Rockwell Automation Allen-Bradley PowerFlex 4M Hardware Service Manual Download Page 58

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Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

Chapter 3

Access Procedures

Install the Control Circuit Board

Install the control board in reverse order of removal.

Control EMI Shield Removal
and Closure

Move the Control EMI Shield

You must move the control EMI shield that holds the control board in order to
access other components within the drive.

Read the

General Safety Precautions on page 10

Remove power from the drive. See

Remove Power from the Drive on

page 42

Remove the covers from the drive. See

Remove the Protective Covers from

the Drive on page 43

Carefully disconnect the cables from connectors XFCD and XR on the
control board.

Disconnect
cables

Summary of Contents for Allen-Bradley PowerFlex 4M

Page 1: ...PowerFlex Digital DC Drive Frame C 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: ...ections 17 Troubleshoot an AC Undervoltage Fault 20 Troubleshoot an Armature Bridge Failure 21 Troubleshoot a Field Current Loss Fault 23 Low or Incorrect Field Current 23 No Field Current 25 Power Component Test Procedures 27 Check the Armature SCR Modules 27 Check the Pulse Transformer Board 32 Check the Field SCR Dual Diode Module 33 Speed Feedback Device Tests 36 Check the Encoder 36 Check the...

Page 4: ...I O Converter Circuit Board 55 Control Circuit Board Removal and Installation 55 Remove the Control Circuit Board 55 Install the Control Circuit Board 58 Control EMI Shield Removal and Closure 58 Move the Control EMI Shield 58 Install the Control EMI Shield 59 Switching Power Supply Circuit Board Fuse Removal and Installation 60 Remove the Fuses on the Switching Power Supply Circuit Board 60 Insta...

Page 5: ...Filter Circuit Board 86 Install the Power Supply Filter Circuit Board 88 Armature Leg Fuses Removal and Installation 89 Remove the Armature Leg Fuses 89 Install the Armature Leg Fuses 92 SCR Modules Removal and Installation 93 Remove the SCR Modules 93 Install the SCR Modules 100 AC Current Transducers Removal and Installation 101 Remove the AC Current Transducers 101 Install the AC Current Transd...

Page 6: ...ation 20P TG003B EN P September 2021 Table of Contents AppendixC Flow Charts List of Flow Charts 139 Control Power Supply Failure 140 Field Current Loss Failure 141 No Field Current 141 Low or Incorrect Field Current 142 Index 143 ...

Page 7: ...ou obtain a copy of the PowerFlex Digital DC Drive User Manual publication 20P UM001 which contains fault alarm and programming information to assist you in troubleshooting drive errors and determining if repairs are necessary See Additional Resources on page 147 for information on related publications and how to obtain manuals Summary of Changes This manual contains new and updated information To...

Page 8: ...8 Rockwell Automation Publication 20P TG003B 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: ...ontrol 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 may...

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 C drive by checking the data nameplate located on the side of the drive The frame size is printed just above the ...

Page 12: ...age 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 1...

Page 13: ... Power Supply Failure 15 Troubleshoot an AC Undervoltage Fault 20 Troubleshoot an Armature Bridge Failure 21 Troubleshoot a Field Current Loss Fault 23 Power ComponentTest Procedures 27 Speed Feedback DeviceTests 36 Thermistors andThermal Switches 39 Relay Outputs 39 Create a Fault Report 40 WhatYou NeedWhenYou CallTech Support 40 IMPORTANT Using the diagnostic tests in this chapter should only be...

Page 14: ...nter a name using the and buttons to select the desired characters and press If there is an existing HIM Set press to overwrite it or select No using the button and use the and buttons to select the desired characters Then press The HIM Set will be saved to nonvolatile memory Download Parameters to an Offline Node File You can save all drive and adapter parameters in the drive to an offline databa...

Page 15: ... control power failure has occurred 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Remove the Protective Covers from the Drive on page 43 3 Measure the signal voltage at the testpoints on the control board as indicated in the following table Note For a flow chart version of the steps that follow see Control Power Supply Failure on page 140 Name T...

Page 16: ...se Removal and Installation on page 60 7 Disconnect the cable at connector XA on the control board See Figure 29 on page 136 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 below If the fuse does not blow continue with Testing the Control and Field Board Connections on page 17 Testing...

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

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

Page 20: ...ge 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 18 and Figure 2 on page 19 for location of the testpoints Also see Figure 16 o...

Page 21: ...red 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 29 on page 136 for location of the XR connector on the control board 1 Read the General Safety Precautions on page 10 2 Remove the protective covers from the drive See Protective Cover Removal and Installation on pa...

Page 22: ...urements taken on an SCR In the figures below The current signal is taken on the testpoint XY17 2 5V offset 0 6V Drive size current The voltage signal is taken on the testpoint XY19 2 5V offset The ground signal is taken on either testpoint XY10 or XY18 Figure 3 Good SCR Gate Pulse and Armature Current Signals Example Figure 4 Good SCR Armature Voltage and Motor Current Signal Example 5V 0V XY19 X...

Page 23: ...he drive faults with a Field Current Loss fault F6 and there is no field current present at the motor as seen in parameter 351 Field Current complete the steps in No Field Current on page 25 Low or Incorrect Field Current Note For a flow chart version of these steps see Low or Incorrect Field Current on page 142 1 Read the General Safety Precautions on page 10 2 Verify the actual value of paramete...

Page 24: ...s set up for 2 A and the motor is rated for 1 5 A the measurement at LA LB will be 1 245 VDC 1 5 x 2 1 66 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 7 Using an ohmmeter measure the resistance across terminals LA LB to verify that the value equals the equivalent resi...

Page 25: ...emove AC power 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 on page 25 If the fuses are not blown complete the steps in Test Field Control Signals on page 25 TestFieldWiringandVoltageSignals 1 Test the resistance of the motor field wiring and motor field for possible sho...

Page 26: ...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 27: ...unction is suspected 1 Read the General Safety Precautions on page 10 2 Remove and lock out all incoming power for the drive See Remove Power from the Drive on page 42 3 Verify that contactor power if used is removed 4 Verify that power to an external field supply if used is removed 5 Check the anode to cathode junction of each SCR With a digital multimeter set to Ohms measure the resistance acros...

Page 28: ...enerative Drives Figure 6 Regenerative Drive SCR Module Layout On SCR Module SCR Measure from Terminal ToTerminal Nominal meter reading 1 1 U C open circuit or megaOhms range 4 U D 2 2 V C 5 V D 3 3 W C 6 W D 01 01 U C 04 U D 02 02 V C 05 V D 03 03 W C 06 W D U V C D W SCR Module 1 SCR Module 01 SCR Module 2 SCR Module 02 SCR Module 3 SCR Module 03 U C V D W ...

Page 29: ...Cathode Junction Measurements for Non Regenerative Drives Figure 7 Non Regenerative Drive SCR Module Layout On SCR Module SCR Measure from Terminal ToTerminal Nominal meter reading 01 01 U C open circuit or megaohms range 04 U D 02 02 V C 05 V D 03 03 W C 06 W D U V C D W SCR Module 01 SCR Module 02 SCR Module 03 U C V D W ...

Page 30: ...es Removal and Installation on page 93v Table 4 SCR Gate to Cathode Junction measurements for Regenerative Drives Figure 8 SCR Gate Lead Connection Pinouts for Regenerative Drives On SCR Module SCR Measure from To Nominal meter reading 1 1 Pin 5 Pin 4 5 20 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 ...

Page 31: ...ive Drives On SCR Module SCR Measure from To Nominal meter reading 01 01 Pin 6 Pin 7 5 20 1 1 The actual reading varies dependinguponthe SCR manufacturer Verify that theactual measured value is consistent for all SCRs 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 SCR Module 01 SCR Module 02 SCR Module 03 Gate Lead Connectors Gate Lead Pinouts 7 6 4 5 TopView of S...

Page 32: ...rd see Pulse Transformer Circuit Board Removal and Installation on 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 27 on page 132 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 33: ...omponents may cause various responses including field and velocity related faults or blown fuses The following procedures can be used if field bridge malfunctions are suspected 1 Read the General Safety Precautions on page 10 2 Remove and lock out all incoming power to the drive See Remove Power from the Drive on page 42 3 Remove the protective covers See Protective Cover Removal and Installation ...

Page 34: ...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 11 on page 35 Table 10 Field SCR Dual Diode Module Anode to Cathode Junction Measurements Figure 10 FieldTerminal Block Location Meter Lead Meter Lead Nominal meter reading Terminal Terminal U1 C1 0 45V U1 D1 open or infinity V1 C1...

Page 35: ...SCR dual diode module With the digital multimeter set to diode test measure the resistance across the modules lead orientation is not critical See Table 11 below If a low resistance is detected replace the SCR dual diode module See Field SCR and Dual Diode Module Removal and Installation on page 72 Table 11 SCR Dual Diode Module Gate Cathode Junction Measurements Measure from To Nominal meter read...

Page 36: ...ewed from the commutator end Channel A leads Channel B Each differential channel has an inverted and non inverted signal Power for the encoder is provided internally and is capable of 200mA of current with a current foldback feature that protects the power supply should the current draw exceed 200mA If different power supply requirements exist for the chosen feedback device the supply must be prov...

Page 37: ... connectors XRE P2 P3 If problems persist replace the resolver interface and or resolver feedback board Measure the signal voltage at the testpoints as indicated in the following table See Figure 12 on page 38 for testpoint locations 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 38: ...t Procedures Figure 12 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 39: ...tal 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 129 for a circuit diagram During normal operation 1 6V DC is present between terminal 78 and drive common When an open circuit exists b...

Page 40: ...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 41: ... and Closure 58 Switching Power Supply Circuit Board Fuse Removal and Installation 60 Switching Power Supply Circuit Board Removal and Installation 61 PulseTransformer Circuit Board Removal and Installation 62 Field Power Circuit Board Removal and Installation 71 Field SCR and Dual Diode Module Removal and Installation 72 AC Line Snubber Circuit Board and Resistors Removal and Installation 74 Tran...

Page 42: ...ve the DPI HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly ATTENTION Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arcmayoccur An electricalarccancause personal injury or propertydamageby sending an erroneous signal to your system s field devices caus...

Page 43: ...ive Covers from the Drive 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Disconnect the DPI cable from the HIM assembly 4 Loosen but do not remove the screws that secure the bottom cover to the drive then slide the cover down and off the drive chassis STS PORT MOD NET A NET B Disconnect DPI cable Tightening torque 0 8 N m...

Page 44: ...nect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside IMPORTANT The HIM assembly is connected via a cable to the control board and thereforewillnotpullfreefromthedriveuntildisconnected Seestep5 below for instructions STS PORT MOD NET A NET B FU1 FV1 U V C D W Tightening torque 0 8 N m 7 lb in Tightening torque 0 8 N m 7 lb in Pul...

Page 45: ...ad the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the lower protective cover only from the drive See Protective Cover Removal and Installation on page 43 4 On the control EMI shield unscrew the fuse holders and remove the existing fuses from the holders Install the Field Circuit Fuses Install the field circuit fuses in th...

Page 46: ...the Drive on page 42 3 Remove the Protective Covers from the drive See Protective Cover Removal and Installation on 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 and washers that secure the communication adapter to the EMI shield and remove the adapter Disconnect ...

Page 47: ... on the control board and remove the EMI shield 8 Remove the three standoffs and washers from the control board Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal Remove three screws and washers Tightening torque 1 0 N m 8 9 lb in Remove three standoffs and washers Tightening torque 1 0 N m 8 9 lb in ...

Page 48: ... Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the protective covers from the drive See Remove the Protective Covers from the Drive on 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 P2 P3 S2 XR...

Page 49: ...arefully 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 Remove screws and board Tightening torque for re ...

Page 50: ...tember 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 Remove stand offs Tightening torque for re assembly is 0 7 N m 6 2 lb in Resolver interface board ...

Page 51: ...d 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 Remove scre...

Page 52: ... Installation on page 43 4 If installed remove the resolver feedback option board See Remove the Resolver Feedback and Interface Circuit Boards on page 48 5 Remove the plug in I O terminal blocks with the wiring kept in place 6 Remove the two screws 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 b...

Page 53: ...control board 9 Install one screw 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 Remove two stand offs and washers Tightening torque for re assembly is 1 0 N m 8 9 lb in Install screw Tightening torque for re assembly is 1 0 N m 8 9 lb in ...

Page 54: ... See Remove the Protective Covers from the Drive on page 43 4 Remove the plug in I O terminal block with the wiring kept in place 5 Remove the two screws 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 and washers from the control board IMPORTANT Mark all connections and wires before removal to avoid incorrec...

Page 55: ...xecutive for more information on HIM Sets or using the HIM 2 Read the General Safety Precautions on page 10 3 Remove power from the drive See Remove Power from the Drive on page 42 4 Remove the protective covers from the drive See Remove the Protective Covers from the Drive on page 43 5 Remove the communication adapter and EMI shield from the control board See Remove the Communication Adapter and ...

Page 56: ...ered in Par 374 Rated Field Curr in the control software when the drive is commissioned S14 1 S14 2 S14 3 S14 4 S14 5 S14 6 S14 7 not used S14 8 not used S15 Configuration of the control circuit board to the appropriate drive size This value is set to the appropriate size at the factory S15 1 S15 2 S15 3 S15 4 S15 5 S15 6 S15 7 S15 8 S20 Monitoring of the Z channel of the Digital Encoder on connec...

Page 57: ... XFCD XA and XR on the control board 10 Remove the plug in I O and control terminal blocks with the wiring kept in place 11 Remove the five screws that secure the control board to the control EMI shield and remove the board Disconnect cables Disconnect I O and control wiring Remove screws Tightening torque for re assembly is 1 0 N m 8 9 lb in ...

Page 58: ... Shield You must move the control EMI shield that holds the control board in order to access other components within the drive 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Carefully disconnect the cables from connectors XFCD an...

Page 59: ...on between the switching power supply board and the pulse transformer board 6 Disconnect the cable from connector XSW on the switching power supply board and lower the control EMI shield until it rests on the drive chassis Install the Control EMI Shield Install the control EMI shield in reverse order of removal IMPORTANT If the drive is not in a vertical position the control EMI shield will not st...

Page 60: ...ve the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the two fuses on the switching power supply board by inserting a screwdriver in the slot on the top of the fuse carefully pushing down and turning the fuse counterclockwise When the fuse holder releases remove the holder and fuse Install the Fuses on the Switching Power Supply Circuit Board Install the fuses on the switc...

Page 61: ...ive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Disconnect the cables from connector XA and XUV on the switching power supply board 6 If present disconnect the jumper from terminals SA SB IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly IMPORTANT Be sure to r...

Page 62: ...former 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 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 IMPORTANT DO NOT remove...

Page 63: ...emove the four screws two on either side of the drive frame that secure the slotted air flow plate to the top of the drive and remove the plate Remove four screws Air flow plate Screws shown removed IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly ...

Page 64: ...ing 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 7 Remove the cable from connector XTA at the bottom center of the board IMPORTANT Carefullyremovethegateleadsbygraspingtheconnector DONOTpull the gate leads off by pulling on the wires Remove cable Remov...

Page 65: ...emove the orange and yellow cables from connectors K1G1 and K2G2 on the top left side of the board 9 Remove the cables from connectors X4 X5 and XTM at the top left side of the board 10 Remove the cables from connectors XCD XUVW and X3 at the top right side of the board Remove cables Remove cables ...

Page 66: ...rd Configure the Pulse Transformer Circuit Board The new pulse transformer circuit board must be configured to match the drive size armature output current and HP rating The steps required to configure the pulse transformer board are different based on the revision code of the pulse transformer board See either Configuring a Pulse Transformer Board FIR3 xx Rev L and Lower on page 67 or Configuring...

Page 67: ... in place on the pulse transformer board or indicate Remove when the resistor should be cut off and removed from the board indicates that this resistor is not contained on the pulse transformer board for the designated drive size Table 12 230V AC Input Drives Table 13 460V AC Input Drives IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm Drive Current...

Page 68: ...ntiometer in the center of the pulse transformer circuit board set the total resistance RTA to the appropriate value as indicated in Table 14 or Table 15 in the Total Resistance Values section on page 69 1 13 33 2 14 34 XR TheXRconnectorislocatedonthe upper right corner of the pulse transformer circuit board TheTA potentiometer is located on the lower right corner of the pulse transformer circuit ...

Page 69: ...ow on the pulse transformer board to the correct settings based on the appropriate AC input voltage armature output current and HP rating shown in Table 16 or Table 17 on page 70 Drive Current Rating Code DC Amps AC Line Amps HP Set RTAValue UsingTA Potentiometer Ohms 521 521 426 150 4 699 Drive Current Rating Code DC Amps AC Line Amps HP Set RTAValue UsingTA Potentiometer Ohms 495 495 404 4 300 4...

Page 70: ...ting Code DC Amps ACLine 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 8 521 521 426 150 ON ON ON ON 70 700 571 200 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 8 495 495 404 4 300 ON ON ON ON 667 667 544 9 40...

Page 71: ...om the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the cables from connectors X3 and XFCD on the board 6 Remove the seven screws washers and wire leads connections 2V1 2U1 and 2C1 and one unmarked from the board and remove the board from the drive IMPORTANT Mark all connections and wires before r...

Page 72: ...odule 1 Read the General Safety Precautions on page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the field power circuit board See Remove the Field Power Circuit Board on page 71 6 Remove the o...

Page 73: ...n reverse order of removal Apply thermal grease to the bottom of the SCR and dual diode modules before securing them to the heatsink Tightening torque for the screws connecting the field SCR and dual diode modules to the heatsink and the screws connecting the field board to the field SCR and dual diode modules is 2 5 4 0 N m 22 35 lb in Remove screws and washers ATTENTION Thermalgreasemustbeapplie...

Page 74: ...from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 DisconnectandRemovethePulseTransformerandFieldPowerCircuitBoards You must remove the pulse transformer and field power circuit boards in order to replace the AC line snubber circuit board and resistors 5 Remove the four screws that secure the slotted ai...

Page 75: ...e 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 7 Remove the cable from connector XTA at the bottom center of the pulse transformer board IMPORTANT Carefullyremovethegateleadsbygraspingtheconnector DONOTpull the gate leads off by pulling on the wires Remove ca...

Page 76: ... on the top left side of the pulse transformer board 9 Remove the cables from connectors XTM X4 and X5 at the top left side of the pulse transformer board 10 Remove the cables from connectors XCD XUVW and X3 at the top right side of the pulse transformer board 11 Remove the cables from connectors X3 and XFCD on the field power board Remove cables Remove cables ...

Page 77: ...s Procedures Chapter 3 12 Remove the four screws and washers that secure the wire leads connections 2V1 2U1 and 2C1 and one unmarked from the field power board and set the wires aside Remove screws washers and wires Remove cable Remove cable Remove screws washers and wires ...

Page 78: ...o on either side of the drive frame that secure the support plate for the pulse transformer and field power boards to the drive frame and remove the support plate and boards 14 If present remove the isolation sheet that is secured to the bus bars Front of Drive Remove screws and washers both sides of drive frame Remove isolation sheet ...

Page 79: ...ts and washers that secure the AC line snubber board red and blue leads and screws and washers that secure the resistor black leads to the bus bars and remove the leads Regenerative Drive Non Regenerative Drive Remove bolts and washers Remove screws and washers Remove bolts and washers Remove screws and washers ...

Page 80: ...rocedures 16 Remove the three screws and washers that secure the AC line snubber board to the drive frame and remove the board 17 Remove the two screws that secure each resistor six total to the drive frame and remove the resistors from the drive Remove screws and washers Remove screws ...

Page 81: ...l diode modules is 2 5 4 0 N m 22 35 lb in Transient Noise Filter Circuit Board Fuses Removal and Installation Remove the Fuses on theTransient Noise Filter 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 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the co...

Page 82: ...nsient Noise Filter Circuit Board Removal and Installation Remove the Transient Noise Filter 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 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Remove the ground wire from the PE ground stud on the drive frame Remove fu...

Page 83: ...lack lead from connection U on the transient noise filter board to the U phase power terminal and remove the lead 6 Remove the two screws and washers that secure the bottom of the transient noise filter board to the drive Transient Noise Filter board Remove ground wire PE ground stud Remove screw and wire Remove screws and washers ...

Page 84: ...e drive 8 Move the control EMI shield See Move the Control EMI Shield on page 58 9 Remove the wires that connect to the back of the control terminals on the power supply filter board 10 Remove the two screws and washers that secure the top of the power supply filter board to the drive and carefully lift the board Remove screws and washers Remove wires Remove screw and washer Remove screw and washe...

Page 85: ... of the transient noise filter board to the drive and carefully lift the board off the drive 12 Remove the screws and washers that secure the black leads from connections V and W on the transient noise filter board to power terminals V and W respectively and remove the leads Remove screws and washers Remove cable ties Remove screws washers and leads ...

Page 86: ...uit Board Install the transient noise filter board and power supply filter board in reverse order of removal Power Supply Filter Circuit Board Removal and Installation Remove the Power Supply Filter 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 42 3 Remove the covers from the drive See Remove the Protective Cove...

Page 87: ...ks on the power supply filter board 5 Remove the two screws and washers that secure the bottom of the power supply filter board to the drive 6 Move the control EMI shield See Move the Control EMI Shield on page 58 7 Disconnect the wires from connectors X5 XTM and XUV on the power supply filter board Remove wires screws and washers Remove connections ...

Page 88: ...blocks on the power supply filter board 9 Remove the two screws and washers that secure the top of the power supply filter board to the drive and remove the board from the drive Install the Power Supply Filter Circuit Board Install the power supply filter board in reverse order of removal Remove wires Remove screw and washer Remove screw and washer ...

Page 89: ...er from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Remove the two screws and washers that secure the bottom of the transient noise filter board to the drive 5 Move the control EMI shield See Move the Control EMI Shield on page 58 IMPORTANT It isnecessaryto remove the transientnoise filter circ...

Page 90: ...he two screws and washers that secure the top of the transient noise filter board to the drive and carefully lift the board off the drive 7 If present remove the isolation sheet that is secured to the bus bars Remove screws and washers Remove cable ties Remove isolation sheet Note Regenerative Drive Shown ...

Page 91: ...leads from the switches mounted on the top of the Armature circuit fuses two each fuse 9 Remove the two screws that secure each switch to the fuse and remove the switch Retain the switch for reuse IMPORTANT Note the numbered position of each wire on the fuse for proper installation of the new fuses Remove wire leads Remove screws ...

Page 92: ...Install the Armature Leg Fuses Install the armature leg fuses in reverse order of removal IMPORTANT Note the order ofthe washers asyou remove them in order to installin the proper order IMPORTANT Verify that the washers are installed in the proper order and that the switches are installed on the correct fuse Remove bolts and washers Bolt Lock washer Large washer Fuse Large washer Small washer Bolt...

Page 93: ...2 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 5 Remove the gate leads from the pulse transformer board IMPORTANT It is recommended that you replace the armature leg fuses for each pair of SCR modules that you replace in the drive See Remove the Armature Leg Fuses on page 89 Re...

Page 94: ...t that is secured to the bus bars 7 Remove the bus bars in order to access the SCR modules in the drive For regenerative drives see Remove the Bus Bars from a Regenerative Drive on page 95 For non regenerative drives see Remove the Bus Bars from a Non Regenerative Drive on page 97 Remove isolation sheet Note Regenerative Drive Shown ...

Page 95: ...size and location of the bolts and the order in which the washers are placed on the bolts Remove bolts and washers Remove bolts and washers Nut Lock washer Flat washer Flat washer Bolt 30mm long Bolt 30mm long Flat washer Flat washer Lock washer Nut Left to right two 2 bolts 40mm long and flat washers Left to right two 2 nuts lock washers and flat washers Lefttoright two 2 flat washers lock washer...

Page 96: ...te the order of the washers on the bolt 10 Remove the bolts 24mm long and washers that secure the L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar Remove bolt 24 mm long lock washer and flat washer Bolt 24 mm long Lock washer Flat washer Fuse Remove 24mm long bolts and washer...

Page 97: ...ules and remove the bus bars Note the order of the washers on the bolts and the position of he bus bars Continue with Remove the SCR Modules on page 99 RemovetheBusBarsfromaNon RegenerativeDrive 8 Remove the nuts and washers that secure the wires red and blue from the AC line snubber board to the bus bars and remove the wires Remove bolts Remove bolts Remove nuts washers and wires ...

Page 98: ...do not need to remove the wires connected to the metal plate secured with the L shaped bus bar 11 Remove the bolts and washers that secure the horizontal bus bars to the C and D vertical power terminal bus bars Note the size and location of the bolts and the order in which the washers are placed on the bolts Bolt Lock washer Flat washer Fuse Remove bolt lock washer and flat washer Removebolt lockw...

Page 99: ...ules below RemovetheSCRModules 1 Remove the remaining bolts washers and metal plates for regenerative drives only from the tops of the SCR modules Note the order of the washers on the bolts Remove bolts and washers and bus bars Remove bolts and metal plates Note Regenerative drive shown Bolt 32 mm long Lock washer Flat washer SCR Module IMPORTANT Mark all connections and wires before removal to av...

Page 100: ...them to the heatsink Use the following table to determine the proper tightening torque for the SCR modules installed on the heatsink Use the following table to determine the proper tightening torque for the bus bars connected to the SCR modules ATTENTION ThermalgreasemustbeappliedtothebottomoftheSCRmodules before securing them to the heatsink or damage to the drive may occur 230V AC Input 460V AC ...

Page 101: ... page 10 2 Remove power from the drive See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Remove the eight screws and washers that secure the Lexan shields to the bottom of the drive and remove the shields 5 Remove the power wiring from the U and W phase AC input power terminals Remove screws and washers Remove...

Page 102: ...wires to the PE terminal from the transient noise filter board and U phase power terminal from the pulse transformer board and remove the wires 7 Remove the lower screw that secures the left side AC current transducer to the U phase terminal Transient noise filter board Remove ground wire PE ground stud Remove screw and wire Remove screw ...

Page 103: ...he drive 9 Move the control EMI shield See Move the Control EMI Shield on page 58 10 Remove the two screws and washers that secure the top of the power supply filter board to the drive and carefully lift the board to gain access to the ground wire connected to the W phase power terminal see next step Remove screws Power supply filter board Remove screw and washer Remove screw and washer ...

Page 104: ...rarily lift the EMI shield and remove the screw that secures the ground wire from the pulse transformer board to W phase power terminal and remove the wire 12 Remove the lower screw that secures the right side AC current transducer to the W phase power terminal Remove screw and wire Remove screw and wire ...

Page 105: ...AC current transducers and remove the wires 14 Remove the upper screw that secures each of the AC current transducer to the U phase power terminal IMPORTANT Note the color and location of each lead to ensure that each wire is properly connected during installation Remove nuts washers and wires Note Left AC current transducer of regenerative drive shown Remove screw Note Left AC current transducer ...

Page 106: ...inals down toward the bottom of the drive slide the AC current transducers off of the terminal bus bars and out of the drive For Non Regenerative drives only remove the bolt and washers that secure the U and W phase power terminals to the internal armature fuse and while pulling the U and W phase power terminals up and into the drive slide the AC current transducers off of the terminal bus bars an...

Page 107: ...Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 IMPORTANT Note the color and location of the signal wires to ensure that each wire is properly connected during installation The wires connected to the left CT are red and white and the wires co...

Page 108: ...tats in the drive For regenerative drives refer to Remove the Bus Bars from a Regenerative Drive on page 3 109 For non regenerative drives refer to Remove the Bus Bars from a Non Regenerative Drive on page 3 111 IMPORTANT You must remove the bus bars and for regenerative drives one SCR modulefromeachpair fornon regenerativedrives allSCRmodules in order to easily access and remove the bimetal therm...

Page 109: ...ote the size and location of the bolts and the order in which the washers are placed on the bolts Remove bolts and washers Remove bolts and washers Nut Lock washer Flat washer Flat washer Bolt 30mm long Bolt 30mm long Flat washer Flat washer Lock washer Nut Left to right two 2 bolts 40mm long and flat washers Left to right two 2 nuts lock washers and flat washers Lefttoright two 2 flat washers loc...

Page 110: ...es Note the order of the washers on the bolt 9 Remove the bolts 24mm long and washers that secure the L shaped bus bars to each of the SCR modules and remove the bus bars Note You do not need to remove the wires connected to the metal plate secured with the L shaped bus bar Remove bolt 24 mm long lock washer and flat washer Bolt 24 mm long Lock washer Flat washer Fuse Remove 24mm long bolts and wa...

Page 111: ...e the bus bars Note the order of the washers on the bolts and the position of the bus bars Continue with Remove the SCR Modules and Bimetal Thermostats on page 3 113 RemovetheBusBarsfromaNon RegenerativeDrive 7 Remove the nuts and washers that secure the wires red and blue from the AC line snubber board to the bus bars and remove the wires Remove bolts Remove bolts Remove nuts washers and wires ...

Page 112: ...ou do not need to remove the wires connected to the metal plate secured with the L shaped bus bar 10 Remove the bolts and washers that secure the horizontal bus bars to the C and D vertical power terminal bus bars Note the size and location of the bolts and the order in which the washers are placed on the bolts Bolt Lock washer Flat washer Fuse Remove bolt lock washer and flat washer Remove bolt l...

Page 113: ...emaining bolts washers and metal plates for regenerative drives only from the tops of the SCR modules Note the order of the washers on the bolts 2 Remove the gate leads that connect the SCR modules to the pulse transformer circuit board from the pulse transformer circuit board end Remove bolts and washers and bus bars Remove bolts and metal plates Note Regenerative drive shown Bolt 32 mm long Lock...

Page 114: ...odules Note the order of the washers on the bolt 4 Remove the wires connected to the bimetal thermostats from connector X4 on the pulse transformer circuit board 5 Remove the solder from the connections on the two leads of the bimetal thermostats 6 Remove the bimetal thermostats from the heatsinks by unscrewing them at the base Remove four screws Remove solder and bimetal thermostats ...

Page 115: ... See Remove Power from the Drive on page 42 3 Remove the covers from the drive See Remove the Protective Covers from the Drive on page 43 4 Move the control EMI shield See Move the Control EMI Shield on page 58 ATTENTION Thermal grease must be applied to the bottom of the bimetal thermostats before securing them to the heatsink or damage to the drive may occur 230V AC Input Drive Current Rating Co...

Page 116: ...pply wires to the terminal block The cooling fan terminal block is located below the internal armature leg fuses and between the phase V and W AC input bus bars 6 At the bottom of the drive remove the two screws that secure the fan to the drive frame and pull the fan away from the drive Loosen screws PhaseV bus bar Armature leg fuse PhaseW bus bar Terminal C of DC output Remove screws ...

Page 117: ...7 Access Procedures Chapter 3 7 Remove the screw that secures the ground wire to the fan chassis and remove the ground wire 8 Remove the loosened fan power supply wires from the terminal block and remove the fan Remove screw and wire Remove wires from terminal block ...

Page 118: ...118 Rockwell Automation Publication 20P TG003B EN P September 2021 Chapter 3 Access Procedures Install the Cooling Fans Install the cooling fans in reverse order of removal ...

Page 119: ...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 nameplate armature voltage 179 Nom Mtr Arm Amps is set to the...

Page 120: ... 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 from zero to base speed by pressing the up button 13 Measure the output vo...

Page 121: ...5 Figure 17 Power Feedback Connections Diagram 125 Figure 18 Field Board and SCR Dual Diode Module Connections Diagram 126 Figure 19 Field Control Circuit Diagram 127 Figure 20 Control Circuit Input Power Diagram 127 Figure 21 Encoder Control Circuit Diagram 128 Figure 22 DCTachometer Control Circuit Diagram 128 Figure 23 MotorThermal Protection Control Circuit Diagram 129 Figure 24 Drive Heatsink...

Page 122: ...2 X4 XCD_I0 1C2 1D2 XP3 TA TA T T T XFCD X3 2C1 2U1 2D1 2C1 2V1 2D1 D1 XA XV XUV XSW XTM XUV X5 D1 C1 U1 V1 U3 V3 1D D 1C C 1U 1V 1W U V W PE T2 T3 T1 T4 T5 T6 Drive Cover Bimetal Thermostats T7 D1 Fans XUV XUV FAN FAN XSW XSW Power Supply Filter Board Switching Power Supply Board W D V C U PE FU1 FV1 Pulse Transformer Board Field Snubber Board Control Board Transient Noise Filter Board Human Inte...

Page 123: ...generative Drive Power Module Diagram G 2 G 1 K 1 G 5 K 5 G 4 K 4 G 6 K 6 G 3 K 3 C D T1 T2 T3 T4 T5 T6 R T3 C T1 C T2 C T3 C T4 C T5 C T6 K 2 R T1 R T2 R T4 R T5 R T6 KG6 KG5 KG4 KG1 KG2 KG3 Pulse transformer circuit board Pulse transformer circuit board Module 1 Module 2 Module 3 U V W F4 F5 F6 F1 F2 F3 ...

Page 124: ...G 4 K 4 K5 G5 G 6 K 6 G 2 K 2 G 3 K 3 G 3 K 3 C D D C T1 T1 T2 T2 T3 T3 T4 T4 T5 T5 T6 T6 R T3 C T1 C T2 C T3 C T4 C T5 C T6 K 2 R T1 R T2 R T4 R T5 R T6 KG6 KG06 5 0 G K 5 G K KG4 KG04 KG1 KG01 KG2 KG02 KG3 KG03 Pulse transformer circuit board K4 G4 G6 K6 Pulse transformer circuit board Module 1 Module 01 Module 2 Module 02 Module 3 Module 03 U V W F4 F5 F6 F1 F2 F3 ...

Page 125: ... Measurement Points Diagram Figure 17 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 126: ...ix A Schematics Figure 18 Field Board and SCR Dual Diode Module Connections Diagram X3 1 1U1 1V1 X3 2 To Pulse Transformer Board X3 Connector 2U1 2D1 D1 2V1 2C1 TA1 N M P XFCD 3 XFCD 2 XFCD 4 XFCD 1 100R V1 470k 470k 470k 470k 470k 470k 470k 470k 100R XP1 1 XP2 1 XP1 2 XP2 2 ...

Page 127: ...d Control Circuit Diagram Figure 20 Control Circuit Input Power Diagram 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 1800 1800 U2 V2 1C2 1D2 230VAC or 115VAC Input To Switch Mode Power Supply SMPS ...

Page 128: ...atics Figure 21 Encoder Control Circuit Diagram Figure 22 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 129: ... Schematics Appendix A Figure 23 Motor Thermal Protection Control Circuit Diagram Figure 24 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 Pulse Transformer Board ...

Page 130: ...021 Appendix A Schematics Figure 25 Contactor Control Relays Control Circuit Diagram Figure 26 AC Line Snubber Circuit 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 C D U V W R6 R5 R4 R3 R2 R1 AC Line Snubber Board ...

Page 131: ...ansformer Board to CurrentTransducers Connections 133 PulseTransformer Board to Field Power Board Connections 133 PulseTransformer Board to Control Board Connections 134 Switching Power Supply Board Layout 135 Switching Power Supply Board to Control Board Connections 135 Control Board Layout 136 Control Board to Field Board Connections 134 Field Power Board Layout 137 Power Supply Filter Board Lay...

Page 132: ...TA 1 T1 K G KG1 T4 K G KG4 T04 K G KG04 T02 K G KG02 T2 K G KG2 T5 K G KG5 T05 K G KG05 T03 K G KG03 T3 K G KG3 T6 K G KG6 T06 K G KG06 XCD XUVW C D W V U 1 X4 K2 G2 XP2 K1 G1 XP1 TR2 TR1 1 XTM XSW XI2CA X3 X5 TR2 TR1 X4 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 PE PE1 XTM XCD S3 S4 T4 XUVW 1 1 XTA TR3 XP2 XP1 XR XY FIR3 xx Rev L and Lo...

Page 133: ...1 1 X3 1U1 field sync signal from U1 2 2 1V1field sync signal fromV1 PulseTransformer Board Connector Pin Number to BimetalThermostat Terminals Description X4 1 e1 e2 e3 24V supply 2 24V common PulseTransformer Board Connector Pin Number to Field SCR Dual Diode Module Connector Description XP1 1 G1 Gate signal G1 2 K1 Common cathode XP2 1 G2 Gate signal G2 2 K2 Common cathode PulseTransformer Boar...

Page 134: ...0V GNDP 4 4 Relay output 35 36 command 5 5 Relay output 75 76 command 6 6 2Q 4Q selection signal 7 7 0V GNDP 8 8 I armature 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 sig...

Page 135: ...upply Board Layout Table 26 Switching Power Supply Board to Control Board Connections XUV SB SA F1 XV F2 XA SwitchingPower 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 8 8 9 9 15V 10 10 11 11 15V common 12 12 13 13 15V 14 14 15 15 24V common 16 16 24V ...

Page 136: ...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 XR XA XFCD To DPI board on HIM Bezel...

Page 137: ...d to PulseTransformer Board Connections Table 29 Power Supply Filter Board to Switching Power Supply Board Connections Power Supply Filter Board Connector Pin Number to Pin Number Pulse Transformer Board Connector Description X5 1 1 X5 24V common 2 2 3 3 24V supply 4 4 not used XTM 1 1 XTM 250V AC maximum from motor PTC 2 2 Power Supply Filter Board Connector Pin Number to Pin Number Switching Pow...

Page 138: ... Table 31 Transient Noise Board to PulseTransformer Board Connections Power Supply Filter Board Connector to FanTerminal Block Description 1V3 1U3 Single phase 115V 230V AC Transient Noise Filter Board Connector to Pin Number PulseTransformer Board Connector Description 1U 1 XUVW Phase U signal 1V 2 PhaseV signal 1W 3 PhaseW signal C 1 XCD Armature C signal D 2 Armature D signal F1 F3 F2 U V W 1U ...

Page 139: ...er 2021 139 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 140 Field Current Loss Failure 141 ...

Page 140: ...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 141: ...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 142: ...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 143: ... shield move 58 control power supply failure 15 cooling fans install 118 remove 115 D DC analog tachometer test 36 DIP switches S3 S4 69 download parameter configuration 14 DPI HIM assembly install 43 remove 42 E Electrostatic Discharge Precaution 10 encoder test 36 F fault field current loss 23 heatsink overtemperature 39 main contactor 39 overcurrent 21 power failture 15 fault report create 40 f...

Page 144: ...se transformer board configure 66 install 70 remove 62 test 32 R relay outputs 39 remove AC current transducers 101 AC line snubber board and resistors 74 armature leg fuses 89 bimetal thermostats 107 communication adapter and EMI shield 46 control circuit board 55 cooling fans 115 DPI HIM assembly 42 field circuit fuses 45 field power board 71 field SCR and dual diode module 72 I O converter circ...

Page 145: ...ormer board 32 testpoints locations 18 19 thermal switch 39 thermistor 39 tools service 12 software 12 total resistance values sizing resistors 69 transient noise filter board install 86 remove 82 transient noise filter board fuses install 82 remove 81 troubleshoot armature bridge failure 21 field current loss 23 overcurrent fault 21 power failure fault 15 V visual inspection 15 ...

Page 146: ...146 Rockwell Automation Publication 20P TG003B EN P September 2021 Index Notes ...

Page 147: ...epts infrastructure components and infrastructure features System Security 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 p...

Page 148: ...s Knowledgebase articles rok 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 f...

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