Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual Download Page 38 | Manualshive

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Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual Download Page 38

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Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Chapter 2

Component Test Procedures

Create a Fault Report

A Technical Support wizard is available in the DriveExecutive and Connected
Components Workbench software application. The wizard gathers
information about the hardware, firmware, non-default parameters, and the
fault and alarm queues, including time stamps. The logged data can be saved as
a text (.txt) file.

Complete fault reports are critical for analysis and repair of modules returned
to the factory. At a minimum, perform and record the following:

• Record the contents of the fault queue (faults and times of occurrence).

See the PowerFlex Digital DC Drive User Manual, publication

, for detailed Fault and Alarm codes and descriptions.

• Make a record of any burn marks on the printed circuit boards, cabling,

bus bars, and SCR modules.

• Make a record of any liquid and condensation marks on the printed

circuit boards, components and mechanical parts.

• Make a record of the amount of dust and other additional particles on

the drive and drive components.

• Make a record of any mechanical damage to the drive and drive

components.

• Record the size and type of main fuses.
• Record any other important marks and damage.

What You Need When You
Call Tech Support

When you contact Technical Support, please be prepared to provide the
following information:

• Order number
• Product catalog number and drives series number (if applicable)
• Product serial number
• Firmware revision level
• Most recent fault code
• Your application

You can use the table below to record the data provided in each PowerFlex DC
drive parameter listed.

Param(s)

Name

Description

Parameter Data

1349

Status1 at Fault

Captures and displays Par 381 [Drive Status 1] bit pattern at the time
of the last fault.

1350

Status2 at Fault

Captures and displays Par 382 [Drive 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 occurrence of the
associated trip fault.

1371

Fault Arm Amps

Captures and displays the armature current (as a percentage of rated
current) at the time of the last fault.

1372

Fault Speed

Captures and displays the output speed (rpm) of the drive at the time
of the last fault.

1373

Fault Field Amps

Captures and displays the field current (as a percentage of rated
current) at the time of the last fault.

1374

Fault Voltage

Captures and displays the armature voltage at the time of the last
fault.

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Summary of Contents for Allen-Bradley PowerFlex 20P

Page 1: ...PowerFlex Digital DC Drive Frame B 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: ...g the Switching Power Supply and Pulse Transformer Boards 16 Testing the Control and Field Board Connections 16 Troubleshoot an AC Undervoltage Fault 19 Troubleshoot an Armature Bridge Failure 20 Troubleshoot a Field Current Loss Fault 22 Low or Incorrect Field Current 22 No Field Current 24 Power Component Test Procedures 26 Check the Armature SCR Modules 26 Check the Pulse Transformer Board 30 C...

Page 4: ...ds 51 I O Expansion Circuit Board Replacement 52 Remove the I O Expansion Circuit Board 52 Install the I O Expansion Circuit Board 53 115V AC to 24V DC I O Converter Circuit Board Replacement 54 Remove the 115V AC to 24V DC I O Converter Circuit Board 54 Install the 115V AC to 24V DC I O Converter Circuit Board 55 Control Circuit Board Replacement 55 Remove the Control Circuit Board 55 Install the...

Page 5: ...Diode Modules 77 AC Line Snubber Circuit Board and Resistors Replacement 78 Remove the AC Line Snubber Circuit Board and Resistors 78 Install the AC Line Snubber Circuit Board and Resistors 80 SCR Modules Replacement 80 Remove the SCR Modules 80 Install the SCR Modules 88 AC Current Transducers Replacement 90 Remove the AC Current Transducers 90 Install the AC Current Transducers 93 Bimetal Thermo...

Page 6: ...ation 20P TG002B EN P February 2018 Table of Contents AppendixC Flow Charts List of Flow Charts 121 Control Power Supply Failure 122 Field Current Loss Failure 123 No Field Current 123 Low or Incorrect Field Current 124 Index 125 ...

Page 7: ...documents contain additional 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 ...

Page 8: ...8 Rockwell Automation Publication 20P TG002B 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: ...onnect 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 oscilloscope c...

Page 11: ... dual bridge capable of two or four quadrant output The field supply consists of single phase full wave rectified bridge Also associated with the power structure are incoming line protection devices and contactor and dynamic brake control circuits Verify that you are working on a frame B drive by checking the data nameplate located on the side of the drive The frame size is printed just above the ...

Page 12: ...ty 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 mm 13 mm 1...

Page 13: ...Failure 15 Troubleshoot an AC Undervoltage Fault 19 Troubleshoot an Armature Bridge Failure 20 Troubleshoot a Field Current Loss Fault 22 Power Component Test Procedures 26 Speed Feedback Device Tests 34 Thermistors and Thermal Switches 37 Relay Outputs 37 Create a Fault Report 38 What You Need When You Call Tech Support 38 IMPORTANT Using the diagnostic tests in this chapter should only be perfor...

Page 14: ...nch 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 Complete these steps to save the drive and adapter parameters to a HIM set 1 On the HIM access the Memory Storage menu 2 Select the HIM CopyCat menu and press 3 Select Device HIM and press 4 Do one of the following If there are no existing HIM S...

Page 15: ...see Control Power Supply Failure on page 122 4 If any of the signals in the table above is incorrect or missing verify that either 115V AC or 230V AC voltage is present at terminals U2 and V2 control circuit power input If the voltage is present and correct continue with step 5 below If the voltage is incorrect or missing remove control power and verify the wiring and power source to U2 V2 and cor...

Page 16: ...he drive see page 42 2 Replace the fuses on the switching power supply board see page 61 3 Remove the switching power supply board from the drive see page 62 4 Reapply power to the switching power supply board only If the power supply fuses do not blow continue with step 5 below If the power supply fuses blow replace the switching power supply board see page 62 5 Remove all incoming AC voltage fro...

Page 17: ...e XFCD cable connector The resistance measurement for both tests should be greater than 200 kΩ If a lower resistance value is measured replace field board Figure 1 Control Board Testpoints Upper Left 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 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 1...

Page 18: ... 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 19: ...e voltage measurements is incorrect or missing remove incoming AC power and verify the wiring to the drive and the power supply source and correct any problems 4 Using a voltmeter measure the combined voltages of the AC lines on the following testpoints on the control board all waveforms have a 2 5V offset See Figure 1 on page 17 and Figure 2 on page 18 for location of the testpoints Also see Figu...

Page 20: ...oints See Figure 27 on page 119 for location of the XR connector on the control board Note If using an AC input contactor this step requires that the cable remain connected to the XR connector on the control board and that an adapter be used to measure these signals 1 Read the General Safety Precautions on page 10 2 Remove the protective covers see page 43 3 If using a DC output contactor disconne...

Page 21: ...ion 20P TG002B EN P February 2018 21 Component Test Procedures Chapter 2 Figure 3 Good SCR Gate Pulse and Armature Current Signals Example Figure 4 Good SCR Armature Voltage and Motor Current Signal Example 5 V 0 V XY19 XY19 XY17 ...

Page 22: ... 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 24 Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 124 1 Read the General Safety Precautions on page 10 2 Verify the actual value of parameter 351 Fi...

Page 23: ...r 1 5 A the measurement at LA LB will be 1 245 VDC 1 5 x 2 1 66 If the voltage measurement 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 see page 55 7 Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance as indicated in the tab...

Page 24: ...wer to the drive and check the fuses at FU1 and FV1 See Remove Power from the Drive on page 42 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...

Page 25: ...sure 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 see page 55 If the gate signals are present replace the field board see page 75 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...

Page 26: ...on page 10 2 Verify that contactor power if used is removed 3 Verify that power to an external field supply if used is removed 4 Check the anode to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance across the SCRs lead orientation is not critical For regenerative drives see Table 2 on page 26 and Figure 6 on page 27 For non regenerative drives see Table 3 on...

Page 27: ...B EN P February 2018 27 Component Test Procedures Chapter 2 Figure 6 Regenerative Drive SCR Module Layout U V C D W 1 2 3 2 1 3 1 2 3 2 1 3 1 2 3 2 1 3 SCR Module 1 SCR Module 01 SCR Module 2 SCR Module 02 SCR Module 3 SCR Module 03 U C V D W ...

Page 28: ...of each SCR With a digital multimeter set to Ohms measure the resistance of each SCR junction For regenerative drives see Table 4 on page 29 and Figure 8 on page 29 For non regenerative drives see Table 5 on page 30 and Figure 9 on page 30 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 U V C D W ...

Page 29: ...generative 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 varies depending upon the SCR manufacturer Verify that the actual measured value is consistent for all SCRs 4 Pin 6 Pin 7 2 2 Pin 5 Pin 4 5 Pin 6 Pin 7 3 3 Pin 5 Pin 4 6 Pin 6 Pin 7 01 01 Pin 6 Pin 7 04 Pin 5 Pin 4 02 02 Pin 6 Pin 7 05 Pin 5 Pin 4 03 03 Pin 6 Pin 7 06 Pin 5 Pin 4...

Page 30: ...ircuitry is suspected 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the pulse transformer board see page 62 4 With a digital multimeter set for a continuity check measure each connection point on the pulse transformer board listed in the tables below See Figure 25 on page 114 for connector locations If any of the actual measurements are out of ...

Page 31: ...enerative Drives Table 9 Armature Pulse Transformer Primary Measurements for Regenerative Drives For SCR MeasureFrom To Meter Reading Connector XY Pinout 1 KG1 XY 4 open circuit 4 KG4 XY 1 2 KG2 XY 5 5 KG5 XY 2 3 KG3 XY 6 6 KG6 XY 3 01 KG01 XY 1 04 KG04 XY 4 02 KG02 XY 2 05 KG05 XY 5 03 KG03 XY 3 06 KG06 XY 6 For SCR MeasureFrom To Meter Reading Connector XY Pinout 01 KG01 XY 1 open circuit 04 KG0...

Page 32: ...ective covers see page 43 4 Verify that contactor power if used is removed 5 Verify that power to an external field supply if used is removed 6 Check the anode to cathode junction of the field SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules See Table 10 and Figure 10 If a low resistance is detected replace the modules see page 77 If a m...

Page 33: ...ter 2 Figure 10 Field Terminal Block Location Figure 11 Field Fuses Location 7 Remove the cable from connector XP on the pulse transformer circuit board See Figure 25 on page 114 for connector location V1 C1 D1 U1 Top of Drive Unscrew fuseholders and remove fuses Front of Drive Top view of Drive ...

Page 34: ...the drive can be measured from V to COM with a digital multimeter If S21 is set to ENC_5 the voltage level should be 2 5 5 4V If S21 is set to ENC_12 the voltage level should be 5 4V 15 2V For reference see Figure 19 on page 110 for a schematic diagram The Channel A and Channel B are square wave type outputs that are 90 degrees out of phase When rotating in the counter clockwise direction as viewe...

Page 35: ...ace board can be used to verify that the board is not damaged Verify that the following light emitting diodes are functioning as expected See Figure 12 on page 36 for light emitting diodes locations and switch settings If any of the light emitting diodes that should turn on when control power is applied fail to do so verify that the resolver interface and resolver feedback boards are properly seat...

Page 36: ...e measurements fails replace the resolver interface board see page 48 Figure 12 Resolver Interface Board Testpoint Locations Testpoint to Testpoint Measurement 12V 0V12 12V DC 5 12V 0V12 12V DC 5 24V_VI 0V24 24V DC 5 5V 0V5 5V DC 5 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 ...

Page 37: ...metal 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 22 on page 111 for a circuit diagram During normal operation 1 6V DC is present between terminal 78 and drive common When an open circuit exists...

Page 38: ...marks and damage What You Need When You Call Tech Support When you contact Technical Support please be prepared to provide the following information Order number Product catalog number and drives series number if applicable Product serial number Firmware revision level Most recent fault code Your application You can use the table below to record the data provided in each PowerFlex DC drive paramet...

Page 39: ... Circuit Board Replacement 52 115V AC to 24V DC I O Converter Circuit Board Replacement 54 Control Circuit Board Replacement 55 Control Electromagnetic Interference Shield Removal and Closure 58 Switching Power Supply Board Fuse Replacement 60 Pulse Transformer Circuit Board Fuse Replacement 62 Pulse Transformer and Switching Power Supply Circuit Boards Replacement 62 Field Circuit Fuses Replaceme...

Page 40: ... Board 20P S520L 54 Control CircuitBoard SK 20P S5RP1 55 Power Circuit Boards Pulse Transformer Board for 230V AC Regen Drives 146 434 A FIR2 41 SK 20P S5N08 62 Pulse Transformer Boardfor460 480VAC Regen Drives 167 412 A FIR2 51 SK 20P S5N18 PulseTransformerBoardfor575VACRegen Drives 67 405A FIR2 61 SK 20P S5N421 Switching Power Supply Board SW2 32 SK 20P S5N10 62 Field Board PFC2A 31 SK 20P S5N25...

Page 41: ... A 460 480V AC Non Regen Drives 330 and 412 A SCR Modules Qty 6 1K8V 130 A 575V AC Regen Drives 67 135 A SK 20P S79F7 SCR Modules Qty 3 1K8V 130 A 575V AC Non Regen Drives 67 135 A SCR Modules Qty 6 1K8V 250 A 575V AC Regen Drive 270 A SK 20P S8HI6 SCR Modules Qty 3 1K8V 250 A 575V AC Non Regen Drive 270 A SCR Modules Qty 6 1K8V 320 A 575V AC Regen Drive 405 A SK 20P S79F9 SCR Modules Qty 3 1K8V 3...

Page 42: ...cautions on page 10 2 Remove power from the drive see page 42 ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electricalarcmayoccur Anelectricalarccancausepersonalinjuryorproperty damage by sending an erroneous signal to your system s field devices causing unintended machine motion causing an explosion in a hazard...

Page 43: ...he DPI HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly Install the DPI HIM Assembly Install the DPI HIM assembly in reverse order of removal Protective Cover Replacement Remove the Protective Covers 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 4...

Page 44: ...ide the cover down and off the drive chassis 5 Loosen but do not remove the screws that secure the top cover to the drive then slide the cover up and off the drive chassis IMPORTANT The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected 3 Tightening torque 1 5 N m 13 3 lb in 4 U V C D W Tightening torque 1 5 N m 13 3 lb in ...

Page 45: ...5 Part Replacement Procedures Chapter 3 6 Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside Install the Protective Covers Install the protective covers in the reverse order of removal 6 ...

Page 46: ...lectromagnetic interference EMI shield 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the protective covers from the drive see page 43 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 ...

Page 47: ...cure the EMI shield to the standoffs on the control board and remove the EMI shield 8 Remove the three standoffs 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 8 Tightening torque 1 0 N m 8 9 lb in ...

Page 48: ...feedback and interface circuit boards 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the protective covers from the drive see page 43 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 P...

Page 49: ...terface 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 Lifttheresolver feedbackboardstraightupduring removaltoavoid 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 re assembly is...

Page 50: ... February 2018 Chapter 3 Part Replacement 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 re assembly is 0 7 N m 6 2 lb in Resolverinterface board ...

Page 51: ...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 7...

Page 52: ...3 Remove the protective covers from the drive see page 43 4 If installed remove the resolver feedback option board see page 48 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 O expansion board off connector XBB on the control board I...

Page 53: ...ter 3 8 Remove the two stand offs from the control board 9 Install one screw in the lower left corner of the control 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 54: ...e General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the protective covers from the drive see page 43 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 IMPORTANT Mark all connections an...

Page 55: ...n loading the drive and adapter parameters to an offline database file using DriveExecutive See to the PowerFlex DC Digital Drive User Manual publication 20P UM001 for information on using the HIM or the on line Help provided with DriveExecutive for more information on HIM Sets or using the HIM 3 Remove power from the drive see page 42 4 Remove the protective covers from the drive see page 43 5 Re...

Page 56: ...with this switch S14 Field current resistors settings The value that is selected with switch S14 must be entered in Par 374 Drv Fld Brdg Cur when the drive is commissioned S14 1 S14 2 S14 3 S14 4 S14 5 S14 6 S14 7 not used S14 8 not used S15 Configures the control circuit board to the appropriate drive size S15 1 S15 2 S15 3 S15 4 S15 5 S15 6 S15 7 S15 8 S20 Monitoring reported by Par 652 Encoder ...

Page 57: ...02B EN P February 2018 57 Part Replacement Procedures Chapter 3 10 Carefully disconnect the cables from connectors XFCD XA and XR on the control board 11 Remove the plug in I O and control terminal blocks with the wiring kept in place 10 11 ...

Page 58: ... Interference Shield Removal and Closure Move the Control Electromagnetic Interference Shield You must move lower the control electromagnetic interference EMI shield that holds the control board in order to access other components within the drive Follow these steps to remove the control electromagnetic interference EMI shield 1 Read the General Safety Precautions on page 10 2 Remove power from th...

Page 59: ...s XA XR and XFCD on the control board 5 Loosen the two captive screws at the top of the control EMI shield and lower shield Close the Control EMI Shield in the Service Position Close the control EMI shield in reverse order IMPORTANT If the drive is not in a vertical position the control EMI shield will not remain open without a means of restraint 4 5 ...

Page 60: ...ese steps to remove the switching power supply circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 At the top of the drive remove the two fuses by inserting a screwdriver in the slot on the top of the fuse holder carefully pushing down and turning the fuse counterclockwise When the fuse holder releases remove the holder and fuse 3 Top View of ...

Page 61: ...ly Circuit Board Install the fuses identified in this table on the switching power supply board in reverse order of removal Circuit Board ID Revision Fuse Designation Fuse 5 x 20 mm SW2 32 H and below F1 3 15 A 250V fast F2 2 5 A 250V slow SW2 32 I and above F1 2 5 A 250V slow F2 Top View of drive Front of drive F1 3 15A 250V fuse F2 2 5A 250V fuse ...

Page 62: ... fuse holders on the pulse transformer board Install the Fuses on the Pulse Transformer Circuit Board Install the fuses on the pulse transformer circuit board in reverse order of removal Pulse Transformer and Switching Power Supply Circuit Boards Replacement Remove the Pulse Transformer and Switching Power Supply Circuit Boards Note The switching power supply circuit board is located on the back o...

Page 63: ...late to the top of the drive chassis 6 Remove the cable from connector XTA at the bottom of the pulse transformer board 7 Remove the plug in terminals from the control power block at the bottom of the pulse transformer board IMPORTANT The air flow plate is also secured to the pulse transformer circuit board and therefore cannot yet be removed Instructions for doing so are included later in this pr...

Page 64: ...the connector from XCD_IO on the lower left corner of the board 9 Move the control EMI shield see page 58 10 Remove the two screws that secure the air flow plate to the top of the pulse transformer board and lift the plate off the drive chassis Note that the air flow plate cannot be completely removed due to the fuse connections at FU1 and FV1 XCD_IO C XTA XM D 78 79 35 36 75 76 U2 V2 S3 S4 1 8 10...

Page 65: ... Part Replacement Procedures Chapter 3 11 Remove the cable from connector XV on the switching power supply board 12 Remove the cables from connectors X3 X4 and XP on the pulse transformer board 11 Front of drive Switching power supply board Pulsetransformer board 12 ...

Page 66: ...66 Rockwell Automation Publication 20P TG002B EN P February 2018 Chapter 3 Part Replacement Procedures 13 Remove the ground connection at the left side of the pulse transformer board 13 ...

Page 67: ...ening in the board For regenerative drive remove each pair of orange and yellow gate lead cables from connectors KG01 KG06 and KG1 KG6 and push each lead through the appropriate opening in the board 15 Remove the seven screws that secure the board to the stand offs on the drive chassis and remove the boards from the drive IMPORTANT Carefully remove the gate leads by grasping the connector DO NOT p...

Page 68: ...68 Rockwell Automation Publication 20P TG002B EN P February 2018 Chapter 3 Part Replacement Procedures 15 Note Regenerative drive shown ...

Page 69: ...e switching power supply board Configure the Pulse Transformer Circuit Board The steps required to configure the pulse transformer board are different based on the revision code of the pulse transformer board See one of these procedures Configure a Pulse Transformer Board FIR2 xx Rev M and Lower on page 69 Configure a Pulse Transformer Board FIR2 xx Rev N and Higher on page 72 ConfigureaPulseTrans...

Page 70: ...t board set the total resistance RTA to the appropriate value as indicated in Table 15 or Table 16 in the Total Resistance Values section on page 72 Drive Current Rating Code DC Amps AC Line Amps Hp R1 R2 R3 R4 R5 146 146 119 40 Remove Remove 5 36 Ω Remove 180 180 147 50 Remove Remove 5 36 Ω Remove 218 218 178 60 Remove Remove 5 36 Ω Remove 265 265 217 75 Remove Remove 5 36 Ω 5 36 Ω 360 360 294 10...

Page 71: ... G KG04 K G KG01 K G KG05 K G KG02 K G KG06 K G KG03 K G KG4 K G KG1 K G KG5 K G KG2 K G KG6 K G KG3 XTA 1 TA 1 78 79 35 36 75 76 U2V2 U C V W TA 1 X4 1 F2 F3 F1 1 13 33 2 14 34 XR TheXRconnectorislocatedneartheupper rightcornerof the pulse transformer circuit board The TA potentiometer is located on the lower right corner of thepulsetransformercircuitboardnexttothecontrolpower terminal block ...

Page 72: ...below Drive Current Rating Code DC Amps AC Line Amps Hp Set RTA Value Using TA Potentiometer Ohms 146 146 119 40 12 575 180 180 147 50 10 2 218 218 178 60 8 422 265 265 217 75 6 928 360 360 294 100 5 1 434 434 355 125 4 23 Drive Current Rating Code DC Amps AC Line Amps Hp Set RTA Value Using TA Potentiometer Ohms 167 167 136 4 100 10 994 207 207 169 1 125 8 87 250 250 204 3 150 7 344 330 330 269 6...

Page 73: ...18 178 60 ON ON ON ON 265 265 217 75 ON ON ON ON 360 360 294 100 ON ON ON 434 434 355 125 ON ON ON ON 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 8 167 167 136 4 100 ON ON ON ON 207 207 169 1 125 ON ON ON 250 250 204 3 150 ON ON ON ON 330 330 269 6 200 ON ON ON 412 412 336 6 250 ON ON ON...

Page 74: ...uit Fuses Replacement Remove the Field Circuit Fuses Follow these steps to remove the field circuit fuses 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 ATTENTION Each gate lead cable must be connected to the exact connector from which it was removed on the pulse transformer circuit board or damage to the drive may occur One plastic stabilizer should be ...

Page 75: ... circuit fuses in the reverse order of removal Field Circuit Board Replacement Remove the Field Circuit Board Follow these steps to remove field circuit board 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the protective covers from the drive see page 43 3 Front of Drive Top view of Drive IMPORTANT Mark all connections and wires before removal t...

Page 76: ...ulse transformer board for this procedure 5 Remove the wires from connectors UF UF1 VF and VF1 6 Remove the six screws and washers that secure the field board to the field SCR and dual diode modules and remove the field board Install the Field Circuit Board Install the field board in reverse order of removal Inspect the existing X3 and XFCD cables for burn marks cracks or loose connectors If neces...

Page 77: ...ive covers from the drive see page 43 4 Remove the pulse transformer and switching power supply boards from the drive see page 62 You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure 5 Remove the field circuit board see page 75 6 Remove the two screws and washers that secure each module to the heatsink and remove the modules fro...

Page 78: ... the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the protective covers from the drive see page 43 4 Remove the pulse transformer and switching power supply boards from the drive see page 62 You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure 5 Remove the field circuit board see page ...

Page 79: ...e the black wires from the resistors to the bus bars and remove the wires 8 Remove the three screws and washers that secure the AC line snubber board to the drive frame and lift the board Note The wires from the resistors are connected to the board Therefore the board cannot be removed until the resistors are removed 6 and 7 Regenerative Drive Shown 8 ...

Page 80: ... and Resistors Install the AC line snubber board and resistors in reverse order of removal SCR Modules Replacement Remove the SCR Modules Follow these steps to remove SCR modules 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields IMPORTANT Therma...

Page 81: ... covers from the drive see page 43 6 Remove the pulse transformer and switching power supply boards from the drive see page 62 You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure 3 3 U Phase V Phase 4 Bottom View of Drive W Phase D C IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reasse...

Page 82: ...move the Bus Bars from a Non Regenerative Drive on page 85 RemovetheBusBarsfromaRegenerativeDrive 8 Remove the two screws or bolts and washers that secure the red and blue wires from the AC line snubber board to the terminal bus bars C and D and remove the wires 9 Remove the three bolts and washers that secure the black wires from the resistors to the terminal bus bars U V and W and remove the wir...

Page 83: ...2B EN P February 2018 83 Part Replacement Procedures Chapter 3 10 Remove the three remaining bolts and washers that secure the AC input bus bars U V and W phases to the anode of the SCR modules and remove the bus bars 10 10 Regenerative Drive ...

Page 84: ...er gate leads from the SCR modules 12 Remove the bolts and washers that secure the DC bus bars to the SCRs and remove the bus bars 13 Remove the four bolts and washers and stand off that secure the power terminal bus bars to the isolation bar and slide the bus bars up and out of the drive 12 11 Regenerative Drive 13 Regenerative Drive ...

Page 85: ...ashers that secure each SCR module to the heatsink and remove the SCR module Continue with Install the SCR Modules on page 88 RemovetheBusBarsfromaNon RegenerativeDrive 15 Remove the bolts and washers and stand off and washer that secure the power terminal bus bars to the isolation bar 14 Regenerative Drive 15 Non Regenerative Drive ...

Page 86: ...ts and washers that secure the C and D terminal bus bars to the horizontal bus bars 17 Remove the bolts and washers that secure the upper horizontal bus bar to the SCR modules and remove the bus bars Bolt Lock washer Flat washer Noteproperorderofwashersfor installation Non Regenerative Drive 16 Non Regenerative Drive 17 ...

Page 87: ...edures Chapter 3 18 Remove the bolts and washers that secure the lower horizontal bus bar to the SCR modules and remove the bus bar 19 Remove the bolts washers and wires that secure the U V and W phase power terminals to the SCR modules Non Regenerative Drive 18 Non Regenerative Drive 19 ...

Page 88: ... the SCR modules installed on the heatsink IMPORTANT Thermal grease must be applied to the bottom of each SCR module before securing it to the heatsink 230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque SK 20P S7F48 2 5 4 0 N m 22 35 4 lb in SK 20P S7F78 2 5 4 0 N m 22 35 4 lb in SK 20P S7F49 4 5 5 5 N m 40 48 7 lb in SK 20P S7F79 4 5 5 5 N m 40 48 7 lb in SK 20P S7F42 4...

Page 89: ...es 230V AC Input 460V AC Input Part Number Final Torque Part Number Final Torque SK 20P S7F48 4 5 5 5 N m 40 48 7 lb in SK 20P S7F78 4 5 5 5 N m 40 48 7 lb in SK 20P S7F49 4 5 5 5 N m 40 48 7 lb in SK 20P S7F79 4 5 5 5 N m 40 48 7 lb in SK 20P S7F42 11 13 N m 97 4 115 lb in SK 20P S7F41 11 13 N m 97 4 115 lb in SK 20P S727F 11 13 N m 97 4 115 lb in SK 20P S737F 11 13 N m 97 4 115 lb in 1 2 3 2 1 3...

Page 90: ...lowing locations AC Current Transducers Replacement Remove the AC Current Transducers Follow these steps to remove the AC current transducers 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 3 Remove the screws and washers that secure the plastic shields to the bottom of the drive and remove the shields 4 Remove the bolts washers and wiring from the U and ...

Page 91: ...ching power supply boards from the drive see page 62 You do not need to remove the switching power supply board from the back of the pulse transformer board for this procedure 7 Remove the bolts and washers that secure the U and V phase AC input bus bars to the isolation bar IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly 7 Regenerative Drive Sho...

Page 92: ...the U and V Phase SCR modules and remove the wires and bus bars 9 For non regenerative drives only remove the bolts and washers that secure the resistor wires and bus bars to the U and V Phase SCR modules and remove the wires and bus bars 10 Slide the U and V phase bus bars that pass through the AC current transducers up and out of the drive 8 Connecting bus bar Connecting bus bar Regenerative Dri...

Page 93: ...e frame and remove the AC current transducers Install the AC Current Transducers Install the AC current transducers in reverse order of removal Note the color and location of each of the four wires connected to the AC current transducers to ensure that each wire is properly connected during installation Use cable ties to bundle wires as shown below 11 Red wire White wire Blue wire Black wire ...

Page 94: ...cure the plastic shields to the bottom of the drive and remove the shields 4 Remove the bolts washers and wiring from the U phase AC input power terminal and the D power terminal 230V AC Input Drive Current Rating Code DC Amps AC Line Amps Hp Final Torque 146 146 119 40 4 5 5 5 N m 40 48 7 lb in 180 180 147 50 218 218 178 60 265 265 217 75 11 13 N m 97 4 115 lb in 360 360 294 100 434 434 355 125 4...

Page 95: ...eed to remove the switching power supply board from the back of the pulse transformer board for this procedure 7 Remove the appropriate bus bars in order to access the bimetal thermostats For a regenerative drive see Remove the Bus Bars from a Regenerative Drive on page 96 For a Non Regenerative drive see Remove the Bus Bars from a Non Regenerative Drive on page 98 IMPORTANT Mark all connections a...

Page 96: ...placement Procedures RemovetheBusBarsfromaRegenerativeDrive 8 Remove the bolt and washer that secures the U phase terminal bus bar to the terminal isolation bar 9 Remove the bolts and washers that secure the connecting bus bar to the U phase SCR modules and remove the bus bars 8 9 9 ...

Page 97: ...he bolt and washers that secure the D terminal bus bar to the terminal isolation bar 11 Remove the screw and washer that secures the wire to the bus bar and the bolt and washer that secures the U phase bus bar to the SCR module and remove the bus bar Continue with Remove the Bimetal Thermostats on page 99 10 11 11 ...

Page 98: ...hree bolts and washers that secure the U Phase and D power terminals to the isolation bar 13 Remove the bolts and washers that secure the wires and bus bars to the U phase SCR Module and D power terminal and remove the bus bars Continue with Remove the Bimetal Thermostats on page 99 12 Non Regenerative Drive U Phase Terminal D Terminal Non Regenerative Drive 13 ...

Page 99: ...inks by unscrewing them at the base Install the Bimetal Thermostats Install the bimetal thermostats in reverse order of removal Cooling Fan Replacement Remove the Cooling Fans Follow these steps to remove the cooling fans 1 Read the General Safety Precautions on page 10 2 Remove power from the drive see page 42 1 and 2 Regenerative Drive Shown IMPORTANT Thermal grease must be applied to the bottom...

Page 100: ...e drive and remove the shield 4 Locate the cooling fan terminal block on the bottom of the drive and loosen the screws that secure the fan power supply wires red and black to the terminal block and remove the wires IMPORTANT Note the color and location of each of the wires connected to the cooling fan to ensure that each wire is properly connected during installation 3 Bottom View 4 ...

Page 101: ...Remove the two screws that secure the fan to the drive frame You must insert a Phillips head screwdriver through the hole in the front of the fan housing to reach and remove the screws Remove the fan from the drive Install the Cooling Fans Install the cooling fans in reverse order of removal Verify that the air flow direction arrow on the fans is pointing toward the heatsink on the drive 5 6 6 ...

Page 102: ...102 Rockwell Automation Publication 20P TG002B EN P February 2018 Chapter 3 Part Replacement Procedures Notes ...

Page 103: ...hes are set correctly See Install the Control Circuit Board on page 58 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 motor rated namepla...

Page 104: ...tor 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 see Chapter 4 Troubleshooting in the PowerFlex Digital DC Drive User Manual publication 20P UM001 12 Increase the speed command fr...

Page 105: ... 16 Field Board and SCR Dual Diode Module Connections Diagram 108 Figure 17 Field Control Circuit Diagram 109 Figure 18 Control Circuit Input Power Diagram 109 Figure 19 Encoder Control Circuit Diagram 110 Figure 20 DC Tachometer Control CircuitDiagram 110 Figure 21 Motor Thermal Protection Control Circuit Diagram 111 Figure 22 Drive Heatsink Monitoring Control Circuit Diagram 111 Figure 23 Contac...

Page 106: ...PE XY XI2CA XTA XCD_I0 X4 1C2 1D2 K G K G K G K G K G K G XA XR XFCD XP3 XA XV XUV T XFCD X3 VF VF1 UF UF1 2C1 2V1 2D1 2U1 2C1 2D1 CT U Bimetal Thermostats T2 T3 T1 1D2 1C2 1C2 1D2 Drive Cover Pulse Transformer Board Control Board Switching Power Supply Board T4 T5 T6 Fans T7 D1 Field Board 1 W D V C U PE FV1 FU1 CT V Human Interface Module 20 HIM Ax ...

Page 107: ...surement Points Diagram Figure 15 Frame B Power Feedback Connections Diagram 100K V W U XR 15 XR 16 XR 17 15V 15V 100K 100K 15 15 15 15 XY 22 XY 21 XY 18 W V U D C XR15 XR16 XR17 XR19 XR18 F1 F2 F3 S9 PE PE 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W 1W ...

Page 108: ...nd SCR Dual Diode Module Connections Diagram X2 V1 U1 X2 B UF VF VF1 UF1 UF VF 2U1 2V1 2C1 2D1 XP 2 XP 1 XP 8 XP 7 D1 C1 X2 X2 A 1U1 1V1 X3 1 X3 2 XFCD 3 XFCD 2 XFCD 4 XFCD 1 N M P To Pulse Transformer Board X3 Connector To Motor Field Connections From Incoming AC Line TA1 470k 470k 470k 470k 470k 470k 470k 470k ...

Page 109: ... Control Circuit Diagram Figure 18 Control Circuit Input Power Diagram 15V 15V 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 1800 1800 U2 V2 1C2 1D2 230 VAC or 115 VAC Input To Switch Mode Power Supply SMPS ...

Page 110: ...tics Figure 19 Encoder Control Circuit Diagram Figure 20 DC Tachometer Control Circuit Diagram 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 S4 8 M3 M3 S4 7 S4 6 S4 1 S2 S4 3 TACHOP S4 5 S4 4 ...

Page 111: ... Schematics Appendix A Figure 21 Motor Thermal Protection Control Circuit Diagram Figure 22 Drive Heatsink Monitoring Control Circuit Diagram 78 79 1K XR 32 0VI 15V XR 12 XR 12 XR 10 XR 10 5V 0V24 XSW 1 24V XSW 2 X4 1 X4 2 U7 OTS Control Board PulseTransformer Board ...

Page 112: ...ppendix A Schematics Figure 23 Contactor Control Relays Control Circuit Diagram Figure 24 AC Line Snubber Circuit Diagram 0V24 U6 K7 K8 24V 35 36 75 76 U2 S1 XR XR XR XR 7 6 5 4 R 2U2 3U2 2V2 3V2 2W2 3W2 C D R R R R R AC Line Snubber Board R1 R2 R3 R 4 R 5 R6 C D U V W ...

Page 113: ...d to Field Board Connections 115 Pulse Transformer Board to Switching Power Supply Connections 115 Pulse Transformer Board to Bimetal Thermostat Connections 115 PulseTransformer Board to Field SCR Dual Diode Module Connections 115 PulseTransformerBoard to Control Board Connections 116 Pulse Transformer Board to Current Transducer Connections 117 Switching Power Supply Board Layout 118 Switching Po...

Page 114: ...KG03 K G KG4 K G KG1 K G KG5 K G KG2 K G KG6 K G KG3 XTA 1 TA 1 78 79 35 36 75 76 U2V2 U C V W TA 1 X4 1 F2 F3 F1 XSW1 XI2CA X3 XP TR2 TR1 XR X4 XY XCD_IO TO5 TO3 TO6 TO1 TO4 TO2 KGO1 KGO4 KGO2 KGO5 KGO3 KGO6 T5 T3 T6 T1 T2 KG1 KG4 KG2 KG5 KG3 KG6 XCT C U PE PE1 V XTA XM D 78 79 35 36 75 76 U2 V2 W S3 S4 1U2 1V2 T4 1 Components shown within dashed lines are only on the pulse transformer board forr...

Page 115: ...Field Board Connector Description X3 1 1 X3 1U1 field sync signal from U1 2 2 1V1field sync signal from V1 PulseTransformer Board Point to Pin Number Switching Power Supply Board Connector Description 1U2 4 XUV Rectified U2 V2 voltage approx 150 300V DC 3 not used 1V2 2 not used 1 Common Pulse Transformer Board Connector Pin Number to Pin Number Bimetal Thermostat Connector Description X4 1 1 X4 2...

Page 116: ...ture 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 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 signal...

Page 117: ...onnections Appendix B Table 25 Pulse Transformer Board to Current Transducer 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 ...

Page 118: ...d to Control Board Connections See Pulse Transformer Board to Switching Power Supply Connections on page 115 1 16 XSW XUV F1 F2 XV XA SB SA 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...

Page 119: ...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 XR XA XFCD To DPI board on HIM Bezel I O terminal block...

Page 120: ...ary 2018 Appendix B Circuit Board Layouts and Connections Field Board Figure 28 Field Board Layout See Control Board to Field Board Connections on page 119 and Pulse Transformer Board to Field Board Connections on page 115 U1 V1 C1 D1 1 X3 XFCD UF1 UF VF1 VF ...

Page 121: ...8 121 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 on page 13 Topic Page Control Power Supply Failure 122 Field Current Loss Failure 123 ...

Page 122: ...d and ohmmeter between pins 1 and 2 and 3 and 2 on the cable to verify no short circuits values should be 200 kilohms Any values lower than 200 kilohms Yes Remove power from the drive and replace the fuse on the switching power supply board Remove the switching power supply board from the drive Apply power to the switching power supply board only No Yes Remove all power from the drive Check all ex...

Page 123: ... circuits No Yes Yes Are the 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 No Yes Replace the control board Disconnect the cable from XR on the control board and measure the U1 V1 voltage synchronization signal at pin 11 on the cable This signal should be a square wave signal with a 90 lag phase dis...

Page 124: ...eter measure the resistance across terminals LA LB to verify that the value equals the equivalent resistance set with DIP switch S14 Isthe resistance measurement correct Replace the field board No Yes Verify that the drive rated field bridge current is set correctly in Par 374 Drv Fld Brdg Cur and DIP switch S14 is configured to match Measure the field current signal at terminals LA LB located on ...

Page 125: ...l 58 remove 55 control EMI shield close 59 move 58 control power supply failure 15 cooling fans install 101 remove 99 D DC analog tachometer test 35 DPI HIM assembly install 43 remove 42 DriveExecutive software 12 E electrostatic discharge precaution 10 encoder test 34 F fault field current loss 22 heatsink overtemperature 37 main contactor 37 overcurrent 20 power failure 15 fault report create 38...

Page 126: ... board fuses install 62 remove 62 R relay outputs 37 remove AC current transducers 90 AClinesnubbercircuitboardandresistors 78 bimetal thermostats 94 communication adapter and EMI shield 46 control circuit board 55 cooling fans 99 DPI HIM assembly 42 field circuit board 75 field circuit fuses 74 field SCR and dual diode modules 77 I O converter circuit board 54 I O expansion circuit board 52 prote...

Page 127: ...tion Publication 20P TG002B EN P February 2018 127 Index thermistor 37 tools service 12 troubleshoot armature bridge failure 20 field current loss 22 overcurrent fault 20 power failure fault 15 V visual inspection 15 ...

Page 128: ...128 Rockwell Automation Publication 20P TG002B EN P February 2018 Index Notes ...

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Page 130: ...de 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 ...

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