . . . . 83

Remove the DR and PE-A (EMC & MOV) Jumper . . . . . . . . . . 83

Install the DR and PE-A (EMC & MOV) Jumper. . . . . . . . . . . . 84

Fan Power Supply Circuit Board Replacement. . . . . . . . . . . . . . . . . . . 84

Remove the Fan Power Supply Circuit Board . . . . . . . . . . . . . . . . 84

Install the Fan Power Supply Circuit Board. . . . . . . . . . . . . . . . . . 86

Power Feedback Circuit Board and Bracket Replacement. . . . . . . . . 87

Remove the Power Feedback Circuit Board and Bracket . . . . . . 87

Install the Power Feedback Circuit Board and Bracket. . . . . . . . 90

LCL Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Remove the LCL Filter Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Install the LCL Filter Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Table of Contents

Chapter 6

Frame 7 Components Frame 7 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

IP54 Exhaust Vent Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 98

IP54, 800 mm Wide Door Vent Filters Replacement . . . . . . . . . . . . . 98

IP21, 800 mm Wide Door Vent Filter Replacement. . . . . . . . . . . . . . 98

Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Remove the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Install the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Control Pod Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . 99

Remove the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . 99

Install the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 100

Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 101

Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . 101

Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . 103

Control Pod Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Remove the Control Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . 104

Install the Control Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Power/Filter Module Heatsink Fan Assembly Replacement. . . . . . 109

Remove the Power/Filter Module Fan Assembly . . . . . . . . . . . . 109

Install the Power/Filter Module Fan Assembly. . . . . . . . . . . . . . 110

Remove the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Remove the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Install the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Control Transformer Fuses (FH4) Replacement. . . . . . . . . . . . . . . . 112

Remove the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . 112

Install the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . . . 112

Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Remove the Power Module from the Enclosure . . . . . . . . . . . . . 113

Install the Power Module in the Enclosure. . . . . . . . . . . . . . . . . . 120

Power Layer Interface Circuit Board Replacement . . . . . . . . . . . . . . 120

Remove the Power Layer Interface Circuit Board. . . . . . . . . . . . 120

Install the Power Layer Interface Circuit Board . . . . . . . . . . . . . 123

Power Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . 124

Remove the Power Interface Circuit Board . . . . . . . . . . . . . . . . . 124

Install the Power Interface Circuit Board . . . . . . . . . . . . . . . . . . . 126

LCL Filter Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Remove the LCL Filter Module from the Enclosure . . . . . . . . . 127

Install the LCL Filter Module in the Enclosure. . . . . . . . . . . . . . 131

Current Sense Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 132

Remove the Current Sense Circuit Board. . . . . . . . . . . . . . . . . . . 132

Install the Current Sense Circuit Board . . . . . . . . . . . . . . . . . . . . 137

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 5

Table of Contents

Chapter 7

Control Bay and Control Pod Components

Control Bay and Control Pod Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

IP21/IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 142

Remove the IP21/IP54 Roof Vent Filter . . . . . . . . . . . . . . . . . . . 142

Install the IP21/IP54 Roof Vent Filter . . . . . . . . . . . . . . . . . . . . . 143

IP54/IP21 Roof Vent Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . 143

Remove the IP21/IP54 Roof Vent Fan . . . . . . . . . . . . . . . . . . . . . 143

Install the IP21/IP54 Roof Vent Fan. . . . . . . . . . . . . . . . . . . . . . . 144

IP21/IP54 Door Vent Filter Replacement. . . . . . . . . . . . . . . . . . . . . . 145

Remove the IP21/IP54 Door Vent Filter . . . . . . . . . . . . . . . . . . . 145

Install the IP21/IP54 Door Vent Filter. . . . . . . . . . . . . . . . . . . . . 145

Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Remove the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Install the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Fiber Transceiver Circuit Board Replacement . . . . . . . . . . . . . . . . . . 148

Remove the Fiber Transceiver Circuit Board. . . . . . . . . . . . . . . . 148

Install the Fiber Transceiver Circuit Board . . . . . . . . . . . . . . . . . 151

Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 152

Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . 152

Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . 154

Backplane Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 155

Remove the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . 155

Install the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . 156

Fiber-optic Interface Circuit Board Replacement . . . . . . . . . . . . . . . 157

Remove the Fiber-optic Interface Circuit Board. . . . . . . . . . . . . 157

Install the Fiber-optic Interface Circuit Board . . . . . . . . . . . . . . 164

Control Pod Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . 164

Remove the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . 164

Install the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 166

Control Pod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Remove the Control Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Install the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Chapter 8

Input Bay Components Input Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

IP21/IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 179

IP54/IP21 Roof Vent Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . 179

IP54/IP21, 400/600 mm Wide Door Vent Filters Replacement. . 179

Remove the IP54/IP21, 400/600 mm Wide Door Vent

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Install the IP54/IP21, 400/600 mm Wide Door Vent

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

IP54, 800/1000 mm Wide Door Vent Filters Replacement . . . . . . 180

Remove the IP54, 800/1000 mm Wide Door Vent Filters . . . 180

Install the IP54, 800/1000 mm Wide Door Vent Filters . . . . . 181

6 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Table of Contents

IP21, 800/1000 mm Wide Door Vent Filter Replacement. . . . . . . 181

Remove the IP21, 800/1000 mm Wide Door Vent Filter . . . . 181

Install the IP21, 800/1000 mm Wide Door Vent Filter . . . . . . 182

IP54/IP21, 1000 mm Wide Door Vent Fan Replacement . . . . . . . 182

Remove the IP54/IP21, 1000 mm Wide Door Vent Fan. . . . . 182

Install the IP21/IP54, 1000 mm Wide Door Vent Fan . . . . . . 183

Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Remove the Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Install the Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

AC Precharge Control Circuit Board Replacement . . . . . . . . . . . . . 186

Remove the AC Precharge Control Circuit Board. . . . . . . . . . . 186

Install the AC Precharge Control Circuit Board . . . . . . . . . . . . 189

AC Precharge Time Delay Relay Replacement . . . . . . . . . . . . . . . . . . 189

Remove the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . 189

Install the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . . . 190

AC Precharge TVSS Module Replacement . . . . . . . . . . . . . . . . . . . . . 190

Remove the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . 190

Install the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . . . 192

AC Precharge Control Circuit Board Fuses (FH1) Replacement . 192

Remove the AC Precharge Control Circuit Board Fuses . . . . . 192

Install the AC Precharge Control Board Fuses . . . . . . . . . . . . . . 193

240V Power Distribution Fuse (FH2) Replacement. . . . . . . . . . . . . 194

Remove the 240V Power Distribution Fuse. . . . . . . . . . . . . . . . . 194

Install the 240V Power Distribution Fuse . . . . . . . . . . . . . . . . . . 195

Roof Fan 240V Control Power Fuse (FH3) Replacement. . . . . . . . 195

Remove the Roof Fan 240V Control Power Fuse. . . . . . . . . . . . 195

Install the Roof Fan 240V Control Power Fuse . . . . . . . . . . . . . 196

Control Transformer Fuses (FH4…FH7) Replacement. . . . . . . . . . 197

Remove the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . 197

Install the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . . . 198

AC Precharge Fused Disconnect (FD1) Fuses Replacement. . . . . . 199

Remove the AC Precharge Fused Disconnect Fuses. . . . . . . . . . 199

Install the AC Precharge Fused Disconnect Fuses . . . . . . . . . . . 200

Control Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Chapter 9

Power Bay Components Power Bay Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

IP54 Exhaust Vent Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . 211

Remove the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . 211

Install the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . . . 211

IP54 Exhaust Fan Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Remove the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . 212

Install the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 213

IP54 Exhaust Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Remove the IP54 Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Install the IP54 Exhaust Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 7

Table of Contents

IP54, 400/600 mm Wide Door Vent Filters Replacement . . . . . . . 220

Remove the IP54, 400/600 mm Wide Door Vent Filters. . . . . 220

Install the IP54, 400/600 mm Wide Door Vent Filters . . . . . . 220

IP21 400/600 mm Wide Door Vent Filter Replacement. . . . . . . . . 221

Remove the IP21, 400/600 mm Wide Door Vent Filter . . . . . 221

Install the IP21, 400/600 mm Wide Door Vent Filter . . . . . . . 222

IP54, 800 mm Wide Door Vent Filters Replacement . . . . . . . . . . . . 222

IP21, 800 mm Wide Door Vent Filter Replacement. . . . . . . . . . . . . 222

DC Precharge Module Disconnect Handle and Shaft

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Remove the DC Precharge Module Disconnect Handle

and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Install the DC Precharge Module Disconnect Handle

and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

DC Precharge Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Remove the DC Precharge Module from the Enclosure . . . . . . 224

Install the DC Precharge Module in the Enclosure . . . . . . . . . . 228

DC Precharge Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 229

Remove the DC Precharge Circuit Board. . . . . . . . . . . . . . . . . . . 229

Install the DC Precharge Circuit Board . . . . . . . . . . . . . . . . . . . . 232

DC Precharge Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Remove the DC Precharge Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Install the DC Precharge Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Remove the Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Install the Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Remove the Power Module from the Enclosure . . . . . . . . . . . . . 236

Install the Power Module in the Enclosure. . . . . . . . . . . . . . . . . . 241

DC Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Remove the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Install the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Power Module PE-B1 Power Jumper Replacement. . . . . . . . . . . . . . 243

Remove the Power Module PE-B1 Power Jumper . . . . . . . . . . . 243

Install the Power Module PE-B1 Power Jumper . . . . . . . . . . . . . 244

Circuit Board Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Remove the Circuit Board Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Install the Circuit Board Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Power Layer Interface Circuit Board Replacement . . . . . . . . . . . . . . 249

Remove the Power Layer Interface Circuit Board. . . . . . . . . . . . 249

Install the Power Layer Interface Circuit Board . . . . . . . . . . . . . 250

Power Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . 250

Remove the Power Interface Circuit Board . . . . . . . . . . . . . . . . . 251

Install the Power Interface Circuit Board

. . . . . . . . . . . . . . . . . . . 252

Balance Resistors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Remove the Balance Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Install the Balance Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

8 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Table of Contents

Current Sensors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Remove the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Install the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

LCL Filter Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Remove the LCL Filter Module from the Enclosure . . . . . . . . . 257

Install the LCL Filter Module in the Enclosure. . . . . . . . . . . . . . 262

AC Input Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Remove the AC Input Link Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . 263

Install the AC Input Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

LCL Filter Capacitor Assembly Replacement. . . . . . . . . . . . . . . . . . . 264

Remove the LCL Filter Capacitor Assembly . . . . . . . . . . . . . . . . 264

Install the LCL Filter Capacitor Assembly. . . . . . . . . . . . . . . . . . 267

AC Common Mode Filter Circuit Board Replacement. . . . . . . . . . 268

Remove the AC Common Mode Filter Circuit Board . . . . . . . 268

Install the AC Common Mode Circuit Board. . . . . . . . . . . . . . . 270

Current Sense Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 270

Remove the Current Sense Circuit Board. . . . . . . . . . . . . . . . . . . 271

Install the Current Sense Circuit Board . . . . . . . . . . . . . . . . . . . . 274

Power/LCL Filter Module Heatsink Fan Fuse Replacement . . . . . 275

Remove the Power/LCL Filter Module Heatsink Fan Fuse. . . 275

Install the Power/LCL Filter Module Heatsink Fan Fuse . . . . 276

Power/LCL Filter Module Heatsink Fan Assembly

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Remove the Power or LCL Filter Module Heatsink Fan

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Install the Power or LCL Filter Module Heatsink Fan

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Torque Accuracy Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . 277

Remove the Torque Accuracy Module . . . . . . . . . . . . . . . . . . . . . 277

Install the Torque Accuracy Module . . . . . . . . . . . . . . . . . . . . . . . 279

DC Bus Conditioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Remove the DC Bus Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . 279

Install the DC Bus Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Wire Entry/Exit Bay Components

Chapter 10

Wire Entry/Exit Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

IP54/IP21, 400 mm Wide Door Vent Filters Replacement . . . . . . 285

IP54/IP21, 800 mm Wide Door Vent Filters Replacement . . . . . . 285

IP54/IP21, 400/800 mm Wide Door Vent Fan and Filter

Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Remove the IP54/IP21, 400/800 mm Wide Door Vent Fan

and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Install the IP54/IP21, 400/800 mm Wide Door Vent Fan

and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Thermal Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Remove the Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Install the Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 9

Table of Contents

Chapter 11

Start Up After Repairs Before You Apply Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 291

Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Frames 7…15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

No-load DC Bus Voltage and Output Current Measurements . . . 298

Appendix A

System Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

10 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preface

This manual provides a recommended preventative maintenance schedule, major component test and hardware replacement procedures, and schematic diagrams for PowerFlex® 750-Series products with TotalFORCE™ control.

It is highly recommended that you obtain a copy of the PowerFlex Drives with TotalFORCE Control Programming Manual, publication 750-PM100 Programming Manual contains fault, alarm, and programming information that can help you troubleshoot drive errors and determine if repairs are necessary.

This manual is intended for qualified service personnel responsible for PowerFlex 750-Series products repairs. You must have previous experience with, and an understanding of, electrical terminology, procedures, required equipment, equipment protection procedures and methods, and safety precautions. See safety-related practices that are contained in publication NFPA 70E, Standard for Electrical Safety in the Work Place.

. The

Summary of Changes

Additional Resources

This manual contains new ad updated information

Top ic Pag e

Updated the steps to Remove Power from the System to include information for frames 5, 6, and 7. 15

Updated the Recommended Preventative Maintenance schedules to include the following information:

• Components and preventative maintenance parameters for frames 5, 6, and 7

• Preventative maintenance parameters for frames 13…15 components

Updated the Component Inspection and Test Procedures chapter to include information for frames 5, 6, and 7.

Added Chapter 4

Added Chapter 5 for frame 6 product parts replacement. 75

Added Chapter 6 for frame 7 product parts replacement. 97

Added procedures for frames 5, 6, and 7 to the Start Up After Repairs chapter. 291

Added schematic diagrams for frames 5, 6, and 7 products. 299

for frame 5 product parts replacement. 55

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

AC Drives Common Bus Application Techniques, publication

750-AT004

Drives in Common Bus Configurations with PowerFlex 755TM Bus Supplies Application Techniques, publication

DRIVES-AT005

PowerFlex 755T Flux Vector Tuning, publication 750-AT006

Provides basic information to properly wire and ground common bus PWM AC drives.

Provides basic information to properly wire and ground the following products in common bus applications:

• PowerFlex 755TM drive system for common bus solutions

• PowerFlex 750-Series AC and DC input drives

• Kinetix® 5700 servo drives

Provides guidance on how to tune Flux Vector position and velocity loops, filters, and other features to achieve the level of performance that is required for a given application. This publication is intended for novice drives users and users with advanced skills.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 11

Preface

Resource Description

PowerFlex 750-Series Products with TotalFORCE Control Installation Instructions, publication 750-IN100

PowerFlex 755TM AC Precharge Modules Unpacking and Lifting Instructions, publication 750-IN102

PowerFlex 755TM DC Precharge Modules Unpacking and Lifting Instructions, publication 750-IN103

PowerFlex 755TM Power and Filter Modules Unpacking and Lifting Instructions, publication 750-IN104

PowerFlex 750-Series Service Cart and DCPC Module Lift Installation Instructions, publication 750-IN105

PowerFlex 755TM Power and Filter Module Storage Hardware Installation Instructions, publication 750-IN106

PowerFlex 755T Module Service Ramp Instructions, publication 750-IN108

PowerFlex 750-Series I/O, Feedback, and Power Option Modules Installation, publication 750-IN111

PowerFlex 755T Frames 5 and 6 Conduit Box and Ground Plate Kits, Installation Instructions, publication 750-IN112

PowerFlex 755T Frames 5 and 6 Marine Discharge Kits, Installation Instructions, publication 750-IN114

PowerFlex Drives with TotalFORCE Control Programming Manual, publication 750-PM100

PowerFlex 750-Series Products with TotalFORCE Control Reference Manual, publication 750-RM100

PowerFlex 750-Series Products with TotalFORCE Control Technical Data, publication 750-TD100

PowerFlex 750-Series Safe Speed Monitor Option Module Safety Reference Manual, publication 750-RM001

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

PowerFlex 750-Series ATEX Option Module User Manual, publication 750-UM003

Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-AT003

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control, publication SGI-1.1

Product Certifications website, http://

www.rockwellautomation.com/global/certification/ overview.page

Provides the basic steps to install PowerFlex 755TL drives, PowerFlex 755TR drives, and PowerFlex 755TM bus supplies.

These publications provide detailed information on:

• Component weights

• Precautions and recommendations

• Hardware attachment points

• Lifting the component out of the packaging

Provides detailed set-up and operating instructions for the module service car t and lift extension option.

Provides detailed installation and usage instructions for this hardware a ccessory.

Provides detailed usage instructions for the module service ramp.

Provides instructions to install and wire 750-Series option modules.

Provides installation instructions for the field-installed frame 5 and 6 conduit box and ground plate option kits.

Provides installation instructions for the field-installed frame 5 and 6 marine discharge option kits.

Provides detailed information on:

• I/O, control, and feedback options

• Parameters and programming

• Faults, alarms, and troubleshooting

Provides detailed setup and programming instructions for common applications.

Provides detailed information on:

• Drive and bus supply specifications

• Option specifications

• Fuse and circuit breaker ratings

These publications provide detailed information on installation, set-up, and operation of the 750-Series safety option modules.

Provides basic information on enclosure systems, considerations to help protect against environmental contaminants, and power and grounding considerations for installing Pulse Width Modulated (PWM) AC drives.

Provides basic information to properly wire and ground PWM AC drives.

Provides general guidelines for installing a Rockwell Automation industrial system.

Provides general guidelines for the application, installation, and maintenance of solid-state control.

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

12 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 1

Before You Begin Tests, Maintenance, or Repairs

Top ic Pa ge

Product Ad visories 14

Remove Power from the System 15

Commonly Used Tools 22

Hardware Instal lation Diagrams 23

Fastener Torque Sequences 24

Read the information in this chapter before you begin tests, maintenance, or repairs on drive components.

IMPORTANT Once the product is connected to a power supply, always verify that system

power is not present before performing any work on the product. See safetyrelated practices that are contained in publication NFPA 70E, Standard for Electrical Safety in the Work Place.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 13

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

Product Advisories

Read the following precautions before you begin to test components, perform maintenance, or repair the drive.

Qualified Personnel

ATT EN TI ON : Only qualified personnel familiar with PowerFlex® 755T products

and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.

Personal Safety

ATT EN TI ON : To avoid an electric shock hazard, verify that the voltage on the

bus capacitors has discharged before servicing.

Frames 5 and 6: Measure the DC bus voltage at the power terminal block by measuring between the +DC and –DC terminals. Also, measure between the +DC terminal and the chassis, and between the –DC terminal and the chassis. The voltage must be zero for all three measurements. See Frames 5 and 6 in the Remove Power from the System section on page 15

Frames 7…15: Measure the DC bus voltage by measuring between the +DC and –DC testpoint sockets on the front of the power module. Also measure between the +DC testpoint and chassis GND, and the –DC testpoint and chassis GND. See Frames 7…15 in the Remove Power from the System section on page 17 locations.

for locations.

for

ATT EN TI ON : Potentially fatal voltages can result from improper usage of an oscilloscope and other test equipment. The oscilloscope chassis can be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high-voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope is used in the A minus B Quasi-differential mode and the oscilloscope chassis is grounded to an earth ground.

Product Safety

ATT EN TI ON : This drive contains ESD (Electrostatic Discharge) sensitive parts

and assemblies. Static control precautions are required when you install, test, service, or repair this assembly. Component damage can result if ESD control procedures are not followed.

Class 1 Light-emitting Diode Product

ATT EN TI ON : Hazard of permanent eye damage exists when using optical

transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber-optic cable connectors.

14 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Before You Begin Tests, Maintenance, or Repairs Chapter 1

Remove Power from the System

Follow the appropriate procedures to remove power from the dive system. Instructions for frames 7…15 begin on page 17

Frames 5 and 6

The following procedures must be followed before attempting to service any part of a frame 5 and 6 drive or frame 6 bus supply.

WARNING: Remove power before you remove or make cable connections. When you remove or insert a cable connector with power applied, an electric arc can occur. An electric arc can cause personal injury or property damage in theses ways:

• An electric arc can send an erroneous signal to system field devices, which can cause unintended machine motion

• An electric arc can cause an explosion in a hazardous environment

Electric arcs cause excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance.

1. Turn off and lockout all input power, including any external power sources.

2. Wait 15 minutes.

3. For frame 5 drives, if the conduit box is present, remove the M6 x 12 mm

torx screw that secures the conduit box cover to the chassis and remove the cover.

4. For frame 6 drives or bus supplies, complete these steps: a. Remove the cover. See Remove the Cover from the Chassis on page 76 b. If the conduit box is present, loosen the four M6 captive torx screws

that secure the cover to the conduit box and remove the cover.

5. Measure the AC input and DC bus voltage to verify that there is no voltage present (see Figure 1 on page 16

• Measure the AC input terminals R/L1, S/L2, and T/L3, L to L and L

to chassis GND (PE).

• Measure the DC output terminals DC+ and DC–, DC+ to DC–,

DC+ to chassis GND (PE), and DC– to chassis GND (PE).

for terminal identification):

on page 16 for terminal locations and Ta b l e 1

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 15

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

21 543

Frame 5 (Shown with Cover Removed for Clarity Only) Frame 6

1 2 3 4 5

Figure 1 - Frame 5 and 6 Drives

Table 1 - Frame 5 and 6 Terminal Identification

Item Name Description Item Name Description

1 PE grounding stud Termination point to chassis ground for AC line

2 R/L1, S/L2, T/L3 AC line input power terminals 5 PE grounding stud Termination point to chassis ground for motor shield

3 DC+, DC– DC bus terminals — — —

16 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

shield

4 U/T1, V/T2, W/T3 AC output motor terminals

Before You Begin Tests, Maintenance, or Repairs Chapter 1

Frames 7…15

The following procedures must be followed before attempting to service any part of the drive system.

• An electric arc can send an erroneous signal to system field devices, which can cause unintended machine motion

• An electric arc can cause an explosion in a hazardous environment

Electric arcs cause excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance.

1. Turn off and lockout all input power, including any external power sources (such as an Active Front End or other DC power source).

ATT EN TI ON : To avoid an electric shock hazard when servicing the drive, a means for lockout/tagout of the external, single-phase 120/240V power source and, if present, external 120V uninterruptible power supply source, must be provided.

2. If present, turn off and lockout any external, single-phase 120/240V power source.

3. For regenerative drives and bus supplies, complete steps a…e. a. On the input bay, turn the AC precharge disconnect switch to the

“Off ” position. b. Wait 15 minutes. c. Open the enclosure door. d. Close and lock the hasp on the circuit breaker. e. Lock the fused disconnect switch.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 17

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

Frame 9, IP21 UL Type 1 Input Bay Shown

4. For common bus inverters with DC precharge, complete steps a…e: a. Turn the DC precharge disconnect switch to the “Off” position. a. Wait 15 minutes. b. Open the enclosure door. c. Close and lock the hasp on the molded case switch. d. Lock the fused disconnect switch. e. If a control bay is used, turn the selector switch to the “Off” position

and lock the switch.

ATT EN TI ON : To avoid an electric shock hazard, verify that there is no AC input and DC bus voltage before servicing by taking these measurements:

• Verify that there is no AC input voltage present using the R/L1, S/L2, and T/L3 test point sockets in the input bay by measuring L to L and L to GND.

• Verify that there is no AC input voltage present using the R, S, and T testpoint sockets in the input bay by measuring L to L and L to GND.

• Verify that there is no DC bus voltage present using the +DC to –DC testpoints in the input bay by measuring +DC to –DC, +DC to GND, and –DC to GND.

5. For regenerative drives and bus supplies, measure the AC input and DC bus voltage at the following testpoint sockets in the input bay to verify that there is no voltage present:

• Using the circuit breaker output (CB1 SEC) testpoints R/L1, S/L2,

and T/L3, measure L to L and L to chassis GND.

• By using the fused disconnect output (FD1 SEC) testpoints R, S, and

T, measure L to L and L to chassis GND.

• By using the DC bus testpoints +DC and –DC, measure +DC to

–DC, +DC to chassis GND, and –DC to chassis GND.

18 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Before You Begin Tests, Maintenance, or Repairs Chapter 1

Frames 8…15 Power Module

ATT EN TI ON : To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. Verify that there is no DC bus voltage present using the +DC to –DC testpoints on all power modules by measuring +DC to –DC, +DC to GND, and –DC to GND.

6. For common bus inverters, by using the DC bus testpoints +DC and –DC on the front of the power modules, measure the DC bus voltage of all power modules and verify that there is no voltage present on the bus capacitors. Measure +DC to –DC, +DC to chassis GND, and –DC to chassis GND.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 19

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

AC Precharge Circuit Breaker

Frame 10 Input Bay Shown AC Precharge Circuit Breaker

7. Measure the 240V AC control voltage at the appropriate terminals:

• For frame 7 drives and bus supplies, measure terminals L and N on

terminal block TB3.

• For frames 8…15 drives and bus supplies, in the input bay, measure

terminals L and N on terminal block TB2.

20 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Before You Begin Tests, Maintenance, or Repairs Chapter 1

• For control bays, measure terminal L at FH2-2 and terminal N at

terminal block TB4.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 21

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

Commonly Used Tools

Ta b l e 2 includes the tools that are needed for test measurements, basic

maintenance, and service repairs.

IMPORTANT Care must be taken to be sure that tools and/or hardware components do not

fall into open drive assemblies. Do not energize the drive unless all loose tools and/or hardware components have been removed from the drive assemblies and enclosure.

Table 2 - Service Tools

Tool Description Details

Allen socket wrench 3 mm

Box wrench 7 mm, 8 mm, 10 mm, 13 mm, 15 mm, 17 mm, 19 mm, 22 mm

Crimp tools For cable terminals 1.5...240

Current clamp 1000 A (AC, rms), signal output

ESD-protected place of work Work surface, Floor cover, seat, and ground connections

ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)

Flash light –

Flat-nose screwdriver 3 mm (0.12 in.), 5 mm (0.19 in.), 6.4 mm (0.25 in.)

Torx, star, or hexalobular screw driver/bit

Hexagonal socket wrench 2.5 mm, 7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 17 mm, 18 mm

Insulation tester 1000V DC

Level –

Lift strap 5/16 in. J-hook style, 24 in. long, 1000 lb. Minimum

Multi-meter Digital multi-meter, capable of AC and DC voltage, continuity, resistance,

Nose pliers –

Oscilloscope Portable, digitizing, dual channel scope, with isolation

Phillips screwdriver/bit #1, #2

Module service cart The optional module service cart (20-750-MCART1) is recommended to handle

Module storage hardware Module storage hardware (20-750-MINV-ATIP) helps to stabilize power and filter

Torque wrench 1...12 N

Torque wrench 6...50 N

Wire c utter –

#15, #20, #25, #30, #40, #45

capacitance measurements, and forward diode bias tests. Fluke model 87 III or equivalent.

and transport power and filter modules.

modules during temporary storage after removal.

•m (8.8…106 lb•in)

•m (53…443 lb•in)

Software Tools

Connected Components Workbench™ software is an application that can be used to upload and download parameter configuration and monitor system parameters. Connected Components Workbench version 10.xx or later is required for use with PowerFlex 755T products.

22 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Before You Begin Tests, Maintenance, or Repairs Chapter 1

Fastener Type

Flat-head screw

Hexagonal bolt

Hexagonal nut or standoff

Hexagonal screw

Tor x s cre w

Phillips screw

Pozid riv scre w

Slotted tor x screw

Sequence Number

M4 x 10 mm T20 or F - 6.4 mm (0.25 in.)

4.8 N

•m (42 lb•in)

Tool Type and Size

FFlat-nose screwdriver Px Phillips screwdriver/bit and size PZx Pozidriv screwdriver/bit and size Txx Torx screwdriver/bit and size xx mm Hexagonal socket wrench

Final Assembly Torque

Fastener Size

Hardware Installation Diagrams

The disassembly illustrations throughout this manual contain diagrams (as shown here) that identify the following: corresponding sequence number (if necessary), type of fastener, fastener size, tool type and size, and final assembly torque.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 23

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

Initial Sequence

Final Sequence

3 4

Initial Sequence

234

Final Sequence

Fastener Torque Sequences

The following illustrates initial and final tightening sequences for components that are fastened to a heat sink by using two, four, and six screws. Initial torque is 1/3 (33%) of final torque, except six-point mountings, which require 0.7 N (6 lb Drive components do not contain these labels.

Figure 2 - Two-point Mounting

ATT EN TI ON : When mounting components to a drive heat sink, component

fastener torque sequences and tolerances are crucial to component-to-heat sink heat dissipation.

Components can be damaged if initial tightening procedure is not performed to specification.

•m

•in) initial torque. The numeric illustration labels are for your assistance.

Figure 3 - Four-point Mounting

24 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Figure 4 - Six-point Mounting

6 42

3 51

3 4

Initial Sequence

1 2 65

Final Sequence

3 41 2 65

Do not exceed 0.7 N•m (6 lb•in) on initial torque of all six screws.

Before You Begin Tests, Maintenance, or Repairs Chapter 1

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 25

Chapter 1 Be fo re You B eg in Tes ts , M ai nt en an ce , or Re pa ir s

Notes:

26 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 2

Preventative Maintenance

Top ic Pag e

Recommended Preventative Maintenance 27

Predictive Maintenance 28

Schedule Codes Explanation 28

Shock Events 41

Maintenance of Industrial Control Equipment 42

This chapter provides information on preventative maintenance for components that can affect the life and operational characteristics of PowerFlex® 750-Series products with TotalFORCE® Control.

Recommended Preventative Maintenance

Rockwell Automation recognizes that following a defined maintenance schedule delivers the maximum product availability. By strictly following the maintenance schedule of tasks that is provided for your operating environment, you can expect the highest possible uptime. A maintenance schedule is provided for each of these environments:

• Ta b l e 3

• Ta b l e 4

• Ta b l e 5

IMPORTANT Duty cycle and load profile can greatly affect the reliability of PowerFlex

Recommended Maintenance Schedule for Normal Operation on page 29 ambient temperature is less than or equal to 40 °C (104 °F).

Operation on page 33 environment where the ambient temperature is above 41 °C (106 °F).

Operation on page 37 reactivity level greater than 1000 angstroms per 30 days exposure. No condensation allowed. Maximum allowable humidity is 60% in the presence of corrosive gases. See ISA-71.04-2013 for details on how to measure reactivity levels on copper and silver test coupons.

. Normal operation is defined as an environment where the

Recommended Maintenance Schedule for High Temperature

. High temperature operation is defined as an

Recommended Maintenance Schedule for Harsh Environment

. Harsh environment is defined as a copper or silver

750-Series Products with TotalFORCE Control.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 27

Chapter 2 Preventative Maintenance

An annual preventative maintenance program includes the following primary tasks:

• A visual inspection of all components accessible from the front of the Module

• Resistance checks on the power components

• Power-supply voltage level checks

• General cleaning and maintenance

• Tightness checks on all accessible power connections

Predictive Maintenance

Schedule Codes Explanation

See Chapter 3 - Component Inspection and Test Procedures on page 45

for

additional information on how to perform inspections and tests.

PowerFlex 750-Series Products with TotalFORCE Control contain algorithms for predictive maintenance that are used to improve the “uptime” of machines, processes, and facilities. These algorithms monitor the lifespan of certain components and display the calculated value in specific parameters. These algorithms can be used to alert personnel when the components are nearing the end of their lifespan so the components can be replaced before they fail. The shaded rows in Ta b l e 3

…Ta b l e 5 on pages 29…37, respectively, identify the components with predictive maintenance parameters. Use the predictive maintenance parameters to determine a replacement schedule for the applicable components. See Predictive Maintenance in the PowerFlex 750-Series Products with TotalFORCE Control Reference Manual, publication 750-RM100

, for

more information.

IMPORTANT Failure to address predictive maintenance alarms can cause unexpected

downtime or premature product failure.

The codes that are listed in this table are used to identify the task that is associated with the components that are identified in the tables on pages 29

Code Task Description

I Inspect Inspect the component for signs of excessive accumulation of dust, dirt, or external

damage. For example, inspect the filters/fan inlet screens for debris that can block the airflow path.

C Clean Clean the components that can be reused, specifically the door-mounted air filters

and fan inlet screens.

M Maintain This type of maintenance task can include an inductance test of line reactors/DC

links, or a full test of an isolation transformer, and so on.

R Replace This component has reached its mean operational life. Replace the component to

decrease the chance of failure. It is likely that components can exceed the designed life in the drive, but component life is dependent on many factors such as usage and heat.

Use the predictive maintenance parameters to determine a replacement schedule for components in shaded table rows.

Rv Review A discussion with Rockwell Automation personnel is recommended to help

determine whether any of the enhancements/changes made to the drive hardware and control could benefit the application.

…37.

28 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

I I I I I I I I I I I I I I I I I I I I

Maintenance

Parameters

Grease Power Stabs -

Frames 8… 15 onlyRBalance Resistors -

Frames 8… 15 only

Power Mod ules,

Years > 01234567891011121314151617181920

Table 3 - Recommended Maintenance Schedule for Normal Operation

Module/Activity Component Predictive

Frames 7…15

340, 440, 540, 640,

740, 840, 940, 1040

Port 12 /14: 143, 243,

343, 443, 543, 643,

743, 843, 943, 1043

(cat. no. SK-RM-INVBRn-F8M)

IGBTs Port 12 /14: 140, 240,

Bus Capacitors (cat. no.

SK-RM-ICP1-xnnnxnnn)

Power Laye r Interf ace Circuit Board

(cat. no. SK-RM-PLI1-F7,

SK-RM-PLI1-F8)RPower Interface Circuit Board

(cat. no. SK-RM-PIBn-xnnnxnnn,

SK-RM-PIB4-xnnnxnnn)RGate Driver Circuit Board -

Frames 8… 15 onlyRHeat Sink Fan (cat. no.

Port 12 /14: 136, 236,

336, 436, 536, 636,

736, 836, 936, 1036

IGBTs Port 12 /14: 140

Power Feedbac k Circuit B oard

SK-RM-INVFAN1-F8,

SK-RM-MFAN-F7)

(cat. no. SK-RM-PFB-F5-F6)RFan Power Supply Circuit Board

Power Components,

Frames 5 and 6

(cat.no. SK-RM-PSB1-F5-F6)RStirring Fan - Frames 5 and 6 (cat.

Port 14: 128 I I I I I I I I I I I I I I I I I I I I

no.

SK-RM-MFAN1-F5,

SK-RM-MFAN1-F6)

I I I I I I I I I I I I I I I I I I I I

Port 14: 136

Heat Sink Fan (cat. no.

SK-RM-HSFAN1-F5,

SK-RM-HSFAN1-F6)

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 29

Chapter 2 Preventative Maintenance

R R

I I I I I I I I I I I I I I I I I I I I

Port 14: 1250, 1450,

1550, 1650, 1750,

Maintenance

Parameters

Grease Power Stabs -

Frames 8… 15 onlyRCapacitors

LCL Filter Modules,

Years > 01234567891011121314151617181920

Table 3 - Recommended Maintenance Schedule for Normal Operation (Continued)

Module/Activity Component Predictive

Frames 7…15

1850, 1950, 2150

(cat. no. SK-RM-LCLCPn-F8M)

Current Sense Circuit Board

(cat. no. SK-RM-CSB1-nnn,

SK-RM-CSB-F7)RAC Common Mode Filter Board -

Frames 8… 15 only

(cat. no. SK-RM-EMCFB1)

Port 14: 1246, 1346,

Heat Sink Fan (cat. no.

1546, 1646, 1746,

SK-RM-INVFAN1-F8,

1846, 1946, 2146

Port 14: 1250 R R

SK-RM-MFAN-F7)

LCL Filter Capacitor (cat. no.

SK-RM-LCLCP4-F5,

SK-RM-LCLCP6-F5,

SK-RM-LCLCP4-F6,

SK-RM-LCLCP6-F6)

Main Circuit Breaker (CB1) Port 14: 1143, 1153

Time Delay Relay (cat. no.

20-750-MACPC-TDR)

AC Precharge Circuit Board (c at. no.

20-750-MACPC1-xx,

LCL Fi lter

Components, Frames

5 and 6

AC Precharge Module,

20-750-MACPC1-xx-F7M)RPrecharge Contactor (M1) Port 14: 1146, 1156

Frames 7…15

Grease Power Stabs R

DC Precharge Module,

DC Prech arge Circuit B oard

Frames 8…15

(cat. no. SK-RM-DCPC1-xx)RMolded Case Switch (CB1) Port 12: 145, 245, 345,

445, 545, 645, 745,

845, 945, 1045

30 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

I I I I I I I I I I I I I I I I I I I I

C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R

Maintenance

Parameters

Door-mounted Ventilation Air

Filters

(1)

Cabinet (IP21/IP54),

Years > 01234567891011121314151617181920

Table 3 - Recommended Maintenance Schedule for Normal Operation (Continued)

Module/Activity Component Predictive

Frames 7…15

Port 0: 523

Roof-mounted Ventilation

Assembly Air Filters

Input Bay Fans -

Frames 8… 15 only

I I I I I I I I I I I I I I I I I I I I

Port 0: 543

Port 0: 553 I I I I I I I I I I I I I I I I I I I I

Power Bay IP54 Roof Fan Port 0: 533 I I I I I I I I I I I I I I I I I I I I

Wiri ng Bay Fa n -

Frames 8… 15 only

Control Bay Roof Fan -

Frames 8… 15 only

Isolation Transformer/Line Reactor M M M M

I I I I I I I I I I I I I I I I I I I I

Port 0: 513

DC Link/Common-Mode Choke M M M M

Frames 7… 15

(cat. no. SK-RM-PODFAN1-F8,

SK-RM-PODFAN-F7)

Main Co ntrol Circuit Board

(cat. no. SK-RM-MCB1-PF755)RDual Transceiver Circuit Board -

Frames 7… 15

(cat. no. 20-750-MFTB1-F8)

Fiber Interface Circuit Board -

Frames 7… 15

(cat. no. SK-RM-FIBn-F8)RBackplane Circuit Board

(cat. no. SK-RM-PODBP1)RFiber-optic Cables IIIIRIIIIRIIIIRIIIIR

Control Pod Assembly Control Pod Cooling Fan -

Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 31

Chapter 2 Preventative Maintenance

Maintenance

Parameters

Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Variables I IRvI IRvI IRvI IRvI IRvI IRvI I

Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Operational

Years > 01234567891011121314151617181920

Table 3 - Recommended Maintenance Schedule for Normal Operation (Continued)

Module/Activity Component Predictive

Conditions

Spare Parts Inventory/Needs I IRvI IRvI IRvI IRvI IRvI IRvI I

(1) There are multiple catalog numbers for the various cabinet roof and door vent filters and fans. See the applicable chapter for a list of the applicable catalog numbers.

32 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

RRR

340, 440, 540, 640,

Maintenance

Parameter (s)

740, 840, 940, 1040

Port 12 /14: 143, 243,

343, 443, 543, 643,

743, 843, 943, 1043

I I I I I I I I I I I I I I I I I I I I

Port 12 /14: 136, 236,

336, 436, 536, 636,

736, 836, 936, 1036

I I I I I I I I I I I I I I I I I I I I

Port 14: 128 I I I I I I I I I I I I I I I I I I I I

Port 14: 136

Table 4 - Recommended Maintenance Schedule for High Temperature Operation

Years > 0 1 2 3 4 5 6 7 8 9 1011121314151617181920

Grease Power Stabs -

Frames 8…15 only

Balance Resistors -

Module/Activity Component Predic tive

Power Mod ule,

Frames 7…15

IGBTs Port 12 /14: 140, 240,

Frames 8…15 only

(cat. no. SK-RM-INVBRn-F8M)

Bus Capacitors (cat. no.

SK-RM-ICP1-xnnnxnnn)

Power Layer Inte rface Circuit Board

(cat. no. SK-RM-PLI1-F7,

SK-RM-PLI1-F8)

Power Interf ace Circ uit Bo ard

(cat. no. SK-RM-PIBn-xnnnxnnn,

SK-RM-PIB4-xnnnxnnn)

Gate Driver Circuit Board -

Frames 8…15 only

Heat Sink Fan (cat. no.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 33

IGBTs Port 12 /14: 140

Power Feedbac k Circuit B oard

(cat. no. SK-RM-PFB-F5-F6)

Fan Power Supply Circuit Board

(cat.no. SK-RM-PSB1-F5-F6)

Stirring Fan - Frames 5 and 6 (cat.

no.

SK-RM-MFAN1-F5,

SK-RM-MFAN1-F6)

Heat Sink Fan (cat. no.

SK-RM-HSFAN1-F5,

SK-RM-INVFAN1-F8,

SK-RM-MFAN-F7)

Power Components,

Frames 5 and 6

SK-RM-HSFAN1-F6)

Chapter 2 Preventative Maintenance

RRR

Maintenance

Parameter (s)

Port 14: 1250, 1450,

1550, 1650, 1750,

1850, 1950, 2150

I I I I I I I I I I I I I I I I I I I I

Port 14: 1246, 1346,

1546, 1646, 1746,

1846, 1946, 2146

Port 14: 1250 R R R

445, 545, 645, 745,

845, 945, 1045

Grease Power Stabs -

Frames 8…15 only

Capacitors

(cat. no. SK-RM-LCLCPn-F8M)

Current Sense Circuit Board

(cat. no. SK-RM-CSB1-nnn,

SK-RM-CSB-F7)

AC Common Mode Filter Board -

Frames 8…15 only

(cat. no. SK-RM-EMCFB1)

Heat Sink Fan (cat. no.

SK-RM-INVFAN1-F8,

SK-RM-MFAN-F7)

LCL Filter Capacitor (cat. no.

SK-RM-LCLCP4-F5,

SK-RM-LCLCP6-F5,

SK-RM-LCLCP4-F6,

SK-RM-LCLCP6-F6)

Main Circuit Breaker (CB1) Port 14: 1143, 1153

Time Delay Relay (cat. no.

20-750-MACPC-TDR)

LCL Filter Modules,

Years > 0 1 2 3 4 5 6 7 8 9 1011121314151617181920

Table 4 - Recommended Maintenance Schedule for High Temperature Operation (Continued)

34 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Module/Activity Component Predic tive

Frames 7…15

LCL Fi lter

Components, Frames

5 and 6

AC Precharge Module,

Frames 7…15

AC Precharge Circuit Board (cat. no.

20-750-MACPC1-xx,

20-750-MACPC1-xx-F7M)

Precharge Contactor (M1) Port 14: 1146, 1156

Grease Power Stabs R R

DC Precharge Circuit Board

(cat. no. SK-RM-DCPC1-xx)

Molded Case Switch (CB1) Port 12: 145, 245, 345,

DC Precharge Module,

Frames 8…15

Preventative Maintenance Chapter 2

Table 4 - Recommended Maintenance Schedule for High Temperature Operation (Continued)

Years > 0 1 2 3 4 5 6 7 8 9 1011121314151617181920

Module/Activity Component Predic tive

Maintenance

Parameter (s)

C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R

Door-mounted Ventilation Air

Cabinet (IP21/IP54),

Filters

(1)

Frames 7…15

C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R

Roof-mounted Ventilation

I I I I I I I I I I I I I I I I I I I I

Port 0: 523

Assembly Air Filters

Input Bay Fans -

Frames 8…15 only

I I I I I I I I I I I I I I I I I I I I

Port 0: 543

Port 0: 553 I I I I I I I I I I I I I I I I I I I I

Power Bay IP54 Roof Fan Port 0: 533 I I I I I I I I I I I I I I I I I I I I

Wiring B ay Fan -

Frames 8…15 only

Control Bay Roo f Fan -

Frames 8…15 only

Isolation Transformer/Line Reactor M M M M

I I I I I I I I I I I I I I I I I I I I

Port 0: 513

DC Link/Common-Mode Choke M M M M

Frames 7…15

(cat. no. SK-RM-PODFAN1-F8,

SK-RM-PODFAN-F7)

Main Control Circuit B oard

(cat. no. SK-RM-MCB1-PF755)

Dual Transceiver Circuit Board -

Frames 7…15

(cat. no. 20-750-MFTB1-F8)

Fiber Interface Circuit Board -

Frames 7…15

(cat. no. SK-RM-FIBn-F8)

Backplane Circuit Board

(cat. no. SK-RM-PODBP1)

Fiber-optic Cables IIIRIIIRIIIRIIIRIIIR

Control Pod Assembly Cont rol Pod Cooling Fan -

Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 35

Chapter 2 Preventative Maintenance

Maintenance

Parameter (s)

Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Variables I IRvI IRvI IRvI IRvI IRvI IRvI I

Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Operational

Table 4 - Recommended Maintenance Schedule for High Temperature Operation (Continued)

Years > 0 1 2 3 4 5 6 7 8 9 1011121314151617181920

Module/Activity Component Predic tive

Conditions

Spare Parts Inventory/Needs I IRvI IRvI IRvI IRvI IRvI IRvI I

(1) There are multiple catalog numbers for the various cabinet roof and door vent filters and fans. See the applicable chapter for a list of the applicable catalog numbers.

36 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

RRRRR

Maintenance

Parameter (s)

Grease Power Stabs -

Frames 8…15 only

RRRRR

340, 440, 540, 640,

740, 840, 940, 1040

Balance Resistors -

Frames 8…15 only

(cat. no. SK-RM-INVBRn-F8M)

IGBTs Port 12 /14: 140, 240,

RRRRR

Port 12 /14: 143, 243,

343, 443, 543, 643,

743, 843, 943, 1043

Bus Capacitors (cat. no.

SK-RM-ICP1-xnnnxnnn)

Power Layer Inte rface Circuit Board

RRRRR

(cat. no. SK-RM-PLI1-F7,

SK-RM-PLI1-F8)

Power Interf ace Circ uit Bo ard

(cat. no. SK-RM-PIBn-xnnnxnnn,

SK-RM-PIB4-xnnnxnnn)

RRRRR

I I I I I I I I I I I I I I I I I I I I

Port 12 /14: 136, 236,

336, 436, 536, 636,

736, 836, 936, 1036

Gate Driver Circuit Board -

Frames 8…15 only

Heat Sink Fan (cat. no.

SK-RM-INVFAN1-F8,

SK-RM-MFAN-F7)

RRRRR

IGBTs Port 12 /14: 140

Power Feedbac k Circuit B oard

(cat. no. SK-RM-PFB-F5-F6)

Fan Power Supply Circuit Board

(cat.no. SK-RM-PSB1-F5-F6)

I I I I I I I I I I I I I I I I I I I I

Port 14: 128 I I I I I I I I I I I I I I I I I I I I

Stirring Fan - Frames 5 and 6 (cat.

no.

Port 14: 136

SK-RM-MFAN1-F5,

SK-RM-MFAN1-F6)

Heat Sink Fan (cat. no.

SK-RM-HSFAN1-F5,

SK-RM-HSFAN1-F6)

Years > 01234567891011121314151617181920

Table 5 - Recommended Maintenance Schedule for Harsh Environment Operation

Module/Activity Component Predic tive

Power Mod ule,

Frames 7…15

Power Components,

Frames 5 and 6

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 37

Chapter 2 Preventative Maintenance

RRRRR

Maintenance

Parameter (s)

Grease Power Stabs -

Frames 8…15 only

RRRRR

Port 14: 1250, 1450,

Capacitors

RRRRR

1550, 1650, 1750,

1850, 1950, 2150

(cat. no. SK-RM-LCLCPn-F8M)

Current Sense Circuit Board

(cat. no. SK-RM-CSB1-nnn,

SK-RM-CSB-F7)

RRRRR

AC Common Mode Filter Board -

Frames 8…15 only

(cat. no. SK-RM-EMCFB1)

I I I I I I I I I I I I I I I I I I I I

Port 14: 1246, 1346,

Heat Sink Fan (cat. no.

RRRRR

1546, 1646, 1746,

1846, 1946, 2146

Port 14: 1250 R R R R R

SK-RM-INVFAN1-F8,

SK-RM-MFAN-F7)

LCL Filter Capacitor (cat. no.

SK-RM-LCLCP4-F5,

SK-RM-LCLCP6-F5,

Main Circuit Breaker Port 14: 1143, 1153

SK-RM-LCLCP4-F6,

SK-RM-LCLCP6-F6)

Time Delay Relay

(cat. no. 20-750-MACPC-TDR)

AC Precharge Circui t Board (cat. no.

20-750-MACPC1-xx,

20-750-MACPC1-xx-F7M)

Precharge Contactor (M1) Port 14: 1146, 1156

RRRRR

445, 545, 645, 745,

845, 945, 1045

Grease Power Stabs RRRRR

DC Precharge Circuit Board

(cat. no. SK-RM-DCPC1-xx)

Molded Case Switch (CB1) Port 12: 145, 245, 345,

AC Precharge Module,

LCL Filter Modules,

Years > 01234567891011121314151617181920

Table 5 - Recommended Maintenance Schedule for Harsh Environment Operation (Continued)

38 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Module/Activity Component Predic tive

Frames 7…15

LCL Fi lter

Components, Frames

5 and 6

Frames 7…15

DC Precharge Module,

Frames 8…15

Preventative Maintenance Chapter 2

Maintenance

Parameter (s)

C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R

Door-mounted Ventilation Air

RRRRR

I I I I I I I I I I I I I I I I I I I I

RRRRR

C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R

Port 0: 523

Filters

Roof-mounted Ventilation

Assembly Air Filters

Input Bay Fans -

Frames 8…15 only

Port 0: 543

Port 0: 553 I I I I I I I I I I I I I I I I I I I I

Power Bay IP54 Roof Fan Port 0: 533 I I I I I I I I I I I I I I I I I I I I

Wiring B ay Fan -

Frames 8…15 only

Control Bay Roo f Fan -

Frames 8…15 only

Isolation Transformer/Line Reactor M M M R

Port 0: 513

DC Link/Common-Mode Choke M M M R

Frames 7…15

(cat. no. SK-RM-PODFAN1-F8,

SK-RM-PODFAN-F7)

Main Control Circuit B oard

(cat. no. SK-RM-MCB1-PF755)

Dual Transceiver Circuit Board -

Frames 7…15

(cat. no. 20-750-MFTB1-F8)

Fiber Interface Circuit Board -

Frames 7…15

(cat. no. SK-RM-FIBn-F8)

Backplane Circuit Board

(cat. no. SK-RM-PODBP1)

Fiber-optic Cables IRIR IRIRIRIRIRIRIRIR

Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Table 5 - Recommended Maintenance Schedule for Harsh Environment Operation (Continued)

Years > 01234567891011121314151617181920

(1)

Cabinet (IP21/IP54),

Module/Activity Component Predic tive

Frames 7…15

Control Pod Assembly Cont rol Pod Cooling Fan -

Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 39

Chapter 2 Preventative Maintenance

Maintenance

Parameter (s)

Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Variables I IRvI IRvI IRvI IRvI IRvI IRvI I

Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I

Operational

Table 5 - Recommended Maintenance Schedule for Harsh Environment Operation (Continued)

Years > 01234567891011121314151617181920

Module/Activity Component Predic tive

Conditions

Spare Parts Inventory/Needs I IRvI IRvI IRvI IRvI IRvI IRvI I

(1) There are multiple catalog numbers for the various cabinet roof and door vent filters and fans. See the applicable chapter for a list of the applicable catalog numbers.

40 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

1.00 10.00 100.00 1000.00

Peak Amplitude (G

peak

)

Maximum number of shock events

Shock Events

PowerFlex 755T products can withstand a finite number of shock events. The maximum allowable number of shock events increases as the peak amplitude decreases. Below 0.7 g peak, the maximum total shock events should not exceed 2000 cycles.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 41

Chapter 2 Preventative Maintenance

Maintenance of Industrial Control Equipment

ATT EN TI ON : Performing service on energized Industrial Control Equipment can

be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present. See National Fire Protection Association Standard No. NFPA 70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (lockout/tagout) and OSHA Electrical Safety Related Work Practices for safety-related work practices. These publications include procedural requirements for lockout/tagout, and appropriate work practices, personnel qualifications, and required training where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.

Periodic Inspection - Periodically inspect industrial control equipment. Base inspection intervals on the environmental and operating conditions and adjust the intervals as necessary. An initial inspection within 3 to 4 months after installation is suggested. See National Electrical Manufacturers Association NEMA) Standard No. ICS 1.3, Preventive Maintenance of Industrial Control and Systems Equipment, for general guidelines for defining a periodic maintenance program. Some specific guidelines for Rockwell Automation products are listed here.

Contamination - If inspection reveals that dust, dirt, moisture, or other contamination has reached the control equipment, the cause must be removed. Contamination can indicate an incorrectly selected or ineffective enclosure, unsealed enclosure openings (conduit or other), or incorrect operating procedures. Replace any improperly selected enclosure with one that is suitable for the environmental conditions. See the Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-AT003 guidance on environmental considerations. See NEMA Standard No. 250, Enclosures for Electrical Equipment, or UL 50E Electrical Equipment Enclosures, for enclosure type descriptions and test criteria. Replace any damaged or cracked elastomer seals and repair or replace any other damaged or malfunctioning parts (for example, hinges and fasteners). Dirty, wet, or contaminated control devices must be replaced. Compressed air is not recommended for cleaning because it can displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.

Blowers and Fans - Inspect blowers and fans that are used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. Apply power momentarily to check operation. If the unit does not operate, check and replace wiring, fuse, or blower or fan motor as appropriate. Clean or change air filters as recommended in the product manual. Also, clean the fins of heat exchangers so convection cooling is not impaired.

, for

Operating Mechanisms - Check for proper function and freedom from sticking or binding. Replace any broken, deformed, or badly worn parts or assemblies according to individual product renewal-parts lists. Check for and re-tighten securely any loose fasteners. Lubricate if specified in individual product

42 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Preventative Maintenance Chapter 2

instructions. Note: Allen-Bradley® magnetic starters, contactors, and relays are designed to operate without lubrication. Do not lubricate these Allen-Bradley devices because oil or grease on the pole faces (mated surfaces) of the operating magnet can cause the device to stick in the “ON” mode. Some parts of other devices are factory lubricated – if lubrication during use or maintenance of these devices is needed, it is specified in their individual instructions. If in doubt, consult your nearest Rockwell Automation sales office for information.

Contacts - Check contacts for excessive wear and dirt accumulation. Wipe contacts with a soft cloth, if necessary, to remove dirt. Discoloration and slight pitting does not harm contacts. Do not file contacts - this action shortens the life of the contact. Do not use contact spray cleaners because residue on magnet pole faces or in operating mechanisms can cause sticking, and on contacts can interfere with electrical continuity. Replace contacts only after the silver has become badly worn. Always replace contacts in complete sets to avoid misalignment and uneven contact pressure.

Te r m i n a l s - Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure. Loose connections in control circuits can cause control malfunctions. Loose bond or ground connections can increase hazards of electrical shock and contribute to electromagnetic interference (EMI). Check the tightness of all terminals and bus bar connections and torque any loose connections properly. Infrared technology can be used to check for hot (high resistance/loose) connections during periodic maintenance. Replace any parts or wiring that is damaged by overheating, and any broken wires or bond straps.

Coils - If a coil is overheated (contains cracked, melted, or burned insulation), it must be replaced. In that event, check for and correct overvoltage or undervoltage conditions, which can cause coil failure. Be sure to clean any residues of melted coil insulation from other parts of the device or replace such parts.

Pilot Lights - Replace any burned out lamps or damaged lenses. Photoelectric Switches-The lenses of photoelectric switches require periodic cleaning with a soft dry cloth. Reflective devices that are used with photoelectric switches also require periodic cleaning. Do not use solvents or detergents on the lenses or reflectors. Replace any damaged lenses and reflectors.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 43

Chapter 2 Preventative Maintenance

Solid-state Devices

ATT EN TI ON : Use of other than factory-recommended test equipment for solid-

state controls can result in damage to the control or test equipment or unintended actuation of the controlled equipment. See paragraph titled HIGH VOLTAGE TESTING.

Solid-state devices require little more than a periodic visual inspection. Discolored, charred, or burned components can indicate the need to replace the component or circuit board. Make necessary replacements only at the circuit board or plug-in component level. Inspect printed circuit boards to determine whether they are properly seated in the edge board connectors. Board locking tabs must also be in place. Solid-state devices must also be protected from contamination, and temperature control provisions must be maintained - refer to paragraphs titled CONTAMINATION and COOLING DEVICES. Do not use solvents on printed circuit boards.

High-Voltage Testing - Do not perform high-voltage insulation resistance (IR) and dielectric withstanding voltage (DWV) tests to check solid-state control equipment. When measuring IR or DWV of electrical equipment such as transformers or motors, a solid-state device that is used for control or monitoring must be disconnected before performing the test. Even though no damage is readily apparent after an IR or DWV test, the solid-state devices are degraded and repeated application of high voltage can lead to failure.

Locking and Interlocking Devices - Check these devices for proper working condition and capability of performing their intended functions. Make any necessary replacements only with Allen-Bradley renewal parts or kits. Adjust or repair only in accordance with Allen-Bradley instructions.

Maintenance After a Fault Condition - An open short circuit protective device (such as a fuse or circuit breaker) in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload. Such conditions can damage control equipment. Before power is restored, the fault condition must be corrected and any necessary repairs or replacements must be made to restore the control equipment to good working order. See NEMA Standards Publication No. ICS-2, Part ICS2-302 for procedures. For replacements, use only parts and devices that Rockwell Automation recommends maintaining the integrity of the equipment. Make sure that the parts are properly matched to the model, series, and revision level of the equipment.

Final Check Out - After maintenance or repair of industrial controls, always test the control system for proper function under controlled conditions to avoid a control malfunction hazard. For additional information, see NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT, published by the National Electrical Manufacturers Association, and NFPA 70B, ELECTRICAL EQUIPMENT MAINTENANCE, published by the National Fire Protection Association.

44 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 3

Component Inspection and Test Procedures

Top ic Pag e

Component Inspection and Maintenance 45

Forward and Reverse Biased IGBT/Diode Tests 47

AC Input Link Fuses Test 52

DC Link Fuse Test 52

Component Fuse Tests 52

This chapter provides details on how to inspect and test the major components of the drive and includes recommendations for repairs. Review the Troubleshooting chapter in the PowerFlex® Drives with TotalFORCE™ Control programming manual, publication 750-PM100 fault or alarm and how to troubleshoot these conditions.

, for information on conditions that can cause a

Component Inspection and Maintenance

Visually inspect the door filters and major components on the control pod, LCL filter and power modules, DC precharge module, and AC precharge module and components for dirt and damage. Dirt build-up on some components can lead to component damage or failure. Avoid damage to the product by replacing components and/or circuit boards with burn marks, breakage, or foil delamination. Follow these inspection and maintenance instructions along with the Recommended Preventative Maintenance information on page 27

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the filters from the enclosure doors and inspect for dirt buildup or blockage. Clean or replace all filters as necessary. See these procedures for removal instructions:

IP21 door filters:

• Input bay, 400/600 mm wide - see page 179

• Input bay, 800/1000 mm wide - see page 181

• Power bay, 400/600 mm wide - see page 221

• Power bay, 800 mm wide - see page 222

• Wire entry/exit bay, 400 mm wide - see page 285

• Wire entry/exit bay, 800 mm wide - see page 285

. .

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 45

Chapter 3 Component Inspection and Test Procedures

IP54 door filters:

• Control bay - see page 145

• Input bay, 400/600 mm wide - see page 179

• Input bay, 800/1000 mm wide - see page 182

• Power bay, 400/600 mm wide - see page 220

• Power bay, 800 mm wide - see page 222

• Wire entry/exit bay, 400 mm wide - see page 285

• Wire entry/exit bay, 800 mm wide - see page 285

. .

4. Remove the filters from the exhaust vent assemblies and inspect for dirt buildup or blockage. Clean or replace all filters as necessary. See these procedures for removal instructions:

IP54 exhaust vent filters:

• Control bay - see page 142

• Input bay - see page 179

• Power bay - see page 211

5. Inspect the enclosure fan assemblies for blockage and verify free rotation. Clean or replace as necessary. See these procedures for removal instructions:

• Frame 5 mixing fan (see page 61

• Frame 6 mixing fan (see page 81

• Control bay roof vent fan - see page 143

• Input bay roof or door vent fans - see page 179

• Power bay IP54 roof vent fans - see page 214

• Frame 7 power and LCL filter module fan assembly - see page 109

• Frames 8…15 LCL filter module fan assembly - see page 276

• Frames 8…15 power module fan assembly - see page 276

• Entry/Exit wire bay door vent fan - see 285

) and heatsink fan (page 62). ) and heatsink fan (see page 82).

or 182.

6. Remove the cover from the control pod and inspect all visible major components, including: circuit boards, wire harnesses, fiber-optic cables, and connectors. If any components show evidence of burn marks or breakage, replace the damaged components without further testing.

• For frame 5, see step 3 only in Remove the Main Control Circuit Board

on page 57

• For frame 6, see step 3 only in Main Control Circuit Board

Replacement on page 77

• For frame 7, see Remove the Control Pod Cover on page 98

• For frames 8…15, see Control Pod Cover Removal on page 146

7. For frames 5 and 6, inspect the power feedback circuit board. If any components, particularly the resistors, show evidence of burn marks or breakage, replace the circuit board without further testing. For frame 5, see page 67

46 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

. For frame 6, see page 87.

Component Inspection and Test Procedures Chapter 3

8. If an AC precharge module or system is installed, inspect all visible major components. If any components show evidence of burn marks or breakage, replace the damaged components without further testing. See Input Bay Kits on page 173

9. If a DC precharge module is installed, inspect all visible major components. If any components show evidence of burn marks or breakage, replace the damaged components without further testing. See Power Bay Kits on page 201

10. Visibly inspect all visible circuit boards, wire harnesses, fiber-optic cables, and connectors through-out the system. Replace any of these circuit boards, wire harnesses, or fiber-optic cables without further testing if they show evidence of burn marks, breakage, or foil delamination. See the appropriate removal and replacement procedures for the affected module/ component.

for a list of AC precharge replacement components.

for a list of DC precharge replacement components.

Forward and Reverse Biased IGBT/Diode Tests

Follow these steps to perform forward and reverse biased IGBT/diode tests on the power modules. A failed test indicates damage to the components in the power modules and requires replacement of the power module.

IMPORTANT The actual voltage readings can vary depending upon your equipment. If your

readings are not near the indicated values in Tab le 6 verify that the actual voltage that is measured is consistent for each phase of the power module.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. For frames 7…15, remove the power module from the enclosure.

• For frame 7, see Remove the Power Module from the Enclosure on page

• For frames 8…15, see Power Module Replacement on page 236

113

and Tab le 7 , on page 48,

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 47

Chapter 3 Component Inspection and Test Procedures

4. Select the “Diode Test” mode on the digital multi-meter and complete the forward and reverse biased diode tests on the power module as identified in Ta b l e 6

• For frames 5 and 6 terminal locations, see Figure 5

• For frame 7 power module terminal locations, see Figure 6

• For frames 8…15 power module terminal locations, see Figure 7

Table 6 - Forward Biased Diode Tests on the IGBT Assembly

Meter Leads

–DC U/T1

–DC V/T2

–DC W/T3

U/T1 +DC

V/T2 +DC

W/T3 +DC

(1) The actual voltage reading can vary depending upon your equipment.

page 51

and Ta b l e 7 .

on page 49.

on page 50.

Nominal Meter Reading+–

The value should gradually rise to between 0.20V and 0.75V. If the value is outside this range, contact Technical Support.

(1)

Table 7 - Reverse Biased Diode Tests on the IGBT Assembly

Meter Leads

Nominal Meter Reading+–

U/T1 –DC

V/T2 –DC

W/T3 –DC

+DC U/T1

+DC V/T2

+DC W/T3

(1) Residual voltage on the DC bus capac itors can affect this reading. If the capacitors are discharged (less than 1 volt), the meter

initially shows a low voltage. This voltage reading is the residual bus voltage plus the drop through the low side diodes. The meter gradually charges the bus, and the voltage slowly increases, until eventually the meter switches to “.OL”. This increase can take several minutes to occur.

“.0L” (open circuit)

(1)

48 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Figure 5 - Frames 5 and 6 Power Terminal Locations

Frame 5 Frame 6

12 3

Component Inspection and Test Procedures Chapter 3

Item Name

1 R/L1, S/L2, T/L3

2DC+, DC–

3 U/T1, V/T2, W/T3

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 49

Chapter 3 Component Inspection and Test Procedures

Figure 6 - Frame 7 Power Module Power Terminal Locations

ID Connec tion ID Connection

1 +DC 3 R/L1, U/T1

2 –DC 4 S/L2, V/T2

5 T/L3, W/T3

50 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Component Inspection and Test Procedures Chapter 3

543

Figure 7 - Frames 8…15 Power Module Power Terminal Locations

ID Connec tion ID Connection

1 +DC 3 R/L1, U/T1

2 –DC 4 S/L2, V/T2

5 T/L3, W/T3

5. If the product fails the measurements identified in Ta b l e 6 or Ta b l e 7 , take the appropriate action:

• For frames 5 and 6, replace the drive or bus supply.

• For frames 7, replace the power module. See Power Module

Replacement on page 113

• For frames 8…15, replace the power module. See Power Module

Replacement on page 236

6. Complete the procedures in Chapter 11 - Chapter on page 291

before

placing the drive back into service.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 51

Chapter 3 Component Inspection and Test Procedures

AC Input Link Fuses Test

DC Link Fuse Test

The AC input link fuses contain fuse indicator switches that signal an open fuse that will fault the drive system. Follow these steps to perform AC input link fuse test.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Open the power bay enclosure door.

4. Continuity test the AC line fuses in circuit. Each LCL filter module is

connected to three AC line fuses.

5. Replace a fuse as necessary.

• For frames 8…15, see AC Input Link Fuses Replacement on page 262

The DC link fuses contain fuse indicator switches that signal an open fuse that will fault the drive system. Follow these steps to perform DC link fuse test.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

Component Fuse Tests

3. Open the power bay enclosure door.

4. Continuity test the DC link fuses in circuit. Each DC link contains two

fuses.

5. Replace a fuse as necessary.

• For frames 8…15, see DC Link Fuses Replacement on page 241

Perform a continuity test on the following fuses:

• AC precharge control board fuses (FH1). For frames 8…15, see AC Precharge Control Circuit Board Fuses (FH1) Replacement on page 192

• 240V power distribution fuse (FH2). For frames 8…15, see 240V Power Distribution Fuse (FH2) Replacement on page 194

• Input bay 240V control power fuse (FH3). See Roof Fan 240V Control Power Fuse (FH3) Replacement on page 195

• Control transformer fuses (FH4…FH7).

• For frame 7, see Control Transformer Fuses (FH4) Replacement on

page 112

• For frames 10…15, see Control Transformer Fuses (FH4…FH7)

Replacement on page 197

• AC precharge fused disconnect fuses. For frames 8…15, see AC Precharge Fused Disconnect (FD1) Fuses Replacement on page 199

• IP54 exhaust fan fuse. See IP54 Exhaust Fan Fuse Replacement on page

212

52 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Component Inspection and Test Procedures Chapter 3

• LCL filter and power modules fan fuse (F1). For frames 8…15, see Power/ LCL Filter Module Heatsink Fan Fuse Replacement on page 275

Follow these steps to check the fuses for other components/modules.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on page 15

3. Continuity test the fuse or fuses.

4. Replace a fuse as necessary.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 53

Chapter 3 Component Inspection and Test Procedures

Notes:

54 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 4

Frame 5 Components

This chapter provides detailed instructions for how to remove and replace frame 5 PowerFlex® 755T product components.

Frame 5 Kits

Ta b l e 8 lists the replacement kits available for frame 5 PowerFlex 755T products.

Table 8 - Frame 5 Replacement Kits

Description Catalog Number Replacement Instructions

Power Module Components

Power Feedback Circuit Board and Bracket SK-RM-PFB-F5-F6 See page 67

LCL Filter Module Components

Capacitor SK-RM-LCLCP4-F5 (400/480V) See page 71

SK-RM-LCLCP6-F5 (600/690V)

Control Pod Components

Main Control Circuit Board SK-RM-MCB1-PF755 See page 57

Cooling Components

Stirring Fan Assembly SK-RM-MFAN1-F5 See page 61

Heatsink Fan Assembly SK-RM-HSFAN1-F5 See page 62

Fan Power Supply Circuit Board SK-RM-PSB1-F5-F6 See page 64

Accessories Kits

Potential Earth (PE) Jumper SK-RM-JMPR1-F5 See page 66

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 55

Chapter 4 Frame 5 Components

M4 x 8 mm F - 6.4 mm (0.25 in.) or 4 mm hex

2.6 N•m (23 lb•in)

Remove the Cover

Remove the Cover from the Chassis

Remove the cover from the chassis to access components within the drive or bus supply.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Loosen the four M4 x 8 mm captive screws that secure the cover to the assembly, and remove the cover.

Install the Cover

Install the cover in the reverse order of removal.

56 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

T15 or F - 6.4 mm (0.25 in.)

0.45 N

•m (4 lb•in)

Main Control Circuit Board Replacement

Replace a main control circuit board with kit catalog number SK-RM-MCB1-PF755.

Remove the Main Control Circuit Board

Follow these steps to remove the main control circuit board.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Loosen the two captive thumb screws on the control pod access cover and remove the cover.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 57

Chapter 4 Frame 5 Components

M3 x 6.4 mm T15 or F - 5 mm (0.19 in.)

0.45 N

•m (4 lb•in)

Control Pod Shown Removed from Drive for Clarity Only.

4. Loosen the screw that secures the HIM bezel to the pod chassis, and rotate the bezel up to a 90° horizontal position.

5. Disconnect the HIM cable from the port on the main control board.

58 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

Control Pod Shown Removed from Drive for Clarity Only.

6. Disconnect any Ethernet cables from the ports on the bottom of the main control board.

7. Disconnect the plug-in terminal block (TB1) on the bottom of the main control board.

8. Disconnect the HIM plug-in terminal block for the mini-DIN (port 2) connector on the control board.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 59

Chapter 4 Frame 5 Components

– T15 or F - 5 mm (0.19 in.)

0.45 N

•m (4 lb•in)

Control Pod Shown Removed from Drive for Clarity Only.

9. Loosen the three captive thumbscrews that secure the main control board to the pod chassis and remove the board.

Install the Main Control Circuit Board

Install the main control circuit board in the reverse order of removal.

60 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

M4 P2

2.6 N

•m (23 lb•in)

P12

Stirring Fan Assembly Replacement

Replace a stirring fan assembly with kit catalog number SK-RM-MFAN1-F5.

Remove the Stirring Fan Assembly

Follow these steps to remove the stirring fan assembly.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 56

4. Disconnect the wire harness connector P12 from connector P1 on the fan

assembly bracket.

5. Loosen the two captive screws that secure the fan assembly to the chassis and remove the fan assembly.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 61

Chapter 4 Frame 5 Components

— P2 2 N•m (18 lb•in)

Install the Stirring Fan Assembly

Install the stirring fan assembly in the reverse order of removal. Verify that you have connected the stirring fan power supply harness connector on the fan assembly to the connector in the control pod support bracket.

Heatsink Fan Assembly Replacement

Replace a heatsink fan assembly with kit catalog number SK-RM-HSFAN1-F5.

Remove the Heatsink Fan Assembly

Follow these steps to remove the heatsink fan assembly.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Loosen the two captive screws that secure the fan assembly to the chassis.

4. Carefully pull the bottom of the fan assembly away from the chassis and

release the three tabs from the chassis. The power wire harness is connected inside the chassis.

62 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

5. Disconnect the fan wire harness connector P2 from connector J2 inside the chassis and remove the fan assembly.

Install the Heatsink Fan Assembly

Install the heatsink fan assembly in the reverse order of removal.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 63

Chapter 4 Frame 5 Components

Fan Power Supply Circuit Board Replacement

Replace a fan power supply circuit board with kit catalog number SK-RM-PSB1-F5-F6.

Remove the Fan Power Supply Circuit Board

Follow these steps to remove the fan power supply circuit board.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 56

4. Disconnect these cable connectors from the fan power supply circuit

board:

•P1 from J1

•P2 from J2

64 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

M4 x 10 mm T20

2.0 N•m (18.0 lb•in)

5. Remove the six M4 x 10 mm torx screws that secure the fan power supply circuit board to the bracket and remove the board.

Install the Fan Power Supply Circuit Board

Install the fan power supply circuit board in the reverse order of removal.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 65

Chapter 4 Frame 5 Components

Potential Earth (PE) Jumper Replacement

Replace a PE jumper with kit catalog number SK-RM-JMPR1-F5.

Remove the PE Jumper

Follow these steps to remove the PE jumper.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 56

4. Remove the PE jumper from the power circuit board.

Install the PE Jumper

Install the PE jumper in the reverse order of removal.

• Verify that the jumper is installed in the correct position as required for your grounding scheme and application. See the PowerFlex 750-Series Products with TotalFORCE Control, Installation Instructions, publication 750-IN100

66 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

, for jumper configuration.

Frame 5 Components Chapter 4

Option Modules Not Shown for Clarity Only.

Control Pod Shown Removed from Drive for Clarity Only.

Power Feedback Circuit Board and Bracket Replacement

Replace a power feedback circuit board and bracket with kit catalog number SK-RM-PFB-F5-F6.

Remove the Power Feedback Circuit Board and Bracket

Follow these steps to remove the power feedback circuit board and bracket.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 56

4. Remove the stirring fan from the drive. See Remove the Stirring Fan

Assembly on page 61

5. To prepare the control pod for removal from the drive, complete these steps:

a. Disconnect any Ethernet cables from the ports on the bottom of the

main control board in the control pod.

b. If used, disconnect the HIM plug-in terminal block for the mini-DIN

(port 2) connector on the main control board.

c. If used, disconnect the plug-in terminal block (TB1) on the bottom of

the main control board.

d. If used, disconnect any I/O wiring terminal blocks from an installed

option module.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 67

Chapter 4 Frame 5 Components

M4 x 10 mm T20 or F - 6.4 mm (0.25 in.)

2.3 N•m (20 lb•in)

M5 x 10 mm T25 or F - 6.4 mm (0.25 in.)

3.6 N•m (32 lb•in)

6. Remove the two M4 x 10 mm slotted torx screws that secure the human machine interface (HMI) flex circuit connector to the power interface circuit board.

IMPORTANT The control pod contains a connector that connec ts to an edge connector on the

power feedback circuit board beneath it. Take care when lifting the control pod off the chassis so circuit board damage does not occur.

7. Remove the six M5 x 10 mm torx screws that secure the control pod support bracket and control pod to the chassis and carefully lift and remove the control pod and bracket from the chassis.

68 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

M4 x 10 mm T20 or F - 6.4 mm (0.25 in.)

2.3 N

•m (20 lb•in)

8. Remove the two M4 x 10 mm torx screws that secure the power feedback circuit board and support bracket to the chassis and carefully lift the bracket and board edge connectors off the connectors on the power circuit board.

9. Dispose of the circuit board and bracket.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 69

Chapter 4 Frame 5 Components

2 mm (0.08 in.)

Install the Power Feedback Circuit Board and Bracket

Follow these steps to install the power feedback circuit board and bracket.

IMPORTANT You must apply a PolySi PST-576 non-silicone, dielectric connector grease to

the edge connectors on the new power feedback circuit board before installation.

1. Apply a dielectric grease to all edge connectors on the power feedback circuit board, according to these requirements:

• PolySi PST-576 is the only approved dielectric grease for use.

• Apply the dielectric grease to a uniform thickness of 1…2 mm on both

sides of the connector.

• Apply the dielectric grease to a minimum of 2 mm beyond the edge of

the gold connectors (ideally in contact with the conformal coating).

2. Install the power feedback board and bracket in the reverse order of removal.

• Verify that the connector on the right side of the control pod seats

properly on the edge connector on the top of the power feedback board when you re-install the control pod.

70 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

M12 19 mm

9.0 N

•m (80 lb•in)

M5 3 MM

1.8 N

•m (16.0 lb•in)

LCL Filter Capacitor Replacement

Replace an LCL filter capacitor with kit catalog number: SK-RM-LCLCP4-F5 (400/480V), SK-RM-LCLCP6-F5 (600/690V).

Remove the LCL Filter Capacitor

Follow these steps to remove the LCL filter capacitor.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 56

4. Loosen the M5 hexagonal screws that secure the capacitor wires to

terminals R, S and T on the capacitor terminal block at the top of the cap, and remove the wires.

5. Remove the M12 hex nut that secures the capacitor to the mounting bracket.

6. Cut the cable tie that secures the capacitor to the bracket, and remove the capacitor.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 71

Chapter 4 Frame 5 Components

1…3

M5 3 mm

1.8 N

•m (16.0 lb•in)

Install the LCL Filter Capacitor

Follow these steps to install a replacement LCL filter capacitor.

1. Inspect the foam pad on the side wall of the chassis for damage.

2. If the pad is damaged, remove the existing pad material.

3. Clean the surface of the chassis with a 50% isopropyl alcohol and 50%

water solution and install the new foam pad that is provided with the kit.

4. Insert all three legs of the resistor that is supplied with the kit into the terminal block at the top of the capacitor and secure the resistor.

72 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 5 Components Chapter 4

Wire Harness From Power Circuit Board

Cable Tie Head

Resistor

Outside of Chassis

5. Install the filter capacitor in the reverse order of removal.

• Verify the placement of the resistor and new cable tie as shown here.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 73

Chapter 4 Frame 5 Components

Notes:

74 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 5

Frame 6 Components

This chapter provides detailed instructions for how to remove and replace frame 6 PowerFlex® 755T product components.

Frame 6 Kits

Ta b l e 9 lists the replacement kits available for frame 6 PowerFlex 755T products.

Table 9 - Frame 6 Replacement Kits

Description Catalog Number Replacement Instructions

Power Module Components

Power Feedback Board and Bracket SK-RM-PFB-F5-F6 See page 87

LCL Filter Module Components

(1)

Capacitor

Control Pod Components

Main Control Circuit Board SK-RM-MCB1-PF755 See page 77

Cooling Components

Stirring Fan Assembly SK-RM-MFAN1-F6 See page 81

Heatsink Fan Assembly SK-RM-HSFAN1-F6 See page 82

Fan Power Supply Circuit Board SK-RM-PSB1-F5-F6 See page 84

Accessories Kits

DR and PE-A (EMC & MOV) Jumper SK-RM-JMPR1-F6 See page 83

(1) 480V 6 A drives have one capacitor. All other drive and bus supply power ratings have two capacitors. You must order two kits to

replace both capacitors, where applicable.

SK-RM-LCLCP4-F6 (400/480V) See page 91

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 75

Chapter 5 Frame 6 Components

Shown with Optional Conduit Box Installed.

M4 x 8 mm F - 6.4 mm (0.25 in.) or 4 mm hex

2.6 N•m (23 lb•in)

Remove the Cover

To remove the cover, follow these procedures.

Remove the Cover from the Chassis

Remove the cover from the chassis to access components within the drive or bus supply.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Loosen the eight M4 x 8 mm captive screws that secure the cover to the assembly, and remove the cover.

Install the Cover

Install the cover in the reverse order of removal.

76 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

T15 or F - 6.4 mm (0.25 in.)

0.45 N

•m (4 lb•in)

Main Control Circuit Board Replacement

Replace a main control circuit board with kit catalog number SK-RM-MCB1-PF755.

Remove the Main Control Circuit Board

Follow these steps to remove the main control circuit board.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Loosen the two captive thumbscrews on the control pod access cover and remove the cover.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 77

Chapter 5 Frame 6 Components

M3 x 6.4 mm T15 or F - 5 mm (0.19 in.)

0.45 N•m (4 lb•in)

Control Pod Shown Removed from Drive for Clarity Only.

4. Loosen the screw that secures the HIM bezel to the pod chassis, and rotate the bezel up to a 90° horizontal position.

5. Disconnect the HIM cable from the port on the main control board.

78 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

Control Pod Shown Removed from Drive for Clarity Only.

6. Disconnect any Ethernet cables from the ports on the bottom of the main control board.

7. Disconnect the plug-in terminal block (TB1) on the bottom of the main control board.

8. Disconnect the HIM plug-in terminal block for the mini-DIN (port 2) connector on the control board.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 79

Chapter 5 Frame 6 Components

– T15 or F - 5 mm (0.19 in.)

0.45 N

•m (4 lb•in)

Control Pod Shown Removed from Drive for Clarity Only.

9. Loosen the three captive thumbscrews that secure the main control board to the pod chassis and remove the board.

Install the Main Control Circuit Board

Install the main control circuit board in the reverse order of removal.

80 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

M4 T20 or F - 6.4 mm (0.25 in.)

2.6 N

•m (23 lb•in)

Stirring Fan Assembly Replacement

Replace a stirring fan assembly with kit catalog number SK-RM-MFAN1-F6.

Remove the Stirring Fan Assembly

Follow these steps to remove the stirring fan assembly.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

4. Disconnect the fan power wire harness connectors from the connectors on

the chassis.

5. Loosen the M4 captive screw that secures each of the fan assemblies to the chassis.

6. Slide the fan assembly away from the chassis until the mounting tabs align with the holes in the fan mounting plate, and remove the fan assembly.

Install the Stirring Fan Assembly

Install the stirring fan assembly in the reverse order of removal.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 81

Chapter 5 Frame 6 Components

M4 x 8 mm P2

2.6 N•m (23 lb•in)

Cover Shown Removed fo r Clarity Onl y.

Heatsink Fan Assembly Replacement

Replace a heatsink fan assembly with kit catalog number SK-RM-HSFAN1-F6.

Remove the Heatsink Fan Assembly

Follow these steps to remove the heatsink fan assembly.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

4. If installed, remove the conduit box. See PowerFlex 755T Frames 5 and 6

Conduit Box and Ground Plate Kits, Installation Instructions, publication

750-IN112

IMPORTANT The heatsink fan power wire harness is connected inside the chassis.

You cannot remove the fan assembly until you disconnect the fan power wire harness.

5. Loosen the four captive screws that secure the fan assembly to the chassis and carefully pull the fan assembly away from the chassis.

6. Disconnect the fan power wire harness connector from the connector inside the chassis and remove the fan assembly.

82 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

M4 T20 or F - 6.4 mm (0.25 in.)

2.3 N

•m (20 lb•in)

Jumper Shown in Default (IN) Position.

Install the Heatsink Fan Assembly

Install the heatsink fan assembly in the reverse order of removal.

DR and PE-A (EMC & MOV) Jumper Replacement

Replace the DR and PE-A (EMC & MOV) jumper with kit catalog number SK-RM-JMPR1-F6.

Remove the DR and PE-A (EMC & MOV) Jumper

Follow these steps to remove the DR and PE-A (EMC & MOV) jumper.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

4. Loosen the three captive, slotted-torx screws that secure the jumper to the

power interface circuit board.

5. Lift the jumper away from the power interface board until the keyholes in the jumper align with the pins on the sidewall and remove the jumper.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 83

Chapter 5 Frame 6 Components

Install the DR and PE-A (EMC & MOV) Jumper

Install the DR and PE-A (EMC & MOV) jumper in the reverse order of removal.

, for jumper configuration.

Fan Power Supply Circuit Board Replacement

Replace a fan power supply circuit board with kit catalog number SK-RM-PSB1-F5-F6.

Remove the Fan Power Supply Circuit Board

Follow these steps to remove the fan power supply circuit board.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

84 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

4. Disconnect the cable connectors from the fan power supply circuit board:

•P1 from J1

•P2 from J2

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 85

Chapter 5 Frame 6 Components

M4 x 10 mm T20 or F - 6.4 mm (0.25 in.)

2.3 N

•m (20 lb•in)

5. Remove the six M4 x 10 mm slotted-torx screws that secure the fan power supply circuit board to the mounting plate and remove the circuit board.

Install the Fan Power Supply Circuit Board

Install the fan power supply circuit board in the reverse order of removal.

86 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

Option Modules Not Shown for Clarity Only.

Control Pod Shown Removed from Drive for Clarity Only.

Power Feedback Circuit Board and Bracket Replacement

Replace a power feedback circuit board and bracket with kit catalog number SK-RM-PFB-F5-F6.

Remove the Power Feedback Circuit Board and Bracket

Follow these steps to remove the power feedback circuit board and bracket.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

4. To prepare the control pod for removal from the drive, complete these

steps: a. Disconnect any Ethernet cables from the ports on the bottom of the

main control board in the control pod.

b. If used, disconnect the HIM plug-in terminal block for the mini-DIN

(port 2) connector on the main control board.

c. If used, disconnect the plug-in terminal block (TB1) on the bottom of

the main control board.

d. If used, disconnect any I/O wiring terminal blocks from an installed

option module.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 87

Chapter 5 Frame 6 Components

5, 6

M4 x 10 mm T20 or F - 6.4 mm (0.25 in.)

2.3 N

•m (20 lb•in)

5. Remove the two M4 x 10 mm slotted torx screws that secure the HMI flex circuit connector to the power interface circuit board.

IMPORTANT The control pod contains a connector that connec ts to an edge connector on the

power feedback circuit board beneath it. Take care when lifting the control pod off the chassis so circuit board damage does not occur.

6. Remove the four M4 x 10 mm slotted torx screws that secure the control pod to the chassis and remove the control pod.

88 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

M4 x 10 mm T20

2.8 N

•m (25 lb•in)

7. Remove the four M4 x 10 mm torx screws that secure the power feedback circuit board and support bracket to the chassis and carefully lift the bracket and board edge connectors off the connectors on the power circuit board.

8. Dispose of the circuit board and bracket.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 89

Chapter 5 Frame 6 Components

2 mm (0.08 in.)

Install the Power Feedback Circuit Board and Bracket

Follow these steps to install the power feedback circuit board and bracket.

IMPORTANT You must apply a PolySi PST-576 non-silicone, dielectric connector grease to

the edge connectors on the new power feedback circuit board before installation.

1. Apply a dielectric grease to all edge connectors on the power feedback circuit board, according to these requirements:

• PolySi PST-576 is the only approved dielectric grease for use.

• Apply the dielectric grease to a uniform thickness of 1…2 mm on both

sides of the connector.

• Apply the dielectric grease to a minimum of 2 mm beyond the edge of

the gold connectors (ideally in contact with the conformal coating).

2. Install the power feedback board and bracket in the reverse order of removal.

• Verify that the connector on the right side of the control pod seats

properly on the edge connector on the top of the power feedback board when you re-install the control pod.

90 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 6 Components Chapter 5

M12 19 mm

9.0 N•m (80 lb•in)

LCL Filter Capacitor Replacement

Replace an LCL filter capacitor with kit catalog number: SK-RM-LCLCP4-F6 (400…690V).

Remove the LCL Filter Capacitor

Follow these steps to remove the LCL filter capacitor.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on

page 15

3. Remove the cover from the chassis. See Remove the Cover on page 76

4. Remove the M12 hex nut that secures the capacitor to the bracket.

5. Cut the cable ties that secures the capacitor to the bracket and discard the

cable ties.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 91

Chapter 5 Frame 6 Components

Resistor

Interconnection

Wires

From Power

Circuit Board

M5 3 mm

1.8 N

•m (16.0 lb•in)

6. Loosen the M5 hexagonal screws that secure the capacitor wires to terminals R, S and T on the capacitor terminal block at the top of the capacitor, and remove the wires. Retain all wires for reuse.

92 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

7. Remove the capacitor from the drive.

Frame 6 Components Chapter 5

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 93

Chapter 5 Frame 6 Components

M5 3 mm

1.8 N•m (16.0 lb•in)

Install the LCL Filter Capacitor

Follow these steps to install a replacement LCL filter capacitor.

1. Insert all three legs of the resistor supplied with the kit into the terminal block at the top of the capacitor and secure the resistor.

• When two capacitors are installed, a single resistor must be installed on

the left side of the left-most capacitor. See step 6

for wiring orientation.

2. If two capacitors are used, secure the interconnection wires to terminals R, S and T on the capacitor terminal block at the top of both capacitors. See

on page 92 for wiring orientation.

step 6

3. Secure the wire harness from the power circuit board to terminals R, S and T on the right side of the capacitor terminal block.

• When two capacitors are used, install the wire harness is connected to

the right side of the right-most capacitor terminal block. See step 6 page 92

94 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

for wiring orientation.

Frame 6 Components Chapter 5

Position the Cable Tie Heads to the Side of the Capacitors.

M12 19 mm

9.0 N

•m (80 lb•in)

4. Insert the cable ties into the notches in the chassis mounting plate.

5. Place the capacitor into the cable ties in the drive and by inserting the

threaded screw through the mounting plate at the bottom of the capacitors.

6. Secure the M12 hex nut to the threaded screw on the bottom of the capacitor.

7. Secure the capacitor to the mounting plate by tightening the cable ties.

• Verify that the cable tie is aligned as it was prior to removal, with the

head of the tie to the side of the capacitor (so it does not interfere with the cover when it is replaced).

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 95

Chapter 5 Frame 6 Components

Notes:

96 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Chapter 6

Frame 7 Components

This chapter provides detailed instructions for how to remove and replace frame 7 PowerFlex® 755T product components.

Frame 7 Kits

Ta b l e 1 0 lists the replacement kits available for frame 7 PowerFlex 755T

products.

Table 10 - Frame 7 Replacement Kits

Description Catalog Number Replacement Instructions

Ventilation Compone nts

IP54 Exhaust Vent Filters SK-RM-PBFAN-54FLTR1

IP54 Door Filters (800 mm) SK-RM-PB8DR-54FLTR1 See page 98

IP21 Door Filter (800 mm) SK-RM-PB8DR-21FLTR1 See page 98

Power Module Components

Power Module 20-750-MI4-CnnnDnnn

20-750-MI4-EnnnFnnn

Power Layer Interface Circuit Board SK-RM-PLI1-F7 See page 120

Power Interface C ircuit Board

LCL Filter Module Components

LCL Filter Module 20-750-ML4-CnnnDnnn

Current Sense Circuit Board SK-RM-CSB-F7 See page 132

Control Pod Components

Control Pod Fan Assembly SK-RM-PODFAN-F7 See page 99

Main Control Circuit Board SK-RM-MCB1-PF755 See page 101

Control Pod Assembly (Regenerative Drive and Bus Supply)

Control Pod Assembly (Low Harmonic Drive)

Control Power Components

Control Transformer Fuses (FH 4) SK-RM-IBFH4-FUSE5A-F7

Control Transformer Fuses (FH 4) SK-RM-IBFH4-FUSE5B-F7

Cooling Components

Power/Filter Module Heatsink Fan Assembly

(1) “C” and “D” in “CnnnDnnn” identifies a circuit board compatible with a power module that is rated for 400/480V, respectively. “E”

and “F” in “EnnnFnnn” identifies a circuit board compatible with a power module that is rated for 600/690V, respectively. “nnn” in “CnnnDnnn” and “EnnnFnnn” identifies the amp rating the power module that the circuit board is compatible with.

(2) Each kit contains two filters. Frame 7 enclosures require two kits (four filters).

(1)

SK-RM-PIB4-CnnnDnnn SK-RM-PIB4-EnnnFnnn

20-750-ML4-EnnnFnnn

20-750-MCPOD1-F7M See page 104

20-750-MCPOD2-F7M See page 104

(400V/480V/600V)

(690V)

SK-RM-MFAN-F7 See page 109

(2)

See page 98

See page 113

See page 124

See page 127

See page 112

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 97

Chapter 6 Frame 7 Components

IP54 Exhaust Vent Filters Replacement

IP54, 800 mm Wide Door Vent Filters Replacement

IP21, 800 mm Wide Door Vent Filter Replacement

Control Pod Cover Removal

The frame 7 IP54 exhaust vent requires four filters. Replace the IP54 exhaust vent filters with two kits of catalog number SK-RM-PBFAN-54FLTR1.

See IP54 Exhaust Vent Filters Replacement on page 211

Replace the IP54, 800 mm wide door vent filters with kit catalog number SK-RM-PB8DR-54FLTR1.

See IP54, 800/1000 mm Wide Door Vent Filters Replacement on page 180

Replace the IP21, 800 mm wide door vent filters with kit catalog number SK-RM-PB8DR-21FLTR1.

See IP21, 800/1000 mm Wide Door Vent Filter Replacement on page 181

You must remove the control pod cover to access other components inside the pod.

Remove the Control Pod Cover

Follow these steps to remove the control pod cover.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on page 15

3. Open the enclosure door.

98 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Frame 7 Components Chapter 6

0.45 N

•m (4 lb•in)

The Control Pod Is Shown Separated from the Power Bay to Clarify the Instructions Only.

4. Loosen the two captive screws at the top of the control pod and pull the cover out from the chassis.

5. Lift the bottom of the cover off the tabs and remove the cover.

Control Pod Fan Assembly Replacement

Install the Control Pod Cover

Install the control pod cover in the reverse order of removal.

Replace the control pod fan assembly with kit catalog number SK-RM-PODFAN-F7.

Remove the Control Pod Fan Assembly

Follow these steps to remove the control pod fan assembly.

1. Review the Product Advisories on page 14

2. Remove power from the system. See Remove Power from the System on page 15

3. Open the enclosure door.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 99

Chapter 6 Frame 7 Components

0.45 N•m (4 lb•in)

Fan Assem bly

4. Remove the control pod cover. See Remove the Control Pod Cover on page 98

5. Disconnect the fan power wire harness connector J1 from connector P1 in the control pod.

6. Loosen the two captive screws that secure the fan assembly to the pod chassis and remove the fan assembly.

Install the Control Pod Fan Assembly

Install the control pod fan assembly in the reverse order of removal.

100 Rockwell Automation Publication 750-TG100B-EN-P - June 2019

Rockwell Automation Allen-Bradley PowerFlex 750 Series, PowerFlex 755TL, PowerFlex 755TM, PowerFlex 755TR Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

Summary of Changes

Additional Resources

Product Advisories

Qualified Personnel

Personal Safety

Product Safety

Class 1 Light-emitting Diode Product

Remove Power from the System

Frames 5 and 6

Frames 7…15

Commonly Used Tools

Software Tools

Hardware Installation Diagrams

Fastener Torque Sequences

Recommended Preventative Maintenance

Predictive Maintenance

Schedule Codes Explanation

Shock Events

Maintenance of Industrial Control Equipment

Solid-state Devices

Component Inspection and Maintenance

Forward and Reverse Biased IGBT/Diode Tests

AC Input Link Fuses Test

DC Link Fuse Test

Component Fuse Tests

Frame 5 Kits

Remove the Cover

Remove the Cover from the Chassis

Install the Cover

Main Control Circuit Board Replacement

Remove the Main Control Circuit Board

Install the Main Control Circuit Board

Stirring Fan Assembly Replacement

Remove the Stirring Fan Assembly

Install the Stirring Fan Assembly

Heatsink Fan Assembly Replacement

Remove the Heatsink Fan Assembly

Install the Heatsink Fan Assembly

Fan Power Supply Circuit Board Replacement

Remove the Fan Power Supply Circuit Board

Install the Fan Power Supply Circuit Board

Potential Earth (PE) Jumper Replacement

Remove the PE Jumper

Install the PE Jumper

Power Feedback Circuit Board and Bracket Replacement

Remove the Power Feedback Circuit Board and Bracket

Install the Power Feedback Circuit Board and Bracket

LCL Filter Capacitor Replacement

Remove the LCL Filter Capacitor

Install the LCL Filter Capacitor

Frame 6 Kits

Remove the Cover

Remove the Cover from the Chassis

Install the Cover

Main Control Circuit Board Replacement

Remove the Main Control Circuit Board

Install the Main Control Circuit Board

Stirring Fan Assembly Replacement

Remove the Stirring Fan Assembly

Install the Stirring Fan Assembly

Heatsink Fan Assembly Replacement

Remove the Heatsink Fan Assembly

Install the Heatsink Fan Assembly

DR and PE-A (EMC & MOV) Jumper Replacement

Remove the DR and PE-A (EMC & MOV) Jumper

Install the DR and PE-A (EMC & MOV) Jumper

Fan Power Supply Circuit Board Replacement

Remove the Fan Power Supply Circuit Board

Install the Fan Power Supply Circuit Board

Power Feedback Circuit Board and Bracket Replacement

Remove the Power Feedback Circuit Board and Bracket

Install the Power Feedback Circuit Board and Bracket

LCL Filter Capacitor Replacement

Remove the LCL Filter Capacitor