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Hardware Service

Original Instructions

PowerFlex 755TS Products

with TotalFORCE Control

Catalog Numbers 20G2, 20GE

Содержание 20G2

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

Страница 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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