Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual
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Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual

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Hardware Service Manual
Original Instructions
PowerFlex Digital DC Drive - Frame B
Catalog Numbers 20P

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 20P

  • Page 1 Hardware Service Manual Original Instructions PowerFlex Digital DC Drive - Frame B Catalog Numbers 20P...
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

  • Page 3: Table Of Contents

    Create a Fault Report ......... . 38 What You Need When You Call Tech Support....38 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 4 Pulse Transformer Circuit Board Fuse Replacement....62 Remove the Fuses on the Pulse Transformer Circuit Board..62 Install the Fuses on the Pulse Transformer Circuit Board ..62 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 5 Field Board ..........120 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 6 ............125 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 7: Preface

    Provides a current list of spare parts available for the PFLEX-SB003 PowerFlex DC field controller. 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 8 Preface Notes: Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 9 Before You Begin Testing, Maintenance or Repairs Topic Page General Safety Precautions Hardware Description Commonly Used Tools This chapter provides information you should know before you begin tests, maintenance, or repairs on drive components. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 10: General Safety Precautions

    Worn contacts may create electrical resistance. ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink surface during operation of the drive. After disconnecting power allow time for cooling. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 11: Hardware Description

    The frame size is printed just above the serial number in the lower right corner of the label. .0/0.5A 1 Phase Frame: B Serial Number: B23E0042 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 12: Commonly Used Tools

    Wrist wrap, shoes, overall clothing (coat) Software Tools You can use Connected Components Workbench® software or DriveExecutive™ software to monitor, upload, or download system parameters. You can also view current alarm and fault information. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 13: Component Test Procedures

    For common drive symptoms and corrective actions and fault troubleshooting information, see the Troubleshooting chapter in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 14: Save The Parameter Configuration

    • If there is an existing HIM Set, press to overwrite it, or select No using the button and use the buttons to select the desired characters. Then press The HIM Set will be saved to nonvolatile memory. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 15: Visual Component Inspection

    U2, V2 and correct any problems. Test the voltage level again to verify that it is correct. If the voltage is correct, but the drive is still inoperable, continue with step 5 below. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 16: Testing The Switching Power Supply And Pulse Transformer

    2. If an encoder and/or tachometer is used, use an ohmmeter to check all wiring on the respective terminals for a possible short circuit condition. Repair any short circuit conditions if found. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 17 11 12 13 14 15 16 17 18 19 20 A+ A- B+ B- Z+ Z- COM +V 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A+ A- B+ B- Z+ Z- COM +V 9 10 11 12 13 14 15 16 17 18 19 20 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 19: Troubleshoot An Ac Undervoltage Fault

    575V AC V and U XY22 … XY18 2.85V AC 1.007V V and W XY21 … XY18 690V AC V and U XY22 … XY18 3.45V AC 1.220V V and W XY21 … XY18 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 20: Troubleshoot An Armature Bridge Failure

    – 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 21 Component Test Procedures Chapter 2 Figure 3 - Good SCR Gate Pulse and Armature Current Signals Example XY19 Figure 4 - Good SCR Armature Voltage and Motor Current Signal Example XY17 XY19 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 22: Troubleshoot A Field Current Loss Fault

    374 [Drv Fld Brdg Cur] and DIP switch S14 is configured to correctly (according to the instructions in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001) and make any necessary corrections. See Control Board on page for DIP switch location. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 23 (OFF) 560.9 333.3 10 A 168.5 13 A 14 A 129.6 17 A 20 A 97.3 20 A 83.1 • If the resistance measurement is incorrect, replace the field board (see page 75). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 24: No Field Current

    1. Disconnect the cable from connector XR on the control board and measure the U1-V1 voltage synchronization signal at pin 11 on the cable. See Figure 27 on page for location of the XR connector on the control board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 25 LA-LB ITF1 Pulse ITF2 Pulse • 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). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 26: Power Component Test Procedures

    (see page 80). Table 2 - SCR Anode to Cathode Junction Measurements for Regenerative Drives On SCR Module Measure from To Terminal Nominal Meter Reading Terminal “open circuit” or “MΩ” range Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 27 Component Test Procedures Chapter 2 Figure 6 - Regenerative Drive SCR Module Layout SCR Module 1 SCR Module 2 SCR Module 3 SCR Module 01 SCR Module 02 SCR Module 03 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 28 Ohms, measure the resistance of each SCR junction. • For regenerative drives, see Table 4 on page Figure 8 on page • For non-regenerative drives, see Table 5 on page Figure 9 page 30. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 29 Figure 8 - SCR Gate Lead Connection Pinouts for Regenerative Drives SCR Module 1 SCR Module 2 SCR Module 3 Gate Lead Pinouts Gate Lead Pinouts SCR Module 01 SCR Module 02 SCR Module 03 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 30: Check The Pulse Transformer Board

    See Figure 25 on page for connector locations. If any of the actual measurements are out of tolerance, replace the pulse transformer board (see page 62). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 31 Table 9 - Armature Pulse Transformer Primary Measurements for Regenerative Drives For SCR (+) Meter Lead (-) Meter Lead Meter Reading Connector XY Pinout XY-7 XY-1 0.41 Ω XY-7 XY-4 XY-7 XY-2 XY-7 XY-5 XY-7 XY-3 XY-7 XY-6 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 32: Check The Field Scr/Dual Diode Module

    Table 10 - Field SCR/Dual Diode Module Anode to Cathode Junction Measurements (+) Meter Lead (-) Meter Lead Nominal Meter Reading Terminal Terminal “open” or ∞ “open” or ∞ “open” or ∞ “open” or ∞ “open” or ∞ “open” or ∞ 0.50V 0.50V 0.45V Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 33 Top view of Drive Unscrew fuse holders and remove fuses Front of Drive 7. Remove the cable from connector XP on the pulse transformer circuit board. See Figure 25 on page for connector location. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 34: Speed Feedback Device Tests

    The frequency is proportional to speed and the pulse rate of the encoder, referred to as the “Pulse/Rev” rating on the nameplate. The speed of the motor can be calculated by: Speed (RPM) = [Frequency (Hz) x 60]/[Pulses/ Revolution]. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 35: Check The Dc Tachometer

    (XRE, P2, P3). If problems persist, replace the resolver interface and/or resolver feedback board (see page 48). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 36 Figure 12 - Resolver Interface Board Testpoint Locations +12V +12V -12V -12V 0V12 0V12 +24V_VI +24V_VI 0V24 0V24 S1 +5V pos. S1 +12V pos. S1 +24V pos. S2 Internal supply pos. S2 External supply pos. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 37: Thermistors And Thermal Switches

    The “Main Contactor” fault (F10) indicates a problems related to a contactor used with the drive. See “Fault Descriptions” in Chapter 4 of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 for details. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 38: Create A Fault Report

    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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 39 AC Line Snubber Circuit Board and Resistors Replacement SCR Modules Replacement AC Current Transducers Replacement Bimetal Thermostats Replacement Cooling Fan Replacement This chapter provides a list of spare parts and detailed procedures for removing and replacing drive components. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 40: Replacement Parts Kits

    460/480V Regen. Drives, 330 and 412, or 575V Regen. Drive, 405 A Bimetal Thermostat, 85 °C ±3 (Qty 2), SK-20P-S7G33 230V Regen. Drives, 146…265 A, 460/480V Regen. Drives, 167…250 A, or 575V Regen. Drives, 67…270 A Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 41 (2) This kit contains one fuse only. Order 1 kit for switching power supply circuit boards, revision “H” and lower. Order 2 kits for switching power supply circuit boards, revision “I” and higher. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 42: Remove Power From The Drive

    Follow these steps to remove the device peripheral interface (DPI) / human interface module (HIM) assembly. 1. Read the General Safety Precautions on page 10. 2. Remove power from the drive (see page 42). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 43: Install The Dpi / Him Assembly

    Protective Cover Remove the Protective Covers Replacement 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 42). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 44 IMPORTANT The HIM assembly is connected via a cable to the Control board and therefore will not pull free from the drive until disconnected. Tightening torque: Tightening torque: 1.5 N m (13.3 lb 1.5 N m (13.3 lb • • • • Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 45: Install The Protective Covers

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

  • Page 46: Communication Adapter And Electromagnetic Interference Shield Replacement

    5. Disconnect any network cables from the adapter and set them aside. 6. Remove the four screws that secure the communication adapter to the electromagnetic interference (EMI) shield and remove the adapter. Tightening torque: 0.9 N m (8.0 lb • • Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 47: Install The Communication Adapter And Emi Shield

    8. Remove the three standoffs from the control board. Tightening torque: 1.0 N m (8.9 lb • • Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 48: Resolver Feedback And Interface Circuit Board Replacement

    3. Remove the protective covers from the drive (see page 43). IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 4. Disconnect the plug-in terminal blocks from the resolver feedback and resolver interface boards. Resolver feedback board Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 49 P2 and P3. Lift the resolver feedback board straight up during removal to avoid any damage to the connector pins. Tightening torque for re- XFCD assembly is 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 50 Chapter 3 Part Replacement Procedures 6. Remove the three stand-offs from the resolver interface board. Resolver interface board XFCD Tightening torque for re- assembly is 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 51: Install The Resolver Feedback And Interface Circuit Boards

    Tightening torque for re- assembly is 0.7 N m (6.2 lb • • Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 52: I/O Expansion Circuit Board Replacement

    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. Tightening torque: 1.0 N•m (8.9 lb•in) 7. Carefully pull the I/O expansion board off connector XBB on the control board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 53: Install The I/O Expansion Circuit Board

    9. Install one screw in the lower left corner of the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Install the I/O Expansion Circuit Board Install the I/O expansion board in reverse order of removal. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 54: Replacement

    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. Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 55: Install The 115V Ac To 24V Dc I/O Converter Circuit

    6. If installed, remove the resolver feedback option board (see page 48). 7. If installed, remove the I/O expansion circuit board (see page 52). 8. If installed, remove the 115V AC to 24V DC I/O converter circuit board (see page 54). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 56 ENC_5 +5V encoder (+2.5…5.4V input range) ENC_12 +12…15V encoder (+5.4V…15.2V input range) IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 58: Install The Control Circuit Board

    2. Remove power from the drive (see page 42). 3. Remove the protective covers from the drive (see page 43). IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 59: Close The Control Emi Shield In The Service Position

    IMPORTANT If the drive is not in a vertical position, the control EMI shield will not remain open without a means of restraint. Close the Control EMI Shield in the Service Position Close the control EMI shield in reverse order. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 60: Switching Power Supply Board Fuse Replacement

    When the fuse holder releases, remove the holder and fuse. Top View of drive Front of drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 61 3.15 A, 250V fast 2.5 A, 250V slow SW2-32 / I and above 2.5 A, 250V slow Top View of drive F1 = 3.15A F2 = 2.5A 250V fuse 250V fuse Front of drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 62: 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). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 63: Rockwell Automation Publication 20P-Tg002B-En-P - February

    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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 64 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. Fuse connections Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 65 11. Remove the cable from connector XV on the switching power supply board. Switching power supply board Pulse transformer board Front of drive 12. Remove the cables from connectors X3, X4, and XP on the pulse transformer board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 66 Chapter 3 Part Replacement Procedures 13. Remove the ground connection at the left side of the pulse transformer board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 67 14 (non-regenerative drives) 14 ( regenerative drives) 15. Remove the seven screws that secure the board to the stand-offs on the drive chassis and remove the boards from the drive. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 68 Chapter 3 Part Replacement Procedures Note: Regenerative drive shown. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 69: Configure The Pulse Transformer Circuit Board

    • Configure a Pulse Transformer Board FIR2-xx Rev. “N” and Higher on page Configure a Pulse Transformer Board FIR2-xx Rev. “M” and Lower IMPORTANT This procedure requires a multimeter that measures resistance to thousandths of an ohm. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 70 TA potentiometer on the lower right corner of the pulse transformer circuit board, set the total resistance (RTA) to the appropriate value as indicated in Table 15 Table 16 in the Total Resistance Values section on page 72. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 71 1 ....13 ....33 78 79 35 36 75 76 U2V2 The TA potentiometer is located on the lower right corner of the pulse transformer circuit board next to the control power terminal block. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 72: Install The Pulse Transformer And Switching Power Supply

    Dip switches S3 and S4 are located at the bottom, XI2CA right corner of the board. KGO3 KGO4 KGO5 KGO6 KGO2 KGO1 1U2 1V2 79 35 36 75 76 U2 V2 XCD_IO 78 79 35 36 75 76 U2 V2 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 73 AC Line DIP Switch S3 DIP Switch S4 Current Amps Amps 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 Rating Code 55.1 82.7 110.3 220.6 330.9 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 74: Boards

    Remove the Field Circuit Fuses Replacement 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). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 75: Install The Field Circuit Fuses

    2. Remove power from the drive (see page 42). 3. Remove the protective covers from the drive (see page 43). IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 76: 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 necessary, replace the cables on the field board with the new cables provided. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 77: Field Scr And Dual Diode Modules Replacement

    6. Remove the two screws and washers that secure each module to the heatsink and remove the modules from the drive. Install the Field SCR and Dual Diode Modules Install the field SCR and dual diode modules in reverse order of removal. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 78: Ac Line Snubber Circuit Board And Resistors Replacement

    5. Remove the field circuit board (see page 75). 6. Remove the two screws and washers that secure the (red and blue) wires from the AC line snubber board to the bus bars and remove the wires. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 79 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 80: Install The Ac Line Snubber Circuit Board And Resistors

    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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 81 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 82 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 wires. Regenerative Drive Note proper order of washers for installation. Bolt Lock washer Flat washer Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 83 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. Regenerative Drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 84 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. Regenerative Drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 85 Continue with Install the SCR Modules on page 88. Remove the Bus Bars from a Non-Regenerative Drive 15. Remove the bolts and washers and stand-off and washer that secure the power terminal bus bars to the isolation bar. Non-Regenerative Drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 86 Note proper order of washers for installation. Bolt Lock washer Flat washer 17. Remove the bolts and washers that secure the upper horizontal bus bar to the SCR modules and remove the bus bars. Non-Regenerative Drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 87 SCR modules and remove the bus bar. Non-Regenerative Drive 19. Remove the bolts, washers and wires that secure the U, V and W phase power terminals to the SCR modules. Non-Regenerative Drive Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 88: Install The Scr Modules

    • SK-20P-S7F42 4.5…5.5 N m (40…48.7 lb SK-20P-S7F41 4.5…5.5 N m (40…48.7 lb • • • • SK-20P-S727F 4.5…5.5 N m (40…48.7 lb SK-20P-S737F 4.5…5.5 N m (40…48.7 lb • • • • Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 89 • For regenerative drives, the longer leg of the intermediate AC input bus bars connect to the top of the SCR modules: Top of Drive Long leg Intermediate SCR module on bus bar heatsink Short leg Phase U, V, or W bus bar Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 90: Ac Current Transducers Replacement

    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 V phase AC input power terminals. Bottom View U Phase V Phase Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 91 7. Remove the bolts and washers that secure the U and V phase AC input bus bars to the isolation bar. Regenerative Drive Shown Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 92 U and V Phase SCR modules and remove the wires and bus bars. Non-Regenerative Drive 10. Slide the U and V phase bus bars that pass through the AC current transducers up and out of the drive. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 93: Install The Ac Current Transducers

    • 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. Red wire White wire Blue wire Black wire Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 94: Bimetal Thermostats Replacement

    4. Remove the bolts, washers and wiring from the U phase AC input power terminal and the D power terminal. Bottom View of Drive D Terminal U Phase Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 95 • 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 96 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 97 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 98 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. Non-Regenerative Drive Continue with Remove the Bimetal Thermostats on page 99. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 99: Install The Bimetal Thermostats

    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). Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 100 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 101: Install The Cooling Fans

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

  • Page 103: Start-Up After Repair

    • 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. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 104 20P-UM001 for assistance. If any of these measurements are incorrect, repeat steps 8…15. If the measurements are still incorrect, repeat the appropriate procedures in Chapter 2 - Component Test Procedures beginning on page Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 105: List Of Schematic Diagrams

    Figure 21 - Motor Thermal Protection Control Circuit Diagram Figure 22 - Drive Heatsink Monitoring Control Circuit Diagram Figure 23 - Contactor Control Relays Control Circuit Diagram Figure 24 - AC Line Snubber Circuit Diagram Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 106 Appendix A Schematics Figure 13 - Circuit Board Interconnection Diagram Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 107 Figure 14 - AC Line Measurement Points Diagram XY-22 XR-15 100K +15V -15V XY-21 XR-16 100K XY-18 XR-17 100K Figure 15 - Frame B Power Feedback Connections Diagram XR15 XR16 XR17 XR19 XR18 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 108 Figure 16 - Field Board and SCR/Dual Diode Module Connections Diagram From Incoming AC Line X3-1 470k 470k 470k 470k To Pulse Transformer Board X3 Connector X3-2 470k 470k 470k 470k XP-8 XFCD-3 XP-7 XFCD-2 XP-2 XFCD-4 XP-1 XFCD-1 To Motor Field Connections Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 109 XFCD-1 -15 V XFCD-3 XFCD-4 S14-8 S14-7 S14-6 S14-5 S14-4 S14-3 S14-2 S14-1 XFCD-2 Figure 18 - Control Circuit Input Power Diagram 230 VAC 115 VAC To Switch Input Mode Power Supply (SMPS) Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 110 Figure 19 - Encoder Control Circuit Diagram +24V Voltage Regulator and Current Feedback Circuit Figure 20 - DC Tachometer Control Circuit Diagram S4-8 S4-7 S4-6 S4-5 M3 - TACHOP M3 + S4-1 S4-3 S4-4 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 111 Figure 21 - Motor Thermal Protection Control Circuit Diagram +15V XR-32 Figure 22 - Drive Heatsink Monitoring Control Circuit Diagram Pulse Transformer Board Control Board XR-12 XR-12 XR-10 XR-10 +24V XSW-1 X4-1 X4-2 XSW-2 0V24 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 112 Appendix A Schematics Figure 23 - Contactor Control Relays Control Circuit Diagram 0V24 +24V Figure 24 - AC Line Snubber Circuit Diagram 2W2 3W2 AC Line Snubber Board Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 113: Circuit Board Layouts And Connections

    Pulse Transformer Board to Control Board Connections Pulse Transformer Board to Current Transducer Connections Switching Power Supply Board Layout Switching Power Supply Board to Control Board Connections Control Board Layout Control Board to Field Board Connections Field Board Layout Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 114: Pulse Transformer Board

    Pulse Transformer Board Figure 25 - Pulse Transformer Board Layout Components shown within dashed lines are only on the pulse transformer board for regenerative drives. Control Power Terminal Block Control Power Terminal Block Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 115 Pin Number Pin Number Field SCR/Dual Description Transformer Diode Module Board Connector Connector … Fastons Gate signal G1 … Common cathode (K1 and K2) for both field SCRs … … Gate signal G2 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 116 … WL1 (not used, grounded) … Gate signal SCR 2/05 … 0V (GNDP) … Gate signal SCR 3/06 … Motor overtemperature … Enable reverse (MN) power bridge … Enable forward (MP) power bridge Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 117 Pin Number Current Description Transformer Transducer Board Connector … Black CT on Phase U Secondary side CT phase U … Brown … Black Secondary side CT phase V CT on Phase V … Brown Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 118: Switching Power Supply Board

    … SMPS supply input undervoltage … … +15V … … 15V common … … -15V … … 24V common … +24V See Pulse Transformer Board to Switching Power Supply Connections on page 115. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 119: Control Board

    … 2 15V Common … 3 -15V … 4 Field CT burden resistors See Pulse Transformer Board to Control Board Connections on page Switching Power Supply Board to Control Board Connections on page 118. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 120: Field Board

    Field Board Figure 28 - Field Board Layout U1 V1 C1 D1 XFCD See Control Board to Field Board Connections on page and Pulse Transformer Board to Field Board Connections on page 115. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 121: List Of 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 Field Current Loss Failure Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 122: Control Power Supply Failure

    Replace the pulse transformer board, Any short circuits? Replace the transformer board. including the motor switching power PTC, if used for a short supply board. circuit condition. Repair the short circuits. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 123: Field Current Loss Failure

    Does a short Are the fuses at FU1 and FV1 Replace the circuit condition fuses blown? and apply power control board. exist? to the drive. Replace the SCR/ Replace the dual diode module. field board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 124: Low Or Incorrect Field Current

    Is the voltage across terminals LA-LB to Replace the resistance measurement measurement verify that the value field board. equals the equivalent correct? correct? resistance set with DIP switch S14. Replace the control board. Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...

  • Page 125: Index

    53 failure 15 remove 52 cooling fans inspection install 101 visual 15 remove 99 DC analog tachometer test 35 DPI / HIM assembly install 43 remove 42 DriveExecutive™ software 12 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 126 DC analog tachometer 35 test 30 encoder 34 pulse transformer circuit board fuses field SCR/dual diode module 32 install 62 pulse transformer circuit board 30 remove 62 testpoints locations 17 thermal switch 37 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 127 Index thermistor 37 tools service 12 troubleshoot armature bridge failure 20 field current loss 22 overcurrent fault 20 power failure fault 15 visual inspection 15 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 128 Index Notes: Rockwell Automation Publication 20P-TG002B-EN-P - February 2018...
  • Page 130 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, DriveExecutive, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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