Rockwell Automation Allen-Bradley PowerFlex 20P Bedienungsanleitung

PowerFlex Digital DC Drive - Frame B

Catalog Numbers 20P

Hardware Service Manual

Original Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are

required to be carried out by suitably trained personnel in accordance with applicable code of practice.

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.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 3

Table of Contents

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 1

Before You Begin Testing,

Maintenance or Repairs

General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Commonly Used Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Software Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2

Component Test Procedures Save the Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Save to a HIM Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Visual Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshoot a Control Power Supply Failure . . . . . . . . . . . . . . . . . . . 15

Testing the Switching Power Supply and Pulse Transformer

Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Testing the Control and Field Board Connections . . . . . . . . . . . 16

Troubleshoot an AC Undervoltage Fault. . . . . . . . . . . . . . . . . . . . . . . . 19

Troubleshoot an Armature Bridge Failure . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshoot a Field Current Loss Fault . . . . . . . . . . . . . . . . . . . . . . . . 22

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Component Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Check the Armature SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . 26

Check the Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . 30

Check the Field SCR/Dual Diode Module . . . . . . . . . . . . . . . . . . 32

Speed Feedback Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Check the DC Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Check the Resolver Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 35

Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Create a Fault Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

What You Need When You Call Tech Support. . . . . . . . . . . . . . . . . . 38

4Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Table of Contents

Chapter 3

Part Replacement Procedures Replacement Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DPI / HIM Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Remove the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Install the DPI / HIM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Protective Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Remove the Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Install the Protective Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Communication Adapter and Electromagnetic Interference

Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Remove the Communication Adapter and Electromagnetic

Interference Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Install the Communication Adapter and EMI Shield . . . . . . . . . 47

Resolver Feedback and Interface Circuit Board Replacement. . . . . . 48

Remove the Resolver Feedback and Interface Circuit Boards . . 48

Install the Resolver Feedback and Interface Circuit Boards . . . . 51

I/O Expansion Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . 52

Remove the I/O Expansion Circuit Board . . . . . . . . . . . . . . . . . . . 52

Install the I/O Expansion Circuit Board. . . . . . . . . . . . . . . . . . . . . 53

115V AC to 24V DC I/O Converter Circuit Board

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Remove the 115V AC to 24V DC I/O Converter Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Install the 115V AC to 24V DC I/O Converter Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Remove the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 55

Install the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Control Electromagnetic Interference Shield Removal and

Closure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Move the Control Electromagnetic Interference Shield . . . . . . . 58

Close the Control EMI Shield in the Service Position. . . . . . . . . 59

Switching Power Supply Board Fuse Replacement . . . . . . . . . . . . . . . 60

Remove the Fuses on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Install the Fuses on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Pulse Transformer Circuit Board Fuse Replacement. . . . . . . . . . . . . . 62

Remove the Fuses on the Pulse Transformer Circuit Board. . . . 62

Install the Fuses on the Pulse Transformer Circuit Board . . . . . 62

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 5

Table of Contents

Pulse Transformer and Switching Power Supply Circuit Boards

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Remove the Pulse Transformer and Switching Power Supply

Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Configure the Pulse Transformer Circuit Board. . . . . . . . . . . . . . 69

Install the Pulse Transformer and Switching Power Supply

Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Field Circuit Fuses Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Remove the Field Circuit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Install the Field Circuit Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Field Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Remove the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Install the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Field SCR and Dual Diode Modules Replacement . . . . . . . . . . . . . . . 77

Remove the Field SCR and Dual Diode Modules. . . . . . . . . . . . . 77

Install the Field SCR and Dual Diode Modules . . . . . . . . . . . . . . 77

AC Line Snubber Circuit Board and Resistors Replacement . . . . . . 78

Remove the AC Line Snubber Circuit Board and Resistors. . . . 78

Install the AC Line Snubber Circuit Board and Resistors . . . . . 80

SCR Modules Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Remove the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Install the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

AC Current Transducers Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 90

Remove the AC Current Transducers . . . . . . . . . . . . . . . . . . . . . . . 90

Install the AC Current Transducers. . . . . . . . . . . . . . . . . . . . . . . . . 93

Bimetal Thermostats Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Remove the Bimetal Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Install the Bimetal Thermostats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Cooling Fan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Remove the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Install the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Chapter 4

Start-Up After Repair Test With the Motor, Without a Mechanical Load . . . . . . . . . . . . . 103

Appendix A

Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Appendix B

Circuit Board Layouts and

Connections

List of Circuit Board Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Switching Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Field Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

6Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Table of Contents

Appendix C

Flow Charts List of Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Control Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Field Current Loss Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 7

Preface

This manual contains component test and hardware replacement information

for PowerFlex® DC frame B drives, 40…300 Hp (30…224 kW).

This manual is intended for qualified service personnel responsible for

troubleshooting and repairing PowerFlex DC drives. You should have previous

experience with, and basic understanding of, electrical terminology,

procedures, required troubleshooting equipment, equipment protection

procedures and methods, and safety precautions.

It is highly recommended that you obtain a copy of the PowerFlex Digital DC

Drive User Manual, publication 20P-UM001, which contains fault/alarm and

programming information to assist you in troubleshooting drive errors and

determining if repairs are necessary. See Additional Resources on page 7for

information on related publications and how to obtain manuals.

Summary of Changes This manual contains new and updated information.

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page.

To order paper copies of technical documentation, contact your local

Allen-Bradley™ distributor or Rockwell Automation sales representative.

Topic Page

Updated the list of Additional Resources to include a link to the PowerFlex DC drive

spare parts list.

Added a table of spare parts kits to Chapter 3. 40

Resource Description

PowerFlex Digital DC Drive User Manual, publication

20P-UM001

Provides basic information that is required to install,

start-up, and troubleshoot the PowerFlex DC drive.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1

Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website, http://

www.rockwellautomation.com/global/certification/

overview.page

Provides declarations of conformity, certificates, and

other certification details.

PowerFlex DC Drive Spare Parts List, publication

PFLEX-SB003

Provides a current list of spare parts available for the

PowerFlex DC field controller.

8Rockwell Automation Publication 20P-TG002B-EN-P - February 2018

Preface

Notes:

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 9

Chapter 1

Before You Begin Testing, Maintenance or

Repairs

This chapter provides information you should know before you begin tests,

maintenance, or repairs on drive components.

Topic Page

General Safety Precautions 10

Hardware Description 11

Commonly Used Tools 12

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

Chapter 1 Before You Begin Testing, Maintenance or Repairs

General Safety Precautions Read the following precautions before you begin testing components,

performing maintenance or repairing the drive.

ATTENTION: Only qualified personnel familiar with DC drives and associated

machinery should plan or implement the installation, start-up and

subsequent maintenance of the system. Failure to comply may result in

personal injury and/or equipment damage.

ATTENTION: This drive contains Electrostatic Discharge (ESD) sensitive parts

and assemblies. Static control precautions are required when installing,

testing, servicing or repairing this assembly. Component damage may result if

ESD control procedures are not followed. If you are not familiar with static

control procedures, reference A-B publication 8000-4.5.2, “Guarding Against

Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: Severe injury or death can result from electrical shock, burn, or

unintended actuation of controlled equipment. Hazardous voltages may exist

in the drive enclosure even with the circuit breaker in the off position.

Recommended practice is to disconnect and lock out control equipment from

power sources. If it is necessary to work in the vicinity of energized equipment,

the safety related work practices of NFPA 70E, Electrical Safety Requirements

for Employee Workplaces, must be followed. DO NOT work alone on energized

equipment.

ATTENTION: Potentially fatal voltages may result from improper usage of an

oscilloscope and other test equipment. The oscilloscope chassis may be at a

potentially fatal voltage if not properly grounded. If an oscilloscope is used to

measure high voltage waveforms, use only a dual channel oscilloscope in the

differential mode with X 100 probes. It is recommended that the oscilloscope

be used in the A minus B Quasi-differential mode with the oscilloscope chassis

correctly grounded to an earth ground.

ATTENTION: Remove power before making or breaking cable connections.

When you remove or insert a cable connector with power applied, an electrical

arc may occur. An electrical arc can cause personal injury or property damage

by:

• sending an erroneous signal to your system’s field devices, causing

unintended machine motion

• causing an explosion in a hazardous environment

Electrical arcing causes excessive wear to contacts on both the module and its

mating connector. Worn contacts may create electrical resistance.

ATTENTION: HOT surfaces can cause severe burns. Do not touch the heatsink

surface duringoperation ofthe drive. After disconnecting power allow time for

cooling.

Andere Handbücher für Allen-Bradley PowerFlex 20P

Inhaltsverzeichnis

Andere Rockwell Automation Gleichstromantrieb Handbücher

Rockwell Automation

Rockwell Automation Trusted TMR 24V DC Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 7000 Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755T Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex Active Front End... Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-BradleyPowerFlex 700H Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley DriveGuard B Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 6000 Kurzanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley IMPACT 1336 Series Programmierhandbuch

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 525 Bedienungsanleitung

Rockwell Automation

Rockwell Automation PowerFlex 40 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 700 B Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 7000 Bedienungsanleitung

Rockwell Automation

Rockwell Automation PowerFlex 7000 Bedienungsanleitung

Rockwell Automation

Rockwell Automation MD60 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 7000 Bedienungsanleitung

Rockwell Automation

Rockwell Automation RELIANCE ELECTRIC DC3N Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation PowerFlex 7000 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley 35E Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley 1397 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Reliance electric GV3000/SE Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 4 FKN6 Series Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 700 Bedienungsanleitung

Rockwell Automation

Rockwell Automation Allen-Bradley Kinetix 5700 Series Benutzerhandbuch

Beliebte Gleichstromantrieb Handbücher anderer Marken

Chamberlain Garog

Chamberlain Garog D Series Bedienungsanleitung

Parker

Parker PDS Series Bedienungsanleitung

Festo

Festo DGC G Series Einrichtungshandbuch

Binks

Binks QS-5012-1-CE Bedienungsanleitung

Danfoss

Danfoss VLT 2800 Series Technisches Datenblatt

ABB

ABB ACQ580-01 Series Installationshandbuch

YASKAWA

YASKAWA CANopen SI-S3 Bedienungsanleitung

GE D20A6 Bedienungsanleitung

Unex

Unex MC-D-250-1000-050W-TW Bedienungsanleitung

Geckodrive

Geckodrive G213V Bedienungsanleitung

ABB

ABB RSYC-01 Bedienungsanleitung

WEG

WEG DeviceNet CFW500 Bedienungsanleitung

Siemens

Siemens SINAMICS G Datenblatt

Siemens

Siemens SINAMICS SM150 6SL3815-7NP41-0AA1 Betriebsanleitung

SOMFY

SOMFY JR RU 30 Bedienungsanleitung

Beckhoff

Beckhoff AX8911 Bedienerhandbuch

Lenze

Lenze 8200 vector Bedienungsanleitung

Danfoss

Danfoss VLT DriveMotor FCP 106 Leitfaden