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Rockwell Automation Allen-Bradley PowerFlex Hardware Service Manual

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PowerFlex Digital DC Drive -
Frame C
Bulletin Number 20P
Hardware Service Manual
Original Instructions

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex

  • Page 1 PowerFlex Digital DC Drive - Frame C 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

    Protective Cover Removal and Installation ..... . 43 Remove the Protective Covers from the Drive....43 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 4 Remove the Field SCR and Dual Diode Module ... . . 72 Install the Field SCR and Dual Diode Module ....73 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 5 Field Power Board..........137 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 6 ............. . .143 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 7: Summary Of Changes

    Changed values in the table Armature Pulse/Snubber Circuit Measurements for Non-Regenerative Drives. Changed the procedure Check the Field SCR/Dual Diode Module. Added the Non-regenerative Drive Power Module Diagram. Added the Regenerative Drive Power Module Diagram. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 8 Preface Notes: Rockwell Automation Publication 20P-TG003B-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-TG003B-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-TG003B-EN-P - September 2021...

  • 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: C Serial Number: C13D0092 Rockwell Automation Publication 20P-TG003B-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 ™ ™ ™ DriveTools SP, DriveExecutive, DriveExplorer and DriveObserver are software tools for uploading, downloading and monitoring system parameters. Rockwell Automation Publication 20P-TG003B-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-TG003B-EN-P - September 2021...

  • Page 14: Save The Parameter Configuration

    3. If you are not connected to a drive, the Connect to Drive dialog displays. Select the drive to which you want to connect and click OK. 4. A dialog displays the status of the upload operation. Click Cancel to cancel the operation. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 15: Visual Component Inspection

    0VEXP Figure 2 on page 19 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 140. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 16: 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-TG003B-EN-P - September 2021...

  • Page 17: 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-TG003B-EN-P - September 2021...
  • 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-TG003B-EN-P - September 2021...
  • Page 19 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-TG003B-EN-P - September 2021...

  • Page 20: Troubleshoot An Ac Undervoltage Fault

    V and U XY22 … XY18 690 VAC 3.45 VAC 1.220 V V and W XY21 … XY18 • If any of the voltage measurements above are incorrect or missing, continue with step 5 below. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 21: 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-TG003B-EN-P - September 2021...
  • Page 22 – The ground signal is taken on either testpoint XY10 or XY18. 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-TG003B-EN-P - September 2021...

  • Page 23: 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. Control Board on page 136 for DIP switch location. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 24 1668 560.9 333.3 Not used (OFF) 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. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 25: 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 29 on page 136 for location of the XR connector on the control board. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 26 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-TG003B-EN-P - September 2021...

  • Page 27: Power Component Test Procedures

    Table 3 on page 29 Figure 7 on page If a low resistance is detected, determine which SCR module(s) is/are damaged based on the tables below and replace that module(s). See Modules Removal and Installation on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 28 SCR… Measure from To Terminal… Nominal meter reading: Terminal… “open circuit” or “megaOhms” range Figure 6 - Regenerative Drive SCR Module Layout Module 1 Module 01 Module 2 Module 02 Module 3 Module 03 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 29 Table 3 - SCR Anode to Cathode Junction Measurements for Non-Regenerative Drives On SCR Module… SCR… Measure from To Terminal… Nominal meter reading: Terminal… “open circuit” or “megaohms” range Figure 7 - Non-Regenerative Drive SCR Module Layout Module 01 Module 02 Module 03 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 30 Figure 8 - SCR Gate Lead Connection Pinouts for Regenerative Drives Gate Lead Connectors Module 1 Module 2 Module 3 Module 01 Module 02 Module 03 Gate Lead Front of Drive Pinouts Drive Heatsink Top View of SCR Module Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 31 Figure 9 - SCR Gate Lead Connection Pinouts for Non-Regenerative Drives Gate Lead Connectors Module 01 Module 02 Module 03 Gate Lead Front of Drive Pinouts Drive Heatsink Top View of SCR Module Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 32: 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-TG003B-EN-P - September 2021...

  • Page 33: Check The Field Scr/Dual Diode Module

    4. Verify that contactor power (if used) is removed. 5. Verify that power to an external field supply (if used) is removed. 6. Disconnect the field wires from C1 and D1. See Figure 10 on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 34 0.9V 0.45V open or infinity Figure 10 - Field Terminal Block Location W phase - AC input terminal Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 35 If a low resistance is detected, replace the SCR/dual diode module. See Field SCR and Dual Diode Module Removal and Installation on page Table 11 - SCR/Dual Diode Module Gate Cathode Junction Measurements Measure from… To… Nominal meter reading: 10…20  Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 36: 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-TG003B-EN-P - September 2021...

  • Page 37: 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-TG003B-EN-P - September 2021...
  • Page 38 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-TG003B-EN-P - September 2021...

  • Page 39: 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-TG003B-EN-P - September 2021...

  • Page 40: 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-TG003B-EN-P - September 2021...

  • Page 41: Access Procedures

    Power Supply Filter Circuit Board Removal and Installation Armature Leg Fuses Removal and Installation SCR Modules Removal and Installation AC Current Transducers Removal and Installation Bimetal Thermostats Removal and Installation Cooling Fans Removal and Installation Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 42: Remove Power From The Drive

    5. Carefully remove the DPI / HIM assembly from the cover and disconnect the cable from the DPI connector on the back side of the assembly. Remove screw Tightening torque: 0.8 N m (7 lb • • Disconnect DPI cable Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 43: Install The Dpi / Him Assembly

    PORT NET A NET B Disconnect DPI cable Tightening torque: Tightening torque: 0.8 N m (7 lb 0.8 N m (7 lb • • • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 44 • • • • 6. Disconnect the HIM communication cable from the connector on the upper right corner of the control board and set the cover aside. Pull tabs out to disconnect cable. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 45: Install The Protective Covers On The Drive

    4. On the control EMI shield, unscrew the fuse holders and remove the existing fuses from the holders. Unscrew fuse caps and Control EMI shield remove fuses Install the Field Circuit Fuses Install the field circuit fuses in the reverse order of removal. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 46: Communication Adapter And Emi Shield Removal And Installation

    6. Remove the four screws and washers that secure the communication adapter to the EMI shield and remove the adapter. Remove four screws and washers Tightening torque: 0.9 N m (8.0 lb • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 47: Install The Communication Adapter And Emi Shield

    Remove three standoffs Tightening torque: and washers 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-TG003B-EN-P - September 2021...

  • Page 48: Resolver Feedback And Interface Circuit Board Removal And Installation

    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 Remove terminal blocks Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 49 Remove screws and board Tightening torque XFCD for re-assembly is 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 50 Chapter 3 Access Procedures 6. Remove the three stand-offs from the resolver interface board. Resolver interface board Remove stand-offs Tightening torque for re-assembly is XFCD 0.7 N m (6.2 lb • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

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

    Tightening torque for XFCD 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-TG003B-EN-P - September 2021...

  • Page 52: I/O Expansion Circuit Board Removal And Installation

    Tightening torque Remove two screws for re-assembly is 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-TG003B-EN-P - September 2021...

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

    9. Install one screw in the lower left corner of the control circuit board. Install screw Tightening torque for re-assembly is 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-TG003B-EN-P - September 2021...

  • Page 54: Installation

    (8.9 lb • • 6. Remove the two stand-offs and washers from the control board. Remove two stand-offs and washers Tightening torque for re-assembly is 1.0 N m (8.9 lb • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 55: Board

    Remove the 115V AC to 24V DC I/O Converter Circuit Board on page 8. Record all switch and jumper settings on the control board. Refer to the PowerFlex DC Digital Drive User Manual, publication 20P-UM001, for more information. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 56 ENC_5 +5 V encoder (+2.5…5.4V input range) ENC_12 +12…15 V encoder (+5.4V…15.2V input range) Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 57 11. Remove the five screws that secure the control board to the control EMI shield and remove the board. Remove screws Tightening torque for re-assembly is 1.0 N m (8.9 lb • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 58: Install The Control Circuit Board

    3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page 4. Carefully disconnect the cables from connectors XFCD and XR on the control board. Disconnect cables Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 59: Install The Control Emi Shield

    If the drive is not in a vertical position, the control EMI shield will not IMPORTANT stay open without a means of restraint. Remove cable Install the Control EMI Shield Install the control EMI shield in reverse order of removal. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 60: Switching Power Supply Circuit Board Fuse Removal And Installation

    Insert the 3.15A 250V fuse in the fuse holder designated F1. Insert the 2.5A IMPORTANT 250V fuse in the fuse holder designated F2. F1 = 3.15A F2 = 2.5A 250V fuse 250V fuse Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 61: Switching Power Supply Circuit Board Removal And Installation

    6. If present, disconnect the jumper from terminals SA-SB. Be sure to replace the jumper between terminals SA-SB if using 115V IMPORTANT AC control input power when installing a new switching power supply board. Disconnect cables and wiring Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 62: Install The Switching Power Supply Circuit Board

    Remove Power from the Drive on page 3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page 4. Move the control EMI shield. See Move the Control EMI Shield on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 63 Air flow plate Remove four screws Screws shown removed Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 64 7. Remove the cable from connector XTA at the bottom center of the board. Non-Regenerative Drive Remove cable Remove gate leads Regenerative Drive Remove cable Remove gate leads Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 65 9. Remove the cables from connectors X4, X5 and XTM at the top left side of the board. Remove cables 10. Remove the cables from connectors XCD, XUVW and X3 at the top right side of the board. Remove cables Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 66: Configure The Pulse Transformer Circuit Board

    See either, Configuring a Pulse Transformer Board FIR3-xx Rev. “L” and Lower on page 67, or Configuring a Pulse Transformer Board FIR3- xx Rev. “M” and Higher on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 67 Amps – Remove 5.36 5.36 5.36 Table 13 - 460V AC Input Drives Drive Current AC Line Rating Code Amps Amps 404.4 – Remove 5.36 5.36 5.36 544.9 – 5.36 5.36 5.36 5.36 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 68 1 ....13 ....33 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-TG003B-EN-P - September 2021...
  • Page 69 AC input voltage, armature output current, and HP rating shown in Table 16 Table 17 on page 70. XCD_IO XUVW XI2CA KGO1 KGO4 KGO2 KGO5 KGO3 KGO6 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 70: Install The Pulse Transformer Circuit Board

    If necessary, replace the gate lead cables with the new cables provided. ATTENTION: Each gate lead cable must be connected to the exact connector from which it was removed on the pulse transformer circuit board or damage to the drive may occur. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 71: Field Power Circuit Board Removal And Installation

    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. Remove cable Remove screws and washers Remove screws and washers Remove cable Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 72: Install The Field Power Circuit Board

    Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. 6. Remove the (orange and yellow) cables from connectors K1G1 and K2G2 on the top left side of the pulse transformer board. Remove cables Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

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

    • 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). • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 74: Ac Line Snubber Circuit Board And Resistors Removal And Installation

    5. Remove the four screws that secure the slotted air flow plate to the top of the drive and remove the plate. Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 75 7. Remove the cable from connector XTA at the bottom center of the pulse transformer board. Non-Regenerative Drive Remove cable Remove gate leads Regenerative Drive Remove cable Remove gate leads Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 76 10. Remove the cables from connectors XCD, XUVW and X3 at the top right side of the pulse transformer board. Remove cables 11. Remove the cables from connectors X3 and XFCD on the field power board. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 77 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 cable Remove screws, washers and wires Remove screws, washers and wires Remove cable Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 78 Front of Drive Remove screws and washers (both sides of drive frame) 14. If present, remove the isolation sheet that is secured to the bus bars. Remove isolation sheet. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 79 (black) leads to the bus bars and remove the leads. Regenerative Drive Remove bolts and washers Remove screws and washers Non-Regenerative Drive Remove bolts and washers Remove screws and washers Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 80 Remove screws and washers 17. Remove the two screws that secure each resistor (six total) to the drive frame and remove the resistors from the drive. Remove screws Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 81: Install The Ac Line Snubber Circuit Board And Resistors

    Remove Power from the Drive on page 3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page 4. Move the control EMI shield. See Move the Control EMI Shield on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 82: Install The Fuses On The Transient Noise Filter Circuit Board

    Remove the Protective Covers from the Drive on page Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. 4. Remove the ground wire from the PE ground stud on the drive frame. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 83 PE ground stud Remove ground wire Remove screw and wire 6. Remove the two screws and washers that secure the bottom of the transient noise filter board to the drive Remove screws and washers Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 84 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 screw and washer Remove screw and washer Remove wires Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 85 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, washers and leads Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 86: Install The Transient Noise Filter Circuit Board

    Remove Power from the Drive on page 3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 87 Remove wires, screws and washers 6. Move the control EMI shield. See Move the Control EMI Shield on page 7. Disconnect the wires from connectors X5, XTM, and XUV on the power supply filter board. Remove connections Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 88: Install The Power Supply Filter Circuit Board

    Remove screw and washer Remove screw and washer Remove wires Install the Power Supply Filter Circuit Board Install the power supply filter board in reverse order of removal. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 89: Armature Leg Fuses Removal And Installation

    4. Remove the two screws and washers that secure the bottom of the transient noise filter board to the drive. Remove screws and washers 5. Move the control EMI shield. See Move the Control EMI Shield on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 90 Remove screws and washers Remove cable ties 7. If present, remove the isolation sheet that is secured to the bus bars. Remove isolation sheet. Note: Regenerative Drive Shown Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 91 Note the numbered position of each wire on the fuse for proper IMPORTANT installation of the new fuses. Remove wire leads 9. Remove the two screws that secure each switch to the fuse and remove the switch. Retain the switch for reuse. Remove screws Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 92: Install The Armature Leg Fuses

    Install the armature leg fuses in reverse order of removal. Verify that the washers are installed in the proper order and that the switches IMPORTANT are installed on the correct fuse. Bolt Lock washer Large washer Fuse Large washer Small washer Bolt Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 93: Scr Modules Removal And Installation

    4. Move the control EMI shield. See Move the Control EMI Shield on page 5. Remove the gate leads from the pulse transformer board. Non-Regenerative Drive Remove gate leads Regenerative Drive Remove gate leads Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 94 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 • For non-regenerative drives, see Remove the Bus Bars from a Non- Regenerative Drive on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 95 Lock washer Lock washer Flat washer Left to right, two (2) flat washers, lock washers Flat washer and nuts Left to right, two (2) flat washers and bolts Bolt (30mm long) (40mm long) Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 96 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 24mm long bolts and washers Leave wires in place Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 97 Remove the Bus Bars from a Non-Regenerative Drive 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 nuts, washers and wires Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 98 Remove bolts, lock washers, flat washers Bolt and Washer Order Left to right, bolts and flat washers Left to right, flat washers, lock washers and nuts Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 99 Remove bolts and metal plates Note: Regenerative drive shown. Bolt (32 mm long) Lock washer Flat washer SCR Module Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 100: Install The Scr Modules

    Final Torque SK-20P-S727F 11…13 N m (97.4…115 lb SK-20P-S737F 11…13 N m (97.4…115 lb • • • • SK-20P-S770F 11…13 N m (97.4…115 lb SK-20P-S771F 11…13 N m (97.4…115 lb • • • • Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 101: Ac Current Transducers Removal And Installation

    4. Remove the eight screws and washers that secure the Lexan shields to the bottom of the drive and remove the shields. Remove screws and washers Remove screws and washers 5. Remove the power wiring from the U and W phase AC input power terminals. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 102 Transient noise filter board PE ground stud Remove ground wire Remove screw and wire 7. Remove the lower screw that secures the left side AC current transducer to the U phase terminal. Remove screw Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 103 W phase power terminal (see next step). Remove screw and washer Remove screw and washer Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 104 (from the pulse transformer board) to W phase power terminal and remove the wire. Remove screw and wire 12. Remove the lower screw that secures the right side AC current transducer to the W phase power terminal. Remove screw and wire Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 105 Note: Left AC current transducer of regenerative drive shown. 14. Remove the upper screw that secures each of the AC current transducer to the U phase power terminal. Remove screw Note: Left AC current transducer of regenerative drive shown. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 106 U and W phase power terminals up and into the drive, slide the AC current transducers off of the terminal bus bars and out of the drive. Non-Regenerative drive Remove bolts, washers and terminal Slide AC Current Transducers off of bar Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 107: Install The Ac Current Transducers

    Remove Power from the Drive on page 3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page 4. Move the control EMI shield. See Move the Control EMI Shield on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 108 • 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. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 109 Lock washer Lock washer Flat washer Left to right, two (2) flat washers, lock washers Flat washer and nuts Left to right, two (2) flat washers and bolts Bolt (30mm long) (40mm long) Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 110 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 24mm long bolts and washers Leave wires in place Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 111 Remove the Bus Bars from a Non-Regenerative Drive 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 nuts, washers and wires Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 112 Remove bolts, lock washers, flat washers Bolt and Washer Order Left to right, bolts and flat washers Left to right, flat washers, lock washers and nuts Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 113 Mark all connections and wires before removal to avoid incorrect IMPORTANT wiring during reassembly. 2. Remove the gate leads that connect the SCR modules to the pulse transformer circuit board from the pulse transformer circuit board end. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 114 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 solder and bimetal thermostats Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 115: Install The Bimetal Thermostats

    Remove Power from the Drive on page 3. Remove the covers from the drive. See Remove the Protective Covers from the Drive on page 4. Move the control EMI shield. See Move the Control EMI Shield on page Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 116 Phase W bus bar 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. Remove screws Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 117 7. Remove the screw that secures the ground wire to the fan chassis and remove the ground wire. Remove screw and wire 8. Remove the loosened fan power supply wires from the terminal block and remove the fan. Remove wires from terminal block Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 118: Install The Cooling Fans

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

  • Page 119: Start Up After Repair

    • 175 [Rated Motor Volt] is set to the motor rated nameplate armature voltage. • 179 [Nom Mtr Arm Amps] is set to the rated motor nameplate armature current. • 280 [Nom Mtr Fld Amps] is set to the rated motor nameplate field current. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 120 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-TG003B-EN-P - September 2021...

  • Page 121: Schematics

    Figure 23 - Motor Thermal Protection Control Circuit Diagram Figure 24 - Drive Heatsink Monitoring Control Circuit Diagram Figure 25 - Contactor Control Relays Control Circuit Diagram Figure 26 - AC Line Snubber Circuit Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 122 Appendix A Schematics Figure 13 - Circuit Board Interconnection Diagram Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 123 Schematics Appendix A Figure 14 - Non-regenerative Drive Power Module Diagram Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 124 Appendix A Schematics Figure 15 - Regenerative Drive Power Module Diagram KG03 KG02 KG01 KG06 KG04 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 125 Appendix A Figure 16 - AC Line Measurement Points Diagram XY-22 XR-15 100K +15V -15V XY-21 XR-16 100K XY-18 XR-17 100K Figure 17 - Power Feedback Connections Diagram XR15 XR16 XR17 XR19 XR18 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 126 Appendix A Schematics Figure 18 - Field Board and SCR/Dual Diode Module Connections Diagram To Pulse Transformer Board X3 Connector X3-1 X3-2 100R 100R XFCD-3 XFCD-2 XFCD-4 XFCD-1 XP1-1 XP1-2 XP2-1 XP2-2 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 127 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 20 - Control Circuit Input Power Diagram 230 VAC 115 VAC To Switch Input Mode Power Supply (SMPS) Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 128 Figure 21 - Encoder Control Circuit Diagram +24V Voltage Regulator and Current Feedback Circuit Figure 22 - 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-TG003B-EN-P - September 2021...
  • Page 129 Figure 23 - Motor Thermal Protection Control Circuit Diagram +15V XR-32 Figure 24 - 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-TG003B-EN-P - September 2021...
  • Page 130 Appendix A Schematics Figure 25 - Contactor Control Relays Control Circuit Diagram 0V24 +24V Figure 26 - AC Line Snubber Circuit AC Line Snubber Board Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 131: Board Layouts And Connections

    Power Supply Filter Board to Pulse Transformer Board Connections Power Supply Filter Board to Switching Power Supply Board Connections Power Supply Filter Board to Fan Connections Transient Noise Filter Board Layout Transient Noise Board to Pulse Transformer Board Connections Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 132: Pulse Transformer Board

    Figure 27 - Pulse Transformer Board Layout FIR3-xx Rev. “L” and Lower FIR3-xx Rev. “M” and Higher KG06 KGO6 XCD_IO XUVW KG03 XUVW KGO3 KG05 KGO5 KGO2 KG02 KGO4 KG04 XI2CA KG01 KGO1 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 133 Current Transducer Description Board Connector Terminals . . . TA-U Secondary side CT phase U White . . . Black . . . TA-V Secondary side CT phase W Blue . . . Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 134 Table 28 Power Supply Filter Board to Pulse Transformer Board Connections on page 137. For connector XCD and XUVW signals, see Table 31 Transient Noise Board to Pulse Transformer Board Connections on page 138. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 135: Switching Power Supply Board

    ..+15V ..15V common ..-15V ..24V common . . . +24V Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 136: Control Board

    15V Common XFCD XFCD . . . -15V . . . Field CT burden resistors For connector XA signals, see Table 26 Switching Power Supply Board to Control Board Connections on page 135. Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 137: Field Power Board

    Description Filter Board Supply Board Connector Connector . . . Single phase 115V / 230V AC . . . (Not used) ..Single phase 115V / 230V AC Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 138 Board Connector . . . XUVW Phase U signal . . . Phase V signal . . . Phase W signal . . . Armature C signal . . . Armature D signal Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...

  • Page 139: 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-TG003B-EN-P - September 2021...

  • Page 140: 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-TG003B-EN-P - September 2021...

  • Page 141: 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-TG003B-EN-P - September 2021...

  • Page 142: 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-TG003B-EN-P - September 2021...

  • Page 143: Index

    53 cooling fans remove 52 install 118 inspection remove 115 visual 15 DC analog tachometer test 36 DIP switches S3, S4 69 download parameter configuration 14 DPI/HIM assembly install 43 remove 42 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 144 45 install 60 remove 43 remove 60 PTC 39 pulse transformer board configure 66 install 70 technical support remove 62 test 32 calling 40 relay outputs 39 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 145 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 visual inspection 15 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 146 Index Notes: Rockwell Automation Publication 20P-TG003B-EN-P - September 2021...
  • Page 147 PowerFlex Digital DC Drive - Frame C Hardware Service Manual Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description Provides basic information that is required to install, start up, and troubleshoot the PowerFlex Digital DC Drive User Manual, publication 20P-UM001 PowerFlex DC drive.
  • Page 148 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, expanding human possibility, Logix, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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