PowerFlex 750 - Man Servicio PDF

Hardware Service Manual
PowerFlex 750-Series AC Drives

Frame 8 and Larger
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, DriveExplorer, DriveTools SP, PowerFlex, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
This manual revision contains the following new and updated information.
Topic Page
Updated the Spare Part Compatibility with Series A and Series B Drives table to include a new Series B 25
Converter Unit part number.
Updated the Converter Components Identification table to reflect the addition of the stirring fan kit. 72
Updated the Converter Assembly Components Diagram 2 to reflect the addition of the stirring fan kit. 76
Added the new Converter Stirring Fan Removal/Installation procedure. 119
Updated the 24V/240V Power Wire Harness Removal/Installation procedure to include disconnecting the 120
stirring fan.
Updated the DC Input with Precharge Assembly Components Identification table to reflect the addition of 146
the stirring fan kit.
Updated the DC Input with Precharge Assembly Components Diagram 2 to reflect the addition of the 150
stirring fan kit.
Updated the 24V/120V/240V Wire Harness Removal/Installation procedure to include disconnecting the 176
stirring fan.
Added the new DC Input with Precharge Assembly Stirring Fan Removal/Installation procedure. 196
Updated the Converter Schematic Diagram (400VAC and 600VAC Classes AC Input Drive) to reflect the 373
addition of the strring fan.
Updated the DC Input with Precharge Assembly Schematic Diagram (540VDC, 650VDC, 810VDC, and 376
932VDC Classes Common DC Input Drives) to reflect the addition of the strring fan.
Rockwell Automation Publication 750-TG001E-EN-P - July 2012 3

Summary of Changes
Notes:
4 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Table of Contents
Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 1
Before You Begin Testing, General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance, or Repairs Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removing Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive Input Power Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drive Series Components Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spare Part Compatibility with Series A and Series B Drives . . . . . . 25
Firmware Version Compatibility with Series A and B Circuit
Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Series A and B Converter Components and Drive Input Power
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fastener/Tool/Torque Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fastener Torque Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 2
Periodic Maintenance Recommended Preventative Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Schedule Codes Explanations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Maintenance Of Industrial Control Equipment . . . . . . . . . . . . . . . . . . . . 34
Solid State Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 3
Component Inspection and Test Component Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Procedures Forward and Reverse Biased SCR/Diode Tests . . . . . . . . . . . . . . . . . . . . . 39
Converter Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Converter Gate Lead Resistance Measurements. . . . . . . . . . . . . . . . . . . . . 43
DC Precharge Assembly Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 4
Control Pod Component Replacement Control Pod Components Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Procedures Control Pod Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removing the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing the Control Pod Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control Pod Cables Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 51
Removing the Control Pod Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the Control Pod Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Table of Contents
Fiber-Optic Cable Removal/Installation (Frame 8). . . . . . . . . . . . . . . . . . 52

Removing the Fiber-Optic Cable (Frame 8) . . . . . . . . . . . . . . . . . . . . . 52
Installing the Fiber-Optic Cable (Frame 8). . . . . . . . . . . . . . . . . . . . . . 55
Main Control Board Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removing the Main Control Board (Control Pod in Drive
Enclosure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installing the Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control Pod Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removing the Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Installing the Control Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fiber Interface Board Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . 64
Removing the Fiber Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Installing the Fiber Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Chapter 5
Converter Component Replacement Converter Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Procedures Converter Left Cover Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 77
Removing the Converter Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Installing the Converter Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Converter Right Cover
(No Control Pod) Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Removing the Converter Right Cover (No Control Pod) . . . . . . . . 78
Installing the Converter Right Cover (No Control Pod) . . . . . . . . . 78
Control Pod Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rotating the Control Pod Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Returning the Control Pod to the Service Position . . . . . . . . . . . . . . 81
Control Transformer Primary Fuses Removal/Installation . . . . . . . . . . . 81
Removing the Control Transformer Primary Fuses (FU4
and FU5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installing the Control Transformer Primary Fuse (FU4 and FU5) 81
Control Transformer Secondary Fuse Removal/Installation. . . . . . . . . . 82
Removing the Control Transformer Secondary Fuse (FU6) . . . . . . 82
Installing the Control Transformer Secondary Fuse (FU6) . . . . . . . 82
Converter EMC Filter Circuit Board Removal/Installation . . . . . . . . . . 83
Removing the Converter EMC Filter Circuit Board . . . . . . . . . . . . . 83
Installing the Converter EMC Filter Circuit Board . . . . . . . . . . . . . . 84
AC Line Fuse Sense Wire Harness Removal/Installation . . . . . . . . . . . . 85
Removing the AC Line Fuse Sense Wire Harness. . . . . . . . . . . . . . . . 85
Installing the AC Line Fuse Sense Wire Harness . . . . . . . . . . . . . . . . 86
AC Line Fuse Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Removing the AC Line Fuses (FU1, FU2, and FU3). . . . . . . . . . . . . 87
Installing AC Line Fuse (FU1, FU2, and FU3) . . . . . . . . . . . . . . . . . . 89
DC Bus Sense Wire Harness Removal/Installation . . . . . . . . . . . . . . . . . . 89
Removing the DC Bus Sense Wire Harness . . . . . . . . . . . . . . . . . . . . . 89
Installing the DC Bus Sense Wire Harness. . . . . . . . . . . . . . . . . . . . . . 91

Table of Contents
Converter Current Sensor Wire Harness Removal/Installation . . . . . . 91

Removing the Converter Current Sensor Wire Harness . . . . . . . . . 91
Installing the Converter Current Sensor Wire Harness . . . . . . . . . . 92
Converter Current Sensor Removal/Installation. . . . . . . . . . . . . . . . . . . . 93
Removing the Converter Current Sensor . . . . . . . . . . . . . . . . . . . . . . . 93
Installing the Converter Current Sensor. . . . . . . . . . . . . . . . . . . . . . . . 97
Converter SCR Gate Wire Harness Removal/Installation . . . . . . . . . . . 97
Removing the Converter SCR Gate Wire Harness . . . . . . . . . . . . . . 97
Installing the Converter SCR Gate Wire Harness . . . . . . . . . . . . . . . 98
Converter SCR Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . 99
Removing the Converter SCR Assembly . . . . . . . . . . . . . . . . . . . . . . . 99
Installing the Converter SCR Assembly . . . . . . . . . . . . . . . . . . . . . . . 108
Converter Heat Sink Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . 108
Removing the Converter Heat Sink Gasket . . . . . . . . . . . . . . . . . . . . 108
Installing the Converter Heat Sink Gasket. . . . . . . . . . . . . . . . . . . . . 109
Inverter Power Supply Wire Harness Removal/Installation . . . . . . . . . 109
Removing the Inverter Power Supply Wire Harness . . . . . . . . . . . . 109
Installing the Inverter Power Supply Wire Harness. . . . . . . . . . . . . 110
AC Line Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . . . . 111
Removing the AC Line Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installing the AC Line Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . 112
Surge Suppressor Sense Wire Harness Removal/Installation . . . . . . . . 113
Removing the Surge Suppressor Sense Wire Harness . . . . . . . . . . . 113
Installing the Surge Suppressor Sense Wire Harness . . . . . . . . . . . . 113
Surge Suppressor Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Removing the Surge Suppressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Installing the Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Surge Suppressor Assembly Removal/Installation . . . . . . . . . . . . . . . . . . 115
Removing the Surge Suppressor Assembly . . . . . . . . . . . . . . . . . . . . . 115
Installing the Surge Suppressor Assembly . . . . . . . . . . . . . . . . . . . . . . 118
Converter Stirring Fan Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 119
Removing the Converter Stirring Fan . . . . . . . . . . . . . . . . . . . . . . . . . 119
Installing the Converter Stirring Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 120
24V/240V Power Wire Harness Removal/Installation . . . . . . . . . . . . . 120
Removing the 24V/240V Power Wire Harness . . . . . . . . . . . . . . . . 120
Installing the 24V/240V Power Wire Harness . . . . . . . . . . . . . . . . . 125
Control Transformer Primary Wire Harness Removal/Installation. . 126
Removing the Control Transformer Primary Wire Harness . . . . . 126
Installing the Control Transformer Primary Wire Harness. . . . . . 128
Control Transformer Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 128
Removing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Installing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
No DC Bus Fuse Wire Harness Removal/Installation (Frame 8 Drives
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Removing the No DC Bus Fuse Wire Harness . . . . . . . . . . . . . . . . . 131
Installing the No DC Bus Fuse Wire Harness. . . . . . . . . . . . . . . . . . 131

Table of Contents
DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger

Drives Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Removing the DC Bus Fuse Wire Harness . . . . . . . . . . . . . . . . . . . . . 132
Installing the DC Bus Fuse Wire Harness. . . . . . . . . . . . . . . . . . . . . . 133
Control Power Isolator Board 24V Wire Harness Removal/Installation
(600/690V AC Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Removing the Control Power Isolator Board 24V Wire Harness. 134
Installing the Control Power Isolator Board 24V Wire Harness . 135
Control Power Isolator Board Removal/Installation (600/690V AC
Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Removing the Control Power Isolator Board . . . . . . . . . . . . . . . . . . . 136
Installing the Control Power Isolator Board. . . . . . . . . . . . . . . . . . . . 137
Converter Gate Circuit Board Removal/Installation . . . . . . . . . . . . . . . 137
Removing the Converter Gate Circuit Board. . . . . . . . . . . . . . . . . . . 137
Installing the Converter Gate Circuit Board . . . . . . . . . . . . . . . . . . . 139
Converter Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Removing the Converter from the Inverter Assembly . . . . . . . . . . . 140
Installing the Converter on the Inverter Assembly . . . . . . . . . . . . . . 143
Converter Duct Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Removing the Converter Duct Gasket . . . . . . . . . . . . . . . . . . . . . . . . . 143
Installing the Converter Duct Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . 143
Chapter 6
DC Input with Precharge Assembly DC Input with Precharge Assembly Components Identification . . . . 146
Component Replacement Procedures DC Input with Precharge Assembly Left Cover, Top Guard and Left
Guard Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Removing the DC Input with Precharge Assembly Left Cover, Top
Guard and Left Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Installing the DC Input with Precharge Assembly Left Cover, Top
Guard and Left Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
DC Input with Precharge Assembly Right Cover (No Control Pod)
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Removing the DC Input with Precharge Assembly Right Cover (No
Control Pod). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Installing the DC Input with Precharge Assembly Right Cover (No
Control Pod). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Control Transformer Secondary Fuses Removal/Installation. . . . . . . . 152
Removing the Control Transformer Secondary Fuses (FU5
and FU6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Installing the Control Transformer Secondary Fuses (FU5
and FU6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
DC Bus Output/Sense Wire Harness Removal/Installation. . . . . . . . . 154
Removing the DC Bus Output/Sense Wire Harness . . . . . . . . . . . . 154
Installing the DC Bus Output/Sense Wire Harness. . . . . . . . . . . . . 157
Precharge Resistor Assembly Removal/Installation . . . . . . . . . . . . . . . . . 158
Removing the Precharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . 158
Installing the Precharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . . 159

Table of Contents
Precharge Resistor Jumper Wires Removal/Installation . . . . . . . . . . . . 159

Removing the Precharge Resistor Jumper Wires. . . . . . . . . . . . . . . . 159
Installing the Precharge Resistor Jumper Wires . . . . . . . . . . . . . . . . 160
DC Line Fuses and Fuse Indicators Removal/Installation. . . . . . . . . . . 160
Removing the DC Line Fuses (FU1 and FU2) and Fuse Indicators
(SW3 and SW4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Installing the DC Line Fuses (FU1 and FU2) and Fuse Indicators
(SW3 and SW4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Precharge Circuit Fuses Removal/Installation . . . . . . . . . . . . . . . . . . . . . 163
Removing the Precharge Circuit Fuses (FU3 and FU4) . . . . . . . . . 163
Installing the Precharge Circuit Fuses (FU3 and FU4). . . . . . . . . . 163
DC Bus Input Wire Harness Removal/Installation . . . . . . . . . . . . . . . . 164
Removing the DC Bus Input Wire Harness. . . . . . . . . . . . . . . . . . . . 164
Installing the DC Bus Input Wire Harness . . . . . . . . . . . . . . . . . . . . 165
Left Wall Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Removing the Left Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Installing the Left Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Molded Case Switch Wire Terminal Support Removal/Installation . 167
Removing the Molded Case Switch Wire Terminal Support . . . . 167
Installing the Molded Case Switch Wire Terminal Support . . . . . 167
24V Control Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . 168
Removing the 24V Control Wire Harness . . . . . . . . . . . . . . . . . . . . . 168
Installing 24V Control Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . 170
Molded Case Switch Control Wire Harness Removal/Installation . . 171
Removing the Molded Case Switch Control Wire Harness . . . . . 171
Installing the Molded Case Switch Control Wire Harness . . . . . . 173
Transformer Primary Wire Harness Removal/Installation. . . . . . . . . . 174
Removing the Transformer Primary Wire Harness . . . . . . . . . . . . . 174
Installing the Transformer Primary Wire Harness. . . . . . . . . . . . . . 175
24V/120V/240V Wire Harness Removal/Installation . . . . . . . . . . . . . 176
Removing the 24V/120V/240V Wire Harness. . . . . . . . . . . . . . . . . 176
Installing the 24V/120V/240V Wire Harness . . . . . . . . . . . . . . . . . 181
Disconnect Switch Jumper Wires Removal/Installation . . . . . . . . . . . . 182
Removing the Disconnect Switch Jumper Wires . . . . . . . . . . . . . . . 182
Installing the Disconnect Switch Jumper Wires . . . . . . . . . . . . . . . . 183
Disconnect Switch (SW2), Auxiliary Contact, and Handle Shaft
Removing the Disconnect Switch, Auxiliary Contact and Handle
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Installing the Disconnect Switch, Auxiliary Contact and
Handle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Disconnect Switch Handle Removal/Installation . . . . . . . . . . . . . . . . . . 184
Removing the Disconnect Switch Handle . . . . . . . . . . . . . . . . . . . . . 184
Installing the Disconnect Switch Handle . . . . . . . . . . . . . . . . . . . . . . 185
Control Transformer Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 185
Removing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Installing the Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Table of Contents
Control Power Isolator Board 24V Wire Harness Removal/Installation

(810/932V DC Input Drives Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Removing the Control Power Isolator Board 24V Wire Harness. 188
Installing the Control Power Isolator Board 24V Wire Harness . 189
Control Power Isolator Board Removal/Installation (810/932V DC
Input Drives Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Removing the Control Power Isolator Board . . . . . . . . . . . . . . . . . . . 189
Installing the Control Power Isolator Board. . . . . . . . . . . . . . . . . . . . 190
Undervoltage Delay Bracket Removal/Installation . . . . . . . . . . . . . . . . . 191
Removing the Undervoltage Delay Bracket . . . . . . . . . . . . . . . . . . . . 191
Installing the Undervoltage Delay Bracket . . . . . . . . . . . . . . . . . . . . . 193
Undervoltage Delay Wire Harness Removal/Installation . . . . . . . . . . . 194
Removing the Undervoltage Delay Wire Harness. . . . . . . . . . . . . . . 194
Installing the Undervoltage Delay Wire Harness . . . . . . . . . . . . . . . 194
Undervoltage Delay Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 195
Removing the Undervoltage Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Installing the Undervoltage Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
DC Input with Precharge Assembly Stirring Fan
Removing the DC Input with Precharge Assembly Stirring Fan. . 196
Installing the DC Input with Precharge Assembly Stirring Fan . . 197
Door Interlock Wire Harness Removal/Installation . . . . . . . . . . . . . . . . 197
Removing the Door Interlock Wire Harness . . . . . . . . . . . . . . . . . . . 197
Installing the Door Interlock Wire Harness . . . . . . . . . . . . . . . . . . . . 199
Digital I/O Wire Harness Removal/Installation . . . . . . . . . . . . . . . . . . . 199
Removing the Digital I/O Wire Harness. . . . . . . . . . . . . . . . . . . . . . . 199
Installing the Digital I/O Wire Harness . . . . . . . . . . . . . . . . . . . . . . . 200
DC Precharge Control Circuit Board Removal/Installation. . . . . . . . . 201
Removing the DC Precharge Control Circuit Board . . . . . . . . . . . . 201
Installing the DC Precharge Control Circuit Board. . . . . . . . . . . . . 202
DC Input with Precharge Assembly Removal/Installation . . . . . . . . . . 203
Removing the DC Input with Precharge Assembly . . . . . . . . . . . . . 203
Installing the DC Input with Precharge Assembly . . . . . . . . . . . . . . 206
DC Input with Precharge Assembly Duct Gasket Replacement. . . . . . 206
Removing the DC Input with Precharge Assembly Duct Gasket . 206
Installing the DC Input with Precharge Assembly Duct Gasket . . 206
Chapter 7
Inverter Component Replacement Inverter Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Procedures Common Mode Core Assembly Removal/Installation. . . . . . . . . . . . . . 215
Removing the Common Mode Core Assembly . . . . . . . . . . . . . . . . . 215
Installing the Common Mode Core Assembly. . . . . . . . . . . . . . . . . . 215
Internal Stirring Fan Tray Removal/Installation . . . . . . . . . . . . . . . . . . . 216
Removing the Internal Stirring Fan Tray . . . . . . . . . . . . . . . . . . . . . . 216
Installing the Internal Stirring Fan Tray . . . . . . . . . . . . . . . . . . . . . . . 216

Table of Contents
Heatsink Fan Inlet Screen Removal/Installation . . . . . . . . . . . . . . . . . . . 217

Removing the Heatsink Fan Inlet Screen . . . . . . . . . . . . . . . . . . . . . . 217
Installing the Heatsink Fan Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . 217
Heatsink Fan Assembly Removal/Installation . . . . . . . . . . . . . . . . . . . . . 218
Removing the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . 218
Installing the Heatsink Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 219
Inverter Circuit Board Connections Cover Removal/Installation . . . 220
Remove the Inverter Circuit Board Connections Cover . . . . . . . . 220
Install the Inverter Circuit Board Connections Cover . . . . . . . . . . 220
Inverter Front Cover Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 221
Removing the Inverter Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Installing the Inverter Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Inverter Current Sensors Removal/Installation . . . . . . . . . . . . . . . . . . . . 222
Removing the Inverter Current Sensors . . . . . . . . . . . . . . . . . . . . . . . 222
Installing the Inverter Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . 224
Inverter Current Sensor Wire Harness Removal/Installation . . . . . . . 225
Removing the Inverter Current Sensor Wire Harness . . . . . . . . . . 225
Installing the Inverter Current Sensor Wire Harness . . . . . . . . . . . 227
Inverter Capacitor Bank Assembly Removal/Installation . . . . . . . . . . . 228
Removing the Inverter Capacitor Bank Assembly . . . . . . . . . . . . . . 228
Installing the Inverter Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . 230
Capacitor Balance Resistor Assembly Removal/Installation. . . . . . . . . 230
Removing the Capacitor Balance Resistor Assembly . . . . . . . . . . . . 230
Installing the Capacitor Balance Resistors . . . . . . . . . . . . . . . . . . . . . 231
IGBT Flex Bus Bars Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . 232
Removing the IGBT Flex Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Installing the IGBT Flex Bus Bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Inverter Gate Board Connection Ribbon Cables
Removing the Inverter Gate Board Connection Ribbon Cables . 233
Installing the Inverter Gate Board Connection Ribbon Cables . . 235
Inverter Gate Circuit Board Removal/Installation . . . . . . . . . . . . . . . . . 235
Removing the Inverter Gate Circuit Board . . . . . . . . . . . . . . . . . . . . 235
Installing the Inverter Gate Circuit Board . . . . . . . . . . . . . . . . . . . . . 236
Rating Plug Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Removing the Rating Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Installing the Rating Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Power Layer Interface Circuit Board Removal/Installation . . . . . . . . . 238
Removing the Power Layer Interface Circuit Board . . . . . . . . . . . . 238
Installing the Power Layer Interface Circuit Board . . . . . . . . . . . . . 240
Power Supply Circuit Board Removal/Installation . . . . . . . . . . . . . . . . . 240
Removing the Power Supply Circuit Board . . . . . . . . . . . . . . . . . . . . 240
Installing the Power Supply Circuit Board . . . . . . . . . . . . . . . . . . . . . 243
Power Control Circuit Board Removal/Installation. . . . . . . . . . . . . . . . 244
Removing the Power Control Circuit Board . . . . . . . . . . . . . . . . . . . 244
Installing the Power Control Circuit Board. . . . . . . . . . . . . . . . . . . . 246

Table of Contents
Inverter Backplane Circuit Board Removal/Installation . . . . . . . . . . . . 247

Removing the Inverter Backplane Circuit Board. . . . . . . . . . . . . . . . 247
Installing the Inverter Backplane Circuit Board . . . . . . . . . . . . . . . . 249
Inverter EMC Capacitor Removal/Installation (AC Input
Drive Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Removing the Inverter EMC Capacitors (AC Input Drive Only) 250
Installing the Inverter EMC Capacitors (AC Input Drive Only) . 253
Inverter Side DC Bus Bar Removal/Installation (AC Input
Drive Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Removing the Inverter Side DC Bus Bars (AC Input
Drive Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Installing the Inverter Side DC Bus Bars (AC Input Drive Only) 261
Inverter Top DC Bus Bar Removal/Installation (Common DC Input
Drive Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Removing the Inverter Top DC Bus Bars (Common DC Input Drive
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Installing the Inverter Top DC Bus Bars (Common DC Input Drive
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Inverter IGBT Assembly Removal/Installation (AC Input
Drive Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Removing the Inverter IGBT Assembly (AC Input Drive Only) . 267
Installing the Inverter IGBT Assembly (AC Input Drive Only). . 272
Inverter IGBT Assembly Removal/Installation (Common DC Input
Drive Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Removing the Inverter IGBT Assembly (Common DC Input Drive
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Installing the Inverter IGBT Assembly (Common DC Input Drive
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Inverter IGBT Assembly Heatsink Gasket Replacement . . . . . . . . . . . . 276
Removing the Inverter IGBT Assembly Heatsink Gasket . . . . . . . 276
Installing the Inverter IGBT Assembly Heatsink Gasket . . . . . . . . 276
DC Choke Removal/Installation (AC Input Drives Only). . . . . . . . . . 278
Removing the DC Choke (AC Input Drives Only) . . . . . . . . . . . . . 278
Installing the DC Choke (AC Input Drives Only). . . . . . . . . . . . . . 280
Inverter Wire Harness Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . 280
Removing the Inverter Wire Harness. . . . . . . . . . . . . . . . . . . . . . . . . . 280
Installing the Inverter Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Discharge Resistor Assembly Removal/Installation . . . . . . . . . . . . . . . . . 284
Removing the Discharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . 284
Installing the Discharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . . 290
Inverter Heatsink Fan Inlet Bottom Cover Removal/Installation. . . . 291
Removing the Inverter Heatsink Fan Inlet Bottom Cover . . . . . . . 291
Installing the Inverter Heatsink Fan Inlet Bottom Cover. . . . . . . . 292
Inlet Bottom Cover Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Removing the Inlet Bottom Cover Gasket . . . . . . . . . . . . . . . . . . . . . 292
Installing the Inlet Bottom Cover Gasket . . . . . . . . . . . . . . . . . . . . . . 292

Table of Contents
Chapter 8
AC Input Drive Enclosure Component AC Input Drive Enclosure Components Identification. . . . . . . . . . . . . 293
Replacement Procedures IP20, NEMA/UL Type 1 Door Filter Removal/Installation . . . . . . . . 294
Removing the Door Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Installing the Door Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Exhaust Duct Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Removing the Exhaust Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Installing the Exhaust Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Top Conduit Plate Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 296
Removing the Top Conduit Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Installing the Top Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Enclosure Door Fan Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 297
Removing the Enclosure Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Installing the Enclosure Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Enclosure Door Fan Harness Removal/Installation . . . . . . . . . . . . . . . . 298
Removing the Enclosure Door Fan Wire Harness . . . . . . . . . . . . . . 298
Installing the Enclosure Door Fan Wire Harness . . . . . . . . . . . . . . . 300
DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger
Drives Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Removing the DC Bus Fuse Wire Harness. . . . . . . . . . . . . . . . . . . . . 301
Installing the DC Bus Fuse Wire Harness . . . . . . . . . . . . . . . . . . . . . 302
DC Bus Fuses and Fuse Indicators Removal/Installation (Frame 9 and
Larger Drives Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Removing the DC Bus Fuses and Fuse Indicators. . . . . . . . . . . . . . . 303
Installing the DC Bus Fuses and Fuse Indicators . . . . . . . . . . . . . . . 305
Input Common Mode Core Removal/Installation (Frame 9 and Larger
Drives Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Removing the Input Common Mode Core . . . . . . . . . . . . . . . . . . . . 306
Installing the Input Common Mode Core . . . . . . . . . . . . . . . . . . . . . 308
Cabinet L Bus Bar(s) Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 309
Removing the Cabinet L Bus Bar(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Installing the Cabinet L Bus Bar(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Cabinet Door EMC Shield Removal/Installation (Frame 10
Drives Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Removing the Cabinet Door EMC Shield . . . . . . . . . . . . . . . . . . . . . 310
Installing the Cabinet Door EMC Shield . . . . . . . . . . . . . . . . . . . . . . 312
Chapter 9
Common DC Input Drive Enclosure Common DC Input Drive Enclosure Components Identification. . . 313
Component Replacement Procedures Enclosure Door Fan Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 314
Removing the Enclosure Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Installing the Enclosure Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Enclosure Door Fan Wire Harness Removal/Installation . . . . . . . . . . . 315
Removing the Enclosure Door Fan Wire Harness . . . . . . . . . . . . . . 315
Installing the Enclosure Door Fan Wire Harness . . . . . . . . . . . . . . . 317

Table of Contents
DC Back Bus Guards Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 317

Removing the DC Back Bus Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Installing the DC Back Bus Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
120/240V Control Power Input Wire Harness Removal/Installation 319
Removing the 120/240V Control Power Input Wire Harness . . . 319
Installing the 120/240V Control Power Input Wire Harness. . . . 320
120/240V Control Power Output Wire Harness
Removing the 120/240V Control Power Output Wire Harness . 320
Installing the 120/240V Control Power Output Wire Harness . . 321
120/240V Circuit Breaker Removal/Installation. . . . . . . . . . . . . . . . . . . 321
Removing the 120/240V Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . 321
Installing the 120/240V Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . 322
120V UPS Power Input Wire Harness Removal/Installation. . . . . . . . 323
Removing the 120V UPS Power Input Wire Harness . . . . . . . . . . . 323
Installing the 120V UPS Power Input Wire Harness. . . . . . . . . . . . 324
Input Common Mode Core Removal/Installation (Common DC Input
Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Removing the Input Common Mode Core . . . . . . . . . . . . . . . . . . . . 324
Installing the Input Common Mode Core . . . . . . . . . . . . . . . . . . . . . 325
Chapter 10
Option Bay Enclosure Component Option Bay Enclosure Components identification . . . . . . . . . . . . . . . . . 327
Replacement Procedures Disconnect Handle Panel Removal/Installation. . . . . . . . . . . . . . . . . . . . 328
Removing the Disconnect Handle Panel . . . . . . . . . . . . . . . . . . . . . . . 328
Installing the Disconnect Handle Panel. . . . . . . . . . . . . . . . . . . . . . . . 328
Door Fan Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Removing the Door Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Installing the Door Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Thermostat Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Removing the Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Installing the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Bottom Conduit Plate Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . 332
Removing the Bottom Conduit Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 332
Installing the Bottom Conduit Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Chapter 11
Enclosure Cable Components Enclosure Cable Components and Part Numbers . . . . . . . . . . . . . . . . . . 333
Replacement Procedures (Frame 9 24V Wire Harness Removal/Installation (Frame 9 and Larger
Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
and Larger Drives)
Removing the 24V Wire Harness (Frame 9 and Larger Drives) . . 334
Installing the 24V Wire Harness (Frame 9 and Larger Drives) . . . 337
First Inverter (INV1) Fiber-optic Cable Removal/Installation . . . . . . 338
Removing the First Inverter (INV1) Fiber-optic Cable. . . . . . . . . . 338
Installing the First Inverter (INV1) Fiber-optic Cable . . . . . . . . . . 341

Table of Contents
Second Inverter (INV2) Fiber-optic Cable Removal/Installation. . . . 342

Removing the Second Inverter (INV2) Fiber-optic Cable . . . . . . . 342
Installing the Second Inverter (INV2) Fiber-optic Cable. . . . . . . . 346
Third Inverter (INV3) Fiber-optic Cable Removal/Installation . . . . . 347
Removing the Third Inverter (INV3) Fiber-optic Cable . . . . . . . . 347
Installing the Third Inverter (INV3) Fiber-optic Cable . . . . . . . . . 351
Fiber-optic Spool Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Removing the Fiber-optic Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Installing the Fiber-optic Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Chapter 12
IP54, NEMA/UL Type 12 Enclosure IP54, NEMA/UL Type 12 Enclosure Components and Part
Components Replacement Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Cabinet Blower Harness Removal/Installation . . . . . . . . . . . . . . . . . . . . 354
Procedures
Removing the Cabinet Blower Harness. . . . . . . . . . . . . . . . . . . . . . . . 354
Installing the Cabinet Blower Harness . . . . . . . . . . . . . . . . . . . . . . . . 355
Cabinet Blower Exhaust Filters Removal/Installation . . . . . . . . . . . . . . 355
Removing the Cabinet Blower Exhaust Filters . . . . . . . . . . . . . . . . . 355
Installing the Cabinet Blower Exhaust Filters . . . . . . . . . . . . . . . . . . 356
Cabinet Door Filters Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 356
Removing the Cabinet Door Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Installing the Cabinet Door Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Cabinet Door Filter Cassette Removal/Installation . . . . . . . . . . . . . . . . 358
Removing the Cabinet Door Filter Cassette . . . . . . . . . . . . . . . . . . . 358
Installing the Cabinet Door Filter Cassette . . . . . . . . . . . . . . . . . . . . 358
Cabinet Door Gasket Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . 359
Removing the Cabinet Door Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Installing the Cabinet Door Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Chapter 13
Start-Up After Repairs Before Applying Power to the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Testing With the Motor Without a Mechanical Load . . . . . . . . . . . . . . 363
Appendix A
Schematics Frame 8 AC Input Drive Schematic Diagram (400VAC and 600VAC
Classes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Frame 9 AC Input Drive Schematic Diagram (400VAC and 600VAC
Classes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Frame 10 AC Input Drive Schematic Diagram (400VAC and 600VAC
Classes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Frame 8 Common DC Input Drive Schematic Diagram (540VDC,
650VDC, 810VDC, and 932VDC Classes) . . . . . . . . . . . . . . . . . . . . . . . 369

Table of Contents
Control Pod Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Converter Schematic Diagram (400VAC and 600VAC Classes AC Input
Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Frame 8 Control Power Isolator Board Wiring Diagrams (600VAC Class
AC Input Drive, and 810VDC and 932VDC Classes Common DC Input
Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
DC Input with Precharge Assembly Schematic Diagram (540VDC,
650VDC, 810VDC, and 932VDC Classes Common DC Input
Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
DC Input with Precharge Devices Schematic Diagrams . . . . . . . . . . . . 377
Inverter Circuit Board Schematic Diagram (All Drive
Configurations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Inverter Power Layer Schematic Diagram (All Drive
Configurations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
AC Input Drive Control Transformer Schematic Diagram . . . . . . . . . 380
DC Input with Precharge Assembly Control Transformer Schematic
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Inverter Main Blower and Capacitor Bank Cooling Fan Wire Harness
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Cabinet Cooling Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Appendix B
Circuit Board Interconnections Inverter Board Interconnections Diagram 1 ....................... 384
Inverter Board Interconnections Diagram 2 ....................... 385
Control Board Interconnections Diagram 1 ....................... 386
Control Board Interconnections Diagram 2 ....................... 387
Appendix C
History of Changes 750-TG001D-EN-P, April 2012. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
750-TG001C-EN-P, January 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
750-TG001B-EN-P, October 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Index

Preface
This manual provides a recommended preventative maintenance schedule, major

component test and hardware replacement procedures, and schematic diagrams
for frame 8 and larger PowerFlex 750-Series AC drives. See Drive Input Power
Configurations on page 23 for more information.
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 and larger 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 Provides basic information needed to properly wire and
Modulated (PWM) AC Drives, publication DRIVES-IN001 ground PWM AC drives.
Safety Guidelines for the Application, Installation and Provides general guidelines for the application,
Maintenance of Solid State Control, publication SGI-1.1 installation, and maintenance of solid-state control.
A Global Reference Guide for Reading Schematic Provides a simple cross-reference of common schematic/
Diagrams, publication 100-2.10 wiring diagram symbols used throughout various parts of
the world.
Guarding Against Electrostatic Damage, publication 8000- Provides practices for guarding against Electrostatic
4.5.2 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- Provides the basic steps required to install a PowerFlex
IN001 750-Series AC drive.
PowerFlex 750-Series AC Drives Programming Manual, Provides information needed to start-up, program and
publication 750-PM001 troubleshoot PowerFlex 750-Series AC drives.
PowerFlex 755 Drive Embedded EtherNet/IP Adapter User Provides information on installing, configuring, and
Manual, publication 750COM-UM001 troubleshooting the Embedded EtherNet/IP Adapter for
PowerFlex 755 AC drives.
Safe Speed Monitor Option Module for PowerFlex 750- Explains how the PowerFlex 750-Series AC drive can be
Series AC Drives Safety Reference Manual, publication used in Safety Integrity Level (SIL) CL3, Performance Level
750-RM001 [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, Provides information on product features and benefits,
publication 750-TD001 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.

Chapter 1
Before You Begin Testing, Maintenance, or

Repairs
Topic Page
General Precautions 20
Removing Power from the Drive 21
Drive Input Power Configurations 23
Drive Series Components Compatibility 25
Commonly Used Tools 27
Fastener/Tool/Torque Information 28
Fastener Torque Sequences 29
This chapter provides information you should know before you begin tests,
maintenance, or repairs on drive components.

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 21 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 Quasi-differential 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.

Before You Begin Testing, Maintenance, or Repairs Chapter 1
Removing Power from the ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
Drive 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 all input power, including any and all external power
sources. For common DC input drives only, turn off input power and lock
the drive disconnect switch SW2 and circuit breaker SW5 (if used).
ATTENTION: To avoid an electric shock hazard when servicing the drive, a

means for Lockout/Tagout of an external 120V uninterruptible power supply
and/or external 120/240V power source must be provided. Or the circuit breaker
SW5 must be locked and tagged. Locking and tagging the common bus
precharge disconnect switch SW2 alone does not provide sufficient protection
when servicing the drive.
Frame 9 Common DC Input Drive Shown

SW2
SW5

2. Wait fifteen minutes and 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.
Frame 8 AC Input Drive Shown

Drive Input Power The PowerFlex 750-Series drives discussed in this manual are available as frame 8,
9, and 10 drives with either AC or common DC input. Refer to Figure 1 and
Configurations Figure 2 on page 24 to familiarize yourself with AC versus DC input drive
configurations and the main drive sections each configuration contains.
Figure 1 - AC Input Drives
Frame 8 Frame 9
Bay 1 Bay 2
Exhaust Vent
Control Wire Way
Converter Section (left)

Control Pod and/or
Control Panel (right)
Note: Only one Control
Pod per Drive (can also
be remotely mounted).
Inverter Section
Frame 10
Bay 1 Bay 2 Bay 3
DC Choke and Main

Cooling Fan Intake
Note: Drives shown with enclosure doors removed.

Figure 2 - Common DC Input Drives
Frame 8 Frame 9
Bay 1 Bay 2
Exhaust Vent
Control Wire Way
DC Input with
Precharge Section (left)
Control Pod and/or
Control Panel (right)
Note: Only one Control
Pod per Drive (can also
be remotely mounted).
Inverter Section
Frame 10
Bay 1 Bay 2 Bay 3
Main Cooling Fan

Intake
Note: Drives shown with enclosure doors removed.

Drive Series Components Depending on the frame size, date of manufacture, and firmware version, the
drive will contain either series A or series B components. The following tables
Compatibility identify which drive components are series specific and their compatibility based
on frame size and firmware version. You must verify which frame size, component
series and firmware version your drive contains before you purchase and replace
any of the identified components to ensure that the drive operates properly after
repairs.
Spare Part Compatibility with Series A and Series B Drives

Series A and series B power core components are not compatible with each other
and cannot be combined.
All frame 8 drives manufactured before August 31, 2011 contain series A
components.
All frame 8, 9, and 10 drives manufactured after August 31, 2011 contain
series B components.
Series Specific Component Frame 8 - Series A Drives Frame 8 and 9 - Series B Drives Frame 810 - Series B Drives
Compatible Component Part No. Compatible Component Part No. Compatible Component Part No.
Converter Unit, AC Input 20-750-C1-C770D740 20-750-C2-C770D740 20-750-C3-C770D740
770 A, 400V / 740 A, 480V 20-750-C3-C770D740 20-750-C4-C770D740
20-750-C4-C770D740
Converter Unit, AC Input 20-750-C2-E510F500 20-750-C3-E510F500
510 A, 600V / 500 A, 690V 20-750-C3-E510F500 20-750-C4-E510F500
20-750-C4-E510F500
Inverter Unit, AC Input 20-750-I1-C460D430 20-750-I1B-C460-D430 20-750-I1B-C460-D430
460 A, 400V / 430 A, 480V
Inverter Unit, AC Input 20-750-I1-C540D485 20-750-I1B-C540D485 20-750-I1B-C540D485
540 A, 400V / 485 A, 480V
567 A, 400V / 545 A, 480V
650 A, 400V / 617 A, 480V
750 A, 400V / 710 A, 480V
770 A, 400V / 740 A, 480V
Converter Gate Board SK-R1-CGDB1-CD-F8 SK-R1-CGDB2-CD-F8 SK-R1-CGDB3-CD-F8
400V/480V AC Input (1)
Converter Gate Board SK-R1-CGDB2-EF-F8 SK-R1-CGDB3-EF-F8
600V/690V AC Input (1)
Inverter Power Layer Interface SK-R1-PINT1-F8 SK-R1-PINT2-F8 SK-R1-PINT2-F8
Board (2)
(1) This board is included with a replacement converter unit.
(2) This board is included with a replacement inverter unit.

Firmware Version Compatibility with Series A and B Circuit Boards
Firmware Drive Frame Converter Gate Board Inverter Power Layer Converter Gate Board Converter Gate Board Inverter Power Layer
Version Series Size SK-R1-CGDB1-CD-F8 Interface Board SK-R1-CGDB2-CD-F8 SK-R1-CGDB3-CD-F8 Interface Board
SK-R1-PINT1-F8 SK-R1-CGDB2-EF-F8 SK-R1-CGDB3-EF-F8 SK-R1-PINT2-F8
2.xxx A 8 Compatible Compatible NOT Compatible NOT Compatible NOT Compatible
3.xxx or higher B 8 and 9 NOT Compatible NOT Compatible Compatible Compatible Compatible
6.xxx B 10 NOT Compatible NOT Compatible NOT Compatible Compatible Compatible
Series A and B Converter Components and Drive Input Power

Compatibility
Series Specific Component Compatible with 400/480VAC Compatible with 600/690VAC
Input Drives Input Drives
Converter EMC Filter Board Yes No
SK-R1-EMCFLT1-F8 (Series A)
Converter EMC Filter Board Yes Yes
SK-R1-EMCFLT2-F8 (Series B)
Converter Current Sensor Yes No
SK-R1-CNVIFB1-F8 (Series A)
Converter Current Sensor Yes Yes
SK-R1-CNVIFB2-F8 (Series B)

Commonly Used Tools 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 (with long extension)
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 3 mm (0.12 in.), 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 2.5 mm, 7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 17 mm, 18 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 drive
assembly 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. DriveTools SP version 5.3 and
DriveExplorer version 6.3 are required for use with PowerFlex 750-Series Frame 8
and larger drives. For more information on Drives Application Software, visit:
http://www.ab.com/drives/drvappsw/

Fastener/Tool/Torque The disassembly illustrations in the following chapters identify the type of
fastener, tool, and tightening torque used for disassembly/assembly of
Information components in the drive.
Fastener/Tool/Torque Information:
T20 or F - 6.4 mm (0.25 in.) Tool Type and Size:

1.8 Nm (16 lbin) F Flat nose screw driver
Px Phillips screw driver/bit and size
PZx POZIDRIV screw driver/bit and size
Tightening Torque Txx Hexalobular screw driver/bit and size
xx mm Hexagonal socket wrench
Fastener Type:
Flat head screw
Hexagonal bolt
Hexagonal nut or standoff
Hexagonal screw
Hexalobular head screw
Phillips head screw (1)
POZIRIV head screw (1)
Slotted Hexalobular head screw
(1) Phillips and POZIDRIV are registered trademarks of the Phillips Screw Company.

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 3 - Two-Point Mounting
1 2
1 2
Initial Sequence
2 1
Final Sequence
Figure 4 - Four-Point Mounting
1 3
4 2
1 2 3 4
Initial Sequence
4 3 2 1
Final Sequence

Figure 5 - Six-Point Mounting
6 2 4
3 1 5
1 2 3 4 5 6
Initial Sequence
Do not exceed 0.7 Nm (6 lbin) on initial torque of all six screws.
1 2 3 4 5 6
Final Sequence

Chapter 2
Periodic Maintenance
Topic Page
Recommended Preventative Maintenance Below
Maintenance Of Industrial Control Equipment 34
This chapter provides information on performing preventative maintenance on

drive components that can affect the life and operability of the drive.
Recommended Preventative Rockwell recognizes that following a defined maintenance schedule will deliver
the maximum product availability. By rigorously following the maintenance
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 on
page 37 for additional information on performing these procedures and tests.
The recommended maintenance tasks and schedule are contained in Table 1 on

page 32. Refer to Schedule Codes Explanations on page 33 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.

Chapter 2 Periodic Maintenance
Table 1 - Recommended Maintenance Tasks and Schedule

Years 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Components and Activities
Air-Cooling Door-mounted Air
C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R
System Filters (1)
Roof-mounted
Assembly Air Filters 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
(1)
Main Heatsink
I I I I R I I I I R I I I I R I I I I R
Cooling Fan Motor(s)
Door-mounted I I I I R I I I I R I I I I R I I I I R
Cooling Fans
Capacitor Bank
Cooling Fans I I I I R I I I I R I I I I R I I I I R
Power Switching Power Devices

I I I I I I I I I I I R I I I I I I I I
Components (IGBTs/SCRs)
Electrolytic Bus I I I I R I I I I R I I I I R I I I I R
Capacitors
Capacitor Balance
Resistors I I I I R I I I I R I I I I R I I I I R
Power Supply Circuit RFB RFB RFB RFB

Board I I I I I I I I I I I I I I I I
/R /R /R /R
Precharge Resistors
(Common DC Input I I I I I I I I I R I I I I I I I I I R
Only)
Molded Case Switch
Only)
Undervoltage Delay
Only)
Integral Isolation
Magnetics/ Transformer/Line I I I I M I I I I M I I I I M I I I I M
Power Filters Reactor
DC Link/Common-
I I I I M I I I I M I I I I M I I I I M
Mode Choke
Control Pod AC/DC and DC/DC I I I I RFB I I I I RFB I I I I RFB I I I I RFB
Components Power Supplies /R /R /R /R
Control Boards I I I I I I I I I I I I I I I I I I I I
Batteries (DCBs and I I R I I R I I R I I R I I R I I R I I
CIB)
Fiber-Optic Cables I I I I R I I I I R I I I I R I I I I R
Enhancements Firmware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Hardware - - Rv - - Rv - - Rv - - Rv - - Rv - - Rv - -
Operational Parameters I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Conditions
Variables I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Application I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
Concerns
Spare Parts Inventory/Needs I I Rv I I Rv I I Rv I I Rv I I Rv I I Rv I I
(1) Inspect and replace filters every three months, depending on the environment.

Periodic Maintenance 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.

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.
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

Periodic Maintenance Chapter 2
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.
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.
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.
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.
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 Allen-
Bradley 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.

Chapter 3
Component Inspection and Test Procedures
Topic Page
Component Inspection and Maintenance 38
Forward and Reverse Biased SCR/Diode Tests 39
Converter Fuse Tests 43
Converter Gate Lead Resistance Measurements 43
DC Precharge Assembly Fuse Tests 45
This chapter provides details on inspecting and testing the major components of
the drive and includes recommendations for repairs.

Chapter 3 Component Inspection and Test Procedures
Component Inspection and Visually inspect the door filters, heatsink fan inlet screen and major components
on the control pod, converter or DC input with precharge assembly, and inverter
Maintenance 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 31.
1. Review the General Precautions on page 20.

2. Remove power from the drive. See Removing Power from the Drive on
page 21.
3. Inspect the door fans for blockage and verify free rotation. Clean or
replace as necessary.
For AC input drives, see Enclosure Door Fan Removal/Installation on
page 297.
For common DC input drives, see Enclosure Door Fan Removal/
Installation on page 314.
For option bays, see Door Fan Removal/Installation on page 329.
4. Remove the filter(s) from the enclosure door(s) and inspect for blockage.
For IP54, NEMA/UL Type 12 enclosures, remove the filters from the
cabinet blower and inspect for blockage. Clean or replace all filters as
necessary. See IP20, NEMA/UL Type 1 Door Filter Removal/Installation
on page 294, and/or Cabinet Blower Exhaust Filters Removal/Installation
on page 355 and Cabinet Door Filters Removal/Installation on page 356.
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 218.
8. Remove the protective covers from the control pod, converter or DC input
with precharge assembly, and inverter assemblies. See Control Pod Cover
Removal/Installation on page 50, Converter Left Cover Removal/
Installation on page 77 or DC Input with Precharge Assembly Left Cover,
Top Guard and Left Guard Removal/Installation on page 151, and
Inverter Front Cover Removal/Installation on page 221.
9. Check all visible major components on the control pod, converter or DC
input with precharge assembly, and inverter assemblies and replace any of
these components without further testing if they show evidence of burn
marks or breakage.

Component Inspection and Test Procedures Chapter 3
10. Check all visible circuit boards, wires and connectors on the control pod,
converter or DC input with precharge assembly, 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. Refer to the PowerFlex 750-
Series AC Drive Installation Instructions, publication number 750-IN001.
For instructions on removing the converter, refer to Converter Removal/
Forward and Reverse Biased This section contains procedures for performing forward and reverse biased
SCR/diode tests on the major power components of the drive. A failed test
SCR/Diode Tests 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 21.
3. Open the drive enclosure door.
4. Remove the control transformer primary fuses (FU4 and FU5). See
Removing the Control Transformer Primary Fuses (FU4 and FU5) on
page 81.

5. Remove the connection bolts from the output power terminals (U, V, W)
and set them aside.
6. 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.
Figure 6 - Power Terminal Connections
All terminals: T40

M8 x 30 machine screws 11.3 Nm (100.0 lbin)
DC Bus Connections
between Converter and
Inverter
AC Input Terminals:
R/L1
S/L2
T/L3
DC- DC+
DC Bus Terminals:
DC+
DC-
Output Power Terminals:

U

7. Complete the forward biased SCR/diode tests on the converter assembly

using Table 2 below.
Table 2 - Forward Biased SCR/Diode Tests on the Converter SCR Assembly

Meter Leads
+ Nominal Meter Reading
DC+ R/L1
DC+ S/L2 Meter should display .0L (open circuit) (1)
DC+ T/L3
R/L1 DC-
The value should gradually rise to between 0.20V and 0.75V. If the value is outside this range,
S/L2 DC- contact Technical Support. (2)
T/L3 DC-
(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.
8. If performing the Reverse Biased Diode Tests on the Converter SCR

Assembly identified in Table 3 below, remove the connection bolts from
the DC bus terminals (DC-, DC+) between the converter and inverter
assemblies and set them aside. See Figure 6 on page 40 for terminal
locations.
9. Insert an appropriate insulation material between the DC bus terminals
(DC-, DC+) between the converter and inverter. In order to receive
accurate readings for these tests, the terminals must not make contact.
10. Complete the reverse biased SCR/diode tests on the converter using the
table below.
Table 3 - Reverse Biased Diode Tests on the Converter SCR Assembly

Meter Leads
R/L1 DC-
S/L2 DC-
T/L3 DC-
Meter should display .0L (open circuit) (1)
DC+ R/L1
DC+ S/L2
DC+ T/L3
minutes to occur.
11. Replace the converter SCR assembly if it fails these measurements. See
Converter SCR Assembly Removal/Installation on page 99.

12. Install the control transformer primary fuses (FU4 and FU5). See
Installing the Control Transformer Primary Fuse (FU4 and FU5) on page
81.
13. 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- U
DC- V
DC- W The value should gradually rise to between 0.20V and 0.75V. If the value is outside this range,
U DC+ contact Technical Support. (1)
V DC+
W DC+
(1) The actual voltage reading may vary depending upon your equipment.
Table 5 - Reverse Biased Diode Tests on the Inverter IGBT Assembly

Meter Leads
U DC-
V DC-
W DC-
Meter should display .0L (open circuit) (1)
DC+ U
DC+ V
DC+ W
minutes to occur.
14. Replace the inverter IGBT assembly if it fails these measurements. See
Inverter IGBT Assembly Removal/Installation (AC Input Drive Only) on
page 267.
15. Complete the procedures in Chapter 13 Start-Up After Repairs beginning
on page 361 before placing the drive back into service.

Converter Fuse Tests This section contains procedures for performing converter fuse tests.

page 21.
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 82.
5. Test the control transformer primary fuses (FU4 and FU5) by removing
them from the fuse holder. See Removing the Control Transformer
Primary Fuses (FU4 and FU5) on page 81.
6. Continuity test the AC line fuses (FU1, FU2, and FU3) in circuit. Replace
a fuse as necessary. See AC Line Fuse Removal/Installation on page 87.
7. Replace the control transformer primary fuses (FU4 and FU5) as
necessary. See Installing the Control Transformer Primary Fuse (FU4 and
FU5) on page 81.
Converter Gate Lead This section contains procedures for performing resistance measurements on the
gate leads for the converter.
Resistance Measurements
page 21.
4. Open the control pod to provide access to the converter gate board. See
Rotating the Control Pod Forward on page 78.

5. Disconnect the SCR gate harness J11 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 J11 harness using the table
below:
Meter Lead + Meter Lead - Nominal Meter Reading
J11-1, SCR Gate L1 J11-2, SCR Cathode L1 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-to-
end 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 99.
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 81.

DC Precharge Assembly Fuse This section contains procedures for performing fuse tests on the DC precharge
assembly.
Tests
page 21.
4. Test the control transformer 240V secondary fuse (FU5) by removing it
from the fuse holder. Replace the fuse as necessary. See Control
Transformer Secondary Fuses Removal/Installation on page 152.
5. Test the control transformer 120V secondary fuse (FU6) by removing it
from the fuse holder. Replace the fuse as necessary. See Control
Transformer Secondary Fuses Removal/Installation on page 152.
6. Test the DC line fuses (FU1 and FU2) in circuit. Replace a fuse as
necessary. See DC Line Fuses and Fuse Indicators Removal/Installation on
page 160.
7. Test the DC precharge fuses (FU3 and FU4) in circuit. Replace a fuse as
necessary. See Precharge Circuit Fuses Removal/Installation on page 163.

Notes:

Chapter 4
Control Pod Component Replacement

Procedures
Topic Page
Control Pod Components Identification 48
Control Pod Cover Removal/Installation 50
Control Pod Cables Removal/Installation 51
Fiber-Optic Cable Removal/Installation (Frame 8) 52
Main Control Board Removal/Installation 56
Fiber Interface Board Removal/Installation 64
This chapter provides detailed procedures for removing and replacing control
pod components.
IMPORTANT Complete the procedures in Chapter 13 Start-Up After Repairs beginning on

page 361 before placing the drive back into service.

Chapter 4 Control Pod Component Replacement Procedures
Control Pod Components The following table lists the components that make up the control pod and the
catalog numbers for components that are available as replacement kits and parts.
Identification Each component is identified by a number that corresponds to that part in the
illustration on the following page.
Allen-Bradley web site at:
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf
ID# Component Name Replacement Kit/Part Cat. No. Kit Qty. Figure Number
Control Pod 20-750-POD1-F8 1 Figure 7 on page 49
1 Frame 8 Main Control Board SK-R1-MCB1-F8 1 Figure 7 on page 49
2 Main Control Board Terminal Block SK-R1-TB-PF755 1 Figure 7 on page 49
3 Backplane Board SK-R1-BP1 1 Figure 7 on page 49
4 Control Pod HIM Bezel SK-R1-BZ1 1 Figure 7 on page 49
5 Fiber Interface Board SK-R1-FIB1-F8 1 Figure 7 on page 49
(Includes a fiber-optic transceiver)
6 Control Pod Cover SK-R1-CVRP1-F8 1 Figure 7 on page 49
7 Fiber Interface Board Insulator Sheet N.A. 1 Figure 7 on page 49
Remote Mount Control Pod Kit 20-750-RPD1-F8 1 See publication 750-IN015

Control Pod Component Replacement Procedures Chapter 4
Figure 7 - Control Pod Components
1
3 2

TIP Refer to Fastener/Tool/Torque Information on page 28 for descriptions of the

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

Installation
page 21.
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 50.

Control Pod Cables Removal/ Removing the Control Pod Cables

Installation
page 21.
4. Remove the control pod cover. See Control Pod Cover Removal/
5. Disconnect the drive internal 24V wire harness 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.
P12
Disconnect P15
connector from
P14 and P13
INV1 INV2 INV3

P14 P13
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 51.

Fiber-Optic Cable Removal/ Removing the Fiber-Optic Cable (Frame 8)

Installation (Frame 8)
Note: For instructions on removing the fiber-optic cables on frame 9 and larger
drives, see Chapter 11 - Enclosure Cable Components Replacement Procedures
(Frame 9 and Larger Drives) beginning on page 47.

page 21.
5. Remove the inverter circuit board connections cover from the inverter. See
Inverter Circuit Board Connections Cover Removal/Installation on page
220.

6. 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.
Fiber interface
board
P12
P15
P14 P13 INV1 INV2 INV3
J7 J6
Power layer
interface board
P2
CONV
INV

7. Disconnect the fiber-optic cable from CONV on the converter gate board
and CONV on the power layer interface board in the inverter card cage.
P13 P8 P11 P10 P9
Converter gate
board P7
P2
P6
CONV
P14
P4
P12 P1
J7 J6
Power layer
interface board
P2
CONV
INV

Installing the Fiber-Optic Cable (Frame 8)
IMPORTANT Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends
with a shorter inside radius can permanently damage the fiber-optic cable.
Signal attenuation increases with decreased inside bend radii.
Install the fiber-optic cable set in the reverse order of removal. See Removing the
Fiber-Optic Cable (Frame 8) on page 52.
IMPORTANT Frame 8 fiber-optic cables from the fiber interface board to the power layer
interface board and from the converter gate board to the power layer interface
board must be the same length. Cables are 560 mm (22 in.) long to meet this
requirement.
Install the new fiber-optic cables from the converter gate board to the
power layer interface board using the two center cable supports provided,
as shown in the illustration below.
Route fiber-optic
cables through
center cable
supports
Note: Other cables and

components not shown
for clarity only

Install the new fiber-optic cables from the fiber interface board to the
power layer interface board using the two outer cable supports provided, as
shown in the illustration below.
Route fiber-optic
cables through outer
cable supports
Note: Other cables and

components not shown
for clarity only
Main Control Board Removal/ Removing the Main Control Board (Control Pod in Drive Enclosure)
Installation
page 21.

5. Loosen the retention screw that secures the HIM cradle to the control pod
frame and swing the cradle upward until the latch engages.

6. If installed, remove the option module 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 (TB1) 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

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) on page 56.
IMPORTANT Verify that the main control board seats properly into the connectors on the
backplane and fiber interface boards when installing a new board.
Control Pod Removal/ Removing the Control Pod

Installation
page 21.
4. Remove the converter left cover. See Removing the Converter Left Cover
on page 77.
220.

7. Disconnect the J14 connector from the fiber interface board P14 terminal.
P12
P15
INV1 INV2 INV3

P14 P13
Disconnect connector from

P14 and P13

9. Disconnect the fiber-optic cable from INV on the power layer interface
board in the inverter card cage. Place the cable ends on the bottom of the
control pod, observing the minimum bend radius requriement.
Fiber interface
board
P12
P15
J7 J6
Power layer
interface board
Disconnect fiber- P2
CONV
optic cable from INV
INV

10. If installed, disconnect the plug-in terminal block (TB1) on the main
control board.
11. 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 (TB1)
from the control board
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)

12. 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 59.

Fiber Interface Board Removing the Fiber Interface Board

Removal/Installation
page 21.
5. Disconnect the J14 connector from the fiber interface board P14 terminal.
7. Disconnect the inverter fiber-optic cable from INV1 on the fiber interface
board and carefully coil the fiber-optic cable, observing the minimum
bend radius requirement, and place it in the bottom of the control pod.
P12
Disconnect fiber-optic cable and

remove transceiver from INV1
P15

P14 and P13
INV1 INV2 INV3

P14 P13

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 re-
installation.
INV1 INV2 INV3

P14 P13
9. Loosen the retention screw that secures the HIM cradle to the control pod
frame and swing the cradle upward until the latch engages.
10. Disconnect all wiring to the main control board terminal block (TB1).
11. If installed, disconnect all wiring to all option module terminal blocks.

12. If installed, remove the option module 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.

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

16. Remove the four M4 x 12 mm screws that secure the control pod chassis to
the standoffs on the control panel, then remove control pod chassis.
IMPORTANT The four M4 x 12 mm screws that secure the control pod chassis to the
control panel are not retentive. Take steps to ensure that the screws do
not fall into the drive below.
17. Remove all routed wiring and six wire anchors from the left sidewall of the
control panel and move the wiring to the outside of the control panel.
Remove wiring and six

wire anchors
Control panel
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

18. Remove the four M4 x 10 mm long screws that secure fiber interface board
to the control pod.
Insulator sheet
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)
19. 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.
20. 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.
21. Inspect the fiber interface board insulator sheet and replace it if damaged.

Installing the Fiber Interface Board
Install the fiber interface board in the reverse order of removal. See Removing the
Fiber Interface Board on page 64.
IMPORTANT The insulator sheet must be installed behind the fiber interface board.

Chapter 5
Converter Component Replacement Procedures
Topic Page
Converter Components Identification 72
Converter Left Cover Removal/Installation 77
Converter Right Cover (No Control Pod) Removal/Installation 78
Control Pod Rotation 78
Control Transformer Primary Fuses Removal/Installation 81
Control Transformer Secondary Fuse Removal/Installation 82
Converter EMC Filter Circuit Board Removal/Installation 83
AC Line Fuse Sense Wire Harness Removal/Installation 85
AC Line Fuse Removal/Installation 87
DC Bus Sense Wire Harness Removal/Installation 89
Converter Current Sensor Wire Harness Removal/Installation 91
Converter Current Sensor Removal/Installation 93
Converter SCR Gate Wire Harness Removal/Installation 97
Converter SCR Assembly Removal/Installation 99
Converter Heat Sink Gasket Replacement 108
Inverter Power Supply Wire Harness Removal/Installation 109
AC Line Wire Harness Removal/Installation 111
Surge Suppressor Sense Wire Harness Removal/Installation 113
Surge Suppressor Removal/Installation 114
Surge Suppressor Assembly Removal/Installation 115
Converter Stirring Fan Removal/Installation 119
24V/240V Power Wire Harness Removal/Installation 120
Control Transformer Primary Wire Harness Removal/Installation 126
Control Transformer Removal/Installation 128
No DC Bus Fuse Wire Harness Removal/Installation (Frame 8 Drives Only) 131
DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger Drives Only) 132
Control Power Isolator Board 24V Wire Harness Removal/Installation (600/690V AC Input Drives Only) 134
Control Power Isolator Board Removal/Installation (600/690V AC Input Drives Only) 136
Converter Gate Circuit Board Removal/Installation 137
Converter Removal/Installation 140
Converter Duct Gasket Replacement 143

Chapter 5 Converter Component Replacement Procedures
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.

Converter Components The following table lists the components that make up the converter assembly
and the catalog numbers for components that are available as replacement kits
Identification and parts. Each component is identified by a number that corresponds to that
part in the illustrations on the following pages.
A complete list of spare parts for PowerFlex 755 Frame 8 and larger drives is
available on the Allen-Bradley web site at:
ID # Component Name Replacement Kit/Part Cat. No. Kit Qty. Figure Number
Converter Unit, AC Input Drives
400V, 770 A / 480V, 740 A 20-750-C1-C770D740 (Series A) 1 N.A.
20-750-C4-C770D740 (Series B)
600V, 510 A / 690V, 500 A 20-750-C4-E510F500 1 N.A.
Control Transformer Fuses, 400/480V AC Input Drives Kit SK-R1-FUSE2-CD-F8 N.A.
1 Fuse, 8A, 690V, IEC Class gG/gl, 14 x 51 mm (FU4 / FU5) 2 Figure 8 on page 75
2 Fuse, 5A, 600V, Class CC, Time-Delay (FU6) 1 Figure 9 on page 76
Control Transformer Fuses, 600/690V AC Input Drives Kit SK-R1-FUSE2-EF-F8 N.A.
1 Fuse, 6A, 690V, IEC Class gG/gl, 14 x 51 mm (FU4 / FU5) 2 Figure 8 on page 75
2 Fuse, 5A, 600V, Class CC, Time-Delay (FU6) 1 Figure 9 on page 76
AC Line Fuse Kit, 1100A, 400/480V AC Input Drives SK-R1-FUSE1-CD-F8 N.A.
3 Fuse, 690/700V, 1100 A 1 Figure 8 on page 75
4 Fuse Indicator 1 Figure 8 on page 75
AC Line Fuse Kit, 900A, 600/690V AC Input Drives SK-R1-FUSE1-EF-F8 N.A.
3 Fuse, 690/700V, 900 A 1 Figure 8 on page 75
5 Converter EMC Filter Board, 400/480V and 600/690V AC Input SK-R1-EMCFLT2-F8 (Series B) 1 Figure 8 on page 75
Drives

Converter Component Replacement Procedures Chapter 5
Frame 8 Converter Wire Harness Kit SK-R1-CNVH1-F8 N.A.
6 AC Line Fuse Wire Harness 1 Figure 8 on page 75
7 Control Transformer Primary Wire Harness 1 Figure 8 on page 75
8 DC Bus Sense Wire Harness 1 Figure 8 on page 75
9 No DC Bus Fuse Wire Harness 1 Figure 9 on page 76
10 Surge Suppressor Sense Wire Harness 1 Figure 9 on page 76
11 24V/240V Power Wire Harness 1 Figure 9 on page 76
12 Inverter Power Supply Wire Harness 1 Figure 9 on page 76
13 Assembly, External NTC 1 Figure 8 on page 75
14 Converter SCR Gate Wire Harness 1 Figure 8 on page 75
15 Converter Current Sensor Wire Harness 1 Figure 8 on page 75
16 AC Line Wire Harness 1 Figure 9 on page 76
17 Converter SCR Assembly, 400/480V AC Input Drives SK-R1-SCR1-CD-F8 1 Figure 8 on page 75
17 Converter SCR Assembly, 600/690V AC Input Drives SK-R1-SCR1-EF-F8 1 Figure 8 on page 75
18 Converter Current Sensor, 400/480V and 600/690V AC Input SK-R1-CNVIFB2-F8 (Series B) 1 Figure 8 on page 75
Drives
19 Control Transformer SK-R1-XFMR1-F8 1 Figure 9 on page 76
20 Converter Surge Suppressor, 400/480V AC Input Drives SK-R1-MOV1-CD-F8 1 Figure 9 on page 76
20 Converter Surge Suppressor, 600/690V AC Input Drives SK-R1-MOV1-EF-F8 1 Figure 9 on page 76
21 Converter Gate Board, 400/480V AC Input Drives (Includes a SK-R1-CGDB1-CD-F8 (Series A) 1 Figure 9 on page 76
fiber-optic transceiver) SK-R1-CGDB3-CD-F8 (Series B)
21 Converter Gate Board, 600/690V AC Input Drives (Includes a SK-R1-CGDB3-EF-F8 1 Figure 9 on page 76
fiber-optic transceiver)
22 One Bay Fiber-Optic Cable Kit 20-750-FCBL1-F8 1 Figure 9 on page 76
23 Fiber-Optic Transceiver SK-R1-FTR1-F8 1 Figure 9 on page 76
24 Converter Left Front Cover with Side Shield SK-R1-CCVR1-F8 1 Figure 8 on page 75
Converter Right Front Cover (No Control Pod) Kit SK-R1-CCVR2-F8 N.A.
25 Right Front Cover 1 Figure 8 on page 75
26 Bracket Cover, 82 mm (3.2 in.) Long 2 Figure 8 on page 75
27 One Bay 24V Wire Harness Kit (Frame 8) 20-750-PH1-F8 1 Figure 9 on page 76
27 Two Bay 24V Wire Harness Kit (Frame 9) 20-750-PH2-F9 1 Figure 9 on page 76
27 Three Bay 24V Wire Harness Kit (Frame 10) 20-750-PH3 -F10 1 Figure 9 on page 76

Frame 8 Gasket Kit 20-750-G1-F8 N.A.
28 Gasket, Converter, Heatsink 1 Figure 8 on page 75
29 Gasket, Converter/DC Input with Precharge Assembly, Duct 1 Figure 9 on page 76
(1)
- Gasket, Inverter, Heatsink 1
(1)
- Gasket, Inverter, Door Interface 1
(1)
- Gasket, Inverter, Exhaust Interface 1
(1)
- Gasket, Inverter, Inlet Ring 1
(1)
- Gasket, Inverter, No Choke 1
(1)
- Gasket, Inverter, Blower Box Bottom 1
(1)
- Gasket, Inverter, Choke 1
30 DC Bus Fuse Wire Harness Kit (Frame 9 AC Input Drives Only) SK-R1-DCBUSH1-F9 1 Figure 9 on page 76
31 Control Power Isolator Board Kit, 600/690V AC Input Drives SK-R1-CPIB1-F8 1 Figure 8 on page 75
32 Control Power Isolator 24V Wire Harness Kit, 600/690V AC SK-R1-CPIH1-F8 1 Figure 8 on page 75
Input Drives
33 Stirring Fan Kit 20-750-CFANKIT-F8 1 Figure 9 on page 76
(1) This gasket is included in the Frame 8 Gasket Kit (20-750-G1-F8), but is identified in Chapter 7 - Inverter Component Replacement Procedures on page 71.

Figure 8 - Converter Assembly Components Diagram 1
15
18
18
18
28
5
13
14
17
8
3
3
3
7
4
25
26
4
6
24
Note: Covers shown at smaller scale than other components.

Figure 9 - Converter Assembly Components Diagram 2
20
10
27
32
31
600/690V AC
16
Drives Only
400/480V AC
Drives Only
27
11
19
12
33
15
Drives Only
9
Frame 8
2
21
23
22
29
Drives Only
AC Input
30
Frame 9


Converter Left Cover Removing the Converter Left Cover

page 21.
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.

Converter Right Cover Removing the Converter Right Cover (No Control Pod)
(No Control Pod) Removal/
Installation
page 21.
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 21.

4. Remove the converter left cover or DC input with precharge assembly left
cover, top guard and left guard. See Removing the Converter Left Cover
on page 77 or Removing the DC Input with Precharge Assembly Left
Cover, Top Guard and Left Guard on page 151.
5. Remove the control pod cover. See Removing the Control Pod Cover on
page 50.
6. Disconnect the drive internal 24V wire harness J14 connector from the
fiber interface board (located in the control pod) P14 terminal.
P12
P15
INV1 INV2 INV3

P14 P13
Disconnect
connector from
P14 and P13
220.

IMPORTANT Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any
bends with a shorter inside radius can permanently damage the fiber-
optic cable. Signal attenuation increases with decreased inside bend
radii.
9. Disconnect the inverter fiber-optic cable from INV and the converter
fiber-optic cable from CONV on the inverter power layer interface board
located in the inverter card cage assembly. Place the cables on the bottom
of the control pod, observing the minimum bend radius requirement.
Verify that the cables will not be damaged when moving the control pod.
10. 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 INV and CONV on

the 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 78.
Control Transformer Primary Removing the Control Transformer Primary Fuses (FU4 and FU5)
Fuses Removal/Installation
page 21.
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.

Control Transformer Removing the Control Transformer Secondary Fuse (FU6)

Secondary Fuse Removal/
Installation
page 21.
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 78.
If the control pod is not installed, then remove the converter right cover.
See Removing the Converter Right Cover (No Control Pod) on page 78.
5. Using a fuse puller, remove the fuse from the 1-position fuse holder.
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
82.

Converter EMC Filter Circuit Removing the Converter EMC Filter Circuit Board
Board Removal/Installation
page 21.
4. Remove the left converter cover. See Removing the Converter Left Cover
on page 77.
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 Disconnect connector from P1
P2 P3
P1
9
11
12
1
2
6
7
5
5
1
Note: Board shown rotated 90 degrees from actual installation position.

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 83.
IMPORTANT Ensure that the J2/J3 connector is re-assembled in the correct location (P2 or
P3) on the EMC filter board.

AC Line Fuse Sense Wire Removing the AC Line Fuse Sense Wire Harness
Harness Removal/
Installation
page 21.
on page 77.
page 78.

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
indicator terminals and remove the AC line fuse sense wire harness.

P7 on gate board
Disconnect wire harness from

indicator 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 85.

AC Line Fuse Removal/ Removing the AC Line Fuses (FU1, FU2, and FU3)
Installation
page 21.
on page 77.
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

6. Remove the AC line fuse sense wire harness leads from the fuse indicator
terminals for the fuse being replaced. See Removing the AC Line Fuse
Sense Wire Harness on page 85.
IMPORTANT Note the orientation of the fuse indicator terminals before removal.
Replace each fuse with the 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 indicator
from the AC line fuse, if necessary.
Important: Note the orientation of the fuse

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

flat washers (3)
FU1 and FU2 - indicator

terminals point
downward.
FU3 - indicator
terminals point
upward.

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 89.
DC Bus Sense Wire Harness Removing the DC Bus Sense Wire Harness
page 21.
on page 77.
page 78.
6. Remove the AC line fuse FU1 (from Phase R/L1) to gain access to the DC
bus sense 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 87.

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 sense wire harness to the
converter SCR assembly and cut the tie wrap securing the harness to the
bracket.
9. Disconnect the DC bus sense wire harness J10 connector from the
converter gate board P10 terminal and remove the 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) Disconnect connector from
P10 on converter gate
board
Note: Some components not

shown for clarity only.

Installing the DC Bus Sense Wire Harness
Install the DC bus fuse wire harness in the reverse order of removal. See
Removing the DC Bus Sense Wire Harness on page 89.
Converter Current Sensor Removing the Converter Current Sensor Wire Harness
Wire Harness Removal/
Installation
page 21.
page 78.

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.
Release wire harness from

cable supports
Disconnect connector from P6 on

converter gate board

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 91.

Converter Current Sensor Removing the Converter Current Sensor

page 21.
on page 77.
page 78.
IMPORTANT Prior to disconnecting the control transformer primary wire harness,

note the terminal locations. The control transformer has multiple input
phase terminals. Refer to the AC Input Drive Control Transformer
Schematic Diagram on page 380 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 Release wire harness from

from terminals cable support
Back side of rotated

control pod
P2
1.8 Nm (16 lbin)

7. Remove the AC line fuse sense wire harness. See Removing the AC Line
Fuse Sense Wire Harness on page 85.
8. Remove the three AC line fuses with fuse indicators. See Removing the
AC Line Fuses (FU1, FU2, and FU3) on page 87.
9. Disconnect the converter current sensor wire harness J6 connector from
the converter gate board P6 terminal.
Back side of rotated

control pod
10. Remove the EMC filter board. See Removing the Converter EMC Filter
Circuit Board on page 83.

11. Remove the right (DC+) 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
T20 or F - 6.4 mm (0.25 in.)

M6
5.1 Nm (45.0 lbin)
T45
M10
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

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 T20 or F - 6.4 mm (0.25 in.)

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

shown removed for clarity only.

Installing the Converter Current Sensor
Install the current sensors in the reverse order of removal. See Removing the
Converter Current Sensor on page 93.
IMPORTANT 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 AC Input Drive Control Transformer
Schematic Diagram on page 380 for more information. Connecting the wires to
the wrong terminals may cause damage to the drive.
Converter SCR Gate Wire Removing the Converter SCR Gate Wire Harness
Harness Removal/
Installation
page 21.
on page 77.
page 78.

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 gate 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 gate connectors from the SCR modules and
remove the SCR gate wire harness from the drive.
SCR gate wire harness
Remove harness from Remove cable tie Disconnect connector from

cable supports (2) from mount P11 on gate board
Remove gate 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 Gate Wire Harness
Install the converter SCR gate wire harness in the reverse order of removal. See
Removing the Converter SCR Gate Wire Harness on page 97.

Converter SCR Assembly Removing the Converter SCR Assembly

page 21.
on page 77.
page 78.



Back side of rotated control pod
P2
1.8 Nm (16 lbin)

7. Remove the J2/J3 connector from connector P2 or P3 on the EMC filter

board.
= Disconnect connectors from P2 or P3
P2 P3
P1
9
11
12
1
2
6
7
5
5
1
Note: Board shown rotated 90 degrees from actual installation position.

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 85.
11. Remove the three AC line fuses with fuse indicators. See Removing the
AC Line Fuses (FU1, FU2, and FU3) on page 87.

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 83.

14. For the right bus bar rail:

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


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

M6
5.1 Nm (45.0 lbin)
T45
M10
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 Sense Wire
Harness on page 89.

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)

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
from P2
P2
P6
P14
P4
P12 P1

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.
IMPORTANT Do NOT remove the SCRs from the 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)

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 108.
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 If you replace the external NTC, you must apply thermal grease to the bottom
of the NTC before securing it to the SCR assembly heatsink.
Converter Heat Sink Gasket Removing the Converter Heat Sink Gasket
Replacement
page 21.
4. Remove the converter SCR assembly. Removing the Converter SCR
Assembly on page 99.
5. Carefully remove the gasket and any gasket material that may be stuck to
the sealing surface.
6. Clean the converter duct surface with a 50% isopropyl alcohol / 50% water
mixture.

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.
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 108.
Inverter Power Supply Wire Removing the Inverter Power Supply Wire Harness
Harness Removal/
Installation
page 21.

page 78.
220.
6. Disconnect the inverter power supply wire harness from the inverter power
supply board P6 terminal and converter terminal block TB1.
7. Remove the inverter power supply harness.
Converter terminal
block TB1
from TB1

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.

AC Line Wire Harness Removing the AC Line Wire Harness

page 21.
page 78.
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. Loosen the Phillips head screws that secure the wires to the surge
suppressor L1, L2, L3 and G terminals and remove the wires.
Disconnect connector Disconnect

J1 from P1 on EMC connector J9 from
filter board P9 on converter
P1
gate board
+ + + +
Disconnect wires
from L1, L2, L3
and G on surge
suppressor
AC line wire harness P2 or F - 4.8 mm (0.19 in)

1.8 Nm (16.0 lbin)

IMPORTANT Prior to disconnecting the jumper wire of the AC line wire harness, note
the wire location (PE-A1 or GND terminal) on the surge suppressor
mounting plate.
8. Loosen the screw that secures the jumper wire to the PE-A1 or GND
terminal and remove the wire.
9. Remove the AC line wire harness.
T20 or F - 6.4 mm (0.25 in) Disconnect jumper wire from
1.8 Nm (16.0 lbin) PE-A1 or GND terminal Connected Disconnected
P1
+ + + +
PE-A1 and GND terminal positions on early production drives.
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 111.
IMPORTANT Ensure that the jumper wire is re-assembled in the appropriate location (PE-A1
or GND terminal) on the surge suppressor mounting plate.

Surge Suppressor Sense Wire Removing the Surge Suppressor Sense Wire Harness
Harness Removal/
Installation
page 21.
page 78.
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.
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.
Disconnect Disconnect
connector connector
from P13 on from shunt
converter trip ST
gate board terminal
Surge suppressor wire harness
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
113.
Surge Suppressor Removal/ Removing the Surge Suppressor

Installation
page 21.
page 78.
5. Loosen the Phillips head screws that secure the wires to the surge
suppressor L1, L2, L3 and G terminals and remove the wires.
P2 or F - 4.8 mm (0.19 in)

Loosen screws and remove wires from
L1, L2, L3 and G on surge suppressor 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.
Installing the Surge Suppressor

Install the surge suppressor in the reverse order of removal. See Removing the
Surge Suppressor on page 114.
Surge Suppressor Assembly Removing the Surge Suppressor Assembly

Note: This procedure is used only for gaining access to the converter gate board.

page 21.
page 78.

5. For 600/690V AC input drives only, disconnect the 24V wire harness 2-
position connector from the bottom of the control power isolator board.
6. For 600/690V AC input drives only, disconnect the upper 24V wire
harness 2-position connector from the top of the control power isolator
board and disengage the harness from the two side entry cable supports.
Disconnect connectors
from control power isolator
board terminal block
Disengage harness from

side entry cable supports
Disconnect connectors
from control power isolator
board terminal block

7. Disconnect the J1 connector from the P1 terminal on the EMC filter

board.
8. Disconnect the J9 connector from the P9 terminal on the converter gate
board.
Disconnect
connector Disconnect
from P1 on connector
EMC filter from P9 on
P1 converter
board
gate board
+ + + +
9. Disconnect the J13 connector from the P13 terminal on the converter gate
board.
10. Disconnect the connector from the ST connector on the 24V/240V wire
harness.
Disconnect Disconnect
connector connector
from P13 on from shunt
converter trip ST
gate board terminal
+ + + +

11. 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 115.

Converter Stirring Fan Removing the Converter Stirring Fan

Removal/Installation 1. Review the General Precautions on page 20.
page 21.
page 78.
5. Remove the surge suppressor assembly. See Removing the Surge
Suppressor Assembly on page 115.
6. Disconnect the 2-position fan connector from the stirring fan to the 24V/
240V wire harness.
7. Remove two M4 x 35 mm long screws securing the stirring fan to the
control panel and remove the stirring fan.
Disconnect fan connector
Remove screws (2)
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)

Installing the Converter Stirring Fan

Install the stirring fan in the reverse order of removal. See Removing the
Converter Stirring Fan on page 119.
24V/240V Power Wire Removing the 24V/240V Power Wire Harness

Harness Removal/
Installation
page 21.
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 78.
7. Disconnect the connector from the shunt trip ST terminal.
Disconnect
connector from
shunt trip ST
terminal
+ + + +

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) P2

1.8 Nm (16.0 lbin) 1.8 Nm (16.0 lbin)
Remove screw and Disconnect leads from

ground wire transformer
Disconnect leads from top and

bottom of fuse block FU6
P2
2.3 Nm (20.0 lbin)

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

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

15. Disconnect the 2-position connector from the stirring fan.

16. Using a pliers, loosen the four cable tie mounts along the outside right
surface of the converter control panel.
17. 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
Disconnect 2-position
stirring fan connector
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 120.

Control Transformer Primary Removing the Control Transformer Primary Wire Harness
Installation
page 21.
page 78.
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.
8. Remove the J2/J3 connector from the P2 or P3 connector on the EMC

filter board.
Release cable supports Disconnect fuse wire Disconnect Disconnect from P2 or

connectors ground wire P3 connector



P2
1.8 Nm (16 lbin)
10. Slide one end of the wire harness through the fuse bracket and remove the
control transformer primary wire harness.

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
126.
IMPORTANT Ensure that the PE-A2 connector is re-assembled in the appropriate location
(P2 or P3) on the EMC filter board.
Control Transformer Removing the Control Transformer

page 21.
page 78.

5. Loosen the M4 screws that secure the four X1 and X2 lead wires to the
control transformer and remove the leads.


P2 P2
1.8 Nm (16 lbin) 1.8 Nm (16.0 lbin)
Disconnect wire leads from terminals Disconnect wire leads from terminals

IMPORTANT The control transformer is heavy. Be sure to support it as you remove

the screws, so it does not fall and damage other components.
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 AC Input Drive Control Transformer

No DC Bus Fuse Wire Harness Removing the No DC Bus Fuse Wire Harness
Removal/Installation (Frame
8 Drives Only)
page 21.
page 78.
5. Remove the no DC bus fuse 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 Fuse Wire Harness
Install the No DC bus fuse wire harness in the reverse order of removal. See
Removing the No DC Bus Fuse Wire Harness on page 131.

DC Bus Fuse Wire Harness Removing the DC Bus Fuse Wire Harness
Note: This procedure is applicable to frame 9 and larger drives only.
9 and Larger Drives Only)
page 21.
page 78.
5. Disconnect the 4-position DC bus fuse wire harness connector J8 from P8
on the converter gate board.
6. Unlatch the two twist-lock cable supports on the AC line filter board
support.

Unlatch cable supports from AC

line filter board support

7. Disconnect the cabinet-side, 3-position DC bus fuse wire harness

connector from terminal block TB6 on the lower left side of the converter.
8. Remove the two M3 x 12 mm screws that secure the harness terminal
block TB6 to the cover support bracket.
9. Disengage the three cable tie push mounts that secure the harness to the
cover support bracket, and remove the harness.
Remove three (3) cable tie mounts T15 or F - 4.8 mm (0.19 in)
from support bracket 0.61 Nm (5.5 lbin)
Remove two (2) screws and
terminal block
Note: Support
bracket shown
removed and
from rear side for
clarity only
Disconnect cabinet-side connector from

terminal block TB6
Installing the DC Bus Fuse Wire Harness
Install the DC bus fuse wire harness in the reverse order of removal. See
Removing the DC Bus Fuse Wire Harness on page 132.

Control Power Isolator Board Removing the Control Power Isolator Board 24V Wire Harness
24V Wire Harness Removal/
Installation (600/690V AC
Input Drives Only) 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
3. Open the door of the enclosure containing the control pod.
4. Rotate the control pod to gain access to the converter control panel. See
5. If necessary, disconnect the 24V wire harness 2-position connector from
P14 on the fiber interface board in the control pod.
If necessary, disconnect
connector from P14 on fiber P14
interface board

6. Disconnect the 24V wire harness 2-position connector from the terminal
block on the bottom of the control power isolator board.
7. Open the twist-lock cable support that secures the wire harness to the
bottom of the control frame and remove the wire harness.
from bottom of control
power isolator board
Open twist-lock cable

support and remove
wire harness
Installing the Control Power Isolator Board 24V Wire Harness
Install the control power isolator board 24V wire harness in the reverse order of
removal. See Removing the Control Power Isolator Board 24V Wire Harness on
page 134.

Control Power Isolator Board Removing the Control Power Isolator Board
Removal/Installation (600/
690V AC Input Drives Only)
page 21.
4. Rotate the control pod to gain access to the converter control panel. See
5. Disconnect the 24V wire harness 2-position connector from the bottom of
the control power isolator board.
6. Disconnect the upper one, two, or three bay 24V wire harness 2-position
connector from the top of the control power isolator board and disengage
the harness from the two side-entry cable supports.
One, two, or three bay Disconnect connector

24V wire harness from control power
isolator board
Disengage harness from

side entry cable supports
Control power isolator

24V wire harness Disconnect connector
from control power
isolator board

7. Loosen the two M4 captive screws that secure the control power isolator
board mounting bracket to the MOV mounting plate and remove the
bracket with the board attached.
8. Remove the two M4 x 12 mm screws that secure the control power isolator
board to the mounting bracket, pull the board out to disengage it from two
non-threaded standoffs, and remove the board.
Loosen two captive

screws and remove
bracket and control
Remove screws
(2) and board
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Bracket and control
Installing the Control Power Isolator Board
Install the control power isolator board in the reverse order of removal. See
Removing the Control Power Isolator Board on page 136.
Converter Gate Circuit Board Removing the Converter Gate Circuit Board
IMPORTANT Determine if the existing converter gate board is series A or series B, and verify
that you have ordered/received a compatible board before replacement. See
Drive Series Components Compatibility on page 25 for details.

page 21.

page 78.
5. Remove the surge suppressor assembly. See Removing the Surge
Suppressor Assembly on page 115.
6. Disconnect all wire harnesses connected to the converter gate board.
7. Disconnect the fiber-optic cable from the port in the lower left corner of
the gate board.
8. 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.
Disconnect all wire P13 P8 P11 P10 P9
harnesses from gate
board
P7
P2
P6
P14
P4
Remove fiber-optic
cables and
transceiver
P12 P1

9. Remove the two M4 x 40 mm hex standoffs.

10. 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 137.

Converter Removal/
ATTENTION: Field replacement of the converter section of the power core (the
Installation 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
IMPORTANT Determine if the existing converter is series A or series B, and verify that you
have ordered/received a compatible unit before replacement. See Drive Series
Components Compatibility on page 25 for details.

page 21.
3. Remove the drive assembly from the enclosure. Refer to the PowerFlex
750-Series AC Drive Installation Instructions, publication number 750-
IN001, for details.
220.
5. Disconnect the inverter power supply wire harness connector from
terminal P6 on the inverter power control board.
6. 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.

7. 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
connector from P6
Disconnect inverter on power control
fiber-optic cable board
8. 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.
9. Connect the lifting hardware to the two lifting holes on the lifting bar at
the top of the converter section.
10. Loosen the two M8 screws securing the converter duct to the inverter duct.
11. Lift and slide the converter away from the inverter assembly.

45
MAX.
45 Connect lifting hardware to

MAX. lifting holes
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)

Installing the Converter on the Inverter Assembly
1. Inspect the gasket at the top of the converter duct for damage and replace
it if necessary. See Converter Duct Gasket Replacement on page 143.
2. Inspect the gasket at the top of the inverter duct for damage and replace it
if necessary.
3. Install the converter on the inverter assembly in the reverse order of
removal. See Removing the Converter from the Inverter Assembly on page
140.
Converter Duct Gasket Removing the Converter Duct Gasket

Replacement
page 21.
IN001, for details.
4. Remove the converter. Removing the Converter from the Inverter
6. 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
adhesive.
the duct edges as shown below and press the gasket into place on the duct.

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 Removing the Converter from the Inverter Assembly on page
140.

Chapter 6
DC Input with Precharge Assembly Component

Replacement Procedures
Topic Page
DC Input with Precharge Assembly Components Identification 146
DC Input with Precharge Assembly Left Cover, Top Guard and Left Guard Removal/Installation 151
DC Input with Precharge Assembly Right Cover (No Control Pod) Removal/Installation 152
Control Transformer Secondary Fuses Removal/Installation 152
DC Bus Output/Sense Wire Harness Removal/Installation 154
Precharge Resistor Assembly Removal/Installation 158
Precharge Resistor Jumper Wires Removal/Installation 159
DC Line Fuses and Fuse Indicators Removal/Installation 160
Precharge Circuit Fuses Removal/Installation 163
DC Bus Input Wire Harness Removal/Installation 164
Left Wall Removal/Installation 165
24V Control Wire Harness Removal/Installation 168
Molded Case Switch Control Wire Harness Removal/Installation 171
Transformer Primary Wire Harness Removal/Installation 174
24V/120V/240V Wire Harness Removal/Installation 176
Disconnect Switch Jumper Wires Removal/Installation 182
Disconnect Switch (SW2), Auxiliary Contact, and Handle Shaft Removal/Installation 183
Disconnect Switch Handle Removal/Installation 184
Control Transformer Removal/Installation 185
Control Power Isolator Board 24V Wire Harness Removal/Installation (810/932V DC Input Drives Only) 188
Control Power Isolator Board Removal/Installation (810/932V DC Input Drives Only) 189
Undervoltage Delay Bracket Removal/Installation 191
Undervoltage Delay Wire Harness Removal/Installation 194
Undervoltage Delay Removal/Installation 195
DC Input with Precharge Assembly Stirring Fan Removal/Installation 196
Door Interlock Wire Harness Removal/Installation 197
Digital I/O Wire Harness Removal/Installation 199
DC Precharge Control Circuit Board Removal/Installation 201
DC Input with Precharge Assembly Removal/Installation 203
DC Input with Precharge Assembly Duct Gasket Replacement 206

Chapter 6 DC Input with Precharge Assembly Component Replacement Procedures
This chapter provides detailed procedures for removing and replacing DC input
with precharge assembly components.
Note: In some illustrations in this chapter the DC input with precharge assembly
and/or control pod are shown removed from the drive for clarity only. Only
remove the DC input with precharge assembly and/or control pod from the drive
if directed to do so.

DC Input with Precharge The following table lists the components that make up the DC input with
precharge assembly and the catalog numbers for components that are available as
Assembly Components replacement kits and parts. Each component is identified by a number that
Identification corresponds to that part in the illustrations on the following pages.
A complete list of spare parts for PowerFlex 755 Frame 8 and larger drives is
available on the Allen-Bradley web site at:
ID# Component Name Replacement Kit/Part Kit Qty. Figure Number
Cat. No.
DC Input with Precharge Unit for Common DC Input Drives
540V, 770 A / 650V, 740 A 20-750-P4-C770D740 1 N.A.
810V, 510 A / 932V, 500 A 20-750-P4-E510F500 1 N.A.
DC Line Fuse Kit, 1600A, 540/650V DC Input Drives SK-R1-CBPFUSE1-F8 N.A.
1 Fuse, 690/700V, 1600 A (FU1 and FU2) 1 Figure 10 on page 149
DC Line Fuse Kit, 1000A, 810/932V DC Input Drives SK-R1-CBPFUSE3-F8 N.A.
1 Fuse, 1250/1300V, 1000 A (FU1 and FU2) 1 Figure 10 on page 149
Precharge & Control Transformer Fuse Kit, 540/932V DC Input Drives SK-R1-CBPFUSE2-F8 N.A.
3 Fuse, 5 A, 600V, Class CC, Time Delay (FU5) 1 Figure 11 on page 150
4 Fuse, 1 A, 600V, Class CC, Time Delay (FU6) 1 Figure 11 on page 150
5 Fuse, Ferrule, Special Purpose, 1000VDC, 20 A (FU3 and FU4) 2 Figure 10 on page 149

DC Input with Precharge Assembly Component Replacement Procedures Chapter 6

Cat. No.
Frame 8 DC Input with Precharge Wire Harness Kit SK-R1-CBPH1-F8 N.A.
6 Wire Harness, 24V/120V/240V 1 Figure 11 on page 150
7 Wire Harness, Digital I/O 1 Figure 11 on page 150
8 Wire Harness, Door Lock 1 Figure 11 on page 150
9 Wire Harness, 120V/240V 1 Figure 11 on page 150
10 Wire Harness, DC Bus Output/Sense 1 Figure 10 on page 149
11 Wire Harness, Undervoltage 1 Figure 11 on page 150
12 Wire Harness, 24V Control 1 Figure 11 on page 150
13 Wire Harness, Molded Case Switch Control 1 Figure 11 on page 150
14 Wire Harness, DC Bus Input 1 Figure 10 on page 149
15 Wire Harness, Disconnect Switch Jumper 1 Figure 10 on page 149
16 Wire Harness, Resistor Jumper 1 Figure 10 on page 149
17 Wire Harness, Inverter Power Supply 1 Figure 11 on page 150
Precharge Resistor Assembly Kit, 540/650V DC Input Drives SK-R1-CBPRES-F8 N.A.
18 Bracket, Resistor 1 Figure 10 on page 149
19 Resistor, 10 Ohm, Metal Case, Ceramic Collar 4 Figure 10 on page 149
20 Screw, M4 x 12 mm, Pan Head Sems 8 Figure 10 on page 149
Precharge Resistor Assembly Kit, 810/932V DC Input Drives SK-R1-CBPRES2-F8 N.A.
18 Bracket, Resistor 1 Figure 10 on page 149
19 Resistor, 20 Ohm, Metal Case, Ceramic Collar 4 Figure 10 on page 149
20 Screw, M4 x 12 mm, Pan Head Sems 8 Figure 10 on page 149
Precharge Disconnect Assembly Kit, 540/932V DC Input Drives SK-R1-CBPSW-F8 N.A.
21 Switch, 8-Pole, 32 A, 750V 1 Figure 10 on page 149
22 Shaft, Extended, 6 mm Dia., 70 mm Long 1 Figure 10 on page 149
23 Handle, Pistol Type, Padlockable, 6 mm Shaft, Indication I-O;On-Off 1 Figure 10 on page 149
24 Auxiliary Contact Block, IP20, Normally Open, Right Side Mountable 1 Figure 10 on page 149
25 Control Transformer, 120/240VAC In, 120/240VAC Out, 1000 VA @240VAC SK-R1-CBPXFMR1-F8 1 Figure 11 on page 150
26 Undervoltage Delay SK-R1-CBPDELAY-F8 1 Figure 11 on page 150
(1)
- Gasket, Converter, Heatsink 1
27 Gasket, Converter/DC Input with Precharge Assembly, Duct 1 Figure 10 on page 149
- Gasket, Inverter, Heatsink 1 (2)
(2)
- Gasket, Inverter, Door Interface 1
(2)
- Gasket, Inverter, Exhaust Interface 1
(2)
- Gasket, Inverter, Inlet Ring 1
(2)
- Gasket, Inverter, No Choke 1
- Gasket, Inverter, Blower Box Bottom 1 (2)
(2
- Gasket, Inverter, Choke 1


Cat. No.
DC Input Control Board Kit, 540/650V DC Input Drives SK-R1-CBPCTRL-F8 N.A.
28 DC Precharge Control Board, 540/650V 1 Figure 11 on page 150
29 Fiber Optic Transceiver 1 Figure 11 on page 150
DC Input Control Board Kit, 810/932V DC Input Drives SK-R1-CBPCTRL2-F8 N.A.
28 DC Precharge Control Board, 810/932V 1 Figure 11 on page 150
29 Fiber Optic Transceiver 1 Figure 11 on page 150
One Bay Fiber Optic Cable Kit 20-750-FCBL1-F8 N.A.
30 CONV Fiber Optic Cable, 560 mm Long 1 Figure 11 on page 150
31 INV Fiber Optic Cable, 560 mm Long 1 Figure 11 on page 150
32 Fiber Optic Transceiver SK-R1-FTR1-F8 1 Figure 11 on page 150
33 One Bay 24V Wire Harness Kit (Frame 8) 20-750-PH1-F8 1 Figure 11 on page 150
33 Two Bay 24V Wire Harness Kit (Frame 9) 20-750-PH2-F9 1 Figure 11 on page 150
33 Three Bay 24V Wire Harness Kit (Frame 10) 20-750-PH3-F10 1 Figure 11 on page 150
Left Front Cover with Shields Kit SK-R1-CBP-CVR1-F8 N.A.
34 Left Front Cover 1 Figure 10 on page 149
35 Top Guard 1 Figure 10 on page 149
36 Left Guard 1 Figure 10 on page 149
Right Front Cover (No Control POD) Kit SK-R1-CCVR2-F8 N.A.
37 Right Front Cover 1 Figure 10 on page 149
38 Bracket, Cover, 59 mm (2.3 in.) Long 2 Figure 11 on page 150
39 Control Power Isolator Board Kit, 600/690V AC and 810/932V DC Input SK-R1-CPIB1-F8 1 Figure 10 on page 149
Drives
40 Control Power Isolator 24V Wire Harness Kit, 600/690V AC and 810/932V DC SK-R1-CPIH1-F8 1 Figure 10 on page 149
Input Drives
41 Stirring Fan Kit 20-750-CFANKIT-F8 1 Figure 11 on page 150
(1) This gasket is included in the Frame 8 Gasket Kit (20-750-G1-F8), but is identified in the table in Converter Components Identification on page 72.
(2) This gasket is included in the Frame 8 Gasket Kit (20-750-G1-F8), but is identified in the table in Inverter Components Identification on page 210.

Figure 10 - DC Input with Precharge Assembly Components Diagram 1
24
22
10
5
21
15
37
14
18 19 20
16
15
2
1
23
27
34
35
36

Figure 11 - DC Input with Precharge Assembly Components Diagram 2
41
3
11
4
28
13 25
26
8
38 12
29
9
6
7
30
540/650V DC
Drives Only 33 32
32 31
33
17
39
40 810/932V
DC Drives
Only


DC Input with Precharge Removing the DC Input with Precharge Assembly Left Cover, Top
Assembly Left Cover, Top Guard and Left Guard
Guard and Left Guard
page 21.
4. Remove only the four M5 x 14 mm screws that secure the cover to the
assembly and remove the cover with the top and left guards attached.
5. If required, remove the four M5 x 14 mm screws that secure the top and
left guards to the cover; and remove the guards.
Remove screws (4)

T25 or F - 6.4 mm (0.25 in)
2.8 Nm (25 lbin)
Installing the DC Input with Precharge Assembly Left Cover, Top

Guard and Left Guard
Install the left cover, top guard and left guard in the reverse order of removal. See
Removing the DC Input with Precharge Assembly Left Cover, Top Guard and
Left Guard above.

DC Input with Precharge Removing the DC Input with Precharge Assembly Right Cover (No
Assembly Right Cover (No Control Pod)
Control Pod) Removal/
Installation
page 21.
Remove screws (4)

T25 or F - 6.4 mm (0.25 in.)
2.8 Nm (25 lbin)
Installing the DC Input with Precharge Assembly Right Cover (No

Control Pod)
Install the right cover in the reverse order of removal. See Removing the DC
Input with Precharge Assembly Right Cover (No Control Pod) above.
Control Transformer Removing the Control Transformer Secondary Fuses (FU5 and FU6)
Secondary Fuses Removal/
Installation
page 21.

4. Remove the left cover, top guard and left guard assembly. See Removing
the DC Input with Precharge Assembly Left Cover, Top Guard and Left
Guard on page 151.
the DC input with precharge assembly control panel. See Rotating the
Control Pod Forward on page 78.
If the control pod is not installed, then remove the right cover. See
Control Pod) on page 152.
6. Using a fuse puller, remove the fuse from the 1-position fuse holder. The
fuses are located on the right wall of the control panel next to the control
transformer.
Control transformer
Use fuse puller to

remove fuses
Installing the Control Transformer Secondary Fuses (FU5 and FU6)
Install the control transformer secondary fuses (FU5 and FU6) in the reverse
order of removal. See Removing the Control Transformer Secondary Fuses (FU5
and FU6) on page 152.

DC Bus Output/Sense Wire Removing the DC Bus Output/Sense Wire Harness

Harness Removal/
Installation
page 21.
Guard on page 151.

6. Remove the two cable ties securing the wire harness to the center wall.
7. Disconnect the connector from P1 on the DC input control board.
Remove cable tie and disconnect connector

from P1 on DC input control board
Remove cable tie
Note: Undervoltage delay and control

transformer not shown for clarity only.
8. Remove the two cable ties securing the wire harness to the disconnect
bracket and the 24/120/240V wire harness.

9. Loosen the screws that secure the +DC and -DC wires to the fuseholder
terminals and remove the wires.
Loosen screws and disconnect +DC and -

DC wires from fuse holder
PZ2
2.5 Nm (22 lbin)
Disconnect
bracket
Remove cable ties
10. Remove the M4 hex nuts that secure the +DC and -DC wires to the +DC
and -DC output bus bars and remove the wires.
Remove nuts (2) and disconnect
wires from bus bars
7 mm
1.8 Nm (16 lbin)
-DC bus bar +DC bus bar
11. Disconnect the connectors from the R1, R2, R3 and, R4 precharge resistor
terminals.

12. Loosen, but do not remove, the two M4 x 12 mm hexalobular screws

securing the wire harness support to the bottom of the precharge resistor
assembly and remove the harness.
DC bus output/sense wire harness
Remove DC bus output/sense harness

connectors (4) from resistor terminals
Loosen screws (2) securing support

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Installing the DC Bus Output/Sense Wire Harness
Install the DC bus output/sense wire harness in the reverse order of removal. See
Removing the DC Bus Output/Sense Wire Harness on page 154.

Precharge Resistor Assembly Removing the Precharge Resistor Assembly

page 21.
Guard on page 151.
5. Loosen but do not remove the two M4 x 12 mm long hexalobular screws
that secure the DC bus output/sense harness wire support to the resistor
assembly.
Remove DC bus output/sense harness

connectors (4) from resistor terminals
Loosen nut
8.0 mm (0.32 in.)

2.8 Nm (25 lbin)
Loosen nut
Loosen screws (2) securing support

T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
6. Remove the four wire connectors of the DC bus output/sense harness

from the R1, R2, R3 and, R4 precharge resistor terminals.
7. Loosen but do not remove the two M5 nuts securing the resistor assembly
to the mounting bracket.
8. Remove the resistor assembly in the following manner.
Rotate the bottom of the assembly to the right to disengage the bottom
bracket slot.

Slide the assembly down to disengage the top bracket slot.

9. Remove the resistor jumper harness from the top four terminals.
Installing the Precharge Resistor Assembly
Install the precharge resistor assembly in the reverse order of removal. See
Removing the Precharge Resistor Assembly on page 158.
Precharge Resistor Jumper Removing the Precharge Resistor Jumper Wires

Wires Removal/Installation
page 21.
Guard on page 151.
5. Remove the precharge resistor assembly. See Removing the Precharge
Resistor Assembly on page 158.

Installing the Precharge Resistor Jumper Wires
Install the precharge resistor jumper wires in the reverse order of removal. See
Removing the Precharge Resistor Jumper Wires above.
DC Line Fuses and Fuse Removing the DC Line Fuses (FU1 and FU2) and Fuse Indicators (SW3
Indicators Removal/ and SW4)
Installation
page 21.
Guard on page 151.

5. Remove the 24V control wire harness leads from the fuse indicator (SW3
or SW4) terminals for the fuse being replaced (FU1 or FU2).
Replace each fuse with the terminals in the same orientation as shown
below.
24V control wire harness
FU1 indicator terminals point

upward to right
downward to left
Note: Fuses shown removed in this illustration for clarity only.

6. Remove the M10 x 35 mm hexalobular screw and flat washer for the fuse
being replaced and remove the DC line fuse. Remove the fuse indicator
from the DC line fuse for reuse, if necessary.
Remove fuse(s)
Remove fuse(s)
Remove screws and washers T45

13.6 Nm (120 lbin)
Installing the DC Line Fuses (FU1 and FU2) and Fuse Indicators (SW3
and SW4)
Install the DC line fuses and fuse indicators in the reverse order of removal. See
Removing the DC Line Fuses (FU1 and FU2) and Fuse Indicators (SW3 and
SW4) on page 160.

Precharge Circuit Fuses Removing the Precharge Circuit Fuses (FU3 and FU4)
page 21.
Guard on page 151.
5. Pull down on the tabs at the top of the fuse holder and remove the fuse.
Installing the Precharge Circuit Fuses (FU3 and FU4)

Install the precharge circuit fuses in the reverse order of removal. See Removing
the Precharge Circuit Fuses (FU3 and FU4) on page 163.

DC Bus Input Wire Harness Removing the DC Bus Input Wire Harness
page 21.
Guard on page 151.
5. Disconnect the +DC and -DC wires from the +DC and -DC bus bars,
respectively.
6. Loosen the screw that secures the +DC wire to terminal SW2-5 on the
disconnect switch, and remove the wire.
7. Loosen the screw that secures the -DC wire to terminal SW2-1 on the
disconnect switch and remove the wire.
8. Remove the -DC wire from the two wire supports on the disconnect
bracket and remove the wire harness.
Disconnect +DC wire
Disconnect +DC and -DC wires from bus bars from SW2-5
P1
0.8 Nm (7 lbin)
Remove -DC wire from supports and

disconnect from SW2-1

Installing the DC Bus Input Wire Harness
Install the DC bus input wire harness in the reverse order of removal. See
Removing the DC Bus Input Wire Harness on page 164.
Left Wall Removal/ Removing the Left Wall

Installation
page 21.
IN001, for details.
5. Remove the DC line fuses and fuse indicators. See Removing the DC Line
Fuses (FU1 and FU2) and Fuse Indicators (SW3 and SW4) on page 160.
6. Disconnect the +DC wire (of the DC bus input wire harness) from the
+DC bus bar and the -DC wire (of the DC bus input wire harness) from
the -DC bus bar.
7. Loosen the two captive M4 panel fasteners securing the disconnect bracket
to the left wall.
8. Remove the six M6 x 12 mm flat head screws securing the left wall to the
drive.

9. Slide the left wall (with input bus bar assembly) off the two mounting pins
and remove the left wall.
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Remove six (6) screws Remove wires from +DC and

-DC bus terminals
Loosen two (2) captive screws
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Installing the Left Wall

Install the left wall in the reverse order of removal. See Removing the Left Wall
on page 165.

Molded Case Switch Wire Removing the Molded Case Switch Wire Terminal Support
Terminal Support Removal/
Installation
page 21.
4. Remove the left wall. See Removing the Left Wall on page 165.
5. Remove the two M3 x 45 mm Phillips head screws securing the wire
terminal support to the molded case switch and remove the support.
Remove two (2) screws
P1
0.6 Nm (5.4 lbin)
Installing the Molded Case Switch Wire Terminal Support

Install the molded case switch wire terminal support in the reverse order of
removal. See Removing the Molded Case Switch Wire Terminal Support above.

24V Control Wire Harness Removing the 24V Control Wire Harness
page 21.
Guard on page 151.
6. Remove the 24V control wire harness leads from the fuse indicators SW3
(on FU1) and SW4 (on FU2).
below.
24V control wire harness fuse

indicator connectors
DC input fuse

upward to right

downward to left
7. Remove the molded case switch wire terminal support. See Removing the
Molded Case Switch Wire Terminal Support on page 167.

8. Using a screw driver (as shown in the illustration below) disconnect the
24V wire harness connector from terminals 31/21 and 32/34 on the
molded case switch.
9. Loosen the Phillips head screws that secure the 24V wire harness wires to
terminals 13 and 14 on the disconnect switch auxiliary contact and remove
the wires.
10. Release the 24V wire harness from the cable support on the top, front of
the disconnect switch.
Removing wire connectors from the

molded case switch terminals
Disconnect connectors from terminals 31/21 and

32/34 on the molded case switch
Release harness from

cable support
Loosen screws (2) and remove wires

from terminals 13 and 14 on the
auxiliary contact
P1
0.8 Nm (7 lbin)

11. Release, but do not remove, the two releasable cable ties from the top rungs
of two cable support ladders on the control panel.
12. Disconnect the 24V control wire harness connector from terminal P3 on
the DC precharge control board and pull the 24V wire harness to the right
through the gap in the center wall and remove the wire harness.
24V wire harness
Release cable ties from

support ladders
Disconnect connector from P3

on DC precharge control board
DC precharge
control board
Note: Undervoltage delay and control transformer not shown and side
wall shown with hidden lines for clarity only.
Installing 24V Control Wire Harness
Install the 24V control wire harness in the reverse order of removal. See Installing
24V Control Wire Harness on page 170.

Molded Case Switch Control Removing the Molded Case Switch Control Wire Harness
Installation
page 21.
Guard on page 151.
6. Remove the 24V control wire harness leads from the fuse indicators SW3
(on FU1) and SW4 (on FU2).
below.
24V control wire harness fuse

indicator connectors
DC input fuse

upward to right

downward to left
7. Remove the molded case switch wire terminal support. See Removing the
Molded Case Switch Wire Terminal Support on page 167.

8. Using a screw driver (as shown in the illustration below), disconnect the
molded case switch (MCS) control wire harness connector from terminals
U1/U2, D1/D2, C1/C2, and C12/C11 on the molded case switch.
9. Release the harness from two cable supports on the top, rear of the
disconnect switch.
Removing wire connectors from the Disconnect connectors Release harness from
molded case switch terminals from terminals U1/U2 cable support
Release harness from Disconnect wires from terminals D1/

cable support D2, C1/C2, and C12/C11

10. Release, but do not remove, the cable tie from the second rung of the left
cable support ladder on the control panel.
11. Disconnect the MCS control wire harness from the UV connector for the
undervoltage delay.
12. Disconnect the MCS control wire harness connector from terminal P2 on
the DC precharge control board.
13. Pull the MCS control wire harness to the right and remove the wire
harness.
Pull harness to right

to remove
Release cable tie from left Disconnect connector from Disconnect connector from P2 terminal
cable support ladder undervoltage delay on DC precharge control board
Installing the Molded Case Switch Control Wire Harness
Install the molded case switch control wire harness in the reverse order of
removal. See Removing the Molded Case Switch Control Wire Harness on page
171.

Transformer Primary Wire Removing the Transformer Primary Wire Harness

Harness Removal/
Installation
page 21.
Guard on page 151.
6. Loosen, but do not remove, the captive screws that secure the control
transformer primary lead wires to terminals H1 and HX and remove the
wires.
Loosen screws and disconnect

wires from H1 and Hx.
P2 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Note: Transformer wiring for

120V AC input shown.
Note: Center wall shown removed for clarity only.

7. Loosen the screws that secure the three wires to terminals SW2-6, SW2-7,
and SW2-8 on the disconnect switch and remove the wires.
8. Loosen the captive screw that secures the wire to TB5-1 on right side of
control panel, and remove the wire.
9. Using pliers, loosen the two cable tie mounts on the center wall and the
cable tie mount on the top of the control panel and remove the harness.
Release cable tie from top of

control panel
Release cable tie from top

of control panel
Loosen screw and disconnect wire
from TB5-1
F - 3 mm (0.12 in.)
0.5 Nm (4.5 lbin)
Release cable tie from

center wall
Loosen screws and disconnect wires

from SW2-6, SW2-7, and SW2-8 on
disconnect switch
P1
0.8 Nm (7 lbin)
Installing the Transformer Primary Wire Harness
Install the transformer primary wire harness in the reverse order of removal. See
Removing the Transformer Primary Wire Harness on page 174.

24V/120V/240V Wire Harness Removing the 24V/120V/240V Wire Harness

page 21.
Guard on page 151.
6. Loosen the screw that secures the transformer primary wire harness to
terminal 1 on terminal block TB5, and remove the wire.
7. Remove the M4 x 12 mm screw and grounding washer that secure the
ground wire lug to the control panel; and remove the ground wire lug.
8. Loosen, but do not remove, the M4 screws that secure the secondary lead
wires to terminals X1, X2 and X3 on the control transformer; and remove
the leads.
9. Loosen, but do not remove, the captive screws that secure the four leads
wires to FU5 and FU6 fuse blocks; and remove the leads.

Remove screw and washer and

remove ground wire
T20 or F - 6.4 mm (0.25 in.)
1.8 Nm (16 lbin)
Loosen screw and disconnect wire

from terminal 1 on TB5
F - 3 mm (0.12 in.)
0.5 Nm (4.5 lbin)

from X1, X2, and X3
F - 3 mm (0.12 in.)
0.5 Nm (4.5 lbin)
24V/120V/240V Wire Harness
Loosen screws (4) and disconnect

wires from fuse block
P2
2.3 Nm (20 lbin)

10. Loosen the screws that secure the 120V control power output wiring (if
used) to terminals 7 and 8 on terminal block TB5, and remove the wires.
11. Remove the two M3 x 12 mm screws that secure terminal block TB5 to
the control panel and remove the terminal block.
12. Remove the plug-in terminal block for the enclosure fan harness, 120/
240V control power input harness, and 120V UPS harness from terminal
block TB2.
13. Remove the two M3 x 12 mm screws that secure terminal block TB2 to
the control panel and remove the terminal block.
P2 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Loosen screws (2) and disconnect wires
from terminals 7 and 8 on TB5
Remove screws (2) in terminal block and

remove terminal block
T15 or F - 4.8 mm (0.19 in)

0.61 Nm (5.5 lbin)
Remove plug-in terminal block

from TB2
Remove screws (2) in terminal block and

remove terminal block
T15 or F - 4.8 mm (0.19 in)

0.61 Nm (5.5 lbin)
14. Disconnect the 5-position inverter power supply harness connector from
terminal block TB1 (see following illustration).
15. Disconnect the 3-position 24V wire harness connector from terminal
block TB1 (see following illustration).
16. Disconnect the enclosure fan 6-position connector from P9 on the DC
precharge control board (see following illustration).

17. Disconnect the system 24V 3-position connector from P10 on the DC
precharge control board.
18. Disconnect the 2-position connector from the stirring fan.
19. Using a pliers, loosen and remove the seven cable tie mounts along the
right surface of the control panel.
Use pliers to loosen seven (7) cable tie mounts and

remove from control panel
Disconnect wire harness

connectors from
terminal block TB1
Disconnect connector from stirring fan
Note: Undervoltage delay not shown for clarity only.

20. Loosen the screws that secure the input wires to terminals SW2-6, SW2-7,
and SW2-8 on the disconnect switch and remove the wires.

from disconnect switch

21. Cut four cable ties between the disconnect switch and terminal block TB1
and pull the three disconnect switch wires SW2-6, SW2-7, and SW2-8
through the opening in the bottom, center wall of the control panel.
22. Release terminal block TB1 from the DIN rail and remove the 24V/
120V/240V wire harness from the control panel.
Cut cable ties between disconnect switch

and terminal block TB1 and pull wires
through center wall
Release terminal block TB1 from DIN rail

Note: Undervoltage delay not shown for clarity only. and remove harness
Installing the 24V/120V/240V Wire Harness
Install the 24V/120V/240V wire harness in the reverse order of removal. See
Removing the 24V/120V/240V Wire Harness on page 176.

Disconnect Switch Jumper Removing the Disconnect Switch Jumper Wires

Wires Removal/Installation
page 21.
Guard on page 151.
5. Disconnect the +DC jumper wire from terminals SW2-5 and SW2-4 on
the bottom of the disconnect switch.
6. Disconnect the +DC jumper wire from terminals SW2-4 and SW2-3 on
the top of the disconnect switch.
7. Disconnect the +DC jumper wire from terminal SW2-3 on the bottom of
the disconnect switch and the top of fuse block FU3.
8. Disconnect the -DC jumper wire from terminals SW2-1 and SW2-2 on
the top of the disconnect switch.
9. Disconnect the -DC jumper wire from terminal SW2-2 on the bottom of
the disconnect switch and the top of fuse block FU4.
Disconnect -DC jumper wires Disconnect +DC jumper wires
Disconnect terminals
P1
0.8 Nm (7 lbin)
Fuse block terminals
PZ2
2.5 Nm (22 lbin)
Disconnect -DC jumper wires Disconnect +DC jumper wires

Installing the Disconnect Switch Jumper Wires

Install the disconnect switch jumper wires in the reverse order of removal. See
Removing the Disconnect Switch Jumper Wires on page 182.
Disconnect Switch (SW2), Removing the Disconnect Switch, Auxiliary Contact and Handle Shaft
Auxiliary Contact, and
Handle Shaft Removal/
Installation 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
Guard on page 151.
5. Remove the DC bus input harness +DC wire from the disconnect switch
terminal SW2-5 and the DC bus input harness -DC wire from the
disconnect switch terminal SW2-1. See Removing the DC Bus Input Wire
Harness on page 164.
6. Remove the 24V control harness wires from terminals 13 and 14 on the
disconnect switch auxiliary contact. See Removing the 24V Control Wire
Harness on page 168.
7. Remove the transformer primary wire harness from the disconnect switch
terminals SW2-6, SW2-7, and SW2-8. See Removing the Transformer
Primary Wire Harness on page 174.
8. Remove the 24V/120V/240V wire harness from the disconnect switch
terminals SW2-6, SW2-7, and SW2-8. See Removing the 24V/120V/
240V Wire Harness on page 176.
9. Remove the five disconnect switch jumper wires from the disconnect
switch SW2. See Removing the Disconnect Switch Jumper Wires on page
182.
10. Extend the two release tabs near poles 4 and 7 on the bottom of the
disconnect switch, and remove the disconnect switch, auxiliary contact
and handle shaft from the mounting rail.
Note: The auxiliary contact snaps fits onto the disconnect switch.
Note: If removed, the handle shaft should be inserted fully to the bottom
of the disconnect switch prior to set screw tightening. A 2.5 mm hex key
and tightening torque of 0.6 Nm (5.4 lbin) is recommended for the set
screw.

Installing the Disconnect Switch, Auxiliary Contact and Handle Shaft

Install the disconnect switch, auxiliary contact and handle shaft in the reverse
order of removal. See Removing the Disconnect Switch, Auxiliary Contact and
Handle Shaft on page 183.
Wiring must be installed as shown in the DC Input with Precharge Assembly

Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC Classes
Common DC Input Drives) on page 380.
Disconnect Switch Handle Removing the Disconnect Switch Handle

page 21.
Guard on page 151.
5. Remove the two M4 x 8 mm long screws and washers that secure the
handle to the disconnect switch handle shaft and remove the handle.
Disconnect switch handle shaft extends

through left cover (not shown)
Remove two (2) screws and handle
P1
1.5 Nm (13.3 lbin)

Installing the Disconnect Switch Handle
Install the disconnect switch handle in the reverse order of removal. See
Removing the Disconnect Switch Handle on page 184.
IMPORTANT The disconnect switch handle must be installed in the orientation shown in the
illustration above.
Control Transformer Removing the Control Transformer

page 21.
Guard on page 151.

6. Loosen, but do not remove, the M4 screws that secure the X1, X2, X3 and
X4 secondary lead wires to the control transformer and remove the wires.
IMPORTANT Prior to disconnecting the control transformer primary wire leads, note
the terminal locations. The control transformer has both 120V and
240V input phase terminals. Refer to the DC Input with Precharge
Assembly Control Transformer Schematic Diagram on page 380 for
more information.
7. Loosen, but do not remove, the M4 screws that secure the H1 and HX
primary lead wires to the control transformer and remove the wires.
Loosen screws (2) and remove wires Loosen screws (3) and remove wires
from terminals H1 and Hx from terminals X1, X2, X3, and X4
Control transformer

8. Remove the four M6 hex nuts that secure the control transformer to the
control panel and slide the control transformer forward off the control
panel studs.
Remove nuts (4) and remove

control transformer
10 mm
5.1 Nm (45 lbin)
Note: Undervoltage delay not shown for clarity only.

Installing the Control Transformer
Install the control transformer in the reverse order of removal. See Removing the
Control Transformer on page 185.
IMPORTANT Ensure that the control transformer primary wire harness lead wires H1 and HX
are connected to the proper input terminals. The control transformer has both
120V and 240V input phase terminals. Refer to the DC Input with Precharge
Assembly Control Transformer Schematic Diagram on page 380 for more
information. Connecting the wires to the wrong terminals may cause damage
to the drive.
Control Power Isolator Board Removing the Control Power Isolator Board 24V Wire Harness
24V Wire Harness Removal/
Installation (810/932V DC
Input Drives Only) 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
4. Rotate the control pod to gain access to the DC input with precharge
assembly control panel. See Rotating the Control Pod Forward on page 78.

5. If necessary, disconnect the 24V wire harness 2-position connector from

P14 on the fiber interface board in the control pod.
both the control power isolator board.
7. Untwist one twist-lock cable support and remove the harness.
If necessary, disconnect the 24V wire P14

harness connector from connector
P14 on the fiber interface board
Installing the Control Power Isolator Board 24V Wire Harness
Install the control power isolator board 24V wire harness in the reverse order of
removal. See Removing the Control Power Isolator Board 24V Wire Harness on
page 188.
Control Power Isolator Board Removing the Control Power Isolator Board
Removal/Installation (810/
932V DC Input Drives Only)
page 21.
4. Rotate the control pod to gain access to the DC input with precharge
assembly control panel. See Rotating the Control Pod Forward on page 78.

the control power isolator board.
6. Disconnect the one, two, or three bay 24V wire harness 2-position
connector from the top of the control power isolator board and disengage
the harness from the two side-entry cable supports.
7. Remove the two M4 x 12 mm screws that secure the control power isolator
board to the mounting bracket, slide the board to the right to disengage it
from the two keyhole standoffs, and remove the board.
Note: Undervoltage Delay bracket shown Disconnect connector

removed from drive for clarity only. from top of control
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Remove screws (2)
Remove wire harness

from cable supports
One, two, or three bay

24V wire harness
Disconnect connector from bottom

Control power isolator of control power isolator board
24V wire harness
Installing the Control Power Isolator Board
Install the control power isolator board in the reverse order of removal. See
Removing the Control Power Isolator Board on page 189.

Undervoltage Delay Bracket Removing the Undervoltage Delay Bracket

page 21.
5. For 810/932V DC input drives only, disconnect the 24V wire harness 2-
position connector from the bottom of the control power isolator board.
6. For 810/932V DC input drives only, disconnect the upper 24V wire
harness 2-position connector from the top of the control power isolator
board and disengage the harness from the two side entry cable supports.
from top of control
Remove wire harness

from cable supports
from bottom of control
Note: Undervoltage Delay bracket shown

removed from drive for clarity only.

7. Disconnect the undervoltage wire harness connector from terminal P5 on

P2
P1
P3
terminal P5
P5
P6
P7
P8
P9
P10

8. Disconnect the undervoltage wire harness connector from connector UV

on the molded case switch control wire harness.
9. Loosen the four M4 captive panel fasteners on the undervoltage delay
bracket and remove bracket.

connection UV

remove delay bracket
Note: Control Power Isolation T20 or F - 6.4 mm (0.25 in.)

board not shown for clarity only. Undervoltage delay 1.8 Nm (16 lbin)
Installing the Undervoltage Delay Bracket

Install the undervoltage delay bracket in the reverse order of removal. See
Removing the Undervoltage Delay Bracket on page 191.

Undervoltage Delay Wire Removing the Undervoltage Delay Wire Harness

Harness Removal/
Installation
page 21.
5. Remove the undervoltage delay bracket from the control panel. See
6. Loosen the captive screws that secure the five harness wires to the
undervoltage delay terminals and remove the wire harness.
P2
0.6 Nm (5.4 lbin)
remove wire harness
Undervoltage delay
Note: Control Power Isolation

board not shown for clarity only.
Installing the Undervoltage Delay Wire Harness
Install the undervoltage delay wire harness in reverse order of removal. See
Removing the Undervoltage Delay Wire Harness on page 194.

Undervoltage Delay Removing the Undervoltage Delay

page 21.
5. Remove the undervoltage delay bracket from the control panel. See
6. Remove the undervoltage delay wire harness. See Removing the
Undervoltage Delay Wire Harness on page 194.
7. Remove two M4 x 16 mm screws securing the undervoltage delay to its
mounting bracket, and remove the undervoltage delay.
Remove screws (2)
T20 or F - 6.4 mm (0.25 in.)

1.8 Nm (16 lbin)
Undervoltage delay
Note: Control Power Isolation

board not shown for clarity only.

Installing the Undervoltage Delay
Install the undervoltage delay in the reverse order of removal. See Removing the
Undervoltage Delay on page 195.
DC Input with Precharge Removing the DC Input with Precharge Assembly Stirring Fan
Assembly Stirring Fan 1. Review the General Precautions on page 20.
page 21.
5. Remove the undervoltage delay bracket. See Removing the Undervoltage
Delay Bracket on page 191.

6. Disconnect the 2-position fan connector from the stirring fan to the 24V/
120V/240V wire harness.
7. Remove two M4 x 35 mm long screws securing the stirring fan to the
control panel and remove the stirring fan.
Disconnect fan connector
Remove screws (2)
T20 or F - 6.4 mm (0.25 in)

1.8 Nm (16.0 lbin)
Installing the DC Input with Precharge Assembly Stirring Fan

Install the stirring fan in the reverse order of removal. See Removing the DC
Input with Precharge Assembly Stirring Fan on page 196.
Door Interlock Wire Harness Removing the Door Interlock Wire Harness
page 21.

5. Disconnect the door interlock wire harness connector J6 from the
connector P6 on the DC precharge control board.
6. Remove the two M3 x 12 mm hexalobular screws that secure the terminal
block TB4 to the control panel and remove the wire harness from the
control panel.
Note: Control pod and undervoltage Disconnect connector J6 from P6 on

delay shown removed for clarity only. DC precharge control board
Remove screws (2)
T15 or F - 4.8 mm (0.19 in)

0.6 Nm (5.4 lbin)

Installing the Door Interlock Wire Harness
Install the door interlock wire harness in the reverse order of removal. See
Removing the Door Interlock Wire Harness on page 197.
Digital I/O Wire Harness Removing the Digital I/O Wire Harness
page 21.
Guard on page 151.

6. Disconnect the digital I/O wire harness connector from connector P7 on

7. Disconnect the digital I/O wire harness connector from connector P8 on
8. Remove the two M3 x 12 mm hexalobular screws that secure the terminal
block TB3 to the control panel and remove the wire harness from the
control panel.
Note: Control pod and undervoltage

delay shown removed for clarity only.
Disconnect connectors from P7 and P8

on DC precharge control board
Remove screws (2)
T15 or F - 4.8 mm (0.19 in.)

0.6 Nm (5.4 lbin)
Installing the Digital I/O Wire Harness
Install the digital I/O wire harness in the reverse order of removal. See Removing
the Digital I/O Wire Harness on page 199.

DC Precharge Control Circuit Removing the DC Precharge Control Circuit Board

page 21.
Guard on page 151.
6. Remove the undervoltage delay bracket. See Removing the Undervoltage
Delay Bracket on page 191.
7. Disconnect all wire harnesses connected to the DC precharge control
board.
8. From the fiber-optic cage in the lower left corner of the DC precharge
control board, remove the fiber-optic transceiver by pulling its bale wire.
Set the transceiver aside and save for re-installation.
P2
P1
P3
DC precharge
control board
P5
P6
P7
P8
P9
Fiber-optic cage
P10

9. Remove the two M4 x 40 mm hex standoffs.

10. Remove the three M4 x 8 mm screws that secure the DC precharge control
board to the DC input control panel, slide the DC precharge control
board up to disengage its four keyhole slots, and remove the board.
T15 or F - 4.8 mm (0.19 in.)

0.6 Nm (5.4 lbin)
Remove standoffs (2)
T15 or F - 4.8 mm (0.19 in.)

0.6 Nm (5.4 lbin) Remove screws (3)
Installing the DC Precharge Control Circuit Board
Install the DC precharge control board in the reverse order of removal. See
Removing the DC Precharge Control Circuit Board on page 201.

DC Input with Precharge ATTENTION: Field replacement of the DC input with precharge assembly of the
Assembly Removal/ power core should only be performed as part of the drive assembly removal
Installation procedure. Otherwise, equipment damage may result.
Removing the DC Input with Precharge Assembly

page 21.
IN001, for details.
220.
5. Disconnect the inverter power supply wire harness connector from
terminal P6 on the inverter power control board.
6. Disconnect the fiber-optic cable from CONV on the inverter power layer
interface board and secure it to the DC input with precharge assembly. Do
not remove the fiber-optic transceiver.
7. If the control pod is assembled on the DC input with precharge assembly,
disconnect the 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 fiber-optic cable
from P6 on power
control board
Disconnect fiber-optic cable

8. Remove the four M8 x 30 mm machine screws that secure the inverter DC

bus bars to the DC input with precharge assembly bus bars.
9. Connect the lifting hardware to the two lifting holes on the lifting bar at
the top of the DC input with precharge assembly.
10. Loosen the two M8 screws securing the DC input with precharge assembly
duct to the inverter duct.
11. Lift and slide the DC input with precharge assembly away from the
inverter assembly.

Connect lifting hardware

to lifting holes
Loosen M8 shoulder
bolts both sides
5.0 mm (0.2 in)

16.5 Nm (146 lbin)
Remove M8 x 30
machine screws (4)
T40
11.3 Nm (100 lbin)

Installing the DC Input with Precharge Assembly
1. Inspect the gasket at the top of the DC input with precharge assembly duct
for damage and replace if necessary. See Removing the DC Input with
Precharge Assembly Duct Gasket on page 206.
2. Inspect the gasket at the top of the inverter duct for damage and replace if
necessary.
3. Install the DC input with precharge assembly on the inverter assembly in
the reverse order of removal. See Removing the DC Input with Precharge
DC Input with Precharge Removing the DC Input with Precharge Assembly Duct Gasket
Assembly Duct Gasket
Replacement
page 21.
IN001, for details.
4. Remove the DC input with precharge assembly. Removing the DC Input
with Precharge Assembly on page 203.
6. Clean the duct surface with a 50% isopropyl alcohol/ 50% water mixture.
Installing the DC Input with Precharge Assembly Duct Gasket

adhesive.

Align gasket
edges with duct
edges
Top, rear view of assembly
2. Install the DC input with precharge assembly on the inverter assembly in

the reverse order of removal. See Removing the DC Input with Precharge

Notes:

Chapter 7
Inverter Component Replacement Procedures
Topic Page
Inverter Components Identification 210
Common Mode Core Assembly Removal/Installation 215
Internal Stirring Fan Tray Removal/Installation 216
Heatsink Fan Inlet Screen Removal/Installation 217
Heatsink Fan Assembly Removal/Installation 218
Inverter Circuit Board Connections Cover Removal/Installation 220
Inverter Front Cover Removal/Installation 221
Inverter Current Sensors Removal/Installation 222
Inverter Current Sensor Wire Harness Removal/Installation 225
Inverter Capacitor Bank Assembly Removal/Installation 228
Capacitor Balance Resistor Assembly Removal/Installation 230
IGBT Flex Bus Bars Removal/Installation 232
Inverter Gate Board Connection Ribbon Cables Removal/Installation 233
Inverter Gate Circuit Board Removal/Installation 235
Rating Plug Removal/Installation 237
Power Layer Interface Circuit Board Removal/Installation 238
Power Supply Circuit Board Removal/Installation 240
Power Control Circuit Board Removal/Installation 244
Inverter Backplane Circuit Board Removal/Installation 247
Inverter EMC Capacitor Removal/Installation (AC Input Drive Only) 250
Inverter Side DC Bus Bar Removal/Installation (AC Input Drive Only) 254
Inverter Top DC Bus Bar Removal/Installation (Common DC Input Drive Only) 262
Inverter IGBT Assembly Removal/Installation (AC Input Drive Only) 267
Inverter IGBT Assembly Removal/Installation (Common DC Input Drive Only) 272
DC Choke Removal/Installation (AC Input Drives Only) 278
Inverter Wire Harness Removal/Installation 280
Discharge Resistor Assembly Removal/Installation 284
Inverter Heatsink Fan Inlet Bottom Cover Removal/Installation 291
Inlet Bottom Cover Gasket Replacement 292

Chapter 7 Inverter Component Replacement Procedures
This chapter provides detailed procedures for removing and replacing inverter
components.

Inverter Components The following table lists the components that make up the inverter assembly and
the catalog numbers for components that are available as replacement kits and
Identification parts. Each component is identified by a number that corresponds to that part in
the illustrations on the following pages.
Allen-Bradley web site at:
Inverter Unit for 400/480v AC Input Drives
- 400V, 460 A / 480V, 430 A 20-750-I1-C460D430 (Series A) 1 N.A.
20-750-I1B-C460D430 (Series B)
20-750-I1B-C540D485 (Series B)
20-750-I1B-C567D545 (Series B)
20-750-I1B-C650D617 (Series B)
20-750-I1B-C750D710 (Series B)
20-750-I1B-C770D740 (Series B)
Inverter Unit for 600/690V AC Input Drives
- 600V, 295 A / 690V, 265 A 20-750-I1B-E295F265 (Series B) 1 N.A.
Inverter Unit for 540/650V DC Input Drives
20-750-I2B-C460D430 (Series B)
20-750-I2B-C540D485 (Series B)
20-750-I2B-C567D545 (Series B)
- 540V, 650 A / 650V 617 A 20-750-I2-C650D617 (Series A) 1 N.A.
20-750-I2B-C650D617 (Series B)
20-750-I2B-C750D710 (Series B)
20-750-I2B-C770D740 (Series B)

Inverter Component Replacement Procedures Chapter 7
Inverter Unit for 810/932V DC Input Drives
- 810V, 295 A / 932V, 265 A 20-750-I2B-E295F265 1 N.A.
- 810V, 355 A / 932V, 330 A 20-750-I2B-E355F330 1 N.A.
- 810V, 395 A / 932V, 370 A 20-750-I2B-E395F370 1 N.A.
- 810V, 435 A / 932V, 415 A 20-750-I2B-E435F415 1 N.A.
- 810V, 460 A / 932V, 460 A 20-750-I2B-E460F460 1 N.A.
- 810V, 510 A / 932V, 500 A 20-750-I2B-E510F500 1 N.A.
1 Inverter Capacitor Bank, 400V 770A, 480V 740A SK-R1-CP1-C770D740 1 Figure 12 on page 213
1 Inverter Capacitor Bank, 400V 567A, 480V 545A SK-R1-CP1-C567D545 1 Figure 12 on page 213
1 Inverter Capacitor Bank, 600V 395A, 690V 370A SK-R1-CP1-E395F370 1 Figure 12 on page 213
1 Inverter Capacitor Bank, 600V 510A, 690V 500A SK-R1-CP1-E510F500 1 Figure 12 on page 213
2 Capacitor Balance Resistors, 400/480V AC Input Drive SK-R1-RB1-CD-F8 1 Figure 12 on page 213
(includes mounting tray)
2 Capacitor Balance Resistors, 600/690V AC Input Drive SK-R1-RB1-EF-F8 1 Figure 12 on page 213
(includes mounting tray)
3 Discharge Resistor Assembly, 400/480V AC Input Drive SK-R1-RD1-F8 1 Figure 12 on page 213
3 Discharge Resistor Assembly, 600/690V AC Input Drive SK-R1-RD2-F8 1 Figure 12 on page 213
4 Inverter IGBT Flexbus, 400V 567A, 480V 545A SK-R1-BS1-C567D545 3 Figure 12 on page 213
4 Inverter IGBT Flexbus, 400V 770A, 480V 740A SK-R1-BS1-C770D740 3 Figure 12 on page 213
5 Inverter Current Sensor SK-R1-INVIFB1-F8 1 Figure 12 on page 213
6 Inverter Heatsink Fan Kit SK-R1-FAN1-F8 1 Figure 12 on page 213
7 Inverter Internal Stir Fans w/Tray SK-R1-FAN2-F8 1 Figure 12 on page 213
8 DC Choke, 33H, 400V 770A, 480V 740A SK-R1-DCCHK1-F8 1 Figure 12 on page 213
9 Inverter Backplane Board SK-R1-IB1-F8 1 Figure 13 on page 214
10 Inverter Power Control Board SK-R1-PC1-F8 1 Figure 13 on page 214
11 Inverter Heatsink Power Supply Board, 400/480V SK-R1-PWRS1-CD-F8 1 Figure 13 on page 214
11 Inverter Heatsink Power Supply Board, 600/690V SK-R1-PWRS1-EF-F8 1 Figure 13 on page 214
12 Inverter Power Layer Interface Board SK-R1-PINT1-F8 (Series A) 1 Figure 13 on page 214
(Includes two fiber-optic transceivers) SK-R1-PINT2-F8 (Series B)
13 Inverter IGBT Assembly, 400V 770A, 480V 740A SK-R1-IT1-C770D740 1 Figure 12 on page 213
13 Inverter IGBT Assembly, 400V 567A, 480V 545A SK-R1-IT1-C567D545 1 Figure 12 on page 213
13 Inverter IGBT Assy,600V 510A,690V 500A SK-R1-IT1-E510F500 1 Figure 12 on page 213
13 Inverter IGBT Assy,600V 395A,690V 370A SK-R1-IT1-E395F370 1 Figure 12 on page 213
14 Inverter Gate Board, 400V 770A, 480V 740A SK-R1-IG1-C770D740 1 Figure 12 on page 213
14 Inverter Gate Board, 400V 567A, 480V 545A SK-R1-IG1-C567D545 1 Figure 12 on page 213
14 Inverter Gate Board, 600V 510A, 690V 500A SK-R1-IG1-E510F500 1 Figure 12 on page 213
14 Inverter Gate Board, 600V 395A, 690V 370A SK-R1-IG1-E395F370 1 Figure 12 on page 213
15 Inverter Ribbon Cable SK-R1-ICBL1-F8 1 Figure 12 on page 213
16 Inverter Front Cover with Side Shield SK-R1-IFCVR1-F8 1 Figure 12 on page 213

17 Inverter Heatsink Fan Inlet Screen SK-R1-IFCVR2-F8 1 Figure 12 on page 213
18 Inverter Heatsink Fan Inlet Bottom Cover SK-R1-IBCVR1-F8 1 Figure 12 on page 213
19 Inverter Wire Harness Kit SK-R1-INVH1-F8 1 Figure 12 on page 213
20 Rating Plug Board, 400V 460A, 480V 430A SK-R1-IR1-C460D430 1 Figure 13 on page 214
20 Rating Plug Board, 600V 510A,690V 500A SK-R1-IR1-E510F500 1 Figure 13 on page 214
21 EMC Capacitors SK-R1-EMCCAP1-F8 3 Figure 12 on page 213
- Gasket, Converter, Heatsink 1 (1)
(1)
- Gasket, Converter/DC Input with Precharge Assembly, Duct 1
22 Gasket, Inverter, IGBT Assembly Heatsink 1 Figure 12 on page 213
23 Gasket, Inverter, Door Interface 1 Figure 12 on page 213
24 Gasket, Inverter, Exhaust Interface 1 Figure 12 on page 213
25 Gasket, Inverter, Inlet Ring 1 Figure 12 on page 213
26 Gasket, Inverter, No Choke 1 Figure 12 on page 213
27 Gasket, Inverter, Fan Inlet Bottom Cover 1 Figure 12 on page 213
28 Gasket, Inverter, Choke 1 Figure 12 on page 213
(1) This gasket is included in the Frame 8 Gasket Kit (20-750-G1-F8), but is identified in the table in Converter Components Identification on page 72.


Figure 12 - Inverter Main Assembly Components Diagram
21
19
26
27
18
24
3
AC Input Drives
Only
21
22
6
13
25
AC Input Drives
21
AC Input Drives
Only
Only
14
15
4
23
17
28
1
4
5
DC Input Drives
Only
16
7
2

Figure 13 - Inverter Card Cage Assembly Components Diagram
12
20
10
11

Common Mode Core Removing the Common Mode Core Assembly

Assembly Removal/
Note: This assembly is field installed only.
Installation
page 21.
4. Remove the inverter assembly from the enclosure. Refer to the PowerFlex
IN001, for details.
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)
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.
IMPORTANT Grounding and Power Jumper configuration must be appropriate for EMC
applications. Refer to Drive Power Jumper Configuration in the Powerflex
750-Series Installation Instructions (Publication 750-IN001) for detailed
information.

Internal Stirring Fan Tray Removing the Internal Stirring Fan Tray
page 21.
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 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 Removing the Heatsink Fan Inlet Screen
page 21.
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.) enclosure for clarity only.
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.

Heatsink Fan Assembly Removing the Heatsink Fan Assembly

page 21.
4. Remove the heatsink fan inlet screen. See Removing the Heatsink Fan
Inlet Screen on page 217.
5. Disconnect the control and power wire connectors P4 and P5 from the
front, right side of the fan assembly.
Disconnect fan control and
power connections
P4
P5
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)

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 (AC

input drives only)
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45 lbin)
Remove screws (2)
Installing the Heatsink Fan Assembly
Install the heatsink fan assembly in the reverse order of removal. See Installing the
Heatsink Fan Assembly on page 219.

Inverter Circuit Board Remove the Inverter Circuit Board Connections Cover
Connections Cover Removal/
Installation
page 21.
4. Loosen the two M5 x 14 mm screws that secure the clear cover to the
inverter front cover and remove the cover.
T25 or F 6.4 mm (0.25 in.)

2.8 Nm (25.0 lbin)
Loosen screws (2)
Install the Inverter Circuit Board Connections Cover
Install the inverter circuit board connections cover in the reverse order of
removal. See Remove the Inverter Circuit Board Connections Cover above.

Inverter Front Cover Removing the Inverter Front Cover

page 21.
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)

Installing the Inverter Front Cover
Install the inverter front cover in the reverse order of removal. See Removing the
Inverter Front Cover on page 221.
Inverter Current Sensors Removing the Inverter Current Sensors

page 21.
IN001, for details.
5. Remove the inverter front cover. See Removing the Inverter Front Cover
on page 221.
6. Disengage the locking tabs and disconnect the wire connector from P1 on
the power control board.
Top view of board

=
P2
P5 P3 P4
from P1
P1
P6
Front of board

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.
P1 connector on power
control board
T25
2.8 Nm (25.0 lbin)
Remove screws (10)

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 222.

Inverter Current Sensor Wire Removing the Inverter Current Sensor Wire Harness
Harness Removal/
Installation
page 21.
IN001, for details.
on page 221.
Top view of board

=
P2
P5 P3 P4
from P1
P1
P6
Front of board

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.
P1 connector on power
T25 control board
2.8 Nm (25.0 lbin)
T25 or F - 5.0 mm (0.19 in.)
2.8 Nm (25.0 lbin)
Remove screws (8)

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

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 Removing the
Inverter Current Sensor Wire Harness.

Inverter Capacitor Bank Removing the Inverter Capacitor Bank Assembly

Assembly Removal/
Installation IMPORTANT A load capacity of 80 kg (175 lb) minimum is required for all lifting equipment
and hardware used for this procedure.

page 21.
4. Remove the internal stirring fan tray. See Removing the Internal Stirring
Fan Tray on page 216.
on page 221.
6. Remove the lower tray in the card cage containing the power control and
power supply circuit boards and store it in a dry, protected, static-free
location. See Removing the Power Control Circuit Board on page 244.
Note, it is not necessary to remove the power control board from the tray
for this procedure.
Note: Inverter shown removed from drive enclosure for clarity only.
IMPORTANT The angle of attachment of the lifting hardware should be no more than 45
degrees from vertical.

7. Connect the lifting hardware to the two lifting holes on the front of the
capacitor bank assembly.
8. Remove the twelve M6 hex nuts and washers from the bus connection tabs
at the top and bottom of the capacitor bank assembly.
9. 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. Remove the six M6 x 50 mm screws (three at the top, three at the bottom),
from the capacitor bank assembly.
10.0 mm
M6
5.1 Nm (45.0 lbin)
T30 or F - 6.4 mm (0.25 in.)
M6
5.1 Nm (45.0 lbin)
45
T40 or F - 6.4 mm (0.25 in.)
MAX. M8
9.0 Nm (80.0 lbin)

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

Assembly Removal/
Installation
page 21.
on page 221.
6. Remove the capacitor bank. See Removing the Inverter Capacitor Bank

7. Remove the six M5 x 16 mm screws from the sides of 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)
Installing the Capacitor Balance Resistors
Install the capacitor balance resistors (on mounting tray) in the reverse order of
removal. See Removing the Capacitor Balance Resistor Assembly on page 230.

IGBT Flex Bus Bars Removal/ Removing the IGBT Flex Bus Bars
Installation
Note: This assembly is field installed only.

page 21.
IN001, for details.
on page 221.
7. Remove the current sensor mounting panel. See Removing the Inverter
Current Sensors on page 222.
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

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 232.
Inverter Gate Board Removing the Inverter Gate Board Connection Ribbon Cables
Connection Ribbon Cables
page 21.
on page 221.

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 Upper ribbon

cable (Type A). cable (Type B).
Jumper ribbon
cables - two
locations
Note: Inverter shown removed from

drive enclosure for clarity only.

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 233.
The gate board connection ribbon cables kit contains one each of the
straight (type A) and folded (type B) upper ribbon cables. Only use the
cable in the kit that matches that cable type that you have removed from
the drive. Use the following drive sizing information for verification of the
appropriate cable type to use with your drive.
Table 6 - Gate Board Upper Ribbon Cable Type

Upper Ribbon Cable Type Drive Cat. No. Pos. 7 and Drive Cat. No. Pos. 810
A (straight) C 460, 540, or 567
D 430, 485, or 545
B (folded) C 650. 750, or 770
D 617, 710, or 740
Inverter Gate Circuit Board Removing the Inverter Gate Circuit Board
page 21.
IN001, for details.
on page 221.
9. Remove the IGBT flex bus bars. See Removing the IGBT Flex Bus Bars on
page 232.
10. Remove the inverter ribbon cables. See Removing the Inverter Gate Board
Connection Ribbon Cables on page 233.
11. Remove the seven M4 x 10 mm screws that secure the gate board to the
IGBT (E1, E2, G1, G2, C1, NTC1, NTC2 connections).

12. Remove the four M4 x 10 mm screws that secure the gate board to the
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 235.

Rating Plug Removal/ Removing the Rating Plug

Installation
page 21.
on page 221.
5. Remove the lower tray in the card cage containing the power control and
power supply circuit boards and store it in a dry, protected, static-free
location. See Removing the Power Control Circuit Board on page 244.
Note, it is not necessary to remove the power control board from the tray
for this procedure.
Note: Inverter shown removed from drive enclosure for clarity only.

6. 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.) Note: Inverter shown removed from drive
1.8 Nm (16.0 lbin) enclosure for clarity only.
Installing the Rating Plug
Install the rating plug in the reverse order of removal. See Removing the Rating
Plug on page 237.
Power Layer Interface Circuit Removing the Power Layer Interface Circuit Board
IMPORTANT Determine if the existing inverter power layer interface board is series A or
series B, and verify that you have ordered/received a compatible board before
replacement. See Drive Series Components Compatibility on page 25 for
details.

page 21.
on page 221.

5. Disconnect the terminal block from P6 on the power control board.
=
Top view of board
P2
P5 P3 P4
P1
P6
Front of board Disconnect terminal

block from P6
6. Disconnect the fiber-optic cables from CONV and INV on the power
layer interface board.
Top view of board
= J7 J6
P2
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.
8. Completely loosen the two captive screws on the face of the top tray in the
card cage, pull forward and remove the tray. Note, the right front corner of
the power layer interface board may not clear the card cage frame. Lift the
tray up to clear the card cage.
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) Note: Inverter shown removed from drive

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 238.
Power Supply Circuit Board Removing the Power Supply Circuit Board
page 21.

on page 221.
= Top view of board
P2
P5 P3 P4
Disconnect
connector from P1
P1
P6

block from P6

7. Disengage the locking tabs and disconnect the wire connector from J1 on
the power supply board.
=
Disconnect connector from J1 Front of board Bottom view of board
J1
J3
J4
J2

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. 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)
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 240.

Power Control Circuit Board Removing the Power Control Circuit Board
page 21.
on page 221.
= Top view of board
P2
P5 P3 P4
Disconnect
connector from P1
P1
P6

block from P6

=
J1
J3
J4
J2

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 244.

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 21.
on page 221.
= Top view of board
P2
P5 P3 P4
Disconnect
connector from P1
P1
P6
Front of board Disconnect terminal block

from P6

=
J1
J3
J4
J2
8. Disconnect the fiber-optic cables from CONV and INV on the power
layer interface board.
Top view of board
= J7 J6
P2
CONV Disconnect fiber-optic cables
from CONV and INV
INV

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. Disconnect the ribbon cable that is connected to the top edge of the
backplane board.
12. 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)
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 247.

Inverter EMC Capacitor Removing the Inverter EMC Capacitors (AC Input Drive Only)
Removal/Installation (AC
Note: There are three sets of EMC capacitors on the inverter. One set is located
Input Drive Only) to the left of the card cage, a second set is located behind the card cage, and a
third set is located below the capacitor bank.

page 21.
IN001, for details.
on page 221.
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

10. Remove the two M3 x 12 mm screws that secure the inverter wire harness
to the backplane in the card cage.
backplane board.
12. 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.
13. Remove the two M4 x 8mm screws that secure the EMC capacitor
assembly to the card cage and remove the capacitor assembly.
T15 or F - 5.0 mm (0.19 in.)

T20 or F - 5.0 mm (0.19 in.) 0.5 Nm (4.0 lbin)
1.8 Nm (16.0 lbin)
Remove screws
Remove screws (2)
Disconnect ribbon cable from

backplane board
Remove screws (2)
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)

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)

16. 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 (AC Input Drive Only)
Install the Inverter EMC Capacitors in the reverse order of removal. See
Removing the Inverter EMC Capacitors (AC Input Drive Only) on page 250.

Inverter Side DC Bus Bar Removing the Inverter Side DC Bus Bars (AC Input Drive Only)
Input Drive Only)
page 21.
IN001, for details.
on page 221.
page Removing the IGBT Flex Bus Bars.
DC choke/converter bus EMC capacitors

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)

backplane board.
T15 or F - 5.0 mm (0.19 in.)

0.5 Nm (4.0 lbin)
Remove screws (2)
Disconnect ribbon cable from

backplane board
Remove screws (2)
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)

14. Completely loosen, but do not remove, the two M6 hex nuts at the back
edge of the AC output bus bar assembly.
15. Remove the three M6 hex nuts and washers that secure the front of the AC
output assembly to the capacitor bank support.
16. 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)

Remove hex nuts and
10.0 mm (0.4 in.) washers (3)
5.1 Nm (45.0 lbin)

17. 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)

capacitors to the DC choke input positive and negative bus bars.
Remove hex 7.0 mm (0.3 in.)
nuts (2) 1.8 Nm (16.0 lbin)
EMC capacitors
19. 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.
20. 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/ Remove screws (4) Remove screws (4) and
converter bus bar and washers (4) washers (4)
assembly
DC input and output positive and

negative bus bars

21. 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
T30
M6
5.1 Nm (45.0 lbin)
Remove screws (3)

capacitors to side DC bus bars.
24. Remove the two M4 x 40 mm standoffs secured to the capacitor bank
support.
25. 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.
26. 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.)
Remove standoffs (2) 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)
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)

Installing the Inverter Side DC Bus Bars (AC Input Drive Only)
Install the inverter side DC bus bars in the reverse order of removal. See
Removing the Inverter Side DC Bus Bars (AC Input Drive Only) on page 254.
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 Top DC Bus Bar Removing the Inverter Top DC Bus Bars (Common DC Input Drive Only)
(Common DC Input Drive
Only) 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
IN001, for details.
on page 221.
page 232.

backplane board.
Disconnect ribbon cable from T15 or F - 5.0 mm (0.19 in.)

backplane board 0.5 Nm (4.0 lbin)
Top DC bus bars Remove M3 screws (2)
Remove M4 screws (2)

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

14. Remove the three M6 hex nuts and washers that secure the front of the AC
output assembly to the capacitor bank support.

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

Remove hex nuts and
10.0 mm (0.4 in.) washers (3)
5.1 Nm (45.0 lbin)

16. Remove the two M6 hex nuts and two M5 x 10 mm hexalobular 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)
T25
Remove hex nuts (2) 2.8 Nm (25.0 lbin)
Remove screws (2)

capacitors to top DC bus bars.
19. Remove the two M4 x 40 mm standoffs secured to the capacitor bank
support.
20. Remove the two M6 hex nuts that secure the two discharge resistor wires
to the inverter top DC bus bars. Move the wires out of the way to allow for
removal of the top DC bus bars.
21. Remove the four M6 x 20 mm screws that secure the top 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.)
Remove standoffs (2) 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)
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)

Installing the Inverter Top DC Bus Bars (Common DC Input Drive Only)
Install the inverter top DC bus bars in the reverse order of removal. See
Removing the Inverter Top DC Bus Bars (Common DC Input Drive Only) on
page 262.
Inverter IGBT Assembly Removing the Inverter IGBT Assembly (AC Input Drive Only)
Input Drive Only)
page 21.
IN001, for details.
on page 221.
page 232.
10. Remove the inverter gate board ribbon cables. See Removing the Inverter
Gate Board Connection Ribbon Cables on page 233.
11. Remove the inverter gate boards. Removing the Inverter Gate Circuit
Board on page 235.
12. Remove the side DC bus bars. See Removing the Inverter Side DC Bus
Bars (AC Input Drive Only) on page 254.

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) T40 or F - 6.4 mm (0.25 in.)
9.0 Nm (80.0 lbin)

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.) Remove screws (3)

5.1 Nm (45.0 lbin)

15. Remove the six M6 x 14 mm screws from the capacitor bank support.
16. Remove the three M6 x 14 mm flat head screws on the lower right-hand
side of the capacitor bank support and remove the support.
17. Cut all of the cable ties that secure the wire harness to the capacitor bank
support and secure the wire harness to the side of the inverter unit away
from the capacitor bank support.
Remove screws (6) Remove screws (3)
T30 or F - 6.4 mm (0.25 in.) T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin) 5.1 Nm (45.0 lbin)

18. Connect the lifting hardware to the lifting holes on the front of the IGBT
assembly.
19. Remove the twelve 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.
Replace heatsink
gasket, if necessary
Lifting holes
Remove screws (12)
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
Remove screws (12)

Installing the Inverter IGBT Assembly (AC Input Drive Only)
1. Inspect the heatsink gasket on the inverter duct for damage and replace it if
necessary. See Inverter IGBT Assembly Heatsink Gasket Replacement on
page 276.
2. Install the inverter IGBT assembly in the reverse order of removal. See
Removing the Inverter IGBT Assembly (AC Input Drive Only) on page
267.
Inverter IGBT Assembly Removing the Inverter IGBT Assembly (Common DC Input Drive Only)
(Common DC Input Drive
Only) 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
IN001, for details.
on page 221.
page 232.
10. Remove the inverter gate board ribbon cables. See Removing the Inverter
Gate Board Connection Ribbon Cables on page 233.
11. Remove the inverter gate boards. Removing the Inverter Gate Circuit
Board on page 235.
12. Remove the inverter top DC bus bars. See Removing the Inverter Top DC
Bus Bars (Common DC Input Drive Only) on page 262.


5.1 Nm (45.0 lbin)

14. Remove the six M6 x 14 mm screws from the capacitor bank support.
15. Remove the three M6 x 14 mm flat head screws on the lower right-hand
side of the capacitor bank support and remove the support.
16. Cut all of the cable ties that secure the wire harness to the capacitor bank
support and secure the wire harness to the side of the inverter unit away
from the capacitor bank support.
Remove screws (6) Remove screws (3)
T30 or F - 6.4 mm (0.25 in.) T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin) 5.1 Nm (45.0 lbin)

17. Connect the lifting hardware to the lifting holes on the front of the IGBT
assembly.
18. Remove the twelve 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.
IGBT assembly gasket
Lifting holes
Remove screws (12)
T30 or F - 6.4 mm (0.25 in.)

5.1 Nm (45.0 lbin)
Remove screws (12)

Installing the Inverter IGBT Assembly (Common DC Input Drive Only)
1. Inspect the heatsink gasket on the inverter duct for damage and replace it if
necessary. See Inverter IGBT Assembly Heatsink Gasket Replacement
below.
2. Install the inverter IGBT assembly in the reverse order of removal. See
Removing the Inverter IGBT Assembly (Common DC Input Drive Only)
on page 272.
Inverter IGBT Assembly Removing the Inverter IGBT Assembly Heatsink Gasket
Heatsink Gasket
Replacement
page 21.
4. Remove the inverter IGBT assembly. See Removing the Inverter IGBT
Assembly (AC Input Drive Only) on page 267, or Removing the Inverter
IGBT Assembly (Common DC Input Drive Only) on page 272.
6. Clean the surface on which the gasket will be installed with a 50%
isopropyl alcohol / 50% water mixture.
Installing the Inverter IGBT Assembly Heatsink Gasket
adhesive.

Align gasket
edges with duct
edges
2. Install the inverter IGBT assembly in the reverse order f removal. See
Installing the Inverter IGBT Assembly (AC Input Drive Only) on page
272, or Installing the Inverter IGBT Assembly (Common DC Input Drive
Only) on page 276.

DC Choke Removal/ Removing the DC Choke (AC Input Drives Only)

Installation (AC Input Drives
Only)
page 21.
IN001, for details.
on page 221.

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. 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.
12. Loosen only, the six M6 x 70 mm screws that secure the DC choke to the
inverter.
13. Remove the four corner 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.
14. Pull the DC choke forward through the fan inlet opening and remove the
choke.
T40 or F - 6.4 mm (0.25 in.)
M8
9.0 Nm (80.0 lbin)
Remove M8 screws (8)
Loosen, then
remove M6 7.0 mm (0.3 in.)
screws (6) 1.8 Nm (16.0 lbin)
Remove M4 hex nuts (5)
T30 or F - 6.4 mm (0.25 in.)

M6
5.1 Nm (45.0 lbin)

Installing the DC Choke (AC Input Drives Only)
Install the DC choke in the reverse order of removal. See Removing the DC
Choke (AC Input Drives Only) on page 278.
Inverter Wire Harness Removing the Inverter Wire Harness

page 21.
IN001, for details.
on page 221.
8. Remove the inverter current sensor mounting panel only. Do not remove
the current sensors from the mounting panel. See Removing the Inverter
10. For AC input drives, remove the side DC bus bar assembly. See Removing
the Inverter Side DC Bus Bars (AC Input Drive Only) on page 254. For
common DC input drives, remove the top DC bus bar assembly. See
Removing the Inverter Top DC Bus Bars (Common DC Input Drive
Only) on page 262.


5.1 Nm (45.0 lbin)

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

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.

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 280.

Discharge Resistor Assembly Removing the Discharge Resistor Assembly

Note: The discharge resistor assembly includes the resistors, harness, and screws.

page 21.
IN001, for details.
on page 221.
page 232.
DC choke/converter bus EMC capacitors

1.8 Nm (16.0 lbin)
Remove hex
nuts (2)

connector to the backplane in the card cage.
T15 or F - 5.0 mm (0.19 in.)

0.5 Nm (4.0 lbin)
Inverter wire harness connector
Remove screws (2)
Remove screws (2)
T20 or F - 5.0 mm (0.19 in.)

1.8 Nm (16.0 lbin)

13. Remove the three M6 screws that secure the front of the AC output
assembly to the capacitor bank support.

bolts and pull
assembly forward.
Loosen hex nuts (2)
10.0 mm (0.4 in.) Remove hex nuts (3)

5.1 Nm (45.0 lbin)

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)

capacitors to the DC choke input positive and negative bus bars.
Remove hex 7.0 mm (0.3 in.)
nuts (2) 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)
Remove screws (4) and Remove screws (4) and
DC choke/converter washers (4) washers (4)
bus bar assembly
DC input and output positive and

negative bus bars

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
T30
M6
5.1 Nm (45.0 lbin)
Remove screws (3)

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 screw
Remove screws (4) Remove hex nuts (2) T20 or F - 5.0 mm (0.19 in.)
1.8 Nm (16.0 lbin)
T20 or F - 5.0 mm (0.19 in.) 7.0 mm (0.3 in.)
1.8 Nm (16.0 lbin) 5.1 Nm (45.0 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 284.

Inverter Heatsink Fan Inlet Removing the Inverter Heatsink Fan Inlet Bottom Cover
Bottom Cover Removal/
Installation
page 21.
IN001, for details.
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)

Installing the Inverter Heatsink Fan Inlet Bottom Cover
1. Inspect the inlet bottom cover gasket for damage and replace it if
necessary. See Inlet Bottom Cover Gasket Replacement on page 292.
2. 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 291.
Inlet Bottom Cover Gasket Removing the Inlet Bottom Cover Gasket
Replacement
page 21.
4. Remove the inverter heatsink fan inlet bottom cover. See Removing the
Inverter Heatsink Fan Inlet Bottom Cover on page 291.
Installing the Inlet Bottom Cover Gasket
adhesive.
the cover edges and press the gasket into place on the duct.
2. Install the inverter heatsink fan inlet bottom cover. See Installing the
Inverter Heatsink Fan Inlet Bottom Cover on page 292.

Chapter 8
AC Input Drive Enclosure Component

Topic Page
AC Input Drive Enclosure Components Identification Below
IP20, NEMA/UL Type 1 Door Filter Removal/Installation 294
Exhaust Duct Removal/Installation 295
Top Conduit Plate Removal/Installation 296
Enclosure Door Fan Removal/Installation 297
Enclosure Door Fan Harness Removal/Installation 298
DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger 301
Drives Only)
DC Bus Fuses and Fuse Indicators Removal/Installation (Frame 9 and 303
Larger Drives Only)
Input Common Mode Core Removal/Installation (Frame 9 and Larger 306
Drives Only)
Cabinet L Bus Bar(s) Removal/Installation 309
Cabinet Door EMC Shield Removal/Installation (Frame 10 Drives Only) 310
This chapter provides detailed procedures for removing and replacing AC input
drive enclosure components.
AC Input Drive Enclosure The following table lists the components that make up the AC input drive
enclosure and the catalog numbers for components that are available as
Components Identification replacement parts.
Component Name Replacement Kit/Part Cat. No. Kit Qty.

IP20, NEMA/UL Type 1 Door Filter 20-750-FLTR1-F8 1
Exhaust Duct 20-750-HOOD1-F8 1
Top Conduit Plate 600 mm SK-R1-CPLT1-F8 1
Top Conduit Plate 800 mm SK-R1-CPLT2-F8 1
Door Fan with Finger Guard 20-750-FAN3-F8 1
Door Fan Harness SK-R1-FANH1-F8 1
DC Bus Fuse, 1400A SK-R1-FUSE3-F9 1
DC Bus Fuse Wire Harness SK-R1-DCBUSH1-F9 1
Input Common Mode Core 20-750-EMCCM1-F9 (Frame 9) 1
Cabinet L Bus Bar 20-750-LBRKT1 1
Cabinet Door Shield Kit (Frame 10) 20-750-EMCDK1-F10 15

Chapter 8 AC Input Drive Enclosure Component Replacement Procedures

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

Filter Removal/Installation
Note: This procedure applies to both AC input and Common DC input drive
enclosures.

page 21.
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 above.

AC Input Drive Enclosure Component Replacement Procedures Chapter 8
Exhaust Duct Removal/ Removing the Exhaust Duct

Installation
page 21.
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 above.

Top Conduit Plate Removal/ Removing the Top Conduit Plate

Installation
page 21.
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 above.

Enclosure Door Fan Removal/ Removing the Enclosure Door Fan

Installation
page 21.
4. Remove the M5 x 8 mm screw that secures the fan power harness ground
wire to the fan and remove the ground wire. Retain the screw for reuse.
5. Disconnect the Fan (+) and Fan (-) power wires from the fan terminals.
Disconnect power wires
Remove screw and ground wire
T25 or F - 6.4 mm (0.25 in.)

2.8 Nm (25 lbin)

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 Enclosure Door Fan

Install the enclosure door fan in the reverse order of removal. See Removing the
Enclosure Door Fan on page 297.
IMPORTANT When installing a new fan, verify that the air flow direction arrow on the fan
points toward the exterior of the drive enclosure.
Enclosure Door Fan Harness Removing the Enclosure Door Fan Wire Harness
page 21.

4. Disconnect the 2-position, fan power connector from terminal TB2-3 and
TB2-4 on the outside, right wall of the drive control panel.
5. Remove the M6 grounding nut from the enclosure wire way ceiling.
6. Cut the cable ties on the enclosure wire way.
10.0 mm
5.1 Nm (45.0 lbin)
Remove hex nut and ground wire
Cut cable ties on wire way
Disconnect connector from TB2

wires to each of the fans and remove the ground wires.
8. Disconnect the Fan (+) and Fan (-) power wires from the terminals on
both fans and remove the fan harness.
T25 or F - 6.4 mm (0.25 in.)

2.8 Nm (25 lbin)
Installing the Enclosure Door Fan Wire Harness
Install the enclosure door fan harness in the reverse order of removal. See
Removing the Enclosure Door Fan Wire Harness on page 298.

DC Bus Fuse Wire Harness Removing the DC Bus Fuse Wire Harness
page 21.
4. The DC bus fuses and fuse indicators, to which the wire harness is
connected, are located at the back of the drive enclosure. Therefore, the
drive assemblies must be removed from the enclosure. Remove the drive
assemblies from the enclosure. Refer to the PowerFlex 750-Series AC
Drive Installation Instructions, publication number 750-IN001, for
details.
IMPORTANT In addition to the wiring removal detailed in the PowerFlex 750-Series

AC Drive Installation Instructions, you must disconnect the 3-position,
DC bus fuse wire harness connector from terminal block TB6 on the
lower left side of the converter (as shown below).
Disconnect connector from terminal block TB6
Note: Converter shown removed from drive enclosure for clarity only.

5. Unlock the cable support on the left wall of the drive enclosure and release
the DC bus wire harness from the support.
6. Remove the DC bus wire harness leads from the fuse indicators and
remove the wire harness.
Unlock cable
DC bus wire harness support
Remove leads from

fuse indicators
Note: Fuse shown removed for

clarity only.
Installing the DC Bus Fuse Wire Harness
Install the DC Bus Fuse Wire Harness in the reverse order of removal. See
Removing the DC Bus Fuse Wire Harness on page 301.

DC Bus Fuses and Fuse Removing the DC Bus Fuses and Fuse Indicators
Indicators Removal/
Installation (Frame 9 and
Larger Drives Only) 2. Remove power from the drive. See Removing Power from the Drive on
page 21.
4. The DC bus fuses and fuse indicators are located at the back of the drive
enclosure. Therefore, the drive assemblies must be removed from the
enclosure. Remove the drive assemblies from the enclosure. Refer to the
PowerFlex 750-Series AC Drive Installation Instructions, publication
number 750-IN001, for details.


5. Remove the two M10 hex nuts that secure each of the L-brackets to the
drive backplane DC bus (extruded bars) at the back of the drive enclosure.
6. Remove the two M10 hex nuts that secure each of the brackets to the DC+
and DC- forward bus bar terminals.
Replace each fuse with the terminals in same orientation.
7. Remove the DC bus wire harness leads from the fuse indicators and slide
the fuse assemblies off of the bolts.
10.0 mm
3.2 Nm (28.0 lbin)
Remove M10 hex nuts
Remove leads from

fuse indicators
Important: Note the orientation of the fuse indicator terminals before removal. Replace
each fuse with the terminals in same orientation.
DC+ (FU7) - terminals point downward.
DC- (FU8) - terminals point upward.

8. Remove the two M12 x 18 mm hex bolts and washers that secure the L-
bracket and connector plate to the fuse and remove the fuse.
Connector plate
12.0 mm
Fuse and fuse indicator 3.2 Nm (28.0 lbin)
Remove M12 hex
bolt and washer
Note: DC+ bus terminal shown removed

from drive for clarity only.
Remove M12 hex
bolt and washer
12.0 mm L-bracket
5.2 Nm (46.0 lbin)
Installing the DC Bus Fuses and Fuse Indicators
Install the DC bus fuses and fuse indicators in the reverse order of removal. See
Removing the DC Bus Fuses and Fuse Indicators on page 303.

Input Common Mode Core Removing the Input Common Mode Core
page 21.
4. The input common mode core is located at the back of the drive enclosure.
Therefore, the drive assemblies must be removed from the enclosure.
Remove the drive assemblies from the enclosure. Refer to the PowerFlex
IN001, for details.


5. Remove the two M10 nuts that secure the center (S/L2) AC input
terminal to the input common mode core assembly.
6. Remove the M8 nut and washer that secures the center (S/L2) AC input
terminal and isolation sheet to the insulator material on the side of the
drive enclosure and remove the terminal and isolation sheet.
7. Remove front plate and aluminum core for the center terminal from the
bolts.
8.0 mm
1.0 Nm (8.3 lbin)
Remove M8 hex nut and washer
10.0 mm
3.2 Nm (28.0 lbin)
Remove M10 hex nuts
Remove front Remove

plate aluminum core

8. Remove the four M10 nuts that secure the remaining (R/L1, T/L3) AC
input terminals to the input common mode core assembly.
9. Remove the two M8 nuts that secure each of the remaining (R/L1, T/L3)
AC input terminals to the insulator material on the side of the drive
enclosure and remove the terminals.
10. While supporting the input common mode core, remove the two front
plates from the bolts connected to the drive backplane DC bus (extruded
bars) at the back of the enclosure.
11. Remove the input common mode core.
12. Remove the two aluminum cores from the bolts.
13. Remove the three back plates from the bolts.
8.0 mm
1.0 Nm (8.3 lbin)
Remove M8 hex nut and washer Remove input common
Remove mode core
aluminum core
Remove back
10.0 mm Remove plates
front plate
3.2 Nm (28.0 lbin)
Remove M10 hex nuts
8.0 mm
1.0 Nm (8.3 lbin)
10.0 mm
3.2 Nm (28.0 lbin)
Remove M10 hex nuts
Remove front plate
Remove aluminum core
Installing the Input Common Mode Core
Install the input common mode core assembly in the reverse order of removal. See
Removing the Input Common Mode Core on page 306.
IMPORTANT The isolation sheet that separates the S/L2 terminal from the other two
terminals must be installed in the same location as it was prior to removal.

Cabinet L Bus Bar(s) Removing the Cabinet L Bus Bar(s)

Note: The cabinet L bus bars are used on both AC input and common DC input
frame 10 drives.

page 21.
4. The cabinet L bus bar is located at the back of the drive enclosure.
Therefore, the drive assemblies must be removed from the enclosure.
Remove the drive assemblies from the enclosure. Refer to the PowerFlex
IN001, for details.
5. Disconnect the AC line input power, output to motor, or DC power
cables from the L bus bar(s).
6. Loosen the two M10 x 1.5 nuts that secure each L bus bar to the extruded
bus bar at the back of the cabinet, slide the L bus bar(s) and hardware to
the notch in the extruded bus bar and pull the bus bar, clamp, and bolt off
the bus bar.
Disconnect AC line input

power, output to motor,
or DC power cables
17.0 mm (0.7 in.)

38.0 Nm (336.0 lbin)

Installing the Cabinet L Bus Bar(s)
Install the cabinet L bus bar(s) in the reverse order of removal. See Removing the
Cabinet L Bus Bar(s) on page 309.
IMPORTANT Verify that the clamp fits squarely in the extruded bus bar slot.
Verify clamp fits

squarely in slot
Cabinet Door EMC Shield Removing the Cabinet Door EMC Shield
Note: The cabinet door EMC shield assembly is used on both AC input and
10 Drives Only) common DC input frame 10 drives.

page 21.

4. Remove the two hex head screws that secure the EMC assembly (five per
cabinet) to the cabinet frame and remove the assembly.
Remove the two (2)

hex head screws
8 mm
25.0 Nm (2.8 lbin)

5. Remove the M5 hex nut that secures the EMC assembly (five per door) to
the cabinet door and remove the assembly.
Remove hex nut
EMC foam
EMC block
Installing the Cabinet Door EMC Shield

Install the cabinet door shield in the reverse order of removal. Verify that the new
EMC shield kit is installed as described in the illustration below. Also, see
Removing the Cabinet Door EMC Shield on page 310.
Align the end of the EMC foam with

the edge of the EMC block. Take
care to properly align the foam
before fully removing the paper 8 mm
liner and exposing the adhesive. 25.0 Nm (2.8 lbin)
Then press the foam into place.
Tighten hex nut
EMC foam EMC block
Align the edge of the

EMC block with the inside
edge of the door flange
16 mm
(0.63 in.)

Chapter 9
Common DC Input Drive Enclosure Component

Topic Page
Common DC Input Drive Enclosure Components Identification Below
Enclosure Door Fan Removal/Installation 314
Enclosure Door Fan Wire Harness Removal/Installation 315
DC Back Bus Guards Removal/Installation 317
120/240V Control Power Input Wire Harness Removal/Installation 319
120/240V Control Power Output Wire Harness Removal/Installation 320
120/240V Circuit Breaker Removal/Installation 321
120V UPS Power Input Wire Harness Removal/Installation 323
Input Common Mode Core Removal/Installation (Common DC Input Drives) 324
This chapter provides detailed procedures for removing and replacing common
DC input drive enclosure components.
Common DC Input Drive The following table lists the components that make up the common DC input
drive enclosure and the catalog numbers for components that are available as
Enclosure Components replacement parts.
Identification
Component Name Replacement Kit/Part Cat. No. Kit Qty.
DC Input Cabinet Wire Harness Kit SK-R1-CBPBRKH1-F8 N.A.
Wire Harness, 120/240V Control Power 1
Wire Harness, Transformer Primary 1
Wire Harness, 120V UPS Input 1
DC Input Cabinet Back Bus Guard Kit SK-R1-CBPGRD1-F8 N.A.
Guard, Control Rail 2
Guard, DC Bus 1
Door Fan with Finger Guard 20-750-FAN3-F8 1
Door Fan Harness SK-R1-FANH1-F8 1
Input Common Mode Core 20-750-CBPEMCCM1-F8 1
Cabinet L Bus Bar (see Cabinet L Bus Bar(s) Removal/ 20-750-LBRKT1 1
Installation on page 309 for instructions)
Circuit Breaker, 2-Pole, 13A 1489-A2D130A 1
Lockout Attachment 1489-AALOA 1
Cabinet Door Shield Kit (Frame 10) (see Cabinet Door EMC 20-750-EMCDK1-F10 1
Shield Removal/Installation (Frame 10 Drives Only) on page
310 for instructions)

Chapter 9 Common DC Input Drive Enclosure Component Replacement Procedures
TIP Refer to Fastener/Tool/Torque Information on page 28for descriptions of the

Enclosure Door Fan Removal/ Removing the Enclosure Door Fan

Installation
page 21.
wire to the fan and remove the ground wire. Retain the screw for reuse.
5. Disconnect the Fan (+) and Fan (-) power wires from the fan terminals.
T25 or F - 6.4 mm (0.25 in.)

2.8 Nm (25 lbin)

Common DC Input Drive Enclosure Component Replacement Procedures Chapter 9
T20 or F - 6.4 mm (0.25 in.)

4.0 Nm (35 lbin)
Remove screws (4)
Air flow direction
Remove screws (4)
T20 or F - 6.4 mm (0.25 in.)

4.5 Nm (40 lbin)
Installing the Enclosure Door Fan

Install the enclosure door fan in the reverse order of removal. See Removing the
Enclosure Door Fan on page 314.
points toward the exterior of the drive enclosure.
Enclosure Door Fan Wire Removing the Enclosure Door Fan Wire Harness
Harness Removal/
Installation
page 21.

5. Remove the M6 grounding nut from the enclosure wire way ceiling.
6. Cut the cable ties that secure the wire harness to the enclosure wire way.
10.0 mm
5.1 Nm (45 lbin)
Remove hex nut and ground wire
Cut cable ties on wire way
Disconnect connector from TB2

wires to each of the fans and remove the ground wires.
8. Disconnect the Fan (+) and Fan (-) power wires from the terminals on
both fans and remove the fan harness.
T25 or F - 6.4 mm (0.25 in.)

2.8 Nm (25 lbin)
Installing the Enclosure Door Fan Wire Harness
Install the enclosure door fan harness in the reverse order of removal. See
Removing the Enclosure Door Fan Wire Harness on page 315.
DC Back Bus Guards Removal/ Removing the DC Back Bus Guards

Installation
page 21.
IN001, for details.

4. Remove the two -20 x 1 in. hex head screws that secure the top guard
(covering the 120V control bus) to the enclosure and remove the guard.
5. Remove the four M10 x 16 mm screws that secure the middle guard
(covering the +DC and -DC bus) to the enclosure and remove the guard.
6. Remove the two -20 x 1 in. hex head screws that secure the bottom guard
(covering the 120V UPS bus) to the enclosure and remove the guard.
7/16 in.
5.1 Nm (45 lbin)
Remove screws (2)
T45
5.1 Nm (45 lbin)
Remove screws (4)
Remove screws (2)

7/16 in.
5.1 Nm (45 lbin)
Installing the DC Back Bus Guards
Install the DC back bus guards in the reverse order of removal. Guards must be
replaced before returning the drive to service. See Removing the DC Back Bus
Guards on page 317.

120/240V Control Power Removing the 120/240V Control Power Input Wire Harness
Input Wire Harness Removal/
Installation
page 21.
IN001, for details.
4. Remove the top DC bus back guard to access the 120V control bus. See
Removing the DC Back Bus Guards on page 317.
5. Loosen the two -20 x in. hex head screws that secure the harness to the
120V control bus and remove the wires.
6. Loosen the screws that secure the input wires to terminals SW5-2 and
SW5-4 on the bottom of the circuit breaker and remove the wires.
7. Cut the cable ties that secure the wire harness to the enclosure wire ways
and remove the harness.
Cut cable ties
Loosen screws (2)
7/16 in.
5.1 Nm (45 lbin)
Loosen screws (2)

PZ2
2.8 Nm (25 lbin)

Installing the 120/240V Control Power Input Wire Harness
Install the 120/240V control power input wire harness in the reverse order of
removal. See Removing the 120/240V Control Power Input Wire Harness on
page 319.
120/240V Control Power Removing the 120/240V Control Power Output Wire Harness
Output Wire Harness
page 21.
4. Loosen the screws that secure the output wires from terminals SW5-1 and
SW5-3 on the top of the circuit breaker and remove the wires.
5. Disconnect the 2-position connector from terminal block TB2-3 and
TB2-4 on the outside right wall of the drive control panel.
6. Cut the cable ties from enclosure wire ways and remove the harness.
Disconnect connector from TB2 Cut cable ties
PZ2
2.8 Nm (25 lbin)
Loosen screws (2)

Installing the 120/240V Control Power Output Wire Harness
Install the 120/240V control power output wire harness in the reverse order of
removal. See 120/240V Control Power Output Wire Harness Removal/
120/240V Circuit Breaker Removing the 120/240V Circuit Breaker

page 21.
4. Loosen the screws that secure the output wires to terminals SW5-1 and
SW5-3 on the top of the circuit breaker, and the input wires to terminals
SW5-2 and SW5-4 on the bottom of the circuit breaker, and remove the
wires.
Remove wires
Loosen screws (4)
PZ2
2.8 Nm (25 lbin)
Remove wires

5. Release the spring-loaded latches at the bottom of the circuit breaker and
lift the circuit breaker off the DIN rail.
Release latches and

remove circuit breaker
from DIN rail
Installing the 120/240V Circuit Breaker

Install the 120/240V circuit breaker in the reverse order of removal. See
Removing the 120/240V Circuit Breaker on page 321.

120V UPS Power Input Wire Removing the 120V UPS Power Input Wire Harness
Harness Removal/
Installation
page 21.
IN001, for details.
4. Remove the bottom DC bus back guard to access the 120V UPS bus. See
Removing the DC Back Bus Guards on page 317.
5. Loosen the two -20 x in. hex head screws that secure the harness to the
120V UPS bus and remove the wires.
6. Disconnect the 2-position connector from terminal block TB2-1 and
7. Cut the cable ties that secure the wire harness to the enclosure wire ways
and remove the harness.

TB2-1 and TB2-2
Cut cable ties

7/16 in.
5.1 Nm (45 lbin)
remove wires

Installing the 120V UPS Power Input Wire Harness
Install the 120V UPS power input wire harness in the reverse order of removal.
See Removing the 120V UPS Power Input Wire Harness on page 323.
Input Common Mode Core Removing the Input Common Mode Core
(Common DC Input Drives)
page 21.
4. The input common mode core is located at the back of the drive enclosure.
Therefore, the drive assembly must be removed from the enclosure.
Remove the drive assembly from the enclosure. Refer to the PowerFlex
IN001, for details.

5. Remove the two M10 nuts and washers that secure each of the DC+ and
DC- input terminals to the input common mode core assembly.
6. Remove the M8 nut and washer that secures each of the DC+ and DC-
input terminals to the insulator material on the side of the drive enclosure
and remove the terminals.
7. While supporting the input common mode core, remove the two front
plates from the bolts connected to the drive backplane DC bus (extruded
bars) at the back of the enclosure.
8. Remove the input common mode core from the back plates.
9. Remove the two aluminum cores from the bolts.
10. Remove the two back plates from the bolts.
8.0 mm
1.0 Nm (8.3 lbin) Remove input common
mode core
Remove back
10.0 mm plates
3.2 Nm (28.0 lbin)
Remove M10 hex nuts Remove aluminum
cores
Remove front
plates
Installing the Input Common Mode Core

Install the input common mode core assembly in the reverse order of removal. See
Removing the Input Common Mode Core on page 324.

Notes:

Chapter 10
Option Bay Enclosure Component Replacement

Procedures
Topic Page
Option Bay Enclosure Components identification Below
Disconnect Handle Panel Removal/Installation 328
Door Fan Removal/Installation 329
Thermostat Removal/Installation 330
Bottom Conduit Plate Removal/Installation 332
This chapter provides detailed procedures for removing and replacing option bay
enclosure components.
Option Bay Enclosure The following table lists the components that make up the option bay enclosure
and the catalog numbers for components that are available as replacement parts.
Components identification
Component Name Spare Kit Catalog Number
Disconnect Handle Panel SK-R1-ODISCP1-F8
Door Fan with Finger Guard 20-750-FAN3-F8
Thermostat SK-R1-OTH1-F8


Chapter 10 Option Bay Enclosure Component Replacement Procedures
Disconnect Handle Panel Removing the Disconnect Handle Panel

page 21.
3. Open the option bay door.
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.

Option Bay Enclosure Component Replacement Procedures Chapter 10
Door Fan Removal/ Removing the Door Fan

Installation
page 21.
3. Open the enclosure door of the drive bay containing the control pod.
Remove fan power connector from TB2

5. Open the option bay enclosure door.

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 329.
points to the exterior of the drive enclosure.
Thermostat Removal/ Removing the Thermostat

Installation
page 21.
3. Open the option bay enclosure door.

Option Bay Enclosure Component Replacement Procedures Chapter 10
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 330.

Bottom Conduit Plate Removing the Bottom Conduit Plate

page 21.
3. Remove the eight M5 x 16 screws that secure the plate to the bottom of the
enclosure and remove the plate.
T20
Remove screws 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 above.

Chapter 11
Enclosure Cable Components Replacement

Procedures (Frame 9 and Larger Drives)
Topic Page
Enclosure Cable Components and Part Numbers Below
24V Wire Harness Removal/Installation (Frame 9 and Larger Drives) 334
First Inverter (INV1) Fiber-optic Cable Removal/Installation 338
Second Inverter (INV2) Fiber-optic Cable Removal/Installation 342
Third Inverter (INV3) Fiber-optic Cable Removal/Installation 347
Fiber-optic Spool Removal/Installation 351
This chapter provides detailed procedures for removing and replacing enclosure
cable components used on frame 9 and larger drives.
Enclosure Cable Components The following table lists the components that make up the frame 9 and larger
drive enclosure cables and the catalog numbers for components that are available
and Part Numbers as replacement parts.
IMPORTANT Use only Rockwell Automation provided fiber-optic cables and transceivers.
Use of third-party components is not supported.
Component Name Spare Kit Catalog Number Kit Qty.

2-Bay 24V Wire Harness Kit 20-750-PH2-F9 1
3-Bay 24V Wire Harness Kit 20-750-PH3-F10 1
Fiber-optic Cable, 2.8 m (110 in.) Long, Kit 20-750-FCBL1-F10 N.A.
Fiber-optic Cable, 2.8 m (110 in.) Long 1
Cable Label 1
Fiber-optic Cable Spool Kit 20-750-SPL1-F10 1
Fiber-optic Transceiver SK-R1-FTR1-F8 1


Chapter 11 Enclosure Cable Components Replacement Procedures (Frame 9 and Larger Drives)
24V Wire Harness Removal/ Removing the 24V Wire Harness (Frame 9 and Larger Drives)
Installation (Frame 9 and
Larger Drives)
page 21.
3. Open the enclosure doors.
4. Complete the following steps in the drive bay that holds the control pod.
a. Remove the control pod cover. See Removing the Control Pod Cover
on page 50.
b. Disconnect the J14 connector from P14 on the fiber interface board in
the control pod.
Fiber Interface Board
P12
P15
P1 P2 P3

Enclosure Cable Components Replacement Procedures (Frame 9 and Larger Drives) Chapter 11
c. Disconnect the 3-position 24V wire harness connector from terminal

block TB1 on the control panel (behind the control pod) and remove
the cable from the cable support on the bottom of the control panel.
Disconnect 24V wire harness

from terminal block TB1
Control pod

d. Unlock the three cable supports along the inside left wall of the control
pod.
e. Open the two releaseable cable ties; one at the top left of the control
pod, and one on the horizontal wire way at the top of the enclosure.
24V wire harness
Wire way
Open releaseable cable ties

and remove 24V wire harness
Unlock cable
supports

5. Complete the following steps in each additional enclosure.

a. Remove the converter or common bus precharge right cover. See
Removing the Converter Right Cover (No Control Pod) on page 78 or
b. Disconnect the 3-position 24V wire harness connector from terminal
block TB1 on the control panel and remove the cable from the cable
support on the bottom of the control panel.
c. Open the three releaseable cable ties along the inside right wall of the
control panel.
6. On the horizontal wire way, open all releaseable cable ties.
7. Remove the 24V wire harness from the enclosures.
24V wire harness
Wire Way

and remove 24V wire
harness
Release cable from

cable support
Disconnect 24V wire harness from

terminal block TB1
Installing the 24V Wire Harness (Frame 9 and Larger Drives)
Install the 24V wire harness in the reverse order of removal. See Removing the
24V Wire Harness (Frame 9 and Larger Drives) on page 334.

First Inverter (INV1) Fiber- Removing the First Inverter (INV1) Fiber-optic Cable
optic Cable Removal/
Installation with a shorter inside radius can permanently damage the fiber-optic cable.

page 21.
4. Remove the control pod cover. See Removing the Control Pod Cover on
page 50.
5. Disconnect the fiber-optic cable from INV1 on the fiber interface board in
the control pod.

6. Disconnect the fiber-optic cable from INV on the power layer interface
board in the inverter card cage (below the control pod).
Fiber interface
board
P12
P15
J7 J6
Power layer
interface board
P2
CONV
INV

7. Unlock the three cable supports along the inside left wall of the control
pod.
8. Open the releaseable cable tie at the top left of the control pod.
9. On the cable spool located at the top of the horizontal enclosure wire way,
open the two releaseable cable ties and unspool the fiber-optic cable from
the cable supports and remove the fiber-optic cable.
Wire way
Open releaseable cable ties and
supports on spool and remove the
fiber-optic cable
Fiber-optic cable
Open releaseable
cable tie
Unlock cable
supports
Fiber-optic cables disconnected from

INV on power layer interface board

Installing the First Inverter (INV1) Fiber-optic Cable
IMPORTANT Frame 9 and larger drives fiber-optic cables connected between the fiber
interface circuit board and the power layer interface circuit board on each
inverter must be the same length. Cables kits are provided with a length of 2.8
m (110 in.) to meet this requirement.
IMPORTANT When installing the new fiber-optic cable on the inverters for frame 9 and 10
drives, the cable must be looped through the cable supports on the fiber-optic
cable spool as directed in the following table and be routed through all existing
cable ties as previously installed.
Drive Enclosure Number of Fiber-optic Cable Loops on Spool

First Inverter 2
Second Inverter 1
Third Inverter 0
Install the first inverter (INV1) fiber-optic cable in the reverse order of removal.
See Removing the First Inverter (INV1) Fiber-optic Cable on page 338.

Second Inverter (INV2) Fiber- Removing the Second Inverter (INV2) Fiber-optic Cable
Installation
page 21.
on page 50.
b. Disconnect the fiber-optic cable from INV2 on the fiber interface
board in the control pod.
Fiber interface
board
P12
P15
Disconnect fiber-
optic cable from INV2

c. Unlock three cable supports along the inside left wall of the control
pod.
d. Open the two releaseable cable ties; one at the top left of the control
Open releaseable
cable tie
Fiber-optic cable
Unlock cable
supports

5. Complete the following steps in the second bay.

b. Disconnect the fiber-optic cable from INV on the power layer interface
board in the inverter card cage (below the control panel).
J7 J6
P2
CONV Disconnect fiber-optic cable from INV on
INV power layer interface board on second
inverter

control panel.
d. Open the two releaseable cable ties on the horizontal enclosure wire
way.
e. On the cable spool located at the top of the horizontal enclosure wire
way, open the two releaseable cable ties and unspool the fiber-optic
cable from the cable supports and remove the fiber-optic cable.
Wire way
Fiber-optic cable
Open releaseable cable ties and
supports and remove the fiber-optic
cable
Open releaseable
cable ties


Installing the Second Inverter (INV2) Fiber-optic Cable

First Inverter 2
Second Inverter 1
Third Inverter 0
Install the second inverter (INV2) fiber-optic cable in the reverse order of
removal. See Removing the Second Inverter (INV2) Fiber-optic Cable on page
342.

Third Inverter (INV3) Fiber- Removing the Third Inverter (INV3) Fiber-optic Cable
Installation
page 21.
on page 50.
b. Disconnect the fiber-optic cable from INV3 on the fiber interface
board in the control pod.
Fiber interface
board
P12
P15
Disconnect fiber-
optic cable from INV3

c. Unlock three cable supports along the inside left wall of the control
pod.
d. Open the two releaseable cable ties; one at the top left of the control
Open releaseable
cable tie
Fiber-optic cable
Unlock cable
supports

5. Complete the following steps in the third bay.

b. Disconnect the fiber-optic cable from INV on the power layer interface
board in the inverter card cage (below the control panel).
J7 J6
P2
CONV Disconnect fiber-optic cable from INV on
INV power layer interface board on second
inverter

control panel.
d. Open the four releaseable cable ties on the horizontal enclosure wire
way and remove the fiber-optic cable.
Wire way
Fiber-optic cable
Open releaseable
cable ties


Installing the Third Inverter (INV3) Fiber-optic Cable

First Inverter 2
Second Inverter 1
Third Inverter 0
Install the third inverter (INV3) fiber-optic cable in the reverse order of removal.
See Removing the Third Inverter (INV3) Fiber-optic Cable on page 347.
Fiber-optic Spool Removal/ Removing the Fiber-optic Spool

Installation
page 21.

4. Open the releaseable cable ties on the fiber-optic spool.

5. Carefully unspool the fiber-optic cable from the cable supports on the
spool.
6. Remove the M6 x 14 mm hex screw that secures the spool to the enclosure
wire way.
7. Lift the spool up to release the it from the tabs on the wire way and remove
the spool.
Open releaseable cable tie
14.0 mm
5.1 Nm (45.0 lbin)
Remove hex
head screw
Unspool fiber-
optic cable
Open releaseable cable tie
Installing the Fiber-optic Spool
Install the fiber-optic spool in the reverse order of removal. See Removing the
Fiber-optic Spool on page 351.

First Inverter 2
Second Inverter 1
Third Inverter 0

Chapter 12
IP54, NEMA/UL Type 12 Enclosure Components

Topic Page
IP54, NEMA/UL Type 12 Enclosure Components and Part Numbers Below
Cabinet Blower Harness Removal/Installation 354
Cabinet Blower Exhaust Filters Removal/Installation 355
Cabinet Door Filters Removal/Installation 356
Cabinet Door Filter Cassette Removal/Installation 358
Cabinet Door Gasket Removal/Installation 359
This chapter provides detailed procedures for removing and replacing IP54,
NEMA/UL Type 12 enclosure components.
IP54, NEMA/UL Type 12 The following table lists the components that make up the IP54, NEMA/UL
Type 12 enclosure and the catalog numbers for components that are available as
Enclosure Components and replacement parts.
Part Numbers
IMPORTANT Use only Rockwell Automation provided filters, gaskets, and components. Use
of third-party components is not supported.
Component Name Spare Kit Catalog Number Kit Qty.

Cabinet Blower Assembly SK-R1-FAN3-F8 1
Cabinet Blower Harness SK-R1-FANH3-F8 1
Cabinet Blower Exhaust Filter, Fiber (Single) SK-R1-FLTR2-F8 1
Cabinet Blower Exhaust Filter, Fiber (Multi) SK-R1-FLTR2M-F8 2
Cabinet Door Filter Cassette SK-R1-FLTRFRM-F8 1
Cabinet Door Inlet Filter, Pleated (Single) SK-R1-FLTR3-F8 1
Cabinet Door Inlet Filter, Pleated (Multi) SK-R1-FLTR3M-F8 2
Cabinet Door Inlet Filter, Metal Mesh SK-R1-FLTR4-F8 1
Cabinet Door Gasket SK-R1-G2-F8 1


Chapter 12 IP54, NEMA/UL Type 12 Enclosure Components Replacement Procedures
Cabinet Blower Harness Removing the Cabinet Blower Harness

page 21.
IN001, for details.
4. Remove the blower assembly from the drive. Refer to the PowerFlex 750-
Series AC Drive Installation Instructions, publication number 750-IN001,
for details.
5. Remove the M6 x 12 mm screw that secures the wire harness ground wire
to the cabinet.
6. Cut all cable ties that secure the blower wire harness to the cabinet and
remove the wire harness.
Remove cable through
opening in roof of enclosure
Remove cable tie
Remove screw
Remove cable tie
10.0 mm
6.7 Nm (60 lbin)

IP54, NEMA/UL Type 12 Enclosure Components Replacement Procedures Chapter 12
Installing the Cabinet Blower Harness
Install the cabinet blower harness in the reverse order of removal. See Removing
the Cabinet Blower Harness on page 354.
Cabinet Blower Exhaust Removing the Cabinet Blower Exhaust Filters

Filters Removal/Installation
page 21.
3. Loosen the two hexalobular screws that secure each of the outer metal
mesh filters to the blower assembly and remove the outer metal and inner
fiber filters from the blower.
Metal filter Fiber filter
Loosen two (2) screws

(one either side of filter)
and remove filters
T25
2.8 Nm (25 lbin)
Fiber filter Metal filter
Loosen two (2) screws

(one either side of filter)
and remove filters

Installing the Cabinet Blower Exhaust Filters
Install the cabinet blower exhaust filters in the reverse order of removal. See
Removing the Cabinet Blower Exhaust Filters on page 355.
Cabinet Door Filters Removing the Cabinet Door Filters

page 21.
3. Remove the four hexalobular screws that secure the filter cassette cover to
the filter cassette chassis and remove the cover.
4. Remove the pleated fiber filter from the cassette on the cabinet door.
Remove pleated
fiber filter
Remove
screws
Remove screws
T25
2.8 Nm (25 lbin)

5. Loosen the four hexalobular screws located on the outside walls of the
cassette chassis that secure the metal mesh filter to the chassis.
6. Rotate the four metal latches on the inside wall of the cassette chassis and
remove the filter.
Loosen
screws
T25
2.8 Nm (25 lbin)
Rotate
latches
Loosen
screws
Loosen
screws
Remove metal mesh filter
Installing the Cabinet Door Filters
Install the cabinet door filters in the reverse order of removal. See Removing the
Cabinet Door Filter Cassette on page 358.

Cabinet Door Filter Cassette Removing the Cabinet Door Filter Cassette
page 21.
3. Remove the cabinet door filters. See Cabinet Door Filters Removal/
4. Remove the 16 hex nuts that secure the filter cassette chassis to the cabinet
door and remove the chassis.
Remove 16 hex nuts

8.0 mm
2.8 Nm (25 lbin)
Installing the Cabinet Door Filter Cassette

Install the cabinet door filter cassette in the reverse order of removal. See
Removing the Cabinet Door Filter Cassette on page 358.

Cabinet Door Gasket Removing the Cabinet Door Gasket

page 21.
Remove existing gasket
Note: Cabinet door not

shown for clarity only.
Installing the Cabinet Door Gasket
Note: One side of the door gasket is coated with an adhesive. Take care to
adhesive.
Begin removing the paper liner as you align the replacement gasket with
the cabinet edges and press the gasket into place.

Notes:

Chapter 13
Start-Up After Repairs
Topic Page
Before Applying Power to the Drive Below
Testing With the Motor Without a Mechanical Load 363
This chapter provides detailed instructions for starting up a drive after you have
made certain repairs.
Before Applying Power to the 1. Check the DC bus voltage at the -DC and +DC testpoints sockets on the
front of the power module.
Drive

Chapter 13 Start-Up After Repairs
2. Perform forward and reverse biased diode tests, using a digital multimeter.
See Forward and Reverse Biased SCR/Diode Tests on page 39.
3. Inspect the drive for loose bolts, disconnected cables, etc.
4. Verify the following connections.
The fiber-optic cables from the control pod to each inverter, and from
each inverter to its corresponding converter, are connected at both ends
and properly supported by cables ties along their entire length when
connected between enclosures.
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:
Converter Transformer Primary Terminal Input Voltage
Connections
H1 & H2 380/415
H1 & H3 440/480
H1 & H4 575/600
H1 & H5 690
If any work was performed on the DC input with precharge assembly,

inspect all DC input wire harnesses to ensure that they are all
connected at both ends.
If any work was performed on the DC input with precharge assembly,
inspect the control transformer primary connections to verify that the
taps are appropriate for the applied voltage:
DC Input with Precharge Assembly Transformer Input Voltage
Primary Terminal Connections
H1 & H2 120
H1 & H3 240
If any work was performed on a frame 9 or larger drive, inspect the 24V
wire harnesses to ensure that they are properly connected at the ends
and properly supported by cables ties along their entire length.
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.

Start-Up After Repairs Chapter 13
Testing With the Motor This test allows you to measure the and diagnose problems without connecting
the motor to its mechanical load.
Without a 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.

Chapter 13 Start-Up After Repairs
Notes:

Appendix A
Schematics
Topic Page
Frame 8 AC Input Drive Schematic Diagram (400VAC and 600VAC Classes) 366
Frame 8 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and 369
932VDC Classes)
932VDC Classes)
932VDC Classes)
Control Pod Schematic Diagram 372
Converter Schematic Diagram (400VAC and 600VAC Classes AC Input Drive) 373
Frame 8 Control Power Isolator Board Wiring Diagrams (600VAC Class AC Input Drive, and 374
810VDC and 932VDC Classes Common DC Input Drive)
DC Input with Precharge Assembly Schematic Diagram (540VDC, 650VDC, 810VDC, and 376
932VDC Classes Common DC Input Drives)
DC Input with Precharge Devices Schematic Diagrams 377
Inverter Circuit Board Schematic Diagram (All Drive Configurations) 378
Inverter Power Layer Schematic Diagram (All Drive Configurations) 379
AC Input Drive Control Transformer Schematic Diagram 380
DC Input with Precharge Assembly Control Transformer Schematic Diagram 380
Inverter Main Blower and Capacitor Bank Cooling Fan Wire Harness Diagram 381
Cabinet Cooling Wiring Diagrams 381

Appendix A Schematics
Frame 8 AC Input Drive Schematic Diagram (400VAC and 600VAC Classes)

Source Ground
PE
Chassis PE
Three R/L1
Phase
AC Input S/L2
T/L3
R S T
TB2-3 Cabinet TB2-3: Fan 240V AC Neutral
Converter Spare Part Cat. No. = Converter TB2-4 Fans TB2-4: Fan 240V AC Hot
20-750-C1-CxxxDxxx (Series A) with Control
20-750-C2-CxxxDxxx (Series B) Pod 24V
TB1-7 1-Bay 24V Wire Harness
20-750-C2-ExxxFxxx (Series B) 24V Com (400V Class Only)
20-750-C3-CxxxDxxx (Series B) TB1-8
Spare Part Cat. No. =
20-750-C3-ExxxFxxx (Series B) 20-750-PH1-F8
20-750-C4-CxxxDxxx (Series B) (For 600V Class, see Control
20-750-C4-ExxxFxxx (Series B) P14
Power Isolator Board Wiring
Control Pod 1 2 Diagram on page 374.)
Spare Part Cat. No. = Fiber Interface
20-750-POD1-F8 Board Fiber-Optic Transceiver
P1 (4 Per Drive, 1 Per Kit)
Converter (Series A)
Gate Board INV1 Spare Part Cat. No. =
SK-R1-FTR-F8
P3
12345 CONV INV Fiber-Optic Cable
P8 560 mm Long
Frame 8 No DC Bus Spare Part Cat. No. =
Fuse Wire Harness. TB1-1
20-750-FCBL1-F8
See Converter Schematic. TB1-2
TB1-3
TB1-4 CONV Fiber-Optic Cable
TB1-5 560 mm Long
DC- DC+ Spare Part Cat. No. =
24V/240V 20-750-FCBL1-F8
Wire Harness.
See Converter
and Inverter
Inverter Schematics.
(AC Input Version)
with DC Link Choke
20-750-I1-CxxxDxxx (Series A)
20-750-I1B-CxxxDxxx (Series B)
20-750-I1B-ExxxFxxx (Series B)
DC- DC+
P6
To use a chopper on a frame DC-

8 AC input drive a 20-750- Chopper
BUS1-F8 kit is required to
connect to the DC bus DC+
(Field-Installed -Bus +Bus P3 CONV
Option)
Inverter P1 INV
Inverter-Mounted Output U V W
Common Mode Core
(Field-Installed Option)
20-750-EMCCM1-F8
U/M1
Three
Phase V/M2
AC Output
W/M3
PE
Chassis PE
Motor Ground

Schematics Appendix A

Source Ground
PE
Chassis PE
Three R/L1
Phase
S/L2
AC Input
T/L3
Cabinet-Mounted Input Cabinet-Mounted Input

Common Mode Core
Common Mode Core Bay 1 Bay 2 (Field-Installed Option)
(Field-Installed Option) Spare Part Cat. No. =
Spare Part Cat. No. = 20-750-EMCCM1-F9
20-750-EMCCM1-F9
R S T R S T
TB2-3 Cabinet TB2-3: Fan 240V AC Neutral Cabinet TB2-3
Converter
Converter TB2-4 Fans TB2-4
with Control Fans TB2-4: Fan 240V AC Hot without Control Pod
Converter Spare Part Cat. No. =
20-750-C2-CxxxDxxx (Series B) Pod 24V
20-750-C2-ExxxFxxx (Series B) TB1-7 TB1-7
24V Com
20-750-C3-CxxxDxxx (Series B) TB1-8 TB1-8
20-750-C3-ExxxFxxx (Series B) 2-Bay 24V Wire Harness
20-750-C4-CxxxDxxx (Series B) (400V Class Only)
20-750-C4-ExxxFxxx (Series B) P14 Spare Part Cat. No. =
Control Pod 20-750-PH2-F9
Spare Part Cat. No. = 1 2 (For 600V Class, see Control Power Isolator
Frame 9 and Larger Only Fiber Interface
DC Bus Fuse 20-750-POD1-F8 Board Wiring Diagram on page 374.)
(Series A) Board
Wire Harness Kit P1 P2 Fiber-Optic Transceiver
(2 Kits Per Drive) Converter (8 Per Drive, 1 Per Kit) Converter
INV1 INV2
Spare Part Cat. No. = Gate Board Spare Part Cat. No. = Gate Board
SK-R1-DCBUSH1-F9 SK-R1-FTR-F8
(2 Harnesses Per) P3 INV2 Fiber-Optic Cable P3
Converter DC Bus Fuse Harness 12345 CONV Fiber-Optic 2800 mm Long 12345
CONV CONV
Cabinet DC Bus Fuse Harness Cable, 560 mm Long Spare Part Cat. No. =
P8
See Converter Schematic P8 (2 Per Drive, 1 Per Kit) 20-750-FCBL1-F10
Spare Part Cat. No. = INV1 Fiber-Optic Cable
TB1-1 20-750-FCBL1-F8 2800 mm Long TB1-1
TB1-2 Spare Part Cat. No. = TB1-2
TB6-1 TB1-3 FU7, FU8 - 20-750-FCBL1-F10 TB1-3
DC Bus Fuse: TB6-1
TB6-2 TB1-4 TB1-4
690V, 1400 A TB6-2
TB6-3 TB1-5 TB1-5
(400V Class); TB6-3
Fuse Indicators DC- DC+ 1250V, 1000 A Fuse Indicators DC- DC+
N.C. (600V Class) N.C.
24V/240V
1 1
Wire Harness. SW7, SW8 - 1 1
See Converter Fuse Indicator:
and Inverter
Schematics Spare Part Cat. No. =
SW8 SW7 SK-R1-FUSE3-F9 SW8 SW7
(FU8) (FU7) (400V Class) (FU8) (FU7)
2 2 SK-R1-FUSE4-F9 2 2
(600V Class)
(One fuse and one
indicator per kit)
Chopper
Drive
Inverter DC- DC+ (Field-Installed Backplane DC- DC+
(AC Input Version) P6 Option) DC Bus P6
with DC Link Choke DC- DC+
DC- DC-
Spare Part Cat. No. = FU8 FU8
20-750-I1B-ExxxFxxx (Series B) DC+ DC+
FU7 FU7
-Bus +Bus -Bus +Bus
P3 CONV CONV
P1
Inverter P1
Inverter P3
INV INV
U V W U V W
Inverter-Mounted Output Bay 1 Cabinet Bay 2 Cabinet Inverter-Mounted Output
Common Mode Core Fiber-Optic Spool Fiber-Optic Spool Common Mode Core
(Field-Installed Option) Spare Part Cat. No. = Spare Part Cat. No. = (Field-Installed Option)
Spare Part Cat. No. = 20-750-SPL1-F10 20-750-SPL1-F10 Spare Part Cat. No. =
20-750-EMCCM1-F8 20-750-EMCCM1-F8
U/M1
Three
Phase V/M2
AC Output
W/M3
Inverter (AC Input Version)
PE with DC Link Choke
Chassis PE
Motor Ground Spare Part Cat. No. =


Cabinet-Mounted Input
Common Mode Core
Note: See the Frame 9 AC Input Drive Schematic
Source Ground Diagram (400VAC and 600VAC Classes) for all (Field-Installed Option)
Chassis PE spare part kit catalog numbers not shown. (3 per Drive, 1 per Kit)
PE Spare Part Cat. No. =
Three R/L1 20-750-EMCCM1-F9
Phase S/L2
AC Input T/L3
Bay 1 Bay 2 Bay 3
24V Com
24V Com
24V
24V
R S T R S T R S T
24V Cabinet TB2-3 Cabinet TB2-3 TB1-7
Cabinet TB2-3 TB1-7 TB1-7
24V Com Fans TB2-4 Fans TB2-4 TB1-8
Fans TB2-4 TB1-8 TB1-8
Converter Converter Converter

P14
3-Bay 24V Wire Harness
TB2-3: Fan 240V AC Neutral with Control without (400V Class Only) without
TB2-4: Fan 240V AC Hot Pod Control Pod
1 2 Control Pod Spare Part Cat. No. =
Control Pod
Fiber Interface 20-750-PH3-F10

Converter Spare Part Cat. No. = Board (For 600V Class, see Control
20-750-C3-CxxxDxxx (Series B) Converter Converter Power Isolator Board Wiring Converter
P1 P2 P3
20-750-C3-ExxxFxxx (Series B) Gate Board Gate Board on page 374.) Gate Board
INV1
INV2
INV3
20-750-C4-CxxxDxxx (Series B)
20-750-C4-ExxxFxxx (Series B) P3 P3 CONV Fiber-Optic Cable, P3
CONV INV3 Fiber-Optic Cable, CONV 560 mm Long CONV
2800 mm Long (3 per Drive, 1 per Kit)
12345 Spare Part Cat. No. = 12345 Spare Part Cat. No. = 12345
20-750-FCBL1-F8
P8 20-750-FCBL1-F10 P8 P8
Fuse Indicators N.C. Fuse Indicators N.C. Fuse Indicators N.C.
TB6-1 TB6-1 TB6-1
1 1 TB6-2 1 1 TB6-2 1 1 TB6-2
TB6-3 TB6-3 TB6-3
TB1-1 TB1-1 TB1-1
TB1-2 TB1-2 TB1-2
SW8 SW7 SW8 SW7 SW8 SW7
(FU8) (FU7) TB1-3 (FU8) (FU7) TB1-3 (FU8) (FU7) TB1-3
TB1-4 TB1-4 TB1-4
2 2 TB1-5 2 2 TB1-5 2 2 TB1-5
DC- DC+ DC- DC+ DC- DC+
Drive
Backplane
DC Bus
Chopper
FU8 FU7 FU8 FU7 FU8 FU7
(Field-Installed
Option)
DC- DC+ DC- DC+ DC- DC+ DC- DC+ DC- DC+ DC- DC+
-Bus +Bus P6 -Bus +Bus P6 -Bus +Bus P6
P3 P3 CONV Inverter P3 CONV

Inverter CONV Inverter
P1 P1 P1
INV INV INV
U V W U V W U V W
Inverter Inverter
(AC Input Version) (AC Input Version) Inverter (AC Input Version)
with DC Link Choke with DC Link Choke with DC Link Choke
Inverter-Mounted Output
Common Mode Core
U/M1 (Field-Installed Option)
Three V/M2 (3 per Drive, 1 per Kit)
Phase W/M3
AC Output Fiber-Optic Transceiver (12 per Drive, 1 per Kit) 20-750-EMCCM1-F8
PE
Chassis PE Spare Part Cat. No. = SK-R1-FTR-F8
Motor Ground

Frame 8 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC
Classes)
Drive
DC-
Backplane Chopper (Field-Installed Option)
DC Bus DC+
Common Mode Core
(Factory-Installed)
20-750-CBPEMCCM1-F8
DC- DC+
TB2-5 Cabinet TB2-5: Fan 240V AC Neutral
DC Input with TB2-6 Fans TB2-6: Fan 240V AC Hot
Precharge Assembly
with Control 24V
Pod TB1-7
24V Com
TB1-8
SW5 - Drive Circuit Breaker, Spare Part Cat. No. = (400V Class Only)
2-Pole, 13A, 120/240V AC Input 20-750-P2-CxxxDxxx (Series B) Spare Part Cat. No. =
(1 per Drive, 1 per Kit) 20-750-P2-ExxxFxxx (Series B) P14
20-750-PH1-F8
Spare Part Cat. No. = 20-750-P4-CxxxDxxx (Series B) Control Pod 1 2 (For 600V Class, see Control Power
1489-A2D130A 20-750-P4-ExxxFxxx (Series B) Fiber Interface
Spare Part Cat. No. = Isolator Board Wiring Diagram on
Circuit Breaker Lock Attachment 20-750-POD1-F8 Board page 374.)
(1 per Drive, 1 per Kit) DC Precharge (Series A) P1
Spare Part Cat. No. = Control Board INV1 Fiber-Optic Transceiver
1489-AALOA (4 Per Drive, 1 Per Kit)
P3
CONV SK-R1-FTR-F8
DC Input Cabinet Wire Harness Kit

Spare Part Cat. No. = TB2-4 TB1-1
SK-R1-CBP-BRKH1-F8 TB2-3 TB1-2 INV Fiber-Optic Cable
(3 Harnesses Per Kit) TB1-3 560 mm Long
120VAC Control Harness TB1-4 Spare Part Cat. No. =
Transformer Primary Harness 3 1 20-750-FCBL1-F8
TB1-5
120VAC UPS Harness
SW5
DC- DC+ CONV Fiber-Optic Cable
TB2-2
TB2-1
4 2 560 mm Long
24V/240V Spare Part Cat. No. =
Wire Harness. 20-750-FCBL1-F8
See DC Input with
Precharge Assembly
and Inverter
Schematics.
User-Provided Drive Control Hot
120/240V AC Bus In Neutral
21G cabinet option code P30 provides bus and
wire harness. See the PowerFlex 750-Series AC
User-Provided Drive UPS
Drives Installation Instructions, publication 750-
Control 120V AC Bus In
120V Hot IN001, for DC Input TB5 jumper settings for use
(Optional) 120V Neutral with Drive UPS Control 120V AC Bus.
Inverter
(DC Input Version)
without DC Link Choke
DC- DC+
Spare Part Cat. No. = P6
-Bus +Bus P3 CONV
Inverter
P1 INV
U V W
Common Mode Core
20-750-EMCCM1-F8
U/M1
Three
Phase V/M2
AC Output
W/M3
PE
Chassis PE
Motor Ground

Classes)
Drive DC-
Backplane Chopper
DC Bus DC+
Cabinet-Mounted Input Common Mode Core
Common Mode Core Bay 1 Bay 2 (Factory-Installed)
(Factory-Installed) Spare Part Cat. No. =
Spare Part Cat. No. = 20-750-CBPEMCCM1-F8
20-750-CBPEMCCM1-F8
DC- DC+ DC- DC+
TB2-5 Cabinet TB2-5: Fan 240V AC Neutral Cabinet TB2-5
DC Input with TB2-6 Fans TB2-6: Fan 240V AC Hot Fans TB2-6 DC Input with
Circuit Breaker Lock Attachment Precharge Assembly
(2 per Drive, 1 per Kit) Precharge Assembly
Spare Part Cat. No. = with Control Pod TB1-7
24V
TB1-7
without Control Pod
24V Com
1489-AALOA TB1-8 TB1-8
SW5 - Drive Circuit Breaker Spare Part Cat. No. =

2-Pole, 13A, 120/240V AC Input 20-750-P2-CxxxDxxx (Series B) 20-750-P2-CxxxDxxx (Series B)
(2 per Drive, 1 per Kit) 20-750-P2-ExxxFxxx (Series B) P14 (400V Class Only) 20-750-P2-ExxxFxxx (Series B)
20-750-P4-CxxxDxxx (Series B)
Control Pod Spare Part Cat. No. = 20-750-P4-CxxxDxxx (Series B)
Spare Part Cat. No. = 1 2
20-750-P4-ExxxFxxx (Series B) Spare Part Cat. No. = Fiber Interface 20-750-PH2-F9 20-750-P4-ExxxFxxx (Series B)
1489-A2D130A 20-750-POD1-F8 Board (For 600V Class, see Control Power Isolator
DC Input Cabinet Wire Harness Kit DC Precharge (Series A) P1 P2 Board Wiring Diagram on page 374.)
DC Precharge
Spare Part Cat. No. = Control Board INV1 INV2 Fiber-Optic Transceiver Control Board
SK-R1-CBP-BRKH1-F8 (8 Per Drive, 1 Per Kit)
(3 Harnesses Per Kit) P3 Spare Part Cat. No. =
CONV P3 CONV
120VAC Control Harness SK-R1-FTR-F8
Transformer Primary Harness INV2 Fiber-Optic Cable
120VAC UPS Harness 2800 mm Long
TB2-4 TB1-1 Spare Part Cat. No. = TB2-4 TB1-1
TB2-3 TB1-2 20-750-FCBL1-F10 TB2-3 TB1-2
TB1-3 TB1-3
TB1-4 TB1-4
3 1 INV1 Fiber-Optic Cable 3 1
TB1-5 TB1-5
2800 mm Long
SW5 Spare Part Cat. No. = SW5
DC- DC+ DC- DC+
TB2-2
TB2-1
24V/240V 20-750-FCBL1-F10
4 2 4 2
(2 Per Drive)
Wire Harness.
See DC Input with CONV Fiber-Optic Cable
Precharge Assembly 560 mm Long
and Inverter Spare Part Cat. No. =
Schematics 20-750-FCBL1-F8
User-Provided Drive Control Hot
120/240V AC Bus In
Neutral
21G cabinet option code P30 provides bus and wire
harness. See the PowerFlex 750-Series AC Drives
User-Provided Drive UPS 120V Hot Installation Instructions, publication 750-IN001, for
Control 120V AC Bus In DC Input TB5 jumper settings for use with Drive UPS
(Optional) 120V Neutral Control 120V AC Bus.
Inverter
Inverter (DC Input Version)
(DC Input Version) without DC Link Choke
without DC Link Choke
DC- DC+
Spare Part Cat. No. = 20-750-I2B-CxxxDxxx (Series B) DC- DC+
20-750-I2B-CxxxDxxx (Series B) P6 P6
-Bus +Bus P3 CONV -Bus +Bus CONV
P1
P3
Inverter Inverter
P1 INV INV
U V W U V W
Common Mode Core Bay 1 Cabinet Bay 2 Cabinet Inverter-Mounted Output
(Field-Installed Option) Fiber-Optic Spool Fiber-Optic Spool Common Mode Core
Spare Part Cat. No. = Spare Part Cat. No. = Spare Part Cat. No. = (Field-Installed Option)
20-750-EMCCM1-F8 20-750-SPL1-F10 20-750-SPL1-F10 Spare Part Cat. No. =
20-750-EMCCM1-F8
U/M1
Three
V/M2
Phase
AC Output W/M3
PE Chassis PE
Motor Ground

Frame 10 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and
932VDC Classes)
See the Frame 9 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, TB2-5: Fan 240V AC Neutral
810VDC, and 932VDC Classes) for all spare part kit catalog numbers not shown. TB2-6: Fan 240V AC Hot (Field-Installed Option)
Drive
DC-
Backplane Chopper
DC Bus DC+
Common Mode Core
(Factory-Installed)
(3 per Drive, 1 per Kit) Bay 1 Bay 2 Bay 3
24V Com
24V Com
20-750-CBPEMCCM1-F8
24V
24V
24V Cabinet TB2-5 Cabinet TB2-5 TB1-7
Cabinet TB2-5 TB1-7 TB1-7
24V Com Fans TB2-6 Fans TB2-6 TB1-8
Fans TB2-6 TB1-8 TB1-8
DC Input with DC Input with DC Input with

Precharge Assembly P14 Precharge Assembly 3-Bay 24V Wire Harness Precharge Assembly
Control Pod
with Control Pod 1 2 without Control Pod (400V Class Only) without Control Pod
Fiber Interface Spare Part Cat. No. =
Board 20-750-PH3-F10
DC Precharge P1 P2 P3 DC Precharge (For 600V Class, see DC Precharge
User-Provided Control Power Isolator Board Wiring
Drive UPS Control Control Board Control Board Control Board
Diagram on page 374.)
INV1
INV2
INV3
120V AC Bus In
(Optional) P3 CONV P3 CONV P3 CONV
CONV Fiber-Optic Cable,
INV3 Fiber-Optic Cable 560 mm Long
120V Hot 2800 mm Long (3 Per Drive, 1 Per Kit)
TB2-2
Spare Part Cat. No. = Spare Part Cat. No. =
120V Neutral TB2-1
20-750-FCBL1-F10 20-750-FCBL1-F8
TB2-4 TB1-1 TB2-4 TB1-1 TB2-4 TB1-1

TB2-3 TB1-2 TB2-3 TB1-2 TB2-3 TB1-2
3 1 TB1-3 3 1 TB1-3 3 1 TB1-3
TB1-4 TB1-4 TB1-4
SW5 SW5 SW5
TB1-5 TB1-5 TB1-5
4 2 4 2 4 2
DC- DC+ DC- DC+
DC- DC+
Circuit Breaker
2-Pole, 13A Circuit Breaker
(3 per Drive, 1 per Kit) Lock Attachment
Spare Part Cat. No. = (3 per Drive, 1 per Kit)
1489-A2D130A Spare Part Cat. No. =
1489-AALOA
User-Provided Hot
Drive Control
120/240V AC Bus In Neutral
-Bus +Bus -Bus +Bus -Bus +Bus

P6 P6 P6
Inverter Inverter Inverter
P3 P3 CONV P3 CONV
CONV
P1 P1 P1
INV INV INV
U V W U V W U V W
Inverter Inverter Inverter
(DC Input Version) (DC Input Version) (DC Input Version)
without DC Link Choke without DC Link Choke without DC Link Choke
Common Mode Core
U/M1 (3 per Drive, 1 per Kit)
V/M2
Three 20-750-EMCCM1-F8
Phase W/M3
AC Output Fiber-Optic Transceiver (12 per Drive, 1 per Kit)
PE Chassis PE Spare Part Cat. No. = SK-R1-FTR-F8
Motor Ground

Control Pod Schematic Diagram

Pod Bucket - Main Control
External To Main Control Board in Control Pod
HIM
J4
64-POS
+I_24V B1 A1 - I_24V_RET
+1_24V I_24V_RET
DGND DGND
DGND DGND
+12V +12V
+12V +12V
+12V +12V
DGND DGND Main Control Board
-12VDGND -12V
CNTR_CLK B11 DGND
TxD11+ - B12 A11 - /MR_CNTR Spare Part Cat. No. =
TxD11- A12 RxD11+
DGND RxD11- SK-R1-MCB1-F8
/SPI_STS_SHFT_LD DGND (Series A)
SPOI_STS_DI SPI_STS_CLK
FO_EE_CLK SPI_FLT_LATCH
FO_EE_DATA SPI_FLT_CLK
Fiber Interface Board DGND DGND
TxD1+ RxD1_
TxD1- RxD1- J3
Spare Part Cat. No. = DGND DGND
TxD2- RxD2+ 64-POS
SK-R1-FIB1-F8 TxD2+ RxD2-
J11
(Includes one board and one fiber- DGND DGND
P12 TxD3+ RxD3_
optic transceiver 98-POS
TxD3- RxD3-
DGND DGND
TxD4- RxD4+
TxD4+ RxD4-
DGND DGND
TxD5- RxD5+
TxD5+ RxD5-
DGND DGND
FIB_P3.3V MCB_TST_P3.3V_SW
SPARE MCB_TST_PV3V_FDBK J5
DGND DGND 98-POS To External
TxD7+ RxD7+
TxD7- RxD7- HIM
DGND DGND
TxD8+ RxD8+
TxD8- RxD8-
DGND DGND J12
TxD9+ RxD9+ TB1
TxD9- RxD9-
DGND DGND
TxD10+ RxD10+
TxD10- RxD10-
DGND B49 A49 - DGND
P15
64-POS Direct Screw
Connection
P1 P2 P3
(3 places)
P14 P13
INV1
INV2
INV3
1 2 3 2 1
See Drive Schematic Direct Screw

AP- (24V DC Com AUX Power Supply)
Diagrams for frame specific Connection

AP+ (24V DC AUX Power Supply)
INV fiber-optic cable (4 places)

SH (Ground AUX Power Supply)
connections.
Fiber-Optic Transceiver (1 Per Kit)
1 per Frame 8 Drive
2 per Frame 9 Drive
3 per Frame 10 Drive
24V Com

24V
SK-R1-FTR-F8
To Converter User-Provided
or DC Input 24V DC
with Auxiliary
Precharge Power Supply
TB1
See Drive Schematic Diagrams for frame specific 24V wire harness connections

Converter Schematic Diagram (400VAC and 600VAC Classes AC Input Drive)

R/L1
Chassis PE S/L2
Removable at User T/L3
2 3 4
Accessible Location
R/L1 1
S/L2 Transformer SK-R1-MOV1-CD-F8
Connected
T/L3 Primary Harness PE-A2 (Default) (400V Class)
2 3 4 L2
SK-R1-MOV1-EF-F8
L1 (600V Class)
1
24V I/O
PE-A2 MOV1 MOV Sense
No
PE-A2 connection
Disconnected Connected
1 5 9 1 5 9 1 2 3 1 2 3 1 2 3 1 2 3
P2 P3
Disconnected L1
1 L1 L2 L3 PE/G
EMC Filter 2
PE-A1
FU1, FU2, FU3 - AC Line Fuse Board Jumper
P1 L2
690V, 1100 A (400V Class) Spare Part Cat. No. = 6
7
690V, 900 A (600V Class) SK-R1-EMCFLT1-F8 A B C D
SW1, SW2, SW3 - Fuse Indicator (Series A - 400V Class) L3
Spare Part Cat. No. = SK-R1-EMCFLT2-F8 11
12
SK-R1-FUSE1-CD-F8 (400V Class) (Series B - 400V 4
SK-R1-FUSE1-EF-F8 (600V Class) and 600V Class)
SCR/Diode Module Connector 5
(One fuse and one fuse indicator per kit) L1 L2 L3 DC+
SCR1 SCR2 SCR3
2 2 2
4 4 4
FU1 CT1 5 5 5 DC Bus to

Three R/L1
FU2 CT2
1
Inverter
S/L2
1
Phase
AC Input FU3 CT3
T/L3
1
PE 1 2
1 2 CT
CT1, CT2, CT3 - 1 2
1 2
CT
3 3 3
Source 2
SW1
2
SW2
2
SW3 Current Transformer 1 2
CT
Ground 1 2
G1
DC-
Spare Part Cat. No. = + - K1
G2
K2
G3
K3
1 1 1 SK-R1-CNVIFB2-F8 NTC1
Fuse (Series B - 400V and L1
Indicators 1 1 2 1 2 3 4 5 6 1 3
600V Classes) Line
NTC
L2 Voltage SCR/Diode DC Bus 1
5 P2 P11 P10
P9 2
(One transformer L3
9 Misc. 3
and cable ties per Harness I/O 4
Present P13
kit) 9
8 DC Bus No DC Bus Fuse
& DGND Current 1
Harness ST
7 2
CT3-
6
Trans Fuse Frame 8 Only 2 1
3 2 1
CT3+
5
P6
Converter Gate Switch 4
DC Bus Fuse Not
CT2- Sense Present
4 P8 5
CT2+
3
Board & DGND
CT1-
2 (Spare Part Cat. No.
CT1+ 1 Listed Below*) DC Bus 1
DC Bus Fuse
Fuse 2
6 3 Harness
Line Switch 4 Frame 9 &
5
T/L3 Bus Fuse Fuse Sense P8 5 Larger Only
4
S/L2 Bus Fuse Sense
3 Power Input Fan
R/L1 Bus Fuse 2 P7 Output System 24V See Frame 9 AC
24V I/O P1 P12 Input Drive
CONV
1
6 5 4 3 2 1 3 2 1 Schematic
L2 L1 T1 - Control Transformer Direct Screw
1 1
Spare Part Cat. No. = 1 Connection
FU5 FU4 SK-R1-XFMR1-F8 FU6 (3 Places)
2
2 2
*T1 Input (50/60 Hz)
H1-H2 380/415 VAC H1 X1
H1-H3 440/480 VAC
H1-H4 575/600 VAC
H1-H5 690 VAC H* X2
T1
TB6-3
TB6-2
TB6-1
TB2-4
TB2-3
TB2-2
TB2-1
1000 VA, 240 VAC, 4.2 A FAN

Direct Screw 1 2
TB1-3
TB1-1
TB1-2
TB1-6
TB1-9
TB1-4
TB1-5
TB1-7
TB1-8
1 2
Connection
Stirring
Shunt Trip Normally Open
Fan
Fuses: 400V Class 600V Class FU4, FU5, FU6 - Control Transformer Fuses
Fan 240V AC Neutral
Shunt Trip Common
FU4, FU5 700VAC, 8A, 700VAC, 4A, Spare Part Cat. No. = Stirring Fan Kit CONV
Fan 240V AC Hot
IEC 14x51 mm IEC 14x51 mm

240V AC Neutral
SK-R1-FUSE2-CD-F8 (400V Class) Spare Part Cat. No.

No Connection
FU6 600VAC, 5A, 600VAC, 5A, SK-R1-FUSE2-EF-F8 (600V Class)

240V AC Hot
20-750-CFANKIT-F8
+Bus Fuse
Class CC Class CC
-Bus Fuse
24V Com
24V Com
Fiber-
24V I/O
Ground
Ground
Optic
24V
24V
Cable
*Converter Gate Board Spare Part Cat. No. =
SK-R1-CGDB1-CD-F8 (Series A - 400V Class) Converter Wire Harness Kit Cat. No. = SK-R1-CNVH1-F8 J6 P14 CONV Cabinet DC Cabinet Door User-Provided
SK-R1-CGDB2-CD-F8 (Series B - 400V Class) (11 Harnesses Per Kit) Inverter Power Board Fiber Interface Inverter Bus Fuse Fans Shunt Trip
SK-R1-CGDB2-EF-F8 (Series B - 600V Class) No DC Bus Fuse Harness, Misc. I/O Harness, Power 24V/240V Harness, Board Power Layer Indicators (Option)
Fiber-Optic Transceiver Interface Frame 9 &
SK-R1-CGDB3-CD-F8 (Series B - 400V Class) Inverter Power Supply Harness, NTC, SCR Gate Harness, DC Bus Harness, Board Larger Only
SK-R1-CGDB3-EF-F8 (Series B - 600V Class) Current Transformer Sense Harness, AC Line Fuse Harness, (1 Per Converter, 1 Per Kit)
One board and one fiber-optic transceiver per kit) Transformer Primary Harness, AC Bus Harness Spare Part Cat. No. = SK-R1-FTR-F8

Frame 8 Control Power Isolator Board Wiring Diagrams (600VAC Class AC Input Drive, and
Control Power Control Power
Isolator Wire Harness Isolator Board 1-Bay 24V Wire Harness
Spare Part Cat. No. = Spare Part Cat. No. = Spare Part Cat. No. =
SK-R1-CPIH1-F8 SK-R1-CPIB1-F8 20-750-PH1-F8
Converter Section
with Control Pod
Spare Part Cat. No. = Control Power Fiber Interface
20-750-C2-ExxxFxxx (Series B) Isolator Board Board
20-750-C3-ExxxFxxx (Series B) 24V 24V
TB1-7 1 1 1
PX PY 24V Com P14 Control Pod
DC Input with Precharge 24V Com 2
Section with Control Pod TB1-8 2 2 Spare Part Cat. No. =
Spare Part Cat. No. = 20-750-POD1-F8
20-750-P2-ExxxFxxx (Series B) (Series A)
PX = P1 for Converter; = P2 for DC Input with Precharge
PY = P2 for Converter; = P1 for DC Input with Precharge
Isolator Wire Harness Isolator Board
SK-R1-CPIH1-F8 SK-R1-CPIB1-F8
Converter Section
with Control Pod Control Power Fiber Interface
Drive Bay 1 Spare Part Cat. No. = Isolator Board Board
20-750-C2-ExxxFxxx (Series B) 24V
20-750-C3-ExxxFxxx (Series B)
24V
TB1-7 1 1 1
24V Com PX PY 24V Com P14 Control Pod
DC Input with Precharge TB1-8 2 2 2
Section with Control Pod Spare Part Cat. No. =
20-750-P2-ExxxFxxx (Series B) PX = P1 for Converter; = P2 for DC Input with Precharge (Series A)

Converter Section Spare Part Cat. No. =
without Control Pod 20-750-PH2-F9
Drive Bay 2 20-750-C3-ExxxFxxx (Series B) 24V
TB1-7
DC Input with Precharge 24V Com
Section without Control Pod TB1-8
20-750-P2-ExxxFxxx (Series B)

Isolator Wire Harness Isolator Board
SK-R1-CPIH1-F8 SK-R1-CPIB1-F8
Converter Section
with Control Pod
Spare Part Cat. No. = Control Power Fiber Interface
Drive Bay 1 20-750-C3-ExxxFxxx (Series B) Isolator Board Board
24V 24V
TB1-7 1 1 1
DC Input with Precharge 24V Com PX PY 24V Com P14 Control Pod
TB1-8 2 2 2
Section with Control Pod Spare Part Cat. No. =
PX = P1 for Converter; = P2 for DC Input with Precharge (Series A)
Converter Section
without Control Pod
Drive Bay 2 24V
TB1-7
DC Input with Precharge 24V Com
Section without Control Pod TB1-8

Converter Section Spare Part Cat. No. =
without Control Pod 20-750-PH3-F10
Drive Bay 3 24V
TB1-7
DC Input with Precharge
Section without Control Pod 24V Com
TB1-8

DC Input with Precharge Assembly Schematic Diagram (540VDC, 650VDC, 810VDC, and
932VDC Classes Common DC Input Drives)
FU1, FU2 - DC Bus Fuse
690V, 1400 A (540V and 650V Classes)
Drive DC Bus to User-Provided Drive 1250V, 1000 A (810V and 932V Classes)
Backplane Inverter Control 120/240V AC SW3, SW4 - Fuse Indicator
SW2 - Disconnect Switch, DC Bus Bus Input Spare Part Cat. No. =
40 A Spare Part Cat. No. = SK-R1-CBPFUSE1-F8 (540V and 650V Classes)
SK-R1-CBPSW-F8 Chassis PE SK-R1-CBPFUSE3-F8 (810V and 932V Classes)
(One 8-pole switch, (One fuse and one fuse indicator per kit)
Neutral
DC+
one auxiliary contact,
DC+
DC-
DC-
Hot
one shaft and one knob TB2-2 Hot User-Provided Drive UPS
per kit) TB2-1 Neutral
120V AC Bus Input
6
(Option)
3 1
See Installation Instructions, publication 750-IN001,
SW5 SW2 for TB5 jumper settings for use with drive UPS 120V
FU2
690V
AC wiring
4 2 6
1600A
TB5-1 UPS 120V AC Out Hot
1 2 3 4 5
TB5-2 120V AC Hot
FU1
SW2 690V TB5-3 Control 120V AC Out Hot
TB2-4
TB2-3
1
1600A TB5-4 UPS 120V AC Out Neutral
1 2 3 4 5 FU6 TB5-5 120V AC Neutral
600V 2 TB5-6 Control 120V AC Out Neutral
7 8
1A TB5-7 Neutral Drive I/O
SW1 SW2 Class CC TB5-8 Hot Control 120V
FU4
1000V IEC DC- DC+ DC+
20A Molded 7 8 FU3, FU4, FU5, FU6 - Fuses
Case T1 Spare Part Cat. No. = SK-R1-CBPFUSE2-F8
Switch H1 X1
N
FU3
1600A
PS1 - Undervoltage Delay
1000V R1 R2 H2 X2 Spare Part Cat. No. = SK-R1-CBPDELAY-F8
20A 120
Factory
R3 R4 Setting SW5 - Drive Circuit Breaker, 13 A
H3 X3
240
120/240V AC Input
R1, R2, R3, R4 - R1,R2,R3,R4 Spare Part Cat. No. = 1489-A2D130A
Precharge Resistors 10 Ohms
10 Ohms
(540V and 650V Classes) T1 - Control Transformer
20 Ohms FU5 1000VA, 50/60 Hz
1 1 1
(810V and 932V Classes) 13 31 SW3 SW4
600V Spare Part Cat. No. = SK-R1-CBPXFMR1-F8
Spare Part Cat. No. = SW2 SW1 Fuse Fuse 5A
Indicator Indicator Class CC 2
SK-R1-CBPRES-F8 Aux. Aux. FAN - Stirring Fan
Contact Contact N.C. N.C.
(540V and 650V Classes) N.O. N.O. Spare Part Cat. No. =
SK-R1-CBPRES2-F8 (FU1) (FU2)
2 2 20-750-CFANKIT-F8
(810V and 932V Classes) 14 34
(Four resistors and
mounting bracket per kit) Direct Screw
Connection
SW1, SW2, SW3, SW4 Terminal Wiring 1 1 Stirring
FAN Fan
2 2
1234567 1 4 7 10
P3 P1
Door Switch Closed TB4-1 1
User-Provided TB1-1 24V Com
I/O 24V TB4-2 2 DC Precharge Control
Door Interlock 4
P6
Board TB1-2 24V J6
240V AC Neutral TB4-3
(Option) 6 TB1-3 Ground Inverter Power
Door 240V AC Hot TB4-4 Spare Part Cat. No. = Board
TB1-4 240V AC Neutral
SK-R1-CBPCTRL-F8 TB1-5 240V AC Hot
I/O 24V TB3-1 1 (540V and 650V Classes)
I/O 24V Com TB3-2 SK-R1-CBPCTRL2-F8 TB1-6 No Connection
Ext. Prchrg Close/Open Input+ TB3-3 (810V and 932V Classes) P10 3 TB1-7 24V P14
Ext. Prchrg Close/Open Input- (One board and one fiber- 1 TB1-8 24V Com Fiber Interface
TB3-4
P7 optic transceiver per kit) TB1-9 Ground Board
Ext. Prchrg Inhibit Input+ TB3-5
Ext. Prchrg Inhibit Input- TB3-6 1
Reset Faults Input+ TB3-7 3
P9 4 TB2-5 Door Fan 240V AC Neutral
Reset Faults Input- TB3-8 8 Cabinet Fans
6 TB2-6 Door Fan 240V AC Hot
Precharge Completed N.O. TB3-9
1
Precharge Completed Com TB3-10
Fault Out N.C. TB3-11 P8 Fiber-Optic CONV
CONV CONV
Fault Out N.O. TB3-12 P2 P5 Cable Inverter Power Layer
Fault Out Com TB3-13 5 2 3 4 8 10 12 3 1 Interface Board
DC Input Wire Harness Kit - Spare Part Cat. No. = SK-R1-CBPH1-F8

C2
(12 Harnesses Per Kit) 24V/120V/240V Harness, Digital I/O Harness, Door Lock Harness,
C12
SW5 Terminal Wiring
U2 120V/240V Harness, DC Output/Sense Harness, Undervoltage Harness, 24V Sense Harness,

D1 PS1
SW1 MCS Control Harness, DC Bus Input Harness, Disconnect Switch Jumper Harness,
SW1 SW1 1 6
Close Shunt Trip Spring SW1 2 7 Precharge Resistor Jumper Harness, Inverter Power Supply Harness
Charge UV Trip UV
Coil Coil
Motor 3 8
D2 11 4 9 Fiber-Optic Transceiver (1 per Unit, 1 per Kit)
C1 C11 U1 22 5 10
Spare Part Cat. No. = SK-R1-FTR-F8

DC Input with Precharge Devices Schematic Diagrams

DC Input Circuit Breaker (SW5) DC Input Disconnect Switch (SW2)
User-Provided Drive Control 120/ Drive Backplane DC To TB5 To Control Transformer
240V AC Bus In Bus In (T1)
Neutral
DC+
DC-
Hot
24V I/O
3 1 1 2 3 4 5 6 7 8 13
To DC Precharge
SW5
Control Board P3
4 2 1 2 3 4 5 6 7 8 14
SW2
Aux. In
N.O.
Neutral
To Disconnect Switch SW2 Via
DC+
DC-
Hot
Hot
TB2
To Precharge User-Provided Drive Control 120/240V AC
Fuses FU3 and Bus In Via TB2
FU4
User-Provided UPS 120V AC Bus In
Via TB2
DC Input Molded Case Switch (SW1) Control
To DC Precharge Control Board To UV To DC Precharge Control Board To DC Precharge Control Board
P2 Connector P2 P3
UV 1 2
240V AC Spring Charge Coil
240V AC Shunt Trip Coil

240V AC Close Coil
SW1 Aux. In N.O.

240V DC Delay +Out
240V AC Neutral
240V AC Neutral
240V DC Delay -Out
240V AC Neutral
24V I/O
U1 D1 C1 C12 31 32
U2 D2 C2 C11 21 34
Spring Under- Close Coil Shunt Trip Switch

Charge voltage Trip Coil Status
Motor
DC Input Molded Case Switch (SW1) Power DC Input Undervoltage Delay Module (PS1)
Drive Backplane DC
Bus In
DC+
DC-
PS1
P5 240V AC Hot
1 1 6
DC+
DC-
To DC Precharge
Control Board P5 2
Delay Setting:
U1 D1 C1 C12 31 32 No Jumper
240V AC Neutral 2 7
U2 D2 C2 C11 21 34
3 Connection
DC- DC+ DC+ 3 8
Time Delay
UV
240V DC Delay +Out = 3 seconds
To SW1 Undervoltage 1 4 9 (Factory Default)
Trip
240V DC Delay -Out
DC+
DC-
2 5 10
DC Bus to
Inverter
DC+
DC-

Inverter Circuit Board Schematic Diagram (All Drive Configurations)

Inverter Gate Driver Board Ribbon Cables Fiber Optic Transceiver
Spare Part Cat. No. = (2 per Inverter, 1 Per Kit)
SK-R1-ICBL1-F8 Inverter Control Spare Part Cat. No. =
Includes one upper ribbon cable (folded), SK-R1-FTR-F8
one upper ribbon cable (straight), Inverter Power Layer Interface Board CONV
and two jumper ribbon cables Fiber-
Usage based on Inverter section replacement or equivalent Spare Part Cat. No. = Converter Gate Board
SK-R1-PINT1-F8 (Series A) CONV Optic
component Cat. No. 20-750-Ixx-Xxxx-Yyyy
Cable or DC Precharge Control
Direct SK-R1-PINT2-F8 (Series B) P3 Board
Includes one board and two CONV
For Cat. No. Position 9= C; and Position 10...12 = 460, 540, or 567 and Screw Fiber-
For Cat. No. Position 13 = D; and Position 14...16 = 430, 485, or 545; or Connection fiber-optic transceivers P1 INV Fiber
For Cat. No. Position 9= E; and Position 10...12 = 295, 355, or 395 and J7 J6
INV INV Optic Interface Board
For Cat. No. Position 13 = F; and Position 14...16 = 265, 330, or 370: Cable
Use one upper ribbon cable (folded) and two jumper ribbon cables
For Cat. No. Position 9= C; and Position 10...12 = 650, 750, or 770 and Main Blower Main P4
For Cat. No. Position 13 = D; and Position 14...16 = 617, 710, or 740; or Spare Part Cat. No. = Blower
For Cat. No. Position 9= E; and Position 10...12 = 435, 460, or 510 and SK-R1-FAN1-F8
For Cat. No. Position 13 = F; and Position 14...16 = 415, 460, or 500: J7 J6 P5
Use one upper ribbon cable (straight) and two jumper ribbon cables
Inverter Backplane Board Direct Screw
J1 Spare Part Cat. No. = J2
Ribbon Cable Connection
SK-R1-IB1-F8
J5 J3 J4 Cap Bank Cooling Fan Tray
FAN1 FAN2 P3
J1 Direct Screw
Gate Driver Board U Connection
Direct Screw (5 Places) Cap Bank Cooling Fan Tray
J2 Connection Direct Screw Spare Part Cat. No. =
Connection SK-R1-FAN2-F8
(2 Places) (Includes 2 Fans, 1 Tray)
Jumper Direct
240V Hot
Screw P5 P3 P4 1 TB1-5
Ribbon Connection 2
240V Neutral To Converter or DC
TB1-4
Cable (3 Places) 3
Ground
TB1-3 Input with
P6
24V
4
24V Com
TB1-2 Precharge TB1
Inverter Power Board 5 TB1-1
J1 +
Spare Part Cat. No. = 1
M
Gate Driver Board V SK-R1-PC1-F8 2
3
- U
4
+
M
To Inverter Current
J2 P1 5
-
W Sensors
6
7 +
M
CTU, CTV & CTW
Jumper Direct 8
-
V
9
Ribbon Screw 10
P8 P2
Connection 11
Cable (3 Places) 12 Jumper
J1 Rating Plug Direct See Inverter Main Blower and Capacitor

Board Screw Connection Bank Cooling Fan Wire Harness Diagram
Gate Driver Board W (3 Places) on page 381 for details.
J2
Inverter Switch Mode Power Supply Rating Plug Board -
Gate Driver Board Direct For Spare Part Cat. Nos., see (1) below Spare Part Cat. Nos. Based on
Spare Part Cat. Nos. Based on Inverter Screw Inverter Equivalent Component
Equivalent Component Voltage and Connection J4 J3 J2 Voltage and Current Ratings:
(3 Places)
Current Ratings (1 Per Kit): J1
4 1 4 1 5 3 1
For 400V 770A, 480V 740A =
For 400V 770 A, 480V 700 A = SK-R1-IR1-C770D740
SK-R1-IG1-C770D740 For 400V 750A, 480V 710A =
DISCONNECTED CONNECTED SK-R1-IR1-C750D710
-DC BUS
For 400V 567 A, 480V 545 A = DC BUS MID To Inverter For 400V 650A, 480V 617A =
SK-R1-IG1-C567D545 +DC BUS DC Bus SK-R1-IR1-C650D617
Removable at User Common Mode For 400V 567A, 480V 544A =
For 600V 510 A, 690V 500 A = Accessible Location Capacitor Jumper SK-R1-IR1-C567D545
PE-B For 400V 540A, 480V 485A =
SK-R1-IG1-E510F500
SK-R1-IR1-C540D485
For 600V 395 A, 690V 370 A = +DC +DC
For 400V 460A, 480V 430A =
SK-R1-IG1-E395F370 SK-R1-IR1-C460D430
For 600V 510A, 690V 500A =

PE-B PE-B SK-R1-IR1-E510F500
For 600V 460A, 690V 460A =
J4 J3
SK-R1-IR1-E460F460
No
Connection For 600V 435A, 690V 415A =
SK-R1-IR1-E435F415
For 600V 395A, 690V 370A =
-DC -DC
SK-R1-IR1-E395F370
DISCONNECTED CONNECTED For 600V 355A, 690V 330A =
Cat. No. Position 11 setting A = PE-B (DC Bus Common Mode Caps) Cat. No. Position 11 setting J = SK-R1-IR1-E355F330
Disconnected with jumper plugged in at J4 Power Jumper Default Configurations Connected with jumper plugged in at J3 For 600V 295A, 690V 265A =
SK-R1-IR1-E295F265
(1) Inverter Switch Mode Power Supply - Spare Part Cat. Nos.
For 400V Class AC Input and 540V and 650V Classes Common DC Input = SK-R1-PWRS1-CD-F8
For 600V Class AC Input and 810V and 932V Classes Common DC Input = SK-R1-PWRS1-EF-F8

Chassis PE
Motor Shield
L1 - DC Link Choke: Spare Part Cat. No. based on Inverter Section
Replacement or Equivalent Component Cat. No. 20-750-Ixx-Xxxx-Yyyy: PE
Motor Ground
For Cat. No. Position 9 = C and Position 10...12 = 460, 540, or 567, and
For Cat. No. Position 13 = D and Position 14...16 = 430, 485, or 545, or R3, R4 - Discharge Bleeder Resistors R1, R2 - Balance Resistors
For Cat. No. Position 9 = E and Position 10...12 = 435, 460, or 510, and Spare Part Cat. Nos.: Spare Part Cat. Nos.:
For Cat. No. Position 13 = F and Position 14...16 = 415, 460, or 500: For 400V Class AC Input and For 400V Class AC Input and Three Phase AC
540V and 650V Classes DC Input = 540V and 650V Classes DC Input = U/M1 V/M2 W/M3 Output
Inductance = 50 uH
SK-R1-RD1-F8 SK-R1-RB1-CD-F8 Inverter-Mounted Output
Spare Part Cat. No. = SK-R1-DCCHK2-F8 (2600 Ohms each) (2600 Ohms each) Common Mode Core
For 600V Class AC Input and For 600V Class AC Input and (Field-Installed Option)
For Cat. No. Position 9 = C and Position 10...12 = 650, 750, or 770, and 810V and 932V Classes DC Input = 810V and 932V Classes DC Input =
For Cat. No. Position 13 = D and Position 14...16 = 617, 710, or 740: SK-R1-RD2-F8 SK-R1-RB1-EF-F8
Inductance = 33 uH (5000 Ohms each) (5000 Ohms each) CT1, CT2, CT3
Spare Part Cat. No. = SK-R1-DCCHK1-F8 Includes two resistors and Includes two resistors, Current Sensor
wire harness mounting plate, (3 Per Unit, 1 Per Kit)
and wire harness Spare Part Cat. No. = Spare Part Cat. No.
For Cat. No. Position 9 = E and Position 10...12 = 295, 355, or 395, and 20-750-EMCCM1-F8 SK-R1-INVIFB1-F8
For Cat. No. Position 13 = F and Position 14...16 = 265, 330, or 370: - - -
Inductance = 69 uH Capacitor Bank M ISENSE M M
ISENSE
Spare Part Cat. Nos.:
ISENSE
Spare Part Cat. No. = SK-R1-DCCHK3-F8 + + +

For 400V 770A, 480V 740A = SK-R1-CP1-C770D740
For 400V 567A, 480V 545A = SK-R1-CP1-C567D545 CTV CTW
AC Input Drives Only For 600V 510A, 690V 500A = SK-R1-CP1-E510F500 CTU
For 600V 395A, 690V 370A = SK-R1-CP1-E395F370
EMC EMC Discharge EMC Caps
Caps Caps Bleeder Balance Capacitor (Cap Bank Output)
(Inverter (Choke L1 Resistors Inverter IGBT Modules
Input) Input) Resistors Bank
DC+ DC+
1 2
R3 R1 7 7 7
POUT PIN
C C
DC
Link 6 6 6
Choke C C NTC NTC NTC
+ - + - + -
NOUT NIN R4 R2 4 3 12 8 4 3 12 8 4 3 12 8
3 4
Rockwell Automation Publication 750-TG001E-EN-P - July 2012

DC- DC-
18 Caps for:
400V 650...770A, 480V 617...740A
Inverter Power Layer Schematic Diagram (All Drive Configurations)
EMC Capacitor Kit 600V 435...510A, 690V 415...500A AC Input

DC- Test Point 12 Caps for: Drives Only
SK-R1-EMCCAP1-F8 400V 460...567A, 480V 430...544A
Includes one inverter input part, DC+ Test Point 600V 295...395A, 690V 265...370A
one choke input part and one
capacitor bank output parts Screw Connections to Screw Connections to Screw Connections to
Gate Driver Board Gate Driver Board Gate Driver Board
DC BUS MID
DC- DC+
Schematics
Inverter Wire Harness Kit To J1 on To P1 on Inverter Power

Spare Part Cat. No. = SK-R1-INVH1-F8 Inverter Board
(4 Harnesses Per Kit) Switch Mode
Bleeder Resistor Harness, Cap Bank Stirring Fans/ Power Supply
Main Blower Harness, Current Sensor Harness, Board
and DC Test Point/Balance Resistor Cables
379
Appendix A
AC Input Drive Control Transformer Schematic Diagram
50/60 Hz H1
X2
380 / 415V
440 / 480V H2
575 / 600V 240V

H3
690V
H4
H5
X1
DC Input with Precharge Assembly Control Transformer Schematic Diagram
50/60 Hz
H1 X3
120V 120V
H2 X2
240V 240V
H3 X1

Inverter Main Blower and Capacitor Bank Cooling Fan Wire Harness Diagram
2 1
Blower Power Hot
1 1
P4
Blower Power Neutral
3 2 P4 (Wire Entry
1 A Side)
Blower Power Ground
2 B 5 3 To Inverter Main 4 3
Blower Control Power Blower
3 C 6 1
Blower Control Com 2
4 D
7 4 3 1
5 E To Blower Speed Control P5 P5
KEY F 3
6 F
Inverter (Wire Entry
Power Blower Control Tach Side)
7 H
J2 H 6
Board Fan 1 Power 6 5 4
8 I 8 1
9 J Fan 1 Tach
10 2 3 2 1
TOP 10 K Fan 1 Com To Inverter
9 3 Capacitor Bank
11 L J3
Fan 2 Power Cooling Tray Fans J3
J 4
12 M (Wire Entry
Fan 2 Tach Side)
L 5
Fan 2 Com
K 6
J2 6 5 4
(Board Mating Side)
Cabinet Cooling Wiring Diagrams

IP54, NEMA/UL Type 12 Drive Bay
IP20, NEMA/UL Type 1 Drive Bay
Cabinet See Note

Option Door Fan 1 Door Fan 2 See Note Blower
Bay G + - G + - TB2 G + - TB2
240V AC Neutral 240V AC Neutral
1
240V AC Hot 240V AC Hot
2
Direct Screw
Connection
Direct Screw Drive Bay Door Fan Harness Door Fan with Finger Guard Cabinet Blower Harness Cabinet Blower Fan
Connection (1 per Bay, 1 per Kit) (2 per Bay, 1 per Kit) (1 per Bay, 1 per Kit) (1 per Bay, 1 per Kit)
Spare Part Cat. No. = Spare Part Cat. No. = Spare Part Cat. No. = Spare Part Cat. No. =
SK-R1-FANH1-F8 20-750-FAN3-F8 SK-R1-FANH3-F8 SK-R1-FAN3-F8
IP20, NEMA/UL Type 1 Option Bay (Frame 8)

Note: For TB2 terminal numbers for AC Input and Common DC
Door Fan 1 Door Fan 2 Option Input drives, see Drive Schematic Diagrams on previous pages.
G + - G + - Bay
240V AC Neutral
1
240V AC Hot
2
Direct Screw Option Bay Door Fan Harness Door Fan with Finger Guard
Connection (1 per Bay, 1 per Kit) (2 per Bay, 1 per Kit)
SK-R1-OFANH1-F8 20-750-FAN3-F8

Notes:

Appendix B
Circuit Board Interconnections
Topic Page
Inverter Board Interconnections Diagram 1 384
Inverter Board Interconnections Diagram 2 385
Control Board Interconnections Diagram 1 386
Control Board Interconnections Diagram 2 387
This chapter provides the interconnection signals between drive circuit boards.

Appendix B Circuit Board Interconnections
Inverter Board Interconnections Diagram 1

J6 A1 ISO 24V COM A1 P4
B1 ISO 24V B1
J2
SYS24V A1
A2 +12V A2
SYS24COM B2
B2,B3 DGND B2,B3
SYS24V A2
A3 +12V A3
SYS24COM B2
A4 +12V A4 SYS24V A3
B4,B5 DGND B4,B5 SYS24COM B3
A5 +12V A5 SYS24V A4
SYS24COM B4
A6 +12V A6
SYS24V A5
B6,B7 DGND B6,B7
SYS24COM B5
A7 +12V A7
SYS24V A6
A8 +I2V A8 SYS24COM B6
B8,B9 DGND B8,B9 SYS24V A7
A9 -12V A9 SYS24COM B7
SYS24V A8
A10 -12V A10 SYS24COM B8
B10,B11 DGND B10,B11 P3 A1 SYS24V SYS24V A9
A11 -12V A11 B1 SYS24COM SYS24COM B9
A2 SYS24V SYS24V A10
A12 EEGND DGND A12 B2 SYS24COM SYS24COM B10
B12 EE3.3V DGND B12 A3 SYS24V SYS24V A11
Power A13 EE SK DGND A13 SYS24COM
Layer B13 EEGND DGND B13
Power B3
A4 SYS24V
SYS24COM B11 Power
EEPROM Control Supply
Interface A14 EE D1 DGND A14 B4 SYS24COM
Board B14 EE DOUT DGND B14 Board A5 SYS24V Board
A15 EEGND DGND A15 B5 SYS24COM
B15 EE CS DGND B15 A6 SYS24V +24V A12
A16 DGND A16 B6 SYS24COM -24V B12
B16 FAN CTRL B16 A7 SYS24V +24V A13
A17 DGND A17 B7 SYS24COM -24V B13
B17 FAN 2 CTRL B17 A8 SYS24V +24V A14
A18,A19 DGND A18,A19 B8 SYS24COM -24V B14
B18 TEMP FLT B18 A9 +24V +24V A15
B19 GND FLT B19 B9 -24V -24V B15
A20,A21 DGND A20,A21 A10 +24V +24V A16
B20 B20 B10 -24V -24V B16
IOC FLT
B21 B21 A11 +24V +24V A17
BRAKE
A22,A23 A22,A23 B11 -24V -24V B17
DGND
+24V A18
B22 U NEG B22
-24V B18
B23 U POS B23 +24V A19
A24,A25 DGND A24,A25 -24V B19
B24 V NEG B24 A12 +24V +24V A20
B25 V POS B25 B12 -24V -24V B20
A26,A27 DGND A26,A27 A13 +24V +24V A21
B26 W NEG B26 B13 -24V -24V B21
B27 W POS B27 A14 +24V +24V A22
A28 IU GND A28 B14 -24V -24V B22
B28 IU FB B28 A15 +24V +24V A23
A29 IV GND A29 B15 -24V -24V B23
B29 IV FB B29 A16 +24V PWRCOM A24
A30 IW GND A30 B16 -24V PWRCOM B24
B30 IW FB B30 A17 +24V PWRCOM A25
A31 IGND GND A31 B17 -24V PWRCOM B25
B31 IGND FB B31 A18 PWRCOM PWRCOM A26
A32,B32 DGND A32,B32 B18 PWRCOM PWRCOM B26
A19 PWRCOM PWRCOM A27
B19 PWRCOM PWRCOM B27
A22 PS NTC PS NTC A30
B22 /PS 480V PS ID B30
A23 BUS POS BUS POS A31
B23 BUS MID BUS MID B31
A24 BUS NEG BUS NEG A32
B24 BUS GND BUS GND B32

Circuit Board Interconnections Appendix B
Inverter Board Interconnections Diagram 2
P5 J1
J7 A1,B1 DGND A1,B1 A25 GATE W- GATE W- 26
A2 VBUS GND A2 B25 GATE W+ GATE W+ 25
B2 VBUS FB B2 A26 GATE V- GATE V- 24
A3 VMID GND A3 B26 GATE V+ GATE V+ 23
B3 VMID FB B3 A27 GATE U- GATE U- 22
A4 DGND A4 B27 GATE U+ GATE U+ 21
Power B4 PH U NTC B4 A28 ID COM ID COM 20
Layer A5 PH V NTC A5 Power B28 ID W ID W 19 Gate
Interface
B5 PH W NTC B5 Control A29 ID V -24V 18 Board
A6 DGND A6 B29 ID U PWRCOM 17
Board B6 AIR TEMP B6
Board A30 NTC W- ID V 16
Cable
A7 FLOW SNSR A7 B30 NTC W+ ID U 15
B7 GATE ID U B7 A31 NTC V- -24V 14
A8 GATE ID V A8 B31 NTC V+ PWRCOM 13
B8 GATE ID W B8 A32 NTC U- NTC W- 12
A9 DGND A9 B32 NTC U+ NTC W+ 11
B9 SP AIN1 B9 -24V 10
A10 PWR SUP NTC A10 PWRCOM 9
B10 ISCALE ID B10 NTC V- 8
A11,B11 DGND A11,B11 NTC V+ 7
A12 IOC U POS A12 -24V 6
B12,B13 DGND B12,B13 PWRCOM 5
A13 IOC U NEG A13 NTC U- 4
A14 IOC V POS A14 NTC U+ 3
B14,B15 DGND B14,B15 -24V 2
A15 IOC V NEG A15 PWR COM 1
A16 IOC W POS A16
B16,B17 DGND B16,B17
A17 IOC W NEG A17
A18 BLWR PS UV A18
B18 BULK PS UV B17
A19 LOC PS UV A18
B19 SYS PS UV B19
A20 SYS PS OC A2 0
B20 DGND B20
A21 BLWR SPD A21
B21 FAN1 SPD B21
A22 FAN2 SPD A22
B22 DGND B22
A23 LEM PD0 A23
B23 LEM PD1 B23
A24 480/690V A24
B24 RP ID0 B24
A25 RP ID1 A25
B25 RP ID2 B25
A26 RP ID3 A26
B26 DGND B26
A27 SP DIO 1 A27
A28 SP DIO 2 A28
A29 SP DIO 3 A29
A30 SP DIO 4 A30
A31 SP DIO 5 A31
A32 SP DIO 6 A32

Control Board Interconnections Diagram 1

Internal Stirring 1 Shield
Fan J16 J5 2 I_24V_RET
3 +I_24V
4 +12V
5 -12V
1 CAN HI 1 6 DGND
2 DGND 2 7 /AUX_OK
3 DGND 3 +I_24V 2,4 2,4 +I_24V
DPI 4 +12V 4 J11 I_24V _RET 1,3
J1
1,3 I_24V_RET
All faceplate
plug/header
Mini-DIN 5 DGND 5 DGND 5,6 5,6 DGND interfaces
6 CAN LO 6 +12V 7,8,9,10 7,8,9,10 +12V should have
7 +12V 7 J4 DGND 11,12 11,12 DGND TBx reference
8 DGND 8 -12V 13,14 13,14 -12V J1 designators
DGND 15,16 J2, J3, J4 15,16 DGND
4,17 +12V 1 SAFE VCC 18 18 SAFE VCC
5,18 DGND 2 /FLT STS 17 17 /FLT STS
HLTH STS 20 20 HLTH STS
HIM Shield SHIELD 3 J6
/SAFE ENA 19 19 /SAFE ENA
23 CAN LO 4
10 CAN HI 5 /HOST_ENA 22 22 /HOST ENA
SAFE VCC STS 21 21 SAFE VCC STS
C EVNT 24 24 C EVNT
1,3 I_24V_RET 1,3 /RESET 23 23 /RESET
P12 J5 IEEE_INT 26 26 IEEE_INT
2,4 +I_24V 2,4
5,6 DGND 5,6 /PWRDWN 25 25 /PWRDWN
7,8 DGND 7,8 S EVNT 28 28 S EVNT
BUS4 27 27 BUS4
9,10 +12V 9,10
11,12 +12V 11,12 BUS5 30 30 BUS5
BUS6 29 29 BUS6
13,14 +12V 13,14
15,16 DGND 15,16 DGND 32,31 32,31 DGND
S3DIN1 34 34 SxDIN1
17,18
19,20
-12V
DGND
17,18
19,20 S3DOUT1 33 Backplane 33 SxDOUT1
21 /MR_CNTR 21 S3CLK1+ 36 Board 36 SxCLK1+
Fiber 22 CNTR_CLK 22 Main S3CLK1- 35 35 SxCLK1- Option
38 38
Interface 23 RxD11+ 23
Control
S3DIN2
S3DOUT2 37 37
SxDIN2
SxDOUT2 Modules
24 TxD11+ 24
Board 25 RxD11- 25 Board S3CLK2+ 40 40 SxCLK2+
26 TxD11- 18 S3CLK2- 39 39 SxCLK2-
27,28 DGND 27,28 DGND 42,41 42,41 DGND
29 SPI_STS_CLK 29 S2DIN1 44 44 FDBK PA+
30 /SPI_STS_SHFT_LD 30 S2DOUT1 43 43 FDBK PA-
31 SPI_FLT_DO 31 S2CLK1+ 46 46 FDBK PB+
32 SPI_STS_DI 32 S2CLK1- 45 45 FDBK PB-
33 SPI_FLT_LATCH 33 S2DIN2 48 48 FDBK SA+
34 FO_EE_CLK 34 S2DOUT2 47 47 FDBK SA-
35 SPI_FLT_CLK 35 S2CLK2+ 50 50 FDBK SB+
36 FO_EE_DATA 36 S2CLK2- 49 49 FDBK SB-
37,38 DGND 37,38 DGND 52,51 52,51 DGND
39 RxD1+ 39 S1DIN1 54 54 SLOT0
40 TxD1+ 40 S1DOUT1 53 53 PWR_ENC_1
41 RxD1- 41 S1CLK1+ 56 56 SLOT 1
42 TxD1- 42 S1CLK1- 55 55 PWR_ENC_2
43,44 DGND 43,44 S1DIN2 58 58 MAC GND
S1DOUT2 57 57 /AUX OK
45 RxD2+ 45
46 TxD2- 46 S1CLK2+ 60 60 MAC VCC
47 RxD2- 47 S1CLK2- 59 59 MAC ID 1
48 TxD2+ 48 SLOT0 62 62 MAC ID3
/AUX OK 61 61 MAC ID 2
49,50 DGND 49,50
CAN HI 64 64 CAN HI
51 RxD3+ 51
CAN LO 63 63 CAN LO
52 TxD3+ 52
53 RxD3- 53
54 TxD3- 54
55,56 DGND 55,56
57 RxD4+ 57
58 TxD4- 58
59 RxD4- 59
60 TxD4+ 60
61,62 DGND 61,62
63 RxD5+ 63
64 TxD5+ 64
65 RxD5- 65
66 TxD5- 66
67,68 DGND 67,68
45 MCB_TST_P3.3V_SW 45
46 FIB_P3.3V 46
47 MCB_TST_P3V3_FDBK 47
48 SPARE 48
39 RxD7+ 39
40 TxD7+ 40
41 RxD7- 41
42 TxD7- 42
43,44 DGND 43,44
45 RxD8+ 45
46 TxD8+ 46
47 RxD8- 47
48 TxD8- 48
49,50 DGND 49,50
39 RxD9+ 39
40 TxD9+ 40
41 RxD9- 41
42 TxD9- 42
91,92 DGND 91,92
93 RxD10+ 93
94 TxD10+ 94
95 RxD10- 95
96 TxD10- 96
97,98 DGND 97,98

Circuit Board Interconnections Appendix B
Control Board Interconnections Diagram 2

1 Shield
+I_24V 2,4 2 I_24V _RET
J3 J1 J5 3 +I_24V
I_24V _RET 1,3 4 +12V
DGND 5,6 5 -12V
+12V 7,8,9,10 6 DGND All faceplate
7 /AUX_OK plug/header
DGND 11,12
+I_24V interfaces
-12V 13,14 2,4
I_24V _RET
should have
DGND 15,16 1,3 TBx reference
SAFE VCC 18 5,6 DGND designators
/FLT STS 17 7,8,9,10 +12V
HLTH STS 20 11,12 DGND
/SAFE ENA 19 13,14 -12V J1
/HOST_ENA 22 J2, J3, J4 15,16 DGND
SAFE VCC STS 21 18 SAFE VCC
C EVNT 24 17 /FLT STS
/RESET 23 20 HLTH STS
IEEE_INT 26 19 /SAFE ENA
/PWRDWN 25 22 /HOST_ENA
S EVNT 28 21 SAFE VCC STS
BUS4 27 24 C EVNT
BUS5 30 23 /RESET
BUS6 29 26 IEEE_INT
DGND 32,31 25 /PWRDWN
S3DIN1 34 28 S EVNT
S3DOUT1 33 27 BUS4
S3CLK1+ 36 30 BUS5
S3CLK1- 35 Backplane 29 BUS6
DGND
S3DIN2
S3DOUT2
38
37
Board 32,31
34 SxDIN1
Main S3CLK2+ 40 33 SxDOUT1
Option
Control S3CLK2- 39 36 SxCLK1+ Modules
42,41 35
Board DGND
S2DIN1 44 38
SxCLK1-
SxDIN2
S2DOUT1 43 37 SxDOUT2
S2CLK1+ 46 40 SxCLK2+
S2CLK1- 45 39 SxCLK2-
S2DIN2 48 42,41 DGND
S2DOUT2 47 44 FDBK PA+
S2CLK2+ 50 43 FDBK PA-
S2CLK2- 49 46 FDBK PB+
DGND 52,51 45 FDBK PB-
S1DIN1 54 48 FDBK SA+
S1DOUT1 53 47 FDBK SA-
S1CLK1+ 56 50 FDBK SB+
S1CLK1- 55 49 FDBK SB-
S1DIN2 58 52,51 DGND
S1DOUT2 57 54 SLOT0
S1CLK2+ 60 53 PWR_ENC_1
S1CLK2- 59 56 SLOT 1
SLOT0 62 55 PWR_ENC_2
/AUX OK 61 58 MAC GND
CAN HI 64 57 /AUX OK
CAN LO 63 60 MAC VCC
59 MAC ID 1
62 MAC ID3
61 MAC ID 2
64 CAN HI
63 CAN LO

Notes:

Appendix C
History of Changes
This appendix summarizes the revisions to this manual. Reference this appendix
if you need information to determine what changes have been made across
multiple revisions. This may be especially useful if you are deciding to upgrade
your hardware based on information added with previous revisions of this
manual.
750-TG001D-EN-P, April 2012 Topic

Added illustrations of Frame 10 drives to the Drive Input Power Configurations section.
Updated the Drive Series Components Compatibility section to include frame 10 drives.
Updated the Recommended Maintenance Tasks and Schedule table to include filters for the IP54 cabinet blower
assembly.
Removed the Series A Converter EMC Filter Board from the Converter Components Identification table.
Removed the Series A Converter Current Sensor kit from the Converter Components Identification table.
Added the Three Bay 24V Wire Harness kit for frame 10 drives to the Converter Components Identification table.
Updated the Control Power Isolator Board Removal/Installation (600/690V AC Input Drives Only) procedures to
include steps for frame 10 drives.
Added the Three Bay 24V Wire Harness kit for frame 10 drives to the DC Input with Precharge Assembly Components
Identification table.
Updated the Control Power Isolator Board Removal/Installation (810/932V DC Input Drives Only) procedures to
include steps for frame 10 drives.
Added the Cabinet L Bus Bar kit to the AC Input Drive Enclosure Components Identification table.
Added the Cabinet Door Shield Kit (Frame 10) kit to the AC Input Drive Enclosure Components Identification table.
Added the Cabinet L Bus Bar(s) Removal/Installation AC input enclosure procedures.
Added the Cabinet Door EMC Shield Removal/Installation (Frame 10 Drives Only) AC input enclosure procedures.
Added the Circuit Breaker kit to the Common DC Input Drive Enclosure Components Identification table.
Added the lockout Attachment kit to the Common DC Input Drive Enclosure Components Identification table.
Updated the Enclosure Cable Components and Part Numbers table to include the 3-Bay 24V Wire Harness Kit.
Added the new Third Inverter (INV3) Fiber-optic Cable Removal/Installation procedure.
Added the new IP54, NEMA/UL Type 12 Enclosure Components Replacement Procedures chapter.
Added the Frame 10 AC Input Drive Schematic Diagram (400VAC and 600VAC Classes).
Added the Frame 10 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC Classes).
Updated the Frame 8 Control Power Isolator Board Wiring Diagrams (600VAC Class AC Input Drive, and 810VDC and
932VDC Classes Common DC Input Drive) for frame 10 drives.
Corrected the terminal labels on Inverter Main Blower and Capacitor Bank Cooling Fan Wire Harness Diagram.
Added the Cabinet Cooling Wiring Diagrams.

Appendix C History of Changes
750-TG001C-EN-P, January Topic

2012 Updated the Converter Components Identification table to include the new kits for 600/690V AC input drives.
Updated the Converter Assembly Components Diagram 2 to include the new Control Power Isolation board.
Updated the Surge Suppressor Sense Wire Harness Removal/Installation procedure to reflect the addition of the new
Control Power Isolation board and 24V wire harness for 600/690V AC input drives.
Updated the Surge Suppressor Removal/Installation procedure to reflect the addition of the new Control Power
Isolation board and 24V wire harness for 600/690V AC input drives.
Updated the Surge Suppressor Assembly Removal/Installation procedure to reflect the addition of the new Control
Power Isolation board and 24V wire harness for 600/690V AC input drives.
Added the new Control Power Isolator Board 24V Wire Harness Removal/Installation (600/690V AC Input Drives Only)
procedure.
Added the new Control Power Isolator Board Removal/Installation (600/690V AC Input Drives Only) procedure.
Updated the DC Input with Precharge Assembly Components Identification table to include the new kits for 810/932V
DC input drives.
Updated the DC Input with Precharge Assembly Components Diagram 2 to include the new Control Power Isolation
board and 24V wire harness.
Added the new Control Power Isolator Board 24V Wire Harness Removal/Installation (810/932V DC Input Drives Only)
procedure.
Added the new Control Power Isolator Board Removal/Installation (810/932V DC Input Drives Only) procedure.
Updated the Undervoltage Delay Bracket Removal/Installation procedure to reflect the addition of the new Control
Power Isolation board.
Updated the Inverter Components Identification table to include the new kits for 600/690V AC input drives.
Updated the following schematic diagrams in Appendix A Schematics to reflect the addition of 600/690V AC input and
810/932V DC input drives:
Frame 8 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC Classes)
Frame 9 Common DC Input Drive Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC Classes)
DC Input with Precharge Assembly Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC Classes Common DC
Input Drives)
Added the following new schematic diagram to Appendix A Schematics:
Frame 8 Control Power Isolator Board Wiring Diagrams (600VAC Class AC Input Drive, and 810VDC and 932VDC
Classes Common DC Input Drive)
Added the new History of Changes appendix.
750-TG001B-EN-P, October
2011 Change
Updated the Lockout/Tagout procedure to include steps for common DC input drives.
Added the new Drive Input Power Configurations section to provide general information on
identifying the main drive components for each available configuration.
Added the new Drive Series Components Compatibility section to provide important information
about drive component compatibility based on the drive series designator.
Updated the list of Commonly Used Tools to include additional required tool sizes.

History of Changes Appendix C
Change
Updated the Fastener/Tool/Torque Information table to include the POZIDRIV fastener and tool
types.
Updated the Component Inspection and Maintenance procedure to include common DC input
drives.
Added the DC Precharge Assembly Fuse Tests procedure.
Added the Fiber-Optic Cable Removal/Installation (Frame 8) procedures to Chapter 4.
Added the new DC Input with Precharge Assembly Component Replacement Procedures chapter.
Updated the Inverter Gate Board Connection Ribbon Cables Removal/Installation procedure to
reflect new ribbon cable variation.
Added the new Inverter Top DC Bus Bar Removal/Installation (Common DC Input Drive Only) to
Chapter 7.
Updated the Inverter IGBT Assembly Removal/Installation (AC Input Drive Only) procedure to
include an additional required step.
Added the new Inverter IGBT Assembly Removal/Installation (Common DC Input Drive Only) to
Chapter 7.
Updated the Enclosure Door Fan Removal/Installation procedure to include an additional required
step.
Added the DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger Drives Only)
procedure.
Added the DC Bus Fuses and Fuse Indicators Removal/Installation (Frame 9 and Larger Drives
Only) procedure.
Added the Input Common Mode Core Removal/Installation (Frame 9 and Larger Drives Only)
procedure.
Added the new Common DC Input Drive Enclosure Component Replacement Procedures chapter.
Added the new Enclosure Cable Components Replacement Procedures (Frame 9 and Larger Drives)
chapter.
Updated the Before Applying Power to the Drive procedure to include steps for common DC input
drives.
Added the following new schematic diagrams to Appendix A Schematics:
Classes)
Classes)
DC Input with Precharge Assembly Schematic Diagram (540VDC, 650VDC, 810VDC, and 932VDC
Classes Common DC Input Drives)
DC Input with Precharge Devices Schematic Diagrams
DC Input with Precharge Assembly Control Transformer Schematic Diagram
Updated the following schematic diagrams in Appendix A Schematics:

Control Pod Schematic Diagram

Appendix C History of Changes
Notes:

Index
Numerics cabinet blower harness

120/240V circuit breaker (DC input drive) install 355
remove 354
install 321 cabinet door EMC shield
remove 322
install 312
120/240V control power input wire harness
remove 310
(DC input drive) cabinet door filter cassette
install 319 install 358
remove 320 remove 358
120/240V control power output wire harness cabinet door gasket
(DC input drive) install 359
install 320 remove 359
remove 321 cabinet L bus bars
120V UPS power input wire harness (DC input install 310
drive) remove 309
install 323 cable components
remove 324 part numbers 333
24V control wire harness (DC input drives) capacitor balance resistors
24V wire harness (frame 9 and larger drives) capacitor bank assembly (inverter)
24V/120V/240V wire harness (DC input drives) catalog number
install 181 control pod 48
remove 176 main control board 48
24V/240V power wire harness circuit boards
install 125 series A and B 26
remove 120 common mode core assembly (inverter)
install 215
remove 215
A compatibility
AC line fuse sense wire harness firmware versions and components 26
install 86 control board interconnections 386
remove 85 control pod
AC line fuses catalog number 48
install 89 install 50, 63
remove 87 remove 50, 59
AC line wire harness return to service position 81
install 112 rotate 78
remove 111 control pod cables
install 51
remove 51
B control pod components
backplane circuit board (inverter) part numbers 48
intsall 249 control power isolator board (converter)
remove 247 install 137
board interconnections remove 136
inverter 384 control power isolator board (DC input with
bottom conduit plate (option bay) precharge)
control power isolator board 24V wire harness
(converter)
C install 135
cabinet blower exhaust filter remove 134
install 356 control power isolator board 24V wire harness
remove 355 (DC input with precharge)
install 189
remove 188

Index
control transformer
install 130
remove 128
control transformer (DC input drives)
install 188
remove 185
control transformer primary fuses
install 81
remove 81
control transformer primary fuses (DC input
drives)
install 153
control transformer primary wire harness
intsall 128
remove 126
control transformer secondary fuse
install 82
remove 82
control transformer secondary fuses (DC input
drives)
install 152
converter
install 143
remove 140
converter components
part numbers 72, 146
converter fuse
tests 43
current sensor (converter)
install 97
remove 93
current sensor wire harness (converter)
install 92
remove 91
current sensor wire harness (inverter)
install 227
remove 225
current sensors (inverter)
install 224
remove 222
D
DC back bus guards
install 318
remove 317
DC bus fuse wire harness
install 133, 302
remove 132, 301
DC bus fuses and fuse indicators
install 305
remove 303
DC bus input wire harness (DC input drives)
install 165
remove 164
DC bus out/sense wire harness (DC input
drives)
install 157
remove 154

Index
DC bus sense wire harness duct gasket (DC input with precharge
install 91 assembly)
DC choke (AC input drive) remove 206
install 280
remove 278
DC input with precharge assembly E
install 206 EMC capacitors (AC input drive)
DC input with precharge assembly fuse remove 250
tests 45 EMC filter circuit board (converter)
DC line fuses install 84
remove 160 enclosure door fan (AC input drive)
DC precharge control circuit board install 298
remove 201 enclosure door fan (DC input drive)
digital I/O wire harness (DC input drives) install 315
remove 199 enclosure door fan wire harness (AC input
discharge resistor assembly drive)
install 290 install 298, 300
remove 284 enclosure door fan wire harness (DC input
disconnect handle panel (option bay)
drive)
install 328
disconnect switch handle remove 315
exhaust duct (drive bay)
install 185
disconnect switch jumper wires remove 295
install 183
remove 182 F
disconnect switch, auxiliary contact and
handle shaft fastener types 28
install 184 fiber interface board
door fan (option bay) remove 64
install 330 fiber-optic cable (frame 8)
door filter (drive bay) remove 52
install 294 fiber-optic spool
door filter (IP20) install 352
door interlock wire harness filter (IP20 door)
remove 197 firmware versions and components
drive enclosure (AC input) components compatibilty 26
part numbers 293 first inverter (INV1) fiber-optic cable
drive enclosure (common DC input) install 341
components remove 338
front cover (inverter)
part numbers 313
drive input power configurations 23 install 222
remove 221
drive series
component compatibility 25
drive series compatibility 25 G
drive start-up test without a motor (no load) gate board connection ribbon cables
363 (inverter)
duct gasket (converter) install 235
remove 143

Index
gate circuit board (converter) 24V wire harness (frame 9 and larger drives)
install 139 337
remove 137 24V/120V/240V wire harness (DC input
gate circuit board (inverter) drives) 181
install 236 24V/240V power wire harness 125
remove 235 AC line fuse sense wire harness 86
gate leads AC line fuses 89
AC line wire harness 112
resistance measurements 43 backplane circuit board (inverter) 249
bottom conduit plate (option bay) 332
cabinet blower exhaust filter 356
H cabinet blower harness 355
heat sink gasket (converter) cabinet door EMC shield 312
install 109 cabinet door filter cassette 358
remove 108 cabinet door gasket 359
heatsink fan cabinet L bus bars 310
inspection 38 capacitor balance resistors 231
heatsink fan assembly capacitor bank assembly (inverter) 230
common mode core assembly (inverter) 215
install 219 control pod 50, 63
remove 218 control pod cables 51
heatsink fan inlet bottom cover (inverter) control power isolator board (converter) 137
install 292 control power isolator board (DC input with
remove 291 precharge) 190
heatsink fan inlet screen control power isolator board 24V wire harness
inspection 38 (converter) 135
remove 217 (DC input with precharge) 189
control transformer 130
control transformer (DC input drives) 188
I control transformer primary fuses 81
IGBT assembly (inverter - AC input drive) control transformer primary fuses (DC input
drives) 153
install 272 control transformer primary wire harness 128
remove 267 control transformer secondary fuse 82
IGBT assembly (inverter - common DC input control transformer secondary fuses (DC input
drive) drives) 152
install 276 converter 143
remove 272 current sensor (converter) 97
IGBT assembly heatsink gasket (inverter) current sensor wire harness (converter) 92
install 276 current sensor wire harness (inverter) 227
remove 276 current sensors (inverter) 224
IGBT flex bus bars DC back bus guards 318
install 233 DC bus fuse wire harness 133, 302
remove 232 DC bus fuses and fuse indicators 305
input common mode core (common DC input DC bus input wire harness (DC input drives)
165
drives) DC bus out/sense wire harness (DC input
install 325 drives) 157
remove 324 DC bus sese wire harness 91
input common mode core (frame 9 and larger DC choke (AC input drive) 280
drives) DC input with precharge assembly 206
install 308 DC line fuses 162
remove 306 DC precharge control circuit board 202
inspect digital I/O wire harness (DC input drives) 200
components 38 discharge resistor assembly 290
install disconnect handle panel (option bay) 328
disconnect switch handle 185
120/240V circuit breaker (DC input drive) 321 disconnect switch jumper wires 183
120/240V control power input wire harness disconnect switch, auxiliary contact and
(DC input drive) 319 handle shaft 184
120/240V control power output wire harness door fan (option bay) 330
(DC input drive) 320 door filter (drive bay) 294
120V UPS power input wire harness (DC input door interlock wire harness 199
drive) 323 duct gasket (converter) 143
24V control wire harness (DC input drives) 170

Index
duct gasket (DC input with precharge thermostat 331

assembly) 206 third inverter (INV3) fiber-optic cable 351
EMC capacitors (AC input drive) 253 top conduit plate (drive bay) 296
EMC filter circuit board (converter) 84 top DC bus bars (inverter - DC input drive) 267
enclosure door fan (AC input drive) 298 transformer primary wire harness (DC input
enclosure door fan (DC input drive) 315 drives) 174
enclosure door fan wire harness (AC input undervoltage delay 196
drive) 298, 300 undervoltage delay bracket 193
enclosure door fan wire harness (DC input undervoltage delay wire harness 194
drive) 317 wire harness (inverter) 283
exhaust duct (drive bay) 295 interconnections
fiber interface board 70 control board 386
fiber-optic cable (frame 8) 55 internal stirring fan tray (inverter)
fiber-optic spool 352 install 216
first inverter (INV1) fiber-optic cable 341 remove 216
front cover (inverter) 222 inverter board interconnections 384
gate board connection ribbon cables
(inverter) 235 inverter components
gate circuit board (converter) 139 part numbers 210
gate circuit board (inverter) 236 IP54 enclosure components
heat sink gasket (converter) 109 part numbers 353
heatsink fan assembly 219
heatsink fan inlet bottom cover (inverter) 292
heatsink fan inlet screen 217 L
IGBT assembly (inverter - AC input drive) 272 left cover (converter)
IGBT assembly (inverter - common DC input
drive) 276 install 77
IGBT assembly heatsink gasket (inverter) 276 remove 77
IGBT flex bus bars 233 left cover (DC input drives)
input common mode core (common DC input install 151
drives) 325 remove 151
input common mode core (frame 9 and larger left wall (DC input drives)
drives) 308 install 166
internal stirring fan tray (inverter) 216 remove 165
left cover (converter) 77
left cover (DC input drives) 151
left wall (DC input drives) 166 M
main control board 59 main control board
molded case switch control wire harness (DC
input drives) 173 catalog number 48
molded case switch wire terminal support (DC install 59
input drives) 167 part number 48
no DC bus fuse wire harness 131 remove 56
power control circuit board 246 maintenance
power layer interface circuit board 240 schedule 32
power supply circuit board 243 tasks 32
power supply wire harness (inverter) 110 molded case switch control wire harness (DC
precharge circuit fuses (DC input drives) 163 input drives)
precharge resistor assembly (DC input drives) install 173
159 remove 171
precharge resistor jumper wires (DC input molded case switch wire terminal support (DC
drives) 160 input drives)
rating plug 238
right cover, no control pod (converter) 78 install 167
right cover, no control pod (DC input drives) remove 167
152
SCR assembly (converter) 108
SCR gate wire harness (converter) 98 N
second inverter (INV2) fiber-optic cable 346 no DC bus fuse wire harness
side DC bus bars (inverter - AC input drive) 261 install 131
stirring fan (converter) 120 remove 131
stirring fan (DC input with precharge
assembly) 197
surge suppressor 115
surge suppressor assembly 118
surge suppressor sense wire harness 113

Index
O AC line fuse sense wire harness 85

AC line fuses 87
option bay enclosure components AC line wire harness 111
part numbers 327 backplane circuit board (inverter) 247
bottom conduit plate (option bay) 332
cabinet blower exhaust filter 355
P cabinet blower harness 354
part number cabinet door EMC shield 310
cabinet door filter cassette 358
main control board 48 cabinet door gasket 359
part numbers
cabinet L bus bars 309
cable components 333 capacitor balance resistors 230
control pod components 48 capacitor bank assembly (inverter) 228
converter components 72, 146 common mode core assembly (inverter) 215
drive enclosure (AC input) components 293 control pod 50, 59
drive enclosure (common DC input) control pod cables 51
components 313 control power isolator board (converter) 136
inverter components 210 control power isolator board (DC input with
IP54 enclosure components 353 precharge) 189
option bay enclosure components 327 control power isolator board 24V wire harness
power control circuit board (converter) 134
remove 244 (DC input with precharge) 188
power layer interface circuit board control transformer 128
install 240 control transformer (DC input drives) 185
remove 238 control transformer primary fuses 81
power supply circuit board control transformer primary wire harness 126
install 243 control transformer secondary fuse 82
remove 240 converter 140
power supply wire harness (inverter) current sensor (converter) 93
current sensor wire harness (converter) 91
install 110
current sensor wire harness (inverter) 225
remove 109
current sensors (inverter) 222
precautions 20
DC back bus guards 317
precharge circuit fuses (DC input drives) DC bus fuse wire harness 132, 301
install 163 DC bus fuses and fuse indicators 303
remove 163 DC bus input wire harness (DC input drives)
precharge resistor assembly (DC input drives) 164
install 159 DC bus out/sense wire harness (DC input
remove 158 drives) 154
precharge resistor jumper wires DC bus sense wire harness 89
remove 159 DC choke (AC input drive) 278
precharge resistor jumper wires (DC input DC input with precharge assembly 203
DC line fuses 160
drives)
DC precharge control circuit board 201
install 160 digital I/O wire harness (DC input drives) 199
discharge resistor assembly 284
disconnect handle panel (option bay) 328
R disconnect switch handle 184
rating plug disconnect switch jumper wires 182
install 238 disconnect switch, auxiliary contact and
remove 237 handle shaft 183
remove door fan (option bay) 329
door filter (IP20) 294
120/240V circuit breaker (DC input drive) 322 door interlock wire harness 197
120/240V control power input wire harness
duct gasket (converter) 143
(DC input drive) 320
duct gasket (DC input with precharge
120/240V control power output wire harness assembly) 206
(DC input drive) 321
EMC capacitors (AC input drive) 250
120V UPS power input wire harness (DC input
EMC filter circuit board (converter) 83
drive) 324
enclosure door fan (AC input drive) 297
24V control wire harness (DC input drives) 168 enclosure door fan (DC input drive) 314
24V wire harness (frame 9 and larger drives)
enclosure door fan wire harness (DC input
334 drive) 315
24V/120V/240V wire harness (DC input exhaust duct (drive bay) 295
drives) 176
24V/240V power wire harness 120 fiber interface board 64

Index
fiber-optic cable (frame 8) 52 resistance measyurements

fiber-optic spool 351 gate leads 43
filter (IP20 door) 294 return to service position
first inverter (INV1) fiber-optic cable 338 control pod 81
front cover (inverter) 221 right cover, no control pod (converter)
gate board connection ribbon cables
(inverter) 233 install 78
gate circuit board (converter) 137 remove 78
gate circuit board (inverter) 235 right cover, no control pod (DC input drives)
heat sink gasket (converter) 108 install 152
heatsink fan assembly 218 remove 152
heatsink fan inlet bottom cover (inverter) 291 rotate
heatsink fan inlet screen 217 control pod 78
IGBT assembly (inverter - AC input drive) 267
IGBT assembly (inverter - common DC input
drive) 272 S
IGBT assembly heatsink gasket (inverter) 276 schematic
IGBT flex bus bars 232
input common mode core (common DC input control pod 372
drives) 324 control power isolator board wiring (600V AC/
input common mode core (frame 9 and larger 810V DC classes) 374, 375
drives) 306 control transformer (AC input drive) 380
internal stirring fan tray (inverter) 216 control transformer (DC input drive) 380
left cover (converter) 77 converter 373
left cover (DC input drives) 151 DC input with precharge 376
left wall (DC input drives) 165 DC input with precharge devices 377
main control board 56 frame 10 AC input drive (400/600V class) 368
molded case switch control wire harness (DC frame 10 DC input drive (540V, 650V, 810V
input drives) 171 and 932V classes) 371
molded case switch wire terminal support (DC frame 8 AC input drive (400/600V class) 366
input drives) 167 frame 8 DC input drive (540V, 650V, 810V, and
no DC bus fuse wire harness 131 932V classes) 369
power 21 frame 9 AC input drive (400/600V class) 367
power control circuit board 244 frame 9 DC input drive (540V, 650V, 810V, and
power layer interface circuit board 238 932V classes) 370
power supply circuit board 240 inverter circuit board (400V class) 378
power supply wire harness (inverter) 109 inverter power layer 379
precharge circuit fuses (DC input drives) 163 SCR assembly (converter)
precharge resistor assembly (DC input drives) install 108
158 remove 99
precharge resistor jumper wires 159 SCR gate wire harness (converter)
rating plug 237 install 98
right cover, no control pod (converter) 78 remove 97
right cover, no control pod (DC input drives) SCR/diode tests 39
152 second inverter (INV2) fiber-optic cable
SCR assembly (converter) 99 install 346
SCR gate wire harness (converter) 97 remove 342
second inverter (INV2) fiber-optic cable 342 series A and B circuit boards 26
side DC bus bars (inverter - AC input drive) 254
stirring fan (converter) 119 series specific components 25
stirring fan (DC input with precharge service tools 27
assembly) 196 side DC bus bars (inverter - AC input drive)
surge suppressor 114 install 261
surge suppressor assembly 115 remove 254
surge suppressor sense wire harness 113 software tools 27
thermostat 330 stirring fan (converter)
third inverter (INV3) fiber-optic cable 347
top conduit plate (drive bay) 296 install 120
top DC bus bars (inverter - DC input drive) 262 remove 119
transformer primary wire harness (DC input stirring fan (DC input with precharge
drives) 175 assembly )
undervoltage delay 195 install 197
undervoltage delay bracket 191 remove 196
undervoltage delay wire harness 194 surge suppressor
wire harness (inverter) 280 install 115
remove 114

Index
surge suppressor assembly

install 118
remove 115
surge suppressor sense wire harness
install 113
remove 113
T
test
converter fuses 43
converter SCRs/diodes 41
DC input with precharge assembly fuses 45
inverter IGBTs 42
no motor (no load) 363
thermostat
install 331
remove 330
third inverter (INV3) fiber-optic cable
install 351
remove 347
tool type and size 28
top conduit plate (drive bay)
install 296
remove 296
top DC bus bars (inverter - DC input drive)
install 267
remove 262
transformer primary wire harness (DC input
drives)
install 174
remove 175
U
undervoltage delay
install 196
remove 195
undervoltage delay bracket
install 193
remove 191
undervoltage delay wire harness
install 194
remove 194
W
wire harness (inverter)
install 283
remove 280

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, 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. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical
information, support chat and forums, software updates, and to sign up for product notification updates.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConnectSM 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.
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Publication 750-TG001E-EN-P - July 2012

Supersedes Publication 750-TG001D-EN-P - April 2012 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Hardware Service Manual

PowerFlex 750-Series AC Drives

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 3

4 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 5

Fiber-Optic Cable Removal/Installation (Frame 8). . . . . . . . . . . . . . . . . . 52

6 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Converter Current Sensor Wire Harness Removal/Installation . . . . . . 91

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 7

DC Bus Fuse Wire Harness Removal/Installation (Frame 9 and Larger

8 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Precharge Resistor Jumper Wires Removal/Installation . . . . . . . . . . . . 159

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 9

Control Power Isolator Board 24V Wire Harness Removal/Installation

10 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Heatsink Fan Inlet Screen Removal/Installation . . . . . . . . . . . . . . . . . . . 217

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 11

Inverter Backplane Circuit Board Removal/Installation . . . . . . . . . . . . 247

12 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 13

DC Back Bus Guards Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 317

14 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Second Inverter (INV2) Fiber-optic Cable Removal/Installation. . . . 342

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 15

Control Pod Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

16 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

This manual provides a recommended preventative maintenance schedule, major

It is highly recommended that you obtain a copy of the PowerFlex 750-Series AC

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 17

You can view or download publications at http://

18 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Before You Begin Testing, Maintenance, or

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 19

ATTENTION: Only qualified personnel familiar with adjustable frequency AC

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts

Class 1 LED Product

ATTENTION: Hazard of permanent eye damage exists when using optical

20 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

ATTENTION: To avoid an electric shock hazard when servicing the drive, a

Frame 9 Common DC Input Drive Shown

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 21

Frame 8 AC Input Drive Shown

22 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Figure 1 - AC Input Drives

Control Wire Way

Converter Section (left)

Bay 1 Bay 2 Bay 3

DC Choke and Main

Note: Drives shown with enclosure doors removed.

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 23

Figure 2 - Common DC Input Drives

Control Wire Way

Bay 1 Bay 2 Bay 3

Main Cooling Fan

Note: Drives shown with enclosure doors removed.

24 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Spare Part Compatibility with Series A and Series B Drives

Rockwell Automation Publication 750-TG001E-EN-P - July 2012 25

Firmware Version Compatibility with Series A and B Circuit Boards

Series A and B Converter Components and Drive Input Power

26 Rockwell Automation Publication 750-TG001E-EN-P - July 2012

Commonly Used Tools Service Tools