Hardware Service Manual, PowerFlex Digital DC Drive, Frame C
Contents
1. 45V 45V ma eee pK i C3 15V E f THY asy 45V i r S21 SRRA o 4 p fa e ENC aK 5v gt E pour Oe 5V a l Eoi pK ict C3 eK 45V m HHH ye 24V LI nN Voltage Regulator and Current Feedback Circuit V t 3 BLO LE tavl 5V S21 Figure 20 DC Tachometer Control Circuit Diagram 84 8 S4 7 S4 6 84 5 4 TOP by H J L a L H HH T L TACHOP C M3 0 C C 4 on I _ __ S4 1 S2 S4 3 S4 4 126 Rockwell Automation Publication 20P TG003A EN P February 2012 Schematics Appendix A Figure 21 Motor Thermal Protection Control Circuit Diagram2. O S15 ooo m Oo ni ooo Oo n ooo nj gnp gcn p ooo oro 3 s2 ES O IHE m gooo pu n nann 20 ooo nu oomm000000 O pgoonagoapnagoanmn 0000 poonaonagonmn o Als ooo N tel Q ON Als S4 den b 11 O denb 821 s 510 O O o p O O O 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 OOOOOOOOOO OOOOOOOOO0 C4 DEBUG ABC ENGS_ENG12 At A B B Ze Z COM V 1234596798910 11 1314151617 18 19 20 OOOOO OOOOOOOO0 0000000000 0000000000 Table 27 Control Board to Field Board Connections Control Board Pin Number to PinNumber Field Board Description Connector Connector 1 1 15V 2 2 15V Common XFCD XFCD 3 3 15V 4 4 Field CT burden resistors For connector XA signals see Table 26 Switching Power Supply Board to Control Board Connections on page 133 134 Rockwell Automation Publication 20P TG003A EN P February 2012 Board Layouts and Connections Appendix B Field Power Board Figure 28 Field Power Board
3. On SCR Module SCR Measure from To Terminal Nominal meter reading Terminal 01 01 U C 04 U D E open circuit or megaohms range 05 v D i i 03 03 W C 06 W D Figure 7 Non Regenerative Drive SCR Module Layout amp 9 9 C e o Oo amp g e A SCR SCR SCR Module 01 Module 02 Module 03 e e e w eC K 9 9 B 9 U C V D W Rockwell Automation Publication 20P TG003A EN P February 2012 29 Chapter2 Component Test Procedures Gate Lead Connectors Gate Lead Pinouts 30 6 Check the gate to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance of each SCR junction e For regenerative drives see Table 4 and Figure 8 below e For non regenerative drives see Table 5 on page 31 and Figure 9 on page 31 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 SCR M
4. 130 FIR3 xx Rev L and Lower FIR3 xx Rev M and Higher PE O PEI To6 KG05 XCD IO TO6 med a x3 q T6 kas KG6 1 XCD T6 TTE k sneme Dre n v re Joe XCD c XUVW T03 KG03 xa KGO3 O T03 es KG z L D V U T05 KG05 L J KGO5 KG J TOS m T5 KGS TR3 DEI LJ KG5 KG T5 E prem XTA 1 B EEEEE XTA i 2 yoo oy on TA o o gan ph oo gan p 2c damp T2 KG dump T2 KG2 S4 do gan ph qoop L z KG rump 5 LS _I cop Eng TO2 ese KGO2 T02 KG02 cop EE an p LL L l XCT EE Bae KG a E 2 Tos kGo4 xy TO4 KGO4 KG x i XI2CA z o T4 KG4 x T4 KG4 3 ry pis KG XSW EN T1 KG1 n K LJ XTM E w KG E TR2 TR1 TOi KGoi TR2 TRI TOt KGO1 XP2 XP1 L 4 m m ka K2 G2 KT G1 xe xe Fe Rockwell Automation Publication 20P TG003A EN P February 2012 Board Layouts and Connections Appendix B Table 20 Pulse Transformer Board to Field Power Board Connections Pulse Field Power Board Description Transformer Connector Board Connector B 1U1 field sy
5. i o a 3 H s Doo adid Rockwell Automation Publication 20P TG003A EN P February 2012 19 Chapter2 Component Test Procedures Troubleshoot an AC 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 Undervoltage Fault AC line input signals as directed in the steps below 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Protective Cover Removal and Installation on page 43 3 Using a voltmeter measure the voltage at terminals U V and W of the drive Note If
6. um o co E rl J O I zl E O XY8 XY10 O m te TE m C oo 0o EX T oo oo oo ug oo oo oo 18 Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Figure 2 Control Board Testpoints Upper Right BE 412VEXP OVEXP 5VEXP
7. TM 1 I 1 I TA e ajs p I 2 9 1 rE d L I Rockwell Automation Publication 20P TG003A EN P February 2012 1U1 1V1 X84 X3 2 V1 I Y 100R ll t XFCD 3 ll 100R N XFCD 2 TAI M XFCD 4 P T URE XFCD 1 L OF EN oM DD ooo At AG XP1 1 XP1 2 XP2 1 xP22 230 VAC or 115 VAC Input Schematics Appendix A Figure 17 Field Control Circuit Diagram 2 415V XFCD 1 Q 45V XFCD 3 XFCD 4 T T LB 14 8 14 7 14 6 S14 5 14 4 14 3 814 2 14 1 XFCD 2 1 LA Figure 18 Control Circuit Input Power Diagram U2 12 Q e e e O 2 e To Switch v dL d Mode Power mum Supply SMPS TOT 1D2 o o Q Rockwell Automation Publication 20P TG003A EN P February 2012 125 AppendixA Schematics Figure 19 Encoder Control Circuit Diagram
8. G e e H FUI m GLI9 GI I9 ap 9 6 o OO aj H OO ENS OO NL 6 Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside Pull tabs out to disconnect cable 44 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Install the Protective Covers on the Drive Install the protective covers in the reverse order of removal Field Circuit Fuses Removal Remove the Field Circuit Fuses and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the lower protective cover only from the drive See Protective Cover Removal and Installation on page 43 4 On the control EMI shield unscrew the fuse holders and remove the existing fuses from the holders Unscrew fuse caps and Control EMI shield remove fuses Install the Field Circuit Fuses Install the field circuit fuses in the reverse order of removal Rockwell Automation Publication 20P TG003A EN P February 2012 45 Chapter3 Access Procedures Communication Adapter Remove the Communication Adapter and EMI Shield and EMI Shield Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power fro
9. Rockwell Automation Publication 20P TG003A EN P February 2012 15V L1 hd e 78 h SH Oe tio KH 1 l XR 32 X EA Yah L OVI Jg LJ gt D Qe 4 i gt KH CO Figure 22 Drive Heatsink Monitoring Control Circuit Diagram Pulse Transformer Board Control Board uf XR 12 XR 12 SS Hs XR 10 XR 10 o OTS 24 pz I XSW 1 mum X4 1 X4 2 4 i XSW 2 0V24 127 Appendix A 128 Schematics Figure 23 Contactor Control Relays Control Circuit Diagram 0V24 Figure 24 AC Line Snubber Circuit U R1 R2 202 3U2 x2 3V2 2W2 AC Line Snubber Board U6 U2 S1 j i AA A V K7 K8 24V O O O O 35 36 75 76 V W R3 R4 R5 R6 R R R R Rockwell Automation Publication 20P TG003A EN P February 2012 Appendix B Board Layouts and Connections List of Board Layouts The following images and tables detail the connection points for the frame C PowerFlex DC drive circuit boards and componen
10. pessesssersscrres pete a S15 mDUJUUUUUIU ugagunasnauu pooo00000000 O olaja 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 OOOOOOOOOCO OOOOOCOOCOO SEU T XIPIPZCICmCEDIP ieee x X D SARGE Av Ae Be B Ze ZOOM 1234598 78 9 i Ji 13 4 516 0 15 9 20 20009 OO000000 OOOOOO0000 0000000000 Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal Rockwell Automation Publication 20P TG003A EN P February 2012 51 Chapter3 Access Procedures 1 0 Expansion Circuit Board Remove the 1 0 Expansion Circuit Board Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Protective Cover Removal and Installation on page 43 4 Ifinstalled remove the resolver feedback option board See Remove the Resolver Feedback and Interface Circuit Boards on page 48 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 5 Remove the p
11. Pulse Transformer Pin to Pin Control Board Description Board Connector Number Number Connector XR 1 i 1 XR Gate signal G1 field SCR1 2 TE 2 Gate signal G2 field SCR2 3 TF 3 OV GNDP 4 ie 4 Relay output 35 36 command 5 5 Relay output 75 76 command 6 6 20 40 selection signal 7 ae 7 OV GNDP 8 n 8 armature 0 signal 9 m 9 0V GNDP 10 10 Heatsink overtemperature 11 oes 11 Digital U1 V1 sync signal 12 12 0V GNDP 13 13 CT burden signal 14 i 14 0V GND 15 15 Reduced U sync signal 16 16 Reduced V sync signal 7 iss 17 Reduced W sync signal 18 He 18 Reduced C armature signal 19 19 Reduced D armature signal 20 m 20 0V GNDP 21 21 Gate signal SCR 4 01 22 m 22 0V GNDP 23 a 23 Gate signal SCR 5 02 24 24 0V GNDP 25 as 25 Gate signal SCR 6 03 26 m 26 WH1 not used grounded 27 27 Gate signal SCR 1 04 28 28 WL1 not used grounded 29 E 29 Gate signal SCR 2 05 30 iv 30 0V GNDP 31 5 31 Gate signal SCR 3 06 32 ss 32 Motor overtemperature 33 33 Enable reverse MN power bridge 34 sis 34 Enable forward MP power bridge For connector X5 and XTM signals see Table 28 Power Supply Filter Board to Pulse Transformer Board Connections on page 135 For connector XCD and XUVW signals see Table 31 Transient Noise Board to Pulse Transformer Board Connections on page 136 132 Rockwell Automation Publication 20
12. MOOO 42 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Install the DPI HIM Assembly Install the DPI HIM assembly in reverse order of removal Protective Cover Removal Remove the Protective Covers from the Drive and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 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 Disconnect DPI cable 8 Tightening torque Tightening torque 0 8 N m 7 Ib in 0 8 N m 7 Ib in Rockwell Automation Publication 20P TG003A EN P February 2012 43 Chapter3 Access Procedures 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 See step 5 below for instructions DENN Tightening torque Tightening torque 0 8 N m 7 Ib in 0 8 N m 7 Ib in
13. 0ccccccecuceeeveueee No Field C uttetbaos vee ioten tion duele isa elem braces Power Component Test Procedures cerei Check the Armature SCR Modules Lseeeeueue Check the Pulse Transformer Board Lueuuue Check the Field SCR Dual Diode Module Speed Feedback Device ests iu see sonas Sono xpi ba PRene te Check the Encoder i eee RE ERE EE ae Check the DC Tachometer ecce ted eret Ree Check the Resolver Interface Board 0 cccceecececeeees Thermistors and Thermal Switches 0 cccccececeseeeees Relay Outputs uos ci uere reo tectae cete Nt pea Lh cuu Create Pale Report sunt teenin ades Fase epo eda dat What You Need When You Call Tech Support Rockwell Automation Publication 20P TG003A EN P February 2012 Table of Contents Access Procedures Chapter 3 Remove Power from the Drive lecce ee 42 DPI HIM Assembly Removal and Installation Lise 42 Remove the DPIAHIM Asset ubly 55523555295 252 99232545 998 SAYS 42 Install the DPI HIM Assembly uec terre et erede 43 Protective Cover Removal and Installation 0c cece eee 43 Remove the Protective Covers from the Drive usus 43 Install the Protective Covers on the Drive 000 00000 45 Field Circuit Fuses Removal and Installation 45 Remove the Field Circuit Fuses 0cccccececeeescnees 45 Install
14. Configure the Pulse Transformer Circuit Board The new pulse transformer circuit board must be configured to match the drive size armature output current and HP rating The steps required to configure the pulse transformer board are different based on the revision code of the pulse transformer board See either Configuring a Pulse Transformer Board FIR3 xx_ Rev L and Lower on page 67 or Configuring a Pulse Transformer Board FIR3 xx Rev M and Higher on page 69 66 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Configuring a Pulse Transformer Board FIR3 xx Rev L and Lower IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm 1 Cutand remove the appropriate sizing resistor s if necessary from the pulse transformer board based on the drive AC input voltage armature output current and HP rating shown in Table 12 and Table 13 in the Sizing Resistors Configuration section below Sizing resistors are located in the center of the pulse transformer circuit board OG en Si Rs eet 9 AA R eomm E o Sizing Resistors Configuration The tables below 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 transfo
15. Replace the pulse transformer board Repair the short circuits 138 Rockwell Automation Publication 20P TG003A EN P February 2012 Flow Charts Appendix C Field Current Loss Failure Measure the voltage at terminals U1 V1 Is the correct voltage present at U1 V1 Remove AC power and remove and test the fuses FU1 FV1 at the bottom of the drive Are the fuses blown Test the resistance of the motor field wiring and motor field for short circuits Are terminals short circuited Repair short circuits No No The charts below presents the steps in flow chart form for troubleshooting a Field Current Loss fault F6 No Field Current Verify the wiring and power source to U1 V1 and correct any problems Disconnect cable from XR on the control board and measure the U1 V1 voltage synchronization signal at pin 11 on the cable This signal should be a square wave signal with a 90 lag phase displacement compared to the AC voltage signal Measure the gate signals at pins XR 1 and XR 2 on the cable Are the signals present and correct Replace the control board Check the field SCR dual diode module for a short circuit condition Replace the field No fuses at FU1 and FV1 and apply power to the drive Does a sh
16. Chapter 2 34 Component Test Procedures 6 Check the anode to cathode junction ofthe field SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules See Table 10 and Figure 10 below If a low resistance is detected replace the modules See Field SCR and Dual Diode Module Removal and Installation on page 72 Ifa 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 on page 35 Table 10 Field SCR Dual Diode Module Anode to Cathode Junction Measurements MeterLead Meter Lead Nominal meter reading Terminal Terminal U1 a open or ee U1 D1 open or ee V1 a open or ee V1 D1 open or co a D1 open or ee a U1 open or co a V1 0 50V D1 a 0 50V D1 U1 0 45V Figure 10 Field Terminal Block Location A DANGER RISK_OF ELECTRIC SHOCK DISCONNECT INPUT POWER BEFORE SERVICING EQUIPMENT D 9 ET AT ME EY LY EE D1 C1 U1 V1 Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Figure 11 Field Fuses Location The field fuses are located on the control EMI shield next to the control board 7 Remove the cable from connector XP on the pulse transformer circuit board See Figure 25 on page 130 for connector location
17. Remove screws and washers Remove cable Rockwell Automation Publication 20P TG003A EN P February 2012 71 Chapter3 Access Procedures Install the Field Power Circuit Board Install the field power board in reverse order of removal e Tightening torque for the screws connecting the field power board to the field SCR and dual diode modules is 2 5 4 0 Nem 22 35 Ib in Field SCR and Dual Diode Remove the Field SCR and Dual Diode Module Module Removal and m Meneral oaiety Precautions on page 1U Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the field power circuit board See Remove the Field Power Circuit Board on page 71 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 6 Remove the orange and yellow cables from connectors KIG1 and K2G2 on the top left side of the pulse transformer board Remove cables gum ume o dm den e TN qon uzo aco ATO agn non Aba igh EN T7 o M o s ron fe d ep ch ome 9 72 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 7 Remove the two screws and washers
18. MP 34 Positive bridge MP active when high 5V Rockwell Automation Publication 20P TG003A EN P February 2012 21 Chapter2 Component Test Procedures Figure 3 Figure 4 and Figure 5 below 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 XY 19 2 5V offset The ground signal is taken on either testpoint XY10 or XY18 Figure 3 Good SCR Gate Pulse and Armature Current Signals Example 9 Feb 96 Inpulsi su X 23 Is su XY17 File Inpulsi tiF REMOTE ENABLE 13 27 59 DEED UU tT 60 TO Z ns LOCAL 5 9 V 5V 2 e ns 200 av 0v 2 XY19 2 nz B 5 v wa A 2280 nV Cj 25 kS s 3 5 v Dij Ll HFREJ 0 1 V 456 nV Cj O STOPPED Figure 4 Good SCR Armature Voltage and Motor Current Signal Example S Feb 96 Chi Vara XY19 Ch2 Ia Xv17 File EMF tif REMOTE ENABLE 16 07 47 qj 4 Go TO 2 ns LOCAL 8 56 V tn 2 2 ns 200 ny XY17 2 XY19 e ns 50 v pc 2 20 nv DC 5 kS s 3 5 V pct L 1 FREJ 6 61 V 4 58 nv DC O STOPPED 22 Rockwell Automation Publication 20P TG003A EN P February 2012 Troubleshoot a Field Current Loss Fault Component Test Procedures Chapter 2 A malfunctioning thyristor is connected to the relative gate
19. 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 Table 11 below Ifa low resistance is detected replace the SCR dual diode module See Field SCR and Dual Diode Module Removal and Installation on page 72 Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Nominal meter reading 10 20Q Measure from XP1 XP3 XP4 Rockwell Automation Publication 20P TG003A EN P February 2012 35 Chapter2 Component Test Procedures Speed Feedback Device Tests 36 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 The encoder power supply from the drive can be measured from V to COM with a digital multimeter If 21 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 AV 15 2V For reference see Figure 19 on page 126 for a schematic diagram The Channel A and Channel B are square wave type outputs that are 90 degrees out of phase When rotat
20. See Move the Control EMI Shield on page 58 7 Disconnect the wires from connectors X5 XTM and XUV on the power supply filter board Remove connections Rockwell Automation Publication 20P TG003A EN P February 2012 87 Chapter3 Access Procedures 8 Remove all connections from the top of the terminal blocks on the power supply filter board 9 Remove the two screws and washers that secure the top of the power supply filter board to the drive and remove the board from the drive Remove screw and washer Remove screw and washer Remove wires Install the Power Supply Filter Circuit Board Install the power supply filter board in reverse order of removal 88 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Armature Leg Fuses Removal Remove the Armature Leg Fuses and Installation Note This procedure requires the use of a 17mm open ended wrench 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 IMPORTANT Itis necessary to remove the transient noise filter circuit board in order to remove the fuses from the V phase input bus bars 4 Remove the two screws and washers that secure the bottom of the es 1 g TAT j transient noise filter board to the drive Remove screws
21. After disconnecting power allow time for cooling 10 Rockwell Automation Publication 20P TG003A EN P February 2012 Hardware Description Before You Begin Testing Maintenance or Repairs Chapter 1 The PowerFlex DC drive contains a power structure that has an armature and field supply The armature supply consists ofa 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 C 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 s 0 0 5A 1 Phase Frame C ee B zn MMT TMM IU Rockwell Automation Publication 20P TG003A EN P February 2012 11 Chapter1 Before You Begin Testing Maintenance or Repairs Commonly Used Tools 12 Service Tools This list of basic service tools which will cover needs of tools for repair and maintenance measurements Item Digital Multimeter Details Digital multimeter capable of ac and dc voltage continuity resistance and forward diode bias tests Fluke model 87 IIl or equivalent recommended Oscilloscope Portable digitizing dual channel scope with
22. Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Preface Before You Begin Testing Maintenance or Repairs Component Test Procedures Table of Contents About This Publication eese Who Should Use this Manual eee Additional Resources lessen Chapter 1 Introductie ien p De a a A E Yen General Safety Precautionse uo ee aed e UE EHE ee Hardware Description srs serie oana a odes at E E tu pim Commonly Used Toolszuii tres drone ee chon Et Ibo ee aad ab de a Service Tools cers horens ute fts E Ope ut ere Software Lools dine dion la coats phere kennel Doha m dote ba ais Soro Chapter 2 Introduction ai coms Se a ee ear iE durs vigeat Save the Parameter Cobfiguratlohs ee catu psyeatonsrweewnetwsnonanan Sav toa HIM S t o etnies sas qur RE eeeees de Download Parameters to an Offline Node File Visual Component Inspections 5232 et e ede da ed E RERRENE oe Troubleshoot a Control Power Supply Failure euuuu Testing the Switching Power Supply and Pulse Transformer Bots eects E docs e cete te idol ues dtm eura n Testing the Control and Field Board Connections Troubleshoot an AC Undervoltage Fault seeeeuueeeue Troubleshoot an Armature Bridge Failure eee evinced vas nr Troubleshoot a Field Current Loss Fault 0 00 c cece eee eee Low or Incorrect Field Current
23. Layout 2V1 X3 2U1 amp 2C1 2C1 amp 2D1 2D1 1 TA1 D CD amp XFCD For connector X3 signal see Table 20 Pulse Transformer Board to Field Power Board Connections on page 131 For connector XFCD signal see Table 27 Control Board to Field Board Connections on page 134 Figure 29 Power Supply Filter Board Layout X5 1 XUV XTM 1U3 1V3 D1 C1 Ui V1 81 82 35 36 75 76 78 79 U2 V2 PE U3 V3 Table 28 Power Supply Filter Board to Pulse Transformer Board Connections Power Supply PinNumber to PinNumber Pulse Transformer Description Filter Board Board Connector Connector 1 1 2 2 24V common X5 X5 3 3 24V supply 4 4 not used 1 1 XTM 2 2 XTM 250V AC maximum from motor PTC Table 29 Power Supply Filter Board to Switching Power Supply Board Connections Power Supply Pin Number to PinNumber SwitchingPower Description Filter Board Supply Board Connector Connector 1 1 Single phase 115V 230V AC 2 2 XUV 3 3 XUV Not used 4 4 Single phase 115V 230V AC Rockwell Automation Publication 20P TG003A EN P February 2012 135 AppendixB Board Layouts and Connections Table 30 Power Supply Filte
24. T XP3 P2 P3 A 15 Resolver interface board E Remove stand offs Tightening torque for re assembly is 0 7 Km 62 Ibin i S1 B B LI m O O 22 23 24 25 26 27 28 29 30 30 32 33 34 35 36 37 38 39 40 E OO00000000 0000000000 kc KEES TON Heseseveeolizunesresn QOOOO 00000000 OOOOOOOOCO OOO0000000 50 Rockwell Automation Publication 20P TG003A EN P February 2012 Remove screws and board Tightening torque for re assembly is 0 7 N m 6 2 Ib in Access Procedures Chapter 3 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
25. 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 Usinga voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5 V offset See Figure 1 on page 18 and Figure 2 on page 19 for location of the testpoints Also see Figure 14 on page 123 for a schematic diagram Table 1 Combined AC Line Input Signal Testpoints IncomingAC Phases MeasureFrom ToTestpoint PeaktoPeak RMS Measurement Line Voltage Testpoint Measurement 240 VAC x E a s o 142VAC 0 500 V 480 VAC MM aa a 2 95 VAC 1 040V 575 VAC n an M 2 85 VAC 1 007 V 690 VAC x RE s a 3 45 VAC 1220V su Er2l zce Flle syel zz tlir REMOTE EH ELE S N 1 08 V PVT LONT beber bb n phe t bee FT POAT TA Y I X f i i j j SPA I A e v Dr TNT Z 1 v nga k5 fiver mE l iiid STOPPED e If any of the voltage measurements above are incorrect or missing continue with step 5 below 20 Rockwell Automation Publication 20P TG003A EN P February 2012 Troubleshoot an Armature Bridge Failure Component Test Procedures Chapter 2 e Ifthe voltage measurements above are correct but the value of pa
26. and washers 5 Move the control EMI shield See Move the Control EMI Shield on page 58 Rockwell Automation Publication 20P TG003A EN P February 2012 89 Chapter3 Access Procedures 6 Remove the two screws and washers that secure the top of the transient noise filter board to the drive and carefully lift the board off the drive Remove screws and washers Remove cable ties 7 If present remove the isolation sheet that is secured to the bus bars Remove isolation sheet Note Regenerative Drive Shown 90 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 8 If necessary disconnect the wire leads from the switches mounted on the top of the Armature circuit fuses two each fuse IMPORTANT Note the numbered position of each wire on the fuse for proper installation ofthe new fuses Remove wire leads 9 Remove the two screws that secure each switch to the fuse and remove the switch Retain the switch for reuse Remove screws Rockwell Automation Publication 20P TG003A EN P February 2012 91 Chapter 3 92 Access Procedures 10 Remove the bolts and washers top and bottom that secure the fuse to the bus bars and remove the fuse IMPORTANT Note the order ofthe washers as you remove them in order to install in the proper order Remove bolts and washers Install the Armature Leg Fuses Install the armature leg fuses in reverse order of remov
27. board in reverse order of removal Pulse Transformer Circuit Remove the Pulse Transformer Circuit Board Board Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 62 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 S Remove the four screws two on either side of the drive frame that secure the slotted air flow plate to the top of the drive and remove the plate Remove four screws Screws shown removed IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly Rockwell Automation Publication 20P TG003A EN P February 2012 63 Chapter3 Access Procedures 6 Remove the appropriate gate leads e For non regenerative drives remove each pair of orange and yellow gate lead cables from connectors KG1 KG6 and push each lead through the appropriate opening in the board e 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
28. e Complete the Test With the Motor Without a Mechanical Load below This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load This procedure requires a HIM to configure and autotune the drive If you prefer you can use the DriveExplorer or DriveExecutive software up procedure Some of the voltages present are at incoming line potential To ATTENTION Power must be applied to the drive to perform the following start BR W N avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to then drive Correct the malfunction before continuing Verify that the input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected Verify that the control board DIP switches are set correctly See Install the Control Circuit Board on page 58 for more information wA Apply power to the control circuits terminals U2 and V2 of the drive 6 Verify that the following parameter values are set correctly 45 Max Ref Speed is set to the motor nameplat
29. modules in the drive e For regenerative drives see Remove the Bus Bars from a Regenerative Drive on page 95 e For non regenerative drives see Remove the Bus Bars from a Non Regenerative Drive on page 97 94 Rockwell Automation Publication 20P TG003A EN P February 2012 Remove the Bus Bars from a Regenerative Drive Access Procedures Chapter 3 8 Remove the six bolts and washers that secure the intermediate bus bars to the U and W phase AC input and DC output terminals C and D bus bars Note the size and location of the bolts and washers are placed on the bolts the order in which the Remove bolts Remove bolts and washers and washers Nut Lock washer Flat washer Bolt Size and Washer Order Left to right two 2 Left to right two 2 bolts 40mm nuts lock washers long and flat washers Bolt 30mm long Flat washer and flat washers i N 4 H E am Left to right two 2 flat Hat washer j Bolt 30mm long amp se washers lock washers Left to right two 2 flat and nuts washers and bolts 40mm long Rockwell Automation Publication 20P TG003A EN P February 2012 gt Hat washer Lock washer I Nut 95 Chapter3 Access Procedures 9 Remove the bolt 24 mm long and washers that secure the L shaped bus bar
30. of bar 106 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Install the AC Current Transducers Install the AC current transducers in reverse order of removal IMPORTANT Notethe color and location of the signal wires to ensure that each wire is properly connected during installation The wires connected to the left CT are red and white and the wires connected to the right CT are blue and black Left AC Current Transducer Right AC Current Transducer Right CT blue and black wires Left CT red and white wires Bimetal Thermostats Remove the Bimetal Thermostats Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 Rockwell Automation Publication 20P TG003A EN P February 2012 107 Chapter3 Access Procedures 5 If present remove the isolation sheet that is secured to the bus bars Remove isolation sheet IMPORTANT You must remove the bus bars and for regenerative drives one SCR module from each pair for non regenerative drives all SCR modules in order to easily access and remove the bimetal thermostats 6 Remove the bus bars in order to access the bimetal thermostats in the dri
31. of the pulse transformer board 9 Remove the cables from connectors XTM X4 and X5 at the top left side of the pulse transformer board Remove cables ES gel asin g AUI un TI acm cu Ly acu oR mco Wc m n wen ma m 10 Remove the cables from connectors XCD XUVW and X3 at the top right side of the pulse transformer board Remove cables 11 Remove the cables from connectors X3 and XFCD on the field power board 76 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 12 Remove the four screws and washers that secure the wire leads connections 2V1 2U1 and 2C1 and one unmarked from the field power board and set the wires aside Remove cable mit cnm Remove screws washers and wires Remove screws washers and wires ECS1817 SN FC c Remove cable Rockwell Automation Publication 20P TG003A EN P February 2012 77 Chapter 3 78 Access Procedures 13 Remove the four screws and washers two on either side of the drive frame that secure the support plate for the pulse transformer and field power boards to the drive frame and remove the support plate and boards Front of Drive Remove screws and washers both sides of drive frame 14 If present remove the isolation sheet that is secured to the bus bars Remove isolation sheet Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 15 Remove the bol
32. persist replace the resolver interface and or resolver feedback board e Measure the signal voltage at the testpoints as indicated in the following table See Figure 12 on page 38 for testpoint locations Testpoint to Testpoint Measurement 12V 0012 12V DC 5 12V 10V12 12V DC 5 24V VI lt 10V24 24V DC 5 45V 1085 5V DC 5 If any of the voltage measurements fails replace the resolver interface board Rockwell Automation Publication 20P TG003A EN P February 2012 37 Chapter2 Component Test Procedures Figure 12 Resolver Interface Board Testpoint Locations 12V 12V npo ay C az P2 P3 D10 j 5V 5V pe BB d is Covs o5 0V12 C 0v12 D26 bres 424V VI 24V_VI B oes D11 pa C B o Mos 03 QE ov24 C VR tal C a mE AD Teor 1 5V pos S1 12V pos D18 B a pe 1 24V pos ne B5 Q s oe che S S1 1 e oe em S2 Internal supply pos E 2 EISNSS S2 External supply pos L C a om PED TB1 TB2 38 Rockwell Automation Publication 20P TG003A EN P February 2012 Thermistors and Thermal Switches Relay Outputs Component Test Procedures Chapter 2 Motor overheating is detected by an external user
33. 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 ATTENTION 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 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 e Sending an erroneous signal to your system s field devices causing unintended machine motion e 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 ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive
34. table below set with DIP switch 14 on the control board Switch ohms 168 5 333 3 182 36 4 845 1668 13333 Equivalent Resistance Field Current Field S14 1 S14 2 S14 3 S14 4 S14 5 S14 6 S14 7 S14 8 Ohms Scale Supply 1A 10A OFF OFF OFF OFF OFF ON 1668 2A OFF OFF OFF OFF ON OFF 845 3A OFF OFF OFF OFF ON ON 560 9 5A OFF ON OFF OFF OFF OFF Notused 3333 10A ON OFF OFF OFF OFF OFF OFF 168 5 13A 14A ON OFF OFF OFF ON ON 129 6 17A 20A OFF ON ON OFF ON ON 97 3 20A ON OFF ON OFF OFF ON 83 1 e If the resistance measurement is incorrect replace the field board 24 Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 No Field Current Note For a flow chart version of these steps see No Field Current on page 139 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Protective Cover Removal and Installation on 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 on page 124 for a schematic diagram e If the voltage is correct continue with step 4 below e If the voltage is incorrect or missing remove power from the drive 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 corre
35. 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 S727F 11 13 Nm 97 4 115 Ib in SK 20P S737F 11 13 Nem 97 4 115 Ib in SK 20P S770F 11 13 Nm 97 4 115 Ib in SK 20P S771F 11 13 Nem 97 4 115 Ib in 100 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 AC Current Transducers Remove the AC Current Transducers Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Remove the eight screws and washers that secure the Lexan shields to the bottom of the drive and remove the shields Remove screws and washers Remove screws and washers 5 Remove the power wiring from the U and W phase AC input power terminals Rockwell Automation Publication 20P TG003A EN P February 2012 101 Chapter3 Access Procedures 6 Remove the screws that secure the ground wires to the PE terminal from the transient noise filter board and U phase power terminal from the pulse transformer board and remove the wires Transient noise filter board PE ground stud Remove ground wire Remove screw and wire 7 Remove the l
36. the last fault 40 Rockwell Automation Publication 20P TG003A EN P February 2012 Chapter 3 Access Procedures opi s Tre RemwePowerfomteDie S qd DPI HIM Assembly Removal and Installation 42 Protective Cover Removal and Installation 43 Field Circuit Fuses Removal and Installation 45 Communication Adapter and EMI Shield Removal and Installation 46 Resolver Feedback and Interface Circuit Board Removal and Installation 48 1 0 Expansion Circuit Board Removal and Installation 52 115V AC to 24V DC 1 0 Converter Circuit Board Removal and Installation 54 Control Circuit Board Removal and Installation 55 Control EMI Shield Removal and Closure 58 Switching Power Supply Circuit Board Fuse Removal and Installation 60 Switching Power Supply Circuit Board Removal and Installation 61 Pulse Transformer Circuit Board Removal and Installation 62 Field Power Circuit Board Removal and Installation 7 Field SCR and Dual Diode Module Removal and Installation Pi AC Line Snubber Circuit Board and Resistors Removal and Installation 74 Transient Noise Filter Circuit Board Fuses Removal and Installation 81 Transient Noise Filter Circuit Board Removal and Installation 82 Power Supply Filter Circuit Board Removal and Installation 86 Armature Leg Fuses Removal and Installation 89 SCR Modules Removal and Installation 91 AC Current Transducers Removal and Installation 101 Bimetal T
37. the value selected with switch 14 must be entered in Par 374 Rated 14 2 Field Curr in the control software when the drive is commissioned 14 3 14 4 14 5 14 6 14 7 not used 14 8 not used 15 Configuration of the control circuit board to the appropriate drive size This value is 15 1 set to the appropriate size at the factory S15 2 15 3 15 4 15 5 15 6 15 7 15 8 20 Monitoring of the Z channel of the Digital Encoder on connector XE2 Off Position Z channel monitored On Position Z channel not monitored The 20 setting should match the value selected in Par 652 Encoder Err Chk for example if S20 Off then Par 652 1 Enabled 21 Encoder power supply voltage and input adaptation selection Note When control power is supplied to the drive the appropriate LED lights to indicate the selection of the switch ENC_5 5 V encoder 2 5 5 4V input range ENC_12 12 15 V encoder 5 4V 15 2V input range IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 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 Disconnect cables Disconnect 1 0 and control wiring 11 Remo
38. three internal armature leg fuses Note the order of the washers on the bolt 9 Remove the bolts and washers that secure the metal plate and L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar Remove bolt lock washer Bot flat washer metal plate and L shaped bus bar Lockwasher es Remove bolt lock washer Flat washer m and flat washer Lr E 1 Fuse I poem 10 Remove the bolts and washers that secure the horizontal bus bars to the C and D vertical power terminal bus bars Note the size and location ofthe bolts and the order in which the washers are placed on the bolts Remove bolts lock washers flat washers Bolt and Washer Order EEJ Ea Hi Left to right bolts and flat washers Left to right flat washers lock washers and nuts 112 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 11 Remove the bolts and washers that secure the horizontal bus bars to the SCR modules and remove the bus bars Remove bolts and washers and bus bars Continue with Remove the SCR Modules and Bimetal Thermostats below Remove the SCR Modules and Bimetal Thermostats 1 Remove the remaining bolts washers
39. 107 remove 101 ACline snubber board and resistors install 81 remove 74 armature bridge failure troubleshoot 21 armature leg fuses install 92 remove 89 armature SCR modules test 27 bimetal thermostats install 115 remove 107 C circuit board connections 129 layouts 129 communication adapter and EMI shield install 47 remove 46 components inspection 15 configure pulse transformer board 66 sizing resistors 67 contactor fault 39 control circuit board install 58 remove 55 control EMI shield move 58 control power supply failure 15 cooling fans install 118 remove 115 D DCanalog tachometer test 36 DIP switches 3 4 69 download parameter configuration 14 DPI HIM assembly install 43 remove 42 Rockwell Automation Publication 20P TG003A EN P February 2012 Index Electrostatic Discharge Precaution 10 encoder test 36 fault field current loss 23 heatsink overtemperature 39 main contactor 39 overcurrent 21 power failture 15 fault report create 40 field circuit fuses install 45 remove 45 field current loss fault 23 field power board install 72 remove 71 field SCR and dual diode module install 73 remove 72 field SCR dual diode module test 33 frame size 11 hardware description 11 heatsink overtemperature fault 39 1 0 converter circuit board install 55 remove 54 1 0 expansion circuit board install 53 remove 52 inspection visual 15 141 install AC current transducers 107 AC line snu
40. 15A F2 2 5A 250V fuse 250V fuse Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Switching Power Supply Remove the Switching Power Supply Circuit Board Circuit Board Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Disconnect the cables from connector XA and XUV on the switching power supply board IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 6 If present disconnect the jumper from terminals SA SB IMPORTANT Besureto replace the jumper between terminals SA SB if using 115V AC control input power when installing a new switching power supply board pP LULL MM Disconnect cables and wiring Rockwell Automation Publication 20P TG003A EN P February 2012 61 Chapter3 Access Procedures 7 Remove the six screws and washers that secure the board to the control EMI shield and remove the board IMPORTANT DO NOT remove the isolation shield below the board unless it is damaged and you are replacing it with a new sheet Remove six screws and washers Install the Switching Power Supply Circuit Board Install the switching power supply
41. 2 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact y
42. 8 Chapter 4 Test With the Motor Without a Mechanical Load 119 Appendix A List of Schematic DEASEAPUS aestus delete cir ait pb DG See tal dps 121 Appendix B List of Board Layouts i tcc o en tr te 129 Pulse Transformer Board vceucecercetbceve Rt ES cte bod slos 130 Switching Power Supply Board i eer rrr e 133 Control Board aoi da SE Use Sra tea die oci etel uf cu a 134 Field Power Board a es co udo hu Puente d S SENSU 135 Rockwell Automation Publication 20P TG003A EN P February 2012 5 Table of Contents Appendix C Flow Charts pascat Flow C Itu ooi ter ED Idas dieit ic idt ti 137 Control Power Supply Pailute s cisces capo tesa See e dag iate 138 Field Current Loss Failitess 2 355075 3226030433 3G SURE 3 2224450 139 No Field Ciirtent recessu terrere Mo Tu ber eSI eed Ti 139 Low or Incorrect Field Current eve ceci rra de Res 140 Index 6 Rockwell Automation Publication 20P TG003A EN P February 2012 About This Publication Who Should Use this Manual Additional Resources Preface This manual contains hardware service information for frame C PowerFlex DC drives only It is highly recommended that you obtain a copy of the PowerFlex Digital DC Drive User Manual publication 20P UM001 which contains fault alarm and programming information to assist you in troubleshooting drive errors and determining if repairs are necessary This manual is intended for qualified service personnel responsible
43. Armature Pulse Transformer Primary Measurements for Regenerative and Non board Regenerative Drives ForSCR MeterLead Meter Lead 1 01 XY 8 XY 1 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 Meter reading 0 410 Connector XY Pinout 0000000000 10 Table 9 Armature Pulse Transformer Primary Measurements for Regenerative Drives ForSCR 4 Meterlead Meter Lead 1 XY 7 XY 1 4 XY 7 XY 4 2 XY 7 XY 2 5 XY 7 XY 5 3 XY 7 XY 3 6 XY 7 XY 6 Meter reading 0 410 Check the Field SCR Dual Diode Module Connector XY Pinout 0000000000 10 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 Read the General Safety Precautions on page 10 Remove and lock out all incoming power to the drive See Remove Power from the Drive on page 42 Remove the protective covers See Protective Cover Removal and Installation on page 43 Verify that contactor power if used is removed Rockwell Automation Publication 20P TG003A EN P February 2012 Verify that power to an external field supply if used is removed 33
44. Automation Publication 20P TG003A EN P February 2012 115 Chapter3 Access Procedures 5 Locate the cooling fan terminal block and loosen the screws that secure the fan power supply wires to the terminal block The cooling fan terminal block is located below the internal armature leg fuses and between the phase V and W AC input bus bars Terminal C of DC output Phase V bus bar Loosen screws Armature leg fuse Phase W bus bar 6 At the bottom of the drive remove the two screws that secure the fan to the drive frame and pull the fan away from the drive Remove screws 116 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 7 Remove the screw that secures the ground wire to the fan chassis and remove the ground wire Remove screw and wire 8 Remove the loosened fan power supply wires from the terminal block and remove the fan Remove wires from terminal block Rockwell Automation Publication 20P TG003A EN P February 2012 17 Chapter3 Access Procedures Install the Cooling Fans Install the cooling fans in reverse order of removal 118 Rockwell Automation Publication 20P TG003A EN P February 2012 Test With the Motor Without a Mechanical Load Chapter 4 Start Up After Repair Before applying power to a repaired drive perform the following tests e Check the Armature SCR Modules on page 27 e Check the Field SCR Dual Diode Module on page 33
45. Circuit Board Removal and Installation on 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 130 for connector locations If any of the actual measurements are out of tolerance replace the pulse transformer board Table 6 Armature Pulse Snubber Circuit Measurements for Regenerative Drives ForSCR Measure From To 1 KG1 XY 4 4 KG4 XY 1 2 KG2 XY 5 5 KG5 XY 2 3 KG3 XY 6 6 KG6 XY 3 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 Meter reading open circuit Connector XY Pinout e 10 o o o o o o o o 4 Table 7 Armature Pulse Snubber Circuit Measurements for Non Regenerative Drives ForSCR Measure From To 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 32 Rockwell Automation Publication 20P TG003A EN P February 2012 Meter reading open circuit Connector XY Pinout o 10 o o o o o o o o j ae Component Test Procedures Chapter 2 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 Table 8
46. Filter Circuit Board 81 Install the Fuses on the Transient Noise Filter Circuit Board 82 Transient Noise Filter Circuit Board Removal and Installation 82 Remove the Transient Noise Filter Circuit Board 82 Install the Transient Noise Filter Circuit Board 86 Power Supply Filter Circuit Board Removal and Installation 86 Remove the Power Supply Filter Circuit Board 86 Install the Power Supply Filter Circuit Board 88 Armature Leg Fuses Removal and Installation isse 89 Remove the Armature Leg Fuses esee S dete y ERE 89 Install the Armature Leg Fuses eset rer ret eee 92 SCR Modules Removal and Installation 0 ccc cece eee ees 93 Remove the SCR Modules ccc cece ccecncceceeeeees 93 Install the SCR Modules acce o tee et ba credet amr 100 AC Current Transducers Removal and Installation 101 Remove the AC Current Transducers 0 0ceeeeeeeeeee 101 Install the AC Current Transducers eeeess 107 Bimetal Thermostats Removal and Installation 107 Remove the Bimetal Thermostats 00cececceeeevece 107 Install the Bimetal Thermostats ccccececceceeeece 115 Cooling Fans Removal and Installation 00 000 115 Remove the Cooling Fans i5 sois recess ee Oe ERG 115 Install che Cooling Fans ers sessu o EN ROTER weak eas seas 11
47. 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 Fab St scr open Ch X825 Ch Ia File scr Fail ti REMOTE ENABLE i 60 TO LOCAL ST 91 99 99 1 O9 719 99 99 pM 999 99 9 i Alan RA LIU NU XY19 Lt E E ree er T V OC z m eo 1 HFREJ 8 1 V 5 V DE i 58 rV OC 5 STOPPED 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 below If the drive faults with a Field Current Loss fault F6 and there is no field current present at the motor as seen in parameter 351 Field Current complete the steps in No Field Current on page 25 Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 140 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 3 Verify that the drive rated field bridge current is set correctly in parameter 374 Drv Fld Brdg Cur and DIP switch S14 is configured to correctly according to the instruction
48. Hardware Service Manual Allen Bradley PowerFlex Digital DC Drive Frame C 150 500 Hp 112 373 kW 3 VUE ITE i m iS t ere E l BRA KL M o TT F a 2 2 ss S 4 VERIS ee eo Mu Hi x hs P E yi Vi rr b rs 1 4l 5 si haf y 454 baie D I E a 74 3 a Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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
49. Markall connections and wires before removal to avoid incorrect wiring during reassembly 4 Remove the plug in I O terminal block with the wiring kept in place 5 Remove the two screws that secure the I O converter board to the stand offs on the control board and remove the I O converter board E gt FE hinu tinne hiiu 5 p E ures SA ole isi a EII Remove two screws Tightening torque for re assembly is 1 0 N m 8 9 Ib in 6 Remove the two stand offs and washers from the control board Remove two stand offs and washers Tightening torque for re assembly is 1 0 N m 8 9 Ib in Rockwell Automation Publication 20P TG003A EN P February 2012 Control Circuit Board Removal and Installation Access Procedures Chapter 3 Install the 115V AC to 24V DC 1 0 Converter Circuit Board Install the 115V AC to 24V DC I O converter board in reverse order of removal Remove the Control Circuit Board 1 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 Refer to the PowerFlex DC Digital Drive User Manual publication 20P UM001 for information on using the HIM or the on line help provided with DriveExecutive for more information on HIM Sets or using the HIM Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the protec
50. N P February 2012 Remove screws and board Tightening torque for re assembly is 0 7 N m 6 2 Ib in Access Procedures Chapter 3 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 Theresolver 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 sms parem e XA F Li O QD B i eti XP3 e 2 P3 15 S1 B La B Hi O O P1 22 23 24 25 26 27 28 29 30 30 32 33 34 35 36 37 38 39 40 E OOOOOOOOOO OOOOOOOOCOO0 SAB C FLIER 1234567881011285 618 1 20 00000 00000000 OOOOO00000 0000000000 Rockwell Automation Publication 20P TG003A EN P February 2012 49 Chapter3 Access Procedures 6 Remove the three stand offs from the resolver interface board ER E aoe eee XR N XA O
51. P TG003A EN P February 2012 Switching Power Supply Board Board Layouts and Connections Appendix B Figure 26 Switching Power Supply Board Layout xy SB SA F UL jJ 4 ir PD c d Z x c i ET S ZAS A SS e SWZ S E F aS DZ ZAS Table 26 Switching Power Supply Board to Control Board Connections Switching Power Supply Board Connector XA Pin Number to PinNumber Control Board Connector 1 1 XA 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 Rockwell Automation Publication 20P TG003A EN P February 2012 Description 5V 5V common 5V 5V common 5V 5V common 15V 15V common 15V 24V common 24V 133 AppendixB Board Layouts and Connections Control Board Figure 27 Control Board Layout XR O To DPI board on as HIM Bezel QO
52. Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the protective covers from the drive See Remove the Protective Covers from the Drive on page 43 IMPORTANT wiring during reassembly Mark all connections and wires before removal to avoid incorrect 4 Disconnect the plug in terminal blocks from the resolver feedback and resolver interface boards A Iesse EE e Aa XA n L Oo D TTSTITTRTSITRTIB TRISTE TETTE T TISTIMTIT XP3 H piti a did GP P2 P3 a Resolver feedback board 81 B B E Oo FEO O P1 22 23 24 25 26 27 28 29 30 3 32 33 34 35 36 37 38 39 40 db 5eee Oo0000000 oooooooooo Z1 3 2 28 25 27 28 25 35 s 32 33 34 38 38 37 38 38 40 A B CES EE COM 1234568789 Dll 2B EBI 1 19 20 00000 eee 000000 lOOOOO0O00000 0000000000 NOE 4 18 1738 18 26 Remove terminal blocks Rockwell Automation Publication 20P TG003A E
53. XA 14 15V analog supply 24V XY8 Figure 1 on page 18 XA 16 24V terminal block GNDV XY9 Figure 1 on page 18 XA 15 24V terminal block ground SVEXP SVEXP Figure 2 on page 19 XP3 1 XP3 2 XP3 3 5V for DPI expansion 12VEXP 12VEXP Figure 2 on page 19 XP3 4 XP3 5 12NV for DPI expansion OVEXP OVEXP Figure 2 on page 19 XP3 7 XP3 8 XP3 9 DPI expansion ground Note For a flow chart version of the steps that follow see Control Power Supply Failure on page 138 Rockwell Automation Publication 20P TG003A EN P February 2012 15 Chapter 2 Component Test Procedures Ifany of the signals in the table above is incorrect or missing verify that either 115 VAC or 230 VAC voltage is present at terminals U2 and V2 control circuit power input e If the voltage is present and correct continue with step 5 below e Ifthe 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 Remove AC control power from terminals U2 and V2 and remove and test the fuses F1 and F2 on the switching power supply board See Switching Power Supply Circuit Board Fuse Removal and Installation on page 60 for fuse location e If the fuse is blown continue with step 6 below e If the fuse is not blown replac
54. al IMPORTANT Verify that the washers are installed in the proper order and that the switches are installed on the correct fuse g e Lock washer L in Large washer Bolt I ra Fuse iem Large washer m Small washer l 4 Bolt Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 SCR Modules Removal and Remove the SCR Modules Installation IMPORTANT Itis recommended that you replace the armature leg fuses for each pair of SCR modules that you replace in the drive See Remove the Armature Leg Fuses on page 89 _ Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the gate leads from the pulse transformer board Non Regenerative Drive A am b WW c ibas MM i Tes seg FEJ Remove gate leads Regenerative Drive Rockwell Automation Publication 20P TG003A EN P February 2012 93 Chapter3 Access Procedures 6 If present remove the isolation sheet that is secured to the bus bars Remove isolation sheet Note Regenerative Drive Shown 7 Remove the bus bars in order to access the SCR
55. al meter reading 01 01 Pin6 Pin7 04 Pin 5 Pin4 02 02 Pin6 Pin7 1 05 Pin 5 Pin 4 5 20 Q 03 03 Pin 6 Pin7 06 Pin5 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 Gate Lead Connectors _ gt D D D D l e amp amp SCR SCR SCR Module 01 Module 02 Module 03 Gate Lead Front of Drive Pinouts Drive Heatsink JY Top View of SCR Module Rockwell Automation Publication 20P TG003A EN P February 2012 31 Chapter2 Component Test Procedures 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 Remove Power from the Drive on page 42 3 Remove the pulse transformer board see Pulse Transformer
56. al plates Bolt 32 mm long E Lock washer Nn Flat washer SCR Module IMPORTANT M Markall connections and wires before removal to avoid incorrect wiring during reassembly Rockwell Automation Publication 20P TG003A EN P February 2012 99 Chapter3 Access Procedures 2 Remove the gate leads that connect the SCR modules to the pulse transformer circuit board from the pulse transformer circuit board end 3 Remove the four screws that secure each SCR module to the heatsink and remove the SCR modules Note the order of the washers on the bolt Remove four screws Install the SCR Modules Install the SCR modules in reverse order of removal e Verify that each gate lead from the SCR modules is connected to the proper connector on the pulse transformer board e Apply thermal grease to the bottom of the SCR modules before securing them to the heatsink ATTENTION Thermal grease must be applied to the bottom of the SCR modules before securing them to the heatsink or damage to the drive may occur e 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 S727F 4 5 5 5 Nem 40 48 7 Ib in SK 20P S737F 4 5 5 5 Nem 40 48 7 Ib in SK 20P S770F 6 Nm 53 Ib in SK 20P S771F 6N m 53 Ib in e Use the following
57. all the Fuses on the Switching Power Supply Circuit Board 60 Switching Power Supply Circuit Board Removal and Installation 61 Remove the Switching Power Supply Circuit Board 61 Install the Switching Power Supply Circuit Board 62 Pulse Transformer Circuit Board Removal and Installation 62 Remove the Pulse Transformer Circuit Board LLL 62 Configure the Pulse Transformer Circuit Board 66 Install the Pulse Transformer Circuit Board Lusu 70 Field Power Circuit Board Removal and Installation 71 Remove the Field Power Circuit Board 0 cece cece e ee 71 Install the Field Power Circuit Board 00 c cece eee e ee 72 Field SCR and Dual Diode Module Removal and Installation 72 Remove the Field SCR and Dual Diode Module 72 Install the Field SCR and Dual Diode Module 73 Rockwell Automation Publication 20P TG003A EN P February 2012 Start Up After Repair Schematics Board Layouts and Connections Table of Contents AC Line Snubber Circuit Board and Resistors Removal and Fnstallatione Seats nose esce UN M rM ases aut beds Dice 74 Remove the AC Line Snubber Circuit Board and Resistors 74 Install the AC Line Snubber Circuit Board and Resistors 81 Transient Noise Filter Circuit Board Fuses Removal and Installation 81 Remove the Fuses on the Transient Noise
58. allation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 Rockwell Automation Publication 20P TG003A EN P February 2012 81 Chapter3 Access Procedures 5 Carefully remove the three fuses from the fuse holders on the transient noise filter board Remove fuses Back side of Control EMI shield Install the Fuses on the Transient Noise Filter Circuit Board Install the fuses on the transient noise filter board in reverse order of removal Transient Noise Filter Circuit Remove the Transient Noise Filter Circuit Board Board Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly Remove the ground wire from the PE ground stud on the drive frame 82 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 5 Remove the screw that secures the black lead from connection U on the transient noise filter board to the U phase po
59. and metal plates for regenerative drives only from the tops of the SCR modules Note the order of the washers on the bolts Note Regenerative drive shown Remove bolts and metal plates Bolt 32 mm long zB Lockwasher Flat washer SCR Module IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 2 Remove the gate leads that connect the SCR modules to the pulse transformer circuit board from the pulse transformer circuit board end Rockwell Automation Publication 20P TG003A EN P February 2012 113 Chapter3 Access Procedures 3 Remove the four screws that secure each SCR module to the heatsink and remove the SCR modules Note the order of the washers on the bolt Remove four screws 4 Remove the wires connected to the bimetal thermostats from connector X4 on the pulse transformer circuit board 5 Remove the solder from the connections on the two leads of the bimetal thermostats 6 Remove the bimetal thermostats from the heatsinks by unscrewing them at the base Remove solder and bimetal thermostats 114 Rockwell Automation Publication 20P TG003A EN P February 2012 Cooling Fans Removal and Installation Install the Bimetal Thermostats Access Procedures Chapter 3 Install the bimetal thermostats in reverse order of removal e Apply thermal grease to the bottom of the bimetal thermost
60. ashers and leads Rockwell Automation Publication 20P TG003A EN P February 2012 85 Chapter3 Access Procedures 13 Disconnect the cables from connector XCD and XUVW on the pulse transformer circuit board Remove cables VTE mm hi Suet V o t ix xx 02 D Ere at Or 14 Cut the cable ties that secure all cables and remove the transient noise filter board and cables from the drive Install the Transient Noise Filter Circuit Board Install the transient noise filter board and power supply filter board in reverse order of removal Power Supply Filter Circuit Remove the Power Supply Filter Circuit Board Board Removal and T General sarety Precautions on page 1U Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 86 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 4 Remove all wires from the bottom of the terminal blocks on the power supply filter board 5 Remove the two screws and washers that secure the bottom of the power supply filter board to the drive E ITE 5 36 75 76 78 79 U2 V2 PE Remove wires screws and washers 6 Move the control EMI shield
61. ative Drive SCR Module Layout 2 o E o o C amp amp e amp B 9 e amp amp e O O O O O O O O O O O O amp amp amp ig amp amp Cc O O O o O O SCR SCR SCR SCR SCR SCR Module 1 Module 01 Module 2 Module 02 Module 3 Module 03 C Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Table 3 SCR Anode to Cathode Junction Measurements for Non Regenerative Drives
62. ats before securing them to the heatsink ATTENTION Thermal grease must be applied to the bottom of the bimetal thermostats before securing them to the heatsink or damage to the drive may e Use the following table to determine the proper tightening torque for the screws that secure the SCR modules to the heatsink 230V AC Input Drive Current DC Amps ACLine Amps HP Final Torque Rating Code 521 521 426 150 6 N m 53 Ib in 460V AC Input Drive Current DCAmps AC Line Amps HP Final Torque Rating Code 495 495 404 4 300 4 5 5 5 Nem 40 48 7 Ib in 667 667 544 9 400 6 N m 53 Ib in e Use the following table to determine the proper tightening torque for the bolts that secure the bus bars to the SCR modules 230V AC Input Drive Current DC Amps AC Line Amps HP Final Torque Rating Code 521 521 426 150 11 13 N m 97 4 115 Ib in 460V AC Input Drive Current DC Amps AC Line Amps HP Final Torque Rating Code 495 495 404 4 300 667 667 5449 400 11 13 N m 97 4 115 Ib in Remove the Cooling Fans 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 Rockwell
63. bber board and resistors 81 armature leg fuses 92 bimetal thermostats 115 communication adapter and EMI shield 47 control circuit board 58 cooling fans 118 DPI HIM assembly 43 field circuit fuses 45 field power board 72 field SCR and dual diode module 73 1 0 converter circuit board 55 1 0 expansion circuit board 53 power supply filter board 88 protective covers 45 pulse transformer board 70 resolver feedback circuit board 51 resolver interface circuit board 51 SCR modules 100 switching power supply board 62 switching power supply board fuses 60 transient noise filter board 86 transient noise filter board fuses 82 M motor overheating 39 move control EMI shield 58 0 outputs relay 39 overcurrent fault 21 overtemperature heatsink 39 P parameter configuration download 14 save 14 power failure fault 15 power supply filter board install 88 remove 86 protective covers install 45 remove 43 PTC 39 pulse transformer board configure 66 install 70 remove 62 test 32 Rockwell Automation Publication 20P TG003A EN P February 2012 relay outputs 39 remove AC current transducers 101 AC line snubber board and resistors 74 armature leg fuses 89 bimetal thermostats 107 communication adapter and EMI shield 46 control circuit board 55 cooling fans 115 DPI HIM assembly 42 field circuit fuses 45 field power board 71 field SCR and dual diode module 72 1 0 converter circuit board 54 1 0 expansion circuit board 52 power sup
64. bles for burn marks cracks or loose connectors If necessary replace the cables connected to connector X3 X4 X5 XCD XR XSW X TA and XUVW on the pulse transformer board with the new cables provided e Inspect the existing gate lead cables for burn marks cracks or loose connectors If necessary replace the gate lead cables with the new cables provided from which it was removed on the pulse transformer circuit board or damage to f ATTENTION Each gate lead cable must be connected to the exact connector the drive may occur 70 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Field Power Circuit Board Remove the Field Power Circuit Board Removal and Installation Remove cable 1 Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 Move the control EMI shield See Move the Control EMI Shield on page 58 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 5 Remove the cables from connectors X3 and XFCD on the board Remove the seven screws washers and wire leads connections 2V1 2U1 and 2C1 and one unmarked from the board and remove the board from the drive Remove screws and washers ECS1817 SN Fc Ch d adi s i
65. bleshooting in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 Increase the speed command from zero to base speed by pressing the up button Measure the output voltage and verify that it is reflected in parameter 233 Output Voltage Measure the armature current and verify that the value is reflected in parameter 199 Arm Current Pct Stop the drive by pressing the stop button If these measurements are correct re configure the drive to suit the application Refer to Chapters 1 and 2 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for assistance If any of these measurements are incorrect repeat steps 8 15 If the measurements are still incorrect repeat the appropriate procedures in Chapter 2 Component Test Procedures beginning on page 13 Rockwell Automation Publication 20P TG003A EN P February 2012 List of Schematic Diagrams Schematics Appendix A Topic Page Figure 13 Circuit Board Interconnection Diagram 122 Figure 14 AC Line Measurement Points Diagram 123 Figure 15 Power Feedback Connections Diagram 123 Figure 16 Field Board and SCR Dual Diode Module Connections Diagram 124 Figure 17 Field Control Circuit Diagram 125 Figure 18 Control Circuit Input Power Diagram 125 Figure 19 Encoder Control Circuit Diagram 126 Figure 20 DC Tachometer Control Circuit Diagram 126 Figure 21 Motor Thermal Protection Control Ci
66. ce gt HIM and press 39 Doone ofthe following e If there are no existing HIM Sets enter a name using the TO and buttons to select the desired characters and press e e If there is an existing HIM Set press e to overwrite it or select No using the e button and use the and e buttons to select the desired characters Then press e The HIM Set will be saved to nonvolatile memory Download Parameters to an Offline Node File You can save all drive and adapter parameters in the drive to an offline database file on your computer using DriveExecutive An offline node file dno contains all information about the node including the necessary databases 1 From the Drive menu select Upload from Drive or click the upload button Ej on the toolbar 2 Click Yes to confirm the operation which cannot be undone 3 Ifyou are not connected to a drive the Connect to Drive dialog displays Select the drive to which you want to connect and click OK 4 A dialog displays the status of the upload operation Click Cancel to cancel the operation Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Visual Com ponent Inspection Visually inspect the drive 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 Remove Power from the Dri
67. ct If the voltage is correct but the fault persists or parameter 351 Field Current is incorrect continue with step 4 below Remove AC power to the drive and check the fuses at FU1 and FV1 See Remove Power from the Drive on page 42 e If the fuses are blown complete the steps in Test Field Wiring and Voltage Signals on page 25 e If the fuses are not blown complete the steps in Test Field Control Signals on page 25 Test Field Wiring and Voltage Signals 1 Test the resistance of the motor field wiring and motor field for possible short circuits e If there are no short circuits continue with step 2 below e Ifashort circuit exists correct any problems 2 Check the field SCR dual diode module for a short circuit condition See Check the Field SCR Dual Diode Module on page 33 e If there are no short circuits continue with step 3 below e Ifashort circuit exists replace the field SCR dual diode module 3 Replace the field fuses at FU1 and FV1 and apply power to the drive 4 Ifthe field fuses blow replace the field board 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 on page 134 for location of the XR connector on the control board Rockwell Automation Publication 20P TG003A EN P February 2012 25 Chapter2 Component Test Procedures This signal is a squar
68. d for resolver connections and the resolver interface board for external power status feedback board reset and encoder output connections Ifa Resolver Error F93 fault occurs and the resolver wiring and configuration are correct the following LED indicators and testpoints on the resolver interface board can be used to verify that the board is not damaged e Verify that the following LEDs are functioning as expected See Figure 12 on page 38 for LED locations and switch settings LED LED On State Off State Code Color D3 Red 24V overload fuse F1 blown This fuse is 24V supply is OK self resetting when it returns to normal operating temperature D10 Green 12V supply is OK Loss of 12V power D11 Green Resolver feedback board voltage is OK Voltage error on resolver feedback board D12 Blue Switch S1 is set to 24V for encoder signal S1is not set for 24V output on TB2 D16 Yellow Switch 1 is set to 12V for encoder signal 1 is not set for 12V output on TB2 D18 Green Switch 1 is set to 5V for encoder signal S1is not set for 5V output on TB2 D26 Red Resolver feedback board is in reset mode Resolver feedback board not in reset mode If any of the LEDs 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
69. d lower the control EMI shield until it rests on the drive chassis IMPORTANT Ifthe drive is not in a vertical position the control EMI shield will not stay open without a means of restraint Remove cable Install the Control EMI Shield Install the control EMI shield in reverse order of removal Rockwell Automation Publication 20P TG003A EN P February 2012 59 Chapter3 Access Procedures Switching Power Supply Circuit Board Fuse Removal and Installation 60 Remove the Fuses on the Switching Power Supply Circuit Board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the two fuses on the switching power supply board by inserting a screwdriver in the slot on the top of the fuse carefully pushing down and turning the fuse counterclockwise When the fuse holder releases remove the holder and fuse Remove fuses from holders Install the Fuses on the Switching Power Supply Circuit Board Install the fuses on the switching power supply board in reverse order of removal IMPORTANT _ Insert the 3 15A 250V fuse in the fuse holder designated F1 Insert the 2 5A 250V fuse in the fuse holder designated F2 LULL LLL Sage TETP F1 3
70. e DIP Switch S3 DIP Switch S4 Rating Code Fira 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 4 2 4 3 4 4 S4 5 4 6 4 7 S48 521 521 426 150 ON ON ON ON 70 700 571 200 ON ON ON ON Table 17 460V AC Input Drives Drive Current DC ACLine HP DIP Switch S3 DIP Switch S4 Rating Code Amps Amps 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 S4 1 4 2 4 3 S4 4 S4 5 S4 6 4 7 S4 8 495 495 4044 300 ON ON ON ON 667 667 5449 400 ON ON ON ON Table 18 575V AC Input Drives Drive Current DC ACLine HP DIP Switch 3 DIP Switch 4 Rating Code Amps Amps 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 4 2 4 3 4 4 4 5 4 6 4 7 S4 8 540 540 441 2 400 ON ON ON ON 675 675 551 5 500 ON ON ON ON Table 19 690V AC Input Drives Drive Current AC Line DIP Switch 3 DIP Switch 4 Rating Code FE 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 S4 1 4 2 4 3 S4 4 4 5 S4 6 4 7 S4 8 452 452 369 400 ON ON ON ON 565 565 462 500 ON ON ON ON Install the Pulse Transformer Circuit Board Install the new pulse transformer board in reverse order of removal e Inspect the existing connection ca
71. e base speed 162 Max Feedback Spd is set to the motor nameplate base speed 175 Rated Motor Volt is set to the motor rated nameplate armature voltage 179 Nom Mtr Arm Amps is set to the rated motor nameplate armature current Rockwell Automation Publication 20P TG003A EN P February 2012 119 Chapter 4 120 Start Up After Repair e 280 Nom Mtr Fld Amps is set to the rated motor nameplate field current e 374 Drv Fld Brdg Amps is set to the rated current of the field bridge regulator Energize the drive 8 Measure the field current and verify that the value is reflected in parameter 10 11 12 13 14 15 16 234 Fld Current Pct Run the following applicable Autotune procedures detailed in Chapter 2 of the PowerFlex Digital DC Drive User Manual publication 20P UMO001 e Tune the Current Regulator e Verify Motor Rotation Direction and Run Feedback Polarity Checks If parameter 414 Fdbk Device Type is set to 3 Armature set parameter 107 Speed Zero Level to a minimum value of 10 of base motor speed e Configure the Speed Feedback Parameters e Tune the Speed Regulator Make configuration changes that allow the HIM to issue start and speed commands Start the drive by pressing ap the start button If the drive will not start verify that you have correctly installed any replacement components If any faults are displayed on the HIM refer to Chapter 4 Trou
72. e the switching power supply board Replace the fuse on the switching power supply board See Switching Power Supply Circuit Board Fuse Removal and Installation on page 60 Disconnect the cable at connector XA on the control board See Figure 27 on page 134 for location of connector XA Apply AC control power to the drive e If the fuse blows continue with Testing the Switching Power Supply and Pulse Transformer Boards below e If the fuse does not blow continue with Testing the Control and Field Board Connections on page 17 Testing the Switching Power Supply and Pulse Transformer Boards Remove power from the drive Replace the fuses on the switching power supply board See Switching Power Supply Circuit Board Fuse Removal and Installation on page 60 Remove the switching power supply board from the drive See Switching Power Supply Circuit Board Removal and Installation on page 61 Reapply power to the switching power supply board only e Ifthe power supply fuses do not blow continue with step 5 below e If the power supply fuses blow replace the switching power supply board 5 Remove all incoming AC voltage from the drive 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 Ifno short circuit conditions exist replace the pulse transform
73. e wave signal with a 90 lag phase displacement compared to the AC voltage signal Fab 96 Chl Sincro XR11 Ch2 UWIAVI File Sincrofc tif REMOTE ENABLE 16 28 59 1 60 TO 5 ns LOCAL 5 8 V 5 ns 209 V ns T 1 5 v be i x 220 nV C ij 18 k5 s 3 5 v mi EEE Line 1 Vv DC amp HU STOPPED 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 1 U1 V1 Sync 4 le LEM current feedback signal taken on LA LB terminal 2 ITF1 pulse 3 ITF2 pulse 9 Fab 56 Chi Suync Ch2 ITFL Ch3 ITF2 Ch4 Ie File Fed pl REMOTE ENABLE 17 01 35 nn tom i 60 TO 5 ns LOCAL UI VISync saw 4 gt ns LA LB 5a ph 2 ns ITF1 Pulse 5 0 v 3 ns ITF2 Pulse 5 0 V 5 as g F x 10 k s 3 5 OH J Line 4 5n OC O STOPPEO e Ifthe gate signals are missing replace the control board e Ifthe gate signals are present replace the field board 26 Rockwell Automation Publication 20P TG003A EN P February 2012 Power Component Test Procedures Component Test Procedures Chapter 2 Check the Armature SCR Modules The PowerFlex DC drive armature supply consists of three non regenerative 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 bl
74. er board Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 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 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 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 kQ If any low resistance measurements are found replace the control board 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 kQ Ifa lower resistance value is measured replace field board Rockwell Automation Publication 20P TG003A EN P February 2012 17 Chapter2 Component Test Procedures Figure 1 Control Board Testpoints Upper Left o o o o i l oe o o o o 00 eeoooooooooooososo oe
75. 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 Additional drive service and software or firmware support information is available on the Allen Bradley Drives Service and Support website http www ab com support abdrives A complete list of spare parts for PowerFlex DC drives is available on the Allen Bradley web site at www ab com support abdrives powerflexdc PowerFlex DC Released Parts pdf The following table lists publications that provide general drive information Title Publication Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Rockwell Automation Publication 20P TG003A EN P February 2012 7 Preface Notes 8 Rockwell Automation Publication 20P TG003A EN P February 2012 Chapter 1 Before You Begin Testing Ma
76. hermostats Removal and Installation 107 Cooling Fans Removal and Installation 115 Rockwell Automation Publication 20P TG003A EN P February 2012 41 Chapter3 Access Procedures Remove Power from the ATTENTION Remove power before making or breaking cable connections Drive N 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 e Sending an erroneous signal to your system s field devices causing unintended machine motion e 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 1 Remove and lock out all incoming power to the drive DPI HIM Assembly Removal Remove the DPI HIM Assembly and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 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 Remove screw Tightening torque 0 8 N m 7 Ib in e Allen Bradley PowerFiex Disconnect DPI cable
77. ing 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 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 Check the DC Tachometer e 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 126 for a circuit diagram e The analog tach signal is fine scaled using parameter 562 Anlg Tach Gain e See Drive Reference and Feedback Scaling in Appendix C of the PowerFlex Digital DC Drive User Manual publication 20P UMO01 for more information Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Check the Resolver Interface Board The resolver feedback option module uses the resolver feedback boar
78. intenance or Repairs introduction This chapter provides information you should know before you begin tests maintenance or repairs on drive components Topic Page General Safety Precautions 10 Hardware Description 11 Commonly Used Tools 12 Rockwell Automation Publication 20P TG003A EN P February 2012 Chapter1 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 gt bP bP BB gt ATTENTION 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 ATTENTION This drive contains ESD Electrostatic Discharge 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 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION 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
79. ion 15 Troubleshoot a Control Power Supply Failure 15 Troubleshoot an AC Undervoltage Fault 20 Troubleshoot an Armature Bridge Failure 21 Troubleshoot a Field Current Loss Fault 23 Power Component Test Procedures 27 Speed Feedback Device Tests 36 Thermistors and Thermal Switches 39 Relay Outputs 39 Create a Fault Report 40 What You Need When You Call Tech Support 40 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 Chapter 4 Troubleshooting in the PowerFlex Digital DC Drive User Manual publication 20P UM001 Rockwell Automation Publication 20P TG003A EN P February 2012 13 Chapter2 Component Test Procedures Save the Parameter Configuration It is recommended that you save the drive and communication adapter parameter configuration to a HIM Set or by up loading the drive and adapter parameters to an offline node file using DriveExecutive before performing any service or testing on the drive HIM sets are files stored in permanent nonvolatile HIM memory 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 3 Select Devi
80. isolation Current damp 3x drive rated armature current output Soldering station Soldering de soldering Torque wrench 1 12 Nem Torque wrench 6 50 Nem 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 cutter Nose pliers Crimping tools For cable terminals 1 5 240 Angle wrench Screw drivers Flat nose 7x2 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 Phillips is a registered trademark of Phillips Screw Company Software Tools DriveTools SP DriveExecutive DriveExplorer and DriveObserver are software tools for uploading downloading and monitoring system parameters Rockwell Automation Publication 20P TG003A EN P February 2012 Introduction Component Test Procedures 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 Topic Page Save the Parameter Configuration 14 Visual Component Inspect
81. it board and resistors 5 Remove the four screws that secure the slotted air flow plate to the top of the drive and remove the plate IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 74 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 6 Remove the appropriate gate leads e For non regenerative drives remove each pair of orange and yellow gate lead cables from connectors KG1 KG6 and push each lead through the appropriate opening in the board e For regenerative drive remove each pair of orange and yellow gate lead cables from connectors KGOI 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 7 Remove the cable from connector XTA at the bottom center of the pulse transformer board Non Regenerative Drive eG cT h E MU y AA 3 ESO AN b pin riet D zi et e 1 brn mp OTD y pre ern quen Cnm Y n d Lal E intr re Tiu Remove cable E ET na d NER ES k we 5 opa Remove gate leads Regenerative Drive Remove cable Remove gate leads Rockwell Automation Publication 20P TG003A EN P February 2012 75 Chapter3 Access Procedures 8 Remove the orange and yellow cables from connectors KIG1 and K2G2 on the top left side
82. leads off by pulling on the wires 7 Remove the cable from connector XTA at the bottom center of the board Non Regenerative Drive ENOL PEN OED y HIE H i m n E TEED Sepe e LE DUUN eler UAST neg ces Remove gate Bn P m wit Hi p r eaii o keii p ki AETHERE THET HD X602 Hu o PERLCIGU 22 30032273 KOs Ko04 a KOOS Regenerative Drive 64 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 8 Remove the orange and yellow cables from connectors KIG1 and K2G2 on the top left side of the board 9 Remove the cables from connectors X4 X5 and XTM at the top left side of the board Remove cables 10 Remove the cables from connectors XCD XUVW and X3 at the top right side of the board Remove cables Rockwell Automation Publication 20P TG003A EN P February 2012 65 Chapter3 Access Procedures 11 For Pulse Transformer boards with an armature voltage feedback terminal block FIR3 XX rev M and higher remove the cable from connector XCD I0 on the upper right corner of the board Remove cable from XCD_10 connector XCD IO TO6 KGO6 XCD T6 e e e 12 Remove the six screws and washers that secure the pulse transformer board to the drive and remove the board Remove screws and washers Note Regenerative Drive Shown
83. 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 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 PEPPP IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley DriveTools SP DriveExecutive DriveExplorer and DriveObserver PowerFlex Rockwell Automation and TechConnect are trademarks of Rockwell
84. ls 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 for more 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 Rockwell Automation Publication 20P TG003A EN P February 2012 39 Chapter2 Component Test Procedures Create a Fault Report Complete fault reports are critical for analysis and repair of modules returned to the factory Ata minimum perform and record the following e Record the contents of the fault queue faults and times of occurrence See the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for detailed Fault and Alarm codes and descriptions e Make a record of any burn marks on the printed circuit boards cabling bus bars and SCR modules e Make a record of any liquid and condensation marks on the printed circuit boards components and mechanical parts e Makea record of the amount of dust and other additional particles on the drive and drive components e Makea record of any mechanical damage to the drive and drive components e Record the size and type of main fuses e Record any other important marks a
85. lug in I O terminal blocks with the wiring kept in place 6 Remove the two screws that secure the I O expansion board to the stand offs on the control board Remove two screws Tightening torque for re assembly is 1 0 N m 8 9 Ib in 7 Carefully pull the I O expansion board off connector XBB on the control board 52 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 8 Remove the two stand offs and washers from the control board Tightening torque for re assembly is 1 0 N m 8 9 Ib in Remove two stand orfs and washers 9 Install one screw in the lower left corner of the control circuit board gt n Ain Ptr oven Riy nee Air wt Air sipa wrrr Yet ais a amp a 9 IA A B B Z Z COM V 0 0 06 JE 20287 Install screw Tightening torque for re assembly is 1 0 N m 8 9 Ib in Install the 1 0 Expansion Circuit Board Install the I O expansion board in reverse order of removal Rockwell Automation Publication 20P TG003A EN P February 2012 53 Chapter3 Access Procedures 115V AC to 24V DC 1 0 Converter Circuit Board Removal and Installation 54 Remove the 115V AC to 24V DC 1 0 Converter Circuit Board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 IMPORTANT
86. m the drive See Remove Power from the Drive on page 42 3 Remove the Protective Covers from the drive See Protective Cover Removal and Installation on page 43 Disconnect the interface cable from the communication adapter and set it aside 5 Disconnect any network cables from the adapter and set them aside Disconnect interface cable Disconnect network cables 6 Remove the four screws and washers that secure the communication adapter to the EMI shield and remove the adapter Remove four Screws and washers Tightening torque 0 9 N m 8 0 Ib in 46 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 7 Remove the three screws and washers that secure the EMI shield to the standoffs on the control board and remove the EMI shield Remove three screws and washers Tightening torque 1 0 N m 8 9 Ib in 8 Remove the three standoffs and washers from the control board Remove three standoffs Tightening torque and washers 1 0 N m 8 9 Ib in Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal Rockwell Automation Publication 20P TG003A EN P February 2012 47 Chapter 3 Resolver Feedback and Interface Circuit Board Removal and Installation 48 Remove the Resolver Feedback and Interface Circuit Boards 1 Read the General Safety Precautions on page 10 2
87. n the bolt 10 Remove the bolts and washers that secure the metal plate and L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar Bolt Remove bolt lock washer flat washer metal plate and L shaped bus bar Lock washer ey Flat washer Remove bolt lock washer and flat washer A En W Fuse Lo 11 Remove the bolts and washers that secure the horizontal bus bars to the C and D vertical power terminal bus bars Note the size and location of the bolts and the order in which the washers are placed on the bolts Remove bolts lock washers flat washers Bolt and Washer Order D t ag i HH Left to right bolts and flat washers Left to right flat washers lock washers and nuts 98 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 12 Remove the bolts and washers that secure the horizontal bus bars to the SCR modules and remove the bus bars Remove bolts and washers and bus bars Continue with Remove the SCR Modules below Remove the SCR Modules 1 Remove the remaining bolts washers and metal plates for regenerative drives only from the tops of the SCR modules Note the order of the washers on the bolts Note Regenerative drive shown Remove bolts and met
88. nc signal from U1 5 1V field sync signal from V1 Table 21 Pulse Transformer Board to Bimetal Thermostats Connections Pulse Transformer Bimetal Thermostat Description Board Connector EJ 7 24V supply EN 24V common e1 e2 e3 Table 22 Pulse Transformer Board to Field SCR Dual Diode Module Connections Pulse Transformer Pin Number to Field SCR DualDiode Description Board Connector Module Connector XP1 1 G1 Gate signal G1 2 K1 Common cathode X02 1 G2 Gate signal G2 2 K2 Common cathode Table 23 Pulse Transformer Board to Switching Power Supply Board Connections Pulse Transformer Pin Number to Pin Number Switching Power Supply Description Board Point Board Connector 1 1 24V supply 2 2 24V common 3 3 XSW 4 4 XSW Internal 18V common 5 5 6 6 Internal 18V supply Table 24 Pulse Transformer Board to Current Transducers Connections CurrentTransducer Description Terminals Pulse Transformer Board Connector E D i i us U Secondary side CT phase U 3 Black on de TA V Secondary side CT phase W 4 Blue ji Rockwell Automation Publication 20P TG003A EN P February 2012 131 AppendixB Board Layouts and Connections Table 25 Pulse Transformer Board to Control Board Connections
89. nd damage What You Need When You When you contact Technical Support please be prepared to provide the Call Tech Support following information e Order number e Product catalog number and drives series number if applicable e Product serial number e Firmware revision level e Most recent fault code e 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 Status at Fault Captures and displays Par 381 Drive Status 1 bit pattern at the time ofthe last fault 1350 Status at Fault Captures and displays Par 382 Drive Status 2 bit pattern at the time ofthe last fault 1351 1360 Fault x Code A code that represents the fault that tripped the drive The codes will appear in these parameters in the order they occur i e Fault 1 Code the most recent fault 1361 1370 Fault x Time The time between initial drive power up and the occurrence of the associated trip fault 1371 Fault Arm Amps Captures and displays the armature current as a percentage of rated current at the time of the last fault 1372 Fault Speed Captures and displays the output speed rpm of the drive at the time of the last fault 1373 Fault Field Amps Captures and displays the field current as a percentage of rated current at the time of the last fault 1374 Fault Voltage Captures and displays the armature voltage at the time of
90. odules Removal and Installation on page 93v Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives On SCR Module SCR Measurefrom To Nominal meter reading 1 1 Pin 5 Pin4 4 Pin 6 Pin7 2 2 Pin 5 Pin4 5 Pin 6 Pin 7 3 3 Pin 5 Pin4 6 Pin 6 Pin7 1 01 01 Pin 6 Pin 7 20Q 04 Pin 5 Pin4 02 02 Pin 6 Pin 7 05 Pin 5 Pin4 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 8 SCR Gate Lead Connection Pinouts for Regenerative Drives O O O O O O O O O O O O O O SCR SCR SCR SCR SCR SCR Module 1 Module 01 Module 2 Module 02 Module 3 Module 03 2 amp D Front of Drive Drive Heatsink JH 3 Top View of SCR Module Rockwell Automation Publication 20P TG003A EN P February 2012 Component Test Procedures Chapter 2 Table 5 SCR Gate to Cathode Junction Measurements for Non Regenerative Drives On SCR Module SCR Measurefrom To Nomin
91. ort circuit condition exist Yes Replace the SCR dual diode module Replace Replace the field board Are the fuses blown Replace the control board Yes the field board Rockwell Automation Publication 20P TG003A EN P February 2012 139 AppendixC Flow Charts Low or Incorrect Field Current Verify Par 351 Field Current value using DC clamp to measure j the DC motor field current i Verify drive rated field bridge current is set correctly in Par 374 Drv Fld Brdg Cur and DIP switch S14 is configured to match Verify Par 280 Nom Mtr Fld Amps value matches the rated field current value on motor nameplate i Measure field current signal at LA LB terminal located on control board This value should be equal to the value of Par 374 Drv Fld Brdg Cur If these values are equivalent the voltage across terminals LA LB should be 1 66 VDC Using an ohmmeter measure the No resistance across terminals LA LB to verify that the value equals the equivalent resistance set with DIP switch S14 Is resistance measurement correct Is voltage measurement correct Replace the field board Replace the control board 140 Rockwell Automation Publication 20P TG003A EN P February 2012 A AC current transducers install
92. our distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20P TG003A EN P February 2012 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
93. ower screw that secures the left side AC current transducer to the U phase terminal 102 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 8 Remove the two screws that secure the bottom of the power supply filter circuit board to the drive Power supply filter board Remove screws 9 Move the control EMI shield See Move the Control EMI Shield on page 58 10 Remove the two screws and washers that secure the top of the power supply filter board to the drive and carefully lift the board to gain access to the ground wire connected to the W phase power terminal see next step Remove screw and washer Remove screw and washer LUE Rockwell Automation Publication 20P TG003A EN P February 2012 103 Chapter 3 104 Access Procedures 11 Temporarily lift the EMI shield and remove the screw that secures the ground wire from the pulse transformer board to W phase power terminal and remove the wire ww um B7 4i i i j z A Mg ere He RY Remove screw and wire 12 Remove the lower screw that secures the right side AC current transducer to the W phase power terminal Remove screw and wire Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 13 Move the EMI shield to the lowered position and remove the nuts and washers that secure the wires red and white to each of the AC cur
94. own 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 Remove and lock out all incoming power for the drive See Remove Power from the Drive on page 42 3 Verify that contactor power if used is removed 4 Verify that power to an external field supply if used is removed 5 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 e For regenerative drives see Table 2 on page 28 and Figure 6 on page 28 e For non regenerative drives see Table 3 on page 29 and Figure 7 on page 29 If a low resistance is detected determine which SCR module s is are damaged based on the tables below and replace that module s See SCR Modules Removal and Installation on page 93 Rockwell Automation Publication 20P TG003A EN P February 2012 27 Chapter 2 28 Component Test Procedures Table 2 SCR Anode to Cathode Junction Measurements for Regenerative Drives Nominal meter reading open circuit or megaOhms range On SCR Module SCR Measure from To Terminal Terminal 1 1 U C 4 U D 2 2 V C 5 V D 3 3 W C 6 W D 01 01 U C 04 U D 02 02 V C 05 V D 03 03 W C 06 W D Figure 6 Regener
95. ply board and apply AC control power Is the fuse blown Is the drive operational Replace the control board Replace the fuse disconnect the cable from connector XA on the control board and apply AC control power A Remove cable from connector XR on control board and ohmmeter all voltage testpoints and commons to verify no Use an ohmmeter to verify that all terminals on the control board terminal blocks are not short circuited Is the fuse blown Are terminals short circuited Any values lower than 200 kohm short circuits values should be gt 200 kohm Remove power from Replace the the drive and replace Repair short circuits the fuse on the switching power supply board J Y Remove cable from Remove the switching connector XFCD on power supply board the control board and from the drive ohmmeter between pins 1 and 2 and 3 Any values lower Y than 200 kohms and 2 on cable to Apply power to the verify no short circuits Switching power values should be gt supply board only 200 kohm Remove all power from the drive Check all external wiring to the pulse transformer board including the motor PTC if used for a short circuit condition Is the fuse blown Replace the field board Replace the switching power supply board
96. ply filter board 86 protective covers 43 pulse transformer board 62 resolver feedback circuit board 48 resolver interface circuit board 48 SCR modules 93 switching power supply board 61 switching power supply board fuses 60 transient noise filter board 82 transient noise filter board fuses 81 resolver feedback circuit board install 51 remove 48 resolver interface circuit board install 51 remove 48 S safety precautions 10 save parameter configuration 14 schematic diagrams 121 SCR modules install 100 remove 93 service tools 12 setting DIP switches S3 4 69 sizing resistors configure 67 total resistance values 69 software tools 12 switching power supply board install 62 remove 61 switching power supply board fuses install 60 remove 60 Index T technical support calling 40 test armature SCR modules 27 DCanalog tachometer 36 encoder 36 field SCR dual diode module 33 pulse transformer board 32 testpoints locations 18 19 thermal switch 39 thermistor 39 tools service 12 software 12 total resistance values sizing resistors 69 transient noise filter board install 86 remove 82 transient noise filter board fuses install 82 remove 81 troubleshoot armature bridge failure 21 field current loss 23 overcurrent fault 21 power failure fault 15 V visual inspection 15 Rockwell Automation Publication 20P TG003A EN P February 2012 143 Index 14 Rockwell Automation Publication 20P TG003A EN P February 201
97. r Board to Fan Connections Power Supply Fan Terminal Description Filter Board Block Connector 13 13 Singlephase 115V 230V AC Figure 30 Transient Noise Filter Board Layout O1V Fi F2 F3 D Table 31 Transient Noise Board to Pulse Transformer Board Connections Transient Noise Filter to PinNumber Pulse Transformer Description Board Connector Board Connector 1U 1 XUVW Phase U signal 1V 2 Phase V signal 1W 3 Phase W signal C 1 XCD Armature C signal D 2 Armature D signal 136 Rockwell Automation Publication 20P TG003A EN P February 2012 Appendix C 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 138 Field Current Loss Failure 139 Rockwell Automation Publication 20P TG003A EN P February 2012 137 AppendixC 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 Is the correct voltage present at U2 V2 Verify the wiring and power source to U2 V2 and correct any problems No Remove AC control power and remove and test the fuse F1 atthe top of the drive Replace the switching power sup
98. rameter 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 Table 25 on page 132 If the measurements on the XR cable are correct replace the pulse transformer board 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 134 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 from the drive See Protective Cover Removal and Installation on page 43 3 Ifusing a DC output contactor disconnect the cable from XR on the control board and measure the signal for each SCR gate as indicated in the table below Signal Name __ XR Cable Pin Gate Note MP MN In 27 Gl G04 I 29 G2 G05 In 31 G3 G06 Im 21 G4 G01 IT5 23 G5 G02 IT6 25 G6 G03 MN 33 Negative bridge MN active when high 5V
99. rcuit Diagram 127 Figure 22 Drive Heatsink Monitoring Control Circuit Diagram 127 Figure 23 Contactor Control Relays Control Circuit Diagram 128 Figure 24 AC Line Snubber Circuit 128 Rockwell Automation Publication 20P TG003A EN P February 2012 121 Schematics Appendix A o o o o o o pseog Ajddns Jamo 6ulysums s pieog 193 I SION 3UaISUeJ AX T M AA 29 9i AJU gt En Jd MX vx ML AL AL LAL HEBUEEHEDI E i j E MSX i e E S Vi VL 5 VX M n d DA 9 59 OY OY OY a MANX 10g 1 WOJSULIJ a
100. rent transducers and remove the wires IMPORTANT _ Note the color and location of each lead to ensure that each wire is properly connected during installation Remove nuts Note Left AC current transducer of regenerative drive shown 14 Remove the upper screw that secures each of the AC current transducer to the U phase power terminal Note Left AC current transducer of regenerative drive shown Rockwell Automation Publication 20P TG003A EN P February 2012 105 Chapter3 Access Procedures 15 Remove the bolt s and washer s that secure the U and W phase power terminals to the L shaped bus bar fuse e For regenerative drives only remove the two bolts and washers that secure the U and W phase power terminals to the L shaped bus bars connected to the fuses and while pulling the U and W phase power terminals down toward the bottom of the drive slide the AC current transducers off of the terminal bus bars and out of the drive Regenerative drive Remove bolts washers and terminal Slide AC current transducers off of bar e For Non Regenerative drives only remove the bolt and washers that secure the U and W phase power terminals to the internal armature fuse and while pulling the U and W phase power terminals up and into the drive slide the AC current transducers off of the terminal bus bars and out of the drive Non Regenerative drive Remove bolts washers and terminal Slide AC Current Transducers off
101. rmer board for the designated drive size Table 12 230V AC Input Drives Drive Current DC ACLine HP R1 R2 R3 R4 R5 Rating Code Amps Amps 521 521 426 150 Remove 5 360 5 360 5 360 Table 13 460V AC Input Drives Drive Current DC ACLine HP R1 R2 R3 R4 R5 Rating Code Amps Amps 495 495 404 4 300 Remove 5 360 5 360 5 360 667 667 544 9 400 5 360 5 360 5 360 5 360 Rockwell Automation Publication 20P TG003A EN P February 2012 67 Chapter3 Access 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 in the center of the pulse transformer circuit board set the total resistance RTA to the appropriate value as indicated in Table 14 or Table 15 in the Total Resistance Values section on page 69 The XR connector is located on the upper right corner of the pulse transformer circuit board oazy COM 20 ua USO a q E d um geh veo i LJ RI 9 R2 e Ro ear 9 o R4 onl m9 a p uk y di T D ag aw The TA potentiometer is located on the lower l i right corner of the pulse transformer circuit board next to the control power terminal block 68 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Total Resistance Values Table 14 230V AC Input Drives Drive C
102. s in the PowerFlex Digital DC Drive User Manual publication 20P UM001 and make any necessary corrections See Control Board on page 134 for DIP switch location Rockwell Automation Publication 20P TG003A EN P February 2012 23 Chapter2 Component Test Procedures 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 Remove the protective covers from the drive See Protective Cover Removal and Installation on 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 e Ifthe voltage measurement is incorrect continue with step 7 below e Ifthe voltage measurement is correct but the Field Current Loss fault still exists replace the control board 7 Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance as indicated in the
103. s to the top of each of the six armature leg fuses Note the order of the washers on the bolt Remove bolt 24 mm long lock washer and flat washer O Lock washer Bolt 24 mm long Flat washer c 3 10 Remove the bolts 24mm long and washers that secure the L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar m Remove 24mm long bolts and washers r Leave wires in D a place ix 96 Rockwell Automation Publication 20P TG003A EN P February 2012 b S T E ES Access Procedures Chapter 3 11 Remove the four bolts and washers that secure the horizontal bus bars to the SCR modules and remove the bus bars Note the order of the washers on the bolts and the position of he bus bars Remove bolts Remove bolts Continue with Remove the SCR Modules on page 99 Remove the Bus Bars from a Non Regenerative Drive 8 Remove the nuts and washers that secure the wires red and blue from the AC line snubber board to the bus bars and remove the wires Remove nuts washers and wires Rockwell Automation Publication 20P TG003A EN P February 2012 97 Chapter3 Access Procedures 9 Remove the bolts and washers that secure the L shaped bus bars to the top of each of the three armature leg fuses Note the order of the washers o
104. sind t T yx p J zh ux 4 a a X zal 2L 0 XX Y i B SX d 5 o o o E amp dX 7 T m d Ur m TH p1eog NX 2 49A0 aAUIG 0 300 MSX E E a 023X 7 04X EX Nyi pyeog p1eog 1931 Sje1souuau jaqqnus pial LT Aiddns amod awug Lac Lac 1 EAEN WIX SX D ag X AX uz LAZ D Wn MX c1 L1 Ld Zl LM sue 1 Lf Rockwell Automation Publication 20P TG003A EN P February 2012 122 Schematics Appendix A Figure 14 AC Line Measurement Points Diagram X22 Vj xr U 100K e e 15 15V PH i e WA E eH 15V 45 V XY 21 XR 16 100K _ _______ 415 15 XY 18 XR 17 W 100K Figure 15 Power Feedback Connections Diagram W V U D C Fi e I e e oe XR15 wW OW w iw WwW Ww wW LI X wW wW w Ww Ww W W F3 xe TWO OW w iw W WwW wW XR19 W W w Ww WwW W W xm8 w OW w w W WwW wW E QQ PE Rockwell Automation Publication 20P TG003A EN P February 2012 123 Appendix A 124 Schematics Figure 16 Field Board and SCR Dual Diode Module Connections Diagram To Pulse Transformer Board X3 Connector
105. supplied themistor 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 on page 130 for terminal block location 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 for details See Figure 21 on page 127 for a circuit diagram e Ifa thermal switch is used a 1 kQresistor must be placed in series between the switch and either terminal 78 or 79 e If neither a thermistor PTC or a thermal switch is installed a 1 kQ 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 OvrIemp fault F8 occurs See Fault Descriptions in Chapter 4 of the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for details See Figure 22 on page 127 for a circuit diagram 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 Terminals 35 and 36 and 75 and 76 are N O relay outputs The relay output between termina
106. that secure each module to the heatsink and remove the modules from the drive Remove screws and washers Install the Field SCR and Dual Diode Module Install the field SCR and dual diode module in reverse order of removal e Apply thermal grease to the bottom of the SCR and dual diode modules before securing them to the heatsink diode modules before securing them to the heatsink or damage to the drive may ATTENTION Thermal grease must be applied to the bottom of the SCR and dual occur e Tightening torque for the screws connecting the field SCR and dual diode modules to the heatsink and the screws connecting the field board to the field SCR and dual diode modules is 2 5 4 0 Nem 22 35 Ib in Rockwell Automation Publication 20P TG003A EN P February 2012 73 Chapter3 Access Procedures ACLine Snubber Circuit Board Remove the ACLine Snubber Circuit Board and Resistors and Resistors Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 Disconnect and Remove the Pulse Transformer and Field Power Circuit Boards You must remove the pulse transformer and field power circuit boards in order to replace the AC line snubber circu
107. the Field Circuit Fuses eee eene 45 Communication Adapter and EMI Shield Removal and Installation 46 Remove the Communication Adapter and EMI Shield 46 Install the Communication Adapter and EMI Shield 47 Resolver Feedback and Interface Circuit Board Removal and Installation es dos thon deett s Opie date etu cM die hen Baka le 48 Remove the Resolver Feedback and Interface Circuit Boards 48 Install the Resolver Feedback and Interface Circuit Boards 51 I O Expansion Circuit Board Removal and Installation 52 Remove the I O Expansion Circuit Board suuue 52 Install the I O Expansion Circuit Board 00 ee eee 53 115V AC to 24V DC I O Converter Circuit Board Removal and Toscallation echoes EE Ne ues Cee ii eet aen c aul 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 Removal and Installation LL 55 Remove the Control Circuit Board 0ccceceeeecnees 55 Install the Control Circuit Board 0 cece cece eee cneee 58 Control EMI Shield Removal and Closure 0 0cec cece eee 58 Move the Control EMI Shield 4 toca cca e re 58 Install the Control EMI Shield e ssec ren 59 Switching Power Supply Circuit Board Fuse Removal and Installation 60 Remove the Fuses on the Switching Power Supply Circuit Board 60 Inst
108. the L shaped bus bars to the top of each of the six internal armature leg fuses Note the order of the washers on the bolt Remove bolt 24 mm long lock washer and flat washer Bolt 24 mm long Lock washer Flat washer 9 Remove the bolts 24mm long and washers that secure the L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar m Remove 24mm long bolts and washers r Leave wires in D a place ix 110 Rockwell Automation Publication 20P TG003A EN P February 2012 b S T E ES Access Procedures Chapter 3 10 Remove the four bolts and washers that secure the horizontal bus bars to the SCR modules and remove the bus bars Note the order of the washers on the bolts and the position of the bus bars Remove bolts Remove bolts Continue with Remove the SCR Modules and Bimetal Thermostats on page 3 113 Remove the Bus Bars from a Non Regenerative Drive 7 Remove the nuts and washers that secure the wires red and blue from the AC line snubber board to the bus bars and remove the wires Remove nuts washers and wires Rockwell Automation Publication 20P TG003A EN P February 2012 111 Chapter3 Access Procedures 8 Remove the bolts and washers that secure the L shaped bus bars to the top of each of the
109. tive covers from the drive See Remove the Protective Covers from the Drive on page 43 Remove the communication adapter and EMI shield from the control board See Remove the Communication Adapter and EMI Shield on page 46 If present remove the I O expansion circuit board See Remove the I O Expansion Circuit Board on page 52 If present remove the 115V AC to 24V DC I O converter circuit board See Remove the 115V AC to 24V DC I O Converter Circuit Board on page 54 Record all switch and jumper settings on the control board Refer to the PowerFlex DC Digital Drive User Manual publication 20P UMO01 for more information Rockwell Automation Publication 20P TG003A EN P February 2012 55 Chapter 3 56 Access Procedures Jumper Function Setting Switch S4 Configures the input voltage of the DC analog tachometer S9 Configures the input signal of Analog Input 1 terminals 1 and 2 Note The input signal type must also be programmed accordingly using Par 71 Anlg In1 Config 10 Configures the input signal of Analog Input 2 terminal 3 and 4 Note The input signal type must also be programmed accordingly using Par 76 Anlg In2 Config S11 Configures the input signal of Analog Input 3 terminals 5 and 6 Note The input signal type must also be programmed accordingly using Par 81 Anlg In3 Config 14 Field current resistors setting 14 1 In addition
110. ts For a Schematic Diagram on See Page Pulse Transformer Board Layout 130 Pulse Transformer Board to Current Transducers Connections 131 Pulse Transformer Board to Bimetal Thermostats Connections 151 Pulse Transformer Board to Field SCR Dual Diode Module Connections 131 Pulse Transformer Board to Current Transducers Connections 131 Pulse Transformer Board to Field Power Board Connections 131 Pulse Transformer Board to Control Board Connections 132 Switching Power Supply Board Layout 133 Switching Power Supply Board to Control Board Connections 133 Control Board Layout 134 Control Board to Field Board Connections 132 Field Power Board Layout 135 Power Supply Filter Board Layout 135 Power Supply Filter Board to Pulse Transformer Board Connections 135 Power Supply Filter Board to Switching Power Supply Board Connections 135 Power Supply Filter Board to Fan Connections 136 Transient Noise Filter Board Layout 136 Transient Noise Board to Pulse Transformer Board Connections 136 Rockwell Automation Publication 20P TG003A EN P February 2012 129 Appendix B Board Layouts and Connections Pulse Tra nsformer Board Figure 25 Pulse Transformer Board Layout
111. ts and washers that secure the AC line snubber board red and blue leads and screws and washers that secure the resistor black leads to the bus bars and remove the leads Regenerative Drive Remove bolts and washers Remove screws and washers Non Regenerative Drive 3 Remove bolts and washers Remove screws and washers Rockwell Automation Publication 20P TG003A EN P February 2012 79 Chapter3 Access Procedures 16 Remove the three screws and washers that secure the AC line snubber board to the drive frame and remove the board Remove screws and washers 17 Remove the two screws that secure each resistor six total to the drive frame and remove the resistors from the drive Remove screws 80 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Install the AC Line Snubber Circuit Board and Resistors Install the AC line snubber board and resistors in reverse order of removal e Apply thermal grease to the bottom of the resistors before securing them to the heatsink ATTENTION Thermal grease must be applied to the bottom ofthe resistors before securing them to the heatsink or damage to the drive may occur e Tightening torque for the screws connecting the field board to the field SCR and dual diode modules is 2 5 4 0 Nem 22 35 Ibein Transient Noise Filter Circuit Remove the Fuses on the Transient Noise Filter Circuit Board Board Fuses Removal and Inst
112. urrent DC ACLine HP Set RTA Value Using TA Rating Code Amps Amps Potentiometer Ohms 521 521 426 150 4 699 Table 15 460V AC Input Drives Drive Current DC ACLine HP SetRTAValue Using TA Rating Code Amps Amps Potentiometer Ohms 495 495 404 4 300 4 945 667 667 544 9 400 3 67 3 Seal the TA potentiometer in place using RV silicon 4 Continue with Install the Pulse Transformer Circuit Board on page 70 Configuring a Pulse Transformer Board FIR3 xx Rev M and Higher Set DIP switches S3 and S4 shown in the illustration below on the pulse transformer board to the correct settings based on the appropriate AC input voltage armature output current and HP rating shown in Table 16 or Table 17 on page 70 lm uasa xs i i Eje Je ties Rockwell Automation Publication 20P TG003A EN P February 2012 69 Chapter3 Access Procedures IMPORTANT A blank cell below a switch in the tables below indicate that the setting is OFF Table 16 230V AC Input Drives Drive Current AC Lin
113. ve e For regenerative drives refer to Remove the Bus Bars from a Regenerative Drive on page 3 109 e For non regenerative drives refer to Remove the Bus Bars from a Non Regenerative Drive on page 3 111 108 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 Remove the Bus Bars from a Regenerative Drive 7 Remove the six bolts and corresponding washers that secure the Remove bolts and washers intermediate bus bars to the U and W phase AC input and DC output terminals C and D bus bars Note the size and location of the bolts and the order in which the washers are placed on the bolts Remove bolts and washers Nut Lock washer Flat washer Left to right two 2 nuts lock washers and flat washers N H Flat washer T Bolt 30mm long amp Bolt Size and Washer Order Left to right two 2 bolts 40mm Bolt 30mm long long and flat washers i ut Flat washer ms Hum r f gt Hat washer Lock washer I Nut a8 Left to right two 2 flat se washers lock washers Leftto right two 2 flat and nuts washers and bolts 40mm long Rockwell Automation Publication 20P TG003A EN P February 2012 109 Chapter3 Access Procedures 8 Remove the bolt 24 mm long and washers that secure
114. ve on page 42 3 Remove the protective covers and lower the control EMI shield when necessary See Remove the Protective Covers from the Drive on page 43 and Move the Control EMI Shield on page 58 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 Troubleshoot a Control Power Supply Failure 1 Read the General Safety Precautions on page 10 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 2 Remove the protective covers from the drive See Remove the Protective Covers from the Drive on page 43 3 Measure the signal voltage at the testpoints on the control board as indicated in the following table Name Testpoint For Testpoint Location Associated Connector Description See Pin 5V XY5 Figure 1 on page 18 XA 1 XA 3 XA 5 5V digital supply GNDD XY6 Figure 1 on page 18 XA 2 XA 4 XA 6 5V digital supply ground GNDD XY7 Figure 2 on page 19 XA 2 XA 4 XA 6 5V digital supply ground 15V XY12 Figure 1 on page 18 XA 9 XA 10 15V analog supply GNDA XY10 Figure 1 on page 18 XM 11 XA 12 15V analog supply ground 15V XY11 Figure 1 on page 18 XA 13
115. ve the five screws that secure the control board to the control EMI shield and remove the board Remove screws Tightening torque for re assembly is 1 0 N m 8 9 Ibin WEW Tp TST TT I on SEQ mum TRA ri os 4 25 26 27 28 29 20 3 323 94 35 36 37 34 2 202 1 SP I Rockwell Automation Publication 20P TG003A EN P February 2012 57 Chapter3 Access Procedures Install the Control Circuit Board Install the control board in reverse order of removal Control EMI Shield Removal Move the Control EMI Shield and Closure You must move the control EMI shield that holds the control board in order to access other components within the drive 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Carefully disconnect the cables from connectors XFCD and XR on the control board Disconnect cables 58 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 5 Loosen the two captive screws at the top of the control EMI shield and partially lower the shield The shield will not open to its full extent due to a cable connection between the switching power supply board and the pulse transformer board Loosen screws 6 Disconnect the cable from connector XSW on the switching power supply board an
116. wer terminal and remove the lead Transient Noise Filter board i PE ground stud Remove ground wire Remove screw and wire 6 Remove the two screws and washers that secure the bottom of the transient noise filter board to the drive Remove screws and washers Rockwell Automation Publication 20P TG003A EN P February 2012 83 Chapter3 Access Procedures 7 Remove the two screws and washers that secure the bottom of the power supply filter circuit board to the drive E ITE 35 36 75 76 78 79 U2 V2 PE Remove screws and washers 8 Move the control EMI shield See Move the Control EMI Shield on page 58 9 Remove the wires that connect to the back of the control terminals on the power supply filter board 10 Remove the two screws and washers that secure the top of the power supply filter board to the drive and carefully lift the board Remove screw and washer Remove screw and washer Remove wires 84 Rockwell Automation Publication 20P TG003A EN P February 2012 Access Procedures Chapter 3 11 Remove the two screws and washers that secure the top of the transient noise filter board to the drive and carefully lift the board off the drive Remove screws and washers Remove cable ties 12 Remove the screws and washers that secure the black leads from connections V and W on the transient noise filter board to power terminals V and W respectively and remove the leads Remove screws w
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