Powerflex 750 Frame 8 Service Manual

Hardware Service Manual
PowerFlex 750-Series AC Drives

Frame 8
Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
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
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
About this Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Before You Begin Testing,
Maintenance or Repairs
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener/Tool/Torque Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
12
12
12
12
13
13
13
14
15
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Chapter 2
Periodic Maintenance
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
Schedule Codes Explanations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Of Industrial Control Equipment . . . . . . . . . . . . . . . . . . . .
Solid State Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
21
22
24
Chapter 3
Component Inspection and Test Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Procedures
Forward and Reverse Biased SCR/Diode Tests . . . . . . . . . . . . . . . . . . . . . 29
Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Converter Gate Lead Resistance Measurements. . . . . . . . . . . . . . . . . . . . . 32
Chapter 4
Control Pod Component
Replacement Procedures
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Pod Components and Part Numbers . . . . . . . . . . . . . . . . . . . . . .
Control Pod Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Pod Cables Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Control Pod Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Control Pod Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fiber-Optic Cable Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Fiber-Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Fiber-Optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rockwell Automation Publication 750-TG001A-EN-P - September 2010
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41
3
Table of Contents
Main Control Board Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 42

Removing the Main Control Board (Control Pod in Drive Enclosure)
42
Installing the Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control Pod Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removing the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installing the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fiber Interface Board Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removing the Fiber Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the Fiber Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 5
Converter Component
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Converter Components and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 56
Converter Left Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 60
Removing the Converter Left Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installing the Converter Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Converter Right Cover (No Control Pod) Removal/Installation . . . . . 61
Removing the Converter Right Cover (No Control Pod) . . . . . . . . 61
Installing the Converter Right Cover (No Control Pod) . . . . . . . . . 61
Control Pod Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Rotating the Control Pod Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Returning the Control Pod to the Service Position. . . . . . . . . . . . . . . 63
Control Transformer Primary Fuses Removal/Installation . . . . . . . . . . . 64
Removing the Control Transformer Primary Fuses (FU4 and FU5). .
64
Installing the Control Transformer Primary Fuse (FU4 and FU5) 64
Control Transformer Secondary Fuse Removal/Installation. . . . . . . . . . 65
Removing the Control Transformer Secondary Fuse (FU6) . . . . . . 65
Installing the Control Transformer Secondary Fuse (FU6) . . . . . . . 65
Converter EMC Filter Circuit Board Removal/Installation . . . . . . . . . . 66
Removing the Converter EMC Filter Circuit Board . . . . . . . . . . . . . 66
Installing the Converter EMC Filter Circuit Board . . . . . . . . . . . . . . 67
AC Line Fuse Sense Wire Harness Removal/Installation. . . . . . . . . . . . . 68
Removing the AC Line Fuse Sense Wire Harness. . . . . . . . . . . . . . . . 68
Installing the AC Line Fuse Sense Wire Harness . . . . . . . . . . . . . . . . 69
AC Line Fuse Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removing the AC Line Fuses (FU1, FU2, and FU3) . . . . . . . . . . . . . 70
Installing AC Line Fuse (FU1, FU2, and FU3) . . . . . . . . . . . . . . . . . . 72
DC Bus Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 72
Removing the DC Bus Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installing the DC Bus Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Converter Current Sensor Wire Harness Removal/Installation. . . . . . . 74
Removing the Converter Current Sensor Wire Harness. . . . . . . . . . 74
Installing the Converter Current Sensor Wire Harness . . . . . . . . . . 75
Table of Contents
Converter Current Sensor Removal/Installation. . . . . . . . . . . . . . . . . . . . 76

Removing the Converter Current Sensor . . . . . . . . . . . . . . . . . . . . . . . 76
Installing the Converter Current Sensor. . . . . . . . . . . . . . . . . . . . . . . . 80
Converter SCR Wire Harness Removal/Installation . . . . . . . . . . . . . . . . 80
Removing the Converter SCR Wire Harness . . . . . . . . . . . . . . . . . . . 80
Installing the Converter SCR Wire Harness . . . . . . . . . . . . . . . . . . . . 81
Converter SCR Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . 82
Removing the Converter SCR Assembly . . . . . . . . . . . . . . . . . . . . . . . 82
Installing the Converter SCR Assembly . . . . . . . . . . . . . . . . . . . . . . . . 92
Converter Heat Sink Gasket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 92
Removing the Converter Heat Sink Gasket . . . . . . . . . . . . . . . . . . . . . 92
Installing the Converter Heat Sink Gasket. . . . . . . . . . . . . . . . . . . . . . 93
Inverter Power Supply Wire Harness Removal/Installation . . . . . . . . . . 93
Removing the Inverter Power Supply Wire Harness . . . . . . . . . . . . . 93
Installing the Inverter Power Supply Wire Harness . . . . . . . . . . . . . . 94
AC Line Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . 95
Removing the AC Line Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installing the AC Line Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Surge Suppressor Sense Wire Harness Removal/Installation . . . . . . . . . 96
Removing the Surge Suppressor Sense Wire Harness . . . . . . . . . . . . 96
Installing the Surge Suppressor Sense Wire Harness . . . . . . . . . . . . . 97
Surge Suppressor Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removing the Surge Suppressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Installing the Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Surge Suppressor Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . 99
Removing the Surge Suppressor Assembly . . . . . . . . . . . . . . . . . . . . . . 99
Installing the Surge Suppressor Assembly . . . . . . . . . . . . . . . . . . . . . . 101
24V/240V Power Wire Harness Removal/Installation . . . . . . . . . . . . . 102
Removing the 24V/240V Power Wire Harness . . . . . . . . . . . . . . . . 102
Installing the 24V/240V Power Wire Harness . . . . . . . . . . . . . . . . . 107
Control Transformer Primary Wire Harness Removal/Installation. . 107
Removing the Control Transformer Primary Wire Harness . . . . . 107
Installing the Control Transformer Primary Wire Harness. . . . . . 110
Control Transformer Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 110
Removing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
No DC Bus Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . 113
Removing the No DC Bus Wire Harness . . . . . . . . . . . . . . . . . . . . . . 113
Installing the No DC Bus Wire Harness. . . . . . . . . . . . . . . . . . . . . . . 113
Converter Gate Circuit Board Removal/Installation . . . . . . . . . . . . . . . 114
Removing the Converter Gate Circuit Board . . . . . . . . . . . . . . . . . . 114
Installing the Converter Gate Circuit Board . . . . . . . . . . . . . . . . . . . 115
Converter Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Removing the Converter from the Inverter Assembly. . . . . . . . . . . 116
Installing the Converter on the Inverter Assembly. . . . . . . . . . . . . . 119
Converter Duct Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Table of Contents
Removing the Converter Duct Gasket . . . . . . . . . . . . . . . . . . . . . . . . . 119

Installing the Converter Duct Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . 119
Chapter 6
Inverter Component
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inverter Components and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Common Mode Core Assembly Removal/Installation . . . . . . . . . . . . . . 125
Removing the Common Mode Core Assembly . . . . . . . . . . . . . . . . . 125
Installing the Common Mode Core Assembly. . . . . . . . . . . . . . . . . . 126
Internal Stirring Fan Tray Removal/Installation . . . . . . . . . . . . . . . . . . . 126
Removing the Internal Stirring Fan Tray. . . . . . . . . . . . . . . . . . . . . . . 126
Installing the Internal Stirring Fan Tray . . . . . . . . . . . . . . . . . . . . . . . 126
Heatsink Fan Inlet Screen Removal/Installation . . . . . . . . . . . . . . . . . . . 127
Removing the Heatsink Fan Inlet Screen. . . . . . . . . . . . . . . . . . . . . . . 127
Installing the Heatsink Fan Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . 127
Heatsink Fan Assembly Removal/Installation. . . . . . . . . . . . . . . . . . . . . . 128
Removing the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 128
Installing the Heatsink Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 129
Inverter Front Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 130
Removing the Inverter Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Installing the Inverter Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Inverter Current Sensors Removal/Installation . . . . . . . . . . . . . . . . . . . . 131
Removing the Inverter Current Sensors. . . . . . . . . . . . . . . . . . . . . . . . 131
Installing the Inverter Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . 133
Inverter Current Sensor Wire Harness Removal/Installation. . . . . . . . 134
Removing the Inverter Current Sensor Wire Harness . . . . . . . . . . . 134
Installing the Inverter Current Sensor Wire Harness. . . . . . . . . . . . 136
Inverter Capacitor Bank Assembly Removal/Installation . . . . . . . . . . . 137
Removing the Inverter Capacitor Bank Assembly. . . . . . . . . . . . . . . 137
Installing the Inverter Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . 140
Capacitor Balance Resistor Assembly Removal/Installation . . . . . . . . . 140
Removing the Capacitor Balance Resistor Assembly . . . . . . . . . . . . 140
Capacitor Balance Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
IGBT Flex Bus Bars Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 142
Removing the IGBT Flex Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Installing the IGBT Flex Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Inverter Gate Board Connection Ribbon Cables Removal/Installation. . .
143
Removing the Inverter Gate Board Connection Ribbon Cables . . 143
Installing the Inverter Gate Board Connection Ribbon Cables. . . 145
Inverter Gate Circuit Board Removal/Installation. . . . . . . . . . . . . . . . . . 145
Removing the Inverter Gate Circuit Board . . . . . . . . . . . . . . . . . . . . . 145
Installing the Inverter Gate Circuit Board. . . . . . . . . . . . . . . . . . . . . . 146
Rating Plug Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Removing the Rating Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Table of Contents
Installing the Rating Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Layer Interface Circuit Board Removal/Installation . . . . . . . . .
Removing the Power Layer Interface Circuit Board. . . . . . . . . . . . .
Installing the Power Layer Interface Circuit Board . . . . . . . . . . . . .
Power Supply Circuit Board Removal/Installation . . . . . . . . . . . . . . . . .
Removing the Power Supply Circuit Board . . . . . . . . . . . . . . . . . . . .
Installing the Power Supply Circuit Board . . . . . . . . . . . . . . . . . . . . .
Power Control Circuit Board Removal/Installation. . . . . . . . . . . . . . . .
Removing the Power Control Circuit Board . . . . . . . . . . . . . . . . . . .
Installing the Power Control Circuit Board. . . . . . . . . . . . . . . . . . . .
Inverter Backplane Circuit Board Removal/Installation . . . . . . . . . . . .
Removing the Inverter Backplane Circuit Board . . . . . . . . . . . . . . .
Installing the Inverter Backplane Circuit Board . . . . . . . . . . . . . . . .
Inverter EMC Capacitor Removal/Installation . . . . . . . . . . . . . . . . . . . .
Removing the Inverter EMC Capacitors. . . . . . . . . . . . . . . . . . . . . . .
Installing the Inverter EMC Capacitors . . . . . . . . . . . . . . . . . . . . . . .
Inverter Side DC Bus Bar Removal/Installation . . . . . . . . . . . . . . . . . . .
Removing the Inverter Side DC Bus Bars . . . . . . . . . . . . . . . . . . . . . .
Installing the Inverter Side DC Bus Bars. . . . . . . . . . . . . . . . . . . . . . .
Inverter IGBT Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . .
Removing the Inverter IGBT Assembly . . . . . . . . . . . . . . . . . . . . . . .
Installing the Inverter IGBT Assembly . . . . . . . . . . . . . . . . . . . . . . . .
DC Choke Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the DC Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the DC Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inverter Wire Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . . .
Removing the Inverter Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Inverter Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . .
Discharge Resistor Assembly Removal/Installation. . . . . . . . . . . . . . . . .
Removing the Discharge Resistor Assembly . . . . . . . . . . . . . . . . . . . .
Installing the Discharge Resistor Assembly. . . . . . . . . . . . . . . . . . . . .
Inverter Heatsink Fan Inlet Bottom Cover Removal/Installation. . . .
Removing the Inverter Heatsink Fan Inlet Bottom Cover. . . . . . .
Installing the Inverter Heatsink Fan Inlet Bottom Cover . . . . . . .
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149
149
151
151
151
153
154
154
156
157
157
159
160
160
163
164
164
171
171
171
176
176
176
178
178
178
181
182
182
188
189
189
190
Chapter 7
Drive Enclosure Component
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Enclosure Components and Part Numbers . . . . . . . . . . . . . . . . . .
IP20, NEMA/UL Type 1 Door Filter Removal/Installation . . . . . . . .
Removing the Door Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Door Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Duct Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Exhaust Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Exhaust Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top Conduit Plate Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . .
191
191
191
191
192
193
193
193
194
Table of Contents
Removing the Top Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Top Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Door Fan Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Cabinet Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Cabinet Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
194
194
195
195
196
Chapter 8
Option Bay Enclosure
Component Replacement
Procedures
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Option Bay Enclosure Components and Part Numbers . . . . . . . . . . . . .
Disconnect Handle Panel Removal/Installation. . . . . . . . . . . . . . . . . . . .
Removing the Disconnect Handle Panel . . . . . . . . . . . . . . . . . . . . . . .
Installing the Disconnect Handle Panel. . . . . . . . . . . . . . . . . . . . . . . .
Door Fan Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Conduit Plate Removal/Installation. . . . . . . . . . . . . . . . . . . . . . .
Removing the Bottom Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Bottom Conduit Plate. . . . . . . . . . . . . . . . . . . . . . . . . . .
197
197
197
197
198
199
199
200
200
200
201
202
202
202
Chapter 9
Start-Up After Repairs
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Before Applying Power to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Testing With the Motor Without a Mechanical Load . . . . . . . . . . . . . . 205
Appendix A
Schematics
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Pod Schematic Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inverter Circuit Board Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . .
Inverter Power Layer Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
Control Transformer Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
207
208
209
210
211
212
Appendix B
Circuit Board Interconnections Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Index
Inverter Board Interconnections Diagram 1. . . . . . . . . . . . . . . . . . . . . . . .

Inverter Board Interconnections Diagram 2. . . . . . . . . . . . . . . . . . . . . . . .
Control Board Interconnections Diagram 1 . . . . . . . . . . . . . . . . . . . . . . .
Control Board Interconnections Diagram 2 . . . . . . . . . . . . . . . . . . . . . . .
................................................................
214
215
216
217
219
Preface
About this Publication
This manual provides a recommended preventative maintenance schedule, major

component test and hardware replacement procedures, and schematic diagrams
for frame 8 PowerFlex 750-Series AC drives. It is highly recommended that you
obtain a copy of the PowerFlex 750-Series AC Drives Programming Manual,
publication 750-PM001, which contains fault/alarm and programming
information to assist you in troubleshooting drive errors and determining if
repairs are necessary.
Who Should Use this

Manual
This manual is intended for qualified service personnel responsible for repairing
frame 8 PowerFlex 750-Series AC drives. You should have previous experience
with, and an understanding of, electrical terminology, procedures, required
troubleshooting equipment, equipment protection procedures and methods, and
safety precautions. See safety related practices contained in publication NFPA
70E, Standard for Electrical Safety in the Work Place.
Additional Resources
Additional drive service and software/firmware support information is available

on the Allen-Bradley Drives Service and Support website: http://www.ab.com/
support/ abdrives/.
A complete list of spare parts for PowerFlex 755 Frame 8 drives is available on the
Allen-Bradley web site at: http://www.ab.com/support/abdrives/powerflex70/
PF7ReleasedParts.pdf
The following table lists publications that provide general drive related
information.
Resource
Description
Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives, publication
DRIVES-IN001
Provides basic information needed to properly

wire and ground PWM AC drives.
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.
A Global Reference Guide for Reading Schematic

Diagrams, publication 100-2.10
Provides a simple cross-reference of common

schematic/wiring diagram symbols used
throughout various parts of the world.
Guarding Against Electrostatic Damage,

publication 8000-4.5.2
Provides practices for guarding against

Electrostatic damage (ESD)
Product Certifications website, http://ab.com
Provides declarations of conformity, certificates,

and other certification details.
Preface
The following table lists publications that provide information about PowerFlex
750-Series drives.
Resource
Description
PowerFlex 750-Series Drive Installation

Instruction, 750-IN001
Provides the basic steps required to install a

PowerFlex 750-Series AC drive.
PowerFlex 750-Series AC Drives Programming

Manual, publication 750-PM001
Provides information needed to start-up, program

and troubleshoot PowerFlex 750-Series AC
drives.
PowerFlex 755 Drive Embedded EtherNet/IP

Adapter User Manual, publication 750COMUM001
Provides information on installing, configuring,

and troubleshooting the Embedded EtherNet/IP
Adapter for PowerFlex 755 AC drives.
Safe Speed Monitor Option Module for

PowerFlex 750-Series AC Drives Safety
Reference Manual, publication 750-RM001
Explains how the PowerFlex 750-Series AC drive

can be used in Safety Integrity Level (SIL) CL3,
Performance Level [PL(e)], or Category (CAT) 4
applications and provides information on
installing, configuring, and troubleshooting the
PowerFlex Safe Speed Monitor Option module.
PowerFlex 750-Series AC Drives Technical Data,

publication 750-TD001
Provides information on product features and

benefits, options and technical specifications
information.
You can view or download publications at http://www.rockwellautomation.com/

literature/. To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
10
Chapter
Before You Begin Testing, Maintenance or

Repairs
Introduction
This chapter provides information you should know before you begin tests,
maintenance or repairs on drive components.
Topic
Page
General Precautions
12
Commonly Used Tools
13
Fastener/Tool/Torque Information
14
Fastener Torque Sequences
15
Removing Power from the Drive
17
11
Chapter 1
Before You Begin Testing, Maintenance or Repairs
General Precautions
Read the following precautions before you begin testing components, performing
maintenance or repairing 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 may 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 completely before servicing. Measure
the DC bus voltage at the -DC and +DC TESTPOINT sockets on the front of
the power module (see Removing Power from the Drive on page 17 for
location).
ATTENTION: Potentially fatal voltages may result from improper usage
of an oscilloscope and other test equipment. The oscilloscope chassis
may 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 be used in the A minus B Quasidifferential mode with the oscilloscope chassis correctly grounded to an
earth ground.
Product Safety
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive
parts and assemblies. Static control precautions are required when
installing, testing, servicing or repairing this assembly. Component
damage may result if ESD control procedures are not followed. If you are
not familiar with static control procedures, reference Guarding Against
Electrostatic Damage, publication 8000-4.5.2 or any other applicable ESD
protection handbook.
Class 1 LED 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
Commonly Used Tools
Chapter 1
Service Tools
IMPORTANT
Care must be taken to ensure 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.
This list includes the tools needed for test measurements, basic maintenance and
service repairs.
Tool Description
Details
Allen socket wrench
4 mm, 5 mm
Allen socket wrench extension
254 mm (10 in)
Box wrench
7 mm, 8 mm, 10 mm, 13 mm, 17mm, 19 mm, 22 mm
Crimping tools
For cable terminals 1.5...240
Current clamp
1000A (ac, rms), signal output
ESD-protected place of work
Working surface, Floor covering, seat and ground connections
ESD-protective clothing
Wrist wrap, shoes, overall clothing (coat)
Flash light
Flat nose screw driver
5 mm (0.19 in.), 6.4 mm (0.25 in.)
Fuse puller
Hexalobular screw driver/bit
#15, #20, #25, #30, #40, #45
Hexagonal socket wrench
7 mm, 10 mm, 17 mm
Insulation tester
1000V DC
Lifting 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 screw driver/bit
#1, #2
Roll-out cart
20-750-CART1-F8.
Note: The roll-out cart is required to remove the Frame 8 drive
from the enclosure.
Torque wrench
1...12 Nm (8.8106 lbin)
Torque wrench
6...50 Nm (53443 lbin)
Wire cutter
Software Tools
DriveTools SP (DriveExecutive and DriveObserver) and DriveExplorer are
software tools for uploading and downloading parameter configuration and
monitoring and trending system parameters. For more information on Drives
Application Software, visit: http://www.ab.com/drives/drvappsw/
13
Chapter 1
Fastener/Tool/Torque
Information
The disassembly illustrations in the following chapters identify the type of

fastener, tool, and tightening torque used for disassembly/assembly of
components in the drive:
Fastener/Tool/Torque Information:
T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Tightening Torque
Tool Type and Size:

F
Px
Txx
xx mm
Flat nose screw driver

Phillips screw driver/bit and size
Hexalobular screw driver/bit and size
Hexagonal socket wrench
Fastener Type:
Flat head screw
Hexagonal bolt
Hexagonal nut or standoff
Hexagonal screw
Hexalobular head screw
Phillips head screw (1)
Slotted Hexalobular head screw
Phillips is a registered trademark of the Phillips Screw Company.
14
Chapter 1
Fastener Torque Sequences

ATTENTION: When mounting components to a drives 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
fastened to a heat sink using two, four, and six screws. Initial torque is 1/3 (33%)
of final torque, except six-point mountings, which require 0.7 Nm (6 lbin)
initial torque. The numeric illustration labels are for your assistance. Drive
components do not contain these labels.
Figure 1 - Two-Point Mounting
2
Initial Sequence
1
Final Sequence
Figure 2 - Four-Point Mounting
Initial Sequence
3
Final Sequence
15
Chapter 1
Figure 3 - Six-Point Mounting
Initial Sequence
Do not exceed 0.7 (6 lbin) on initial torque of all six screws.
Final Sequence
16
Removing Power from the

Drive
Chapter 1
ATTENTION: To avoid an electric shock hazard, verify that the voltage on

the bus capacitors has discharged completely before servicing. Measure
the DC bus voltage at the -DC and +DC TESTPOINT sockets on the front of
the power module (see below for location).
Remove power before making or breaking cable connections. When you
remove or insert a cable connector with power applied, an electrical arc may
occur. An electrical arc can cause personal injury or property damage by:
sending an erroneous signal to your systems field devices, causing

unintended machine motion
causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and
its mating connector. Worn contacts may create electrical resistance.
1. Turn off and lock out input power. Wait fifteen minutes.
L1
L2
L3
2. Verify that there is no voltage at the drives input power terminals.

3. Measure the DC bus voltage at the -DC and +DC TESTPOINT sockets
on the front of the power module.
17
Chapter 1
18
Chapter
Introduction
This chapter provides information on performing preventative maintenance on

drive components that can affect the life and operability of the drive.
Recommended
Preventative Maintenance
Topic
Page
Recommended Preventative Maintenance
Below
Maintenance Of Industrial Control Equipment
22
Rockwell recognizes that following a defined maintenance schedule will deliver

the maximum product availability. By rigorously following the maintenance
schedule provided, you can expect the highest possible uptime. This annual
preventative maintenance program includes a visual inspection of all drive
components visible from the front of the unit, resistance checks on the power
components, power supply voltage level checks, general cleaning and
maintenance, checking of all accessible power connections for tightness, and
other tasks. See Chapter 3 Component Inspection and Test Procedures for
additional information on performing these procedures and tests.
The recommended maintenance tasks and schedule are contained in Table 1 on
page 20. Refer to Schedule Codes Explanations on page 21 for an explanation of
the codes contained in the table below.
IMPORTANT
Duty cycle, load profile and other operating/environmental conditions

greatly affect reliability of a drive.
19
Chapter 2
Table 1 - Recommended Maintenance Tasks and Schedule

Years
10
11
12
13
14
15
16
17
18
19
20
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
Entire Heatsink
Cooling Fan
Motor
Entire Redundant
Cooling Fan
Motor
Small Aux.
Cooling Fans
Power Devices
(IGBTs/SCRs)
Electrolytic Bus
Capacitors
Snubber
Resistors/
Sharing
Resistors/HECS
Converter
Snubber
Capacitors
Inverter Snubber
Capacitors
Integrated Gate
Driver Power
Supply
RFB
/R
RFB
/R
RFB
/R
RFB
/R
Isolation
Transformer/Line
Reactor
DC Link/
Common-Mode
Choke
Line/Motor Filter
Capacitors
AC/DC and DC/

DC Power
Supplies
RFB
/R
RFB
/R
RFB
/R
RFB
/R
Control Boards
Batteries (DCBs
and CIB)
Fiber-Optic
Cables
Enhancements Firmware
Rv
Rv
Rv
Rv
Rv
Rv
Hardware
Rv
Rv
Rv
Rv
Rv
Rv
Parameters
Rv
Rv
Rv
Rv
Rv
Rv
Variables
Rv
Rv
Rv
Rv
Rv
Rv
Application
Concerns
Rv
Rv
Rv
Rv
Rv
Rv
Inventory/Needs
Rv
Rv
Rv
Rv
Rv
Rv
Components and Activities

Air-Cooling
System
Power
Switching
Components
Integral
Magnetics/
Power Filters
Control Pod
Components
Operational
Conditions
Spare Parts
20
Door Mounted
Air Filters
Chapter 2
Schedule Codes Explanations

I - Inspection
This indicates that the component should be inspected for signs of excessive
accumulation of dust/dirt/etc. or external damage (For example, looking at filter
capacitors for bulges in the case, inspecting the filters/fan inlet screens for debris
clogging the air flow path, etc.).
C - Cleaning
This indicates the cleaning of a part that can be reused, and refers specifically to
the door-mounted air filters and fan inlet screens.
M - Maintenance
This indicates a maintenance task that is outside the normal preventative

maintenance tasks, and can include the inductance testing of line reactors/DC
links, or the full testing of an isolation transformer.
R - Replacement
This indicates that the component has reached its mean operational life, and
should be replaced to decrease the chance of component failure. It is very likely
that components will exceed the design life in the drive, and that is dependent on
many factors such as usage, heating, etc.
RFB/R - Refurbishment/Replacement
The parts can be refurbished at lower cost OR the parts can be replaced with new
ones.
Rv - Review
This refers to a discussion with Rockwell Automation to determine whether any

of the enhancements/changes made to the drive hardware and control would be
valuable to the application.
21
Chapter 2
Maintenance Of Industrial
Control Equipment
ATTENTION: Servicing 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. Refer to National Fire Protection
Association Standard No. NFPA70E, 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,
including procedural requirements for lockout-tagout, and appropriate
work practices, personnel qualifications and training requirements 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 - Industrial control equipment should be inspected

periodically. Inspection intervals should be based on environmental and
operating conditions and adjusted as indicated by experience. 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 setting-up a periodic maintenance program. Some specific
guidelines for Rockwell Automation products are listed below.
Contamination - If inspection reveals that dust, dirt, moisture or other
contamination has reached the control equipment, the cause must be eliminated.
This could 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 - refer to NEMA Standard No. 250, Enclosures for Electrical
Equipment for enclosure type descriptions and test criteria. Replace any damaged
or cracked elastomer seals and repair or replace any other damaged or
malfunctioning parts (e.g., hinges, fasteners, etc.). Dirty, wet or contaminated
control devices must be replaced unless they can be cleaned effectively by
vacuuming or wiping. Compressed air is not recommended for cleaning because
it may displace dirt, dust, or debris into other parts or equipment, or damage
delicate parts.
Cooling Devices - Inspect blowers and fans 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 unit does not operate, check and
replace wiring, fuse, or blower or fan motor as appropriate. Clean or change air
fitters as recommended in the product manual. Also, clean fins of heat exchangers
so convection cooling is not impaired.
22
Chapter 2
Operating Mechanisms - Check for proper functioning and freedom from

sticking or binding. Replace any broken, deformed or badly wont parts or
assemblies according to individual product renewal parts lists. Check for and
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 devices because oil
or grease on the pole faces (mating surfaces) of the operating magnet may 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
will be specified in their individual instructions. if in doubt, consult your nearest
Allen-Bradley Sales Office for information.
Contacts - Check contacts for excessive wear and dirt accumulations. Vacuum or
wipe contacts with a soft cloth if necessary to remove dirt. Contacts are not
harmed by discoloration and slight pitting. Contacts should never be filed, as
dressing only shortens contact life. Contact spray cleaners should not be used as
their residues on magnet pole faces or in operating mechanisms may cause
sticking, and on contacts can interfere with electrical continuity. Contacts should
only be replaced after silver has become badly worn. Always replace contacts in
complete sets to avoid misalignment and uneven contact pressure.
Vacuum Contactors - Contacts of vacuum contactors are not visible, so contact
wear must be checked indirectly. Vacuum bottles should be replaced when:
1. The estimated number of operations equals one million, or
2. The contact life line indicator shows need for replacement, or
3. The vacuum bottle integrity tests show need for replacement. Replace all
vacuum bottles in the contactor at the same time to avoid misalignment
and uneven contact wear. If the vacuum battles do not require replacement,
check and adjust overtravel to the value listed on the maintenance
instructions.
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 bonding or grounding connections can
Increase hazards of electrical shock and contribute to electromagnetic
interference (EMI). Check the tightness of all terminals and bus bar connections
and tighten securely any loose connections. Replace any parts or wiring damaged
by overheating, and any broken wires or bonding straps.
Arc Hood - Check for cracks, breaks, or deep erosion. Arc hoods and arc chutes
should be replaced if damaged or deeply eroded.
Coils - If a coil exhibits evidence of overheating (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 dean any
residues of melted coil insulation from other parts of the device or replace such
parts.
23
Chapter 2
Batteries - Replace batteries periodically as specified in product manual or if a

battery shows signs of electrolyte leakage. Use tools to handle batteries that have
leaked electrolyte; most electrolytes are corrosive and can cause burns. Dispose of
the old battery in accordance with instructions supplied with the new battery or
as specified In the manual for the product.
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 used in conjunction with photoelectric switches
also require periodic cleaning. Do not use solvents or cleaning agents on the
lenses or reflectors. Replace any damaged lenses and reflectors.
Solid State Devices

ATTENTION: Use of other than factory recommended test equipment for
solid state controls may result in damage to the control or test equipment
or unintended actuation of the controlled equipment. Refer to paragraph
titled HIGH VOLTAGE TESTING.
Solid state devices require little more than a periodic visual inspection.
Discolored, charred or burned components may indicate the need to replace
the component or circuit board. Necessary replacements should be made
only at the PC board or plug-in component level. Printed circuit boards should
be inspected to determine whether they are properly seated in the edge
board connectors. Board locking tabs should also be in place. Solid state
devices must also be protected from contamination, and cooling provisions
must be maintained - refer to paragraphs titled CONTAMINATION and
COOLING DEVICES. Solvents should not be used on printed circuit boards.
High Voltage Testing - High voltage insulation resistance (IR) and dielectric
withstanding voltage (DWV) tests should not be used to check solid state control
equipment. When measuring IR or DWV of electrical equipment such as
transformers or motors, a solid state device 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.
24
Chapter 2
Maintenance After a Fault Condition - Opening of the short circuit protective

device (such as fuses or circuit breakers) in a properly coordinated motor branch
circuit is an indication of a fault condition in excess of operating overload. Such
conditions can cause damage to control equipment. Before restoring power, the
fault condition must be corrected and any necessary repairs or replacements must
be made to restore the control equipment to good working order. Refer to
NEMA Standards Publication No. ICS-2, Part ICS2-302 for procedures.
Replacements-Use only replacement parts and devices recommended by AllenBradley to maintain the integrity of the equipment Make sure 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 functioning under controlled conditions; that avoid
hazards in the event of a control malfunction. For additional information, refer to
NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL
CONTROL AND SYSTEMS EQUIPMENT, published by the National
Electrical Manufacturers Association, and NFPA70B, ELECTRICAL
EQUIPMENT MAINTENANCE, published by the National Fire Protection
Association.
25
Chapter 2
26
Chapter
Component Inspection and Test Procedures
Introduction
This chapter provides details on inspecting and testing the major components of
the drive and includes recommendations for repairs.
Topic
Page
Component Inspection and Maintenance
28
Forward and Reverse Biased SCR/Diode Tests
29
Fuse Tests
32
Converter Gate Lead Resistance Measurements
32
27
Chapter 3
Component Inspection and

Maintenance
Visually inspect the door filters, heatsink fan inlet screen and major components
on the control pod, converter, and inverter for dirt and damage. Dirt build up on
some components may lead to component damage or failure. Identifying burn
marks, breakage or foil delamination on the components and/or circuit boards
and replacing those components can prevent damage to the drive. Use this
procedure in conjunction with the Recommended Preventative Maintenance on
page 19.
1. Review the General Precautions on page 12.
2. Remove power from the drive. See Removing Power from the Drive on
page 17.
3. Inspect the door fans for blockage and verify free rotation. Clean or replace
as necessary. See Cabinet Door Fan Removal/Installation on page 195 and
Door Fan Removal/Installation on page 199.
4. Remove the filter from the enclosure door(s) and inspect for blockage.
Clean or replace as necessary. See IP20, NEMA/UL Type 1 Door Filter
Removal/Installation on page 191.
5. Open the enclosure door.
6. Inspect the heatsink fan inlet screen for blockage and clean it, if necessary.
7. Inspect the heatsink fan blower for dirt build-up and/or damage and verify
free rotation. Clean or replace as necessary. See Heatsink Fan Assembly
Removal/Installation on page 128.
8. Remove the protective covers from the control pod, converter and inverter
assemblies. See Control Pod Cover Removal/Installation on page 37,
Converter Left Cover Removal/Installation on page 60 and Inverter Front
Cover Removal/Installation on page 130.
9. Check all visible major components on the control pod, converter and
inverter assemblies and replace any of these components without further
testing if they show evidence of burn marks or breakage.
10. Check all visible circuit boards, wires and connectors on the control pod,
converter and inverter assemblies and replace any of these circuit boards
and/or wires without further testing if they show evidence of burn marks,
breakage or foil delamination.
11. If the inspections performed in steps 37 above resulted in heavy build-up
of dirt and or debris, inspect the cooling tunnels and heatsink fins on the
converter and inverter assemblies and clean them, if necessary. In order to
inspect the cooling tunnels and heatsink fins, you must remove the drive
from the enclosure and remove the converter. For instructions on removing
the drive from the enclosure, refer to the PowerFlex 750-Series AC Drive
Installation Instructions, publication number 750-IN001. For instructions
on removing the converter, refer to Converter Removal/Installation on
page 116.
28
Forward and Reverse

Biased SCR/Diode Tests
Chapter 3
This section contains procedures for performing forward and reverse biased
SCR/diode tests on the major power components of the drive. A failed test
indicates damage to the components in the converter or inverter and requires
replacement.
IMPORTANT
The actual voltage readings may vary depending upon your equipment. If
your readings are not near the indicated values in the tables below, verify
that the actual voltage measured is consistent for each phase of the
converter and inverter.

page 17.
3. Open the drive enclosure door.
4. Remove the connection bolts from the output power terminals (U, V, W)
and set them aside.
AC Input Terminals:
R/L1
S/L2
T/L3
DC Bus Terminals:
DC+
DCOutput Power Terminals:
U
5. Insert an appropriate insulation material between the terminals (U, V, W)

on the drive power unit and the enclosure. In order to receive accurate
readings for these tests, the terminals must not make contact.
6. Remove the control transformer primary fuses (FU4 and FU5). See
Removing the Control Transformer Primary Fuses (FU4 and FU5) on
page 64.
29
Chapter 3
7. Complete the forward and reverse biased SCR/diode tests on the

converter using the tables below.
Table 2 - Forward Biased SCR/Diode Tests on the Converter SCR Assembly
Meter Leads
DC+
R/L1
DC+
S/L2
DC+
T/L3
R/L1
DC-
S/L2
DC-
T/L3
DC-
Nominal Meter Reading

Meter should display .0L (open circuit) (1)
The value should gradually rise to about 0.35V (2)
(1) Note that residual voltage on the DC bus capacitors may affect this reading. If the caps are completely
discharged (less than 1 volt), the meter will initially show a low voltage, which is the residual bus voltage plus
the drop through the low side diodes. The meter will gradually charge the bus, and the voltage will slowly
increase, until eventually the meter switches to .OL. This may take several minutes to occur.
(2) The actual voltage reading may vary depending upon your equipment.
Table 3 - Reverse Biased Diode Tests on the Converter SCR Assembly

Meter Leads
+
R/L1
DC-
S/L2
DC-
T/L3
DC-
DC+
R/L1
DC+
S/L2
DC+
T/L3
8. Replace the converter SCR assembly if it fails these measurements. See

Converter SCR Assembly Removal/Installation on page 82.
9. Install the control transformer primary fuses (FU4 and FU5). See
Installing the Control Transformer Primary Fuse (FU4 and FU5) on
page 64.
30
Chapter 3
10. Complete the forward and reverse biased diode tests on the inverter IGBT
assembly using the tables below.
Table 4 - Forward Biased Diode Tests on the Inverter IGBT Assembly
Meter Leads
+
DC-
DC-
DC-
DC+
DC+
DC+
The value should gradually rise to about 0.28V (1)
(1) The actual voltage reading may vary depending upon your equipment.
Table 5 - Reverse Biased Diode Tests on the Inverter IGBT Assembly

Meter Leads
+
DC-
DC-
DC-
DC+
DC+
DC+
11. Replace the inverter IGBT assembly if it fails these measurements. See
Inverter IGBT Assembly Removal/Installation on page 171.
12. Complete the procedures in Chapter 9 Start-Up After Repairs before
placing the drive back into service.
31
Chapter 3
Fuse Tests
This section contains procedures for performing fuse tests.

page 17.
4. Test the control transformer secondary fuse (FU6) by removing it from the
fuse holder. Replace the fuse as necessary. See Control Transformer
Secondary Fuse Removal/Installation on page 65.
5. Test the control transformer primary fuses (FU4 and FU5) by removing
them from the fuse holder. Do not replace either of these fuses until testing
on the AC line fuses have been completed (step 6 below). See Removing
the Control Transformer Primary Fuses (FU4 and FU5) on page 64.
6. Test the AC line fuses (FU1, FU2, and FU3) in circuit. Replace a fuse as
necessary. See AC Line Fuse Removal/Installation on page 70.
7. Replace the control transformer primary fuses (FU4 and FU5) as
necessary. See Installing the Control Transformer Primary Fuse (FU4 and
FU5) on page 64.
Converter Gate Lead

Resistance Measurements
This section contains procedures for performing resistance measurements on the

gate leads for the converter.
page 17.
4. Open the control pod to provide access to the converter gate board. See
Rotating the Control Pod Forward on page 61.
32
Chapter 3
5. Disconnect the SCR gate harness from P11 on the converter gate board.
Disconnect harness from P11
P13
P8
P11
P10
P9
P7
P2
P6
P14
P4
P12
P1
6. Complete the gate circuit measurements on the P11 harness using the table
below:
Meter Lead +
Meter Lead -
P11-1, SCR Gate L1
P11-2, SCR Cathode L1
12 30 ohms
P11-3, SCR Gate L2
12 30 ohms
P11-5, SCR Gate L3
12 30 ohms
An OL reading may indicate an open wire harness or a disconnected

intermediate connector. Verify the harness integrity by making an end-toend continuity measurement. Replace a faulty harness if indicated by these
measurements.
A shorted meter reading may indicate a failed SCR. Replace the
converter SCR assembly if it fails these measurements. See Converter SCR
Assembly Removal/Installation on page 82.
33
Chapter 3
7. Connect the SCR gate harness to P11 on the converter gate board.
8. Return the control pod to the service position. See Returning the Control
Pod to the Service Position on page 63.
34
Chapter
Control Pod Component Replacement

Procedures
Introduction
This chapter provides detailed procedures for removing and replacing control
pod components.
Topic
Page
Control Pod Components and Part Numbers
35
Control Pod Cover Removal/Installation
37
Control Pod Cables Removal/Installation
38
Fiber-Optic Cable Removal/Installation
39
Main Control Board Removal/Installation
42
Fiber Interface Board Removal/Installation
48
IMPORTANT
Control Pod Components

and Part Numbers
Complete the procedures in Chapter 9 Start-Up After Repairs before

The following table lists the components that make up the control pod. Each
table lists an ID number that corresponds to a component identified in the
corresponding illustration. The table also identifies each component by name and
includes the corresponding spare part kit catalog number and part number (if
applicable.
ID
Component Name
Spare Kit Catalog Number
Component Part Number
Control Pod
20-750-POD1-F8
N.A.
Figure Number
Frame 8 Main Control Board
SK-R1-MCB1-F8
PN-78196
Figure 4 on page 36
Main Control Board Terminal Blocks
SK-R1-TB-PF755
325217-Q03
Figure 4 on page 36
Backplane Board
SK-R1-BP1
395775-A01
Figure 4 on page 36
Control Pod HIM Bezel
SK-R1-BZ1
397771-C01
Figure 4 on page 36
Fiber Interface Board (includes a fiber-optic

transceiver)
SK-R1-FIB1-F8
PN-40886
Figure 4 on page 36
Control Pod Cover
SK-R1-CVRP1-F8
PN-66524
Figure 4 on page 36
Fiber Interface Board Insulator Sheet
N.A.
PN-46892
Figure 4 on page 36
Remote Mount Control Pod Kit
20-750-RPD1-F8
N.A.
35
Chapter 4
Control Pod Component Replacement Procedures
Figure 4 - Control Pod Components
1
3
5
7
36
Chapter 4
Refer to Fastener/Tool/Torque Information on page 14 for descriptions of

the fasteners, tools, and tightening torque figures used in the
disassembly/assembly procedures in this chapter.
TIP
Control Pod Cover Removal/ Removing the Control Pod Cover

Installation

page 17.

4. Loosen, but do not remove, the bottom two M4 x 12 mm slotted
hexalobular screws that secure the cover to the assembly.
5. Remove the top two M4 x 12 mm slotted hexalobular screws that secure
the cover to the assembly and remove the cover.
=
Remove screws (2)

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Note: Control pod shown separately

for clarity only.
Loosen screws (2)
Installing the Control Pod Cover

Install the control pod cover in the reverse order of removal. See Control Pod
Cover Removal/Installation on page 37.
37
Chapter 4
Control Pod Cables

Removal/Installation
Removing the Control Pod Cables

page 17.
4. Remove the control pod cover. See Control Pod Cover Removal/
Installation on page 37.
5. Disconnect the J14 connector from the fiber interface board P14 terminal.
6. If installed, disconnect the customer supplied 24V supply power wiring
from the fiber interface board P13 terminal.
=
P11
P12
P15
P14 P13
INV1
INV2
Disconnect
connector from
P14 and P13
38
INV3
INV4
INV5
Chapter 4
Installing the Control Pod Cables

Install the control pod cable set in the reverse order of removal. See Removing the
Control Pod Cables on page 38.
Fiber-Optic Cable Removal/ Removing the Fiber-Optic Cable

Installation

page 17.

39
Chapter 4
5. Disconnect the fiber-optic cable from INV1 on the fiber interface board
and INV on the power layer interface board in the inverter card cage.
=
P11
Fiber interface
board
P12
P15
P14 P13
INV1
INV2
INV3
INV4
INV5
J7
J6
Power layer
interface board
P2
CONV
INV
40
Chapter 4
6. Disconnect the fiber-optic cable from the fiber-optic cage in the lower left
corner of the converter gate board and CONV on the power layer interface
board in the inverter card cage.
P13
Converter gate
board
P8
P11
P10
P9
P7
P2
P6
P14
P4
P12
J7
P1
J6
Power layer
interface board
P2
CONV
INV
Installing the Fiber-Optic Cable

Install the fiber-optic cable set in the reverse order of removal. See Removing the
Fiber-Optic Cable above.
41
Chapter 4
Main Control Board

Removing the Main Control Board (Control Pod in Drive

Enclosure)
page 17.
4. Remove the control pod cover. See Removing the Control Pod Cover on
page 37.
5. Loosen the retention screw that secures the HIM cradle to the control pod
frame and swing the cradle upward until the latch engages.
42
Chapter 4
6. If installed, remove the option module(s) in slot 7, by loosening the two

captive thumb screws on the module and pulling the board out of the
control pod. The tightening torque for installation is the same as for the
main control board.
7. Disconnect the plug-in terminal block on the main control board.
8. Disconnect the HIM and stirring fan power wire connectors from the
main control board.
9. Loosen the three captive thumb screws and remove the board.
Disconnect HIM and fan connections
Loosen screw
Remove any option module from slot 7
Loosen screws (2)

T15 or F - 5 mm (0.19 in.)
0.45 Nm (4 lbin)
Note: control pod shown separately
for clarity only.
Disconnect terminal block
with wiring in place
43
Chapter 4
Installing the Main Control Board

Install the Main Control board in the reverse order of removal. See Removing the
Main Control Board (Control Pod in Drive Enclosure) above.
IMPORTANT
Control Pod Removal/

Installation
Verify that the main control board seats properly into the connectors on
the backplane and fiber interface boards when installing a new board.
Removing the Control Pod

page 17.
4. Remove the converter left cover. See Removing the Converter Left Cover
on page 60.
page 37.
44
Chapter 4
=
P11
P12
P15
P14 P13
INV1
INV2
INV3
INV4
INV5
Disconnect connector
from P14 and P13
45
Chapter 4
8. Disconnect the plug-in terminal block on the main control board.

9. Loosen the two M4 captive panel fasteners that secure the control pod to
the converter control panel and rotate the assembly forward to the right.
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Loosen captive screw
Rotate control pod

forward to right
Disconnect the
plug-in terminal
block from the
control board

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
46
Chapter 4
10. Remove the four M4 x 12 mm screws that secure the control pod to the
converter control panel right side wall and remove the control pod.
Remove screws (4)

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Installing the Control Pod

Install the control pod in the reverse order of removal. See Removing the Control
Pod on page 44.
47
Chapter 4
Fiber Interface Board

Removing the Fiber Interface Board

page 17.
7. Disconnect the inverter fiber-optic cable from INV1 on the fiber interface
board. Place cable end on top of the inverter card cage assembly.
8. From fiber-optic cage INV1 on the fiber interface board, remove the
transceiver by pulling its bale wire. Set the transceiver aside and save for reinstallation.
=
P11
P12
Disconnect fiber-optic
cable and remove
transceiver from INV1
P15
from P14 and P13
P14 P13
48
INV1
INV2
INV3
INV4
INV5
Chapter 4
9. Disconnect all wiring to the main control board terminal blocks.

10. If installed, disconnect all wiring to all option module terminal blocks.
11. Loosen the retention screw that secures the HIM cradle to the control pod
frame and swing the cradle upward until the latch engages.
49
Chapter 4
12. If installed, remove the option module(s) in slot 7, by loosening the two
captive thumb screws on the module and pulling the board out of the
control pod. The tightening torque for installation is the same as for the
main control board.
13. Disconnect the HIM and stirring fan power wire connectors from the
main control board.
14. Loosen the three captive thumb screws and remove the board.
Disconnect HIM and fan connections
Loosen screw
Remove any option module from slot 7
Loosen screws (2)

T15 or F - 5 mm (0.19 in.)
0.45 Nm (4 lbin)
Note: control pod shown separately
for clarity only.
50
Chapter 4
15. Remove the stirring fan assembly from the control pod chassis by pressing
in on the two tabs on the sides of the fan housing and pulling up on the
fan.
Remove stirring fan
51
Chapter 4
16. Remove the four M4 x 12 mm screws that secure the control pod chassis to
the standoffs on the control pod, then remove control pod chassis.
17. Remove the hex standoff in the center of the fiber interface board from the
control pod.
18. Remove all routed wiring and six wire anchors from the left sidewall of the
control pod and move the wiring to the outside of the control pod.
Remove wiring and

six wire anchors
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Remove screws (4) and

control pod
Remove hex standoff in center
of fiber interface board
52
Chapter 4
19. Remove the four M4 x 10 mm long screws that secure fiber interface board
to the control pod.
Lift board until mounting posts

are in keyholes in board
Remove screws (2)
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Remove screws (2)
20. Move the fiber interface board slightly upward toward top of the control
pod, so that keyholes on board clear the mounting posts and lift the board
off.
21. While slowly rotating the left side of fiber interface board away from the
control pod, verify that the right side of board clears the mounting tab in
right sidewall of control pod, and remove the board from the control pod.
22. Inspect the fiber interface board insulator sheet. If undamaged, leave the
sheet in place on control pod.
53
Chapter 4
Installing the Fiber Interface Board

Install the fiber interface board in the reverse order of removal. See Removing the
Fiber Interface Board on page 48.
If the insulator sheet behind the fiber interface board is damaged, replace
the sheet.
54
Chapter
Converter Component Replacement

Procedures
Introduction
This chapter provides detailed procedures for removing and replacing converter
components.
Note: In some illustrations in this chapter the converter and/or control pod are
shown removed from the drive for clarity only. Only remove the converter and/or
control pod from the drive if directed to do so.
Topic
Page
Converter Components and Part Numbers
56
Converter Left Cover Removal/Installation
60
Converter Right Cover (No Control Pod) Removal/Installation
61
Control Pod Rotation
61
Control Transformer Primary Fuses Removal/Installation
64
Control Transformer Secondary Fuse Removal/Installation
65
Converter EMC Filter Circuit Board Removal/Installation
66
AC Line Fuse Sense Wire Harness Removal/Installation
68
AC Line Fuse Removal/Installation
70
DC Bus Wire Harness Removal/Installation
72
Converter Current Sensor Wire Harness Removal/Installation
74
Converter Current Sensor Removal/Installation
76
Converter SCR Wire Harness Removal/Installation
80
Converter SCR Assembly Removal/Installation
82
Converter Heat Sink Gasket Replacement
92
Inverter Power Supply Wire Harness Removal/Installation
93
AC Line Wire Harness Removal/Installation
95
Surge Suppressor Sense Wire Harness Removal/Installation
96
Surge Suppressor Removal/Installation
97
Surge Suppressor Assembly Removal/Installation
99
24V/240V Power Wire Harness Removal/Installation
102
Control Transformer Primary Wire Harness Removal/Installation
107
Control Transformer Removal/Installation
110
No DC Bus Wire Harness Removal/Installation
113
Converter Gate Circuit Board Removal/Installation
114
Converter Removal/Installation
116
Converter Duct Gasket Replacement
119
55
Chapter 5
Converter Component Replacement Procedures
IMPORTANT
Converter Components and

Part Numbers

The following table lists the components that make up the converter assembly.
Each table lists an ID number that corresponds to a component identified in the
corresponding illustrations. The table also identifies each component by name
and includes the corresponding spare part kit catalog number and part number (if
applicable).
ID # Component Name
Control Transformer Fuses, 400/480V AC Input Drives
SK-R1-FUSE2-CD-F8
N.A.
Figure Number
Fuse, 8A, 690V, IEC Class gG/gl, 14x51 mm (FU4 / FU5)
PN-62710
Figure 5 on page 58
Fuse, 5A, 600V, Class CC, Time-Delay (FU6)
64676-64L
Figure 6 on page 59
AC Line Fuse Kit, 1100A, 400/480V AC Input Drives
SK-R1-FUSE1-CD-F8
N.A.
Fuse, 690/700V, 1100A
PN-49583
Figure 5 on page 58
Switch Indicator
178219
Figure 5 on page 58
Converter EMC Filter Board
SK-R1-EMCFLT1-F8
PN-56696
Figure 5 on page 58
Frame 8 Converter Wire Harness Kit
SK-R1-CNVH1-F8
N.A.
Wire Harness, AC Line Fuse
PN-47773
Figure 5 on page 58
Wire Harness, Transformer Primary
PN-48334
Figure 5 on page 58
Wire Harness, DC Bus
PN-48335
Figure 5 on page 58
Wire Harness, No DC Bus Fuse
PN-47514
Figure 6 on page 59
10
Wire Harness, Misc. I/O
PN-48342
Figure 6 on page 59
11
Wire Harness, Power, 24V/240V
PN-49147
Figure 6 on page 59
12
Wire Harness, Inv Power Supply
PN-36983
Figure 6 on page 59
13
Assembly, External NTC
PN-45447
Figure 5 on page 58
14
Wire Harness, SCR Gate
PN-36989
Figure 5 on page 58
15
Wire Harness, Current Transformer Sense
PN-48081
Figure 5 on page 58
16
Wire Harness, AC Bus
PN-57337
Figure 6 on page 59
17
Converter SCR Assembly, 400/480V AC Input Drives
SK-R1-SCR1-CD-F8
N.A.
Figure 5 on page 58
18
Converter Current Sensor
SK-R1-CNVIFB1-F8
PN-45377
Figure 5 on page 58
19
Control Transformer
SK-R1-XFMR1-F8
PN-53064
Figure 6 on page 59
20
Converter Surge Suppressor, 400/480V AC Input Drives
SK-R1-MOV1-CD-F8
N.A.
Figure 6 on page 59
21
Converter Gate Board, 400/480V AC Input Drives

(includes a fiber-optic transceiver)
SK-R1-CGDB1-CD-F8
PN-41513
Figure 6 on page 59
22
Single-Bay Fiber-Optic Cable Kit
20-750-FCBL1-F8
PN-48448 (converter)
PN-73822 (inverter)
Figure 6 on page 59
56
ID # Component Name
Chapter 5
Figure Number
23
Fiber-Optic Transceiver
SK-R1-FTR1-F8
374625-Q01
Figure 6 on page 59
24
Converter Left Front Cover with Side Shield
SK-R1-CCVR1-F8
PN-65346
Figure 5 on page 58
25
Converter Right Front Cover (No Control Pod)
SK-R1-CCVR2-F8
PN-65332
Figure 5 on page 58
26
Single-bay 24V Wire Harness Kit
20-750-PH1-F8
PN-48436
Figure 6 on page 59
Frame 8 Gasket Kit
20-750-G1-F8
N.A.
27
28
Gasket, Converter, Heatsink
PN-44257
Figure 5 on page 58
Gasket, Inverter, Heatsink
PN-46313
(1)
Gasket, Converter, Duct
PN-41289
Figure 6 on page 59
Gasket, Inverter, Door Interface
PN-46315
(1)
Gasket, Inverter, Exhaust Interface
PN-46317
(1)
Gasket, Inverter, Inlet Ring
PN-49141
(1)
Gasket, Inverter, No Choke
PN-52821
(1)
Gasket, Inverter, Blower Box Bottom
PN-54326
(1)
Gasket, Inverter, Choke
PN-45668
(1)
(1) This gasket is included in the Frame 8 Gasket Kit (20-750-G1-F8), but is identified in Chapter 6 - Inverter Component Replacement Procedures.
57
Chapter 5
Note: Covers shown at smaller scale than other components.
58
24
25
17
13
14
27
18
18
18
15
Figure 5 - Converter Assembly Components Diagram 1
Chapter 5
22
28
23
21
26
15
19
12
10
11
16
20
Figure 6 - Converter Assembly Components Diagram 2
59
Chapter 5
TIP
Converter Left Cover


Removing the Converter Left Cover

page 17.
4. Remove the four M5 x 14 mm screws that secure the cover to the assembly
and remove the cover.
Remove screws (4)

T25 or F - 6.4 mm (0.25 in)
2.8 Nm (25.0 lbin)
Installing the Converter Left Cover

Install the converter cover in the reverse order of removal. See Removing the
Converter Left Cover above.
60
Converter Right Cover (No

Control Pod) Removal/
Installation
Chapter 5
Removing the Converter Right Cover (No Control Pod)

page 17.
4. Remove the four M5 x 14 mm screws that secure the cover to the assembly
and remove the cover.
Remove screws (4)

T25 or F - 6.4 mm (0.25 in)
2.8 Nm (25.0 lbin)
Installing the Converter Right Cover (No Control Pod)

Install the converter cover (no control pod) in the reverse order of removal. See
Removing the Converter Right Cover (No Control Pod) above.
Control Pod Rotation
Rotating the Control Pod Forward

Use this procedure to move the control pod, when it is installed on the converter
assembly, to access other components located behind it.
page 17.
61
Chapter 5
page 37.
5. Disconnect the single-bay 24V wire harness J14 connector from the fiber
interface board (located in the control pod) P14 terminal.
=
P11
P12
P15
P14 P13
INV1
INV2
Disconnect
connector from
P14 and P13
62
INV3
INV4
INV5
Chapter 5
7. Disconnect the converter fiber-optic cable from CONV and the inverter
fiber-optic cable from INV on the inverter power layer interface board
located in the card cage assembly. Place the cable ends on the bottom of the
control pod.
8. Loosen the two M4 captive panel fasteners that secure the control pod to
the converter control panel and rotate the control pod forward.

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Rotate control pod
forward to right
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Inverter power layer interface board

J7
J6
Disconnect fiber-optic cables from power

layer interface board in card cage
P2
CONV
INV
Returning the Control Pod to the Service Position

Return the control pod to the service position in the reverse order. See Rotating
the Control Pod Forward on page 61.
63
Chapter 5
Control Transformer
Primary Fuses Removal/
Installation
Removing the Control Transformer Primary Fuses (FU4 and FU5)

page 17.
4. Remove the converter left cover. See Removing the Converter Left Cover.
5. Using a fuse puller, remove the fuse from the 2-position fuse holder.
FU4 and FU5
Installing the Control Transformer Primary Fuse (FU4 and FU5)

Install the control transformer primary fuse (FU4 and FU5) in the reverse order
of removal. See Removing the Control Transformer Primary Fuses (FU4 and
FU5) above.
64
Control Transformer
Secondary Fuse Removal/
Installation
Chapter 5
Removing the Control Transformer Secondary Fuse (FU6)

page 17.
4. If the control pod is installed, then rotate the control pod to gain access to
the converter control panel. See Rotating the Control Pod Forward on
page 61.
If the control pod is not installed, then remove the converter right cover.
See Removing the Converter Right Cover (No Control Pod) on page 61.
5. Using a fuse puller, remove the fuse from the 1-position fuse holder. See ID
#2 in the Converter Assembly Components Diagram 2 on page 59 for
location.
FU6
Installing the Control Transformer Secondary Fuse (FU6)

Install the control transformer secondary fuse (FU6) in the reverse order of
removal. See Removing the Control Transformer Secondary Fuse (FU6) on
page 65.
65
Chapter 5
Converter EMC Filter

Circuit Board Removal/
Installation
Removing the Converter EMC Filter Circuit Board

page 17.
4. Remove the left converter cover. See Removing the Converter Left Cover
on page 60.
IMPORTANT
Prior to disconnecting the control transformer primary wire

harness J2/J3 connector from the EMC filter board, note the J2/
J3 location. The P3 (PE-A2) terminal is grounded. The P2 terminal
is not grounded.
The jumper settings are provided in the PowerFlex 750-Series
Power Jumpers Installation Instructions, publication 750-IN011,
available at http://www.rockwellautomation.com/literature/.
5. Remove the J2/J3 connector from the P2 or P3 connector on the EMC

filter board.
6. Remove the AC line wire harness J1 connector from the P1 connector on
the EMC filter board P1 terminal.
=
Disconnect connectors from P2 or P3
11
12
6
7
5
1
P1
1
2
P3
P2
Disconnect connector from P1
Note: Board shown rotated 90 degrees from actual installation position.
66
Chapter 5
7. Remove the three M4 x 8 mm screws that secure the EMC filter board to
the AC line bus bar.
8. Release the three board mounting clips along the right edge of the EMC
filter board and remove the board.
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Release right-side
mounting clips to
remove board
Remove screws (3)
Installing the Converter EMC Filter Circuit Board

Install the EMC filter board in the reverse order of removal. See Removing the
Converter EMC Filter Circuit Board on page 66.
IMPORTANT
Ensure that the J2/J3 connector is re-assembled in the correct location

(P2 or P3) on the EMC filter board.
67
Chapter 5
AC Line Fuse Sense Wire

Harness Removal/
Installation
Removing the AC Line Fuse Sense Wire Harness

page 17.
on page 60.
page 61.
68
Chapter 5
6. Disconnect the AC line fuse sense wire harness J7 connector from the
converter gate board P7 terminal.
7. Release the AC line fuse sense wire harness from the cable support on the
left side of the bus bar support rail.
8. Disconnect the AC line fuse sense wire harness from the six AC line fuse
switch terminals and remove the AC line fuse sense wire harness.
from P7 on gate board
Disconnect wire harness

from switch terminals
Release wire harness

from cable support
Installing the AC Line Fuse Sense Wire Harness

Install the AC line fuse sense harness in the reverse order of removal. See
Removing the AC Line Fuse Sense Wire Harness on page 68.
69
Chapter 5
AC Line Fuse Removal/

Installation
Removing the AC Line Fuses (FU1, FU2, and FU3)

page 17.
on page 60.
5. If replacing FU3, remove the three M6 x 14 mm screws that secure the
label bracket to the rail support and remove the label bracket.
FU3
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Remove screw
Remove screw
70
Chapter 5
6. Remove the AC line fuse sense wire harness leads to the fuse switch for the
fuse being replaced. See Removing the AC Line Fuse Sense Wire Harness
on page 68.
IMPORTANT
Note the orientation of the fuse switch terminals before removal.

Replace each fuse with the switch terminals in same orientation.
7. Remove the two M10 x 35 mm screws and two flat washers for the fuse
being replaced and remove the AC line fuse. Remove the fuse switch from
the AC line fuse, if necessary.
Important: Note the orientation of the

fuse switch terminals before removal.
Replace each fuse with the switch
terminals in same orientation.
T45
13.6 Nm (120.0 lbin)
Remove screws (3)

and flat washers (3)
FU1 and FU2 switch terminals

point downward.
FU3 - switch
terminals point
upward.
71
Chapter 5
Installing AC Line Fuse (FU1, FU2, and FU3)

Install the AC line fuse in the reverse order of removal. See Installing AC Line
Fuse (FU1, FU2, and FU3) on page 72.
DC Bus Wire Harness

Removing the DC Bus Wire Harness

page 17.
on page 60.
page 61.
6. Remove the AC line fuse FU1 (from Phase R/L1) to gain access to the DC
bus wire harness connections at the top of the DC and +DC bus bars. See
Removing the AC Line Fuses (FU1, FU2, and FU3) on page 70.
72
Chapter 5
7. Loosen, but do not remove, the two M4 x 12 mm screws at the top of the
DC and +DC bus bars and slide the wire harness fork terminals off the bus
bars.
8. Release the cable support securing the DC bus wire harness to the
converter SCR assembly and cut the tie wrap securing the harness to the
bracket.
9. Disconnect the DC bus wire harness J10 connector from the converter
gate board P10 terminal and remove the DC bus wire harness.
Cable support for wire harness routing
Tie wrap used to secure harness to bracket
Loosen screws (2)

and remove wires
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
from P10 on converter
gate board
Note: Some components

not shown for clarity only.
73
Chapter 5
Installing the DC Bus Wire Harness

Install the DC bus wire harness in the reverse order of removal. See Removing the
DC Bus Wire Harness on page 72.

Wire Harness Removal/
Installation
Removing the Converter Current Sensor Wire Harness

page 17.
page 61.
74
Chapter 5
5. Disconnect the converter current sensor wire harness CT1, CT2, and CT3
connectors from the three converter current sensor connectors.
6. Release the cable supports on the right side of the bus bar support rail.
7. Disconnect the converter current sense wire harness J6 connector from the
converter gate board P6 terminal and remove the converter current sensor
wire harness.

from cable supports

on converter gate board
Disconnect wire harness from

current sensor connectors
Installing the Converter Current Sensor Wire Harness

Install the converter current sensor wire harness in the reverse order of removal.
See Removing the Converter Current Sensor Wire Harness on page 74.
75
Chapter 5

Removing the Converter Current Sensor

page 17.
on page 60.
page 61.
IMPORTANT

harness, note the terminal locations. The control transformer has
multiple input phase terminals. Refer to the Control Transformer
Schematic Diagram on page 212 for more information.
6. Disconnect the control transformer primary wire harness lead wires H1

and Hx from the control transformer input terminals and release the cable
support securing the harness to the EMC filter plastic support.
Disconnect wire
leads from terminals

from cable support
Back side of rotated

control pod
P2
1.8 Nm (16 lbin)
76
Chapter 5
7. Remove the AC line fuse sense wire harness. See Removing the AC Line
Fuse Sense Wire Harness on page 68.
8. Remove the three AC line fuses with fuse switches. See Removing the AC
Line Fuses (FU1, FU2, and FU3) on page 70.
9. Disconnect the converter current sensor wire harness J6 connector from
the converter gate board P6 terminal.

10. Remove the EMC filter board. See Removing the Converter EMC Filter
Circuit Board on page 66.
77
Chapter 5
11. Remove the right bus bar rail:

a. Remove the three M10 x 30 mm screws securing the AC input bus bars
to the SCR.
b. Remove the two M6 x 14 mm screws securing the right bus bar rail to
the rail support and remove the right bus bar rail with three AC input
bus bars, three current sensors, current sensor wire harness, and EMC
filter board plastic support attached.
Remove M6 screw
M6
T20 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
M10
T45
11.3 Nm (100.0 lbin)
Bus bar rail below
plastic mounting
support for EMC
filter board
AC input bus bars

Remove
M10
screws (3)
Remove M6 screw
78
Chapter 5
12. For the phase being replaced, remove the two M6 x 25 mm screws
connecting the AC bus bar to the right bus bar rail.
13. Cut the three cable ties connecting the current sensor to the plastic support
and remove the current sensor.
Remove screws (2)
and cable ties
T20 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
AC bus bars
Bus bar rail
Note: EMC filter board plastic mounting

support shown removed for clarity only.
79
Chapter 5
Installing the Converter Current Sensor

Install the current sensors in the reverse order of removal. See Removing the
Converter Current Sensor on page 76.
IMPORTANT
Converter SCR Wire

Harness Removal/
Installation
Ensure that the control transformer primary wire harness lead wires H1
and Hx are connected to the proper input terminals. The control
transformer has multiple input phase terminals. Refer to the Control
Transformer Schematic Diagram on page 212 for more information.
Connecting the wires to the wrong terminals may cause damage to the
drive.
Removing the Converter SCR Wire Harness

page 17.
on page 60.
page 61.
80
Chapter 5
6. Remove the three M4 x 12 mm screws that secure the shield to the

converter heatsink and remove the shield.
7. Disconnect the SCR wire harness J11 connector from the converter gate
board P11 terminal.
8. Disengage the cable tie from the cable tie mount on the wire harness
ladder.
9. Release the wire harness from the two cable supports securing the harness
to the converter heatsink.
10. Remove the three SCR connectors from the SCR modules and remove the
SCR wire harness from the drive.
SCR wire harness
Remove harness from

cable supports (2)
Remove cable tie

from mount
from P11 on gate board
Remove connectors
from SCR modules
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Remove screws (3)
and shield
Note: components
shown removed
for clarity only
Installing the Converter SCR Wire Harness

Install the converter SCR wire harness in the reverse order of removal. See
Removing the Converter SCR Wire Harness.
81
Chapter 5
Converter SCR Assembly

Removing the Converter SCR Assembly

page 17.
on page 60.
page 61.
82
IMPORTANT
Chapter 5


Disconnect wire

from cable support

control pod
P2
1.8 Nm (16 lbin)
83
Chapter 5
IMPORTANT

is not grounded.
7. Remove the J2/J3 connector from connector P2 or P3 on the EMC filter

board.
Disconnect connectors from P2 or P3
P3
11
12
6
7
5
1
P1
1
2
5
1
P2
Note: Board shown rotated 90 degrees from actual installation position.
84
Chapter 5
8. Remove the three M6 x 14 mm screws that secure the fuse bracket to the
left and right rail supports and remove the fuse bracket with the control
transformer primary wire harness attached.
9. Remove the three M6 x 14 mm screws that secure the label bracket to the
rail support and remove the label bracket.
Left rail support
Right rail support
Fuse bracket
Remove screw
Remove screws (2)
Label bracket
Remove screw
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Remove screws (2)
10. Remove the AC line fuse sense wire harness. See Removing the AC Line
Fuse Sense Wire Harness on page 68.
11. Remove the three AC line fuses with fuse switches. See Removing the AC
Line Fuses (FU1, FU2, and FU3) on page 70.
85
Chapter 5
12. Remove the two M6 x 14 mm screws that secure the left bus bar rail to the
left rail supports and remove the left rail with the three AC input bus bars
attached.
Remove left bus

bar rail and AC
input bus bars
Remove screws (2)
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
13. Remove the EMC filter board. See Removing the Converter EMC Filter
Circuit Board on page 66.
86
Chapter 5
14. For the right bus bar rail:

a. Disconnect the current sensor wire harness J6 connector from the
converter gate board P6 terminal.

87
Chapter 5
b. Remove the three M10 x 30 mm screws securing the AC input bus bars
to the SCRs.
c. Remove the two M6 x 14 mm screws securing the right bus bar rail to
the right rail supports and remove the right bus bar rail with three AC
input bus bars, three current sensors, current sensor wire harness, and
EMC filter board plastic support attached.
M6
T20 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
M10
T45
11.3 Nm (100.0 lbin)
Remove M6 screw
Remove M10
screws (3)
Remove right bus bar rail with three AC input bus
bars, three current sensors, current sensor wire
harness, and EMC filter board plastic support
Remove M6 screw
15. Remove the DC bus wire harness. See Removing the DC Bus Wire
Harness on page 72.
88
Chapter 5
16. Remove the three M10 x 30 mm screws that secure the DC bus bars to
the SCRs and remove the -DC bus bars.
17. Remove the three M10 x 30 mm screws that secure the +DC bus bars
(with insulation sheet attached) to the SCRs and remove the +DC bus
bars and insulation sheet.
+DC bus bar and

insulation sheet
-DC bus bar
T45
11.3 Nm (100.0 lbin)
Remove screws (3)
Remove screws (3)
89
Chapter 5
18. Disconnect the SCR wire harness J11 connector from the converter gate
board P11 terminal.
19. Disconnect the NTC wire harness connector from the converter gate
board P2 terminal.
Disconnect
connector from P11
=
P13
P8
P11
P10
P9
P7
Disconnect
connector from P2
P2
P6
P14
P4
P12
90
P1
Chapter 5
20. Secure equipment and hardware capable of lifting 17 kg (37 lb) to the
lifting holes identified on the SCR assembly.
21. Remove the twelve M5 x 20 mm screws that secure the assembly to the
converter duct.
22. Remove the converter SCR assembly.
Replace heatsink gasket,

if necessary
6,4 (0.25)
lifting holes
6,4 (0.25)
lifting hole
6,4 (0.25)
lifting hole
Remove screws (12)
T25 or F - 6.4 mm (0.25 in)

2.8 Nm (25.0 lbin)
91
Chapter 5
Installing the Converter SCR Assembly

1. Inspect the converter heat sink gasket on the converter duct for damage
and replace it if necessary. See Converter Heat Sink Gasket Replacement
on page 92.
2. Install the converter SCR assembly in the reverse order of removal.
IMPORTANT
Ensure the J2/J3 connector is re-assembled in the appropriate location

(P2 or P3) on the EMC filter board.
IMPORTANT
drive.
Converter Heat Sink Gasket Removing the Converter Heat Sink Gasket
Replacement
1. Remove the converter SCR assembly. Removing the Converter SCR

Assembly on page 82.
2. Remove the existing gasket using a flat blade.
3. Clean the converter duct surface with a 50% isopropyl alcohol/ 50% water
mixture.
92
Chapter 5
Installing the Converter Heat Sink Gasket

Note: One side of the heat sink gasket is coated with an adhesive. Take care to
properly align the gasket, before fully removing the paper liner and exposing the
adhesive and pressing the gasket into place.
1. Begin removing the paper liner as you align the replacement gasket with
the duct edges and cutouts as shown below and press the gasket into place
on the duct.
Align gasket edges

with duct edges
Align cutouts
Align gasket edges

with duct edges
2. Install the converter SCR assembly in the reverse order of removal. See
Installing the Converter SCR Assembly on page 92.
Inverter Power Supply Wire Removing the Inverter Power Supply Wire Harness
Harness Removal/
Installation
page 17.
93
Chapter 5
page 61.
5. Disconnect the inverter power supply wire harness from the inverter power
supply board P6 terminal and converter terminal block TB1.
6. Remove the inverter power supply harness.
Converter terminal
block TB1
Disconnect
connector from TB1
from P6 on power
supply board in inverter
card cage
Installing the Inverter Power Supply Wire Harness

Install the inverter power supply wire harness in the reverse order of removal. See
Removing the Inverter Power Supply Wire Harness above.
94
AC Line Wire Harness

Chapter 5
Removing the AC Line Wire Harness

page 17.
page 61.
IMPORTANT
Prior to disconnecting the GND wire of the AC line wire harness,

note the GND wire location (PE-A1 or GND terminal) on the surge
suppressor mounting plate.
5. Disconnect the J9 connector from P9 on the converter gate board.

6. Disconnect the J1 connector from P1 on the EMC filter board.
7. Disconnect the wires from the surge suppressor L1, L2, L3 and G
terminals.
8. Disconnect the wires from the PE-A1 or GND terminal as noted in the
Important statement above.
9. Remove the AC line wire harness.
Disconnect
connector
from P1 on
EMC filter
board
Disconnect
connector
from P9 on
converter
gate board
P1
AC line wire harness
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Disconnect
wire from
PE-A1 or
GND
terminal
Disconnect
wires from
L1, L2, L3
and G on
surge
suppressor
P2 or F - 4.8 mm (0.19 in)

1.8 Nm (16.0 lbin)
95
Chapter 5
Installing the AC Line Wire Harness

Install the AC line wire harness in the reverse order of removal. See Removing the
AC Line Wire Harness on page 95.
IMPORTANT
Surge Suppressor Sense

Installation
Ensure that the GND wire is re-assembled in the appropriate location

(PE-A1 or GND terminal) on the surge suppressor mounting plate.
Removing the Surge Suppressor Sense Wire Harness

page 17.
page 61.
5. Disconnect the J13 connector from P13 on the converter gate board.
6. Remove the four 3-position surge suppressor sense wire terminal blocks
from the surge suppressor.
96
Chapter 5
7. Disconnect the connector from the shunt trip ST terminal.

8. Release the cable support on the surge suppressor mounting plate and
remove the surge suppressor sense wire harness.
Surge suppressor wire harness
Disconnect
connector
from shunt
trip ST
terminal
Disconnect
connector
from P13
on
converter
gate board
Remove
wire
harness
from cable
support
Disconnect
terminal
blocks from
surge
suppressor
F - 2.4 mm (0.09 in)

0.2 Nm (1.8 lbin)
Installing the Surge Suppressor Sense Wire Harness

1. Remove the four three-position plug terminals from the original wire
harness and install them on the replacement wire harness.
2. Install the surge suppressor sense wire harness in the reverse order of
removal. See Removing the Surge Suppressor Sense Wire Harness on
page 96.
Surge Suppressor Removal/ Removing the Surge Suppressor

Installation

page 17.

page 61.
97
Chapter 5
5. Remove the AC line wire harness lead wires from the surge suppressor L1,
L2, L3 and G terminals.
Disconnect
wires from
L1, L2, L3
and G on
surge
suppressor
P2 or F - 4.8 mm (0.19 in)

1.8 Nm (16.0 lbin)
6. Remove the four, 3-position surge suppressor sense wire terminal blocks
from the surge suppressor.
Disconnect
terminal
blocks from
surge
suppressor
7. Release the surge suppressor from the DIN rail and remove the surge
suppressor.
98
Chapter 5
Installing the Surge Suppressor

Install the surge suppressor in the reverse order of removal. See Removing the
Surge Suppressor on page 97.
Surge Suppressor
Assembly Removal/
Installation
Removing the Surge Suppressor Assembly

Note: This procedure is used only for gaining access to the converter gate board.
page 17.
page 61.
5. Disconnect the J1 connector from the P1 terminal on the EMC filter
board.
6. Disconnect the J9 connector from the P9 terminal on the converter gate
board.
Disconnect
connector
from P1 on
EMC filter
board
Disconnect
connector
from P9 on
converter
gate board
P1
99
Chapter 5
7. Disconnect the J13 connector from the P13 terminal on the converter gate
board.
8. Disconnect the connector from the ST connector on the 24V/240V wire
harness.
Disconnect
connector
from P13
on
converter
gate board
Disconnect
connector
from shunt
trip ST
terminal
100
Chapter 5
9. Loosen the four, captive M4 panel fasteners on the surge suppressor

mounting plate and remove the surge suppressor assembly.
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Loosen
screws
(2)
Loosen
screws (2)
Installing the Surge Suppressor Assembly

Install the surge suppressor assembly in the reverse order of removal. See
Removing the Surge Suppressor Assembly on page 99.
101
Chapter 5
24V/240V Power Wire

Harness Removal/
Installation
Removing the 24V/240V Power Wire Harness

page 17.
4. Disconnect the enclosure fan harness and enclosure shunt trip harness
from TB2.
5. Remove the two M3 screws from TB2.
=
Disconnect wire
harnesses from TB2
Remove screws (2)

T15 or F - 4.8 mm (0.19 in)
0.6 Nm (5.4 lbin)
page 61.
102
Chapter 5
7. Disconnect the connector from the shunt trip ST terminal.
Disconnect
connector from
shunt trip ST
terminal
103
Chapter 5
8. Remove the M4 screw that secures the ground wire lug to the converter
control panel and remove the ground wire lug.
9. Loosen the M4 screws that secure the four X1 and X2 lead wires to the
control transformer and remove the leads.
10. Loosen the captive screws that secure the two X2 lead wires from the FU6
fuse block and remove the leads.
T20 or F - 6.4 mm (0.25 in)
1.8 Nm (16.0 lbin)
Remove screw
and ground wire
P2
1.8 Nm (16.0 lbin)
Disconnect leads
from transformer
Disconnect leads from top and

bottom of fuse block FU6
P2
2.3 Nm (20.0 lbin)
104
Chapter 5
11. Disconnect the 5-position inverter power supply wire harness connector
from TB1.
12. Disconnect the 3-position 24V wire harness connector from TB1.
Disconnect inverter power

supply and 24V wire harnesses
from terminal block TB1
105
Chapter 5
13. Disconnect the enclosure fan 6-position connector from converter gate
board P1.
14. Disconnect the system 24V 3-position connector from converter gate
board P12.
P13
P8
P11
P10
P9
P7
P2
P6
P14
P4
P12
P1
Disconnect connectors
from P1 and P12
106
Chapter 5
15. Using a pliers, loosen the four cable tie mounts along the outside right
surface of the converter control panel.
16. Release terminal block TB1 from the DIN rail and remove the 24V/240V
power wire harness from the converter control panel.
Remove cable tie

mounts from panel
Remove TB1
from DIN rail
Installing the 24V/240V Power Wire Harness

Install the 24V/240V power wire harness in reverse order of removal. See
Removing the 24V/240V Power Wire Harness on page 102.
Control Transformer
Primary Wire Harness
Removing the Control Transformer Primary Wire Harness

page 17.
107
Chapter 5

page 61.
5. Disconnect the wire harness FU4-1, FU4-2, FU5-1 and FU5-2 connectors
from the FU4/FU5 fuse block.
6. Loosen screw to disconnect the ground wire from the fuse bracket.
7. Release the two cable tie supports from the fuse bracket.
IMPORTANT

is not grounded.
8. Remove the J2/J3 connector from the P2 or P3 connector on the EMC

filter board.
Release cable supports
108
Disconnect fuse
wire connectors
Disconnect
ground wire
Disconnect from
P2 or P3 connector
IMPORTANT
Chapter 5


P2
1.8 Nm (16 lbin)
Disconnect wire

from cable support

control pod
10. Slide one end of the wire harness through the fuse bracket and remove the
control transformer primary wire harness.
109
Chapter 5
Installing the Control Transformer Primary Wire Harness

Install the control transformer primary wire harness in the reverse order of
removal. See Removing the Control Transformer Primary Wire Harness on
page 107.
Control Transformer
IMPORTANT
Ensure that the PE-A2 connector is re-assembled in the appropriate

location (P2 or P3) on the EMC filter board.
IMPORTANT
drive.
Removing the Control Transformer

page 17.
page 61.
If the control pod is not installed, then remove the right converter cover.
110
Chapter 5
5. Loosen the M4 screws that secure the four X1 and X2 lead wires to the
control transformer and remove the leads.
IMPORTANT


P2
1.8 Nm (16 lbin)
Disconnect wire leads from terminals
P2
1.8 Nm (16.0 lbin)
Disconnect wire leads from terminals
111
Chapter 5
7. Remove four M6 hex nuts that secure the control transformer to the
chassis and slide the control transformer forward off the control panel
mounting studs.
10.0 mm
5.1 Nm (45.0 lbin)
Remove hex nuts (4)
Installing the Control Transformer

Install the control transformer in the reverse order of removal. See Removing the
Control Transformer above. Refer to Control Transformer Schematic Diagram
on page 212 for more information.
IMPORTANT
112
drive.
No DC Bus Wire Harness

Chapter 5
Removing the No DC Bus Wire Harness

page 17.
page 61.
5. Remove the No DC bus wire harness from the converter gate board P8
terminal.
Disconnect terminal block from P8
P13
P8
P11
P10
P9
P7
No DC bus
wire harness
P2
P6
P14
P4
P12
P1
Installing the No DC Bus Wire Harness

Install the No DC bus wire harness in the reverse order of removal. See Removing
the No DC Bus Wire Harness on page 113.
113
Chapter 5
Removing the Converter Gate Circuit Board

Converter Gate Circuit
Board Removal/Installation
page 17.
page 61.
5. Remove the surge suppressor assembly. See Removing the Surge Suppressor
6. Disconnect all wire harnesses connected to the converter gate board.
7. From the fiber-optic cage in the lower left corner of the converter gate
board, remove the fiber-optic transceiver by pulling its bale wire. Set the
transceiver aside and save for re-installation.
P13
Disconnect all
wire harnesses
from gate board
P8
P11
P10
P9
P7
P2
P6
P14
P4
Remove fiberoptic transceiver
P12
114
P1
Chapter 5
8. Remove the two M4 x 40 mm hex standoffs.

9. Remove the four M4 x 6 mm screws that secure the converter gate board to
the converter control panel, slide the converter gate board up to disengage
its four keyhole slots, and remove the board.
IMPORTANT
Do not remove the insulation sheet attached to the converter

duct.
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Remove screws (4)
8.0 mm (0.32 in)

1.8 Nm (16.0 lbin)
Remove standoffs (2)
Installing the Converter Gate Circuit Board

1. Verify the insulation sheet is attached to the converter duct.
2. Install the converter gate board in the reverse order of removal. See
Removing the Converter Gate Circuit Board on page 114.
115
Chapter 5
Converter Removal/
Installation
ATTENTION: Field replacement of the converter section of the power

core (the converter is attached to the inverter) should only be performed
as part of the drive assembly removal procedure. Otherwise, equipment
damage may result.
Removing the Converter from the Inverter Assembly

page 17.
3. Remove the drive assembly from the enclosure. Refer to the PowerFlex
750-Series AC Drive Installation Instructions, publication number 750IN001, for details.
4. Disconnect the inverter power supply wire harness J6 connector from the
inverter power layer interface board P6 terminal.
5. Disconnect the converter fiber-optic cable from CONV on the inverter
power layer interface board and secure it to the converter. Do not remove
the fiber-optic transceiver.
6. If the control pod is assembled on the converter, disconnect the inverter
fiber-optic cable from INV on the inverter power layer interface board and
secure it to the control pod. Do not remove the fiber-optic transceiver.
Disconnect converter
fiber-optic cable
Disconnect inverter
fiber-optic cable
116
Disconnect
connector from P6
on power layer
interface board
Chapter 5
7. Remove the four M8 x 30 mm machine screws that secure the inverter DC

bus bars to the converter DC bus bars.
IMPORTANT
A load capacity of 80 kg [175 lbs] minimum is required for all

lifting equipment and hardware used for this procedure.
The angle of attachment of the lifting hardware should be no
more than 45 degrees from vertical.
8. Connect the lifting hardware to the two lifting holes on the lifting bar at
the top of the converter section.
9. Loosen the two M8 screws securing the converter duct to the inverter duct.
10. Lift and slide the converter away from the inverter assembly.
117
Chapter 5
45
MAX.
45
MAX.
Loosen M8 shoulder
bolts both sides
5.0 mm (0.2 in)
16.5 Nm (146.0 lbin)
Remove M8 x 30
machine screws (4)
T40
11.3 Nm (100.0 lbin)
118
Connect lifting hardware

to lifting holes
Chapter 5
Installing the Converter on the Inverter Assembly

1. Inspect the gasket at the top of the converter duct for damage and replace if
necessary. See Removing the Converter Duct Gasket on page 119.
2. Inspect the gasket at the top of the inverter duct for damage and replace if
necessary. Removing the Converter Duct Gasket on page 119.
3. Install the converter on the inverter assembly in the reverse order of
removal.
Converter Duct Gasket

Replacement
Removing the Converter Duct Gasket

1. Remove the converter. Removing the Converter from the Inverter
2. Remove the existing gasket on the inverter duct using a flat blade.
3. Clean the duct surface with a 50% isopropyl alcohol/ 50% water mixture.
Installing the Converter Duct Gasket

Note: One side of the duct gasket is coated with an adhesive. Take care to
properly align the gasket, before fully removing the paper liner and exposing the
adhesive and pressing the gasket into place.
1. Begin removing the paper liner as you align the replacement gasket with
the duct edges as shown below and press the gasket into place on the duct.
119
Chapter 5
Align gasket
edges with
duct edges
Top, rear view of converter assembly
2. Install the converter on the inverter assembly in the reverse order of

removal. See Installing the Converter on the Inverter Assembly on
page 119.
120
Chapter
Inverter Component Replacement Procedures
Introduction
This chapter provides detailed procedures for removing and replacing inverter
components.
Topic
Page
Inverter Components and Part Numbers
122
Common Mode Core Assembly Removal/Installation
125
Internal Stirring Fan Tray Removal/Installation
126
Heatsink Fan Inlet Screen Removal/Installation
127
Heatsink Fan Assembly Removal/Installation
128
Inverter Front Cover Removal/Installation
130
Inverter Current Sensors Removal/Installation
131
Inverter Current Sensor Wire Harness Removal/Installation
134
Inverter Capacitor Bank Assembly Removal/Installation
137
Capacitor Balance Resistor Assembly Removal/Installation
140
IGBT Flex Bus Bars Removal/Installation
142
Inverter Gate Board Connection Ribbon Cables Removal/Installation
143
Inverter Gate Circuit Board Removal/Installation
145
Rating Plug Removal/Installation
147
Power Layer Interface Circuit Board Removal/Installation
149
Power Supply Circuit Board Removal/Installation
151
Power Control Circuit Board Removal/Installation
154
Inverter Backplane Circuit Board Removal/Installation
157
Inverter EMC Capacitor Removal/Installation
160
Inverter Side DC Bus Bar Removal/Installation
164
Inverter IGBT Assembly Removal/Installation
171
DC Choke Removal/Installation
176
Inverter Wire Harness Removal/Installation
178
Discharge Resistor Assembly Removal/Installation
182
Inverter Heatsink Fan Inlet Bottom Cover Removal/Installation
189
IMPORTANT

121
Chapter 6
Inverter Components and

Part Numbers
The following table lists the components that make up the inverter assembly.
Each table lists an ID number that corresponds to a component identified in the
corresponding illustrations. The table also identifies each component by name
and includes the corresponding spare part kit catalog number and part number (if
applicable).
ID
Component Name
Figure Number
Inverter Capacitor Bank, 400V 770A, 480V 740A
SK-R1-CP1-C770D740
PN-72182
Figure 7 on page 123
Inverter Capacitor Bank, 400V 567A, 480V 545A
SK-R1-CP1-C567D545
PN-72183
Capacitor Balance Resistors, 400/480V
SK-R1-RB1-CD-F8
PN-72184
Discharge Resistor Assembly, 400/480V
SK-R1-RD1-F8
PN-72185
Inverter IGBT Flexbus, 400V 567A, 480V 545A
SK-R1-BS1-C567D545
PN-85564
Inverter IGBT Flexbus, 400V 770A, 480V 740A
SK-R1-BS1-C770D740
PN-72186
Inverter Current Sensor
SK-R1-INVIFB1-F8
PN-72188
Inverter Heatsink Fan Kit
SK-R1-FAN1-F8
PN-72189
Inverter Internal Stir Fans w/Tray
SK-R1-FAN2-F8
PN-72190
DC Choke, 33uH, 400V 770A, 480V 740A
SK-R1-DCCHK1-F8
PN-72191
DC Choke, 50uH, 400V 567A, 480V 545A
SK-R1-DCCHK2-F8
PN-72192
Inverter Backplane Board
SK-R1-IB1-F8
PN-72193
10
Inverter Power Control Board
SK-R1-PWRS1-CD-F8
PN-72200
11
Inverter Heatsink Power Supply Board, 400/480V
SK-R1-PC1-F8
PN-72199
12
Inverter Power Layer Interface Board (includes two fiberoptic transceivers)
SK-R1-PINT1-F8
PN-72201
13
Inverter IGBT Assembly, 400V 770A, 480V 740A
SK-R1-IT1-C770D740
PN-72202
13
Inverter IGBT Assembly, 400V 567A, 480V 545A
SK-R1-IT1-C567D545
PN-72203
14
Inverter Gate Board, 400V 770A, 480V 740A
SK-R1-IG1-C770D740
PN-72204
14
Inverter Gate Board, 400V 567A, 480V 545A
SK-R1-IG1-C567D545
PN-72205
15
Inverter Ribbon Cable
SK-R1-ICBL1-F8
PN-72206
16
Inverter Front Cover
SK-R1-IFCVR1-F8
PN-72207
17
Inverter Heatsink Fan Inlet Screen
SK-R1-IFCVR2-F8
PN-72208
18
Inverter Heatsink Fan Inlet Bottom Cover
SK-R1-IBCVR1-F8
PN-72209
19
Inverter Wire Harness Kit
SK-R1-INVH1-F8
PN-72210
20
Rating Plug Board, 400V 770A, 480V 740A
SK-R1-IR1-C770D740
PN-72211
20
SK-R1-IR1-C750D710
PN-72212
20
SK-R1-IR1-C650D617
PN-72213
20
SK-R1-IR1-C567D545
PN-72214
20
SK-R1-IR1-C540D485
PN-72215
21
EMC Capacitors
SK-R1-EMCCAP1-F8
PN-85587
122
Chapter 6
16
17
15
14
21
13
21
19
21
Figure 7 - Inverter Main Assembly Components Diagram
123
Chapter 6
Figure 8 - Inverter Card Cage Assembly Components Diagram
12
20
10
11
124
TIP
Common Mode Core

Assembly Removal/
Installation
Chapter 6

Removing the Common Mode Core Assembly

Note: This assembly is field installed only.
page 17.
4. Remove the inverter assembly from the enclosure. Refer to the PowerFlex
5. Remove the two M6 x 25 mm screws that secure the common mode core
assembly to the drive frame and slide the assembly off of the AC output
bus terminals.
Remove screws (2)
T30 or F 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
125
Chapter 6
Installing the Common Mode Core Assembly

Install the common mode core assembly in the reverse order of removal. See
Removing the Common Mode Core Assembly above.
Internal Stirring Fan Tray

Removing the Internal Stirring Fan Tray

page 17.
4. Loosen the two captive screws on the face of the fan tray and pull the tray
straight out from the inverter frame.
Loosen captive screws (2)

T20 or F 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
Note: Inverter shown removed from
drive enclosure for clarity only.
Installing the Internal Stirring Fan Tray

Install in the internal stirring fan tray in the reverse order of removal. See
Removing the Internal Stirring Fan Tray above.
IMPORTANT
126
The power wire connector for the fans is located at the right, rear of the
fan mounting tray. Verify that the connector mates with the socket at the
back of the enclosure when sliding the tray into the inverter frame.
Heatsink Fan Inlet Screen

Chapter 6
Removing the Heatsink Fan Inlet Screen

page 17.
4. Remove the four M5 x 14 mm screws that secure the screen to the drive
frame pull down and out on the bottom screen.
Remove screws (4)

T20 or F - 6.4 mm (0.25 in.)
2.8 Nm (25 lbin)

Installing the Heatsink Fan Inlet Screen

Install the heatsink fan inlet screen in the reverse order of removal. See Removing
the Heatsink Fan Assembly above.
127
Chapter 6
Heatsink Fan Assembly

Removing the Heatsink Fan Assembly

page 17.
4. Remove the heatsink fan inlet screen. See Removing the Heatsink Fan
Inlet Screen on page 127.
5. Disconnect the control and power wire connectors from the front, right
side of the fan assembly.
Disconnect fan control

and power connections
6. Remove the eight M6 x 20 mm screws that secure the inlet seal mounting
plate to the chassis and remove the plate.
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Remove screws (8)
128
Chapter 6
7. Remove the two M6 x 20 mm screws from the fan assembly. The assembly
will rest on the two guide pins on the back wall.
8. Remove the fan assembly:
a. Using both hands, pull the assembly slightly forward until it comes off
of the guide pins.
b. Pull the bottom of the assembly toward the front of the inverter chassis
and tilt the top backward in order to clear the DC choke assembly (if
installed) and remove the assembly.
DC choke assembly
Remove screws (2)
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Installing the Heatsink Fan Assembly

Install the heatsink fan assembly in the reverse order of removal. See Installing the
Heatsink Fan Assembly above.
129
Chapter 6
Inverter Front Cover

Removing the Inverter Front Cover

page 17.
4. Loosen the four M5 x 14 mm screws, raise the front cover vertically and lift
it off of the screws.
T25 or F 6.4 mm (0.25 in.)
2.8 Nm (25.0 lbin)
Loosen screws (4)
130
Chapter 6
Installing the Inverter Front Cover

Install the inverter front cover in the reverse order of removal. See Removing the
Inverter Front Cover above.
Inverter Current Sensors

Removing the Inverter Current Sensors

page 17.
5. Remove the inverter front cover. See Removing the Inverter Front Cover
on page 130.
6. Disengage the locking tabs and disconnect the wire connector from P1 on
the power control board.
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
131
Chapter 6
7. Remove the eight M5 x 12 mm screws and the two M5 x 10 mm screws

from the current sensor mounting panel on the left side of the inverter.
T25
2.8 Nm (25.0 lbin)
Remove screws (10)
132
Chapter 6
8. Disengage the locking tabs and disconnect the connector labeled U, V, or

W attached to the current sensor and remove the current sensor.
9. Remove the four M6 x 14 mm screws that secure each of the current
sensors to the mounting panel.
T30 or F - 6.4 mm (0.25 in)

5.1 Nm (45.0 lbin)
Remove screws (4)
Installing the Inverter Current Sensors

Install the inverter current sensor in the reverse order of removal. See Removing
the Inverter Current Sensors on page 131.
133
Chapter 6
Inverter Current Sensor

Installation
Removing the Inverter Current Sensor Wire Harness

page 17.
on page 130.
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
134
Chapter 6
7. Remove the eight M5 x 12 mm screws and the two M5 x 10 mm screws

from the current sensor mounting panel on the left side of the inverter.
T25
2.8 Nm (25.0 lbin)
T25 or F - 5.0 mm (0.19 in.)
2.8 Nm (25.0 lbin)
Remove screws (8)
135
Chapter 6
8. Disengage the locking tabs and disconnect the connector labeled U, V, or

W attached to the current sensor and remove the current sensor.
9. Cut all wire ties from the tie locations and remove the harness.
Cut cable ties and

remove wire harness
Disconnect wire harness from

connectors on current sensors
Installing the Inverter Current Sensor Wire Harness

Install the inverter current sensor wire harness in the reverse order of removal. See
Removing the Inverter Current Sensor Wire Harness on page 134.
136
Inverter Capacitor Bank

Assembly Removal/
Installation
Chapter 6
Removing the Inverter Capacitor Bank Assembly

page 17.
4. Remove the internal stirring fan tray. See Removing the Internal Stirring
Fan Tray on page 126.
on page 130.
7. Disconnect the terminal block from P6 on the power control board.
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
Disconnect terminal
block from P6
137
Chapter 6
8. Disengage the locking tabs and disconnect the wire connector from J1 on
the power supply board.
=
Disconnect connector from J1
Front of board
J1
J3
J4
J2
9. Completely loosen the two captive screws on the lower tray in the card
cage, remove the tray and store it in a protected, dry, static-free location.
=
Loosen screws (2)

and remove tray
T20 or F 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)
IMPORTANT


138
Chapter 6
10. Connect the lifting hardware to the two lifting holes on the front of the
capacitor bank assembly.
11. Remove the twelve M6 hex nuts from the bus connection tabs at the top
and bottom of the capacitor bank assembly.
12. Remove the six M6 x 50 mm screws (three at the top, three at the bottom),
from the capacitor bank assembly.
13. Remove the six or twelve M8 x 20 mm IGBT connection screws from the
capacitor bank assembly and, using the lifting equipment, pull the
assembly forward and out of the inverter.
10.0 mm
5.1 Nm (45.0 lbin)
45
MAX.
M6
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
M8
T40 or F - 6.4 mm (0.25 in.)

9.0 Nm (80.0 lbin)
139
Chapter 6
Installing the Inverter Capacitor Bank

Install in the reverse order of removal. See Removing the Inverter Capacitor Bank
Assembly above.
Capacitor Balance Resistor Removing the Capacitor Balance Resistor Assembly

Assembly Removal/
Installation
page 17.
on page 130.
6. Remove the capacitor bank. See Removing the Inverter Capacitor Bank
140
Chapter 6
7. Remove the six M5 x 16 mm screws from the capacitor balance resistor

mounting tray.
8. Disconnect the POS, NEG and MIDP wire connections from the three
faston terminals on the capacitor bank assembly.
9. Slide the capacitor balance resistor mounting tray up and out of the
capacitor bank assembly.
Disconnect connectors from
POS, NEG and MIDP on
capacitor bank assembly
Remove screws (3)
Remove screws (3)
T25
2.8 Nm (25.0 lbin)
Capacitor Balance Resistors

Install the capacitor balance resistors in the reverse order of removal. See
Removing the Capacitor Balance Resistor Assembly on page 140.
141
Chapter 6
IGBT Flex Bus Bars

Removing the IGBT Flex Bus Bars

Note: This assembly is field installed only.
page 17.
on page 130.
7. Remove the current sensor mounting panel. See Removing the Inverter
Current Sensors on page 131.
9. Remove the M10 hex nut that secures each IGBT flex bus bar to the AC
output bus bar assembly.
17.0 mm
13.6 Nm (120.0 lbin)
Remove hex nuts (3)
IGBT flex
bus bar
AC output bus bar assembly
142
Chapter 6
10. Remove the two M8 x 30 mm screws that secures each IGBT flex bus bar
to the IGBT connections.
11. Slide each of the IGBT flex bus bars out of the front of the inverter.
IMPORTANT
Remove the IGBT flex bus bars carefully, so as not to damage the
inverter gate boards.
T40 or F - 6.4 mm (0.25 in)

9.0 Nm (80.0 lbin)
Remove screws (6)
Installing the IGBT Flex Bus Bars

Install the IGBT flex bus bars in the reverse order of removal. See Removing the
IGBT Flex Bus Bars on page 142.
Inverter Gate Board

Connection Ribbon Cables
Removing the Inverter Gate Board Connection Ribbon Cables

page 17.
143
Chapter 6
on page 130.
7. Disengage the locking tabs and disconnect each end of the jumper ribbon
cable from the inverter gate board and remove the ribbon cable.
8. Disengage the locking tabs and disconnect one end of the upper ribbon
cable from the gate board, disconnect the opposite end of the ribbon cable
from the backplane in the card cage and remove the upper ribbon cable by
pulling it vertically out of the top of the inverter.
=
Upper ribbon
cable

Jumper ribbon
cables - two
locations
144
Chapter 6
Installing the Inverter Gate Board Connection Ribbon Cables

Install the inverter gate board connection ribbon cables in the reverse order of
removal. See Removing the Inverter Gate Board Connection Ribbon Cables on
page 143.
Inverter Gate Circuit Board Removing the Inverter Gate Circuit Board
page 17.
on page 130.
9. Remove the IGBT flex bus bars. See Removing the IGBT Flex Bus Bars on
page 142.
10. Remove the inverter ribbon cables. See Removing the Inverter Gate Board
Connection Ribbon Cables on page 143.
145
Chapter 6
11. Remove the 11 M4 x 10 mm screws that secure the gate board to the IGBT
and standoffs and remove the board.
=
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)
Remove screws (11)
Installing the Inverter Gate Circuit Board

Install the inverter gate board in the reverse order of removal. See Removing the
Inverter Gate Circuit Board on page 145.
146
Rating Plug Removal/

Installation
Chapter 6
Removing the Rating Plug

page 17.
on page 130.
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Rating plug
Front of board
Disconnect terminal
block from P6
147
Chapter 6
=
Front of board
J1
J3
J4
J2
148
Chapter 6
8. Completely loosen the two captive screws on the face of the bottom tray in
the card cage and pull the tray out of the cage.
9. Unlatch the two metal clips that secure the rating plug in the slot, tilt
slightly upward and gently pull forward to remove the plug.
=
Loosen screws (2)
Remove rating plug
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)

Installing the Rating Plug

Install the rating plug in the reverse order of removal. See Removing the Rating
Plug on page 147.
Power Layer Interface

Circuit Board Removal/
Installation
Removing the Power Layer Interface Circuit Board

page 17.
on page 130.
149
Chapter 6

=
P2
P3
P5
P4
P1
P6
Disconnect terminal
block from P6
Front of board
6. Disconnect the fiber-optic cables from CONV and INV on the power
layer interface board.
=
J7
P2
J6
CONV
Disconnect fiber-optic
cables from CONV and INV
INV
7. From the INV and CONV fiber-optic cages on the power layer interface
board, remove each fiber-optic transceiver by pulling its bale wire. Set the
transceivers aside and save for re-installation.
150
Chapter 6
8. Completely loosen the two captive screws on the face of the top tray in the
card cage, pull forward and remove the tray.
9. Remove the three M4 x 8 mm screws that secure the power layer interface
board to the tray, push the board slightly back and then up to remove it
from the two keyhole standoffs on the tray.
T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
Remove screws (3)
Loosen screws (2)

Installing the Power Layer Interface Circuit Board

Install the power layer interface board in the reverse order of removal. See
Removing the Power Layer Interface Circuit Board on page 149.
Power Supply Circuit Board Removing the Power Supply Circuit Board
page 17.
on page 130.
151
Chapter 6
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
Disconnect terminal
block from P6
=
Front of board
J1
J3
J4
J2
152
Chapter 6
9. Remove the five M4 x 8mm screws that secure the power supply board to
the tray, pull the board slightly forward and then down to remove it from
the two keyhole standoffs on the tray.
=
Loosen screws (2)
Remove screws (5)

T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)

Installing the Power Supply Circuit Board

Install the power supply board in the reverse order of removal. See Removing the
Power Supply Circuit Board on page 151.
153
Chapter 6
Removing the Power Control Circuit Board

Power Control Circuit
page 17.
on page 130.
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
154
Disconnect terminal
block from P6
Chapter 6
=
Front of board
J1
J3
J4
J2
155
Chapter 6
9. Remove the five M4 x 8mm screws that secure the power control board to
the tray, pull the board slightly back and then up to remove it from the two
keyhole standoffs on the tray.
T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
Remove screws (5)
Loosen screws (2)

Installing the Power Control Circuit Board

Install the power control board in the reverse order of removal. See Removing the
Power Control Circuit Board on page 154.
156
Chapter 6
Inverter Backplane Circuit Removing the Inverter Backplane Circuit Board

IMPORTANT
Firmware must be loaded into the inverter backplane circuit board by

qualified Rockwell Automation service personnel in order for this board
to be operational.

page 17.
on page 130.
=
P2
P5
P3
P4
Disconnect
connector from P1
P1
P6
Front of board
Disconnect terminal
block from P6
157
Chapter 6
=
Front of board
J1
J3
J4
J2
158
Chapter 6
8. Disconnect the ribbon cable that is connected to the top edge of the
backplane board.
9. Completely loosen the two captive screws on the face of the top tray in the
card cage, pull forward and remove the tray.
11. Remove the three M4 x 8 mm screws that secure the backplane board to
the tray and pull the backplane gently forward to release it from the four
snap-top standoffs.
=
Disconnect ribbon cable
Backplane board
Loosen screws (2)
Top tray
Bottom tray
Loosen screws (2)
Remove screws (3)

T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)

Installing the Inverter Backplane Circuit Board

Install the inverter backplane board in the reverse order of removal. See
Removing the Inverter Backplane Circuit Board on page 157.
159
Chapter 6
Inverter EMC Capacitor

Removing the Inverter EMC Capacitors

page 17.
on page 130.
9. Remove the two M4 hex nuts that secure the connections from the EMC
capacitors to DC choke/converter bus bar assembly.
DC choke/converter
bus bar assembly
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)
EMC capacitors
160
Chapter 6
10. Remove the two M3 x 12 mm screws that secure the inverter wire harness
to the backplane in the card cage.
11. Remove the two M4 x 10 mm screws that secure the card cage to the
inverter frame and slide the card cage out and up to remove it.
12. Remove the two M4 x 8mm screws that secure the EMC capacitor
assembly to the card cage and remove the capacitor assembly.
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)
Remove screws (2)
T15 or F - 5.0 mm (0.19 in.)

0.5 Nm (4.0 lbin)
Remove screws
Remove screws (2)

T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
161
Chapter 6
assembly to the standoffs on the capacitor bank support and remove the
EMC capacitor assembly.
DC choke/converter
bus bar assembly
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)
Remove screws (2)
EMC
capacitors
Remove hex nuts (2)

7.0 mm (0.3 in.)
1.8 Nm (16.0 lbin)
162
Chapter 6
15. Remove the five M4 hex nuts that secure the connections from the EMC
capacitors to the DC choke input positive and negative bus bars and the
EMC capacitor assembly to the drive chassis and remove the EMC
capacitor assembly.
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
Remove hex nuts (5)
EMC capacitor
assembly
Installing the Inverter EMC Capacitors

Install the Inverter EMC Capacitors in the reverse order of removal. See
Removing the Inverter EMC Capacitors on page 160.
163
Chapter 6
Inverter Side DC Bus Bar

Removing the Inverter Side DC Bus Bars

page 17.
on page 130.
page 142.
DC choke/converter
bus bar assembly
EMC capacitors
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)
164
Chapter 6
T15 or F - 5.0 mm (0.19 in.)
0.5 Nm (4.0 lbin)
Remove screws (2)
Remove screws (2)

T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
165
Chapter 6
13. Completely loosen, but do not remove, the two M6 hex nuts at the back
edge of the AC output bus bar assembly.
14. Remove the three M6 screws that secure the front of the AC output
assembly to the capacitor bank support.
15. Lift the assembly off of the front three bolts and pull forward to remove
the AC output assembly.
Lift off front three

bolts and pull
assembly forward.
Loosen hex nuts (2)

10.0 mm (0.4 in.)
5.1 Nm (45.0 lbin)
166
Remove hex nuts (3)
Chapter 6
16. Remove the two M6 hex nuts and two M5 x 10 mm screws that secure the
capacitor bank gusset to the capacitor bank support and drive chassis and
remove the gusset.
10.0 mm (0.4 in.)
5.1 Nm (45.0 lbin)
Remove hex nuts (2)
T25
2.8 Nm (25.0 lbin)
Remove screws (2)
167
Chapter 6
capacitors to the DC choke input positive and negative bus bars.
Remove hex
nuts (2)
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
EMC capacitors
18. Remove the four M8 x 30 mm screws and four M8 flat washers that secure
the bottom of the DC choke/converter bus bar assembly to the DC choke
input positive and negative bus bars.
19. Remove the four M8 x 30 mm screws and M8 flat washers from the DC
input and output positive and negative bus bars where they connect to the
top of the DC choke and remove the bus bars.
T40 or F - 6.4 mm (0.25 in.)
9.0 Nm (80.0 lbin)
DC choke/
converter bus
bar assembly
Remove screws (4)

and washers (4)
Remove screws (4)

and washers (4)
DC input and output positive

and negative bus bars
168
Chapter 6
20. Remove the three M6 x 16 mm screws that secure the DC choke/converter

bus bar assembly to the chassis and remove the DC choke/converter bus
bar assembly.
Side DC
bus bars
M6
T30
5.1 Nm (45.0 lbin)
Remove screws (3)
169
Chapter 6
capacitors to side DC bus bars.
assembly to the standoffs on the capacitor bank support and remove the
EMC capacitor assembly.
23. Remove the two M4 x 40 mm standoffs secured to the capacitor bank
support.
24. Remove the two M6 hex nuts that secure the two discharge resistor wires
to the inverter side DC bus bars. Move the wires out of the way to allow for
removal of the side DC bus bars.
25. Remove the four M6 x 20 mm screws that secure the side DC bus bars to
the chassis and remove the bus bars.
7.0 mm (0.3 in.)
1.8 Nm (16.0 lbin)
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)
Remove standoffs (2)
Remove screws (2)

EMC
capacitors
Remove hex nuts (2)

7.0 mm (0.3 in.)
1.8 Nm (16.0 lbin)
Remove hex nuts (2)

10.0 mm (0.4 in.)
5.1 Nm (45.0 lbin)
Remove screws (4) and washers (4)

T30 or F - 6.4 mm (0.25 in.)
5.1 Nm (45.0 lbin)
170
Chapter 6
Installing the Inverter Side DC Bus Bars

Install the inverter side DC bus bars in the reverse order of removal. See
Removing the Inverter Side DC Bus Bars on page 164.
IMPORTANT
The new side DC bus bar assembly is shipped with a stabilizer bar
secured to the upper connection bolts. This stabilizer bar must be
removed before installing the new assembly.
Remove the four nuts and washers

and stabilizer bar from the side DC
bus bar assembly before installation.
Inverter IGBT Assembly

Removing the Inverter IGBT Assembly

page 17.
on page 130.
171
Chapter 6
page 142.
10. Remove the inverter gate board ribbon cables. See Removing the Inverter
Gate Board Connection Ribbon Cables on page 143.
11. Remove the inverter gate boards. Removing the Inverter Gate Circuit
Board on page 145.
12. Remove the side DC bus bars. See Removing the Inverter Side DC Bus
Bars on page 164.
13. Remove the four M8 x 30mm screws and four M8 flat washers that secure
the DC choke input positive and negative bus bars to the DC choke.
Remove screws (4) and washers (4)
172
T40 or F - 6.4 mm (0.25 in.)

9.0 Nm (80.0 lbin)
Chapter 6
14. Remove the three M6 x 20 mm screws that secure the top bus bar support
to the capacitor bank support and remove the bus bar support.
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
Remove screws (3)
173
Chapter 6
15. Remove the six M6 x 14 mm screws from the capacitor bank support.
16. Remove the two M5 x 10 mm flat head screws on the lower right-hand side
of the capacitor bank support and remove the support.
Remove screws (2)

Remove screws (6)
T30 or F - 6.4 mm (0.25 in.)
5.1 Nm (45.0 lbin)
174
T25
2.8 Nm (25.0 lbin)
IMPORTANT
Chapter 6

17. Connect the lifting hardware to the lifting holes on the front of the IGBT
assembly.
18. Remove the 12 M6 x 25 mm screws that secure the inverter IGBT
assembly to the inverter duct and using the lifting equipment, remove the
inverter IGBT assembly.
Lifting holes
Remove screws (12)

T30 or F - 6.4 mm (0.25 in.)
5.1 Nm (45.0 lbin)
175
Chapter 6
Installing the Inverter IGBT Assembly

Install the inverter IGBT assembly in the reverse order of removal. See Removing
the Inverter IGBT Assembly on page 171.
DC Choke Removal/
Installation
Removing the DC Choke

page 17.
on page 130.
176
Chapter 6
10. Remove the eight M8 x 30 mm screws and eight M8 flat washers from the
DC input and output positive and negative bus bars where they connect to
the top of the DC choke.
11. Loosen only, the six M6 x 70 mm screws that secure the DC choke to the
inverter.
12. Remove four of the six screws that were loosened in the previous step and
then slowly loosen the remaining two screws to lower the DC choke onto
the two angle brackets on either side of the fan inlet. Once the DC choke is
resting on the two angle brackets, the remaining two screws can be
removed.
13. Pull the DC choke forward through the fan inlet opening and remove the
choke.
M6
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
M8
T40 or F - 6.4 mm (0.25 in.)

9.0 Nm (80.0 lbin)
Remove M8 screws (8)
Loosen, then
remove M6
screws (6)
177
Chapter 6
Installing the DC Choke

Install the DC choke in the reverse order of removal. See Removing the DC
Choke on page 176.
Inverter Wire Harness

Removing the Inverter Wire Harness

page 17.
on page 130.
8. Remove the inverter current sensor mounting panel only. Do not remove
the current sensors from the mounting panel. See Removing the Inverter
10. Remove the side DC bus bar assembly. See Removing the Inverter Side DC
Bus Bars on page 164.
178
Chapter 6
11. Remove the three M6 x 20 mm screws that secure the top bus bar support
to the capacitor bank support and remove the bus bar support.
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
Remove screws (3)
179
Chapter 6
12. Cut the wire ties from the group of blue control wires running down the
inside, right-rear corner of the capacitor bank support.
13. Depress the tabs on the stirring fan connector and disconnect it from the
mounting bracket.
Cut cable ties
from stirring fan bracket
14. Cut the two remaining cables ties where the blue fan control wires are
routed through the right side of the heatsink fan inlet.
15. Remove the bushing and blue wires from the heatsink fan inlet side plate.
16. On the inside of the heatsink fan inlet, depress the tabs on the blue control
wire connector to remove it from the heatsink fan connection.
17. Remove the two M4 hex nuts that secure the black power wires at the top
of the inverter.
18. Cut the remaining wire ties where the wires are routed down the outside of
the inverter.
19. Remove the bushing and black wires from the heatsink fan inlet side plate.
180
Chapter 6
20. On the inside of the heatsink fan inlet, depress the tabs on the black power
wire connector to remove it from the heatsink fan connection.
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)
Cut cable ties and

remove busings
and wires
Installing the Inverter Wire Harness

Install the inverter wire harness in the reverse order of removal. See Removing the
Inverter Wire Harness on page 178.
181
Chapter 6
Discharge Resistor
Assembly Removal/
Installation
Removing the Discharge Resistor Assembly

page 17.
on page 130.
page 142.
DC choke/converter
bus bar assembly
EMC capacitors
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)
182
Chapter 6
T15 or F - 5.0 mm (0.19 in.)
0.5 Nm (4.0 lbin)
Remove screws (2)
Remove screws (2)

T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
183
Chapter 6
12. Completely loosen, but do not remove, the two M6 hex nuts at the back
edge of the AC output bus bar assembly.
13. Remove the three M6 screws that secure the front of the AC output
assembly to the capacitor bank support.
14. Lift the assembly off of the front three bolts and pull forward to remove
the AC output assembly.
Lift off front three

bolts and pull
assembly forward.
Loosen hex nuts (2)

10.0 mm (0.4 in.)
5.1 Nm (45.0 lbin)
184
Remove hex nuts (3)
Chapter 6
15. Remove the two M6 hex nuts and two M5 x 10 mm screws that secure the
capacitor bank gusset to the capacitor bank support and drive chassis and
remove the gusset.
10.0 mm (0.4 in.)
5.1 Nm (45.0 lbin)
Remove hex nuts (2)
T25
2.8 Nm (25.0 lbin)
Remove screws (2)
185
Chapter 6
capacitors to the DC choke input positive and negative bus bars.
Remove hex
nuts (2)
7.0 mm (0.3 in.)

1.8 Nm (16.0 lbin)
EMC capacitors
17. Remove the four M8 x 30 mm screws and four M8 flat washers that secure
the bottom of the DC choke/converter bus bar assembly to the DC choke
input positive and negative bus bars.
18. Remove the four M8 x 30 mm screws and M8 flat washers from the DC
input and output positive and negative bus bars where they connect to the
top of the DC choke and remove the bus bars.
T40 or F - 6.4 mm (0.25 in.)
9.0 Nm (80.0 lbin)
DC choke/
converter bus
bar assembly
Remove screws (4)

and washers (4)
Remove screws (4)

and washers (4)
DC input and output positive

and negative bus bars
186
Chapter 6
19. Remove the three M6 x 16 mm screws that secure the DC choke/converter

bus bar assembly to the chassis and remove the DC choke/converter bus
bar assembly.
Side DC
bus bars
M6
T30
5.1 Nm (45.0 lbin)
Remove screws (3)
187
Chapter 6
20. Remove the two M4 hex nuts used to secure the connections from the
EMC capacitors to the side DC bus bar assembly.
21. Remove the M4 x 8 mm screw that secures the EMC capacitor assembly to
the standoff on the capacitor bank support.
22. Remove the four M4 x 8 mm screws from the discharge resistors.
23. Remove the two M6 hex nuts from the wire connections on the side DC
bus bars and remove the discharge resistor assembly.
Side DC bus bars
EMC
capacitor
assembly
Remove hex nuts (2)

7.0 mm (0.3 in.)
1.8 Nm (16.0 lbin)
Discharge resistor
assembly
Remove screws (4)
T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
Remove hex nuts (2)

7.0 mm (0.3 in.)
5.1 Nm (45.0 lbin)
Remove screw
T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
Installing the Discharge Resistor Assembly

Install the discharge resistor assembly in the reverse order of removal. See
Removing the Discharge Resistor Assembly on page 182.
188
Inverter Heatsink Fan Inlet

Bottom Cover Removal/
Installation
Chapter 6
Removing the Inverter Heatsink Fan Inlet Bottom Cover

page 17.
5. Lay the inverter on the back panel. Refer to the Lifting instructions
contained in the PowerFlex 750-Series AC Drive Installation Instructions,
publication number 750-IN001.
6. Remove the 12 M6 x 12 mm screws that secure the bottom cover and
gasket to the inverter frame and remove the cover and gasket.
T30 or F - 6.4 mm (0.25 in)

5.1 Nm (45.0 lbin)
Remove screws (12)
189
Chapter 6
Installing the Inverter Heatsink Fan Inlet Bottom Cover

Install the inverter heatsink fan inlet bottom cover in the reverse order of
removal. See Removing the Inverter Heatsink Fan Inlet Bottom Cover on
page 189.
190
Chapter
Drive Enclosure Component Replacement

Procedures
Introduction
Drive Enclosure
Components and Part
Numbers
This chapter provides detailed procedures for removing and replacing drive
enclosure components.
Topic
Page
Drive Enclosure Components and Part Numbers
Below
IP20, NEMA/UL Type 1 Door Filter Removal/Installation
Below
Exhaust Duct Removal/Installation
193
Top Conduit Plate Removal/Installation
194
Cabinet Door Fan Removal/Installation
195
The following table lists the components that make up the drive enclosure. The
table also identifies each component by name and includes the corresponding
spare part kit catalog number and part number (if applicable).
Component Name
IP20, NEMA/UL Type 1 Door Filter
20-750-FLTR1-F8
PN-37965
Exhaust Duct
20-750-HOOD1-F8
PN-37543
Top Conduit Plate 600 mm
SK-R1-CPLT1-F8
PN-54205
Top Conduit Plate 800 mm
SK-R1-CPLT2-F8
PN-38605
Door Fan
20-750-FAN3-F8
PN-53452
TIP

IP20, NEMA/UL Type 1 Door Removing the Door Filter

Filter Removal/Installation

page 17.
191
Chapter 7
Drive Enclosure Component Replacement Procedures
3. Remove the two M6 x 16 mm screws that secure the filter bracket to the
enclosure door and remove the bracket.
4. Remove the filter from the holder.
Remove screws
T25
4.5 Nm (40 lbin)
Installing the Door Filter

Install the door filter in the reverse order of removal. See Removing the Door
Filter on page 191 above.
192
Exhaust Duct Removal/

Installation
Chapter 7
Removing the Exhaust Duct

page 17.
3. Remove the four M5 x 16 screws that secure the exhaust duct to the top of
the enclosure and remove the duct.
T25
4.0 Nm (35 lbin)
Remove screws
Installing the Exhaust Duct

Install the exhaust duct in the reverse order of removal. See Removing the
Exhaust Duct on page 193.
193
Chapter 7
Top Conduit Plate Removal/ Removing the Top Conduit Plate

Installation

page 17.
3. Remove the eight (for 600 mm deep enclosures) or ten (for 800 mm deep
enclosures) M5 x 16 screws that secure the conduit plate to the top of the
enclosure and remove the plate.
Remove screws
T25
4.0 Nm (35 lbin)
Note: Exhaust duct shown
removed for clarity only.
Installing the Top Conduit Plate

Install the top conduit plate in the reverse order of removal. See Removing the
Top Conduit Plate on page 194.
194
Chapter 7
Cabinet Door Fan Removal/ Removing the Cabinet Door Fan

Installation

page 17.

4. Disconnect the fan power connector from TB2-3/TB2-4 on the right side
of the control pod.
Remove fan power connector from TB2
195
Chapter 7
5. Remove the four M5 x 20 screws that secure the inner guard to the fan
housing and remove the guard.
6. Remove the four M5 x 20 screws that secure the outer fan guard and fan to
the enclosure door and remove the outer fan guard and fan.
T20 or F - 6.4 mm (0.25 in.)
4.0 Nm (35 lbin)
Remove screws
Air flow direction
Remove screws
T20 or F - 6.4 mm (0.25 in.)
4.5 Nm (40 lbin)
Installing the Cabinet Door Fan

Install the cabinet door fan in the reverse order of removal. See Removing the
Cabinet Door Fan on page 195.
IMPORTANT
196
When installing a new fan, verify that the air flow direction arrow on the
fan points to the exterior of the drive enclosure.
Chapter
Option Bay Enclosure Component

Introduction
This chapter provides detailed procedures for removing and replacing option bay
enclosure components.
Option Bay Enclosure

Components and Part
Numbers
Topic
Page
Option Bay Enclosure Components and Part Numbers
Below
Disconnect Handle Panel Removal/Installation
Below
Door Fan Removal/Installation
199
Thermostat Removal/Installation
200
Bottom Conduit Plate Removal/Installation
202
The following table lists the components that make up the option bay enclosure.
The table also identifies each component by name and includes the
corresponding spare part kit catalog number and part number (if applicable).
Component Name
Disconnect Handle Panel
SK-R1-ODISCP1-F8
PN-55643
Door Fan
20-750-FAN3-F8
PN-53452
Thermostat
SK-R1-OTH1-F8
PN-72880
TIP
Disconnect Handle Panel


Removing the Disconnect Handle Panel

page 17.
3. Open the option bay door.
197
Chapter 8
Option Bay Enclosure Component Replacement Procedures
4. Remove the three M5 screws hex screws that secure the disconnect handle
panel to the enclosure frame and remove the panel.
8 mm
4.0 Nm (35 lbin)
Remove screws
Installing the Disconnect Handle Panel

Install the disconnect handle panel in the reverse order of removal. See Removing
the Disconnect Handle Panel above.
198
Door Fan Removal/

Installation
Chapter 8
Removing the Door Fan

page 17.
3. Open the drive bay enclosure door.
4. Disconnect the fan power connector from TB2-3/TB2-4 on the right side
of the control pod.
Remove fan power connector from TB2
199
Chapter 8
5. Open the option bay enclosure door.

6. Remove the four M5 x 20 screws that secure the inner guard to the fan
housing and remove the guard.
7. Remove the four M5 x 20 screws that secure the outer fan guard and fan to
the enclosure door and remove the outer fan guard and fan.
T20 or F - 6.4 mm (0.25 in.)
4.0 Nm (35 lbin)
Remove screws
Air flow direction
Remove screws
T20 or F - 6.4 mm (0.25 in.)
4.5 Nm (40 lbin)
Installing the Door Fan

Install the door fan in the reverse order of removal. See Removing the Door Fan
on page 199.
IMPORTANT
Thermostat Removal/
Installation
When installing a new fan, verify that the air flow direction arrow on the
fan points to the exterior of the drive enclosure.
Removing the Thermostat

page 17.
3. Open the option bay enclosure door.
200
Chapter 8
4. Remove the nylon screw that secures the closed end of the thermostat to
the mounting standoff and remove the screw.
5. Loosen the nylon screw that secures the open end of the thermostat to the
standoff and remove the thermostat.
Remove screw
(hand tighten)
Loosen screw
(hand tighten)
Installing the Thermostat

Install the thermostat in the reverse order of removal. See Removing the
Thermostat on page 200.
201
Chapter 8
Bottom Conduit Plate

Removing the Bottom Conduit Plate

page 17.
3. Remove the eight M5 x 16 screws that secure the plate to the bottom of the
enclosure and remove the plate.
Remove screws
T20
4.0 Nm (35 lbin)
Installing the Bottom Conduit Plate

Install the bottom conduit plate in the reverse order of removal. See Removing
the Bottom Conduit Plate on page 202.
202
Chapter
Introduction
This chapter provides detailed instructions for starting up a drive after you have
made certain repairs.
Topic
Page
Before Applying Power to the Drive
Below
Testing With the Motor Without a Mechanical Load
205
203
Chapter 9
Before Applying Power to

the Drive
1. Check the DC bus voltage at the -DC and +DC Testpoints sockets on the
front of the power module.
2. Perform forward and reverse biased diode tests, using a digital multimeter.
See Forward and Reverse Biased SCR/Diode Tests on page 29.
3. Inspect the drive for loose bolts, disconnected cables, etc.
4. Verify the following:
If any work was performed on the converter, inspect all converter wire
harnesses to ensure that they are all connected at both ends.
If any work was performed on the converter, inspect the control
transformer primary connections to verify that the taps are appropriate
for the applied voltage:
Transformer Terminal Connections
Input Voltage
H1 & H2
380/415
H1 & H3
440/480
H1 & H4
575/600
H1 & H5
690
The fiber-optic cables from the control pod to the inverter, and from
the inverter to the converter, are connected.
If any work was performed to or around the inverter card cage, verify
that the current feedback cable is connected to the inverter power
board, and to all three current sensors. Also verify that the P6 cable is
connected to the inverter power board, and that the J1 cable is
connected to the main power supply board.
The two heatsink fan cables are connected to the fan terminal block.
204
Testing With the Motor

Without a Mechanical Load
Chapter 9
This test allows you to measure the and diagnose problems without connecting
the motor to its mechanical load.
1. Verify that the input power wiring and grounding is connected.
2. Verify that the motor cables are connected.
3. Verify that the motor load is disconnected.
4. Energize the drive.
5. Measure the DC bus voltage and verify that the value is reflected in
parameter 11 [DC Bus Volts].
6. Start the drive and increase the speed from zero to base speed.
7. Measure drive output current and verify that the value is reflected in the
parameter 7 [Output Current].
8. Stop the drive.
205
Chapter 9
206
Appendix
Schematics
Introduction
This chapter provides drive schematics.

Topic
Page
Control Pod Schematic Diagram
208
Converter Schematic Diagram
209
Inverter Circuit Board Schematic Diagram
210
Inverter Power Layer Schematic Diagram
211
Control Transformer Schematic Diagram
212
207
Appendix A
Schematics
Control Pod Schematic Diagram
POD Bucket Main Control

External
HIM
To Frame 8 Drive Main Control Board in POD

J4
64-POS
Frame 8 Main
Control Board
P11
AFE
Spare Part Cat. No.

SK-R1-MCB1-F8
Fiber Interface Board

Spare Part Cat. No.
SK-R1-FIB1-F8
J3
64-POS
J11
P12
98-POS
J5
98-POS
To
External
HIM
J12
TB1
Direct Screw
Connection
(3 Places)
P15
P1 P2 P3
P4 P5
INV1 INV2 INV3 INV4 INV5
P14 P13
24V Wire Harness

Spare Part Cat. No.
20-750-PH1-F8
To Converter Gate
Board TB1
TB1-7
TB1-8
3 2 1
24V
24V COM
24 VDC Aux Pwr Supply
User Provided
24V Supply
24 VDC Common Aux Pwr Sup

Ground Aux Pwr Supply
Fiber Optic Cable to

Inverter Power Layer
Interface Board P1
208
Direct Screw
Connection
(4 Places)
Fiber-Optic Cable (1 Per)

Spare Part Cat. No.
20-750-FCBL1-F8
Fiber-Optic Transceiver (1 Per)

Spare Part Cat. No.
SK-R1-FTR-F8
Schematics
Appendix A
R/L1
S/L2
T/L3
Chassis PE
R/L1
S/L2
T/L3
PE-A2
AC EMI Cap Harness
Removable at customer
accessible location
2
CONNECTED (Default)
Converter Schematic Diagram
PE-A2
PE-A2
Spare Part 400/480V Cat. No.

SK-R1-MOV1-CD-F8
MOV1
DISCONNECTED CONNECTED
(Default)
DC-
4
3
1 2
FU4
1 3
4 5 6
SCR/Diode DC Bus
P10
P11
DC Bus
Fuse P8
MISC
I/O
P13
1
2
3
4
5
1
2
3
4
Converter
Gate Board
Line
Fuse
Sense
P7
Power Input
Fan Output
F1
System
24V
P12
3 2 1
5 4
3 2 1
P3
FU6
H1
Cabinet Door Fan Wire Harness Cat. No. SK-R1-FANH1-F8

Cabinet Door Fan (1 Per w/Finger Guard) Cat. No. 20-750-FAN3-F8
TB1-3
TB1-4
TB1-5
TB1-6
TB1-7
TB1-8
TB1-9
J6
Inverter Power
Board
24V
Direct Screw
Connection
No Connection
Spare Part Cat. No. SK-R1-XFMR1-F8

Converter Wire Harness Cat. No. SK-R1-CNVH1-F8 (10 Harnesses Per)
No DC Bus Fues Harness, Misc. I/O Harness, Power 24V/240V Harness,
Inverter Power Supply Harness, SCR Gate Harness, DC Bus Harness,
CT Sonsor Harness, AC Line Fuse Harness, Transformer Primary Harness,
AC Bus Harness
Ground
240V Neutral
240V Hot
Control Transformer
1000 VA, 240 VAC, 4.2 A
TB1-1
X2
T1
24V COM
H*
TB1-2
X1
24V
2 3
K3
Current
Transformers
P6
Direct Screw
Connection
(3 places)
1
G3
K2
Spare Part Cat. No.

SK-R1-CGDB1-CD-F8
2
1
6
5
4
3
G2
K1
Line
NTC
Voltage P2
P9
9
8
7
6
5
P14
Fiber
Interface
Board
Fiber
Optic
Cables
P3
Inverter
Power Layer
Interface
Board
TB2-1
NTC1
TB2-3
SW1 SW2 SW3
Spare Part 400/480V

Cat. No.
SK-R1-SCR1-CD-F8
G1
4
5
To POD
DC+
Spare Part Cat. No.

Current Trans. (1 per)
SK-R1-CNVIFB1-F8
Control Transformer Fuses: 400/480V

FU4 700VAC, 8A, IEC 14x51mm
FU5 700VAC, 8A, IEC 14x51mm
FU6 600VAC, 5A, Class CC
Spare Part Cat. No. SK-R1-FUSE2-CD-F8
CT3
1 4 2
5: G (White)
TB2-2
FU3
4: K (Black)
SCR3
CT2
FU5
Shunt Trip Normally Open

Shunt Trip Common
External
HIM
SCR1 SCR2
CT1
FU2
1 4 2
PE/G
L3
SCR/Diode Modules
Current
Transformers
FU1
1 4 2
Spare Part Cat. No.

SK-R1-EMCFLT1-F8
L1 L2 L3
PE
Source
Ground
L2
1 2 3
PE-A1
Jumper
P1 6
7
AC Line Input Fuses

R/L1
S/L2
T/L3
L1
1
2
1 2 3
1 2 3
11
12
AC Line Input Fuses: 400/480V

FU1, FU2, FU3
Frame 8 690/700 V 1000A
Spare Part Cat. No.
SK-R1-FUSE1-CD-F8
Three
Phase
AC
Input
1 2 3
TB2-4
EMC
Filter
Board
5 9
P3
Door Fan Power - Switched 240V Hot
Door Fan Power - Switched 240V Neutral
DISCONNECTED
5
P2
24V COM
Ground
User
Provided
Cab. Cab.
Door Door
Fan 1 Fan 2
209
Appendix A
Schematics
Inverter Circuit Board Schematic Diagram

PF755 Frame 8 Inverter Control
Power Layer
Interface Board
Direct Screw
Connection
Spare Part Cat. No.

SK-R1-PINT1-F8
Inverter Ribbon
Cable Spare
Part Cat. No.
SK-R1-ICBL1-F8
J7
Gate Board U
Fiber-Optic Cable (1 Per)

Spare Part Cat. No.
20-750-FCBL1-F8
J6
Backplane Board
J1
J1
Fiber-Optic Cable To P1
on Fiber Interface Board
in Control POD
P1
J6
J7
Fiber-Optic Cable To P3
on Converter Gate Board
P3
Fiber-Optic Transceiver
(1 Per)
Spare Part Cat. No.
SK-R1-FTR-F8
J2
Spare Part Cat. No.

SK-R1-IB1-F8
J5
J3
J4
P5
P3
P4
Direct Screw
Connection
J2
Direct Screw
Connection
(3 places)
Direct Screw
Connection
(5 places)
Spare Part Cat. No.

Current
SK-R1-PC1-F8
Feedback
J1
Gate Board V
J2
Direct Screw
Connection
(3 places)
J1
Gate Board W
J2
Gate Board (1 Per)

Spare Part Cat. Nos.
400V 770A, 480V 740A
SK-R1-IG1-C770D740
400V 567A, 480V 545A
SK-R1-IG1-C567D545
P1
P8
Rating Plug Spare Part
Cat. Nos.
400V 770A, 480V 740A
SK-R1-IR1-C770D740
400V 750A, 480V 710A
SK-R1-IR1-C750D710
400V 650A, 480V 617A
SK-R1-IR1-C650D617
400V 567A, 480V 544A
SK-R1-IR1-C567D545
400V 540A, 480V 485A
SK-R1-IR1-C540D485
400V 460A, 480V 430A
SK-R1-IR1-C460D430
240V HOT
240V NEUTRAL
GROUND
24V
24V COM
TB1-5
TB1-4
TB1-3
TB1-2
TB1-1
To Converter
Gate Board TB1
P2
To Heatsink Fan &

Capacitor Bank
Cooling Fan1 & Fan2
To CT1, CT2 & CT3
Rating Plug
Direct Screw
Connection
(3 places)
Heatsink Fan
Spare Part Cat. No.
SK-R1-FAN1-F8
Power Supply Board

J3
J4
Direct Screw
Connection
(3 places)
400/480V
Spare Part Cat. No.
SK-R1-PWRS1-CD-F8 J2
Cap. Bank Cooling Fans

Spare Part Cat. No.
SK-R1-FAN2-F8
J1
5 31
Disconnected Connected
Removable at
Customer Accessible
CM Cap Jumper
Location
PE-B
+DC
PE-B
J4
No
Connection
-DC
Disconnected
Cat. No. Position 11 setting A =
Disconnected with jumper plugged in at J4
210
1
2
P6 3
4
5
Power Control Board
to -DC BUS
to DC BUS MID
to +DC BUS
+DC
PE-B
J3
PE-B (DC Bus

Common Mode Caps)
Power Jumper
Default Configurations
-DC
Connected
Cat. No. Position 11 setting J =
Connected with jumper plugged in at J3
DC-
DC+
POUT
NOUT
EMC
Caps
NIN
PIN
EMC
Caps

C
Capacitor Bank
+DC BUS
Capacitor Bank
400V 770A, 480V 740A
SK-R1-CP1-C770D740
400V 567A, 480V 545A
SK-R1-CP1-C567D545
2.6k = 480V
5.0k = 690V
2.6k = 480V
5.0k = 690V
Balance
Resistors
Bal. Resistors
Spare Part Cat. No.
SK-R1-RB1-CD-F8
To J1 on
Inverter
Switch Mode
Power Supply
Board
-DC BUS
Bleeder
Resistors
Bleeder Resistors
Spare Part Cat. No.
SK-R1-RD1-F8
DC+ Test Point
DC- Test Point
DC
Link
Choke
L1
DC Link Choke
33uH = SK-R1-DCCHK1-F8
50uH = SK-R1-DCCHK2-F8
DC BUS MID
4 3 12
8
Screw
Connection
to Gate Driver
Board
NTC
M
+
4 3 12
Screw
Connection
to Gate Driver
Board
NTC
Inverter Modules
CT1
U/M1
Inverter Modules
400V 770A, 480V 740A
SK-R1-IT1-C770D740
400V, 567A, 480V 545A
SK-R1-IT1-C567D545
Current Sensor (1 Per)

Spare Part Cat. No.
SK-R1-INVIFB1-F8
Spare Part Cat. No.

20-750-EMCCM1-F8
Common Mode
Core (Option)
Motor
Ground
ISENSE
Motor Shield
ISENSE
M
+
4 3 12
Screw
Connection
to Gate Driver
Board
NTC
CT2
V/M2
M
+
To P1 on
Inverter
Power
Board
EMC
Caps
CT3
W/M3
DC-
DC+
Three Phase
AC Output
ISENSE
Chassis PE
Schematics
Appendix A
Inverter Power Layer Schematic Diagram
211
Appendix A
Schematics
Control Transformer Schematic Diagram

50/
60 Hz
H1
X2
380 / 415V
H2
440 / 480V
575 / 600V
690V
H3
H4
H5
212
240V
X1
Appendix
Circuit Board Interconnections
Introduction
This chapter provides the interconnection signals between drive circuit boards.
Topic
Page
Inverter Board Interconnections Diagram 1
214
215
Control Board Interconnections Diagram 1
216
217
213
Appendix B

J6
Power
Layer
Interface
Board
A1
B1
A2
B2,B3
A3
A1
B1
A2
B2,B3
A3
A4
B4,B5
A5
+12V
DGND
+12V
A4
B4,B5
A5
A6
B6,B7
A7
+12V
DGND
+12V
A6
B6,B7
A7
A8
B8,B9
A9
+I2V
DGND
-12V
A8
B8,B9
A9
A10
B10,B11
A11
-12V
DGND
-12V
A10
B10,B11
A11
A12
B12
A13
B13
A14
B14
A15
B15
EEGND
EE3.3V
EE SK
EEGND
EE D1
EE DOUT
EEGND
EE CS
A16
B16
A17
B17
A18,A19
B18
B19
A20,A21
B20
B21
A22,A23
B22
B23
A24,A25
B24
B25
A26,A27
B26
B27
A28
B28
A29
B29
A30
B30
A31
B31
A32,B32
214
ISO 24V COM

ISO 24V
+12V
DGND
+12V
EEPROM
DGND
FAN CTRL
DGND
FAN 2 CTRL
DGND
TEMP FLT
GND FLT
DGND
IOC FLT
BRAKE
DGND
U NEG
U POS
DGND
V NEG
V POS
DGND
W NEG
W POS
IU GND
IU FB
IV GND
IV FB
IW GND
IW FB
IGND GND
IGND FB
DGND
A12
B12
A13
B13
A14
B14
A15
B15
A16
B16
A17
B17
A18,A19
B18
B19
A20,A21
B20
B21
A22,A23
B22
B23
A24,A25
B24
B25
A26,A27
B26
B27
A28
B28
A29
B29
A30
B30
A31
B31
A32,B32
DGND
DGND
DGND
DGND
DGND
DGND
DGND
DGND
P4
J2
P3
Power
Control
Board
A1
B1
A2
B2
A3
B3
A4
B4
A5
B5
A6
B6
A7
B7
A8
B8
A9
B9
A10
B10
A11
B11
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
+24V
-24V
+24V
-24V
+24V
-24V
A12
B12
A13
B13
A14
B14
A15
B15
A16
B16
A17
B17
A18
B18
A19
B19
A20
B20
A21
B21
A22
B22
A23
B23
A24
B24
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PS NTC
/PS 480V
BUS POS
BUS MID
BUS NEG
BUS GND
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
SYS24V
SYS24COM
A1
B2
A2
B2
A3
B3
A4
B4
A5
B5
A6
B6
A7
B7
A8
B8
A9
B9
A10
B10
A11
B11
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
+24V
-24V
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PWRCOM
PS NTC
PS ID
BUS POS
BUS MID
BUS NEG
BUS GND
A12
B12
A13
B13
A14
B14
A15
B15
A16
B16
A17
B17
A18
B18
A19
B19
A20
B20
A21
B21
A22
B22
A23
B23
A24
B24
A25
B25
A26
B26
A27
B27
A28
B28
A29
B29
A30
B30
A31
B31
A32
B32
Power
Supply
Board
Appendix B

J7
Power
Layer
Interface
Board
A1,B1
A2
B2
A3
B3
A4
B4
A5
B5
A6
B6
A7
B7
A8
B8
A9
B9
A10
B10
A11,B11
A12
B12,B13
A13
A14
B14,B15
A15
A16
B16,B17
A17
A18
B18
A19
B19
A20
B20
A21
B21
A22
B22
A23
B23
A24
B24
A25
B25
A26
B26
A27
B27,B28
A28
A29
B29,B30
A30
A31
B31,B32
A32
DGND
VBUS GND
VBUS FB
VMID GND
VMID FB
DGND
PH U NTC
PH V NTC
PH W NTC
DGND
AIR TEMP
FLOW SNSR
GATE ID U
GATE ID V
GATE ID W
DGND
SP AIN1
PWR SUP NTC
ISCALE ID
DGND
IOC U POS
DGND
IOC U NEG
IOC V POS
DGND
IOC V NEG
IOC W POS
DGND
IOC W NEG
BLWR PS UV
BULK PS UV
LOC PS UV
SYS PS UV
SYS PS OC
DGND
BLWR SPD
FAN1 SPD
FAN2 SPD
DGND
LEM PD0
LEM PD1
480/690V
RP ID0
RP ID1
RP ID2
RP ID3
DGND
SP DIO 1
DGND
SP DIO 2
SP DIO 3
DGND
SP DIO 4
SP DIO 5
DGND
SP DIO 6
A1,B1
A2
B2
A3
B3
A4
B4
A5
B5
A6
B6
A7
B7
A8
B8
A9
B9
A10
B10
A11,B11
A12
B12,B13
A13
A14
B14,B15
A15
A16
B16,B17
A17
A18
B17
A18
B19
A20
B20
A21
B21
A22
B22
A23
B23
A24
B24
A25
B25
A26
B26
A27
B27,B28
A28
A29
B29,B30
A30
A31
B31,B32
A32
P5
Power
Control
Board
A25
B25
A26
B26
A27
B27
A28
B28
A29
B29
A30
B30
A31
B31
A32
B32
GATE WGATE W+
GATE VGATE V+
GATE UGATE U+
ID COM
ID W
ID V
ID U
NTC WNTC W+
NTC VNTC V+
NTC UNTC U+
GATE WGATE W+
GATE VGATE V+
GATE UGATE U+
ID COM
ID W
-24V
PWRCOM
ID V
ID U
-24V
PWRCOM
NTC WNTC W+
-24V
PWRCOM
NTC VNTC V+
-24V
PWRCOM
NTC UNTC U+
-24V
PWR COM
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J1
Gate
Board
Cable
215
Appendix B

Internal Stirring
Fan
DPI
Mini-DIN
4,17
5,18
Shield
23
10
HIM
P12
Fiber
Interface
Board
216
1
2
3
4
5
6
7
8
CAN HI
DGND
DGND
+12V
DGND
CAN LO
+12V
DGND
+12V
DGND
SHIELD
CAN LO
CAN HI
J16
1
2
3
4
5
6
7
8
1
2
3
4
5
1,3
I_24V_RET
1,3
2,4
+I_24V
2,4
5,6
DGND
5,6
7,8
DGND
7,8
9,10
+12V
9,10
11,12
+12V
11,12
13,14
13,14
+12V
15,16
15,16
DGND
17,18
17,18
-12V
19,20
19,20
DGND
21
21
/MR_CNTR
22
22
CNTR_CLK
RxD11+
23
23
TxD11+
24
24
25
25
RxD1118
26
TxD1127,28
27,28
DGND
29
29
SPI_STS_CLK
30
30
/SPI_STS_SHFT_LD
31
31
SPI_FLT_DO
32
SPI_STS_DI
32
SPI_FLT_LATCH
33
33
34
FO_EE_CLK
34
35
SPI_FLT_CLK
35
36
FO_EE_DATA
36
37,38
DGND
37,38
39
RxD1+
39
40
TxD1+
40
41
RxD141
42
TxD142
43,44
43,44
DGND
45
45
RxD2+
46
46
TxD247
47
RxD248
48
TxD2+
49,50
49,50
DGND
51
51
RxD3+
52
52
TxD3+
53
53
RxD354
54
TxD355,56
55,56
DGND
57
57
RxD4+
58
58
TxD459
59
RxD460
60
TxD4+
61,62
61,62
DGND
RxD5+
63
63
TxD5+
64
64
RxD565
65
TxD566
66
DGND
67,68
67,68
45
MCB_TST_P3.3V_SW 45
46
46
FIB_P3.3V
47 MCB_TST_P3V3_FDBK 47
48
48
SPARE
RxD7+
39
39
40
40
TxD7+
41
41
RxD742
42
TxD7DGND
43,44
43,44
RxD8+
45
45
TxD8+
46
46
RxD847
47
TxD848
48
DGND
49,50
49,50
39
39
RxD9+
40
40
TxD9+
41
41
RxD942
42
TxD991,92
91,92
DGND
RxD10+
93
93
TxD10+
94
94
RxD1095
95
TxD1096
96
DGND
97,98
97,98
J5
J11
J4
J6
J5
Main
Control
+I_24V
I_24V _RET
DGND
+12V
DGND
-12V
DGND
SAFE VCC
/FLT STS
HLTH STS
/SAFE ENA
/HOST_ENA
SAFE VCC STS
C EVNT
/RESET
IEEE_INT
/PWRDWN
S EVNT
BUS4
BUS5
BUS6
DGND
S3DIN1
S3DOUT1
S3CLK1+
S3CLK1S3DIN2
S3DOUT2
S3CLK2+
S3CLK2DGND
S2DIN1
S2DOUT1
S2CLK1+
S2CLK1S2DIN2
S2DOUT2
S2CLK2+
S2CLK2DGND
S1DIN1
S1DOUT1
S1CLK1+
S1CLK1S1DIN2
S1DOUT2
S1CLK2+
S1CLK2SLOT0
/AUX OK
CAN HI
CAN LO
2,4
1,3
5,6
7,8,9,10
11,12
13,14
15,16
18
17
20
19
22
21
24
23
26
25
28
27
30
29
32,31
34
33
36
35
38
37
40
39
42,41
44
43
46
45
48
47
50
49
52,51
54
53
56
55
58
57
60
59
62
61
64
63
J1
J2, J3, J4
Backplane
1
2
3
4
5
6
7
Shield
I_24V_RET
+I_24V
+12V
-12V
DGND
/AUX_OK
2,4
1,3
5,6
7,8,9,10
11,12
13,14
15,16
18
17
20
19
22
21
24
23
26
25
28
27
30
29
32,31
34
33
36
35
38
37
40
39
42,41
44
43
46
45
48
47
50
49
52,51
54
53
56
55
58
57
60
59
62
61
64
63
+I_24V
I_24V_RET
DGND
+12V
DGND
-12V
DGND
SAFE VCC
/FLT STS
HLTH STS
/SAFE ENA
/HOST ENA
SAFE VCC STS
C EVNT
/RESET
IEEE_INT
/PWRDWN
S EVNT
BUS4
BUS5
BUS6
DGND
SxDIN1
SxDOUT1
SxCLK1+
SxCLK1SxDIN2
SxDOUT2
SxCLK2+
SxCLK2DGND
FDBK PA+
FDBK PAFDBK PB+
FDBK PBFDBK SA+
FDBK SAFDBK SB+
FDBK SBDGND
SLOT0
PWR_ENC_1
SLOT 1
PWR_ENC_2
MAC GND
/AUX OK
MAC VCC
MAC ID 1
MAC ID3
MAC ID 2
CAN HI
CAN LO
All faceplate plug/

header interfaces
should have TBx
reference designators
J1
Option
Modules
Appendix B

J3
Main
Control
+I_24V
I_24V _RET
DGND
+12V
DGND
-12V
DGND
SAFE VCC
/FLT STS
HLTH STS
/SAFE ENA
/HOST_ENA
SAFE VCC STS
C EVNT
/RESET
IEEE_INT
/PWRDWN
S EVNT
BUS4
BUS5
BUS6
DGND
S3DIN1
S3DOUT1
S3CLK1+
S3CLK1S3DIN2
S3DOUT2
S3CLK2+
S3CLK2DGND
S2DIN1
S2DOUT1
S2CLK1+
S2CLK1S2DIN2
S2DOUT2
S2CLK2+
S2CLK2DGND
S1DIN1
S1DOUT1
S1CLK1+
S1CLK1S1DIN2
S1DOUT2
S1CLK2+
S1CLK2SLOT0
/AUX OK
CAN HI
CAN LO
2,4
1,3
5,6
7,8,9,10
11,12
13,14
15,16
18
17
20
19
22
21
24
23
26
25
28
27
30
29
32,31
34
33
36
35
38
37
40
39
42,41
44
43
46
45
48
47
50
49
52,51
54
53
56
55
58
57
60
59
62
61
64
63
J1
J5
J2, J3, J4
Backplane
1
2
3
4
5
6
7
Shield
I_24V _RET
+I_24V
+12V
-12V
DGND
/AUX_OK
2,4
1,3
5,6
7,8,9,10
11,12
13,14
15,16
18
17
20
19
22
21
24
23
26
25
28
27
30
29
32,31
34
33
36
35
38
37
40
39
42,41
44
43
46
45
48
47
50
49
52,51
54
53
56
55
58
57
60
59
62
61
64
63
+I_24V
I_24V _RET
DGND
+12V
DGND
-12V
DGND
SAFE VCC
/FLT STS
HLTH STS
/SAFE ENA
/HOST_ENA
SAFE VCC STS
C EVNT
/RESET
IEEE_INT
/PWRDWN
S EVNT
BUS4
BUS5
BUS6
DGND
SxDIN1
SxDOUT1
SxCLK1+
SxCLK1SxDIN2
SxDOUT2
SxCLK2+
SxCLK2DGND
FDBK PA+
FDBK PAFDBK PB+
FDBK PBFDBK SA+
FDBK SAFDBK SB+
FDBK SBDGND
SLOT0
PWR_ENC_1
SLOT 1
PWR_ENC_2
MAC GND
/AUX OK
MAC VCC
MAC ID 1
MAC ID3
MAC ID 2
CAN HI
CAN LO
All faceplate plug/

header interfaces
should have TBx
reference designators
J1
Option
Modules
217
Appendix B
218
Index
Numerics
24V/240V power wire harness
install 107
remove 102
A
AC line fuse sense wire harness
install 69
remove 68
AC line fuses
install 72
remove 70
AC line wire harness
install 96
remove 95
B
backplane circuit board (inverter)
intsall 159
remove 157
board interconnections
inverter 214
bottom conduit plate (option bay)
install 202
remove 202
C
cabinet door fan (drive bay)
install 196
remove 195
capacitor balance resistors
install 141
remove 140
capacitor bank assembly (inverter)
install 140
remove 137
catalog number
control pod 35
main control board 35
common mode core assembly (inverter) 125
install 126
remove 125
control board interconnections 216
control pod 76
catalog number 35
install 37, 47
remove 37, 44
return to service position 63
rotate 61
control pod cables
install 39
remove 38
control pod components
part numbers 35
control transformer
install 112
remove 110
control transformer primary fuses
install 64
remove 64
control transformer primary wire harness
intsall 110
remove 107
control transformer secondary fuse
install 65
remove 65
converter
install 119
remove 116
converter components
part numbers 56
current sensor (converter)
install 80
remove 76
current sensor wire harness (converter) 74
install 75
remove 74
current sensors (inverter)
install 133
remove 131
D
DC bus wire harness
install 74
remove 72
DC choke
install 178
remove 176
discharge resistor assembly
install 188
remove 182
disconnect handle panel (option bay)
install 198
remove 197
door fan (option bay)
install 200
remove 199
door filter (drive bay)
install 192
remove 191
drive enclosure components
part numbers 191
duct gasket (converter)
install 119
remove 119
E
EMC capacitors
install 163
remove 160
EMC filter circuit board (converter)
install 67
remove 66
219
Index
exhaust duct (drive bay)

install 193
remove 193
F
fastener types 14
fiber interface board
install 54
remove 48
fiber-optic cable
install 41
remove 39
front cover (inverter)
install 131
remove 130
fuse
tests 32
G
gate board connection ribbon cables
(inverter)
install 145
remove 143
gate circuit board (converter)
install 115
remove 114
gate circuit board (inverter)
install 146
remove 145
gate leads
resistance measurements 32
H
heat sink gasket (converter)
install 93
remove 92
heatsink fan
inspection 28
heatsink fan assembly
install 129
remove 128
heatsink fan inlet bottom cover (inverter) 189
install 190
remove 189
heatsink fan inlet screen
inspection 28
install 127
remove 127
I
IGBT assembly (inverter)
install 176
remove 171
220
IGBT flex bus bars

install 143
remove 142
inspect
components 28
install
24V/240V power wire harness 107
AC line fuse sense wire harness 69
AC line fuses 72
AC line wire harness 96
backplane circuit board (inverter) 159
bottom conduit plate (option bay) 202
cabinet door fan (drive bay) 196
capacitor balance resistors 141
capacitor bank assembly (inverter) 140
common mode core assembly (inverter) 126
control pod 37, 47
control pod cables 39
control transformer 112
control transformer primary fuses 64
control transformer primary wire harness 110
control transformer secondary fuse 65
converter 119
current sensor (converter) 80
current sensor wire harness (converter) 75
current sensors (inverter) 133
DC bus wire harness 74
DC choke 178
discharge resistor assembly 188
disconnect handle panel (option bay) 198
door fan (option bay) 200
door filter (drive bay) 192
duct gasket (converter) 119
EMC capacitors 163
EMC filter circuit board (converter) 67
exhaust duct (drive bay) 193
fiber interface board 54
fiber-optic cable 41
front cover (inverter) 131
(inverter) 145
gate circuit board (converter) 115
gate circuit board (inverter) 146
heat sink gasket (converter) 93
heatsink fan assembly 129
heatsink fan inlet bottom cover (inverter) 190
heatsink fan inlet screen 127
IGBT assembly (inverter) 176
IGBT flex bus bars 143
internal stirring fan tray (inverter) 126
left cover (converter) 60
no DC bus wire harness 113
power control circuit board 156
power layer interface circuit board 151
power supply circuit board 153
power supply wire harness (inverter) 94
rating plug 149
right cover, no control pod (converter) 61
SCR assembly (converter) 92
side DC bus bars 171
surge suppressor 99
surge suppressor assembly 101
surge suppressor sense wire harness 97
Index
thermostat 201
top conduit plate (drive bay) 194
wire harness (inverter) 181
interconnections
control board 216
internal stirring fan tray (inverter)
install 126
remove 126
inverter board interconnections 214
inverter components
part numbers 122
L
left cover (converter)
install 60
remove 60
M
main control board
catalog number 35
install 44
part number 35
remove 42
maintenance
schedule 20
tasks 20
N
no DC bus wire harness
install 113
remove 113
O
option bay enclosure components
part numbers 197
P
part number
part numbers
control pod components 35
converter components 56
drive enclosure components 191
inverter components 122
option bay enclosure components 197
power control circuit board
install 156
remove 154
power layer interface circuit board
install 151
remove 149
power supply circuit board
install 153
remove 151
power supply wire harness (inverter)

install 94
remove 93
precautions 12
R
rating plug
install 149
remove 147
remove 74, 125, 178, 189
24V/240V power wire harness 102
AC line fuse sense wire harness 68
AC line fuses 70
AC line wire harness 95
backplane circuit board (inverter) 157
bottom conduit plate (option bay) 202
cabinet door fan (drive bay) 195
capacitor balance resistors 140
capacitor bank assembly (inverter) 137
control pod 37, 44
control pod cables 38
control transformer primary fuses 64
control transformer primary wire harness 107
control transformer secondary fuse 65
converter 116
current sensor (converter) 76
current sensors (inverter) 131
DC bus wire harness 72
DC choke 176
discharge resistor assembly 182
disconnect handle panel (option bay) 197
door fan (option bay) 199
door filter (drive bay) 191
duct gasket (converter) 119
EMC capacitors 160
EMC filter circuit board (converter) 66
exhaust duct (drive bay) 193
fiber interface board 48
fiber-optic cable 39
front cover (inverter) 130
(inverter) 143
gate circuit board (converter) 114
gate circuit board (inverter) 145
heat sink gasket (converter) 92
heatsink fan assembly 128
heatsink fan inlet screen 127
IGBT assembly (inverter) 171
IGBT flex bus bars 142
internal stirring fan tray (inverter) 126
left cover (converter) 60
no DC bus wire harness 113
power 17
power control circuit board 154
power layer interface circuit board 149
power supply circuit board 151
power supply wire harness (inverter) 93
rating plug 147
right cover, no control pod (converter) 61
SCR assembly (converter) 82
221
Index
side DC bus bars 164

surge suppressor 97
surge suppressor assembly 99
surge suppressor sense wire harness 96
thermostat 200
top conduit plate (drive bay) 194
resistance measyurements
gate leads 32
return to service position
control pod 63
right cover, no control pod (converter)
install 61
remove 61
rotate
control pod 61
S
schematic
control pod 208
converter 209
inverter circuit board 210
inverter power layer 211
SCR assembly (converter)
install 92
remove 82
SCR/diode tests 29
service tools 13
side DC bus bars
install 171
remove 164
software tools 13
222
surge suppressor
install 99
remove 97
surge suppressor assembly
install 101
remove 99
surge suppressor sense wire harness
install 97
remove 96
T
test
converter SCRs/diodes 30
fuses 32
inverter IGBTs 31
no motor (no load) 205
test without a motor (no load) 205
thermostat
install 201
remove 200
tool type and size 14
top conduit plate (drive bay)
install 194
remove 194
W
wire harness (inverter) 178
install 181
remove 178
Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.
At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and
application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the
best use of these tools.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect
support programs. For more information, contact your local distributor or Rockwell Automation representative,
or visit http://www.rockwellautomation.com/support/.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual.
You can contact Customer Support for initial help in getting your product up and running.
United States or Canada
1.440.646.3434
Outside United States or

Canada
Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html, or contact

your local Rockwell Automation representative.
New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility.
However, if your product is not functioning and needs to be returned, follow these procedures.
United States
Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain
one) to your distributor to complete the return process.
Outside United States
Please contact your local Rockwell Automation representative for the return procedure.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document,
complete this form, publication RA-DU002, available at http://www.rockwellautomation.com/literature/.
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Publication 750-TG001A-EN-P - September 2010 224

Copyright 2010 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Hardware Service Manual

PowerFlex 750-Series AC Drives

Important User Information

About this Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Main Control Board Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 42

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Converter Current Sensor Removal/Installation. . . . . . . . . . . . . . . . . . . . 76

Removing the Converter Duct Gasket . . . . . . . . . . . . . . . . . . . . . . . . . 119

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Installing the Rating Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Removing the Top Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inverter Board Interconnections Diagram 1. . . . . . . . . . . . . . . . . . . . . . . .

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

About this Publication

This manual provides a recommended preventative maintenance schedule, major

Who Should Use this

Additional drive service and software/firmware support information is available

Wiring and Grounding Guidelines for Pulse Width

Provides basic information needed to properly

Safety Guidelines for the Application,

Provides general guidelines for the application,

A Global Reference Guide for Reading Schematic

Provides a simple cross-reference of common

Guarding Against Electrostatic Damage,

Provides practices for guarding against

Product Certifications website, http://ab.com

Provides declarations of conformity, certificates,

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

PowerFlex 750-Series Drive Installation

Provides the basic steps required to install a

PowerFlex 750-Series AC Drives Programming

Provides information needed to start-up, program

PowerFlex 755 Drive Embedded EtherNet/IP

Provides information on installing, configuring,

Safe Speed Monitor Option Module for

Explains how the PowerFlex 750-Series AC drive

PowerFlex 750-Series AC Drives Technical Data,

Provides information on product features and

You can view or download publications at http://www.rockwellautomation.com/

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Before You Begin Testing, Maintenance or

Commonly Used Tools

Fastener Torque Sequences

Removing Power from the Drive

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Before You Begin Testing, Maintenance or Repairs

Class 1 LED Product

Rockwell Automation Publication 750-TG001A-EN-P - September 2010

Before You Begin Testing, Maintenance or Repairs

Commonly Used Tools

Care must be taken to ensure that tools and/or hardware components do

Allen socket wrench

Allen socket wrench extension

254 mm (10 in)

7 mm, 8 mm, 10 mm, 13 mm, 17mm, 19 mm, 22 mm

For cable terminals 1.5...240

1000A (ac, rms), signal output

ESD-protected place of work

Working surface, Floor covering, seat and ground connections

Wrist wrap, shoes, overall clothing (coat)

5 mm (0.19 in.), 6.4 mm (0.25 in.)

#15, #20, #25, #30, #40, #45

Hexagonal socket wrench