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).
 Table of Contents

Preface Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1
Before You Begin Tests, General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance, or Repairs Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Class 1 Light-emitting Diode Product . . . . . . . . . . . . . . . . . . . . . . 12
Remove Power from the Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hardware Installation Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 2
Preventative Maintenance Recommended Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . 21
Predictive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Schedule Codes Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shock Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance of Industrial Control Equipment . . . . . . . . . . . . . . . . . . 32
Solid-state Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 3
Component Inspection and Test Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 35
Procedures Forward and Reverse Biased IGBT/Diode Tests . . . . . . . . . . . . . . . . . 37
AC Input Link Fuses Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DC Link Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Component Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chapter 4
Control Bay and Control Pod Control Bay and Control Pod Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Components IP/21IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . 46
Remove the IP21/IP54 Roof Vent Filter. . . . . . . . . . . . . . . . . . . . . 46
Install the IP21/IP54 Roof Vent Filter . . . . . . . . . . . . . . . . . . . . . . 47
IP54/IP21 Roof Vent Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove the IP21/IP54 Roof Vent Fan . . . . . . . . . . . . . . . . . . . . . . 47
Install the IP21/IP54 Roof Vent Fan . . . . . . . . . . . . . . . . . . . . . . . . 48
IP21/IP54 Door Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . 49
Remove the IP21/IP54 Door Vent Filter . . . . . . . . . . . . . . . . . . . . 49
Install the IP21/IP54 Door Vent Filter . . . . . . . . . . . . . . . . . . . . . . 49
Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Remove the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fiber Transceiver Circuit Board Replacement . . . . . . . . . . . . . . . . . . . 52

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 3

Table of Contents

Remove the Fiber Transceiver Circuit Board. . . . . . . . . . . . . . . . . 52

Install the Fiber Transceiver Circuit Board . . . . . . . . . . . . . . . . . . 55
Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 56
Remove the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . 56
Install the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . . . . 58
Backplane Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Remove the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 59
Install the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fiber-optic Interface Circuit Board Replacement . . . . . . . . . . . . . . . . 61
Remove the Fiber-optic Interface Circuit Board . . . . . . . . . . . . . . 61
Install the Fiber-optic Interface Circuit Board . . . . . . . . . . . . . . . 68
Control Pod Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 68
Remove the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . 68
Install the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . 70
Control Pod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove the Control Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Install the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Chapter 5
Input Bay Components Input Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
IP21/IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . 83
IP54/IP21 Roof Vent Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 83
IP54/IP21, 400/600 mm Wide Door Vent Filters Replacement. . . 83
Remove the IP54/IP21, 400/600 mm Wide Door Vent
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Install the IP54/IP21, 400/600 mm Wide Door Vent Filters . . 84
IP54, 800/1000 mm Wide Door Vent Filters Replacement . . . . . . . 84
Remove the IP54, 800/1000 mm Wide Door Vent Filters . . . . 84
Install the IP54, 800/1000 mm Wide Door Vent Filters . . . . . . 85
IP21, 800/1000 mm Wide Door Vent Filter Replacement . . . . . . . . 85
Remove the IP21, 800/1000 mm Wide Door Vent Filter . . . . . 85
Install the IP21, 800/1000 mm Wide Door Vent Filter . . . . . . . 86
IP54/IP21, 1000 mm Wide Door Vent Fan Replacement . . . . . . . . 86
Remove the IP54/IP21, 1000 mm Wide Door Vent Fan . . . . . . 86
Install the IP21/IP54, 1000 mm Wide Door Vent Fan. . . . . . . . 87
Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Remove the Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Install the Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
AC Precharge Control Circuit Board Replacement . . . . . . . . . . . . . . 90
Remove the AC Precharge Control Circuit Board . . . . . . . . . . . . 90
Install the AC Precharge Control Circuit Board . . . . . . . . . . . . . 93
AC Precharge Time Delay Relay Replacement . . . . . . . . . . . . . . . . . . . 93
Remove the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . . 93
Install the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . . . . 94
AC Precharge TVSS Module Replacement . . . . . . . . . . . . . . . . . . . . . . 94
Remove the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . . 94
Install the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . . . . 96

4 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Table of Contents

AC Precharge Control Circuit Board Fuses (FH1) Replacement . . 96

Remove the AC Precharge Control Circuit Board Fuses . . . . . . 96
Install the AC Precharge Control Board Fuses . . . . . . . . . . . . . . . 97
240V Power Distribution Fuse (FH2) Replacement . . . . . . . . . . . . . . 98
Remove the 240V Power Distribution Fuse . . . . . . . . . . . . . . . . . . 98
Install the 240V Power Distribution Fuse. . . . . . . . . . . . . . . . . . . . 99
Roof Fan 240V Control Power Fuse (FH3) Replacement. . . . . . . . . 99
Remove the Roof Fan 240V Control Power Fuse . . . . . . . . . . . . . 99
Install the Roof Fan 240V Control Power Fuse . . . . . . . . . . . . . 100
Control Transformer Fuses (FH4…FH7) Replacement. . . . . . . . . . 101
Remove the Control Transformer Fuses . . . . . . . . . . . . . . . . . . . . 101
Install the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . . . 102
AC Precharge Fused Disconnect (FD1) Fuses Replacement. . . . . . 103
Remove the AC Precharge Fused Disconnect Fuses. . . . . . . . . . 103
Install the AC Precharge Fused Disconnect Fuses . . . . . . . . . . . 104
Control Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Chapter 6
Power Bay Components Power Bay Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
IP54 Exhaust Vent Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . 115
Remove the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . 115
Install the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . . . 115
IP54 Exhaust Fan Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Remove the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . 116
Install the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 117
IP54 Exhaust Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Remove the IP54 Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Install the IP54 Exhaust Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
IP54, 400/600 mm Wide Door Vent Filters Replacement . . . . . . . 124
Remove the IP54, 400/600 mm Wide Door Vent Filters. . . . . 124
Install the IP54, 400/600 mm Wide Door Vent Filters . . . . . . 124
IP21 400/600 mm Wide Door Vent Filter Replacement. . . . . . . . . 125
Remove the IP21, 400/600 mm Wide Door Vent Filter . . . . . 125
Install the IP21, 400/600 mm Wide Door Vent Filter . . . . . . . 126
IP54, 800 mm Wide Door Vent Filters Replacement . . . . . . . . . . . . 126
IP21, 800 mm Wide Door Vent Filter Replacement. . . . . . . . . . . . . 126
DC Precharge Module Disconnect Handle and Shaft
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Remove the DC Precharge Module Disconnect Handle
and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Install the DC Precharge Module Disconnect Handle
and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DC Precharge Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Remove the DC Precharge Module from the Enclosure . . . . . . 128
Install the DC Precharge Module in the Enclosure . . . . . . . . . . 132

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Table of Contents

DC Precharge Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 133

Remove the DC Precharge Circuit Board . . . . . . . . . . . . . . . . . . . 133
Install the DC Precharge Circuit Board . . . . . . . . . . . . . . . . . . . . 136
DC Precharge Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Remove the DC Precharge Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Install the DC Precharge Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Remove the Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Install the Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Remove the Power Module from the Enclosure . . . . . . . . . . . . . 140
Install the Power Module in the Enclosure . . . . . . . . . . . . . . . . . . 145
DC Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Remove the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Install the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Power Module PE-B1 Power Jumper Replacement . . . . . . . . . . . . . . 147
Remove the Power Module PE-B1 Power Jumper . . . . . . . . . . . 147
Install the Power Module PE-B1 Power Jumper . . . . . . . . . . . . . 148
Circuit Board Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Remove the Circuit Board Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Install the Circuit Board Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Power Layer Interface Circuit Board Replacement . . . . . . . . . . . . . . 153
Remove the Power Layer Interface Circuit Board. . . . . . . . . . . . 153
Install the Power Layer Interface Circuit Board . . . . . . . . . . . . . 154
Power Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . 154
Remove the Power Interface Circuit Board . . . . . . . . . . . . . . . . . 155
Install the Power Interface Circuit Board . . . . . . . . . . . . . . . . . . . 156
Balance Resistors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Remove the Balance Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Install the Balance Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Current Sensors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Remove the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Install the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
LCL Filter Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Remove the LCL Filter Module from the Enclosure . . . . . . . . . 160
Install the LCL Filter Module in the Enclosure. . . . . . . . . . . . . . 165
AC Input Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Remove the AC Input Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Install the AC Input Link Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
LCL Filter Capacitor Assembly Replacement . . . . . . . . . . . . . . . . . . . 167
Remove the LCL Filter Capacitor Assembly . . . . . . . . . . . . . . . . 167
Install the LCL Filter Capacitor Assembly . . . . . . . . . . . . . . . . . . 170
EMC Filter Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . 171
Remove the EMC Filter Circuit Board . . . . . . . . . . . . . . . . . . . . . 171
Install the EMC Filter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 173
Current Sense Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 173
Remove the Current Sense Circuit Board. . . . . . . . . . . . . . . . . . . 174

6 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Table of Contents

Install the Current Sense Circuit Board . . . . . . . . . . . . . . . . . . . . 177

Power/LCL Filter Module Fan Fuse Replacement . . . . . . . . . . . . . . 178
Remove the Power/LCL Filter Module Fan Fuse. . . . . . . . . . . . 178
Install the Power/LCL Filter Module Fan Fuse . . . . . . . . . . . . . 179
Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Remove the Power or LCL Filter Module Fan Assembly . . . . . 179
Install the Power or LCL Filter Module Fan Assembly . . . . . . . 180
Torque Accuracy Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . 180
Remove the Torque Accuracy Module. . . . . . . . . . . . . . . . . . . . . . 180
Install the Torque Accuracy Module . . . . . . . . . . . . . . . . . . . . . . . 182
DC Bus Conditioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Remove the DC Bus Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . 182
Install the DC Bus Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Chapter 7
Wire Entry/Exit Bay Components Wire Entry/Exit Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
IP54/IP21, 400 mm Wide Door Vent Filters Replacement . . . . . . 189
IP54/IP21, 800 mm Wide Door Vent Filters Replacement . . . . . . 189
IP54/IP21, 400/800 mm Wide Door Vent Fan and Filter
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Remove the IP54/IP21, 400/800 mm Wide Door Vent
Fan and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Install the IP54/IP21, 400/800 mm Wide Door Vent
Fan and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Thermal Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Remove the Thermal Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Install the Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Chapter 8
Start Up After Repairs Before You Apply Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 195
No-load DC Bus Voltage and Output Current Measurements . . . 199

Appendix A
System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 7

Table of Contents

Notes:

8 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 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. The
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.

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
AC Drives Common Bus Application Techniques, Provides basic information to properly wire and
publication 750-AT004 ground common bus PWM AC drives.
PowerFlex 750-Series Products with TotalFORCE Control Provides the basic steps to install PowerFlex 755TL
Installation Instructions, publication 750-IN100 drives, PowerFlex 755TR drives, and PowerFlex 755TM
bus supplies.
PowerFlex 755TM AC Precharge Modules Unpacking and These publications provide detailed information on:
Lifting Instructions, publication 750-IN102 • Component weights
• Precautions and recommendations
PowerFlex 755TM DC Precharge Modules Unpacking and • Hardware attachment points
Lifting Instructions, publication 750-IN103 • Lifting the component out of the packaging
PowerFlex 755TM Power and Filter Modules Unpacking
and Lifting Instructions, publication 750-IN104
PowerFlex 750-Series Service Cart and DCPC Module Lift Provides detailed set-up and operating instructions
Installation Instructions, publication 750-IN105 for the module service cart and lift extension option.
PowerFlex 755TM Power and Filter Module Storage Provides detailed installation and usage instructions
Hardware Installation Instructions, publication 750-IN106 for this hardware accessory.
PowerFlex 755T Module Service Ramp Instructions, Provides detailed usage instructions for the module
publication 750-IN108 service ramp.
PowerFlex Drives with TotalFORCE Control Programming Provides detailed information on:
Manual, publication 750-PM100 • I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series Products with TotalFORCE Control Provides detailed information on:
Technical Data, publication 750-TD100 • Drive and bus supply specifications
• Option specifications
• Fuse and circuit breaker ratings

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 9

Preface

Resource Description
PowerFlex 750-Series Safe Speed Monitor Option Module These publications provide detailed information on
Safety Reference Manual, publication 750-RM001 installation, set-up, and operation of the 750-Series
safety option modules.
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 Provides basic information on enclosure systems,
(PWM) AC Drives, publication DRIVES-AT003 considerations to help protect against environmental
contaminants, and power and grounding
considerations for installing Pulse Width Modulated
(PWM) AC drives.
Wiring and Grounding Guidelines for Pulse Width Provides basic information to properly wire and
Modulated (PWM) AC Drives, publication DRIVES-IN001 ground PWM AC drives.
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system.
Safety Guidelines for the Application, Installation, and Provides general guidelines for the application,
Maintenance of Solid State Control, publication SGI-1.1 installation, and maintenance of solid-state control.

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.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.

10 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 1

Before You Begin Tests, Maintenance, or

Repairs

Topic Page
General Precautions 12
Remove Power from the Drive System 13
Commonly Used Tools 17
Hardware Installation Diagrams 18
Fastener Torque Sequences 18

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

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 11

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

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

Qualified Personnel

ATTENTION: Only qualified personnel familiar with adjustable frequency AC

drives 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

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before servicing. Measure the DC bus voltage
at the -DC and +DC TESTPOINT sockets on the front of the power module
(see Remove Power from the Drive System on page 13 for location).
ATTENTION: 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

ATTENTION: 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

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.

12 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Before You Begin Tests, Maintenance, or Repairs Chapter 1

Remove Power from the The following procedures must be followed before attempting to service any
part of the drive system.
Drive System
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 (such as an Active Front End or other DC power source).

ATTENTION: 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…d.
a. On the input bay, turn the AC precharge disconnect switch to the
“Off ” position.
b. Wait 15 minutes and open the enclosure door.
c. Close and lock the hasp on the circuit breaker.
d. Lock the fused disconnect switch.
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 and open the enclosure door.
b. Close and lock the hasp on the molded case switch.
c. Lock the fused disconnect switch.
d. If a control bay is used, turn the selector switch to the “Off ” position
and lock the switch.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 13

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

ATTENTION: 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 test point sockets in the input bay to verify
that there is no voltage present:
• Using the circuit breaker output (CB1 SEC) test points R/L1, S/L2,
and T/L3, measure L to L and L to chassis GND.
• By using the fused disconnect output (FD1 SEC) test points R, S,
and T, measure L to L and L to chassis GND.
• By using the DC bus test points +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

14 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Before You Begin Tests, Maintenance, or Repairs Chapter 1

ATTENTION: 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 test points +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-TG100A-EN-P - July 2017 15

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

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

• For regenerative drives and bus supplies, in the input bay, measure
terminals L, and N on terminal block TB2.

Frame 10 Input Bay Shown

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

terminal block TB4.

16 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Before You Begin Tests, Maintenance, or Repairs Chapter 1

Commonly Used Tools Table 1 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 1 - Service Tools

Tool Description Details
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 #15, #20, #25, #30, #40, #45
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,
capacitance measurements, and forward diode bias tests. Fluke model 87 III or
equivalent.
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 and transport power and filter modules.
Module storage hardware Module storage hardware (20-750-MINV-ATIP) helps to stabilize power and
filter modules during temporary storage after removal.
Torque wrench 1...12 N•m (8.8…106 lb•in)
Torque wrench 6...50 N•m (53…443 lb•in)
Wire cutter –

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.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 17

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

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

M4 x 10 mm Fastener Size
1 T20 or F - 6.4 mm (0.25 in.) Tool Type and Size
4.8 N•m (42 lb•in) F Flat-nose screwdriver
Sequence Px Phillips screwdriver/bit and size
Number Final Assembly Torque PZx Pozidriv screwdriver/bit and size
Txx 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

Fastener Torque Sequences

ATTENTION: 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.

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•m (6 lb•in) initial torque. The numeric illustration labels are for your
assistance. Drive components do not contain these labels.

18 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Before You Begin Tests, Maintenance, or Repairs Chapter 1

Figure 1 - Two-point Mounting

1 2

1 2

Initial Sequence

2 1

Final Sequence

Figure 2 - Four-point Mounting

1 3

4 2

1 2 3 4

Initial Sequence

4 3 2 1

Final Sequence

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 19

Chapter 1 Before You Begin Tests, Maintenance, or Repairs

Figure 3 - Six-point Mounting

6 2 4

3 1 5

1 2 3 4 5 6

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

1 2 3 4 5 6

Final Sequence

20 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 2

Preventative Maintenance

Topic Page
Recommended Preventative Maintenance 21
Predictive Maintenance 22
Schedule Codes Explanation 22
Shock Events 31
Maintenance of Industrial Control Equipment 32

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 Rockwell Automation recognizes that following a defined maintenance

schedule delivers the maximum product availability. By strictly following the
Maintenance 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:
• Table 2 Recommended Maintenance Schedule for Normal Operation
on page 23. Normal operation is defined as an environment where the
ambient temperature is less than or equal to 40 °C (104 °F).
• Table 3 Recommended Maintenance Schedule for High Temperature
Operation on page 26. High temperature operation is defined as an
environment where the ambient temperature is 41 °C (106 °F) to 55 °C
(134 °F).
• Table 4 Recommended Maintenance Schedule for Harsh Environment
Operation on page 29. Harsh environment is defined as a copper or
silver 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.

IMPORTANT Duty cycle and load profile can greatly affect the reliability of PowerFlex
750-Series Products with TotalFORCE Control.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 21

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
See Chapter 3 - Component Inspection and Test Procedures on page 35 for
additional information on how to perform inspections and tests.

Predictive Maintenance 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 Table 2…Table 4 on pages 23…29, 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 with Logix in the
PowerFlex Drives with TotalFORCE Control Programming Manual,
publication 750-PM100, for more information.

IMPORTANT Failure to address predictive maintenance alarms can cause unexpected

downtime.

Schedule Codes Explanation 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
23…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.

22 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Table 2 - Recommended Maintenance Schedule for Normal Operation
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameters
Power Module Grease Power Stabs R
Balance Resistors R R
(cat. no. SK-RM-INVBRn-F8M)
IGBTs Port 12 /14: 140, 240,
340, 440, 540
Bus Capacitors Port 12 /14: 143, 243,
(cat. no SK-RM-ICP1-xnnnxnnn) 343, 443, 543
Power Layer Interface Circuit Board R
(cat. no. SK-RM-PLI1-F8)
Power Interface Circuit Board (cat. R
no. SK-RM-PIBn-xnnnxnnn)
Gate Driver Circuit Board R
Heat Sink Fan Port 12 /14: 136, 236, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 336, 436, 536
LCL Filter Module Grease Power Stabs R
Capacitors R R
(cat. no. SK-RM-LCLCPn-F8M)
Current Sense Circuit Board R
(cat. no. SK-RM-CSB1-nnn)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

AC Common Mode Filter Board R
(cat. no. SK-RM-EMCFB1)
Heat Sink Fan Port 14: 1246, 1346, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 1546
AC Precharge Module Main Circuit Breaker (CB1) Port 14: 1143, 1150
Time Delay Relay R R
(cat. no. 20-750-MACPC-TDR)
AC Precharge Circuit Board R
(cat. no. 20-750-MACPC1-xx)
Preventative Maintenance

Precharge Contactor (M1) Port 14: 1146, 1153

23
Chapter 2
24
Table 2 - Recommended Maintenance Schedule for Normal Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Chapter 2

Module/Activity Component Predictive

Maintenance
Parameters
DC Precharge Module Grease Power Stabs R
DC Precharge Circuit Board R
(cat. no. SK-RM-DCPC1-xx)
Preventative Maintenance

Molded Case Switch (CB1) Port 12: 146, 246, 346,

446, 546
Cabinet (IP21/IP54) (1) Door-mounted Ventilation Air 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
Filters
Roof-mounted Ventilation 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
Assembly Air Filters
Input Bay Fans Port 0: 523 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 Bay Fan Port 0: 543 I I I I I I I I I I I I I I I I I I I I
Control Bay Roof Fan Port 0: 553 I I I I I I I I I I I I I I I I I I I I
Isolation Transformer/Line Reactor M M M M
DC Link/Common-Mode Choke M M M M
Control Pod Assembly Control Pod Cooling Fan Port 0: 513 I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-PODFAN1-F8)
Main Control Circuit Board R
(cat. no. SK-RM-MCB1-PF755)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

Dual Transceiver Circuit Board R
(cat. no. 20-750-MFTB1-F8)
Fiber Interface Circuit Board R
(cat. no. SK-RM-FIBn-F8)
Backplane Circuit Board R
(cat. no. SK-RM-PODBP1)
Fiber-optic Cables I I I I R I I I I R I I I I R I I I I R
Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
 Table 2 - Recommended Maintenance Schedule for Normal Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameters
Operational Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Conditions
Variables I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Spare Parts Inventory/Needs I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I 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.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

Preventative Maintenance

25
Chapter 2
26
Table 3 - Recommended Maintenance Schedule for High Temperature Operation
Chapter 2

Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameter (s)
Power Module Grease Power Stabs R R
Balance Resistors R R R
(cat. no. SK-RM-INVBRn-F8M)
Preventative Maintenance

IGBTs Port 12 /14: 140, 240,

340, 440, 540

Bus Capacitors Port 12 /14: 143, 243,

(cat. no SK-RM-ICP1-xnnnxnnn) 343, 443, 543

Power Layer Interface Circuit Board R R

(cat. no. SK-RM-PLI1-F8)
Power Interface Circuit Board (cat. R R
no. SK-RM-PIBn-xnnnxnnn)
Gate Driver Circuit Board R R
Heat Sink Fan Port 12 /14: 136, 236, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 336, 436, 536

LCL Filter Module Grease Power Stabs R R

Capacitors R R R
(cat. no. SK-RM-LCLCPn-F8M)
Current Sense Circuit Board R R
(cat. no. SK-RM-CSB1-nnn)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

AC Common Mode Filter Board R R
(cat. no. SK-RM-EMCFB1)
Heat Sink Fan Port 14: 1246, 1346, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 1546
AC Precharge Module Main Circuit Breaker Port 14: 1143, 1150

Time Delay Relay R R

(cat. no. 20-750-MACPC-TDR)
AC Precharge Circuit Board R R
(cat. no. 20-750-MACPC1-xx)
Precharge Contactor (M1) Port 14: 1146, 1153
 Table 3 - Recommended Maintenance Schedule for High Temperature Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameter (s)
DC Precharge Module Grease Power Stabs R R
DC Precharge Circuit Board R R
(cat. no. SK-RM-DCPC1-xx)
Molded Case Switch (CB1) Port 12: 146, 246, 346,
446, 546
Cabinet (IP21/IP54) (1) Door-mounted Ventilation Air 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
Filters
Roof-mounted Ventilation 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
Assembly Air Filters
Input Bay Fans Port 0: 523 I I I I I I I I I I I I I I I I I I I I
Power Bay 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 Bay Fan Port 0: 543 I I I I I I I I I I I I I I I I I I I I
Control Bay Roof Fan Port 0: 553 I I I I I I I I I I I I I I I I I I I I
Isolation Transformer/Line Reactor M M M M
DC Link/Common-Mode Choke M M M M
Control POD Assembly Control Pod Cooling Fan Port 0: 513 I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-PODFAN1-F8)
Main Control Circuit Board R R
(cat. no. SK-RM-MCB1-PF755)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

Dual Transceiver Circuit Board R R
(cat. no. 20-750-MFTB1-F8)
Fiber Interface Circuit Board R R
(cat. no. SK-RM-FIBn-F8)
Backplane Circuit Board R R
(cat. no. SK-RM-PODBP1)
Fiber-optic Cables I I I R I I I R I I I R I I I R I I I R
Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Preventative Maintenance

27
Chapter 2
28
Table 3 - Recommended Maintenance Schedule for High Temperature Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Chapter 2

Module/Activity Component Predictive

Maintenance
Parameter (s)
Operational Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Conditions
Variables I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Preventative Maintenance

Spare Parts Inventory/Needs I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I 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.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Table 4 - Recommended Maintenance Schedule for Harsh Environment Operation
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameter (s)
Power Module Grease Power Stabs R R R R R
Balance Resistors R R R R R
(cat. no. SK-RM-INVBRn-F8M)
IGBTs Port 12 /14: 140, 240,
340, 440, 540
Bus Capacitors Port 12 /14: 143, 243,
(cat. no SK-RM-ICP1-xnnnxnnn) 343, 443, 543
Power Layer Interface Circuit Board R R R R R
(cat. no. SK-RM-PLI1-F8)
Power Interface Circuit Board (cat. R R R R R
no. SK-RM-PIBn-xnnnxnnn)
Gate Driver Circuit Board R R R R R
Heat Sink Fan Port 12 /14: 136, 236, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 336, 436, 536
LCL Filer Module Grease Power Stabs R R R R R
Capacitors R R R R R
(cat. no. SK-RM-LCLCPn-F8M)
Current Sense Circuit Board R R R R R
(cat. no. SK-RM-CSB1-nnn)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

AC Common Mode Filter Board R R R R R
(cat. no. SK-RM-EMCFB1)
Heat Sink Fan Port 14: 1246, 1346, I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-INVFAN1-F8) 1546
AC Precharge Module Main Circuit Breaker Port 14: 1143, 1150
Time Delay Relay R R R R R
(cat. no. 20-750-MACPC-TDR)
AC Precharge Circuit Board R R R R R
(cat. no. 20-750-MACPC1-xx)
Preventative Maintenance

Precharge Contactor (M1) Port 14: 1146, 1153

29
Chapter 2
30
Table 4 - Recommended Maintenance Schedule for Harsh Environment Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Chapter 2

Module/Activity Component Predictive

Maintenance
Parameter (s)
DC Precharge Module Grease Power Stabs R R R R R
DC Precharge Circuit Board R R R R R
(cat. no. SK-RM-DCPC1-xx)
Preventative Maintenance

Molded Case Switch (CB1) Port 12: 146, 246, 346,

446, 546
Cabinet (IP21/IP54) (1) Door-mounted Ventilation Air 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
Filters
Roof-mounted Ventilation 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
Assembly Air Filters
Input Bay Fans Port 0: 523 I I I I I I I I I I I I I I I I I I I I
Power Bay 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 Bay Fan Port 0: 543 I I I I I I I I I I I I I I I I I I I I
Control Bay Roof Fan Port 0: 553 I I I I I I I I I I I I I I I I I I I I
Isolation Transformer/Line Reactor M M M R
DC Link/Common-Mode Choke M M M R
Control POD Assembly Control Pod Cooling Fan Port 0: 513 I I I I I I I I I I I I I I I I I I I I
(cat. no. SK-RM-PODFAN1-F8)
Main Control Circuit Board R R R R R
(cat. no. SK-RM-MCB1-PF755)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

Dual Transceiver Circuit Board R R R R R
(cat. no. 20-750-MFTB1-F8)
Fiber Interface Circuit Board R R R R R
(cat. no. SK-RM-FIBn-F8)
Backplane Circuit Board R R R R R
(cat. no. SK-RM-PODBP1)
Fiber-optic Cables I R I R I R I R I R I R I R I R I R I R
Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
 Table 4 - Recommended Maintenance Schedule for Harsh Environment Operation (Continued)
Years > 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Module/Activity Component Predictive
Maintenance
Parameter (s)
Operational Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Conditions
Variables I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Application Concerns I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Spare Parts Inventory/Needs I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I 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.

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.
12

11

10

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

6

Peak Amplitude (Gpeak)

4

1
Preventative Maintenance

0
1.00 10.00 100.00 1000.00
Maximum number of shock events

31
Chapter 2
Chapter 2 Preventative Maintenance

Maintenance of Industrial
Control Equipment ATTENTION: 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, for
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.

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

32 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Preventative Maintenance Chapter 2

retighten securely any loose fasteners. Lubricate if specified in individual

product 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.

Terminals - 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-TG100A-EN-P - July 2017 33

Chapter 2 Preventative Maintenance

Solid-state Devices

ATTENTION: 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.

34 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 3

Component Inspection and Test Procedures

Topic Page
Component Inspection and Maintenance 35
Forward and Reverse Biased IGBT/Diode Tests 37
AC Input Link Fuses Test 39
DC Link Fuse Test 39
Component Fuse Tests 40

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, for information on conditions that can cause a
fault or alarm and how to troubleshoot these conditions.

Component Inspection and 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
Maintenance 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 21.

1. Review the General Precautions on page 12.

2. Remove power from the drive. See Remove Power from the Drive System
on page 13.
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 83.
• Input bay, 1000 mm wide - see page 85.
• Power bay, 400/600 mm wide - see page 125.
• Power bay, 800 mm wide - see page 85.
• Wire entry/exit bay, 400 mm wide - see page 189.
• Wire entry/exit bay, 800 mm wide - see page 189.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 35

Chapter 3 Component Inspection and Test Procedures

IP54 door filters:

• Control bay - see page 49.
• Input bay, 400/600 mm wide - see page 83.
• Input bay, 1000 mm wide - see page 84.
• Power bay, 400/600 mm wide - see page 124.
• Power bay, 800 mm wide - see page 84.
• Wire entry/exit bay, 400 mm wide - see page 189.
• Wire entry/exit bay, 800 mm wide - see page 189.
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 46.
• Input bay - see page 46.
• Power bay - see page 115.
5. Inspect the fan assemblies for blockage and verify free rotation. Clean or
replace as necessary. See these procedures for removal instructions:
• Control bay - see page 47.
• Input bay - see page 47.
• Power bay - see page 118.
• LCL filter module - see page 179.
• Power module - see page 179.
• Entry/Exit wire bays - see
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. See
Control Pod Cover Removal on page 50.
7. If an AC 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 Input Bay
Kits on page 77 for a list of AC precharge replacement components.
8. 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 105 for a list of DC precharge replacement components.
9. 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.

36 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Component Inspection and Test Procedures Chapter 3

Forward and Reverse Biased 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
IGBT/Diode Tests 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 Table 5 and Table 6, on page 38,
verify that the actual voltage that is measured is consistent for each phase of
the power module.

1. Review the General Precautions on page 12.

2. Remove power from the drive. See Remove Power from the Drive System
on page 13.
3. Remove the power module from the enclosure. See Power Module
Replacement on page 140.
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 Table 5 and Table 6 on page 39. See Figure 4 for power module terminal
locations.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 37

Chapter 3 Component Inspection and Test Procedures

Figure 4 - Power Module Power Terminal Designations

1 2

5 4 3

ID Connection ID Connection
1 +DC 3 R/L1, U/T1
2 -DC 4 S/L2, V/T2
5 T/L3, W/T3

Table 5 - Forward Biased Diode Tests on the IGBT Assembly

Meter Leads
+ – Nominal Meter Reading
-DC U/T1
-DC V/T2
-DC W/T3 The value should gradually rise to between 0.20V and 0.75V. If the value is outside this range,
U/T1 +DC contact Technical Support. (1)

V/T2 +DC
W/T3 +DC
(1) The actual voltage reading can vary depending upon your equipment.

38 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Component Inspection and Test Procedures Chapter 3

Table 6 - Reverse Biased Diode Tests on the IGBT Assembly

Meter Leads
+ – Nominal Meter Reading
U/T1 -DC
V/T2 -DC
W/T3 -DC
“.0L” (open circuit) (1)
+DC U/T1
+DC V/T2
+DC W/T3
(1) Residual voltage on the DC bus capacitors 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.

5. Replace the power module if it fails these measurements. See Power

Module Replacement on page 140.
6. Complete the procedures in Chapter 6 - Power Bay Components on page
105 before placing the drive back into service.

AC Input Link Fuses 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 General Precautions on page 12.

2. Remove power from the drive. See Remove Power from the Drive System
on page 13.
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. See AC Input Link Fuses Replacement on page
165.

DC Link Fuse Test 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 General Precautions on page 12.

2. Remove power from the drive. See Remove Power from the Drive System
on page 13.
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. See DC Link Fuses Replacement on page 145.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 39

Chapter 3 Component Inspection and Test Procedures

Component Fuse Tests Perform a continuity test on the following fuses:

• AC precharge control board fuses (FH1). See AC Precharge Control
Circuit Board Fuses (FH1) Replacement on page 96.
• 240V power distribution fuse (FH2). See 240V Power Distribution Fuse
(FH2) Replacement on page 98.
• Input bay 240V control power fuse (FH3). See Roof Fan 240V Control
Power Fuse (FH3) Replacement on page 99.
• Control transformer fuses (FH4…FH7). See Control Transformer Fuses
(FH4…FH7) Replacement on page 101.
• AC precharge fused disconnect fuses. See AC Precharge Fused Disconnect
(FD1) Fuses Replacement on page 103.
• IP54 exhaust fan fuse. See IP54 Exhaust Fan Fuse Replacement on page
116.
• LCL filter and power modules fan fuse (F1). See Power/LCL Filter
Module Fan Fuse Replacement on page 178.

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

1. Review the General Precautions on page 12.

2. Remove power from the drive. See Remove Power from the Drive System
on page 13.
3. Continuity test the fuse or fuses.
4. Replace a fuse as necessary.

40 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Component Inspection and Test Procedures Chapter 3

Notes:

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 41

Chapter 3 Component Inspection and Test Procedures

42 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 4

Control Bay and Control Pod Components

This chapter provides detailed instructions for how to remove and replace
control bay and control pod components.

Control Bay and Control Pod Table 7 lists the replacement kits available for the control bay and control pod.
Kits A current list of spare parts for PowerFlex® 750-Series products with
TotalFORCE™ Control is available on the Allen-Bradley® website at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Table 7 - Control Bay/Control Pod Replacement Kits
Description Catalog Number Identification Identification No. Replacement Instructions
Ventilation Components
IP21/IP54 Roof Vent Filter SK-RM-IBFAN-54FLTR1 See Figure 5 on page 44 1 See page 46
IP21/IP54 Roof Vent Fan SK-RM-IBFAN1-F8 2 See page 47
IP21/IP54, 300 mm Wide Door Vent Filter SK-RM-CB3DR-FLTR1 3 See page 49
Control Pod Components
Fiber Transceiver Circuit Board 20-750-MFTB1-F8 See Figure 6 on page 45 4 See page 52
Regenerative/Low Harmonic/Inverter SK-RM-MCB1-PF755 5 See page 56
Main Control Circuit Board
Control Pod Backplane Circuit Board SK-RM-PODBP1 6 See page 59
Fiber-optic Interface Circuit Board, SK-RM-FIB1-F8, 7 See page 61
Regenerative and Low Harmonic
Fiber-optic Interface Circuit Board, Low SK-RM-FIB2-F8 7 See page 61
Harmonic
Control Pod Fan Assembly SK-RM-PODFAN1-F8 8 See page 68
Control Pod Assembly, Regenerative and 20-750-MCPOD1-F8M – See page 70
Low Harmonic
Control Pod Assembly, Low Harmonic 20-750-MCPOD2-F8M – See page 70
Control Power Components (1)
240V Power Distribution Fuse (FH2) SK-RM-IBFH2-FUSE2x-Fn See Figure 11 on page 82 13 See page 98
Roof Fan 240V Control Power Fuse (FH3) SK-RM-IBFH3-FUSE3x-Fn 14 See page 99
(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-TG100A-EN-P - July 2017 43

Chapter 4 Control Bay and Control Pod Components

Figure 5 - Control Bay Ventilation Kits Identification

44 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Control Bay and Control Pod Components Chapter 4

Figure 6 - Control Pod Assembly Kits Identification

4
5

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Chapter 4 Control Bay and Control Pod Components

IP/21IP54 Roof Vent Filter Replace an IP21/IP54 roof vent filter on a control or input bay with kit catalog
number SK-RM-IBFAN-54FLTR1.
Replacement

Remove the IP21/IP54 Roof Vent Filter

Follow these steps to remove the IP21/IP54 roof vent filter.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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.

46 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Control Bay and Control Pod Components Chapter 4

Install the IP21/IP54 Roof Vent Filter

IMPORTANT Verify that the ‘X’ on the filter media is on the side that faces away from the
roof vent.

Install the IP21/IP54 roof vent filter in the reverse order of removal.

IP54/IP21 Roof Vent Fan Replace an IP21/IP54 roof vent fan on a control or input bay with kit catalog
number SK-RM-IBFAN1-F8.
Replacement

Remove the IP21/IP54 Roof Vent Fan

Follow these steps to remove the IP21/IP54 roof vent fan.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay or input bay enclosure door.

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Chapter 4 Control Bay and Control Pod Components

4. Disconnect the fan P2 connector from connector P12 on the inside of

the enclosure.
5. Remove the M8 hex nut and washer that secure the ground wire to the
inside of the enclosure roof and remove the wire.
6. Remove the nine M4 x 10 mm slotted-torx screws that secure the vent
cover to the top of the vent assembly and remove the cover.
7. Remove the four M4 hex nuts that secure the fan assembly to the vent.
8. Lift the side of the fan opposite from the connector and, while holding
the fan at an angle to the housing, remove the fan.

M4 x 10 mm
6 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

M4
7 7 mm
2.6 N•m (23 lb•in)

P2 P12

M8
5 13 mm
2.6 N•m (23 lb•in)

Install the IP21/IP54 Roof Vent Fan

Install the IP21/IP54 roof vent fan in the reverse order of removal.

48 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Control Bay and Control Pod Components Chapter 4

IP21/IP54 Door Vent Filter Replace an IP21/IP54 door vent filter with kit catalog number
SK-RM-CB3DR-FLTR1.
Replacement

Remove the IP21/IP54 Door Vent Filter

Follow these steps to remove the IP21/IP54 door vent filter.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Lift the tab on the top center of the vent cover and rotate out the cover.
5. Remove the filter media from the vent.

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.

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Chapter 4 Control Bay and Control Pod Components

Control Pod Cover Removal 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 General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.

50 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Control Bay and Control Pod Components Chapter 4

4. Loosen, but do not remove, the bottom two M4 x 8 mm slotted-torx

screws that secure the cover to the assembly.
5. Remove the top two M4 x 8 mm slotted-torx screws that secure the
cover to the assembly and remove the cover.

M4 x 8 mm
4, 5 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

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.

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Chapter 4 Control Bay and Control Pod Components

Fiber Transceiver Circuit Replace a fiber transceiver circuit board with kit catalog number
20-750-MFTB1-F8.
Board Replacement

Remove the Fiber Transceiver Circuit Board

Follow these steps to remove the fiber transceiver circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.

IMPORTANT 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 50 mm
cable. Signal attenuation increases with (2 in.)
decreased inside bend radii.

5. Remove the fiber-optic cables for the corresponding fiber transceiver

circuit board from the cable management devices in the control pod.

TIP When all or many of the fiber-optic ports are used, it is easier to
remove the fiber transceiver circuit boards from the pod before
removing the fiber-optic cables. However, it is possible to remove
the fiber-optic cables without removing the boards. This procedure
assumes that all fiber-optic ports are used.

52 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Control Bay and Control Pod Components Chapter 4

ACP0 L0 L1

ACP1 / TAM
M0
M1

L8 M2
L6 M4
L4 M6
L2 M8
L3 M9
L5 M7
L7 M5
L9 M3

Table 8 - Fiber Transceiver Circuit Board Connections

Port Name Description
ACP0 Fiber transceiver port for the fiber-optic connection from ACP on the AC precharge control board.
ACP1 TAM Fiber transceiver port for the fiber-optic connection from TAM on the torque accuracy module.
L0…L9 Fiber transceiver ports for the fiber-optic connections from CNTL on the power layer interface board
in power modules that are used as line side converters.
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.

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Chapter 4 Control Bay and Control Pod Components

6. Loosen the two captive thumb screws that secure the board and fiber-
optic cables to the chassis and remove the board and cables.

–
6 T15 or F - 5 mm (0.19 in.)
0.45 N•m (4 lb•in)

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.

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 Control Bay and Control Pod Components Chapter 4

Install the Fiber Transceiver Circuit Board

Install the fiber transceiver circuit board in the reverse order of removal.

When installing the fiber-optic cables:

IMPORTANT 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 50 mm
cable. Signal attenuation increases with (2 in.)
decreased inside bend radii.

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.’

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Chapter 4 Control Bay and Control Pod Components

Main Control Circuit Board Replace a main control circuit board with kit catalog number
SK-RM-MCB1-PF755.
Replacement

Remove the Main Control Circuit Board

Follow these steps to remove the main control circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.
5. Loosen the screw that secures the HIM bezel to the pod chassis, and
rotate the bezel up to a 90° horizontal position.
6. Disconnect the HIM cable from the port on the main control board.

M3 x 6.4 mm
5 T15 or F - 5 mm (0.19 in.)
0.45 N•m (4 lb•in)

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 Control Bay and Control Pod Components Chapter 4

7. Disconnect the HIM plug-in terminal block for the mini-DIN

connector on the control board.
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.

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Chapter 4 Control Bay and Control Pod Components

10. Loosen the three captive thumb screws that secure the main control
board to the pod chassis and remove the board.

10

–
10 T15 or F - 5 mm (0.19 in.)
0.45 N•m (4 lb•in)

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.

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 Control Bay and Control Pod Components Chapter 4

Backplane Circuit Board Replace a control pod backplane circuit board with kit catalog number
SK-RM-PODBP1.
Replacement

Remove the Backplane Circuit Board

Follow these steps to remove the backplane circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.
5. Remove the main control circuit board. See Main Control Circuit
Board Replacement on page 56.
6. Disconnect and remove any option modules from the backplane circuit
boards.

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Chapter 4 Control Bay and Control Pod Components

7. Remove the two M4 x 8 mm torx screws that secure the backplane

circuit board to the pod chassis and remove the board.

M4 x 8 mm
7 T20 or F - 5 mm (0.19 in.)
2.6 N•m (23 lb•in)

Install the Backplane Circuit Board

Install the backplane circuit board in the reverse order of removal.

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Fiber-optic Interface Circuit Replace a fiber-optic interface board with kit catalog number
SK-RM-FIB1-F8 or SK-RM-FIB2-F8.
Board Replacement

Remove the Fiber-optic Interface Circuit Board

Follow these steps to remove the fiber-optic interface circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.
5. Disconnect connector P14 from connector J14 on the fiber-optic
interface board.
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.

J14 J13 J25

J18

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Chapter 4 Control Bay and Control Pod Components

IMPORTANT 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 50 mm
cable. Signal attenuation increases with (2 in.)
decreased inside bend radii.

8. Remove the fiber-optic cables from the cable management devices in the
control pod.
9. Disconnect the AC precharge circuit board and torque accuracy module
fiber-optic cables from the ACP0 and ACPC1/TAM port on the fiber
transceiver board, respectively. Carefully coil the fiber-optic cable and
secure in a protected location. Follow the minimum bend radius
requirement.
10. 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.
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 L0 L1

ACP1 / TAM
M0
M1

L8 M2
L6 M4
L4 M6
L2 M8
L3 M9
L5 M7
L7 M5
L9 M3

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12. Loosen the screw that secures the HIM bezel to the pod chassis, and
rotate the bezel up to a 90° horizontal position.
13. Disconnect the HIM cable from the port on the main control board.

12

M3 x 6.4 mm
12 T15 or F - 5 mm (0.19 in.)
0.45 N•m (4 lb•in)

13

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Chapter 4 Control Bay and Control Pod Components

14. Disconnect the HIM plug-in terminal block for the mini-DIN
connector on the control board.
15. Disconnect any Ethernet cables from the ports on the bottom of the
main control board.
16. Disconnect the plug-in terminal block (TB1) on the bottom of the
main control board.

14

15

16

17. If installed, disconnect all option module plug-in terminal blocks.

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.

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 Control Bay and Control Pod Components Chapter 4

19. Loosen the three captive thumb screws that secure the main control
board to the pod chassis and remove the board.

19

–
19 T15 or F - 5 mm (0.19 in.)
0.45 N•m (4 lb•in)

HIM Bezel Not Shown for Clarity Only.

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Chapter 4 Control Bay and Control Pod Components

20. Remove the four M4 x 8-mm screws that secure the control pod chassis
to the standoffs on the control panel, then remove control pod chassis.

IMPORTANT The four M4 x 8-mm screws that secure the control pod chassis to
the control panel are not retentive. Take steps to be sure that the
screws do not fall into the drive below.

M4 x 8 mm
20 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

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21. Remove the three M4 x 8-mm long screws that secure the fiber-optic
interface board to the control pod.
22. Move the fiber-optic interface board slightly upward toward top of the
control pod, so that keyholes on board clear the mounting posts and lift
off the board.
23. Rotate the left side of fiber-optic interface board away from the control
pod so that the board clears the mounting tab on right sidewall of the
control pod. Remove the board from the control pod.

M4 x 8 mm
21 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

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Chapter 4 Control Bay and Control Pod Components

Install the Fiber-optic Interface Circuit Board

Install the fiber-optic interface circuit board in the reverse order of removal.

When installing the fiber-optic cables:

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

Control Pod Fan Assembly Replace the control pod fan assembly with kit catalog number
SK-RM-PODFAN1-F8.
Replacement

Remove the Control Pod Fan Assembly

Follow these steps to remove the control pod fan assembly.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.

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5. Disconnect the two fan power supply connectors from connectors J18
and J25 on the fiber-optic interface board.
6. Remove the harness from the cable supports on the side of the pod
chassis.

J25

J18

7. Loosen the two captive thumb screws on the fan assembly and pull the
assembly out and off the pod chassis.

–
7 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

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Chapter 4 Control Bay and Control Pod Components

Install the Control Pod Fan Assembly

Install the control pod fan assembly in the reverse order of removal.

Control Pod Replacement Replace the control pod assembly with kit catalog number
20-750-MCPOD1-F8M or 20-750-MCPOD2-F8M.

Remove the Control Pod

Follow these steps to remove the control pod.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the control bay enclosure door.
4. Remove the control pod cover. See Control Pod Cover Removal on page
50.

IMPORTANT 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 50 mm
cable. Signal attenuation increases with (2 in.)
decreased inside bend radii.

5. Remove the fiber-optic cables from the cable management devices in the
control pod.
6. Disconnect the AC precharge circuit board and torque accuracy module
fiber-optic cables from the ACP0 and ACPC1/TAM port on the fiber
transceiver board, respectively. Carefully coil the fiber-optic cable and
secure in a protected location. Follow the minimum bend radius
requirement.
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.

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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 L0 L1

ACP1 / TAM
M0
M1

L8 M2
L6 M4
L4 M6
L2 M8
L3 M9
L5 M7
L7 M5
L9 M3

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Chapter 4 Control Bay and Control Pod Components

9. Disconnect the HIM plug-in terminal block for the mini-DIN

connector on the control board.
10. Disconnect any Ethernet cables from the ports on the bottom of the
main control board.
11. Disconnect the plug-in terminal block (TB1) on the bottom of the
main control board.

10

11

12. If installed, disconnect all option module plug-in terminal blocks.

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13. Disconnect connector P14 from connector J14 on the fiber-optic

interface board.
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.

J14 J13 J25

J18

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Chapter 4 Control Bay and Control Pod Components

16. Loosen the four M4 x 8 mm torx screws that secure the pod chassis to
the back panel.
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
16 T20 or F - 5 mm (0.19 in.)
2.6 N•m (23 lb•in)

Install the Control Pod

Install the control pod in the reverse order of removal.

When installing the fiber-optic cables:

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 Control Bay and Control Pod Components Chapter 4

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

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Chapter 4 Control Bay and Control Pod Components

Notes:

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 Chapter 5

Input Bay Components

This chapter provides detailed instructions for how to remove and replace
input bay components.

Input Bay Kits Table 9 lists the replacement kits available for the input bay.

A current list of spare parts for PowerFlex® 750-Series products with

TotalFORCE™ Control is available on the Allen-Bradley website at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Table 9 - Input Bay Replacement Kits
Description Catalog Number Identification Identification No. Replacement Instructions
Ventilation Components
IP21/IP54 Roof Vent Filter SK-RM-IBFAN-54FLTR1 See Figure 7 on page 78 1 See page 83
IP54/IP21 Roof Vent Fan SK-RM-IBFAN1-F8 2 See page 83
IP54/IP21 Door Vent Filter (400 mm) SK-RM-IB4DR-FLTR1 3 See page 83
IP54/IP21 Door Vent Filter (600 mm) SK-RM-IB6DR-FLTR1 3 See page 83
IP54 Door Vent Filter (1000 mm) SK-RM-PB8DR-54FLTR1 See Figure 8 on page 79 4 See page 84
IP21 Door Vent Filter (1000 mm) SK-RM-PB8DR-21FLTR1 5 See page 85
IP54/IP21 Door Vent Fan (1000 mm) SK-RM-IBDR-FAN1 6 See page 86
AC Precharge Components
AC Precharge Control Circuit Board 20-750-MACPC1-CD (400/480V) Frame 8 and 9, see Figure 9 on 7 See page 90
20-750-MACPC1-EF (600/690V) page 80
Frame 10…12, see Figure 10 on
AC Precharge Control Circuit Board Fuses SK-RM-IBCB-FUSE1A-F8 page 81 8 See page 96
(FH1) SK-RM-IBCB-FUSE1B-F9
AC Precharge Time Delay Relay 20-750-MACPC-TDR 9 See page 93
AC Precharge TVSS Module 20-750-MACP-xx-TVSS 10 See page 94
Control Transformer Fuses (FH4…FH7) SK-RM-IBFH4-FUSE4x-Fn 11 See page 101
AC Precharge Fused Disconnect (FD1) SK-RM-IBD-FUSEx-Fn 12 See page 103
Fuses
AC Precharge Control Transformers – – – See page 104
Control Power Components
240V Power Distribution Fuse (FH2) SK-RM-IBFH2-FUSE2x-Fn Frame 8 and 9, seeFigure 11 on 13 See page 98
page 82
Roof Fan 240V Control Power Fuse (FH3) SK-RM-IBFH3-FUSE3x-Fn Frame 10…12, see Figure 10 on 14 See page 99
page 81

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Chapter 5 Input Bay Components

Figure 7 - Frame 8 and 9 Input Bay Ventilation Kits Identification

Frame 9 Input Bay Shown

Vent Cover Shown Removed for Clarity Only

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 Input Bay Components Chapter 5

Figure 8 - Frame 10…12 Input Bay Ventilation Kits Identification

Frame 10 Input Bay Shown

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Chapter 5 Input Bay Components

Figure 9 - Input Bay Frame 8 and 9 AC Precharge Module Kits Identification

Frame 8 AC Precharge Module Frame 9AC Precharge Module

10
9 12

8 7

7
12

9
11
8

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 Input Bay Components Chapter 5

Figure 10 - Input Bay Frame 10…12 AC Precharge Module and Control Components Kits
Identification
Frame 12 Input Bay Shown

10
12
8

11

7
14
13

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Chapter 5 Input Bay Components

Figure 11 - Frame 8 and 9 Input Bay Control Power Kits Identification

14 13

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 Input Bay Components Chapter 5

IP21/IP54 Roof Vent Filter Replace the IP21/IP54 roof vent filters with kit catalog number
SK-RM-IBFAN-54FLTR1. See IP/21IP54 Roof Vent Filter Replacement on
Replacement page 46.

IP54/IP21 Roof Vent Fan Replace the IP54/IP21 roof vent fan with kit catalog number
SK-RM-IBFAN1-F8. See IP54/IP21 Roof Vent Fan Replacement on page 47.
Replacement

IP54/IP21, 400/600 mm Wide Replace the IP54/IP21, 400/600 mm wide door vent filters with the
appropriate kit catalog number:
Door Vent Filters
• 400 mm, SK-RM-IB4DR-FLTR1
Replacement • 600 mm, SK-RM-IB6DR-FLTR1

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

Follow these steps to remove the IP54/IP21, 400/600 mm wide door vent
filters.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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

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Chapter 5 Input Bay Components

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

IMPORTANT Verify that the Rittal logo on the fiber filter media points inward, toward the
interior of the enclosure.

Install the IP54/IP21, 400/600 mm wide door vent filters in the reverse order
of removal.

IP54, 800/1000 mm Wide Replace the IP54 door vent filters for an 800 mm wide power bay or 1000 mm
wide input bay with kit catalog number SK-RM-PB8DR-54FLTR1.
Door Vent Filters
Replacement
Remove the IP54, 800/1000 mm Wide Door Vent Filters
Follow these steps to remove the IP54, 800/1000 mm wide door vent filters.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Loosen the four slotted-Phillips head, captive screws that secure the
filter cassette cover and metal mesh filter to the cassette chassis on the
door and remove the cover and metal mesh filter.
4. Remove the metal mesh filter from the cover.
5. Pull the top edge of the fiber filter out and lift it off the cassette.

M4 x 10 mm
3 P2 or F - 6.4 mm (0.25 in.)
1.1 N•m (10 lb•in)

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 Input Bay Components Chapter 5

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

Follow theses steps to install the IP54, 800/1000 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.
2. Place the slots on the cassette cover on the tabs on the door vent chassis.

IMPORTANT Verify that the airflow direction arrow on the fiber filter media points
inward, toward the interior of the enclosure.

3. Insert the fiber filter in the cassette chassis on the door and close and
secure the cassette cover to the door.

IP21, 800/1000 mm Wide Replace the IP21 door vent filters for an 800 mm wide power bay or 1000 mm
wide input bay with kit catalog number SK-RM-PB8DR-21FLTR1.
Door Vent Filter
Replacement
Remove the IP21, 800/1000 mm Wide Door Vent Filter

Follow these steps to remove the IP21, 800/1000 mm wide door vent filter.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.

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Chapter 5 Input Bay Components

3. Loosen the four slotted-Phillips head, captive screws that secure the
filter cassette cover and metal mesh filter to the cassette chassis on the
door and remove the cover and filter.

M4 x 10 mm
3 P2 or F - 6.4 mm (0.25 in.)
1.1 N•m (10 lb•in)

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

Follow theses steps to install the IP21, 800/1000 mm wide door vent filter.

IMPORTANT Verify that the weep holes on the metal mesh filter are at the bottom of the
filter when installed.

1. Place the slots on the cassette cover on the tabs on the door vent chassis.
2. Insert the filter in the cassette chassis on the door and close and secure
the cassette cover to the door.

IP54/IP21, 1000 mm Wide Replace the IP54/IP21, 1000 mm wide door vent fan for an input bay with kit
catalog number SK-RM-IBDR-FAN1.
Door Vent Fan Replacement
Remove the IP54/IP21, 1000 mm Wide Door Vent Fan

Follow these steps to remove the IP54/21, 1000 mm wide door vent fan.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.

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 Input Bay Components Chapter 5

3. Open the input bay enclosure door.

4. Disconnect the connectors P12 or P13 from the fans on the door.
5. Remove the four M4 x 14 mm torx screws that secure the fan to the door
and remove the fan.

M4 x 14 mm
5 T20
2.6 N•m (23 lb•in)

P12
P13

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

Follow theses steps to install the IP21/IP54, 1000 mm wide door vent fan.

IMPORTANT Verify that the airflow direction arrow on the fan points inward, toward the
interior of the enclosure.

Guard Removal 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 General Precautions on page 12.

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Chapter 5 Input Bay Components

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Loosen the M5.5 x 13 mm torx screws that secure the guard to the
enclosure and remove the guard.
• 400 mm wide input bay guards require removal of six screws.
• 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
4 T25
2.6 N•m (23 lb•in)
Frame 8 Input Bay Frame 9 Input Bay

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 Input Bay Components Chapter 5

Frame 10…12 Input Bays (Frame 10 Shown)

M5.5 x 13 mm
4 T25
2.6 N•m (23 lb•in)

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Chapter 5 Input Bay Components

Install the Guards

Install the guards in the reverse order of removal.

AC Precharge Control Circuit Replace the AC precharge control circuit board with kit catalog numbers
20-750-MACPC1-CD and 20-750-MACPC1-EF.
Board Replacement

Remove the AC Precharge Control Circuit Board

Follow these steps to remove and replace the AC precharge control circuit
board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.

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 Input Bay Components Chapter 5

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

5. Without bending the cable to a radius less than 50 mm (2 in.), remove

the fiber-optic cable from the transceiver in the ACP port on the AC
precharge control circuit board.
6. Remove the transceiver from the ACP port. Retain the transceiver for
reuse.
7. Loosen the two 5 x 12 mm slotted-torx screws that secure the circuit
board panel to the AC precharge module chassis or enclosure side sheet
and slide the panel out of the chassis.

M5 x 12 mm
7 T25
2.6 N•m (23 lb•in)

5 and 6

8. Disconnect these wire harness connectors from the connectors on the

AC precharge circuit board and remove the board and mounting panel
from the drive:
• P1 from J1
• P2 from J2
• P3 from J3

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Chapter 5 Input Bay Components

• P4 from J4
• P5 from J5
• P6 from J6
• P7 from J7
• P11 from J11
• P12 from J12, if present

= ACP
3 3 1
1

J1 J12
+
+
+

+
8
6

J2
1

8 7 6 5 4 3 2 1

1 2
ON

J11
2
1

2
15 16

10
9
J3
6
1
12
10
8
6
5
4
3
2
1

J4
1

J8
3

J5 J7 J6
6 1 4 1 9 1

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Install the AC Precharge Control Circuit Board

Install the AC precharge control circuit board in the reverse order of removal.

When installing the fiber-optic cable:

1. Remove the transceiver from the fiber-optic connector port on the

circuit board.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.

IMPORTANT Verify that the two pins on the back of the AC precharge module chassis are
properly inserted into the two holes on the circuit board panel before
tightening the panel mounting screws.

AC Precharge Time Delay Replace the AC precharge time delay relay with kit catalog number
20-750-MACPC-TDR.
Relay Replacement

Remove the AC Precharge Time Delay Relay

Follow these steps to remove and replace the AC precharge time delay relay.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.
5. Disconnect the wires from top terminals on the time delay relay.

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Chapter 5 Input Bay Components

6. Pull up on the bottom of the relay chassis and lift it up and off the DIN
rail.

Install the AC Precharge Time Delay Relay

Install the AC precharge time delay relay in the reverse order of removal.

AC Precharge TVSS Module Replace the AC precharge TVSS module with kit catalog number
20-750-MACP-xx-TVSS.
Replacement
Remove the AC Precharge TVSS Module

Follow these steps to remove and replace the AC precharge TVSS module.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.
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.

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7. Loosen the terminal block screws that secure the wires to terminals R/
L1, S/L2, T/L3, and remove the wires.

= 7
6

M6 x 10 mm
6 T25
5.9 N•m (52 lb•in)

M6
6 10 mm 5
5.9 N•m (52 lb•in)

–
7 P2
4.0 N•m (35 lb•in)

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
7 T20 or F - 6.4 mm (0.25 in.)
2.6 N•m (23 lb•in)

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Chapter 5 Input Bay Components

Install the AC Precharge TVSS Module

Install the AC precharge TVSS module in the reverse order of removal.

AC Precharge Control Circuit Replace the AC precharge control circuit board fuses (labeled FH1) with the
appropriate kit catalog number that is identified in Table 10.
Board Fuses (FH1)
Replacement Table 10 - AC Precharge Control Circuit Board Fuse (FH1) Kit Ratings
Frame Size Voltage Class Fuse Kit Cat. No. Fuse Amp Quantity
Rating
8…12 400V/480V/600V SK-RM-IBCB-FUSE1A-F8 1 3
8…12 690V SK-RM-IBCB-FUSE1B-F9 1 3

Remove the AC Precharge Control Circuit Board Fuses

For frames 8 and 9, the fuse holders (labeled FH1) are located in the AC
precharge module in the input bay. For frames 10…12, the fuse holders (labeled
FH1) are on the control panel in the input bay. Follow these steps to remove
and replace the AC precharge control circuit board fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.

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 Input Bay Components Chapter 5

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.

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240V Power Distribution Fuse Replace the 240V power distribution fuse (labeled FH2) with the appropriate
kit catalog number that is identified in Table 11.
(FH2) Replacement
Table 11 - 240V Power Distribution Fuse (FH2) Kit Ratings
Frame Size Voltage Class IP Rating Fuse Kit Cat. No. Fuse Amp Rating
8 400V/480V/600V IP21 SK-RM-IBFH2-FUSE2A-F8 15
690V SK-RM-IBFH2-FUSE2B-F8 16
400V/480V/600V IP54 SK-RM-IBFH2-FUSE2C-F8 20
690V SK-RM-IBFH2-FUSE2D-F8 20
9 400V/480V/600V IP21 SK-RM-IBFH2-FUSE2E-F9 25
690V SK-RM-IBFH2-FUSE2F-F9 25
400V/480V/600V IP54 SK-RM-IBFH2-FUSE2G-F9 35
690V SK-RM-IBFH2-FUSE2H-F9 40
10 400V/480V/600V IP21 SK-RM-IBFH2-FUSE2G-F9 35
690V SK-RM-IBFH2-FUSE2H-F9 40
400V/480V/600V IP54 SK-RM-IBFH2-FUSE2I-F10 60
690V SK-RM-IBFH2-FUSE2J-F10 63
11 400V/480V/600V IP21 SK-RM-IBFH2-FUSE2K-F11 45
690V SK-RM-IBFH2-FUSE2L-F11 50
400V/480V/600V IP54 SK-RM-IBFH2-FUSE2M-F11 70
690V SK-RM-IBFH2-FUSE2N-F11 80
12 400V/480V/600V IP21 SK-RM-IBFH2-FUSE2I-F10 60
690V SK-RM-IBFH2-FUSE2J-F10 63
400V/480V/600V IP54 SK-RM-IBFH2-FUSE2O-F12 70
690V SK-RM-IBFH2-FUSE2P-F12 80

Remove the 240V Power Distribution Fuse

Fuse holder (labeled FH2) is on the control panel in the input bay. Follow
these steps to remove and replace the 240V power distribution fuse.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.

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5. Pull out on the tab at the top of the fuse holder and remove the fuse.
Frame 8 Input Bay Frame 10 Input Bay

Install the 240V Power Distribution Fuse

Install the 240V power distribution fuse in the reverse order of removal.

Roof Fan 240V Control Power Replace the roof fan 240V control power fuse (labeled FH3) with the
appropriate kit catalog number that is identified in Table 12.
Fuse (FH3) Replacement
Table 12 - Roof Fan 240V Control Power Fuse (FH3) Kit Ratings
Frame Size Voltage Class IP Rating Fuse Kit Cat. No. Fuse Amp
Rating
8 and 9 400V/480V/600V IP21 / IP54 SK-RM-IBFH3-FUSE3B-F8 2
690V SK-RM-IBFH3-FUSE3A-F8 2
10…12 400V/480V/600V IP21 / IP54 SK-RM-IBFH3-FUSE3D-F10 4
690V SK-RM-IBFH3-FUSE3C-F10 4

Remove the Roof Fan 240V Control Power 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 General Precautions on page 12.

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Chapter 5 Input Bay Components

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.
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.

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Control Transformer Fuses Replace the control transformer fuses (labeled FH4…FH7) with the
appropriate kit catalog number that is identified in Table 13.
(FH4…FH7) Replacement
IMPORTANT Control transformer fuse quantities vary based on the product voltage class
and IP rating. It is recommended that you replace all control transformer
fuses.

Table 13 - Control Transformer Fuses (FH4…FH7) Kit Ratings

Frame Size Voltage Class IP Rating Kit Cat. No. Fuse Amp Qty
Rating
8 400V/480V/600V IP21 SK-RM-IBFH4-FUSE4A-F8 20 2
690V SK-RM-IBFH4-FUSE4B-F8
9 400V/480V/600V IP21 SK-RM-IBFH4-FUSE4C-F8 30 2
690V SK-RM-IBFH4-FUSE4D-F8 20 2
10, 11 400V/480V/600V IP21 SK-RM-IBFH4-FUSE4F-F9 30 4
690V SK-RM-IBFH4-FUSE4H-F9 20 4
12 400V/480V/600V IP21 SK-RM-IBFH4-FUSE4J-F11 30 6
690V SK-RM-IBFH4-FUSE4K-F11 20 6
8 400V/480V/600V IP54 SK-RM-IBFH4-FUSE4C-F8 30 2
690V SK-RM-IBFH4-FUSE4D-F8 20 2
9 400V/480V/600V IP54 SK-RM-IBFH4-FUSE4F-F9 30 4
9, 10 690V IP54 SK-RM-IBFH4-FUSE4H-F9 20 4
10 400V/480V/600V IP54 SK-RM-IBFH4-FUSE4J-F11 30 6
11 400V/480V/600V IP54 SK-RM-IBFH4-FUSE4J-F11 30 6
690V SK-RM-IBFH4-FUSE4K-F11 20 6
12 400V/480V/600V IP54 SK-RM-IBFH4-FUSE4L-F12 20 8
690V SK-RM-IBFH4-FUSE4M-F12

Remove the Control Transformer Fuses

For frame 8, the fuse holders (labeled FH4) are located in the AC precharge
module in the input bay. For frames 9…12, the fuse holders (labeled
FH4…FH7) are on the control panel in the input bay. Follow these steps to
remove and replace the control transformer fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.

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Chapter 5 Input Bay Components

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.

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AC Precharge Fused Replace the AC precharge fused disconnect (FD1) fuses with the appropriate
kit catalog number that is identified in Table 14.
Disconnect (FD1) Fuses
Replacement Table 14 - AC Precharge Fused Disconnect (FD1) Fuse Kit Ratings
Frame Size Voltage Class Kit Cat. No. Fuse Amp Rating Qty
8 400V/480V/600V SK-RM-IBD-FUSEA-F8 30 3
690V SK-RM-IBD-FUSEB-F8 32 3
9 400V/480V SK-RM-IBD-FUSEC-F9 70 3
600V SK-RM-IBD-FUSED-F9 60 3
690V SK-RM-IBD-FUSEE-F9 63 3
10 400V/480V SK-RM-IBD-FUSEF-F10 110 3
600V SK-RM-IBD-FUSEG-F10 80 3
690V SK-RM-IBD-FUSEH-F10 80 3
11 400V/480V SK-RM-IBD-FUSEI-F11 150 3
600V SK-RM-IBD-FUSEF-F10 110 3
690V SK-RM-IBD-FUSEJ-F12 125 3
12 400V/480V SK-RM-IBD-FUSEK-F12 200 3
600V SK-RM-IBD-FUSEI-F11 150 3
690V SK-RM-IBD-FUSEL-F12 160 3

Remove the AC Precharge Fused Disconnect Fuses

For frames 8 and 9, the fused disconnect fuse holders (FD1) are located in the
AC precharge module in the input bay. For frames 10…12, the fused
disconnect fuse holders (FD1) are on the control panel in the input bay. Follow
these steps to remove and replace the AC precharge fused disconnect fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the input bay enclosure door.
4. Remove the guard from the enclosure. See Guard Removal on page 87.

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Chapter 5 Input Bay Components

5. Pull the front of the fuse assembly out and remove the fuses.
Frame 8 AC Precharge Module Frame 10 Input Bay

Install the AC Precharge Fused Disconnect Fuses

Install the AC precharge fused disconnect fuses in the reverse order of removal.

Control Transformers 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.

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 Chapter 6

Power Bay Components

This chapter provides detailed instructions for how to remove and replace
power bay components.

Power Bay Kits Table 15 lists the replacement kits available for the power bay.

A current list of spare parts for PowerFlex® 750-Series products with

TotalFORCE™ Control is available on the Allen-Bradley website at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Table 15 - Power Bay Replacement Kits
Description Catalog Number Identification Identification No. Replacement Instructions
Ventilation Kits
IP54 Exhaust Vent Filter SK-RM-PBFAN-54FLTR1 See Figure 12 on page 108 1 See page 115
IP54 Exhaust Fan Fuse SK-RM-INVFAN1-FUSE 2 See page 116
IP54 Exhaust Fan SK-RM-PBFAN1-F8 3 See page 118
IP54 Door Filter (400 mm) SK-RM-PB4DR-54FLTR1 4 See page 124
IP21 Door Filter (400 mm) SK-RM-PB4DR-21FLTR1 5 See page 125
IP54 Door Filter (600 mm) SK-RM-PB6DR-54FLTR1 4 See page 124
IP21 Door Filter (600 mm) SK-RM-PB6DR-21FLTR1 5 See page 125
IP54 Door Filter (800 mm) SK-RM-PB8DR-54FLTR1 4 See page 126
IP21 Door Filter (800 mm) SK-RM-PB8DR-21FLTR1 5 See page 126
DC Precharge Module Kits
DC Precharge Module Disconnect Handle SK-RM-DCPC-HNDL See Figure 13 on page 109 6 See page 126
and Shaft
DC Precharge Circuit Board SK-RM-DCPC1-CD (400V/480V) 7 See page 133
SK-RM-DCPC1-EF (600V/690V)
DC Precharge Fuses SK-RM-DCFUSE1-F8 (400V/480V) 8 See page 137
SK-RM-DCFUSE2-F8 (600V/690V)

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Chapter 6 Power Bay Components

Table 15 - Power Bay Replacement Kits (Continued)

Description Catalog Number Identification Identification No. Replacement Instructions
Power Module Kits
Power Module (1) 20-750-MI1-CnnnDnnn – – See page 140
20-750-MI1-EnnnFnnn
20-750-MI2-CnnnDnnn
20-750-MI2-EnnnFnnn
20-750-MI3-CnnnDnnn
20-750-MI3-EnnnFnnn
DC Link Fuses SK-RM-DCFUSE1-F8 (400V/480V) See Figure 14 on page 109 9 See page 145
SK-RM-DCFUSE2-F8 (600V/690V)
Power Module Power Jumper (P5/P6) SK-RM-INV-JMPR-F8 See Figure 15 on page 110 10 See page 147
Power Layer Interface Circuit Board SK-RM-PLI1-F8 11 See page 153
Power Interface Circuit Board (2) SK-RM-PIB1-CnnnDnnn 12 See page 154
SK-RM-PIB1-EnnnFnnn
SK-RM-PIB2-CnnnDnnn
SK-RM-PIB2-EnnnFnnn
SK-RM-PIB3-CnnnDnnn
SK-RM-PIB3-EnnnFnnn
Balance Resistors SK-RM-INVBR1-F8M (400/480V) See Figure 16 on page 111 13 See page 156
SK-RM-INVBR2-F8M (600/690V)
Current Sensor SK-RM-INVCS1-F8M (622 A) 14 See page 158
SK-RM-INVCS2-F8M (1000 A)
LCL Filter Module Kits
LCL Filter Module (3) 20-750-ML1-CnnnDnnn See Figure 17 on page 112 – See page 160
20-750-ML1-EnnnFnnn
AC Input Link Fuses SK-RM-ACFUSE1-F8 15 See page 165
(400/480V, 600V/690V)
SK-RM-ACFUSE2-F8
(400/480V, 600V/690V)
SK-RM-ACFUSE3-F9
(400/480V)
SK-RM-ACFUSE4-F9
(400/480V)
SK-RM-ACFUSE5-F8
(600V/690V)
SK-RM-ACFUSE6-F9
(600V/690V)
Capacitor Canister SK-RM-LCLCP1-F8M (30 μF) 16 See page 167
SK-RM-LCLCP2-F8M (41 μF)
SK-RM-LCLCP3-F8M (62 μF)
SK-RM-LCLCP4-F8M (80 μF)
EMC Filter Board SK-RM-EMCFB1 17 See page 171
Current Sense Board SK-RM-CSB1-700 (700 A) 18 See page 173
SK-RM-CSB1-525 (525 A)
SK-RM-CSB1-350 (350 A)
SK-RM-CSB1-263 (263 A)

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Table 15 - Power Bay Replacement Kits (Continued)

Description Catalog Number Identification Identification No. Replacement Instructions
Power and LCL Filter Module Kits
Power/LCL Filter Module Fan Fuse SK-RM-INVFAN1-FUSE See Figure 18 on page 113 20 See page 178
Power/LCL Filter Module Fan Assembly SK-RM-INVFAN1-F8 21 See page 179
Accessories Kits
Torque Accuracy Module 20-750-MTAM1-CD (400/480V) See Figure 19 on page 114 24 See page 180
20-750-MTAM1-EF (600/690V)
DC Bus Conditioner 20-750-MDCBUS-COND 25 See page 182
(1) “MI1” identifies a power module with no paralleling inductor and no reflected wave filter. “MI2” identifies a power module with a paralleling inductor only. “MI3” identifies a power module with a
reflected wave filter only. “C” and “D” in “CnnnDnnn” identifies a power module that is rated for 400/480V, respectively. “E” and “F” in “EnnnFnnn” identifies a power module that is rated for 600/
690V, respectively. “nnn” in “CnnnDnnn” and “EnnnFnnn” identifies the power module amp rating.
(2) “PIB1” identifies a circuit board compatible with a power module with no paralleling inductor and no reflected wave filter. “PIB2” identifies a circuit board compatible with a power module with a
paralleling inductor only. “PIB3” identifies a circuit board compatible with a power module with a reflected wave filter only. “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.
(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.

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Chapter 6 Power Bay Components

Figure 12 - Power Bay Ventilation Kits Identification

400 mm Wide Input Bay Shown

4 5

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Figure 13 - DC Precharge Kits Identification

7
6

8
Figure 14 - DC Link/Fuse Kits Identification

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Chapter 6 Power Bay Components

Figure 15 - Power Module Circuit Board and Jumper Kits Identification

10

12

11

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 Power Bay Components Chapter 6

Figure 16 - Power Module Kits Identification

13

14

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Chapter 6 Power Bay Components

Figure 17 - LCL Filter Module Kits Identification

18
15

17 16

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Figure 18 - LCL Filter and Power Module Fan Assembly and Fan Fuse Kits Identification

21

20

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Chapter 6 Power Bay Components

Figure 19 - Accessory Kits Identification

24

25

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IP54 Exhaust Vent Filters Replace the IP54 exhaust vent filters on a power bay with kit catalog number
SK-RM-PBFAN-54FLTR1.
Replacement

Remove the IP54 Exhaust Vent Filters

Follow these steps to remove the IP54 exhaust vent filters on a power bay.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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.

Install the IP54 Exhaust Vent Filters

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.

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IP54 Exhaust Fan Fuse Replace the exhaust fan fuse on a power bay with kit catalog number
SK-RM-INVFAN1-FUSE (Time Delay, 250V, 3.5 A, Cartridge).
Replacement

Remove the IP54 Exhaust Fan Fuse

Follow these steps to remove the IP54 exhaust fan fuse on a power bay.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Slide the front vent up to release the tabs from the slots in the vent hood
and remove the vent.

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4. Remove the four M8 x 12 mm torx screws that secure the screen to the
front of the fan housing and remove the screen.
5. Unscrew the fuse holder and fuse and remove the fuse.

M8 x 12 mm
4 T30
19.8 N•m (175 lb•in)

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).

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IP54 Exhaust Fan Replace the exhaust fan on a power bay with kit catalog number
SK-RM-PBFAN1-F8.
Replacement

Remove the IP54 Exhaust Fan

Follow these steps to remove and replace the IP54 exhaust fan on a power bay.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the power bay enclosure door.
4. Remove the M8 hex nut that secures the ground wire terminal to the
grounding stud on the inside of the enclosure and remove the wire.
5. Disconnect connector P1 from connector P12 on the inside of the
enclosure.

M8
4 13 mm
10.2 N•m (90 lb•in)

PE

P1
P12

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6. Slide the front and rear vent covers up until the tabs on the vent cover
clear the slots on the vent housing, and remove the vent covers.
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
4 T25
19.8 N•m (175 lb•in)

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Chapter 6 Power Bay Components

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
5 T25
6 N•m (53 lb•in)

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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.

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11. Remove the two M3 x 20 mm Phillips head screws (white) that secure
the interconnection terminal block to the fan housing and remove the
terminal block.
12. Remove the two M4 x 11 mm torx screws that secure the fan power
connector to the fan and remove the connector and wires.
13. Remove the four M5 x 5 mm nuts that secure the fan assembly and
housing to fan base and carefully lift the fan assembly and housing from
off the base. As you lift the fan assembly and housing, pull the wire
harness carefully through the opening in the enclosure roof.
M3 x 20 mm
8 P1 10
8
0.6 N•m (5.3 lb•in) 9
M4 x 11 mm
9 T20 10
3 N•m (26.5 lb•in)

M5 x 5 mm
10 8 mm
6.5 N•m (58 lb•in)

10

10

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14. Place the fan and housing assembly on a support block that is on a solid
work surface, with only the fan in contact with a support block. The
support under the fan allows you to lift the metal housing off the fan
unit after the screws have been removed.
15. Remove the four M6 x 16 mm torx screws that secure the fan to the roof
assembly housing and lift the fan housing off the fan.

M6 x 16 mm
12 T30
10 N•m (90 lb•in)

Install the IP54 Exhaust Fan

Install the IP54 exhaust fan on a power bay in the reverse order of removal.

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IP54, 400/600 mm Wide Door Replace the IP54, 400/600 mm wide door vent filters with the appropriate kit
catalog number:
Vent Filters Replacement
• 400 mm, SK-RM-PB4DR-54FLTR1
• 600 mm, SK-RM-PB6DR-54FLTR1

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

Follow these steps to remove the IP54, 400/600 mm wide door vent filters.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Loosen the two or three slotted-Phillips head, captive screws that secure
the filter cassette cover and metal mesh filter to the cassette chassis on
the door and remove the cover and metal mesh filter.
4. Remove the metal mesh filter from the cover.
5. Pull the top edge of the fiber filter out and lift it off the cassette.
600 mm Wide Door Vent Shown.
M4 x 10 mm
3 P2 or F - 6.4 mm (0.25 in.)
1.1 N•m (10 lb•in)

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

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.

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 Power Bay Components Chapter 6

2. Place the slots on the cassette cover on the tabs on the door vent chassis.

IMPORTANT Verify that the airflow direction arrow on the fiber filter media points
inward, toward the interior of the enclosure.

3. Insert the fiber filter in the cassette chassis on the door and close and
secure the cassette cover to the door.

IP21 400/600 mm Wide Door Replace the IP21, 400/600 mm wide door vent filter with the appropriate kit
catalog number:
Vent Filter Replacement
• 400 mm, SK-RM-PB4DR-21FLTR1
• 600 mm, SK-RM-PB6DR-21FLTR1

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

Follow these steps to remove the IP21, 400/600 mm wide door vent filter.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Loosen the two or three slotted-Phillips head, captive screws that secure
the filter cassette cover and metal mesh screen to the cassette chassis on
the door and remove the cover and metal mesh filter.
4. Remove the metal mesh filter from the cover.
600 mm Wide Door Vent Shown.
M4 x 10 mm
3 P2 or F - 6.4 mm (0.25 in.)
1.1 N•m (10 lb•in)

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Chapter 6 Power Bay Components

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

Follow theses steps to install the IP21, 400/600 mm wide door vent filter.

IMPORTANT Verify that the weep holes on the metal mesh filter are at the bottom of the
filter when installed.

1. Place the slots on the cassette cover on the tabs on the door vent chassis.
2. Insert the filter in the cassette chassis on the door and close and secure
the cassette cover to the door.

IP54, 800 mm Wide Door 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
Vent Filters Replacement Replacement on page 84.

IP21, 800 mm Wide Door 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
Vent Filter Replacement Replacement on page 85.

DC Precharge Module Replace the DC precharge module disconnect handle and shaft with kit
catalog number SK-RM-DCPC-HNDL.
Disconnect Handle and Shaft
Replacement
Remove the DC Precharge Module Disconnect Handle and Shaft

Follow these steps to remove and replace the DC precharge module disconnect
handle and shaft.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.

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 Power Bay Components Chapter 6

4. Remove the two M4 x 12 mm screws that secure the disconnect handle

to the door and remove the handle.

M4 x 12 mm
4 T20
6.2 N•m (55 lb•in)

5. Remove the six M5 x 10 mm screws that secure the front cover to the
DC precharge unit and remove the cover.
6. Loosen the hexagonal screw that secures the disconnect handle shaft to
the disconnect switch and remove the handle.
M5 x 10 mm
5 T20
6.2 N•m (55 lb•in)

–
6 2.5 mm
0.6 N•m (5.4 lb•in)

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Chapter 6 Power Bay Components

Install the DC Precharge Module Disconnect Handle and Shaft

Install the DC precharge module disconnect handle and shaft in the reverse
order of removal.

DC Precharge Module You must remove the DC precharge module from the enclosure to access
components inside the module. To remove the DC precharge module, you
must first remove the power module that is connected to the DC precharge
module. See Power Module Replacement on page 140.

DC precharge modules weight 41 kg (90 lb). Equipment is available that is

designed to help you safely handle the DC precharge module. The following
equipment is recommended:
• PowerFlex 750-Series module service cart, catalog number
20-750-MCART1, publication 750-IN105
• PowerFlex 755T DC precharge module lift, catalog number
20-750-MCART2, publication 750-IN105

Remove the DC Precharge Module from the Enclosure

Follow these steps to remove the DC precharge module from the enclosure.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.

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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 T30
4.8 N•m (42 lb•in)

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Chapter 6 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.

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8. Loosen the thumb screw that secures the connections cover to the front
of the power module.
9. Use the screw to lift the connections cover up and off the power module
chassis.
10. Disconnect connector P3 from J3 on the power module I/O control
panel.
11. Disconnect connector P4 from J4 on the power module I/O control
panel.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

12. Without bending the cable to a radius less than 50 mm (2 in.), remove
the fiber-optic cable from the transceiver in the PDI port on the power
layer interface circuit board.
–
5 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

10
11

12

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 140.

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Chapter 6 Power Bay Components

15. Remove the two M6 x 16 mm hex screws that secure the bottom of the
DC precharge module to the control bus support.
16. Remove the two M6 x 16 mm hex screws that secure the top of the DC
precharge module to the enclosure roof support bracket.

M6 x 16 mm
15, T30
16
10.2 N•m (90 lb•in)

17. To remove the module by using the service cart and DC precharge
module lift, follow the detailed instructions in the PowerFlex 750-Series
Service Cart and DCPC Module Lift Installation Instructions,
publication 750-IN105.
18. Remove the module out of the enclosure.

Install the DC Precharge Module in the Enclosure

Install the DC precharge module into the enclosure in the reverse order of
removal.

When installing the fiber-optic cable:

1. Remove the transceiver from the fiber-optic port on the power layer
interface circuit board.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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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.’

DC Precharge Circuit Board Replace the DC precharge module circuit board with the appropriate kit
catalog number:
Replacement
• SK-RM-DCPC1-CD (400V/480V)
• SK-RM-DCPC1-EF (600V/690V)

Remove the DC Precharge Circuit Board

Follow these steps to remove and replace the DC precharge circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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 128.

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Chapter 6 Power Bay Components

5. Remove the six M5 x 10 mm torx screws that secure the circuit board
cover to the DC precharge chassis.
M5 x 10 mm =
5 T25
2.8 N•m (25 lb•in)

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

6. Without bending the cable to a radius less than 50 mm (2 in.), remove

the fiber-optic cable from the transceiver in the DCP port on the DC
precharge circuit board.
7. Remove the transceiver from the DCP port on the DC precharge circuit
board. 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

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 Power Bay Components Chapter 6

= J2
J1

J3

J7

+
DCP

+
+
J9

+
+
+

1 J10

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Chapter 6 Power Bay Components

9. Remove the five M4 x 8 mm slotted-torx screws that secure the DC

precharge circuit board to the standoffs on the chassis. Lift the board up
so that the keyholes on the board clear the mounting posts and remove
the board.
M4 x 8 mm =
9 T20
2.6 N•m (23 lb•in)

Install the DC Precharge Circuit Board

Install the DC precharge circuit board in the reverse order of removal.

When installing the fiber-optic cable:

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

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DC Precharge Fuses Replace the DC precharge fuses with the appropriate kit catalog number that is
identified in Table 16.
Replacement
IMPORTANT It is recommended that you replace both DC precharge fuses.

Table 16 - DC Precharge Module Fuse Ratings

DC Precharge Module Cat. No. DC Precharge Fuse Fuses Fuse Rating
Kit Cat. No Per
No Filtering With DC Common Mode Kit Amps/Leg 1/Leg
Core
20-750-MDCP1-CD-F8M 20-750-MDCP2-CD-F8M SK-RM-DCFUSE1-F8 2 1400 170M6467
20-750-MDCP1-EF-F8M 20-750-MDCP2-EF-F8M SK-RM-DCFUSE2-F8 2 1100 170M6499

Remove the DC Precharge Fuses

Follow these steps to remove and replace the DC precharge fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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
128.

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Chapter 6 Power Bay Components

5. Remove the four M12 hex nuts that secure the fuses to the bus bars.
6. Pull the fuses out of the chassis and disconnect the signal cables from the
indicator switches.
Side and Back Panels Not Shown for Clarity Only.

M12
5 19 mm
45.0 N•m (398 lb•in)

Install the DC Precharge Fuses

Install the DC precharge fuses in the reverse order of removal.

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Guard Removal When AC input bus bars and fuses or DC link and fuse assemblies are installed
in the power bay, you must remove the upper guard to access other
components.

Remove the Guard

Follow these steps to remove and replace the upper guard.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Loosen the six M5.5 x 13 mm torx screws that secure the guard from the
enclosure.

800 mm Wide Frame 8 Drive Power Bay Shown

M5.5 x 13 mm
4 T25
2.6 N•m (23 lb•in)

Install the Guard

Install the guard in the reverse order of removal.

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Chapter 6 Power Bay Components

Power Module Replacement Replace the power module with the appropriate kit catalog number:
• 20-750-MI1-CnnnDnnn
• 20-750-MI1-EnnnFnnn
• 20-750-MI2-CnnnDnnn
• 20-750-MI2-EnnnFnnn
• 20-750-MI3-CnnnDnnn
• 20-750-MI3-EnnnFnnn

Equipment is available that is designed to help you safely handle the power
modules. The following equipment is recommended:
• PowerFlex 750-Series module service cart, catalog number 20-750-
MCART1, publication 750-IN105
• PowerFlex 750TM power and LCL filter module storage hardware,
catalog number 20-750-MINV-ATIP, publication 750-IN106
• PowerFlex 755T power module service ramp, catalog number 20-750-
MRAMP1, publication 750-IN108

IMPORTANT The service ramp is used only with power module when the cabinet is
mounted directly to the floor. Do not use the ramp to remove LCL filter
modules from the cabinet. Review service ramp instructions before using.

Remove the Power Module from the Enclosure

Follow these steps to remove the power module from the enclosure.

ATTENTION: IGBT power and LCL filter modules have a high center of gravity
and a tip-over hazard exists. To guard against death, serious personal injury,
or equipment damage, do not subject the module to high rates of
acceleration or deceleration while transporting. Do not push or pull above
the points that are indicated on the module.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
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 139.

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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
5 T30
4.8 N•m (42 lb•in)

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Chapter 6 Power Bay Components

6. Loosen the thumb screw that secures the connections cover to the front
of the power module.
7. Use the screw to lift the connections cover up and off the power module
chassis.

–
6 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

8. Without bending the cable to a radius less than 50 mm (2 in.), remove

the fiber-optic cables from the transceiver in the 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 one line LCL filter with two line
side converter. side converters

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9. If present, 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.
10. If present, disconnect the cable connector P2 from connector J2 on the
I/O panel in the power module remove the cable from the power
module chassis.
11. Disconnect the cable connector P3 from connector J3 on the I/O panel
in the power module remove the cable from the power module chassis.
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.

P1
P3 P4

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13. Loosen the two M10 x 10 mm hex nuts and bolts that secure the power
input/output terminals to the DC precharge module or DC link fuse
terminals.
14. Remove the two M10 x 20 mm torx screws that secure the power
module chassis to the control bus frame.
15. Leave the two M10 x 20 mm screws that secure the power module
chassis to the floor mounting bracket while preparing the PowerFlex
750-Series service cart or service ramp.

Control bus frame

14

13 14

M10 x 10 mm
13 17 mm
38 N•m (336 lb•in)

15: Leave these M10 screws in place while

preparing the service cart or ramp.
17: Remove these M10 screws.

M10 x 20 mm
14, T45
17 42.4 N•m (375 lb•in)

16. To remove the module by using the service cart, follow the detailed
instructions in the 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.

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17. To release the LCL filter module, remove the two remaining M10
screws.
18. Remove the power modules from the enclosure.

Install the Power Module in the Enclosure

Install the power module into the enclosure in the reverse order of removal.

When installing the fiber-optic cables:

1. Remove the transceiver from the fiber-optic port on the power layer
interface circuit board.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

DC Link Fuses Replacement Replace the DC link fuses with the appropriate kit catalog number that is
identified in Table 17.

IMPORTANT It is recommended that you replace both DC link fuses for each power
module installed.

Table 17 - DC Link/Fuse Assembly Fuse Ratings

DC Link/Fuse Assembly Fuse Kit Cat. No Voltage Class Fuses Fuse Size
Kit Cat. No. Per
Kit Amps/Leg 1/Leg

20-750-MDCL1-CD-F8M SK-RM-DCFUSE1-F8 400/480V AC 2 1400 170M6467

20-750-MDCL2-CD-F8M
20-750-MDCL1-EF-F8M SK-RM-DCFUSE2-F8 600/690V AC 2 1100 170M6499
20-750-MDCL2-EF-F8M

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Chapter 6 Power Bay Components

Remove the DC Link Fuses

Follow these steps to remove and replace the DC link fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the guards from the enclosure. See Guard Removal on page
139.
5. Loosen the thumb screw that secures the connections cover to the front
of the power module.
6. By using the screw, lift the connections cover up and off the power
module chassis.
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.

–
5 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

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8. Remove the four M12 x 13 mm hex nuts that secure the fuses to the DC
link bus bars and remove the fuses.
M12 x 13 mm
8 19 mm
45 N•m (398 lb•in)

DC Link/Fuse and Bus Bar for

Single Power Module Shown.

Install the DC Link Fuses

Install the DC link fuses in the reverse order of removal.

Power Module PE-B1 Power Replace the power module PE-B1 power jumper with kit catalog number
SK-RM-INV-JMPR-F8.
Jumper Replacement

Remove the Power Module PE-B1 Power Jumper

Follow these steps to remove and replace the power module PE-B1 power
jumper.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.

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Chapter 6 Power Bay Components

4. If present, remove the guards from the enclosure. See Guard Removal on
page 139.
5. Loosen the torx thumb screw that secures the connections cover to the
front of the power module. 1.8 N•m (16 lb•in)
6. By using the thumb screw, lift the connections cover up and off the
power module chassis.
7. Remove the jumper from connector P5/P6 on the power layer interface
circuit board.

–
5 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

Install the Power Module PE-B1 Power Jumper

Install the power module PE-B1 power jumper in the reverse order of removal.

Circuit Board Tray Removal 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 General Precautions on page 12.

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2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the power module from the enclosure. See Power Module
Replacement on page 140.
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 T30
5.2 N•m (46 lb•in)

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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Chapter 6 Power Bay Components

6. Without bending the cables to a radius less than 50 mm (2 in.),

disconnect the fiber-optic cables from the transceivers in the PDI and
CTL ports on the power layer interface circuit board.
7. Disconnect the cable connector P13 from connector J13 on the power
layer interface circuit board.

4
2
J13 +
=

3
+

PDI CTL

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8. Disconnect these cable connectors from the power interface circuit

board:
• J3 from P3
• J4 from P4
• J7 from P7
• J8 from P8
• J9 from P9
• J10 from P10
• J11 from P11
• J12 from P12

P4 P5
+ P6
P12

+
+
+

+
+

P10
+ P11
+
+

+ +

+
+
+
+
+

P3
P7 P8 P9 E2

9. Remove all cables from the cable mounts on the front of the circuit
board tray.

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10. Remove the three M5 x 12 mm slotted-torx screws that secure the circuit
board tray to the power module chassis and, remove the tray by rotating
the left side away from the chassis and by sliding the tabs on the right
side of the tray out of the mounting slots.

M5 x 12 mm
10 T25
6 N•m (53 lb•in)

Install the Circuit Board Tray

Install the circuit board tray in the reverse order of removal.

When installing the fiber-optic cables:

1. Remove the transceiver from the fiber-optic port on the circuit board.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

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Power Layer Interface Circuit Replace the power module power layer interface circuit board with kit catalog
number SK-RM-PLI1-F8.
Board Replacement
Two versions of the circuit board tray are released. Each version of the tray uses
different screw sizes to secure the power layer interface circuit board to the tray.
Circuit board trays and screw combinations for the power layer interface board
include:
• Part number PN-371633 contains five M3 x 20 mm slotted-torx screws
• Part number PN-417691 contains five M4 x 18 mm slotted-torx screws

Remove the Power Layer Interface Circuit Board

Follow these steps to remove and replace the power layer interface circuit
board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the power module from the enclosure. See Power Module
Replacement on page 140.
5. Remove the circuit board tray from the power module. See Circuit
Board Tray Removal on page 148.
6. Remove the transceivers from the PDI and CTL ports on the power
layer interface circuit board. Retain the transceivers for reuse.
7. Remove the five M3 x 20 mm or M4 x 18 mm slotted-torx screws that
secure the power layer interface circuit board to the standoffs on the
circuit board tray and remove the circuit board. Retain the screws for
reuse.

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.

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Chapter 6 Power Bay Components

8. Slide the board to the right to disconnect the two 64-pin edge
connectors and remove the circuit board.

M3 x 3 mm
7 T20
0.6 N•m (5.0 lb•in)
OR

M4 x 18 mm
7 T20
2.6 N•m (23.0 lb•in)

Install the Power Layer Interface Circuit Board

Install the power layer interface circuit board in the reverse order of removal.

Power Interface Circuit Board Replace the power module power interface circuit board with the appropriate
kit catalog number:
Replacement
• SK-RM-PIB1-CnnnDnnn
• SK-RM-PIB1-EnnnFnnn
• SK-RM-PIB2-CnnnDnnn
• SK-RM-PIB2-EnnnFnnn
• SK-RM-PIB3-CnnnDnnn
• SK-RM-PIB3-EnnnFnnn

Two versions of the circuit board tray are released. Each version of the tray uses
different screw sizes to secure the power interface circuit board to the tray.
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

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Remove the Power Interface Circuit Board

Follow these steps to remove and replace the power interface circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the power module from the enclosure. See Power Module
Replacement on page 140.
5. Remove the circuit board tray from the power module. See Circuit
Board Tray Removal on page 148.
6. Remove the power layer interface circuit board. See Power Layer
Interface Circuit Board Replacement on page 153.
7. Remove the seven M4 x 10 mm or M4 x 18 mm torx screws that secure
the power interface circuit board to the circuit board tray and remove
the circuit board by lifting the board up and off the supports on the tray.
Retain the screws for reuse.

IMPORTANT The power 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.

M4 x 10 mm
7 T20
2.6 N•m (23.0 lb•in)
OR
M4 x 18 mm
7 T20
2.6 N•m (23.0 lb•in)

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Install the Power Interface Circuit Board

Install the power interface circuit board in the reverse order of removal.

Balance Resistors Replace the power module balance resistors with the appropriate kit catalog
number:
Replacement
• SK-RM-INVBR1-F8M (400/480V)
• SK-RM-INVBR2-F8M (600/690V)

Remove the Balance Resistors

Follow these steps to remove and replace the balance resistors.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the power module from the enclosure. See Power Module
Replacement on page 140.

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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 T30
5.2 N•m (46 lb•in)

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Chapter 6 Power Bay Components

6. Disconnect the stab connectors from the terminals on the balance

resistors.
7. Remove the upper M4 nut that secures each balance resistor to the
power module chassis.
8. Loosen the lower M4 nut that secures each balance resistor to the power
module chassis and remove the resistors.

M4 =
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.

Current Sensors Replace the power module current sensors with the appropriate kit catalog
number:
Replacement
• SK-RM-INVCS1-F8M (622 A)
• SK-RM-INVCS2-F8M (1000 A)

Remove the Current Sensors

Follow these steps to remove and replace the current sensors.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.

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4. Remove the power module from the enclosure. See Power Module
Replacement on page 140.
5. Remove the circuit board tray from the power module. See Circuit
Board Tray Removal on page 148.
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.
7. Remove the six M4 x 10 mm torx screws that secure the three current
sensors to the power module chassis and remove the current sensors.

M8 x 20 mm
6 T40
15 N•m (133 lb•in)

M4 x 10 mm
7 T25
2.6 N•m (23 lb•in)

Install the Current Sensors

Install the current sensors in the reverse order of removal.

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LCL Filter Module Replace the LCL filter module with the appropriate kit catalog number:
Replacement • 20-750-ML1-CnnnDnnn
• 20-750-ML1-EnnnFnnn
Equipment is available that is designed to help you safely handle the LCL filter
modules. The following equipment is recommended:
• PowerFlex 750-Series module service cart, catalog number 20-750-
MCART1, publication 750-IN105
• PowerFlex 750TM power and LCL filter module storage hardware,
catalog number 20-750-MINV-ATIP, publication 750-IN106

Remove the LCL Filter Module from the Enclosure

Follow these steps to remove the LCL filter module from the enclosure.

ATTENTION: IGBT power and LCL filter modules have a high center of gravity
and a tip-over hazard exists. To guard against death, serious personal injury,
or equipment damage, do not subject the module to high rates of
acceleration or deceleration while transporting. Do not push or pull above the
points that are indicated on the module.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. If present, remove the guards from the enclosure. See Guard Removal on
page 139.

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5. Loosen the screw that secures the connections cover to the front of the
adjoining power modules.
6. Use the screw to lift the connections cover up and off the power module
chassis.
–
5 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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7. Without bending the cable to a radius less than 50 mm (2 in.),

disconnect the fiber-optic cable from the transceiver in the PDI and
CTL port on the power layer interface circuit board and carefully
remove one or more cables from the power module chassis.

=
LCL filter with one line side converter. 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.

P3

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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.

9 10

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11. Remove the three M12 x 13 mm hex nuts that secure the flexible bus
cables to the AC input fuse terminals and remove the flexible bus cables.
12. Remove the two M10 x 20 mm torx screws that secure the LCL filter
module chassis to the control bus frame.
13. Leave the two M10 x 20 mm screws that secure the LCL filter module
chassis to the floor mounting bracket while preparing the PowerFlex
750-Series service cart.

M12 x 13 mm
11 19 mm
45 N•m (398 lb•in)

11

12

M10 x 20 mm
12, T40
15 42.4 N•m (375 lb•in)

13: Leave these M10 screws in place while

preparing the service cart or ramp.
15: Remove these M10 screws.

15

14. Secure the service cart to the floor mounting bracket in the enclosure.
See the PowerFlex 750-Series Service Cart and DCPC Module Lift
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.

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Install the LCL Filter Module in the Enclosure

Install the LCL filter module into the enclosure in the reverse order of removal.

When installing the fiber-optic cables:

1. Remove the transceiver from the fiber-optic port on the power layer
interface circuit board on the adjoining power module.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.’

AC Input Link Fuses Replace the AC input link fuses with the appropriate kit catalog number that is
identified in Table 18:
Replacement
IMPORTANT It is recommended that you replace all three AC line fuses.

Table 18 - AC Input Link Bus Bar and Fuse Assembly Kit Fuses
AC Input Link Bus Bar Frame LCL Filter Voltage Fuse Kit Cat. No. Bussman Fuse Fuse Rating Fuse
and Fuse Kit Cat. No. Rating Number Qty.
20-750-MACL1-F8M 8 One 20-750-ML1-C540D505 400/480V SK-RM-ACFUSE1-F8 170M6463 690/700V (IEC/U.L.), 900 A (1) 3
20-750-MACL3-F8M One 20-750-ML1-E395F370 600/690V SK-RM-ACFUSE5-F8 170M6461 690/700V (IEC/U.L.), 700 A (1) 3
20-750-MACL2-F8M One 20-750-ML1-C770D740 400/480V SK-RM-ACFUSE2-F8 170M6466 690/700V (IEC/U.L.), 1250 A (1) 3
20-750-MACL1-F8M One 20-750-ML1-E395F370 600/690V SK-RM-ACFUSE1-F8 170M6463 690/700V (IEC/U.L.), 900 A (1) 3
20-750-MACL1-F9M 9 One 20-750-ML1-C1K1D1K0 400/480V SK-RM-ACFUSE3-F9 170M6470 690/700V (IEC), 1800 A (2) 3
20-750-MACL2-F8M One 20-750-ML1-E760F735 600/690V SK-RM-ACFUSE2-F8 170M6466 690/700V (IEC/U.L.), 1250 A (1) 3
20-750-MACL2-F9M One 20-750-ML1-C1K4D1K3 400/480V SK-RM-ACFUSE4-F9 170M6471 690/700V (IEC), 2000 A (3) 3
20-750-MACL3-F9M One 20-750-ML1-E980F920 600/690V SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A (1) 3
20-750-MACL2-F8M 10 One 20-750-ML1-C770D740 and 400/480V SK-RM-ACFUSE2-F8 170M6466 690/700V (IEC/U.L.), 1250 A (1) 3
one 20-750-ML1-C1K4D1K3
20-750-MACL2-F9M SK-RM-ACFUSE4-F9 170M6471 690/700V (IEC), 2000 A (3) 3
20-750-MACL1-F8M One 20-750-ML1-E545F505 and 600/690V SK-RM-ACFUSE1-F8 170M6463 690/700V (IEC/U.L.), 900 A (1) 3
one 20-750-ML1-E980F920
20-750-MACL3-F9M SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A (1) 3
20-750-MACL2-F9M 11 Two 20-750-ML1-C1K4D1K3 400/480V SK-RM-ACFUSE4-F9 170M6471 690/700V (IEC/U.L.), 1600 A (3) 3
20-750-MACL3-F9M Two 20-750-ML1-E980F920 600/690V SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A (1) 3

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Table 18 - AC Input Link Bus Bar and Fuse Assembly Kit Fuses
AC Input Link Bus Bar Frame LCL Filter Voltage Fuse Kit Cat. No. Bussman Fuse Fuse Rating Fuse
and Fuse Kit Cat. No. Rating Number Qty.
20-750-MACL2-F8M 12 One 20-750-ML1-C770D740 400/480V SK-RM-ACFUSE2-F8 170M6466 690/700V (IEC/U.L.), 1250 A (1) 3
and two 20-750-ML1-C1K4D1K3
20-750-MACL2-F9M SK-RM-ACFUSE1-F8 170M6463 690/700V (IEC), 2000 A (3) 3
(1)
20-750-MACL1-F8M One 20-750-ML1-E545F505 and 600/690V SK-RM-ACFUSE1-F8 170M6463 690/700V (IEC/U.L.), 900 A 3
two 20-750-ML1-E980F920 (1)
20-750-MACL3-F9M SK-RM-ACFUSE6-F9 170M6469 690/700V (IEC/U.L.), 1600 A 3
(1) Bussman Square Body - Flush End Contact -BKN/- Type K Indicator.
(2) Bussman Square Body - Flush End Contact -BKN/- Type K Indicator. Rated Voltage IEC 600V (Consult Bussmann for U.L. Recognition/ CSA Component Acceptance status.)
(3) Bussman Square Body - Flush End Contact -BKN/- Type K Indicator. Rated Voltage IEC 550V (Consult Bussmann for U.L. Recognition/ CSA Component Acceptance status.)

Remove the AC Input Link Fuses

Follow these steps to remove the AC input link fuses.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. If present, remove the guards from the enclosure. See Guard Removal on
page 139.
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.

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7. Remove the three M12 x 13 mm hex nuts that secure the flexible bus
cables to the AC input fuse terminals and remove the flexible bus cables.
8. Remove the three M12 x 13 mm hex nuts that secure the fuse to the AC
input bus bars and remove the fuses.

M12 x 13 mm
7 19 mm
Frame 9…12 Power Bay Shown 45 N•m (398 lb•in)

P5
P1
8

M12 x 13 mm
8 19 mm
45 N•m (398 lb•in)

Install the AC Input Link Fuses

Install the AC input link fuses in the reverse order of removal.

LCL Filter Capacitor Assembly Replace the LCL filter module capacitor assembly with the appropriate kit
catalog number:
Replacement
• 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.

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IMPORTANT It is recommended that you replace all capacitors in the module.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the LCL filter module from the enclosure. See LCL Filter
Module Replacement on page 160.

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5. Remove the wire access cover to more easily feed the wiring through the
back of the chassis when a capacitor assembly is removed. 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
5 T25
3 N•m (26 lb•in)

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Chapter 6 Power Bay Components

IMPORTANT The interconnection wires cannot be removed from the terminal block on
the top of the capacitor until the capacitor assembly has been removed from
the chassis.

6. Complete these steps for each capacitor in the module.

a. Loosen, but do not remove, the upper two M6 x 16 mm torx screws
that secure the capacitor assembly to the chassis.
b. Remove the lower two M6 x 16 mm torx screws that secure the
capacitor assembly to the chassis.
c. Lift the capacitor assembly up and off the top screws and slide the
assembly out of the chassis.
d. Disconnect the wires from terminals at the top of the capacitor and
remove the capacitor assembly.
M6 x 16 mm
6a, T30
6b
12.5 N•m (110.6 lb•in)

6a

6b

TIP The contents of the capacitor canisters is classified as not hazardous

according to regulation (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.

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EMC Filter Circuit Board Replace the LCL filter module EMC filter circuit board with kit catalog
number SK-RM-EMCFB1.
Replacement

Remove the EMC Filter Circuit Board

Follow these steps to remove and replace the EMC filter circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the LCL filter module from the enclosure. See LCL Filter
Module Replacement on page 160.
5. Remove the two barb fasteners that secure the screen to the chassis and
remove the screen. The barb fasteners are not reusable.

5 =

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6. Remove the four cables from the connectors at the top and side of the
EMC filter circuit board.
6
=

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7. Remove the two M6 x 16 mm screws that secure the EMC filter circuit
board to the support bracket and remove the circuit board.

M6 x 16 mm
7 T30
12.5 N•m (110.6 lb•in)
7
=

Install the EMC Filter Circuit Board

Install the EMC filter circuit board in the reverse order of removal.

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)

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Remove the Current Sense Circuit Board

Follow these steps to remove and replace the current sense circuit board.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the LCL filter module from the enclosure. See LCL Filter
Module Replacement on page 160.
5. If installed, remove the EMC filter circuit board from the LCL filter
module. See EMC Filter Circuit Board Replacement on page 171.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

6. Without bending the cable to a radius less than 50 mm (2 in.),

disconnect the fiber-optic cable from the transceiver in the 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.

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8. If the top-most receptacle on the back of the LCL filter module contains
a DC capacitor, remove the capacitor. See Remove the LCL Filter
Capacitor Assembly on page 167. If the top-most receptacle on the back
of the LCL filter module does not contain a DC capacitor, complete
steps a and b.
a. 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
8 T30
12.5 N•m (110.6 lb•in)

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9. Remove the two M5 x 10 mm torx screws that secure the current sense
circuit board tray to the side of the chassis.
10. While supporting the circuit board tray, loosen, but do not remove, the
two M5 x 12 mm torx screws that secure the current sense circuit board
tray to the back of the chassis and lift the tray off the screws.

M5 x 10 mm M5 x 12 mm
9 T25 10 T25
4 N•m (35.4 lb•in) 4 N•m (35.4 lb•in)

9 10

11. Cut the cable ties that secure the wires to the circuit board tray.
12. Disconnect these connectors from the current sense circuit board:
• P8 from J8
• P5 from J5
• P6 from J6
• 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.

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14. Remove the five M4 x 8 mm torx screws that secure the current sense
circuit board to the circuit board tray and remove the circuit board.

M4 x 8 mm
14 T25
1.8 N•m (15.5 lb•in)

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:

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IMPORTANT
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.

a. 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 port on the board,
until you hear an audible ‘click.’

Power/LCL Filter Module Fan Replace the power or LCL filter module fan fuse with kit catalog number
SK-RM-INVFAN1-FUSE (Time Delay, 250V, 3.5 A, Cartridge).
Fuse Replacement

Remove the Power/LCL Filter Module Fan Fuse

Follow these steps to remove and replace the power /LCL filter module fan
fuse.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the guard form the enclosure. See Guard Removal on page 139.

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5. Unscrew the fuse holder cover and fuse and remove the fuse.
Fan Shown Removed from Module for Clarity Only

Install the Power/LCL Filter Module Fan Fuse

Install the power /LCL filter module fan fuse in the reverse order of removal.

Fan Assembly Replacement Replace the power or LCL filter module fan assembly with kit catalog number
SK-RM-INVFAN1-F8.

Remove the Power or LCL Filter Module Fan Assembly

Follow these steps to remove and replace the power or LCL filter module fan
assembly.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. Remove the guard form the enclosure. See Guard Removal on page 139.

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5. Disconnect connector P13 from connector J13 on the fan assembly

housing.
6. Loosen the M6 slotted-torx screw that secures the fan housing to the
power module chassis and slide the fan assembly out of the chassis.

M6
6 T30
2.6 N•m (23 lb•in)

Install the Power or LCL Filter Module Fan Assembly

Install the power or LCL filter module fan assembly in the reverse order of
removal.

Torque Accuracy Module Replace the torque accuracy module with the appropriate kit catalog number:
Replacement • 20-750-MTAM1-CD (400/480V)
• 20-750-MTAM1-EF (600/690V)

Remove the Torque Accuracy Module

Follow these steps to remove and replace the torque accuracy module.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.

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4. Remove the right-most power module from the enclosure. See Power
Module Replacement from the Enclosure on page 140.

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

5. Without bending the cable to a radius less than 50 mm (2 in.), remove

the fiber-optic cable from the transceiver in the TAM port on the torque
accuracy module.
6. Remove the transceiver from the TAM port on the board. Retain the
transceiver for reuse.
7. Disconnect connector P1 from J1 on the torque accuracy module.
8. Disconnect connector P2 from J2 on the torque accuracy module.
9. Loosen the two upper M4 hex nuts and washers that secure the torque
accuracy module panel to the mounting bracket.
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.

M4
9, 7 mm
10
2.6 N•m (23 lb•in)

9
5

10

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Install the Torque Accuracy Module

Install the torque accuracy module in the reverse order of removal.

When installing the fiber-optic cable:

IMPORTANT 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
attenuation increases as inside bend radius is (2 in.)
decreased.

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.

DC Bus Conditioner Replace the DC bus conditioner with kit catalog number
20-750-MDCBUS-COND.
Replacement

Remove the DC Bus Conditioner

Follow these steps to remove the DC bus conditioner.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the corresponding power bay enclosure door.
4. If present, remove the guards from the enclosure. See Guard Removal on
page 139.

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5. Loosen the thumb screw that secures the connections cover to the front
of the power module.
6. By using the screw, lift the connections cover up and off the power
module chassis.
7. Disconnect the DC bus conditioner cable connector P2 from J2 on the
I/O panel in the power module.
–
5 P2 or F - 6.4 mm (0.25 in.)
1.8 N•m (16 lb•in)

7
6

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8. Remove the clear-plastic connections cover from the front of the DC

bus conditioner.

9. Remove the two M6 x 12 mm torx screws that secure the +DC and -DC
cables to the +DC and -DC terminals on the DC bus conditioner,
respectively, and remove the cables.
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
9, T30
10
5 N•m (44 lb•in)

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11. Remove the two M5 hexagonal nuts and washers that secure the DC bus
conditioner to the sheet metal mounting panel and remove the DC bus
conditioner.

M5
11 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.

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Chapter 6 Power Bay Components

Notes:

186 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 7

Wire Entry/Exit Bay Components

This chapter provides detailed instructions for how to remove and replace wire
entry/exit bay components.

Wire Entry/Exit Bay Kits Table 19 lists the replacement kits available for the wire entry/exit bay.

A current list of spare parts for PowerFlex® 750-Series products with

TotalFORCE™ Control is available on the Allen-Bradley website at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
Table 19 - Wire Entry/Exit Bay Replacement Kits
Description Catalog Number Identification Identification No. Replacement Instructions
Ventilation Components
IP21/IP54, 400 mm Wide Door Vent Filter SK-RM-WBDR-FLTR1 See Figure 20 on page 188 1 See page 189
IP21/IP54, 800 mm Wide Door Vent Filter SK-RM-WBDR-FLTR1 1 See page 189
IP21/IP54, 400 mm Wide Door Vent Fan SK-RM-WBDR-FANFLR1 2 See page 189
and Filter
IP21/IP54, 800 mm Wide Door Vent Fan SK-RM-WBDR-FANFLR2 2 See page 189
and Filter
Electrical Components
Thermal Switch SK-RM-THRMSW-WB See Figure 20 on page 188 3 See page 191

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 187

Chapter 7 Wire Entry/Exit Bay Components

Figure 20 - Wire Entry/Exit Bay Kits Identification

800 mm Wide Wire Entry/Exit Bay Shown

2 3

188 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Wire Entry/Exit Bay Components Chapter 7

IP54/IP21, 400 mm Wide Replace the IP54/IP21, 400 mm wide door vent filters with kit catalog number
SK-RM-IB4DR-FLTR1.
Door Vent Filters
Replacement See IP54/IP21, 400/600 mm Wide Door Vent Filters Replacement on page
83.

IP54/IP21, 800 mm Wide Replace the IP54/IP21, 800 mm wide door vent filters with kit catalog number
SK-RM-IB4DR-FLTR1.
Door Vent Filters
Replacement See IP54/IP21, 400/600 mm Wide Door Vent Filters Replacement on page
83.

IP54/IP21, 400/800 mm Wide Replace the IP54/IP21, 400 mm or 800 mm wide door vent fan and filter
assembly with the appropriate kit catalog numbers:
Door Vent Fan and Filter
• 400 mm, SK-RM-WBDR-FANFLR1
Assembly Replacement • 800 mm, SK-RM-WBDR-FANFLR2

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

Follow these steps to remove the IP54/IP21, 400/800 mm wide door vent fan,
and filter assembly.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the wire bay enclosure door.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 189

Chapter 7 Wire Entry/Exit Bay Components

4. On the inside of the enclosure door, remove the M8 hex nut and washer
that secures the two ground wire lugs to the door, and remove the wires.
5. Disconnect the fan power wires from connector P1 on the fan assembly.
6. Press the tabs on the vent cover inward and pull the vent off the front of
the enclosure door.

M8
4 13 mm
10.2 N•m (90 lb•in)

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.

190 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Wire Entry/Exit Bay Components Chapter 7

Thermal Switch Replacement Replace the thermal switch with kit catalog number SK-RM-THRMSW-WB.

Remove the Thermal Switch

Follow these steps to remove the thermal switch.

1. Review the General Precautions on page 12.

2. Remove system power. See Remove Power from the Drive System on
page 13.
3. Open the wire bay enclosure door.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 191

Chapter 7 Wire Entry/Exit Bay Components

4. Loosen the 12 screws that secure the guards to the enclosure and remove
the guards.
M5.5 x 13 mm
4 T25
2.6 N•m (23 lb•in)

400 mm Wide Entry/Exit Wire Bay Shown.

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.

192 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Wire Entry/Exit Bay Components Chapter 7

6. Disconnect the wires from the two terminals on the thermal switch.

M6 x 25 mm
5 T30
4.8 N•m (42 lb•in)

Install the Thermal Switch

Install the thermal switch in the reverse order of removal.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 193

Chapter 7 Wire Entry/Exit Bay Components

Notes:

194 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Chapter 8

Start Up After Repairs

Topic Page
Before You Apply Power to the Drive 195
No-load DC Bus Voltage and Output Current Measurements 199

This chapter provides detailed instructions for starting up a regenerative drive,

regenerative bus supply, and common bus inverter after you have completed
repairs.

Before You Apply Power to ATTENTION: To avoid an electric shock hazard, verify that there is no AC
the Drive 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.
• Verify that there is no AC input voltage present using the R, S, and T test
point 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 test
points in the input bay by measuring +DC to -DC, +DC to GND, and -DC to
GND.

1. For regenerative drives and bus supplies, measure the AC input and DC
bus voltage at the following test point sockets in the power bay to verify
that there is no voltage present:
• Using the circuit breaker output (CB1 SEC) test points R/L1, S/L2,
and T/L3, measure L to L and L to chassis GND.
• Using the fused disconnect output (FD1 SEC) test points R, S, and
T, measure L to L and L to chassis GND.
• Using the DC bus test points +DC and -DC, measure +DC to -DC,
+DC to chassis GND, and -DC to chassis GND.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 195

Chapter 8 Start Up After Repairs

ATTENTION: 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 test points on all power
modules by measuring +DC to -DC, +DC to GND, and -DC to GND.

2. For common bus inverters, using the DC bus test points +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.

196 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Start Up After Repairs Chapter 8

3. Measure the 240V AC control voltage at the appropriate terminals and

verify that there is no voltage present:
• For regenerative drives and bus supplies, in the power input bay,
measure terminals L and N on terminal block TB2.
Frame 10 Input Bay Shown

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

terminal block TB4.

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 197

Chapter 8 Start Up After Repairs

4. For all products, perform phase to ground resistance tests to verify that
there are no shorts on the following test points.:
In an input bay:
• Using the circuit breaker output (CB1 SEC) test points R/L1, S/L2,
and T/L3, measure L to chassis GND.
• Using the fused disconnect output (FD1 SEC) test points R, S, and
T, measure L to chassis GND.
• Using the DC bus test points +DC and -DC, measure +DC to
chassis GND, and -DC to chassis GND.
In a power bay:
• Using the DC bus test points +DC and -DC on the front of the
power modules, measure +DC to chassis GND, and -DC to chassis
GND.
5. If the measured value of any resistance test is less than 1 kΩ,
troubleshoot to find the short, correct the problem, and repeat step 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.

IMPORTANT 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 50 mm
cable. Signal attenuation increases with (2 in.)
decreased inside bend radii.

• If applicable, verify that all fiber-optic cables are connected at both

ends and properly secured and supported by cable ties along their
entire length when routed between enclosures.
• Verify that all interconnection wire harnesses are connected at both
ends and properly supported by cable ties along their entire length
when routed between enclosures.
7. When service has been completed on the control pod, verify that all
fiber-optic, and control power and I/O wires are connected and
properly secured and supported by cable ties along their entire length
when routed between enclosures.

198 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Start Up After Repairs Chapter 8

No-load DC Bus Voltage and Follow theses steps to measure the DC bus voltage and output current and
diagnose problems without connecting the motor to its mechanical load.
Output Current
Measurements 1. Verify that the input power and ground wires are connected.
2. Verify that the AC line power at the disconnect device is within the
rated value for the drive or bus supply.
3. Verify that the control power voltage is correct.
4. Verify that the motor cables are connected.
5. Verify that the motor load is disconnected.
6. Energize the system. See Remove Power from the Drive System on page
13.
7. Measure the DC bus voltage and verify that the measured value is
displayed in port 0, parameter 3 [DC Bus Volts].
8. Start the system and increase the speed from zero to base speed.
9. Measure the system output current and verify that the measured value is
displayed in port 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-TG100A-EN-P - July 2017 199

Chapter 8 Start Up After Repairs

Notes:

200 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Appendix A

System Schematics

Topic Page
PowerFlex 755TM LCL Filter Module 203
PowerFlex 755TM Power Module 204
PowerFlex 755TM DC Precharge Module 205
PowerFlex 755TM DC Bus Conditioner 206
PowerFlex 755TM Frame 8 AC Input Bay 207
PowerFlex 755TM Frame 9 AC Input Bay 208
PowerFlex 755TM Frame 10 AC Input Bay 209
PowerFlex 755TM Frame 11 AC Input Bay 210
PowerFlex 755TM Frame 12 AC Input Bay 211
PowerFlex 755TM Frame 8 Regenerative Drive with DC Bus Conditioner 212
PowerFlex 755TM Frame 8 Regenerative Drive with no DC Bus Conditioner 213
PowerFlex 755TM Frame 9 Regenerative Drive 214
PowerFlex 755TM Frame 10 Regenerative Drive (Page 1 of 2) 215
PowerFlex 755TM Frame 10 Regenerative Drive (Page 2 of 2) 216
PowerFlex 755TM Frame 11 Regenerative Drive (Page 1 of 2) 217
PowerFlex 755TM Frame 11 Regenerative Drive (Page 2 of 2) 218
PowerFlex 755TM Frame 12 Regenerative Drive (Page 1 of 2) 219
PowerFlex 755TM Frame 12 Regenerative Drive (Page 2 of 2) 220
PowerFlex 755TM Frame 8 Regenerative Bus Supply with DC Bus Conditioner 221
PowerFlex 755TM Frame 8 Regenerative Bus Supply with no DC Bus Conditioner 222
PowerFlex 755TM Frame 9 Regenerative Bus Supply 223
PowerFlex 755TM Frame 10 Regenerative Bus Supply 224
PowerFlex 755TM Frame 11 Regenerative Bus Supply 225
PowerFlex 755TM Frame 12 Regenerative Bus Supply 226
PowerFlex 755TM Common Bus Inverter Control Bay 227
PowerFlex 755TM Frame 8 Common Bus Inverter with DC Link Fuses 228
PowerFlex 755TM Frame 9 Common Bus Inverter with DC Link Fuses 229
PowerFlex 755TM Frame 10 Common Bus Inverter with DC Link Fuses 230
PowerFlex 755TM Frame 11 Common Bus Inverter with DC Link Fuses 231
PowerFlex 755TM Frame 12 Common Bus Inverter with DC Link Fuses 232
PowerFlex 755TM Frame 8 Common Bus Inverter with DC Precharge Module 233
PowerFlex 755TM Frame 9 Common Bus Inverter with DC Precharge Module 234

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 201

Appendix A System Schematics

Topic Page
PowerFlex 755TM Frame 10 Common Bus Inverter with DC Precharge Module 235
PowerFlex 755TM Frame 11 Common Bus Inverter with DC Precharge Module 236
PowerFlex 755TM Frame 12 Common Bus Inverter with DC Precharge Module 237
Entry Wire Bay 238
Exit Wire Bay 239

This chapter provides schematics for PowerFlex® 755T modules and products.

202 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 21 - PowerFlex 755TM LCL Filter Module

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 203

 POS BUS BAR
TP1
PF750R, IGBT PS, SCHEMATIC
CATALOG NUMBER: 20-750-MIx-xxxxxxxx
+POS
+POS

+DC IGBT1 IGBT2 IGBT3

OPTIONAL
+ + + + +
U-Phase V-Phase W-Phase L1
IGBT IGBT CS1
C1 C3 C5 C7 C9 IGBT
LEM U/T1 Busbar
- - - - - U
U/T1
+DC CS2
LEM V/T2 Busbar
V
V/T2
MID BUS BAR
CS3
MID

MID

LEM W/T3 Busbar

W
W/T3
Thermal Switch(N/C)
(STABS)

VRFY

VRFY

VRFY
TO

+24V

+24V
+24V
-24V

-24V
-24V
M

M
M
+ + + + +
ONLY FOR FR-8C

J12-PCBA1
2 1
-DC 4 3 2 1 4 3 2 1 4 3 2 1
C2 C4 C6 C8 C10

NTC
NTC
NTC

- - - - - R5
CHASSIS
R6

Rockwell Automation Publication 750-TG100A-EN-P - July 2017

R7
Figure 22 - PowerFlex 755TM Power Module

OPTIONAL
NEG BUS BAR GATE BOARD
-NEG

-NEG

J1
(ONLY FOR 20-750-MI3-xxxxxxx)

Ver
TP2 40 PINS
P1 (PCBA3)
-DC
TP3

10001416614
Of
2 /DC FUSE GOOD
1

1 2
J1
2 1 DC FUSE COM
On Panel, IGBT PS
/BUS_COND_GOOD
1 1

1 2 3
2 BUS_COND_COM

J2
2
3 /BUS_COND_PRESENT
4 3
40 PIN RIBBON CABLE

On Panel, IGBT PS
3
2
1 3

/BUS_COND_PRESENT
4
5

/BUS_COND_GOOD
2 1 +24 OUT
5 1

BUS_COND_COM
2 COM OUT

BLOWER_CONTROL
/DC FUSE GOOD
1

/AC FUSE GOOD

3 /AC FUSE GOOD

DC FUSE COM

AC FUSE COM

INTAKE_TEMP_A
INTAKE_TEMP_B
6 2

BLOWER_FDBK
4 AC FUSE COM

BLOWER_COM
P5/P6 must be connected to J5(PE-B1 IN) For

J3
1 CONV_A_TEST
+POS

Sheet
COM OUT
-NEG
MID

FFE Converter only, otherwise should be

+24 OUT
2 CONV_VARY_A 7 3
R4-1 R2-1 R1-1 connected to J6(PE-B1 OUT)

Size
R3-1 3 CONV_VARY_B
P5/P6 4 CONV_B_TEST 8 4
P4 On Panel, IGBT PS
1 2 34
ONLY FOR FR-8C

1 2 3 4 5 On Panel, IGBT PS
ONLY FOR FR-8C

1 2 3 4 5 1234 1234
J4 J5 J6 P13 1. CONV_A_TEST 2 240VAC_H
4 3 240VAC_N

3
4 3

1
11 4 4 11
10 3 3 10

12 5 5 12
13 6 6 13
14 7 7 14
PE-B1 IN PE-B1 OUT 3. CONV_VARY_A 1

8 1 1 8
9 2 2 9
J13

J4
64 PINS
R4 R2 R3 R1 2 1 2 1 2. CONV_VARY_B CUST_+24V

J18
1
P10 1

4
2
2 4. CONV_B_TEST CUST_COM
2
3 On Panel, IGBT PS
4
PLI BOARD
J10
(PCBA2)
R4-2 R2-2 R3-2 R1-2 CUST_+24V
1

Fiberlink

Fiberlink
1 2
1 2
J11
FIBER LINK to DCP / LCL

64 PINS

CTL
PDI
P3

J19
40 PINS 2
J3 P11 CUST_COM
On Panel, IGBT PS FIBER LINK to Mx-POD1
1 PIB BOARD

1 2 3
1 2 3
J12
2
J7 (PCBA1) J8 J9
1. Thermal switch_1 3 4 3 4 3 4

P12
2. Thermal switch_2 1 2 1 2 1 2
1 2 1 2 1 2
1. CS1_+24V 1. CS2_+24v 1. CS3_+24V
3 4 3 4 3 4 2. CS3_-24V
2. CS1_-24V 2. CS2_-24V
3. CS3_M

1 2 3 P12
3. CS1_M 3. CS2_M
3 2 3 2 4. CS3_VERY
1 4 4. CS1_VERY 1 3 24 4. CS2_VERY 1 4
Label for Test Points on Front
TP1= +DC
TP2= -DC
System Schematics

TP3= Chassis (ONLY FOR 20-750-MI1-xxxxxxx) CHASSIS

240VAC_N 240VAC_N 1
240VAC_H 5 1 1 5
BLOWER F1 2
INTAKE_TEMP_A 240VAC_H
FAN1 NTC INTAKE_TEMP_B 6 2 2 6 INTAKE_TEMP_A 1
10V CNTRL REF INTAKE_TEMP_B 2
4 BLOWER_FDBK 7 3 3 7
BLOWER_COM BLOWER_FDBK 4
BLOWER_CONTROL 8 4 4 8 BLOWER_COM 3
BLOWER_CONTROL 5
J13 P13
Appendix A

204
 System Schematics Appendix A

Figure 23 - PowerFlex 755TM DC Precharge Module

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 205

Appendix A System Schematics

Figure 24 - PowerFlex 755TM DC Bus Conditioner

206 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 25 - PowerFlex 755TM Frame 8 AC Input Bay

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 207

Appendix A System Schematics

Figure 26 - PowerFlex 755TM Frame 9 AC Input Bay

208 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 27 - PowerFlex 755TM Frame 10 AC Input Bay

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 209

Appendix A System Schematics

Figure 28 - PowerFlex 755TM Frame 11 AC Input Bay

210 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 29 - PowerFlex 755TM Frame 12 AC Input Bay

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 211

Appendix A System Schematics

Figure 30 - PowerFlex 755TM Frame 8 Regenerative Drive with DC Bus Conditioner

212 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 31 - PowerFlex 755TM Frame 8 Regenerative Drive with no DC Bus Conditioner

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 213

Appendix A System Schematics

Figure 32 - PowerFlex 755TM Frame 9 Regenerative Drive

214 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 33 - PowerFlex 755TM Frame 10 Regenerative Drive (Page 1 of 2)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 215

Appendix A System Schematics

Figure 34 - PowerFlex 755TM Frame 10 Regenerative Drive (Page 2 of 2)

216 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 35 - PowerFlex 755TM Frame 11 Regenerative Drive (Page 1 of 2)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 217

Appendix A System Schematics

Figure 36 - PowerFlex 755TM Frame 11 Regenerative Drive (Page 2 of 2)

218 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 37 - PowerFlex 755TM Frame 12 Regenerative Drive (Page 1 of 2)

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 219

Appendix A System Schematics

Figure 38 - PowerFlex 755TM Frame 12 Regenerative Drive (Page 2 of 2)

220 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 39 - PowerFlex 755TM Frame 8 Regenerative Bus Supply with DC Bus Conditioner

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 221

Appendix A System Schematics

Figure 40 - PowerFlex 755TM Frame 8 Regenerative Bus Supply with no DC Bus Conditioner

222 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 41 - PowerFlex 755TM Frame 9 Regenerative Bus Supply

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 223

Appendix A System Schematics

Figure 42 - PowerFlex 755TM Frame 10 Regenerative Bus Supply

224 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 43 - PowerFlex 755TM Frame 11 Regenerative Bus Supply

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 225

Appendix A System Schematics

Figure 44 - PowerFlex 755TM Frame 12 Regenerative Bus Supply

226 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 45 - PowerFlex 755TM Common Bus Inverter Control Bay

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 227

Appendix A System Schematics

Figure 46 - PowerFlex 755TM Frame 8 Common Bus Inverter with DC Link Fuses

228 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 47 - PowerFlex 755TM Frame 9 Common Bus Inverter with DC Link Fuses

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 229

Appendix A System Schematics

Figure 48 - PowerFlex 755TM Frame 10 Common Bus Inverter with DC Link Fuses

230 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 49 - PowerFlex 755TM Frame 11 Common Bus Inverter with DC Link Fuses

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 231

Appendix A System Schematics

Figure 50 - PowerFlex 755TM Frame 12 Common Bus Inverter with DC Link Fuses

232 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 51 - PowerFlex 755TM Frame 8 Common Bus Inverter with DC Precharge Module

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 233

Appendix A System Schematics

Figure 52 - PowerFlex 755TM Frame 9 Common Bus Inverter with DC Precharge Module

234 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 53 - PowerFlex 755TM Frame 10 Common Bus Inverter with DC Precharge Module

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 235

Appendix A System Schematics

Figure 54 - PowerFlex 755TM Frame 11 Common Bus Inverter with DC Precharge Module

236 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 55 - PowerFlex 755TM Frame 12 Common Bus Inverter with DC Precharge Module

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 237

Appendix A System Schematics

Figure 56 - Entry Wire Bay

238 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 System Schematics Appendix A

Figure 57 - Exit Wire Bay

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 239

Appendix A System Schematics

Notes:

240 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Index

Numerics circuit board tray (power module)

240V control power fuse install 152
remove 148
continuity test 40 coil
install 100
inspection 33
remove 99
component
240V power distribution fuse
inspection 35
continuity test 40
install 99 lifespan 22
contact
remove 98
inspection 33
contamination
A equipment 32
continuity test
AC input link fuses
240V control power fuse 40
install 167 240V power distribution fuse 40
remove 166 AC precharge control circuit board fuses 40
test 39
AC precharge components AC precharge fused disconnect fuses 40
control transformer fuses 40
kits 77 LCL filter module fan fuse 40
AC precharge control circuit board power module fan fuse 40
install 93 control bay
remove 90 kits 43
AC precharge control circuit board fuses control bay ventilation
continuity test 40 kits 43
install 97 control pod
remove 96
AC precharge fused disconnect fuses inspect 36
install 74
continuity test 40 kits 43
install 104 remove 70
remove 103 control pod cover
AC precharge module
install 51
inspect 36 remove 50
AC precharge time delay relay control pod fan assembly
install 94 install 70
remove 93 remove 68
AC precharge TVSS module control transformer 104
install 96 control transformer fuses
remove 94
continuity test 40
accessories (power bay)
install 102
kits 107 remove 101
apply power 13 current sense circuit board (LCL filter
assembly torque 18 module)
install 177
remove 174
B current sensors (power module)
backplane circuit board install 159
install 60 remove 158
remove 59
balance resistors (power module)
install 158 D
remove 156 DC bus conditioner
blower install 185
inspection 32 remove 182
DC link fuse
test 39
C DC link fuses
check install 147
interlocking device 34 remove 146
locking device 34

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 1

Index

DC precharge circuit board G

install 136 guard (AC bus bars and fuses module)
remove 133
DC precharge fuses insall 139
remove 139
install 138
guard (DC link and fuses module)
remove 137
DC precharge module install 139
remove 139
inspect 36
install 132
kits 105 H
remove 128
DC precharge module disconnect handle and harsh environment 21
shaft harsh environment operation
install 128 maintenance schedule 29
remove 126 high temperature operation
diagram 18 maintenance schedule 26
assembly torque 18
fastener size 18
fastener type 18 I
sequence number 18 IGBT/diode test 37
tool size 18
tool type 18 input bay
dielectric withstand voltage kits 77
input bay control power
test 34
kits 43, 77
input bay guards
E install 90
remove 87
EMC filter circuit board (LCL filter module)
input bay ventilation
install 173
kits 77
remove 171
inspect
equipment
AC precharge module 36
contamination 32
components 35
inspection 32
control pod 36
maintenance 32
DC precharge module 36
filter 35
F inspection
blower 32
fan coil 33
inspection 32, 36 contact 33
fastener size equipment 32
diagram 18 fan 32, 36
fastener type operating mechanism 32
diagram 18 terminals 33
fault condition 34 insulation resistance
fiber transceiver circuit board test 34
interlocking device
install 55
remove 52 check 34
fiber-optic interface circuit board IP/21IP54 roof vent filter (control/input bay)
install 68 install 47
remove 61 remove 46
filter IP21, 400/600 mm wide door vent filter
inspect 35 (power bay)
filter capacitor assembly (LCL filter module) install 126
install 170 remove 125
remove 167 IP21, 800 mm wide door vent filters (power
final check bay)
after maintenance 34 remove 126
forward biased diode test IP21, 800/1000 mm wide door vent filter
meter reading 38 install 86
remove 85

2 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Index

IP21/IP54 door vent filter (control bay) K

install 49 kits
remove 49
IP21/IP54 roof vent fan (control/input bay) AC precharge components 77
accessories (power bay) 107
install 48
control bay 43
remove 47
control pod 43
IP21/IP54 roof vent filters (input bay)
control power (input bay) 43, 77
install 83 input bay 77
remove 83 LCL filter module 106
IP54 exhaust fan (power bay) power bay 105
install 123 power module 106
remove 118 power/LCL filter module 107
IP54 exhaust fan fuse (power bay) ventilation (control bay) 43
install 117 ventilation (input bay) 77
remove 116 ventilation (power bay) 105
IP54 exhaust vent filters (power bay) ventilation (wire entry/exit bay) 187
install 115 wire entry/exit bay 187
remove 115
IP54, 400/600 mm wide door vent filters
(power bay)
L
install 124 LCL filter module
remove 124 install 165
IP54, 800 mm wide door vent filters (power kits 106
bay) remove 160
LCL filter module fan fuse
remove 126
IP54, 800/1000 mm wide door vent filters continuity test 40
lifespan
install 85
remove 84 component 22
IP54/IP21 roof vent fan (input bay) locking device
install 83 check 34
remove 83
IP54/IP21, 400 mm wide door vent filters
(entry/exit wire bay)
M
install 189 main control circuit board
remove 189 install 58
IP54/IP21, 400/600 mm wide door vent remove 56
filters maintenance
install 84 equipment 32
remove 83 final check 34
IP54/IP21, 400/800 mm wide door vent fan predictive 22
preventative 21
and filter assembly (entry/exit primary tasks 22
wire bay) schedules 21
install 190 maintenance schedule
remove 189 codes 22
IP54/IP21, 800 mm wide door vent filters harsh environment operation 29
(entry/exit wire bay) high temperature operation 26
install 189 normal operation 23
remove 189 meter reading
forward biased diode test 38
reverse biased diode test 39

N
normal operation
maintenance schedule 23

O
operating mechanism
inspection 32

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 3

Index

P PowerFlex 755TM frame 10 common bus

inverter with DC precharge
PE-B1 power jumper (power module) module 235
install 148 PowerFlex 755TM frame 10 regenerative bus
remove 147 supply 224
periodic inspection 32 PowerFlex 755TM frame 10 regenerative
pilot light drive (page 1 of 2) 215
replacement 33 PowerFlex 755TM frame 10 regenerative
power drive (page 2 of 2) 216
PowerFlex 755TM frame 11 AC input bay 210
apply 13
PowerFlex 755TM frame 11 common bus
remove 13
inverter with DC link fuses 231
power /LCL filter module fan fuse
PowerFlex 755TM frame 11 common bus
install 179 inverter with DC precharge
remove 178 module 236
power bay PowerFlex 755TM frame 11 regenerative bus
kits 105 supply 225
power bay ventilation PowerFlex 755TM frame 11 regenerative
kits 105 drive (page 1 of 2) 217
power interface circuit board (power PowerFlex 755TM frame 11 regenerative
module) drive (page 2 of 2) 218
PowerFlex 755TM frame 12 AC input bay 211
install 156
PowerFlex 755TM frame 12 common bus
remove 155 inverter with DC link fuses 232
power layer interface circuit board (power
PowerFlex 755TM frame 12 common bus
module) inverter with DC precharge
install 154 module 237
remove 153 PowerFlex 755TM frame 12 regenerative
power module drive (page 1 of 2) 219
install 145 PowerFlex 755TM frame 12 regenerative
kits 106 drive (page 2 of 2) 220
remove 140 PowerFlex 755TM frame 8 AC input bay 207
power module fan fuse PowerFlex 755TM frame 8 common bus
continuity test 40 inverter with DC link fuses 228
power/LCL filter module PowerFlex 755TM frame 8 common bus
inverter with DC precharge
kits 107 module 233
power/LCL filter module fan assembly
PowerFlex 755TM frame 8 regenerative bus
install 180 supply with DC b 221
remove 179 PowerFlex 755TM frame 8 regenerative bus
precautions 12 supply with no DC bus
predictive maintenance 22 conditioner 222
preventative maintenance 21 PowerFlex 755TM frame 8 regenerative
drive with no DC bus conditioner
213
R PowerFlex 755TM frame 8 regenerative frive
with DC bus conditioner 212
remove power 13 PowerFlex 755TM frame 9 208
replacement PowerFlex 755TM frame 9 common bus
pilot light 33 inverter with DC link fuses 229
reverse biased diode test PowerFlex 755TM frame 9 common bus
meter reading 39 inverter with DC precharge
module 234
PowerFlex 755TM frame 9 regenerative bus
S supply 223
PowerFlex 755TM frame 9 regenerative
schematics drive 214
entry wire bay 238 PowerFlex 755TM LCL filter module 203
exit wire bay 239 PowerFlex 755TM power module 204
PowerFlex 755TM common bus inverter PowerFlex755TM frame 12 regenerative bus
control bay 227 supply 226
PowerFlex 755TM DC bus conditioner 206 sequence number
PowerFlex 755TM DC precharge module 205 diagram 18
PowerFlex 755TM frame 10 AC input bay 209 software tools 17
PowerFlex 755TM frame 10 common bus
inverter with DC link fuses 230 startup
after repairs 195

4 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

 Index

T
terminals
inspection 33
test
AC input link fuses 39
DC link fuses 39
dielectric withstand voltage 34
insulation resistance 34
thermal switch (wire entry/exit bay)
install 193
remove 191
tool size
diagram 18
tool type
diagram 18
torque accuracy module
install 182
remove 180

V
visual inspection 35

W
wire entry/exit bay
kits 187
wire entry/exit bay ventilation
kits 187

Rockwell Automation Publication 750-TG100A-EN-P - July 2017 5

Index

Notes:

6 Rockwell Automation Publication 750-TG100A-EN-P - July 2017

.

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Publication 750-TG100A-EN-P - July 2017

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