Allen-Bradley PowerFlex 20P Hardware Service Manual
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Allen-Bradley PowerFlex 20P Hardware Service Manual

Digital dc drive, frame a
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Hardware Service Manual
Original Instructions
PowerFlex Digital DC Drive, Frame A
Catalog Numbers 20P
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Summary of Contents for Allen-Bradley PowerFlex 20P

  • Page 1 Hardware Service Manual Original Instructions PowerFlex Digital DC Drive, Frame A 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.

  • Page 3: Table Of Contents

    Table of Contents Preface Summary of Changes ......... . . 7 Additional Resources .
  • Page 4 Table of Contents Chapter 3 Part Replacement Procedures Replacement Part Kits ......... 44 Remove Power from the Drive .
  • Page 5 Table of Contents Pulse Transformer and Switching Power Supply Circuit Boards Replacement ......... . . 68 Remove the Pulse Transformer and Switching Power Supply Circuit Boards.
  • Page 6 Table of Contents Appendix C Flow Charts List of Flow Charts ......... . . 127 Control Power Supply Failure .

  • Page 7: Preface

    Provides a current list of spare parts available for the PFLEX-SB003 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-TG001C-EN-P - February 2018...
  • Page 8 Preface Notes: Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 9 Chapter Before You Begin Testing, Maintenance or Repairs Topic Page General Safety Precautions Hardware Description Commonly Used Tools This chapter provides information you should know before you begin tests, maintenance, or repairs on drive components. Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 10: General Safety Precautions

    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. ATTENTION: Only qualified personnel familiar with DC drives, field controllers, and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system.

  • Page 11: Hardware Description

    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.

  • Page 12: Commonly Used Tools

    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.

  • Page 13: Component Test Procedures

    Chapter Component Test Procedures Topic Page Save the Parameter Configuration Visual Component Inspection Troubleshoot a Control Power Supply Failure Troubleshoot an AC Undervoltage Fault Troubleshoot an Armature Bridge Failure Troubleshoot a Field Current Loss Fault Power Component Test Procedures Speed Feedback Device Tests Thermistors and Thermal Switches Relay Outputs Create a Fault Report...

  • Page 14: Save The Parameter Configuration

    Chapter 2 Component Test Procedures Save the Parameter It is recommended that you save the drive and communication adapter parameter configuration before performing any service. You can save the drive Configuration configuration in one of these ways: • Upload the drive configuration to a HIM Set •...

  • Page 15: Visual Component Inspection

    Component Test Procedures Chapter 2 Visual Component Inspection 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 46). 3.
  • Page 16 Chapter 2 Component Test Procedures 4. Measure the signal voltage at the control circuit board testpoints as indicated in the following table. Name Testpoint For Testpoint Location Associated Connector- Description + 5V Figure 1 on page XA-1 / XA-3 / XA-5 +5V digital supply GNDD Figure 1...

  • Page 17: Test The Switching Power Supply And Pulse Transformer

    Component Test Procedures Chapter 2 Test the Switching Power Supply and Pulse Transformer Boards Complete these steps to test the switching power supply and pulse transformer circuit boards. 1. Replace the fuse on the switching power supply board (see page 47). 2.
  • Page 18 Chapter 2 Component Test Procedures Figure 1 - Control Board Testpoints - Upper Left XY18 XY17 XY19 XY10 XY12 XY11 XY6 XY5 XY20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40...
  • Page 19 Component Test Procedures Chapter 2 Figure 2 - Control Board Testpoints - Upper Right +12VEXP 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 - A B C + ENC_5 ENC_12...

  • Page 20: Troubleshoot An Ac Undervoltage Fault

    Chapter 2 Component Test Procedures Troubleshoot an AC If one of the following occurs, measure the AC line input signals as directed in these steps: Undervoltage Fault • The drive faults with an AC Undervoltage Fault (F4) • The value of parameter 466 [AC Line Voltage] does not equal the expected incoming AC line voltage ATTENTION: Servicing energized equipment can be hazardous.
  • Page 21 Component Test Procedures Chapter 2 • If any of the voltage measurements are incorrect or missing, continue with step 5. • If the voltage measurements are correct but the value of parameter 466 [AC Line Voltage] is incorrect, replace the control board. 5.

  • Page 22: Troubleshoot An Armature Bridge Failure

    Chapter 2 Component Test Procedures Troubleshoot an Armature If the drive is running unstable, or faults with an Overcurrent Fault (F13), an armature bridge failure can have occurred. The signals to and from the SCR Bridge Failure bridges are transmitted via the ribbon cable that is connected to XR on the control board and can be measured at these points.
  • Page 23 Component Test Procedures Chapter 2 Figure Figure 4, and Figure 5 on page are examples of gate pulse, current, and voltage signal measurements taken on an SCR. In these figures: – The current signal is taken on the testpoint XY17 (+2.5V offset; +0.6V=Drive size current).

  • Page 24: Troubleshoot A Field Current Loss Fault

    Chapter 2 Component Test Procedures 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 the following figure you can deduce that SCR connected to gate G6 is open. Figure 5 - Open Thyristor Example XY19 Troubleshoot a Field Current...

  • Page 25: Low Or Incorrect Field Current

    Component Test Procedures Chapter 2 Low or Incorrect Field Current For a flow chart version of these steps, see Low or Incorrect Field Current Flow Chart on page 130. 1. Read the General Safety Precautions on page 10. 2. Verify the actual value of parameter 351 [Field Current] by measuring the DC motor field current using a DC clamp.

  • Page 26: No Field Current

    Chapter 2 Component Test Procedures No Field Current For a flow chart version of these steps, see No Field Current Flow Chart on page 129. 1. Read the General Safety Precautions on page 10. 2. Remove the protective covers from the drive (see page 50). 3.
  • Page 27 Component Test Procedures Chapter 2 This signal is a square wave signal with a 90° lag phase displacement as compared to the AC voltage signal. 2. Measure the gate signals at pins XR-1 and XR-2 on the cable. The figure that is shown here displays the following signals from top to bottom: Channel Signal...

  • Page 28: Power Component Test Procedures

    Chapter 2 Component Test Procedures Power Component Test Follow the applicable procedure for the affected power components. Procedures Check the Armature SCR Modules The frame A PowerFlex DC drive armature supply consists of three (non- regenerative drives) or six (regenerative drives) SCR modules that are mounted on the main heat sink.
  • Page 29 Component Test Procedures Chapter 2 Table 2 - SCR Anode to Cathode Junction Measurements for Regenerative Drives On SCR Module Measure from To Terminal Nominal Meter Reading Terminal “open circuit” or “MΩ” range Figure 6 - Regenerative Drive SCR Module Layout SCR Module SCR Module SCR Module...
  • Page 30 Chapter 2 Component Test Procedures Table 3 - SCR Anode to Cathode Junction Measurements for Non-regenerative Drives On SCR Module Measure from To Terminal Nominal meter Reading Terminal “open circuit” or “MΩ” range Figure 7 - Non-regenerative Drive SCR Module Layout SCR Module SCR Module SCR Module...
  • Page 31 Component Test Procedures Chapter 2 6. 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, refer to Table 4 Figure 8. For non- regenerative drives, refer to Table 5 on page...

  • Page 32: Check The Pulse Transformer Board

    Chapter 2 Component Test Procedures Table 5 - SCR Gate to Cathode Junction Measurements for Non-regenerative Drives On SCR Module Measure from Nominal Meter Reading Pin 6 Pin 7 5…20 Ω Pin 5 Pin 4 Pin 6 Pin 7 Pin 5 Pin 4 Pin 6 Pin 7...
  • Page 33 Component Test Procedures Chapter 2 • For a 38 A/10 Hp or 55 A/15 Hp drive with 230V AC input and 35 A/20 Hp, 45 A/25 Hp, and 52 A/30 Hp drives with 460V AC input, remove the four screws that secure the slotted air flow plate to the top of the drive, remove the fan cable from connector XV on the switching power supply board and remove the plate.
  • Page 34 Chapter 2 Component Test Procedures IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 6. Remove the pulse transformer board. See Pulse Transformer and Switching Power Supply Circuit Boards Replacement on page 68. The switching power supply board is mounted on the back of the pulse transformer board but does not need to be removed from the pulse transformer board for this test.

  • Page 35: Check The Field Scr/Dual Diode Module (Drives Only)

    Component Test Procedures Chapter 2 8. With the digital multimeter set to “diode test”, measure each connection point on the pulse transformer board that is listed in these tables. If any of the actual measurements are out of tolerance, replace the pulse transformer board.
  • Page 36 Chapter 2 Component Test Procedures Table 10 - SCR/Dual Diode Module Anode to Cathode Junction Measurements (+) Meter Lead (-) Meter Lead Nominal Meter Reading Terminal Terminal “open” or ∞ “open” or ∞ “open” or ∞ “open” or ∞ “open” or ∞ “open”...

  • Page 37: Speed Feedback Device Tests

    Component Test Procedures Chapter 2 Speed Feedback Device Tests Complete the appropriate test for the feedback device installed. Check the Encoder The encoder feedback device provides a dual-channel quadrature output waveform and requires differential line-driver output at +5 or +12…15V signal levels.

  • Page 38: Check The Resolver Interface Board

    Chapter 2 Component Test Procedures 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 light-emitting diodes (LEDs) and testpoints on the resolver interface board can be used to verify that the board is not damaged.
  • Page 39 Component Test Procedures Chapter 2 Figure 11 - Resolver Interface Board - Testpoint Locations +12V +12V -12V -12V 0V12 0V12 +24V_VI +24V_VI 0V24 0V24 S1 +5V pos. S1 +12V pos. S1 +24V pos. S2 Internal supply pos. S2 External supply pos. Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 40: Thermistors And Thermal Switches

    Chapter 2 Component Test Procedures Thermistors and Thermal An external, user-supplied thermistor (PTC) or thermal switch can detect motor overheating. The PTC or thermal switch must be connected to Switches terminals 78 and 79 on the control power terminal block on the pulse transformer circuit board.

  • Page 41: Create A Fault Report

    Component Test Procedures Chapter 2 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.

  • Page 42: What You Need When You Call Tech Support

    Chapter 2 Component Test Procedures What You Need When You When you contact Technical Support, please be prepared to provide the following information: Call Tech Support • Order number • Product catalog number and drive series number (if applicable) • Product serial number •...
  • Page 43 Chapter Part Replacement Procedures Topic Page Replacement Part Kits Remove Power from the Drive Switching Power Supply Fuse Replacement Field Circuit Fuse Replacement DPI / HIM Assembly Replacement Protective Cover Replacement Communication Adapter and EMI Shield Replacement Resolver Feedback and Interface Circuit Board Replacement I/O Expansion Circuit Board Replacement 115V AC to 24V DC I/O Converter Circuit Board Replacement Control Circuit Board Replacement...

  • Page 44: Replacement Part Kits

    Chapter 3 Part Replacement Procedures Replacement Part Kits Table 13 lists the spare parts kits available for PowerFlex® DC frame A drives. Table 13 - Spare Part Kits Description Kit Cat. No. Instructions Page Fuses Switching Power Supply Board (Revision H and Lower) Fuse - Ferrule SK-20P-S8B28 5 x 20 mm, 1 A 250V Switching Power Supply Board (Revision I and Higher) Fuse - Ferrule...
  • Page 45 Part Replacement Procedures Chapter 3 Table 13 - Spare Part Kits (continued) Description Kit Cat. No. Instructions Page 28 A Field SCR/Dual Diode Module for 230V AC Regen. Drive, 38…110 SK-20P-S79F1 28 A Field SCR/Dual Diode Module for 460/480V AC Regen. or Non- Regen.

  • Page 46: Remove Power From The Drive

    Chapter 3 Part Replacement Procedures 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 can occur. An electrical arc can cause personal injury or property damage by: •...

  • Page 47: Switching Power Supply Fuse Replacement

    Part Replacement Procedures Chapter 3 Switching Power Supply Fuse Remove the Fuse on the Switching Power Supply Circuit Board Replacement IMPORTANT For PowerFlex DC drives, the replacement fuse that is used for the switching power supply circuit board depends on the revision of the board. See the Fuses section in the Spare Part Kits table on page for details.

  • Page 48: Field Circuit Fuse Replacement

    Chapter 3 Part Replacement Procedures Field Circuit Fuse 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 46). 3.

  • Page 49: Dpi / Him Assembly Replacement

    Part Replacement Procedures Chapter 3 DPI / HIM Assembly Remove the DPI / HIM Assembly from the Protective Cover Replacement 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.

  • Page 50: Protective Cover Replacement

    Chapter 3 Part Replacement Procedures Protective Cover Remove the Protective Covers Replacement You must remove both the lower protective cover and the power terminal cover to access the power terminals. Follow these steps to remove the protective covers. 1. Read the General Safety Precautions on page 10. 2.
  • Page 51 Part Replacement Procedures Chapter 3 4. Disconnect the DPI cable from the HIM assembly. 5. Remove the two screws that secure the bottom protective cover to the drive. 6. While gently lifting along the top edge of the cover, slide it down and off the drive chassis.

  • Page 52: Install The Protective Covers

    Chapter 3 Part Replacement Procedures 10. 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 reverse order of removal. ATTENTION: Risk of electric shock exists when power is applied to the power terminals of the drive.
  • Page 53 Part Replacement Procedures Chapter 3 3. Disconnect the interface cable from the communication adapter and set it aside. 4. Disconnect any network cables from the adapter and set them aside. 5. Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter.

  • Page 54: Install The Communication Adapter And Emi Shield

    Chapter 3 Part Replacement Procedures 6. Remove the three screws that secure the EMI shield to the stand-offs on the control board and remove the EMI shield. Tightening torque: 1.0 N•m (8.9 lb•in) 7. Remove the three stand-offs from the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Install the Communication Adapter and EMI Shield...

  • Page 55: Resolver Feedback And Interface Circuit Board Replacement

    Part Replacement Procedures Chapter 3 Resolver Feedback and Remove the Resolver Feedback and Interface Circuit Boards Interface Circuit Board Follow these steps to remove the resolver feedback and interface circuit boards. Replacement 1. Read the General Safety Precautions on page 10. 2.
  • Page 56 Chapter 3 Part Replacement Procedures 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.
  • Page 57 Part Replacement Procedures Chapter 3 6. Remove the three stand-offs from the resolver interface board. Resolver interface board XFCD Tightening torque for reassembly is 0.7 N•m (6.2 lb•in) Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 58: Boards

    Chapter 3 Part Replacement Procedures 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.

  • Page 59: I/O Expansion Circuit Board Replacement

    Part Replacement Procedures Chapter 3 I/O Expansion Circuit Board Remove the I/O Expansion Circuit Board Replacement 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 46). 3.
  • Page 60 Chapter 3 Part Replacement Procedures 7. Carefully pull the I/O expansion board off connector XBB on the control board. 8. Remove the two stand-offs from the control board. Tightening torque: 1.0 N•m (8.9 lb•in) 9. Install one of the existing screws in the lower left corner of the control circuit board.

  • Page 61: Install The I/O Expansion Circuit Board

    Part Replacement Procedures Chapter 3 Install the I/O Expansion Circuit Board Install the I/O expansion board in reverse order of removal. 115V AC to 24V DC I/O Remove the 115V AC to 24V DC I/O Converter Circuit Board Converter Circuit Board Follow these steps to remove the 115V AC to 24V DC I/O converter circuit Replacement board.

  • Page 62: Install The 115V Ac To 24V Dc I/O Converter

    Chapter 3 Part Replacement Procedures 6. Remove the two stand-offs from the control board. Tightening torque: 1.0 N•m (8.9 lb•in) 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.
  • Page 63 Part Replacement Procedures Chapter 3 8. 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/ Function Setting Switch Configures the input voltage of the DC analog tachometer. Configures the input signal of analog input 1 (terminals 1 and 2): Note: The same input signal type must be programmed in Par 71 [Anlg In1 Config].
  • Page 64 Chapter 3 Part Replacement Procedures 9. Carefully disconnect the cables from connectors XFCD, XA, and XR on the control board. 10. Remove the plug-in I/O and control terminal blocks with the wiring kept in place. Communication adapter and optional boards not shown. Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 65: Install The Control Circuit Board

    Part Replacement Procedures Chapter 3 11. Remove the five M3 x 6 mm screws and washers that secure the control board to the control EMI shield and remove the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Install the Control Circuit Board Install the control board in reverse order of removal.

  • Page 66: Control Emi Shield And Control Circuit Board Replacement

    Chapter 3 Part Replacement Procedures Control EMI Shield and Remove the Control EMI Shield and Control Circuit Board Control Circuit Board You must remove the control EMI shield that holds the control board to access Replacement other components within the drive. Follow these steps to remove the control EMI shield and control circuit board.
  • Page 67 Part Replacement Procedures Chapter 3 6. Remove the five M4 x 9.5 mm screws that secure the control EMI shield and ground wire (in the lower left corner) to the chassis. 7. Slide the control EMI shield and control board up and out of the drive. IMPORTANT Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the pulse transformer circuit board below the EMI shield.

  • Page 68: Board

    Chapter 3 Part Replacement Procedures Pulse Transformer and Remove the Pulse Transformer and Switching Power Supply Circuit Switching Power Supply Boards Circuit Boards Replacement The switching power supply circuit board is on the back of the pulse transformer circuit board. You must remove both boards to replace either board.
  • Page 69 Part Replacement Procedures Chapter 3 • For all other drives, remove the two screws that secure the slotted air flow plate to the top of the drive and remove the plate. Tightening torque: 1.0 N•m (8.9 lb•in) Air flow plate Tightening torque: 1.0 N•m (8.9 lb•in) IMPORTANT Mark all connections and wires before removal to avoid incorrect...
  • Page 70 Chapter 3 Part Replacement Procedures 7. Remove the cables from connectors X3, X4, and XP at the top of the pulse transformer board. Connector X4 contains a jumper for drives without a fan - leave in place. 8. For pulse transformer boards with an armature voltage feedback terminal block, FIR1- , rev “Q”...
  • Page 71 Part Replacement Procedures Chapter 3 10. Remove the appropriate gate leads: • For regenerative drives, 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. •...
  • Page 72 Chapter 3 Part Replacement Procedures 12. Remove the six M3 x 6 mm screws and washers that secure the bottom of the pulse transformer board to the drive 13. While lifting slightly on the board, slide it toward the top of the drive and out of the chassis.
  • Page 73 Part Replacement Procedures Chapter 3 14. Remove the cable from connector XUV on the left side of the switching power supply board. 15. Remove the four M3 x 6 mm screws and washers that secure the switching power supply board to the stand-offs on the back of the pulse transformer board.

  • Page 74: Install The Pulse Transformer And Switching Power

    Chapter 3 Part Replacement Procedures Install the Pulse Transformer and Switching Power Supply Circuit Boards The pulse transformer circuit board must be configured to match the drive size (armature output current and Hp rating). The steps that are required to complete the configuration are different based on the revision code of the board.
  • Page 75 Part Replacement Procedures Chapter 3 Sizing Resistor Configuration Table 14 Table 15 to determine the correct resistor configuration on the pulse transformer board for your drive size. The tables use these conventions: • A resistance value in a cell indicates that the resistor must be left on the board •...
  • Page 76 Chapter 3 Part Replacement Procedures 2. Connect the leads of the multimeter to pins 13 and 14 of connector XR 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 Table 16...
  • Page 77 Part Replacement Procedures Chapter 3 Total Resistance Values Table 16 - 230V AC Input Drives Drive Current AC Line Set RTA Value Using TA Rating Code Amps Amps Potentiometer (Ohms) 34.971 45.333 61.2 42.207 32.211 22.255 16.767 13.161 11.127 Table 17 - 460V AC Input Drives Drive Current AC Line Set RTA Value Using TA...
  • Page 78 Chapter 3 Part Replacement Procedures Configure a Pulse Transformer Board FIR1-xx Rev. “Q” and Higher 1. Set DIP switches S3 and S4, on the pulse transformer board (see illustration), to the correct settings based on the drive current rating. See 230V AC Input Drives on page and 460V AC Input Drives on page 79.

  • Page 79: Install The Configured Pulse Transformer Circuit Board And The Switching Power Supply Circuit Boards

    Part Replacement Procedures Chapter 3 IMPORTANT A blank cell below a switch in Table 18 Table 19 indicate that the setting is “OFF”. Table 18 - 230V AC Input Drives Drive AC Line Hp DIP Switch S3 DIP Switch S4 Current Amps Amps...

  • Page 80: Ac Current Transducer Replacement

    Chapter 3 Part Replacement Procedures 1. Install the Isolation sheet (if present) before installing the pulse transformer and switching power supply boards. ATTENTION: Failure to install the Isolation sheet below the pulse transformer and switching power supply boards can result in damage to the drive. 2.
  • Page 81 Part Replacement Procedures Chapter 3 AC Current Transducers on Drives with a Power Traces Board The drive size determines how the AC current transducers are secured to the power traces board. See Remove the Current Transducers with Connection Bars for drives with one metal bar and no windings on the AC current transducers.
  • Page 82 Chapter 3 Part Replacement Procedures Remove the Current Transducers with No Connection Bars 6. Remove the two M3 x 6 mm screws and washers that secure the top wire leads to the power traces board. 7. Remove the two stand-offs and washers that secure the bottom wire leads to the power traces board.
  • Page 83 Part Replacement Procedures Chapter 3 AC Current Transducers on Drives with Bus Bars IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 6. Remove the power connections from terminals U and V at the bottom of the drive.
  • Page 84 Chapter 3 Part Replacement Procedures 8. Remove the two 5 x 10 mm screws and washers that secure each of the U and V phase terminal bus bars to the terminal isolation strip at the bottom of the drive. Tightening torque: U Phase bus bar V Phase bus bar 2.5 N•m (22.0 lb•in)

  • Page 85: Install The Ac Current Transducers

    Part Replacement Procedures Chapter 3 • For Non-Regenerative drives, remove the screws and washers that secure the U and V Phase terminal bus bars to the corresponding SCR modules. Tightening torque: 2.5…4 N•m (22…35.4 lb•in) 10. While lifting the terminal bus bars out of the drive, slide the AC current transducers off the bus bars.

  • Page 86: Power Traces Circuit Board Replacement

    Chapter 3 Part Replacement Procedures Power Traces Circuit Board Remove the Power Traces Circuit Board Replacement The power traces circuit board is only contained in frame A drives rated up to 55 A/15 Hp with 230V AC input and up to 52 A/30 Hp with 460V AC input. follow these steps to remove the power traces circuit board.
  • Page 87 Part Replacement Procedures Chapter 3 7. Remove the six stand-offs (and the ground wire) from the power traces circuit board. 8. Remove all M5 x 10 mm screws and washers that secure the board to the SCR modules and power terminal isolation strip and remove the power traces board from the drive.
  • Page 88 Chapter 3 Part Replacement Procedures 9. Remove the screw and washer that secures the top of each of the AC current transducers to the power traces board and remove the current transducers. Regenerative drive shown AC current transducers with connections bars 10.

  • Page 89: Install The Power Traces Circuit Board

    Part Replacement Procedures Chapter 3 Install the Power Traces Circuit Board Install the power traces circuit board in reverse order of removal. • Verify the following actions are taken for proper installation: • The connecting wire on the board is placed in the exact location as previously installed.
  • Page 90 Chapter 3 Part Replacement Procedures 6. Remove all wires from the field SCR/dual diode module on the drive heat sink. (You will also need to remove the small red wire that is staked to the large red wire.) 7. Remove the two M5 x 10 mm screws and washers that secure the field SCR/dual diode module to the drive heat sink and remove the module.
  • Page 91 Part Replacement Procedures Chapter 3 8. If necessary, remove the power wiring from terminals U, V, W, C, D, and 9. Remove the plug-in field terminal block on the bottom of the drive, with the wiring kept in place. 10. Remove the two M4 x 12 mm screws that secure the bottom air flow plate to the power terminal isolation strip.
  • Page 92 Chapter 3 Part Replacement Procedures 11. Remove the M4 x 12.5 mm screws that secure the bottom air flow plate to the drive chassis and carefully pull the air flow plate and fan (if present) assembly down and off the drive. The bottom air flow plate on a frame A drive that is rated up to 55 A/ 15 Hp with 230V AC input or up to 52 A/30 Hp with 460V AC input, is secured to the drive chassis with four screws.
  • Page 93 Part Replacement Procedures Chapter 3 12. Remove the two M3 x 6 mm screws that secure the field circuit board to the drive and remove the field board and connected wires from the drive. There is an isolation sheet below the board; do not remove this sheet unless it is damaged.

  • Page 94: Circuit Board

    Chapter 3 Part Replacement Procedures 13. Remove the wires that connect the field fuses (UF, UF1, VF, VF1) to the field circuit board. 14. Remove the wire from connector X3 on the field board. Field fuses Install the Field SCR/Dual Diode Module and Field Circuit Board •...

  • Page 95: Bimetal Thermostat Replacement

    Part Replacement Procedures Chapter 3 Bimetal Thermostat Remove the Bimetal Thermostat Replacement Follow these steps to remove the bimetal thermostat. 1. Read the General Safety Precautions on page 10. 2. Remove power from the drive (see page 46). 3. Remove the protective covers (see page 50). 4.

  • Page 96: Scr Module Replacement

    Chapter 3 Part Replacement Procedures SCR Module Replacement Remove the SCR Modules IMPORTANT For regenerative drives, the SCR modules must be replaced in pairs for each input phase in order that the gating resistance of each pair of modules is the same.
  • Page 97 Part Replacement Procedures Chapter 3 SCR Modules on Drives Rated up to 55 A/15 Hp with 230V AC Input or up to 52 A/30 Hp with 460V AC Input 6. Remove the power traces circuit board. See Power Traces Circuit Board Replacement on page 86.
  • Page 98 Chapter 3 Part Replacement Procedures SCR Modules on Drives Rated 73 A/20 Hp with 230V AC Input and Higher or 73 A/40 Hp with 460V AC Input and Higher 8. Remove the isolation sheet. 9. Remove the M5 x 10 mm screws that secure the U, V, W, C, and D terminal bus bars to the power terminal isolation strip at the bottom of the drive.
  • Page 99 Part Replacement Procedures Chapter 3 10. For regenerative drives only, remove the screws and washers that secure the connecting bus bars to the anodes of the corresponding SCR modules and remove the bus bars. In addition, remove the U, V, and W phase terminal bus bars from the drive.
  • Page 100 Chapter 3 Part Replacement Procedures 11. Remove the four screws and washers that secure the C and D terminal bus bars to the horizontal bus bars and remove the C and D terminal bus bars. IMPORTANT For regenerative drives only, the screws that secure these bus bars to the SCR modules are M5 x 16.
  • Page 101 Part Replacement Procedures Chapter 3 12. Remove the screws and washers that secure the connecting bus bars to the SCR modules and remove the bus bars. Non-Regenerative drive Regenerative drive Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 102 Chapter 3 Part Replacement Procedures 13. For non-regenerative drives only, remove the screws and washers that secure the U, V, and W terminal bus bars to the SCR modules and remove the bus bars. Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 103 Part Replacement Procedures Chapter 3 14. Remove the screws and washers that secure each SCR module to the heat sink and remove the SCR modules. Non-Regenerative drive Regenerative drive Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 104: Install The Scr Modules

    Chapter 3 Part Replacement Procedures Install the SCR Modules • Install the SCR modules in reverse order of removal using these tables for proper tightening torque. IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heat sink.
  • Page 105 Part Replacement Procedures Chapter 3 Cooling Fan on Drives Rated 38 A/10 Hp and 55 A/15 Hp with 230V AC Input and 35 A/20 Hp, 45 A/25 Hp, and 52 A/30 Hp with 460V AC Input The following frame A drives have a cooling fan at the top of the chassis: •...
  • Page 106 Chapter 3 Part Replacement Procedures Cooling Fan on Drives Rated 73 A / 20 Hp with 230V AC Input and 73 A / 40 Hp with 460V AC Input Frame A drives rated 73A/20 Hp with 230V AC and 73A/40 Hp with 460V AC and higher have a cooling fan that is installed on the bottom of the drive.
  • Page 107 Part Replacement Procedures Chapter 3 9. Remove the two screws that secure the armature-voltage feedback terminal block to the air flow plate and remove the terminal block. 10. Remove the six M4 x 12.5 mm screws that secure the air flow plate to the bottom of the drive chassis.

  • Page 108: Install The Cooling Fan

    Chapter 3 Part Replacement Procedures 13. Using a flathead screwdriver, pry the fan cover plate off the air flow plate. 14. Slide the fan out of the air flow housing. Install the Cooling Fan Install the cooling fan in reverse order of removal. IMPORTANT For both drive/fan configurations, verify that the air flow arrow on the fan is pointed toward the top of the drive.

  • Page 109: Start-Up After Repair

    Chapter Start-Up After Repair Before applying power to a repaired drive, perform the following tests: • Check the Armature SCR Modules on page • Check the Field SCR/Dual Diode Module (Drives Only) on page • For drives, complete the Test With the Motor, Without a Mechanical Load Test With the Motor, Without This test allows you to measure several operating parameters and diagnose...
  • Page 110 Chapter 4 Start-Up After Repair • 179 [Nom Mtr Arm Amps] is set to the rated motor nameplate armature current. • 280 [Nom Mtr Fld Amps] is set to the rated motor nameplate field current. • 374 [Drv Fld Brdg Amps] is set to the rated current of the field bridge regulator 7.

  • Page 111: List Of Schematic Diagrams

    Appendix Schematics List of Schematic Diagrams Topic Page Drive Interconnection Diagram AC Line Measurement Points Diagram Power Feedback Connections Diagram SCR to Pulse Transformer Board Gate Lead Pinout - Regenerative Drive Diagram SCR to Pulse Transformer Board Gate Lead Pinout - Non-regenerative Drive Diagram Field Board and SCR/Dual Diode Module Connections Diagram Field Control Circuit Diagram Control Circuit Input Power Diagram...
  • Page 112 Appendix A Schematics Figure 12 - Drive Interconnection Diagram Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 113 Schematics Appendix A Figure 13 - AC Line Measurement Points Diagram XY22 XR-15 100 K +15 V -15 V XY21 XR-16 100 K XY18 XR-17 100 K Figure 14 - Power Feedback Connections Diagram Hardware connections to power structure bus bars. XR19 *Note XR18...
  • Page 114 Appendix A Schematics Figure 15 - SCR to Pulse Transformer Board Gate Lead Pinout - Regenerative Drive Diagram SCR Module 1 SCR Module 01 SCR Module 2 SCR Module 02 SCR Module 3 SCR Module 03 G01 K01 K04 G04 G02 K02 K05 G05 G03 K03 K06 G06 6 6 7 7...
  • Page 115 Schematics Appendix A Figure 17 - Field Board and SCR/Dual Diode Module Connections Diagram Incoming AC Line X3-2 To Pulse Transformer Board X3 X3-1 Connector 0.1uF 0.1 uF XP-2 XP-3 XFCD-1 XP-4 XP-1 10 uF XFCD-4 XFCD-2 10 uF XFCD-3 To Motor Field Connections Figure 18 - Field Control Circuit Diagram...
  • Page 116 Appendix A Schematics Figure 19 - Control Circuit Input Power Diagram 230V AC or To Switch Mode Power 115V AC input Supply (SMPS) Figure 20 - Encoder Control Circuit Diagram +24V Voltage Regulator and Current Feedback Circuit Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 117 Schematics Appendix A Figure 21 - DC Tachometer Control Circuit Diagram S4-8 S4-7 S4-6 S4-5 M3 - TACHOP M3 + S4-1 S4-3 S4-4 Figure 22 - Motor Thermal Protection Control Circuit Diagram +24V Overtemp Fault Signal Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...
  • Page 118 Appendix A Schematics Figure 23 - Drive Heat Sink Monitoring Control Circuit Diagram Control Board XR-10 XR-10 XR-12 XR-12 X4-1 XSW-1 +24V X4-2 0V24 XSW-2 Figure 24 - Contactor Control Relays Control Circuit Diagram 0V24 +24V Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 119: Circuit Board Layouts And Connections

    Appendix Circuit Board Layouts and Connections List of Circuit Board Layouts The following images and tables detail the connection points for the frame A PowerFlex® DC drive circuit boards and components. Topic Page Pulse Transformer Board Layout Pulse Transformer Board to Field Board Connections Pulse Transformer Board to Switching Power Supply Connections Pulse Transformer Board to Bimetal Thermostat Connections Pulse Transformer Board to Field SCR/Dual Diode Module Connections...

  • Page 120: Pulse Transformer Board

    Appendix B Circuit Board Layouts and Connections Pulse Transformer Board Figure 25 - Pulse Transformer Board Layout Components shown within dashed lines are only on the pulse transformer board for regenerative drives. Control power terminal block Control power terminal block Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 121: Pulse Transformer Board To Field Board Connections

    Circuit Board Layouts and Connections Appendix B Table 20 - Pulse Transformer Board to Field Board Connections Pulse Pin Number Field Board Description Transformer Number Connector Board Connector … 1U1 field sync signal (from U1) … 1V1field sync signal (from V1) Table 21 - Pulse Transformer Board to Switching Power Supply Connections Pulse Transformer Switching Power Supply...

  • Page 122: Pulse Transformer Board To Control Board Connections

    Appendix B Circuit Board Layouts and Connections Table 24 - Pulse Transformer Board to Control Board Connections Pulse Control Board Description Transformer Number Number Connector Board Connector … 1 Gate signal G1 field SCR1 … 2 Gate signal G2 field SCR2 …...

  • Page 123: Switching Power Supply Board

    Circuit Board Layouts and Connections Appendix B Table 25 - Pulse Transformer Board to Current Transducer Connections Pulse Pin Number Pin Number Current Description Transformer Transducer Board Connector … Black CT on Phase U Secondary side CT phase U … Brown …...

  • Page 124: Switching Power Supply Board To Control Board Connections

    Appendix B Circuit Board Layouts and Connections Table 27 - Switching Power Supply Board to Control Board Connections Switching Pin Number Pin Number Control Board Description Power Supply Connector Board Connector … … 5V common … … 5V common … …...

  • Page 125: Control Board

    Circuit Board Layouts and Connections Appendix B Control Board Figure 27 - Control Board Layout To DPI board on HIM Bezel LA LB XFCD 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DEBUG 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40...

  • Page 126: Field Board

    Appendix B Circuit Board Layouts and Connections Field Board Figure 28 - Field Board Layout Field fuse connections terminal block See Control Board to Field Board Connections on page Control Board to Field Board Connections and Pulse Transformer Board to Field Board Connections on page 121.

  • Page 127: List Of Flow Charts

    Appendix Flow Charts List of Flow Charts The following pages contain flow chart versions of troubleshooting procedures contained in Chapter 2 - Component Test Procedures. Topic Page Control Power Supply Failure Field Current Loss Failure Rockwell Automation Publication 20P-TG001C-EN-P - February 2018...

  • Page 128: Control Power Supply Failure

    Appendix C Flow Charts Control Power Supply Failure This chart presents the steps for troubleshooting a Power Failure fault (F3). Measure the voltage at terminals U2, V2. Verify the wiring and Is the correct power source to U2, voltage present at V2 and correct any U2, V2? problems.

  • Page 129: Field Current Loss Failure

    Flow Charts Appendix C Field Current Loss Failure The charts below presents the steps in flow chart form for troubleshooting a Field Current Loss fault (F6). No Field Current Flow Chart Measure the voltage at terminals U1, V1. Verify the wiring and Is the correct power source to U1, voltage present at...

  • Page 130: Low Or Incorrect Field Current Flow Chart

    Appendix C Flow Charts Low or Incorrect Field Current Flow Chart Verify Par 351 [Field Current] value using DC clamp to measure the DC motor field current. Verify drive rated field bridge current is set correctly in Par 374 [Drv Fld Brdg Cur] and DIP switch S14 is configured to match.

  • Page 131: Index

    Index Numerics 115V AC to 24V DC I/O converter board fault install 62 field current loss 24 remove 61 heatsink overtemperature 40 main contactor 40 overcurrent 22 power failture 15 fault report AC current transducers create 41 install 85 field board remove 80 install 94 armature bridge failure...
  • Page 132 Index save parameter configuration 14 schematic diagrams 111 layout drawings SCR modules circuit boards 119 install 104 remove 96 service tools 12 switching power supply board motor overheating 40 fuse 47 install 74 remove 68 outputs relay 40 overcurrent fault 22 technical support overtemperature calling 42...
  • Page 134 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, DriveExecutive, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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