PowerFlex 750-Series Products with TotalFORCE Control Hardware Service Manual - Frames 7...15

Important User Information

Download Firmware, AOP, EDS, and Other Files

Download Firmware, AOP, EDS, and Other Files

Summary of Changes

Summary of Changes

Additional Resources

Additional Resources

Before You Begin

Qualified Personnel

Qualified Personnel

Personal Safety

Personal Safety

Class 1 LED Product

Class 1 LED Product

Product Safety

Electrostatic Discharge Icon

Electrostatic Discharge Icon

Remove Power from the System for Frame 7

Remove Power from the System for Frame 7

Remove Power from the System for Frames 8...15

Remove Power from the System for Frames 8...15

Renewal Kits for PowerFlex 755T Products with Corrosive Gas Protection (XT)

Renewal Kits for PowerFlex 755T Products with Corrosive Gas Protection (XT)

Dielectric Grease Application (XT)

Dielectric Grease Application (XT)

Installation Tools

Installation Tools

Software Tools

Hardware Installation Diagrams

Hardware Installation Diagrams

Fastener Torque Sequences

Fastener Torque Sequences

Preventative and Predictive Maintenance

Recommended Preventative Maintenance

Recommended Preventative Maintenance

Recommended Maintenance Schedule Task Descriptions

Recommended Maintenance Schedule Task Descriptions

Predictive Maintenance

Predictive Maintenance

Shock Events

Maintenance of Industrial Control Equipment

Maintenance of Industrial Control Equipment

Maintenance of Solid-state Devices

Maintenance of Solid-state Devices

Component Inspection and Tests

Inspect Air Filters and Vents for Maintenance

Inspect Air Filters and Vents for Maintenance

Inspect Fan Assemblies for Maintenance of Floor-mount Products

Inspect Fan Assemblies for Maintenance of Floor-mount Products

Inspect Circuit Boards, Wire Harnesses, and Fiber-optic Cables for Maintenance

Inspect Circuit Boards, Wire Harnesses, and Fiber-optic Cables for Maintenance

Perform Forward and Reverse Biased IGBT/Diode Tests for Frame 7

Perform Forward and Reverse Biased IGBT/Diode Tests for Frame 7

Perform Forward and Reverse Biased IGBT/Diode Tests for Frames 8...15

Perform Forward and Reverse Biased IGBT/Diode Tests for Frames 8...15

Test AC Input Link Fuses

Test AC Input Link Fuses

Test DC link Fuses

Test DC link Fuses

Test Frame 7 Component Fuses

Test Frame 7 Component Fuses

Test Frame 8...15 Component Fuses

Test Frame 8...15 Component Fuses

Remove and Install the IP54 Roof Vent Filters for Frame 7

Remove and Install the IP54 Roof Vent Filters for Frame 7

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frame 7

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frame 7

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frame 7

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frame 7

Remove and Install the Control Pod Cover for Frame 7

Remove and Install the Control Pod Cover for Frame 7

Remove and Install the Control Pod HIM Cradle with DPI Connector (XT) for Frame 7

Remove and Install the Control Pod HIM Cradle with DPI Connector (XT) for Frame 7

Remove and Install the Control Pod Printed Circuit Board Fan Assembly for Frame 7

Remove and Install the Control Pod Printed Circuit Board Fan Assembly for Frame 7

Remove and Install the Main Control Circuit Board (XT) for Frame 7

Remove and Install the Main Control Circuit Board (XT) for Frame 7

Remove and Install the Backplane Circuit Board (XT) for Frame 7

Remove and Install the Backplane Circuit Board (XT) for Frame 7

Remove and Install the Fiber Transceiver Circuit Board (XT) for Frame 7

Remove and Install the Fiber Transceiver Circuit Board (XT) for Frame 7

Remove and Install the Control Pod (XT) for Frame 7

Remove and Install the Control Pod (XT) for Frame 7

Remove and Install the Main Control Circuit Board (Standard) for Frame 7

Remove and Install the Main Control Circuit Board (Standard) for Frame 7

Remove and Install the Control Pod (Standard) for Frame 7

Remove and Install the Control Pod (Standard) for Frame 7

Remove and Install the LCL Filter/Power Module Heatsink Fan Assembly for Frame 7

Remove and Install the LCL Filter/Power Module Heatsink Fan Assembly for Frame 7

Remove and Install the Protective Guard for Frame 7

Remove and Install the Protective Guard for Frame 7

Remove and Install the AC Common Mode Filter Circuit Board for Frame 7

Remove and Install the AC Common Mode Filter Circuit Board for Frame 7

Remove and Install the 240V Power Distribution Fuse (FH2) for Frame 7

Remove and Install the 240V Power Distribution Fuse (FH2) for Frame 7

Remove and Install the AC Precharge Control Circuit Board Fuse (FH3) for Frame 7

Remove and Install the AC Precharge Control Circuit Board Fuse (FH3) for Frame 7

Remove and Install the Control Transformer Fuses (FH4) for Frame 7

Remove and Install the Control Transformer Fuses (FH4) for Frame 7

Remove and Install the AC Precharge Fused Disconnect (FD1) Fuses for Frame 7

Remove and Install the AC Precharge Fused Disconnect (FD1) Fuses for Frame 7

Remove and Install the AC Precharge Control Circuit Board for Frame 7

Remove and Install the AC Precharge Control Circuit Board for Frame 7

Open and Close the AC Precharge Components Panel for Frame 7

Open and Close the AC Precharge Components Panel for Frame 7

Remove and Install the AC Precharge Time Delay Relay for Frame 7

Remove and Install the AC Precharge Time Delay Relay for Frame 7

Remove and Install the AC Precharge TVSS Module for Frame 7

Remove and Install the AC Precharge TVSS Module for Frame 7

Remove and Install the DC Link Fuses for Frame 7

Remove and Install the DC Link Fuses for Frame 7

Remove and Install a Power Module for Frame 7

Remove and Install a Power Module for Frame 7

Remove and Install the Power Layer Interface Circuit Board for Frame 7

Remove and Install the Power Layer Interface Circuit Board for Frame 7

Remove and Install the Power Interface Circuit Board for Frame 7

Remove and Install the Power Interface Circuit Board for Frame 7

Remove and Install the AC Input Link Fuses for Frame 7

Remove and Install the AC Input Link Fuses for Frame 7

Remove and Install the LCL Filter Module for Frame 7

Remove and Install the LCL Filter Module for Frame 7

Remove and Install the Current Sense Circuit Board for Frame 7

Remove and Install the Current Sense Circuit Board for Frame 7

Frames 8…15 Control Bay and Control Pod Kits

Remove and Install the IP21/IP54 Roof Vent Filter for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Filter for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP21/IP54 Door Vent Filter for Frames 8...15

Remove and Install the IP21/IP54 Door Vent Filter for Frames 8...15

Remove and Install the Control Bay Roof Fan 240V Control Power Fuse (FH1) for Frames 8...15

Remove and Install the Control Bay Roof Fan 240V Control Power Fuse (FH1) for Frames 8...15

Remove and Install the Control Pod Cover for Frames 8...15

Remove and Install the Control Pod Cover for Frames 8...15

Remove and Install the Control Pod HIM Cradle with DPI Connector (XT) for Frames 8...15

Remove and Install the Control Pod HIM Cradle with DPI Connector (XT) for Frames 8...15

Remove and Install the Main Control Circuit Board (XT) for Frames 8...15

Remove and Install the Main Control Circuit Board (XT) for Frames 8...15

Remove and Install the Backplane Circuit Board (XT) for Frames 8…15

Remove and Install the Backplane Circuit Board (XT) for Frames 8…15

Remove and Install a Fiber Transceiver (XT) for Frames 8...15

Remove and Install a Fiber Transceiver (XT) for Frames 8...15

Remove and Install the Fiber Transceiver Circuit Board (XT) for Frames 8…15

Remove and Install the Fiber Transceiver Circuit Board (XT) for Frames 8…15

Remove and Install the Fiber-optic Interface Circuit Board for Frames 8...15

Remove and Install the Fiber-optic Interface Circuit Board for Frames 8...15

Remove and Install the Control Pod Printed Circuit Board Fan Assembly for Frames 8...15

Remove and Install the Control Pod Printed Circuit Board Fan Assembly for Frames 8...15

Remove and Install the Control Pod (XT) for Frames 8...15

Remove and Install the Control Pod (XT) for Frames 8...15

Remove and Install the Main Control Circuit Board (Standard) for Frames 8...15

Remove and Install the Main Control Circuit Board (Standard) for Frames 8...15

Remove and Install the Control Pod (Standard) for Frames 8...15

Remove and Install the Control Pod (Standard) for Frames 8...15

Frames 8…15 Input Bay Kits

Remove and Install the IP21/IP54 Roof Vent Filter for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Filter for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP21/IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP54/IP21, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP54/IP21, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54/IP21, 1000 mm Wide Door Vent Fan for Frames 8...15

Remove and Install the IP54/IP21, 1000 mm Wide Door Vent Fan for Frames 8...15

Remove and Install the Input Bay Guard for Frames 8...15

Remove and Install the Input Bay Guard for Frames 8...15

Remove and Install the AC Precharge Control Circuit Board for Frames 8...15

Remove and Install the AC Precharge Control Circuit Board for Frames 8...15

Remove and Install the AC Precharge Time Delay Relay for Frames 8...15

Remove and Install the AC Precharge Time Delay Relay for Frames 8...15

Remove and Install the AC Precharge TVSS Module for Frames 8...15

Remove and Install the AC Precharge TVSS Module for Frames 8...15

Remove and Install the AC Precharge Control Circuit Board Fuses (FH1) for Frames 8...15

Remove and Install the AC Precharge Control Circuit Board Fuses (FH1) for Frames 8...15

Remove and Install the Input Bay 240V Power Distribution Fuse (FH2) for Frames 8...15

Remove and Install the Input Bay 240V Power Distribution Fuse (FH2) for Frames 8...15

Remove and Install the Input Bay Roof Fan 240V Control Power Fuse (FH3) for Frames 8...15

Remove and Install the Input Bay Roof Fan 240V Control Power Fuse (FH3) for Frames 8...15

Remove and Install the Control Transformer Fuses (FH4...FH7) for Frames 8...15

Remove and Install the Control Transformer Fuses (FH4...FH7) for Frames 8...15

Remove and Install the AC Precharge Fused Disconnect (FD1) Fuses for Frames 8...15

Remove and Install the AC Precharge Fused Disconnect (FD1) Fuses for Frames 8...15

Remove and Install the AC Precharge Circuit Breaker for Frame 8

Remove and Install the AC Precharge Circuit Breaker for Frame 8

Control Transformers

Control Transformers

Frames 8…15 Power Bay Kits

Remove and Install the IP54 Roof Vent Filters for Frames 8…15

Remove and Install the IP54 Roof Vent Filters for Frames 8…15

Remove and Install the IP54 Roof Vent Fan Fuse for Frames 8...15

Remove and Install the IP54 Roof Vent Fan Fuse for Frames 8...15

Remove and Install the IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP54 Roof Vent Fan for Frames 8...15

Remove and Install the IP54, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP54, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP21, 400/600 mm Wide Door Vent Filter for Frames 8...15

Remove and Install the IP21, 400/600 mm Wide Door Vent Filter for Frames 8...15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP21, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the DC Precharge Module Disconnect Handle and Shaft for Frames 8...15

Remove and Install the DC Precharge Module Disconnect Handle and Shaft for Frames 8...15

Remove and Install the DC Precharge Module for Frames 8...15

Remove and Install the DC Precharge Module for Frames 8...15

Remove and Install the DC Precharge Circuit Board for Frames 8...15

Remove and Install the DC Precharge Circuit Board for Frames 8...15

Remove and Install the DC Precharge Module Fuses for Frames 8...15

Remove and Install the DC Precharge Module Fuses for Frames 8...15

Remove and Install the Power Bay Guard for Frames 8...15

Remove and Install the Power Bay Guard for Frames 8...15

Remove and Install the DC Link Fuses for Frames 8...15

Remove and Install the DC Link Fuses for Frames 8...15

Remove and Install a Power Module for Frames 8...15

Remove and Install a Power Module for Frames 8...15

Remove and Install the Power Module PE-B1 Power Jumper for Frames 8...15

Remove and Install the Power Module PE-B1 Power Jumper for Frames 8...15

Remove and Install the Power Module Circuit Board Tray for Frames 8...15

Remove and Install the Power Module Circuit Board Tray for Frames 8...15

Remove and Install the Power Layer Interface Circuit Board for Frames 8...15

Remove and Install the Power Layer Interface Circuit Board for Frames 8...15

Remove and Install the Power Interface Circuit Board for Frames 8...15

Remove and Install the Power Interface Circuit Board for Frames 8...15

Remove and Install the Power Module Balance Resistors for Frames 8...15

Remove and Install the Power Module Balance Resistors for Frames 8...15

Remove and Install the Power Module Current Sensors for Frames 8...15

Remove and Install the Power Module Current Sensors for Frames 8...15

Remove and Install the Power Module Gate Driver Circuit Board for Frames 8...15

Remove and Install the Power Module Gate Driver Circuit Board for Frames 8...15

Remove and Install the Power Module DC Bus Capacitor Assembly for Frames 8…15

Remove and Install the Power Module DC Bus Capacitor Assembly for Frames 8…15

Remove and Install a LCL Filter Module from the Enclosure for Frames 8...15

Remove and Install a LCL Filter Module from the Enclosure for Frames 8...15

Remove and Install the AC Input Link Fuses for Frames 8...15

Remove and Install the AC Input Link Fuses for Frames 8...15

Remove and Install the LCL Filter Capacitor Assembly for Frames 8...15

Remove and Install the LCL Filter Capacitor Assembly for Frames 8...15

Remove and Install the LCL Filter Module AC Common Mode Filter Circuit Board for Frames 8...15

Remove and Install the LCL Filter Module AC Common Mode Filter Circuit Board for Frames 8...15

Remove and Install the LCL Filter Module Current Sense Circuit Board for Frames 8...15

Remove and Install the LCL Filter Module Current Sense Circuit Board for Frames 8...15

Remove and Install the LCL Filter or Power Module Heatsink Fan Fuse for Frames 8...15

Remove and Install the LCL Filter or Power Module Heatsink Fan Fuse for Frames 8...15

Remove and Install the LCL Filter or Power Module Heatsink Fan Assembly for Frames 8...15

Remove and Install the LCL Filter or Power Module Heatsink Fan Assembly for Frames 8...15

Remove and Install the Torque Accuracy Module for Frames 8...15

Remove and Install the Torque Accuracy Module for Frames 8...15

Remove and Install the DC Bus Conditioner for Frames 8...15

Remove and Install the DC Bus Conditioner for Frames 8...15

Frames 8...15 Wire Entry/Exit Bay Kits

Remove and Install the IP54/IP21, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP54/IP21, 400/600 mm Wide Door Vent Filters for Frames 8...15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54, 800/1000 mm Wide Door Vent Filters for Frames 8…15

Remove and Install the IP54/IP21, 400/800 mm Wide Door Vent Exhaust Fan and Filter Assembly for Frames 8...15

Remove and Install the IP54/IP21, 400/800 mm Wide Door Vent Exhaust Fan and Filter Assembly for Frames 8...15

Remove and Install the Wire Bay Thermal Switch for Frames 8...15

Remove and Install the Wire Bay Thermal Switch for Frames 8...15

Start Up After Repairs

Before You Apply Power to Frame 7

Before You Apply Power to Frame 7

Before You Apply Power to Frames 8...15

Before You Apply Power to Frames 8...15

Measure No-load DC Bus Voltage and Output Current

Measure No-load DC Bus Voltage and Output Current

System Schematics

PowerFlex 755TR LCL Filter Module Schematic Diagrams for Frames 7…15

PowerFlex 755TR LCL Filter Module Schematic Diagrams for Frames 7…15

PowerFlex 755TR Power Module Schematic Diagrams for 7...15

PowerFlex 755TR Power Module Schematic Diagrams for 7...15

PowerFlex 755T DC Precharge Module Schematic Diagram

PowerFlex 755T DC Precharge Module Schematic Diagram

PowerFlex 755T DC Bus Conditioner Schematic Diagram for Frames 8…15

PowerFlex 755T DC Bus Conditioner Schematic Diagram for Frames 8…15

PowerFlex 755T AC Precharge Schematic Diagram for Frame 7

PowerFlex 755T AC Precharge Schematic Diagram for Frame 7

PowerFlex 755T AC Input Bay Schematic Diagrams for Frames 8...12

PowerFlex 755T AC Input Bay Schematic Diagrams for Frames 8...12

PowerFlex 755TL/TR Drives Schematic Diagrams for Frames 7...12

PowerFlex 755TL/TR Drives Schematic Diagrams for Frames 7...12

PowerFlex 755TM Regenerative Bus Supply Schematic Diagrams for Frames 7...12

PowerFlex 755TM Regenerative Bus Supply Schematic Diagrams for Frames 7...12

PowerFlex 755TM Common Bus Inverters for Frames 8...12

PowerFlex 755TM Common Bus Inverters for Frames 8...12

PowerFlex 755T Entry and Exit Wire Bays for Frames 8...12

PowerFlex 755T Entry and Exit Wire Bays for Frames 8...12