Spec Sheet - The Reynolds Company
Contents
1. Drive Input Power The PowerFlex 750 Series drives discussed in this manual are available as frame 8 Confiqurations 9 and 10 drives with either AC or common DC input Refer to Figure 1 and g 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 o F J Bay 1 Bay 2 Exhaust Vent C Te ud Control Wire Way ee H 277 Converter Section left en e F 4 o aqa gt C2. Due 9 Ck MES P y Lo W la n LJ 4 pes LE d b Em 3 b 3 es R 2s 3 b PE ae li re Lo f EN EM b b ll P MI al Cs al Le B o o amp 6 lll oe b o e d 4 3 L H 6 aH 5 2 zb ode dl e ANS e09 E B m id e09 24 Rockwell Automation Publication 750 TG001E EN P July 2012 D
3. Rockwell Automation Publication 750 TGO01E EN P July 2012 21 Chapter1 Before You Begin Testing Maintenance or Repairs 2 Wait fifteen minutes and verify that there is no voltage at the drive 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 z B o B al TI il INVERTER ID STS CONTROL PWR INPUT TESTPOINTS DC Lb oT TEL RJ 8 8 oJ E o o 8 8 fo w amp e um e I omg Ej E EL B 22 Rockwell Automation Publication 750 TGO01E EN P July 2012 Before You Begin Testing Maintenance or Repairs Chapter 1
4. 0 000 08 93 Installing the Converter Current Sensor 00 0000s eee 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 sssuses 99 Installing the Converter SCR Assembly sssuue 108 Converter Heat Sink Gasket Replacement 1224544 door trip r nn 108 Removing the Converter Heat Sink Gasket teet 108 Installing the Converter Heat Sink Gasket ssuuu 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 0000005 I Removing the AC Line Wire Harness iieseersostesco tr rs 111 Installing the AC Line Wire Harness essa teo rrt 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 Reimoval Dustallagton iaa census dtu Pr ad ERR 114 Removing the Surge Suppressor eiae cn aea t duae d a eU a it 114 Installing the Surge Suppressor vis eeucks exero atr e RES ES 115
5. 160 DC Line Fuses and Fuse Indicators Removal Installation 160 Removing the DC Line Fuses FU1 and FU2 and Fuse Indicators SW add iis tana eda dmn ER M e PUE EU Lad d ERI 160 Installing the DC Line Fuses FU1 and FU2 and Fuse Indicators SW3 and SWS jj cessas sank t aEkaaaed RE dba aA KE Rad 162 Precharge Circuit Fuses Removal Installation LL 163 Removing the Precharge Circuit Fuses FU3 and FU4 163 Installing the Precharge Circuit Fuses FU3 and FUA 163 DC Bus Input Wire Harness Removal Installation 164 Removing the DC Bus Input Wire Harness 45 164 Installing the DC Bus Input Wire Harness sessuee 165 Left Wall Removal Installation 222 oos cx eve ted vasos peres 165 Removing the Left Wall esessaawa n esnyd ask ye SEES E 165 Installing the Lett Wall ccaciniiasnatacnnaunys eR Caaadiesinge 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 000005 168 Installing 24V Control Wire Harness 00 eee eee 170 Molded Case Switch Control Wire Harness Removal Installation 171 Removing the Molded Case Switch Control Wire Harness 171 Installing the Molde
6. suuuse 230 Capacitor Balance Resistor Assembly Removal Installation 230 Removing the Capacitor Balance Resistor Assembly 230 Installing the Capacitor Balance Resistors 000005 231 IGBT Flex Bus Bars Removal Installation 0 00 eee eee 232 Removing the IGBT Flex Dus Bat s ii deseos urn kh tote 232 Installing the IGBT Flex Bus Bats eee oae rene 233 Inverter Gate Board Connection Ribbon Cables Removals astallutioit i sre rebez as e bp ale ida walate HR EUEE PET 233 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 s 235 Installing the Inverter Gate Circuit Board ssuuu 236 Rating Plug Removal Installation 42s te ook a rRR RR hh 237 Removitie the Rating DUE copier RE U ERR RREA REPERI FARA PE 237 Installing the Rating Plug ccc ennai pen abus dete pene ah 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 suu 240 Installing the Power Supply Circuit Board suuuuu 243 Pow
7. 55 Main Control Board Removal Installation Leeuuel 56 Removing the Main Control Board Control Pod in Drive Enelos re oere vae dai pita cet b pbi Re bE Fa aUa E Is 56 Installing the Main Control Board 0 cece eee eee 59 Control Pod Removal Installation ccc cece cence eee eees 59 Removing the Control Pod usi des aeekes eu adr E EIE EE REOR 59 Installitte the Control Pod accwrdsas reet tts 63 Fiber Interface Board Removal Installation LL eueusue 64 Removing the Fiber Interface Board 0 0ssccessccesees 64 Installing the Fiber Interface Board i052 orar 70 Chapter 5 Converter Components Identification Liuius dx er rra eoa ve 72 Converter Left Cover Removal Installation sssuuuu 77 Removing the Converter Left Cover Laos shag sva ees x dedi vi Installing the Converter Left Cover s cccsccevey aces sentaodecens 77 Converter Right Cover No Control Pod Removal Installation rre ccasacaen ces 78 Removing the Converter Right Cover No Control Pod 78 Installing the Converter Right Cover No Control Pod 78 Control Pad Rot23tol iud oecesoteststePcr EX T rer E PINE REP ES 78 Rotating the Control Pod Forward 1 eret eer es 78 Returning the Control Pod to the Service Position 81 Control Transformer Primary Fuses Removal Installation 81 Removing the Control Transformer Primary Fuses FU4 Gi BU s ences nan P
8. Harness Removal Installation 197 Removing the Door Interlock Wire Harness 4 197 Installing the Door Interlock Wire Harness suueee 199 Digital I O Wire Harness Removal Installation 199 Removing the Digital I O Wire Harness ls eesssess 199 Installing the Digital I O Wire Harness 0 2008 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 Components Identification i a esa rcv rrr wa 210 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 ioceseeseccar otn 216 Installing the Internal Stirring Fan Tray 12 e eese eere 216 Rockwell Automation
9. Inverter IGBT Assembly AC Input Drive Only 272 Inverter IGBT Assembly Removal Installation Common DC Input Drive Only E P aoo 272 Removing the Inverter IGBT Assembly Common DC Input Drive Qr NTC 22 Installing the Inverter IGBT Assembly Common DC Input Drive aC 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 0000005 280 Removing the Inverter Ware Harness coenae cess cea pep peROCHES 280 Installing the Inverter Wire Harness ius dosstodus eie deterius 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 29 Installing the Inverter Heatsink Fan Inlet Bottom Cover 292 Inlet Bottom Cover Gasket Replacement 00 eee eee 292 Removing the Inlet Bottom Cover Gasket ssuuue 292 Installing the Inlet Bottom Cove
10. 012 9 Table of Contents Inverter Component Replacement Procedures Control Power Isolator Board 24V Wire Harness Removal Installation 810 932V DC Input Drives Only cic ccccssenskuusacenenancewese 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 i aaeiuckeeziyossstri vem bDacbue ca mbREEE Iq 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 seeuuuue 195 Removing the Undervoltage Delay sseeeuuueue 195 Installing the Undervoltage Delay n iune 196 DC Input with Precharge Assembly Stirring Fan Removal InstallattGn i ees od bene Suet de pavers taseerbedeebase 196 Removing the DC Input with Precharge Assembly Stirring Fan 196 Installing the DC Input with Precharge Assembly Stirring Fan 197 Door Interlock Wire
11. After Repairs Schematics 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 00 00 eee eee 351 Removing the Fiber optic Spool Le eoo erro etra I nies 351 Installing the Fiber optic Spool aaccckseticudersaveseasdenn doa 352 Chapter 12 IP54 NEMA UL Type 12 Enclosure Components and Part TEES ce omeiuvace cuam prd PrWER NEN Fas SUR ERKELQUS GENE RU id 353 Cabinet Blower Harness Removal Installation 354 Removing the Cabinet Blower Harness esee essuue 354 Installing the Cabinet Blower Harness 25222 eva rrt nn 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 0000000 356 Removing the Cabinet Door Filters 0 cece eee 356 Installing the Cabinet Door Firersyciusstrancserdeesseeeoauave 357 Cabinet Door Filter Cassette Removal Installation 358 Removi
12. HIS NIME 132 Removing the DC Bus Fuse Wire Hatness c iisesse eee te ebrres 132 Installing the DC Bus Fuse Wire Haiiess iacccivewsvsacncnaies 133 Control Power Isolator Board 24V Wire Harness Removal Installation 600 690V AC Input Drives Only eese 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 Oily siesoroossdetesPe hbbrtix PeRO ad aaa 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 5 eee nn 140 Removing the Converter from the Inverter Assembly 140 Installing the Converter on the Inverter Assembly 143 Converter Duct Gasket Replacement lt i8 esessas er ro arr enun 143 Removing the Converter Duct Gaskets ee etra bee soeben 143 Installing the Converter Duct Gasket eere err nen 143 Chapter 6 DC Input with Precharge Assembly Components Identification 146 DC Input with Precharge Assembly Left Cover Top Guard and Left Guard Remosal Installation ando eoLbi e Rao EP Pr I E dobbeber 151 Removing th
13. Hardware Service Manual Allen Bradley PowerFlex 750 Series AC Drives Frame 8 and Larger Allen Bradley Rockwell Software Automation 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
14. I 373 Frame 8 Control Power Isolator Board Wiring Diagrams 600V AC Class AC Input Drive and 810VDC and 932VDC Classes Common DC Input Drive P ae 374 Frame 9 Control Power Isolator Board Wiring Diagrams 600V AC Class AC Input Drive and 810VDC and 932VDC Classes Common DC Input gc 374 Frame 10 Control Power Isolator Board Wiring Diagrams 600V AC Class AC Input Drive and 810VDC and 932VDC Classes Common DC Input n METTE 375 DC Input with Precharge Assembly Schematic Diagram 540VDC 650VDC 810VDC and 932VDC Classes Common DC Input Dici er apeten E MENFE PP EKMEoEPRE M MPO EIS 376 DC Input with Precharge Devices Schematic Diagrams 377 Inverter Circuit Board Schematic Diagram All Drive won M 378 Inverter Power Layer Schematic Diagram All Drive Confiou atioli seeen Eta aaee EE EAE EE EEEE 379 AC Input Drive Control Transformer Schematic Diagram 380 DC Input with Precharge Assembly Control Transformer Schematic DIAC UU a na S MEET 380 Inverter Main Blower and Capacitor Bank Cooling Fan Wire Harness ruo M 381 Cabinet Cooling Wiring Diagrams eere et arbres E Eee bush 381 Appendix B Inverter Board Interconnections Diagram 1 lesus 384 Inverter Board Interconnections Diagram 2 0 00 ee eee 385 Control Board Interconnections Diagram 1 0 00 0005 386 Control Board Interc
15. M MC ET ENS 81 Installing the Control Transformer Primary Fuse FU4 and FUS 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 cccsceescceceasees 87 Removing the AC Line Fuses FU1 FU2 and FU3 87 Installing AC Line Fuse FU T FU2 and FU3 i reor note 89 DC Bus Sense Wire Harness Removal Installation 89 Removing the DC Bus Sense Wire Harness 00085 89 Installing the DC Bus Sense Wire Harness ees eeeceer ror hn nta 9 Rockwell Automation Publication 750 TGO01E EN P July 2012 Table of Contents Converter Current Sensor Wire Harness Removal Installation 9 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
16. Publication 750 TGOO1E EN P July 2012 Table of Contents Heatsink Fan Inlet Screen Removal Installation 217 Removing the Heatsink Fan Inlet Screen iier eorr eteth nns 217 Installing the Heatsink Fan Inlet Screen 4s dss05 iecore 217 Heatsink Fan Assembly Removal Installation Le 218 Removing the Heatsink Fan Assembly 000005 218 Installing the Heatsink Fan Assembly ssuuuue 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 000 00 eee 221 Removing the Inverter Front Cover 0 0 ce eee e eens 221 Installing the Inverter Front Cover 00 cee e eee e eens 222 Inverter Current Sensors Removal Installation LL 222 Removing the Inverter Current Sensors iode ducat oem ed aires 222 Installing the Inverter Current Sensots iia caiusvs vane ope rhon 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
17. Surge Suppressor Assembly Removal Installation 115 Removing the Surge Suppressor Assembly 0 045 115 Installing the Surge Suppressor Assembly suue 118 Converter Stirring Fan Removal Installation Lees 119 Removing the Converter Stirring Pan eicere cauto e roe 119 Installing the Converter Stirring Fan eeeeeeeeese 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 Lue 128 Removing the Control Transformer 255 erste er arr rh un 128 Installing the Control Transformer 2122s cere assi rr ttr hrs 130 No DC Bus Fuse Wire Harness Removal Installation Frame 8 Drives Oily e m REPRE 131 Removing the No DC Bus Fuse Wire Harness 44 131 Installing the No DC Bus Fuse Wire Harness 131 Rockwell Automation Publication 750 TGO01E EN P July 2012 7 Table of Contents DC Input with Precharge Assembly Component Replacement Procedures DC Bus Fuse Wire Harness Removal Installation Frame 9 and Larger Dives lu oossquedo xen ipn BE dS UAE T
18. ation 327 Disconnect Handle Panel Removal Installation 328 Removing the Disconnect Handle Panel ssue 328 Installing the Disconnect Handle Panel sussue 328 Door Fan Removal Installatiot caswstrsiciiacieniabiiaioscesaved 329 Removing the Door Pats cesboeeset e ke tbEpRT TRE pA RE 329 Installing the Door Fan 1oosasdudk avaa abd densi e I RU ord ape 330 Thermostat Removal Installation 445 330 Removing the I ieriGstat lt icacs supe ex pab REIN UPPER QS 330 Installing the Thermostat 22 2 eibi resei ri PP Raga rar RE ERE 331 Bottom Conduit Plate Removal Installation Lese 332 Removing the Bottom Conduit Plate 00 2008 332 Installing the Bottom Conduit Plate siscic sexveeseedadewnowe s 332 Chapter 11 Enclosure Cable Components and Part Numbers 333 24V Wire Harness Removal Installation Frame 9 and Larger n MC T m 334 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 INVI Fiber optic Cable 338 Installing the First Inverter INVI Fiber optic Cable 341 Rockwell Automation Publication 750 TGOO1E EN P July 2012 IP54 NEMA UL Type 12 Enclosure Components Replacement Procedures Start Up
19. d 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 sss 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 Bemoval Installatioh iue ev Ek esa o Ex Sa E xd a Red Xa dee eee daa 183 Removing the Disconnect Switch Auxiliary Contact and Handle Shalt s estexerepEUuVe o diss uU SEN EEPEEN AD ncaa MUN MEM US 183 Installing the Disconnect Switch Auxiliary Contact and Handle Shaft cis 4 5ncdactsdeanesdhate A EERUEER PAZ TR ARE RE 184 Disconnect Switch Handle Removal Installation 184 Removing the Disconnect Switch Handle u 184 Installing the Disconnect Switch Handle 185 Control Transformer Removal Installation Lue 185 Removing tha Control Transformer 26i ociece rrr tiep nu 185 Installing the Control Transformer asas uet k v RARE 188 Rockwell Automation Publication 750 TGO01E EN P July 2
20. e 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 Rockwell Automation Publication 750 TGO01E EN P July 2012 19 Chapter1 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 A 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 A A 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 n
21. e DC Input with Precharge Assembly Left Cover Top Guard and Left Guard uia ius es adnexa ERRARE PAR DARE 151 Installing the DC Input with Precharge Assembly Left Cover Top Guard and Left Guard s uocis eeu are ibu on vevebrV WIDE ER EUREN RAE 151 DC Input with Precharge Assembly Right Cover No Control Pod Repbioal Installatioft 2a eecuect depre ex VeRO IC CREDE E 152 Removing the DC Input with Precharge Assembly Right Cover No Control Pod audeo cnwscitwdn roire E eE RERE 152 Installing the DC Input with Precharge Assembly Right Cover No Control Pod eesscceree nena E EE 152 Control Transformer Secondary Fuses Removal Installation 152 Removing the Control Transformer Secondary Fuses FUS ana PUG Tm 152 Installing the Control Transformer Secondary Fuses FUS and EUG PP 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 s s 158 Installing the Precharge Resistor Assembly Ls 159 Rockwell Automation Publication 750 TGO01E EN P July 2012 Table of Contents Precharge Resistor Jumper Wires Removal Installation 159 Removing the Precharge Resistor Jumper Wires 159 Installing the Precharge Resistor Jumper Wires
22. e 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 Provides basic information needed to properly wire and ground PWM AC drives Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES INO01 Provides general guidelines for the application installation and maintenance of solid state control Safety Guidelines for the Application Installation and Maintenance of Solid State Control publication SGI 1 1 Provides a simple cross reference of common schematic wiring diagram symbols used throughout various parts of the world A Global Reference Guide for Reading Schematic Diagrams publication 100 2 10 Provides practices for guarding against Electrostatic damage ESD Guarding Against Electrostatic Damage publication 8000 4 5 2 Provides declarations of conformity certificates and other certification details Product Certifications website http ab com Rockwell Automation Publication 750 TGO01E EN P July 2012 17 Preface 18 The following table lists publications that provide information about PowerFlex 750 Series drives Resource PowerFlex 750 S
23. ell Automation Publication 750 TGO01E EN P July 2012 13 Table of Contents Option Bay Enclosure Component Replacement Procedures Enclosure Cable Components Replacement Procedures Frame 9 and Larger Drives DC Back Bus Guards Removal Installation 000e0e 317 Removing the DC Back Bus Guards eo csasrcwersnaranceaseve 317 Installing the DC Back Bus Guaids ccscecucasdesiedaddensesse 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 Removal Installation lesse 320 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 cccessscissavnencies 321 Installing the 120 240V Circuit Breaker ies esee tor 222 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 o 324 Removing the Input Common Mode Core se 324 Installing the Input Common Mode Core sssues 325 Chapter 10 Option Bay Enclosure Components identific
24. er Control Circuit Board Removal Installation 244 Removing the Power Control Circuit Board Luu 244 Installing the Power Control Circuit Board L 246 Rockwell Automation Publication 750 TGO01E EN P July 2012 11 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 Dive Only jacere enra EE ai ebereseunseuseeeieveats 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 Dive Only estea ronen EEn EE EEE EE P 254 Removing the Inverter Side DC Bus Bars AC Input Diye Only raiat a aaae a aa 254 Installing the Inverter Side DC Bus Bars AC Input Drive Only 261 Inverter Top DC Bus Bar Removal Installation Common DC Input Dive Only sedana a e aT a EEA E O 262 Removing the Inverter Top DC Bus Bars Common DC Input Drive OR m 262 Installing the Inverter Top DC Bus Bars Common DC Input Drive Oily T 267 Inverter IGBT Assembly Removal Installation AC Input oce T 267 Removing the Inverter IGBT Assembly AC Input Drive Only 267 Installing the
25. eries Drive Installation Instruction 750 IN001 Description Provides the basic steps required to install a PowerFlex 750 Series AC drive PowerFlex 750 Series AC Drives Programming Manual publication 750 PM001 Provides information needed to start up program and troubleshoot PowerFlex 750 Series AC drives PowerFlex 755 Drive Embedded EtherNet IP Adapter User Manual publication 750COM UM001 Provides information on installing configuring and troubleshooting the Embedded EtherNet IP Adapter for PowerFlex 755 AC drives Safe Speed Monitor Option Module for PowerFlex 750 Series AC Drives Safety Reference Manual publication 750 RM001 Explains how the PowerFlex 750 Series AC drive can be used in Safety Integrity Level SIL CL3 Performance Level PL e or Category CAT 4 applications and provides information on installing configuring and troubleshooting the PowerFlex Safe Speed Monitor Option module PowerFlex 750 Series AC Drives Technical Data publication 750 TD001 Provides information on product features and benefits options and technical specifications information You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Rockwell Automation Publication 750 TGO01E EN P July 2012 Chapter 1 Before You Begin Testing Maintenanc
26. es c ar akt kan Tn 28 Fastener Torque Sequences sodes seeesrdieseoiee ir pede tix PER E ad 29 Chapter 2 Recommended Preventative Maintenance cece cece eeees 31 Schedule Codes Explanations ncscsisrciawineseecesdvenveaoad en 33 Maintenance Of Industrial Control Equipment 34 Solid State Devices Lua esu pat P ERERRAACUDEUERI ARA RENE ERE 36 Chapter 3 Component Inspection and Maintenance sucre haee a rh 38 Forward and Reverse Biased SCR Diode Tests 000 cece eee 39 Converter Fuse Tests soso snes nese nes eserer e EP I E er ePpes qs 43 Converter Gate Lead Resistance Measurements 00000005 43 DC Precharge Assembly Fuse Testscssccicecceeeecececcxeecorseuunsus 45 Chapter 4 Control Pod Components Identification 00 e eee eee ee 48 Control Pod Cover Removal Installation 52 22 icc erba 50 Removing the Control Pad Cover iis ci pk eaa aera ud 50 Installing the Control Pod Cover iiec eh eren e ed 50 Control Pod Cables Removal Installation 0000eceeeeee 51 Removing the Control Pod Cables iere e rts 51 Installing the Control Pod Cables tise lias k eb rkr ee orbita 51 Rockwell Automation Publication 750 TGO01E EN P July 2012 5 Table of Contents Converter Component Replacement Procedures Fiber Optic Cable Removal Installation Frame 8 52 Removing the Fiber Optic Cable Frame 8 eee 52 Installing the Fiber Optic Cable Frame 8
27. ng the Cabinet Door Filter Cassette suu 358 Installing the Cabinet Door Filter Cassette suuuuu 358 Cabinet Door Gasket Removal Installation Lese 359 Removing the Cabinet Door Gasket 00 cece eee 359 Installing the Cabinet Door Gasket iu ida eee n Era ERE nw Y 359 Chapter 13 Before Applying Power to the Drive cosaved asses ouo ERA Ie Y 361 Testing With the Motor Without a Mechanical Load 363 Appendix A Frame 8 AC Input Drive Schematic Diagram 400VAC and 600VAC ANG toate teenies Ur EEE E C EDEUE UU 366 Frame 9 AC Input Drive Schematic Diagram 400VAC and 600VAC Qo U 367 Frame 10 AC Input Drive Schematic Diagram 400VAC and 600VAC Classes P PRISEREUREO ENCORE E ESEE E EEES E E MR cones 368 Frame 8 Common DC Input Drive Schematic Diagram 540VDC 650VDC 810VDC and 932VDC Classes cece cence eens 369 Frame 9 Common DC Input Drive Schematic Diagram 540VDC 650VDC 810VDC and 932VDC Classes i cdecdies tas tianteaakt 370 Frame 10 Common DC Input Drive Schematic Diagram 540VDC 650VDC 810VDC and 932VDC Classes esee 371 Rockwell Automation Publication 750 TG001E EN P July 2012 15 Table of Contents Circuit Board Interconnections History of Changes Index Control Pod Schematic Diagram piiiiicieiieadiiacdseisiadeesabes 372 Converter Schematic Diagram 400VAC and 600VAC Classes AC Input VS RM DRMER ONE eR POT NOD
28. onnections Diagram 2 0 eee eee 387 Appendix C 750 TG001D EN P April 2012 389 750 T GOOTC EN P January 2012 1 esesesk2h ee thbbu Pe totos 390 750 TG001B EN P October 2011 2 0 0 ccc cece cece eee eee 390 Rockwell Automation Publication 750 TGOO1E EN P July 2012 Who Should Use this Manual Additional Resources 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 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 drive service and software firmware support information is available on the Allen Bradley Drives Servic
29. ontrol Pod and or Be Pig c i Control Panel right 3 o dimus 2 dm s ko Note Only one Control 1 F 3 Pod per Drive can also Ki a B oe eg be remotely mounted 4 S T i g J B No B 9 a L_ 5 foe le o C B g g A BE N E ls s ls 8 EI F 2 8 8 oe 9 P 4 b 4 rz O dE UAM OD Inverter Section 4 Frame 10 g j Bay 1 Bay 2 Bay 3 8 8 4 C je e E E B 8 DC Choke and Main Cooling Fan Intake 4 F I j j Vote Drives shown with enclosure doors removed Rockwell Automation Publication 750 TGO01E EN P July 2012 23 Chapter1 Before You Begin Testing Maintenance or Repairs Figure 2 Common DC Input Drives
30. opic 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 TGO01E EN P July 2012 3 Summary of Changes Notes 4 Rockwell Automa
31. ot 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 A 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 A transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors 20 Rockwell Automation Publication 750 TG001E EN P July 2012 Removing Power from the Drive N Before You Begin Testing Maintenance or Repairs Chapter 1 ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Measure the DC bus voltage at the DC and DC TESTPOINT sockets on the front of the power module see below for location Remo
32. r Gasket i iiie esu eser rw 292 Rockwell Automation Publication 750 TGOO1E EN P July 2012 AC Input Drive Enclosure Component Replacement Procedures Common DC Input Drive Enclosure Component Replacement Procedures Table of Contents Chapter 8 AC Input Drive Enclosure Components Identification 293 IP20 NEMA UL Type 1 Door Filter Removal Installation 294 Removing the Door Filter ciiisiasindaciudesars eek brane 294 Installing the Door Filter 224 vaakes tn a EAR ERE EAR ER EE n EE 294 Exhaust Duct Removal Installation eeeesesess 295 Removing the Exhaust DIE asscas Daakian abd edendo doa wees 295 Installing the Exhaust Duct iieeesos exero eer rena 295 Top Conduit Plate Removal Installation 00 eee 296 Removing the Top Conduit Plate onunu 296 Installing the Top Conduit Plat i ei aveo pe Fr au 296 Enclosure Door Fan Removal Installation Lsuuuu 297 Removing the Enclosure Door Fab iiusieosesss o err br rok EY 297 Installing the Enclosure Door Fan 000 eee e eee ee eee 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 PP H 301 Removing the DC Bus Fuse Wire Harness 008 301 Installing the DC Bu
33. s Fuse Wire Harness sseeseees 302 DC Bus Fuses and Fuse Indicators Removal Installation Frame 9 and Larger Drives Only cioosebisiuaoenePsuau aede bd sedu SES 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 ied iswasdebptenb ici re eP dedu E Qe DER MEUS 306 Removing the Input Common Mode Core sss 306 Installing the Input Common Mode Core ssuue 308 Cabinet L Bus Bar s Removal Installation lesse 309 Removing the Cabinet L Bus Bats ao tuor earn PER s 309 Installing the Cabinet L Bus Bat s 22 22 eb t be br es 310 Cabinet Door EMC Shield Removal Installation Frame 10 Drives ly oele rarecd oionn edad M duce OdsRde S NEOEN IU UNE 310 Removing the Cabinet Door EMC Shield Luu 310 Installing the Cabinet Door EMC Shield suuuuu 312 Chapter 9 Common DC Input Drive Enclosure Components Identification 313 Enclosure Door Fan Removal Installation Lssuuu 314 Removing the Enclosure Door Fan leeeseeeesue 314 Installing the Enclosure Door Fan 11 2 snerb utar barro an 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 Rockw
34. 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 Pe eD 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 T
35. tion Publication 750 TGO01E EN P July 2012 Preface Before You Begin Testing Maintenance or Repairs Periodic Maintenance Component Inspection and Test Procedures Control Pod Component Replacement Procedures Table of Contents Who Should Use this Manuali eee usadas tama uro E ERR rae 17 Additional Resoutces aues opaca xor donde Rads E oxde E EP ERE RE 17 Chapter 1 General Precautions cu desves eet ore bek e TR EET e o Pere EE 20 Qualified Personnel 2eieo ores vex prox ke SE MPEOCK EE PPPEO FEN 20 Personal Safety escepep d Ce rEPRREEFOCC E EPRE IE CU ER EE Ces 20 Prod ct Salety ead ER ed a arae Eb VR AE XR d RR e dd 20 Nass LED Pollack sccssactkrtUtdezesuuubuss edt erret k ors 20 Removing Power from the Drive c oeoo deese ese kh orent b ren 21 Drive Input Power Configurations 1 se caxwskekke teer rna es 23 Drive Series Components Compatibility sseeeuueee 25 Spare Part Compatibility with Series A and Series B Drives 25 Firmware Version Compatibility with Series A and B Circuit PORE adsbdvsntcagaseieeaiea bere saschoGe dus que OE SpU VR EE 26 Series A and B Converter Components and Drive Input Power Compatibility 2 essesa xke xeu dex x EXE ERRAT WERE EN Few d Ke 26 Commonly Used Tools iie pad Eee rox RO P SEY EO RP ERE aqu 27 Service Tool o cessdaxasAuss VoqERF E E P IRRIRROSAaSOICSRE RENE 27 Software Lonls ai duse a ser E FER SARNTEREES ERA CNEERERR IAS 27 Fasteoer Tool Torque Infotmatlon isdss
36. ve 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 e Sending an erroneous signal to your system s field devices causing unintended machine motion e 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
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