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

Rockwell Automation Allen-Bradley PowerFlex 20P Hardware Service Manual

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

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

  • Page 1 PowerFlex Digital DC Drive-Frame A 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 I/O Expansion Circuit Board Replacement........56 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 4 Field Board............. . 128 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 5 Additional Resources ........... . . 137 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 6 Table of Contents Notes: Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 7 Catalog Number SK-20P-S5RPI, now has a Series B, which has been added to this publication; connections and terminals between series A and B are in the same locations except for components and test points, refer to images on page 62 for more details. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 8 Preface Notes: Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 9 This chapter provides information you should know before you begin tests, maintenance, or repairs on drive components. General Safety Precautions Read the following precautions before you begin testing components, performing maintenance or repairing the drive. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 10 The field supply consists of single phase, full wave rectified bridge. Also associated with the power structure, are incoming line protection devices and contactor and dynamic brake control circuits. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 11 7 x 2 mm Flat nose #1, 2, 3 Phillips Hexagonal wrench #4, 5, 6 ESD-protected place of work Working surface, Floor covering, seat and ground connections ESD-protective clothing Wrist wrap, shoes, overall clothing (coat) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 12 Before You Begin Testing, Maintenance, or Repairs 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-TG001E-EN-P - February 2025...
  • Page 13 Save to a HIM Set Follow these steps to save the drive and adapter parameters to a HIM set. 1. On the HIM, access the Memory Storage menu. 2. Select the HIM CopyCat menu and press Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 14 +12V for DPI expansion 0VEXP 0VEXP Figure 3 on page XP3-7 / XP3-8 / XP3-9 DPI expansion ground For a flow chart version of the steps that follow, see Control Power Supply Failure on page 130. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 15 5. Use an ohmmeter to measure between pins 1 and 2 and pins 3 and 2 on the XFCD cable connector on the field circuit board, if installed. Resistance measurements greater than 200 kΩ are expected for both tests. If a lower resistance value is measured, replace field board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 16 11 12 13 14 15 16 17 18 19 20 - A B C + A+ A- B+ B- Z+ Z- COM +V 9 10 11 12 13 14 15 16 17 18 19 20 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 17 Chapter 2 Component Test Procedures Figure 2 - Series B Control Board Testpoints - Upper Left Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 18 11 12 13 14 15 16 17 18 19 20 - A B C + A+ A- B+ B- Z+ Z- COM +V 9 10 11 12 13 14 15 16 17 18 19 20 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 19 Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. 1. Read the General Safety Precautions on page 9. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 20 XY22 … XY18 575V AC 2.85V AC 1.007V V and W XY21 … XY18 V and U XY22 … XY18 690V AC 3.45V AC 1.220V V and W XY21 … XY18 Series A Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 21 Follow Safety related practices of NFPA 70E, ELECTRICAL SAFETY FOR EMPLOYEE WORKPLACES. 1. Read the General Safety Precautions on page 9. 2. Remove the protective covers from the drive (see page 47). Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 22 – The voltage signal is taken on the testpoint XY19 (+2.5V offset). – The ground signal is taken on either testpoint XY10 or XY18. Figure 5 - Good SCR Gate Pulse and Armature Current Signals Example XY19 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 23 – The current signal is taken on the testpoint XY17 (+2.53V offset; +0.6V=Drive size current). – The voltage signal is taken on the testpoint XY19 (+1.5V offset). – The ground signal is taken on either testpoint XY10 or XY18. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 24 A malfunctioning thyristor is connected to the relative gate. For example, if the tested signal is at XR25 and the positive bridge is active (MP high) from the following figure you can deduce that SCR connected to gate G6 is open. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 25 2 A and the motor is rated for 1.5 A, the measurement at LA-LB will be 1.245V DC (1.5 / x = 2 / 1.66). • If the voltage measurement is incorrect, continue with step 7. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 26 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 29 on page location of the XR connector on the control board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 27 • If the gate signals are missing, replace the control board. • If the gate signals are present, replace the field board. Power Component Test Follow the applicable procedure for the affected power components. Procedures Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 28 (see SCR Module Replacement on page 95). Table 1 - SCR Anode to Cathode Junction Measurements for Regenerative Drives Measure from On SCR Module To Terminal Nominal Meter Reading Terminal “open circuit” or “MΩ” range Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 29 SCR Module 02 SCR Module 01 Table 2 - SCR Anode to Cathode Junction Measurements for Non-regenerative Drives Measure from On SCR Module To Terminal Nominal meter Reading Terminal “open circuit” or “MΩ” range Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 30 Pin 5 Pin 4 Pin 6 Pin 7 Pin 5 Pin 4 (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-TG001E-EN-P - February 2025...
  • Page 31 SCR modules. One of the following can indicate a Transformer Board malfunction of these modules: • An Overcurrent fault (F13) • Blown or tripped incoming protection devices Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 32 XV on the switching power supply board and remove the plate. Remove Screws PowerFlex DC Drive Shown Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 33 Table 5 - Armature Pulse/Snubber Circuit Measurements for Regenerative Drives Measure For SCR To… Meter Reading Connector XY Pinout from… XY-4 XY-1 XY-5 XY-2 XY-6 XY-3 “open circuit” KG01 XY-1 KG04 XY-4 KG02 XY-2 KG05 XY-5 KG03 XY-3 KG06 XY-6 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 34 If a measurement results in an “infinity” reading, check the fuses at FV1 and FU1 on the bottom of the drive to determine if they are open. See Figure 10 on page 35. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 35 See “DIP Switch and Jumper Settings” in the PowerFlex Digital DC Drive User Manual, publication 20P-UM001). The encoder power supply from the drive can be measured from +V (+) to Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 36 If any of the applicable LEDs fail to turn on when control power is applied, verify that the resolver interface and resolver feedback boards are properly seated on the appropriate connectors (XRE, P2, P3). If problems persist, replace the resolver interface and/or resolver feedback board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 37 Figure 15 - 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-TG001E-EN-P - February 2025...
  • Page 38 What You Need When You When you contact Technical Support, please be prepared to provide the following information: Call Tech Support • Order number • Product catalog number and drive series number (if applicable) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 39 Captures and displays the field current (as a percentage of 1373 Fault Field Amps rated current) at the time of the last fault. Captures and displays the armature voltage at the time of the 1374 Fault Voltage last fault. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 40 Chapter 2 Component Test Procedures Notes: Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 41 DPI / HIM Assembly SK-DC1-CVR1-A1 Upper Cover SK-20P-S75BT Lower Cover SK-20P-S77BT Control Circuit Boards Resolver Feedback and Interface Boards 20P-RES-A0 I/O Expansion Board (TBO-32) 20P-S5V62 115V AC to 24V DC I/O Converter Board 20P-S520L Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 42 Bimetal Thermostat 80 °C ±3 °C for 230V AC Drive, 93…110 A SK-20P-S7GA1 Bimetal Thermostat 80 °C ±3 °C for 460/480V AC Drive, 100…129 Bimetal Thermostat 70 °C ±3 °C for 460/480V AC Drive, 86 A SK-20P-S7GA0 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 43 • causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector. Worn contacts can create electrical resistance. • Remove and lock-out all incoming power to the drive. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 44 Remove the Field Circuit Fuses Replacement Follow these steps to remove the field circuit fuses. 1. Read the General Safety Precautions on page 9. 2. Remove power from the drive (see page 43). Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 45 3. Press downward on the tab at the top of the HIM assembly and, by pressing upward at the bottom, slide the HIM out of the cradle. 4. Disconnect the DPI cable from the HIM assembly. 5. Remove the screw that secures the DPI / HIM assembly to the drive. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 46 PORT NET A NET B Tightening torque: 0.8 N•m (7 lb•in) Install the DPI / HIM Assembly on the Protective Cover Install the DPI / HIM assembly in reverse order of removal. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 47 Tightening torque: 1.0 N•m (8.9 lb•in) 4. Disconnect the DPI cable from the HIM assembly. 5. Remove the two screws that secure the bottom protective cover to the drive. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 48 The HIM assembly is connected via a cable to the control board and therefore will not pull free from the drive until disconnected. See step 10 for instructions. 8 and 9 PORT NET A NET B Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 49 2. Remove power from the drive (see page 43). 3. Disconnect the interface cable from the communication adapter and set it aside. 4. Disconnect any network cables from the adapter and set them aside. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 50 Tightening torque: \ 0.9 N•m (8 lb•in) 6. Remove the three screws that secure the EMI shield to the stand-offs on the control board and remove the EMI shield. Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 51 7. Remove the three stand-offs from the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Install the Communication Adapter and EMI Shield Install the communication adapter and EMI shield in reverse order of removal. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 52 3. Remove the protective covers (see page 47). 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 XFCD Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 53 P2 and P3. Lift the resolver feedback board straight up during removal to avoid any damage to the connector pins. XFCD Tightening torque for reassembly is 0.7 N•m (6.2 lb•in) 6. Remove the three stand-offs from the resolver interface board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 54 Chapter 3 Part Replacement Procedures Resolver interface board XFCD Tightening torque for reassembly is 0.7 N•m (6.2 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 55 XFCD Tightening torque for reassembly is 0.7 N•m (6.2 lb•in) Install the Resolver Feedback and Interface Circuit Boards Install the resolver feedback and interface boards in reverse order of removal. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 56 5. Remove the plug-in I/O terminal blocks with the wiring kept in place. 6. Remove the two M3 x 6 mm screws and washers that secure the I/O expansion board to the stand-offs on the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 57 8. Remove the two stand-offs from the control board. Tightening torque: 1.0 N•m (8.9 lb•in) 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•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 58 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-TG001E-EN-P - February 2025...
  • Page 59 5. Remove the communication adapter and EMI shield from the control board (see page 49). 6. If installed, remove the I/O expansion circuit board (see page 56). 7. If installed, remove the 115V AC to 24V DC I/O converter circuit board (see page 58). Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 60 12…15V ❾ When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch. ENC_5 +5V encoder (2.5…5.4V input range) ENC_12 +12…15V encoder (+5.4V…15.2V input range) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 61 When control power is supplied to the drive, the appropriate LED lights to indicate the selection of the switch. Position On +12…15V encoder (+5.4V…15.2V input range) Position Off +5V encoder (2.5…5.4V input range) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 62 10. Remove the plug-in I/O and control terminal blocks with the wiring kept in place. Communication adapter and optional boards not shown. Series A Communication adapter and optional boards not shown. Series B Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 63 11. Remove the five M3 x 6 mm screws and washers that secure the control board to the control EMI shield and remove the control board. Tightening torque: 1.0 N•m (8.9 lb•in) Series A Tightening torque: 1.0 N•m (8.9 lb•in) Series B Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 64 4. Carefully disconnect the cables from connectors XFCD, XA, and XR on the control board. 5. Remove the plug-in I/O, analog tachometer, and encoder terminal blocks with the wiring kept in place (if used). Communication adapter and optional boards not shown. Series A Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 65 7. Slide the control EMI shield and control board up and out of the drive. IMPORTANT Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the pulse transformer circuit board below the EMI shield. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 66 Chapter 3 Part Replacement Procedures Tightening torque: 1.0 N•m (8.9 lb•in) Series A Tightening torque: 1.0 N•m (8.9 lb•in) Series B Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 67 • Remove the fan cable from connector XV on the switching power supply board and remove the plate. Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 68 IMPORTANT Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 6. Remove the plug-in control power terminal block from the lower right corner of the pulse transformer circuit board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 69 “Q” and higher, remove the connector from XCD_10 on the upper left corner of the board. XSW1 XCD_10 9. Remove the plastic screw near the top of the pulse transformer board and retain for reuse. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 70 DO NOT pull the gate leads off by pulling on the wires. 11. Remove the cable from connectors XTA on the lower right side of the board. 10: Regenerative drives 10: Non-regenerative drives Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 71 Take care not to damage these cables and connectors. Tightening torque: 1.0 N•m (8.9 lb•in) Regenerative drive shown Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 72 Tightening torque: 1.0 N•m (8.9 lb•in) 16. Remove the plastic stand-off and nut that secures the switching power supply board to the back of the pulse transformer board. Secure nut Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 73 See Table 13 Table 14 in the Sizing Resistor Configuration section on page for the appropriate configuration. Sizing resistors are on the lower right corner of the pulse transformer circuit board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 74 27.4 Ω Remove Remove – 59.6 Remove 27.4 Ω 39.2 Ω Remove – 70.3 Remove Remove Remove 6.98 Ω – 81.7 Remove Remove Remove 6.98 Ω – 105.4 Remove Remove Remove 6.98 Ω – Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 75 1 ....13 ....33 corner of the pulse transformer circuit board. The TA potentiometer is on the lower right corner of the pulse transformer circuit board next to the control power terminal block. Shown sealed. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 76 12.24 105.4 9.488 3. Seal the TA potentiometer in place using RTV (silicon). 4. Continue with Install the Configured Pulse Transformer Circuit Board and the Switching Power Supply Circuit Boards on page 79. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 77 460V AC Input Drives on page 78. XSW1 XCD_IO KGO5 KGO6 KGO1 KGO4 KGO3 KGO2 KG1 KG4 KG2 KG5 KG3 KG6 DIP Switches S4 and S3 78 79 35 36 75 76 U2 V2 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 78 S4-2 S4-3 S4-4 S4-5 S4-6 S4-7 S4-8 Rating Amps Code 11.4 15.5 22.1 28.6 36.8 42.5 59.6 70.3 81.7 105.4 2. Continue with Install the Configured Pulse Transformer Circuit Board and the Switching Power Supply Circuit Boards. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 79 - 230V AC input: 73 A / 20 Hp and higher - 460V AC input: 73 A / 40 Hp and higher See AC Current Transducers on Drives with Bus Bars on page 82. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 80 AC current transducers from the drive. AC current Tightening torque: transducers 0.5 N•m (4.4 lb•in) Non-regenerative drive shown 8. Continue with Install the AC Current Transducers on page 84. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 81 However, note the position and number of wire lead windings for proper installation of the new AC current transducers. Tightening torque: 0.5 N•m (4.4 lb•in) 12. Continue with Install the AC Current Transducers on page 84. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 82 14. Remove the M4 x12.5 mm screws and washers that secure each of the AC current transducers to the U and V Phase terminal bus bars. Tightening torque: 3.0 N•m (26.5 lb•in) U Phase bus bar V Phase bus bar Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 83 • For Regenerative drives, remove the top and bottom screws and washers that secure the connecting bus bars and U and V phase terminal bus bars to the SCR modules and remove the connecting bus bars. Tightening torque: 2.5…4 N•m (22…35.4 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 84 • Wind the wires in the same position as the wires on the old AC current transducers • Crimp the connection lugs onto the wire leads before they are secured to the power traces board. Crimp connection lug onto wire ends Wrap wire around AC Current Transducer Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 85 5. Remove the control EMI shield and control board (see page 64). 6. Remove the pulse transformer and switching power supply circuit boards (see page 67). 7. Remove the six stand-offs (and the ground wire) from the power traces circuit board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 86 Non-Regenerative drive with AC current transducers with connection bars Tightening torque: 2.5 N•m (22.0 lb•in) Regenerative drive with AC current transducers with connection bars Tightening torque: 2.5 N•m (22.0 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 87 • Turn the board over and remove the two screws and washers that secure the AC current transducers to the board. • Remove the AC current transducers and windings (if present) from the drive. IMPORTANT You do not need to remove the windings from the AC current transducers. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 88 7. Remove the two M5 x 10 mm screws and washers that secure the field SCR/dual diode module to the drive heat sink and remove the module. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 89 Chapter 3 Part Replacement Procedures Tightening torque: 2.5 N•m (22.0 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 90 10. Remove the two M4 x 12 mm screws that secure the bottom air flow plate to the power terminal isolation strip. Tightening torque: 1.2 N•m (10.6 lb•in) Drive with fan shown. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 91 The bottom air flow plate on a frame A drive with a fan are secured to the chassis with six screws. Tightening torque: 3.0 N•m (26.5 lb•in) Tightening torque: 3.0 N•m (26.5 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 92 There is an isolation sheet below the board; do not remove this sheet unless it is damaged. Field circuit board Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 93 Wire Description Signal Thick brown To field circuit Thick red To field circuit board board Thick blue To field circuit Thin red board Thick black To field circuit Thin black board Thin blue Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 94 1.0 N•m (8.9 lb•in) Install the Bimetal Thermostat Install the thermostat in reverse order of removal. IMPORTANT Thermal grease must be applied to the bottom of the thermostat before securing it to the heatsink. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 95 73 A/40 Hp with 460V AC input and higher, see SCR Modules on Drives Rated 73 A/20 Hp with 230V AC Input and Higher or 73 A/40 Hp with 460V AC Input and Higher on page 97. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 96 7. Remove the two screws and washers that secure each SCR module to the heat sink and remove the SCR modules. Non-Regenerative drive Regenerative drive Continue with Install the SCR Modules on page 103. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 97 9. Remove the M5 x 10 mm screws that secure the U, V, W, C, and D terminal bus bars to the power terminal isolation strip at the bottom of the drive. Tightening torque: 2.5 N•m (22.0 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 98 The screws that secure these bus bars to the SCR modules are M5 x 16. Retain for reuse with these bus bars only. Connecting bus bars U Phase bus bar V Phase bus bar W Phase bus bar Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 99 C and D terminal bus bars. IMPORTANT For regenerative drives only, the screws that secure these bus bars to the SCR modules are M5 x 16. Retain for reuse with these bus bars only. Non-Regenerative drive Regenerative drive Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 100 Chapter 3 Part Replacement Procedures 12. Remove the screws and washers that secure the connecting bus bars to the SCR modules and remove the bus bars. Non-Regenerative drive Regenerative drive Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 101 Chapter 3 Part Replacement Procedures 13. For non-regenerative drives only, remove the screws and washers that secure the U, V, and W terminal bus bars to the SCR modules and remove the bus bars. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 102 Chapter 3 Part Replacement Procedures 14. Remove the screws and washers that secure each SCR module to the heat sink and remove the SCR modules. Non-Regenerative drive Regenerative drive Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 103 35 A/20 Hp, 45 A/25 Hp, and 52 A/30 Hp with 460V AC Input on page 104. • See Cooling Fan on Drives Rated 73 A / 20 Hp with 230V AC Input and 73 A / 40 Hp with 460V AC Input on page 105. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 104 5. Remove the twoM4 x 12.5 mm screws that secure the fan and spacers to the air flow plate and remove the fan. Tightening torque: 3.0 N•m (26.5 lb•in) Continue with Install the Cooling Fan on page 107. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 105 6. Loosen the two screws that secure the power terminal cover to the drive and slide the cover down and off the chassis. 7. Remove the field terminal block. 8. If necessary, remove the power wiring from the drive terminals. Tightening torque: 1.0 N•m (8.9 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 106 12. Disconnect the (black and red) wires from the fan terminal block on the air flow plate. Tightening torque: Tightening torque: 3.0 N•m (26.5 lb•in) 3.0 N•m (26.5 lb•in) Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 107 For drives with a fan that is connected to the top air flow plate, verify that the two spacers are properly placed during installation. Spacers Top of Drive Air Flow Plate Air flow arrow must point toward top of drive Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 108 Chapter 3 Part Replacement Procedures Notes: Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 109 8. Measure the field current and verify that the value is reflected in parameter 234 [Fld Current Pct]. 9. Run the following applicable Autotune procedures detailed in Chapter 2 of the PowerFlex® Digital DC Drive User Manual, publication 20P-UM001. • Tune the Current Regulator Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 110 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-TG001E-EN-P - February 2025...
  • Page 111 - DC Tachometer Control Circuit Diagram Figure 28 - Motor Thermal Protection Control Circuit Diagram Figure 29 - Drive Heat Sink Monitoring Control Circuit Diagram Figure 30 - Contactor Control Relays Control Circuit Diagram Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 112 Appendix A Schematics Figure 16 - Drive Interconnection Diagram Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 113 Appendix A Schematics Figure 17 - Non-regenerative Drive Power Module Diagram KG03 KG02 KG01 KG06 KG04 KG05 Figure 18 - Regenerative Drive Power Module Diagram Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 114 Appendix A Schematics KG03 KG02 KG01 KG06 KG04 KG05 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 115 *Note *Note XR17 *Note: 6 x 665 kohm resistors 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 1 M0 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 116 Figure 22 - SCR to Pulse Transformer Board Gate Lead Pinout - Non-regenerative Drive Diagram SCR Module 01 SCR Module 02 SCR Module 03 G01 K01 K04 G04 G02 K02 K05 G05 G03 K03 K06 G06 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 117 XFCD -2 10 uF XFCD -3 To Motor Field Connections Figure 24 - 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-TG001E-EN-P - February 2025...
  • Page 118 V 91 1 C 2 1 D 2 230V AC or To Switch Mode Power 115V AC input Supply (SMPS) Figure 26 - Encoder Control Circuit Diagram +24V Voltage Regulator and Current Feedback Circuit Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 119 Figure 27 - DC Tachometer Control Circuit Diagram S4-8 S4-7 S4-6 S4-5 M3 - TACHOP M3 + S4-1 S4-3 S4-4 Figure 28 - Motor Thermal Protection Control Circuit Diagram +24V Overtemp Fault Signal Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 120 Figure 29 - Drive Heat Sink 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 30 - Contactor Control Relays Control Circuit Diagram 0V24 +24V Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 121 Switching Power Supply Board Layout Switching Power Supply to Fan Connections Switching Power Supply Board to Control Board Connections Control Board Layout Control Board to Field Board Connections Series A Field Board Layout Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 122 Pulse Transformer Board Figure 31 - 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-TG001E-EN-P - February 2025...
  • Page 123 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-TG001E-EN-P - February 2025...
  • Page 124 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-TG001E-EN-P - February 2025...
  • Page 125 … SMPS supply input undervoltage … … +15V … … 15V common … … -15V … … 24V common … +24V See Pulse Transformer Board to Switching Power Supply Connections on page 123. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 126 +15V … 15V Common … -15V … Field CT burden resistors See Pulse Transformer Board to Control Board Connections on page and Switching Power Supply Board to Control Board Connections on page 125. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 127 +15V … 15V Common … -15V … Field CT burden resistors See Pulse Transformer Board to Control Board Connections on page and Switching Power Supply Board to Control Board Connections on page 125. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 128 Field fuse connections terminal block See Control Board to Field Board Connections Series A on page Control Board to Field Board Connections Series A and Pulse Transformer Board to Field Board Connections on page 123. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 129 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-TG001E-EN-P - February 2025...
  • Page 130 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-TG001E-EN-P - February 2025...
  • Page 131 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/ Replace the field dual diode module. board. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 132 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-TG001E-EN-P - February 2025...
  • Page 133 2018 Change Updated the list of Additional Resources to include a link to the PowerFlex DC drive spare parts list. Added a table of spare part kits and catalog numbers to Chapter 3. Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 134 Appendix D History of Changes History of Changes Notes: Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 135 88 DriveExecutive™ software 12 protective covers 49 pulse transformer board 73 SCR modules 103 switching power supply board 73 Electrostatic Discharge Precaution 10 switching power supply fuse 44 encoder test 35 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 136 85 protective covers 47 pulse transformer board 67 SCR modules 95 switching power supply board 67 switching power supply board fuse 44 safety precautions 9 save parameter configuration 13 schematic diagrams 111 Rockwell Automation Publication 20P-TG001E-EN-P - February 2025...
  • Page 137 PowerFlex Digital DC Drive - Frame A Hardware Service Manual Additional Resources These documents contain additional information concerning related products from Rockwell Automation. You can view or download publications at rok.auto/literature. Resource Description Provides basic information that is required to install, start up, and troubleshoot the...
  • Page 138 At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, Connected Components Workbench, DriveExecutive, expanding human possibility, PowerFlex, and Rockwell Automation, are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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