Rockwell Automation Allen-Bradley PowerFlex 750 Series User manual

PowerFlex 750-Series Products with TotalFORCE Control
Catalog Numbers 20G, 20J
Hardware Service Manual
Original Instructions

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

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 3
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
Before You Begin Tests,
Maintenance, or Repairs
Product Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Class 1 Light-emitting Diode Product . . . . . . . . . . . . . . . . . . . . . . 14
Remove Power from the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Frames 7…15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hardware Installation Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 2
Preventative Maintenance Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . 27
Predictive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Schedule Codes Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shock Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Maintenance of Industrial Control Equipment . . . . . . . . . . . . . . . . . . 42
Solid-state Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 3
Component Inspection and Test
Procedures
Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 45
Forward and Reverse Biased IGBT/Diode Tests . . . . . . . . . . . . . . . . . 47
AC Input Link Fuses Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DC Link Fuse Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Component Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 4
Frame 5 Components Frame 5 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Remove the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Remove the Cover from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . 56
Install the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 57
Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . . 57
Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . 60
Stirring Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Remove the Stirring Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install the Stirring Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Table of Contents
Heatsink Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Remove the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . 62
Install the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fan Power Supply Circuit Board Replacement. . . . . . . . . . . . . . . . . . . 64
Remove the Fan Power Supply Circuit Board . . . . . . . . . . . . . . . . 64
Install the Fan Power Supply Circuit Board. . . . . . . . . . . . . . . . . . 65
Potential Earth (PE) Jumper Replacement . . . . . . . . . . . . . . . . . . . . . . 66
Remove the PE Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Install the PE Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Power Feedback Circuit Board and Bracket Replacement. . . . . . . . . 67
Remove the Power Feedback Circuit Board and Bracket . . . . . . 67
Install the Power Feedback Circuit Board and Bracket. . . . . . . . 70
LCL Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Remove the LCL Filter Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Install the LCL Filter Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chapter 5
Frame 6 Components Frame 6 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Remove the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Remove the Cover from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . 76
Install the Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . 77
Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . . 77
Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . . 80
Stirring Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Remove the Stirring Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Install the Stirring Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Heatsink Fan Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Remove the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . 82
Install the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 83
DR and PE-A (EMC & MOV) Jumper Replacement. . . . . . . . . . . . . 83
Remove the DR and PE-A (EMC & MOV) Jumper . . . . . . . . . . 83
Install the DR and PE-A (EMC & MOV) Jumper. . . . . . . . . . . . 84
Fan Power Supply Circuit Board Replacement. . . . . . . . . . . . . . . . . . . 84
Remove the Fan Power Supply Circuit Board . . . . . . . . . . . . . . . . 84
Install the Fan Power Supply Circuit Board. . . . . . . . . . . . . . . . . . 86
Power Feedback Circuit Board and Bracket Replacement. . . . . . . . . 87
Remove the Power Feedback Circuit Board and Bracket . . . . . . 87
Install the Power Feedback Circuit Board and Bracket. . . . . . . . 90
LCL Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Remove the LCL Filter Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Install the LCL Filter Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 5
Table of Contents
Chapter 6
Frame 7 Components Frame 7 Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
IP54 Exhaust Vent Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 98
IP54, 800 mm Wide Door Vent Filters Replacement . . . . . . . . . . . . . 98
IP21, 800 mm Wide Door Vent Filter Replacement. . . . . . . . . . . . . . 98
Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Remove the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Install the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Control Pod Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . 99
Remove the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . 99
Install the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 100
Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 101
Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . 101
Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . 103
Control Pod Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Remove the Control Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . 104
Install the Control Pod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Power/Filter Module Heatsink Fan Assembly Replacement. . . . . . 109
Remove the Power/Filter Module Fan Assembly . . . . . . . . . . . . 109
Install the Power/Filter Module Fan Assembly. . . . . . . . . . . . . . 110
Remove the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Remove the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Install the Protective Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Control Transformer Fuses (FH4) Replacement. . . . . . . . . . . . . . . . 112
Remove the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . 112
Install the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . . . 112
Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Remove the Power Module from the Enclosure . . . . . . . . . . . . . 113
Install the Power Module in the Enclosure. . . . . . . . . . . . . . . . . . 120
Power Layer Interface Circuit Board Replacement . . . . . . . . . . . . . . 120
Remove the Power Layer Interface Circuit Board. . . . . . . . . . . . 120
Install the Power Layer Interface Circuit Board . . . . . . . . . . . . . 123
Power Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . 124
Remove the Power Interface Circuit Board . . . . . . . . . . . . . . . . . 124
Install the Power Interface Circuit Board . . . . . . . . . . . . . . . . . . . 126
LCL Filter Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Remove the LCL Filter Module from the Enclosure . . . . . . . . . 127
Install the LCL Filter Module in the Enclosure. . . . . . . . . . . . . . 131
Current Sense Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 132
Remove the Current Sense Circuit Board. . . . . . . . . . . . . . . . . . . 132
Install the Current Sense Circuit Board . . . . . . . . . . . . . . . . . . . . 137

6Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Table of Contents
Chapter 7
Control Bay and Control Pod
Components
Control Bay and Control Pod Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
IP21/IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 142
Remove the IP21/IP54 Roof Vent Filter . . . . . . . . . . . . . . . . . . . 142
Install the IP21/IP54 Roof Vent Filter . . . . . . . . . . . . . . . . . . . . . 143
IP54/IP21 Roof Vent Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . 143
Remove the IP21/IP54 Roof Vent Fan . . . . . . . . . . . . . . . . . . . . . 143
Install the IP21/IP54 Roof Vent Fan. . . . . . . . . . . . . . . . . . . . . . . 144
IP21/IP54 Door Vent Filter Replacement. . . . . . . . . . . . . . . . . . . . . . 145
Remove the IP21/IP54 Door Vent Filter . . . . . . . . . . . . . . . . . . . 145
Install the IP21/IP54 Door Vent Filter. . . . . . . . . . . . . . . . . . . . . 145
Control Pod Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Remove the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Install the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Fiber Transceiver Circuit Board Replacement . . . . . . . . . . . . . . . . . . 148
Remove the Fiber Transceiver Circuit Board. . . . . . . . . . . . . . . . 148
Install the Fiber Transceiver Circuit Board . . . . . . . . . . . . . . . . . 151
Main Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 152
Remove the Main Control Circuit Board. . . . . . . . . . . . . . . . . . . 152
Install the Main Control Circuit Board . . . . . . . . . . . . . . . . . . . . 154
Backplane Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 155
Remove the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . 155
Install the Backplane Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . 156
Fiber-optic Interface Circuit Board Replacement . . . . . . . . . . . . . . . 157
Remove the Fiber-optic Interface Circuit Board. . . . . . . . . . . . . 157
Install the Fiber-optic Interface Circuit Board . . . . . . . . . . . . . . 164
Control Pod Fan Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . 164
Remove the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . 164
Install the Control Pod Fan Assembly . . . . . . . . . . . . . . . . . . . . . . 166
Control Pod Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Remove the Control Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Install the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Chapter 8
Input Bay Components Input Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
IP21/IP54 Roof Vent Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 179
IP54/IP21 Roof Vent Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . 179
IP54/IP21, 400/600 mm Wide Door Vent Filters Replacement. . 179
Remove the IP54/IP21, 400/600 mm Wide Door Vent
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Install the IP54/IP21, 400/600 mm Wide Door Vent
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
IP54, 800/1000 mm Wide Door Vent Filters Replacement . . . . . . 180
Remove the IP54, 800/1000 mm Wide Door Vent Filters . . . 180
Install the IP54, 800/1000 mm Wide Door Vent Filters . . . . . 181

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 7
Table of Contents
IP21, 800/1000 mm Wide Door Vent Filter Replacement. . . . . . . 181
Remove the IP21, 800/1000 mm Wide Door Vent Filter . . . . 181
Install the IP21, 800/1000 mm Wide Door Vent Filter . . . . . . 182
IP54/IP21, 1000 mm Wide Door Vent Fan Replacement . . . . . . . 182
Remove the IP54/IP21, 1000 mm Wide Door Vent Fan. . . . . 182
Install the IP21/IP54, 1000 mm Wide Door Vent Fan . . . . . . 183
Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Remove the Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Install the Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
AC Precharge Control Circuit Board Replacement . . . . . . . . . . . . . 186
Remove the AC Precharge Control Circuit Board. . . . . . . . . . . 186
Install the AC Precharge Control Circuit Board . . . . . . . . . . . . 189
AC Precharge Time Delay Relay Replacement . . . . . . . . . . . . . . . . . . 189
Remove the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . 189
Install the AC Precharge Time Delay Relay . . . . . . . . . . . . . . . . . 190
AC Precharge TVSS Module Replacement . . . . . . . . . . . . . . . . . . . . . 190
Remove the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . 190
Install the AC Precharge TVSS Module . . . . . . . . . . . . . . . . . . . . 192
AC Precharge Control Circuit Board Fuses (FH1) Replacement . 192
Remove the AC Precharge Control Circuit Board Fuses . . . . . 192
Install the AC Precharge Control Board Fuses . . . . . . . . . . . . . . 193
240V Power Distribution Fuse (FH2) Replacement. . . . . . . . . . . . . 194
Remove the 240V Power Distribution Fuse. . . . . . . . . . . . . . . . . 194
Install the 240V Power Distribution Fuse . . . . . . . . . . . . . . . . . . 195
Roof Fan 240V Control Power Fuse (FH3) Replacement. . . . . . . . 195
Remove the Roof Fan 240V Control Power Fuse. . . . . . . . . . . . 195
Install the Roof Fan 240V Control Power Fuse . . . . . . . . . . . . . 196
Control Transformer Fuses (FH4…FH7) Replacement. . . . . . . . . . 197
Remove the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . 197
Install the Control Transformer Fuses. . . . . . . . . . . . . . . . . . . . . . 198
AC Precharge Fused Disconnect (FD1) Fuses Replacement. . . . . . 199
Remove the AC Precharge Fused Disconnect Fuses. . . . . . . . . . 199
Install the AC Precharge Fused Disconnect Fuses . . . . . . . . . . . 200
Control Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Chapter 9
Power Bay Components Power Bay Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
IP54 Exhaust Vent Filters Replacement . . . . . . . . . . . . . . . . . . . . . . . . 211
Remove the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . 211
Install the IP54 Exhaust Vent Filters . . . . . . . . . . . . . . . . . . . . . . . 211
IP54 Exhaust Fan Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Remove the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . 212
Install the IP54 Exhaust Fan Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 213
IP54 Exhaust Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Remove the IP54 Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Install the IP54 Exhaust Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

8Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Table of Contents
IP54, 400/600 mm Wide Door Vent Filters Replacement . . . . . . . 220
Remove the IP54, 400/600 mm Wide Door Vent Filters. . . . . 220
Install the IP54, 400/600 mm Wide Door Vent Filters . . . . . . 220
IP21 400/600 mm Wide Door Vent Filter Replacement. . . . . . . . . 221
Remove the IP21, 400/600 mm Wide Door Vent Filter . . . . . 221
Install the IP21, 400/600 mm Wide Door Vent Filter . . . . . . . 222
IP54, 800 mm Wide Door Vent Filters Replacement . . . . . . . . . . . . 222
IP21, 800 mm Wide Door Vent Filter Replacement. . . . . . . . . . . . . 222
DC Precharge Module Disconnect Handle and Shaft
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Remove the DC Precharge Module Disconnect Handle
and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Install the DC Precharge Module Disconnect Handle
and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
DC Precharge Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Remove the DC Precharge Module from the Enclosure . . . . . . 224
Install the DC Precharge Module in the Enclosure . . . . . . . . . . 228
DC Precharge Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 229
Remove the DC Precharge Circuit Board. . . . . . . . . . . . . . . . . . . 229
Install the DC Precharge Circuit Board . . . . . . . . . . . . . . . . . . . . 232
DC Precharge Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Remove the DC Precharge Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Install the DC Precharge Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Remove the Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Install the Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Power Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Remove the Power Module from the Enclosure . . . . . . . . . . . . . 236
Install the Power Module in the Enclosure. . . . . . . . . . . . . . . . . . 241
DC Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Remove the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Install the DC Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Power Module PE-B1 Power Jumper Replacement. . . . . . . . . . . . . . 243
Remove the Power Module PE-B1 Power Jumper . . . . . . . . . . . 243
Install the Power Module PE-B1 Power Jumper . . . . . . . . . . . . . 244
Circuit Board Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Remove the Circuit Board Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Install the Circuit Board Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Power Layer Interface Circuit Board Replacement . . . . . . . . . . . . . . 249
Remove the Power Layer Interface Circuit Board. . . . . . . . . . . . 249
Install the Power Layer Interface Circuit Board . . . . . . . . . . . . . 250
Power Interface Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . 250
Remove the Power Interface Circuit Board . . . . . . . . . . . . . . . . . 251
Install the Power Interface Circuit Board . . . . . . . . . . . . . . . . . . . 252
Balance Resistors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Remove the Balance Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Install the Balance Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 9
Table of Contents
Current Sensors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Remove the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Install the Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
LCL Filter Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Remove the LCL Filter Module from the Enclosure . . . . . . . . . 257
Install the LCL Filter Module in the Enclosure. . . . . . . . . . . . . . 262
AC Input Link Fuses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Remove the AC Input Link Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . 263
Install the AC Input Link Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
LCL Filter Capacitor Assembly Replacement. . . . . . . . . . . . . . . . . . . 264
Remove the LCL Filter Capacitor Assembly . . . . . . . . . . . . . . . . 264
Install the LCL Filter Capacitor Assembly. . . . . . . . . . . . . . . . . . 267
AC Common Mode Filter Circuit Board Replacement. . . . . . . . . . 268
Remove the AC Common Mode Filter Circuit Board . . . . . . . 268
Install the AC Common Mode Circuit Board. . . . . . . . . . . . . . . 270
Current Sense Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . 270
Remove the Current Sense Circuit Board. . . . . . . . . . . . . . . . . . . 271
Install the Current Sense Circuit Board . . . . . . . . . . . . . . . . . . . . 274
Power/LCL Filter Module Heatsink Fan Fuse Replacement . . . . . 275
Remove the Power/LCL Filter Module Heatsink Fan Fuse. . . 275
Install the Power/LCL Filter Module Heatsink Fan Fuse . . . . 276
Power/LCL Filter Module Heatsink Fan Assembly
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Remove the Power or LCL Filter Module Heatsink Fan
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Install the Power or LCL Filter Module Heatsink Fan
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Torque Accuracy Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . 277
Remove the Torque Accuracy Module . . . . . . . . . . . . . . . . . . . . . 277
Install the Torque Accuracy Module . . . . . . . . . . . . . . . . . . . . . . . 279
DC Bus Conditioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Remove the DC Bus Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . 279
Install the DC Bus Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Chapter 10
Wire Entry/Exit Bay
Components
Wire Entry/Exit Bay Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
IP54/IP21, 400 mm Wide Door Vent Filters Replacement . . . . . . 285
IP54/IP21, 800 mm Wide Door Vent Filters Replacement . . . . . . 285
IP54/IP21, 400/800 mm Wide Door Vent Fan and Filter
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Remove the IP54/IP21, 400/800 mm Wide Door Vent Fan
and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Install the IP54/IP21, 400/800 mm Wide Door Vent Fan
and Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Thermal Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Remove the Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Install the Thermal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

10 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Table of Contents
Chapter 11
Start Up After Repairs Before You Apply Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 291
Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Frames 7…15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
No-load DC Bus Voltage and Output Current Measurements . . . 298
Appendix A
System Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 11
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.
Summary of Changes This manual contains new ad updated information
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Topic Page
Updated the steps to Remove Power from the System to include information for frames 5, 6, and 7. 15
Updated the Recommended Preventative Maintenance schedules to include the following
information:
• Components and preventative maintenance parameters for frames 5, 6, and 7
• Preventative maintenance parameters for frames 13…15 components
27
Updated the Component Inspection and Test Procedures chapter to include information for frames 5,
6, and 7.
45
Added Chapter 4 for frame 5 product parts replacement. 55
Added Chapter 5 for frame 6 product parts replacement. 75
Added Chapter 6 for frame 7 product parts replacement. 97
Added procedures for frames 5, 6, and 7 to the Start Up After Repairs chapter. 291
Added schematic diagrams for frames 5, 6, and 7 products. 299
Resource Description
AC Drives Common Bus Application Techniques, publication
750-AT004
Provides basic information to properly wire and ground
common bus PWM AC drives.
Drives in Common Bus Configurations with PowerFlex
755TM Bus Supplies Application Techniques, publication
DRIVES-AT005
Provides basic information to properly wire and ground
the following products in common bus applications:
• PowerFlex 755TM drive system for common bus
solutions
• PowerFlex 750-Series AC and DC input drives
• Kinetix® 5700 servo drives
PowerFlex 755T Flux Vector Tuning, publication 750-AT006 Provides guidance on how to tune Flux Vector position
and velocity loops, filters, and other features to achieve
the level of performance that is required for a given
application. This publication is intended for novice
drives users and users with advanced skills.

12 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Preface
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
PowerFlex 750-Series Products with TotalFORCE Control
Installation Instructions, publication 750-IN100
Provides the basic steps to install PowerFlex 755TL
drives, PowerFlex 755TR drives, and PowerFlex 755TM
bus supplies.
PowerFlex 755TM AC Precharge Modules Unpacking and
Lifting Instructions, publication 750-IN102
These publications provide detailed information on:
• Component weights
• Precautions and recommendations
• Hardware attachment points
• Lifting the component out of the packaging
PowerFlex 755TM DC Precharge Modules Unpacking and
Lifting Instructions, publication 750-IN103
PowerFlex 755TM Power and Filter Modules Unpacking and
Lifting Instructions, publication 750-IN104
PowerFlex 750-Series Service Cart and DCPC Module Lift
Installation Instructions, publication 750-IN105
Provides detailed set-up and operating instructions for
the module service cart and lift extension option.
PowerFlex 755TM Power and Filter Module Storage
Hardware Installation Instructions, publication 750-IN106
Provides detailed installation and usage instructions for
this hardware accessory.
PowerFlex 755T Module Service Ramp Instructions,
publication 750-IN108
Provides detailed usage instructions for the module
service ramp.
PowerFlex 750-Series I/O, Feedback, and Power Option
Modules Installation, publication 750-IN111
Provides instructions to install and wire 750-Series
option modules.
PowerFlex 755T Frames 5 and 6 Conduit Box and Ground
Plate Kits, Installation Instructions, publication 750-IN112
Provides installation instructions for the field-installed
frame 5 and 6 conduit box and ground plate option kits.
PowerFlex 755T Frames 5 and 6 Marine Discharge Kits,
Installation Instructions, publication 750-IN114
Provides installation instructions for the field-installed
frame 5 and 6 marine discharge option kits.
PowerFlex Drives with TotalFORCE Control Programming
Manual, publication 750-PM100
Provides detailed information on:
• I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series Products with TotalFORCE Control
Reference Manual, publication 750-RM100
Provides detailed setup and programming instructions
for common applications.
PowerFlex 750-Series Products with TotalFORCE Control
Technical Data, publication 750-TD100
Provides detailed information on:
• Drive and bus supply specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 750-Series Safe Speed Monitor Option Module
Safety Reference Manual, publication 750-RM001
These publications provide detailed information on
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
(PWM) AC Drives, publication DRIVES-AT003
Provides basic information on enclosure systems,
considerations to help protect against environmental
contaminants, and power and grounding
considerations for installing Pulse Width Modulated
(PWM) AC drives.
Wiring and Grounding Guidelines for Pulse Width Modulated
(PWM) AC Drives, publication DRIVES-IN001
Provides basic information to properly wire and ground
PWM AC drives.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Safety Guidelines for the Application, Installation, and
Maintenance of Solid State Control, publication SGI-1.1
Provides general guidelines for the application,
installation, and maintenance of solid-state control.
Product Certifications website, http://
www.rockwellautomation.com/global/certification/
overview.page
Provides declarations of conformity, certificates, and
other certification details.
Resource Description

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 13
Chapter 1
Before You Begin Tests, Maintenance, or Repairs
Read the information in this chapter before you begin tests, maintenance, or
repairs on drive components.
Topic Page
Product Advisories 14
Remove Power from the System 15
Commonly Used Tools 22
Hardware Installation Diagrams 23
Fastener Torque Sequences 24
IMPORTANT Once the product is connected to a power supply, always verify that system
power is not present before performing any work on the product. See safety-
related practices that are contained in publication NFPA 70E, Standard for
Electrical Safety in the Work Place.

14 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Chapter 1 Before You Begin Tests, Maintenance, or Repairs
Product Advisories Read the following precautions before you begin to test components, perform
maintenance, or repair the drive.
Qualified Personnel
Personal Safety
Product Safety
Class 1 Light-emitting Diode Product
ATTENTION: Only qualified personnel familiar with PowerFlex® 755T products
and associated machinery should plan or implement the installation, start-up
and subsequent maintenance of the system. Failure to comply can result in
personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before servicing.
Frames 5 and 6: Measure the DC bus voltage at the power terminal block by
measuring between the +DC and –DC terminals. Also, measure between the +DC
terminal and the chassis, and between the –DC terminal and the chassis. The
voltage must be zero for all three measurements. See Frames 5 and 6 in the
Remove Power from the System section on page 15 for locations.
Frames 7…15: Measure the DC bus voltage by measuring between the +DC and
–DC testpoint sockets on the front of the power module. Also measure between
the +DC testpoint and chassis GND, and the –DC testpoint and chassis GND. See
Frames 7…15 in the Remove Power from the System section on page 17 for
locations.
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.
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.
ATTENTION: Hazard of permanent eye damage exists when using optical
transmission equipment. This product emits intense light and invisible
radiation. Do not look into module ports or fiber-optic cable connectors.

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 15
Before You Begin Tests, Maintenance, or Repairs Chapter 1
Remove Power from the
System
Follow the appropriate procedures to remove power from the dive system.
Instructions for frames 7…15 begin on page 17.
Frames 5 and 6
The following procedures must be followed before attempting to service any part
of a frame 5 and 6 drive or frame 6 bus supply.
1. Turn off and lockout all input power, including any external power
sources.
2. Wait 15 minutes.
3. For frame 5 drives, if the conduit box is present, remove the M6 x 12 mm
torx screw that secures the conduit box cover to the chassis and remove the
cover.
4. For frame 6 drives or bus supplies, complete these steps:
a. Remove the cover. See Remove the Cover from the Chassis on page 76.
b. If the conduit box is present, loosen the four M6 captive torx screws
that secure the cover to the conduit box and remove the cover.
5. Measure the AC input and DC bus voltage to verify that there is no
voltage present (see Figure 1 on page 16 for terminal locations and Table 1
on page 16 for terminal identification):
• Measure the AC input terminals R/L1, S/L2, and T/L3, L to L and L
to chassis GND (PE).
• Measure the DC output terminals DC+ and DC–, DC+ to DC–,
DC+ to chassis GND (PE), and DC– to chassis GND (PE).
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.

16 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Chapter 1 Before You Begin Tests, Maintenance, or Repairs
Figure 1 - Frame 5 and 6 Drives
21 543
Frame 5 (Shown with Cover Removed for Clarity Only) Frame 6
1 2 3 4 5
Table 1 - Frame 5 and 6 Terminal Identification
Item Name Description Item Name Description
1 PE grounding stud Termination point to chassis ground for AC line
shield
4 U/T1, V/T2, W/T3 AC output motor terminals
2 R/L1, S/L2, T/L3 AC line input power terminals 5 PE grounding stud Termination point to chassis ground for motor shield
3 DC+, DC– DC bus terminals — — —

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 17
Before You Begin Tests, Maintenance, or Repairs Chapter 1
Frames 7…15
The following procedures must be followed before attempting to service any part
of the drive system.
1. Turn off and lockout all input power, including any external power sources
(such as an Active Front End or other DC power source).
2. If present, turn off and lockout any external, single-phase 120/240V power
source.
3. For regenerative drives and bus supplies, complete steps a…e.
a. On the input bay, turn the AC precharge disconnect switch to the
“Off ” position.
b. Wait 15 minutes.
c. Open the enclosure door.
d. Close and lock the hasp on the circuit breaker.
e. Lock the fused disconnect switch.
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.
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.

18 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Chapter 1 Before You Begin Tests, Maintenance, or Repairs
4. For common bus inverters with DC precharge, complete steps a…e:
a. Turn the DC precharge disconnect switch to the “Off ” position.
a. Wait 15 minutes.
b. Open the enclosure door.
c. Close and lock the hasp on the molded case switch.
d. Lock the fused disconnect switch.
e. If a control bay is used, turn the selector switch to the “Off ” position
and lock the switch.
5. For regenerative drives and bus supplies, measure the AC input and DC
bus voltage at the following testpoint sockets in the input bay to verify that
there is no voltage present:
• Using the circuit breaker output (CB1 SEC) testpoints R/L1, S/L2,
and T/L3, measure L to L and L to chassis GND.
• By using the fused disconnect output (FD1 SEC) testpoints R, S, and
T, measure L to L and L to chassis GND.
• By using the DC bus testpoints +DC and –DC, measure +DC to
–DC, +DC to chassis GND, and –DC to chassis GND.
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.
Frame 9, IP21 UL Type 1 Input Bay Shown

Rockwell Automation Publication 750-TG100B-EN-P - June 2019 19
Before You Begin Tests, Maintenance, or Repairs Chapter 1
6. For common bus inverters, by using the DC bus testpoints +DC and
–DC on the front of the power modules, measure the DC bus voltage of
all power modules and verify that there is no voltage present on the bus
capacitors. Measure +DC to –DC, +DC to chassis GND, and –DC to
chassis GND.
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.
Frames 8…15 Power Module

20 Rockwell Automation Publication 750-TG100B-EN-P - June 2019
Chapter 1 Before You Begin Tests, Maintenance, or Repairs
7. Measure the 240V AC control voltage at the appropriate terminals:
• For frame 7 drives and bus supplies, measure terminals L and N on
terminal block TB3.
• For frames 8…15 drives and bus supplies, in the input bay, measure
terminals L and N on terminal block TB2.
AC Precharge Circuit Breaker
Frame 10 Input Bay Shown AC Precharge Circuit Breaker