Rockwell Automation PowerFlex 755TL

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PowerFlex 750-Series Products with TotalFORCE Control

Catalog Numbers 20G, 20J

Hardware Service Manual

Original Instructions

Main Page

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

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Rockwell Automation PowerFlex 755TL Specifications

General

Category	DC Drives
Input Voltage	380-480V AC
Voltage	380-480V AC
Output Voltage	0-480V AC
Frequency Range	0 - 400 Hz
Control	Digital
Horsepower	1-2500 HP
Control Method	Vector Control
Communication Protocols	EtherNet/IP, ControlNet, DeviceNet, Modbus TCP
Connectivity	Ethernet, Serial
Enclosure Type	NEMA 1, NEMA 12, NEMA 3R
Enclosure Rating	IP00, IP20/UL Type Open
Cooling Method	Air-cooled, Liquid-cooled
Protection Features	Overcurrent, Overvoltage, Undervoltage, Overload, Overtemperature, Short Circuit, Ground Fault
Safety	Safe Torque-Off
Ambient Temperature Range	-10°C to +50°C (14°F to 122°F)