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Hardware Service Manual, PowerFlex DC Frame B Drives

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1. Rockwell Automation Publication 20P TG002A EN P February 2012 N L ie opl KeA LO o D D eu eu eu 3 O 3 O 3 O 2 0 1O 2 o 1 O lo 1 0 SCR SCR SCR Module 01 Module 02 Module 03 W 9 lol lal lol lol lol amp LTU Wu U C V D Ww 29 Chapter 2 Component Test Procedures 5 Check the gate to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance of each SCR junction For regenerative drives see Table 4 and Figure 8 below For non regenerative drives see Table 5 on page 31 and Figure 9 on page 31 Ifa measurement is outside of the range specified in the table or if one reading deviates significantly from the majority then module replacement may be necessary See SCR Modules Removal and Installation on Nominal meter reading 5 20Q page 83 Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives On SCR Module SCR Measure from To 1 1 Pin 5 Pin 4 4 Pin 6 Pin 7 2 2 Pin 5 Pin 4 5 Pin 6 Pin 7 3 3 Pin 5 Pin 4 6 Pin 6 Pin 7 01 01 Pin 6 Pin 7 04 Pind Pin 4 02 02 Pin 6 Pin 7 05 Pin 5 Pin 4 03 03 Pin 6 Pin 7 06 Pin 5 Pin 4
2. Appendix A Schematics Figure 16 Field Board and SCR Dual Diode Module Connections Diagram From Incoming AC Line V1 U1 xT ey UF mr a a a en aM VF as CEX 58 UF VF Je aan 4 AT 470k 470k 470k acl 1U1 UFI a a ee i M a To Pulse 2U1 Transformer cn necem G Board X3 Connector uc 470k 470k 470k 470k BE LUN L I I ln anni I mE cem qom dg 201 fae ar a ake eae D i Hoty LPS c XKD 3 x 1 XP 7 t A XFCD2 p2 t P2 TAI XFCD 4 k XP 1 dL ii L4 XFCD 1 I 2D1 Wc ey iret SAE A XD roe LI X2 y SEE 4j C1 To Motor Field Connections 110 Rockwell Automation Publication 20P TGO02A EN P February 2012 230 VAC or 115 VAC Input Schematics Appendix A Figure 17 Field Control Circuit Diagram 3 H5V XFCD 1 J 45V XFCD 3 XFCD 4 T T T TT I LB 14 8 8147 sas 8144 514 3 142 814 1 XFCD 2 LA Figure 18 Control Circuit Input Power Diagram U2 1C2 Q o L o e o Q Q L To Switch V2 d d Mode Power T T L 9 Supply SMPS 7E 1D2 o e o e Q Rockwell Automation Pu
3. I XP3 UuUuUUUUU Remove screws and board Tightening torque for poonnonnon re assembly is l 0 7 Nem 6 2 Ibein H co m Oo O ee 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 OOOOOOOOOO OOOOCOOCOOOO SABC Ar A BY B Ze ZCOMV 1234567989 ONZE MEET 620 OOOOO OOOOOO00 UR E OOOOOOOOOO OOO00000000 Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal 52 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 l 0 Expansion Circuit Board Remove the 1 0 Expansion Circuit Board Removal and Installation 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 protective covers 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 If installed remove the res
4. 67 45 67 45 eo eo 3 0 3 0 210 210 11O 1 O e e SCR SCR Module 02 Module 03 Rockwell Automation Publication 20P TG002A EN P February 2012 31 Chapter2 Component Test Procedures Check the Pulse Transformer Board The armature pulse transformer circuit board contains an isolated gate firing circuit and also provides dv dt protection for the armature SCR modules A malfunction of these devices will be indicated by either an Overcurrent fault F13 blown or tripped incoming protection devices or erratic motor operation Use the following procedure if a malfunction in this circuitry is suspected 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the pulse transformer board see Remove the Pulse Transformer and Switching Power Supply Circuit Boards on page 63 4 With a digital multimeter set for a continuity check measure each connection point on the pulse transformer board listed in the tables below See Figure 25 on page 116 for connector locations If any ofthe actual measurements are out of tolerance replace the pulse transformer board Table 6 Armature Pulse Snubber Circuit Measurements for Regenerative Drives For SCR Measure To Meter reading Connector XY Pinout From 1 KG1 XY
5. Drive DC AC HP DIP Switch S3 DIP Switch S4 Current Amps Line S3 1 S3 2 S3 3 S3 4 S3 5 S3 6 S3 7 S3 8 S4 1 S4 2 S4 3 S4 4 S4 b S4 6 S4 7 S4 8 Rating Amps Code 167 167 136 4 100 ON ON ON ON 207 207 169 1 1125 ON ON ON 250 250 204 3 1150 ON ON ON ON 330 330 269 6 200 ON ON ON 412 412 336 6 250 ON ON ON ON Table 18 575V AC Input Drives Drive DC ACLine HP DIP Switch S3 DIP Switch S4 Han Amps Amps 3 1 83 2 S3 3 S3 4 S3 5 S3 6 S3 7 S3 8 S4 1 S4 2 S4 3 S4 4 S4 b S4 6 S4 7 S4 8 Code 67 67 55 1 50 ON ON ON ON 101 101 827 75 ON ON ON ON 135 135 110 3 100 ON ON ON ON 270 270 220 6 200 ON ON ON ON 405 405 330 9 300 ON ON ON ON Rockwell Automation Publication 20P TG002A EN P February 2012 75 Chapter3 Access Procedures Install the Pulse Transformer and Switching Power Supply Boards Install the new pulse transformer board in reverse order of removal connector from which it was removed on the pulse transformer circuit ATTENTION Fach gate lead cable must be connected to the exact AN board or damage to the drive may occur e Verify that the four plastic board stabilizers mounted on the top air flow plate are placed one on either side of each board Side cut away view Top view of pulse transformer board Air flow plate One plastic stabilizer should be on either side of each board
6. XR 32 AS OVI Figure 22 Drive Heatsink Monitoring Control Circuit Diagram 5V i e ipo OTS 79 Q 1 4 Pulse Transformer Board ed XR 12 AT XR 10 a HMM o i XSW 1 NEN X4 1 X4 2 Py XSW 2 0V24 Rockwell Automation Publication 20P TG002A EN P February 2012 113 Appendix A 114 Schematics Figure 23 Contactor Control Relays Control Circuit Diagram 0V24 U6 U2 S1 A5 AA V V K7 K8 24V O O O O 35 36 75 76 Figure 24 AC Line Snubber Circuit Diagram U W C R R2 R3 R4 R5 R6 R R R R R AC Line Snubber Board D Rockwell Automation Publication 20P TG002A EN P February 2012 Appendix B Circuit Board Layouts and Connections List of Circuit Board The following images and tables detail the connection points for the frame A Lay outs Pow
7. LCIGI ioanoaanooaonn Q pooaogaoogaaoaod m o a rcm m na Exp Q ON Als S4dcnb 11 Coo len S21 so S H O O ES O O 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 oo OOOOOOOOOO OOOOOOO0O000 E ENC 5 ENC_12 Ar A BrB Z Z COM V DEBUG ABC 5 NC EA BY Bee E 1284598798910 11 131415161718 1920 OOOOO OOOO00000 oooooooooo oooooooooo ll T L gt ssa 77 1895 DC analog Encoder terminal 1 0 terminal blocks tachometer terminal block block 120 Table 26 Control Board to Field Board Connections Control Board Connector XFCD Pin Number to Pin Number Field Board Connector XFCD 1 2 3 4 1 2 3 4 Description 15V 15V Common 15V Field CT burden resistors See Pulse Transformer Board to Control Board Connections on page 118 and Switching Power Supply Board to Control Board Connections on page 119 Rockwell Automation Publication 20P TG002A EN P February 2012 Circuit Board Layouts and Connections Appendix B Figure 28 Field Board Layout Field Board U1 V1 C1 D1 X3 1 UF1 l UF D XFCD See Control Board to Field Board Connections on page 120 and Pulse Transformer Board to Field Board Connections on page 117
8. Meter Lead Meter Lead Nominal meter reading Terminal Terminal U1 C1 open or co U1 D1 open or co V1 C1 open or ee V D1 open or ee C D1 open or ee C U1 open or ee C V1 0 50V D C1 0 50V D U1 0 45V Figure 10 Field Terminal Block Location bAd ind Top of Drive 34 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 Figure 11 Field Fuses Location Top view of Drive Unscrew fuse holders and remove fuses lilt IM AI Front of Drive 7 Remove the cable from connector XP on the pulse transformer circuit board See Figure 25 on page 116 for connector location 8 Check the gate cathode junction of the field SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules lead orientation is not critical See Table 11 below If a low resistance is detected replace the SCR dual diode module See Field SCR and Dual Diode Modules Removal and Installation on page 79 Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Nominal meter reading 10 20 Q Measure from XP1 XP3 XP4 Rockwell Automation Publication 20P TG002A EN P February 2012 35 Chapter2 Component Test Procedures Speed Feedback Device Tests 36 Check the Encoder The encoder feedback device provides a dual channel quadrature outp
9. ooooo ooo 9l Sl bl el A LL Ld LM VOZIX x 9 E VIX 1 9 prog 3 zai a M 1 W10 4SUL1 E 8S nd A e Ol 02X 94 x 9 E Ux HE X dx o 7 A L 093X EX Laz Laz we peogpigj x iz Ww Ld HN dO WA 4A LL sje1souuau je1aulg oA dd Rockwell Automation Publication 20P TGO02A EN P February 2012 108 Schematics Appendix A Figure 14 AC Line Measurement Points Diagram X2 Nj XR 15 U 100K 415 415V P HA i 15V q 45 V XY 21 XR 16 100K XR 17 Ww 100K Figure 15 Power Feedback Connections Diagram W V U F3 Rockwell Automation Publication 20P TG002A EN P February 2012 109
10. Chapter3 Access Procedures Configuring a Pulse Transformer Board FIR2 xx Rev N and Higher Set DIP switches 3 and S4 located at the bottom right corner of the pulse transformer board shown below to the correct settings based on the appropriate table below Tou Sr aa a i fie Dip switches S3 and S4 are located at the bottom right corner of the board E me Bj E TOS LI XCT KGO4 H Eli oot E E D T T To2 18 S3 S4 B da EEEEEEEEI EEEEREEE KGa B m 15 H i EVI JE 5 J CA A A AA A A E NA A A A A AS a iios nl Oooog 1 Do E 79 35 36 75 76U2 V2 PE e e y SSS Qu XCD_IO amp pus LLL ON s3 E o Jan CREER RERBA G 78 79 35 36 75 76U2 V2 IMPORTANT Ablankcell below a switch in the Table 16 Table 17 and Table 18 below indicate that the setting is OFF Table 16 230V AC Input Drives Drive DC AC HP DIP Switch S3 DIP Switch S4 Current Amps Line 3 1 3 2 3 3 S3 4 S3 5 S3 6 S3 7 S3 8 S4 1 S4 2 S4 3 S4 4 S4 5 S4 6 S4 7 S4 8 Rating Amps Code 146 146 119 40 ON ON ON 180 180 147 50 ON ON ON ON 218 218 178 60 ON ON ON ON 265 265 217 75 ON ON ON ON 360 360 294 100 ON ON ON 434 434 355 125 ON ON ON ON 74 Rockwell Automation Publication 20P TG002A EN P February 2012 Table 17 460V AC Input Drives Access Procedures Chapter 3
11. F2 mL Table 25 Switching Power Supply Board to Control Board Connections Switching Power Supply Board Connector XA Pin Number to Pin Number a CO CO NI MD on A CO Ni a CO NMI OD on A cw rh 0 1 2 13 14 5 6 0 1 112 13 14 5 6 Control Board Connector XA Description 5V 5V common 5V 5V common 5V 5V common SMPS supply input undervoltage 15V 15V common 15V 24V common 24V See Pulse Transformer Board to Switching Power Supply Connections on page 117 Rockwell Automation Publication 20P TG002A EN P February 2012 119 AppendixB Circuit Board Layouts and Connections Control Board Figure 27 Control Board Layout XR O Q O O To DPI board on HIM Bezel eee ee RST EET 25 HE
12. 00 00 ccceeeeeees 27 Check the Pulse Transformer Board 00cececceeneee 32 Check the Field SCR Dual Diode Module 33 Speed Feedback Device Tests sese noe tese dad vet ae PR HEP 36 Check the Encoder 2e re Re D OP V e EE EU 36 Check the DG Tachot tet ice nere etre enin 36 Check the Resolver Interface Board cceccececeeeees 37 Thermistors and Thermal Switches 0ccccececcecneveveee 39 Relay Outputs siecle tele bol lene t nean Lc ceu 39 Created Faule Reports ene aena utere eiua VERSER RM US 40 What You Need When You Call Tech Support sse 40 Rockwell Automation Publication 20P TG002A EN P February 2012 3 Table of Contents Access Procedures Chapter 3 Remove Power from the Drive ccc ccc cece eceeeecesenens 42 DPI HIM Assembly Removal and Installation 4 43 Remove the DPI HIM Assembly 0 eee eee eens 43 Install the DPI HIM Assembly ictor erue deinen er etes 43 Protective Cover Removal and Installation seueue 44 Remove the Protective Covers csse 44 Install the Protective Covers La ces eer een theta ete tia 46 Communication Adapter and EMI Shield Removal and Installation 46 Remove the Communication Adapter and EMI Shield 46 Install the Communication Adapter and EMI Shield 48 Resolver Feedback and Interface Circuit Board Removal and TIovstallqttoftco o
13. Ie 000 n MM The TA potentiometer is located on the lower right corner of the pulse transformer circuit board next to the control power terminal block 78 79 35 36 75 76 U2 V2 72 Rockwell Automation Publication 20P TG002A EN P February 2012 Total Resistance Values Table 14 230V AC Input Drives Access Procedures Chapter 3 Drive Current DC AC Line HP SetRTA Value Using Rating Code Amps Amps TA Potentiometer Ohms 146 146 119 40 12575 180 180 147 50 102 218 218 178 60 18 422 265 265 217 75 16 928 360 360 294 100 5 1 434 434 355 125 423 Table 15 460V AC Input Drives Drive Current DC AC Line HP Set RTA Value Using Rating Code Amps Amps TA Potentiometer Ohms 167 167 136 4 100 10 994 207 207 169 1 1125 8 87 250 250 204 3 150 7 344 330 330 269 6 200 5 564 412 412 336 6 250 4 456 3 Seal the TA potentiometer in place using RV silicon Continue with Install the Pulse Transformer and Switching Power Supply Boards on page 76 Rockwell Automation Publication 20P TG002A EN P February 2012 73
14. Rockwell Automation Publication 20P TG002A EN P February 2012 121 AppendixB Circuit Board Layouts and Connections Notes 122 Rockwell Automation Publication 20P TG002A EN P February 2012 Appendix C Flow Charts List of Flow Charts The following pages contain flow chart versions of troubleshooting procedures contained in Chapter 2 Component Test Procedures Topic Page Control Power Supply Failure 124 Field Current Loss Failure 125 Rockwell Automation Publication 20P TG002A EN P February 2012 123 Appendix C Control Power Supply Flow Charts Failure 124 Measure the voltage at terminals U2 V2 Is the correct voltage present at U2 V2 Remove AC control power and remove and test the fuse F1 at the top of the drive Is the fuse blown Replace the fuse disconnect the cable from connector XA on the control board and apply AC control power Verify the wiring and No power source to U2 V2 and correct any problems Replace the switching power supply board and apply AC control power This chart presents the steps for troubleshooting a Power Failure fault F3 Is the drive operational Replace the control board Is the fuse blown Remove power from the drive and replace the fuse on the switching power supply board v Remove the switching power supply board f
15. 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for all SCRs Figure 8 SCR Gate Lead Connection Pinouts for Regenerative Drives SCR Module 1 Ol Q2 O 3 Le Gate Lead 54 76 Pinouts SCR Module 01 SCR Module 2 SCR Module 02 30 Rockwell Automation Publication 20P TGO02A EN P February 2012 SCR Module 3 QJ 67 45 q Gate Lead Pinouts or TT 2113 OJ amp O Ol3 12 S 54 76 lo fo SCR Module 03 Component Test Procedures Chapter 2 Table 5 SCR Gate to Cathode Junction Measurements for Non Regenerative Drives On SCR Module SCR Measure from To 01 01 Pin 6 Pin 7 04 Pin 5 Pin 4 02 02 Pin 6 Pin 7 05 Pin 5 Pin 4 03 03 Pin 6 Pin 7 06 Pin 5 Pin 4 1 The actual reading varies depending upon the SCR man value is consistent for all SCRs Nominal meter reading 5 20 Q0 facturer Verify that the actual measured Figure 9 SCR Gate Lead Connection Pinouts for Non Regenerative Drives Gate Lead p 67 45 Pinouts Module 01 3 2 1 O o o SCR
16. Verify Par 351 Field Current value using DC clamp to measure 4 4 the DC motor field current i Verify drive rated field bridge current is set correctly in Par 374 Drv Fld Brdg Cur and DIP switch S14 is configured to match i 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 No Is voltage measurement correct Yes Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance set with DIP switch S14 Is resistance measurement correct Replace the control board Rockwell Automation Publication 20P TG002A EN P February 2012 Replace the field board A AC current transducers install 96 remove 93 AC line snubber circuit board and resistors install 82 remove 80 armature bridge failure troubleshoot 21 armature SCR modules test 27 bimetal thermostats install 101 remove 97 C circuit board connections 115 layout drawings 115 close control EMI shield 61 communication adapter and EMI shield install 48 remove 46 components inspection 15 con
17. pulse transformer board switching power supply board Plastic stabilizers 76 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Field Circuit Fuses Removal Remove the Field Circuit Fuses and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 On the top of the drive unscrew the fuse holders and remove the fuses from the holders Top view of Drive Unscrew fuse holders and remove fuses Front of Drive Install the Field Circuit Fuses Install the field circuit fuses in the reverse order of removal Field Circuit Board Remove the Field 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 Rockwell Automation Publication 20P TG002A EN P February 2012 71 Chapter3 Access Procedures 3 Remove the protective covers from the drive See Remove the Protective Covers on page 44 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure See Pulse Transformer and Switching Power
18. 0 41 Q Connector XY Pinout 10 0000000000 The field supply consists of a dual pack SCR dual diode module arranged in a single phase full wave rectifier configuration Malfunction of either of these components may cause various responses including field and velocity related faults or blown fuses The following procedures can be used if field bridge malfunctions are suspected Read the General Safety Precautions on page 10 Remove and lock out all incoming power to the drive See Remove Power from the Drive on page 42 Remove the protective covers See Remove the Protective Covers on page 44 Verify that contactor power if used is removed Rockwell Automation Publication 20P TG002A EN P February 2012 Verify that power to an external field supply if used is removed 33 Chapter2 Component Test Procedures 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 and Figure 10 below If a low resistance is detected replace the modules See Field SCR and Dual Diode Modules Removal and Installation on page 79 Ifa measurement results in an infinity reading check the fuses at FU1 and FV1 on the control panel to determine if they are open See Figure 11 on page 35 Table 10 Field SCR Dual Diode Module Anode to Cathode Junction Measurements
19. FU1 FV1 atthe bottom of the drive Are the fuses blown Test the resistance of the motor field wiring and motor field for short circuits No Are terminals short circuited Repair short circuits The charts below presents the steps in flow chart form for troubleshooting a Field Current Loss fault F6 No Field Current Verify the wiring and power source to U1 V1 and correct any problems Disconnect cable from XR on the control board and measure the U1 V1 voltage synchronization signal at pin 11 on the cable This signal should be a square wave signal with a 90 lag phase displacement compared to the AC voltage signal Measure the gate signals at pins XR 1 and XR 2 on the cable Are the signals present and correct 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 the field board Are the fuses blown Replace the control board Yes Replace the field board Rockwell Automation Publication 20P TG002A EN P February 2012 Replace the control board 125 Appendix C 126 Flow Charts Low or Incorrect Field Current
20. Interface Circuit Board Removal and Installation Remove the Resolver Feedback and Interface Circuit Boards 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 protective covers 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 Disconnect the plug in terminal blocks from the resolver feedback and resolver interface boards seam OR REESE XR XA m L Oo amp 29020000009000039 09090200990009909 XP3 a KERRE EH T ES P2 P3 4 15 Resolver feedback board i Bosnnonnnn B S1 B B zm E 0 O P1 22 23 24 26 26 27 28 29 30 3 32 33 34 35 36 37 38 39 40 Sy Bed Oooooooooo oooooooooo e Clee SS ad 12345679891 81 59515592 OOOCO N IMESINSISUISD OOOO0000000 0000000000 Remove terminal blocks Rockwell Auto
21. Remove the protective covers 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 6 Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure See Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation on page 63 7 Remove the appropriate bus bars in order to access the bimetal thermostats Ifremoving the bus bars from a Regenerative drive refer to Remove the Bus Bars from a Regenerative Drive on page 98 Ifremoving the bus bars from a Non Regenerative drive refer to Remove the Bus Bars from a Non Regenerative Drive on page 100 Rockwell Automation Publication 20P TG002A EN P February 2012 97 Chapter3 Access Procedures Remove the Bus Bars from a Regenerative Drive 8 Remove the bolt and washer that secures the U phase terminal bus bar to the terminal isolation bar 9 Remove the bolts and washers that secure the connecting bus bar to the U phase SCR modules and remove the bus bars 9 Remove bolts and washers 9 Remove bus bars 8 Remove bolt and washer from isolation bar 98 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 10 Remove the bolt and washer
22. 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 GF el 9f Scr open Chi x amp 25 Ch Ia File scr Fail ti REMOTE ENABLE 15 25 13 i I 60 TO 5 ns 1 LOCAL 5 ov t i 1 i 4 T 5V 2 1 zoome n R 4 i l ov RATEN bn it fy dut LUE a d ULL a xia T 5 V OC amp n 280 rV OC amp 18 3 5 v OC x 1 1 HFREJ 8 1 V 458 nv DC v O STOPPED If the drive faults with a Field Current Loss fault F6 and there is low or incorrect field current present at the motor as seen in parameter 351 Field Current complete the steps in Low or Incorrect Field Current below If the drive faults with a Field Current Loss fault F6 and there is no field current present at the motor as seen in parameter 351 Field Current complete the steps in No Field Current on page 25 Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 126 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 Rockwell Automation Publication 20P TG002A EN P February 2012 23 Chapter 2 Component Test Procedures Verify that the drive rated field bridge current is set correctl
23. orange and yellow gate lead cables from connectors KGO1 KG06 and push each lead through the appropriate opening in the board For regenerative drive remove each pair of orange and yellow gate lead cables from connectors KGOI KG06 and KG1 KG6 and push each lead through the appropriate opening in the board IMPORTANT Carefully remove the gate leads by grasping the connector DO NOT pull the gate leads off by pulling on the wires For non regenerative drives remove six gate pe leads and route through openings in board For regenerative drives remove 12 gate leads and route through openings in board 68 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 15 Remove the seven screws that secure the board to the stand offs on the drive chassis and remove the boards from the drive Remove screws Note Regenerative drive shown Rockwell Automation Publication 20P TG002A EN P February 2012 69 Chapter3 Access Procedures 16 Remove the cable from connector XUV on the switching power supply board 17 Remove the six screws and washers that secure the switching power supply board to the stand offs on the back of the pulse transformer board and remove the switching power supply board Remove cable from XUV Remove screws Configure the Pulse Transformer Circuit Board The steps required to configure the pulse transformer board are different
24. 4 4 KG4 XY 2 99 2 KG2 XY 5 5 KG5 XY 2 3 KG3 XY 6 6 KG6 XY 3 r SS e j 01 KG01 X1 open circuit o 4 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 Table 7 Armature Pulse Snubber Circuit Measurements for Non Regenerative Drives ForSCR Measure To Meterreading Connector XY Pinout From 01 KG01 XY 1 Sm 04 KG04 XY 4 o 02 KG02 XY 2 05 KG05 XY 5 open circuit 03 KG03 XY 3 06 KG06 XY 6 e 32 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 5 With the digital multimeter set to diode test measure each connection point on the pulse transformer board listed in the tables below If any of the actual measurements are out of tolerance replace the pulse transformer board Table 8 Armature Pulse Transformer Primary Measurements for Regenerative and Non Regenerative Drives For SCR Meter Lead 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 41 Q Connector XY Pinout 10 0000000000 Table 9 Armature Pulse Transformer Primary Measurements for Regenerative Drives For SCR 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 Check the Field SCR Dual Diode Module Meter reading
25. Drive SCR Module Layout m N Ke e 6 e Mel O O O e amp Ol jen Ol Gen o Geo ol lsJo ol l3 O2 a O o s 2 o ols 2 o o s 2 O 1 O l 1 O 110 S SCR SCR SCR Module 1 SCR Module 2 SCR Module 3 SCR _ Module 01 Module 02 Module 03 O W S oj O O le Ta 28 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 Table 3 SCR Anode to Cathode Junction Measurements for Non Regenerative Drives On SCR Module SCR Measure from To Terminal Terminal 01 01 U C 04 U D 02 02 V C 05 V D 03 03 W C 06 W D Figure 7 Non Regenerative Drive SCR Module Layout Nominal meter reading open circuit or megaohms range
26. Fans Install the Cooling Fans in reverse order of removal Verify that the air flow direction arrow on the fans is pointing toward the heatsink on the drive Rockwell Automation Publication 20P TGO02A EN P February 2012 103 Chapter3 Access Procedures Notes 104 Rockwell Automation Publication 20P TG002A EN P February 2012 Chapter 4 Start Up After Repair Before applying power to a repaired drive perform the following tests e Check the Armature SCR Modules on page 27 e Check the Field SCR Dual Diode Module on page 33 Complete the Test With the Motor Without a Mechanical Load below Test With the Moto r This test allows you to measure several operating parameters and diagnose With out a M e ch ani c al Lo a d 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 avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to then drive Correct the malfunc
27. Ifremoving the SCR modules from a regenerative drive refer to Remove the Bus Bars from a Regenerative Drive on page 84 Ifremoving the SCR modules from a non regenerative drive refer to Remove the Bus Bars from a Non Regenerative Drive on page 88 Rockwell Automation Publication 20P TG002A EN P February 2012 83 Chapter3 Access Procedures Remove the Bus Bars from a Regenerative Drive 8 Remove the two screws or bolts and washers that secure the red and blue wires from the AC line snubber board to the terminal bus bars C and D and remove the wires 9 Remove the three bolts and washers that secure the black wires from the resistors to the terminal bus bars U V and W and remove the wires fu Regenerative Drive Remove bolts washers and wires Note proper order of washers for installation Bolt L Lock washer Flat washer 3j Remove screws washers and wires 84 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 10 Remove the three remaining bolts and washers that secure the AC input bus bars U V and W phases to the anode of the SCR modules and remove the bus bars Regenerative Drive Remove bolts and washers Remove bus bars Rockwell Automation Publication 20P TG002A EN P February 2012 85 Chapter3 Access Procedures 11 Remove the three pairs of upper gate leads from the
28. Publication 20P TG002A EN P February 2012 93 Chapter3 Access Procedures 7 Remove the bolts and washers that secure the U and V phase AC input bus bars to the isolation bar Regenerative Drive Shown Remove bolts and washers 8 For regenerative drives only remove the bolts and washers that secure the resistor wires and the connecting bus bars to the U and V Phase SCR modules and remove the wires and bus bars Regenerative Drive Remove bolts wires and bus bars Connecting bus bar Connecting bus bar 94 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 9 For non regenerative drives only remove the bolts and washers that secure the resistor wires and bus bars to the U and V Phase SCR modules and remove the wires and bus bars Non Regenerative Drive Remove bolts wires and bus bars 10 Slide the U and V phase bus bars that pass through the AC current transducers up and out of the drive 11 Remove the screw and washer that secures each of the AC current transducers to the drive frame and remove the AC current transducers Remove screw and washer a Rockwell Automation Publication 20P TG002A EN P February 2012 95 Chapter3 Access Procedures Install the AC Current Transducers Install the AC current transducers in reverse order of removal Note the color and location of each of the four wires connected to the AC current transducers to ensure that e
29. R1 R2 R3 R4 R5 Rating Code Amps Amps 146 146 119 40 Remove Remove 5 36Q Remove 180 180 147 50 Remove Remove 5 36Q Remove 218 218 178 60 Remove Remove 5 36Q Remove 265 265 217 75 Remove Remove 5 36Q 5 36 360 360 294 100 Remove 5 362 5 360 5 36Q 434 434 355 125 Remove 5 362 5 360 5 3642 Table 13 460V AC Input Drives Drive Current DC AC Line HP R1 R2 R3 R4 R5 Rating Code Amps Amps 167 167 136 4 100 Remove 5 36Q Remove Remove 207 207 169 1 125 Remove Remove 5 36Q Remove 250 250 204 3 150 Remove Remove 5 36Q 5 362 330 330 269 6 1200 Remove 5 3680 5 360 5 360 412 412 3366 250 Remove 5 362 5 360 5 362 Rockwell Automation Publication 20P TG002A EN P February 2012 n Chapter3 Access Procedures 2 Connect the leads of the multimeter to pins 13 and 14 of connector XR on the pulse transformer board polarity is not important and using the TA potentiometer on the lower right corner of the pulse transformer circuit board set the total resistance RTA to the appropriate value as indicated in Table 14 or Table 15 in the Total Resistance Values section on page 73 The XR connector is located near the upper right SN corner of the pulse transformer circuit board M is L1
30. SCR modules 12 Remove the bolts and washers that secure the DC bus bars to the SCRs and remove the bus bars Regenerative Drive Remove upper gate leads Remove bolts and washers 86 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 13 Remove the four bolts and washers and stand off that secure the power terminal bus bars to the isolation bar and slide the bus bars up and out of the drive Regenerative Drive Remove bolts and washers 14 Remove the two screws and washers that secure each SCR module to the heatsink and remove the SCR module Regenerative Drive Remove two screws and washers from each SCR Module Rockwell Automation Publication 20P TG002A EN P February 2012 87 Chapter3 Access Procedures Continue with Install the SCR Modules on page 91 Remove the Bus Bars from a Non Regenerative Drive 15 Remove the bolts and washers and stand off and washer that secure the power terminal bus bars to the isolation bar Non Regenerative Drive Remove bolts washers and wires 16 Remove the bolts and washers that secure the C and D terminal bus bars to the horizontal bus bars Non Regenerative Drive Remove bolts and washers Note proper order of washers for installation Bolt zo d Lock washer Flat washer 3 88 Rockwell Automation Publication 20P TG002A EN P February 2012 Acces
31. Shield 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 protective covers from the drive 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 p q AMen Bradiey V3 A Disconnect interface cable Disconnect network cables 46 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 6 Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter Remove four screws Tightening torque 0 9 Nem 8 0 Ibein 7 Remove the three screws that secure the EMI shield to the standoffs on the control board and remove the EMI shield Remove three Screws Tightening torque 1 0 Nem 8 9 Ibein Rockwell Automation Publication 20P TG002A EN P February 2012 47 Chapter3 Access Procedures 8 Remove the three standoffs from the control board Remove three standoffs Tightening torque 1 0 Nem 8 9 Ibein Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal 48 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Resolver Feedback and
32. 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 Fa c tField Amps Captures and displays the field current as a percentage of rated current at the time of the last fault 1374 Fault Voltage Captures and displays the armature voltage at the time of the last fault 40 Rockwell Automation Publication 20P TG002A EN P February 2012 Chapter 3 Access Procedures This chapter provides detailed procedures for removing and replacing drive components Topic Page Remove Power from the Drive 42 DPI HIM Assembly Removal and Installation 43 Protective Cover Removal and Installation 44 Communication Adapter and EMI Shield Removal and Installation 46 Resolver Feedback and Interface Circuit Board Removal and Installation 49 1 0 Expansion Circuit Board Removal and Installation 53 115V A
33. Supply Circuit Boards Removal and Installation on page 63 5 Remove the wires from connectors UF UF1 VF and VFI 6 Remove the six screws and washers that secure the field board to the field SCR and dual diode modules and remove the field board v v wwe PAX i Remove wires 1 vi 1 A eis Remove screws Remove screws ELENA DR F 1 Install the Field Circuit Board Install the field board in reverse order of removal e Inspect the existing X3 and XFCD cables for burn marks cracks or loose connectors If necessary replace the cables on the field board with the new cables provided 78 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Field SCR and Dual Diode Remove the Field SCR and Dual Diode Modules Modules Removal and Installation 1 2 It is recommended that you replace both modules at the same time Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the protective covers 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 Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure
34. 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 Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact Canada your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact 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 http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters America
35. based on the revision code of the pulse transformer board See either Configuring a Pulse Transformer Board FIR2 xx Rev M and Lower on page 71 below or Configuring a Pulse Transformer Board FIR2 xx Rev N and Higher on page 74 70 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Configuring a Pulse Transformer Board FIR2 xx Rev M and Lower IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm 1 Cutand remove the appropriate sizing resistor s if necessary from the pulse transformer board based on the drive size Refer to Table 12 or Table 13 below for the appropriate configuration Sizing resistors are located near the center of the pulse transformer circuit board Sizing Resistor Configuration gasi 7 F zy d cs qn The tables below indicate the value of the designated resistor R1 R5 when left in place on the pulse transformer board or indicate Remove when the resistor should be cut off and removed from the board indicates that this resistor is not contained on the pulse transformer board for the designated drive size Table 12 230V AC Input Drives Drive Current DC AC Line HP
36. c S3 S4 BEHBBERIBBHBEEHH XTA xii VUVVVVUVIVVVVVVUV 78 79 35 36 75 76 U2 V2 9 Move the control EMI shield See Move the Control EMI Shield on page 59 10 Remove the two screws that secure the air flow plate to the top of the pulse transformer board and lift the plate off the drive chassis Note that the air flow plate cannot be completely removed due to the fuse connections at FUI and FVI Remove screws cM amp 3 F eae bpe et Fuse connections Rockwell Automation Publication 20P TG002A EN P February 2012 65 Chapter3 Access Procedures 11 Remove the cable from connector XV on the switching power supply board Switching power supply board Remove cable from XV Pulse transformer board Front of Drive 12 Remove the cables from connectors X3 X4 and XP on the pulse transformer board Remove cable Remove cable Remove cable E ET T o o ECS 1800 4 FIR2 51 66 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 13 Remove the ground connection at the left side of the pulse transformer board Remove ground connection 1j eg mag LL e dL IL cR EI me FORTON E e e y ee 8 AB P p e R E Rockwell Automation Publication 20P TG002A EN P February 2012 67 Chapter3 Access Procedures 14 Remove the appropriate gate leads e For non regenerative drives remove each pair of
37. confirm the operation which cannot be undone 3 If you 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 TG002A EN P February 2012 Component Test Procedures Chapter 2 Visu al Component Visually inspect the drive circuit boards and power components before energizing Inspection 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 Remove the protective covers and lower the control EMI shield when necessary See Remove the Protective Covers on page 44 and Move the Control EMI Shield on page 59 4 Check components for burn marks breakage or foil delamination on all circuit boards Replace any of these components without further testing if they show evidence of burn marks breakage or foil delamination Troubleshoot a Control Ifa 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 protective covers from the drive See Remove the Protective Covers
38. save parameter configuration 14 schematic diagrams 107 SCR modules install 91 remove 83 service tools 12 software tools 12 switching power supply circuit board install 76 remove 63 switching power supply circuit board fuses install 62 remove 61 T technical support calling 40 test armature SCR modules 27 DC analog tachometer 36 encoder 36 field SCR dual diode module 33 pulse transformer circuit board 32 testpoints locations 18 19 thermal switch 39 thermistor 39 tools service 12 software 12 troubleshoot armature bridge failure 21 field current loss 23 overcurrent fault 21 power failure fault 15 V visual inspection 15 Rockwell Automation Publication 20P TG002A EN P February 2012 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http 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
39. 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 check the fuses at FU1 and FV1 See Remove Power from the Drive on page 42 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 fthere are no short circuits continue with step 2 below e Ifashort circuit exists correct any problems 2 Check the field SCR dual diode module for a short circuit condition See Check the Field SCR Dual Diode Module on page 33 fthere are no short circuits continue with step 3 below 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 If the field fuses blow replace the field board Test Field Control Signals 1 Disconnect the cable from connector XR on the control board and measure the U1 V1 voltage synchronization signal at pin 11 on the cable See Figure 27 on page 120 for location of the XR connector on the control board Rockwell Automation Publication 20P TG002
40. the three stand offs from the resolver interface board IUE m EET XR 1G XA m L O DERMERPIIRIIPRIIS EEEE XP3 P2 P3 Resolver 55 interface board Remove stand offs ARES Tightening torque for i EEEEEEEEEE re assembly is l Si H 0 7 Nem 6 2 Ibein A LLI e EG O O 22 23 24 25 26 27 28 29 30 30 32 33 34 36 36 37 38 39 40 amp OO00000000 0000000000 SABCH At A B B Zt ZCOMV 12345967891 5E 7B 920 eres eee SPIES SISSIES SSIS PSS S Rockwell Automation Publication 20P TG002A EN P February 2012 51 Chapter3 Access Procedures 7 Remove the four hexalobular screws that secure the resolver interface board to the control board and remove the resolver interface board IMPORTANT Theresolver 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
41. 012 57 Chapter3 Access Procedures 10 Carefully disconnect the cables from connectors XFCD XA and XR on the control board 11 Remove the plug in I O and control terminal blocks with the wiring kept in place Disconnect cables Disconnect 1 0 _ and control wiring 21 22 2 24 25 26 27 28 29 20 31 32 39 34 35 34 37 24 20 a I9 de o 8 0 0 8 58 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 12 Remove the five screws that secure the control board to the control EMI shield and remove the board Remove Mr sige gal aiiin screws d Tightening torque 1 0 Nem 8 9 Ibein 20 31 32 33 34 35 36 77 38 29 M Install the Control Circuit Board Install the control board in reverse order of removal Verify that all DIP switches are set to the correct configuration based on your recorded settings Control EMI Shield Move the Control EMI Shield Removal and Closure You must move lower the control EMI shield that holds the control board in order to access other components within the drive 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the protective covers from the drive See Remove the Protective Covers on page 44 Rockwell Automation Publication 20P TG002A EN P February 2012 59 Chapter 3 Access Procedures 60 IMPORTANT Mark all
42. 7F79 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F42 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F41 4 5 5 5 Nem 40 48 7 Ibein SK 20P S727F 4 5 5 5 Nem 40 48 7 Ibein SK 20P S737F 4 5 5 5 Nem 40 48 7 Ibein Use the following orientation for installing the SCR modules This SCR module only present in regenerative drives Gate leads at bottom O O O 3 Sio ol lolle _ 8ate leads at top Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules 230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque SK 20P S7F48 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F78 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F49 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F79 4 5 5 5 Nem 40 48 7 Ibein SK 20P S7F42 11 13 Nem 97 4 115 Ibein SK 20P S7FA41 11 13 Nem 87 4 115 Ibein SK 20P S727F 11 13 Nem 97 4 115 Ibein SK 20P S737F 11 13 Nem 87 4 115 Ibein Rockwell Automation Publication 20P TG002A EN P February 2012 91 Chapter3 Access Procedures For regenerative drives the longer leg of the intermediate AC input bus bars connect to the top of the SCR modules Top of Drive Long leg Intermediate SCR module bus bar on heatsink Short leg Phase U
43. A EN P February 2012 25 Chapter2 Component Test Procedures This signal is a square wave signal with a 90 lag phase displacement compared to the AC voltage signal 3 Fab 36 Chi Sincro XR11 Ch2 U1 Vj File Sincrnfc tif REMOTE ENABLE 16 28 58 1 60 TO 5 ns LOCAL 5 9 V 1 5 ns 2090 V ns 1 5 v C i3 220 nV DC 18 kS s 3 5 v Dm i EE Line Biv cCA 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 Fab 96 Chi Sync Ch2 ITFL Ch3 ITF2 Cn4 Ie File Fed pl REMOTE ENABLE 17 01 35 i 60 TO E ne LOCAL U1 V1 Sync 5 0 V n 4 LALB sani 2 5 ns ITF1 Pulse 5 0 V 3 gt ns ITF2 Pulse 8 V 5 ms 5 v OCG Sv Dt i 18 kS s 3 5 v OH f Line 4 5n DCi O STOPPED e Ifthe gate signals are missing replace the control board e Ifthe gate signals are present replace the field board 26 Rockwell Automation Publication 20P TG002A EN P February 2012 Power Component Test Procedures Component Test Procedures Chapter 2 Check the Armature SCR Modules The frame B PowerFlex DC drive armature supply consists of three non regenerative drives or six regenerative drives SCR modules mounted on heat sinks within the l
44. About This Publication onde terti dass qM os ete ee 7 Who Should Use this Manual ec detec oie tata teen 7 Additional Resources o 525 a cw to p Pado das RP E pido 7 Chapter 1 Tnfbroducttohicu ee oc Seed dal ecd battre AAA A done 9 General Safety Precautions ici m ed e DRE EIS TE 10 Hardware Descriptions oes crete ane ei a tee seta Done 11 Commonly Used Toolscz o tense loo e puse Y on rererere 12 Service 1 ool Sok ede Ae cats eens ta e HEAR ss 12 Software Tools donee aas ine aod shat nein Met i Pues E anaes 12 Chapter 2 Inttod ettohu ss comcs e v e AE Rhe tdi ore EE 13 Save the Parameter Configuration cus cattiva e mes e cp pP VE SP ra 14 Save tO QU HIM Seb re ond eu ELENA 14 Download Parameters to an Offline Node File 14 Visual Component Insp Ctloh s s i 9 erorecex ea uda So RE REN FS 15 Troubleshoot a Control Power Supply Failure ssuuee 15 Testing the Switching Power Supply and Pulse Transformer Boards ui Eds ge cust eut E bord GN TN Cutie pietra d 16 Testing the Control and Field Board Connections 17 Troubleshoot an AC Undervoltage Fault 000 0 000 20 Troubleshoot an Armature Bridge Failure 1 secedere rea 21 Troubleshoot a Field Current Loss Fault 0 0c eee eee eee 23 Low or Incorrect Field Current 00cccceccececvevecees 23 INO Field COUfkelibos cpi oe ve eme ce oe tall ene es 25 Power Component Test Procedures 1 e eR 27 Check the Armature SCR Modules
45. C to 24V DC 1 0 Converter Circuit Board Removal and Installation Bh Control Circuit Board Removal and Installation 56 Control EMI Shield Removal and Closure 59 Switching Power Supply Board Fuse Removal and Installation 61 Pulse Transformer Circuit Board Fuse Removal and Installation 63 Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation 63 Field Circuit Fuses Removal and Installation H Field Circuit Board Removal and Installation ii Field SCR and Dual Diode Modules Removal and Installation 79 AC Line Snubber Circuit Board and Resistors Removal and Installation 80 SCR Modules Removal and Installation 83 AC Current Transducers Removal and Installation 93 Bimetal Thermostats Removal and Installation gr Cooling Fan Removal and Installation 102 Rockwell Automation Publication 20P TG002A EN P February 2012 41 Chapter3 Access Procedures Remove Power from the Drive 42 ATTENTION Remove power before making or breaking cable A connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by sending an erroneous signal to your system s field devices causing unintended machine motion causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance Remove and loc
46. CR2 0V GNDP Relay output 35 36 command Relay output 75 76 command 20 40 selection signal 0V GNDP armature 0 signal 0V GNDP Heatsink overtemperature Digital U1 V1 sync signal 0V GNDP CT burden signal 0V GND Reduced U sync signal Reduced V sync signal Reduced W sync signal Reduced C armature signal Reduced D armature signal 0V GNDP Gate signal SCR 4 0 0V GNDP Gate signal SCR 5 02 OV GNDP Gate signal SCR 6 03 WH1 not used grounded Gate signal SCR 1 04 WL1 not used grounded Gate signal SCR 2 05 OV GNDP Gate signal SCR 3 06 Motor overtemperature Enable reverse MN power bridge Enable forward MP power bridge Circuit Board Layouts and Connections Appendix B Table 24 Pulse Transformer Board to Current Transducer Connections Pulse Pin Number to Pin Number Current Description Transformer Transducer Board Connector 1 Black CT on Phase U Secondary side CT phase U 2 Brown nl 3 Black CT on Phase V Secondary side CT phase V 4 Brown Switching Power Supply Figure 26 Switching Power Supply Board Layout Board B SA SL I XUV Fil oll
47. Hardware Service Manual Allen Bradley PowerFlex Digital DC Drive Frame B 40 300 Hp 30 224 kW 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 information circuits equipment or software describe
48. See Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation on page 63 Remove the field circuit board See Remove the Field Circuit Board on page 77 Remove the two screws and washers that secure each module to the heatsink and remove the modules from the drive Remove screws iU ne 23 E iS 4 K 2 Rockwell Automation Publication 20P TG002A EN P February 2012 79 Chapter 3 Access Procedures Install the Field SCR and Dual Diode Modules Install the field SCR and dual diode modules in reverse order of removal Apply thermal grease to the bottom of the SCR and dual diode modules before securing it to the heatsink and dual diode modules before securing them to the heatsink or damage to ATTENTION Thermal grease must be applied to the bottom of the SCR A the drive may occur Tightening torque for the screws connecting the SCR and dual diode modules to the heatsink and the screws connecting the field circuit board to the SCR and dual diode modules is 2 5 4 0 Nem 22 35 lbein AC Line Snubber Circuit Remove the AC Line Snubber Circuit Board and Resistors Board and Resistors Removal and Installation 80 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 protective covers from the drive See Remove the Protective Covers on page 44 IMPORTANT Mark al
49. See Remove Power from the Drive on page 42 Remove the protective covers from the drive See Remove the Protective Covers on page 44 Rockwell Automation Publication 20P TG002A EN P February 2012 63 Chapter3 Access Procedures 4 Remove the plug in terminal from the field input block at the top of the drive 5 Remove the four screws that secure the slotted air flow plate to the top of the drive chassis IMPORTANT The air flow plate is also secured to the pulse transformer circuit board and therefore cannot yet be removed Instructions for doing so are included later in this procedure A Remove screws Remove plug in terminal NH 4 Front of Drive gy Air flow plate 6 Remove the cable from connector XTA at the bottom of the pulse transformer board 7 Remove the plug in terminals from the control power block at the bottom of the pulse transformer board Remove cable Remove plug in terminals 64 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures 8 For Pulse Transformer boards with an armature voltage feedback Chapter 3 terminal block FIR2 XX rev N and higher remove the connector from XCD_IO on the lower left corner of the board Remove connector from XCD 10 XCD IO D E B EIEE E
50. V or W bus bar For regenerative drives five of the bolts are 24mm long and the rest are 20mm long For non regenerative drives two of the bolts are 24 mm long and the rest are 20 mm long Install the 24mm bolts in the following locations Regenerative Drive Shown 24mm bolt locations 92 Rockwell Automation Publication 20P TGO02A EN P February 2012 AC Current Transducers Removal and Installation Access Procedures Chapter 3 Remove the AC Current Transducers 1 Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the screws and washers that secure the lexan shields to the bottom of the drive and remove the shields Remove the bolts washers and wiring from the U and V phase AC input power terminals Remove screws and shield Remove screws and shield Bottom View Remove bolts and wiring 5 Remove the protective covers 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 Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure See Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation on page 63 Rockwell Automation
51. ach wire is properly connected during installation Use cable ties to bundle wires as shown below Red wire White wire Blue wire Black wire e Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules 230V AC Input Drive Current DC Amps AC Line Amps HP Final Torque Rating Code 146 146 119 40 180 180 147 50 4 5 5 5 Nem 40 48 7 Ibein 218 218 178 60 265 265 217 75 360 360 294 100 11 13 Nem 97 4 115 Ibein 434 434 355 125 460V AC Input Drive Current DC Amps AC Line Amps HP Final Torque Rating Code 167 167 136 4 100 207 207 1591 125 4 5 5 5 Nem 40 48 7 Ibein 250 250 204 3 150 330 330 269 6 200 11 13 Nem 97 4 115 Ibein 412 412 336 6 250 96 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Bimetal Thermostats Remove the Bimetal Thermostats Removal and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the screws and washers that secure the lexan shields to the bottom of the drive and remove the shields 4 Remove the bolts washers and wiring from the U phase AC input power terminal and the D power terminal Remove screws and shield Remove screws and shield Bottom View of Drive Remove bolts and wiring 5
52. alled a 1 kQ resistor must be connected between terminals 78 and 79 The drive heatsink temperature is monitored by a bimetal thermostat connected directly to the heatsink When the heatsink temperature is too high a Heatsink OvrIemp fault F8 occurs See Fault Descriptions in Chapter 4 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details See Figure 22 on page 113 for a circuit diagram During normal operation 1 6V DC is present between terminal 78 and drive common When an open circuit exists between terminals 78 and 79 24V DC will be present at terminal 78 to drive common If the 24V is missing the pulse transformer board may need replacement Terminals 35 and 36 and 75 and 76 are N O relay outputs The relay output between 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 TG002A EN P February 2012 39 Chapter 2 Component Test Procedures Cre ate a Fault Report Pol ai fault reports a
53. ant A stated aad ghd aca nine hanced 127 Rockwell Automation Publication 20P TGO02A EN P February 2012 5 Table of Contents 6 Rockwell Automation Publication 20P TGO02A EN P February 2012 About This Publication Who Should Use this Manual Additional Resources Preface This manual contains hardware service information for frame B PowerFlex DC drives only It is highly recommended that you obtain a copy of the PowerFlex Digital DC Drive User Manual publication 20P UMO01 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 and methods and safety precautions Additional drive service and software or firmware support information is available on the Allen Bradley Drives Service and Support website http www ab com support abdrives A complete list of spare parts for PowerFlex DC drives is available on the Allen Bradley web site at www ab com support abdrives powerflexdc PowerFlex_DC_Released_Parts pdf The following table lists publications that provide general drive information Title Publication Preventive Maintenanc
54. blication 20P TG002A EN P February 2012 Appendix A Schematics List of Schematic Diagrams Topic Page Figure 13 Circuit Board Interconnection Diagram 108 Figure 14 AC Line Measurement Points Diagram 109 Figure 15 Power Feedback Connections Diagram 109 Figure 16 Field Board and SCR Dual Diode Module Connections Diagram 110 Figure 17 Field Control Circuit Diagram 111 Figure 18 Control Circuit Input Power Diagram 111 Figure 19 Encoder Control Circuit Diagram 112 Figure 20 DC Tachometer Control Circuit Diagram 112 Figure 21 Motor Thermal Protection Control Circuit Diagram 113 Figure 22 Drive Heatsink Monitoring Control Circuit Diagram 113 Figure 23 Contactor Control Relays Control Circuit Diagram 114 Figure 24 AC Line Snubber Circuit Diagram 114 Rockwell Automation Publication 20P TG002A EN P February 2012 107 Schematics Appendix A iagram lon t Board Interconnecti ircui Figure 13 C 3d N19 N 13 pjeog 01 U09 dX ux AA 93X V INIH 0Z 9 npoj y e2eyiaju ueumnp 13A09 BAU TH Vx MX AX pueog Ajddns Jamog bury MS sue4
55. blication 20P TG002A EN P February 2012 111 Appendix A Schematics Figure 19 Encoder Control Circuit Diagram 5V P pees 5V 7 r 4 921 paio D gt H c BAI ssy gt TH s T T 5V B S21 I L i ENC i 45V m pe uou CIT ote einem T 5V al g OE i t ym I 45V H LT gt 24V LI A Voltage Regulator and Current Feedback Circuit C A h Dp 12V 5V S21 Figure 20 DC Tachometer Control Circuit Diagram S4 8 S4 7 S4 6 4 5 gt TACHOP S4 1 S2 S4 3 S4 4 112 Rockwell Automation Publication 20P TGO02A EN P February 2012 Schematics Appendix A Figure 21 Motor Thermal Protection Control Circuit Diagram 0 i t he 1 o i y leiret o 1 lt
56. bove the serial number in the lower right corner of the label Rockwell Automation Publication 20P TG002A EN P February 2012 11 Chapter 1 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 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm socket extension 230 mm Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm Wire cutter Nose pliers Crimping tools For cable terminals 1 5 240 Angle wrench Screw drivers Hat 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 an
57. connections and wires before removal to avoid incorrect wiring during reassembly 4 Carefully disconnect the cables from connectors XA XR and XFCD on the control board Disconnect cables 212 2 24 25 26 17 28 29 20 31 32 20 34 35 36 77 38 15 a be OOO iif 5 Loosen the two captive screws at the top of the control EMI shield and lower shield IMPORTANT Ifthe drive is not in a vertical position the control EMI shield will not remain open without a means of restraint Loosen screws and lower shield Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 Close the Control EMI Shield in the Service Position Close the control EMI shield in reverse order Switching Power Supply Remove the Fuses on the Switching Power Supply Circuit Board Board Fuse 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 Atthe top of the drive remove the two fuses by inserting a screwdriver in the slot on the top of the fuse holder carefully pushing down and turning the fuse counterclockwise When the fuse holder releases remove the holder and fuse Top View of Drive Switching power supply board fuses i Front of Drive Rockwell Automation Publication 20P TG002A EN P February 2012 61 Chapter3 Access Procedures Install the Fuses on the Switching Power Supply Circ
58. crews Install the AC Line Snubber Circuit Board and Resistors Install the AC line snubber board and resistors in reverse order of removal IMPORTANT Thermal grease must be applied to the bottom of the resistors before securing them to the heatsink 82 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 SCR Modules Removal and Remove the SCR Modules 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 screws and washers that secure the lexan shields to the bottom of the drive and remove the shields 4 Remove the bolts washers and wiring from the power terminals U V W C and D Remove screws and shield Remove screws and shield Bottom View of Drive Remove bolts and wiring 5 Remove the protective covers 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 6 Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure See Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation on page 63 7 Remove the bus bars in order to access the SCR modules in the drive
59. d DriveObserver are software tools for uploading downloading and monitoring system parameters Rockwell Automation Publication 20P TGO02A EN P February 2012 Introduction Component Test Procedures Chapter 2 This chapter provides general procedures for inspecting and testing the major components of the drive and includes recommendations for repairs Due to the technical nature of this product and the variety of possible applications not all possible fault conditions and troubleshooting solutions can be described in this manual Topic Page Save the Parameter Configuration 14 Visual Component 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 Procedures 27 Speed Feedback Device Tests 36 Thermistors and Thermal Switches 39 Relay Outputs 39 Create a Fault Report 40 What You Need When You Call Tech Support 40 IMPORTANT Using the diagnostic tests in this chapter should only be performed by qualified personnel and only when other corrective actions have failed All tests assume that the control board connections have been properly made For common drive symptoms and corrective actions and fault troubleshooting information see Chapter 4 Troubleshooting in the PowerFlex Digital DC Drive User Manual publication 20P UM001 Rockwell Aut
60. d 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 Fadl al ol IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley DriveExecutive DriveExplorer PowerFlex 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 Repairs Component Test Procedures Table of Contents
61. e See Remove the Pulse Transformer and Switching Power Supply Circuit Boards on page 63 Reapply power to the switching power supply board only If the power supply fuses do not blow continue with step 5 below Ifthe power supply fuses blow replace the switching power supply board 5 Remove all incoming AC voltage from the drive Check all external wiring connected to the pulse transformer board including the motor PTC if used for a possible short circuit condition Repair any short circuit conditions if found Ifno short circuit conditions exist replace the pulse transformer board Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 Testing the Control and Field Board Connections 1 Using an ohmmeter check all input and output wiring on terminals 1 40 on terminal blocks TB1 and TB2 on the control board for a possible short circuit condition Repair any short circuit conditions if found 2 Ifan 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 3 Remove the cables from connector XR and XFCD on the control board and use an ohmmeter to check between all voltage test points and common on the control board for possible short circuit conditions The ohmmeter measurements should be greater than 200 kQ If any low resistance mea
62. e Remove the Protective Covers on page 44 Remove the communication adapter and EMI shield from the control board See Remove the Communication Adapter and EMI Shield on page 46 Ifinstalled remove the resolver feedback option board See Remove the Resolver Feedback and Interface Circuit Boards on page 49 Ifinstalled remove the I O expansion circuit board See Remove the I O Expansion Circuit Board on page 53 56 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 8 Ifinstalled remove the 115V AC to 24V DC I O converter circuit board See Remove the 115V AC to 24V DC I O Converter Circuit Board on 9 Record all switch and jumper settings on the control board Refer to the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for more information Jumper Function Setting Switch S4 Configures the input voltage of the DC analog tachometer S9 Configures the input signal of analog input 1 terminals 1 and 2 Note The input signal type must also be programmed accordingly using Par 71 Anlg In1 Config S10 Configures the input signal of analog input 2 terminal 3 and 4 Note The input signal type must also be programmed accordingly using Par 76 Anlg In2 Config S11 Configures the input signal of analog input 3 terminals 5 and 6 Note The input signal type must also be programmed accordingly using Par 81 Anlg In3 Config S14 Field cur
63. e eee 83 Remove the SCR Modules esee 83 Install the SCR Modules esee 91 AC Current Transducers Removal and Installation 93 Remove the AC Current Transducers leeeseee sees 93 Install the AC Current Transducers cece eee ee eeee 96 Bimetal Thermostats Removal and Installation 97 Remove the Bimetal Thermostats uses eese 97 Install the Bimetal Thermostats ueseeee eese 101 Cooling Fan Removal and Installation sseeeeuueeee 102 Remove the Cooling Fans cere eer veo rh ede emen 102 Install the Cooling Patsy used obe e e EE de a eer 103 Chapter 4 Test With the Motor Without a Mechanical Load 105 Appendix A List of Schematic Diagrams esis 0 25 25 i Pep ts Vea quA S aye PS 107 Appendix B List of Circuit Board Layout amp xii ceci pees ERR ce EX EHE Ce 115 Pulse Transformer Board esee 116 Switching Power Supply Boatd ees ete rry e ees eons 119 Control Boatd i cn uer br eT Lies 120 Field Boatdz ci cbe EI d wath AP eee oe 121 Appendix C Listof Flow Ch tts s ee erc err iRE OE IU rel 123 Control Power Supply Failute ss 2d zd dee tcr repr ett RSS 124 Field Current Loss Failure eese 125 No Field Current cesses e 125 Low or Incorrect Field Current 0 cess cence eeees 126 SG saeaith Nahai Oi eed cnet a den scl sah ten
64. e of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid State SGI 1 1 Control 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 TG002A EN P February 2012 7 Preface Notes 8 Rockwell Automation Publication 20P TG002A EN P February 2012 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 General Safety Precautions Hardware Description Commonly Used Tools 12 Rockwell Automation Publication 20P TG002A EN P February 2012 9 Chapter 1 Before You Begin Testing Maintenance or Repairs General Safety Precautions ead the following precautions before you begin testing components performing maintenance or repairing the drive gt bP BP bb A 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 p
65. egs assemblies A malfunction of any of these devices will be indicated by either an Overcurrent fault F13 blown or tripped incoming protection devices or erratic motor operation The following procedure can be used if an armature bridge component malfunction is suspected 1 Read the General Safety Precautions on page 10 2 Verify that contactor power if used is removed 3 Verify that power to an external field supply if used is removed 4 Check the anode to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance across the SCRs lead orientation is not critical For regenerative drives see 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 Modules Removal and Installation on page 83 Rockwell Automation Publication 20P TG002A EN P February 2012 21 Chapter 2 Component Test Procedures Table 2 SCR Anode to Cathode Junction Measurements for Regenerative Drives On SCR Module SCR Measure from To Nominal meter reading Terminal Terminal 1 1 U C 4 U D 2 2 V C 5 V D 3 3 W 6 W D open circuit or megaOhms 01 01 U C range 04 U D 02 02 V C 05 V D 03 03 W C 06 W D Figure 6 Regenerative
66. er from the Drive on page 42 3 Disconnect the DPI cable from the HIM assembly Loosen but do not remove the screws that secure the bottom cover to the drive then slide the cover down and off the drive chassis Disconnect DPI cable mo ai Y Loosen screws Tightening torque 1 5 Nem 13 3 Ibsein 8 44 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 5 Loosen but do not remove the screws that secure the top cover to the drive then slide the cover up and off the drive chassis IMPORTANT The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected Loosen screws Tightening torque 1 5 Nem 13 3 Ibsein Loosen screws Tightening torque 1 5 Nem 13 3 Ibsein Q 6 Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside Pull tabs out to disconnect cable Rockwell Automation Publication 20P TG002A EN P February 2012 45 Chapter3 Access Procedures Install the Protective Covers Install the protective covers in the reverse order of removal Communication Adapter Remove the Communication Adapter and EMI Shield and EMI
67. erFlex DC drive circuit boards and components Topic Page Pulse Transformer Board Layout 116 Pulse Transformer Board to Field Board Connections uz Pulse Transformer Board to Switching Power Supply Connections 117 Pulse Transformer Board to Bimetal Thermostat Connections 117 Pulse Transformer Board to Field SCR Dual Diode Module Connections 117 Pulse Transformer Board to Control Board Connections 118 Pulse Transformer Board to Current Transducer Connections 119 Switching Power Supply Board Layout 119 Switching Power Supply Board to Control Board Connections 119 Control Board Layout 120 Control Board to Field Board Connections 120 Field Board Layout 121 Rockwell Automation Publication 20P TG002A EN P February 2012 115 AppendixB Circuit Board Layouts and Connections Pulse Transformer Board Figure 25 Pulse Transformer Board Layout Components shown within dashed lines are only on the pulse transformer board for regenerative drives gs Fd 8 e 42 Control Power Lig g n BI F ds erminal Block us neg de 8 E xo ng g L Js 8 g E p en x sp 8 A 7 a E n xo x PDA z 2 x L J Ba S F E lt 7 s aS SS er mo
68. erify that DIP switch S 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 20 on page 112 for a circuit diagram Theanalog tach signal is fine scaled using parameter 562 Anlg Tach Gain See Drive Reference and Feedback Scaling in Appendix C of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for more information Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 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 Verify that the following LEDs are functioning as expected See Figure 12 on page 38 for LED locations and switch settings LED LED On State Off State Code Color D3 Red 24V overload fuse F1 blown This 24V supply is OK fuse is self resetting when it returns to normal operating temperature D10 Green 12V supply is OK Loss of 12V power D11 Green Resol
69. ersonal 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 Safety Requirements for Employee Workplaces must be followed DO NOT work alone on energized equipment ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential m
70. es cov vs tort dece odo Pa autem cb a NL NER 49 Remove the Resolver Feedback and Interface Circuit Boards 49 Install the Resolver Feedback and Interface Circuit Boards 52 I O Expansion Circuit Board Removal and Installation 53 Remove the I O Expansion Circuit Board ssssuue 53 Install the I O Expansion Circuit Board suus 55 115V AC to 24V DC I O Converter Circuit Board Removal and Tostallatiofut d oo Doubs tate a tanto tet erence ea rh a aes eae 55 Remove the 115V AC to 24V DC I O Converter Circuit Board 55 Install the 115V AC to 24V DC I O Converter Circuit Board 56 Control Circuit Board Removal and Installation LLL 56 Remove the Control Circuit Board 0 00 cece cece eee eens 56 Install the Control Circuit Board ivl paced rct rcs 59 Control EMI Shield Removal and Closure 0 0 ccc cece eens 59 Move the Control EMI Shield 03 05 ccc eese e 59 Close the Control EMI Shield in the Service Position 61 Switching Power Supply Board Fuse Removal and Installation 61 Remove the Fuses on the Switching Power Supply Circuit Board 61 Install the Fuses on the Switching Power Supply Circuit Board 62 Pulse Transformer Circuit Board Fuse Removal and Installation 63 Remove the Fuses on the Pulse Transformer Circuit Board 63 Install the Fuses on the Pulse Transformer Circuit Board 63 Pulse Transformer and Switchi
71. figure pulse transformer circuit board 70 contactor fault 39 control circuit board install 59 remove 56 control EMI shield close 61 move 59 control power supply failure 15 cooling fans install 103 remove 102 D DC analog tachometer test 36 download parameter configuration 14 DPI HIM assembly install 43 remove 43 E Electrostatic Discharge Precaution 10 encoder test 36 Index F fault field current loss 23 heatsink overtemperature 39 main contactor 39 overcurrent 21 power failture 15 fault report create 40 field circuit board install 78 remove 77 field circuit fuses install 77 remove 77 field current loss fault 23 field SCR and dual diode modules install 80 remove 79 field SCR dual diode module test 33 frame size 11 H hardware description 11 heatsink overtemperature fault 39 1 0 converter circuit board install 56 remove 55 1 0 expansion circuit board install 55 remove 53 inspection visual 15 install AC current transducers 96 AC line snubber circuit board and resistors 82 bimetal thermostats 101 communication adapter and EMI shield 48 control circuit board 59 cooling fans 103 DPI HIM assembly 43 field circuit board 78 field circuit fuses 77 field SCR and dual diode modules 80 1 0 converter circuit board 56 0 expansion circuit board 55 protective covers 46 pulse transformer circuit board 76 pulse transformer circuit board fuses 63 resolver feedback circuit board 52 resolver i
72. h 14 on the control board Switch ohms 168 5 333 3 182 36 4 845 11668 3333 Equivalent Resistance Field Current Field S14 1 S14 2 S14 3 S14 4 S14 5 S14 6 S14 7 S14 8 Ohm Scale 1A Supply 10A OFF OFF OFF OFF OFF N 1668 2A OFF OFF OFF OFF ON mu mn 845 3A OFF OFF OFF OFF ON 560 9 zZ 5A OFF JON OFF OFF OFF Notused 333 3 10A ON OFF OFF OFF OFF OFF 168 5 baa 1 13A 14A JON OFF OFF OFF ON 129 6 17A 20A OFF ON JON OFF ON 97 3 20A o oD gocdocogdo nm zm ON OFF JON OFF OFF 83 1 Ifthe resistance measurement is incorrect replace the field board 24 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 No Field Current Note For a flow chart version of these steps see No Field Current on page 125 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Remove the Protective Covers 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 16 on page 110 for a schematic diagram If the voltage is correct continue with step 4 below e If the voltage is incorrect or missing remove power from the drive and verify the wiring to the drive and the power
73. k out all incoming power to the drive L1 L2 L3 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 DPI HIM Assembly Remove the DPI HIM 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 Disconnect the DPI cable from the HIM assembly 4 Remove the screw that secures the DPI HIM assembly to the drive 5 Carefully remove the DPI HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly UUUUU Sess af q A c io PTO woo E wr eO Cc q q q q q q Remove screw Tightening torque XS Lf 8 0 8 Nem 7 Ibin 1_ Disconnect DPI cable Install the DPI HIM Assembly Install the DPI HIM assembly in reverse order of removal Rockwell Automation Publication 20P TG002A EN P February 2012 43 Chapter3 Access Procedures Protective Cover Removal Remove the Protective Covers and Installation 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Pow
74. l connections and wires before removal to avoid incorrect wiring during reassembly 4 Remove the pulse transformer and switching power supply boards from the drive Note You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure See Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation on page 63 5 Remove the field circuit board See Remove the Field Circuit Board on page 77 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 6 Remove the two screws and washers that secure the red and blue wires from the AC line snubber board to the bus bars and remove the wires 7 Remove the three screws and washers that secure the black wires from the resistors to the bus bars and remove the wires N Regenerative Drive Shown Au p b mE m n Remove screws and wires 8 Remove the three screws and washers that secure the AC line snubber board to the drive frame and lift the board Note The wires from the resistors are connected to the board Therefore the board cannot be removed until the resistors are removed Remove Screws Rockwell Automation Publication 20P TG002A EN P February 2012 81 Chapter3 Access Procedures 9 Remove the two screws that secure each resistor six total to the drive heatsink and remove the resistors and AC line snubber board from the drive Remove s
75. ll Automation Publication 20P TG002A EN P February 2012 21 Chapter2 Component Test Procedures Figure 3 Figure 4 and Figure 5 below are examples representing gate pulse current and voltage signal measurements taken on an SCR In the figures below The current signal is taken on the testpoint XY17 2 5V offset 0 6V Drive size current The voltage signal is taken on the testpoint XY19 42 5V offset The ground signal is taken on either testpoint XY10 or XY18 Figure 3 Good SCR Gate Pulse and Armature Current Signals Example 9 Feb 96 Inpulsi su 23 Is su XY17 File Inpulsi tiF REMOTE ENABLE 13 27 59 i 60 TO e ns LOCAL 5 0 v 5V 2 gt RS 260 V OV 2 XY19 2 ms il 5 v KG 5h kS c 220 nv DC amp 25 kS s 3 5 v mi Ll 1 HFREJ 8 1 V 4 58 nv ji O STOPPED Figure 4 Good SCR Armature Voltage and Motor Current Signal Example 9 Feb 96 Chl Vara XY19 Ch Ia XV17 File EMF tiF REMOTE ENABLE 16 07 47 1 60 TO 2 n5 LOCAL 0 50 V 2 2 ns 200 nv t XY17 Peet Peter tthe 2 XY19 e nz i 50 nV DC ou 2 20 nv DC 5 kS s 3 5 V DC g L 1 FREJ 0 01 V 458 m DC g O STOPPED 22 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 Troubleshoot a Field Current Loss Fault A malfunctioning thyristor is connected to the relative gate For example
76. m E e X 3 Hs Masc o ae z ae oO c x x O5 iD t 3 ia xo L 18 8 L 18 ifm B L o xO x lt 5 T a a Cle s Fo xo Se id i EJ a oo es _ o gt x Oo i o x0 Cis g xu 8 salle are e E xo 18 gt x H 8 guls o d GLEE ga os PI 3 d B 8 3 r 83 m 8 3 8 3 amp E mS all o BB Control Power 8 g A re EJ BE erminal Block E E J Ajs e Pe ts ie Q z 25 5 io B zx IU E g ee fF iil sz i T j i E E a a cag F x 8 dE rae H E tog x Ee x gt EN S 8 amp o o Elg B E E a ge zi B N a Q9 Sr 8 on 116 Rockwell Automation Publication 20P TGO02A EN P February 2012 Circuit Board Layouts an d Connections Appendix B Table 19 Pulse Transformer Board to Field Board Connections Pulse Transformer Board Connector X3 Field Board Connector 2 Description 1U1 field sync signal from U1 1V1field sync signal from V1 Table 20 Pulse Transformer Board to Switching Power Supply Connections Switching Power Supply Board Connector Description Rectified U2 V2 voltage XUV Pulse to Pin Number Transformer Boa
77. mation Publication 20P TG002A EN P February 2012 49 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 ee Te eee nase 9 T XA I LJ O 009099020000003 XP3 AEAEE P3 15 Remove screws and board Tightening torque for re assembly is i FEEEEEEREE 0 7 Nem 6 2 Ibein A 1 B Ln oo O O 22 23 24 25 26 27 28 29 30 3i 32 33 34 36 36 37 38 39 40 E O000000000 0000000000 is ABCH Ar A B B Zt ZCOMV 12345967891 5 5117 9 20 OOOOO Q0000000 OOO0000000 0000000000 50 Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 6 Remove
78. nd output sides of the contactor If any ofthe voltage measurements is incorrect or missing remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems Usinga voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5 V offset See Figure 1 on page 18 and Figure 2 on page 19 for location of the testpoints Also see Figure 14 on page 109 for a schematic diagram Table 1 Combined AC Line Input Signal Testpoints Incoming AC Phases MeasureFrom To Testpoint Peak to Peak RMS Line Voltage Testpoint Measurement Measurement Van XY22 XY18 240 VAC Van x YIB 1 42 VAC 0 500 V Van XY22 XY18 480 VAC Vai Xv X18 2 95 VAC 1 040 V Van XY22 XY18 575 VAC Van Xv X18 2 85 VAC 1 007 V Van XY22 XY18 690 VAC ar xvn X18 3 45 VAC 1 220 V gS Fen h SE tik REMOTE EWARELE l2 Jb BE i Tu 5 oe Local 1 88 W T r l i 1 5 AG IIV ii as 3 2 ng HFRES 8 82 v Bs n STOPPED 20 Rockwell Automation Publication 20P TGO02A EN P February 2012 Troubleshoot an Armature Bridge Failure Component Test Procedures Chapter 2 Ifany of the voltage measurements above are incorrect or missing continue with step 5 below Ifthe voltage measurements above are correct but the value of parameter 466 AC Line Voltage is incorrect replace
79. ng Power Supply Circuit Boards Removal abd I stallatiotizai deus bua eeu tesi obse da orar eR ri T uds 63 Remove the Pulse Transformer and Switching Power Supply Circuit BOSE Shank undis bu Radar hanson tana hd qd a a MT LEE 63 Configure the Pulse Transformer Circuit Board 70 Install the Pulse Transformer and Switching Power Supply Boards 76 Field Circuit Fuses Removal and Installation Lsuuuu 77 Remove the Field Circuit Fuses cccccceceececececens 77 Install the Field Circuit Puses 22 E eher t OR a 77 Field Circuit Board Removal and Installation 0000 00 TI Remove the Field Circuit Board c ccc c eee eeececeeees 77 Install the Field Circuit Board a i ceecce ice et orate ee ox enu 78 Rockwell Automation Publication 20P TG002A EN P February 2012 Start Up After Repair Schematics Circuit Board Layouts and Connections Flow Charts Index Table of Contents Field SCR and Dual Diode Modules Removal and Installation 79 Remove the Field SCR and Dual Diode Modules 79 Install che Field SCR and Dual Diode Modules 80 AC Line Snubber Circuit Board and Resistors Removal and Installati nzsz e ere ce oe Oto tel ESO eo in ser teat 80 Remove the AC Line Snubber Circuit Board and Resistors 80 Install the AC Line Snubber Circuit Board and Resistors 82 SCR Modules Removal and Installation 0c ee eee e
80. nnnnnmnnnmononsnnonnsnannannmnon nmnsrnsnsonsonsonsnsnsonsonsonsonson non 24V VI C o Bbps D3 0V24 Cg oo n Ba uu C 5V ipe 45V Covs D26 0V5 H p D11 D11 H mew C VR 1 45V pos 1 12V pos EE S1 424V pos 1 L m ER 38 amp Rockwell Automation Publication 20P TG002A EN P February 2012 Thermistors and Thermal Switches Relay Outputs Component Test Procedures Chapter 2 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 25 on page 116 for terminal block location Motor overheating is typically identified by a Motor Over Temp fault F16 See Fault Descriptions in Chapter 4 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details See Figure 21 on page 113 fora circuit diagram e Ifa thermal switch is used a 1 kQ resistor must be placed in series between the switch and either terminal 78 or 79 If neither a thermistor PTC or a thermal switch is inst
81. nterface circuit board 52 SCR modules 91 switching power supply circuit board 76 switching power supply circuit board fuses 62 Rockwell Automation Publication 20P TG002A EN P February 2012 127 Index 128 L layout drawings circuit boards 115 motor overheating 39 move control EMI shield 59 0 outputs relay 39 overcurrent fault 21 overtemperature heatsink 39 P parameter configuration download 14 save 14 power failure fault 15 protective covers install 46 remove 44 PTC 39 pulse transformer circuit board configure 70 install 76 remove 63 test 32 pulse transformer circuit board fuses install 63 remove 63 relay outputs 39 remove AC current transducers 93 AC line snubber circuit board and resistors 80 bimetal thermostats 97 communication adapter and EMI shield 46 control circuit board 56 cooling fans 102 DPI HIM assembly 43 field circuit board 77 field circuit fuses 77 field SCR and dual diode modules 79 0 converter circuit board 55 0 expansion circuit board 53 protective covers 44 pulse transformer circuit board 63 pulse transformer circuit board fuses 63 resolver feedback circuit board 49 resolver interface circuit board 49 SCR modules 83 switching power supply circuit board 63 switching power supply circuit board fuses 61 remove power 42 resolver feedback circuit board install 52 remove 49 resolver interface circuit board install 52 remove 49 S safety precautions 10
82. ode 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 sending an erroneous signal to your systems field devices causing unintended machine motion causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance 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 TG002A EN P February 2012 Before You Begin Testing Maintenance or Repairs Chapter 1 Hardware Description The PowerFlex DC drive contains a power structure that has an armature and field supply The armature supply consists of a three phase full wave rectified dual bridge capable of two or four quadrant output The field supply consists of single phase full wave rectified bridge Also associated with the power structure are incoming line protection devices and contactor and dynamic brake control circuits Verify that you are working on a frame B drive by checking the data nameplate located on the side of the drive The frame size is printed just a
83. olver feedback option board See Remove the Resolver Feedback and Interface Circuit Boards on page 49 5 Remove the plug in I O terminal blocks with the wiring kept in place D 7 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 Remove two screws Tightening torque 1 0 Nem 8 9 Ibein Carefully pull the I O expansion board off connector XBB on the control board Rockwell Automation Publication 20P TG002A EN P February 2012 53 Chapter3 Access Procedures 8 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 Nem 8 9 Ibein 9 Install one screw in the lower left corner of the control board Qe Sa Fim Die Per oer oy ee Ay ee et au TOUT m m ts LA A B B Zs Z con VP LOL LOL OLOR A Install screw Tightening torque 1 0 Nem 8 9 Ibein 54 Rockwell Automation Publication 20P TG002A EN P February 2012 115V AC to 24V DC 1 0 Converter Circuit Board Removal and Installation Access Procedures Chapter 3 Install the 1 0 Expansion Circuit Board Install the I O expansion board in reverse order of removal Remove the 115V AC to 24V DC 1 0 Converter Circuit Board 1 Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Remove the protective covers from the drive See Remove the Protecti
84. omation Publication 20P TG002A EN P February 2012 13 Chapter2 Component Test Procedures Save the Parameter Configuration 14 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 839 3 Select Device gt HIM and press 839 Doone ofthe following fthere are no existing HIM Sets enter a name using the A and buttons to select the desired characters and press eo fthere is an existing HIM Set press e to overwrite it or select No using the P 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
85. 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 Associated Description Location See Connector 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 XA 6 5V digital supply ground GNDD XY7 Figure 2 on page 19 XA 2 XA 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 XY8 Figure 1 on page 18 XA 16 24V terminal block GNDV XY9 Figure 1 on page 18 XA 15 24V terminal block ground 5VEXP 5VEXP Figure 2 on page 19 XP3 1 XP3 2 XP3 3 5V for DPI expansion 12VEXP 12VEXP Figure20n 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 124 Rockwell Automation Publication 20P TG002A EN P February 2012 15 Chapter 2 16 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 Ifthe voltage is present and cor
86. rd Point 4 1U2 ES 1V2 a 1 approx 150 300V DC not used not used Common Table 21 Pulse Transformer Board to Bimetal Thermostat Connections Pulse Transformer Board Connector X4 Pin Number to Pin Number Bimetal Thermostat Connector 1 zx 2 E A Description 24V supply through resistor 24V common de Module Connections Table 22 Pulse Transformer Board to Field SCR Dual Dio Pulse Transformer Board Connector Description Gate signal G1 XP Pin Number to Pin Number Field SCR Dual Diode Module Connector 1 enh 2 Fastons 3 mi 4 1 Common cathode K1 and K2 for both field SCRs A Gate signal G2 Rockwell Automation Publication 20P TG002A EN P February 2012 117 AppendixB Circuit Board Layouts and Connections Table 23 Pulse Transformer Board to Control Board Connections Pulse Transformer Board Connector XR Pin to Pin Number Number 1 1 2 2 3 3 4 4 5 5 6 6 7 gi 8 8 9 9 10 0 11 1 12 12 3 3 14 4 15 15 6 6 17 7 8 8 19 9 20 20 21 21 22 22 23 23 24 24 25 25 26 26 27 27 28 28 29 29 30 30 31 31 32 32 33 33 34 34 Control Board Connector XR 118 Rockwell Automation Publication 20P TG002A EN P February 2012 Description Gate signal G1 field SCR1 Gate signal G2 field S
87. re critical for analysis and repair of modules returned to the factory At a minimum perform and record the following Record the contents of the fault queue faults and times of occurrence See the PowerFlex Digital DC Drive User Manual publication 20P UMO001 for detailed Fault and Alarm codes and descriptions e Make a record of any burn marks on the printed circuit boards cabling bus bars and SCR modules Makearecord ofany liquid and condensation marks on the printed circuit boards components and mechanical parts Makea record of the amount of dust and other additional particles on the drive and drive components e Make a record of any mechanical damage to the drive and drive components e Record the size and type of main fuses Record any other important marks and damage What You Need When You When you contact Technical Support please be prepared to provide the Call Tech Support following information Order number Product catalog number and drives series number if applicable Product serial number Firmware revision level 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 Status1 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
88. rect 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 Remove the Fuses on the Switching Power Supply Circuit Board on page 61 for fuse location e Ifthe fuse is blown continue with step 6 below If the fuse is not blown replace the switching power supply board Replace the fuse on the switching power supply board See Install che Fuses on the Switching Power Supply Circuit Board on page 62 Disconnect the cable at connector XA on the control board See Figure 27 on page 120 for location of connector XA Apply AC control power to the drive Ifthe fuse blows continue with Testing the Switching Power Supply and Pulse Transformer Boards below 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 fuses on the switching power supply board See Switching Power Supply Board Fuse Removal and Installation on page 61 Remove the switching power supply board from the driv
89. rent resistors setting n addition the value selected with switch S14 must be entered in Par 374 Rated Field Curr in the control software when the drive is commissioned 14 1 14 2 14 3 14 4 14 5 14 6 14 7 not used 14 8 not used 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 Configuration of the control circuit board to the appropriate drive size This value is set to the appropriate size at the factory Q5 C2 C20 C20 C2 CO C2 C2 CO CO CO C2 C2 C2 C2 C2 S20 Monitoring of the Z channel of the Digital Encoder on connector XE2 Off Position Z channel monitored On Position Z channel not monitored The S20 setting should match the value selected in Par 652 Encoder Err Chk for example if S20 Off then Par 652 1 Enabled 821 Encoder power 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 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Rockwell Automation Publication 20P TG002A EN P February 2
90. rom the drive v Apply power to the switching power supply board only Is the fuse blown Replace the switching power supply board Use an ohmmeter to verify that all terminals on the control board terminal blocks are not short circuited Remove cable from connector XR on control board and ohmmeter all voltage testpoints and commons to verify no short circuits values should be 200 kohm Are terminals short circuited Any values lower than 200 kohm Remove all power from the drive v Check all external wiring to the pulse transformer board including the motor PTC if used for a short circuit condition Repair short circuits Replace the control board Y Remove cable from connector XFCD on the control board and ohmmeter between pins 1 and 2 and 3 and 2 on cable to verify no short circuits values should be gt 200 kohm Any values lower than 200 kohms Replace the field board Replace the pulse transformer board Repair the short circuits Rockwell Automation Publication 20P TG002A EN P February 2012 Flow Charts Appendix C Field Current Loss Failure Measure the voltage at terminals U1 V1 Is the correct voltage present at U1 V1 No Remove AC power and remove and test the fuses
91. s 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 TG002A EN P February 2012 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
92. s Procedures Chapter 3 17 Remove the bolts and washers that secure the upper horizontal bus bar to the SCR modules and remove the bus bars Non Regenerative Drive Remove bolts and washers 18 Remove the bolts and washers that secure the lower horizontal bus bar to the SCR modules and remove the bus bar Non Regenerative Drive Remove bolts and washers Rockwell Automation Publication 20P TG002A EN P February 2012 89 Chapter3 Access Procedures 19 Remove the bolts washers and wires that secure the U V and W phase power terminals to the SCR modules Non Regenerative Drive Remove bolts and washers 20 Remove the screws and washers that secure each SCR module to the heatsink and remove the SCR module from the drive Non Regenerative Drive Remove screws and washers 90 Rockwell Automation Publication 20P TG002A EN P February 2012 Install the SCR Modules Access Procedures Install the SCR modules in reverse order of removal Chapter 3 IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heatsink Use the following table to determine the proper tightening torque for the SCR modules installed on the heatsink 230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque SK 20P S7F48 2 5 4 0 Nem 22 35 4Ibein SK 20P S7F78 2 5 4 0 Nem 22 35 4 Ibein SK 20P S7F49 4 5 5 5 Nem 40 48 7 Ibein SK 20P S
93. s in reverse order of removal IMPORTANT Thermal grease must be applied to the bottom of the Bimetal Thermostats before securing them to the heatsink Rockwell Automation Publication 20P TG002A EN P February 2012 101 Chapter3 Access Procedures Cooling Fan Removal and Remove the Cooling Fans Installation 102 1 Remove power from the drive refer to Remove Power from the Drive on page 42 2 Remove the two screws that secure the rear Lexan shield to the bottom of the drive and remove the shield Bottom View Remove screws and shield 3 Locate the Cooling Fan terminal block on the bottom of the drive and loosen the screws that secure the fan power supply wires red and black to the terminal block and remove the wires IMPORTANT _ Note the color and location of each of the wires connected to the cooling fan to ensure that each wire is properly connected during installation Loosen screws Rockwell Automation Publication 20P TG002A EN P February 2012 Access Procedures Chapter 3 4 Using a flathead screwdriver carefully pry the fan cover plate off of the fan housing Remove fan cover plate 5 Remove the two screws that secure the fan to the drive frame You must insert a Phillips head screwdriver through the hole in the front of the fan housing to reach and remove the screws Remove the fan from the drive Insert screwdriver through hole in fan housing Remove screws Install the Cooling
94. s that secure the D terminal bus bar to the terminal isolation bar 11 Remove the screw and washer that secures the wire to the bus bar and the bolt and washer that secures the U phase bus bar to the SCR module and remove the bus bar 11 Remove bolt screw and washers 11 Remove bus bar 10 Remove bolt and washer from isolation bar Continue with Remove the Bimetal Thermostats on page 101 Rockwell Automation Publication 20P TG002A EN P February 2012 99 Chapter3 Access Procedures Remove the Bus Bars from a Non Regenerative Drive 12 Remove the three bolts and washers that secure the U Phase and D power terminals to the isolation bar Non Regenerative Drive U Phase Terminal D Terminal Remove bolts washers and wires 13 Remove the bolts and washers that secure the wires and bus bars to the U phase SCR Module and D power terminal and remove the bus bars Non Regenerative Drive Remove bolts washers and wires Continue with Remove the Bimetal Thermostats on page 101 100 Rockwell Automation Publication 20P TGO02A EN P February 2012 Access Procedures Chapter 3 Remove the Bimetal Thermostats 1 Remove the solder from the connections on the two leads of the bimetal thermostats 2 Remove the bimetal thermostats from the heatsinks by unscrewing them at the base Regenerative Drive Shown Remove solder and Install the Bimetal Thermostats Install the Bimetal Thermostat
95. stpoints Upper Right m 12VEXP O OVEXP O 45VEXP XY7 q jo ao S12 S18 S4 ON rises aly o sa S5sE o 9 co o Rockwell Automation Publication 20P TG002A EN P February 2012 19 Chapter2 Component Test Procedures Troubleshoot an AC Undervoltage Fault 1 Read the General Safety Precautions on page 10 If the drive faults with an AC Undervoltage Fault F4 or parameter 466 AC Line Voltage does not equal the expected incoming AC line voltage measure the AC line input signals as directed in the steps below 2 Remove the protective covers from the drive See Remove the Protective Covers on page 44 3 Usinga voltmeter measure the voltage at terminals U V and W of the drive Note If an AC input contactor is used the voltage must be measured on both the input a
96. surements are found replace the control board Usingan 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 If a lower resistance value is measured replace field board Rockwell Automation Publication 20P TG002A EN P February 2012 17 Chapter2 Component Test Procedures Figure 1 Control Board Testpoints Upper Left o o o o o o o o 9o o o Sz QA LIE XY18 P XYi7 Q XY19 N amp A zl E O ee S OK XY9 XY12 XY11 XY6 XY5 18 Rockwell Automation Publication 20P TG002A EN P February 2012 Component Test Procedures Chapter 2 Figure 2 Control Board Te
97. 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 23 on page 118 Ifthe measurements on the XR cable are correct replace the pulse transformer board If the drive is running unstable or faults with an Overcurrent Fault F13 an armature bridge failure may have occurred All of the signals going to and coming from the SCR bridges are transmitted via the ribbon cable connected to XR on the control board and can be measured at these points See Figure 27 on page 120 for location of the XR connector on the control board Note If using an AC input contactor this step requires that the cable remain connected to the XR connector on the control board and that an adapter be used to measure these signals 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Remove the Protective Covers on page 44 3 Ifusinga DC output contactor disconnect the cable from XR on the control board and measure the signal for each SCR gate as indicated in the table below Signal Name XR Cable Pin Gate Note MP MN m 2 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 45V MP 34 Positive bridge MP active when high 45V Rockwe
98. tion before continuing A ATTENTION Power must be applied to the drive to perform the following start Verify that the input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected BR BY N Verify that the control board DIP switches are set correctly See Install the Control Circuit Board on page 59 for more information wn Apply power to the control circuits terminals U2 and V2 of the drive 6 Verify that the following parameter values are set correctly e 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 TG002A EN P February 2012 105 Chapter 4 106 Start Up After Repair 280 Nom Mtr Fld Amps is set to the rated motor nameplate field current e 374 Dry Fld Brdg Amps is set to the rated current of the field bridge regulator Energize the drive 8 Measure the field current and verify that the value is reflected in parameter 10 11 12 13 14 15 16 234 Fld Current Pct Run the following applicable Autotune procedures detailed in Chapter 2 of the PowerFlex Digital DC Drive User Manual publication 20P UMOOI T
99. uit Board Install the fuses on the switching power supply board in reverse order of removal IMPORTANT Insert the 3 15A 250V fuse in the fuse holder designated F1 Insert the 2 5A 250V fuse in the fuse holder designated F2 Top View of Drive F123 15A F2 2 5A 250V fuse 250V fuse i 4 Front of Drive 62 Rockwell Automation Publication 20P TG002A EN P February 2012 Pulse Transformer Circuit Board Fuse Removal and Installation Pulse Transformer and Switching Power Supply Access Procedures Chapter 3 Remove the Fuses on the Pulse Transformer Circuit Board Read the General Safety Precautions on page 10 Remove power from the drive See Remove Power from the Drive on page 42 Move the control EMI shield See Move the Control EMI Shield on Usinga fuse puller carefully remove the three fuses from the fuse holders on the pulse transformer board Remove fuses ed Install the Fuses on the Pulse Transformer Circuit Board Install the fuses on the pulse transformer circuit board in reverse order of removal Remove the Pulse Transformer and Switching Power Supply Circuit Boards Removal and Installation Circuit Boards Note The switching power supply circuit board is located on the back of the pulse transformer circuit board You must remove both boards in order to replace either board 1 2 3 Read the General Safety Precautions on page 10 Remove power from the drive
100. une 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 Configure the Speed Feedback Parameters Tune the Speed Regulator Make configuration changes that allow the HIM to issue start and speed commands Start the drive by pressing p 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 UMO01 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 UMO001 for assistance If any of these measurements are incorrect repeat steps 8 15 If the measurements are still incorrect repeat the appropriate procedures in Chapter 2 Component Test Procedures beginning on page 13 Rockwell Automation Pu
101. ut 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 5 the voltage level should be 2 5 5 4V If S21 is set to ENC_12 the voltage level should be 5 AV 15 2V For reference see Figure 19 on page 112 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 counter clockwise direction as viewed from the commutator end Channel A leads Channel B Each differential channel has an inverted and non inverted signal Power for the encoder is provided internally and is capable of 200mA of current with a current foldback feature that protects the power supply should the current draw exceed 200mA If different power supply requirements exist for the chosen feedback device the supply must be provided external to the drive The frequency is proportional to speed and the pulse rate of the encoder referred to as the Pulse Rev rating on the nameplate The speed of the motor can be calculated by Speed RPM Frequency Hz x 60 Pulses Revolution Check the DC Tachometer V
102. ve Covers on page 44 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Remove the plug in I O terminal blocks with the wiring kept in place 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 ME LEASIEL Remove two screws Tightening torque 1 0 Nem 8 9 Ibein Rockwell Automation Publication 20P TG002A EN P February 2012 55 Chapter3 Access Procedures Control Circuit Board Removal and Installation 6 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 Nem 8 9 Ibein Install the 115V AC to 24V DC 1 0 Converter Circuit Board Install the 115V AC to 24V DC I O converter board in reverse order of removal Remove the Control Circuit Board 1 Read the General Safety Precautions on page 10 Save the drive and adapter parameter configuration to a HIM Set or by down loading the drive and adapter parameters to an offline database file using DriveExecutive Refer to the PowerFlex DC Digital Drive User Manual publication 20P UM001 for information on using the HIM or the on line Help provided with DriveExecutive for more information on HIM Sets or using the HIM Remove power from the drive See Remove Power from the Drive on page 42 Remove the protective covers from the drive Se
103. ver feedback board voltage is Voltage error on resolver feedback OK board D12 Blue Switch S1 is set to 24V for encoder S1 is not set for 24V signal output on TB2 D16 Yellow Switch S1 is set to 12V for encoder S1 is not set for 12V signal output on TB2 D18 Green Switch S1 is set to 5V for encoder S1 is not set for 5V signal output on TB2 D26 Red Resolver feedback board is in reset Resolver feedback board not in reset mode mode If any of the LEDs that should turn on when control power is applied fail to do so verify that the resolver interface and resolver feedback boards are properly seated on the appropriate connectors XRE P2 P3 If problems persist replace the resolver interface and or resolver feedback board Measure the signal voltage at the testpoints as indicated in the following table See Figure 12 on page 38 for testpoint locations Testpoint to Testpoint Measurement 12V 0V12 12V DC 5 12V 0V12 12V DC 5 24V_VI 0V24 24V DC 5 5V 0V5 5V DC 5 If any of the voltage measurements fails replace the resolver interface board Rockwell Automation Publication 20P TG002A EN P February 2012 37 Chapter2 Component Test Procedures Figure 12 Resolver Interface Board Testpoint Locations D10 0V12 24V V 34 0V24 D12 LB e a S2 Internal supply pos S2 External supply pos
104. y in parameter 374 Drv Fld Brdg Cur and DIP switch S14 is configured to correctly according to the instructions in the PowerFlex Digital DC Drive User Manual publication 20P UMO001 and make any necessary corrections See Control Board on page 120 for DIP switch location Verify that the value of parameter 280 Nom Mtr Fld Amps matches the rated field current value on motor nameplate and make any necessary corrections Remove the protective covers from the drive See Remove the Protective Covers 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 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 switc

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