Allen-Bradley PowerFlex 20P Hardware Service Manual Download Page 45

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Rockwell Automation Publication 20P-TG001C-EN-P - February 2018

Part Replacement Procedures

Chapter 3

28 A Field SCR/Dual Diode Module for 230V AC Regen. Drive, 38…110
A

SK-20P-S79F1

28 A Field SCR/Dual Diode Module for 460/480V AC Regen. or Non-
Regen. Drive, 35…129 A

Bimetal Thermostat 85 °C ±3 °C for 230V AC Drive, 38…73 A

SK-20P-S7G37

Bimetal Thermostat 85 °C ±3 °C for 460/480V AC Drive, 35…73

Bimetal Thermostat 80 °C ±3 °C for 230V AC Drive, 93…110 A

SK-20P-S7GA1

Bimetal Thermostat 80 °C ±3 °C for 460/480V AC Drive, 100…129 A

Bimetal Thermostat 70 °C ±3 °C for 460/480V AC Drive, 86 A

SK-20P-S7GA0

SCR Modules (Qty 6) 1K2V 25 A for 230V AC Regen. Drive, 7…20 A

SK-20P-S7F44

SCR Modules (Qty 6) 1K2V 40 A for 230V AC Regen. Drive, 29…55 A

SK-20P-S7F45

SCR Modules (Qty 6) 1K6V 25 A for 460/480V Regen. Drive, 4.1…19 A

SK-20P-S7F73

SCR Modules (Qty 3) 1K6V 25 A for 460/480V Non-Regen. Drive,
4.1…19 A

SCR Modules (Qty 6) 1K6V 40 A for 460/480V Regen. Drive, 27…52 A

SK-20P-S7F74

SCR Modules (Qty 3) 1K6V 40 A for 460/480V Non-Regen. Drive,
27…52 A

SCR Modules (Qty 6) 1K2V 55 A for 230V AC Regen. Drive, 73 A

SK-20P-S7F46

SCR Modules (Qty 6) 1K2V 90 A for 230V AC Regen. Drive, 93…110 A

SK-20P-S7F47

SCR Modules (Qty 6) 1K6V 55 A for 460/480V Regen. Drive, 73…86 A

SK-20P-S7F75

SCR Modules (Qty 3) 1K6V 55 A for 460/480V Non-Regen. Drive,
73…86 A

SCR Modules (Qty 6) 1K6V 90 A for 460/480V Regen. Drive,
100…129 A

SK-20P-S7F77

SCR Modules (Qty 3) 1K6V 90 A for 460/480V Non-Regen. Drive,
100…129 A

Ventilation Components

Cooling Fan, 37 CFM, for 230V AC Drive 38 A and 55 A, 460/480V AC
Drive 35…52 A

SK-20P-S7G76

104

Cooling Fan, 100 CFM, for 230V AC and 460/480V AC Drives 73 A and
Higher

SK-20P-S7G71

Table 13 - Spare Part Kits (continued)

Description

Kit Cat. No.

Instructions
Page

Summary of Contents for PowerFlex 20P

Page 1: ...PowerFlex Digital DC Drive Frame A Catalog Numbers 20P Hardware Service Manual OriginalInstructions ...

Page 2: ...information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...Switching Power Supply and Pulse Transformer Boards 17 Test the Control and Field Board Connections 17 Troubleshoot an AC Undervoltage Fault 20 Troubleshoot an Armature Bridge Failure 22 Troubleshoot a Field Current Loss Fault 24 Low or Incorrect Field Current 25 No Field Current 26 Power Component Test Procedures 28 Check the Armature SCR Modules 28 Check the Pulse Transformer Board 32 Check the ...

Page 4: ...nd EMI Shield Replacement 52 Remove the Communication Adapter and EMI Shield 52 Install the Communication Adapter and EMI Shield 54 Resolver Feedback and Interface Circuit Board Replacement 55 Remove the Resolver Feedback and Interface Circuit Boards 55 Install the Resolver Feedback and Interface Circuit Boards 58 I O Expansion Circuit Board Replacement 59 Remove the I O Expansion Circuit Board 59...

Page 5: ...all the Power Traces Circuit Board 89 Field SCR Dual Diode Module and Field Circuit Board Replacement 89 Remove the Field SCR Dual Diode Module and Field Circuit Board 89 Install the Field SCR Dual Diode Module and Field Circuit Board 94 Bimetal Thermostat Replacement 95 Remove the Bimetal Thermostat 95 Install the Bimetal Thermostat 95 SCR Module Replacement 96 Remove the SCR Modules 96 Install t...

Page 6: ...G001C EN P February 2018 Table of Contents AppendixC Flow Charts List of Flow Charts 127 Control Power Supply Failure 128 Field Current Loss Failure 129 No Field Current Flow Chart 129 Low or Incorrect Field Current Flow Chart 130 Index 131 ...

Page 7: ...tional information concerning related products from Rockwell Automation You can view or download publications at http www rockwellautomation com global literature library overview page To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Topic Page Updated the list of Additional Resources to include a link to the ...

Page 8: ...8 Rockwell Automation Publication 20P TG001C EN P February 2018 Preface Notes ...

Page 9: ...9 Chapter 1 Before You Begin Testing Maintenance or Repairs This chapter provides information you should know before you begin tests maintenance or repairs on drive components Topic Page General Safety Precautions 10 Hardware Description 11 Commonly Used Tools 12 ...

Page 10: ...s to disconnect and lock out control equipment from powersources Ifitisnecessarytoworkinthevicinityofenergizedequipment 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 oscil...

Page 11: ...idge 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 n...

Page 12: ...oltage continuity resistance and forward diode bias tests Fluke model 87 III or equivalent recommended Oscilloscope Portable digitizing dual channel scope with isolation Current clamp 3x drive rated armature current output Soldering station Soldering de soldering Torque wrench 1 12 N m Torque wrench 6 50 N m Box wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm Socket extension 230 mm Wrench 7 mm 8 m...

Page 13: ...ly Failure 15 Troubleshoot an AC Undervoltage Fault 20 Troubleshoot an Armature Bridge Failure 22 Troubleshoot a Field Current Loss Fault 24 Power Component Test Procedures 28 Speed Feedback Device Tests 37 Thermistors and Thermal Switches 40 Relay Outputs 40 Create a Fault Report 41 What You Need When You Call Tech Support 42 IMPORTANT The diagnostic tests in this chapter should only be performed...

Page 14: ...bench file iuux See the specific software online help for instructions on how to save or export the drive configuration to an offline file Save to a HIM Set Follow these steps to save the drive and adapter parameters to a HIM set 1 On the HIM access the Memory Storage menu 2 Select the HIM CopyCat menu and press 3 Select Device HIM and press 4 Do one of the following If there is no existing HIM Se...

Page 15: ...rks breakage or foil delamination on all circuit boards Replace any of these components without further testing if they show evidence of burn marks breakage or foil delamination Troubleshoot a Control Power Supply Failure If a drive Power Failure fault F3 has occurred and the drive is inoperable by using the HIM or other means of control a control power failure can have occurred Compete these step...

Page 16: ... replace the switching power supply board 7 Replace the fuse on the switching power supply board see page 47 8 Disconnect the cable at connector XA on the control board See Control Board Layout on page 125 for location of connector XA 9 Apply AC control power to the drive If the fuse opens continue with Test the Switching Power Supply and Pulse Transformer Boards on page 17 If the fuse does not op...

Page 17: ...nsformer board Test the Control and Field Board Connections Complete these steps to test the field circuit board 1 Use an ohmmeter to check all input and output wiring on terminals 1 40 on terminal blocks TB1 and TB2 on the control board for a possible short circuit condition Repair any short circuit conditions if found 2 If an encoder and or tachometer is used use an ohmmeter to check all wiring ...

Page 18: ...5 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 31 32 33 34 35 36 37 38 39 40 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40 DEBUG S15 S3 S2 S1 S0 RST ACT RUN PWR 1 2 3 4 5 6 7 8 S18 S12 S10 S21 ENC_5 ENC_12 S4 1 2 3 4 5 6 7 8 S14 1 2 3 4 5 6 7 8 S20 S11 S9 ON ON XY18 XY17 XY19 XY9 XY8 XY12 XY10 XY11 XY6 XY5 XY21 X...

Page 19: ... A B C 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 31 32 33 34 35 36 37 38 39 40 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40 DEBUG S15 S3 S2 S1 S0 RST ACT RUN PWR 1 2 3 4 5 6 7 8 S18 S12 S10 S21 ENC_5 ENC_12 S4 1 2 3 4 5 6 7 8 S14 1 2 3 4 5 6 7 8 S20 S11 S9 ON ON XY7 12VEXP 0VEXP 5VEXP ...

Page 20: ...he drive and the power supply source and correct any problems 4 Using a voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5V offset See Figure 1 on page 18 and Figure 2 on page 19 for location of the testpoints See Figure 3 on page 23 for a schematic diagram ATTENTION Servicing energized equipment can be hazardous Severe...

Page 21: ...he voltage measurements are correct but the value of parameter 466 AC Line Voltage is incorrect replace the control board 5 Remove the ribbon cable that is connected to XR on the control board and pulse transformer board and test the continuity of the cable using the measurements in Table 24 on page 122 If the measurements on the XR cable are correct replace the pulse transformer board ...

Page 22: ...or on the control board and use an adapter to measure these signals 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive see page 50 3 If a DC output contactor is installed disconnect the cable from XR on the control board and measure the signal for each SCR gate as indicated in this table ATTENTION Servicing energized equipment can be hazardous Severe inj...

Page 23: ...rements taken on an SCR In these figures 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 Current Signals Example Figure 4 Good SCR Armature Voltage and Motor Current Signal Example 5V 0V XY19 XY19 X...

Page 24: ...te G6 is open Figure 5 Open Thyristor Example Troubleshoot a Field Current Loss Fault If the drive faults with a Field Current Loss fault F6 and there is low or incorrect field current present at the motor as seen in parameter 351 Field Current complete the steps in Low or Incorrect Field Current on page 25 If the drive faults with a Field Current Loss fault F6 and there is no field current presen...

Page 25: ...rminal LA is the ground and LB is field current signal and verify the following The measured value of the field current at LA LB is equal to the value of parameter 374 Drv Fld Brdg Cur The expected voltage across these terminals is 1 66V DC For lower field current values the voltage will be proportional For example if the field is configured for 2 A and the motor is rated for 1 5 A the measurement...

Page 26: ...ith step 4 4 Remove AC power to the drive and check the fuses at FU1 and FV1 If the fuses are blown complete the steps in Test Field Wiring and Voltage Signals If the fuses are not blown complete the steps in Test Field Control Signals TestFieldWiringandVoltageSignals 1 Test the resistance of the motor field wiring and motor field for possible short circuits If there are no short circuits continue...

Page 27: ...Measure the gate signals at pins XR 1 and XR 2 on the cable The figure that is shown here displays the following signals from top to bottom If the gate signals are missing replace the control board If the gate signals are present replace the field board Channel Signal 1 U1 V1 Sync 4 Ie LEM current feedback signal that is taken on LA LB terminal 2 ITF1 pulse 3 ITF2 pulse LA LB U1 V1 Sync ITF1 Pulse...

Page 28: ...eration If an armature bridge component malfunction is suspected follow these steps 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 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 resistanc...

Page 29: ...le 2 SCR Anode to Cathode Junction Measurements for Regenerative Drives On SCR Module SCR Measure from Terminal To Terminal Nominal Meter Reading 1 1 U C open circuit or MΩ range 4 U D 2 2 V C 5 V D 3 3 W C 6 W D 01 01 U C 04 U D 02 02 V C 05 V D 03 03 W C 06 W D SCR Module 1 SCR Module 01 SCRModule 2 SCR Module 02 SCRModule 3 SCR Module 03 U C V D W ...

Page 30: ...egenerative Drive SCR Module Layout Table 3 SCR Anode to Cathode Junction Measurements for Non regenerative Drives On SCR Module SCR Measure from Terminal To Terminal Nominal meter Reading 01 01 U C open circuit or MΩ range 04 U D 02 02 V C 05 V D 03 03 W C 06 W D SCR Module 01 SCR Module 02 SCR Module 03 U C V D W ...

Page 31: ...ee SCR Module Replacement on page 96 Figure 8 SCR Connection Pinouts for Regenerative Drives Table 4 SCR Gate to Cathode Junction Measurements for Regenerative Drives On SCR Module SCR Measure from To Nominal Meter Reading 1 1 Pin 5 Pin 4 5 20 Ω 1 1 The actual reading variesdepending upon the SCRmanufacturer Verify that the actualmeasured value isconsistentforallSCRs 4 Pin 6 Pin 7 2 2 Pin 5 Pin 4 ...

Page 32: ...llow theses steps 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers from the drive see page 50 4 Remove the control EMI shield and control board see page 66 5 Remove the slotted air flow plate from the top of the drive Table 5 SCR Gate to Cathode Junction Measurements for Non regenerative Drives On SCR Module SCR Measure from ...

Page 33: ...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 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 Screws PowerFlex DC Drive Shown Air flow Plate Remove Screw Remove Screw Power...

Page 34: ...n page 120 for connector locations If any of the actual measurements are out of tolerance replace the pulse transformer board IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Table 6 Armature Pulse Snubber Circuit Measurements for Regenerative Drives For SCR Measure from To Meter Reading Connector XY Pinout 1 KG1 XY 4 open circuit 4 KG4 XY 1 2 KG2...

Page 35: ... 4 Verify that power to an external field supply if used is removed 5 Check the anode to cathode junction of the field SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules See Table 10 on page 36 and Figure 10 on page 36 If a low resistance is detected replace the modules See Field SCR Dual Diode Module and Field Circuit Board Replacement on...

Page 36: ...tation is not critical See Table 11 If a low resistance is detected replace the SCR dual diode module Table 10 SCR Dual Diode Module Anode to Cathode Junction Measurements Meter Lead Meter Lead Nominal Meter Reading Terminal Terminal U1 C1 open or U1 D1 open or V1 C1 open or V1 D1 open or C1 D1 open or C1 U1 open or C1 V1 0 50V D1 C1 0 50V D1 U1 0 45V Table 11 SCR Dual Diode Module Gate Cathode Ju...

Page 37: ...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 The power source provides up to 200 mA of current with a current foldback feature If the current draw exceeds 200 mA the current foldback feature protects the power supply If different power supply requirements exist for the chosen feedback dev...

Page 38: ...nnectors XRE P2 P3 If problems persist replace the resolver interface and or resolver feedback board Measure the signal voltage at the testpoints as indicated in the following table See Figure 11 on page 39 for testpoint locations If any of the voltage measurements fails replace the resolver interface board LED Code LED Color On State Off State D3 Red 24V overload fuse F1 blown This fuse is self r...

Page 39: ...es Chapter 2 Figure 11 Resolver Interface Board Testpoint Locations P3 P2 TB1 TB2 12V 12V 0V12 24V_VI 0V24 S1 VR 0V5 5V D10 D3 D18 D16 D12 D26 D11 F1 S2 12V 12V 0V12 24V_VI 0V24 5V 0V5 D26 D11 D10 D18 D16 D12 D3 S1 5V pos S1 12V pos S1 24V pos S2 Internal supply pos S2 External supply pos ...

Page 40: ...hermostat that is installed directly on the heat sink monitors the drive heat sink temperature When the heat sink temperature is too high a Heatsink OvrTemp fault F8 occurs See Fault Descriptions in 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 com...

Page 41: ...itical for analysis and repair of modules that are returned to the factory At a minimum perform and record the following Record the contents of the fault queue faults and times of occurrence 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 M...

Page 42: ...the time of the last fault 1350 Status2 at Fault Captures and displays Par 382 Drive Status 2 bit pattern at the time of the last fault 1351 1360 Fault x Code A code that represents the fault that tripped the drive The codes will appear in these parameters in the order they occur for example Fault 1 Code the most recent fault 1361 1370 Fault x Time The time between initial drive power up and the o...

Page 43: ...50 Communication Adapter and EMI Shield Replacement 52 Resolver Feedback and Interface Circuit Board Replacement 55 I O Expansion Circuit Board Replacement 59 115V AC to 24V DC I O Converter Circuit Board Replacement 61 Control Circuit Board Replacement 62 Control EMI Shield and Control Circuit Board Replacement 66 Pulse Transformer and Switching Power Supply Circuit Boards Replacement 68 AC Curre...

Page 44: ... 20P S520L 61 Control Circuit Board SK 20P S5RP1 62 Power Circuit Boards Pulse Transformer Board for 230V AC Regen Drive 7 29 A FIR 41 SK 20P S5N02 68 Pulse Transformer Board for 230V AC Regen Drive 38 110 A FIR 42 SK 20P S5N07 Pulse Transformer Board for 460 480V AC Regen Drive 4 1 27 A FIR 51 SK 20P S5N12 Pulse Transformer Board for 460 480V AC Regen Drive 35 129 A FIR 52 SK 20P S5N17 Pulse Tran...

Page 45: ...for 460 480VRegen Drive 4 1 19A SK 20P S7F73 SCR Modules Qty 3 1K6V 25 A for 460 480V Non Regen Drive 4 1 19 A SCR Modules Qty 6 1K6V 40 A for 460 480V Regen Drive 27 52 A SK 20P S7F74 SCR Modules Qty 3 1K6V 40 A for 460 480V Non Regen Drive 27 52 A SCR Modules Qty 6 1K2V 55 A for 230V AC Regen Drive 73 A SK 20P S7F46 SCR Modules Qty 6 1K2V 90 A for 230V AC Regen Drive 93 110 A SK 20P S7F47 SCR Mo...

Page 46: ...ions When you remove or insert a cable connector with power applied an electrical arc can occur An electrical arc can cause personal injury or property damage by sendinganerroneoussignaltoyoursystemfielddevices causingunintended machine motion causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contact...

Page 47: ... is on the top of the drive Insert a screwdriver in the slot on the top of the fuse holder carefully push down and turn the fuse counterclockwise When the fuse holder releases remove the holder and 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 IMPORTANT For PowerFlex DC drives thereplacement fuse t...

Page 48: ...ecautions on page 10 2 Remove power from the drive see page 46 3 The fuse is on the bottom of the drive Insert a screwdriver in the slot on the top of the fuse holder carefully push down and turn the fuse counterclockwise When the fuse holder releases remove the holder and fuse Install the Field Circuit Fuses Install the field circuit fuses in reverse order of removal 3 Bottom View of Drives Drive...

Page 49: ...e see page 46 3 Press downward on the tab at the top of the HIM assembly and by pressing upward at the bottom slide the HIM out of the cradle 4 Disconnect the DPI cable from the HIM assembly 5 Remove the screw that secures the DPI HIM assembly to the drive 6 Carefully remove the DPI HIM assembly from the cover and disconnect the cable from the connector on the back side of the assembly Install the...

Page 50: ...the lower protective cover and the power terminal cover to access the power terminals Follow these steps to remove the protective covers 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Loosen the two screws that secure the power terminal cover to the drive and slide the cover down and off the chassis 3 Tightening torque 1 0 N m 8 9 lb in ...

Page 51: ...ottom edge of the top cover and simultaneously pull the cover toward you to pull it partially off the drive chassis 8 At the top of the drive pull the cover away from the drive until the pins fit in the keyhole in the top of the cover 9 Carefully lift the cover off the drive chassis IMPORTANT The HIM assembly is connected via a cable to the control board and therefore will not pull free from the d...

Page 52: ...otective covers in reverse order of removal Communication Adapter and EMI Shield Replacement Remove the Communication Adapter and EMI Shield Follow these steps to communication adapter and EMI shield 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 ATTENTION Risk of electric shock exists when power is applied to the power terminals of the drive The power t...

Page 53: ...ter 3 3 Disconnect the interface cable from the communication adapter and set it aside 4 Disconnect any network cables from the adapter and set them aside 5 Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter 3 4 5 Tightening torque 0 9 N m 8 lb in ...

Page 54: ...ure the EMI shield to the stand offs on the control board and remove the EMI shield 7 Remove the three stand offs from the control board Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal 6 Tightening torque 1 0 N m 8 9 lb in 7 Tightening torque 1 0 N m 8 9 lb in ...

Page 55: ...er feedback and interface circuit boards 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 Disconnect the plug in terminal blocks from the resolver feedback and resolver interface boards IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly S15 XR XA XP3 XRE XFCD S21 ...

Page 56: ...rface 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 feedbackboard straightup during removal to avoid any damage to the connector pins S15 XR XA XP3 XRE XFCD S21 S4 J1 J2 P1 S1 TB1 TB2 P4 P2 P3 P1 5 Tightening torque for reassembly...

Page 57: ...ebruary 2018 57 Part Replacement Procedures Chapter 3 6 Remove the three stand offs from the resolver interface board S15 XR XA XP3 XRE XFCD S21 S4 P2 P3 S1 TB1 TB2 XRE S2 6 Tightening torque for reassembly is 0 7 N m 6 2 lb in Resolverinterface board ...

Page 58: ... Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal IMPORTANT Theresolverinterfaceboardisconnectedtothecontrolboardbelow 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 S15 XR XA XP3 XRE XFCD S21 S4 P2 P3 S1 TB1 TB2 XRE S2 ...

Page 59: ...Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 If installed remove the resolver feedback option and interface boards see page 55 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 IMPORTANT Mark all connections and wires ...

Page 60: ...res 7 Carefully pull the I O expansion board off connector XBB on the control board 8 Remove the two stand offs from the control board 9 Install one of the existing screws in the lower left corner of the control circuit board 8 Tightening torque 1 0 N m 8 9 lb in 9 Tightening torque 1 0 N m 8 9 lb in ...

Page 61: ...the 115V AC to 24V DC I O converter circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 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 conve...

Page 62: ...ing the drive and adapter parameters to an offline database file using DriveExecutive See the PowerFlex DC Digital Drive User Manual publication 20P UM001 for information on using the HIM See the on line Help provided with DriveExecutive for more information on HIM Sets or using the HIM 2 Read the General Safety Precautions on page 10 3 Remove power from the drive see page 46 4 Remove the protecti...

Page 63: ... and 6 Note The same input signal type must beprogrammed in Par 81 Anlg In3 Config S14 Field current resistors setting In addition the value that is selected with switch S14 must be entered in Par 374 Rated Field Curr in the control software when the drive is commissioned S14 1 S14 2 S14 3 S14 4 S14 5 S14 6 S15 Configuration of the control circuit board to the appropriate drive size This value is ...

Page 64: ... Chapter 3 Part Replacement Procedures 9 Carefully disconnect the cables from connectors XFCD XA and XR on the control board 10 Remove the plug in I O and control terminal blocks with the wiring kept in place 9 10 Communication adapter and optional boards not shown ...

Page 65: ...ews and washers that secure the control board to the control EMI shield and remove the control board Install the Control Circuit Board Install the control board in reverse order of removal Verify that all DIP switches are set to the correct configuration based on your recorded settings see page 63 11 Tightening torque 1 0 N m 8 9 lb in ...

Page 66: ...other components within the drive Follow these steps to remove the control EMI shield and control circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 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 bloc...

Page 67: ...he chassis 7 Slide the control EMI shield and control board up and out of the drive Install the Control EMI Shield and Control Circuit Board Install the control EMI shield and control board in reverse order of removal IMPORTANT Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the pulse transformer circuit board below the EMI shield 6 Tightening torq...

Page 68: ...r and switching power supply circuit boards 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 Remove the control EMI shield and control board see page 66 5 Remove the slotted air flow plate from the top of the drive For 38 A 10 Hp and 55 A 15 Hp drives with 230V AC input and 35 A 20 Hp 45 A 25 Hp and 52 A 30 Hp d...

Page 69: ... air flow plate to the top of the drive and remove the plate 6 Remove the plug in control power terminal block from the lower right corner of the pulse transformer circuit board IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly Air flow plate 5 5 Tightening torque 1 0 N m 8 9 lb in Tightening torque 1 0 N m 8 9 lb in 6 ...

Page 70: ...board Connector X4 contains a jumper for drives without a fan leave in place 8 For pulse transformer boards with an armature voltage feedback terminal block FIR1 xx rev Q and higher remove the connector from XCD_10 on the upper left corner of the board 9 Remove the plastic screw near the top of the pulse transformer board and retain for reuse 7 XSW1 XSW X3 XP TR2 TR1 XR X4 XY XCD_10 8 9 ...

Page 71: ...d through the appropriate opening in the board For non regenerative drives remove each pair of orange and yellow gate lead cables from connectors KG01 KG06 and push each lead through the appropriate opening in the board 11 Remove the cable from connectors XTA on the lower right side of the board IMPORTANT Carefully remove the gate leads by grasping the connector DO NOT pull the gate leads off by p...

Page 72: ...ile lifting slightly on the board slide it toward the top of the drive and out of the chassis There is an isolation sheet below the board do not remove this sheet unless it is damaged IMPORTANT The cables from connectors X4 and XTA must slide through the openingsintheboardasitisliftedoutofthedrivechassis Takecare not to damage these cables and connectors 12 13 Regenerative drive shown Tightening t...

Page 73: ...ly board 15 Remove the four M3 x 6 mm screws and washers that secure the switching power supply board to the stand offs on the back of the pulse transformer board Remove the switching power supply board 16 Remove the plastic stand off and nut that secures the switching power supply board to the back of the pulse transformer board 15 14 Tightening torque 1 0 N m 8 9 lb in Secure nut 16 ...

Page 74: ...nfiguring the Pulse Transformer Board FIR1 xx Rev P and Lower or Configure a Pulse Transformer Board FIR1 xx Rev Q and Higher on page 78 ConfiguringthePulseTransformerBoardFIR1 xxRev P andLower 1 Based on the drive size cut and remove one or more appropriate sizing resistors if necessary from the pulse transformer board See Table 14 or Table 15 in the Sizing Resistor Configuration section on page ...

Page 75: ...ove 27 4 Ω Remove Remove 020 20 16 5 56 2 Ω Remove Remove Remove 029 29 24 7 5 Remove Remove 39 2 Ω Remove 038 38 31 10 Remove 27 4 Ω Remove Remove 055 55 45 15 56 2 Ω 27 4 Ω Remove Remove 073 73 60 20 Remove 27 4 Ω 39 2 Ω Remove 093 93 76 25 Remove Remove Remove 6 98 Ω 110 110 90 30 Remove Remove Remove 6 98 Ω Drive Current Rating Code DC Amps AC Line Amps Hp R1 R2 R3 R4 R5 4P1 4 1 3 3 2 56 2 Ω R...

Page 76: ...tiometer on the lower right corner of the pulse transformer circuit board set the total resistance RTA to the appropriate value as indicated in Table 16 or Table 17 in the Total Resistance Values section on page 77 1 13 33 2 14 34 XR The XR connector is on the upper right corner of the pulse transformer circuit board TheTApotentiometerisonthelower right corner of the pulse transformer circuit boar...

Page 77: ...Amps Hp Set RTA Value Using TA Potentiometer Ohms 7P0 7 5 7 1 5 34 971 9P0 9 7 4 2 45 333 012 12 9 8 3 34 020 20 16 5 61 2 029 29 24 7 5 42 207 038 38 31 10 32 211 055 55 45 15 22 255 073 73 60 20 16 767 093 93 76 25 13 161 110 110 90 30 11 127 Drive Current Rating Code DC Amps AC Line Amps Hp Set RTA Value Using TA Potentiometer Ohms 4P1 4 1 3 3 2 59 707 6P0 6 4 9 3 40 8 010 10 8 2 5 40 8 014 14 ...

Page 78: ...lse transformer board see illustration to the correct settings based on the drive current rating See 230V AC Input Drives on page 79 and 460V AC Input Drives on page 79 XSW1 XSW X3 XP TR2 TR1 XR X4 XY XCD_IO TO1 TO4 TO2 TO5 TO3 TO6 KGO1 KGO4 KGO2 KGO5 TO1 TO4 TO2 KGO1 KGO4 KGO2 KGO5 KGO3 KGO6 T5 T3 T6 T1 T4 T2 KG1 KG4 KG2 KG5 KG3 KG6 XTA S4 S3 1 1 78 79 35 36 75 76 U2 V2 DIP Switches S4 and S3 ...

Page 79: ...Switch S3 DIP Switch S4 S3 1 S3 2 S3 3 S3 4 S3 5 S3 6 S3 7 S3 8 S4 1 S4 2 S4 3 S4 4 S4 5 S4 6 S4 7 S4 8 7P0 7 5 7 1 5 ON ON ON 9P0 9 7 4 2 ON ON ON 012 12 9 8 3 ON ON ON 020 20 16 5 ON ON ON 029 29 24 7 5 ON ON ON 038 38 31 10 ON ON 055 55 45 15 ON ON ON ON 073 73 60 20 ON ON ON ON 093 93 76 25 ON ON ON ON 110 110 90 30 ON ON ON ON Drive Current Rating Code DC Amps ACLine Amps Hp DIP Switch S3 DIP...

Page 80: ...mines the power bridge configuration and where the AC current transducers are in the drive For these drive ratings the AC current transducers are installed on the power traces board 230V AC input 55 A 15 Hp 460V AC input up to 52A 30 Hp See AC Current Transducers on Drives with a Power Traces Board on page 81 For these drive ratings the AC current transducers are installed on bus bars inside the d...

Page 81: ...Transducers with No Connection Bars on page 82 for drives no metal bar and windings on the AC current transducers RemovetheCurrentTransducerswithConnectionBars 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 stand offs that secure the bottom of the AC current transducers to the power traces circuit board an...

Page 82: ...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 9 Continue with Install the AC Current Transducers on page 85 7 6 AC current transducers Tightening torque 0 5 N m 4 4 lb in IMPORTANT You do not need to remove the windings from the AC current transduce...

Page 83: ... connections from terminals U and V at the bottom of the drive 7 Remove the M4 x12 5 mm screws and washers that secure each of the AC current transducers to the U and V Phase terminal bus bars IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 7 U Phase bus bar V Phase bus bar Tightening torque 3 0 N m 26 5 lb in ...

Page 84: ...ive 9 Remove the screws and washers that secure each of the U and V phase terminal bus bars which contain the AC current transducers to the SCR modules 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 U Phase bus bar V Phase bus bar 8 Tightening torque 2...

Page 85: ...nsducers Install the AC current transducers in reverse order of removal For AC current transducers that must be wound with wire leads Wind the wire leads around the new AC current transducers Wind the wires the same number of times as the wires on the old AC current transducers Wind the wires in the same position as the wires on the old AC current transducers Crimp the connection lugs onto the wir...

Page 86: ...r traces circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 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 5 Remove the control EMI shield and control board see page 66 6 Remove the...

Page 87: ...Remove all M5 x 10 mm screws and washers that secure the board to the SCR modules and power terminal isolation strip and remove the power traces board from the drive Non Regenerative drive with AC current transducers with connection bars 8 7 8 7 8 8 Regenerative drive with AC current transducers with connection bars Tightening torque 2 5 N m 22 0 lb in Tightening torque 2 5 N m 22 0 lb in ...

Page 88: ... the current transducers 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 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 9 AC current transducers with connections bar...

Page 89: ...eviously installed Field SCR Dual Diode Module and Field Circuit Board Replacement Remove the Field SCR Dual Diode Module and Field Circuit Board Follow these steps to remove the field SCR dual diode module and field circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 46 3 Remove the protective covers see page 50 4 Remove the control EMI shield and...

Page 90: ... from the field SCR dual diode module on the drive heat sink You will also need to remove the small red wire that is staked to the large red wire 7 Remove the two M5 x 10 mm screws and washers that secure the field SCR dual diode module to the drive heat sink and remove the module 7 6 Tightening torque 2 5 N m 22 0 lb in ...

Page 91: ...e the power wiring from terminals U V W C D and PE 9 Remove the plug in field terminal block on the bottom of the drive with the wiring kept in place 10 Remove the two M4 x 12 mm screws that secure the bottom air flow plate to the power terminal isolation strip 9 10 Drive with fan shown Tightening torque 1 2 N m 10 6 lb in ...

Page 92: ... flow plate and fan if present assembly down and off the drive The bottom air flow plate on a frame A drive that is rated up to 55 A 15 Hp with 230V AC input or up to 52 A 30 Hp with 460V AC input is secured to the drive chassis with four screws The bottom air flow plate on a frame A drive with a fan are secured to the chassis with six screws 11 11 Tightening torque 3 0 N m 26 5 lb in Tightening t...

Page 93: ...r 3 12 Remove the two M3 x 6 mm screws that secure the field circuit board to the drive and remove the field board and connected wires from the drive There is an isolation sheet below the board do not remove this sheet unless it is damaged 12 12 Field circuit board Tightening torque 1 0 N m 8 9 lb in ...

Page 94: ...ule 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 heat sink IMPORTANT Verifythatthefieldcircuitwiresareconnectedtothecorrectlocationonthe field SCR dual diode module ID Wire Description Signal ID Wire Description Signal 1 Thick brown To field circuit board 5 Thick red To field ...

Page 95: ...ntrol circuit board see page 66 5 Remove the pulse transformer and switching power supply circuit boards see page 68 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 Install the Bimetal Thermostat Install the thermostat in reverse order of removal IMPORTANT Mark all connections and wires before removal ...

Page 96: ...is configured and the steps that are required to remove the SCR modules To remove the SCR modules from a frame A drive that is rated up to 55 A 15 Hp with 230V AC input or up to 52 A 30 Hp with 460V AC input see SCR Modules on Drives Rated up to 55 A 15 Hp with 230V AC Input or up to 52 A 30 Hp with 460V AC Input on page 97 To remove the SCR modules from a frame A drive rated 73 A 20 Hp with 230V ...

Page 97: ...ut 6 Remove the power traces circuit board See Power Traces Circuit Board Replacement on page 86 In this case do not remove the AC current transducers from the power traces board 7 Remove the two screws and washers that secure each SCR module to the heat sink and remove the SCR modules Continue with Install the SCR Modules on page 104 Regenerative drive Non Regenerative drive 7 7 ...

Page 98: ...dulesonDrivesRated73A 20Hpwith230VACInputandHigheror73A 40Hpwith 460VACInputandHigher 8 Remove the isolation sheet 9 Remove the M5 x 10 mm screws that secure the U V W C and D terminal bus bars to the power terminal isolation strip at the bottom of the drive 8 9 U Tightening torque 2 5 N m 22 0 lb in C V D W ...

Page 99: ...t secure the connecting bus bars to the anodes of the corresponding SCR modules and remove the bus bars In addition remove the U V and W phase terminal bus bars from the drive IMPORTANT The screws that secure these bus bars to the SCR modules are M5 x 16 Retain for reuse with these bus bars only 10 10 Connecting bus bars U Phase bus bar V Phase bus bar W Phase bus bar ...

Page 100: ...our 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 Forregenerativedrivesonly thescrewsthatsecurethesebusbarsto the SCR modules are M5 x 16 Retain for reuse with these bus bars only Regenerative drive Non Regenerative drive 11 11 ...

Page 101: ... 20P TG001C EN P February 2018 101 Part Replacement Procedures Chapter 3 12 Remove the screws and washers that secure the connecting bus bars to the SCR modules and remove the bus bars Regenerative drive Non Regenerative drive 12 12 ...

Page 102: ...cation 20P TG001C EN P February 2018 Chapter 3 Part Replacement Procedures 13 For non regenerative drives only remove the screws and washers that secure the U V and W terminal bus bars to the SCR modules and remove the bus bars 13 ...

Page 103: ...tion 20P TG001C EN P February 2018 103 Part Replacement Procedures Chapter 3 14 Remove the screws and washers that secure each SCR module to the heat sink and remove the SCR modules Regenerative drive Non Regenerative drive 14 14 ...

Page 104: ... 10 Hp and 55 A 15 Hp with 230V AC Input and 35 A 20 Hp 45 A 25 Hp and 52 A 30 Hp with 460V AC Input on page 105 See Cooling Fan on Drives Rated 73 A 20 Hp with 230V AC Input and 73 A 40 Hp with 460V AC Input on page 106 IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heat sink 230V AC Input 460V AC Input Part Number Final Torque Part Number Fina...

Page 105: ...at secure the slotted air flow plate and fan to the top of the 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 for instructions 4 Disconnect the fan cable from connector XV on the switching power supply board and remove the fan and air flow plate 5 Remove the twoM4 x 12 5 mm screws...

Page 106: ...es rated 73A 20 Hp with 230V AC and 73A 40 Hp with 460V AC and higher have a cooling fan that is installed on the bottom of the drive 6 Loosen the two screws that secure the power terminal cover to the drive and slide the cover down and off the chassis 7 Remove the field terminal block 8 If necessary remove the power wiring from the drive terminals 6 Tightening torque 1 0 N m 8 9 lb in 7 8 ...

Page 107: ... the six M4 x 12 5 mm screws that secure the air flow plate to the bottom of the drive chassis 11 Carefully pull the air flow plate and fan assembly down and off the drive 12 Disconnect the black and red wires from the fan terminal block on the air flow plate IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 9 11 12 Tightening torque 3 0 N m 26 5 l...

Page 108: ...sing Install the Cooling Fan Install the cooling fan in reverse order of removal 13 14 IMPORTANT Forbothdrive fanconfigurations verifythattheairflowarrowonthefanis pointed toward the top of the drive IMPORTANT For drives with a fan that is connected to the top air flow plate verify that the two spacers are properly placed during installation Air flow arrow must point toward top of drive Spacers To...

Page 109: ...l board DIP switches are set correctly See Install the Control Circuit Board on page 65 for more information 5 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 mo...

Page 110: ...0 Make configuration changes that allow the HIM to issue start and speed commands 11 Start the drive by pressing 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 12 Increase the speed command fr...

Page 111: ...Regenerative Drive Diagram 114 SCR to Pulse Transformer Board Gate Lead Pinout Non regenerative Drive Diagram 114 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 117 Drive Heat Sink Mon...

Page 112: ...1D2 1C2 KG4 KG2 KG5 KG6 KG3 KG01 KG04 KG02 KG05 KG03 KG06 KG1 D V C U PE W X3 XP XR PE XY XI2CA XTA XCD_10 X4 1C2 1D2 Cooling Fan Note Not all frame A drives contain a fan Bimetal Thermostat Field Module Field Board Switching Power Supply Board Drive Cover Human Interface Module 20 HIM Ax CT U CT V Control Board Pulse Transformer Board FV1 FU1 Certain drives do not have bus bars These drives conta...

Page 113: ...s Diagram Figure 14 Power Feedback Connections Diagram 100 K 100 K 100 K V W U XR 15 XR 16 XR 17 15 V 15 V XY22 XY21 15 15 15 15 XY18 Hardware connections to power structure bus bars U V W XR15 XR16 XR17 C D XR19 XR18 1M0 1M0 1M0 1M0 1M0 1M0 1M0 1M0 1M0 1M0 1M0 1M0 U V W Note 6 x 665 kohm resistors Note Note Note Note Note ...

Page 114: ...teLeadPinout Non regenerativeDriveDiagram 5 5 4 4 7 7 6 6 5 5 4 4 7 7 6 6 6 6 7 7 4 4 5 5 5 5 4 4 7 7 6 6 6 6 7 7 4 4 5 5 6 6 7 7 4 4 5 5 G01 K01 K04 G04 G02 K02 K05 G05 G03 K03 K06 G06 G1 K1 K4 G4 G2 K2 K5 G5 G3 K3 K6 G6 SCR Module 1 SCR Module 01 SCR Module 2 SCR Module 02 SCR Module 3 SCR Module 03 6 7 4 5 6 7 4 5 6 7 4 5 G01 K01 K04 G04 G02 K02 K05 G05 G03 K03 K06 G06 SCR Module 01 SCRModule02...

Page 115: ...n TA1 Out 0 1uF 0 1 uF XP 3 XP 4 XP 2 XP 1 10 uF 10 uF VF UF U1 V1 X2 X2 1V1 1U1 1 4 2 3 XFCD 1 XFCD 4 XFCD 2 XFCD 3 D1 C1 X2 X2 2D1 2C1 2U1 2V1 VF UF UF1 VF1 V1 X3 2 X3 1 Incoming AC Line To Pulse Transformer Board X3 Connector To Motor Field Connections 15 V 15 V XFCD 1 XFCD 3 XFCD 4 LB S14 8 S14 7 S14 6 S14 5 S14 4 S14 3 S14 2 S14 1 XFCD 2 LA 1210 845 845 1000 1000 1000 120 47 5 1000 1800 1800 ...

Page 116: ...9 Control Circuit Input Power Diagram Figure 20 Encoder Control Circuit Diagram L1 1C2 1D2 V2 U2 V91 230V AC or 115V AC input To Switch Mode Power Supply SMPS ENC 1 2 3 4 5 6 7 8 A A B B Z Z COM V S21 12V 5V S21 24V S21 S21 5V 5V 5V 5V 5V 5V 5V 5V 5V Voltage Regulator and Current Feedback Circuit ...

Page 117: ...N P February 2018 117 Schematics Appendix A Figure 21 DC Tachometer Control Circuit Diagram Figure 22 Motor Thermal Protection Control Circuit Diagram S4 8 M3 M3 S4 7 S4 6 S4 1 S2 S4 3 TACHOP S4 5 S4 4 24V XR 32 0VI 78 79 1K Overtemp Fault Signal ...

Page 118: ...ndix A Schematics Figure 23 Drive Heat Sink Monitoring Control Circuit Diagram Figure 24 Contactor Control Relays Control Circuit Diagram XR 10 XR 12 XR 10 XR 12 X4 1 X4 2 XSW 2 XSW 1 24V 0V24 U3 5V OTS Control Board 0V24 U6 K7 K8 24V 35 36 75 76 U2 S1 XR XR XR XR 7 6 5 4 ...

Page 119: ...tions 121 Pulse Transformer Board to Switching Power Supply Connections 121 Pulse Transformer Board to Bimetal Thermostat Connections 121 PulseTransformer Board to Field SCR Dual Diode Module Connections 121 PulseTransformerBoard to Control Board Connections 122 Pulse Transformer Board to Current Transducer Connections 123 Switching Power Supply Board Layout 123 Switching Power Supply to Fan Conne...

Page 120: ...K G KG03 K G KG4 K G KG1 K G KG5 K G KG2 K G KG6 K G KG3 XTA 1 TA U C V W W V C U X4 1 78 79 35 36 75 76 U2 V2 XSW1 XSW X3 XP TR2 TR1 XR X4 XY XCD_IO TO1 TO4 TO2 TO5 TO3 TO6 KGO1 KGO4 KGO2 KGO5 TO1 TO4 TO2 KGO1 KGO4 KGO2 KGO5 KGO3 KGO6 T5 T3 T6 T1 T4 T2 KG1 KG4 KG2 KG5 KG3 KG6 XTA S4 S3 1 1 78 79 35 36 75 76 U2 V2 Components shown within dashed lines are only on the pulse transformer board for reg...

Page 121: ...eld Board Connector Description X3 1 1 X3 1U1 field sync signal from U1 2 2 1V1field sync signal from V1 Pulse Transformer Board Point to Pin Number Switching Power Supply Board Connector Description 1C2 4 XUV Rectified U2 V2 voltage approx 150 300V DC 3 not used 1D2 2 not used 1 Common Pulse Transformer Board Connector Pin Number to Pin Number Bimetal Thermostat Connector Description X4 1 1 X4 24...

Page 122: ...ure 0 signal 9 9 0V GNDP 10 10 Heat sink over temperature 11 11 Digital U1 V1 sync signal 12 12 0V GNDP 13 13 CT burden signal 14 14 0V GND 15 15 Reduced U sync signal 16 16 Reduced V sync signal 17 17 Reduced W sync signal 18 18 Reduced C armature signal 19 19 Reduced D armature signal 20 20 0V GNDP 21 21 Gate signal SCR 4 01 22 22 0V GNDP 23 23 Gate signal SCR 5 02 24 24 0V GNDP 25 25 Gate signa...

Page 123: ...ayout Table 26 Switching Power Supply to Fan Connections Pulse Transformer Board Connector Pin Number to Pin Number Current Transducer Description XTA 1 Black CT on Phase U Secondary side CT phase U 2 Brown 3 Black CT on Phase V Secondary side CT phase V 4 Brown XA 1 2 15 16 6 1 XSW XY1 1 4 XSW1 1 4 XV F1 1C2 1D2 XUV Fuse location Control Board Connector Pin Number to Pin Number Fan Connector Desc...

Page 124: ...nections See Pulse Transformer Board to Switching Power Supply Connections on page 121 Switching Power Supply Board Connector Pin Number to Pin Number Control Board Connector Description XA 1 1 XA 5V 2 2 5V common 3 3 5V 4 4 5V common 5 5 5V 6 6 5V common 7 7 SMPS supply input undervoltage 8 8 9 9 15V 10 10 11 11 15V common 12 12 13 13 15V 14 14 15 15 24V common 16 16 24V ...

Page 125: ...27 28 29 30 1 2 3 4 5 6 7 8 9 10 31 32 33 34 35 36 37 38 39 40 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 31 32 33 34 35 36 37 38 39 40 DEBUG S15 S3 S2 S1 S0 RST ACT RUN PWR 1 2 3 4 5 6 7 8 S18 S12 S10 S21 ENC_5 ENC_12 S4 1 2 3 4 5 6 7 8 S14 1 2 3 4 5 6 7 8 S20 S11 S9 ON XR XA XFCD LA LB XP3 To DPI board on HIM Bezel I O terminal ...

Page 126: ...Layouts and Connections Field Board Figure 28 Field Board Layout See Control Board to Field Board Connections on page Control Board to Field Board Connections and Pulse Transformer Board to Field Board Connections on page 121 X3 1 XFCD 1 X2 UF1 VF1 VF UF Field fuse connections terminal block ...

Page 127: ...ry 2018 127 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 ...

Page 128: ...uited Are terminals short circuited No Yes 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 Repair short circuits Any values lower than 200 kohm Replace the control board Yes No 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...

Page 129: ...for short circuits No Yes Yes Are terminals short circuited Are the fuses blown Yes Measure the gate signals at pins XR 1 and XR 2 on the cable Are the signals present and correct Replace the field board No Yes Replace the control board 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 signa...

Page 130: ... 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 field board No Yes Verify drive rated field bridge current is set correctly in Par 374 Drv Fld Brdg Cur and DIP switch S14 is configured to match Measure field current signal at LA LB terminal located on control board This va...

Page 131: ...est 37 F fault field current loss 24 heatsink overtemperature 40 main contactor 40 overcurrent 22 power failture 15 fault report create 41 field board install 94 remove 89 field circuit fuses install 48 remove 48 field current loss fault 24 field SCR dual diode module install 94 remove 89 test 35 frame size 11 fuse field circuit 48 switching power supply 47 switching power supply board 47 H hardwa...

Page 132: ...ly 49 field board 89 field circuit fuses 48 field SCR dual diode module 89 I O expansion board 59 power 46 power traces board 86 protective covers 50 pulse transformer board 68 SCR modules 96 switching power supply board 68 switching power supply board fuse 47 S safety precautions 10 save parameter configuration 14 schematic diagrams 111 SCR modules install 104 remove 96 service tools 12 switching...

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Page 134: ...e for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Gethelp determining how products interact c...

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