Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual

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Page 1

Hardware Service Manual

Original Instructions

PowerFlex Digital DC Drive - Frame B

Catalog Numbers 20P

Page 2

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Page 3

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1 Before You Begin Testing, Maintenance or Repairs

Component Test Procedures Save the Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2

Save to a HIM Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Visual Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshoot a Control Power Supply Failure . . . . . . . . . . . . . . . . . . . 15

Testing the Switching Power Supply and Pulse Transformer

Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Testing the Control and Field Board Connections . . . . . . . . . . . 16

Troubleshoot an AC Undervoltage Fault. . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshoot an Armature Bridge Failure . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshoot a Field Current Loss Fault . . . . . . . . . . . . . . . . . . . . . . . . 22

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Component Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Check the Armature SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . 26

Check the Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . 30

Check the Field SCR/Dual Diode Module . . . . . . . . . . . . . . . . . . 32

Speed Feedback Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check the DC Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Check the Resolver Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 35

Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Create a Fault Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

What You Need When You Call Tech Support. . . . . . . . . . . . . . . . . . 38

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Table of Contents

Chapter 3

Part Replacement Procedures Replacement Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DPI / HIM Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Install the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Protective Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Remove the Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Install the Protective Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Communication Adapter and Electromagnetic Interference

Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Remove the Communication Adapter and Electromagnetic

Interference Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install the Communication Adapter and EMI Shield . . . . . . . . . 47

Resolver Feedback and Interface Circuit Board Replacement. . . . . . 48

Remove the Resolver Feedback and Interface Circuit Boards . . 48

Install the Resolver Feedback and Interface Circuit Boards . . . . 51

I/O Expansion Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . 52

Remove the I/O Expansion Circuit Board . . . . . . . . . . . . . . . . . . . 52

Install the I/O Expansion Circuit Board. . . . . . . . . . . . . . . . . . . . . 53

115V AC to 24V DC I/O Converter Circuit Board

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Remove the 115V AC to 24V DC I/O Converter Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Install the 115V AC to 24V DC I/O Converter Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remove the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 55

Install the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Control Electromagnetic Interference Shield Removal and

Closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Move the Control Electromagnetic Interference Shield . . . . . . . 58

Close the Control EMI Shield in the Service Position. . . . . . . . . 59

Switching Power Supply Board Fuse Replacement . . . . . . . . . . . . . . . 60

Remove the Fuses on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Install the Fuses on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Pulse Transformer Circuit Board Fuse Replacement. . . . . . . . . . . . . . 62

Remove the Fuses on the Pulse Transformer Circuit Board. . . . 62

Install the Fuses on the Pulse Transformer Circuit Board . . . . . 62

4 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 5

Table of Contents

Pulse Transformer and Switching Power Supply Circuit Boards

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Remove the Pulse Transformer and Switching Power Supply

Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Configure the Pulse Transformer Circuit Board. . . . . . . . . . . . . . 69

Install the Pulse Transformer and Switching Power Supply

Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Field Circuit Fuses Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Remove the Field Circuit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Install the Field Circuit Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Field Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Remove the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Install the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Field SCR and Dual Diode Modules Replacement . . . . . . . . . . . . . . . 77

Remove the Field SCR and Dual Diode Modules. . . . . . . . . . . . . 77

Install the Field SCR and Dual Diode Modules . . . . . . . . . . . . . . 77

AC Line Snubber Circuit Board and Resistors Replacement . . . . . . 78

Remove the AC Line Snubber Circuit Board and Resistors. . . . 78

Install the AC Line Snubber Circuit Board and Resistors . . . . . 80

SCR Modules Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Remove the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Install the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

AC Current Transducers Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 90

Remove the AC Current Transducers . . . . . . . . . . . . . . . . . . . . . . . 90

Install the AC Current Transducers. . . . . . . . . . . . . . . . . . . . . . . . . 93

Bimetal Thermostats Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Remove the Bimetal Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Install the Bimetal Thermostats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Cooling Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Remove the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Install the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Chapter 4

Start-Up After Repair Test With the Motor, Without a Mechanical Load . . . . . . . . . . . . . 103

Appendix A

Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Appendix B

Circuit Board Layouts and Connections

List of Circuit Board Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Switching Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Field Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 5

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Table of Contents

Appendix C

Flow Charts List of Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Control Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Field Current Loss Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 7

Preface

This manual contains component test and hardware replacement information for PowerFlex® DC frame B drives, 40…300 Hp (30…224 kW).

This manual is intended for qualified service personnel responsible for troubleshooting and repairing PowerFlex DC drives. You should have previous experience with, and basic understanding of, electrical terminology, procedures, required troubleshooting equipment, equipment protection procedures and methods, and safety precautions.

It is highly recommended that you obtain a copy of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 programming information to assist you in troubleshooting drive errors and determining if repairs are necessary. See Additional Resources on page 7 information on related publications and how to obtain manuals.

, which contains fault/alarm and

for

Summary of Changes

Additional Resources

This manual contains new and updated information.

Top ic Pag e

Updated the list of Additional Resources to include a link to the PowerFlex DC drive spare parts list.

Added a table of spare parts kits to Chapter 3. 40

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

PowerFlex Digital DC Drive User Manual, publication

20P-UM001

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Product Certifications website, http://

www.rockwellautomation.com/global/certification/ overview.page

PowerFlex DC Drive Spare Parts List, publication

PFLEX-SB003

Provides basic information that is required to install, start-up, and troubleshoot the PowerFlex DC drive.

Provides general guidelines for installing a Rockwell Automation industrial system.

Provides declarations of conformity, certificates, and other certification details.

Provides a current list of spare parts available for the PowerFlex DC field controller.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

To order paper copies of technical documentation, contact your local Allen-Bradley™ distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 7

Page 8

Preface

Notes:

8 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 9

Chapter 1

Before You Begin Testing, Maintenance or Repairs

Top ic Pag e

General Safety Precautions 10

Hardware Description 11

Commonly Used Tools 12

This chapter provides information you should know before you begin tests, maintenance, or repairs on drive components.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 9

Page 10

Chapter 1 Before You Begin Testing, Maintenance or Repairs

General Safety Precautions

Read the following precautions before you begin testing components, performing maintenance or repairing the drive.

AT TE NT IO N: Only qualified personnel familiar with DC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

AT TE NT IO N: This drive contains Electrostatic Discharge (ESD) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2 Electrostatic Damage” or any other applicable ESD protection handbook.

AT TE NT IO N: Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Hazardous voltages may exist in the drive enclosure even with the circuit breaker in the off position. Recommended practice is to disconnect and lock out control equipment from power sources. If it is necessary to work in the vicinity of energized equipment, the safety related work practices of NFPA 70E, Electrical Safety Requirements for Employee Workplaces, must be followed. DO NOT work alone on energized equipment.

, “Guarding Against

AT TE NT IO N: Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope be used in the A minus B Quasi-differential mode with the oscilloscope chassis correctly grounded to an earth ground.

AT TE NT IO N: Remove power before making or breaking cable connections. When you remove or inser t a cable connec tor with power ap plied, an ele ctrical arc may occur. An electrical arc can cause personal injury or property damage by:

• sending an erroneous signal to your system’s field devices, causing unintended machine motion

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.

AT TE NT IO N: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power allow time for cooling.

10 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 11

Before You Begin Testing, Maintenance or Repairs Chapter 1

Hardware Description

The PowerFlex® DC drive contains a power structure that has an armature and field supply. The armature supply consists of a three–phase, full wave rectified, dual bridge, capable of two or four quadrant output. The field supply consists of single phase, full wave rectified bridge. Also associated with the power structure are incoming line protection devices and contactor and dynamic brake control circuits.

Verify that you are working on a frame B drive by checking the data nameplate located on the side of the drive. The frame size is printed just above the serial number in the lower right corner of the label.

.0/0.5A 1 Phase

Frame: B

Serial Number: B23E0042

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 11

Page 12

Chapter 1 Before You Begin Testing, Maintenance or Repairs

Commonly Used Tools

Service Tools

This list of basic service tools which will cover needs of tools for repair and maintenance measurements.

Item Details

Digital multimeter Digital multimeter, capable of AC and DC voltage, continuity, resistance, and

forward diode bias tests. Fluke model 87 III or equivalent (recommended).

Oscilloscope Portable, digitizing, dual channel scope, with isolation

Current clamp 3x drive rated armature current output

Soldering station Soldering / de soldering

Torque wrench 1…12 N•m

Torque wrench 6…50 N•m

Box wrench 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm

Socket extension 230 mm

Wrench 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm

Wire c utter

Nose pliers

Crimping tools For cable terminals 1.5…240

Angle wrench

Screw drivers:

Flat nose 7 x 2 mm

Hexalobular T15, T20, T25

Phillips #1, 2, 3

Hexagonal wrench #4, 5, 6

ESD-protected place of work Working surface, floor covering, seat and ground connections

ESD-protective clothing Wrist wrap, shoes, overall clothing (coat)

Software Tools

You can use Connected Components Workbench® software or DriveExecutive™ software to monitor, upload, or download system parameters. You can also view current alarm and fault information.

12 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 13

Component Test Procedures

Top ic Pag e

Save the Parameter Configuration 14

Visual Component Inspection 15

Troubleshoot a Control Power Supply Failure 15

Troubleshoot an AC Undervoltage Fault 19

Troubleshoot an Armature Bridge Failure 20

Troubleshoot a Field Current Loss Fault 22

Power Component Test Procedures 26

Speed Feedback Device Tests 34

Thermis tors and Therm al Switches 37

Relay Outputs 37

Create a Fault Report 38

Wh at Yo u Ne ed Whe n You Cal l Te ch S upp or t 38

Chapter 2

This chapter provides general procedures for inspecting and testing the major components of the drive and includes recommendations for repairs. Due to the technical nature of this product and the variety of possible applications, not all possible fault conditions and troubleshooting solutions can be described in this manual.

IMPORTANT Using the diagnostic tests in this chapter should only be performed by

qualified personnel and only when other corrective actions have failed. All tests assume that the control board connections have been properly made.

For common drive symptoms and corrective actions and fault troubleshooting information, see the Troubleshooting chapter in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 13

Page 14

Chapter 2 Component Test Procedures

Save the Parameter Configuration

It is recommended that you save the drive and communication adapter parameter configuration before performing any service. You can save the drive configuration in one of these ways:

• Upload the drive configuration to a HIM Set

• Upload the drive configuration to a DriveExecutive file (.dno)

• Export the drive configuration to Connected Components Workbench file (.iuux)

See the specific software online help for instructions on how to save or export the drive configuration to an offline file.

Save to a HIM Set

Complete these steps to save the drive and adapter parameters to a HIM set.

1. On the HIM, access the Memory Storage menu.

2. Select the HIM CopyCat menu and press .

3. Select Device -> HIM and press .

4. Do one of the following:

• If there are no existing HIM Sets, enter a name using the and

buttons to select the desired characters and press .

• If there is an existing HIM Set, press to overwrite it, or select

No using the button and use the and buttons to

select the desired characters. Then press .

The HIM Set will be saved to nonvolatile memory.

14 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 15

Component Test Procedures Chapter 2

Visual Component Inspection

Troubleshoot a Control Power Supply Failure

Visually inspect the circuit boards and power components before energizing the drive for any of the component test procedures.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers (see page 43 shield (see page 58

) when necessary.

) and lower the control EMI

4. Check components for burn marks, breakage or foil delamination on all circuit boards.

Replace any of these components without further testing if they show evidence of burn marks, breakage, or foil delamination.

If a drive Power Failure fault (F3) has occurred and the drive is inoperable via the HIM or other means of control, compete the steps below to determine where the control power failure has occurred.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Measure the signal voltage at the testpoints on the control board as indicated in the following table.

Name Testpoint For Testpoint Loc at ion

+ 5V XY5 Figure 1 GNDD XY6 Figure 1 GNDD XY7 Figure 2 +15V XY12 Figure 1 GNDA XY10 Figure 1

-15 V XY11 Figu re 1

+24V XY8 Figure 1 on page 17 XA-16 +24V terminal block GNDV XY9 Figure 1

+5VEXP +5VEXP Figu re 2 on page 18 XP3-1 / XP3-2 / XP3-3 +5V for DPI expansion +12VEXP +12VEXP Figure 2 0VEXP 0VEXP Fig ure 2

See…

on page 17 XA-1 / XA-3 / XA-5 +5V digital supply on page 17 XA-2 / XA-4 / XA-6 +5V digital supply ground on page 18 XA-2 / XA-4 / XA-6 +5V digital supply ground on page 17 XA-9 / XA-10 +15V analog supply on page 17 XA-11 / XA-12 15V analog supply ground on page 17 XA-13 / XA-14 -15V analog supply

on page 17 XA-15 +24V terminal block ground

on page 18 XP3-4 / XP3-5 +12V for DPI expansion on page 18 XP3-7 / XP3-8 / XP3-9 DPI expansion ground

Associated ConnectorPin

Description

Note: For a flow chart version of the steps that follow, see Control Power Supply Failure on page 122

4. If any of the signals in the table above is incorrect or missing, verify that either 115V AC or 230V AC voltage is present at terminals U2 and V2 (control circuit power input).

• If the voltage is present and correct, continue with step 5 below.

• If the voltage is incorrect or missing , remove control power and verify

the wiring and power source to U2, V2 and correct any problems. Test the voltage level again to verify that it is correct. If the voltage is correct, but the drive is still inoperable, continue with step 5 below.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 15

Page 16

Chapter 2 Component Test Procedures

5. Remove AC control power from terminals U2 and V2 and remove and test the fuse (F1) at the top of the drive. See Remove the Fuses on the Switching Power Supply Circuit Board on page 60

• If the fuse is blown, continue with step 6 below.

• If the fuse is not

(see page 62

blown, replace the switching power supply board

for fuse location.

6. Replace the fuse on the switching power supply board (see page 61

7. Disconnect the cable at connector XA on the control board. See

Figure 27

8. Apply AC control power to the drive.

• If the fuse blows, continue with Testing the Switching Power Supply

• If the fuse does not

on page 119 for location of connector XA.

and Pulse Transformer Boards.

blow, continue with Testing the Control and

Field Board Connections on page 16

Testing the Switching Power Supply and Pulse Transformer Boards

1. Remove power from the drive (see page 42).

2. Replace the fuses on the switching power supply board (see page 61

3. Remove the switching power supply board from the drive (see page 62

4. Reapply power to the switching power supply board only.

• If the power supply fuses do not

• If the power supply fuses blow, replace the switching power supply

board (see page 62

blow, continue with step 5 below.

5. Remove all incoming AC voltage from the drive.

6. Check all external wiring connected to the pulse transformer board, including the motor PTC if used, for a possible short circuit condition. Repair any short circuit conditions if found.

7. If no short circuit conditions exist, replace the pulse transformer board (see page 62

Testing the Control and Field Board Connections

1. Using an ohmmeter, check all input and output wiring on terminals 1…40 on terminal blocks TB1 and TB2 on the control board for a possible short circuit condition. Repair any short circuit conditions if found.

2. If an encoder and/or tachometer is used, use an ohmmeter to check all wiring on the respective terminals for a possible short circuit condition. Repair any short circuit conditions if found.

16 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 17

XY18

XY17

XY19

Component Test Procedures Chapter 2

3. Remove the cables from connector XR and XFCD on the control board and use an ohmmeter to check between all voltage test points and common on the control board for possible short circuit conditions. The ohmmeter measurements should be greater than 200 kΩ. If any low resistance measurements are found, replace the control board.

4. Using an ohmmeter, measure between pins 1 and 2 and pins 3 and 2 on the XFCD cable connector. The resistance measurement for both tests should be greater than 200 kΩ. If a lower resistance value is measured, replace field board.

Figure 1 - Control Board Testpoints - Upper Left

XY9

XY21

XY8

XY12

XY10

XY11 XY6 XY5

XY22

XY20

1 2 3 4 5 6 7 8

- A B C +

S15

1 2 3 4 5 6 7 8

S14

S20

S11

S10

A+ A- B+ B- Z+ Z- COM +V

21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10

31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

S21

ENC_5

ENC_12

RST

ACT RUN

PWR

S18

S12

DEBUG

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 17

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Chapter 2 Component Test Procedures

Figure 2 - Control Board Testpoints - Upper Right

+12VEXP

0VEXP+5VEXP

- A B C +

XY7

S15

1 2 3 4 5 6 7 8

S14

S21

ENC_5 ENC_12

S20

A+ A- B+ B- Z+ Z- COM +V

S11

S10

21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10

31 32 33 34 35 36 37 38 39 40

11 12 13 14 15 16 17 18 19 20

1 2 3 4 5 6 7 8

RST

ACT RUN

PWR

S18

S12

DEBUG

18 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Component Test Procedures Chapter 2

Troubleshoot an AC Undervoltage Fault

If the drive faults with an AC Undervoltage Fault (F4), or parameter 466 [AC Line Voltage] does not equal the expected incoming AC line voltage, measure the AC line input signals as directed in the steps below.

1. Read the General Safety Precautions on page 10

2. Remove the protective covers (see page 43

3. Using a voltmeter, measure the voltage at terminals U, V, and W of the drive.

If an AC input contactor is used, the voltage must be measured on both the input and output sides of the contactor.

If any of the voltage measurements is incorrect or missing, remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems.

4. Using a voltmeter, measure the combined voltages of the AC lines on the following testpoints on the control board (all waveforms have a 2.5V offset). See Figure 1 the testpoints. Also, see Figure 14

Table 1 - Combined AC Line Input Signal Testpoints

on page 17 and Figure 2 on page 18 for location of

on page 107 for a schematic diagram.

Incoming AC Line Voltage

240V AC V and U XY22 … XY18 1.42V AC 0.500V

480V AC V and U XY22 … XY18 2.95V AC 1.040V

575V AC V and U XY22 … XY18 2.85V AC 1.007V

690V AC V and U XY22 … XY18 3.45V AC 1.220V

Phases Measure from

Tes tpo in t

V and W XY21 … XY18

… To Testpoint Peak to Peak

Measurement

RMS Measurement

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 19

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Chapter 2 Component Test Procedures

• If any of the voltage measurements above are incorrect or missing,

continue with step 5.

• If the voltage measurements above are correct but the value of

parameter 466 [AC Line Voltage] is incorrect, replace the control board.

5. Remove the ribbon cable connected to XR on the control board and pulse transformer board and test the continuity of the cable using the measurements in Ta b l e 2 4

on page 116.

If the measurements on the XR cable are correct, replace the pulse transformer board.

Troubleshoot an Armature Bridge Failure

If the drive is running unstable or faults with an Overcurrent Fault (F13) an armature bridge failure may have occurred. All of the signals going to and coming from the SCR bridges are transmitted via the ribbon cable connected to XR on the control board and can be measured at these points. See Figure 27 on page 119

for location of the XR connector on the control board.

Note: If using an AC input contactor, this step requires that the cable remain connected to the XR connector on the control board and that an adapter be used to measure these signals.

1. Read the General Safety Precautions on page 10

2. Remove the protective covers (see page 43

3. If using a DC output contactor, disconnect the cable from XR on the control board and measure the signal for each SCR gate as indicated in this table:

Signal Name XR Cable Pin Gate Note

MP MN

IT1 27 G1 G04 IT2 29 G2 G05 IT3 31 G3 G06 IT4 21 G4 G01 IT5 23 G5 G02 IT6 25 G6 G03 MN 33 – – Negative bridge MN - active when high (+5V) MP 34 – – Positive bridge MP - active when high (+5V)

Figure 3

and Figure 4 on page 21, and Figure 5 on page 22 are examples representing gate pulse, current and voltage signal measurements taken on an SCR. In the figures below:

– The current signal is taken on the testpoint XY17 (+2.5V offset;

+0.6V=Drive size current). – The voltage signal is taken on the testpoint XY19 (+2.5V offset). – The ground signal is taken on either testpoint XY10 or XY18.

20 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 21

Component Test Procedures Chapter 2

5 V

0 V

XY19

XY17

Figure 3 - Good SCR Gate Pulse and Armature Current Signals Example

Figure 4 - Good SCR Armature Voltage and Motor Current Signal Example

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 21

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Chapter 2 Component Test Procedures

5 V

0 V

XY19

A malfunctioning thyristor is connected to the relative gate. For example, if the tested signal is at XR25 and the positive bridge is active (MP high) from this figure you can deduce that SCR connected to gate G6 is open.

Figure 5 - Open Thyristor Example

Troubleshoot a Field Current Loss Fault

If the drive faults with a “Field Current Loss” fault (F6) and there is low or incorrect field current present at the motor, as seen in parameter 351 [Field Current], complete the steps in Low or Incorrect Field Current. If the drive faults with a “Field Current Loss” fault (F6) and there is no present at the motor, as seen in parameter 351 [Field Current], complete the steps in No Field Current on page 24

field current

Low or Incorrect Field Current

Note: For a flow chart version of these steps, see Low or Incorrect Field Current on page 124

1. Read the General Safety Precautions on page 10

2. Verify the actual value of parameter 351 [Field Current] by measuring

3. Verify that the drive rated field bridge current is set correctly in

the DC motor field current using a DC clamp.

parameter 374 [Drv Fld Brdg Cur] and DIP switch S14 is configured to correctly (according to the instructions in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 corrections. See Control Board on page 119

) and make any necessary

for DIP switch location.

22 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 23

Component Test Procedures Chapter 2

4. Verify that the value of parameter 280 [Nom Mtr Fld Amps] matches the rated field current value on motor nameplate and make any necessary corrections.

5. Remove the protective covers (see page 43

6. Measure the field current signal on the green LA-LB terminal located on the control board: LA is the ground and LB is field current signal. The measured value of the field current at LA-LB should be equal to the value of parameter 374 [Drv Fld Brdg Cur]. If these values are equivalent, the voltage across these terminals should be 1.66 VDC.

Note: For lower field current values, the voltage will be proportional. For example, if the field is set up for 2 A and the motor is rated for 1.5 A, the measurement at LA-LB will be 1.245 VDC (1.5 / x = 2 / 1.66).

• If the voltage measurement is incorrect, continue with step 7 below.

• If the voltage measurement is correct, but the “Field Current Loss”

fault still exists, replace the control board (see page 55

7. Using an ohmmeter, measure the resistance across terminals LA-LB to verify that the value equals the equivalent resistance as indicated in the table below (set with DIP switch S14 on the control board).

Switch Ohms: 168.5 333.3 182 36.4 845 1668 3333 – Equivalent

Field Current Scale

1 A 10 A OFF OFF OFF OFF OFF ON Not used 2 A OFF OFF OFF OFF ON OFF 845 3 A OFF OFF OFF OFF ON ON 560.9 5 A OFF ON OFF OFF OFF OFF 333.3 10 A ON OFF OFF OFF OFF OFF 168.5 13 A 14 A ON OFF OFF OFF ON ON 129.6 17 A 20 A OFF ON ON OFF ON ON 97.3 20 A ON OFF ON OFF OFF ON 83.1

Field

S14-1 S14-2 S14-3 S14-4 S14-5 S14-6 S14-7 S14-8 Ohm

Supply

(OFF)

Resistance

1668

• If the resistance measurement is incorrect, replace the field board (see

page 75

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 23

Page 24

Chapter 2 Component Test Procedures

No Field Current

Note: For a flow chart version of these steps, see No Field Current on page 123.

1. Read the General Safety Precautions on page 10

2. Remove the protective covers (see page 43

3. Verify that the correct AC voltage is present at terminals U1 and V1 at the top of the field fuse holder mounted on the control panel. See

Figure 16

• If the voltage is correct, continue with step 4 below.

• If the voltage is incorrect or missing, remove power from the drive

4. Remove AC power to the drive and check the fuses at FU1 and FV1. See Remove Power from the Drive on page 42

• If the fuses are blown, complete the steps in Test Field Wiring and

• If the fuses are not

on page 108 for a schematic diagram.

and verify the wiring to the drive and the power supply source and correct any problems. Test the voltage level again to verify that it is correct. If the voltage is correct, but the fault persists or parameter 351 [Field Current] is incorrect, continue with step 4 below.

Voltage Signals.

blown, complete the steps in Test Field Control

Signals.

Test Field Wiring and Voltage Signals

1. Test the resistance of the motor field wiring and motor field for possible short circuits.

• If there are no short circuits, continue with step 2 below.

• If a short circuit exists, correct any problems.

2. Check the field SCR/dual diode module for a short circuit condition (see page 32

• If there are no short circuits, continue with step 3 below.

• If a short circuit exists, replace the field SCR/dual diode module (see

page 77

3. Replace the field fuses at FU1 and FV1 and apply power to the drive.

4. If the field fuses blow, replace the field board (see page 75

Test Field Control Signals

1. Disconnect the cable from connector XR on the control board and measure the U1-V1 voltage synchronization signal at pin 11 on the cable. See Figure 27 the control board.

on page 119 for location of the XR connector on

24 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 25

Component Test Procedures Chapter 2

LA-LB

U1-V1 Sync

ITF1 Pulse

ITF2 Pulse

This signal is a square wave signal with a 90° lag phase displacement compared to the AC voltage signal.

2. Measure the gate signals at pins XR-1 and XR-2 on the cable. The figure below displays the following signals from top to bottom:

Channel Signal

1U1-V1 Sync

4 Ie - LEM current feedback signal taken on LA-LB terminal

2ITF1 pulse

3ITF2 pulse

• If the gate signals are missing, replace the control board (see page 55

• If the gate signals are present, replace the field board (see page 75

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 25

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Chapter 2 Component Test Procedures

Power Component Test Procedures

Check the Armature SCR Modules

The frame B PowerFlex DC drive armature supply consists of three (nonregenerative drives) or six (regenerative drives) SCR modules mounted on heat sinks within the legs assemblies. A malfunction of any of these devices will be indicated by either an Overcurrent fault (F13), blown or tripped incoming protection devices, or erratic motor operation. The following procedure can be used if an armature bridge component malfunction is suspected.

1. Read the General Safety Precautions on page 10

2. Verify that contactor power (if used) is removed.

3. Verify that power to an external field supply (if used) is removed.

4. Check the anode to cathode junction of each SCR. With a digital multimeter set to Ohms, measure the resistance across the SCRs (lead orientation is not critical).

• For regenerative drives, see Ta b l e 2

page 27

on page 26 and Figure 6 on

• For non-regenerative drives, see Ta b l e 3

page 28

If a low resistance is detected, determine which SCR module(s) is/are damaged based on the tables below and replace that module (see page 80

on page 28 and Figure 7 on

Table 2 - SCR Anode to Cathode Junction Measurements for Regenerative Drives

On SCR Module SCR Measure from

Ter min al

1 1 U C “open circuit” or “MΩ” range

4U D

22V C

5V D

33W C

6W D

01 01 U C

04 U D

02 02 V C

05 V D

03 03 W C

06 W D

To Te rmin al Nom inal Meter Read ing

26 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 27

Figure 6 - Regenerative Drive SCR Module Layout

SCR Module 1

SCR Module 01

SCR Module 2

SCR Module 02

SCR Module 3

SCR Module 03

U CV

Component Test Procedures Chapter 2

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 27

Page 28

Chapter 2 Component Test Procedures

SCR Module 01 SCR Module 02 SCR Module 03

U CVDW

Table 3 - SCR Anode to Cathode Junction Measurements for Non-Regenerative Drives

On SCR Module SCR Measure from

To Te rmin al N ominal M eter Readi ng

Ter min al

01 01 U C “open circuit” or “MΩ” range

04 U D

02 02 V C

05 V D

03 03 W C

06 W D

Figure 7 - Non-Regenerative Drive SCR Module Layout

5. Check the gate to cathode junction of each SCR. With a digital multimeter set to Ohms, measure the resistance of each SCR junction.

• For regenerative drives, see Ta b l e 4

• For non-regenerative drives, see Ta b l e 5

page 30

on page 29 and Figure 8 on page

on page 30 and Figure 9 on

28 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Component Test Procedures Chapter 2

SCR Module 1

SCR Module 01

SCR Module 2

SCR Module 02

SCR Module 3

SCR Module 03

5 4

7 6

4 5

6 7

Gate Lead

Pinouts

Gate Lead Pinouts

5 4

7 6

5 4

7 6

4 5

6 7

4 5

6 7

If a measurement is outside of the range specified in the table, or if one reading deviates significantly from the majority, then module replacement may be necessary (see page 80

Table 4 - SCR Gate to Cathode Junction measurements for Regenerative Drives

On SCR Module SCR Measure from To Nominal Meter Reading

1 1 Pin 5 Pin 4 5…20 Ω

4 Pin 6 Pin 7

22Pin 5Pin 4

5 Pin 6 Pin 7

33Pin 5Pin 4

6 Pin 6 Pin 7

01 01 Pin 6 Pin 7

04 Pin 5 Pin 4

02 02 Pin 6 Pin 7

05 Pin 5 Pin 4

03 03 Pin 6 Pin 7

06 Pin 5 Pin 4

(1) The actual reading varies depending upon the SCR manufacturer. Verify that the actual measured value is consistent

for all SCRs.

(1)

Figure 8 - SCR Gate Lead Connection Pinouts for Regenerative Drives

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 29

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Chapter 2 Component Test Procedures

SCR Module 01 SCR Module 02 SCR Module 03

Gate Lead

Pinouts

4 56 7 4 56 7 4 56 7

Table 5 - SCR Gate to Cathode Junction Measurements for Non-Regenerative Drives

On SCR Module SCR Measure from To Nominal Meter Reading

01 01 Pin 6 Pin 7 5…20 Ω

04 Pin 5 Pin 4

02 02 Pin 6 Pin 7

05 Pin 5 Pin 4

03 03 Pin 6 Pin 7

06 Pin 5 Pin 4

(1) The actual reading varies depending upon the SCR manufacturer. Verify that the actual measured value is consistent

for all SCRs.

Figure 9 - SCR Gate Lead Connection Pinouts for Non-Regenerative Drives

(1)

Check the Pulse Transformer Board

The armature pulse transformer circuit board contains an isolated gate firing circuit and also provides dv/dt protection for the armature SCR modules. A malfunction of these devices will be indicated by either an Overcurrent fault (F13), blown or tripped incoming protection devices or erratic motor operation. Use the following procedure if a malfunction in this circuitry is suspected.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the pulse transformer board (see page 62

4. With a digital multimeter set for a “continuity check”, measure each connection point on the pulse transformer board listed in the tables below. See Figure 25

on page 114 for connector locations.

If any of the actual measurements are out of tolerance, replace the pulse transformer board (see page 62

30 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Component Test Procedures Chapter 2

10 . . . . . 1

Table 6 - Armature Pulse/Snubber Circuit Measurements for Regenerative Drives

For SCR Measure From To Meter Reading Connector XY Pinout

1KG1XY-4“open circuit” 4KG4XY-1 2KG2XY-5 5KG5XY-2 3KG3XY-6 6KG6XY-3

01 KG01 XY-1

10 . . . . . 1

04 KG04 XY-4 02 KG02 XY-2 05 KG05 XY-5 03 KG03 XY-3 06 KG06 XY-6

Table 7 - Armature Pulse/Snubber Circuit Measurements for Non-Regenerative Drives

For SCR Measure From To Meter Reading Connector XY Pinout

01 KG01 XY-1 “open circuit” 04 KG04 XY-4 02 KG02 XY-2 05 KG05 XY-5 03 KG03 XY-3 06 KG06 XY-6

10 . . . . . 1

5. With the digital multimeter set to “diode test”, measure each connection point on the pulse transformer board listed in the tables below. If any of the actual measurements are out of tolerance, replace the pulse transformer board (see page 62

Table 8 - Armature Pulse Transformer Primary Measurements for Regenerative and NonRegenerative Drives

For SCR (+) Meter Lead (-) Meter Lead Meter Reading Connector XY Pinout

1/01 XY-8 XY-1 0.41 Ω

4/04 XY-8 XY-4

2/02 XY-8 XY-2

5/05 XY-8 XY-5

3/03 XY-8 XY-3

6/06 XY-8 XY-6

Table 9 - Armature Pulse Transformer Primary Measurements for Regenerative Drives

For SCR (+) Meter Lead (-) Meter Lead Meter Reading Connector X Y Pinout

1 XY-7 X Y-1 0. 41 Ω

4 XY-7 XY-4

2 XY-7 X Y-2

5 XY-7 XY-5

3 XY-7 X Y-3

6 XY-7 XY-6

10 . . . . . 1

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Chapter 2 Component Test Procedures

Check the Field SCR/Dual Diode Module

The field supply consists of a dual pack SCR/dual diode module arranged in a single–phase full wave rectifier configuration. Malfunction of either of these components may cause various responses including field and velocity related faults, or blown fuses. The following procedures can be used if field bridge malfunctions are suspected.

1. Read the General Safety Precautions on page 10

2. Remove and lock-out all incoming power to the drive (see page 42).

3. Remove the protective covers (see page 43

4. Verify that contactor power (if used) is removed.

5. Verify that power to an external field supply (if used) is removed.

6. Check the anode to cathode junction of the field SCR/dual diode module. With the digital multimeter set to “diode test”, measure the resistance across the modules. See Ta b l e 1 0

and Figure 10.

If a low resistance is detected, replace the modules (see page 77

If a measurement results in an “infinity” reading, check the fuses at FU1 and FV1 on the control panel to determine if they are open. See

Figure 11

Table 10 - Field SCR/Dual Diode Module Anode to Cathode Junction Measurements

(+) Meter Lead (-) Meter Lead Nominal Meter Reading Ter min al Term in al

U1 C1 “open” or ∞ U1 D1 “open” or ∞ V1 C1 “open” or ∞ V1 D1 “open” or ∞ C1 D1 “open” or ∞ C1 U1 “open” or ∞ C1 V1 0.50V D1 C1 0.50V D1 U1 0.45V

on page 33.

32 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 33

Figure 10 - Field Terminal Block Location

Top of Dr ive

Unscrew fuse holders and remove fuses

Front of Drive

Top view of D rive

Component Test Procedures Chapter 2

Figure 11 - Field Fuses Location

7. Remove the cable from connector XP on the pulse transformer circuit board. See Figure 25

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 33

on page 114 for connector location.

Page 34

Chapter 2 Component Test Procedures

8. Check the gate cathode junction of the field SCR/dual diode module. With the digital multimeter set to “diode test” measure the resistance across the modules (lead orientation is not critical). See Ta b l e 1 1

If a low resistance is detected, replace the SCR/dual diode module (see page 77

Table 11 - SCR/Dual Diode Module Gate Cathode Junction Measurements

Measure from To Nominal Meter Reading

XP1 XP2 10…20 Ω XP3 XP4

Speed Feedback Device Tests

Check the Encoder

The encoder feedback device provides a dual channel quadrature output waveform and requires that the output be differential line drivers at +5 or +12…15V signal levels. The encoder power supply voltage and input selection is controlled by DIP switch S21 on the control board (see “DIP Switch and Jumper Settings” in the PowerFlex Digital DC Drive User Manual, publication

20P-UM001

+V (+) to COM (-) with a digital multimeter. If S21 is set to ENC_5, the voltage level should be +2.5…5.4V. If S21 is set to ENC_12, the voltage level should be +5.4V…15.2V. For reference, see Figure 19 schematic diagram.

The Channel A and Channel B are square wave type outputs that are 90 degrees out of phase. When rotating in the counter clockwise direction, as viewed from the commutator end, Channel A leads Channel B. Each differential channel has an inverted and non–inverted signal.

Power for the encoder is provided internally and is capable of 200mA of current with a current foldback feature that protects the power supply should the current draw exceed 200mA. If different power supply requirements exist for the chosen feedback device, the supply must be provided external to the drive.

). The encoder power supply from the drive can be measured from

on page 110 for a

The frequency is proportional to speed and the pulse rate of the encoder, referred to as the “Pulse/Rev” rating on the nameplate. The speed of the motor can be calculated by: Speed (RPM) = [Frequency (Hz) x 60]/[Pulses/ Revolution].

34 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Component Test Procedures Chapter 2

Check the DC Tachometer

• Verify that DIP switch S4 on the control board is set to the correct input voltage of the DC analog tachometer. See “DIP Switch and Jumper Settings” in the PowerFlex Digital DC Drive User Manual, publication

20P-UM001

. Also, see Figure 20 on page 110 for a circuit diagram.

• The analog tach signal is fine scaled using parameter 562 [Anlg Tach Gain].

• See “Drive Reference and Feedback Scaling” in Appendix C of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 for more information.

Check the Resolver Interface Board

The resolver feedback option module uses the resolver feedback board for resolver connections, and the resolver interface board for external power, status, feedback board reset, and encoder output connections.

If a “Resolver Error” (F93) fault occurs and the resolver wiring and configuration are correct, the following light-emitting diode indicators and testpoints on the resolver interface board can be used to verify that the board is not damaged.

• Verify that the following light-emitting diodes are functioning as expected. See Figure 12

on page 36 for light-emitting diodes locations

and switch settings.

Light-emitting Diode Code

D3 Red 24V overload (fuse F1 blown).

D10 Green 12V supply is OK. Loss of 12V power. D11 Green Resolver feedback board voltage

D12 Blue Switch S1 is set to +24V for

D16 Yellow Switch S1 is set to +12V for

D18 Green Switch S1 is set to +5V for

D26 Red Resolver feedback board is in

Light-emitting Diode Color

On State Off State

This fuse is self-resetting when it returns to normal operating temperature.

is OK.

encoder signal output on TB2.

reset mode.

24V supply is OK.

Voltage error on resolver feedback board.

S1 is not

Resolver feedback board not reset mode.

set for +24V.

set for +12V.

set for +5V.

If any of the light-emitting diodes that should turn on when control power is applied fail to do so, verify that the resolver interface and resolver feedback boards are properly seated on the appropriate connectors (XRE, P2, P3). If problems persist, replace the resolver interface and/or resolver feedback board (see page 48

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 35

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Chapter 2 Component Test Procedures

+12V

-12V

0V12

+24V_VI

0V24

+5V

0V5

D26

D11

D10

D18 D16 D12

S1 +5V pos. S1 +12V pos. S1 +24V pos.

S2 Internal supply pos. S2 External supply pos.

+12V

-12V

• Measure the signal voltage at the testpoints as indicated in the following table. See Figure 12

Testpoint to Testpoint Measurement

+12V … 0V12 12V DC ±5%

-12V … 0V12 -12V DC ±5% +24V_VI … 0V24 24V DC ±5% +5V … 0V5 5V DC ±5%

on page 36 for testpoint locations.

If any of the voltage measurements fails, replace the resolver interface board (see page 48

Figure 12 - Resolver Interface Board Testpoint Locations

P3P2

+24V_VI

0V24

D10

0V12

D18D16D12

TB1 TB2

+5V

0V5

D26

D11

+VR

36 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Component Test Procedures Chapter 2

Thermistors and Thermal Switches

Motor overheating is detected by an external, user-supplied thermistor (PTC) or thermal switch connected to terminals 78 and 79 on the control power terminal block on the lower, right corner of the pulse transformer circuit board. See Figure 25

Motor overheating is typically identified by a “Motor Over Temp” fault (F16). See “Fault Descriptions” in Chapter 4 of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 circuit diagram.

• If a thermal switch is used, a 1 kΩ resistor must be placed in series between the switch and either terminal 78 or 79.

• If neither a thermistor (PTC) or a thermal switch is installed, a 1 kΩ resistor must be connected between terminals 78 and 79.

The drive heatsink temperature is monitored by a bimetal thermostat connected directly to the heatsink. When the heatsink temperature is too high, a “Heatsink OvrTemp” fault (F8) occurs. See “Fault Descriptions” in Chapter 4 of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 details. See Figure 22

During normal operation, 1.6V DC is present between terminal 78 and drive common. When an open circuit exists between terminals 78 and 79, 24V DC will be present at terminal 78 to drive common. If the 24V is missing, the pulse transformer board may need replacement.

on page 114 for terminal block location.

for details. See Figure 21 on page 109 for a

for

on page 111 for a circuit diagram.

Relay Outputs

Terminals 35 and 36 and 75 and 76 are N.O. relay outputs. The relay output between terminals 35 and 36 is configured with parameter 1392 [Relay Out 1 Sel]. The relay output between terminals 75 and 76 is configured with parameter 629 [Relay Out 2 Sel]. See “Using Contactors” in Chapter 1 of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 information.

The “Main Contactor” fault (F10) indicates a problems related to a contactor used with the drive. See “Fault Descriptions” in Chapter 4 of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001

for details.

, for more

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 37

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Chapter 2 Component Test Procedures

Create a Fault Report

A Technical Support wizard is available in the DriveExecutive and Connected Components Workbench software application. The wizard gathers information about the hardware, firmware, non-default parameters, and the fault and alarm queues, including time stamps. The logged data can be saved as a text (.txt) file.

Complete fault reports are critical for analysis and repair of modules returned to the factory. At a minimum, perform and record the following:

• Record the contents of the fault queue (faults and times of occurrence). See the PowerFlex Digital DC Drive User Manual, publication

20P-UM001

, for detailed Fault and Alarm codes and descriptions.

• Make a record of any burn marks on the printed circuit boards, cabling, bus bars, and SCR modules.

• Make a record of any liquid and condensation marks on the printed circuit boards, components and mechanical parts.

• Make a record of the amount of dust and other additional particles on the drive and drive components.

• Make a record of any mechanical damage to the drive and drive components.

• Record the size and type of main fuses.

• Record any other important marks and damage.

What You Need When You Call Tech Support

When you contact Technical Support, please be prepared to provide the following information:

• Order number

• Product catalog number and drives series number (if applicable)

• Product serial number

• Firmware revision level

• Most recent fault code

• Your application

You can use the table below to record the data provided in each PowerFlex DC drive parameter listed.

Param( s) Name Description Parameter Data

1349 Status1 at Fault Captures and displays Par 381 [Drive Status 1] bit pattern at the time

1350 Status2 at Fault Captures and displays Par 382 [Drive Status 2] bit pattern at the time

1351…1360 Fault x Code A code that represents the fault that tripped the drive. The codes will

1361…1370 Fault x Time The time between initial drive power up and the occurrence of the

1371 Fault Arm Amps Captures and displays the armature current (as a percentage of rated

1372 Fault Speed Captures and displays the output speed (rpm) of the drive at the ti me

1373 Fault Field Amps Captures and displays the field current (as a percentage of rated

1374 Fault Voltage Captures and displays the armature voltage at the time of the last

of the last fault.

appear in these parameters in the order they occur (for example, [Fault 1 Code] = the most recent fault).

associated trip fault.

current) at the time of the last fault.

of the last fault.

current) at the time of the last fault.

fault.

38 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Page 39

Part Replacement Procedures

Top ic Pa ge

Remove Power from the Drive 42

DPI / HIM Assembly Replacement 42

Protective Cover Replacement 43

Communication Adapter and Electromagnetic Interference Shield Replacement 46

Resolver Feedback and Interface Circuit Board Replacement 48

I/O Expansion Circuit Board Replacement 52

115V AC to 24V DC I/O Converter Circuit Board Replacement 54

Control Circuit Board Replacement 55

Control Electromagnetic Interference Shield Removal and Closure 58

Switching Power Supply Board Fuse Replacement 60

Pulse Transformer Circuit Board Fuse Replacement 62

Pulse Transformer and Switching Power Supply Circuit Boards Replacement 62

Field Circuit Fuses Replacement 74

Field Circuit Board Replacement 75

Field SCR and Dual Diode Modules Replacement 77

AC Line Snubber Circuit Board and Resistors Replacement 78

SCR Modules Replacement 80

AC Current Transducers Replacement 90

Bimetal Thermostats Replacement 94

Cooling Fan Replacement 99

Chapter 3

This chapter provides a list of spare parts and detailed procedures for removing and replacing drive components.

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Chapter 3 Part Replacement Procedures

Replacement Parts Kits

Ta b l e 1 2 lists the spare parts kits available for PowerFlex DC frame B drives.

Table 12 - Spare Part Kits

Description Kit Cat. No. Instructions

Fuses/Fuse Holders

Switching Power Supply Board (Revision H and Lower only) Fuse Ferrule 5 x 20 mm, 3.15 A 250V (SW2-32)

Switching Power Supply Board Fuse - Ferrule 5 x 20 mm, 2.5 A 250V

(2)

(SW2-32)

Switching Power Supply Board Fuse Holder SK-20P-S7G84 60

Pulse Transformer Board (FIR1) Fuses (Qty 3) - Ferrule 6 x 32 mm, 16 A 500V

Field Circuit Fuses (Qty 2) - Ferrule 10 x 38 mm, 25 A 600V SK-20P-S823B 74

Field Circuit Fuse Holder SK-20P-S8N29 74

Accessori es

DPI / HIM Assembly SK-DC1-CVR1-A1 42

Control Circuit Boards

Resolver Feedback and Interface Boards 20P-RES-A0 48

I/O Expansion Board (TBO-32) 20P-S5V62 52

115V AC to 24V DC I/O Converter Board 20P-S520L 54

Control Circuit Board SK-20P-S5RP1 55

Power Circuit Boards

Pulse Transformer Board for 230V AC Regen. Drives, 146…434 A (FIR2-41)

Pulse Transformer Board for 460/480V AC Regen. Drives, 167…412 A (FIR2-51)

Pulse Transformer Board for 575V AC Regen. Drives, 67…405 A (FIR2-

61)

Switching Power Supply Board (SW2-32) SK-20P-S5N10 62

Field Board (PFC2A-31) SK-20P-S5N25 75

AC Line Snubber Board for 230V AC Regen. Drive (SN4-31) SK-20P-S5N13 78

AC Line Snubber Board for 460/480V AC Regen. Drive (SN5-31) SK-20P-S5N14

AC Line Snubber Board 0.22 μF for 575V AC Regen. Drive (SN7-32) SK-20P-S5N425

AC Line Snubber Board 0.33 μF for 575V AC Regen. Drive (SN7-32) SK-20P-S5N428

Power Components

AC Current Transducers (Qty 2), 600 A / 0.2 A SK-20P-S777H 90

Field Dual Diode Module, 1K6V, 40 A SK-20P-S799F 77

Field SCR Module, 1K6V, 25 A SK-20P-S7F73

Bimetal Thermostat, 80 °C ± 3 (Qty 2), 230V Regen. Drives, 360 and 434 A, 460/480V Regen. Drives, 330 and 412, or 575V Regen. Drive, 405 A

Bimetal Thermostat, 85 °C ±3 (Qty 2), 230V Regen. Drives, 146…265 A, 460/480V Regen. Drives, 167…250 A, or 575V Regen. Drives, 67…270 A

(1)

SK-20P-S7169 60

SK-20P-S8B29

SK-20P-S824B 62

SK-20P-S5N08 62

SK-20P-S5N18

SK-20P-S5N421

SK-20P-S7G29 94

SK-20P-S7G33

Page

40 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

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Table 12 - Spare Part Kits (Continued)

Part Replacement Procedures Chapter 3

Description Kit Cat. No. Instructions

Page

SCR Modules (Qty 6) 1K2V 130 A, 230V AC Regen. Drives, 146 and

SK-20P-S7F48 80

180 A

SCR Modules (Qty 6) 1K2V 160 A, 230V AC Regen. Drive, 218 A SK-20P-S7F49

SCR Modules (Qty 6) 1K2V 210 A, 230V AC Regen. Drive, 265 A SK-20P-S7F42

SCR Modules (Qty 6) 1K2V 320 A, 230V AC Regen. Drives, 360 and

SK-20P-S727F

434 A

SCR Modules (Qty 6) 1K6V 210 A, 460/480V AC Regen. Drive, 250 A SK-20P-S7F41

SCR Modules (Qty 3) 1K6V 210 A, 460/480V AC Non-Regen. Drive, 250 A

SCR Modules (Qty 6) 1K6V 160 A, 460/480V AC Regen. Drive, 207 A SK-20P-S7F79

SCR Modules (Qty 3) 1K6V 160 A, 460/480V AC Non-Regen. Drive, 207 A

SCR Modules (Qty 6) 1K2V 130 A, 460/480V AC Regen. Drive, 167A SK-20P-S7F78

SCR Modules (Qty 3) 1K2V 130 A, 460/480V AC Non-Regen. Drive, 167A

SCR Modules (Qty 6) 1K6V 320 A, 460/480V AC Regen. Drives, 330 and

SK-20P-S737F

412 A

SCR Modules (Qty 3) 1K6V 320 A, 460/480V AC Non-Regen. Drives, 330 and 412 A

SCR Modules (Qty 6) 1K8V 130 A, 575V AC Regen. Drives, 67…135 A SK-20P-S79F7

SCR Modules (Qty 3) 1K8V 130 A, 575V AC Non-Regen. Drives, 67…135 A

SCR Modules (Qty 6) 1K8V 250 A, 575V AC Regen. Drive, 270 A SK-20P-S8HI6

SCR Modules (Qty 3) 1K8V 250 A, 575V AC Non-Regen. Drive, 270 A

SCR Modules (Qty 6) 1K8V 320 A, 575V AC Regen. Drive, 405 A SK-20P-S79F9

SCR Modules (Qty 3) 1K8V 320 A, 575V AC Non-Regen. Drive, 405 A

Ventilation Comp onents

Cooling Fans, (Qty 2) 24V DC, 100 CFM,

SK-20P-S7G71 99 230V AC Drives, 146…265 A, 460/480V AC Drives, 167…250 A, or 575V AC Drives, 67…270 A

Cooling Fans, (Qty 2) 150 x 55 mm, 24V DC, 212 CFM,

SK-20P-S7G78 230V AC Drives, 360 and 434 A 460/480V AC Drives, 320 and 412 A 575V AC Drives, 405 A

(1) This kit contains one fuse only. Order 1 kit for switching power supply circuit boards, revision “H” and lower. (2) This kit contains one fuse only. Order 1 kit for switching power supply circuit boards, revision “H” and lower. Order 2 kits for

switching power supply circuit boards, revision “I” and higher.

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Chapter 3 Part Replacement Procedures

L1 L2 L3

Remove Power from the Drive

ATTENTION: Remove power before making or breaking cable connections.

When you remove or insert a cable connector with power applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by:

• sending an erroneous signal to your system’s field devices, causing unintended machine motion

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance.

Remove and lock-out all incoming power to the drive.

DPI / HIM Assembly Replacement

Remove the DPI / HIM Assembly

Follow these steps to remove the device peripheral interface (DPI) / human interface module (HIM) assembly.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

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Part Replacement Procedures Chapter 3

Tightening torque:

0.8 N

•m (7 lb•in)

3. Disconnect the DPI cable from the HIM assembly.

4. Remove the screw that secures the DPI / HIM assembly to the drive.

5. Carefully remove the DPI / HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly.

Protective Cover Replacement

Install the DPI / HIM Assembly

Install the DPI / HIM assembly in reverse order of removal.

Remove the Protective Covers

Follow these steps to remove the protective covers.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

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Chapter 3 Part Replacement Procedures

Tightening torque:

1.5 N

•m (13.3 lb•in)

Tightening torque:

1.5 N

•m (13.3 lb•in)

Tightening torque:

1.5 N

•m (13.3 lb•in)

3. Disconnect the DPI cable from the HIM assembly.

4. Loosen, but do not remove, the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis.

5. Loosen, but do not remove, the screws that secure the top cover to the drive, then slide the cover up and off the drive chassis.

IMPORTANT The HIM assembly is connected via a cable to the Control board and

therefore will not pull free from the drive until disconnected.

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Part Replacement Procedures Chapter 3

6. Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside.

Install the Protective Covers

Install the protective covers in the reverse order of removal.

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Chapter 3 Part Replacement Procedures

Tightening torque:

0.9 N

•m (8.0 lb•in)

Communication Adapter and Electromagnetic Interference Shield Replacement

Remove the Communication Adapter and Electromagnetic Interference Shield

Follow these steps to remove the communication adapter and electromagnetic interference (EMI) shield.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

4. Disconnect the interface cable from the communication adapter and set it aside.

5. Disconnect any network cables from the adapter and set them aside.

6. Remove the four screws that secure the communication adapter to the electromagnetic interference (EMI) shield and remove the adapter.

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Part Replacement Procedures Chapter 3

Tightening torque:

1.0 N

•m (8.9 lb•in)

Tightening torque:

1.0 N

•m (8.9 lb•in)

7. Remove the three screws that secure the EMI shield to the standoffs on the control board and remove the EMI shield.

8. Remove the three standoffs from the control board.

Install the Communication Adapter and EMI Shield

Install the communication adapter and EMI shield in reverse order of removal.

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Chapter 3 Part Replacement Procedures

S15

XP3

P2 P3

XRE

TB1 TB2

P2 P3

Resolver feedback board

Resolver Feedback and Interface Circuit Board Replacement

Remove the Resolver Feedback and Interface Circuit Boards

Follow these steps to remove the resolver feedback and interface circuit boards.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

4. Disconnect the plug-in terminal blocks from the resolver feedback and resolver interface boards.

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Part Replacement Procedures Chapter 3

S15

XP3

XRE

XFCD

S21

J1 J2

TB1 TB2

P2 P3

Tightening torque for reassembly is

0.7 N•m (6.2 lb•in)

5. Remove the three hexalobular screws that secure the resolver feedback board to the stand-offs on the resolver interface board and carefully remove the resolver feedback board.

IMPORTANT The resolver feedback board is connected to the resolver interface

board below it via stacker connector pins at connectors P2 and P3. Lift the resolver feedback board straight up during removal to avoid any damage to the connector pins.

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Chapter 3 Part Replacement Procedures

Tightening torque for reassembly is

0.7 N•m (6.2 lb•in)

Resolver interface board

6. Remove the three stand-offs from the resolver interface board.

P2 P3

XRE

XFCD

XP3

S15

TB1 TB2

S21

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Part Replacement Procedures Chapter 3

Tightening torque for reassembly is

0.7 N•m (6.2 lb•in)

7. Remove the four hexalobular screws that secure the resolver interface board to the control board and remove the resolver interface board.

IMPORTANT The resolver interface board is connected to the control board below

it via a stacker connector pin at connector XRE. Lift the resolver interface board straight up during removal to avoid any damage to the connector pin.

XP3

P2 P3

S15

XRE

XFCD

S21

TB1 TB2

Install the Resolver Feedback and Interface Circuit Boards

Install the resolver feedback and interface boards in reverse order of removal.

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Chapter 3 Part Replacement Procedures

Tightening torque:

1.0 N•m (8.9 lb•in)

I/O Expansion Circuit Board Replacement

Remove the I/O Expansion Circuit Board

Follow these steps to remove the I/O expansion circuit board.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

4. If installed, remove the resolver feedback option board (see page 48

5. Remove the plug-in I/O terminal blocks with the wiring kept in place.

6. Remove the two M3 x 6 mm screws and washers that secure the I/O expansion board to the stand-offs on the control board.

7. Carefully pull the I/O expansion board off connector XBB on the control board.

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Part Replacement Procedures Chapter 3

Tightening torque:

1.0 N•m (8.9 lb•in)

Tightening torque:

1.0 N•m (8.9 lb•in)

8. Remove the two stand-offs from the control board.

9. Install one screw in the lower left corner of the control board.

Install the I/O Expansion Circuit Board

Install the I/O expansion board in reverse order of removal.

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Chapter 3 Part Replacement Procedures

Tightening torque:

1.0 N•m (8.9 lb•in)

115V AC to 24V DC I/O Converter Circuit Board Replacement

Remove the 115V AC to 24V DC I/O Converter Circuit Board

Follow these steps to remove 115V AC to 24V DC I/O converter circuit board.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

4. Remove the plug-in I/O terminal blocks with the wiring kept in place.

5. Remove the two M3 x 6 mm screws and washers that secure the I/O converter board to the stand-offs on the control board and remove the I/O converter board.

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Part Replacement Procedures Chapter 3

Tightening torque:

1.0 N•m (8.9 lb•in)

6. Remove the two stand-offs from the control board.

Control Circuit Board Replacement

Install the 115V AC to 24V DC I/O Converter Circuit Board

Install the 115V AC to 24V DC I/O converter board in reverse order of removal.

Remove the Control Circuit Board

Follow these steps to remove the control circuit board.

1. Read the General Safety Precautions on page 10

2. Save the drive and adapter parameter configuration to a HIM Set or by down loading the drive and adapter parameters to an offline database file using DriveExecutive™. See to the PowerFlex DC Digital Drive User Manual, publication 20P-UM001 the on-line Help provided with DriveExecutive for more information on HIM Sets or using the HIM.

3. Remove power from the drive (see page 42

4. Remove the protective covers from the drive (see page 43

5. Remove the communication adapter and EMI shield from the control board (see page 46

, for information on using the HIM or

6. If installed, remove the resolver feedback option board (see page 48

7. If installed, remove the I/O expansion circuit board (see page 52

8. If installed, remove the 115V AC to 24V DC I/O converter circuit board (see page 54

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Chapter 3 Part Replacement Procedures

9. Record all switch and jumper settings on the control board. See the PowerFlex DC Digital Drive User Manual, publication 20P-UM001 for more information.

Jumper /Switch

S4 Configures the input voltage of the DC analog tachometer.

S9 Configures the input signal of analog input 1 (terminals 1 and 2):

S10 Configures the input signal of analog input 2 (terminal 3 and 4):

S11 Configures the input signal of analog input 3 (terminals 5 and 6):

S14 Field current resistors settings.

S15 Configures the control circuit board to the appropriate drive size. S15-1 =

S20 Monitoring (reported by Par 652 [Encoder Err Chk]) of the Z channel of the

S21 Encoder power supply voltage and input adaptation selection:

Function Setting

Par 71 [Anlg In1 Config] must be programmed to match the input signal type selected with this switch.

Par 76 [Anlg In2 Config] must be programmed to match the input signal type selected with this switch.

Par 81 [Anlg In3 Config] must be programmed to match the input signal type selected with this switch.

S14-1 =

The value that is selected with switch S14 must be entered in Par 374 [Drv Fld Brdg Cur] when the drive is commissioned.

Digital Encoder on connector XE2.

Off Position Z-channel monitored

On Position Z-channel not mo nitored

This switch setting determines both the power supply (input) and feedback level (output) voltage of the connected encoder.

Note: When control power is supplied to the drive, the appropriate lightemitting diode lights to indicate the selection of the switch.

ENC_5 +5V encoder (+2.5…5.4V input range)

ENC_12 +12…15V encoder (+5.4V…15.2V input range)

S14-2 = S14-3 = S14-4 = S14-5 = S14-6 = S14-7 = (not used) S14-8 = (not used)

S15-2 = S15-3 = S15-4 = S15-5 = S15-6 = S15-7 = S15-8 =

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

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Part Replacement Procedures Chapter 3

10. Carefully disconnect the cables from connectors XFCD, XA and XR on the control board.

11. Remove the plug-in I/O and control terminal blocks with the wiring kept in place.

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Chapter 3 Part Replacement Procedures

Tightening torque:

1.0 N•m (8.9 lb•in)

12. Remove the five screws that secure the control board to the control EMI shield and remove the board.

Control Electromagnetic Interference Shield Removal and Closure

Install the Control Circuit Board

Install the control board in reverse order of removal.

• Verify that all DIP switches are set to the correct configuration based on your recorded settings.

Move the Control Electromagnetic Interference Shield

You must move (lower) the control electromagnetic interference (EMI) shield that holds the control board in order to access other components within the drive. Follow these steps to remove the control electromagnetic interference (EMI) shield.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

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Part Replacement Procedures Chapter 3

4. Carefully disconnect the cables from connectors XA, XR and XFCD on the control board.

5. Loosen the two captive screws at the top of the control EMI shield and lower shield.

IMPORTANT If the drive is not in a vertical position, the control EMI shield will

not remain open without a means of restraint.

Close the Control EMI Shield in the Service Position

Close the control EMI shield in reverse order.

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Chapter 3 Part Replacement Procedures

Top View of drive

Front of drive

Switching Power Supply Board Fuse Replacement

Remove the Fuses on the Switching Power Supply Circuit Board

Follow these steps to remove the switching power supply circuit board.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. At the top of the drive, remove the two fuses by inserting a screwdriver in the slot on the top of the fuse holder, carefully pushing down and turning the fuse counterclockwise. When the fuse holder releases, remove the holder and fuse.

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Part Replacement Procedures Chapter 3

Top View of drive

Front of drive

F1 = 3.15A 250V fuse

F2 = 2.5A 250V fuse

Install the Fuses on the Switching Power Supply Circuit Board

Install the fuses identified in this table on the switching power supply board in reverse order of removal.

Circuit Board ID / Revision Fuse Designation Fuse (5 x 20 mm)

SW2-32 / H and below F1 3.15 A, 250V fast

F2 2.5 A, 250V slow

SW2-32 / I and above F1 2.5 A, 250V slow

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Chapter 3 Part Replacement Procedures

Pulse Transformer Circuit Board Fuse Replacement

Remove the Fuses on the Pulse Transformer Circuit Board

Follow these steps to remove the fuses on the pulse transformer circuit board.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

4. Move the control EMI shield (see page 58

5. Using a fuse puller, carefully remove the three fuses from the fuse holders on the pulse transformer board.

Pulse Transformer and Switching Power Supply Circuit Boards Replacement

Install the Fuses on the Pulse Transformer Circuit Board

Install the fuses on the pulse transformer circuit board in reverse order of removal.

Remove the Pulse Transformer and Switching Power Supply Circuit Boards

Note: The switching power supply circuit board is located on the back of the pulse transformer circuit board. You must remove both boards in order to replace either board. Follow these steps to remove the pulse transformer and switching power supply circuit boards.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

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Part Replacement Procedures Chapter 3

Air flow plate

Front of drive

4. Remove the plug-in terminal from the field input block at the top of the drive.

5. Remove the four screws that secure the slotted air flow plate to the top of the drive chassis.

IMPORTANT The air flow plate is also secured to the pulse transformer circuit

board and therefore cannot yet be removed. Instructions for doing so are included later in this procedure.

6. Remove the cable from connector XTA at the bottom of the pulse transformer board.

7. Remove the plug-in terminals from the control power block at the bottom of the pulse transformer board.

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Chapter 3 Part Replacement Procedures

XCD_IO

XTA

78 79 35 36 75 76 U2 V2

S3 S4

Fuse conne ctions

8. For Pulse Transformer boards with an armature voltage feedback terminal block, FIR2-XX, rev. “N” and higher, remove the connector from XCD_IO on the lower left corner of the board.

9. Move the control EMI shield (see page 58

10. Remove the two screws that secure the air flow plate to the top of the pulse transformer board and lift the plate off the drive chassis. Note that the air flow plate cannot be completely removed due to the fuse connections at FU1 and FV1.

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Part Replacement Procedures Chapter 3

Front of drive

Switching power supply board

Pulse transformer board

11. Remove the cable from connector XV on the switching power supply board.

12. Remove the cables from connectors X3, X4, and XP on the pulse transformer board.

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Chapter 3 Part Replacement Procedures

13. Remove the ground connection at the left side of the pulse transformer board.

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Part Replacement Procedures Chapter 3

14 ( regenerative drives)

14 (non-regenerative drives)

14. Remove the appropriate gate leads:

• For non-regenerative drives, remove each pair of (orange and yellow)

gate lead cables from connectors KG01…KG06 and push each lead through the appropriate opening in the board.

• For regenerative drive, remove each pair of (orange and yellow) gate

lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board.

IMPORTANT Carefully remove the gate leads by grasping the connector. DO NOT

pull the gate leads off by pulling on the wires.

15. Remove the seven screws that secure the board to the stand-offs on the drive chassis and remove the boards from the drive.

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Chapter 3 Part Replacement Procedures

Note: Regenerative drive shown.

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Part Replacement Procedures Chapter 3

16. Remove the cable from connector XUV on the switching power supply board.

17. Remove the six screws and washers that secure the switching power supply board to the stand-offs on the back of the pulse transformer board and remove the switching power supply board.

Configure the Pulse Transformer Circuit Board

The steps required to configure the pulse transformer board are different based on the revision code of the pulse transformer board. See one of these procedures:

• Configure a Pulse Transformer Board FIR2-xx Rev. “M” and Lower on page 69

• Configure a Pulse Transformer Board FIR2-xx Rev. “N” and Higher on page 72

Configure a Pulse Transformer Board FIR2-xx Rev. “M” and Lower

IMPORTANT This procedure requires a multimeter that measures resistance to

thousandths of an ohm.

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Chapter 3 Part Replacement Procedures

XSW

TR2 TR1

0V1

T04T01

T05T02

T06T03

T2 T5

T3 T6

K G

KG04

K G

KG01

K G

KG05

K G

KG02

K G

KG06

K G

KG03

K G

KG4

K G

KG1

K G

KG5

K G

KG2

K G

KG6

K G

KG3

XTA

7879 3536 7576 U2V2

UCVW

Sizing resistors are located near the center of the pulse transformer circuit board.

1. Cut and remove the appropriate sizing resistor(s) (if necessary) from the pulse transformer board based on the drive size. See Ta b l e 1 3

or Ta b l e 1 4

for the appropriate configuration.

Sizing Resistor Configuration

Ta b l e 1 3 and Ta b l e 1 4 indicate the value of the designated resistor (R1 - R5)

when left in place on the pulse transformer board, or indicate “Remove” when the resistor should be cut off and removed from the board. “–” indicates that this resistor is not contained on the pulse transformer board for the designated drive size.

Table 13 - 230V AC Input Drives

Drive Current Rating Code

146 146 119 40 – Remove Remove 5.36 Ω Remove 180 180 147 50 – Remove Remove 5.36 Ω Remove 218 218 178 60 – Remove Remove 5.36 Ω Remove 265 265 217 75 – Remove Remove 5.36 Ω 5.36 Ω 360 360 294 100 – Remove 5.36 Ω 5.36 Ω 5.36 Ω 434 434 355 125 – Remove 5.36 Ω 5.36 Ω 5.36 Ω

Table 14 - 460V AC Input Drives

Drive Current Rating Code

167 167 136.4 100 – Remove 5.36 Ω Remove Remove 207 207 169.1 125 – Remove Remove 5.36 Ω Remove 250 250 204.3 150 – Remove Remove 5.36 Ω 5.36 Ω 330 330 269.6 200 – Remove 5.36 Ω 5.36 Ω 5.36 Ω 412 412 336.6 250 – Remove 5.36 Ω 5.36 Ω 5.36 Ω

2. Connect the leads of the multimeter to pins 13 and 14 of connector XR

DC Amps

AC Line Amps

Hp R1 R2 R3 R4 R5

on the pulse transformer board (polarity is not important) and, using the TA potentiometer on the lower right corner of the pulse transformer circuit board, set the total resistance (RTA) to the appropriate value as indicated in Ta b l e 1 5 on page 72

or Ta b l e 1 6 in the Total Resistance Values section

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XSW

TR2 TR1

0V1

T04T01

T05T02

T06T03

T2 T5

T3 T6

K G

KG04

K G

KG01

K G

KG05

K G

KG02

K G

KG06

K G

KG03

K G

KG4

K G

KG1

K G

KG5

K G

KG2

K G

KG6

K G

KG3

XTA

7879 3536 7576 U2V2

UCVW

1 . . . . . . . . . . . . . .13 . . . . . . . . . . . . . . . . . . . . 33

2 . . . . . . . . . . . . . 1 4 . . . . . . . . . . . . . . . . . . . 3 4

The XR connector is located near the upper right corner of the pulse transformer circuit board.

The TA potentiometer is loc ated on the lower right corner of the pulse transformer circuit board next to the control power terminal block.

Part Replacement Procedures Chapter 3

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Chapter 3 Part Replacement Procedures

Dip switches S3 and S4 are located at the bottom, right corner of the board.

Total Resistance Values

Table 15 - 230V AC Input Drives

Drive Current Rating Code

DC Amps

AC Line Amps

Hp Set RTA Value Using TA

Potentiometer (Ohms)

146 146 119 40 12.575 180 180 147 50 10.2 218 218 178 60 8.422 265 265 217 75 6.928 360 360 294 100 5.1 434 434 355 125 4.23

Table 16 - 460V AC Input Drives

Drive Current Rating Code

167 167 136.4 100 10.994 207 207 169.1 125 8.87 250 250 204.3 150 7.344 330 330 269.6 200 5.564 412 412 336.6 250 4.456

DC Amps

AC Line Amps

Hp Set RTA Value Using TA

Potentiometer (Ohms)

3. Seal the TA potentiometer in place using RV (silicon).

4. Continue with Install the Pulse Transformer and Switching Power Supply Boards on page 74

Configure a Pulse Transformer Board FIR2-xx Rev. “N” and Higher

Set DIP switches S3 and S4, located at the bottom right corner of the pulse transformer board (shown below), to the correct settings based on the appropriate table below.

TR2 TR1

KG3

78 79 35 36 75 76 U2 V2

XI2CA

TO3

KGO3

KGO6

TO6

KG6

1V2

1U2

S3 S4

79 35 36 75 76 U2 V2

S3 S4

XSW1

TO4

KGO4

KGO1

TO1

KG4

KG1

PE1

XCD_IO

TO5

KGO2

KG2

KG5

XCT

KGO5

TO2

XTA

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Part Replacement Procedures Chapter 3

IMPORTANT A blank cell below a switch in Ta bl e 1 7, Ta bl e 1 8 , and Tab le 19 indicates that

the setting is “OFF”.

Table 17 - 230V AC Input Drives

Drive Current Rating Code

146 146 119 40 ON ON ON 180 180 147 50 ON ON ON ON 218 218 178 60 ON ON ON ON 265 265 217 75 ON ON ON ON 360 360 294 100 ON ON ON 434 434 355 125 ON ON ON ON

DC Amps

AC Line

Hp DIP Switch S3 DIP Switch S4

Amps

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

Table 18 - 460V AC Input Drives

Drive Current Rating Code

167 167 136.4 100 ON ON ON ON 207 207 169.1 125 ON ON ON 250 250 204.3 150 ON ON ON ON 330 330 269.6 200 ON ON ON 412 412 336.6 250 ON ON ON ON

DC Amps

AC Line Amps

Hp DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

Table 19 - 575V AC Input Drives

Drive Current Rating Code

67 67 55.1 50 ON ON ON ON 101 101 82.7 75 ON ON ON ON 135 135 110.3 100 ON ON ON ON 270 270 220.6 200 ON ON ON ON 405 405 330.9 300 ON ON ON ON

DC Amps

AC Line Amps

Hp DIP Switch S3 DIP Switch S4

S3-1 S3-2 S3-3 S3-4 S3-5 S3-6 S3-7 S3-8 S4-1 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8

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Chapter 3 Part Replacement Procedures

One plastic stabilizer should be on either side of each boardAir flow plate

Plastic stabilizers

Top view of pulse transformer boardSide cut-away vi ew

pulse transformer board

switching power supply board

Install the Pulse Transformer and Switching Power Supply Boards

Install the new pulse transformer board in reverse order of removal.

ATTENTION: Each gate lead cable must be connected to the exact connector from which it was removed on the pulse transformer circuit board or damage to the drive may occur.

• Verify that the four plastic board stabilizers mounted on the top air flow plate are placed one on either side of each board.

Field Circuit Fuses

Remove the Field Circuit Fuses

Replacement

Follow these steps to remove the field circuit fuses.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

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Part Replacement Procedures Chapter 3

Front of Drive

Top view of D rive

3. On the top of the drive, unscrew the fuse holders and remove the fuses from the holders.

Field Circuit Board Replacement

Install the Field Circuit Fuses

Install the field circuit fuses in the reverse order of removal.

Remove the Field Circuit Board

Follow these steps to remove field circuit board.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

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Chapter 3 Part Replacement Procedures

4. Remove the pulse transformer and switching power supply boards from the drive (see page 62

). You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure.

5. Remove the wires from connectors UF, UF1, VF, and VF1.

6. Remove the six screws and washers that secure the field board to the field SCR and dual diode modules and remove the field board.

Install the Field Circuit Board

Install the field board in reverse order of removal.

• Inspect the existing X3 and XFCD cables for burn marks, cracks or loose connectors. If necessary, replace the cables on the field board with

76 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

the new cables provided.

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Part Replacement Procedures Chapter 3

Field SCR and Dual Diode Modules Replacement

Remove the Field SCR and Dual Diode Modules

It is recommended that you replace both modules at the same time. Follow these steps to remove field SCR and dual diode modules.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

4. Remove the pulse transformer and switching power supply boards from the drive (see page 62 supply board from the back of the pulse transformer board for this procedure.

5. Remove the field circuit board (see page 75

6. Remove the two screws and washers that secure each module to the heatsink and remove the modules from the drive.

). You do not need to remove the switching power

Install the Field SCR and Dual Diode Modules

Install the field SCR and dual diode modules in reverse order of removal.

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Chapter 3 Part Replacement Procedures

• Apply thermal grease to the bottom of the SCR and dual diode modules before securing it to the heatsink.

ATTENTION: Thermal grease must be applied to the bottom of the SCR and dual diode modules before securing them to the heatsink or damage to the drive may occur.

• Tightening torque for the screws connecting the SCR and dual diode modules to the heatsink and the screws connecting the field circuit board to the SCR and dual diode modules is 2.5…4.0 N (22…35 lb

•in).

•m

AC Line Snubber Circuit Board and Resistors Replacement

Remove the AC Line Snubber Circuit Board and Resistors

Follow these steps to remove the AC line snubber circuit board and resistors.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

4. Remove the pulse transformer and switching power supply boards from the drive (see page 62 supply board from the back of the pulse transformer board for this procedure.

5. Remove the field circuit board (see page 75

6. Remove the two screws and washers that secure the (red and blue) wires from the AC line snubber board to the bus bars and remove the wires.

). You do not need to remove the switching power

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Part Replacement Procedures Chapter 3

6 and 7

Regenerative Drive Shown

7. Remove the three screws and washers that secure the (black) wires from the resistors to the bus bars and remove the wires.

8. Remove the three screws and washers that secure the AC line snubber board to the drive frame and lift the board. Note: The wires from the resistors are connected to the board. Therefore, the board cannot be removed until the resistors are removed.

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Chapter 3 Part Replacement Procedures

9. Remove the two screws that secure each resistor (six total) to the drive heatsink and remove the resistors and AC line snubber board from the drive.

SCR Modules Replacement

Install the AC Line Snubber Circuit Board and Resistors

Install the AC line snubber board and resistors in reverse order of removal.

IMPORTANT Thermal grease must be applied to the bottom of the resistors before

securing them to the heatsink.

Remove the SCR Modules

Follow these steps to remove SCR modules.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields.

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Part Replacement Procedures Chapter 3

U Phase V Phase

Bottom View of Drive

W Phase

4. Remove the bolts, washers and wiring from the power terminals (U, V, W, C , a nd D) .

5. Remove the protective covers from the drive (see page 43

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

6. Remove the pulse transformer and switching power supply boards from the drive (see page 62

). You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure.

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Chapter 3 Part Replacement Procedures

Bolt

Lock washer

Flat washer

Note proper order of washers for installation.

Regenerative Drive

7. Remove the bus bars in order to access the SCR modules in the drive:

• For a regenerative drive, see Remove the Bus Bars from a

Regenerative Drive on page 82

• For a non-regenerative drive, see Remove the Bus Bars from a Non-

Regenerative Drive on page 85

Remove the Bus Bars from a Regenerative Drive

8. Remove the two screws or bolts and washers that secure the (red and blue) wires from the AC line snubber board to the terminal bus bars (C and D) and remove the wires.

9. Remove the three bolts and washers that secure the (black) wires from the resistors to the terminal bus bars (U, V, and W) and remove the wires.

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Part Replacement Procedures Chapter 3

Regenerative Drive

10. Remove the three remaining bolts and washers that secure the AC input bus bars (U, V, and W phases) to the anode of the SCR modules and remove the bus bars.

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Chapter 3 Part Replacement Procedures

11Regenerative Drive

Regenerative Drive

11. Remove the three pairs of upper gate leads from the SCR modules.

12. Remove the bolts and washers that secure the DC bus bars to the SCRs and remove the bus bars.

13. Remove the four bolts and washers and stand-off that secure the power terminal bus bars to the isolation bar and slide the bus bars up and out of the drive.

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Part Replacement Procedures Chapter 3

Regenerative Drive

Non-Regenerative Drive

14. Remove the two screws and washers that secure each SCR module to the heatsink and remove the SCR module.

Continue with Install the SCR Modules on page 88

Remove the Bus Bars from a Non-Regenerative Drive

15. Remove the bolts and washers and stand-off and washer that secure the power terminal bus bars to the isolation bar.

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Chapter 3 Part Replacement Procedures

Bolt

Lock washer

Flat washer

Note proper order of washers for installation.

Non-Regenerative Drive

16. Remove the bolts and washers that secure the C and D terminal bus bars to the horizontal bus bars.

17. Remove the bolts and washers that secure the upper horizontal bus bar to the SCR modules and remove the bus bars.

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Part Replacement Procedures Chapter 3

Non-Regenerative Drive

18. Remove the bolts and washers that secure the lower horizontal bus bar to the SCR modules and remove the bus bar.

19. Remove the bolts, washers and wires that secure the U, V and W phase power terminals to the SCR modules.

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Chapter 3 Part Replacement Procedures

Non-Regenerative Drive

20. Remove the screws and washers that secure each SCR module to the heatsink and remove the SCR module from the drive.

Install the SCR Modules

Install the SCR modules in reverse order of removal.

IMPORTANT Thermal grease must be applied to the bottom of each SCR module before

securing it to the heatsink.

• Use the following table to determine the proper tightening torque for the SCR modules installed on the heatsink.

230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque

SK-20P-S7F48 2.5…4.0 N SK-20P-S7F49 4.5…5.5 N SK-20P-S7F42 4.5…5.5 N SK-20P-S727F 4.5…5.5 N

•m (22…35.4 lb•in) SK-20P-S7F78 2.5…4.0 N•m (22…35.4 lb•in)

•m (40…48.7 lb•in) SK-20P-S7F79 4.5…5.5 N•m (40…48.7 lb•in)

•m (40…48.7 lb•in) SK-20P-S7F41 4.5…5.5 N•m (40…48.7 lb•in)

•m (40…48.7 lb•in) SK-20P-S737F 4.5…5.5 N•m (40…48.7 lb•in)

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Part Replacement Procedures Chapter 3

Gate leads at top

Gate leads at bottom

This SCR module only present in regenerative drives.

Intermediate bus bar

Phase U, V, or W bus bar

SCR module on heatsink

Top of Dr ive

Long le g

Short leg

• Use the following orientation for installing the SCR modules:

• Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules:

230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque

SK-20P-S7F48 4.5…5.5 N SK-20P-S7F49 4.5…5.5 N SK-20P-S7F42 11…13 N SK-20P-S727F 11…13 N

•m (40…48.7 lb•in) SK-20P-S7F78 4.5…5.5 N•m (40…48.7 lb•in)

•m (40…48.7 lb•in) SK-20P-S7F79 4.5…5.5 N•m (40…48.7 lb•in)

•m (97.4…115 lb•in) SK-20P-S7F41 11…13 N•m (97.4…115 lb•in

•m (97.4…115 lb•in) SK-20P-S737F 11…13 N•m (97.4…115 lb•in)

• For regenerative drives, the longer leg of the intermediate AC input bus bars connect to the top of the SCR modules:

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Chapter 3 Part Replacement Procedures

24 mm bolt locations

Regenerative Drive Shown

U Phase V Phase

Bottom View

• For regenerative drives, five of the bolts are 24 mm long and the rest are 20 mm long. For non-regenerative drives, two of the bolts are 24 mm long and the rest are 20 mm long. Install the 24 mm bolts in the following locations:

AC Current Transducers Replacement

Remove the AC Current Transducers

Follow these steps to remove the AC current transducers.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields.

4. Remove the bolts, washers and wiring from the U and V phase AC input power terminals.

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Part Replacement Procedures Chapter 3

Regenerative Drive Shown

5. Remove the protective covers from the drive (see page 43).

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

6. Remove the pulse transformer and switching power supply boards from the drive (see page 62

). You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure.

7. Remove the bolts and washers that secure the U and V phase AC input bus bars to the isolation bar.

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Chapter 3 Part Replacement Procedures

Connecting bus bar

Regenerative Drive

Non-Regenerative Drive

8. For regenerative drives only, remove the bolts and washers that secure the resistor wires and the connecting bus bars to the U and V Phase SCR modules and remove the wires and bus bars.

9. For non-regenerative drives only, remove the bolts and washers that secure the resistor wires and bus bars to the U and V Phase SCR modules and remove the wires and bus bars.

10. Slide the U and V phase bus bars that pass through the AC current transducers up and out of the drive.

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Part Replacement Procedures Chapter 3

Red wire White wire Blue wire Black wire

11. Remove the screw and washer that secures each of the AC current transducers to the drive frame and remove the AC current transducers.

Install the AC Current Transducers

Install the AC current transducers in reverse order of removal.

• Note the color and location of each of the four wires connected to the AC current transducers to ensure that each wire is properly connected during installation. Use cable ties to bundle wires as shown below.

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Chapter 3 Part Replacement Procedures

U Phase

Bottom View of Drive

D Terminal

• Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules:

230V AC Input Drive Current

Rating Code

146 146 119 40 4.5…5.5 N 180 180 147 50 218 218 178 60 265 265 217 75 11…13 N 360 360 294 100 434 434 355 125

460V AC Input Drive Current

Rating Code

167 167 136.4 100 4.5…5.5 N 207 207 169.1 125 250 250 204.3 150 11…13 N 330 330 269.6 200 412 412 336.6 250

DC Amps AC Line Amps Hp Final Torque

•m (40…48.7 lb•in)

•m (97.4…115 lb•in)

DC Amps AC Line Amps Hp Final Torque

•m (40…48.7 lb•in)

•m (97.4…115 lb•in)

Bimetal Thermostats Replacement

Remove the Bimetal Thermostats

Follow these steps to remove the bimetal thermostats.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

3. Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields.

4. Remove the bolts, washers and wiring from the U phase AC input power terminal and the D power terminal.

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Part Replacement Procedures Chapter 3

5. Remove the protective covers from the drive (see page 43).

IMPORTANT Mark all connections and wires before removal to avoid incorrect

wiring during reassembly.

6. Remove the pulse transformer and switching power supply boards from the drive (see page 62

). You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure.

7. Remove the appropriate bus bars in order to access the bimetal thermostats.

• For a regenerative drive, see Remove the Bus Bars from a

Regenerative Drive on page 96

• For a Non-Regenerative drive, see Remove the Bus Bars from a Non-

Regenerative Drive on page 98

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Chapter 3 Part Replacement Procedures

Remove the Bus Bars from a Regenerative Drive

8. Remove the bolt and washer that secures the U phase terminal bus bar to the terminal isolation bar.

9. Remove the bolts and washers that secure the connecting bus bar to the U phase SCR modules and remove the bus bars.

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Part Replacement Procedures Chapter 3

10. Remove the bolt and washers that secure the D terminal bus bar to the terminal isolation bar.

11. Remove the screw and washer that secures the wire to the bus bar and the bolt and washer that secures the U phase bus bar to the SCR module and remove the bus bar.

Continue with Remove the Bimetal Thermostats on page 99

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Chapter 3 Part Replacement Procedures

Non-Regenerative Drive

U Phase Terminal

D Terminal

Non-Regenerative Drive

Remove the Bus Bars from a Non-Regenerative Drive

12. Remove the three bolts and washers that secure the U Phase and D power terminals to the isolation bar.

13. Remove the bolts and washers that secure the wires and bus bars to the U phase SCR Module and D power terminal and remove the bus bars.

Continue with Remove the Bimetal Thermostats on page 99

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Part Replacement Procedures Chapter 3

1 and 2

Regenerative Drive Shown

Remove the Bimetal Thermostats

1. Remove the solder from the connections on the two leads of the bimetal thermostats.

2. Remove the bimetal thermostats from the heatsinks by unscrewing them at the base.

Cooling Fan Replacement

Install the Bimetal Thermostats

Install the bimetal thermostats in reverse order of removal.

IMPORTANT Thermal grease must be applied to the bottom of the bimetal thermostats

before securing them to the heatsink.

Remove the Cooling Fans

Follow these steps to remove the cooling fans.

1. Read the General Safety Precautions on page 10

2. Remove power from the drive (see page 42

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Chapter 3 Part Replacement Procedures

Bottom View

3. Remove the two screws that secure the rear plastic shield to the bottom of the drive and remove the shield.

4. Locate the cooling fan terminal block on the bottom of the drive and loosen the screws that secure the fan power supply wires (red and black) to the terminal block and remove the wires.

IMPORTANT Note the color and location of each of the wires connected to the

cooling fan to ensure that each wire is properly connected during installation.

100 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

Summary of Changes

Additional Resources

General Safety Precautions

Hardware Description

Commonly Used Tools

Service Tools

Software Tools

Save the Parameter Configuration

Save to a HIM Set

Visual Component Inspection

Troubleshoot a Control Power Supply Failure

Testing the Switching Power Supply and Pulse Transformer Boards

Testing the Control and Field Board Connections

Troubleshoot an AC Undervoltage Fault

Troubleshoot an Armature Bridge Failure

Troubleshoot a Field Current Loss Fault

Low or Incorrect Field Current

No Field Current

Power Component Test Procedures

Check the Armature SCR Modules

Check the Pulse Transformer Board

Check the Field SCR/Dual Diode Module

Speed Feedback Device Tests

Check the Encoder

Check the DC Tachometer

Check the Resolver Interface Board

Thermistors and Thermal Switches

Relay Outputs

Create a Fault Report

What You Need When You Call Tech Support

Replacement Parts Kits

Remove Power from the Drive

DPI / HIM Assembly Replacement

Remove the DPI / HIM Assembly

Protective Cover Replacement

Install the DPI / HIM Assembly

Remove the Protective Covers

Install the Protective Covers

Communication Adapter and Electromagnetic Interference Shield Replacement

Remove the Communication Adapter and Electromagnetic Interference Shield

Install the Communication Adapter and EMI Shield

Resolver Feedback and Interface Circuit Board Replacement

Remove the Resolver Feedback and Interface Circuit Boards

Install the Resolver Feedback and Interface Circuit Boards

I/O Expansion Circuit Board Replacement

Remove the I/O Expansion Circuit Board

Install the I/O Expansion Circuit Board

115V AC to 24V DC I/O Converter Circuit Board Replacement

Remove the 115V AC to 24V DC I/O Converter Circuit Board

Control Circuit Board Replacement

Install the 115V AC to 24V DC I/O Converter Circuit Board

Remove the Control Circuit Board

Control Electromagnetic Interference Shield Removal and Closure

Install the Control Circuit Board

Move the Control Electromagnetic Interference Shield

Close the Control EMI Shield in the Service Position

Switching Power Supply Board Fuse Replacement

Remove the Fuses on the Switching Power Supply Circuit Board

Install the Fuses on the Switching Power Supply Circuit Board

Pulse Transformer Circuit Board Fuse Replacement

Remove the Fuses on the Pulse Transformer Circuit Board

Pulse Transformer and Switching Power Supply Circuit Boards Replacement

Install the Fuses on the Pulse Transformer Circuit Board

Remove the Pulse Transformer and Switching Power Supply Circuit Boards

Configure the Pulse Transformer Circuit Board

Install the Pulse Transformer and Switching Power Supply Boards

Remove the Field Circuit Fuses

Field Circuit Board Replacement

Install the Field Circuit Fuses

Remove the Field Circuit Board

Install the Field Circuit Board

Field SCR and Dual Diode Modules Replacement

Remove the Field SCR and Dual Diode Modules

Install the Field SCR and Dual Diode Modules