Name: Rockwell Automation Allen-Bradley PowerFlex 700 Series
Brand: Rockwell Automation
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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.

Default Chapter3
- Table of Contents3
- Additional Resources11
Preface11
- Summary of Changes11
Precautions12
Chapter 114
- Class 1 Light-Emitting Diode Product14
- Personal Safety14
- Product Advisories14
- Product Safety14
- Qualified Personnel14
- Remove Power from the System15
- Commonly Used Tools22
  - Software Tools22
- Hardware Installation Diagrams23
- Fastener Torque Sequences24
Recommended Preventative Maintenance27
Predictive Maintenance27
Preventative Maintenance27
Chapter 228
- Predictive Maintenance28
- Schedule Codes Explanation28
- Shock Events41
- Maintenance of Industrial Control Equipment42
  - Solid-State Devices44
- Component Inspection and Maintenance45
Chapter 347
- Forward and Reverse Biased Igbt/Diode Tests47
- AC Input Link Fuses Test52
- Component Fuse Tests52
- DC Link Fuse Test52
Power Feedback Circuit Board and Bracket55
Frame 5 Kits55
Chapter 4 Remove the Cover56
- Remove the Cover from the Chassis56
- Install the Cover56
- Main Control Circuit Board Replacement57
  - Remove the Main Control Circuit Board57
  - Install the Main Control Circuit Board60
- Stirring Fan Assembly Replacement61
  - Remove the Stirring Fan Assembly61
  - Install the Stirring Fan Assembly62
- Heatsink Fan Assembly Replacement62
  - Remove the Heatsink Fan Assembly62
  - Install the Heatsink Fan Assembly63
- Fan Power Supply Circuit Board Replacement64
  - Remove the Fan Power Supply Circuit Board64
  - Install the Fan Power Supply Circuit Board65
- Potential Earth (PE) Jumper Replacement66
  - Remove the PE Jumper66
  - Install the PE Jumper66
- Power Feedback Circuit Board and Bracket Replacement67
  - Remove the Power Feedback Circuit Board and Bracket67
Power Feedback Circuit Board and Bracket67
- Install the Power Feedback Circuit Board and Bracket70
- LCL Filter Capacitor Replacement71
  - Remove the LCL Filter Capacitor71
  - Install the LCL Filter Capacitor72
Chapter 5 Frame 6 Kits75
Frame 6 Components75
- Remove the Cover76
  - Remove the Cover from the Chassis76
  - Install the Cover76
- Main Control Circuit Board Replacement77
  - Remove the Main Control Circuit Board77
  - Install the Main Control Circuit Board80
- Stirring Fan Assembly Replacement81
  - Remove the Stirring Fan Assembly81
  - Install the Stirring Fan Assembly81
- Heatsink Fan Assembly Replacement82
  - Remove the Heatsink Fan Assembly82
  - Install the Heatsink Fan Assembly83
- DR and PE-A (EMC & MOV) Jumper Replacement83
  - Remove the DR and PE-A (EMC & MOV) Jumper83
  - Install the DR and PE-A (EMC & MOV) Jumper84
- Fan Power Supply Circuit Board Replacement84
  - Remove the Fan Power Supply Circuit Board84
  - Install the Fan Power Supply Circuit Board86
- Power Feedback Circuit Board and Bracket Replacement87
  - Remove the Power Feedback Circuit Board and Bracket87
Remove Power87
- Install the Power Feedback Circuit Board and Bracket90
- LCL Filter Capacitor Replacement91
Frame 7 Kits97
Power Interface Circuit Board97
Power Layer Interface Circuit Board97
Power Module97
Chapter 698
- Control Pod Cover Removal98
  - Remove the Control Pod Cover98
  - Install the Control Pod Cover99
- IP21, 800 MM Wide Door Vent Filter Replacement98
- IP54 Exhaust Vent Filters Replacement98
- IP54, 800 MM Wide Door Vent Filters Replacement98
- Control Pod Fan Assembly Replacement99
  - Remove the Control Pod Fan Assembly99
  - Install the Control Pod Fan Assembly100
- Main Control Circuit Board Replacement101
  - Remove the Main Control Circuit Board101
  - Install the Main Control Circuit Board103
- Control Pod Assembly Replacement104
  - Remove the Control Pod Assembly104
  - Install the Control Pod Assembly108
- Power/Filter Module Heatsink Fan Assembly Replacement109
  - Remove the Power/Filter Module Fan Assembly109
  - Install the Power/Filter Module Fan Assembly110
- Remove the Protective Guard110
  - Install the Protective Guard111
- Control Transformer Fuses (FH4) Replacement112
  - Remove the Control Transformer Fuses112
  - Install the Control Transformer Fuses112
- Power Module Replacement113
  - Remove the Power Module from the Enclosure113
  - Install the Power Module in the Enclosure120
- Power Layer Interface Circuit Board Replacement120
  - Remove the Power Layer Interface Circuit Board120
  - Install the Power Layer Interface Circuit Board123
- Power Interface Circuit Board Replacement124
  - Remove the Power Interface Circuit Board124
  - Install the Power Interface Circuit Board126
- LCL Filter Module Replacement127
  - Remove the LCL Filter Module from the Enclosure127
  - Install the LCL Filter Module in the Enclosure131
- Current Sense Circuit Board Replacement132
  - Remove the Current Sense Circuit Board132
  - Install the Current Sense Circuit Board137
Chapter 7139
- Control Bay and Control Pod Kits139
  - (Frames 8139
Control Bay and Control Pod Components140
- IP21/IP54 Roof Vent Filter Replacement142
  - Remove the IP21/IP54 Roof Vent Filter142
  - Install the IP21/IP54 Roof Vent Filter143
- IP54/IP21 Roof Vent Fan Replacement143
  - Remove the IP21/IP54 Roof Vent Fan143
  - Install the IP21/IP54 Roof Vent Fan144
- IP21/IP54 Door Vent Filter Replacement145
  - Remove the IP21/IP54 Door Vent Filter145
  - Install the IP21/IP54 Door Vent Filter145
- Control Pod Cover Removal146
  - Remove the Control Pod Cover146
  - Install the Control Pod Cover147
- Fiber Transceiver Circuit Board Replacement148
  - Remove the Fiber Transceiver Circuit Board148
  - Install the Fiber Transceiver Circuit Board151
- Main Control Circuit Board Replacement152
  - Remove the Main Control Circuit Board152
  - Install the Main Control Circuit Board154
- Backplane Circuit Board Replacement155
  - Remove the Backplane Circuit Board155
  - Install the Backplane Circuit Board156
- Fiber-Optic Interface Circuit Board Replacement157
  - Remove the Fiber-Optic Interface Circuit Board157
  - Install the Fiber-Optic Interface Circuit Board164
- Control Pod Fan Assembly Replacement164
  - Remove the Control Pod Fan Assembly164
  - Install the Control Pod Fan Assembly166
- Control Pod Replacement166
  - Remove the Control Pod166
  - Install the Control Pod171
Chapter 8 Input Bay Kits173
Input Bay Components173
- IP21/IP54 Roof Vent Filter Replacement179
- IP54/IP21 Roof Vent Fan Replacement179
- IP54/IP21, 400/600 MM Wide Door Vent Filters Replacement179
- IP54, 800/1000 MM Wide Door Vent Filters Replacement180
  - Remove the IP54, 800/1000 MM Wide Door Vent Filters180
  - Install the IP54, 800/1000 MM Wide Door Vent Filters181
- IP21, 800/1000 MM Wide Door Vent Filter Replacement181
  - Remove the IP21, 800/1000 MM Wide Door Vent Filter181
  - Install the IP21, 800/1000 MM Wide Door Vent Filter182
- IP54/IP21, 1000 MM Wide Door Vent Fan Replacement182
- Guard Removal183
  - Remove the Guards183
  - Install the Guards186
- AC Precharge Control Circuit Board Replacement186
  - Remove the AC Precharge Control Circuit Board186
  - Install the AC Precharge Control Circuit Board189
- AC Precharge Time Delay Relay Replacement189
  - Remove the AC Precharge Time Delay Relay189
  - Install the AC Precharge Time Delay Relay190
- AC Precharge TVSS Module Replacement190
  - Remove the AC Precharge TVSS Module190
  - Install the AC Precharge TVSS Module192
- AC Precharge Control Circuit Board Fuses (FH1) Replacement192
  - Remove the AC Precharge Control Circuit Board Fuses192
  - Install the AC Precharge Control Board Fuses193
- Power Distribution Fuse (FH2) Replacement194
  - Remove the 240V Power Distribution Fuse194
  - Install the 240V Power Distribution Fuse195
- Roof Fan 240V Control Power Fuse (FH3) Replacement195
  - Remove the Roof Fan 240V Control Power Fuse195
  - Install the Roof Fan 240V Control Power Fuse196
- Control Transformer Fuses (FH4197
  - Remove the Control Transformer Fuses197
  - Install the Control Transformer Fuses198
- AC Precharge Fused Disconnect (FD1) Fuses Replacement199
  - Remove the AC Precharge Fused Disconnect Fuses199
  - Install the AC Precharge Fused Disconnect Fuses200
- Control Transformers200
Chapter 9 Power Bay Kits201
- AC Input Link Fuses202
- DC Link Fuses202
Power Bay Components201
- IP54 Exhaust Vent Filters Replacement211
  - Remove the IP54 Exhaust Vent Filters211
  - Install the IP54 Exhaust Vent Filters211
- IP54 Exhaust Fan Fuse Replacement212
  - Remove the IP54 Exhaust Fan Fuse212
  - Install the IP54 Exhaust Fan Fuse213
- IP54 Exhaust Fan Replacement214
  - Remove the IP54 Exhaust Fan214
  - Install the IP54 Exhaust Fan219
- IP54, 400/600 MM Wide Door Vent Filters Replacement220
  - Remove the IP54, 400/600 MM Wide Door Vent Filters220
  - Install the IP54, 400/600 MM Wide Door Vent Filters220
- IP21 400/600 MM Wide Door Vent Filter Replacement221
  - Remove the IP21, 400/600 MM Wide Door Vent Filter221
  - Install the IP21, 400/600 MM Wide Door Vent Filter222
- IP21, 800 MM Wide Door Vent Filter Replacement222
- IP54, 800 MM Wide Door Vent Filters Replacement222
- Replacement222
  - And Shaft222
  - And Shaft224
- DC Precharge Module224
  - Remove the DC Precharge Module from the Enclosure224
  - Install the DC Precharge Module in the Enclosure228
- DC Precharge Circuit Board Replacement229
  - Remove the DC Precharge Circuit Board229
  - Install the DC Precharge Circuit Board232
- DC Precharge Fuses Replacement233
  - Remove the DC Precharge Fuses233
  - Install the DC Precharge Fuses234
- Guard Removal235
  - Remove the Guard235
  - Install the Guard235
- Power Module Replacement236
  - Remove the Power Module from the Enclosure236
  - Install the Power Module in the Enclosure241
- DC Link Fuses Replacement241
  - Remove the DC Link Fuses242
  - Install the DC Link Fuses243
- Power Module PE-B1 Power Jumper Replacement243
  - Remove the Power Module PE-B1 Power Jumper243
  - Install the Power Module PE-B1 Power Jumper244
- Circuit Board Tray Removal244
  - Remove the Circuit Board Tray244
  - Install the Circuit Board Tray248
- Power Layer Interface Circuit Board Replacement249
  - Remove the Power Layer Interface Circuit Board249
  - Install the Power Layer Interface Circuit Board250
- Power Interface Circuit Board Replacement250
  - Remove the Power Interface Circuit Board251
  - Install the Power Interface Circuit Board252
- Balance Resistors Replacement252
  - Remove the Balance Resistors252
  - Install the Balance Resistors254
- Current Sensors Replacement255
  - Remove the Current Sensors255
  - Rockwell Automation Publication 750-TG100B-EN-P - June255
  - Install the Current Sensors256
- LCL Filter Module Replacement257
  - Remove the LCL Filter Module from the Enclosure257
  - Install the LCL Filter Module in the Enclosure262
- AC Input Link Fuses Replacement262
  - Remove the AC Input Link Fuses263
  - Install the AC Input Link Fuses264
- LCL Filter Capacitor Assembly Replacement264
  - Remove the LCL Filter Capacitor Assembly264
  - Install the LCL Filter Capacitor Assembly267
- AC Common Mode Filter Circuit Board Replacement268
  - Remove the AC Common Mode Filter Circuit Board268
  - Install the AC Common Mode Circuit Board270
- Current Sense Circuit Board Replacement270
  - Remove the Current Sense Circuit Board271
  - Install the Current Sense Circuit Board274
- Power/Lcl Filter Module Heatsink Fan Fuse Replacement275
  - Remove the Power/Lcl Filter Module Heatsink Fan Fuse275
  - Install the Power/Lcl Filter Module Heatsink Fan Fuse276
- Power/Lcl Filter Module Heatsink Fan Assembly276
- Replacement276
  - Assembly276
  - Assembly277
- Torque Accuracy Module Replacement277
  - Remove the Torque Accuracy Module277
  - Install the Torque Accuracy Module279
- DC Bus Conditioner Replacement279
  - Remove the DC Bus Conditioner279
  - Install the DC Bus Conditioner282
Chapter 10283
- Wire Entry/Exit Bay Kits283
- Assembly Replacement285
  - And Filter Assembly285
  - And Filter Assembly286
- IP54/IP21, 400 MM Wide Door Vent Filters Replacement285
- IP54/IP21, 800 MM Wide Door Vent Filters Replacement285
- Thermal Switch Replacement287
  - Remove the Thermal Switch287
  - Install the Thermal Switch289
Before You Apply Power to the Drive291
Chapter 11292
- Frames 5 and 6292
- Frames 7294
- No-Load DC Bus Voltage and Output Current Measurements298
Appendix A299
List of Schematic Diagrams299
- Powerflex 755TL/TR Frame 5 Drive299
- Powerflex 755TL/TR Frame 6 Drive299
- Powerflex 755TM DC Bus Conditioner299
- Powerflex 755TM DC Precharge Module299
- Powerflex 755TM Frame 10 AC Input Bay299
- Powerflex 755TM Frame 10 Regenerative Bus299
- Powerflex 755TM Frame 10 Regenerative Drive (Page 1 of 2)299
- Powerflex 755TM Frame 10 Regenerative Drive (Page 2 of 2)299
- Powerflex 755TM Frame 11 AC Input Bay299
- Powerflex 755TM Common Bus Inverter Control Bay300
- Powerflex 755TM Frame 10 Common Bus Inverter with DC Link Fuses300
- Powerflex 755TM Frame 11 Common Bus Inverter with DC Link Fuses300
- Powerflex 755TM Frame 11 Common Bus300
- Powerflex 755TM Frame 11 Regenerative Bus300
- Powerflex 755TM Frame 12 Common Bus Inverter with DC Link Fuses300
- Powerflex 755TM Frame 12 Common Bus300
- Powerflex 755TM Frame 8 Common Bus Inverter with DC Link Fuses300
- Powerflex 755TM Frame 8 Common Bus300
- Powerflex 755TM Frame 9 Common Bus300
- Powerflex 755TL/TR Frame 7 Drive311
- Powerflex 755TM Frame 10 Common Bus335
- Entry Wire Bay343
- Exit Wire Bay344
Index345

Brand	Rockwell Automation
Model	Allen-Bradley PowerFlex 700 Series
Category	DC Drives
Language	English

Rockwell Automation Allen-Bradley PowerFlex 700 Series Service Manual

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