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Field Circuit Board Removal and Installation

1. IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Remove the wires connected to the terminal block at XF on the fan loss detection circuit board located at the top of the drive to the left of the fan blower and cut the cable ties that secure the fan blower motor wires to the fan capacitor wires Ol Ol Ol on v2 O K1 NZ C1 jamms V1 PE XF XC fp L pay t st Remove wires from R4 no ececc se i terminal block XF Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 6 Using a 12 5 mm 0 5 in socket wrench loosen the four nuts two at each side that secure the fan assembly bracket to the drive frame and lift the fan assembly bracket up in order to clear the fan blower inlet and remove the bracket and fan assembly from the drive Take precautions to
2. Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 7 Remove the two hexalobular screws that secure the bottom of the fuse holder to the control pan Retain the screws for reuse 8 Place the tip of a flathead screwdriver in the slot of the two tabs at the base of the fuse holder and pull down until the tabs pull out from the fuse holder body When then fuse holder is loose remove it from the metal support flange Pull tabs down and Remove screws remove fuse block Install the Field Fuse Holder Install the field fuse hol
3. 44 Rockwell Automation Publication 20P TGO04A EN P October 2011 o0 has mV vw W COND 000000000000000000000000 0000000000000000 1 ai ap Top terminal cover i PANDAAN P oosen screws M OOOO il both sides oi HALON CNC LON CNC LUNN 8 000000000000000000000000000000000000000000000000 000000000000000000000000000l e 00000000000000000000000 Top control panel ren oo j cover 8 8 8 8 Bottom control Loosen screws panel cover both sides Disconnect 8 8 DPI cable 8 000000000000000000 1 0 and control 00000040000000 0000000000000000 j anno VNO s MO COMME ek Loosen screws oooooooo0o0o00000 p e tare d oon 8 Poth sides ea or n Borrom terminal T POOO O0uCO L00 orel OuOOLOOUCOLOCUOOUO c M 00000000000000 SoN g ETa TD ol T oe e000 00o oo eee 00e Access Procedures Chapter 3 5 Disconnect the HIM communication cable from the connector on the upper right corner of the control board and remove the bottom control panel cover Pull tabs out to disconnect cable Install the Protective Covers Install the protective covers in reverse order of removal terminals of the drive The protective covers must be replaced after servicing the i AT
4. a Loosen y ON a screw tit oe an board m 5 TON Loosen soose zj il E screws screw r ail sot T 28 oF a rm e O m A bo a O al al SS sai g o i a 3 Wsp P loosen BRNE mo screw i DT i Tightening torque 0 8 N m 7 Ib in Pt 125 Rockwell Automation Publication 20P TG004A EN P October 2011 71 Chapter3 Access Procedures 5 Loosen the screws that secure the input and output wires to the fuse holder terminals and remove the wires 6 Ifyou are reusing the field fuses pull down on the tabs on the front of the fuse holder and remove the fuses O l 7 E __ Loosen screws and l i remove wires o o l S mH e 5 Pull tabs down and _ _ remove fuses Loosen screws and remove wires 72
5. 11 Remove the six hexalobular screws that secure the pulse transformer board to the control pan and remove the board Components shown within dashed lines are only on the pulse transformer board for regenerative drives XSW1 XSW o o X3 PE B XUV O OZ XP1 TR2 XP2 4 O TR1 L d XCD_IO XUVW ee ae KGI KGO1 xD H n FI tot LL KG4 KG04 T4 T04 L d XR O KG2 KG02 T2 T02 O Ld KG5 _q KG05 T5 T05 A KG3 KG03 T3 T03 XY es KG6 KG06 Ou T6 T06 XSPF a XTA X4 X5 X6 S3 S4 XCT AAAAAS AA AAA AAA ABARAREB HBBEBBHE bad POU EAn A E E E E ODODOOOOOO 78 79 35 36 75 76 81 82 U2 V2 Rockwell Automation Publication 20P TGO04A EN P October 2011 65 Chapter3 Access Procedures Install the Pulse Transformer Board Install the new pulse transformer board in reverse order of removal e Inspect the existing gate lead cables for burn marks cracks or loose connectors Replace the cables if necessary with the new cables provided e Set DIP switches S3 and S4 on the pulse transformer board to the correct
6. 3 Le _ joo J00 exe ele U phase bus bar W phase bus bar Signal wire Remove bolts and washers from U and W phase bus bars Install the AC Current Transducers Install the AC current transducers in reverse order of removal e Tightening torque for the M12 bolts is 45 Nem 398 lbein e Verify that signal wire that was disconnected from the U and W phase bus bars when removing the current transducers is re installed Rockwell Automation Publication 20P TGO04A EN P October 2011 81 Chapter3 Access Procedures Overvoltage Clipping Circuit Remove the Overvoltage Clipping Circuit Board Fuses Board Fuse Removal and m TTO 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 Open the control panel See Open the Control Panel on page 46 4 Remove the three fuses at locations F11 F21 and F31 X1UVW1 29 Install the Overvoltage Clipping Circuit Board Fuses Install the overvoltage clipping circuit board fuses in the reverse order o
7. Loosen Sean ce jut aA Switching Power L Supply board ET zs Loosen ie i Loosen screw a alk ao og screws 7 08 K Ai e O es fa O a al cj mod g 2 3 Wsp P loosen BRE mo screw cl MT i Tightening torque 3 0 8 N m 7 Ib in 19 Fame IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 62 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 5 Disconnect the cables from connector XA and XUV on the switching power supply board 6 Remove the five screws that secure the board to the control EMI shield and remove the board T15 Tightening torque 1 0 1 2N m 9 10 5 Ib in Remove five screws 1D2 102 XA FA xswi l XV Pa XSW N Gs if 15 O10 _ oe Disconnect cable from XA and XUV Install the Switching Power Supply Circuit Board Install the switching power supply circuit board in the reverse order of removal e Inspect the 16 Pin cable that connects to connector XA on the switching power supply board for burn marks cracks or a loose connec
8. Main input aes Loosen upper bolts Remove wires from fuse switch terminals Loosen lower bolts and washers SCR module leg TEE E terminal IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Rockwell Automation Publication 20P TGO04A EN P October 2011 87 Chapter3 Access Procedures 8 Disconnect the gate lead wires from the connectors mounted at the top of each SCR module leg assembly Note there are three connectors at the front for non regenerative drives There are six connectors three in front and three behind for regenerative drives 9 Disconnect the wires for the bimetal thermostat from the connector mounted on the middle of the left SCR module leg assembly 10 Disconnect the wires for the capacitors and resistors from the connectors mounted at the bottom of each SCR module leg assembly
9. Rockwell Automation Publication 20P TGO04A EN P October 2011 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 bottom control panel and I O and control terminal covers from the drive See Protective Cover Removal and Installation on page 44 3 Using a voltmeter measure the voltage at terminals U V and W of the drive Note Ifan AC input contactor is used the voltage must be measured on both the input and output sides of the contactor If any of the voltage measurements is incorrect or missing remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems 4 Using a voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5V offset See Figure 1 on page 18 and Figure 2 on page 19 for location of the testpoints Also see Figure 12 on page 106 for a schematic diagram Table 1 Combined AC Line Input Signal Testpoints Incoming AC Phases MeasureFrom j ToTestpoint Peak
10. X3 2 To Pulse 470K 470K 470K 470K V1 Transformer 470K 470K 470K 1U1 Board X3 X3 1 Connector K2 G2 XFCD 1 gt XFCD 2 _ XFCD 3 gt e XFCD 4 gt iS M TA_1 D1 C1 To Motor Field Connections Figure 15 Field Control Circuit Diagram gt __ 15 V XFCD 1 gt 15 V XFCD 3 XFCD 4 T LB 14 8 S14 7 814 6 514 5 814 4 S14 3 14 2 S141 XFCD 2 1 i LA Rockwell Automation Publication 20P TG004A EN P October 2011 107 AppendixA Schematics Figure 16 Control Circuit Input Power Diagram 108 U2 v91 O E 1C2 e _ ad ib2 V2 L z es O e e me hd 230 VAC or To Switch Mode Power 115 VAC input Supply SMPS Figure 17 Encoder Control Circuit Diagram fot S21 t ENC D S21 I Ke 24V LJ R Voltage Regulator and Current Feedbac
11. LI O XP3 15 l 4 Resolver feedback board i pooooooco0 S1 fe El a Co HO O P1 22324 5 2 27 8 2 32 33 34 5 6 37 38 39 00 QOCOOOOCOOVOJOOOCOOCC0O _ Eee ee DEBUG A 8 CSS IT 1234567389012814 5617B9 20 SR O00000 12345678 0 0000 29000 80Z0099 _ 9000000009 0900000000 Remove terminal blocks Rockwell Automation Publication 20P TGO04A EN P October 2011 51 Chapter3 Access Procedures 5 Remove the three hexalobular screws that secure the resolver feedback board to the stand offs on the resolver interface board and carefully remove the resolver feedback board IMPORTANT The resolver feedback board is connected to the resolver interface board below it via stacker connector pins at connectors P2 and P3 Lift the resolver feedback board straight up during removal to avoid any damage to the connector pins oe eerie FO XA F L L O gg XP3 P3 S15 ToT ooo Remove screws and board Tightening torque for re assembly is i
12. Table 22 Switching Power Supply Board to Control Board Connections Switching Power Pin Number to Pin Number Control Board Description Supply Board Connector Connector XA 1 1 XA 5V 2 2 5V common 3 3 5V 4 4 5V common 5 5 5V 6 6 5V common 7 7 3 3 SMPS supply input undervoltage 9 9 10 10 15V 11 11 1 n 15V common 13 13 14 14 ad 15 si 15 24V common 16 nas 16 24V See Pulse Transformer Board to Switching Power Supply Connections on page 115 Rockwell Automation Publication 20P TGO04A EN P October 2011 117 AppendixB Circuit Board Layouts and Connections Control Board Figure 25 Control Board Layout ees Eee aD O XA D To DPI board on e OO o pie a o Ba Ba f LA LB h E 5 LJ z PWR mg X
13. Disconnect F31 F21 F11 i unsolder connectors X1UVW1 from XR 1 XR 6 omy I GS O O O O O GS Older overvoltage clipping board Rockwell Automation Publication 20P TGO04A EN P October 2011 95 Chapter3 Access Procedures 5 Remove the four screws that secure the resistor to the drive frame and remove the resistor and wires Remove screw Install the In Rush Limiting Resistor Remove screws Instal the in rush limiting resistor in the reverse order of removal Snubber Capacitors Removal Remove the Snubber Capacitors 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 bottom terminal cover from the drive See Remove the Protective Covers on page 44 4 Remove the nut and washer that secures each of the snubber capacitors to the mounting bracket at the bottom of the drive chassis and lift the capacitors off the brackets 96 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 5 Disconnect the wires from the top of each capacitor and remove the capacitors Note Bus bars shown removed for clarity only Disconnect capacitor wires Remove nuts and wa
14. B 0 E G B pe lo Lae BS oT 5 O a Cl co a E e gi a g 2 gi o e S a Wg S EE mo Omo Omo Field board I Loosen screws A Loosen screw Tightening torque 0 8 N m 7 Ib in Rockwell Automation Publication 20P TG004A EN P October 2011 Fe 67 Chapter3 Access Procedures IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 5 Disconnect the cables from connector XFCD and X3 on the field board 6 Remove the eleven hexalobular screws that secure the field board to the control EMI shield and remove the board Note Field board for 70A field supply shown X3 n A XFCD R4 R1 T25 rE Tightening torque 2 5 4 0 N m U U 22 35 Ib in C7 C4 Tightening torque 1 0 1 2 Nem 9 10 5 Ib in Install the Field Circuit Board Install the field circuit board in the reverse order of removal e Inspect the cables that connect to connectors XFCD and X3 on the field board for burn marks cracks or a loose connector If necessary replace the existing cables with the new cables
15. C XY20 E o o o o o Oo o o o 00g0oogpgoaagpagagg S a O00 O EN U fie oo TAEC Ss ece AENEON 00000 09000000 2 EERE Tr 18 Rockwell Automation Publication 20P TG004A EN P October 2011 Component Test Procedures Chapter 2 Figure 2 Control Board Testpoints Upper Right a 12VEXP 4 OVEXP 5VEXP XY7
16. X1UVW1 Oo a XUVW C XR 4 O O C7blu C7gn Table 24 Overvoltage Clipping Board to Pulse Transformer Board Connections Overvoltage Pin Number to PinNumber Pulse Transformer Description Clipping Board Board Connector Connector Signal from C Phase XCD not used wln Signal from D Phase XCD not used Signal from DC output terminal C not used Signal from DC output terminal D Signal from U Phase not used X1UVW1 not used 1 2 3 XUVW Signal from V Phase 4 5 Signal from W Phase Signal from AC input terminal U not used XUVW Signal from AC input terminal V not used Mm Rel wl rm e nm A I wl rm NIAI Ae Ww rm Signal from AC input terminal W 120 Rockwell Automation Publication 20P TGO04A EN P October 2011 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 122 Field Current Loss Failure 123 Rockwell Automation Publication 20P TGO04A EN P October 2011 121 AppendixC Flow Charts Control Power Supply Failure This chart presents t
17. Install the Fan Loss Detection Circuit Board ot ro ik S XE K O C1 V1 PE XF XC V2 Install the fan loss detection circuit board in the reverse order of removal Refer to the Fan Power and Loss Detection Circuit Diagram on page 111 for wiring details Rockwell Automation Publication 20P TGO04A EN P October 2011 75 Chapter3 Access Procedures Fan Assembly Removal and Installation 76 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the top terminal cover from the drive See Remove the Protective Covers on page 44 4 Loosen but do not remove the six hexalobular screws that secure the top air flow plate to the drive then slide the plate forward to lift it off the screws Note The air flow plate cannot be removed from the drive unless the AC input wiring and bus bar extensions if installed are removed Fan loss detection board Top View of Drive 7 T15 TOE FAROR EAT e FP ooon 00000000000000 on Tightening torque hii 1 5 Nem 13 Ib in Rii o ii Loosen i Loosen screws screws O 5 Remove the Fan Assembly Read the General Safety Precautions on page 10
18. Gate lead wire color White _ j A e P B E o f order Red Xo e i o a White on Ti o i pa Red we a B a A 3 Disconnect gate lead wire connectors Disconnect thermostat wire connector SCR module assembly Disconnect capacitor and resistor wire connectors 7 TT y IL 11 Remove the four bolts and washers that secure each SCR module leg assembly output terminal to a DC output bus bar C and D at the bottom of the drive IMPORTANT Once the connecting bolts and washers are removed the C shaped bus bar between the middle and right SCR module leg assembly can be re
19. bo 9 Z09 Ly 109 cet SS Ee PETA 19 a 19 pueog ynau JOWUOJSUEL SNd 105 Rockwell Automation Publication 20P TGO04A EN P October 2011 AppendixA Schematics Figure 12 AC Line Measurement Points Diagram XY 22 AJ XR 15 U 100 K o 15 asv x 15V fq I 15 XY21 mee _ 15 t a 15 XY 18 XR 17 Ww 100 K Figure 13 Power Feedback Connections Diagram Hardware connections to power structure bus bars C D U V W XR19 Note i XR18 Note XR15 Note Y XR16 Note ty H XR17 Note 106 Note 6 x 715 kohm resistors g i g g orood g elel e Rockwell Automation Publication 20P TG004A EN P October 2011 Schematics Appendix A Figure 14 Field Board and SCR Dual Diode Module Connections Diagram Incoming AC Line V1 U1
20. Pulse Transformer to PinNumber Switching Power Supply Board Description Board Point Connector 4 Rectified U2 V2 voltage approx 102 150 300V DC 3 XUV not used 102 2 not used 1 Common Table 18 Pulse Transformer Board to Bimetal Thermostat Connections Pulse Bimetal Description Transformer Thermostat Board Connector Connector 1 thes 1 XA 24V supply through resistor 2 he 2 24V common Table 19 Pulse Transformer Board to Field SCR Dual Diode Module Connections Pulse Pin Number to PinNumber Field SCR Dual Description Transformer Diode Module Board Connector Connector 1 3 Gate signal G1 2 2 Common cathode K1 and K2 for a 3 A Fastons both field SCRs 4 1 Gate signal G2 Rockwell Automation Publication 20P TG004A EN P October 2011 115 AppendixB Circuit Board Layouts and Connections Table 20 Pulse Transformer Board to Control Board Connections Pulse Transformer Pin to Pin Control Board Description Board Connector Number Number Connector XR 1 i 1 XR Gate signal G1 field SCR1 2 oe 2 Gate signal G2 field SCR2 3 sa 3 OV GNDP 4 aoe 4 Relay output 35 36 command 5 ae 5 Relay output 75 76 command 6 et 6 20 40 selection signal 7 ne 7 OV GNDP 8 es 8 armature
21. 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Open the control panel See Open the Control Panel on page 46 92 Rockwell Automation Publication 20P TG004A EN P October 2011 O IMPORTANT Access Procedures Chapter 3 Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Disconnect the resistor wires from connectors XR 1 XR 6 on the overvoltage clipping board Note On older boards these connections are soldered directly to the board In this case unsolder the connections X1UVW1 O O xr s XR 4 C5gn C4blu F31 XUVW C OO Rockwell Automation Publication 20P TGO04A EN P October 2011 C7blu C7gn Newer overvoltage clipping board Disconnect unsolder connectors from XR 1 XR 6 Older overvoltage clipping board 93 Chapter3 Access Procedures 5 Remove the four screws that secure each of the resistors to the drive frame and remove the resistors and wires Remove Remove screw crews Install the Discharge Resistors Inst
22. 0 signal 9 ca 9 OV GNDP 10 ae 10 Heatsink overtemperature 11 ai 11 Digital U1 V1 sync signal 12 Ser 12 OV GNDP 13 an 13 CT burden signal 14 ee 14 OV GND 15 vei 15 Reduced U sync signal 16 wi 16 Reduced V sync signal 17 x 17 Reduced W sync signal 18 a 18 Reduced C armature signal 19 Pe 19 Reduced D armature signal 20 ve 20 OV GNDP 21 et 21 Gate signal SCR 4 01 22 a 22 OV GNDP 23 wd 23 Gate signal SCR 5 02 24 ue 24 OV GNDP 25 ten 25 Gate signal SCR 6 03 26 es 26 WH1 not used grounded 27 ee 27 Gate signal SCR 1 04 28 igs 28 WL1 not used grounded 29 wid 29 Gate signal SCR 2 05 30 ue 30 OV GNDP 31 den 31 Gate signal SCR 3 06 32 Ane 32 Motor overtemperature 33 a 33 Enable reverse MN power bridge 34 ost 34 Enable forward MP power bridge 116 Rockwell Automation Publication 20P TGO04A EN P October 2011 Circuit Board Layouts and Connections Appendix B Table 21 Pulse Transformer Board to Current Transducer Connections Pulse Pin Number to PinNumber Current Transducer Description Transformer Board Connector 1 Red i CTonPhaseU Secondary side CT phase U 2 White a 3 Red 4 White CTonPhaseW Secondary side CT phase W Switching Power Supply Figure 24 Switching Power Supply Board Layout Board 1D2 1C2 XA xSw1 XV XSW 2 16 Aly 41 4 1 6 XUV
23. Cooling Fan Schematics Appendix A yellow green RE Fan Supply blue grey OU3F pV 230VAC brown OV3F VS 90 60 Hz black __ OZ2F co OZ2C 32 Fan OU3C 31 Fault Fan Capacitor _ S_s_ id Rockwell Automation Publication 20P TGO04A EN P October 2011 111 AppendixA Schematics Notes 112 Rockwell Automation Publication 20P TGO04A EN P October 2011 Appendix B Circuit Board Layouts and Connections List of Circuit Board Layouts The following images and tables detail the connection points for the frame A PowerFlex DC drive circuit boards and components Topic Page Pulse Transformer Board Layout 114 Pulse Transformer Board to Field Board Connections 115 Pulse Transformer Board to Switching Power Supply Connections 115 Pulse Transformer Board to Bimetal Thermostat Connections 115 Pulse Transformer Board to Field SCR Dual Diode Module Connections 145 Pulse Transformer Board to Control Board Connections 116 Pulse Transformer Board to Current Transducer Connections 117 Switching Power Supply Board Layout 117 Switching Power Supply Board to Control Board Connections 117 Control Board Layout 118 Control Board to Field Board Connections 118 Field Board Layout 119 Overvoltage Clipping Board 120 Overvoltage Clipping Board to Pulse Transformer Board Connections 120 Rockwell Automation Publication 20P TGO04A EN P
24. 22 44 Ib in Ol O O Remove screws and washer Install the Field SCR and Dual Diode Modules Install the field SCR and dual diode modules in the reverse order of removal e Apply thermal grease to the bottom of the SCR and dual diode modules before securing them to the heatsink and dual diode modules before securing them to the heatsink or damage to the ATTENTION Thermal grease must be applied to the bottom of the field SCR drive may occur 70 Rockwell Automation Publication 20P TG004A EN P October 2011 Access Procedures Chapter 3 Field Fuse Holder Removal Remove the Field Fuse Holder 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 top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover
25. 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 Open the control panel See Open the Control Panel on page 46 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 Measurements must be taken below the AC input leg fuses on the U V and W phases for the specific SCR module For regenerative drives see Table 2 on page 28 and Figure 6 on page 28 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 Module Leg Assembly Removal and Installation on page 86 Phase U Phase V Phase W Rockwell Automation Publication 20P TGO04A EN P October 2011 27 Chapter2 Component Test Procedures Phase U Rear Gate Lead Terminal Block Table 2 SCR Anode to Cathode Junction Measurements for Regenerative Drives For SCR Measure from To Terminal Terminal 1 U C 4 U D 2 V C 5 V D 3 Ww C 6 Ww D 01 U C 04 U D 02 V C 05 V D 03 Ww C 06 Ww D Nominal meter reading open circuit or megaOhms range Figure 6 Regenerative Dr
26. 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 Pull down on the tabs at the top of the fuse holder on the front of the drive and remove the fuses Dr at at a aw aw ant ant I OC Ar SIAN OVO oN a as q Ns VU WY VU NA AA NA Y Y J VY VU fe Niet as ab fea AEEA CSNY ant i Nf ON SN ON ION PN ONO VY VY VY VY VY GY YY YY YY UY YY FUI FV gt Install the Field Circuit Fuses Install the new field circuit fuses in reverse order of removal 42 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 DPI HIM Assembly Removal Remove the DPI HIM Assembly from the Protective Cover 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 s
27. 1017 834 900 ON ON ON ON 1K1 1130 927 1000 ON ON ON ON 66 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 Drive DC ACLine HP DIP Switch 3 DIP Switch 4 pees Amps Amps 53 1 3 2 3 3 53 4 53 5 3 6 3 7 3 8 S4 1 S4 2 4 3 54 4 54 5 S4 6 S4 7 54 8 Code 1K2 1243 1019 1100 ON ON ON ON 1K4 1413 1159 1250 ON ON ON ON 1K5 1582 1297 1400 ON ON ON ON Field Circuit Board Removal and Installation Remove the Field Circuit Board bs i Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover Loosen screw Loosen screw
28. 2 Newer overvoltage clipping board Disconnect unsolder connectors from XR 1 XR 6 O O O O O O O G3 Older overvoltage clipping board Rockwell Automation Publication 20P TGO04A EN P October 2011 83 Chapter3 Access Procedures Install the Overvoltage Clipping Circuit Board Install the overvoltage clipping circuit board in the reverse order of removal Armature Leg Fuse Removal Remove the Armature Leg Fuse 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 Open the control panel See Open the Control Panel on page 46 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Remove the screws that secure the switch to the fuse and remove the switch and fuse wires Retain the switch screws and wires for reuse Remove screws switch and wires 84 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 5 Loosen the two bolts that secure the fuse to the bus bar and SCR leg terminal Rotate the top of the fuse out and downward and pull the fuse off of the lower bolt and out of the drive Loosen bolt Remove fuse Loosen bolt Install the Armature Leg Fuse Install the armature leg fuse in the reverse order of removal e Tightening torque for the fuse bolt is 45 Nem 39
29. 91 Bimetal Thermostat Removal and Installation 0085 92 Remove the Bimetal Thermostat 0cccceececeeeeens 92 Install the Bimetal Thermostat ccccceceececeeeeees 92 Discharge Resistors Removal and Installation 08 92 Remove the Discharge Resistors 2 5 sssys nai gaerracsss os 92 Install the Discharge Resistors s g 303 4otw xiv ent ance ows mraains 94 In Rush Limiting Resistor Removal and Installation 94 Remove the In Rush Limiting Resistor 0 000 cee ees 94 Install the In Rush Limiting Resistor 00 0000 0 96 Snubber Capacitors Removal and Installation 00005 96 Remove the Snubber Capacitors s 0 4 cecdeide Be acueioudeoehedeen 96 Install che Snubber Capacitors 2522 inenjet 22rd eer des oh oadinee 97 Snubber Resistors Removal and Installation 0 0ce cece ee 98 Remove the Snubber Resistors 00 eee ececeeneeeeenees 98 Install the Snubber Resistors 00cccccccecucscueeeavus 99 Chapter 4 Test With the Motor Without a Mechanical Load 101 Rockwell Automation Publication 20P TGO04A EN P October 2011 5 Table of Contents Schematics Circuit Board Layouts and Connections Flow Charts Index Appendix A List of Schematic Diagtaiis un erie i ee os eS 103 Appendix B List of Circuit Board Layouts 16 20 net ae era toe rua amet 113 Pulse Transformer Board
30. Loss l Detection soard yellow green O CE brown V3F black 9 Z2F blue grey O U3F 104 XTA 1 Cooling Fan Switching Power Supply Board XCD XA nou i Overvoltage Clipping Board XUV ge Ulipping Lor 1 X1UVW1 j XUV XP1 m XSW XCD XP2 Pulse Transformer Board 4 XUVW xs e nA sR a XR KG1 KGO1 l TL KG4 KG04 XFCD KG2 KG02 Control Board KG5 KG05 XY e KG3 KG03 Test Connector l T CT U CT W KG6 KGO6 i re X4 2 XTA 2 XTA 3 XTA 4 Rockwell Automation Publication 20P TG004A EN P October 2011 Appendix A Schematics Figure 11 Regenerative Drive Power Module Block Diagram 909 fost tesa laa ia 99 Soo al eee fo Lili SOM t09 a SIX beel pE Lees voy pieogynaig Jouuojsues asing Vix of v9 09 T1 Leo a1
31. ON Als S4 den sii ten s21 s SER O O 21 22 23 24 25 26 27 28 29 30 I 31 32 33 34 35 36 37 38 39 40 o o oOoo0o0o000000f0000000000 BEE SAB Ce ENS ENG At A B B Z Z COM V 1234567 8 9 10 it 12 1314 15 1617 18 1920 OOQ0Q0Q0Q00Q ooooooooooloooooooooo L__ kenne Install the Control Circuit Board Install the control board in reverse order of removal e Verify that all DIP switches are set to the correct configuration based on your recorded settings See page 58 Rockwell Automation Publication 20P TGO04A EN P October 2011 61 Chapter3 Access Procedures 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 top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover
32. Regenerative Drives Measure from Terminal For SCR To Terminal Dl wl nn rn S z sS e elce S oS es oe Nominal meter reading open circuit or megaohms range Figure 7 Non Regenerative Drive SCR Module Layout SCR5 G fo SCR 5 K 0 Phase V Front Gate Lead Terminal Block SCR 1 G _ SCR 1 K _ Phase V Rear Gate Lead Terminal Block Phase W Front Gate Lead Terminal Block Phase W Rear Gate Lead Terminal Block SCR6 G SCR6 K Rockwell Automation Publication 20P TG004A EN P October 2011 29 Chapter 2 30 Component Test Procedures 6 Disconnect the gate lead connectors from the terminal blocks at the top of each phase leg assembly With a digital multimeter set to Ohms measure the resistance of each SCR junction using the pins on the terminal block as identified in the table below For regenerative drives see Table 4 below and Figure 6 on page 28 For non regenerative drives see Table 5 below and Figure 7 on page 29 Ifa measurement is outside of the range specified in the tables below or if one reading deviates significantly from the majority then m
33. board may need replacement Terminals 35 and 36 and 75 and 76 are N O relay outputs The relay output between terminals 35 and 36 is configured with parameter 1392 Relay Out 1 Sel The relay output between terminals 75 and 76 is configured with parameter 629 Relay Out 2 Sel See Using Contactors in Chapter 1 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 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 TGO04A EN P October 2011 Create a Fault Report What You Need When You Call Tech Support the factory Component Test Procedures Chapter 2 Complete fault reports are critical for analysis and repair of modules returned to 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 UM001 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 dri
34. in e T25 IMPORTANT ORP C Mark all connections and wires before removal to avoid incorrect wiring during reassembly Remove the switching power supply circuit board See Remove the Switching Power Supply Circuit Board on page 62 Disconnect the red and white gate leads from connectors XP1 and XP2 at the top left corner of the board Refer to the pulse transformer board layout on the following page Disconnect the appropriate gate leads from the pulse transformer board e For non regenerative drives each pair of red and white gate lead cables from connectors KG1 KG6 For regenerative drives each pair of red and white gate lead cables from connectors KG1 KG6 and KG01 KG06 Disconnect the cables from the following connectors XUV XCD_IO XUVW XCD XR XTA X3 X4 and XSPE Also carefully remove the ribbon cable from XR from the cable standoff on the board board 64 Rockwell Automation Publication 20P TGO04A EN P October 2011 Remove the plug in terminal block at the bottom of the pulse transformer T15 E Tightening torque 1 0 1 2 Nem 9 10 5 Ib in 10 Access Procedures Chapter 3 Remove the two hexagonal standoffs and washers from the pulse transformer board
35. mm socket extension 230mm Wrench 7mm 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 TGO04A EN P October 2011 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 Inspection 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 Procedu
36. protect against personal injury when handling the ATTENTION The edges of the blades on the fan blower may be sharp fan assembly Loosen nuts two each side of bracket Tightening torque 18 0 N m 159 3 Ib in Lift bracket and fan and pull out of drive Install the Fan Assembly Install the fan assembly in the reverse order of removal Refer to the Fan Power and Loss Detection Circuit Diagram on page 111 for wiring details e Secure the fan power wires using cable ties as previously installed to ensure that the wires do not make contact with moving parts Rockwell Automation Publication 20P TGO04A EN P October 2011 77 Chapter3 Access Procedures 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 top terminal cover from the drive See Remove the Protective Covers on page 44 4 Loosen but do not remove the six hexalobular screws that secure the top air flow plate to the drive then slide the plate forward to lift it off the screws Note The air flow plate cannot be removed from the drive unless the AC input wiring and bus bar extensions if installed are removed Fan loss detection board Top View of Dri
37. provided 68 Rockwell Automation Publication 20P TGO04A EN P October 2011 Field SCR and Dual Diode Module Removal and Installation Gate lead wires Access Procedures Chapter 3 Remove the Field SCR and Dual Diode Modules Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 Remove the field circuit board from the drive See Remove the Field Circuit Board on page 67 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Disconnect the gate lead wires from the connectors at the top of the SCR module P J f gt Ea J SCR module aaloe aaae Rockwell Automation Publication 20P TG004A EN P October 2011 69 Chapter3 Access Procedures 6 Remove the four screws and washers that secure the SCR and dual diode modules to the heatsink and remove the modules Remove screws and washers ef M oojoo Tightening orgue O i Q Q
38. removed Remove control cover to access terminals Field fuses FU1 FV1 c1 D1 Bottom Left Side of Drive 7 Remove the cable from connector XP on the pulse transformer circuit board 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 on page 34 below Ifa low resistance is detected replace the SCR dual diode module Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Measure from To e Nominal meter reading XP1 XP2 P3 PA 10 20Q 34 Rockwell Automation Publication 20P TGO04A EN P October 2011 Speed Feedback Device Tests Component Test Procedures Chapter 2 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 21 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_S 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 17 on page 1
39. ribbon cable connected to XR on the control board and can be measured at these points See Figure 25 on page 118 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 bottom control panel and I O and control terminal covers from the drive See Protective Cover Removal and Installation on page 44 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 SignalName _ XR Cable Pin Gate Note MP MN 11 27 G1 G04 IT2 29 G2 G05 IT3 31 G3 G06 IT4 21 G4 G01 IT5 23 G5 G02 IT6 25 G6 G03 MN 33 Negative bridge MN active when high 5V MP 34 Positive bridge MP active when high 5V Rockwell Automation Publication 20P TGO04A EN P October 2011 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 XY19 2 5V offset The ground signal is tak
40. settings based on the appropriate table below Refer to the illustration on the previous page for location IMPORTANT Ablank cell below a switch in tables below indicate that the setting is OFF Table 12 230V AC Input Drives Drive DC ACLine HP DIP Switch 3 DIP Switch 4 ay Amps Amps 53 1 3 2 53 3 3 4 53 5 3 6 3 7 53 8 S4 1 4 2 4 3 s4 4 s4 5 S4 6 54 7 54 8 Code 875 875 718 250 ON ON ON 1050 1050 861 300 ON ON ON ON Table 13 460V AC Input Drives Drive DC ACLine HP DIP Switch 3 DIP Switch 4 iti Amps Amps 53 1 3 2 53 3 3 4 3 5 53 6 3 7 53 8 S4 1 4 2 43 4 4 s4 5 54 6 S4 7 54 8 Code 830 830 681 500 ON ON ON 996 996 817 600 ON ON ON 1K1 1162 953 700 ON ON ON ON 1K3 1328 1089 800 ON ON ON ON 1K4 1494 1225 900 ON ON ON ON Table 14 575V AC Input Drives Drive DC ACLine HP DIP Switch 3 DIP Switch 4 patti Amps Amps 3 1 3 2 3 3 3 4 3 5 3 6 3 7 S3 8 S4 1 S4 2 4 3 S4 4 S4 5 S4 6 S4 7 S4 8 Code 810 810 664 600 ON ON ON 1K0 1080 886 800 ON ON ON ON 1K2 1215 996 900 ON ON ON ON 1K3 1350 1107 1000 ON ON ON ON 1K4 1668 1384 1250 ON ON ON ON Table 15 690V AC Input Drives Drive DC ACLine HP DIP Switch 3 DIP Switch 4 alte Amps Amps 53 1 53 2 53 3 3 4 3 5 3 6 3 7 3 8 4 1 s4 2 54 3 s4 4 54 5 54 6 S4 7 54 8 Code 678 678 556 600 ON ON 791 791 649 700 ON ON ON 904 904 74 800 ON ON ON 1K0
41. starting capacitor in the reverse order of removal Refer to the Fan Power and Loss Detection Circuit Diagram on page 111 for wiring details 74 Rockwell Automation Publication 20P TGO04A EN P October 2011 Fan Loss Detection Circuit Board Removal and Installation Access Procedures Remove the Fan Loss Detection Circuit Board 1 Read the General Safety Precautions on page 10 Chapter 3 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the top terminal cover from the drive See Remove the Protective Covers on page 44 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Loosen the screws that secure the plug in terminal block at XE to the top of the fan loss board and remove the terminal block 5 Remove the plug in terminal blocks at XF and XC from the fan loss board 6 Disconnect the ground wire from connector PE 7 Remove the four hexalobular screws that secure the fan loss board to the insulator and remove the board Tightening torque is noted in the illustration for reassembly Remove plug in terminal block at XE Remove four screws Fe Tightening torque 1 0 1 2N m 9 10 5 Ib in Remove plug in terminal blocks at XF and XC SS a a eat ea
42. terminal covers See Protective Cover Removal and Installation on page 44 Verify that contactor power if used is removed Verify that power to an external field supply if used is removed 32 Rockwell Automation Publication 20P TGO04A EN P October 2011 Component Test Procedures Chapter 2 6 Check the anode to cathode junction of the field SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules See Table 10 below and Figure 8 on page 34 Ifa low resistance is detected replace the modules See Field SCR and Dual Diode Module Removal and Installation on page 69 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 8 on page 34 Table 10 SCR Dual Diode Module Anode to Cathode Junction Measurements MeterLead Meter Lead Nominal meter reading Terminal Terminal U1 q open or co U1 D1 open or co V1 q open or co V1 D1 open or co q D1 open or co q U1 open or co c1 V1 0 50V D1 C1 0 50V D1 U1 0 45V Rockwell Automation Publication 20P TGO04A EN P October 2011 33 Chapter2 Component Test Procedures Figure 8 Field Terminal Block and Field Fuse Locations Top Left Side of Control Panel e Field AC input terminals U1 V1 at top of fuse holder Shown with control cover
43. the drive See Remove Power from the Drive on page 42 3 Remove the bottom control panel cover See Remove the Protective Covers on page 44 4 Disconnect the interface cable from the communication adapter and set it aside 5 Disconnect any network cables from the adapter and set them aside Allen Bradiey A Disconnect interface cable Disconnect network cables Note Frame A shown 6 Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter lt Allen Bradle s zo conn D CD 188 Remove four ce Ong screws Tightening torque 0 9 N m 8 Ib in Note Frame A shown Rockwell Automation Publication 20P TGO04A EN P October 2011 47 Chapter3 Access Procedures 7 Remove the three screws that secure the EMI shield to the stand offs on the control board and remove the EMI shield Remove three screws Tightening torque 1 0 N m 8 9 Ib in Note Frame A shown 8 Remove the three stand offs from the control board Remove three stand offs Tightening torque 1 0 N m 8 9 Ib in Note Frame A shown Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal 48 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 Switching Power Supply Fuse Remove the Fuse on the Switching Power Supply Circuit Board Removal and Installatio
44. 0 c cece cece cee ee enneren 114 Switching Power Supply Beatds 5 lt sesccedswaeubiasueu seen gunenns 117 Control Board LEIME EAEE EE ET EET 118 Field Board 1 0 00 cece cece cece cee cece eee erneer erore erreen 119 Overvoltage Clipping Board cn inure cecsedeussautrtaneoupeedts 120 Appendix C List of Flow Charts 0 cece eee e cece eeeceeeeeeeeeeaeens 121 Control Power Supply Failte i ii2 ketelnse a lwaann decane ass 122 Field Current Loss Failure 0 c cece cece e cece eee ee neces 123 No Field Current 0 cece eee cece cece eee eeneeenaee 123 Low or Incorrect Field Current 0c cee eee eee ee eee 124 Rockwell Automation Publication 20P TGO04A EN P October 2011 About This Publication Who Should Use this Manual Additional Resources Preface This manual contains hardware service information for frame D 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 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 a
45. 08 for a schematic diagram The Channel A and Channel B are square wave type outputs that are 90 degrees out of phase When rotating in the CCW 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 UMO001 Also see Figure 18 on page 109 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 UM001 for more information Rockwell Automation Publication 20P TGO04A EN P October 2011 35 Chapter 2 36 Com
46. 1 0 Expansion Circuit Board _ 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 bottom and I O and control terminal protective covers See Protective Cover Removal and Installation on page 44 4 Ifinstalled remove the resolver feedback option and interface boards See Resolver Feedback and Interface Circuit Board Removal and Installation on page 51 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 5 Remove the plug in I O terminal blocks with the wiring kept in place 6 Remove the two M3 x 6 mm screws and washers that secure the I O expansion board to the stand offs on the control board ose el Remove two screws Tightening torque and washers 1 0 N m 8 9 Ib in 7 Carefully pull the I O expansion board off connector XBB on the control board Rockwell Automation Publication 20P TGO04A EN P October 2011 55 56 Chapter 3 Access Procedures 8 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 N m 8 9 Ib in circuit board 9 Install one of the existing screws in the lower left corner of the control ofr Pie te ore Roy Ree Rey ee Aer Typa WPT HYI w e inis s s e sina HAs A Be B Z Z COM V CR J Install screw Tightening torque 1 0 N m 8 9 Ib in Install the 1 0 E
47. 168 5 Q 30A ON ON OFF OFF OFF OFF OFF 111 9Q 40A ON OFF ON OFF OFF ON OFF 83 10 1A OFF OFF OFF OFF OFF ON OFF 1668 Q 5A OFF ON OFF OFF OFF OFF OFF 33330 10A HA ON OFF OFF OFF OFF OFF OFF hee 168 5 Q 20A ON OFF ON OFF OFF ON OFF OFF 83 10 50A OFF ON OFF ON OFF OFF OFF 32 80 70A ON ON ON ON OFF OFF OFF 23 90 e Ifthe resistance measurement is incorrect replace the field board Rockwell Automation Publication 20P TGO04A EN P October 2011 Component Test Procedures Chapter 2 No Field Current Note For a flow chart version of these steps see No Field Current on page 123 1 Read the General Safety Precautions on page 10 2 Remove the top control panel cover from the drive See Protective Cover Removal and Installation on page 44 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 14 on page 107 for a schematic diagram e Ifthe 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 correct If the voltage is correct but the fault persists or parameter 351 Field Current is incorrect continue with step 4 below 4 Remove AC power to the drive and
48. 2 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 UMO01 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 aD 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 Troubleshooting 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 measurement
49. 3 2 XP3 3 5V for DPI expansion 12VEXP 12VEXP Figure 2 on page 19 XP3 4 XP3 5 12V 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 122 Rockwell Automation Publication 20P TGO04A EN P October 2011 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 fuse F1 at the top of the drive See Switching Power Supply Fuse Removal and Installation on page 49 for fuse location e Ifthe fuse is blown continue with step 6 below e If the fuse is not blown replace the switching power supply board Replace the fuse on the switching power supply board See Switching Power Supply Fuse Removal and Installation on page 49 Disconnect the cable at connector XA on the control b
50. 8 Ibein e Install the existing fuse switch on the fuse body using the existing hardware Verify that all wires are properly connected to the fuse switch Rockwell Automation Publication 20P TGO04A EN P October 2011 85 Chapter3 Access Procedures SCR Module Leg Assembly Remove the SCR Module Leg Assembly 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 bottom terminal cover from the drive See Remove the Protective Covers on page 44 4 Open the control panel See Open the Control Panel on page 46 IMPORTANT Note the terminal number on the fuse switch to which the signal wires are connected for proper re installation Note terminal numbers on fuses for wire connections 86 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 5 Remove the signal wires from the fuse switch connectors and secure the wires in a position above the input terminals 6 Loosen the lower bolt and washer that secures the bottom of each leg fuse to the SCR module leg input terminal 7 Loosen the upper bolt and washer that secures the top of the fuse to the AC input terminal rotate the top of the fuse out and downward and remove the fuse from the lower terminal Rotate top of fuse out and downward lift off lower terminal
51. AL 5 0 y 5 AS 260 V 7 nS 1 5 be 220 Av DC 16 kS s 3 5 vV eH f Line 1 v C O 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 Feb 95 Chi Sync Ch2 ITFL Ch3 ITF2 0h4 Ie File Fed pl REMOTE ENABLE 17 01 35 60 TO 5 ns LOCAL U1 V1 Sync 5 0 V A gt ns LA LB 5A ri 2 m 2 ns ITF1 Pulse 5 4 3 3 2 ns ITF2 Pulse 5 0 5 as S Y OC ERRA 10 5 5 3 5 v OR _J Line 4 S5nv C O STOPPED e Ifthe gate signals are missing replace the control board e Ifthe gate signals are present replace the field board Rockwell Automation Publication 20P TGO04A EN P October 2011 Component Test Procedures Chapter 2 Power Component Test Check the Armature SCR Modules Procedures Leg fuses Take measurements on the terminal below the leg fuse The frame D PowerFlex DC drive armature supply consists of three non regenerative drives or six regenerative drives SCR modules mounted on heat sinks within the leg assemblies A malfunction of any of these devices will be indicated by either an Overcurrent fault F13 blown or tripped incoming protection devices or erratic motor operation The following procedure can be used ifan armature bridge component malfunction is suspected
52. DOoaaoooEG 0 7 N m 6 2 Ib in o S1 E oo Co O O 22 23 24 25 26 27 28 29 30 3l 32 33 34 35 36 37 38 39 40 ey COOCDOCOODOJOCOCOOCOOO A BC At Ay Be B Zt ZCOMW T23456769 Ol 124 6 6 7 181 20 C0000 00000000 lt 229909 p299999999 0999999999 52 Rockwell Automation Publication 20P TG004A EN P October 2011 Remove stand offs Tightening torque for re assembly is 0 7 N m 6 2 Ib in Access Procedures 6 Remove the three stand offs from the resolver interface board Chapter 3 i XP3 orroit o ala DEBUG TEE Meen a XA T LI fo Resolver interface board Dooonoonon E O0 O O O 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Oocoocooocoolloooooooo0o A kB BZ ZCN 2s a4S678 0 O TZEME BI 6B 20 QO0000 0000000 e ooo 0000999999 Rockwell Automation Publication 20P TG004A EN P October 2011 53 Chapter3 Access Procedures Remove screws and board Tight
53. FCD ooooo0o0o0gog a ooo og opo00000000 E g m p N cca E O ON D S4 n E 11 gt aD fee e e hh O O O 21 22 23 24 25 26 27 28 29 30 I31 32 33 34 35 36 37 38 39 40 oo OOOOOCOOOOOJOOOOOCOCO0O _ ABC Enoe ENG TAs A B Be 24 Z COM AV T2345 678 9 10Iil 12 131415 1617 18 1920 210101010 joo0000000C o000000000 _ L_ SS P DC analog tachometer Encoder terminal block 1 0 KFA terminal block Table 23 Control Board to Field Board Connections Control Board Pin Number j 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 See Pulse Transformer Board to Control Board Connections on page 116 and Switching Power Supply Board to Control Board Connections on page 117 118 Rockwell Automation Publication 20P TGO04A EN P October 2011 Circuit Board Layouts and Connections Appendix B Field Board Figure 26 Field Board Layout i n n R4 R1 T T C7 C4 See Control Board to Field Board Connections on page 118 and Pulse Transformer Board to Field Board Connections on page 115 Rockwell Automation Publication 20P TGO04A EN P October 2011 119 AppendixB Circuit Board Layouts and Connections Overvoltage Clipping Board Figure 27 Overvoltage Clipping Board
54. Hardware Service Manual Allen Bradley PowerFlex Digital DC Drive Frame D 250 1400 Hp 186 1044 kW 4 st _ ut at st we 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 liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of informa
55. II 31 32 33 34 35 36 37 38 39 40 oo OQOOOOOOCOOJOOOOCO000O DE ABC ENOS Eloi yA A Bi B 24 2 COM V 1234567 8 910M 12 13 14 15 1617181920 OOOO OOOO0000 OO00000000 0000000000 lt TSesatser7as oto JE EEEEETEEECEK LCECE Disconnect 1 0 and control wiring 60 Rockwell Automation Publication 20P TG004A EN P October 2011 Access Procedures Chapter 3 12 Remove the five M3 x 6 mm screws and washers that secure the control board to the control EMI shield and remove the control board OO QO Ie x lt U eo Ef og S15 io Oo gon p io Oo gop fo Do Jamb Remove screws Do gE and washers LALB 4hb gF l Te i ae Tightening torque Sep 82 HE an sha S1 RuN 1 0 Nem 8 9 Ibein O J So i B s20 O EEE FE iooog oooo000000 ooooooo0o0o00j on0o0o0j oopoopoo00o00j Als ia ooo N oa O
56. Installation 58 Remove the Control Circuit Board c0cceceeeeceees 58 Install the Control Circuit Board c0ccceceacecucns 61 Switching Power Supply Circuit Board Removal and Installation 62 Remove the Switching Power Supply Circuit Board 62 Install the Switching Power Supply Circuit Board 63 Pulse Transformer Circuit Board Removal and Installation 63 Remove the Pulse Transformer Circuit Board 000 63 Install the Pulse Transformer Board 0c ccc e cence eee 66 Field Circuit Board Removal and Installation 0 0005 67 Remove the Field Circuit Board 0 0 0 cece cece cecneee 67 Install the Field Circuit Boatd pcsisci chasse Caen ktwe ay ivleradex 68 Field SCR and Dual Diode Module Removal and Installation 69 Remove the Field SCR and Dual Diode Modules 69 Install the Field SCR and Dual Diode Modules 70 Rockwell Automation Publication 20P TGO04A EN P October 2011 Start Up After Repair Table of Contents Field Fuse Holder Removal and Installation 0000 00s 71 Remove the Field Fuse Holder ccccceececeeeeees 71 Install the Field Fuse Holder 0 cece ccc cecceceeenens 73 Fan Starting Capacitor Removal and Installation 73 Remove the Fan Starting Capacitor i i0cs sasandackdvsendeens be 73 Install the Fan Star
57. October 2011 113 AppendixB Circuit Board Layouts and Connections Pulse Tra nsformer Board Figure 23 Pulse Transformer Board Layout Components shown within dashed lines are only on the pulse transformer board for regenerative drives XSW1 XSW o o X3 PE XUV O O XP1 TR2 XP2 j o TRI XCD_IO XUVW m o _ KG1 KG01 XCD m m i E T KG4 KG04 T4 T04 XR O KG2 Ke2 T2 T02 KG5 KG05 T5 T05 LU UCU KG3 KG03 T3 T03 XY KG6 KG06 OU T6 T06 XSPF _____a an X4 X5 X6 S3 S4 XCT HEBHEEEE BHBBERHE e OTOOTO 78 79 35 36 75 76 81 82 U2 V2 Control power terminal block 114 Rockwell Automation Publication 20P TG004A EN P October 2011 Circuit Board Layouts and Connections Appendix B Table 16 Pulse Transformer Board to Field Board Connections Pulse Field Board Description Transformer Connector Board Connector B 1 ee 1 3 1U1 field sync signal from U1 2 ows 2 1V 1field sync signal from V1 Table 17 Pulse Transformer Board to Switching Power Supply Connections
58. Repairs Component Test Procedures Table of Contents About This Publication 0 00 ccc cece cece cece ee eneeeeaas Who Should Use this Manual 0 00 eee eee eeeee Additional Resources 0 cece cece eee ccc e cc eeeeeeeceuneeeaas Chapter 1 Tnttodtictioitec ac bi ee OR AA ee e it BA ANAS a orden General Safety Precautionige 242u i os aed Vea cen ieas ee Hardware Description ars serina a odes wp see E ES Commonly Used Toolesita tres drone ee chon heehee ee kale Service Tools cers horens reo eae en eiy snee eae eee Software OOS iin Sion ba cates oa a E REES Chapter 2 Introduction ss lars os Se a a ete E Nas i oa iene Save the Parameter CoM eutatio nasnatus psyeatonsrwetewnetwsionanan Save toa HIM Setare daster etnies pod dagd owes eeeees badass Download Parameters to an Offline Node File Visual Component Inspection 923 2524 biaccchsatcnddesens aoeacne oe Troubleshoot a Control Power Supply Failure 00005 Testing the Switching Power Supply and Pulse Transformer OAEUS circ seiner asia E E Ades oleae ty acta ola eee dee Testing the Control and Field Board Connections Troubleshoot an AC Undervoltage Fault 0 0 cee eee ee Troubleshoot an Armature Bridge Failutesc o uiscte evinced vas ncoaes Troubleshoot a Field Current Loss Fault 0 00 c cece eee eee Low or Incorrect Field Current 0ccccccecuceeeveueee No Field Clitemtnees vee iot
59. 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 TGO04A EN P October 2011 17 Chapter2 Component Test Procedures Figure 1 Control Board Testpoints Upper Left gt x lt xy8 XY10 O xy9 xY12 XY11 XY6 XY5 C O a I ID
60. TENTION Risk of electric shock exists when power is applied to the power drive Rockwell Automation Publication 20P TG004A EN P October 2011 45 Chapter3 Access Procedures Open and Close the Control Open the Control Panel Panel Opening the control panel provides access to the armature leg fuses overvoltage clipping board SCR gate lead terminals SCR modules bimetal thermostat discharge resistors and in rush limiting resistors 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 if present 4 Insert a flathead screwdriver into the holes in the right side of the protective covers on the drive and turn the latch 90 counter clockwise 5 Open the control panel to the left 0000000000000000000000000000000000000000000000 8 KOVOVO 000000000000000 0000000000000000000000000000000000000000000000 Disconnect DPI cable Close the Control Panel Close the control panel in the reverse order 46 Rockwell Automation Publication 20P TG004A EN P October 2011 Access Procedures Chapter 3 Communication Adapter and Remove the Communication Adapter and EMI Shield EMI Shield Removal and Installation _ Read the General Safety Precautions on page 10 2 Remove power from
61. all the new discharge resistors in reverse order of removal In Rush Limiting Resistor Remove the In Rush Limiting Resistor Removal and Installation The in rush resistor is secured to the back wall of the drive frame below the control pan EO 1 T a CT em l c In rush resistor 0 1 Read the General Safety Precautions on page 10 94 Rockwell Automation Publication 20P TGO04A EN P October 2011 Newer overvoltage clipping board Access Procedures Chapter 3 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Open the control panel See Open the Control Panel on page 46 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Disconnect the resistor wires from connector XR 6 on the overvoltage clipping board Note On older boards these connections are soldered directly to the board In this case unsolder the connections XCD F31 X1UVW1 XUVW xrs E 3 5 OO C4blu C7blu C7gn
62. 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 the last fault Rockwell Automation Publication 20P TGO04A EN P October 2011 39 Chapter2 Component Test Procedures Notes 40 Rockwell Automation Publication 20P TGO04A EN P October 2011 Introduction Access Procedures This chapter provides detailed procedures for removing and replacing drive Chapter 3 components Topic Page Remove Power from the Drive 42 Field Circuit Fuse Removal and Installation 42 DPI HIM Assembly Removal and Installation 43 Protective Cover Removal and Installation 44 Open and Close the Control Panel 46 Communication Adapter and EMI Shield Removal and Installation 47 Switching Power Supply Fuse Removal and Installation 49 Resolver Feedback and Interface Circuit Board Removal and Installation 51 1 0 Expansion Circuit Board Removal and Installation 55 115V AC to 24V DC 1 0 Converter Circuit Board Removal and Installation 57 Control Circuit Board Removal and Installation 58 Switching Power Supply Circuit Board Removal and Installation 62 Pulse Transformer Circuit Board Removal and Installation 63 Field Circuit Board Removal and Installation 67 Field SCR and Dual Diode Module Removal and Installation 69 Field Fuse Holder Removal and Installation 71 Fan Starting Capacitor Re
63. cedures Thermistors and Thermal Switches Relay Outputs 38 Motor overheating is detected by an external user 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 23 on page 114 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 19 on page 109 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 Ifneither 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 OvrTemp fault F8 occurs See Fault Descriptions in Chapter 4 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details See Figure 20 on page 110 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
64. check the fuses at FU1 and FV1 e Ifthe fuses are blown complete the steps in Test Field Wiring and Voltage Signals on page 25 e Ifthe 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 Ifthere 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 32 e Ifthere 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 25 on page 118 for location of the XR connector on the control board Rockwell Automation Publication 20P TGO04A EN P October 2011 25 Chapter 2 26 Component Test Procedures This signal is a square wave signal with a 90 lag phase displacement compared to the AC voltage signal 9 Fab 96 Chi Sincro XR11 Ch2 UIA File Sincrofc tif REMOTE ENABLE 16 28 50 1 60 TO 5 AS LOC
65. communications adapter parameter configuration to a HIM Set or by down loading the drive and adapter parameters to an offline database file using DriveExecutive See the PowerFlex Digital DC 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 bottom and I O and control terminal protective covers See Protective Cover Removal and Installation on page 44 Remove the communication adapter and EMI shield from the control board See Communication Adapter and EMI Shield Removal and Installation on page 47 If installed remove the resolver feedback option and interface boards See Resolver Feedback and Interface Circuit Board Removal and Installation on page 51 If installed remove the I O expansion circuit board See I O Expansion Circuit Board Removal and Installation on page 55 Ifinstalled remove the 115V AC to 24V DC I O converter circuit board See 115V AC to 24V DC I O Converter Circuit Board Removal and Installation on page 57 Record all switch and jumper settings on the control board See the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for more information Jumper Function Setting Configures the in
66. contains a power structure that has an armature and field supply The armature supply consists of a three phase full wave rectified dual bridge capable of two or four quadrant output The field supply consists of single phase full wave rectified bridge Also associated with the power structure are incoming line protection devices and contactor and dynamic brake control circuits Verify that you are working on a Frame D 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 Frame D aa dle Serial Number D12F0031 eared ONION Rockwell Automation Publication 20P TGO04A EN P October 2011 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 III or equivalent recommended Oscilloscope Portable digitizing dual channel scope with isolation Current clamp 3x drive rated armature current output Soldering station Soldering de soldering Torque wrench 1 12 Nem Torque wrench 6 50 Nem box wrench 7mm 8 mm 10 mm 13 mm 17 mm 19 mm 22
67. crew 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 connector on the back side of the assembly 8 8 O AMen Bradtoy Remove screw Tightening torque 0 8 N m 7 Ib in Disconnect DPI cable Install the DPI HIM Assembly on the Protective Cover Install the DPI HIM assembly in reverse order of removal Rockwell Automation Publication 20P TGO04A EN P October 2011 43 Chapter3 Access Procedures Protective Cover Removal and Installation 1 Read the General Safety Precautions on page 10 Remove the Protective Covers 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Ifnecessary disconnect the DPI cable from the HIM if present IMPORTANT The HIM is connected via a cable to the control board and therefore the bottom control pane
68. crews 15 Ifyou are reusing the bimetal thermostat mounted on the left SCR module leg assembly disconnect the wires from the connector mounted on the middle left side of the assembly 90 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 16 Remove the two hexalobular screws that secure the thermostat to the heat sink and remove the thermostat E Remove screws lt o a Disconnect wires from connector O Ooh Install the SCR Module Leg Assembly Install the new SCR module leg assemblies in the reverse order of removal IMPORTANT Apply thermal grease to the bottom of the bimetal thermostat before installation e Tightening torque for the bimetal thermostat is 1 0 Nem 8 9 Ibein e Tightening torque for the SCR module leg assemblies is 4 5 5 0 Nem 40 0 44 4 Ibein e Tightening torque for the SCR module input and output terminals to the fuse terminals and DC output bus bars is 45 Nem 398 lbein Rockwell Automation Publication 20P TGO04A EN P October 2011 91 Chapter3 Access Procedures Bimetal Thermostat Removal Remove the Bimetal Thermostat and In
69. der in the reverse order of removal Fan Starting Capacitor Remove the Fan Starting Capacitor 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 top terminal cover from the drive See Remove the Protective Covers on page 44 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Cut the cable ties that secure the fan capacitor and fan power wires together 5 Loosen the screws that secure the fan capacitor wires to the plug in terminal block at XC on the fan loss board and remove the wires Rockwell Automation Publication 20P TGO04A EN P October 2011 73 Chapter3 Access Procedures 6 Unscrew the fan capacitor from the back of the drive frame and remove the capacitor U Fan loss detection _ ard Cut cable ties Unscrew capacitor Disconnect capacitor wires from from drive frame terminal block XC fal fal fal ey U U V V Wi gt atl La x a ae EPIS Eon Q qo y N qT Install the Fan Starting Capacitor Install the fan
70. e AC input terminal bus bars Top insulator bar i m Sek term bolts and ashers and insulator bar Fo AC current transducers Rockwell Automation Publication 20P TGO04A EN P October 2011 79 Chapter3 Access Procedures 8 Remove the bolt and washer that secures each of the U and W phase AC input terminal bus bars to the rear insulator bar Remove bolt and washer a Sass o 6 O O O oo o l o ba Lyo 9 Remove the two nuts and washers that secure the signal wires to the terminals on each of the AC current transducers and remove the wires 10 Loosen the two screws that secure each of the AC current transducers to the U and W phase terminal bus bar The current transducers wi
71. e 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 Replace the pulse transformer board Repair the short circuits 122 Rockwell Automation Publication 20P TG004A EN P October 2011 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
72. en add eid elem braces Power Component Test Procedures cc andi ees Check the Armature SCR Modules ccccceceeeeees Check the Pulse Transformer Board cceceecucenees Check the Field SCR Dual Diode Module 04 Speed Feedback Device ests oi 95 2Siawonesch teed epee ba Poemete Check the b ne det iced loeb iii d s tan el werent ae Check the DC Tachometer oss ina covatae a cdtosneweaeeeerecds Check the Resolver Interface Board 0 ccccceeececeeees Thermistors and Thermal Switches cc cccccecececeeeees RelayiQutpiite ccs ckt ite dole tors bel choke Nik eee ou Create Pale Report sunt Sarees oad nar An ene acne aurea What You Need When You Call Tech Support 0 004 Rockwell Automation Publication 20P TGO04A EN P October 2011 Table of Contents Access Procedures Chapter 3 trod ctioi sesin Roi Vedi eee a hehe Bhat eh hs 4 Remove Power from the Drive ccccccccceccceceeescuens 42 Field Circuit Fuse Removal and Installation 000 eee eee 42 Remove the Field Circuit Fuses ccccecececeeeecees 42 Install the Field Circuit Pusesity overs hedce ee dlaiwewyowerdcus 42 DPI HIM Assembly Removal and Installation 6 43 Remove the DPI HIM Assembly from the Protective Cover 43 Install the DPI HIM Assembly on the Protective Cover 43 Protective Cover Removal and Installation 0c cece eee 44 Re
73. en on either testpoint XY10 or XY18 Figure 3 Good SCR Gate Pulse and Armature Current Signals Example 9 Feb 96 Inpulsi su X 23 Ia su XY17 File Inpulsi tiF REMOTE ENABLE 13 27 59 o tT 60 TO Z AS LOCAL S v 5V 2 eons 200 ay oV tett ttti trttt tetepi tttit tetit tti ttt 2 XY19 2 na 0 5 wi aad 2 20 nv be amp 9 kS s 3 5 vV wa L 1 HFREJ 0 1 456 nv C O STOPPED Figure 4 Good SCR Armature Voltage and Motor Current Signal Example 9 Feb 96 Chi Vara K 19 Ch2 Ia XY 7 File ENF tif RENOTE ENABLE 16 07 47 G0 TO LOCAL 2 2 m5 200 nv XY17 Tet Pett th pth he 2 XY19 e ns fsa nv pe g a PE 2 20 nv DC g 25 kS s 3 5 V Deg L 1 KFREJ 0 01 V 450 nv DC amp O STOPPED 22 Rockwell Automation Publication 20P TG004A EN P October 2011 Troubleshoot a Field Current Loss Fault Component Test Procedures Chapter 2 A malfunctioning thyristor is connected to the relative gate For example if the tested signal is at XR25 and the positive bridge is active MP high from the following figure you can deduce that SCR connected to gate G6 is open Figure 5 Open Thyristor Example 8 Feb SF Scr open Chi X825 Ch Ia File ser Pail ti REMOTE ENABLE 15 25 13 i 60 TO i LOCAL 5 0 V 5V 2 re 5 n 2800 a ov XY19 Das T 0 5 v oc x 220w OCR 10 K 3 5 V OC X 1 HFRES 8 1 y q 5a nw DC U STOPPED I
74. ening torque for re assembly is 0 7 N m 6 2 Ib in 54 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 re eran epee renee ogre cranny XR T XA i O XP3 E E Co O O 22 23 24 25 26 27 28 29 30 3I 32 33 34 35 36 37 38 39 40 QOOOOOOOOO OOOOOO000O0 ABCH At A Br Be Zt Z COMV ese eSTSO OTT E EIT B20 _ 00000 00000000 oooooo00000 looo0000000 z Tes ses 7e eon nnne eree Rockwell Automation Publication 20P TG004A EN P October 2011 Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal 1 0 Expansion Circuit Board Removal and Installation Access Procedures Chapter 3 Remove the
75. er interface and resolver feedback boards are properly seated on the appropriate connectors XRE P2 P3 If problems persist replace the resolver interface and or resolver feedback board e Measure the signal voltage at the testpoints as indicated in the following table See Figure 9 on page 37 for testpoint locations Testpoint to Testpoint Measurement 12V 10V12 12V DC 5 12V 10V12 12V DC 5 24V_VI lt 10V24 24V DC 5 5V OVS 5V DC 5 If any of the voltage measurements fails replace the resolver interface board Rockwell Automation Publication 20P TG004A EN P October 2011 Component Test Procedures Chapter 2 Figure 9 Resolver Interface Board Testpoint Locations 12V CH2Vv ee ay C az P2 P3 D10 j 5V 5V 29 C ol Covs ___ 0v5 0V12 _ C ovi2 D26 m D26 D11 gel 24V_V 24V_VI G fos D3 O24 a lov24 C VR lt fet nooo mu A ooo S1 5V pos Q 1 12V pos D18 i S1 24 pos Dn Ba OD a noe S1 D12 Ee yom We em S2 Internal supply pos a Se ee S2 External supply pos J amp D z E TB1 TB2 SSeSSSE 666666 Rockwell Automation Publication 20P TG004A EN P October 2011 37 Chapter2 Component Test Pro
76. es remove the holder and fuse Fuse holder XA xswi XV XSW Ea bi mi oe E O 15 O10 O A ecm ce ee lt Install the Fuse on the Switching Power Supply Circuit Board Install the new fuse in the reverse order of removal 50 Rockwell Automation Publication 20P TG004A EN P October 2011 Access Procedures Chapter 3 Resolver Feedback and Remove the Resolver Feedback and Interface Circuit Boards Interface 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 bottom and I O and control terminal protective covers See Protective Cover Removal and Installation on page 44 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Disconnect the plug in terminal blocks from the resolver feedback and resolver interface boards _ freer p XR PE a XA I
77. f removal 82 Rockwell Automation Publication 20P TGO04A EN P October 2011 Overvoltage Clipping Circuit Board Removal and Installation Remove seven screws Tightening torque 1 0 1 2N m 9 10 5 Ib in Disconnect connectors from XCD X1UVW1 XUVW O Access Procedures Chapter 3 Remove the Overvoltage Clipping Circuit Board Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Open the control panel See Open the Control Panel on page 46 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Disconnect the wires from connectors XCD X1IUVW1 and XUVW on the overvoltage clipping board Disconnect the resistor wires from connectors XR 1 XR 6 on the overvoltage clipping board Note On older boards these connections are soldered directly to the board In this case unsolder the connections Remove the seven hexalobular screws and washers that secure the overvoltage clipping board to the drive frame and remove the board XCD F31 F21 F11 X1UVWw1 XUVW C
78. f 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 124 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 14 is configured to correctly according to the instructions in the PowerFlex Digital DC Drive User Manual publication 20P UM001 and make any necessary corrections See Control Board on page 118 for DIP switch location Rockwell Automation Publication 20P TGO04A EN P October 2011 23 Chapter 2 24 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 bottom control panel and I O and control terminal covers from the drive See Protective C
79. following procedure if a malfunction in this circuitry is suspected 1 2 Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the pulse transformer board see Pulse Transformer Circuit Board Removal and Installation on page 63 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 23 on page 114 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 o 10 eji Table 7 Armature Pulse Snubber Circuit Measurements for Non Regenerative Drives ForSCR Measure From iTo 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 Rockwell Automation Publication 20P TGO04A EN P October 2011 Meter reading open circuit Connector XY Pinout 10 000000000 31 Chapter2 Component Test Procedures 5 With the digital mu
80. he 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 at the top of the drive Replace the switching power supply 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 x 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 i than 200 kohms and 2 on cabl
81. ing the two handles lift the SCR assembly up and off the mounting screws and lift the assembly up and forward so that the output terminals clear the holes in the bottom of the drive frame 14 Repeat steps 12 and 13 above for each SCR assembly Loosen screws Loosen screws e KI el 9 q agh Ate C eA Co a Lifting handles eg Loosen screw i aoa pot Lifting oe ex C Loosen screws Loosen screws Loosen s
82. ive SCR Module Layout 0000 SCR 04 G SCR 04 K SCR4 G SCR4 K Phase U Front Gate Lead Terminal Block s R1 G 1 o scR1 K ScRO1 G 1 9 SCR 01 K l 28 Phase V Front Gate Lead Terminal Block ScR2 G 0 ScR2 K __ SCR 02 G 0O Phase V Rear Gate Lead Terminal Block SCR 05 G SCR 05 K _ SCR5 G SCR5 K ___ 0000 0000 Phase W Rear Gate Lead Terminal Block SCR 06 G SCR 06 K SCR6 G __ SCR 6 K Phase W Front Gate Lead Terminal Block SCR3 G 0O SCR3 K 0 SCR 03 G 0 SCR 03 K HO Rockwell Automation Publication 20P TG004A EN P October 2011 Phase U Front Gate Lead Terminal Block SCR 1 G _ SCR 1 K Phase U Rear Gate Lead Terminal Block SCR4 G fo SCR4 K 0 Component Test Procedures Chapter 2 Table 3 SCR Anode to Cathode Junction Measurements for Non
83. k Circuit E i i pO O 12V 5V S21 Rockwell Automation Publication 20P TG004A EN P October 2011 Schematics Appendix A Figure 18 DC Tachometer Control Circuit Diagram S4 8 S4 7 S4 6 S4 5 eer oo Tr HE HH n anaa S a a L gt gt TACHOP LH M3 0 __ C __ C LHL __ C T C C S4 1 2 4 3 S4 4 li Figure 19 Motor Thermal Protection Control Circuit Diagram 24V IN T T XR ries L ovI Overtemp Fault Signal Rockwell Automation Publication 20P TGO04A EN P October 2011 109 AppendixA Schematics Figure 20 Drive Heatsink Monitoring Control Circuit Diagram E Control Board Ss 5V XR 10 XR 10 _ D gt gt OTS XR 12 XR 12 UL me l U3 X4 1 L vA XSW 1 T as 24V X42 0V24 XSW 2 Figure 21 Contactor Control Relays Control Circuit Diagram 0V24 XR U6 U2 S1 XR XR XR Y K7 K8 24V O Q O O 35 36 75 76 110 Rockwell Automation Publication 20P TG004A EN P October 2011 Figure 22 Fan Power and Loss Detection Circuit Diagram
84. k 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 If a drive Power Failure fault F3 has occurred and the drive is inoperable via the Power Supply Failure HIM or other means of control compete the steps below to determine where the control power failure has occurred 1 Read the General Safety Precautions on page 10 2 Remove the bottom control panel and I O and control terminal covers from the drive See Protective Cover Removal and Installation on page 44 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 XA 11 XA 12 15V analog supply ground 15V XY11 Figure 1 on page 18 XA 13 XA 14 15V analog supply 24V XY 8 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 XP
85. l cover will not pull free from the drive until the cable is disconnected The cover does however have notches on the side in order that it can be hung on the screws without disconnecting the HIM cable 4 Loosen but do not remove the hexalobular screws that secure the cover to the drive chassis slide the cover up or down and lift the cover off the drive oo _ Tightening torque 1 5 N m 13 Ib in Removing this cover provides access to the fan loss detection board fan motor and blower and AC current transducers Removing these covers provides access to the field board field SCR and dual diode modules switching power supply board pulse transformer board and control board Removing this cover provides access to the control power relay thermistor thermal switch armature fuse signal 1 0 digital encoder DC analog tachometer and resolver feedback terminals Removing this cover provides access to the snubber capacitors and snubber resistors
86. ll be loose on the bus bars Remove nut washer and signal wires a ii H lo p gt J mi oo ole ole E O b ol Ll loo 80 Rockwell Automation Publication 20P TGO04A EN P October 2011 Oo ia J OO OLO mn n A T T TS L BU va W W i 4 A OOl pl Loosen two screws on CTs Access Procedures Chapter 3 11 Remove the four M12 bolts and washers that secure each of the U and W phase AC input terminal bus bars to the input bus bars and carefully slide the terminal bus bars up until the AC current transducers can be removed from the bus bars Slide bus bars up until AC current transducers can be removed T T Oo o S U uyi V amp W W le mm Mi I I _ I a T O I J q 7 A gt N O l o ONCE i four ft om
87. ltimeter set to diode test measure each connection point on the pulse transformer board listed in the tables below If any of the actual measurements are out of tolerance replace the Pulse Transformer board Table 8 Armature Pulse Transformer Primary Measurements for Regenerative and Non 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 000000000 10 Table 9 Armature Pulse Transformer Primary Measurements for Regenerative Drives ForSCR Meter Lead 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 top and bottom control panel and I O and control
88. mmonly Used Tools 12 Rockwell Automation Publication 20P TGO04A EN P October 2011 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 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 Safet
89. moval and Installation B Fan Loss Detection Circuit Board Removal and Installation 75 Fan Assembly Removal and Installation 76 AC Current Transducers Removal and Installation 78 Overvoltage Clipping Circuit Board Fuse Removal and Installation 82 Overvoltage Clipping Circuit Board Removal and Installation 83 Armature Leg Fuse Removal and Installation 84 SCR Module Leg Assembly Removal and Installation 86 Bimetal Thermostat Removal and Installation 92 Discharge Resistors Removal and Installation 92 In Rush Limiting Resistor Removal and Installation 94 Snubber Capacitors Removal and Installation 96 Snubber Resistors Removal and Installation 98 Rockwell Automation Publication 20P TG004A EN P October 2011 41 Chapter3 Access Procedures Remove Power from the ee Drive ATTENTION Remove power before making or breaking cable connections A 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 Remove and lock out all incoming power to the drive Li L2 L3 Field Circuit Fuse Removal Remove the Field Circuit Fuses and Installation
90. move the Protective Covers ccc cece cence eee eenenes 44 Install the Protective Covers cccccececcecececeeescnees 45 Open and Close the Control Panel vc snus cinta ce ceuxtendeaeeedets 46 Open the Control Panels un5 52sec eeee ee eas ee 46 Close the Control Panel iccs 0scgacde ote tavamwe ges deasiaaaeiwsas 46 Communication Adapter and EMI Shield Removal and Installation 47 Remove the Communication Adapter and EMI Shield 47 Install the Communication Adapter and EMI Shield 48 Switching Power Supply Fuse Removal and Installation 49 Remove the Fuse on the Switching Power Supply Circuit Board 49 Install the Fuse on the Switching Power Supply Circuit Board 50 Resolver Feedback and Interface Circuit Board Removal and ETETETT AAE Shui ttle Oe A ST Wk ad elt 51 Remove the Resolver Feedback and Interface Circuit Boards 51 Install the Resolver Feedback and Interface Circuit Boards 54 I O Expansion Circuit Board Removal and Installation 55 Remove the I O Expansion Circuit Board 002000 55 Install the I O Expansion Circuit Board 00 e eee eee 56 115V AC to 24V DC I O Converter Circuit Board Removal and Live tallAtiOnh qa wari t cst eye A S EE E cece eV eM uwcs E can ds 57 Remove the 115V AC to 24V DC I O Converter Circuit Board 57 Install the 115V AC to 24V DC I O Converter Circuit Board 58 Control Circuit Board Removal and
91. moved allowing access to the rear terminals 88 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 Remove bolts and SCR assembly Remove bolts and SCR assembly Remove bolts and washers output terminal washers output terminal washers al o 2 E D gin aiis O C shaped bus A bar i Ayo oi OO a Q ljololojo O O O O paa arS o lololol a T T Llaw A DANGER cipizssz L LE DC output bus C D DC output bus D bar bar Lg Angled view showing regenerative drive Remove bolts and Rockwell Automation Publication 20P TGO04A EN P October 2011 89 Chapter3 Access Procedures IMPORTANT _ Prior to removing the SCR assemblies ensure that the area around the drive is clear of equipment Only lift the assemblies using the handles provided 12 Loosen the six hexalobular screws that secure the SCR module leg assembly to the back wall of the drive chassis 13 Us
92. n 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 top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover ks 2D Loosen screw aA Switching Power _ Supply board Loosen screw Loosen screws L A e e i eo Py Loosen WA o screw i w 0000 Ou amp Gi B E B E B pe B B E B B E Tightening torque 0 8 N m 7 Ib in lo Rockwell Automation Publication 20P TGO04A EN P October 2011 49 Chapter3 Access Procedures 5 Remove the fuse by inserting a screwdriver in the slot on the fuse holder F1 carefully pushing up and turning the fuse counterclockwise When the fuse holder releas
93. nd 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 TGO04A EN P October 2011 7 Preface Notes 8 Rockwell Automation Publication 20P TGO04A EN P October 2011 Chapter 1 Before You Begin Testing Maintenance 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 ai Co
94. ng 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 61 for more information vA 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 nameplate 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 TGO04A EN P October 2011 101 Chapter 4 102 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 1
95. oard See Figure 25 on page 118 for location of connector XA Apply AC control power to the drive e Ifthe fuse blows continue with Testing the Switching Power Supply and Pulse Transformer Boards below e Ifthe 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 fuse on the switching power supply board See Switching Power Supply Fuse Removal and Installation on page 49 Remove the switching power supply board from the drive See Remove the Pulse Transformer Circuit Board on page 63 Reapply power to the switching power supply board only e Ifthe power supply fuse does not blow continue with step 5 below e Ifthe power supply fuse blows replace the switching power supply board 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 transformer board Rockwell Automation Publication 20P TGO04A EN P October 2011 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
96. odule replacement may be necessary See SCR Module Leg Assembly Removal and Installation on page 86 Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives SCR Measurefrom To 1 Pin G Pin K 4 Pin G Pin K 2 PinG Pin K 5 Pin G Pin K 3 PinG Pin K 6 PinG Pin K 01 Pin G Pin K 04 Pin G Pin K 02 Pin G Pin K 05 Pin G Pin K 03 Pin G Pin K 06 Pin G Pin K Nominal meter reading 5 30Q 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for a I SCRs Table 5 SCR Gate to Cathode Junction Measurements for Non Regenerative Drives SCR Measurefrom To 1 PinG Pin K 4 PinG Pin K 2 PinG Pin K 5 PinG Pin K 3 PinG Pin K 6 PinG Pin K Nominal meter reading 5 30Q 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for all SCRs Rockwell Automation Publication 20P TGO04A EN P October 2011 Check the Pulse Transformer Board Component Test Procedures Chapter 2 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
97. or terminals Retain the wires for reuse 8 Remove the two hexalobular screws and washers that secure each of the Ol snubber resistors to standoffs on the back wall of the drive chassis and remove the resistors Remove screws and washers Remove screws and washers Install the Snubber Resistors Install the snubber resistors in the reverse order of removal Rockwell Automation Publication 20P TG004A EN P October 2011 99 Chapter3 Access Procedures Notes 100 Rockwell Automation Publication 20P TGO04A EN P October 2011 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 32 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 followi
98. over Removal and Installation on page 44 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 Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance as indicated in the table below set with DIP switch 14 on the control board Field Current Field S14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 Equivalent Scale Supply Resistance 1A OFF OFF OFF OFF OFF OFF ON 33330 2A OFF OFF OFF OFF OFF ON OFF 1668 Q 4A OFF OFF OFF OFF ON OFF OFF 845 Q 6A 40A OFF OFF OFF OFF ON ON OFF Hes 560 9 Q 10A OFF ON OFF OFF OFF OFF OFF OFF 33330 20A ON OFF OFF OFF OFF OFF OFF
99. ower supply voltage and input adaptation selection This switch setting determines both the power supply input and feedback level output voltage of the connected encoder Note When control power is supplied to the drive the appropriate 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 Rockwell Automation Publication 20P TGO04A EN P October 2011 59 Chapter3 Access Procedures 10 Carefully disconnect the cables from connectors XA XR and XFCD on the control board 11 Remove the plug in I O and control terminal blocks with the wiring kept in place FN LE EA a O O OO XP3 Disconnect cables XFCD XA and XR joooo ooooo oo0o0000000 ay on0o00 onoo0o000000 oooo0o0o0000j ooo oF oooo0o0o0000 D E Q S B ON 5 s4 dE s11 OD E s10 LO O O 21 s fo O O 21 22 23 24 25 26 27 28 29 30
100. 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 short 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 TGO04A EN P October 2011 123 AppendixC Flow Charts Low or Incorrect Field Current Verify Par 351 Field Current value using DC clamp to measure _ the DC motor field current J 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 acros
101. ponent Test Procedures Check the Resolver Interface Board The resolver feedback option module uses the resolver feedback board for resolver connections and the resolver interface board for external power status feedback board reset and encoder output connections 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 9 on page 37 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 1 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 S1 is set to 5V for encoder signal S1 is 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 resolv
102. put voltage of the DC analog tachometer 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 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 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 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 Jumper Function Setting Switch 14 Field current resistors setting 14 1 In addition 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 514 3 14 4 14 5 14 6 14 7 15 Configuration of the control circuit board to the appropriate drive size This value is 515 1 set to the appropriate size at the factory 15 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 821 Encoder p
103. rd 31 testpoints locations 18 19 thermal switch 38 thermistor 38 126 Rockwell Automation Publication 20P TG004A EN P October 2011 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 manufac
104. res 27 Speed Feedback Device Tests 35 Thermistors and Thermal Switches 38 Relay Outputs 38 Create a Fault Report 39 What You Need When You Call Tech Support 39 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 TGO04A EN P October 2011 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 Select Device gt HIM and press 4 Do one of the following e If there are no existing HIM Sets enter a name using the and buttons to select the desired characters and press e e Ifthere is an exis
105. s 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 124 Rockwell Automation Publication 20P TGO04A EN P October 2011 Numerics 115V AC to 24V DC 1 0 converter board install 58 remove 57 A armature bridge failure troubleshoot 21 armature SCR modules test 27 C circuit board connections 113 layout drawings 113 communication adapter install 48 remove 47 components inspection 15 contactor fault 38 control board install 61 remove 58 control power supply failure 15 D DC analog tachometer test 35 download parameter configuration 14 DPI HIM assembly install 43 remove 43 Electrostatic Discharge Precaution 10 encoder test 35 fault field current loss 23 heatsink overtemperature 38 main contactor 38 overcurrent 21 power failture 15 fault report create 39 Rockwell Automation Publication 20P TG004A EN P October 2011 Index field circuit fuses install 42 remove 42 field current loss fault 23 field SCR dual diode module test 32 frame size 11 fuse field circuit 42 switching power supply 50 switching power supply board 49 hardware description 11 heatsink overtemperature fault 38 1 0 expansion board install 56 remove 55 inspection visual 15 in
106. s 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 TGO04A EN P October 2011 List of Schematic Diagrams Schematics Appendix A Topic Page Figure 10 Circuit Board Interconnection Diagram 104 Figure 11 Regenerative Drive Power Module Block Diagram Figure 12 AC Line Measurement Points Diagram Figure 13 Power Feedback Connections Diagram Figure 14 Field Board and SCR Dual Diode Module Connections Diagram Figure 15 Field Control Circuit Diagram Figure 16 Control Circuit Input Power Diagram Figure 17 Encoder Control Circuit Diagram Figure 18 DC Tachometer Control Circuit Diagram Figure 19 Motor Thermal Protection Control Circuit Diagram Figure 20 Drive Heatsink Monitoring Control Circuit Diagram Figure 21 Contactor Control Relays Control Circuit Diagram Rockwell Automation Publication 20P TGO04A EN P October 2011 a a m a a a a a a a a a I gt J INO J ICO J ICO IN IN ION oA a e Figure 22 Fan Power and Loss Detection Circuit Diagram 1 103 Figure 10 Circuit Board Interconnection Diagram AppendixA Schematics fee se eh ae XFCD Field Board From External Fan Power Supply 230V AC 50 60 Hz PE PE a Fan
107. shers Install the Snubber Capacitors Install the snubber capacitors in the reverse order of removal Rockwell Automation Publication 20P TGO04A EN P October 2011 97 Chapter3 Access Procedures Snubber Resistors Removal Remove the Snubber Resistors 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 bottom terminal cover from the drive See Remove the Protective Covers on page 44 4 Open the control panel See Open the Control Panel on page 46 5 Remove the SCR module leg assemblies from the drive You do not need to remove the bimetal thermostat from the left SCR module assembly for this procedure See Remove the SCR Module Leg Assembly on page 3 86 6 Remove the 12 hexalobular screws and washers that secure the metal plate to the back wall of the drive chassis and remove the metal plate Remove screws and washers iv o oO Oo Oo sQ ee a 4g fy pes x e NY e e S Lo o ARR WS QgQQgygQy Mw N N S A N CY Note Output terminals shown removed for clarity only 98 Rockwell Automation Publication 20P TG004A EN P October 2011 OJOJO O STO lololo cipi dais a oO Access Procedures Chapter 3 7 Unsolder the wire leads from all resist
108. stall 115V AC to 24V DC 1 0 converter board 58 communication adapter 48 control board 61 DPI HIM assembly 43 field circuit fuses 42 1 0 expansion board 56 protective covers 45 pulse transformer board 66 switching power supply board 63 switching power supply fuse 50 L layout drawings circuit boards 113 M motor overheating 38 0 outputs relay 38 overcurrent fault 21 overtemperature heatsink 38 125 Index P tools 7 service 12 parameter configuration software 12 eap 14 troubleshoot save 7 armature bridge failure 21 power field current loss 23 removing 42 overcurrent fault 21 power failure fault 15 power failure fault 15 protective covers install 45 remove 44 V PTC 38 visual inspection 15 pulse transformer board install 66 remove 63 test 31 relay outputs 38 remove 115V AC to 24V DC 1 0 converter board 57 communication adapter 47 control board 58 DPI HIM assembly 43 field circuit fuses 42 1 0 expansion board 55 power 42 protective covers 44 pulse transformer board 63 switching power supply board 62 switching power supply board fuse 49 S safety precautions 10 save parameter configuration 14 schematic diagrams 103 service tools 12 software tools 12 switching power supply board fuse 49 install 63 remove 62 T technical support calling 39 test armature SCR modules 27 DC analog tachometer 35 encoder 35 field SCR dual diode module 32 pulse transformer boa
109. stallation Note The bimetal thermostat is mounted on the left SCR module leg assembly heatsink 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 bottom terminal cover from the drive See Remove the Protective Covers on page 44 4 Open the control panel See Open the Control Panel on page 46 5 Remove the left SCR module leg assembly from only the drive and remove the bimetal thermostat from the assembly heat sink See Remove the SCR Module Leg Assembly on page 3 86 Install the Bimetal Thermostat Install the new bimetal thermostat in the reverse order of removal Discharge Resistors Removal Remove the Discharge Resistors and Installation The discharge resistors are secured to the back wall of the drive frame behind the control panel Discharge Resistors ool loo o W E Tie 5 o K mala Be ti a a E 1 Read the General Safety Precautions on page 10
110. ting Capacitor icici ses cenees seed ec ewes 74 Fan Loss Detection Circuit Board Removal and Installation 75 Remove the Fan Loss Detection Circuit Board 0 75 Install the Fan Loss Detection Circuit Board 0 005 75 Fan Assembly Removal and Installation 0 0 ee cee eee ee ee 76 Remove the Fan Assembly igus catcocie ee teasinessenadugs seas 76 Install the Fan Assembly su owdcua i acco ectiatateestna ie catenin TI AC Current Transducers Removal and Installation 78 Remove the AC Current Transducers 0 cceececeeeeees 78 Install the AC Current Transducers 0ccccecececeeees 81 Overvoltage Clipping Circuit Board Fuse Removal and Installation 82 Remove the Overvoltage Clipping Circuit Board Fuses 82 Install the Overvoltage Clipping Circuit Board Fuses 82 Overvoltage Clipping Circuit Board Removal and Installation 83 Remove the Overvoltage Clipping Circuit Board 83 Install the Overvoltage Clipping Circuit Board 84 Armature Leg Fuse Removal and Installation 008 84 Remove the Armature Leg Fuse sic cvtetonatsenexen seeew amine ae 84 Install the Armature Leg Fuse n wdvdrne suse Ss culty dces 85 SCR Module Leg Assembly Removal and Installation 86 Remove the SCR Module Leg Assembly 00000 86 Install the SCR Module Leg Assembly 00 000005
111. ting HIM Set press to overwrite it or select No using the ED button and use the and 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 amp 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 TGO04A EN P October 2011 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 Drive on page 42 3 Open the control pan See Open the Control Panel on page 46 4 Remove the protective covers from the drive See Protective Cover Removal and Installation on page 44 5 Chec
112. tion 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 Pe BIE IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley DriveExplorer DriveTools SP PowerFlex Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Preface Before You Begin Testing Maintenance or
113. to Peak RMS Measurement Line Voltage Testpoint Measurement Vand U XY22 ae XY18 240 VAC i Vand W XY21 te XY18 oe 00N Vand U XY22 a XY18 480 VAC F Vand W XY21 et XY18 een ee Vand U XY22 kit XY18 575 VAC i Vand W XY21 lis XY18 ZVA ee Vand U XY22 P XY18 690 VAC f i Vand W XY21 sb XY18 vous bee Se F mene Sih Segnali su 2lece Fille syel 2z tl REMOTE EAGLE 12 46 be i a1 To E i LHL 1 09 Y Yo E a i Fi 1 1 63 4 H 4 f T 7 F ee tenes ee ee ia f i f ANY Y Ga I 1 1 a OG fi 7 1 Wg LU kir 3 Z Y OC g l 1 HFREJ g a Y H taw of g STOPPED 20 Rockwell Automation Publication 20P TGO04A EN P October 2011 Troubleshoot an Armature Bridge Failure Component Test Procedures Chapter 2 e Ifany of the voltage measurements above are incorrect or missing continue with step 5 below e Ifthe voltage measurements above are correct but the value of parameter 466 AC Line Voltage is incorrect replace the control board 5 Remove the ribbon cable connected to XR on the control board and pulse transformer board and test the continuity of the cable using the measurements in Table 20 on page 116 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
114. tor If necessary replace the existing cable with the new cable provided 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 top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 44 Rockwell Automation Publication 20P TGO04A EN P October 2011 63 Chapter3 Access Procedures 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover Loosen i LI Loosen screw B E B E B pe B E E B B E a al i Toe Omo screw A Switching Power L Supply board Loosen Screws Pulse Transformer board A Loosen screw Tightening torque 0 8 N m 7 Ib
115. turing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your 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 hrtp 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 TG004A EN P October 2011 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in the U S A
116. ve y T15 or Se G 0000000000000 0000000000 Tightening torque 1 5 N m 13 Ib in 7A Loosen screws Loosen screws E 5 Open the control panel See Open the Control Panel on page 46 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 78 Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 6 The U and W phase AC input terminal bus bars must be disconnected and pulled up in order to remove the AC current transducers Remove the wiring from the U and W phase AC input terminal bus bars if necessary 7 Remove the four bolts and washers that secure the top insulator bar over the AC input terminal bus bars to the drive frame and remove the insulator bar Disconnect wiring from U and W phas
117. ve components e Make a 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 and damage following information e Order number When you contact Technical Support please be prepared to provide the 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 of the last fault 1350 Status2 at Fault Captures and displays Par 382 Drive Status 2 bit pattern at the time of the 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
118. xpansion Circuit Board Install the I O expansion board in reverse order of removal Rockwell Automation Publication 20P TGO04A EN P October 2011 Access Procedures Chapter 3 115V AC to 24V DC 1 0 Remove the 115V AC to 24V DC 1 0 Converter Circuit Board Converter 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 bottom and I O and control terminal protective covers See Protective Cover Removal and Installation on page 44 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 4 Remove the plug in I O terminal blocks with the wiring kept in place 5 Remove the two M3 x 6 mm screws and washers that secure the I O converter board to the stand offs on the control board and remove the I O converter board Remove two screws and Tightening torque washers 1 0 N m 8 9 Ib in 6 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 N m 8 9 Ib in Rockwell Automation Publication 20P TGO04A EN P October 2011 57 Chapter3 Access Procedures Control Circuit Board Removal and Installation 58 Install the 115V AC to 24V DC 1 0 Converter Circuit Board Install the 115V AC to 24V DCI O converter board in reverse order of removal Remove the Control Circuit Board 1 Save the drive and
119. y 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 After disconnecting power allow time for cooling 10 Rockwell Automation Publication 20P TGO04A EN P October 2011 Hardware Description Before You Begin Testing Maintenance or Repairs Chapter 1 The PowerFlex DC drive

Field Circuit Board Removal and Installation

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