Page 1 Hardware Service Manual Original Instructions PowerFlex 750-Series Products with TotalFORCE Control Catalog Numbers 20G, 20J...
Page 2 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.
Page 3: Table Of Contents
Install the Stirring Fan Assembly......62 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 4 Install the LCL Filter Capacitor ......94 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 5 Remove the Current Sense Circuit Board....132 Install the Current Sense Circuit Board ....137 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 6 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 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 7 Install the IP54 Exhaust Fan....... 219 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 8 Install the Balance Resistors ....... 254 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 9 Install the Thermal Switch ....... . 289 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 10 ............345 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 11: Preface
This publication is intended for novice drives users and users with advanced skills. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 12: Precautions
Maintenance of Solid State Control, publication SGI-1.1 Product Certifications website, http:// Provides declarations of conformity, certificates, and www.rockwellautomation.com/global/certification/ other certification details. overview.page You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 13 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 safety- related 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...
Page 14: Product Advisories
Class 1 Light-emitting Diode Product ATTENTION: 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 15: Remove Power From The System
• 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). Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 16 U/T1, V/T2, W/T3 AC output motor terminals shield R/L1, S/L2, T/L3 AC line input power terminals PE grounding stud Termination point to chassis ground for motor shield DC+, DC– DC bus terminals — — — Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 17: Frames 7
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...
Page 18 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. Frame 9, IP21 UL Type 1 Input Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 19 –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. Frames 8…15 Power Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 20 AC Precharge Circuit Breaker • For frames 8…15 drives and bus supplies, in the input bay, measure terminals L and N on terminal block TB2. Frame 10 Input Bay Shown AC Precharge Circuit Breaker Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 21 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...
Page 22: Commonly Used 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 23: Hardware Installation Diagrams
Pozidriv screwdriver/bit and size Torx screwdriver/bit and size Fastener Type xx mm Hexagonal socket wrench Flat-head screw Hexagonal bolt Hexagonal nut or standoff Hexagonal screw Torx screw Phillips screw Pozidriv screw Slotted torx screw Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 24: Fastener Torque Sequences
The numeric illustration labels are for your assistance. • Drive components do not contain these labels. Figure 2 - Two-point Mounting Initial Sequence Final Sequence Figure 3 - Four-point Mounting Initial Sequence Final Sequence Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 25 Before You Begin Tests, Maintenance, or Repairs Chapter 1 Figure 4 - Six-point Mounting Initial Sequence Do not exceed 0.7 N m (6 lb in) on initial torque of all six screws. • • Final Sequence Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 26 Chapter 1 Before You Begin Tests, Maintenance, or Repairs Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 27: Recommended Preventative Maintenance
PowerFlex® 750-Series products with TotalFORCE® Control. Recommended Rockwell Automation recognizes that following a defined maintenance schedule delivers the maximum product availability. By strictly following the maintenance Preventative Maintenance schedule of tasks that is provided for your operating environment, you can expect the highest possible uptime.
Page 28: Predictive Maintenance
Use the predictive maintenance parameters to determine a replacement schedule for components in shaded table rows. 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.
Page 29 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 30 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 31 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 32 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 33 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 34 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 35 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 36 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 37 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 38 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 39 Preventative Maintenance Chapter 2 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 40 Chapter 2 Preventative Maintenance Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 41: Shock Events
Below 0.7 g peak, the maximum total shock events should not exceed 2000 cycles. 1.00 10.00 100.00 1000.00 Maximum number of shock events Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 42: Maintenance Of Industrial Control Equipment
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.
Page 43 – 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.
Page 44: Solid-State Devices
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.
Page 45: Component Inspection And Maintenance
• 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...
Page 46 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. For frame 6, see page 87. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 47: Forward And Reverse Biased Igbt/Diode Tests
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 113. • For frames 8…15, see Power Module Replacement on page 236. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 48 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 49 Component Inspection and Test Procedures Chapter 3 Figure 5 - Frames 5 and 6 Power Terminal Locations Frame 5 Frame 6 Item Name R/L1, S/L2, T/L3 DC+, DC– U/T1, V/T2, W/T3 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 50 Chapter 3 Component Inspection and Test Procedures Figure 6 - Frame 7 Power Module Power Terminal Locations Connection Connection R/L1, U/T1 –DC S/L2, V/T2 T/L3, W/T3 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 51 • 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 before placing the drive back into service. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 52: Ac Input Link Fuses Test
• 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 53 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...
Page 54 Chapter 3 Component Inspection and Test Procedures Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 55: Frame 5 Kits
See page Cooling Components Stirring Fan Assembly SK-RM-MFAN1-F5 See page Heatsink Fan Assembly SK-RM-HSFAN1-F5 See page Fan Power Supply Circuit Board SK-RM-PSB1-F5-F6 See page Accessories Kits Potential Earth (PE) Jumper SK-RM-JMPR1-F5 See page Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 56: Remove The Cover
M4 x 8 mm F - 6.4 mm (0.25 in.) or 4 mm hex 2.6 N m (23 lb • • Install the Cover Install the cover in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 57: Main Control Circuit Board Replacement
15. 3. Loosen the two captive thumb screws on the control pod access cover and remove the cover. T15 or F - 6.4 mm (0.25 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 58 5. Disconnect the HIM cable from the port on the main control board. M3 x 6.4 mm T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Control Pod Shown Removed from Drive for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 59 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. Control Pod Shown Removed from Drive for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 60: Install The Main Control Circuit Board
T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Install the Main Control Circuit Board Install the main control circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 61: Stirring Fan Assembly Replacement
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. 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 62: Install The Stirring Fan Assembly
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. — 2 N•m (18 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 63: Install The Heatsink Fan Assembly
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...
Page 64: Fan Power Supply Circuit Board Replacement
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 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 65: Install The Fan Power Supply Circuit Board
M4 x 10 mm 2.0 N•m (18.0 lb•in) 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...
Page 66: Potential Earth (Pe) Jumper Replacement
• 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, for jumper configuration. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 67: Power Feedback Circuit Board And Bracket Replacement
If used, disconnect any I/O wiring terminal blocks from an installed option module. Control Pod Shown Removed from Drive for Clarity Only. Option Modules Not Shown for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 68 T20 or F - 6.4 mm (0.25 in.) 2.3 N m (20 lb • • M5 x 10 mm T25 or F - 6.4 mm (0.25 in.) 3.6 N m (32 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 69 M4 x 10 mm T20 or F - 6.4 mm (0.25 in.) 2.3 N m (20 lb • • 9. Dispose of the circuit board and bracket. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 70: Install The Power Feedback Circuit Board And Bracket
• 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 71: Lcl Filter Capacitor Replacement
6. Cut the cable tie that secures the capacitor to the bracket, and remove the capacitor. 3 MM 1.8 N m (16.0 lb • • 19 mm 9.0 N m (80 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 72: Install The Lcl Filter Capacitor
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. 3 mm 1.8 N m (16.0 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 73 5. Install the filter capacitor in the reverse order of removal. • Verify the placement of the resistor and new cable tie as shown here. Wire Harness From Power Circuit Board Outside of Resistor Chassis Cable Tie Head Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 74 Chapter 4 Frame 5 Components Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 75: Frame 6 Components
SK-RM-JMPR1-F6 See page (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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 76: Remove The Cover
M4 x 8 mm F - 6.4 mm (0.25 in.) or 4 mm hex 2.6 N m (23 lb • • Install the Cover Install the cover in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 77: Main Control Circuit Board Replacement
15. 3. Loosen the two captive thumbscrews on the control pod access cover and remove the cover. T15 or F - 6.4 mm (0.25 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 78 5. Disconnect the HIM cable from the port on the main control board. Control Pod Shown Removed from Drive for Clarity Only. M3 x 6.4 mm T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 79 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. Control Pod Shown Removed from Drive for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 80: Install The Main Control Circuit Board
T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Install the Main Control Circuit Board Install the main control circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 81: Stirring Fan Assembly Replacement
T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • 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...
Page 82: Heatsink Fan Assembly Replacement
6. Disconnect the fan power wire harness connector from the connector inside the chassis and remove the fan assembly. M4 x 8 mm 2.6 N m (23 lb • • Cover Shown Removed for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 83: Install The Heatsink Fan Assembly
T20 or F - 6.4 mm (0.25 in.) 2.3 N m (20 lb • • Jumper Shown in Default (IN) Position. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 84: Install 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 85 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...
Page 86: Install The Fan Power Supply Circuit Board
T20 or F - 6.4 mm (0.25 in.) 2.3 N m (20 lb • • 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...
Page 87: Power Feedback Circuit Board And Bracket Replacement
If used, disconnect any I/O wiring terminal blocks from an installed option module. Control Pod Shown Removed from Drive for Clarity Only. Option Modules Not Shown for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 88 6. Remove the four M4 x 10 mm slotted torx screws that secure the control pod to the chassis and remove the control pod. M4 x 10 mm 5, 6 T20 or F - 6.4 mm (0.25 in.) 2.3 N m (20 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 89 M4 x 10 mm 2.8 N m (25 lb • • 8. Dispose of the circuit board and bracket. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 90: Install The Power Feedback Circuit Board And Bracket
• 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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 91: Lcl Filter Capacitor Replacement
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. 19 mm 9.0 N m (80 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 92 R, S and T on the capacitor terminal block at the top of the capacitor, and remove the wires. Retain all wires for reuse. 3 mm 1.8 N m (16.0 lb Interconnection • • Wires From Power Circuit Board Resistor Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 93 Frame 6 Components Chapter 5 7. Remove the capacitor from the drive. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 94: Install The Lcl Filter Capacitor
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 for wiring orientation. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 95: Rockwell Automation Publication 750-Tg100B-En-P - June
(so it does not interfere with the cover when it is replaced). Position the Cable Tie Heads to the Side of the Capacitors. 19 mm 9.0 N m (80 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 96 Chapter 5 Frame 6 Components Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 97: Frame 7 Kits
“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). Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 98: Ip54 Exhaust Vent Filters Replacement
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. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 99: Install The Control Pod Cover
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...
Page 100: Install The Control Pod Fan Assembly
Fan Assembly 0.45 N m (4 lb • • Install the Control Pod Fan Assembly Install the control pod fan assembly in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 101: Main Control Circuit Board Replacement
Control Pod Shown Removed from Drive and Outer Control Pod Chassis for Clarity Only. M3 x 6.4 mm T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 102 9. Disconnect the HIM plug-in terminal block for the mini-DIN (port 2) connector on the control board. Control Pod Shown Removed from Drive and Outer Control Pod Chassis for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 103: Install The Main Control Circuit Board
T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Install the Main Control Circuit Board Install the main control circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 104: Control Pod Assembly Replacement
9. Route the fiber optic cables through the grommets in the bottom of the control pod carefully, and coil the fiber-optic cable and secure in a protected location. Follow the minimum bend radius requirement. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 105 Disconnect the plug-in terminal blocks. b. Loosen the two captive thumb screws that secure the option module to the control pod chassis and remove the option module. Final torque for re-assembly is 0.45 N•m (4 lb•in). Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 106 15. If installed, disconnect the customer supplied 24V supply power wire connector P13 from connector J13 on the fiber-optic interface board. Route Cables Through Grommets 16. Route all cables through the grommets in the bottom of the control pod. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 107 13 mm torx screws that secure the hinged mounting bracket to the inside edge of the enclosure and remove the control pod assembly. M5.5 x 13 mm 4.8 N m (42 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 108: Install The Control Pod Assembly
Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. b. Insert the transceiver and fiber-optic cable into the connector on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 109: Power/Filter Module Heatsink Fan Assembly Replacement
4. Below the fan assembly, reach through the opening in the front of the power or LCL filter module chassis, and disconnect the fan power supply connector P4 from J4 on the fan assembly. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 110: Install The Power/Filter Module Fan Assembly
Follow these steps to remove the protective guard. 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...
Page 111: Install The Protective Guard
• Be sure to secure the HIM cable to the guard with a new cable tie. ATTENTION: To avoid an electric shock or burn hazard, never energize the drive or bus supply with the protective guards removed. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 112: Control Transformer Fuses (Fh4) Replacement
5. Pull out on the tabs at the top of the fuse holder and remove the fuse. Install the Control Transformer Fuses Install the control transformer fuses in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 113: Power Module Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the enclosure door. 4. Remove the protective guard. See Remove the Protective Guard on page 110. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 114 Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm (2 in.) attenuation increases as inside bend radius is decreased. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 115 P3 from J3 on the I/O panel on the power module. 10. Disconnect the 240V AC and optional 24V DC power supply wire harness connector P4 from J4 on the I/O panel on the power module. Fiber-optic Ports Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 116 DC terminals on the motor side converter power module and remove the DC link/fuse assembly. Regenerative Drive Configuration Shown. 19 mm 45 N•m (398 lb•in) LCL Filter Module Not Shown for Clarity Only 17 mm 37.9 N•m (336 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 117 13. For the line side converter power module, remove the six M8 x 30 mm torx screws that secure the AC input flexible bus bars to the AC input terminals on the power module, and remove the flexible bus bars. M8 x 30 mm 19.8 N•m (175 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 118 14. For the motor side inverter module, remove the six M8 x 30 mm torx screws that secure the AC output flexible bus bars to the AC output terminals on the power module, and remove the flexible bus bars. M8 x 30 mm 19.8 N•m (175 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 119 PowerFlex 755T Module Service Ramp Instructions, publication 750-IN108. 18. To release the power module, remove the two remaining M10 screws. 19. Remove the power module from the enclosure. M10 x 20 mm 19.8 N•m (175 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 120: Install The Power Module In The Enclosure
3. Open the enclosure door. 4. Remove the protective guard. See Remove the Protective Guard on page 110. 5. Remove the power module from the enclosure. See Remove the Power Module from the Enclosure on page 113. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 121 8. Remove the 13 M5 x 10 mm torx screws that secure the right side cover to the power module and remove the cover. M5 x 12 mm 6, 7 2.6 N•m (23.0 lb•in) M5 x 10 mm 6.0 N•m (53.0 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 122 Chapter 6 Frame 7 Components 9. Disconnect the cable connector P13 from connector J13 on the power layer interface circuit board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 123: Install The Power Layer Interface Circuit Board
Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm (2 in.) attenuation increases as inside bend radius is decreased. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 124: Power Interface Circuit Board Replacement
5. Remove the power module from the enclosure. See Remove the Power Module from the Enclosure on page 113. 6. Remove the power layer interface circuit board from the power module. See Power Layer Interface Circuit Board Replacement on page 120. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 125 7. Disconnect these cable connectors from the power interface circuit board: • P3 from J3 • P4 from J4 • P7 from J7 • P8 from J8 • P9 from J9 • P10 from J10 • P11 from J11 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 126: Install The Power Interface Circuit Board
EMI shield and remove the board. M4 x 18 mm 2.6 N•m (23.0 lb•in) Install the Power Interface Circuit Board Install the power interface circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 127: Lcl Filter Module Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the enclosure door. 4. Remove the protective guard. See Remove the Protective Guard on page 110. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 128 8. Disconnect the 24V DC signal wire harness connector P3 from J3 on the I/O panel in the line side converter power module. – 8 (J3) P2 or F - 6.4 mm (0.25 in.) 1.8 N m (16 lb • • 7 (PDI Fiber-optic Port) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 129 10. Remove the two M8 x 30 mm torx screws that secure each of the LCL filter AC output flexible bus bars to the AC input terminals on the line side converter power module and remove the bus bars. M8 x 30 mm 19.8 N•m (175 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 130 M10 x 20 mm 19.8 N•m (175 lb•in) Circuit Breaker AC Output Flexible Bus Bars and Fuses Not Shown for Clarity Only. Fuse and 240V AC Power Harness Connections at Back of Module. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 131: Install The Lcl Filter Module In The Enclosure
Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm (2 in.) attenuation increases as inside bend radius is decreased. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 132: Current Sense Circuit Board Replacement
4. Remove the protective guard. See Remove the Protective Guard on page 110. 5. Remove the LCL filter module from the enclosure. See Remove the LCL Filter Module from the Enclosure on page 127. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 133 6. Remove the two M5 x 12 mm torx screws that secure the connector mounting plate and connectors J1 and J2 to the protective cover on the back of the LCL filter module. M5 x 12 mm 2.6 N•m (23.0 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 134 LCL filter module chassis and remove the cover. 8. Route the 24V DC control power supply wire harness and connector P3 through the grommet on the cover. M5 x 12 mm 2.6 N•m (23 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 135 • P4 from J4 • P5 from J5 • P6 from J6 • P8 from J8 • P13 from J13 • P14 from J14 (must be reused to maintain the rating of the LCL filter module) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 136 Frame 7 Components 11. Remove the five M4 x 12 mm torx screws that secure the current sense circuit board to the chassis and remove the board. M4 x 12 mm 2.6 N•m (23 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 137: Install The Current Sense Circuit Board
2. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. 3. Insert the transceiver and fiber-optic cable into the port on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 138 Chapter 6 Frame 7 Components Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 139: Control Bay And Control Pod Kits
Roof Fan 240V Control Power Fuse (FH3) SK-RM-IBFH3-FUSE3x-Fn See page (1) These components are contained in the control bay for frame 8 and 9 drives and bus supplies. Removal procedures are included in Chapter 6 - Power Bay Components. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 140: Control Bay And Control Pod Components
Chapter 7 Control Bay and Control Pod Components Figure 8 - Control Bay Ventilation Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 141 Control Bay and Control Pod Components Chapter 7 Figure 9 - Control Pod Assembly Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 142: Ip21/Ip54 Roof Vent Filter Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Slide the vent up to release the tabs from the slots in the vent assembly and remove the vent. 4. Remove the filter from the vent cover. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 143: Install The Ip21/Ip54 Roof Vent Filter
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 control bay or input bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 144: Install The Ip21/Ip54 Roof Vent Fan
2.6 N m (23 lb • • 13 mm 2.6 N m (23 lb • • Install the IP21/IP54 Roof Vent Fan Install the IP21/IP54 roof vent fan in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 145: Ip21/Ip54 Door Vent Filter Replacement
Install the IP21/IP54 Door Vent Filter IMPORTANT Verify that the Rittal logo on the fiber filter media points inward, toward the interior of the enclosure. Install the IP21/IP54 door vent filter in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 146: Control Pod Cover Removal
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 control bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 147: Install The Control Pod Cover
• • The Control Pod is Shown Separated from the Control/Input Bay to Clarify the Instructions Only. Install the Control Pod Cover Install the control pod cover in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 148: Fiber Transceiver Circuit Board Replacement
However, it is possible to remove the fiber-optic cables without removing the boards. This procedure assumes that all fiber-optic ports are used. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 149 M0…M9 Fiber transceiver ports for the fiber-optic connections from CNTL on the power layer interface board in power modules that are used as motor side inverters. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 150 • • 7. For each fiber-optic cable, remove the cable from the transceiver. 8. For each fiber transceiver board, remove the transceivers from the connector on the board. Retain the transceivers for reuse. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 151: Install The Fiber Transceiver Circuit Board
1. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. 2. Insert the transceiver with fiber-optic cable into the port on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 152: Main Control Circuit Board Replacement
90° horizontal position. 6. Disconnect the HIM cable from the port on the main control board. M3 x 6.4 mm T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 153 8. Disconnect any Ethernet cables from the ports on the bottom of the main control board. 9. Disconnect the plug-in terminal block (TB1) on the bottom of the main control board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 154: Install The Main Control Circuit Board
T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • HIM Bezel Not Shown for Clarity Only. Install the Main Control Circuit Board Install the main control circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 155: Backplane Circuit Board Replacement
4. Remove the control pod cover. See Control Pod Cover Removal on page 146. 5. Remove the main control circuit board. See Main Control Circuit Board Replacement on page 152. 6. Disconnect and remove any option modules from the backplane circuit boards. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 156: Install The Backplane Circuit Board
M4 x 8 mm T20 or F - 5 mm (0.19 in.) 2.6 N m (23 lb • • Install the Backplane Circuit Board Install the backplane circuit board in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 157: Fiber-Optic Interface Circuit Board Replacement
6. Disconnect the two fan power supply connectors from connectors J18 and J25 on the fiber-optic interface board. 7. If installed, disconnect the customer supplied 24V supply power wire connector P13 from connector J13 on the fiber-optic interface board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 158 11. For each motor side converter, disconnect the fiber-optic cable from the Mn port on the fiber transceiver board. Carefully coil the fiber-optic cable and secure in a protected location. Follow the minimum bend radius requirement. ACP0 ACP1 / TAM Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 159 90° horizontal position. 13. Disconnect the HIM cable from the port on the main control board. M3 x 6.4 mm T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 160 18. If installed, remove the option module in slot 7, by loosening the two captive thumb screws on the module and by pulling the board out of the control pod. The tightening torque for installation is the same as for the main control board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 161 19. Loosen the three captive thumb screws that secure the main control board to the pod chassis and remove the board. – T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb • • HIM Bezel Not Shown for Clarity Only. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 162 Take steps to be sure that the screws do not fall into the drive below. M4 x 8 mm T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 163 Remove the board from the control pod. M4 x 8 mm T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 164: Install The Fiber-Optic Interface Circuit Board
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the control bay enclosure door. 4. Remove the control pod cover. See Control Pod Cover Removal on page 146. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 165 7. Loosen the two captive thumb screws on the fan assembly and pull the assembly out and off the pod chassis. – T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 166: Install The Control Pod Fan Assembly
7. For each line side inverter, disconnect the fiber-optic cable from the Ln port on the fiber transceiver board. Carefully coil the fiber-optic cable and secure in a protected location. Follow the minimum bend radius requirement. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 167 8. For each motor side converter, disconnect the fiber-optic cable from the Mn port on the fiber transceiver board. Carefully coil the fiber-optic cable and secure in a protected location. Follow the minimum bend radius requirement. ACP0 ACP1 / TAM Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 168 Disconnect the plug-in terminal blocks. b. Loosen the two captive thumb screws that secure the option module to the control pod chassis and remove the option module. Final torque for re-assembly is 0.45 N•m (4 lb•in). Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 169 14. Disconnect the two fan power supply connectors from connectors J18 and J25 on the fiber-optic interface board. 15. If installed, disconnect the customer supplied 24V supply power wire connector P13 from connector J13 on the fiber-optic interface board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 170 17. Slide the pod up, so that the keyholes on the pod clear the mounting screws, and remove the control pod. M4 x 8 mm T20 or F - 5 mm (0.19 in.) 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 171: Install The Control Pod
1. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. 2. Insert the transceiver and fiber-optic cable into the connector on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 172 Chapter 7 Control Bay and Control Pod Components Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 173: Input Bay Components
Control Power Components 240V Power Distribution Fuse (FH2) SK-RM-IBFH2-FUSE2x-Fn Frame 8 and 9, seeFigure 14 See page page Roof Fan 240V Control Power Fuse (FH3) SK-RM-IBFH3-FUSE3x-Fn See page Frame 10…12, see Figure 13 page Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 174 Chapter 8 Input Bay Components Figure 10 - Frame 8 and 9 Input Bay Ventilation Kits Identification Frame 9 Input Bay Shown Vent Cover Shown Removed for Clarity Only Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 175 Input Bay Components Chapter 8 Figure 11 - Frame 10…12 Input Bay Ventilation Kits Identification Frame 10 Input Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 176 Chapter 8 Input Bay Components Figure 12 - Input Bay Frame 8 and 9 AC Precharge Module Kits Identification Frame 9AC Precharge Module Frame 8 AC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 177 Input Bay Components Chapter 8 Figure 13 - Input Bay Frame 10…12 AC Precharge Module and Control Components Kits Identification Frame 12 Input Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 178 Chapter 8 Input Bay Components Figure 14 - Frame 8 and 9 Input Bay Control Power Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 179: Ip21/Ip54 Roof Vent Filter Replacement
3. Lift the tab on the top center of the vent cover and rotate out the cover. 4. Remove the fiber filter from the vent housing. Vent Cover Shown Removed for Clarity Only Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 180: Install The Ip54/Ip21, 400/600 Mm Wide Door Vent
5. Pull the top edge of the fiber filter out and lift it off the cassette. M4 x 10 mm P2 or F - 6.4 mm (0.25 in.) 1.1 N m (10 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 181: Install The Ip54, 800/1000 Mm Wide Door Vent Filters
Follow these steps to remove the IP21, 800/1000 mm wide door vent filter. 1. Review the Product Advisories on page 14. 2. Remove power from the system. See Remove Power from the System on page 15. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 182: Install The Ip21, 800/1000 Mm Wide Door Vent Filter
Follow these steps to remove the IP54/21, 1000 mm wide door vent fan. 1. Review the Product Advisories on page 14.Remove power from the system. 2. See Remove Power from the System on page 15. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 183: Install The Ip21/Ip54, 1000 Mm Wide Door Vent Fan
You must remove the guards to access other components inside the input bay. Remove the Guards Follow these steps to remove and replace the guards. 1. Review the Product Advisories on page 14. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 184 • 600 mm wide input bay guards require removal of six screws. • 1000 mm wide input bay guards require removal of 28 screws. M5.5 x 13 mm 2.6 N m (23 lb • • Frame 8 Input Bay Frame 9 Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 185 Input Bay Components Chapter 8 Frames 10…15 Input Bay (Frame 10 Shown) M5.5 x 13 mm 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 186: Install The Guards
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 187 AC precharge module chassis or enclosure side sheet and slide the panel out of the chassis. M5 x 12 mm 2.6 N m (23 lb • • 5 and 6 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 188 • P2 from J2 • P3 from J3 • P4 from J4 • P5 from J5 • P6 from J6 • P7 from J7 • P11 from J11 • P12 from J12, if present Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 189: Install The Ac Precharge Control Circuit Board
15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. 5. Disconnect the wires from top terminals on the time delay relay. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 190: Install The Ac Precharge Time Delay Relay
4. Remove the guard from the enclosure. See Guard Removal on page 183. 5. Disconnect connector P15 from the module. 6. Remove the torx screw or hex nut that secures the ground wire to the appropriate PE-A1 terminal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 191 8. Remove the two M4 x 10 mm slotted-torx screws that secure the TVSS module to the panel and remove the module. M4 x 10 mm T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 192: Install The Ac Precharge Tvss Module
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 193: Install The Ac Precharge Control Board Fuses
5. Pull out the tabs at the top of the fuse holders and remove the fuses. Frame 8 AC Precharge Module Frame 10 Input Bay Install the AC Precharge Control Board Fuses Install the AC precharge control circuit board fuses in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 194: Power Distribution Fuse (Fh2) Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 195: Install The 240V Power Distribution Fuse
Fuse holder (labeled FH3) is on the control panel in the input bay. Follow these steps to remove and replace the roof fan 240V control power fuse. 1. Review the Product Advisories on page 14. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 196: Install The Roof Fan 240V Control Power Fuse
5. Pull out on the tab on the fuse holder and remove the fuse. Control Bay Frame 10 Input Bay Install the Roof Fan 240V Control Power Fuse Install the roof fan 240V control power fuse in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 197: Control Transformer Fuses (Fh4
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 198: Install The Control Transformer Fuses
5. Pull out on the tabs at the top of the fuse holder and remove the fuse. Frame 8 AC Precharge Module Frame 10 Input Bay Install the Control Transformer Fuses Install the control transformer fuses in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 199: Ac Precharge Fused Disconnect (Fd1) Fuses Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the input bay enclosure door. 4. Remove the guard from the enclosure. See Guard Removal on page 183. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 200: Install The Ac Precharge Fused Disconnect Fuses
Control transformers are not available as a replacement kit. See the PowerFlex 755TM IP00 Open Type Kits, Technical Data, publication 750-TD101, for a complete list of Rockwell Automation recommended control transformer vendor catalog numbers. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 201: Power Bay Components
DC Precharge Module Disconnect Handle SK-RM-DCPC-HNDL Figure 16 on page See page and Shaft DC Precharge Circuit Board SK-RM-DCPC1-CD (400V/480V) See page SK-RM-DCPC1-EF (600V/690V) DC Precharge Fuses SK-RM-DCFUSE1-F8 (400V/480V) See page SK-RM-DCFUSE2-F8 (600V/690V) Power Module Kits Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 202: Ac Input Link Fuses
SK-RM-LCLCP4-F8M (80 µF) AC Common Mode Filter Board SK-RM-EMCFB1 See page Current Sense Board SK-RM-CSB1-700 (700 A) See page SK-RM-CSB1-525 (525 A) SK-RM-CSB1-350 (350 A) SK-RM-CSB1-263 (263 A) Power and LCL Filter Module Kits Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 203 (3) “C” and “D” in “CnnnDnnn” identifies an LCL filter module that is rated for 400/480V, respectively. “E” and “F” in “EnnnFnnn” identifies an LCL filter module that is rated for 600/690V, respectively. “nnn” in “CnnnDnnn” and “EnnnFnnn” identifies the LCL filter module amp rating. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 204 Chapter 9 Power Bay Components Figure 15 - Power Bay Ventilation Kits Identification 400 mm Wide Input Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 205 Power Bay Components Chapter 9 Figure 16 - DC Precharge Kits Identification Figure 17 - DC Link/Fuse Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 206 Chapter 9 Power Bay Components Figure 18 - Power Module Circuit Board and Jumper Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 207 Power Bay Components Chapter 9 Figure 19 - Power Module Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 208 Chapter 9 Power Bay Components Figure 20 - LCL Filter Module Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 209 Power Bay Components Chapter 9 Figure 21 - LCL Filter and Power Module Fan Assembly and Fan Fuse Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 210 Chapter 9 Power Bay Components Figure 22 - Accessory Kits Identification Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 211: Ip54 Exhaust Vent Filters Replacement
IMPORTANT Verify that the airflow direction arrow and “X” on the fiber filter media points inward, toward the interior of the enclosure. Install the IP54 exhaust vent filters on a power bay in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 212: Ip54 Exhaust Fan Fuse Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Slide the front vent up to release the tabs from the slots in the vent hood and remove the vent. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 213: Install The Ip54 Exhaust Fan Fuse
Install the IP54 Exhaust Fan Fuse Install the IP54 exhaust fan fuse on a power bay in the reverse order of removal. Tightening torque for the fuse holder is 3.4 N•m (30 lb•in). Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 214: Ip54 Exhaust Fan Replacement
5. Disconnect connector P1 from connector P12 on the inside of the enclosure. 13 mm 10.2 N m (90 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 215 7. Remove the eight M8 x 12 mm torx screws that secure the metal screens to the front and rear of the vent housing and remove the screens. M8 x 12 mm 19.8 N m (175 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 216 8. Remove the four M5 x 12 mm torx screws that secure the vent assembly cover to the fan assembly and remove the cover. M5 x 12 mm m (53 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 217 Power Bay Components Chapter 9 9. Cut the cable ties that secure the wire harness to the fan housing. 10. Disconnect the two wires from the fuse holder on the front of the vent housing. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 218 M3 x 20 mm 0.6 N•m (5.3 lb•in) M4 x 11 mm 3 N•m (26.5 lb•in) M5 x 5 mm 8 mm 6.5 N m (58 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 219: Install The Ip54 Exhaust Fan
M6 x 16 mm 10 N m (90 lb • • Install the IP54 Exhaust Fan Install the IP54 exhaust fan on a power bay in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 220: Ip54, 400/600 Mm Wide Door Vent Filters Replacement
Follow theses steps to install the IP54, 400/600 mm wide door vent filters. IMPORTANT Verify that the weep holes on the metal mesh filter are at the bottom of the filter when installed. 1. Insert the metal mesh filter into the filter cassette cover. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 221: Ip21 400/600 Mm Wide Door Vent Filter Replacement
4. Remove the metal mesh filter from the cover. 600 mm Wide Door Vent Shown. M4 x 10 mm P2 or F - 6.4 mm (0.25 in.) 1.1 N m (10 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 222: Install The Ip21, 400/600 Mm Wide Door Vent Filter
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 corresponding power bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 223 6. Loosen the hexagonal screw that secures the disconnect handle shaft to the disconnect switch and remove the handle. M5 x 10 mm 6.2 N m (55 lb • • – 2.5 mm 0.6 N•m (5.4 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 224: And Shaft
Follow these steps to remove the DC precharge module from the enclosure. 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 corresponding power bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 225 4. Loosen the two M6 x 16 mm torx screws that secure the side guards to the enclosure. 5. Loosen the two M6 x 16 mm torx screws that secure the bottom guard to the enclosure. M6 x 16 mm 4, 5 4.8 N m (42 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 226 Chapter 9 Power Bay Components 6. Disconnect connector P13 from J13 on the DC precharge module. 7. If present, disconnect connector P12 from J12 on the DC precharge module. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 227 P2 or F - 6.4 mm (0.25 in.) 1.8 N m (16 lb • • 13. Remove the fiber-optic cable from the power module chassis. 14. Remove the power module from the enclosure. See Power Module Replacement n page 236. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 228: Install The Dc Precharge Module In The Enclosure
Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm (2 in.) attenuation increases as inside bend radius is decreased. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 229: Dc Precharge Circuit Board Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. Remove the DC precharge module from the enclosure. See Remove the DC Precharge Module from the Enclosure on page 224. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 230 Retain the transceiver for reuse. 8. Disconnect these cable connectors from the DC precharge circuit board: • P1 from J1 • P2 from J2 • P3 from J3 • P9 from J9 • P10 from J10 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 231 Power Bay Components Chapter 9 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 232: Install The Dc Precharge Circuit Board
1. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. 2. Insert the transceiver and fiber-optic cable into the port on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 233: Dc Precharge Fuses Replacement
15. 3. Open the corresponding power bay enclosure door. 4. Remove the DC precharge module from the enclosure. See Remove the DC Precharge Module from the Enclosure from the Enclosure on page 224. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 234: Install The Dc Precharge Fuses
Side and Back Panels Not Shown for Clarity Only. 19 mm 45.0 N m (398 lb • • Install the DC Precharge Fuses Install the DC precharge fuses in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 235: Guard Removal
800 mm Wide Frame 8 Drive Power Bay Shown M5.5 x 13 mm 2.6 N m (23 lb • • Install the Guard Install the guard in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 236: Power Module Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. If a DC link fuse assembly is installed, remove the upper guard from the enclosure. See Guard Removal on page 235. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 237 5. If a DC precharge module is installed, loosen the two M6 x 16 mm torx screws that secure the bottom guard to the enclosure, and remove the bottom guard. M6 x 16 mm 4.8 N m (42 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 238 CTL and PDI (if present) ports on the power layer interface circuit board and remove the fiber-optic cable from the power module chassis. LCL filter with two line LCL filter with one line side converter. side converters Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 239 12. Disconnect the cable connector P4 from connector J4 on the I/O panel in the power module remove the cable from the power module chassis. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 240 PowerFlex 750-Series Service Cart and DCPC Module Lift Installation Instructions, publication 750-IN105. To remove the module using PowerFlex 755TM service ramp, follow the procedures that are detailed in the PowerFlex 755T Module Service Ramp Instructions, publication 750-IN108. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 241: Install The Power Module In The Enclosure
Table 21 - DC Link/Fuse Assembly Fuse Ratings DC Link/Fuse Assembly Fuse Kit Cat. No Voltage Class Fuses Fuse Size Kit Cat. No. Amps/Leg 1/Leg 20-750-MDCL1-CD-F8M SK-RM-DCFUSE1-F8 400/480V AC 1400 170M6467 20-750-MDCL2-CD-F8M 20-750-MDCL1-EF-F8M SK-RM-DCFUSE2-F8 600/690V AC 1100 170M6499 20-750-MDCL2-EF-F8M Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 242: Remove The Dc Link Fuses
7. Disconnect the cable connector P1 from connector J1 on the I/O panel in the power module remove the cable from the power module chassis. – P2 or F - 6.4 mm (0.25 in.) 1.8 N m (16 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 243: Install The Dc Link Fuses
Follow these steps to remove and replace the power module PE-B1 power 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. Open the corresponding power bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 244: Install The Power Module Pe-B1 Power Jumper
You must remove the circuit board tray from the power module to access the power layer interface and power interface circuit boards. Remove the Circuit Board Tray Follow these steps to remove the circuit board tray. 1. Review the Product Advisories on page 14. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 245 Replacement on page 236. 5. Remove the three M6 x 16 mm torx screws that secure the left-side cover to the power module chassis and remove the cover. M6 x 16 mm 5.2 N•m (46 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 246 Chapter 9 Power Bay Components 6. Disconnect the cable connector P13 from connector J13 on the power layer interface circuit board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 247 • P8 from J8 • P9 from J9 • P10 from J10 • P11 from J11 • P12 from J12 8. Remove all cables from the cable mounts on the front of the circuit board tray. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 248: Install The Circuit Board Tray
2. Without bending the cable to a radius less than 50 mm (2 in.), fully insert the fiber-optic cable into the transceiver. 3. Insert the transceiver and fiber-optic cable into the port on the board, until you hear an audible ‘click.’ Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 249: Power Layer Interface Circuit Board Replacement
IMPORTANT The power layer interface circuit board replacement kit excludes screws. Therefore, all existing screws for this board must be reused. Verify the screw size that is supplied with your circuit board tray and apply the recommended torque during reinstallation. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 250: Install The Power Layer Interface Circuit Board
Circuit board trays and screw combinations for the power interface board include: • Part number PN-371633 contains five M4 x 10 mm slotted-torx screws • Part number PN-417691 contains five M4 x 18 mm slotted-torx screws Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 251: Remove The Power Interface Circuit Board
Verify the screw size that is supplied with your circuit board tray and apply the recommended torque during reinstallation. M4 x 10 mm 2.6 N•m (23.0 lb•in) M4 x 18 mm 2.6 N•m (23.0 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 252: Install The Power Interface Circuit Board
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. Remove the power module from the enclosure. See Power Module Replacement on page 236. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 253 Chapter 9 5. Remove the three M6 x 16 mm torx screws that secure the right-side cover to the power module chassis and remove the cover. M6 x 16 mm 5.2 N•m (46 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 254: Install The Balance Resistors
8. Loosen the lower M4 nut that secures the balance resistor to the power module chassis and remove the resistors. 7, 8 7 mm 2.6 N•m (23 lb•in) Install the Balance Resistors Install the balance resistors in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 255: Current Sensors Replacement
6. Remove the six M8 x 20 mm torx screws that secure the three flexible bus cables to the IGBT power terminals and pull the flexible bus cables through the opening in the current sensors. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 256: Install The Current Sensors
M8 x 20 mm 15 N•m (133 lb•in) Power Module without an Inductor Shown. M4 x 10 mm 2.6 N•m (23 lb•in) Install the Current Sensors Install the current sensors in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 257: Lcl Filter Module Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. If present, remove the guards from the enclosure. See Guard Removal on page 235. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 258 Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal 50 mm (2 in.) attenuation increases as inside bend radius is decreased. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 259 LCL filter with two line side converters. 8. Disconnect the 24V cable connector P3 from connector J3 on the I/O panel in one or more power modules and remove the cable from the chassis. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 260 9. Disconnect the 240V AC control power wire harness connector P4 from P2 on the LCL filter module. 10. Disconnect the AC input fuse wire harness connector P5 from P1 on the LCL filter module. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 261 Installation Instructions, publication 750-IN105, for information on by using the service cart. 15. To release the LCL filter module, remove the two remaining M10 screws. 16. Remove the LCL1 filter module from the enclosure. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 262: Install The Lcl Filter Module In The Enclosure
690/700V (IEC/U.L.), 900 A one 20-750-ML1-E980F920 20-750-MACL3-F9M SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A 20-750-MACL2-F9M Two 20-750-ML1-C1K4D1K3 400/480V SK-RM-ACFUSE4-F9 170M6471 690/700V (IEC/U.L.), 1600 A 20-750-MACL3-F9M Two 20-750-ML1-E980F920 600/690V SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 263: Remove The Ac Input Link Fuses
5. Disconnect the AC input fuse wire harness connector from fuse indicator switches on the fuses. 6. Disconnect the AC input fuse wire harness connector P5 from P1 on the LCL filter module. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 264: Install The Ac Input Link Fuses
• SK-RM-LCLCP1-F8M (30 µF) • SK-RM-LCLCP2-F8M (41 µF) • SK-RM-LCLCP3-F8M (62 µF) • SK-RM-LCLCP4-F8M (80 µF) Remove the LCL Filter Capacitor Assembly Follow these steps to remove and replace the LCL filter capacitor assembly. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 265 2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. Remove the LCL filter module from the enclosure. See LCL Filter Module Replacement on page 257. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 266 Remove the eight M4 x 10 mm torx screws that secure the capacitor wire access cover to the chassis and remove the cover. M4 x 10 mm 3 N•m (26 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 267: Install The Lcl Filter Capacitor Assembly
(EC) 1272/2008 [CLP] and classified as not dangerous according to 76/548/EEC / 1999/24/EEC. Install the LCL Filter Capacitor Assembly Install the LCL filter capacitor assembly in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 268: Ac Common Mode Filter Circuit Board Replacement
4. Remove the LCL filter module from the enclosure. See LCL Filter Module Replacement on page 257. 5. Remove the two barb fasteners that secure the screen to the chassis and remove the screen. The barb fasteners are not reusable. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 269 Power Bay Components Chapter 9 6. Remove the four cables from the connectors at the top and side of the EMC filter circuit board. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 270: Install The Ac Common Mode Circuit Board
Current Sense Circuit Board Replace the LCL filter module current sense circuit board with the appropriate kit catalog number: Replacement • SK-RM-CSB1-700 (700 A) • SK-RM-CSB1-525 (525 A) • SK-RM-CSB1-350 (350 A) • SK-RM-CSB1-263 (263 A) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 271: Remove The Current Sense Circuit Board
LCL port on the current sense circuit board. 7. Remove the transceiver from the LCL port on the current sense circuit board. Retain the transceiver for reuse. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 272 Remove the lower two M6 x 16 mm torx screws that secure the cover to the chassis. b. Loosen the upper two M6 x 16 mm torx screws that secure the cover to the chassis and remove the cover. M6 x 16 mm 12.5 N•m (110.6 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 273 • P13 from J13 • P4 from J4 • P1 from J1 • P14 from J14 (must be reused to maintain the rating of the module) 13. Remove the circuit board tray from the module chassis. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 274: Install The Current Sense Circuit Board
Install the current sense circuit board in the reverse order of removal. 1. Secure the wires to the circuit board tray by using cable ties in the same locations as previously secured. 2. When installing the fiber-optic cables: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 275: Power/Lcl Filter Module Heatsink Fan Fuse Replacement
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. Remove the guard form the enclosure. See Guard Removal on page 235. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 276: Install The Power/Lcl Filter Module Heatsink Fan Fuse
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 corresponding power bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 277: Assembly
Follow these steps to remove and replace the torque accuracy module. 1. Review the Product Advisories on page 14. 2. Remove power from the system. See Remove Power from the System on page 15. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 278 10. Remove the lower two M4 hex nuts and washers that secure the torque accuracy module panel to the mounting bracket and remove the module and panel. 7 mm 2.6 N•m (23 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 279: Install The Torque Accuracy Module
2. Remove power from the system. See Remove Power from the System on page 15. 3. Open the corresponding power bay enclosure door. 4. If present, remove the guards from the enclosure. See Guard Removal on page 235. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 280 7. Disconnect the DC bus conditioner cable connector P2 from J2 on the I/ O panel in the power module. – P2 or F - 6.4 mm (0.25 in.) 1.8 N m (16 lb • • Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 281 10. Remove the M6 x 12 mm torx screw that secures the ground cable to the GND (PE) terminal on the DC bus conditioner and remove the cable. M6 x 12 mm 5 N•m (44 lb•in) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 282: Install The Dc Bus Conditioner
DC bus conditioner. 8 mm 4.8 N•m (42 lb•in) Install the DC Bus Conditioner Install the DC bus conditioner in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 283: Wire Entry/Exit Bay Kits
IP21/IP54, 400 mm Wide Door Vent Fan SK-RM-WBDR-FANFLR1 See page and Filter IP21/IP54, 800 mm Wide Door Vent Fan SK-RM-WBDR-FANFLR2 See page and Filter Electrical Components Thermal Switch SK-RM-THRMSW-WB Figure 23 on page See page Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 284 Chapter 10 Wire Entry/Exit Bay Components Figure 23 - Wire Entry/Exit Bay Kits Identification 800 mm Wide Wire Entry/Exit Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 285: Ip54/Ip21, 400 Mm Wide Door Vent Filters Replacement
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 wire bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 286: And Filter Assembly
(90 lb • • Install the IP54/IP21, 400/800 mm Wide Door Vent Fan and Filter Assembly Install the IP54/IP21, 400/800 mm wide door vent fan, and filter assembly in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 287: Thermal Switch Replacement
Follow these steps to remove the thermal switch. 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 wire bay enclosure door. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 288 5. Remove the two M6 x 25 mm torx screws that secure the thermal switch assembly to the mounting bracket on the bus bar and remove the assembly. Retain the screws, guard, and clamp for reuse. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 289: Install The Thermal Switch
6. Disconnect the wires from the two terminals on the thermal switch. M6 x 25 mm 4.8 N m (42 lb • • Install the Thermal Switch Install the thermal switch in the reverse order of removal. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 290 Chapter 10 Wire Entry/Exit Bay Components Notes: Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 291: Before You Apply Power To The Drive
Drive • Instructions for frames 5 and 6 begin on page 292. • Instructions for frames 7…15 begin on page 294. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 292: Frames 5 And 6
• Use terminals +DC and –DC to measure +DC to chassis GND (PE), and –DC to chassis GND (PE). 3. If the measured value of any resistance test is less than 1 k, troubleshoot to find the short, correct the problem, and repeat step 2. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 293 I/O wires are connected and properly secured and supported by cable ties along their entire length when routed between enclosures. 6. Continue with No-load DC Bus Voltage and Output Current Measurements on page 298. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 294: Frames 7
• Use the fused disconnect output (FD1 SEC) testpoints R, S, and T to measure L to L and L to chassis GND. • Use the DC bus testpoints +DC and –DC to measure +DC to –DC, +DC to chassis GND, and –DC to chassis GND. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 295 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...
Page 296 • 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. Frame 10 Input Bay Shown Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 297 4. 6. For any module or component that has been removed and re-installed, complete the following: • Verify that all hardware connections have been replaced and are properly torqued. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 298: No-Load Dc Bus Voltage And Output Current Measurements
10, parameter 3 [Output Current]. 10. Stop the system. 11. Reconnect the load to the motor before proceeding with drive startup. For startup information see the PowerFlex® Drives with TotalFORCE™ Control Programming Manual, publication 750-PM100. Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 299: List Of Schematic Diagrams
PowerFlex 755TM Frame 8 Regenerative Bus Supply with DC Bus Conditioner PowerFlex 755TM Frame 8 Regenerative Bus Supply with no DC Bus Conditioner PowerFlex 755TM Frame 9 Regenerative Bus Supply PowerFlex 755TM Frame 10 Regenerative Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 300: Powerflex 755Tm Common Bus Inverter Control Bay
PowerFlex 755TM Frame 10 Common Bus Inverter with DC Precharge Module PowerFlex 755TM Frame 11 Common Bus Inverter with DC Precharge Module PowerFlex 755TM Frame 12 Common Bus Inverter with DC Precharge Module Entry Wire Bay Exit Wire Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 301 System Schematics Appendix A Figure 24 - PowerFlex 755TM LCL Filter Module (Frame 7) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 302 Appendix A System Schematics Figure 25 - PowerFlex 755TM LCL Filter Module (Frames 8…15) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 303 System Schematics Appendix A Figure 26 - PowerFlex 755TM Power Module (Frame 7) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 304 /DC FUSE GOOD DC FUSE COM /AC FUSE GOOD AC FUSE COM /BUS_COND_PRESENT BUS_COND_COM /BUS_COND_GOOD BLOWER_COM BLOWER_FDBK BLOWER_CONTROL INTAKE_TEMP_B INTAKE_TEMP_A Fiberlink Fiberlink VRFY -24V +24V VRFY -24V +24V VRFY -24V +24V Sheet Size 10001416614 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 305 System Schematics Appendix A Figure 28 - PowerFlex 755TM DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 306 Appendix A System Schematics Figure 29 - PowerFlex 755TM DC Bus Conditioner (Frames 8…15) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 307 System Schematics Appendix A Figure 30 - PowerFlex 755TL/TR Frame 5 Drive Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 308 Appendix A System Schematics Figure 31 - PowerFlex 755TL/TR Frame 6 Drive Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 309 System Schematics Appendix A Figure 32 - PowerFlex 755TM Frame 6 Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 310 Appendix A System Schematics Figure 33 - PowerFlex 755TM Frame 7 AC Precharge Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 311: Powerflex 755Tl/Tr Frame 7 Drive
System Schematics Appendix A Figure 34 - PowerFlex 755TL/TR Frame 7 Drive and PowerFlex 755TM Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 312 Appendix A System Schematics Figure 35 - PowerFlex 755TM Frame 8 AC Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 313 System Schematics Appendix A Figure 36 - PowerFlex 755TM Frame 9 AC Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 314 Appendix A System Schematics Figure 37 - PowerFlex 755TM Frame 10 AC Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 315 System Schematics Appendix A Figure 38 - PowerFlex 755TM Frame 11 AC Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 316 Appendix A System Schematics Figure 39 - PowerFlex 755TM Frame 12 AC Input Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 317 System Schematics Appendix A Figure 40 - PowerFlex 755TM Frame 8 Regenerative Drive with DC Bus Conditioner Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 318 Appendix A System Schematics Figure 41 - PowerFlex 755TM Frame 8 Regenerative Drive with no DC Bus Conditioner Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 319 System Schematics Appendix A Figure 42 - PowerFlex 755TM Frame 9 Regenerative Drive Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 320 Appendix A System Schematics Figure 43 - PowerFlex 755TM Frame 10 Regenerative Drive (Page 1 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 321 System Schematics Appendix A Figure 44 - PowerFlex 755TM Frame 10 Regenerative Drive (Page 2 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 322 Appendix A System Schematics Figure 45 - PowerFlex 755TM Frame 11 Regenerative Drive (Page 1 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 323 System Schematics Appendix A Figure 46 - PowerFlex 755TM Frame 11 Regenerative Drive (Page 2 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 324 Appendix A System Schematics Figure 47 - PowerFlex 755TM Frame 12 Regenerative Drive (Page 1 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 325 System Schematics Appendix A Figure 48 - PowerFlex 755TM Frame 12 Regenerative Drive (Page 2 of 2) Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 326 Appendix A System Schematics Figure 49 - PowerFlex 755TM Frame 8 Regenerative Bus Supply with DC Bus Conditioner Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 327 System Schematics Appendix A Figure 50 - PowerFlex 755TM Frame 8 Regenerative Bus Supply with no DC Bus Conditioner Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 328 Appendix A System Schematics Figure 51 - PowerFlex 755TM Frame 9 Regenerative Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 329 System Schematics Appendix A Figure 52 - PowerFlex 755TM Frame 10 Regenerative Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 330 Appendix A System Schematics Figure 53 - PowerFlex 755TM Frame 11 Regenerative Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 331 System Schematics Appendix A Figure 54 - PowerFlex 755TM Frame 12 Regenerative Bus Supply Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 332 Appendix A System Schematics Figure 55 - PowerFlex 755TM Common Bus Inverter Control Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 333 System Schematics Appendix A Figure 56 - PowerFlex 755TM Frame 8 Common Bus Inverter with DC Link Fuses Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 334 Appendix A System Schematics Figure 57 - PowerFlex 755TM Frame 9 Common Bus Inverter with DC Link Fuses Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 335: Powerflex 755Tm Frame 10 Common Bus
System Schematics Appendix A Figure 58 - PowerFlex 755TM Frame 10 Common Bus Inverter with DC Link Fuses Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 336 Appendix A System Schematics Figure 59 - PowerFlex 755TM Frame 11 Common Bus Inverter with DC Link Fuses Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 337 System Schematics Appendix A Figure 60 - PowerFlex 755TM Frame 12 Common Bus Inverter with DC Link Fuses Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 338 Appendix A System Schematics Figure 61 - PowerFlex 755TM Frame 8 Common Bus Inverter with DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 339 System Schematics Appendix A Figure 62 - PowerFlex 755TM Frame 9 Common Bus Inverter with DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 340 Appendix A System Schematics Figure 63 - PowerFlex 755TM Frame 10 Common Bus Inverter with DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 341 System Schematics Appendix A Figure 64 - PowerFlex 755TM Frame 11 Common Bus Inverter with DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 342 Appendix A System Schematics Figure 65 - PowerFlex 755TM Frame 12 Common Bus Inverter with DC Precharge Module Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 343: Entry Wire Bay
System Schematics Appendix A Figure 66 - Entry Wire Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 344: Exit Wire Bay
Appendix A System Schematics Figure 67 - Exit Wire Bay Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 345: Index
99 remove 155 control power balance resistors (power module) kits (frame 7) 97 install 254 control transformer 200 remove 252 control transformer fuses blower continuity test 52 inspection 42 install 198 remove 197 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 346 27 test 44 harsh environment operation DR and PE-A (EMC & MOV) jumper (frame 6) maintenance schedule 37 install 84 heatsink fan assembly (frame 5) remove 83 install 63 remove 62 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 347 182 remove 181 IP21/IP54 door vent filter (control bay) install 145 remove 145 IP21/IP54 roof vent fan (control/input bay) install 144 remove 143 IP21/IP54 roof vent filters (input bay) install 179 remove 179 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 348 /LCL filter module heatsink fan fuse continuity test 52 install 276 LCL fitler module (frame 7) remove 275 install 131 power bay (frames 8...15) lifespan kits 201 component 28 power bay ventilation locking device kits 201 check 44 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 349 PowerFlex 755TM frame 8 regenerative bus meter reading 48 supply with no DC bus conditioner 327 PowerFlex 755TM frame 8 regenerative drive with no DC bus conditioner PowerFlex 755TM frame 8 regenerative frive with DC bus conditioner 317 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 350 44 thermal switch (wire entry/exit bay) install 289 remove 287 tool size diagram 23 tool type diagram 23 torque accuracy module install 279 remove 277 ventilation (frame 7) kits 97 visual inspection 45 Rockwell Automation Publication 750-TG100B-EN-P - June 2019...
Page 352 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, Kinetix, PowerFlex, Rockwell Software, Rockwell Automation, and TotalFORCE are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual is also suitable for:

Powerflex 755tl Powerflex 755tm Powerflex 755tr

Rockwell Automation Allen-Bradley PowerFlex 750 Series Service Manual

Preface

Precautions

Chapter 1

Recommended Preventative Maintenance

Predictive Maintenance

Preventative Maintenance

Chapter 2

Chapter 3

Power Feedback Circuit Board and Bracket

Frame 5 Kits

Chapter 4 Remove the Cover

Power Feedback Circuit Board and Bracket

Chapter 5 Frame 6 Kits

Frame 6 Components

Remove Power

Frame 7 Kits

Power Interface Circuit Board

Power Layer Interface Circuit Board

Power Module

Chapter 6

Chapter 7

Control Bay and Control Pod Components

Chapter 8 Input Bay Kits

Input Bay Components

Chapter 9 Power Bay Kits

Power Bay Components

Quick Links

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 750 Series