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Rockwell Automation Allen-Bradley PowerFlex 20P, Manual

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Rockwell Automation Allen-Bradley PowerFlex 20P Manual Download Page 5

Rockwell Automation Publication 20P-TG004C-EN-P - September 2021

5

Table of Contents

Install the Field SCR and Dual Diode Modules  . . . . . . . . . . . . . .  73

Field Fuse Holder Removal and Installation . . . . . . . . . . . . . . . . . . . . .  74

Remove the Field Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  74
Install the Field Fuse Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76

Fan Starting Capacitor Removal and Installation. . . . . . . . . . . . . . . . .  76

Remove the Fan Starting Capacitor . . . . . . . . . . . . . . . . . . . . . . . . .  76
Install the Fan Starting Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . .  77

Series A Fan Circuit Board Removal and Installation . . . . . . . . . . . . .  78

Remove the Series A Fan Circuit Board. . . . . . . . . . . . . . . . . . . . . .  78
Install the Series A Fan Circuit Board  . . . . . . . . . . . . . . . . . . . . . . .  78

Series B Fan Circuit Board Removal and Installation . . . . . . . . . . . . .  79

Remove the Series B Fan Circuit Board. . . . . . . . . . . . . . . . . . . . . .  79
Install the Series B Fan Circuit Board  . . . . . . . . . . . . . . . . . . . . . . .  79

Series A Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . .  80

Remove the Series A Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .  80
Install the Series A Fan Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . .  81

Series B Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . .  82

Remove the Series B Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .  82
Install the Series B Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . .  83

Series C Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . .  84

Remove the Series C Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .  84
Install the Series C Fan Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . .  85

AC Current Transducers Removal and Installation  . . . . . . . . . . . . . .  86

Remove the AC Current Transducers . . . . . . . . . . . . . . . . . . . . . . .  86
Install the AC Current Transducers. . . . . . . . . . . . . . . . . . . . . . . . .  89

Overvoltage Clipping Circuit Board Fuse Removal and 
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  90

Remove the Overvoltage Clipping Circuit Board Fuses . . . . . . .  90
Install the Overvoltage Clipping Circuit Board Fuses . . . . . . . . .  90

Overvoltage Clipping Circuit Board Removal and Installation . . . .  91

Remove the Overvoltage Clipping Circuit Board . . . . . . . . . . . . .  91
Install the Overvoltage Clipping Circuit Board. . . . . . . . . . . . . . .  92

Armature Leg Fuse Removal and Installation . . . . . . . . . . . . . . . . . . . .  92

Remove the Armature Leg Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  92
Install the Armature Leg Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  93

SCR Module Leg Assembly Removal and Installation  . . . . . . . . . . . .  94

Remove the SCR Module Leg Assembly . . . . . . . . . . . . . . . . . . . . .  94
Install the SCR Module Leg Assembly. . . . . . . . . . . . . . . . . . . . . . .  99

Bimetal Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . 100

Remove the Bimetal Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Install the Bimetal Thermostat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Discharge Resistors Removal and Installation . . . . . . . . . . . . . . . . . . . 100

Remove the Discharge Resistors  . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Install the Discharge Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Inrush Limiting Resistor Removal and Installation . . . . . . . . . . . . . . 102

Remove the Inrush Limiting Resistor. . . . . . . . . . . . . . . . . . . . . . . 102
Install the Inrush Limiting Resistor  . . . . . . . . . . . . . . . . . . . . . . . . 104

Summary of Contents for Allen-Bradley PowerFlex 20P

Page 1: ...PowerFlex Digital DC Drive Frame D Bulletin Number 20P Hardware Service Manual Original Instructions ...

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

Page 3: ...pply Failure 17 Testing the Switching Power Supply and Pulse Transformer Boards 18 Testing the Control and Field Board Connections 19 Troubleshoot an AC Undervoltage Fault 22 Troubleshoot an Armature Bridge Failure 23 Troubleshoot a Field Current Loss Fault 25 Low or Incorrect Field Current 25 No Field Current 27 Power Component Test Procedures 29 Check the Armature SCR Modules 29 Check the Pulse ...

Page 4: ...ation 54 Remove the Resolver Feedback and Interface Circuit Boards 54 Install the Resolver Feedback and Interface Circuit Boards 57 I O Expansion Circuit Board Removal and Installation 58 Remove the I O Expansion Circuit Board 58 Install the I O Expansion Circuit Board 59 115V AC to 24V DC I O Converter Circuit Board Removal and Installation 60 Remove the 115V AC to 24V DC I O Converter Circuit Bo...

Page 5: ...e the Series C Fan Assembly 84 Install the Series C Fan Assembly 85 AC Current Transducers Removal and Installation 86 Remove the AC Current Transducers 86 Install the AC Current Transducers 89 Overvoltage Clipping Circuit Board Fuse Removal and Installation 90 Remove the Overvoltage Clipping Circuit Board Fuses 90 Install the Overvoltage Clipping Circuit Board Fuses 90 Overvoltage Clipping Circui...

Page 6: ...r Without a Mechanical Load 109 AppendixA Schematics List of Schematic Diagrams 111 AppendixB Circuit Board Layouts and Connections List of Circuit Board Layouts 123 Pulse Transformer Board 124 Switching Power Supply Board 127 Control Board 128 Field Board 129 Overvoltage Clipping Board 130 AppendixC Flow Charts List of Flow Charts 131 Control Power Supply Failure 132 Field Current Loss Failure 13...

Page 7: ...al contains new and updated information in the following sections Topic Page Added a note to the procedure Troubleshoot an Armature Bridge Failure 23 Changed values in the table Armature Pulse Snubber Circuit Measurements for Non Regenerative Drives 33 Changed the procedure Check the Field SCR Dual Diode Module 34 Changed figure in the procedure Remove the Field Circuit Fuses 45 Changed figure in ...

Page 8: ...8 Rockwell Automation Publication 20P TG004C EN P September 2021 Preface Notes ...

Page 9: ...apter 1 BeforeYou BeginTesting Maintenance or Repairs Introduction This chapter provides information you should know before you begin tests maintenance or repairs on drive components Topic Page General Safety Precautions 10 Hardware Description 11 Commonly UsedTools 12 ...

Page 10: ...t 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 EmployeeWorkplaces 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 ...

Page 11: ...e incoming line protection devices and contactor and dynamic brake control circuits Frame D drives may contain series B fan components Verify that you are working on a Frame D series A or series B drive by checking the data nameplate label on the lower right side of the drive The frame size is printed just above the serial number in the lower right corner of the label The series letter is printed ...

Page 12: ... 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 mm 10 m...

Page 13: ... Power Supply Failure 17 Troubleshoot an AC Undervoltage Fault 22 Troubleshoot an Armature Bridge Failure 23 Troubleshoot a Field Current Loss Fault 25 Power ComponentTest Procedures 29 Speed Feedback DeviceTests 37 Thermistors andThermal Switches 40 Relay Outputs 40 Create a Fault Report 41 WhatYou NeedWhenYou CallTech Support 41 IMPORTANT Using the diagnostic tests in this chapter should only be...

Page 14: ... drive HIM sets are files stored in permanent nonvolatile HIM memory Save to a HIM Set Follow these steps to save the drive and communication 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 are no existing HIM sets enter a name using the and buttons to select the des...

Page 15: ...hange The Connection Browser opens Select the device from which you want to upload configuration settings and click OK A status window opens and shows the progress of the connection Note The communication path can only be changed when disconnected from the device 3 Click Error Check Upload to upload the configuration settings from the connected device parameter by parameter while checking for erro...

Page 16: ...Executive software from the Drive menu choose Connect to Drive 2 From the Connect to Drive dialog box select the drive for which you want to save the parameter configuration and click OK 3 Click Upload on the toolbar 4 A dialog displays the status of the upload operation Click Cancel to cancel the operation 5 From the File menu click Save 6 In the Save As dialog box enter a name for the file and c...

Page 17: ...ersion of the steps that follow see Control Power Supply Failure on page 132 Name Testpoint ForTestpoint Location See Associated Connector Pin Description 5V XY5 Figure 2 on page 20 XA 1 XA 3 XA 5 5V digital supply GNDD XY6 Figure 2 on page 20 XA 2 XA 4 XA 6 5V digital supply ground GNDD XY7 Figure 3 on page 21 XA 2 XA 4 XA 6 5V digital supply ground 15V XY12 Figure 2 on page 20 XA 9 XA 10 15V ana...

Page 18: ...nstallation on page 52 7 Disconnect the cable at connector XA on the control board See Figure 31 on page 128 for location of connector XA 8 Apply AC control power to the drive If the fuse blows continue with Testing the Switching Power Supply and Pulse Transformer Boards on page 18 below If the fuse does not blow continue with Testing the Control and Field Board Connections on page 19 Testing the ...

Page 19: ...ctive terminals for a possible short circuit condition Repair any short circuit conditions if found 3 Remove the cables from connector XR and XFCD on the control board and use an ohmmeter to check between all voltage test points and common on the control board for possible short circuit conditions The ohmmeter measurements should be greater than 200 k If any low resistance measurements are found r...

Page 20: ...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 21: ... 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 22: ...th the input and output sides of the contactor If any of the voltage measurements is incorrect or missing remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems 4 Using a voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5V offset See Figure 2 on page 20 and Figur...

Page 23: ...idge failure may have occurred All of the signals going to and coming from the SCR bridges are transmitted via the ribbon cable connected to XR on the control board and can be measured at these points See Figure 31 on page 128 for location of the XR connector on the control board 1 Read the General Safety Precautions on page 10 2 Remove the bottom control panel and I O and control terminal covers ...

Page 24: ...asurements 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 4 Good SCR Gate Pulse and Armature Current Signals Example Figure 5 Good SCR Armature Voltage and Motor Current Signal Example 5V 0V XY19...

Page 25: ...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 Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 134 1 Read the General Safety Precautions on page 10 2 Verify the actual value of parameter 3...

Page 26: ...easurement is incorrect continue with step 7 below If the voltage measurement is correct but the Field Current Loss fault still exists replace the control board 7 Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance as indicated in the table below set with DIP switch S14 on the control board If the resistance measurement is incor...

Page 27: ...ue with step 4 below 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 on page 27 If the fuses are not blown complete the steps in Test Field Control Signals on page 27 TestFieldWiringandVoltageSignals 1 Test the resistance of the motor field wiring and motor field for possible short circuits If ther...

Page 28: ...signal 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 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 taken on LA LB terminal 2 ITF1 pulse 3 ITF2 pulse LA LB U1 V1 Sync ITF1 Pulse ITF2 Pulse ...

Page 29: ... drive See Remove Power from the Drive on page 44 3 Open the control panel See Open the Control Panel on page 49 4 Verify that power to an external field supply if used is removed 5 Check the anode to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance across the SCRs lead orientation is not critical Measurements must be taken below the AC input leg fuses on t...

Page 30: ...Ohms range 4 U D 2 V C 5 V D 3 W C 6 W D 01 U C 04 U D 02 V C 05 V D 03 W C 06 W D SCR 1 G SCR 1 K SCR 01 G SCR 01 K SCR 04 G SCR 04 K SCR 4 G SCR 4 K Front Gate Lead Terminal Block SCR 2 G SCR 2 K SCR 02 G SCR 02 K SCR 05 G SCR 05 K SCR 5 G SCR 5 K SCR 3 G SCR 3 K SCR 03 G SCR 03 K SCR 06 G SCR 06 K SCR 6 G SCR 6 K Phase U Rear Gate Lead Terminal Block Phase U Rear Gate Lead Terminal Block PhaseV...

Page 31: ...asure from Terminal ToTerminal Nominal meter reading 1 U C open circuit or megaohms range 4 U D 2 V C 5 V D 3 W C 6 W D SCR 1 G SCR 1 K SCR 4 G SCR 4 K SCR 5 G SCR 5 K SCR 6 G SCR 6 K Front Gate Lead Terminal Block Phase U Rear Gate Lead Terminal Block Phase U Rear Gate Lead Terminal Block PhaseV Rear Gate Lead Terminal Block PhaseW SCR 1 G SCR 1 K Front Gate Lead Terminal Block PhaseV SCR 1 G SCR...

Page 32: ... may be necessary See SCR Module Leg Assembly Removal and Installation on page 94 Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives Table 5 SCR Gate to Cathode Junction Measurements for Non Regenerative Drives SCR Measure from To Nominal meter reading 1 Pin G Pin K 5 30 1 1 The actual reading varies depending upon the SCR manufacturer Verify that the actual measured value i...

Page 33: ...rd See Pulse Transformer Circuit Board Removal and Installation on page 66 4 With a digital multimeter set for a continuity check measure each connection point on the pulse transformer board listed in the tables below See Figure 29 on page 124 for connector locations If any of the actual measurements are out of tolerance replace the Pulse Transformer board Table 6 Armature Pulse Snubber Circuit Me...

Page 34: ...s responses including field and velocity related faults or blown fuses The following procedures can be used if field bridge malfunctions are suspected 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the top and bottom control panel and I O and control terminal covers See Protective Cover Removal and Installation on ...

Page 35: ...es See Field SCR and Dual Diode Module Removal and Installation on page 72 If a measurement results in an infinity reading check the fuses at FU1 and FV1 on the control panel to determine if they are open See Figure 9 on page 36 Table 10 SCR Dual Diode Module Anode to Cathode Junction Measurements Meter Lead Meter Lead Nominal meter reading Terminal Terminal U1 C1 0 45V U1 D1 open or infinity V1 C...

Page 36: ...multimeter set to diode test measure the resistance across the modules lead orientation is not critical See Table 11 If a low resistance is detected replace the SCR dual diode module Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Measure from To Nominal meter reading XP1 XP2 10 20 XP3 XP4 Bottom Left Side of Drive Top Left Side of Control Panel Shown with control cover removed R...

Page 37: ...m 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 ext...

Page 38: ... connectors XRE P2 P3 If problems persist replace the resolver interface and or resolver feedback board Measure the signal voltage at the testpoints as indicated in the following table See Figure 10 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 sel...

Page 39: ...es Chapter 2 Figure 10 Resolver Interface Board Testpoint Locations P3 P2 TB1 TB2 12V 12V 0V12 24V_VI 0V24 S2 S1 VR 0V5 5V D10 D3 D18 D16 D12 D26 D11 F1 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: ...etal 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 24 on page 121 for a circuit diagram During normal operation 1 6V DC is present between terminal 78 and drive common When an open circuit exists ...

Page 41: ...n 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 Status1 at Fault Captures and displays Par 381 Drive Status 1 bit pattern at the time of the...

Page 42: ...42 Rockwell Automation Publication 20P TG004C EN P September 2021 Chapter 2 ComponentTest Procedures Notes ...

Page 43: ...llation 61 Switching Power Supply Circuit Board Removal and Installation 65 PulseTransformer Circuit Board Removal and Installation 66 Field Circuit Board Removal and Installation 70 Field SCR and Dual Diode Module Removal and Installation 72 Field Fuse Holder Removal and Installation 74 Fan Starting Capacitor Removal and Installation 76 Series A Fan Circuit Board Removal and Installation 78 Serie...

Page 44: ...llation 106 Topic Page ATTENTION Remove power before making or breaking cable connections Whenyouremoveorinsertacableconnectorwithpowerapplied anelectricarc may occur An electric arc can cause personal injury or property damage by sending an erroneous signal to your system s field devices causing unintended machine motion causing an explosion in a hazardous environment Electricarcingcausesexcessiv...

Page 45: ...e Field Circuit Fuses 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Pull down on the tabs at the top of the fuse holder on the front of the drive and remove the fuses Install the Field Circuit Fuses Install the new field circuit fuses in reverse order of removal FV1 FU1 ...

Page 46: ...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 Install the DPI HIM Assembly on the Protective Cover Install the DPI HIM assembly in reverse or...

Page 47: ... is disconnected The cover does however have notches on the side in order that it can be hung on the screws without disconnecting the HIM cable 3 Tightening torque 1 5 N m 13 lb in T15 4 Removingthiscoverprovides access to the fanlossdetection board fan motor and blower and AC current transducers Top control panel cover Bottom control panel cover Top terminal cover I O and control terminal cover B...

Page 48: ... connector on the upper right corner of the control board and remove the bottom control panel cover Install the Protective Covers Install the protective covers in reverse order of removal ATTENTION Risk of electric shock exists when power is applied to the power terminalsofthedrive Theprotective coversmustbe replaced afterservicing the drive 5 ...

Page 49: ...l thermostat discharge resistors and inrush limiting resistors 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Disconnect the DPI cable from the HIM if present 4 Insert a flathead screwdriver into the holes in the right side of the protective covers on the drive and turn the latch 90 counter clockwise 5 Open the control pa...

Page 50: ...rom the drive See Remove Power from the Drive on page 44 3 Remove the bottom control panel cover See Remove the Protective Covers on page 47 4 Disconnect the interface cable from the communication adapter and set it aside 5 Disconnect any network cables from the adapter and set them aside 6 Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter 4 5 No...

Page 51: ...he stand offs on the control board and remove the EMI shield 8 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 7 Tightening torque 1 0 N m 8 9 lb in Note Frame A shown 8 Tightening torque 1 0 N m 8 9 lb in Note Frame A shown ...

Page 52: ...ons on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 47 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover PFC XX FV1 FU1 4 4 4 4 Switching Power Supply ...

Page 53: ...driver in the slot on the fuse holder F1 carefully pushing up and turning 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 new fuse in the reverse order of removal XA 1 2 15 16 XSW 1 4 XSW1 1 4 XV F1 1C2 1D2 XUV 1 6 Fuse holder ...

Page 54: ...age 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the bottom and I O and control terminal protective covers See Remove the Protective Covers on page 47 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 X...

Page 55: ...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 S15 XR XA XP3 XRE XFCD S21 S4 J1 J2 P1 S1 TB1 TB2 P4 P2 P3 P1 5 Tightening torque for reassembly is ...

Page 56: ... EN P September 2021 Chapter 3 Access Procedures 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 57: ...Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal 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 S15 XR XA XP3 XRE XFCD S21 S4 P2 P3 S1 TB1 TB2 XRE S2 ...

Page 58: ...otective Covers on page 47 4 If installed remove the resolver feedback option and interface boards See Resolver Feedback and Interface Circuit Board Removal and Installation on page 54 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 7 Carefully pull the I ...

Page 59: ...e two stand offs from the control board 9 Install one of the existing screws in the lower left corner of the control circuit board Install the I O Expansion Circuit Board Install the I O expansion board in reverse order of removal 8 Tightening torque 1 0 N m 8 9 lb in 9 Tightening torque 1 0 N m 8 9 lb in ...

Page 60: ...the bottom and I O and control terminal protective covers See Remove the Protective Covers on page 47 4 Remove the plug in I O terminal blocks with the wiring kept in place 5 Remove the two M3 x 6 mm screws and washers that secure the I O converter board to the stand offs on the control board and remove the I O converter board 6 Remove the two stand offs from the control board IMPORTANT Mark all c...

Page 61: ... Adapter and EMI Shield Removal and Installation on page 50 5 If installed remove the resolver feedback option and interface boards See Resolver Feedback and Interface Circuit Board Removal and Installation on page 54 6 If installed remove the I O expansion circuit board See I O Expansion Circuit Board Removal and Installation on page 58 7 If installed remove the 115V AC to 24V DC I O converter ci...

Page 62: ... S15 7 S15 8 S20 Monitoring of the Z channel of the digital encoder on connector XE2 Off Position Z channel monitored On Position Z channel not monitored The S20 setting should match the value selected in Par 652 Encoder Err Chk for example if S20 Off then Par 652 1 Enabled S21 Encoder power supply voltage and input adaptation selection This switch setting determines both the power supply input an...

Page 63: ...ng kept in place A B C A A B B Z Z COM V A A B B Z Z COM V 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...

Page 64: ...are set to the correct configuration based on your recorded settings See page 61 A B C A A B B Z Z COM V A A B B Z Z COM V 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...

Page 65: ...ove Power from the Drive on page 44 3 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 47 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembl...

Page 66: ...nects to connector XA on the switching power supply board for burn marks cracks or a loose connector If necessary replace the existing cable with the new cable provided Pulse Transformer Circuit Board Removal and Installation Remove the PulseTransformer Circuit Board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove t...

Page 67: ...iate gate leads from the pulse transformer board For non regenerative drives each pair of red and white gate lead cables from connectors KG1 KG6 For regenerative drives each pair of red and white gate lead cables from connectors KG1 KG6 and KG01 KG06 8 Disconnect the cables from the following connectors XUV XCD_IO XUVW XCD XR XTA X3 X4 and XSPF Also carefully remove the ribbon cable from XR from t...

Page 68: ...e pulse transformer board to the control pan and remove the board XUV XSW XSW1 XCD_IO XUVW XCD XR XSPF S3 78 79 35 36 75 76 81 82 U2 V2 X4 X5 X6 XTA TR2 TR1 T1 T4 T2 T5 T3 T6 PE XP1 XP2 KG1 KG4 KG2 KG5 KG3 KG6 KG01 KG04 KG02 KG05 KG03 KG06 T01 T04 T02 T05 T03 T06 XCT S4 XY X3 Components that are shownwithindashedlines are only onthe pulse transformer board for regenerative drives T15 Tightening to...

Page 69: ... 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 8 875 875 718 250 ON ON ON 1050 1050 861 300 ON ON ON ON Drive Current Rating Code DC Amps AC Line Amps HP DIP 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 8 830 830 681 500 ON ON ON 996 996 817 600 ON ON ON 1K1 1162 953 700 ON ON ON ON 1K3 1328 1089 800 ON ON ON ON 1K4 149...

Page 70: ...nel and I O and control terminal covers from the drive See Remove the Protective Covers on page 47 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover 1K2 1243 1019 1100 ON ON ON ON 1K4 1413 1159 1250 ON ON ON ON 1K5 1582 1297 1400 ON ON ON ON Drive Current Rating Code DC Amps AC Line Amps HP DIP Switch S3 DIP Switch S4 S3 1 S3 2 S...

Page 71: ...he field circuit board in the reverse order of removal Inspect the cables that connect to connectors XFCD and X3 on the field board for burn marks cracks or a loose connector If necessary replace the existing cables with the new cables provided IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly XFCD X3 1 TA_1 PFC XX R1 R4 C4 C7 Note Field board for ...

Page 72: ...ee Remove Power from the Drive on page 44 3 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 47 4 Remove the field circuit board from the drive See Remove the Field Circuit Board on page 70 5 Disconnect the gate lead wires from the connectors at the top of the SCR module IMPORTANT Mark all connections and ...

Page 73: ...the Field SCR and Dual Diode Modules Install the field SCR and dual diode modules in the reverse order of removal Apply thermal grease to the bottom of the SCR and dual diode modules before securing them to the heatsink ATTENTION Thermal grease must be applied to the bottom of the field SCR anddualdiodemodulesbefore securingthemtotheheatsinkor damagetothe drive may occur Tightening torque 2 5 5 0 ...

Page 74: ...10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the top control panel bottom control panel and I O and control terminal covers from the drive See Remove the Protective Covers on page 47 4 Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover PFC XX FV1 FU1 4 4 Field board Tightening torque 0 8 N m 7...

Page 75: ...021 75 Access Procedures Chapter 3 5 Loosen the screws that secure the input and output wires to the fuse holder terminals and remove the wires 6 If you are reusing the field fuses pull down on the tabs on the front of the fuse holder and remove the fuses 5 5 6 ...

Page 76: ...l support flange Install the Field Fuse Holder Install the field fuse holder in the reverse order of removal Fan Starting Capacitor Removal and Installation Remove the Fan Starting Capacitor Note A fan capacitor is only used on series A frame D drives See Figure 1 on page 11 for information on identifying series A drives 1 Read the General Safety Precautions on page 10 2 Remove power from the driv...

Page 77: ...s to the plug in terminal block at XC on the fan circuit board and remove the wires 6 Unscrew the fan capacitor from the back of the drive frame and remove the capacitor Install the Fan Starting Capacitor Install the fan starting capacitor in the reverse order of removal See the Series A Fan Circuit Diagram on page 122 for wiring details XF XC Disconnect capacitor wires from terminal blockXC 6 Fan...

Page 78: ... and remove the terminal block 5 Remove the plug in terminal blocks at XF and XC from the fan circuit board 6 Disconnect the ground wire from connector PE 7 Remove the four hexalobular screws that secure the fan circuit board to the insulator and remove the board Tightening torque is noted in the illustration for reassembly Install the Series A Fan Circuit Board Install the series A fan circuit bo...

Page 79: ...t board 5 Remove the plug in terminal block TB2 at XF from the fan circuit board 6 Remove the plug in terminal block TB3 at XE from the fan circuit board 7 Disconnect the ground wire from connector PE 8 Remove the four hexalobular screws that secure the fan circuit board to the insulator and remove the board Tightening torque is noted in the illustration for reassembly Install the Series B Fan Cir...

Page 80: ...cure the top airflow plate to the drive then slide the plate forward to lift it off the screws Note The airflow plate cannot be removed from the drive unless the AC input wiring and busbar extensions if installed are removed 5 Remove the wires connected to the terminal block at XF on the fan circuit board at the top of the drive to the left of the fan blower Cut the cable ties that secure the fan ...

Page 81: ...an assembly from the drive Install the Series A Fan Assembly Install the series A fan assembly in the reverse order of removal See the Series A Fan Circuit Diagram on page 122 for wiring details Secure the fan power wires using cable ties as previously installed to make sure that the wires do not make contact with moving parts ATTENTION The edges of the blades on the fan blower may be sharp Take p...

Page 82: ...the top airflow plate to the drive then slide the plate forward to lift it off the screws Note The airflow plate cannot be removed from the drive unless the AC input wiring and busbar extensions if installed are removed 5 Remove the wires connected to terminal block TB1 at XF2 on the fan circuit board at the top of the drive to the left of the fan blower Tightening torque 1 5 N m 13 lb in T15 4 4 ...

Page 83: ...assembly from the drive Install the Series B Fan Assembly Install the Series B fan assembly in the reverse order of removal See the Series B Fan Circuit Diagram on page 122 for wiring details Secure the fan power wires using cable ties as previously installed to make sure that the wires do not make contact with moving parts ATTENTION The edges of the blades on the fan blower may be sharp Take prec...

Page 84: ...w plate to the drive Slide the plate forward to lift it off the screws Note The airflow plate cannot be removed from the drive unless the AC input wiring and busbar extensions if installed are removed 5 Remove the wires that are connected to the terminal blocks at XF and XF2 on the three phase fan loss detection circuit board at the top of the drive to the left of the fan blower Tightening torque ...

Page 85: ...for wiring details Secure the fan power wires using cable ties as previously installed to make sure that the wires do not make contact with moving parts ATTENTION Edges of the fan blades can be sharp Take precautions to help protect against personal injury when handling the fan assembly IMPORTANT The Frame D series C drive cooling fan requires three phase 50 60 Hz 400 460V AC input power If source...

Page 86: ...Protective Covers on page 47 4 Loosen but do not remove the six hexalobular screws that secure the top airflow plate to the drive then slide the plate forward to lift it off the screws Note The airflow plate cannot be removed from the drive unless the AC input wiring and busbar extensions if installed are removed 5 Open the control panel See Open the Control Panel on page 49 Tightening torque 1 5 ...

Page 87: ...connected and pulled up in order to remove the AC current transducers Remove the wiring from the U and W phase AC input terminal busbars if necessary 7 Remove the four bolts and washers that secure the top insulator bar over the AC input terminal busbars to the drive frame and remove the insulator bar XF XC 6 7 AC current transducers Top insulator bar ...

Page 88: ...input terminal busbars to the rear insulator bar 9 Remove the two nuts and washers that secure the signal wires to the terminals on each of the AC current transducers and remove the wires 10 Loosen the two screws that secure each of the AC current transducers to the U and W phase terminal busbar so that the current transducers are loose on the busbars XF XC 8 10 9 ...

Page 89: ...rs up until the AC current transducers can be removed from the busbars Install the AC Current Transducers Install the AC current transducers in reverse order of removal Tightening torque for the M12 bolts is 45 N m 398 lb in Verify that signal wire that was disconnected from the U and W phase busbars when removing the current transducers is reinstalled 11 Signal wire U phase busbar W phase busbar ...

Page 90: ...ety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Open the control panel See Open the Control Panel on page 49 4 Remove the three fuses at locations F11 F21 and F31 Install the Overvoltage Clipping Circuit Board Fuses Install the overvoltage clipping circuit board fuses in the reverse order of removal XCD X1UVW1 XUVW XR 5 XR 4 XR 3 XR 2 XR 1 C5gn...

Page 91: ...g board 5 Disconnect the resistor wires from connectors XR 1 XR 6 on the overvoltage clipping board Note On older boards these connections are soldered directly to the board In this case unsolder the connections 6 Remove the seven hexalobular screws and washers that secure the overvoltage clipping board to the drive frame and remove the board IMPORTANT Mark all connections and wires before removal...

Page 92: ...ation Remove the Armature Leg Fuse 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Open the control panel See Open the Control Panel on page 49 4 Remove the screws that secure the switch to the fuse and remove the switch and fuse wires Retain the switch screws and wires for reuse IMPORTANT Mark all connections and wires be...

Page 93: ...p of the fuse out and downward and pull the fuse off of the lower bolt and out of the drive Install the Armature Leg Fuse Install the armature leg fuse in the reverse order of removal Tightening torque for the fuse bolt is 45 N m 398 lb in Install the existing fuse switch on the fuse body using the existing hardware Verify that all wires are properly connected to the fuse switch 5 5 5 ...

Page 94: ...ions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the bottom terminal cover from the drive See Remove the Protective Covers on page 47 4 Open the control panel See Open the Control Panel on page 49 IMPORTANT Notetheterminalnumberonthefuse switchto whichthesignalwires are connected for proper reinstallation 1 4 2 Note terminal numbers on fuses for wir...

Page 95: ... the bottom of each leg fuse to the SCR module leg input terminal 7 Loosen the upper bolt and washer that secures the top of the fuse to the AC input terminal rotate the top of the fuse out and downward and remove the fuse from the lower terminal SCR module leg input terminal Main input terminal 7 6 5 Rotate top of fuse out and downward lift off lower terminal IMPORTANT Mark all connections and wi...

Page 96: ...he connector mounted on the middle of the left SCR module leg assembly 10 Disconnect the wires for the capacitors and resistors from the connectors that are mounted at the bottom of each SCR module leg assembly 11 Remove the four bolts and washers that secure each SCR module leg assembly output terminal to a DC output busbar C and D at the bottom of the drive 8 9 10 SCR module assembly White Red W...

Page 97: ...tion 20P TG004C EN P September 2021 97 Access Procedures Chapter 3 Angled view showing regenerative drive 11 11 11 11 SCR assembly output terminal SCR assembly output terminal C shaped busbar DC output busbar DC output busbar 11 ...

Page 98: ...s lift the SCR assembly up and off the mounting screws and lift the assembly up and forward so that the output terminals clear the holes in the bottom of the drive frame 14 Repeat steps 12 and 13 above for each SCR assembly IMPORTANT Before removing the SCR assemblies make sure that the area around the drive is clear of equipment Only lift the assemblies using the handles provided 12 12 12 12 12 1...

Page 99: ...he thermostat to the heatsink and remove the thermostat Install the SCR Module Leg Assembly Install the new SCR module leg assemblies in the reverse order of removal Tightening torque for the bimetal thermostat is 1 0 N m 8 9 lb in Tightening torque for the SCR module leg assemblies is 4 5 5 0 N m 40 0 44 4 lb in Tightening torque for the SCR module input and output terminals to the fuse terminals...

Page 100: ...nel See Open the Control Panel on page 49 5 Remove the left SCR module leg assembly from only the drive and remove the bimetal thermostat from the assembly heatsink See Remove the SCR Module Leg Assembly on page 94 Install the BimetalThermostat Install the new bimetal thermostat in the reverse order of removal Discharge Resistors Removal and Installation Remove the Discharge Resistors The discharg...

Page 101: ... Note On older boards these connections are soldered directly to the board In this case unsolder the connections IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly XCD X1UVW1 XUVW F31 F21 F11 XCD X1UVW1 XUVW F31 F21 F11 XR 5 XR 4 XR 3 XR 2 XR 1 C5gn C4blu C7gn C7blu XR 6 4 Newer overvoltage clipping board Older overvoltage clipping board ...

Page 102: ...and remove the resistors and wires Install the Discharge Resistors Install the new discharge resistors in reverse order of removal Inrush Limiting Resistor Removal and Installation Remove the Inrush Limiting Resistor The inrush resistor is secured to the back wall of the drive frame below the control pan 1 Read the General Safety Precautions on page 10 5 5 Inrush resistor ...

Page 103: ...istor wires from connector XR 6 on the overvoltage clipping board Note On older boards these connections are soldered directly to the board In this case unsolder the connections IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly XCD X1UVW1 XUVW F31 F21 F11 XCD X1UVW1 XUVW F31 F21 F11 XR 5 XR 4 XR 3 XR 2 XR 1 C5gn C4blu C7gn C7blu XR 6 4 Newer overvo...

Page 104: ...Install the Inrush Limiting Resistor Install the inrush limiting resistor in the reverse order of removal Snubber Capacitors Removal and Installation Remove the Snubber Capacitors 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 44 3 Remove the bottom terminal cover from the drive See Remove the Protective Covers on page 47 5 5 ...

Page 105: ... the snubber capacitors to the mounting bracket at the bottom of the drive chassis and lift the capacitors off the brackets 5 Disconnect the wires from the top of each capacitor and remove the capacitors Install the Snubber Capacitors Install the snubber capacitors in the reverse order of removal 4 Note Busbars shown removed for clarity only 5 ...

Page 106: ...r from the drive See Remove the Protective Covers on page 47 4 Open the control panel See Open the Control Panel on page 49 5 Remove the SCR module leg assemblies from the drive You do not need to remove the bimetal thermostat from the left SCR module assembly for this procedure See Remove the SCR Module Leg Assembly on page 94 6 Remove the 12 hexalobular screws and washers that secure the metal p...

Page 107: ...ds from all resistor terminals Retain the wires for reuse 8 Remove the two hexalobular screws and washers that secure each of the snubber resistors to standoffs on the back wall of the drive chassis and remove the resistors Install the Snubber Resistors Install the snubber resistors in the reverse order of removal 8 8 ...

Page 108: ...108 Rockwell Automation Publication 20P TG004C EN P September 2021 Chapter 3 Access Procedures Notes ...

Page 109: ...the control board DIP switches are set correctly See Install the Control Circuit Board on page 64 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...

Page 110: ...10 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 f...

Page 111: ...Fuses 116 Figure 16 AC Line Measurement Points Diagram 117 Figure 17 Power Feedback Connections Diagram 117 Figure 18 Field Board and SCR Dual Diode Module Connections Diagram 118 Figure 19 Field Control Circuit Diagram 118 Figure 20 Control Circuit Input Power Diagram 119 Figure 21 Encoder Control Circuit Diagram 119 Figure 22 DCTachometer Control Circuit Diagram 120 Figure 23 MotorThermal Protec...

Page 112: ...grey brown black XCD X1UVW1 Overvoltage Clipping Board XUV XUVW XCD XR XTA XP1 XP2 KG1 KG4 KG2 KG5 KG3 KG6 KG01 KG04 KG02 KG05 KG03 KG06 X4 Pulse Transformer Board XA XUV Switching Power Supply Board XFCD X3 X4 1 X4 2 T XTA 1 CT U CT W XTA 2 XTA 3 XTA 4 Field Board X3 XY Test Connector XSW XSW Series B Fan Circuit Board From External Power Supply 400 460V AC 50 60 Hz 31 32 PE W3 V3 U3 TB TB PE W3F...

Page 113: ...Non regenerative Drive Power Module with Six Fuses U V W C D D C T1 T2 T3 T4 T5 T6 F1 F2 F3 F4 F5 F6 R T1 R T3 R T2 R T4 R T5 R T6 C T1 C T2 C T3 C T4 C T5 C T6 G1 K1 G2 K2 G3 K3 G4 K4 K5 G5 K6 G6 KG1 KG2 KG3 KG4 KG5 KG6 Pulse transformer circuit board XSPF 1 3 XT4 XT5 XT6 XT1 XT2 XT3 Pulse transformer circuit board ...

Page 114: ...nerative Drive Power Module with 12 Fuses U V W C D D C T1 T2 T3 T4 T5 T6 F1 F1 F2 F2 F3 F3 F4 F4 F5 F5 F6 F6 R T1 R T3 R T2 R T4 R T5 R T6 C T1 C T2 C T3 C T4 C T5 C T6 G1 K1 G2 K2 G3 K3 G4 K4 K5 G5 K6 G6 KG1 KG2 KG3 KG4 KG5 KG6 Pulse transformer circuit board XSPF 1 3 XT4 XT5 XT6 XT1 XT2 XT3 Pulse transformer circuit board ...

Page 115: ... Fuses U V W C D D C T1 T1 T2 T2 T3 T3 T4 T4 T5 T5 T6 T6 F1 F2 F3 F4 F5 F6 R T1 R T3 R T2 R T4 R T5 R T6 C T1 C T2 C T3 C T4 C T5 C T6 G1 K1 G1 K1 G2 K2 G2 K2 G3 K3 G3 K3 G4 K4 G4 K4 K5 G5 K5 G5 K6 G6 K6 G6 KG1 KG01 KG2 KG02 KG3 KG03 KG4 KG04 KG5 KG05 KG6 KG06 Pulse transformer circuit board XSPF 1 3 XT4 XT5 XT6 XT1 XT2 XT3 Pulse transformer circuit board ...

Page 116: ...V W C D D C T1 T1 T2 T2 T3 T3 T4 T4 T5 T5 T6 T6 F1 F1 F2 F2 F3 F3 F4 F4 F5 F5 F6 F6 R T1 R T3 R T2 R T4 R T5 R T6 C T1 C T2 C T3 C T4 C T5 C T6 G1 K1 G1 K1 G2 K2 G2 K2 G3 K3 G3 K3 G4 K4 G4 K4 K5 G5 K5 G5 K6 G6 K6 G6 KG1 KG01 KG2 KG02 KG3 KG03 KG4 KG04 KG5 KG05 KG6 KG06 Pulse transformer circuit board XSPF 1 3 XT4 XT5 XT6 XT1 XT2 XT3 Pulse transformer circuit board ...

Page 117: ...ts Diagram Figure 17 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 715 kohm resistors Note Note Note Note Note ...

Page 118: ... 470K 470K 470K 470K 470K 470K 470K 470K 1V1 1U1 X3 2 X3 1 100R 100R 100R 100R T1 T2 D1 D2 MOD2 MOD1 K1 G1 K2 G2 XFCD 1 XFCD 2 XFCD 3 XFCD 4 TA_1 M TA1 M D1 C1 To Pulse Transformer Board X3 Connector Incoming AC Line 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 1800 1800 18...

Page 119: ... 20 Control Circuit Input Power Diagram Figure 21 Encoder Control Circuit Diagram L1 1C2 1D2 V2 U2 V91 230VAC or 115VAC 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 120: ...C EN P September 2021 Appendix A Schematics Figure 22 DC Tachometer Control Circuit Diagram Figure 23 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 121: ...ematics Appendix A Figure 24 Drive Heatsink Monitoring Control Circuit Diagram Figure 25 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 122: ...Fan Fault U3F V3F Z2F Z2C U3C yellow green blue grey brown black PE FNLS Fan Capacitor FNLS3 31 32 PE W3 V3 U3 TB TB PE W3F V3F U3F Z3F Y3F X3F Fan Fault Fan Supply 3 Phase 400V AC 50 Hz 400 460V AC 60 Hz To Fan Motor White White Yellow Green Black Gray Red Orange Blue Brown FNLS3 31 32 PE W3 V3 U3 TB TB PE W3F V3F U3F Z3F Y3F X3F Fan Fault Fan Supply 3 Phase 400V AC 50 Hz 400 460V AC 60 Hz To Fan...

Page 123: ... Board to Switching Power Supply Connections 125 PulseTransformer Board to BimetalThermostat Connections 125 PulseTransformer Board to Field SCR Dual Diode Module Connections 125 PulseTransformer Board to Control Board Connections 126 PulseTransformer Board to CurrentTransducer Connections 127 Switching Power Supply Board Layout 127 Switching Power Supply Board to Control Board Connections 127 Con...

Page 124: ...sformer Board Layout XUV XSW XSW1 XCD_IO XUVW XCD XR XSPF S3 78 79 35 36 75 76 81 82 U2 V2 X4 X5 X6 XTA TR2 TR1 T1 T4 T2 T5 T3 T6 PE XP1 XP2 KG1 KG4 KG2 KG5 KG3 KG6 KG01 KG04 KG02 KG05 KG03 KG06 T01 T04 T02 T05 T03 T06 XCT S4 XY X3 Components shown within dashed lines are only on the pulse transformer board for regenerative drives Control power terminal block ...

Page 125: ...ield Board Connector Description X3 1 1 X3 1U1 field sync signal from U1 2 2 1V1field sync signal fromV1 PulseTransformer 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 24V...

Page 126: ...ature 0 signal 9 9 0V GNDP 10 10 Heatsink overtemperature 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 ReducedV sync signal 17 17 ReducedW 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 signal ...

Page 127: ... Supply Connections on page 125 Pulse Transformer Board Connector Pin Number to Pin Number CurrentTransducer Description XTA 1 Red CT on Phase U Secondary side CT phase U 2 White 3 Red CT on PhaseW Secondary side CT phaseW 4 White XA 1 2 15 16 XSW 1 4 XSW1 1 4 XV 1C2 1D2 F1 XUV 1 6 SwitchingPower Supply Board Connector Pin Number to Pin Number Control Board Connector Description XA 1 1 XA 5V 2 2 5...

Page 128: ... 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 129: ...er 2021 129 Circuit BoardLayoutsand Connections Appendix B Field Board Figure 32 Field Board Layout See Control Board to Field Board Connections on page 128 and Pulse Transformer Board to Field Board Connections on page 125 XFCD X3 1 TA_1 PFC XX R1 R4 C4 C7 ...

Page 130: ... C7gn C7blu XR 6 Overvoltage Clipping Board Connector Pin Number to Pin Number Pulse Transformer Board Connector Description XCD 1 1 XCD Signal from C Phase 2 2 not used 3 3 Signal from D Phase 4 not used 5 Signal from DC output terminal C 6 not used 7 Signal from DC output terminal D X1UVW1 1 1 XUVW Signal from U Phase 2 2 not used 3 3 Signal fromV Phase 4 4 not used 5 5 Signal fromW Phase XUVW 1...

Page 131: ...er 2021 131 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 132 Field Current Loss Failure 133 ...

Page 132: ...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 133: ...hort 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 signal wit...

Page 134: ...ure 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 value s...

Page 135: ...ocedure Remove the Field Fuse Holder Added the section Series C Fan Assembly Removal and Installation Added the Block Diagram of Non regenerative Drive Power Module with Six Fuses Added the Block Diagram of Non regenerative Drive Power Module with 12 Fuses Added the Block Diagram of Regenerative Drive Power Module with Six Fuses Added the Series C Fan Circuit Diagram Change Added information on ho...

Page 136: ...136 Rockwell Automation Publication 20P TG004C EN P September 2021 Appendix D History of Changes Notes ...

Page 137: ...Electrostatic Discharge Precaution 10 encoder test 37 F fan circuit board series A install 78 remove 78 fan circuit board series B install 79 remove 79 fan starting capacitor install 77 remove 76 fault field current loss 25 heatsink overtemperature 40 main contactor 40 overcurrent 23 power failture 17 fault report create 41 field circuit board install 71 remove 70 field circuit fuses install 45 re...

Page 138: ...perature heatsink 40 overvoltage clipping circuit board install 92 remove 91 overvoltage clipping circuit board fuses install 90 remove 90 P parameter configuration save 14 15 16 power removing 44 power failure fault 17 protective covers install 48 remove 47 PTC 40 pulse transformer board install 69 remove 66 test 33 R relay outputs 40 remove 115V AC to 24V DC I O converter board 60 AC current tra...

Page 139: ...assembly install 85 remove 84 service tools 12 snubber capacitors install 105 remove 104 snubber resistors install 107 remove 106 software tools 12 switching power supply board fuse 52 install 66 remove 65 T technical support calling 41 test armature SCR modules 29 DC analog tachometer 37 encoder 37 field SCR dual diode module 34 pulse transformer board 33 testpoints locations 20 21 thermal switch...

Page 140: ...140 Rockwell Automation Publication 20P TG004C EN P September 2021 Index Notes ...

Page 141: ...ecurity Design Guidelines Reference Manual SECURE RM001 Provides guidance on how to conduct security assessments implement Rockwell Automation products in a secure system harden the control system manage user access and dispose of equipment Industrial Components Preventive Maintenance Enclosures and Contact Ratings Specifications publication IC TD002 Provides a quick reference tool for Allen Bradl...

Page 142: ...ok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Get help determining how products interact check features and capabilities and find associated firmware ro...

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