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Rockwell Automation Publication 750-TG101A-EN-P - June 2022

Chapter 2 Preventative and Predictive Maintenance

Predictive Maintenance

PowerFlex 755TS Products with TotalFORCE Control contain algorithms for
predictive maintenance that are used to improve the uptime of machines,
processes, and facilities. These algorithms monitor the lifespan of certain
components and display the percentage of remaining life and the number of
hours or counts of remaining life in specific parameters or a software
interface. These algorithms can be used to alert personnel when the
components are nearing the end of their lifespan so the components can be
replaced before they fail. For an overview of predictive maintenance, see the
Predictive Maintenance section in the PowerFlex 750-Series Products with
TotalFORCE Control Reference Manual, publication

.

The predicted remaining life of components appears on the Predictive
Maintenance page in these software applications:

•

Connected Components Workbench

•

Studio Logix 5000 Designer

provides an example of a Predictive Maintenance page for a drive.

Figure 10 - Connected Components Workbench - Predictive Maintenance Page Example

IMPORTANT

Failure to address predictive maintenance alarms can cause unexpected

downtime or premature product failure.

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Summary of Contents for 20G2

Page 1: ...Hardware Service Original Instructions PowerFlex 755TS Products with TotalFORCE Control Catalog Numbers 20G2 20GE ...

Page 2: ...oftware 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 These labels may also be on or inside the equipment to provide specific precautions The following icon may appear in the text of this documen...

Page 3: ...pter 2 Preventative and Predictive Maintenance Recommended Preventative Maintenance 25 Predictive Maintenance 26 Maintenance of Industrial Control Equipment 27 Solid state Devices 28 Chapter 3 Component Inspection and Tests Component Inspection and Maintenance 31 Forward and Reverse Biased IGBT Diode Tests 32 Chapter 4 Frames 1 5 Renewal Kits Installation Frames 1 5 Kits 33 Remove the Power Termin...

Page 4: ...61 Remove the Control Pod HIM Cradle Frames 2 5 61 Install the Control Pod HIM Cradle Frames 2 5 63 Main Control Circuit Board Replacement Frame 1 64 Remove the Main Control Circuit Board Frame 1 64 Install the Main Control Circuit Board Frame 1 67 Main Control Circuit Board Replacement Frames 2 5 69 Remove the Main Control Circuit Board Frames 2 5 69 Install the Main Control Circuit Board Frames ...

Page 5: ...to Power Interface Board Ribbon Cable Replacement 94 Remove the Main Control Board to Power Interface Board Ribbon Cable 94 Install the Main Control Board to Power Interface Board Ribbon Cable 95 Backplane Circuit Board Replacement 96 Remove the Backplane Circuit Board 96 Install the Backplane Circuit Board 97 Heatsink Fan Replacement 97 Remove the Heatsink Fan 97 Install the Heatsink Fan 98 Upper...

Page 6: ...le 131 Install the Control Pod HIM Cradle 133 Main Control Circuit Board Replacement 134 Remove the Main Control Circuit Board 134 Install the Main Control Circuit Board 137 Main Control Board to Power Interface Board Ribbon Cable Replacement 139 Remove the Main Control Board to Power Interface Board Ribbon Cable 139 Install the Main Control Board to Power Interface Board Ribbon Cable 140 Backplan...

Page 7: ...all the AC Precharge Circuit Board 400 480V 169 DC Precharge Circuit Board Replacement 170 Remove the DC Precharge Circuit Board 170 Install the DC Precharge Circuit Board 178 Appendix A Start Up After Repairs Before You Apply Power to the Drive 179 No load DC Bus Voltage and Output Current Measurements 180 Appendix B Schematics List of Drive Schematics 181 Index 189 ...

Page 8: ...8 Rockwell Automation Publication 750 TG101A EN P June 2022 Notes ...

Page 9: ...ublication NFPA 70E Standard for Electrical Safety in the Work Place For product programming and troubleshooting information that can help you determine if your product requires repairs see these publications See the PowerFlex Drives with TotalFORCE Control Programming Manual firmware revision 10 xxx and later publication 750 PM101 for general programming information See the PowerFlex Drives with ...

Page 10: ...Provides basic information to properly wire and ground PWM AC drives EtherNet IP Network Devices User Manual publication ENET UM006 Describes how to configure and use EtherNet IP devices to communicate on the EtherNet IP network Ethernet Reference Manual publication ENET RM002 Describes basic Ethernet concepts infrastructure components and infrastructure features System Security Design Guidelines ...

Page 11: ...and or equipment damage Personal Safety ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before servicing Measure the DC bus voltage at the power terminal block by measuring between the DC and DC terminals Also measure between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three me...

Page 12: ...MA UL Type 12 Enclosure on page 129 4 To verify that there is no voltage present measure the AC input and DC bus voltage For AC input drives and bus supplies only measure the AC input terminals R L1 S L2 and T L3 L to L and L to chassis GND PE For all products measure the DC output terminals DC and DC DC to DC DC to chassis GND PE and DC to chassis GND PE For terminal locations and identification ...

Page 13: ... EN P June 2022 13 Chapter 1 Before You Begin Tests Maintenance or Repairs Figure 1 Frames 1 3 Power Terminal Block and PE Ground Locations Frame 1 Frame 2 Frame 3 2 1 2 1 2 1 Item Name 1 R L1 S L2 T L3 BR1 BR2 DC DC U T1 V T2 W T3 2 PE Ground ...

Page 14: ...1 Before You Begin Tests Maintenance or Repairs Figure 2 Frames 4 and 5 Power Terminal Block and PE Ground Locations Frame 4 with EMC C2 Ground Plate Shown Frame 5 with EMC C2 Ground Plate Shown 2 1 2 1 Item Name 1 R L1 S L2 T L3 BR1 BR2 DC DC U T1 V T2 W T3 2 PE Ground ...

Page 15: ...22 15 Chapter 1 Before You Begin Tests Maintenance or Repairs Figure 3 Frames 6 and 7 Power Terminal Block and PE Ground Locations Frame 7 2 1 Frame 6 3 2 4 1 3 4 Item Name 1 DC and DC test points 2 DC DC BR1 BR2 3 R L1 S L2 T L3 U T1 V T2 W T3 4 PE Ground ...

Page 16: ...is in storage Protective Covers on Kits with XT Some renewal kits with XT use protective covers to seal terminal bocks circuit board connectors and wire harness connectors The covers protect against contamination and corrosion in corrosive gas environments For the product to meet the corrosive atmosphere rating protective covers must remain installed in or on unused connectors during storage and o...

Page 17: ...When you install a new circuit board with dielectric grease on the edge connectors by holding the protective cover only carefully remove the covers from the edge connectors on the circuit board Do not allow the edge connectors to contact surfaces other than the receiving connector Figure 5 Circuit Board with Protective Covers and Connectors with Dielectric Grease Example IMPORTANT Edge connectors ...

Page 18: ...roughly before you install the new circuit board or reinstall the existing circuit board Apply Dielectric Grease to an Edge Connector If any of the following conditions exist for an edge connector on a circuit board with XT do not install the circuit board Debris or particulate matter is present on the greased surfaces of a circuit board edge connector Any of the gold finger surfaces on the edge c...

Page 19: ...e large applicator puncture the seal on the end of the tube 4 Install the large grease applicator on the threaded tip of the tube 5 Close the applicator cover 6 Press the tube until the applicator tip chamber is completely filled with grease 7 Open the applicator cover and verify that the chamber is full of grease 8 If the chamber is not full of grease repeat steps 5 7 Item Description Item Descri...

Page 20: ...ffected edge connector 11 After use remove the grease applicator from the grease tube 12 Replace the cap on the grease tube 13 By using a clean cloth wipe the remaining grease out of the applicator tip and close the cover Be sure that the grease is applied beyond the edge of the gold finger surfaces on the edge connector ideally in contact with the conformal coating on the board Edge Connector Gol...

Page 21: ...oved from the drive assemblies and enclosure Service Tools Tool Description Details Allen hex socket wrench 4 mm Box wrench 7 mm 8 mm 10 mm Crimp tools For cable terminals 1 5 240 Current clamp 1000 A AC rms signal output ESD protected place of work Work surface floor cover seat and ground connections ESD protective clothing Wrist wrap shoes overall clothing coat Flash light Task light For inspect...

Page 22: ...gs which require 0 7 N m 6 lb in initial torque The numeric illustration labels are for your assistance Drive components do not contain these labels Figure 7 Two point Mounting Fastener Type Flat head screw Hexagonal bolt Hexagonal nut or standoff Hexagonal screw Torx screw Slotted Torx screw Sequence Number 1 M4 x 10 mm T20 or F 6 4 mm 0 25 in 4 8 N m 42 lb in Tool Type and Size F Flat nose screw...

Page 23: ... Begin Tests Maintenance or Repairs Figure 8 Four point Mounting Figure 9 Six point Mounting 1 2 3 4 3 4 Initial Sequence 1 2 1 2 3 4 Final Sequence 6 4 2 3 5 1 3 4 Initial Sequence 1 2 6 5 Final Sequence 3 4 1 2 6 5 Do not exceed 0 7 N m 6 lb in on initial torque of all six screws ...

Page 24: ...24 Rockwell Automation Publication 750 TG101A EN P June 2022 Chapter 1 Before You Begin Tests Maintenance or Repairs Notes ...

Page 25: ...or recommended maintenance tasks and schedules see the PowerFlex 755TS Products with TotalFORCE Control Installation Instructions publication 750 IN119 An annual preventative maintenance program includes the following primary tasks A visual inspection of all components accessible from the front of the drive Resistance checks on the power components Power supply voltage level checks General cleanin...

Page 26: ... personnel when the components are nearing the end of their lifespan so the components can be replaced before they fail For an overview of predictive maintenance see the Predictive Maintenance section in the PowerFlex 750 Series Products with TotalFORCE Control Reference Manual publication 750 RM100 The predicted remaining life of components appears on the Predictive Maintenance page in these soft...

Page 27: ...debris or other contaminants If contamination is found thoroughly clean receiving surfaces and reapply dielectric grease as described in the dielectric grease section See Dielectric Grease Application on page 17 for details Fans Inspect fans that are 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 chec...

Page 28: ...tions Be sure to clean any residues of melted coil insulation from other parts of the device or replace such parts 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 that are used with photoelectric switches also require periodic cleaning Do not use solvents or de...

Page 29: ...fault condition must be corrected and any necessary repairs or replacements must be made to restore the control equipment to good working order See NEMA Standards Publication No ICS 2 Part ICS2 302 for procedures For replacements use only parts and devices that Rockwell Automation recommends maintaining the integrity of the equipment Make sure that the parts are properly matched to the model serie...

Page 30: ...30 Rockwell Automation Publication 750 TG101A EN P June 2022 Chapter 2 Preventative and Predictive Maintenance Notes ...

Page 31: ...page 12 3 Remove the drive cover See the applicable chapter for your frame size Frames 1 5 Renewal Kits Installation on page 33 Frame 6 Renewal Kits Installation on page 81 Frame 7 Renewal Kits Installation on page 127 4 Inspect the fan assemblies for blockage and verify free rotation Clean or replace as necessary See these procedures for replacement instructions Frames 2 5 control pod printed cir...

Page 32: ...iode tests on the power module for your product frame size See Figure 1 on page 13 and Figure 2 on page 14 for terminal locations and identification 4 If the product fails the measurements that are identified in Table 1 or Table 2 replace the drive 5 Complete the procedures in Appendix A on page 179 before placing the drive back into service IMPORTANT The actual voltage readings can vary depending...

Page 33: ... F4 SK RT CVR1 F4 XT 4 SK RT CVR1 F5 SK RT CVR1 F5 XT 5 IP54 NEMA UL Type 12 Enclosure Cover SK RT CVR12 F2 SK RT CVR12 F2 XT 2 See page 40 SK RT CVR12 F3 SK RT CVR12 F3 XT 3 SK RT CVR12 F4 SK RT CVR12 F4 XT 4 SK RT CVR12 F5 SK RT CVR12 F5 XT 5 Chassis for IP20 NEMA UL Open Type IP20 NEMA UL Type 1 and Flange NEMA UL Type 4X 12 Back Enclosures SK RT CHSS1 F1 SK RT CHSS1 F1 XT 1 See page 41 SK RT C...

Page 34: ...page 69 3 4 5 Main Control Board to Power Interface Board Ribbon Cable SK RT PIC1 F1 XT 1 See page 74 SK RT PIC1 F27 XT 2 See page 75 3 4 5 Backplane Circuit Board Kit Contains 1 Circuit Board SK RT BKPLN SK RT BKPLN XT 1 See page 76 2 See page 77 3 4 5 EMC C3 Ground Plate 400 480V SK RT EMC3 F1 1 1 SK RT EMC3 F2 2 SK RT EMC3 F3 3 SK RT EMC3 F4 4 SK RT EMC3 F5 5 1 The EMC C3 ground plate and hardw...

Page 35: ...es Remove the Power Terminal Cover Frames 1 5 Follow these steps to remove the power terminal cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 For IP20 NEMA UL Type 1 enclosures only remove the M4 x 16 mm slotted Torx screw that secures the cover to the conduit box Retain the screw for reuse 4 Press inward on the ...

Page 36: ...ace the tab on the cover into the slot or slots on the chassis 2 Rotate the bottom of the cover inward and press the tabs on the lower sides of the cover into the slots on the chassis 3 For IP20 NEMA UL Type 1 enclosures only replace the M4 x 16 slotted Torx screw that secures the cover to the conduit box NEMA UL Type 1 Only 1 2 3 Frame 4 Open Type Shown 3 M4 x 16 mm T20 or F 6 4 mm 0 25 in 0 23 N...

Page 37: ...applicable Remove the IP54 NEMA UL Type 12 Cover Frames 2 5 Follow theses steps to remove the cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 For all frame sizes remove the two M4 hex nuts at the bottom of the drive cover 4 Remove the slotted Torx screws Frames 2 4 Remove the 13 M4 x 16 mm slotted Torx screws Fra...

Page 38: ...ware 2 Apply the torque value in the sequence shown 3 Apply final torque in the sequence shown 2 M4 x 16 mm T20 or F 6 4 mm 0 25 in 0 12 N m 1 0 lb in M4 7 mm 0 12 N m 1 0 lb in 3 M4 x 16 mm T20 or F 6 4 mm 0 25 in 0 23 N m 2 0 lb in M4 7 mm 0 23 N m 2 0 lb in 1 1 5 7 3 10 14 15 11 8 6 2 4 12 9 13 5 10 7 1 3 8 11 6 2 4 12 9 13 14 15 5 9 7 3 1 8 10 6 2 11 13 12 4 14 15 5 9 7 3 1 15 17 18 13 11 16 1...

Page 39: ...res Remove the Power Terminal Cover Frames 1 5 Follow these steps to remove the power terminal cover for frames 1 5 drives 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12l 3 Remove the IP20 NEMA UL Type 1 power terminal cover See Remove the Power Terminal Cover Frames 1 5 on page 35 Install the Power Terminal Cover Frame...

Page 40: ...SK RT CVR12 F2 XT SK RT CVR12 F3 SK RT CVR12 F3 XT SK RT CVR12 F4 SK RT CVR12 F4 XT SK RT CVR12 F5 SK RT CVR12 F5 XT Remove the IP54 NEMA UL Type 12 Cover Frames 2 5 Follow theses steps to remove the cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the cover See Remove the IP54 NEMA UL Type 12 Cover Frames ...

Page 41: ...F1 SK RT CHSS1 F1 XT These kits can be used for IP20 NEMA UL Open Type IP20 NEMA UL Type 1 and Flange NEMA UL Type 4X 12 back enclosures Remove the Chassis Frame 1 Follow these steps to remove the chassis 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page Remove Power from the System on page 12 3 Remove the power terminal cove...

Page 42: ...tom of the HIM cradle 6 Loosen the captive M3 Torx screw that secures the plastic chassis to the metal bracket 7 Use a screwdriver to lift the two slotted tabs on the bottom of the chassis off the brackets If a cable is not connected to the DPI port on the HIM cradle be sure to leave the protective cover installed 5 6 M4 x 16 mm T20 or F 6 4 mm 0 25 in 0 23 N m 2 0 lb in ...

Page 43: ...cation 750 TG101A EN P June 2022 43 Chapter 4 Frames 1 5 Renewal Kits Installation 8 Rotate the chassis 90 until the chassis locks in place 9 Disconnect the HIM DPI circuit board connector from the main control circuit board 9 ...

Page 44: ...al Kits Installation 10 At the top of the plastic chassis pull outward on the tabs and lift the chassis off the drive Install the Chassis Frame 1 Follow these steps to install the chassis 1 At the top of the new chassis pull outward on the tabs and snap the chassis into place on the drive ...

Page 45: ...llation 2 Verify that the HIM DPI cable is routed and clipped to the plastic chassis 3 If a HIM and DPI cable is used remove the protective cover from the HIM and DPI connectors on the chassis 4 Secure the chassis to the drive in the reverse order of removal Top Inside View of Frame 1 Chassis DPI Port ...

Page 46: ... be used for IP20 NEMA UL Open Type IP20 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures Remove the Chassis Frames 2 5 Follow these steps to remove the chassis 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 For IP20 NEMA UL Type 1 enclosures only insert a screwdriver under the drip hood press outward to d...

Page 47: ...5 For frames 4 and 5 drives only complete steps a c a Pull the tab away from the fan assembly and pull the fan assembly partially out of the chassis b Disconnect the power wire harness connector from the stirring fan connector and remove the stirring fan assembly from the chassis Retain the fan assembly for reuse c Push the power wire harness through the hole in the chassis Frame 4 Shown 5a 5b 5c ...

Page 48: ...P June 2022 Chapter 4 Frames 1 5 Renewal Kits Installation 6 Use a screwdriver to lift the two slotted tabs on the bottom of the chassis off the brackets 7 At the top of the drive lift the chassis off the tabs and remove the chassis Frame 4 Shown 6 7 ...

Page 49: ... cover from the drive See Remove the Power Terminal Cover Frames 1 5 on page 35 4 If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 6 If used disconnect the plug in terminal block TB1 on the bottom of the main control board 7 If an option module is installe...

Page 50: ...es 1 5 Renewal Kits Installation 8 Disconnect the power wiring from the power terminals 9 Remove the 10 16 x 1 in hexagonal head screws that secure the flange to the mounting surface and remove the drive and gasket Discard the gasket Frame 2 Drive Shown 9 10 16 x 1 in 5 16 in ...

Page 51: ...50 TG101A EN P June 2022 51 Chapter 4 Frames 1 5 Renewal Kits Installation 10 Remove the M4 x 10 mm slotted Torx screws that secure the flange to the drive chassis and remove the flange 11 Remove the gasket from the flange and discard ...

Page 52: ...on Publication 750 TG101A EN P June 2022 Chapter 4 Frames 1 5 Renewal Kits Installation Install the Flange Gasket Frames 2 5 Follow these steps to Install the flange gasket 1 Insert the new gasket and drive into the flange ...

Page 53: ...s to the flange Finger tighten the clamps and screws only 3 To secure the drive to the flange apply final torque by using the sequence that is shown 1 5 14 7 11 12 8 13 6 4 9 10 3 2 5 7 3 1 8 6 2 4 9 10 11 12 5 9 7 3 1 13 15 11 14 8 12 6 2 4 10 16 18 17 5 7 3 1 8 6 2 9 10 4 11 12 3 M4 x 10 mm T20 or F 6 4 mm 0 25 in 1 8 N m 16 0 lb in Frame 2 Frame 3 Frame 4 Frame 5 ...

Page 54: ...minal torque specifications see the PowerFlex 755TS Products with TotalFORCE Control Installation Instructions publication 750 IN119 Control Pod Printed Circuit Board Fan Replacement Frames 2 5 Replacement kit catalog numbers SK RT PODFAN1 SK RT PODFAN1 XT These kits can be used on all enclosure types Remove the Control Pod Printed Circuit Board Fan Frames 2 5 Follow theses steps to remove the con...

Page 55: ... Frames 2 5 on page 46 5 If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle 6 Loosen the screw that secures the HIM cradle to the pod chassis and rotate the cradle up to a 90 horizontal position 7 If an option module is installed next to the main control circuit board remove the option module not shown in this image 8 Disconnect the fan power wire harness three pin co...

Page 56: ... 1 5 Renewal Kits Installation 9 Press in on the two tabs on either side of the fan and remove the fan from the chassis Install the Control Pod Printed Circuit Board Fan Frames 2 5 Install the control pod printed circuit board fan in the reverse order of removal Frame 2 Frame 4 ...

Page 57: ...SFAN2 F3 XT These kits can be used for flange NEMA UL Type 4X 12 back and IP54 NEMA UL Type 12 enclosures Remove the Heatsink Fan Frames 1 3 Follow these steps to replace the heatsink fan 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Press in on the two tabs on either side of the fan and remove the fan partially from...

Page 58: ...hese kits can be used for flange NEMA UL Type 4X 12 back and IP54 NEMA UL Type 12 enclosures Remove the Heatsink Fan Frames 4 and 5 Follow these steps to remove the heatsink fan 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Press in on the two tabs on either side of the fan and partially remove the fan from the chass...

Page 59: ...rom the drive For IP20 NEMA UL Open Type IP20 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures remove the power terminal cover See Remove the Power Terminal Cover Frames 1 5 on page 35 For IP54 NEMA UL Type 12 enclosures remove the drive cover See Remove the IP54 NEMA UL Type 12 Cover Frames 2 5 on page 37 4 For IP20 NEMA UL Open Type IP20 NEMA UL Type 1 and flange NEMA UL Type 4X 12 b...

Page 60: ... the touch shield from the drive b Disconnect the fan power wire harness connector from the connector on the chassis and remove the fan c Remove the M4 x 35 mm two slotted Torx screws that secure the fan assembly to the bracket and remove the fan assembly Install the Stirring Fan Frames 4 and 5 Install the stirring fan in the reverse order of removal Frame 4 Shown 5a M4 x 10 mm T20 or F 6 4 mm 0 2...

Page 61: ... Cover Frames 1 5 on page 35 For IP54 NEMA UL Type 12 enclosures remove the cover See Remove the IP54 NEMA UL Type 12 Cover Frames 2 5 on page 37 4 If a HIM is installed in the cradle remove the HIM 5 If used disconnect the DPI cable from the connector on the bottom of the HIM cradle 6 Loosen the screw that secures the HIM cradle to the pod chassis and rotate the cradle up to a 90 horizontal posit...

Page 62: ...n Publication 750 TG101A EN P June 2022 Chapter 4 Frames 1 5 Renewal Kits Installation 8 Press in on the tabs at the top of the HIM cradle where it connects to the control pod chassis and release the cradle from the chassis ...

Page 63: ... from these connectors on the HIM cradle unless a connection is made during reinstallation IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage and operation See Protective Covers on Kits with XT on page 16 for details Item Description Ite...

Page 64: ... Remove Power from the System on page 12 3 Remove the power terminal cover See Remove the Power Terminal Cover Frames 1 5 on page 35 4 If used disconnect the DPI cable from the connector on the bottom of the HIM cradle 5 Loosen the captive M3 Torx screw that secures the plastic chassis to the metal bracket 6 Use a screwdriver to lift the two slotted tabs on the bottom of the chassis off the bracke...

Page 65: ...sconnect the terminal block for the HIM DPI wire harness from the connector on the main control circuit board 10 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 11 If used disconnect the plug in terminal block TB1 on the bottom of the main control board 12 If an option module is installed disconnect any I O wiring terminal blocks and re...

Page 66: ... setting the programming mode 2 EtherNet IP address switches Rotary switches for setting the lowest octet of an EtherNet IP address forces address to 192 168 1 xxx See the PowerFlex Drives with TotalFORCE Control Built in EtherNet IP Adapter User Manual publication 750COM UM009 for instructions on setting the IP address 3 ENABLE jumper Hardware enable jumper P7 TB1 becomes an Enable when this jump...

Page 67: ...e the main control board Install the Main Control Circuit Board Frame 1 Follow these steps to install the main control circuit board IMPORTANT Circuit boards that are contained in renewal kits with XT contain dielectric grease on the edge connectors where present Do not touch or remove the grease from circuit board edge connectors A non greased connector can lead to corrosion 14 M3 x 6 4 mm T15 or...

Page 68: ...rcuit board See Apply Dielectric Grease to an Edge Connector on page 18 for instructions on how to clean and grease an edge connector IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage and operation See Protective Covers on Kits with XT ...

Page 69: ...ove the power terminal cover See Remove the Power Terminal Cover Frames 1 5 on page 35 For IP54 NEMA UL Type 12 enclosures remove the drive cover See Remove the IP54 NEMA UL Type 12 Cover Frames 2 5 on page 37 4 If used disconnect the DPI cable from the connector on the bottom of the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the cont...

Page 70: ...rames 4 and 5 IP54 NEMA UL Type 12 drives only J16 connector from the connector P16 on the main control circuit board Retain the jumper for reuse with the new main control board 10 Disconnect the HIM wire harness connector from the connector on the main control board Control Pod Shown Removed from the Drive Chassis for Clarity Only IP20 NEMA UL Open Type Frame 2 Drive Shown Drive Chassis Shown Rem...

Page 71: ... setting the programming mode 2 EtherNet IP address switches Rotary switches for setting the lowest octet of an EtherNet IP address forces address to 192 168 1 xxx See the PowerFlex Drives with TotalFORCE Control Built in EtherNet IP Adapter User Manual publication 750COM UM009 for instructions on setting the IP address 3 ENABLE jumper Hardware enable jumper P7 TB1 becomes an Enable when this jump...

Page 72: ...tall the Main Control Circuit Board Frames 2 5 Follow these steps to install the main control circuit board 12 M3 x 6 4 mm T15 or F 5 mm 0 19 in 0 45 N m 4 0 lb in 12 Frame 2 Shown Chassis Shown Removed for Clarity Only IMPORTANT Circuit boards that are contained in renewal kits with XT contain dielectric grease on the edge connectors where present Do not touch or remove the grease from circuit bo...

Page 73: ...ge connector or is contaminated do not install the circuit board See Apply Dielectric Grease to an Edge Connector on page 18 for instructions on how to clean and grease an edge connector IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage...

Page 74: ... from the System on page 12 3 Remove the power terminal cover See Remove the Power Terminal Cover Frames 1 5 on page 35 4 Remove the main control circuit board See Remove the Main Control Circuit Board Frame 1 on page 64 5 Pull the ribbon cable off the mounting clip on the side of the drive chassis 6 Disconnect the ribbon cable connector from connector J1 on the power circuit board and remove the ...

Page 75: ...on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board Frames 2 5 on page 69 4 Remove the drive chassis See Remove the Chassis Frames 2 5 on page 46 5 Remove the ribbon cable connector from the mounting tab on the inside of the control pod chassis 6 Pull the cable through the sl...

Page 76: ...e Backplane Circuit Board Frame 1 Follow these steps to remove the backplane circuit board 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board Frame 1 on page 64 4 Compress the mounting two posts that secure the backplane circuit board to the c...

Page 77: ...uit boards It is recommended that you replace both backplane circuit boards simultaneously Remove the Backplane Circuit Board Frames 2 5 Follow these steps to remove the backplane circuit board 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Boar...

Page 78: ...EN P June 2022 Chapter 4 Frames 1 5 Renewal Kits Installation 4 Remove the two M4 x 8 mm Torx screws that secure the backplane circuit board to the pod chassis and remove the board 4 M4 x 8 mm T20 or F 5 mm 0 19 in 2 6 N m 23 0 lb in Frame 2 Shown ...

Page 79: ...ot remove the protective covers from the connectors on the new backplane circuit boards unless a connection must be made during installation IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage and operation See Protective Covers on Kits w...

Page 80: ...80 Rockwell Automation Publication 750 TG101A EN P June 2022 Chapter 4 Frames 1 5 Renewal Kits Installation Notes ...

Page 81: ... 12 Back Enclosures SK RT CVR1 F6 SK RT CVR1 F6 XT See page 86 Control Pod Human Interface Module HIM Cradle for All Enclosure Types SK RT BZL1 SK RT BZL1 XT See page 86 Main Control Board SK RT MCB1 PF755 SK RT MCB1 PF755 XT See page 89 Main Control Board to Power Interface Board Ribbon Cable SK RT PIC1 F27 XT See page 94 Backplane Circuit Board SK RT BKPLN SK RT BKPLN XT See page 96 Heatsink Fan...

Page 82: ...PIB1 C170D156 XT Power Interface Circuit Board 205 A 400V 186 A 480V SK RT PIB1 C205D186 SK RT PIB1 C205D186 XT Power Interface Circuit Board 260 A 400V 248 A 480V 2 SK RT PIB1 C260D248 SK RT PIB1 C260D248 XT AC Precharge Circuit Board 400 480V SK RT ACPC CDF6 SK RT ACPC CDF6 XT See page 113 DC Precharge Circuit Board SK RT DCPC F67 SK RT DCPC F67 XT See page 119 1 Use for drives installed in an I...

Page 83: ... internal components in the drive Remove the Cover Follow these steps to remove the cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Loosen the four M4 x 8 mm captive screws that secure the cover to the assembly and remove the cover Install the Cover Install the cover in the reverse order of removal 3 M4 x 8 mm F ...

Page 84: ...tive Guard IP54 NEMA UL Type 12 Enclosure Follow these steps to remove the protective guard from an IP54 NEMA UL Type 12 enclosure 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Loosen the captive screws that secure the protective guard to the drive chassis and remove the guard Install the Protective Guard IP54 NEMA U...

Page 85: ... Remove the Control Pod Access Cover Follow these steps to remove the control pod access cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Loosen the two M3 x 6 4 mm slotted Torx screws that secure the control pod access cover to the drive cover and remove the access cover Install the Control Pod Access Cover Insta...

Page 86: ...access cover for reuse 4 Remove the cover See Remove the Cover on page 83 Install the Cover Install the cover in the reverse order of removal Control Pod HIM Cradle Replacement Replacement kit catalog numbers SK RT BZL1 SK RT BZL1 XT These kits can be used for all enclosure types Remove the Control Pod HIM Cradle Follow these steps to remove the control pod HIM cradle 1 Review the Product Advisori...

Page 87: ...zontal position 7 Disconnect the jumper J16 connector from the connector P16 on the main control circuit board Retain the jumper for reuse with the new main control board 8 Disconnect the HIM wire harness connector from the connector on the main control board If a cable is not connected to the DPI port on the HIM cradle be sure to leave the protective cover installed 7 Control Pod Shown Removed fr...

Page 88: ...e reverse order of removal Do not remove the protective cover from these connectors on the HIM cradle unless a connection is made during reinstallation IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage and operation See Protective Cover...

Page 89: ...85 For IP54 NEMA UL Type 12 enclosures open the enclosure door 4 If used disconnect the DPI cable from the connector on the bottom of the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 6 If used disconnect the plug in terminal block TB1 on the bottom of the main control board 7 Loosen the screw that secures the HIM cradle ...

Page 90: ...connect the terminal block for the HIM DPI wire harness from the connector on the main control circuit board 10 Disconnect the jumper J16 from P16 on the main control circuit board Retain the jumper for reuse with the new main control board Control Pod Shown Removed from the Drive Chassis for Clarity Only 9 10 ...

Page 91: ...switch for setting the programming mode 2 EtherNet IP address switches Rotary switches for setting the lowest octet of an EtherNet IP address forces address to 192 168 1 xxx See the PowerFlex Drives with TotalFORCE Control Built in EtherNet IP Adapter User Manual publication 750COM UM009 for instructions on setting the IP address 3 ENABLE jumper Hardware enable jumper P7 TB1 becomes an Enable when...

Page 92: ...emove the main control board Install the Main Control Circuit Board Follow these steps to install the main control circuit board 12 M3 x 6 4 mm T15 or F 5 mm 0 19 in 0 45 N m 4 0 lb in 12 IMPORTANT Circuit boards that are contained in renewal kits with XT contain dielectric grease on the edge connectors where present Do not touch or remove the grease from circuit board edge connectors A non grease...

Page 93: ...se is removed from an edge connector or is contaminated do not install the circuit board See Apply Dielectric Grease to an Edge Connector on page 18 for instructions on how to clean and grease an edge connector IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused c...

Page 94: ...sories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board on page 89 4 If a torque accuracy module TAM is installed on the interior of the control pod chassis compress the two posts that secure the TAM to the control pod and push the posts through the mounting holes The TAM ...

Page 95: ...move the two M6 x 12 mm Torx screw that secures the lower control pod chassis to the drive chassis 8 Remove the control pod carefully from the drive and remove the ribbon cable from the opening in the back of the control pod chassis 9 Disconnect the ribbon cable from the power interface circuit board below the control pod Install the Main Control Board to Power Interface Board Ribbon Cable Install...

Page 96: ...t boards simultaneously Remove the Backplane Circuit Board Follow these steps to remove the backplane circuit board 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board on page 89 4 Remove the two M4 x 8 mm Torx screws that secure the backplane ...

Page 97: ...SK RT HSFAN2 F6 XT This kit can be used for flange NEMA UL Type 4X 12 back and IP54 NEMA UL Type 12 enclosures Remove the Heatsink Fan Follow these steps to remove the heatsink fan 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 For IP54 NEMA UL Type 12 enclosures open the enclosure door and remove the protective guard...

Page 98: ... Fan Install the heatsink fan in the reverse order of removal IMPORTANT The fan assembly cannot be removed from the drive chassis completely until the fan power harnesses are disconnected 4 M4 x 8 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb in 4 4 View of wire harness and connectors inside the chassis IP00 NEMA UL Open Type Drive with Cover Removed Shown Wire Harness Connectors for the IP00 NEMA UL...

Page 99: ...f and lock out incoming power See Remove Power from the System on page 12 3 Access the drive interior For IP00 NEMA UL Open Type IP21 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures remove the drive cover See Remove the Cover on page 83 For IP54 NEMA UL Type 12 enclosures open the enclosure door and remove the protective guard 4 Reach through the right lower side of the chassis and di...

Page 100: ...tirring Fan Assembly Follow these steps to remove the lower stirring fan assembly 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Access the drive interior For IP00 NEMA UL Open Type IP21 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures remove the drive cover See Remove the Cover on page 83 For IP54 NEMA UL...

Page 101: ...the two M4 x 8 mm slotted Torx screws that secure the fan assembly to the chassis and remove the fan assembly partially 8 Disconnect the fan power wire harness connector P5 from J5 on the power interface circuit board and remove the fan assembly Install the Lower Stirring Fan Assembly Install the lower stirring fan assembly in the reverse order of removal 7 M4 x 8 mm T20 or F 6 4 mm 0 25 in 2 6 N ...

Page 102: ... flange and gaskets 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the cover See Remove the Cover on page 83 4 If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 6 If use...

Page 103: ...re and equipment to the drive according to this illustration 10 Remove the two M5 x 0 8 hexagonal nuts that secure the drive chassis to the flange 11 Remove the 18 M5 x 25 mm slotted Torx screws that secure the drive chassis to the flange 1 2 A A 45 1 2 A A 45 Lifting Hardware Not Shown for Clarity Only Panel Mount Surface 10 11 11 M5 x 25 mm T25 4 5 N m 40 0 lb in 10 M5 x 0 8 8 mm 4 5 N m 40 0 lb...

Page 104: ...nal injury or equipment damage Inspect all lifting hardware for proper attachment before lifting the equipment Do not allow any part of the equipment to contact electrically charged conductors or components Do not subject the equipment to high rates of acceleration or deceleration while moving the drive Do not allow personnel or their limbs directly underneath the equipment when lifting or mountin...

Page 105: ...tallation 14 Remove the four M5 x 0 8 hexagonal nuts that secure the rear gasket and flange to the panel mount surface and remove the gasket and flange Discard the gasket Install the Flange Gasket Install the flange and gaskets in the reverse order of removal 14 14 M5 x 0 8 8 mm 4 5 N m 40 0 lb in ...

Page 106: ... back enclosures remove the drive cover See Remove the Cover on page 83 For IP54 NEMA UL Type 12 enclosures open the enclosure door and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 84 Drive Rating Power Interface Circuit Board Catalog Number Standard XT 104 A 400V 96 A 480V 1 1 Drives installed in an IP54 NEMA UL Type 12 enclosure only SK RT PI...

Page 107: ...ition remove the jumper wire from the connector on the power interface circuit board 7 Below the control pod disconnect the ribbon cable connector from connector J1 on the power interface circuit board 8 If a torque accuracy module TAM is installed complete steps a and b a Disconnect the wire harness connector P4 from J4 on the power interface circuit board b Disconnect the wires from connectors U...

Page 108: ...108 Rockwell Automation Publication 750 TG101A EN P June 2022 Chapter 5 Frame 6 Renewal Kits Installation 5 M4 x 12 mm T20 2 6 N m 23 0 lb in 6 11 7 9 10 8 PE A PE B J1 P4 U V W P6 P5 ...

Page 109: ...rx screws that secure the lower stirring fan assembly to the chassis 15 Lift the bus capacitor cover upper support bracket and lower stirring fan assembly off the drive partially IMPORTANT An edge connector on the main control circuit board in the control pod is connected to the power interface circuit board below with a ribbon cable The ribbon cable fits through an opening in the back of the cont...

Page 110: ... right side of the power interface circuit board 17 Disconnect the NTC wire harness connector P8 from connector J8 on the right center of the power interface circuit board 18 Disconnect the heatsink fans power wire harness connector P2 from connector J2 at the bottom of the power interface circuit board 19 Disconnect the precharge wire harness connector P10 from connector J10 on the AC or DC prech...

Page 111: ...oard 22 Remove the five M4 x 14 mm slotted Torx screws from the power interface circuit board 23 Remove the five M4 x 8 mm Torx screws that secure the power interface circuit board to the standoffs on the chassis and remove the board 23 M4 x 8 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb in 22 M4 x 14 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb in 20 M4 x 8 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb ...

Page 112: ...ircuit board 1 Peel the protective sheet off the back of the circuit board stiffeners and apply them to the capacitor components as shown 2 Install the power interface circuit board in the reverse order of removal IMPORTANT Take care to connect the connector on the back of the power interface circuit board to the connector on the top of the gate driver circuit board carefully ...

Page 113: ...or and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 84 4 To prepare the control pod for removal from the drive complete these steps a If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle b Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod c If used disconnec...

Page 114: ...e TAM is installed complete steps a and b a Disconnect the wire harness connector P4 from J4 on the power interface circuit board b Disconnect the wires from connectors U V and W on the power interface circuit board 9 Disconnect the lower stirring fan power wire harness connector P5 from J5 on the power interface circuit board 10 Disconnect the upper stirring fan power wire harness connector P6 fr...

Page 115: ... Torx screws that secure the lower stirring fan assembly to the chassis 15 Lift the bus capacitor cover upper support bracket and lower stirring fan assembly off the drive IMPORTANT An edge connector on the main control circuit board in the control pod is connected to the power interface circuit board below with a ribbon cable The ribbon cable fits through an opening in the back of the control pod...

Page 116: ...50 TG101A EN P June 2022 Chapter 5 Frame 6 Renewal Kits Installation 16 If the DC bus bars are installed remove the two M6 hexagonal nuts that secure the DC bus bars to the laminated bus 16 M6 10 mm 5 2 N m 46 0 lb in DC Bus Bar DC Bus Bar ...

Page 117: ...or P10 from connector J10 on the AC precharge circuit board 18 Remove the nine M4 x 12 mm slotted Torx screws and remove the board and plastic board support IMPORTANT The back side of the AC precharge circuit board contains solid gate lead connectors that connect to the IGBTs below the board 18 M4 x 12 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb in 17 P10 ...

Page 118: ... Remove the five M4 x 12 mm Torx screws that secure the board to the plastic support Retain the plastic support for reuse Install the AC Precharge Circuit Board 400 480V Install the AC precharge circuit board 1 Peel the protective sheet off the back of the circuit board stiffener and apply the stiffener to the capacitor components as shown 20 M4 x 12 mm T20 2 6 N m 23 0 lb in 19 ...

Page 119: ...visories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Access the drive interior For IP00 NEMA UL Open Type IP21 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures remove the drive cover See Remove the Cover on page 83 For IP54 NEMA UL Type 12 enclosures open the enclosure door and remove the protective guard See Remove the Protective Gua...

Page 120: ...connect any cables from the Ethernet connectors on the bottom of the main control board in the control pod c If used disconnect the plug in terminal block TB1 on the bottom of the main control board d If an option module is installed disconnect any I O wiring terminal blocks not shown in image If a cable is not connected to the DPI port on the HIM cradle be sure to leave the protective cover insta...

Page 121: ...he ribbon cable connector from connector J1 on the power interface circuit board 8 If a torque accuracy module TAM is installed complete steps a and b a Disconnect the wire harness connector P4 from J4 on the power interface circuit board b Disconnect the wires from connectors U V and W on the power interface circuit board 9 Disconnect the lower stirring fan power wire harness connector P5 from J5...

Page 122: ... stirring fan assembly to the chassis 14 Lift the bus capacitor cover upper support bracket and lower stirring fan assembly off the drive IMPORTANT An edge connector on the main control circuit board in the control pod is connected to the power interface circuit board below with a ribbon cable The ribbon cable fits through an opening in the back of the control pod chassis 12 M4 x 8 mm T20 or F 6 4...

Page 123: ...llation 15 For DC input drives with a dynamic brake option installed remove the M6 hexagonal nut that secures the brake bus bar to the DC bus bar 16 Remove the two M6 hexagonal nuts that secure the DC bus bars to the laminated bus 16 M6 10 mm 5 2 N m 46 0 lb in Brake Bus Bar DC Bus Bar DC Bus Bar 15 ...

Page 124: ...hapter 5 Frame 6 Renewal Kits Installation 17 Disconnect the SCR wire harness connector P11 from J11 on the DC precharge circuit board 18 Disconnect the precharge wire harness connector P10 from connector J10 on the DC precharge circuit board 17 J11 J10 P11 P10 18 ...

Page 125: ...lation 19 Remove the four M4 x mm slotted Torx screws that secure the DC precharge circuit board to the standoffs and remove the board Install the DC Precharge Circuit Board Install the DC precharge circuit board in the reverse order of removal 19 M4 x 8 mm T20 or F 6 4 mm 0 25 in 2 6 N m 23 0 lb in ...

Page 126: ...126 Rockwell Automation Publication 750 TG101A EN P June 2022 Chapter 5 Frame 6 Renewal Kits Installation Notes ...

Page 127: ...See page 131 Main Control Board SK RT MCB1 PF755 SK RT MCB1 PF755 XT See page 134 Main Control Board to Power Interface Board Ribbon Cable SK RT PIC1 F27 XT See page 139 Backplane Circuit Board Kit Contains 1 Circuit Board SK RT BKPLN SK RT BKPLN XT See page 141 Heatsink Fan Assembly for IP00 NEMA UL Open Type and IP21 NEMA UL Type 1 Enclosures SK RT HSFAN1 F7 SK RT HSFAN1 F7 XT See page 142 Heats...

Page 128: ...nal components in the drive Remove the Cover Follow these steps to remove the cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Loosen the four M4 x 8 mm captive screws that secure the cover to the assembly and remove the cover Install the Cover Install the cover in the reverse order of removal 3 M4 x 8 mm F 6 4 mm...

Page 129: ... IP54 NEMA UL Type 12 enclosure 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the M4 x 8 mm slotted Torx screw that secures the upper guard to the standoff on the drive chassis 4 Remove the two M5 x 12 mm Torx screws that secure the lower guard to the chassis terminal support bracket and remove the guard Insta...

Page 130: ... Remove the Control Pod Access Cover Follow these steps to remove the control pod access cover 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Loosen the two M3 x 6 4 mm slotted Torx screws that secure the control pod access cover to the drive cover and remove the access cover Install the Control Pod Access Cover Insta...

Page 131: ...ess cover for reuse 4 Remove the drive cover See Remove the Cover on page 128 Install the Cover Install the cover in the reverse order of removal Control Pod HIM Cradle Replacement Replacement kit catalog numbers SK RT BZL1 SK RT BZL1 XT These kits can be used for all enclosure types Remove the Control Pod HIM Cradle Follow these steps to remove the control pod HIM cradle 1 Review the Product Advi...

Page 132: ...zontal position 7 Disconnect the jumper J16 connector from the connector P16 on the main control circuit board Retain the jumper for reuse with the new main control board 8 Disconnect the HIM wire harness connector from the connector on the main control board If a cable is not connected to the DPI port on the HIM cradle be sure to leave the protective cover installed 7 Control Pod Shown Removed fr...

Page 133: ...he reverse order of removal Do not remove the protective cover from these connectors on the HIM cradle unless a connection is made during reinstallation IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused connectors during storage and operation See Protective Cove...

Page 134: ...Type 12 enclosures open the enclosure door 4 If used disconnect the DPI cable from the connector on the bottom of the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 6 If used disconnect the plug in terminal block TB1 on the bottom of the main control board 7 Loosen the screw that secures the HIM cradle to the pod chassis a...

Page 135: ...sconnect the terminal block for the HIM DPI wire harness from the connector on the main control circuit board 10 Disconnect the jumper J16 from P16 on the main control circuit board Retain the jumper for reuse with the new main control board Control Pod Shown Removed from the Drive Chassis for Clarity Only 9 10 ...

Page 136: ...setting the programming mode 2 EtherNet IP address switches Rotary switches for setting the lowest octet of an EtherNet IP address forces address to 192 168 1 xxx See the PowerFlex Drives with TotalFORCE Control Built in EtherNet IP Adapter User Manual publication 750COM UM009 for instructions on setting the IP address 3 ENABLE jumper Hardware enable jumper P7 TB1 becomes an Enable when this jumpe...

Page 137: ...nstall the Main Control Circuit Board Follow these steps to install the main control circuit board 12 M3 x 6 4 mm T15 or F 5 mm 0 19 in 0 45 N m 4 0 lb in 12 Control Pod Shown Separated from the Drive for Clarity Only IMPORTANT Circuit boards that are contained in renewal kits with XT contain dielectric grease on the edge connectors where present Do not touch or remove the grease from circuit boar...

Page 138: ...se is removed from an edge connector or is contaminated do not install the circuit board See Apply Dielectric Grease to an Edge Connector on page 18 for instructions on how to clean and grease an edge connector IMPORTANT Do not remove protective covers unless used at the time of installation For the product to meet the corrosive atmosphere rating protective covers must remain installed in unused c...

Page 139: ...ies on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board on page 134 4 If a torque accuracy module TAM is installed on the interior of the control pod chassis compress the two posts that secure the TAM to the control pod and push the posts through the mounting holes The TAM re...

Page 140: ...Remove the M6 x 12 mm Torx screw that secures the lower control pod chassis to the drive chassis 8 Remove the control pod carefully from the drive and remove the ribbon cable from the opening in the back of the control pod chassis 9 Disconnect the ribbon cable from the power interface circuit board below the control pod Install the Main Control Board to Power Interface Board Ribbon Cable Install t...

Page 141: ...e Backplane Circuit Board Follow these steps to remove the backplane circuit board 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the main control circuit board See Remove the Main Control Circuit Board on page 134 4 Remove the two M4 x 8 mm Torx screws that secure the backplane circuit board to the pod chassis...

Page 142: ...Type 1 enclosures Replacement kit catalog number SK RT HSFAN2 F7 XT This kit can be used for flange NEMA UL Type 4X 12 back and IP54 NEMA UL Type 12 enclosures Remove the Heatsink Fan Assembly Follow these steps to replace the heatsink fan assembly 1 Review the Product Advisories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 For IP54 NEMA UL Type 1...

Page 143: ...power wire harness connectors from the three connectors inside the chassis and remove the fan assembly Install the Heatsink Fan Assembly Install the heatsink fan assembly in the reverse order of removal 5 Quantity 3 4 M6 x 50 mm T30 1 36 N m 12 0 lb in Wire Harness Connectors for the IP00 NEMA UL Open Type and IP21 NEMA UL Type 1 Fan Assemblies Shown IP00 NEMA UL Open Type Drive Shown IMPORTANT Be...

Page 144: ...2 3 Access the drive interior For IP00 NEMA UL Open Type IP21 NEMA UL Type 1 and flange NEMA UL Type 4X 12 back enclosures remove the cover See Remove the Cover on page 128 For IP54 NEMA UL Type 12 enclosures open the enclosure and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 129 4 If the brake bus bar BR1 is installed complete these steps a Re...

Page 145: ...ide the fan assembly to the right lift the fan assembly off the screws and remove the assembly 8 Disconnect the fan assembly power wire harness connectors P5 and P6 from connectors J5 and J6 respectively on the power interface circuit board left side of the fan assembly Install the Stirring Fan Assembly Install the stirring fan assembly in the reverse order of removal 6 M6 x 16 mm T30 5 2 N m 46 0...

Page 146: ...ories on page 11 2 Turn off and lock out incoming power See Remove Power from the System on page 12 3 Remove the cover See Remove the Cover on page 128 4 If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle 5 Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod 6 If used disconnect the plug in terminal block TB1 o...

Page 147: ...A EN P June 2022 147 Chapter 6 Frame 7 Renewal Kits Installation 8 If installed disconnect the power wiring from the power terminals 9 Attach the lifting hardware and equipment to the drive according to this illustration 1 2 A A 45 1 2 A A 45 ...

Page 148: ... P June 2022 Chapter 6 Frame 7 Renewal Kits Installation 10 Remove the 12 M5 x 0 8 hexagonal nuts that secure the drive chassis to the flange 11 Remove the 16 M5 x 25 mm slotted Torx screws that secure the drive to the flange Panel Mount Surface 10 11 ...

Page 149: ...nal injury or equipment damage Inspect all lifting hardware for proper attachment before lifting the equipment Do not allow any part of the equipment to contact electrically charged conductors or components Do not subject the equipment to high rates of acceleration or deceleration while moving the drive Do not allow personnel or their limbs directly underneath the equipment when lifting or mountin...

Page 150: ... the gasket Install the Flange Gasket Install the gaskets support brackets and flange in the reverse order of removal Follow these steps to install the hardware that secures the drive chassis to the panel mount surface 1 Install the M5 x 0 8 hexagonal nuts that secure the drive chassis to the flange in the sequence shown here 2 Install the M5 x 25 mm slotted Torx screws that secure the drive chass...

Page 151: ...nd flange NEMA UL Type 4X 12 back enclosures remove the cover See Remove the Cover on page 128 For IP54 NEMA UL Type 12 enclosures open the enclosure and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 129 3 4 5 7 8 6 1 2 9 11 12 10 14 13 15 16 1 2 3 4 5 6 7 8 9 14 15 16 10 11 12 13 M5 x 25 mm T25 4 5 N m 40 0 lb in M5 x 0 8 8 mm 4 5 N m 40 0 lb i...

Page 152: ...s from the Ethernet connectors on the bottom of the main control board in the control pod c If used disconnect the plug in terminal block TB1 on the bottom of the main control board d If an option module is installed disconnect any I O wiring terminal blocks and remove the option module not shown in this image If a cable is not connected to the DPI port on the HIM cradle be sure to leave the prote...

Page 153: ...sen the three M3 captive slotted Torx screws that secure the main control circuit board to the control pod chassis and remove the main control board c On the interior of the control pod chassis compress the two posts that secure the TAM to the control pod and push the posts through the mounting holes The TAM remains in the drive chassis and connected to the power interface circuit board via a wire...

Page 154: ...emove the two M4 x 8 mm slotted Torx screws that secure the upper control pod chassis to the drive chassis 8 Remove the M6 x 12 mm Torx screw that secures the lower control pod chassis to the drive chassis 9 Remove the control pod carefully from the drive 7 M4 x 8 mm T20 2 3 N m 20 0 lb in 8 M6 x 12 mm T30 2 6 N m 23 0 lb in 6 Ribbon Cable Shown Removed from the Back of the Control Pod Chassis for...

Page 155: ...r right side of the control pod support bracket b Remove the two M6 x 16 mm Torx screws from the upper and lower right side of the control pod support bracket and remove the bracket from the chassis The power interface circuit board ground wire harness is connected to the screw on the lower right side of the control pod support bracket 10 M6 x 16 mm T30 6 0 N m 53 0 lb in 11b M6 x 16 mm T30 6 0 N ...

Page 156: ...BR1 terminal and remove the bus bar c Remove the two M6 nuts that secure the long bus bar BR1 to the lower bus bars d Remove the M5 x 16 mm Torx screw that secures the short bus bar to the BR2 terminal e Remove the two M6 x 20 Torx screws that secure the short bus bar to the BR2 terminal and remove the bus bar 12c 12b 12e 12d 12b M5 x 16 mm T25 4 9 N m 43 0 lb in 12d M5 x 16 mm T25 4 9 N m 43 0 lb...

Page 157: ...m Torx screw that secures the upper fan assembly to the chassis side bracket 15 Slide the fan assembly to the right lift the fan assembly off the screws and remove the assembly 16 Disconnect the fan assembly power wire harness connectors P5 and P6 from connectors J5 and J6 respectively on the power interface circuit board left side of the fan assembly 14 M6 x 16 mm T30 5 2 N m 46 0 lb in 13 M5 T30...

Page 158: ...enewal Kits Installation 17 Disconnect the PE B jumper wire from the power interface circuit board top left 18 Disconnect the heatsink fan power wire harness connector P2 from connector J2 on the power interface circuit board bottom left PE B Jumper Wire J2 PE B IN PE B OUT 17 18 P2 ...

Page 159: ... Installation 19 Disconnect the current transformer wire harness connector P3 from J3 on the power interface circuit board mid right 20 If a torque accuracy module TAM is installed disconnect the wire harness connector P4 from connector J4 on the power interface circuit board P3 J3 P4 J4 19 20 ...

Page 160: ...l the power interface circuit board in the reverse order of removal IMPORTANT A connector on the back side of the power interface circuit board is connected to a mating connector on the gate driver circuit board Side Rails and Other Components Not Shown for Clarity Only 21 M5 x 12 mm T25 or F 6 4 mm 0 25 in 4 86 N m 43 0 lb in 23 M5 x 20 mm T25 4 86 N m 43 0 lb in 22 M4 x 8 mm T20 or F 6 4 mm 0 25...

Page 161: ...28 For IP54 NEMA UL Type 12 enclosures open the enclosure and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 129 4 Remove these connections from the control pod a If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle b Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the cont...

Page 162: ...sen the three M3 captive slotted Torx screws that secure the main control circuit board to the control pod chassis and remove the main control board c On the interior of the control pod chassis compress the two posts that secure the TAM to the control pod and push the posts through the mounting holes The TAM remains in the drive chassis and connected to the power interface circuit board via a wire...

Page 163: ...emove the two M4 x 8 mm slotted Torx screws that secure the upper control pod chassis to the drive chassis 8 Remove the M6 x 12 mm Torx screw that secures the lower control pod chassis to the drive chassis 9 Remove the control pod carefully from the drive 7 M4 x 8 mm T20 2 3 N m 20 0 lb in 8 M6 x 12 mm T30 2 6 N m 23 0 lb in 9 6 Ribbon Cable Shown Removed from the Back of the Control Pod Chassis f...

Page 164: ...x 16 mm Torx screw that secures the long bus bar to the BR1 terminal and remove the bus bar c Remove the two M6 nuts that secure the long bus bar BR1 to the lower bus bars d Remove the M5 x 16 mm Torx screw that secures the short bus bar to the BR2 terminal e Remove the two M6 x 20 Torx screws that secure the short bus bar to the BR2 terminal and remove the bus bar 10 M6 x 16 mm T30 5 2 N m 46 0 l...

Page 165: ...o the chassis b Remove the upper M6 x 16 mm Torx screw that secures the upper fan assembly to the chassis side bracket c Slide the fan assembly to the right lift the fan assembly off the screws and remove the assembly d Disconnect the fan assembly power wire harness connectors P5 and P6 from connectors J5 and J6 respectively on the power interface circuit board left side of the fan assembly 12b M6...

Page 166: ...e three M6 nuts that secure the left side rail to the chassis b Remove the four M6 hexagonal nuts that secure the bus bars to the laminated bus c Remove the two M5 x 16 mm Torx screws that secure the bus bars to the terminal support and remove the bus bars 13b M6 10 mm 5 2 N m 46 0 lb in 13c M5 x 16 mm T25 4 9 N m 43 0 lb in DC Bus Bar DC Bus Bar 13a M6 x 16 mm T30 5 2 N m 46 0 lb in Loosen Only L...

Page 167: ... the four M6 x 16 mm Torx screws that secure the upper terminal block support to the chassis and remove the support 15 Remove the two M6 x 20 mm Torx screws that secure the lower dynamic brake bus bar to the brake module and remove the bus bar 14 M6 x 16 mm T30 5 2 N m 46 0 lb in 15 M6 x 20 mm T30 5 2 N m 46 0 lb in ...

Page 168: ...me 7 Renewal Kits Installation 16 Note the PE A jumper position and remove the PE A jumper wire from the jumper assembly on the chassis 17 Remove the wire harness connector P10 from connector J10 on the right side of the AC precharge circuit board PE A IN or OUT P10 J10 16 17 ...

Page 169: ...screws that secure the board to the standoffs 19 Remove the five M4 x 12 mm Torx screws that secure the board to the plastic support tray and remove the board Install the AC Precharge Circuit Board 400 480V Install the AC precharge circuit board in the reverse order of removal 18 M4 x 8 mm T20 2 6 N m 23 0 lb in 19 M4 x 12 mm T20 2 6 N m 23 0 lb in ...

Page 170: ...NEMA UL Type 12 enclosures open the enclosure and remove the protective guard See Remove the Protective Guard IP54 NEMA UL Type 12 Enclosure on page 129 4 Remove these connections from the control pod a If used disconnect the HIM DPI cable from the connector port 2 on the HIM cradle b Disconnect any cables from the Ethernet connectors on the bottom of the main control board in the control pod c If...

Page 171: ...sen the three M3 captive slotted Torx screws that secure the main control circuit board to the control pod chassis and remove the main control board c On the interior of the control pod chassis compress the two posts that secure the TAM to the control pod and push the posts through the mounting holes The TAM remains in the drive chassis and connected to the power interface circuit board via a wire...

Page 172: ...emove the two M4 x 8 mm slotted Torx screws that secure the upper control pod chassis to the drive chassis 8 Remove the M6 x 12 mm Torx screw that secures the lower control pod chassis to the drive chassis 9 Remove the control pod carefully from the drive 7 M4 x 8 mm T20 2 3 N m 20 0 lb in 8 M6 x 12 mm T30 2 6 N m 23 0 lb in 9 6 Ribbon Cable Shown Removed from the Back of the Control Pod Chassis f...

Page 173: ...w that secures the long bus bar to the BR1 terminal and remove the bus bar c Remove the two M6 nuts that secure the long bus bar BR1 to the lower bus bars d Remove the M5 x 16 mm Torx screw that secures the short bus bar to the BR2 terminal e Remove the two M6 x 20 Torx screws that secure the short bus bar to the BR2 terminal and remove the bus bar 10 M6 x 16 mm T30 5 2 N m 46 0 lb in 11b 11a 11d ...

Page 174: ...Torx screw that secures the upper fan assembly to the chassis side bracket 14 Slide the fan assembly to the right lift the fan assembly off the screws and remove the assembly 15 Disconnect the fan assembly power wire harness connectors P5 and P6 from connectors J5 and J6 respectively on the power interface circuit board left side of the fan assembly 13 M6 x 16 mm T30 5 2 N m 46 0 lb in 12 M5 2x T3...

Page 175: ...secure the DC bus bars to the laminated bus 18 Remove the two M6 x 20 mm Torx screws that secure the DC bus bar to the lower connecting DC brake bus bar 19 Remove the two M5 x 16 mm Torx screws that secure the DC bus bars to the terminal support and remove the bus bars 17 M6 10 mm 5 2 N m 46 0 lb in 19 M5 x 16 mm T25 4 9 N m 43 0 lb in 18 M6 x 20 mm T30 5 2 N m 46 0 lb in DC Bus Bar DC Bus Bar 16 ...

Page 176: ... the four M6 x 16 mm Torx screws that secure the upper terminal block support to the chassis and remove the support 21 Remove the two M6 x 20 mm Torx screws that secure the lower dynamic brake bus bar to the brake module and remove the bus bar 20 M6 x 16 mm T30 5 2 N m 46 0 lb in 21 M6 x 20 mm T30 5 2 N m 46 0 lb in ...

Page 177: ... Frame 7 Renewal Kits Installation 22 Remove the IGBT wire harness P11 from connector J1 on the left side of the AC precharge circuit board 23 Remove the wire harness connector P10 from connector J10 on the right side of the AC precharge circuit board P10 J10 J11 P11 23 22 ...

Page 178: ...allation 24 Remove the four M4 x 8 mm slotted Torx screws that secure the DC precharge circuit board to the standoffs and remove the board from the drive Install the DC Precharge Circuit Board Install the DC precharge circuit board in the reverse order of removal 24 M4 x 8 mm T20 2 6 N m 23 0 lb in ...

Page 179: ...C to chassis GND PE and DC to chassis GND PE 3 If the measured value of any resistance test is less than 1 k troubleshoot to find the short correct the problem and repeat step 2 4 For any fan or circuit board that has been removed and re installed complete the following Verify that all hardware connections have been replaced and are properly torqued Verify that all interconnection wire harnesses a...

Page 180: ...l power voltage is correct 4 Verify that the motor cables are connected to the proper terminals 5 Verify that the motor load is disconnected 6 Energize the system 7 Measure the DC bus voltage and verify that the measured value is displayed in port 0 parameter 3 DC Bus Volts 8 Start the system and increase the speed from zero to base speed 9 Measure the system output current and verify that the mea...

Page 181: ...5TS drives List of Drive Schematics Topic Page PowerFlex 755TS Frame 1 AC Input Drive 182 PowerFlex 755TS Frames 2 4 AC Input Drives 183 PowerFlex 755TS Frame 5 AC Input Drive 184 PowerFlex 755TS Frame 6 AC Input Drive 185 PowerFlex 755TS Frame 6 DC Input Drive 186 PowerFlex 755TS Frame 7 AC Input Drive 187 PowerFlex 755TS Frame 7 DC Input Drive 188 ...

Page 182: ...182 Rockwell Automation Publication 750 TG101A EN P June 2022 Appendix B Schematics Figure 11 PowerFlex 755TS Frame 1 AC Input Drive ...

Page 183: ...ons Precharge Relay Chassis PE Control Structure Interface J1 R L1 S L2 T L3 TB1 1 TB1 2 TB1 3 PE B POUT PIN NOUT NIN TB1 6 TB1 7 TB1 8 TB1 9 TB1 10 U T1 V T2 W T3 BR1 BR2 TB1 4 TB1 5 50 Pin Connector To Control Structure PE A PE ISENSE ISENSE ISENSE Motor Ground PE A PE B Chassis Chassis Chassis E2 DC Link Choke DC DC Input Ground PE Heat sink fan U1 V1 W1 TAM Option J4 J8 Note Frame 2 and 3 have...

Page 184: ...ke Resistor Connections Chassis PE Control Structure Interface J1 for detailed information see DIR 10001486836 R L1 S L2 T L3 TB1 1 TB1 2 TB1 3 PE B POUT PIN NOUT NIN TB1 6 TB1 7 TB1 8 TB1 9 TB1 10 U T1 V T2 W T3 BR1 BR2 TB1 4 TB1 5 50 Pin Connector To Control Structure PE A PE ISENSE ISENSE ISENSE Motor Ground PE A PE B Chassis Chassis Chassis E2 DC Link Choke DC DC Input Ground PE Heat sink fans...

Page 185: ...Rockwell Automation Publication 750 TG101A EN P June 2022 185 Appendix B Schematics Figure 14 PowerFlex 755TS Frame 6 AC Input Drive ...

Page 186: ...186 Rockwell Automation Publication 750 TG101A EN P June 2022 Appendix B Schematics Figure 15 PowerFlex 755TS Frame 6 DC Input Drive ...

Page 187: ...Rockwell Automation Publication 750 TG101A EN P June 2022 187 Appendix B Schematics Figure 16 PowerFlex 755TS Frame 7 AC Input Drive ...

Page 188: ...188 Rockwell Automation Publication 750 TG101A EN P June 2022 Appendix B Schematics Figure 17 PowerFlex 755TS Frame 7 DC Input Drive ...

Page 189: ... equipment 27 control pod inspect 31 control pod access cover frame 6 install 85 remove 85 control pod access cover frame 7 install 130 remove 130 control pod fan frames 2 5 install 56 remove 54 cover frame 6 install 86 remove 86 D DC precharge circuit board frame 6 install 125 remove 119 DC precharge circuit board frame 7 install 178 remove 170 DC precharge circuit board frames 6 and 7 inspect 32...

Page 190: ... board replacement 170 flange gasket replacement 146 heatsink fan replacement 142 IP20 NEMA UL Type Open cover replacement 131 kits 127 main control circuit board replacement 134 power interface circuit board replacement 151 power terminal block 15 stirring fan replacement 144 frame7 HIM cradle replacement 131 frames 1 3 heatsink fan replacement 57 frames 1 5 power terminal cover replacement 39 fr...

Page 191: ...rames 1 5 36 protective guard frame 6 84 protective guard frame 7 129 ribbon cable main control board to power interface board frame 1 74 ribbon cable main control board to power interface board frame 6 95 ribbon cable main control board to power interface board frame 7 140 ribbon cable main control board to power interface board frames 2 5 76 stirring fan frame 7 145 stirring fan frames 4 and 5 6...

Page 192: ...e 12 cover frames 2 5 40 lower stirring fan frame 6 100 main control circuit board frame 1 64 main control circuit board frame 6 89 main control circuit board frame 7 134 main control circuit board frames 2 5 69 power interface circuit board frame 6 106 power interface circuit board frame 7 151 power terminal cover frames 1 5 35 39 protective guard frame 6 84 protective guard frame 7 129 ribbon ca...

Page 193: ...Rockwell Automation Publication 750 TG101A EN P June 2022 193 Index U upload parameters 21 upper stirring fan frame 6 install 100 remove 99 ...

Page 194: ...194 Rockwell Automation Publication 750 TG101A EN P June 2022 Index Notes ...

Page 195: ...Rockwell Automation Publication 750 TG101A EN P June 2022 195 PowerFlex 755TS Products with TotalFORCE Control Hardware Service Manual ...

Page 196: ...al Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and access product release notes rok auto pcdc At the end of life this e...

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