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Rockwell Automation Allen-Bradley 20P Manual

Powerflex digital dc drive - frame d
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PowerFlex Digital DC Drive -
Frame D
Bulletin Number: 20P
Hardware Service Manual
Original Instructions

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Summary of Contents for Rockwell Automation Allen-Bradley 20P

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

    Remove Power from the Drive ....... . . 44 Field Circuit Fuse Removal and Installation ..... 45 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 4 Field SCR and Dual Diode Module Removal and Installation ..72 Remove the Field SCR and Dual Diode Modules... . . 72 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 5 Remove the Inrush Limiting Resistor..... . . 102 Install the Inrush Limiting Resistor ......104 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 6 ............. . .137 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 7: Summary Of Changes

    Added the Block Diagram of Non-regenerative Drive Power Module with Six Fuses. Added the Block Diagram of Non-regenerative Drive Power Module with 12 Fuses. Added the Block Diagram of Regenerative Drive Power Module with Six Fuses. Added the Series C Fan Circuit Diagram. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 8 Preface Notes: Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 9: Introduction

    Before You Begin Testing, 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 Hardware Description Commonly Used Tools Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • 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-TG004C-EN-P - September 2021...

  • Page 11: Hardware Description

    Figure 1 - Drive Data Nameplate Label A0NNN Series: B I/O: 24VDC (Standard) 3 Phase Original Firmware V. 5.007 500HP N223 Listed Ind. Cont. Eq. 31KF max. 1 Phase Hz 1.0/0.5A 1 Phase Frame: D Serial Number: D23E0042 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 12: Commonly Used Tools

    Wrist wrap, shoes, overall clothing (coat) Phillips® is a registered trademark of Phillips Screw Company. Software Tools You can use Connected Components Workbench™ software and DriveExecutive software for configuring and monitoring drive parameters. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 13: Component Test Procedures

    For common drive symptoms and corrective actions and fault troubleshooting information, see Chapter 4 “Troubleshooting” in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • 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-TG004C-EN-P - September 2021...

  • Page 15: Save Parameters To A Project File Using Connected Components Workbench Software

    Mismatch or Revision Mismatch window and view the rating and/or revision level differences. Click Continue to complete the upload and change the rating and/or revision of the device in your project to match the online device. Click Cancel to cancel the upload. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 16: Save Parameters To An Offline Node File Using Driveexecutive

    5. Check components for burn marks, breakage or foil delamination on all circuit boards. Replace any of these components without further testing if they show evidence of burn marks, breakage or foil delamination. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 17: Troubleshoot A Control Power Supply Failure

    0VEXP 0VEXP Figure 3 on page XP3-7 / XP3-8 / XP3-9 DPI expansion ground Note: For a flow chart version of the steps that follow, see Control Power Supply Failure on page 132. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 18: Testing The Switching Power Supply And Pulse Transformer

    6. Check all external wiring connected to the pulse transformer board, including the motor PTC if used, for a possible short circuit condition. Repair any short circuit conditions if found. 7. If no short circuit conditions exist, replace the pulse transformer board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 19: Testing The Control And Field Board Connections

    4. Using an ohmmeter, measure between pins 1 and 2 and pins 3 and 2 on the XFCD cable connector. The resistance measurement for both tests should be greater than 200 k . If a lower resistance value is measured, replace field board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 20 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-TG004C-EN-P - September 2021...
  • Page 21 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-TG004C-EN-P - September 2021...

  • Page 22: Troubleshoot An Ac Undervoltage Fault

    XY22 … XY18 575 VAC 2.85 VAC 1.007 V V and W XY21 … XY18 V and U XY22 … XY18 690 VAC 3.45 VAC 1.220 V V and W XY21 … XY18 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 23: Troubleshoot An Armature Bridge Failure

    SCR gate as indicated in the table below: Signal Name XR Cable Pin Gate Note – – Negative bridge MN - active when high (+5V) – – Positive bridge MP - active when high (+5V) Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 24 – The ground signal is taken on either testpoint XY10 or XY18. Figure 4 - Good SCR Gate Pulse and Armature Current Signals Example XY19 Figure 5 - Good SCR Armature Voltage and Motor Current Signal Example XY17 XY19 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 25: 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-TG004C-EN-P - September 2021...
  • Page 26 Frame D drives with a rated field supply of 70 A 1668  333.3  168.5  10 A used 83.1  20 A (OFF) 32.8  50 A 23.9  70 A If the resistance measurement is incorrect, replace the field board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 27: 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. Figure 31 on page for location of the XR connector on the control board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 28 ITF1 pulse ITF2 pulse U1-V1 Sync LA-LB ITF1 Pulse ITF2 Pulse • If the gate signals are missing, replace the control board. • If the gate signals are present, replace the field board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 29: Power Component Test Procedures

    See SCR Module Leg Assembly Removal and Installation on page 94. Leg fuses Take measurements on the terminal below the leg fuse Phase U Phase V Phase W Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 30 SCR 2 - K SCR 3 - K SCR 1 - K SCR 02 - G SCR 03 - G SCR 01 - G SCR 03 - K SCR 02 - K SCR 01 - K Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 31 Front Gate Lead Terminal Block Terminal Block Terminal Block SCR 1 - G SCR 1 - G SCR 1 - G SCR 1 - K SCR 1 - K SCR 1 - K Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 32 Pin G Pin K Pin G Pin K Pin G Pin K (1) The actual reading varies depending upon the SCR manufacturer. Verify that the actual measured value is consistent for all SCRs. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 33: Check The Pulse Transformer Board

    Table 7 - Armature Pulse/Snubber Circuit Measurements for Non-Regenerative Drives For SCR Measure From To . . . Meter reading: Connector XY Pinout . . . XY-1 XY-4 XY-2 “open circuit” XY-5 XY-3 XY-6 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 34: Check The Field Scr/Dual Diode Module

    5. Verify that power to an external field supply (if used) is removed. 6. Disconnect the field wires from C1 and D1. See Bottom, Left Side of Drive in Figure 9 on page Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 35 (+) Meter Lead (-) Meter Lead Nominal meter reading: Terminal Terminal 0.45V open or infinity open or infinity open or infinity open or infinity open or infinity open or infinity 0.9V 0.45V open or infinity Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 36 (lead orientation is not critical). See Table If a low resistance is detected, replace the SCR/dual diode module. Table 11 - SCR/Dual Diode Module Gate Cathode Junction Measurements Measure from… To… Nominal meter reading: 10…20  Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 37: Speed Feedback Device Tests

    • The analog tach signal is fine scaled using parameter 562 [Anlg Tach Gain]. • See “Drive Reference and Feedback Scaling” in Appendix C of the PowerFlex Digital DC Drive User Manual, publication 20P-UM001, for more information. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 38: Check The Resolver Interface Board

    … 0V12 12V DC ±5% -12V … 0V12 -12V DC ±5% +24V_VI … 0V24 24V DC ±5% … 0V5 5V DC ±5% If any of the voltage measurements fails, replace the resolver interface board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 39 Figure 10 - 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-TG004C-EN-P - September 2021...

  • Page 40: 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-TG004C-EN-P - September 2021...

  • Page 41: 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-TG004C-EN-P - September 2021...
  • Page 42 Component Test Procedures Chapter 2 Notes: Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 43: Access Procedures

    Overvoltage Clipping Circuit Board Fuse Removal and Installation Overvoltage Clipping Circuit Board Removal and Installation Armature Leg Fuse Removal and Installation SCR Module Leg Assembly Removal and Installation Bimetal Thermostat Removal and Installation Discharge Resistors Removal and Installation Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 44: Remove Power From The Drive

    • causing an explosion in a hazardous environment Electric arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts may create electrical resistance. Remove and lockout all incoming power to the drive. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 45: Field Circuit Fuse Removal And Installation

    3. Pull down on the tabs at the top of the fuse holder on the front of the drive and remove the fuses. Install the Field Circuit Fuses Install the new field circuit fuses in reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 46: Dpi / Him Assembly Removal And Installation

    Tightening torque: 0.8 N m (7 lb • • Install the DPI / HIM Assembly on the Protective Cover Install the DPI / HIM assembly in reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 47: Protective Cover Removal And Installation

    I/O, I/O and control digital encoder, DC analog tachometer, and resolver feedback terminal cover terminals. Bottom terminal Removing this cover provides access to the snubber cover capacitors and snubber resistors. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 48: Install The Protective Covers

    Install the protective covers in reverse order of removal. ATTENTION: Risk of electric shock exists when power is applied to the power terminals of the drive. The protective covers must be replaced after servicing the drive. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 49: Open And Close The Control Panel

    4. Insert a flathead screwdriver into the holes in the right side of the protective covers on the drive and turn the latch 90° counter-clockwise. 5. Open the control panel to the left. 90° Close the Control Panel Close the control panel in the reverse order. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 50: Communication Adapter And Emi Shield Removal And Installation

    Note: Frame A shown. 6. Remove the four screws that secure the communication adapter to the EMI shield and remove the adapter. Tightening torque: 0.9 N m (8 lb • • Note: Frame A shown. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 51: Install The Communication Adapter And Emi Shield

    8. Remove the three stand-offs from the control board. Tightening torque: 1.0 N m (8.9 lb • • Note: Frame A shown. Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 52: Switching Power Supply Fuse Removal And Installation

    4. Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover. PFC -XX Switching Power Supply board Tightening torque: 0.8 N m (7 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 53 (F1), carefully pushing up and turning the fuse counterclockwise. When the fuse holder releases, remove the holder and fuse. Fuse holder XSW1 Install the Fuse on the Switching Power Supply Circuit Board Install the new fuse in the reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 54: Remove The Resolver Feedback And Interface Circuit Boards

    Remove the Protective Covers on page 47. Mark all connections and wires before removal to avoid incorrect IMPORTANT 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-TG004C-EN-P - September 2021...
  • Page 55 P2 and P3. Lift the resolver feedback board straight up during removal to avoid any damage to the connector pins. Tightening torque for XFCD reassembly is 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 56 Access Procedures Chapter 3 6. Remove the three stand-offs from the resolver interface board. Resolver interface board Tightening torque for reassembly is XFCD 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 57: Install The Resolver Feedback And Interface Circuit Boards

    XFCD Tightening torque for reassembly 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-TG004C-EN-P - September 2021...

  • Page 58: Board

    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 • • 7. Carefully pull the I/O expansion board off connector XBB on the control board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 59: Install The I/O Expansion Circuit Board

    9. Install one of the existing screws in the lower left corner of the control circuit board. Tightening torque: 1.0 N m (8.9 lb • • Install the I/O Expansion Circuit Board Install the I/O expansion board in reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 60: Ac To 24V Dc I/O Converter Circuit Board Removal And Installation

    I/O converter board. Tightening torque: 1.0 N m (8.9 lb • • 6. Remove the two stand-offs from the control board. Tightening torque: 1.0 N m (8.9 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 61: Installation

    Note: The input signal type must also be programmed accordingly using Par 76 [Anlg In2 Config]. Configures the input signal of analog input 3 (terminals 5 and 6): Note: The input signal type must also be programmed accordingly using Par 81 [Anlg In3 Config]. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 62 Note: When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch. ENC_5 +5 V encoder (+2.5…5.4V input range) ENC_12 +12…15 V encoder (+5.4V…15.2V input range) Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 63 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-TG004C-EN-P - September 2021...

  • Page 64: Install The Control Circuit Board

    Install the Control Circuit Board Install the control board in reverse order of removal. • Verify that all DIP switches are set to the correct configuration based on your recorded settings. See page 61. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 65: Switching Power Supply Circuit Board Removal And Installation

    PFC-XX Switching Power Supply board Tightening torque: 0.8 N m (7 lb • • Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 66: Install The Switching Power Supply Circuit Board

    2. Remove power from the drive. See Remove Power from the Drive on page 3. Remove the top control panel, bottom control panel, and I/O and control terminal covers from the drive. See Remove the Protective Covers on page Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 67 XUVW, XCD, XR, XTA, X3, X4 and XSPF. Also, carefully remove the ribbon cable (from XR) from the cable standoff on the board. 9. Remove the plug-in terminal block at the bottom of the pulse transformer board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 68 XSW1 Tightening torque: 1.0…1.2 N • (9…10.5 lb • XCD_IO XUVW KG01 KG04 KG02 KG05 KG03 KG06 XSPF 78 79 35 36 75 76 81 82 U2 V2 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 69: Install The Pulse Transformer Board

    Drive 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 1017 1130 1000 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 70: Field Circuit Board Removal And Installation

    4. Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover. Field board PFC -XX Tightening torque: 0.8 N m (7 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 71: Install The Field Circuit Board

    • Inspect the cables that connect to connectors XFCD and X3 on the field board for burn marks, cracks, or a loose connector. If necessary, replace the existing cables with the new cables provided. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 72: Field Scr And Dual Diode Module Removal And Installation

    Circuit Board on page 70. Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. 5. Disconnect the gate lead wires from the connectors at the top of the SCR module. SCR module Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 73: Install The Field Scr And Dual Diode Modules

    ATTENTION: Thermal grease must be applied to the bottom of the field SCR and dual diode modules before securing them to the heatsink or damage to the drive may occur. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 74: Field Fuse Holder Removal And Installation

    4. Loosen the eight hexalobular screws that secure the protective plastic cover to the control pan and remove the cover. Field board PFC -XX Tightening torque: 0.8 N m (7 lb • • Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 75 5. Loosen the screws that secure the input and output wires to the fuse holder terminals and remove the wires. 6. If you are reusing the field fuses, pull down on the tabs on the front of the fuse holder and remove the fuses. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 76: Install The Field Fuse Holder

    2. Remove power from the drive. See Remove Power from the Drive on page 3. Remove the top terminal cover from the drive. See Remove the Protective Covers on page 47. Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 77: Install The Fan Starting Capacitor

    Disconnect capacitor wires from terminal block XC Install the Fan Starting Capacitor Install the fan starting capacitor in the reverse order of removal. See the Series A Fan Circuit Diagram on page for wiring details. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 78: Series A Fan Circuit Board Removal And Installation

    • Install the Series A Fan Circuit Board Install the series A fan circuit board in the reverse order of removal. See the Series A Fan Circuit Diagram on page for wiring details. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 79: Series B Fan Circuit Board Removal And Installation

    Z3F Y3F X3F Install the Series B Fan Circuit Board Install the Series B fan circuit board in the reverse order of removal. See the Series B Fan Circuit Diagram on page for wiring details. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 80: Series A Fan Assembly Removal And Installation

    5. Remove the wires connected to the terminal block at XF on the fan circuit board (at the top of the drive, to the left of the fan blower). Cut the cable ties that secure the fan blower motor wires to the fan capacitor wires. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 81: Install The Series A Fan Assembly

    Install the series A fan assembly in the reverse order of removal. See the Series A Fan Circuit Diagram on page for wiring details. Secure the fan power wires using cable ties, as previously installed, to make sure that the wires do not make contact with moving parts. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 82: Series B Fan Assembly Removal And Installation

    5. Remove the wires connected to terminal block TB1 at XF2 on the fan circuit board (at the top of the drive, to the left of the fan blower). W3F V3F U3F Z3F Y3F X3F Remove wires from terminal blocks XF and XF2. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 83: Install The Series B Fan Assembly

    Install the Series B fan assembly in the reverse order of removal. See the Series B Fan Circuit Diagram on page for wiring details. Secure the fan power wires using cable ties, as previously installed, to make sure that the wires do not make contact with moving parts. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 84: Series C Fan Assembly Removal And Installation

    (at the top of the drive, to the left of the fan blower). 32 31 PE W3 V3 U3 TB TB PE W3F V3F U3F Z3F Y3F X3F Remove wires from terminal blocks XF and XF2. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 85: Install The Series C Fan Assembly

    (clean power). Secure the fan power wires using cable ties, as previously installed, to make sure that the wires do not make contact with moving parts. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 86: Ac Current Transducers Removal And Installation

    1.5 N m (13 lb • • 5. Open the control panel. See Open the Control Panel on page 49. Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 87 7. Remove the four bolts and washers that secure the top insulator bar, over the AC input terminal busbars, to the drive frame and remove the insulator bar. Top insulator bar AC current transducers Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 88 AC current transducers and remove the wires. 10. Loosen the two screws that secure each of the AC current transducers to the U and W phase terminal busbar, so that the current transducers are loose on the busbars. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 89: Install The Ac Current Transducers

    • Tightening torque for the M12 bolts is 45 N•m (398 lb•in). • Verify that signal wire that was disconnected from the U and W phase busbars when removing the current transducers is reinstalled. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 90: Overvoltage Clipping Circuit Board Fuse Removal And Installation

    4. Remove the three fuses at locations F11, F21, and F31. X1UVW1 XUVW XR-5 XR-4 XR-3 XR-2 XR-1 XR-6 C5gn C4blu C7blu C7gn Install the Overvoltage Clipping Circuit Board Fuses Install the overvoltage clipping circuit board fuses in the reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 91: Overvoltage Clipping Circuit Board Removal And Installation

    Tightening torque: 1.0…1.2 N • (9…10.5 lb • X1UVW1 XUVW XR-5 XR-4 XR-3 XR-2 XR-1 XR-6 C5gn C4blu C7blu C7gn Newer overvoltage clipping board X1UVW1 XUVW Older overvoltage clipping board Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 92: Install The Overvoltage Clipping Circuit Board

    Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. 4. Remove the screws that secure the switch to the fuse and remove the switch and fuse wires. Retain the switch, screws, and wires for reuse. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 93: Install The Armature Leg Fuse

    • Tightening torque for the fuse bolt is 45 N•m (398 lb•in). • Install the existing fuse switch on the fuse body using the existing hardware. Verify that all wires are properly connected to the fuse switch. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 94: Scr Module Leg Assembly Removal And Installation

    4. Open the control panel. See Open the Control Panel on page 49. Note the terminal number on the fuse switch to which the signal wires IMPORTANT are connected for proper reinstallation. Note terminal numbers on fuses for wire connections Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 95 Rotate top of fuse out and downward lift off lower terminal Main input terminal SCR module leg input terminal Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 96 Once the connecting bolts and washers are removed, the “C” shaped IMPORTANT busbar between the middle and right SCR module leg assembly can be removed, allowing access to the rear terminals. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 97 Access Procedures Chapter 3 SCR assembly SCR assembly output terminal output terminal “C” shaped busbar DC output DC output busbar busbar Angled view showing regenerative drive Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 98 14. Repeat steps 12 and 13 above for each SCR assembly. Lifting handles Lifting handles Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 99: Install The Scr Module Leg Assembly

    • Tightening torque for the SCR module leg assemblies is 4.5…5.0 N•m (40.0…44.4 lb•in). • Tightening torque for the SCR module input and output terminals to the fuse terminals and DC output busbars is 45 N•m (398 lb•in). Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 100: Bimetal Thermostat Removal And Installation

    1. Read the General Safety Precautions on page 10. 2. Remove power from the drive. See Remove Power from the Drive on page 3. Open the control panel. See Open the Control Panel on page 49. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 101 In this case, unsolder the connections. X1UVW1 XUVW XR-5 XR-4 XR-3 XR-2 XR-1 XR-6 C5gn C4blu C7blu C7gn Newer overvoltage clipping board X1UVW1 XUVW Older overvoltage clipping board Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 102: Install The Discharge Resistors

    Remove the Inrush Limiting Resistor Removal and Installation The inrush resistor is secured to the back wall of the drive frame below the control pan. Inrush resistor 1. Read the General Safety Precautions on page 10. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 103 Note: On older boards, these connections are soldered directly to the board. In this case, unsolder the connections. Newer overvoltage clipping board X1UVW1 XUVW XR-5 XR-4 XR-3 XR-2 XR-1 XR-6 C5gn C4blu C7blu C7gn X1UVW1 XUVW Older overvoltage clipping board Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 104: Install The Inrush Limiting Resistor

    1. Read the General Safety Precautions on page 10. 2. Remove power from the drive. See Remove Power from the Drive on page 3. Remove the bottom terminal cover from the drive. See Remove the Protective Covers on page 47. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 105: Install The Snubber Capacitors

    5. Disconnect the wires from the top of each capacitor and remove the capacitors. Note: Busbars shown removed for clarity only. Install the Snubber Capacitors Install the snubber capacitors in the reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 106: Snubber Resistors Removal And Installation

    6. Remove the 12 hexalobular screws and washers that secure the metal plate to the back wall of the drive chassis and remove the metal plate. Note: Output terminals shown removed for clarity only. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 107: Install The Snubber Resistors

    8. Remove the two hexalobular screws and washers that secure each of the snubber resistors to standoffs on the back wall of the drive chassis and remove the resistors. Install the Snubber Resistors Install the snubber resistors in the reverse order of removal. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 108 Access Procedures Chapter 3 Notes: Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 109: Test With The Motor, Without A Mechanical Load

    • 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-TG004C-EN-P - September 2021...
  • Page 110 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 13. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 111: List Of Schematic Diagrams

    Figure 25 - Contactor Control Relays Control Circuit Diagram Figure 26 - Series A Fan Circuit Diagram Figure 27 - Series B Fan Circuit Diagram Figure 27 - Series C Fan Circuit Diagram Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 112 Cooling Fan Switching Power Supply Board Overvoltage Clipping Board X1UVW1 Pulse Transformer Board XUVW KG01 KG04 XFCD KG02 Control Board KG05 X4-1 Test Connector KG03 CT-U CT-W X4-2 KG06 XTA-1 XTA-2 XTA-3 XTA-4 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 113 Schematics Appendix A Figure 12 - Block Diagram of Non-regenerative Drive Power Module with Six Fuses Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 114 Schematics Appendix A Figure 13 - Block Diagram of Non-regenerative Drive Power Module with 12 Fuses Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 115 Schematics Appendix A Figure 14 - Block Diagram of Regenerative Drive Power Module with Six Fuses Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 116 Schematics Appendix A Figure 15 - Block Diagram of Regenerative Drive Power Module with 12 Fuses Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 117 XR-17 100 K Figure 17 - Power Feedback Connections Diagram Hardware connections to power structure bus bars. XR19 *Note XR18 *Note XR15 *Note XR16 *Note XR17 *Note *Note: 6 x 715 kohm resistors Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 118 100R XFCD-1 XFCD-2 XFCD-3 XFCD-4 TA_1 To Motor Field Connections Figure 19 - Field Control Circuit Diagram +15 V 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 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 119 Figure 20 - Control Circuit Input Power Diagram 230 VAC or To Switch Mode Power 115 VAC input Supply (SMPS) Figure 21 - Encoder Control Circuit Diagram +24V Voltage Regulator and Current Feedback Circuit Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 120 Figure 22 - DC Tachometer Control Circuit Diagram S4-8 S4-7 S4-6 S4-5 M3 - TACHOP M3 + S4-1 S4-3 S4-4 Figure 23 - Motor Thermal Protection Control Circuit Diagram +24V Overtemp Fault Signal Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 121 Appendix A Figure 24 - Drive Heatsink Monitoring Control Circuit Diagram Control Board XR-10 XR-10 XR-12 XR-12 X4-1 XSW-1 +24V X4-2 0V24 XSW-2 Figure 25 - Contactor Control Relays Control Circuit Diagram 0V24 +24V Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 122 400...460V AC, 60 Hz Orange Gray Figure 28 - Series C Fan Circuit Diagram White White Yellow/Green Fan Fault Black Blue Brown Fan Supply 3 Phase 400V AC, 50 Hz 400...460V AC, 60 Hz Orange Gray Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 123: List Of Circuit Board Layouts

    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 Overvoltage Clipping Board Overvoltage Clipping Board to Pulse Transformer Board Connections Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 124: Pulse Transformer Board

    Components shown within dashed lines are only on the pulse transformer board for regenerative drives. XSW1 XCD_IO XUVW KG01 KG04 KG02 KG05 KG03 KG06 XSPF 78 79 35 36 75 76 81 82 U2 V2 Control power terminal block Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 125: Pulse Transformer Board To Field Board Connections

    Pin Number to Pin Number Field SCR/Dual Description Transformer Diode Module Board Connector Connector … Gate signal G1 … Common cathode (K1 and K2) for Fastons both field SCRs … … Gate signal G2 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 126: Pulse Transformer Board To Control Board Connections

    … 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-TG004C-EN-P - September 2021...

  • Page 127: 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 125. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 128: Control Board

    … 15V Common XFCD XFCD … -15V … Field CT burden resistors See Pulse Transformer Board to Control Board Connections on page Switching Power Supply Board to Control Board Connections on page 127. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 129: Field Board

    Figure 32 - Field Board Layout XFCD TA_1 P F C- X X See Control Board to Field Board Connections on page and Pulse Transformer Board to Field Board Connections on page 125. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 130: Overvoltage Clipping Board

    … Signal from W Phase … Signal from AC input terminal U … not used XUVW … Signal from AC input terminal V … not used … Signal from AC input terminal W Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 131: List Of Flow Charts

    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 Field Current Loss Failure Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 132: Control Power Supply Failure

    Replace the pulse Any short circuits? Replace the including the motor transformer board. switching power PTC if used for a short supply board. circuit condition. Repair the short circuits. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 133: Field Current Loss Failure

    Does a short fuses at FU1 and FV1 Are the fuses Replace the circuit condition and apply power to blown? control board. exist? the drive. Replace the SCR/ dual diode module. Replace the field board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 134: Low Or Incorrect Field Current

    Is voltage Is resistance terminals LA-LB to Replace the field measurement measurement verify that the value board. correct? correct? equals the equivalent resistance set with DIP switch S14. Replace the control board. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 135: Tg004C-En-P, September 2021

    Updated the Series A Fan Assembly Removal and Installation procedures to indicate use for series A only. Added the new Series B Fan Assembly Removal and Installation. Updated the Circuit Board Interconnection Diagram to reflect series B fan components. Added the Series B Fan Circuit Diagram. Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 136 History of Changes Appendix D Notes: Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...

  • Page 137: Index

    102 remove 100 DPI/HIM assembly install 46 I/O expansion board remove 46 install 59 remove 58 in-rush limiting resistor install 104 Electrostatic Discharge Precaution 10 remove 102 encoder inspection test 37 visual 16 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 138 40 discharge resistors 100 overvoltage clipping circuit board resolver feedback board install 92 install 57 remove 91 remove 54 overvoltage clipping circuit board fuses install 90 remove 90 safety precautions 10 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 139 33 testpoints locations 20 thermal switch 40 thermistor 40 tools service 12 software 12 troubleshoot armature bridge failure 23 field current loss 25 overcurrent fault 23 power failure fault 17 visual inspection 16 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 140 Index Notes: Rockwell Automation Publication 20P-TG004C-EN-P - September 2021...
  • Page 141 PowerFlex Digital DC Drive - Frame D Hardware Service Manual Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex Digital DC Drive User Manual, publication Provides installation, startup, programming, and troubleshooting information for the 20P-UM001 PowerFlex DC drive.
  • Page 142 At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental information on its website at rok.auto/pec. Allen-Bradley, Connected Components Workbench, DriveExecutive, expanding human possibility, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc.

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