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20P-TG001 - Rockwell Automation

1. Rockwell Automation Publication 20P TG001B EN P October 2011 21 Chapter2 Component Test Procedures Troubleshoot an AC If the drive faults with an AC Undervoltage Fault F4 or parameter 466 AC Line Voltage does not equal the expected incoming AC line voltage measure the Undervoltage Fault AC line input signals as directed in the steps below 1 Read the General Safety Precautions on page 12 2 Remove the protective covers from the drive Refer to Protective Cover Removal and Installation on page 48 3 Using a 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 and output sides of the contactor If any of the voltage measurements is incorrect or missing remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems Usinga voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5 V offset See Figure 1 on page 20 and Figure 2 on page 21 for location of the testpoints Also see Figure 13 on page 113 for a schematic di
2. Ut vi l VE T L OF 4 seg den C To Pulse 1M 1M vi Transformer YT Board X3 GP mM 1M uz Connector Od e SONETS P E ab XP 2 XP 3 aI p ea E AN XPA A 2 bh M es uL Lil ll D1 Ci To Motor Field Connections Figure 18 Field Control Circuit Diagram 2 415V XFCD 1 J 45V XFCD 3 XFCD 4 LB 814 8 814 7 814 6 14 5 14 4 14 3 514 2 14 1 A io o io 2o e o o o o o o e o e E o o e e o e e e o a eo e o ceo co ceo eo eo ceo e e e a 4 4 4 a 4 4 4 4 4 XFCD 2 1 LA Rockwell Automation Publication 20P TG001B EN P October 2011 115 Appendix A U2 O Schematics Figure 19 Control Circuit Input Power Diagram V2 O ih 230 VAC or 115 VAC input o batts To Switch Mode Power
3. 116 Supply SMPS Figure 20 Encoder Control Circuit Diagram 5V 5V i r S21 I qaaa D gt S m 45V D I tor 45V En 45V r r 921 p 1 Do H T T ul 45V rt 5V Ou gt EP sv D i i S21 pois U E RT PI CJ M 45V eH 24V LI Voltage Regulator and Current Feedback Circuit f VA 1 3 tavl 5V S21 Rockwell Automation Publication 20P TG001B EN P October 2011 Figure 21 DC Tachometer Control Circuit Diagram M3 o M3 UL S4 78 Schematics Appendix A S4 8 S4 7 S4 6 4 5 MH c3 I OHH ee S 1 S2 4 3 S4 4 gt gt TACHOP Figure 22 Motor Thermal Protection Control Circuit Diagram 24V L od Tq T XR 32 OVI 1K Rockwell Automation Publication 20P TG001B EN P October 2011 Overtemp Fault Signal 117 Appendix A Schematics Figure 23 Drive Heatsink Monitoring Control Circuit Diagram Control Board
4. mue eerie HL 19 xA E L O 2003 XP3 P3 15 UUUTUUUUU Ceecee Remove screws and board Tightening torque for re peseeccess assembly is S1 El 0 7 Nem 6 2 Ib in p LI LL O O 22 23 24 25 26 27 28 29 30 3 32 33 34 35 36 37 38 39 40 SU ooooooooo oooooooooo emm ABCH A Ay Bt B Zt zCOMV 4123459678 91 117 8 5511 920 OOOOO 00000000 229909 p299999999 0999999999 54 Rockwell Automation Publication 20P TG001B EN P October 2011 Remove stand offs Tightening torque for re assembly is 0 7 Nem 6 2 Ib in 6 Remove the three stand offs from the resolver interface board Access Procedures Chapter 3
5. 45V XR 10 XR 10 S E i gt ors XR 12 XR 12 L Eu X4 1 AN XSW 1 i 24V X4 2 0V24 XSW 2 Figure 24 Contactor Control Relays Control Circuit Diagram 0V24 XR U6 U2 A XR A AA XR XR V V K7 K8 24V Q O O O 35 36 75 76 118 Rockwell Automation Publication 20P TG001B EN P October 2011 Appendix D Circuit Board Layouts and Connections List of Circuit Board The following images and tables detail the connection points for the frame A Lay outs PowerFlex DC drive circuit boards and components Topic Page Pulse Transformer Board Layout Pulse Transformer Board to Field Board Connections Pulse Transformer Board to Switching Power Supply Connections Pulse Transformer Board to Bimetal Thermostat Connections Pulse Transformer Board to Field SCR Dual Diode Module Connections P P ulse Transformer Board to Control Board Connections ulse Transformer Board to Current Transducer Connections Switching Power Supply Board Layout Switching Power Supply to Fan Connections Switching Power Supply Board to Control Board Connections Control Board Layout Control Board to Field Board Connections Field Board Layout SbBBSBEBBRRERSRRIS iO O1 OT I 109 100 J IO
6. gt x lt XY8 XY10 G O O 000 I ID XY9 xvi2 xvii XY6 XY5 C naugugaugaagadgacu pnagagaagaagau E ek Bet ze ceo 20 Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 Figure 2 Control Board Testpoints Upper Right a 12VEXP 4 OVEXP 5VEXP XY7
7. Drive DC ACLine HP DIP Switch S3 DIP Switch 4 Peak Amps Amps 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 S4 1 4 2 43 S4 4 S45 S4 6 47 S4 8 Code 7P0 7 57 15 ON ON ON 9P0 9 74 2 ON ON ON 012 1 98 3 ON ON ON 020 20 16 5 ON ON ON 029 29 24 75 ON ON ON 038 38 31 10 ON ON 055 55 45 15 ON ON ON ON 073 B 60 20 ON ON ON ON 093 93 76 25 ON ON ON ON 110 110 90 30 ON ON ON ON Table 17 460V AC Input Drives Drive DC ACLine HP DIP Switch S3 DIP Switch S4 Pod Amps Amps 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 422 S4 3 S4 4 S4 5 4 6 S4 7 S4 8 Code 4P1 41 33 2 ON ON ON 6P0 6 49 3 ON ON ON 010 10 82 5 ON ON ON 014 4 114 75 ON ON ON 019 19 155 10 ON ON ON 027 27 221 15 ON ON ON 035 35 286 20 ON ON ON 045 45 368 25 ON ON ON ON 052 52 425 30 ON ON ON ON 073 73 596 40 ON ON ON ON 086 86 703 50 ON ON ON 100 100 81 7 60 ON ON ON ON 129 129 1054 75 ON ON ON ON 2 Continue with Install the Configured Pulse Transformer Circuit Board and the Switching Power Supply Circuit Board below Install the Configured Pulse Transformer Circuit Board
8. 12V C 12V ay C az P2 P3 D10 j 5V 5V INE C f Covs 05 0V12 C 0v12 D26 ap D11 DM 24V V 24V M A C p Mo D3 v24 P C VR HR Cea lt lt Eme us poan Eb x ICE ANZ S1 5V pos Q 1 12V pos DB m m EN 1 24V pos 8 OG e m zB gt ax se el FEN a o S2 Internal supply ps EARS S2Externalsupplypos L Q Q C gp re m TB1 TB2 40 Rockwell Automation Publication 20P TG001B EN P October 2011 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 120 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 22 on page 117 for a circuit diagram e Ifa thermal switch is used a 1 kQresistor must be placed in series between the switc
9. Note 6 x 665 kohm resistors t He e 1M Tuo e 1M0 iud 1mo e iw 1v0 e iw Le m e iw lL Two Rockwell Automation Publication 20P TG001B EN P October 2011 113 Appendix A Schematics SCR Module 1 SCR Module 01 G01 K01 K04 G04 LL e il 67 45 e e Wl 11 G1 K1 K4 G4 SCR Module 01 G01 K01 K04 G04 LTT ii Figure 15 SCR to Pulse Transformer Board Gate Lead Pinout Regenerative Drive Diagram SCR Module 2 54 7 6 G2 K2 K5 G5 SCR Module 02 G02 K02 K05 G05 Lf JL SCR Module 3 SCR Module 03 G03 K03 K06 G06 LII 67 45 5 4 76 Hil O r l G3 K3 K6 G6 Figure 16 SCR to Pulse Transformer Board Gate Lead Pinout Non regenerative Drive Diagram SCR Module 02 G02 K02 K05 G05 LIU ii 114 Rockwell Automation Publication 20P TG001B EN P October 2011 SCR Module 03 G03 K03 K06 G06 LT JL Schematics Appendix A Figure 17 Field Board and SCR Dual Diode Module Connections Diagram Incoming AC Line
10. Pin Pin Number to 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 122 Rockwell Automation Publication 20P TG001B EN P October 2011 Description Gate signal G1 field SCR1 Gate signal G2 field SCR2 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 Switching Power Supply Board XUV i 1D2 xvi Pulse Transformer Board Connector XTA Circuit Board La
11. Lus LI zee ud f XA m LI Oo XP3 Resolver interface 15 board E i benoanounun si BI H EH 6 oo O O 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 i OOOOO00000 0000000000 ABCH A A B BZ ZCOMN 12345967989 1 12 BY 5 6 1 15 S 20 OOOOO O0000000 SE eee aes Rockwell Automation Publication 20P TG001B EN P October 2011 55 Chapter3 Access Procedures Remove screws and board Tightening torque for re assembly is 0 7 Nem 6 2 Ib in 56 7 Remove the four hexalobular screws that secure the resolver interface board to the control board and remove the resolver interface board IMPORTANT The resolver interface board is connected to the control board below it via a stacker connector pin at connector XRE Lift the resolver interface board straight up during removal to avoid any damage to the connector pin dia Pee epee renee ogre ODE XR Et XA i O XP3 E E
12. erou pug v 9 8 SInpojA pj8td o0oooooQo ooo 2 VOZIX Ax 9095 6055 509 vix 2093 peog lt zal z7 a PWO y asind 9 or ax 893 z9 v9 peog 01007 ux PA x lt vx x dx eax S VX 03x ex x 3 pjeog p 8H B w i wn aN LAA dA i preog Adang NX T8 og DUIM x und T Uej e Urejuo2 S8AUp Y SWE IIE JON 810N Ue Duijo03 Rockwell Automation Publication 20P TG001B EN P October 2011 112 Schematics Appendix A Figure 13 AC Line Measurement Points Diagram AJ U XR 15 100 K 15 asy gt a i i 5v e 15V A5 XY21 V XH 16 100 K e e 15 V 15 XY18 XR 17 100 K e ud Figure 14 Power Feedback Connections Diagram Hardware connections to power structure bus bars U v w C D 0 EE m XR19 Note XR18 XR15 Note B XR16 Note f XR17 Note E 4 Note
13. 44 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 Switching Power Supply Fuse Remove the Fuse on the Switching Power Supply Circuit Board Removal and Installation IMPORTANT The fuse used for the switching power supply circuit board depends on the revision of the board e Fuse for switching power supply circuit board SW 1 31 rev H amp below 5x20mm 1A 250V Fuse e Fuse for switching power supply circuit board SW 1 31 rev I amp above 5x20mm 2 5A 250V Fuse 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 On the top of the drive remove the fuse 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 Remove fuse holder to replace fuse Install the Fuse on the Switching Power Supply Circuit Board Install the fuse on the switching power supply board in reverse order of removal Rockwell Automation Publication 20P TG001B EN P October 2011 45 Chapter3 Access Procedures Field Circuit Fuse Removal Remove the Field Circuit Fuses and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 On the bottom of the drive
14. 78 Remove the AC Current Transducers 0c0c eee ee eeeee 78 Install the AC Current Transducers 0cccceceececnees 84 Rockwell Automation Publication 20P TG001B EN P October 2011 Start Up After Repair Schematics Circuit Board Layouts and Connections Flow Charts Index Table of Contents Power Traces Circuit Board Removal and Installation 85 Remove the Power Traces Circuit Board suu 85 Install the Power Traces Circuit Board 0 0 cece eee eens 88 Field SCR Dual Diode Module and Field Circuit Board Removal and Install tloft 22 euet Sau dediti e seule wenn ees as ra EE 88 Remove the Field SCR Dual Diode Module and Field Circuit Board css o veTet als ub uon rasura drea wi Ea Sc rft itd 88 Install the Field SCR Dual Diode Module and Field Circuit Bo tdsccudeta fed hub dioe din cen Eo te end 93 Bimetal Thermostat Removal and Installation LL usus 94 Remove the Bimetal Thermostat oe op rev eaa I 94 Install the Bimetal Thermostat eese 94 SCR Module Removal and Installation ssseeueue 95 Remove the SCR Modules 5 eee reed eer eR e Ran 95 Install the SCR Modales oido Nr de Debes 103 Cooling Fan Removal and Installation eee men 103 Remove the Cooling Patio asst giclee EN EH da aiu 103 Install che Cooling Fan cd rH o etude eee ERN 107 Chapter 4 Test With the Motor Without a Mechanical Load
15. On SCR Module SCR Measure from To Terminal Nominal meter reading Terminal 01 01 U C 04 U D 02 02 V C 5 uL 05 Y D open circuit or megaohms range 03 03 W C 06 W D Figure 7 Non Regenerative Drive SCR Module Layout e mJ M LA SCR Module SCR Module SCR Module 01 02 03 LO Q O O O o LO O O us nJ B LA gl i19 i9J Q9 A IL Rockwell Automation Publication 20P TG001B EN P October 2011 31 Chapter2 Component Test Procedures 6 Check the gate to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance of each SCR junction For regenerative drives refer to Table 4 and Figure 8 below For non regenerative drives refer to Table 5 on page 33 and Figure 9 on page 33 If a measurement is outside of the range specified in the tables below or if one reading deviates significantly from the majority then module replacement may be necessary Refer to SCR Module Removal and Installation on page 95 Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives On SCR Module SCR Measurefrom To Nominal meter readin
16. Any values lower than 200 kohms Replace the field board Replace the pulse transformer board Repair the short circuits Rockwell Automation Publication 20P TG001B EN P October 2011 Flow Charts Appendix C Field Current Loss Failure Measure the voltage at terminals U1 V1 Is the correct voltage present at U1 V1 No Remove AC power and remove and test the fuses 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 an
17. 3 Select Device gt HIM and press 39 Doone ofthe following e If there are no existing HIM Sets enter a name using the qe and buttons to select the desired characters and press e e If there is an existing HIM Set press e to overwrite it or select No using the v button and use the and GP buttons to select the desired characters Then press e The HIM Set will be saved to nonvolatile memory Download Parameters to an Offline Node File You can save all drive and adapter parameters in the drive to an offline database file on your computer using DriveExecutive An offline node file dno contains all information about the node including the necessary databases 1 From the Drive menu select Upload from Drive or click the upload button Ej on the toolbar 2 Click Yes to confirm the operation which cannot be undone 3 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 A dialog displays the status of the upload operation Click Cancel to cancel the operation Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 Visual Com ponent Inspection Visually inspect the drive circuit boards and power components before energizing the drive for any of the component test procedures 1 Read the General Safety Precautions on page 12 2 Remove power from the drive Refer to Re
18. 109 Appendix A List of Schematic Diagrams uses eusetes ene Tena bo o PER E ERE 111 Appendix B List of Circuit Board Layouts 2905 5 es eet EET 119 Pulse Transformer Board 22e eec rad yer RC Ret porn 120 Switching Power Supply Boatd ones ests chr t rERPEERA RR eet 123 Control Mont duisi dote ovs tr taa wets Rotae dr i er eios 125 Field Boardi vettura D dca or ad haces inate Eos trud ode ada cee 126 Appendix C List of Flow Charis So sascha bya cito d ab oe pes d RA d 127 Control Power Supply Failure 4 2 55 sede ued eae Pn PRU 128 Field Current Loss Failure zu be Tiere EE NEA SERT 129 No Eield C bre be 2 qoe L unu Ucet vez ee n oui i etaed d 129 Low or Incorrect Field Current 0c0cececcecucvecees 130 Rockwell Automation Publication 20P TG001B EN P October 2011 7 Table of Contents 8 Rockwell Automation Publication 20P TG001B EN P October 2011 About This Publication Who Should Use this Manual Additional Resources Preface This manual contains hardware service information for frame A PowerFlex DC drives only It is highly recommended that you obtain a copy of the PowerFlex Digital DC Drive User Manual publication 20P UM001 which contains fault alarm and programming information to assist you in troubleshooting drive errors and determining if repairs are necessary This manual is intended for qualified service personnel responsible for troubleshooting and repairing PowerFlex DC drives You should h
19. Check the DC Tachometer e Verify that DIP switch S4 on the control board is set to the correct input voltage of the DC analog tachometer See DIP Switch and Jumper Settings in the PowerFlex Digital DC Drive User Manual publication 20P UM001 Also see Figure 21 on page 117 for a circuit diagram e The analog tach signal is fine scaled using parameter 562 Anlg Tach Gain e Refer to Drive Reference and Feedback Scaling in Appendix C of the PowerFlex Digital DC Drive User Manual publication 20P UMO01 for more information Rockwell Automation Publication 20P TG001B EN P October 2011 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 e Verify that the following LEDs are functioning as expected See Figure 11 on page 40 for LED locations and switch settings LED LED On State Off State Code Color D3 Red 24V overload fuse F1 blown This fuse is 24V supply is OK self resetting when it returns to normal operating temperatur
20. Rockwell Automation Publication 20P TG001B EN P October 2011 63 Chapter3 Access Procedures Control EMI Shield and Remove the Control EMI Shield and Control Circuit Board Control Circuit Board Removal and Installation You must remove 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 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Carefully disconnect the cables from connectors XFCD XA and XR on the control board 5 Remove the plug in I O analog tachometer and encoder terminal blocks with the wiring kept in place if used A M yen n a pi E B Bal Disconnect cables XFCD pS Ie Pm XA and XR Li Foy ae 71 fuu mum Disconnect 1 0 and M Peon nana n HET 00 geri control wiring J pe Note Control board shown with communication adapter and optional boards removed 64 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 6 Remove the five M4 x 9 5 mm screws that secure the control EMI shield and ground wire in the lower left corner to the chassis and slide the control EMI shield and control board up and out of the drive IMPORTANT Be careful when removing the EMI shield not to pull free any of the
21. INO I9 J I J I lo Rockwell Automation Publication 20P TG001B EN P October 2011 119 Appendix B Circuit Board Layouts and Connections Pulse Transformer Board 120 Components shown within dashed lines are only on the pulse transformer board for regenerative drives Figure 25 Pulse Transformer Board Layout Control power terminal block 78 79 35 36 75 76U2 V va DOOOO000 FIR1 XX rev P and lower lt E SS i SS x Mus CJ o x o fg xo E E e C18 T E x o 3 8 ee a 9 x g m e g E xo 2 T L J8 Y O5 8 g Jg 7 i x fd Le iD H x o x o P1 g 8 a e k XOq g 7 x L lg x x a m x E FE xo 8 T 0 x x x m hl eo 2 i xO FE x oz Cg o gt oo E s LJ8 02 d x E 18 2202 g 0000 B LJ EJ Nn i lt gt d e Fi 8 7 8 R o 8 E z e Lj m ipse Rockwell Automation Publication 20P TG001B EN P October 2011 Control power terminal block FI
22. Rockwell Automation Publication 20P TG001B EN P October 2011 59 Chapter3 Access Procedures Control Circuit Board Removal and Installation 60 6 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 Nem 8 9 Ib in Install the 115V AC to 24V DC 1 0 Converter Circuit Board Install the 115V AC to 24V DC I O converter board in reverse order of removal Remove the Control Circuit Board 1 Save the drive and adapter parameter configuration to a HIM Set or by down loading the drive and adapter parameters to an offline database file using DriveExecutive See the PowerFlex DC Digital Drive User Manual publication 20P UMO001 for information on using the HIM or the on line Help provided with DriveExecutive for more information on HIM Sets or using the HIM Read the General Safety Precautions on page 12 Remove power from the drive see Remove Power from the Drive on page 44 Remove the protective covers see Protective Cover Removal and Installation on page 48 Remove the communication adapter and EMI shield from the control board see Communication Adapter and EMI Shield Removal and Installation on page 50 Ifinstalled remove the I O expansion circuit board see I O Expansion Circuit Board Removal and Installation on page 57 Ifinstalled remove the 115V AC to 24V DC I O converter circuit board see 115V AC to 24V DC I O Converter Circu
23. 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 from 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
24. LL O O 22 23 24 25 26 27 28 29 30 3I 32 33 34 35 36 37 38 39 40 QOOOOOOOOO OOOOOO0000 ABCH Av A Be B Ze ZCOMN 234596799 0 T7 3155171 20 _ 00000 00000000 OOOCOO0000 0000000000 Tes ses 7 8 s iG 1 121334 15 1 17 18 1 zo Rockwell Automation Publication 20P TG001B EN P October 2011 Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal 1 0 Expansion Circuit Board Removal and Installation Access Procedures Chapter3 Remove the 1 0 Expansion Circuit Board _ Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Ifinstalled remove the resolver feedback option and interface boards See Resolver Feedback and Interface Circuit Board Removal and Installation on page 33 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 5 Remove the plug in I O terminal blocks with the wiring kept in place 6 Remove the two M3 x 6 mm screws and washers that secure the I O expansion board to the stand offs on the control board Remove two screws and washers Tightening torque 1 0 Nem 8 9 Ib in 7 Carefully pull the I O expansion board off connector XBB on the control board Rockw
25. October 2011 Component Test Procedures Chapter 2 Testing the Control and Field Board Connections 1 Using an ohmmeter check all input and output wiring on terminals 1 40 on terminal blocks TB1 and TB2 on the control board for a possible short circuit condition Repair any short circuit conditions if found If an encoder and or tachometer is used use an ohmmeter to check all wiring on the respective terminals for a possible short circuit condition Repair any short circuit conditions if found Remove the cables from connector XR and XFCD on the control board and use an ohmmeter to check between all voltage test points and common on the control board for possible short circuit conditions The ohmmeter measurements should be greater than 200 kQ If any low resistance measurements are found replace the control board Using an ohmmeter measure between pins 1 and 2 and pins 3 and 2 on the XFCD cable connector The resistance measurement for both tests should be greater than 200 kQ Ifa lower resistance value is measured replace field board Rockwell Automation Publication 20P TG001B EN P October 2011 19 Chapter2 Component Test Procedures Figure 1 Control Board Testpoints Upper Left o o o l l oe o o
26. SCR to Pulse Transformer Board Gate Lead Pinout Non regenerative Drive 114 Diagram Field Board and SCR Dual Diode Module Connections Diagram 115 Field Control Circuit Diagram 115 Control Circuit Input Power Diagram 116 Encoder Control Circuit Diagram 116 DC Tachometer Control Circuit Diagram 117 Motor Thermal Protection Control Circuit Diagram T Drive Heatsink Monitoring Control Circuit Diagram 118 Contactor Control Relays Control Circuit Diagram 118 Rockwell Automation Publication 20P TG001B EN P October 2011 111 Schematics Appendix A Figure 12 Drive Interconnection Diagram N19 N peaisui pleoq Saved JaMOY Y U1LJUOI sep S YL sueq snq 3ALY jou op SaAup ULAJ gL Sl dX ooooc looooo looooo looooo looooo LJ xv iNIH 0Z 9 npo A a2epieiuj uewny TOA SAT zal vl el cl LL 3d
27. To Nominal meter reading 01 01 Pin 6 Pin 7 04 Pin 5 Pin4 02 02 Pin 6 Pin 7 1 05 Pin 5 Pin 4 5 20 Q 03 03 Pin 6 Pin 7 06 Pin 5 Pin 4 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for all SCRs Figure 9 SCR Connection Pinouts for Non Regenerative Drives SCR Module 01 SCR Module 02 SCR Module 03 Gate Lead Pinouts 67 45 a mu 5E LO o a Li o 9 o o OQ O O O O Ole fo oJ 480 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 12 2 Remove power from the drive refer to Remove Power from the Drive on page 44 3 Remove the protective covers refer to Protective Cover Removal and Installation on page 48 Remove the control EMI sh
28. assembly down and off the drive IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 8 Disconnect the black and red wires from the fan terminal block located on the air flow plate Remove screws and terminal block Remove screws Remove screws Tightening torque Tightening t 3 0 Nem 26 5 Ib in ightening torque 3 0 Nem 26 5 Ib in Pull air flow plate and fan out of drive chassis Remove wires from fan terminal block 106 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 9 Usinga flathead screwdriver pry the fan cover plate off of the air flow plate and slide the fan out of the air flow housing Remove fan cover plate Slide fan out of air flow housing Install the Cooling Fan Install the cooling fan in reverse order of removal IMPORTANT For both drive fan configurations verify that the air flow arrow on the fan is pointed toward the top of the drive IMPORTANT For drives with a fan connected to the top air flow plate verify that the two spacers are properly placed during installation Poe ru Top of Drive Spacers Air Flow Plate wee Air flow arrow must point toward top of drive Rockwell Automation Publication 20P TG001B EN P October 2011 107 Chapter3 Access Procedures Notes 108 Rockwell Automation Publication 20P TG001B EN P October 2011 T
29. remove a fuse 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 Bottom View of Drives Drive with no Fan at Bottom Drive with Fan at Bottom AULLTLTITITITITTTIETET I iaon Field circuit fuses tbe Install the Field Circuit Fuses Install the field circuit fuses in reverse order of removal 46 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 DPI HIM Assembly Removal Remove the DPI HIM Assembly from the Protective Cover and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 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 connector on the back side of the assembly ae Allen Bradley Disconnect DPI cable PowerFlex DC ite Remove screw Tightening torque 0 8 Nem 7 Ib in 02 AAAAAAAARAARAARAAAAA ft Install the DPI HIM Assembly on the Protective Cover Install the DPI HIM assembly in reverse order of removal Rockwell Automation Publication 20P TG001B EN P Oct
30. 20 XA 13 XA 14 15V analog supply 24V XY8 Figure 1 on page 20 XA 16 24V terminal block GNDV XY9 Figure 1 on page 20 XA 15 24V terminal block ground 5VEXP 5VEXP Figure 2 on page 21 XP3 1 XP3 2 XP3 3 5V for DPI expansion 12VEXP 12VEXP Figure 2 on page 21 XP3 4 XP3 5 12V for DPI expansion OVEXP OVEXP Figure 2 on page 21 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 128 Rockwell Automation Publication 20P TG001B EN P October 2011 17 Chapter 2 Component Test Procedures Ifany ofthe signals in the table above is incorrect or missing verify that either 115 VAC or 230 VAC voltage is present at terminals U2 and V2 control circuit power input e If the voltage is present and correct continue with step 5 below e If the voltage is incorrect or missing remove control power and verify the wiring and power source to U2 V2 and correct any problems Test the voltage level again to verify that it is correct If the voltage is correct but the drive is still inoperable continue with step 5 below Remove AC control power from terminals U2 and V2 and remove and test the fuse F1 at the top ofthe drive See Switching Power Supply Fuse Removal and Installation on page 45 for fuse location e If the fuse is blown continue with step 6 below e If the fuse is not blown replace the switching power suppl
31. Connections on page 121 124 Rockwell Automation Publication 20P TG001B EN P October 2011 Circuit Board Layouts and Connections Appendix B Control Board Figure 27 Control Board Layout XR en hh Q T To DPI board on Q HIM Bezel O XP3 ale on muUuuuui iaa ol S3 oj Oa o 5 op cap Q ON Als S4 doo 6 s1 OO cub S21 sg S H O O O O 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 oooooooooo oooooooooo mm c3 IDEBUG ABC ENGS ENO I2 JALA Bt BZZ COM aV 1234567 8 910 flit 12 13 14 151617 18 1920 OOO00 QooooooQ OOOOO000000 0000000000 DC analog Encoder terminal I 0 terminal blocks tachometer terminal block block Table 26 Control Board to Field Board Connections Control Board Field Board Connector Pin Number to Pin Number Connector Description 1 zs 15V 2 mri 15V Common XFCD XFCD 3 3 15V 4 4 Field CT burden res
32. Current Transducer 84 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 Power Traces Circuit Board Remove the Power Traces Circuit Board Removal and Installation Note The power traces circuit board is only contained in frame A drives rated up to 55A 15 HP with 230V AC input and up to 52A 30 HP with 460V AC input 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Remove the M5 x 10 mm screws and washers that secure the terminal lugs if present and power and ground wiring to terminals U V W C D and PE at the bottom of the drive Note Non regenerative drive without terminal lugs shown Ae Remove screws and washers Tightening torque A 2 5 Nem 22 0 Ibs 5 Remove the control EMI shield and control board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 6 Remove the pulse transformer and switching power supply circuit boards see Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation on page 66 Rockwell Automation Publication 20P TG001B EN P October 2011 85 Chapter3 Access Procedures 7 Remove the six stand offs and the ground wire from the power traces circuit board 8 Remove all
33. M5 x 10 mm screws and washers that secure the board to the SCR modules and power terminal isolation strip and remove the power traces board from the drive SEN Non Regenerative drive with AC current transducers with connection bars Remove all screws and washers Tightening torque 2 5 Nem 22 0 Ib in Remove six stand offs and PE ground wire E Remove six screws E c Regenerative drive with AC current transducers with connection bars Remove all screws and washers Tightening torque 2 5 Nem 22 0 Ib in Remove six stand offs and PE ground wire Remove six screws 86 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 9 Remove the screw and washer that secures the top of each of the AC current transducers to the power traces board and remove the current transducers Regenerative drive shown AC current transducers with connections bars Remove screws and washers 10 For drives with AC current transducers with no connection bars turn the board over and remove the two screws and washers that secure the AC current transducers to the board and remove the AC current transducers and windings if present from the drive IMPORTANT You do not need to remove the windings from the AC current transducers Remove two screws and washers Rockwell Automation Publication 20P TG001B EN P October 2011 87 Chapter3 Access Procedures Install t
34. SCR Dual Diode Module on page 36 e If there are no short circuits continue with step 3 below e If ashort circuit exists replace the field SCR dual diode module 3 Replace the field fuses at FU1 and FV1 and apply power to the drive 4 Ifthe field fuses blow replace the field board Test Field Control Signals 1 Disconnect the cable from connector XR on the control board and measure the U1 V1 voltage synchronization signal at pin 11 on the cable See Figure 27 on page 125 for location of the XR connector on the control board Rockwell Automation Publication 20P TG001B EN P October 2011 27 Chapter 2 28 Component Test Procedures This signal is a square wave signal with a 90 lag phase displacement compared to the AC voltage signal 3 Fab 936 Chi Sincro XR11 Ch2 U1 Vj File Sincrofc tif REMOTE ENABLE 16 28 58 1 4 I co TO 5 ne I LOCAL 5 8 V 5 ns 208 V 5 ns T 1 5 v gui 220 nV DC ij 18 k5 s 3 5 V n i Line Biv ck 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 Chi Sunc Ch ITFL Ch3 ITF2 Ch4 Ie File Fed pl REMOTE ENABLE E TO LOCAL U1 V1 Sync 4 LA LB com 2 2 ns ITF1 Pulse 5 0 V 3 n
35. Test Procedures Chapter 2 No Field Current Note For a flow chart version of these steps see No Field Current on page 129 1 Read the General Safety Precautions on page 12 2 Remove the protective covers from the drive Refer to Protective Cover Removal and Installation on page 48 3 Verify that the correct AC voltage is present at terminals U1 and V1 on the bottom of the drive See Figure 17 on page 115 for a schematic diagram e Ifthe voltage is correct continue with step 4 below e Ifthe voltage is incorrect or missing remove power from the drive and verify the wiring to the drive and the power supply source and correct any problems Test the voltage level again to verify that it is correct If the voltage is correct but the fault persists or parameter 351 Field Current is incorrect continue with step 4 below 4 Remove AC power to the drive and check the fuses at FU1 and FV1 e If the fuses are blown complete the steps in Test Field Wiring and Voltage Signals on page 27 e Ifthe fuses are not blown complete the steps in Test Field Control Signals on page 27 Test Field Wiring and Voltage Signals 1 Test the resistance of the motor field wiring and motor field for possible short circuits e Ifthere are no short circuits continue with step 2 below e Ifashort circuit exists correct any problems 2 Check the field SCR dual diode module for a short circuit condition See Check the Field
36. adapter and set them aside QD Allen Bradley A e dm Disconnect interface cable Disconnect network cables 5 Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter Allen Bradley Ra 20 COMI D mE Rar a de Remove four Screws Tightening torque V 0 9 Nem 8 Ib in Rockwell Automation Publication 20P TG001B EN P October 2011 51 Chapter3 Access Procedures 6 Remove the three screws that secure the EMI shield to the stand offs on the control board and remove the EMI shield Remove three screws Tightening torque 1 0 Nem 8 9 Ib in 7 Remove the three stand offs from the control board Remove three stand offs Tightening torque 1 0 Nem 8 9 Ib in Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal 52 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 Resolver Feedback and Remove the Resolver Feedback and Interface Circuit Boards Interface Circuit Board Removal and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassem
37. and Interface Circuit Boards 56 I O Expansion Circuit Board Removal and Installation 57 Remove the I O Expansion Circuit Board usus 57 Install the I O Expansion Circuit Board 00 200 ee eee 59 115V AC to 24V DC I O Converter Circuit Board Removal and TG HAL ATION a Rae hare tale ote eRe eo Mute ee eS 59 Remove the 115V AC to 24V DC I O Converter Circuit Board 59 Install the 115V AC to 24V DC I O Converter Circuit Board 60 Control Circuit Board Removal and Installation 60 Remove the Control Circuit Board cccce cece eceees 60 Install the Control Circuit Board ir uve ods canes 63 Control EMI Shield and Control Circuit Board Removal and Linstead eens erecti sotto eis acs we ae oa Oe Es 64 Remove the Control EMI Shield and Control Circuit Board 64 Install the Control EMI Shield and Control Circuit Board 65 Pulse Transformer and Switching Power Supply Circuit Board Removal and Insrallatigt s cde ta EE cs M e ERE EA EUR 66 Remove the Pulse Transformer and Switching Power Supply Circuit TIN MPEORPORSRDSTNTNUEIMEPORDO RESET ia ae a ce 66 Install the Pulse Transformer and Switching Power Supply Circuit Boutdenauesss anna aed ae ai dtc ede a tutela hod pax ert 72 Install the Configured Pulse Transformer Circuit Board and the Switching Power Supply Circuit Board 0 00008 TE AC Current Transducer Removal and Installation
38. board and therefore will not pull free from the drive until disconnected See step 7 below for instructions When metal pin fits in keyhole A lift cover off drive chassis Rockwell Automation Publication 20P TG001B EN P October 2011 49 Chapter3 Access Procedures 7 Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside s Pull tabs out to disconnect cable Install the Protective Covers Install the protective covers in reverse order of removal terminals of the drive The power terminal cover and protective covers must be 1 ATTENTION Risk of electric shock exists when power is applied to the power replaced after servicing the drive Communication Adapter and Remove the Communication Adapter and EMI Shield EMI Shield Removal and Installation 50 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Disconnect the interface cable from the communication adapter and set it aside Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 Disconnect any network cables from the
39. bottom plate Tightening torque 3 0 Nem 26 5 Ib in eur Vt CI DI Remove six screws for drives with fan on bottom air flow plate Tightening torque 3 0 Nem 26 5 Ib in Rockwell Automation Publication 20P TG001B EN P October 2011 91 Chapter3 Access Procedures 12 Remove the two M3 x 6 mm screws that secure the field circuit board to the drive and remove the field board and connected wires from the drive Note that there is an isolation sheet below the board do not remove this sheet unless it is damaged Field circuit board Mounting screws Tightening torque Remove screws 1 0 Nem 8 9 Ib in 92 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 13 Remove the wires that connect the field fuses UF UF1 VF VF1 to the field circuit board and the wire from connector X3 on the field board Field fuses Remove wires from Remove wire from X3 board end connector Install the Field SCR Dual Diode Module and Field Circuit Board e Install the field SCR dual diode bridge module and field circuit board in reverse order of removal IMPORTANT Thermal grease must be applied to the bottom of the field SCR dual diode module before securing it to the heatsink IMPORTANT Verify that the field circuit wires are connected to the correct location on the field SCR dual diode module Thick Brown Wire Thick Blue Wire Thick Black wire To Field circuit To Fie
40. gate leads or other cables on the pulse transformer circuit board below the EMI shield Remove screws Tightening torque 1 0 Nem 8 9 Ib in Sy ses IULEL FECUCPCELCUPITe Cen m Install the Control EMI Shield and Control Circuit Board Install the control EMI shield and control board in reverse order of removal Rockwell Automation Publication 20P TG001B EN P October 2011 65 Chapter3 Access Procedures Pulse Transformer and Remove the Pulse Transformer and Switching Power Supply Circuit Switching Power Supply Board Circuit Board Removal and 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 Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Remove the control EMI shield and control board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 5 Remove the slotted air flow plate from the top of the drive e For 38A 10 HP and 55A 15 HP drives with 230V AC input and 35A 20 HP 45A 25 HP and 52A 30 HP drives with 460V AC input remove the four screws that secure the slotted air flow plate to the top of the drive remove the fan cable from connector XV on the swi
41. in the tables below Refer to Figure 25 on page 120 for connector locations Ifany of the actual measurements are out of tolerance replace the pulse transformer board Table 6 Armature Pulse Snubber Circuit Measurements for Regenerative Drives ForSCR MeasureFrom To 1 KG1 XY 4 4 KG4 XY 1 2 KG2 XY 5 5 KG5 XY 2 3 KG3 XY 6 6 KG6 XY 3 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 Meter reading open circuit Connector XY Pinout 10 0000000000 Table 7 Armature Pulse Snubber Circuit Measurements for Non Regenerative Drives ForSCR MeasureFrom To 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 Meter reading open circuit Rockwell Automation Publication 20P TG001B EN P October 2011 Connector XY Pinout 10 0000000000 35 Chapter2 Component Test Procedures 8 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 ForSCR MeterLead Meter Lead Meter reading Connector XY Pinout 1 01 XY
42. measured at these points See Figure 27 on page 125 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 12 2 Remove the protective covers from the drive Refer to Protective Cover Removal and Installation on page 48 3 Ifusing a DC output contactor disconnect the cable from XR on the control board and measure the signal for each SCR gate as indicated in the table below Signal Name _ XR Cable Pin Gate Note MP MN I 27 Gl G04 I2 29 G2 G05 IT3 31 G3 G06 IT4 2 G4 G01 IT5 23 G5 G02 IT6 25 G6 G03 MN 33 Negative bridge MN active when high 5V MP 34 Positive bridge MP active when high 5V Rockwell Automation Publication 20P TG001B EN P October 2011 23 Chapter2 Component Test Procedures Figure 3 Figure 4 and Figure 5 below are examples representing gate pulse current and voltage signal measurements taken on an SCR In the figures below The current signal is taken on the testpoint XY17 2 5V offset 0 6V Drive size current The voltage signal is taken on the testpoint XY19 2 5V offset The ground signal is taken on either testpoint XY10 or XY18 Figure 3 Good SCR Gate Pulse and Armature
43. on the green LA LB terminal located on the control board LA is the ground and LB is field current signal The measured value of the field current at LA LB should be equal to the value of parameter 374 Drv Fld Brdg Cur If these values are equivalent the voltage across these terminals should be 1 66 VDC Note For lower field current values the voltage will be proportional For example if the field is set up for 2 A and the motor is rated for 1 5 A the measurement at LA LB will be 1 245 VDC 1 5 x 2 1 66 e Ifthe voltage measurement is incorrect continue with step 7 below e Ifthe voltage measurement is correct but the Field Current Loss fault still exists replace the control board Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance as indicated in the table below set with DIP switch 14 on the control board Field 14 1 14 2 14 3 514 4 S145 14 6 147 Supply 14 8 Equivalent Resistance 10A OFF OFF OFF OFF OFF ON 1668 2A 10A OFF OFF OFF OFF ON OFF 845 3A 10A OFF OFF OFF OFF ON ON 560 9 Not Used 5A 10A OFF ON OFF OFF OFF OFF 333 3 10A 10A ON OFF OFF OFF OFF OFF 168 5 13A 14A ON OFF OFF OFF ON ON 129 6 e If the resistance measurement is incorrect replace the field board 26 Rockwell Automation Publication 20P TG001B EN P October 2011 Component
44. the HIM to issue start and speed commands Start the drive by pressing am 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 UM001 Increase the speed command from zero to base speed by pressing the up button Measure the output voltage and verify that it is reflected in parameter 233 Output Voltage Measure the armature current and verify that the value is reflected in parameter 199 Arm Current Pct Stop the drive by pressing the stop button If these measurements are correct re configure the drive to suit the application Refer to Chapters 1 and 2 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for assistance If any of these measurements are incorrect repeat steps 8 15 If the measurements are still incorrect repeat the appropriate procedures in Chapter 2 Component Test Procedures beginning on page 15 Rockwell Automation Publication 20P TG001B EN P October 2011 Appendix A Schematics List of Schematic Diagrams Topic Page Drive Interconnection Diagram 112 AC Line Measurement Points Diagram 113 Power Feedback Connections Diagram 113 SCR to Pulse Transformer Board Gate Lead Pinout Regenerative Drive Diagram 114
45. 1 Replace the field board Numerics 115V AC to 24V DC 1 0 converter board install 60 remove 59 A AC current transducers install 84 remove 78 armature bridge failure troubleshoot 23 armature SCR modules test 29 bimetal thermostat install 94 remove 94 C circuit board connections 119 layout drawings 119 communication adapter install 52 remove 50 components inspection 17 contactor fault 41 control board install 63 65 remove 60 64 control power supply failure 17 cooling fan install 107 remove 103 D DCanalog tachometer test 38 download parameter configuration 16 DPI HIM assembly install 47 remove 47 E Electrostatic Discharge Precaution 12 encoder test 38 Rockwell Automation Publication 20P TG001B EN P October 2011 Index fault field current loss 25 heatsink overtemperature 41 main contactor 41 overcurrent 23 power failture 17 fault report create 42 field board install 93 remove 88 field circuit fuses install 46 remove 46 field current loss fault 25 field SCR dual diode module install 93 remove 88 test 36 frame size 13 fuse field circuit 46 Switching power supply 45 Switching power supply board 45 hardware description 13 heatsink overtemperature fault 41 1 0 expansion board install 59 remove 57 inspection visual 17 install 115V AC to 24V DC 1 0 converter board 60 AC current transducers 84 bimetal thermostat 94 communication adapter 52 contr
46. 8 25 27 2 052 52 42 5 30 23 538 073 73 59 6 40 16 767 086 86 70 3 50 14 233 100 100 817 60 12 24 129 129 105 4 75 9 488 3 Seal the TA potentiometer in place using RTV silicon Continue with Install the Configured Pulse Transformer Circuit Board and the Switching Power Supply Circuit Board on page 77 Rockwell Automation Publication 20P TG001B EN P October 2011 75 Chapter3 Access Procedures Configure a Pulse Transformer Board FIR 1 XX Rev Q and Higher 1 Set DIP switches S3 and S4 located on the pulse transformer board see illustration below for location to the correct settings based on the drive current rating See 230V AC Input Drives on page 77 and 460V AC Input Drives on page 77 XSW XP Xswi TR2 TRI x D EJ D XR Cd XCD_IO xy TO TO4 T02 TOS T03 TOs L L J KGO1 KGO4 C KG05 Keos KGO6 KG02 ji CIC 303 CI KGi KG4 KG2 KG5 KG3 KG6 J DIP Switches 4 and 3 S4 1 1 HLL ss Dann 78 79 35 36 75 76 U2 V2 76 Rockwell Automation Publication 20P TG001B EN P October 2011 Table 16 230V AC Input Drives IMPORTANT Access Procedures Chapter 3 A blank cell below a switch in Table 16 and Table 17 below indicate that the setting is OFF
47. 8 XY 1 4 04 XY 8 X4 E 2 02 XY 8 XY 2 a 5 05 XY 8 XY 5 0 41 3 03 XY 8 XY 3 6 06 XY 8 XY 6 1 Table 9 Armature Pulse Transformer Primary Measurements for Regenerative Drives ForSCR MeterLead Meter Lead Meterreading Connector XY Pinout 1 XY 7 XY 1 4 XY 7 XY 4 21 38 2 XY 7 XY 2 s 5 XY 7 XY 5 0410 7 3 XY 7 XY 3 s 6 XY 7 XY 6 1 Check the Field SCR Dual Diode Module The field supply consists of a dual pack SCR Dual Diode module arranged in a single phase full wave rectifier configuration Malfunction of either of these components may cause various responses including field and velocity related faults or blown fuses The following procedures can be used if field bridge malfunctions are suspected 1 2 Read the General Safety Precautions on page 12 Remove and lock out all incoming power to the drive Refer to Remove Power from the Drive on page 44 3 Verify that contactor power if used is removed Verify that power to an external field supply if used is removed 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 Refer to Table 10 on page 37 and Figure 10 on page 37 Ifa low resistance is detected replace the modules Refer to Field SCR Dual Diode Module and Field Circuit Board Removal and Installation on page 88 Ifa measurement resul
48. Amps 7P0 7 5 7 1 5 Remove 27 4Q Remove Remove 9P0 9 7 4 2 Remove Remove 39 20 Remove 012 12 9 8 3 Remove 27 4Q Remove Remove 020 20 16 5 56 2Q Remove Remove Remove 029 29 24 75 Remove Remove 39 20 Remove 038 38 31 10 Remove 27 4 Remove Remove 055 55 45 15 56 2 27 4Q Remove Remove 073 73 60 20 Remove 27 4Q 39 20 Remove 093 93 76 25 Remove Remove Remove 6 98 110 110 90 30 Remove Remove Remove 6 98 Table 13 460V AC Input Drives Drive Current DC ACLine HP R1 R2 R3 R4 R5 Rating Code Amps Amps 4P1 4 1 33 2 56 2 Remove Remove Remove 6P0 6 4 9 3 Remove Remove 39 20 Remove 010 10 8 2 5 Remove Remove 39 20 Remove 014 14 11 4 75 Remove 27 4Q Remove Remove 019 19 15 5 10 56 2 Remove Remove Remove 027 27 22 1 15 Remove Remove 39 20 Remove 035 35 28 6 20 Remove 27 4Q Remove Remove 045 45 36 8 25 56 2 Remove 39 20 Remove 052 52 42 5 30 56 2 27 4Q Remove Remove 073 73 59 6 40 Remove 27 4Q 39 20 Remove 086 86 70 3 50 Remove Remove Remove 6 98 100 100 81 7 60 Remove Remove Remove 6 98 129 129 105 4 75 Remove Remove Remove 6 98 Rockwell Automation Publication 20P TG001B EN P October 2011 73 74 Chapter 3 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 circui
49. Chapter 2 Create a Fault Report What You Need When You Call Tech Support Component Test Procedures Complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum perform and record the following Record the contents of the fault queue faults and times of occurrence Refer to the PowerFlex Digital DC Drive User Manual publication 20P UM001 for detailed Fault and Alarm codes and descriptions Make a record of any burn marks on the printed circuit boards cabling bus bars and SCR modules Make a record of any liquid and condensation marks on the printed circuit boards components and mechanical parts Make a record of the amount of dust and other additional particles on the drive and drive components Make a record of any mechanical damage to the drive and drive components Record the size and type of main fuses Record any other important marks and damage When you contact Technical Support please be prepared to provide the following information Order number Product catalog number and drives series number if applicable Product serial number Firmware revision level Most recent fault code Your application You can use the table below to record the data provided in each PowerFlex DC drive parameter listed Param s Name Description Parameter Data 1349 Status at Fault Captures and displays Par 381 Drive Status 1 bit pattern at the ti
50. Chapter 2 Introduction ai cents eeu Sax EIS ere durs vsus eae Save the Parameter Configuration us catu vuvavied e aute pta ute Gave Sav toa HIM S t eoo Eee sas qur RR ESCUPI dn Download Parameters to an Offline Node File Visual Component Inspections 2523 2e etu ede da ed RS RERRENE US Troubleshoot a Control Power Supply Failure suuuu Testing the Switching Power Supply and Pulse Transformer Boats iss E E Rh uos e cete te idol ue tacts cola cc dela Testing the Control and Field Board Connections Troubleshoot an AC Undervoltage Fault seeeuuueeueue Troubleshoot an Armature Bridge Failure eee eere ter enm Troubleshoot a Field Current Loss Fault 0 0 0 cee eeeeeee Low or Incorrect Field Current 0 cccccececeeeeeneee No Field C uttetbasos vee iietra aa aE ied eke threces Power Component Test Procedures cereis Check the Armature SCR Modules 0 cceececeeeeees Check the Pulse Transformer Board LsLueuuue Check the Field SCR Dual Diode Module Speed Feedback Device Lest neenon Sido vai a PRene te Check the Encoder ele RE ERE ERE AU Check the DC Tachometer ec cete deret eren Check the Resolver Interface Board 0 0 cceeeececeeees Thermistors and Thermal Switches 0 cccccecececceeeees Relay Outputs uos ci ue e reo tectae eL eo tI pea Lh cue Creates Fault Report sunt arcos dk adus k le Pe
51. Current Signals Example 9 Feb 96 Inpulsi su XvYv23 Is su XY17 File Inpulsi tiF REMOTE ENRELE 13 27 59 CCC i 60 TO 2 nc LOCRL 5 9 v 5V 2 e ns 260 av 0v ttt ttem pp ttti ttti 2 XY19 2 nt B 5 v mj 220 nv Cj 25 kS s 3 5 v mx id L 1 HFREJ 0 1 V 458 nv Cj O TOPPEO Figure 4 Good SCR Armature Voltage and Motor Current Signal Example S Feb 96 Chi Vara XY19 Ch Ia XvY17 File EMF tiF REMOTE ENABLE 16 07 47 GO TO 2 ns LOCAL 8 56 V 2 2 ns 200 nv XY17 ttt th mennng9 9 2 XY19 e nz f 50 nv pc u 2 20 m DC 25 kS s 3 5 v Dc L 1 FREJ 0 01 V 450 nv Dt O STOPPED 24 Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 A malfunctioning thyristor is connected to the relative gate For example if the tested signal is at XR25 and the positive bridge is active MP high from the following figure you can deduce that SCR connected to gate G6 is open Figure 5 Open Thyristor Example 8 Feb 9f Scr open Ch X825 Ch Ia File scr Fail ti REMOTE EWFBLE 15 25 13 60 TO 5 ns LOCRL 5 8 V 5V 2 e y ns 280 nv 0v i2 Xv 5 ms 0 5 v ori 29 rV OCX 10 K 3 5 v OC E 1 HFREJ 8 1 V 458 nw DC Zz d OPPED Troubleshoot a Field Current _ f the drive faults with a Field Current Loss fault F6 and there is low or Loss Faul
52. EN P October 2011 101 Chapter3 Access Procedures 12 Remove the screws and washers that secure each SCR module to the heatsink and remove the SCR modules Non Regenerative drive Remove screws Regenerative drive Remove screws 102 Rockwell Automation Publication 20P TG001B EN P October 2011 Install the SCR Modules Access Procedures Chapter3 e Install the SCR modules in reverse order of removal using the tables below for proper tightening torque 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 S7F46 2 5 4 Nem 22 35 4 Ibein SK 20P S7F75 2 5 4Nem 22 35 4 Ibein SK 20P S7F47 2 5 4 Nem 22 35 4 Ib in SK 20P S7F77 2 5 4 Nem 22 35 4 Ibein Use the following table to determine the proper tightening torque for the bus bars to SCR modules connections 230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque SK 20P S7F46 2 5 4 Nem 22 35 4Ib in SK 20P S7F75 2 5 4Nem 22 35 4 Ibein SK 20P S7F47 2 5 4 Nem 22 35 4Ib in SK 20P S7F77 2 5 4 Nem 22 35 4 b in IMPORTANT Verify that the SCR modules are installed with the gate leads in the
53. Hardware Service Manual Allen Bradley PowerFlex Digital DC Drive Frame A 1 5 75 Hp 1 2 56 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 ofthis 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
54. R1 XX rev Q and higher Circuit Board Layouts an d Connections Appendix B Table 18 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 19 Pulse Transformer Board to Switching Power Supply Connections Description approx 150 300V DC not used not used Pulse Transformer Switching Power Supply Board Point to Pin Number Board Connector 4 Rectified U2 V2 voltage 12 d XUV 1D2 ae 1 Common Table 20 Pulse Transformer Board to Bimetal Thermostat Connections Pulse Transformer Board Connector X4 Bimetal Thermostat Pin Number to Pin Number Connector 1 E 2 22 x Description 24V supply through resistor 24V common de Module Connections Table 21 Pulse Transformer Board to Field SCR Dual Dio Pulse Transformer Board Connector Field SCR Dual Diode Module Pin Number XP to Pin Number Connector 1 3 ule Fastons 3 A2 4 1 Description Gate signal G1 Common cathode K1 and K2 for both field SCRs us Gate signal G2 Rockwell Automation Publication 20P TG001B EN P October 2011 121 AppendixB Circuit Board Layouts and Connections Table 22 Pulse Transformer Board to Control Board Connections Pulse Transformer Board Connector XR
55. X4 and XTA must slide through the openings in the board as it is lifted out of the drive chassis Take care not to damage these cables and connectors Tightening torque Remove six screws and washers 1 0 Nem 8 9 Ib in Carefully route cables through openings as the board is removed Regenerative drive shown Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 13 Remove the cable from connector XUV on the left side of the switching power supply board 14 Remove the four M3 x 6 mm screws and washers that secure the switching power supply board to the stand offs on the back of the pulse transformer board and remove the switching power supply board Remove cable Tightening torque 1 0 Nem 8 9 Ib in Remove screws and washers 15 Remove the plastic stand off and nut that secures the switching power supply board to the back of the pulse transformer board 4 00 Secure nut N we lt Ex Remove stand off Rockwell Automation Publication 20P TG001B EN P October 2011 71 Chapter3 Access Procedures Install the Pulse Transformer and Switching Power Supply Circuit Boards The pulse transformer circuit board must be configured to match the drive size armature output current and HP rating The steps required to complete the configuration are different based on the revision code of the board See either Configuring the Pulse Transfor
56. ack device provides a dual channel quadrature output waveform and requires that the output be differential line drivers at 5 or 12 15V signal levels The encoder power supply voltage and input selection is controlled by DIP switch S21 on the control board see DIP Switch and Jumper Settings in the PowerFlex Digital DC Drive User Manual publication 20P UMO0O01 The encoder power supply from the drive can be measured from V to COM with a digital multimeter If 21 is set to ENC_S the voltage level should be 2 5 5 4V If S21 is set to ENC 12 the voltage level should be 5 AV 15 2V For reference see Figure 20 on page 116 for a schematic diagram The Channel A and Channel B are square wave type outputs that are 90 degrees out of phase When rotating in the CCW direction as viewed from the commutator end Channel A leads Channel B Each differential channel has an inverted and non inverted signal Power for the encoder is provided internally and is capable of 200mA of current with a current foldback feature that protects the power supply should the current draw exceed 200mA If different power supply requirements exist for the chosen feedback device the supply must be provided external to the drive The frequency is proportional to speed and the pulse rate of the encoder referred to as the Pulse Rev rating on the nameplate The speed of the motor can be calculated by Speed RPM Frequency Hz x 60 Pulses Revolution
57. ade to this revision Information Topic Page Updated the Resolver Interface Board Testpoint Locations image to reflect the new resolver 39 interface board Updated the Resolver Feedback and Interface Circuit Board Removal and Installation procedures 53 to reflect the new resolver interface board Updated the Test With the Motor Without a Mechanical Load procedure and corrected the 109 chapter number in the header for Chapter 4 Updated the Drive Interconnection Diagram 112 Updated the Power Feedback Connections Diagram 113 Added the SCR to Pulse Transformer Board Gate Lead Pinout Regenerative Drive Diagram 114 Added the SCR to Pulse Transformer Board Gate Lead Pinout Non regenerative Drive Diagram 114 Rockwell Automation Publication 20P TG001B EN P October 2011 3 Summary of Changes Notes 4 Rockwell Automation Publication 20P TG001B EN P October 2011 Preface Before You Begin Testing Maintenance or Repairs Component Test Procedures Table of Contents About This Publication eese Who Should Use this Manual eene Additional Resources lesse e Chapter 1 Introductions eera ret alii edat ate loti RA L E aa General Safety Precautions uo ees EDI Lp E UE ECHOS d Hardware Description srs rerien a odes wooo teas piae Commonly Used Toolszuii tedio aet hone o t Ibo eee deed Service Tools reos orate cute feda ne Ope t ETE Software Doolsdine deca ba cxtesr oa a tm dote ba drei
58. agram Table 1 Combined AC Line Input Signal Testpoints IncomingAC Phases MeasureFrom ToTestpoint PeaktoPeak RMS Measurement Line Voltage Testpoint Measurement 240 VAC x E an oe 1 42 VAC 0 500 V 480 VAC RUE aa s 2 95 VAC 1 040V 575 VAC RUM a s 2 85 VAC 1 007 V 690 VAC x M A s 345 VAC 1220V su Er2l ce Flle syel zz tlir REMOTE EH ELE i SR n ilo Of fi 1 DE Dr l 1 HFREJ H B2 V 5B me DC STOFFE LW ESF EMi hj a m 22 Rockwell Automation Publication 20P TG001B EN P October 2011 Troubleshoot an Armature Bridge Failure Component Test Procedures Chapter 2 e Ifany of the voltage measurements above are incorrect or missing continue with step 5 below e Ifthe voltage measurements above are correct but the value of parameter 466 AC Line Voltage is incorrect replace the control board 5 Remove the ribbon cable connected to XR on the control board and pulse transformer board and test the continuity of the cable using the measurements in Table 22 on page 122 If the measurements on the XR cable are correct replace the pulse transformer board If the drive is running unstable or faults with an Overcurrent Fault F13 an armature bridge failure may have occurred All of the signals going to and coming from the SCR bridges are transmitted via the ribbon cable connected to XR on the control board and can be
59. and the Switching Power Supply Circuit Board 1 Install the Isolation sheet if present before installing the pulse transformer and switching power supply boards A ATTENTION Failure to install the Isolation sheet below the pulse transformer and switching power supply boards may result in damage to the drive Rockwell Automation Publication 20P TG001B EN P October 2011 77 Chapter3 Access Procedures 2 Install the configured pulse transformer board and switching power supply board in reverse order of removal from which it was removed on the pulse transformer circuit board or damage to ATTENTION Each gate lead cable must be connected to the exact connector the drive may occur See Figure 15 on page 114 or Figure 16 on page 114for gate lead pinouts AC Current Transducer Remove the AC Current Transducers Removal and Installation IMPORTANT AC current transducers must be replaced in pairs 1 2 Read the General Safety Precautions on page 12 Remove power from the drive see Remove Power from the Drive on page 44 Remove the protective covers see Protective Cover Removal and Installation on page 48 Remove the control EMI shield and control circuit board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 Remove the pulse transformer and switching power supply circuit boards see Pulse Transformer and Switching Power Supply Circu
60. ave previous experience with and basic understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions Additional drive service and software or firmware support information is available on the Allen Bradley Drives Service and Support website http www ab com support abdrives A complete list of spare parts for PowerFlex DC drives is available on the Allen Bradley web site at www ab com support abdrives powerflexdc PowerFlex DC Released Parts pdf The following table lists publications that provide general drive information Title Publication Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Rockwell Automation Publication 20P TG001B EN P October 2011 9 Preface Notes 10 Rockwell Automation Publication 20P TG001B EN P October 2011 Chapter 1 Before You Begin Testing Maintenance or Repairs Introduction This chapter provides info
61. bly Disconnect the plug in terminal blocks from the resolver feedback and resolver interface boards a TEE Sees XR Ne Aus Z ow LI Oo XP3 15 Resolver feedback board i boonnonoun 8 81 B LT O O P1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 QD B5eee OOOOOO0000 0000000000 _ A B Cip Sie 123456789011211 E 6 17 920 OOOOO 12345678DO 20000 00900 78DOZOOO0 0000000000 0000000000 Remove terminal blocks Rockwell Automation Publication 20P TG001B EN P October 2011 53 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
62. cable from connector XV on the switching power supply board and remove the fan and air flow plate 5 Remove the twoM x 12 5 mm screws that secure the fan and spacers to the air flow plate and remove the fan a Remove two screws Tightening torque a 3 0 Nem 26 5 Ib in Continue with Install the Cooling Fan on page 107 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 Cooling Fan on Drives Rated 73A 20 HP with 230V AC Input and 73A 40 HP with 460V AC Input Frame A drives rated 73A 20 HP with 230V AC and 73A 40 HP with 460V AC and higher have a cooling fan installed on the bottom of the drive 3 Loosen the two screws that secure the power terminal cover to the drive and slide the cover down and off the chassis 4 Remove the field terminal block 5 If necessary remove the power wiring from the drive terminals Remove screws and Tightening torque Power Terminal Cover 1 0 Nem 8 9 Ib in dit Ce em mmm ZAER i If necessary remove power Remove field wiring terminal block Rockwell Automation Publication 20P TG001B EN P October 2011 105 Chapter3 Access Procedures 6 Remove the two screws that secure the armature voltage feedback terminal block to the air flow plate and remove the terminal block 7 Remove the six M x 12 5 mm screws that secure the air flow plate to the bottom of the drive chassis and carefully pull the air flow plate and fan
63. d 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 TG001B EN P October 2011 Replace the control board 129 Appendix C 130 Flow Charts Low or Incorrect Field Current 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 TGO001B EN P October 201
64. 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 gt eee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information New and Updated This table contains the changes m
65. ducers for proper installation of the new AC current transducers Continue with Install the AC Current Transducers on page 84 Remove two Tightening torque screws and 0 5 Nem 4 4 Ibein washers 9 Continue with Install the AC Current Transducers on page 84 80 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 AC Current Transducers from Drives Rated 734 20 HP with 230V AC Input and Higher or 73A 40 HP with 460V AC Input and Higher IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 6 Remove the power connections from terminals U and V at the bottom of the drive 7 Remove the M x12 5 mm screws and washers that secure each of the AC current transducers to the U and V Phase terminal bus bars Remove screws Tightening torque 3 0 Nem 26 5 Ib in U Phase bus bar V Phase bus bar Rockwell Automation Publication 20P TG001B EN P October 2011 81 Chapter3 Access Procedures 8 Remove the two 5 x 10 mm screws and washers that secure each of the U and V phase terminal bus bars to the terminal isolation strip at the bottom of the drive U Phase bus bar Remove screws and V Phase bus bar Tightening torque washers 2 5 Nem 22 0 Ib in 82 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 9 Remove the screws and washe
66. e D10 Green 12V supply is OK Loss of 12V power D11 Green Resolver feedback board voltage is OK Voltage error on resolver feedback board D12 Blue Switch S1 is set to 24V for encoder signal S1is not set for 24V output on TB2 D16 Yellow Switch 1 is set to 12V for encoder signal S1 is not set for 12V output on TB2 D18 Green Switch S1 is set to 5V for encoder signal _ S1 is not set for 5V output on TB2 D26 Red Resolver feedback board is in reset mode Resolver feedback board not in reset mode If any ofthe 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 e Measure the signal voltage at the testpoints as indicated in the following table See Figure 11 on page 40 for testpoint locations Testpoint to Testpoint Measurement 12V 0012 12V DC 5 12V 0012 12V DC 5 24V VI lt 10V24 24V DC 5 45V 1005 5V DC 5 If any of the voltage measurements fails replace the resolver interface board Rockwell Automation Publication 20P TG001B EN P October 2011 39 Chapter2 Component Test Procedures Figure 11 Resolver Interface Board Testpoint Locations
67. e 66 T technical support calling 42 test armature SCR modules 29 DCanalog tachometer 38 encoder 38 field SCR dual diode module 36 pulse transformer board 33 testpoints locations 20 21 thermal switch 41 thermistor 41 tools service 14 software 14 troubleshoot armature bridge failure 23 field current loss 25 overcurrent fault 23 power failure fault 17 V visual inspection 17 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomat
68. ell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 SCR Module Removal and Remove the SCR Modules Installation IMPORTANT For regenerative drives the SCR modules must be replaced in pairs for each input phase in order that the gating resistance of each pair of modules is the same 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Remove the control EMI shield and control circuit board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 5 Remove the pulse transformer and switching power supply circuit boards see Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation on page 66 The drive rating determines how the power bridge of the drive is configured and the steps required to remove the SCR modules e Ifremoving the SCR modules from a frame A drive rated up to 55A 15 HP with 230V AC input or up to 52A 30 HP with 460V AC input see SCR Modules on Drives Rated up to 55A 15 HP with 230V AC Input or up to 52A 30 HP with 460V AC input on page 96 OR e If removing the SCR modules from a frame A drive rated 73A 20 HP with 230V AC input and higher or 73A 40 HP with 460V AC input and higher see SCR Modules on Drives Rated 73A 20 HP w
69. ell Automation Publication 20P TG001B EN P October 2011 57 Chapter3 Access Procedures 8 Remove the two stand offs from the control board Remove two stand offs Tightening torque 1 0 Nem 8 9 Ib in 9 Install one of the existing screws in the lower left corner of the control circuit board I Me gt d oven Rit nee Ate tee et Team wxwp ovx m 59 I A Be B Z Z COM VIP LOL COL OLOR 20287 Tightening torque Install screw 1 0 Nem 8 9 Ib in 58 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 Install the I 0 Expansion Circuit Board Install the I O expansion board in reverse order of removal 115V AC to 24V DC 1 0 Remove the 115V AC to 24V DC 1 0 Converter Circuit Board Converter Circuit Board Removal and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 IMPORTANT Markall 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 5 Remove the two M3 x 6 mm screws and washers that secure the I O converter board to the stand offs on the control board and remove the I O converter board Remove two screws and washers Tightening torque 1 0 N m 8 9 Ib in
70. est With the Motor Without a Mechanical Load Chapter 4 Start Up After Repair Before applying power to a repaired drive perform the following tests e Check the Armature SCR Modules on page 29 e Check the Field SCR Dual Diode Module on page 36 e Complete the Test With the Motor Without a Mechanical Load below This test allows you to measure several operating parameters and diagnose problems without connecting the motor to its mechanical load This procedure requires a HIM to configure and autotune the drive If you prefer you can use the DriveExplorer or DriveExecutive software up procedure Some of the voltages present are at incoming line potential To ATTENTION Power must be applied to the drive to perform the following start A W N avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to then drive Correct the malfunction before continuing Verify that the input power wiring and grounding is connected Verify that the motor cables are connected Verify that the motor load is disconnected Verify that the control board DIP switches are set correctly See I
71. g 1 1 Pin 5 Pin4 4 Pin 6 Pin7 2 2 Pin 5 Pin 4 5 Pin 6 Pin7 3 3 Pin 5 Pin 4 6 Pin 6 Pin7 1 01 01 Pin 6 Pin7 209 04 Pin 5 Pin4 02 02 Pin 6 Pin 7 05 Pin 5 Pin4 03 03 Pin 6 Pin 7 06 Pin 5 Pin 4 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for all SCRs Figure 8 SCR Connection Pinouts for Regenerative Drives SCR Module 01 SCR Module 02 SCR Module 03 Ol 67 45 Ol 67 45 Lo n O no j ro o n GAE QO Gate Lead Pus 54 76 C 54 76 Gate Lead Pinouts 67 45 LO O gt I 0 AD 54 76 C SCR Module 1 SCR Module 2 SCR Module 3 O aale gafo 6 O o eJ le 3 O 32 Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 Table 5 SCR Gate to Cathode Junction Measurements for Non Regenerative Drives On SCR Module SCR Measurefrom
72. h and either terminal 78 or 79 e If neither a thermistor PTC or a thermal switch is installed a 1 kQ resistor must be connected between terminals 78 and 79 The drive heatsink temperature is monitored by a bimetal thermostat connected directly to the heatsink When the heatsink temperature is too high a Heatsink OvrTemp fault F8 occurs See Fault Descriptions in Chapter 4 of the PowerFlex Digital DC Drive User Manual publication 20P UM001 for details See Figure 23 on page 118 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 TG001B EN P October 2011 41
73. he Power Traces Circuit Board Install the power traces circuit board in reverse order of removal e Verify that the connecting wire on the board is placed in the exact location as previously installed and that the wires leads wound around the current transducers if present are in the same location as when previously installed Regenerative drive Non Regenerative drive Field SCR Dual Diode Module Remove the Field SCR Dual Diode Module and Field Circuit Board and Field Circuit Board Removal and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Remove the control EMI shield and control circuit board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 5 Remove the pulse transformer and switching power supply circuit boards see Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation on page 66 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 88 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 6 Remove all wires from the field SCR dual diode module on the drive heat sink You will also need to remove the small red wire staked to the large red wire 7 Remo
74. ield and control board refer to Control EMI Shield and Control Circuit Board Removal and Installation on page 64 Rockwell Automation Publication 20P TG001B EN P October 2011 33 Chapter2 Component Test Procedures 5 Remove the slotted air flow plate from the top of the drive e For 38A 10 HP and 55A 15 HP drives with 230V AC input and 35A 20 HP 45A 25 HP and 524 30 HP drives with 460V AC input remove the four screws that secure the slotted air flow plate to the top of the drive remove the fan cable from connector XV on the switching power supply board and remove the plate ae Remove screws e Forall ae er remove the two screws that secure the slotted air flow plate to the top of the drive and remove the plate Remove screw Air flow plate Remove screw 34 Rockwell Automation Publication 20P TG001B EN P October 2011 IMPORTANT Component Test Procedures Chapter 2 Mark all connections and wires before removal to avoid incorrect wiring during reassembly 6 Remove the pulse transformer board refer to Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation on page 66 Note The switching power supply board is mounted on the back of the pulse transformer board but does not need to be removed from the pulse transformer board for this test With a digital multimeter set for a continuity check measure each connection point on the pulse transformer board listed
75. ion 50 Resolver Feedback and Interface Circuit Board Removal and Installation 53 1 0 Expansion Circuit Board Removal and Installation 57 115V AC to 24V DC 1 0 Converter Circuit Board Removal and Installation 59 Control Circuit Board Removal and Installation 60 Control EMI Shield and Control Circuit Board Removal and Installation 64 Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation 66 AC Current Transducer Removal and Installation 78 Power Traces Circuit Board Removal and Installation 85 Field SCR Dual Diode Module and Field Circuit Board Removal and Installation 88 Bimetal Thermostat Removal and Installation 94 SCR Module Removal and Installation 95 Cooling Fan Removal and Installation 103 Rockwell Automation Publication 20P TG001B EN P October 2011 43 Chapter3 Access Procedures Remove Power from the ATTENTION Remove power before making or breaking cable connections Drive N When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e Sending an erroneous signal to your system s field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance e Remove and lock out all incoming power to the drive L1 L2 L3
76. ion com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact 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 Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberpo
77. istors See Pulse Transformer Board to Control Board Connections on page 122 and Switching Power Supply Board to Control Board Connections on page 124 Rockwell Automation Publication 20P TG001B EN P October 2011 125 AppendixB Circuit Board Layouts and Connections Field Board Figure 28 Field Board Layout x3 r 1 GEN VFI XFCD UF1 x2 UF VF Field fuse connections terminal block See Control Board to Field Board Connections on page 125 and Pulse Transformer Board to Field Board Connections on page 121 126 Rockwell Automation Publication 20P TG001B EN P October 2011 Appendix C Flow Charts List of Flow Charts The following pages contain flow chart versions of troubleshooting procedures contained in Chapter 2 Component Test Procedures Topic Page Control Power Supply Failure 128 Field Current Loss Failure 129 Rockwell Automation Publication 20P TG001B EN P October 2011 127 Appendix C Control Power Supply Flow Charts Failure 128 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
78. it Board Removal and Installation on page 66 The drive rating determines the power bridge configuration and where the AC current transducers are located in the drive e Frame A drives rated up to 55A 15 HP with 230V AC input or up to 52A 30 HP with 460V AC input have AC Current transducers installed on the power traces board See AC Current Transducers on Drives with a Power Traces Board on page 79 OR e Frame A drives rated 73A 20 HP with 230V AC input and higher and 734 40 HP with 460V AC input and higher have AC current transducers installed on the bus bars inside the drive See AC Current Transducers from Drives Rated 73A 20 HP with 230V AC Input and Higher or 73A 40 HP with 460V AC Input and Higher on page 81 78 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 AC Current Transducers on Drives with a Power Traces Board The drive size determines how the AC current transducers are secured to the power traces board See Remove the Current Transducers with Connection Bars on page 79 below for drives with a single metal bar and no windings on the AC current transducers See Remove the Current Transducers with No Connection Bars on page 80 for drives no metal bar and windings on the AC current transducers Remove the Current Transducers with Connection Bars 6 Remove the four M3 x 6 mm screws and washers that secure the top of the AC current transducers to the power
79. it Board Removal and Installation on page 59 Rockwell Automation Publication 20P TG001B EN P October 2011 8 Record all switch and jumper settings on the control board See the Access Procedures Chapter 3 PowerFlex DC Digital Drive User Manual publication 20P UMO01 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 11 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 current resistors setting 14 1 In addition the value selected with switch 14 must be entered in Par 374 Rated 14 2 Field Curr in the control software when the drive is commissioned 14 3 14 4 14 5 14 6 15 Configuration of the control circuit board to the appropriate drive size This value is 15 1 set to the appropriate size at the factory 15 2 15 3 515 4 15 5 15 6 15 7 15 8 20 Monitoring of the Z channel of the digital encoder on connector XE2 Off P
80. ith 230V AC Input and Higher or 73A 40 HP with 460V AC Input and Higher on page 97 Rockwell Automation Publication 20P TG001B EN P October 2011 95 Chapter3 Access Procedures SCR Modules on Drives Rated up to 55A 15 HP with 230V AC Input or up to 524 30 HP with 460V AC input 6 Remove the power traces circuit board See Power Traces Circuit Board Removal and Installation on page 85 Note The AC current transducers do NOT need to be removed from the power traces board in order to remove the SCR modules 7 Remove the two screws and washers that secure each SCR module to the heatsink and remove the SCR modules Remove screws Remove screws v aii 3 ti Continue with Install the SCR Modules on page 103 96 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 SCR Modules on Drives Rated 73A 20 HP with 230V AC Input and Higher or 734 40 HP with 460V AC Input and Higher 6 Remove the isolation sheet SEN Remove isolation sheet 7 Remove the M5 x 10 mm screws that secure the U V W C and D terminal bus bars to the power terminal isolation strip at the bottom of the drive Remove screws Tightening torque 2 5 Nem 22 0 Ib in Rockwell Automation Publication 20P TG001B EN P October 2011 97 Chapter3 Access Procedures 8 For regenerative drives only remove the screws and washers that secure the connecting bus bars to the anodes of the co
81. kwell Automation Publication 20P TG001B EN P October 2011 Hardware Description oooo Before You Begin Testing Maintenance or Repairs Chapter 1 The PowerFlex DC drive contains a power structure that has an armature and field supply The armature supply consists 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 A drive by checking the data nameplate located on the side of the drive The frame size is printed just above the serial number in the lower right corner of the label Frame A Serial Number A23E0042 T TH d TREE Rockwell Automation Publication 20P TG001B EN P October 2011 13 Chapter1 Before You Begin Testing Maintenance or Repairs Commonly Used Tools 14 Service Tools This list of basic service tools which will cover needs of tools for repair and maintenance measurements Item Details Digital Multimeter Digital multimeter capable of ac and dc voltage continuity resistance and forward diode bias tests Fluke model 87 IIl or equivalent recommended Oscil
82. ld circuit To Field circuit board board board Thin Blue Wire Thick Red Wire To Thin Black Wire Field circuit board amp Thin Red Wire Rockwell Automation Publication 20P TG001B EN P October 2011 93 Chapter3 Access Procedures Bimetal Thermostat Removal Remove the Bimetal Thermostat and Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Remove the protective covers see Protective Cover Removal and Installation on page 48 4 Remove the control EMI shield and control circuit board see Control EMI Shield and Control Circuit Board Removal and Installation on page 64 5 Remove the pulse transformer and switching power supply circuit boards see Pulse Transformer and Switching Power Supply Circuit Board Removal and Installation on page 66 IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 6 Remove the two M3 x 6 mm screws that secure the thermostat to the drive heat sink and remove the thermostat and connected wires from the drive Remove screws Tightening torque 1 0 Nem 8 9 Ib in Install the Bimetal Thermostat Install the thermostat in reverse order of removal IMPORTANT Thermal grease must be applied to the bottom of the thermostat before securing it to the heatsink 94 Rockw
83. loscope Portable digitizing dual channel scope with isolation Current damp 3x drive rated armature current output Soldering station Soldering de soldering Torque wrench 1 12 Nem Torque wrench 6 50 Nem box wrench 7mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm Socket extension 230 mm Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm Wire cutter Nose pliers Crimping tools For cable terminals 1 5 240 Angle wrench Screw drivers Flat nose 7x2 mm Phillips 1 2 3 Hexagonal wrench 4 5 6 ESD protected place of work Working surface Floor covering seat and ground connections ESD protective clothing Wrist wrap shoes overall clothing coat Phillips is a registered trademark of Phillips Screw Company Software Tools DriveTools SP DriveExecutive DriveExplorer and DriveObserver are software tools for uploading downloading and monitoring system parameters Rockwell Automation Publication 20P TG001B EN P October 2011 Introduction Component Test Procedures Chapter 2 This chapter provides general procedures for inspecting and testing the major components of the drive and includes recommendations for repairs Due to the technical nature of this product and the variety of possible applications not all possible fault conditions and troubleshooting solutions can be described in this manual Topic Page Save the Parameter Configuration 16 Visual C
84. me ofthe last fault 1350 Status at Fault Captures and displays Par 382 Drive Status 2 bit pattern at the time ofthe last fault 1351 1360 Fault x Code A code that represents the fault that tripped the drive The codes will appear in these parameters in the order they occur i e Fault 1 Code the most recent fault 1361 1370 Fault x Time The time between initial drive power up and the occurrence of the associated trip fault 1371 Fault Arm Amps Captures and displays the armature current as a percentage of rated current at the time of the last fault 1372 Fault Speed Captures and displays the output speed rpm of the drive at the time of the last fault 1373 Fault Field Amps Captures and displays the field current as a percentage of rated current at the time of the last fault 1374 Fault Voltage Captures and displays the armature voltage at the time of the last fault 42 Rockwell Automation Publication 20P TG001B EN P October 2011 Introduction Access Procedures This chapter provides detailed procedures for removing and replacing drive Chapter 3 components Topic Page Remove Power from the Drive 44 Switching Power Supply Fuse Removal and Installation 45 Field Circuit Fuse Removal and Installation 46 DPI HIM Assembly Removal and Installation 4 Protective Cover Removal and Installation 48 Communication Adapter and EMI Shield Removal and Installat
85. mer Board FIR1 XX Rev P and Lower below or Configure a Pulse Transformer Board FIRI XX Rev Q and Higher on page 76 Configuring the Pulse Transformer Board FIR1 XX Rev P 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 See Table 12 or Table 13 in the Sizing Resistor Configuration section on page 73 for the appropriate configuration Sizing resistors are located on the lower right corner of CUT 20A R2 3 4 the pulse transformer circuit board 40A R1 3 4 4 Y 70A R1 2 4 FOR 110A R4 M R eM o R2 c n R3 c helms R4 FREER BEE 18 79135 36 75 76 U2 V2 72 Rockwell Automation Publication 20P TG001B EN P October 2011 Sizing Resistor Configuration Table 12 and Table 13 below indicate the value of the designated resistor R1 R5 when left in place on the pulse transformer board or indicate Access Procedures Chapter 3 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 ACLine HP R1 R2 R3 R4 R5 Rating Code Amps
86. move Power from the Drive on page 44 3 Remove the protective covers from the drive Refer to Protective Cover Removal and Installation on page 48 circuit boards Check components for burn marks breakage or foil delamination on all Replace any of these components without further testing if they show evidence of burn marks breakage or foil delamination Troubleshoot a Control Power Supply Failure 1 Read the General Safety Precautions on page 12 2 Remove power from the drive Refer to Remove Power from the Drive on page 44 3 Remove the protective covers from the drive Refer to Protective Cover Removal and Installation on page 48 Ifa drive Power Failure fault F3 has occurred and the drive is inoperable via the HIM or other means of control compete the steps below to determine where the control power failure has occurred 4 Measure the signal voltage at the testpoints as indicated in the following table Name Testpoint For Testpoint Location AssociatedConnector Description See Pin 5V XY5 Figure 1 on page 20 XA 1 XA 3 XA 5 5V digital supply GNDD XY6 Figure 1 on page 20 XA 2 XA 4 XA 6 5V digital supply ground GNDD XY7 Figure 2 on page 21 XA 2 XA 4 XA 6 5V digital supply ground 15V XY12 Figure 1 on page 20 XA 9 XA 10 15V analog supply GNDA XY10 Figure 1 on page 20 XA 11 XA 12 15V analog supply ground 15V XY11 Figure 1 on page
87. nstall the Control Circuit Board on page 63 for more information an Apply power to the control circuits terminals U2 and V2 of the drive 6 Verify that the following parameter values are set correctly 45 Max Ref Speed is set to the motor nameplate base speed 162 Max Feedback Spd is set to the motor nameplate base speed 175 Rated Motor Volt is set to the motor rated nameplate armature voltage 179 Nom Mtr Arm Amps is set to the rated motor nameplate armature current Rockwell Automation Publication 20P TG001B EN P October 2011 109 Chapter 4 110 Start Up After Repair e 280 Nom Mtr Fld Amps is set to the rated motor nameplate field current e 374 Drv Fld Brdg Amps is set to the rated current of the field bridge regulator Energize the drive 8 Measure the field current and verify that the value is reflected in parameter 10 11 12 13 14 15 16 234 Fld Current Pct Run the following applicable Autotune procedures detailed in Chapter 2 of the PowerFlex Digital DC Drive User Manual publication 20P UMO001 e Tune the Current Regulator e Verify Motor Rotation Direction and Run Feedback Polarity Checks If parameter 414 Fdbk Device Type is set to 3 Armature set parameter 107 Speed Zero Level to a minimum value of 10 of base motor speed e Configure the Speed Feedback Parameters e Tune the Speed Regulator Make configuration changes that allow
88. ober 2011 47 Chapter3 Access Procedures Protective Cover Removal Remove the Protective Covers and Installation You must remove both the lower protective cover and the power terminal cover in order to access the power terminals 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 3 Loosen the two screws that secure the power terminal cover to the drive and slide the cover down and off the chassis Remove power terminal cover Tightening torque 1 0 Nem 8 9 Ib in Disconnect the DPI cable from the HIM assembly 48 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 5 Remove the two screws that secure the bottom protective cover to the drive and while gently lifting along the top edge of the cover slide it down and off the drive chassis UUUUUUUUUUUUUUUUUUUU ie Disconnect DPI cable Tightening torque 1 5 Nem 13 Ib in 6 Press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis Next at the top of the drive pull the cover forward away from the drive until the pins fit in the keyhole in the top of the cover then carefully lift the cover off of the drive chassis IMPORTANT The HIM assembly is connected via a cable to the control
89. odule s is are damaged based on the tables below and replace that module s Refer to SCR Module Removal and Installation on page 95 Rockwell Automation Publication 20P TG001B EN P October 2011 29 Chapter2 Component Test Procedures Table 2 SCR Anode to Cathode Junction Measurements for Regenerative Drives On SCR Module SCR Measure from To Terminal Nominal meter reading Terminal 1 1 U C 4 U D 2 2 V C 5 V D 3 3 W C 6 W D Mr P al T cC open circuit or megaOhms range 04 U D 02 02 V C 05 V D 03 03 W C 06 W D Figure 6 Regenerative Drive SCR Module Layout d ae V L SCR Module SCR Module SCR Module 1 2 3 SCR Module SCR Module SCR Module 01 02 03 T t t i t LO O Q ole oll Le o 19 o i Le o O Q O E ae V L rer e el Te E ei E U 30 Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 Table 3 SCR Anode to Cathode Junction Measurements for Non Regenerative Drives
90. ol board 63 65 cooling fan 107 DPI HIM assembly 47 field board 93 field circuit fuses 46 field SCR dual diode module 93 1 0 expansion board 59 power traces board 88 protective covers 50 pulse transformer board 72 SCR modules 103 switching power supply board 72 switching power supply fuse 45 131 Index 132 L layout drawings circuit boards 119 M motor overheating 41 0 outputs relay 41 overcurrent fault 23 overtemperature heatsink 41 P parameter configuration download 16 save 16 power removing 44 power failure fault 17 power traces board install 88 remove 85 protective covers install 50 remove 48 PTC 41 pulse transformer board install 72 remove 66 test 33 relay outputs 41 remove 115V AC to 24V DC 1 0 converter board 59 AC current transducers 78 bimetal thermostat 94 communication adapter 50 control board 60 64 cooling fan 103 DPI HIM assembly 47 field board 88 field circuit fuses 46 field SCR dual diode module 88 1 0 expansion board 57 power 44 power traces board 85 protective covers 48 pulse transformer board 66 SCR modules 95 switching power supply board 66 Switching power supply board fuse 45 Rockwell Automation Publication 20P TG001B EN P October 2011 S safety precautions 12 save parameter configuration 16 schematic diagrams 111 SCR modules install 103 remove 95 service tools 14 software tools 14 switching power supply board fuse 45 install 72 remov
91. omponent Inspection 17 Troubleshoot a Control Power Supply Failure 17 Troubleshoot an AC Undervoltage Fault 22 Troubleshoot an Armature Bridge Failure 23 Troubleshoot a Field Current Loss Fault 25 Power Component Test Procedures 29 Speed Feedback Device Tests 38 Thermistors and Thermal Switches 41 Relay Outputs 41 Create a Fault Report 42 What You Need When You Call Tech Support 42 IMPORTANT Using the diagnostic tests in this chapter should only be performed by qualified personnel and only when other corrective actions have failed All tests assume that the control board connections have been properly made For common drive symptoms and corrective actions and fault troubleshooting information see Chapter 4 Troubleshooting in the PowerFlex Digital DC Drive User Manual publication 20P UM001 Rockwell Automation Publication 20P TG001B EN P October 2011 15 Chapter2 Component Test Procedures Save the Parameter Configuration It is recommended that you save the drive and communication adapter parameter configuration to a HIM Set or by up loading the drive and adapter parameters to an offline node file using DriveExecutive before performing any service or testing on the drive HIM sets are files stored in permanent nonvolatile HIM memory Save to a HIM Set Complete these steps to save the drive and adapter parameters to a HIM set 1 On the HIM access the Memory Storage menu 2 Select the HIM CopyCat menu and press
92. osition Z channel monitored On Position Z channel not monitored 21 Encoder power supply voltage and input adaptation selection Note When control power is supplied to the drive the appropriate LED lights to indicate the selection of the switch ENC_5 5 V encoder 2 5 5 4V input range ENC_12 12 15 V encoder 5 4V 15 2V input range Rockwell Automation Publication 20P TG001B EN P October 2011 61 Chapter 3 62 Access Procedures 9 Carefully disconnect the cables from connectors XFCD XA and XR on the control board 10 Remove the plug in I O and control terminal blocks with the wiring kept in place Disconnect cables XFCD XA and XR m s ERIT pen FX32 E mme TTE ti oe mmm Disconnect I 0 and Bess control wiring Note Control board shown with communication adapter and optional boards removed Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 11 Remove the five M3 x 6 mm screws and washers that secure the control board to the control EMI shield and remove the control board ALTINI Remove screws and washers Tightening torque O DN c 3r SSH o i j m EL 1 0 Nem 8 9 Ib in SS penn ah A TN Install the Control Circuit Board Install the control board in reverse order of removal e Verify that all DIP switches are set to the correct configuration based on your recorded settings See page 61
93. pe Rt eda edat What You Need When You Call Tech Support Rockwell Automation Publication 20P TG001B EN P October 2011 Table of Contents Access Procedures Chapter 3 ntrod ctiOl osi b ll ad eek PE ae eR M E RAEN 43 Remove Power from the Drive esee 44 Switching Power Supply Fuse Removal and Installation 45 Remove the Fuse on the Switching Power Supply Circuit Board 45 Install the Fuse on the Switching Power Supply Circuit Board 45 Field Circuit Fuse Removal and Installation suus 46 Remove the Field Circuit Fuses 0ccccecececeeeecees 46 Install the Field Circuit Pusess242 22 ees Casein os te oko 46 DPI HIM Assembly Removal and Installation Lise 47 Remove the DPI HIM Assembly from the Protective Cover 47 Install the DPI HIM Assembly on the Protective Cover 47 Protective Cover Removal and Installation 00c cece eee 48 Remove the Protective COVElS A a Ig sak ates e PREX RICH Y 48 Install the Protective Covers sedora ee sea EC EPIS BAS onim t 50 Communication Adapter and EMI Shield Removal and Installation 50 Remove the Communication Adapter and EMI Shield 50 Install the Communication Adapter and EMI Shield 52 Resolver Feedback and Interface Circuit Board Removal and CEMENTERIO TTE 53 Remove the Resolver Feedback and Interface Circuit Boards 53 Install the Resolver Feedback
94. proper position See Figure 15 on page 114 and Figure 16 on page 114 for SCR gate lead pinouts Cooling Fan Removal and Remove the Cooling Fan Installation 1 Read the General Safety Precautions on page 12 2 Remove power from the drive see Remove Power from the Drive on page 44 The drive rating determines where the cooling fan if any is located in on the drive e See Cooling Fan on Drives Rated 38A 10 HP and 55A 15 HP with 230V AC Input and 35A 20 HP 45A 25 HP and 52A 30 HP with 460V AC Input on page 104 OR e See Cooling Fan on Drives Rated 73A 20 HP with 230V AC Input and 73A 40 HP with 460V AC Input on page 105 Rockwell Automation Publication 20P TG001B EN P October 2011 103 Chapter 3 104 Access Procedures Cooling Fan on Drives Rated 384 10 HP and 554 15 HP with 230V AC Input and 354 20 HP 454 25 HP and 524 30 HP with 460V AC Input Frame A drives rated 38A 10 HP and 55A 15 HP with 230V AC input and 35A 20 HP 45A 25 HP and 52A 30 HP with 460V AC input have a cooling fan installed at the top of the drive 3 Remove the four screws that secure the slotted air flow plate and fan to the top ofthe drive The fan is connected via a cable to the switching power supply board and therefore will not pull free from the drive until the cable is disconnected See Step 3 below for instructions Remove four screws Tightening torque 1 0 Nem 8 9 Ib in Disconnect the fan
95. r the top of the pulse transformer board and retain for reuse Remove plastic screw Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 10 Remove the appropriate gate leads e For regenerative drives 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 e For non regenerative drives remove each pair of orange and yellow gate lead cables from connectors KGO1 KG06 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 11 Remove the cable from connectors XTA on the lower right side of the board For regenerative drives remove 12 gate Remove cable from XTA For non regenerative drives remove six gate leads and push through holes in board Remove cable from XTA Rockwell Automation Publication 20P TG001B EN P October 2011 69 Chapter 3 70 Access Procedures 12 Remove the six M3 x 6 mm screws and washers that secure the bottom of the pulse transformer board to the drive and while lifting up slightly on the board slide it toward the top of the drive and out of the chassis Note that there is an isolation sheet below the board do not remove this sheet unless it is damaged IMPORTANT The cables from connectors
96. rmation you should know before you begin tests maintenance or repairs on drive components Topic Page General Safety Precautions 12 Hardware Description 13 iz Commonly Used Tools Rockwell Automation Publication 20P TG001B EN P October 2011 11 Chapter1 Before You Begin Testing Maintenance or Repairs General Safety Precautions Read the following precautions before you begin testing components performing maintenance or repairing the drive gt bP bP BB gt ATTENTION Only qualified personnel familiar with DC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION Severe injury or death can result from electrical shock burn or unintended actuation of controlled equipment Hazardous voltages may exist in the drive enclosure even with the circuit breaker in the off position Recommended practice is to disconnect and lock o
97. rresponding SCR modules and remove the bus bars In addition remove the U V and W phase terminal bus bars from the drive IMPORTANT The screws that secure these bus bars to the SCR modules are M5 x 16 Retain for reuse with these bus bars only Remove screws Remove screws Connecting bus bars U Phase bus par V Phase bus bar W Phase bus bar 98 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 9 Remove the four screws and washers that secure the C and D terminal bus bars to the horizontal bus bars and remove the C and D terminal bus bars IMPORTANT For regenerative drives only the screws that secure these bus bars to the SCR modules are M5 x 16 Retain for reuse with these bus bars only Non Regenerative drive Remove screws Regenerative drive Remove screws Rockwell Automation Publication 20P TG001B EN P October 2011 99 Chapter3 Access Procedures 10 Remove the screws and washers that secure the connecting bus bars to the SCR modules and remove the bus bars Non Regenerative drive Remove screws Regenerative drive Remove screws 100 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 11 For non regenerative drives only remove the screws and washers that secure the U V and W terminal bus bars to the SCR modules and remove the bus bars Remove screws Rockwell Automation Publication 20P TG001B
98. rs that secure each of the U and V phase terminal bus bars containing the AC current transducers to the SCR modules e For Regenerative drives remove the top and bottom screws and washers that secure the connecting bus bars and U and V phase terminal bus bars to the SCR modules and remove the connecting bus bars Tightening torque Remove two screws from U and V phase connecting bus bars 2 5 4Nem 22 35 4 Ib in vat e For Non Regenerative drives remove the screws and washers that secure the U and V Phase terminal bus bars to the corresponding SCR modules Remove two screws from U and V phase terminal bus bars Tightening torque 2 5 4Nem 22 35 4 Ib in Rockwell Automation Publication 20P TG001B EN P October 2011 83 Chapter3 Access Procedures 10 While lifting the terminal bus bars out of the drive slide the AC current transducers off of the bus bars Install the AC Current Transducers Install the AC current transducers in reverse order of removal For AC current transducers that must be wound with wire leads e Wind the wire leads around the new AC current transducers the exact number of times and in the same position as the wires on the AC current transducers that were removed from the power traces board e Crimp the connection lugs onto the wire leads before they are secured to the power traces board Crimp connection lug onto wire ends WrapwirearoundAC
99. rt 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20P TG001B EN P October 2011 Supersedes Publication 20P TG001A EN P April 2011 Copyright 2011 Rockwell Automation Inc All rights reserved Printed in the U S A
100. s ITF2 Pulse 9 0 V 5 as ITE 18 kS s 3 5 v OCR Line 4 5n C O STOPPED e Ifthe gate signals are missing replace the control board e Ifthe gate signals are present replace the field board Rockwell Automation Publication 20P TG001B EN P October 2011 Power Component Test Procedures Component Test Procedures Chapter 2 Check the Armature SCR Modules The frame A PowerFlex DC drive armature supply consists of three non regenerative drives or six regenerative drives SCR modules mounted on the main heat sink 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 12 2 Remove and lock out all incoming power to the drive Refer to Remove Power from the Drive on page 44 3 Verify that contactor power if used is removed 4 Verify that power to an external field supply if used is removed 5 Check the anode to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance across the SCRs lead orientation is not critical For regenerative drives refer to Table 2 on page 30 and Figure 6 on page 30 For non regenerative drives refer to Table 3 on page 31 and Figure 7 on page 31 If a low resistance is detected determine which SCR m
101. t 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 75 The XR connector is located on the upper right corner of the pulse transformer circuit board 20A R2 3 4 40A R1 3 4 70A R1 2 4 SFOR 110A R4 Hos RI o 4 Hit o R2 omit ORS c helo R4 NEC R5 a p 31 ae j I 3 qu NE The TA potentiometer is located on the lower right corner of the pulse transformer circuit board next to the control power terminal block Shown sealed NS 9135 36 75 76 U2 V2 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 Total Resistance Values Table 14 230V AC Input Drives Drive Current DC ACLine HP Set RTA Value Using TA RatingCode Amps Amps Potentiometer Ohms 7P0 7 5 7 15 34 971 9P0 9 74 2 45 333 012 12 9 8 3 34 020 20 16 5 612 029 29 24 7 5 42 207 038 38 31 10 32211 055 55 45 15 22 255 073 73 60 20 16 767 093 93 76 25 13 161 110 110 90 30 11 127 Table 15 460V AC Input Drives Drive Current DC ACLine HP Set RTA Value Using TA Rating Code Amps Amps Potentiometer Ohms 4P1 4 1 33 2 59 707 6P0 6 49 3 40 8 010 10 8 2 5 40 8 014 14 11 4 75 29 143 019 19 15 5 10 64 421 027 27 22 1 15 45 333 035 35 28 6 20 34971 045 45 36
102. t 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 27 Rockwell Automation Publication 20P TG001B EN P October 2011 25 Chapter2 Component Test Procedures Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 130 1 2 Field Curr Scale 1A Read the General Safety Precautions on page 12 Verify the actual value of parameter 351 Field Current by measuring the DC motor field current using a DC clamp Verify that the drive rated field bridge current is set correctly in parameter 374 Drv Fld Brdg Cur and DIP switch S14 is configured to correctly according to the instructions in the PowerFlex Digital DC Drive User Manual publication 20P UM001 and make any necessary corrections See Control Board on page 125 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 Refer to Protective Cover Removal and Installation on page 48 Measure the field current signal
103. tching power supply board and remove the plate Remove screws Tightening torque 1 0 Nem 8 9 Ib in 66 Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter 3 e For all other drives remove the two screws that secure the slotted air flow plate to the top of the drive and remove the plate Remove screw Tightening torque 1 0 Nem 8 9 Ib in Air flow plate Remove screw Tightening torque 1 0 Nem 8 9 Ib in IMPORTANT Markall connections and wires before removal to avoid incorrect wiring during reassembly 6 Remove the plug in control power terminal block from the lower right corner of the pulse transformer circuit board Remove plug in terminal block Rockwell Automation Publication 20P TG001B EN P October 2011 67 Chapter 3 Access Procedures 68 7 Remove the cables from connectors X3 X4 and XP at the top of the pulse transformer board Note Connector X4 contains a jumper for drives without a fan leave in place Remove cables from X3 X4 and XP 8 For pulse transformer boards with an armature voltage feedback terminal block FIR1 XX rev Q and higher remove the connector from XCD_10 on the upper left corner of the board XSW XP x C J C XSW1 TR2 TRI Remove connector x4 from XCD_10 Rod XR XCD 10 XY 9 Remove the plastic screw nea
104. traces board 7 Remove the two stand offs that secure the bottom of the AC current transducers to the power traces circuit board and remove the AC current transducers from the drive Continue with Install the AC Current Transducers on page 84 Remove four screws and washers Tightening torque AC current 0 5 Nem 4 4 Ib in eS f transducers Remove two stand offs Note non regenerative drive shown 8 Continue with Install the AC Current Transducers on page 84 Rockwell Automation Publication 20P TG001B EN P October 2011 79 Chapter3 Access Procedures Remove the Current Transducers with No Connection Bars 6 Remove the four M3 x 6 mm screws and washers that secure the top of the AC current transducers to the power traces board 7 Remove the two screws and washers that secure the top of the wire leads to the power traces board Remove two A screws and O Aa washers Tightening torque 0 5 Nem 4 4 Ib in O BE BE O AC current transducers Remove two stand offs 8 Turn the board over and remove the two M3 x 6 mm screws and washers that secure the AC current transducers to the board and remove the AC current transducers and windings if present from the drive IMPORTANT You do not need to remove the windings from the AC current transducers however note the number of times the wire lead is wound around the AC current trans
105. ts in an infinity reading check the fuses at FV1 and FU1 on the bottom of the drive to determine if they are open See Figure 10 on page 37 36 Rockwell Automation Publication 20P TG001B EN P October 2011 Component Test Procedures Chapter 2 Table 10 SCR Dual Diode Module Anode to Cathode Junction Measurements MeterLead Meter Lead Nominal meter reading Terminal Terminal U1 a open or co U1 D1 open or co V1 a open or eo V1 D1 open or co a D1 open or co a U1 open or co a V1 0 50V D1 a 0 50V D1 U1 0 45V Figure 10 Field Terminal Block and Field Fuse Locations Bottom View of Drives Drive with no Fan on Bottom Aum ELI Field terminal block Field fuses Drive with Fan on Bottom 6 Remove the cable from connector XP on the pulse transformer circuit board 7 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 Refer to Table 11 below Ifa low resistance is detected replace the SCR dual diode module Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Measure from Nominal meter reading XP1 XP2 XP3 XP4 Mette Rockwell Automation Publication 20P TG001B EN P October 2011 37 Chapter2 Component Test Procedures Speed Feedback Device Tests 38 Check the Encoder The encoder feedb
106. ut control equipment from power sources If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Workplaces must be followed DO NOT work alone on energized equipment ATTENTION Potentially fatal voltages may result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc may occur An electrical arc can cause personal injury or property damage by e Sending an erroneous signal to your systems field devices causing unintended machine motion e causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts may create electrical resistance ATTENTION HOT surfaces can cause severe burns Do not touch the heatsink surface during operation of the drive After disconnecting power allow time for cooling 12 Roc
107. ve the two M5 x 10 mm screws and washers that secure the field SCR dual diode module to the drive heat sink and remove the module Remove bundled Av wires from terminal Aa block Remove two screws and washers PAY had Tightening torque Ub dlida sis Yom j 2 5 Nem 22 0 Ib in Y EA E j bi 4 8 If necessary remove the power wiring from terminals U V W C D and PE Rockwell Automation Publication 20P TG001B EN P October 2011 89 Chapter 3 90 Access Procedures 9 Remove the plug in field terminal block on the bottom of the drive with the wiring kept in place 10 Remove the two M x 12 mm screws that secure the bottom air flow plate to the power terminal isolation strip Remove plug in field terminal block Remove two screws Tightening torque 1 2 Nem 10 6 Ib in Note Drive with fan shown Rockwell Automation Publication 20P TG001B EN P October 2011 Access Procedures Chapter3 11 Remove the M x 12 5 mm screws that secure the bottom air flow plate to the drive chassis and carefully pull the air flow plate and fan if present assembly down and off the drive Note Bottom air flow plates on frame A drives rated up to 55A 15 HP with 230V AC input or up to 52A 30 HP with 460V AC input are secured to the drive chassis with four screws Bottom air flow plates on frame A drives with a fan are secured to the chassis with six screws Remove four screws for drives without fan on
108. y board Replace the fuse on the switching power supply board See Switching Power Supply Fuse Removal and Installation on page 45 Disconnect the cable at connector XA on the control board See Figure 27 on page 125 for location of connector XA Apply AC control power to the drive e If the fuse blows continue with Testing the Switching Power Supply and Pulse Transformer Boards below e If the fuse does not blow continue with Testing the Control and Field Board Connections on page 19 Testing the Switching Power Supply and Pulse Transformer Boards Replace the fuse on the switching power supply board See Switching Power Supply Fuse Removal and Installation on page 45 Remove the switching power supply board from the pulse transformer board See Remove the Pulse Transformer and Switching Power Supply Circuit Board on page 66 Reapply power to the switching power supply board only e If the power supply fuse does not blow continue with step 5 below e If the power supply fuse blows replace the switching power supply board Remove all incoming AC voltage from the drive Check all external wiring connected to the pulse transformer board including the motor PTC if used for a possible short circuit condition Repair any short circuit conditions if found If no short circuit conditions exist replace the pulse transformer board Rockwell Automation Publication 20P TG001B EN P
109. youts and Connections Appendix B Table 23 Pulse Transformer Board to Current Transducer Connections Current Pin Number to Pin Number Transducer Description 1 Black a CT on Phase U Secondary side CT phase U 2 Brown 3 a BIG CT on Phase V Secondary side CT phase V 4 Brown Figure 26 Switching Power Supply Board Layout Fuse location XV F1 15 16 Table 24 Switching Power Supply to Fan Connections Control Board Connector XV Pin Number Pin Number Fan Connector XV Rockwell Automation Publication 20P TG001B EN P October 2011 Description 24V AIIN AJIN 24V supply common 123 AppendixB Circuit Board Layouts and Connections Table 25 Switching Power Supply Board to Control Board Connections Switching Power Supply Board Connector XA Pin Number Pin Number col c O1 e IN gt CO CO NM al e Cw NM co 110 M 112 13 14 15 olan e ws nr o 116 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

20P-TG001 - Rockwell Automation

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