Rockwell Automation Allen-Bradley PowerFlex 4M Bedienungsanleitung

PowerFlex Digital DC Drive -

Frame C

Bulletin Number 20P

Hardware Service Manual Original Instructions

2Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

PowerFlex Digital DC Drive - Frame C Hardware Service Manual

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-TG003B-EN-P - September 2021 3

Table of Contents

Preface

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

Chapter 1

Before You Begin Testing,

Maintenance, or Repairs

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

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

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

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

Chapter 2

Component Test Procedures Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Save the Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

Download Parameters to an Offline Node File . . . . . . . . . . . . . . . 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 . . . . . . . . . . . 17

Troubleshoot an AC Undervoltage Fault. . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshoot an Armature Bridge Failure . . . . . . . . . . . . . . . . . . . . . . . 21

Troubleshoot a Field Current Loss Fault . . . . . . . . . . . . . . . . . . . . . . . . 23

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Component Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check the Armature SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . 27

Check the Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . 32

Check the Field SCR/Dual Diode Module . . . . . . . . . . . . . . . . . . 33

Speed Feedback Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Check the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Check the DC Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Check the Resolver Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 37

Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Create a Fault Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

What You Need When You Call Tech Support. . . . . . . . . . . . . . . . . . 40

Chapter 3

Access Procedures Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DPI / HIM Assembly Removal and Installation . . . . . . . . . . . . . . . . . 42

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

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

Protective Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 43

Remove the Protective Covers from the Drive. . . . . . . . . . . . . . . . 43

4Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

Table of Contents

Install the Protective Covers on the Drive . . . . . . . . . . . . . . . . . . . 45

Field Circuit Fuses Removal and Installation . . . . . . . . . . . . . . . . . . . . 45

Remove the Field Circuit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Install the Field Circuit Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Communication Adapter and EMI Shield Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Remove the Communication Adapter and EMI Shield . . . . . . . 46

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

Resolver Feedback and Interface Circuit Board Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Remove the Resolver Feedback and Interface Circuit Boards . . 48

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

I/O Expansion Circuit Board Removal and Installation . . . . . . . . . . 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 Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Removal and Installation. . . . . . . . . . . . . . . . . 55

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

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

Control EMI Shield Removal and Closure . . . . . . . . . . . . . . . . . . . . . . 58

Move the Control EMI Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Install the Control EMI Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Switching Power Supply Circuit Board Fuse Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Remove the Fuses on the Switching Power Supply Circuit

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

Install the Fuses on the Switching Power Supply Circuit

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

Switching Power Supply Circuit Board Removal and Installation. . 61

Remove the Switching Power Supply Circuit Board . . . . . . . . . . 61

Install the Switching Power Supply Circuit Board . . . . . . . . . . . . 62

Pulse Transformer Circuit Board Removal and Installation . . . . . . . 62

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

Configure the Pulse Transformer Circuit Board. . . . . . . . . . . . . . 66

Install the Pulse Transformer Circuit Board . . . . . . . . . . . . . . . . . 70

Field Power Circuit Board Removal and Installation . . . . . . . . . . . . . 71

Remove the Field Power Circuit Board . . . . . . . . . . . . . . . . . . . . . . 71

Install the Field Power Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . 72

Field SCR and Dual Diode Module Removal and Installation. . . . . 72

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 5

Table of Contents

AC Line Snubber Circuit Board and Resistors Removal and Installation

Remove the AC Line Snubber Circuit Board and Resistors. . . . 74

Install the AC Line Snubber Circuit Board and Resistors . . . . . 81

Transient Noise Filter Circuit Board Fuses Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Remove the Fuses on the Transient Noise Filter Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Install the Fuses on the Transient Noise Filter Circuit Board . . 82

Transient Noise Filter Circuit Board Removal and Installation. . . . 82

Remove the Transient Noise Filter Circuit Board . . . . . . . . . . . . 82

Install the Transient Noise Filter Circuit Board . . . . . . . . . . . . . . 86

Power Supply Filter Circuit Board Removal and Installation . . . . . . 86

Remove the Power Supply Filter Circuit Board. . . . . . . . . . . . . . . 86

Install the Power Supply Filter Circuit Board . . . . . . . . . . . . . . . . 88

Armature Leg Fuses Removal and Installation . . . . . . . . . . . . . . . . . . . 89

Remove the Armature Leg Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Install the Armature Leg Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

SCR Modules Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . 93

Remove the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Install the SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

AC Current Transducers Removal and Installation . . . . . . . . . . . . . 101

Remove the AC Current Transducers . . . . . . . . . . . . . . . . . . . . . . 101

Install the AC Current Transducers. . . . . . . . . . . . . . . . . . . . . . . . 107

Bimetal Thermostats Removal and Installation . . . . . . . . . . . . . . . . . 107

Remove the Bimetal Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Install the Bimetal Thermostats. . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Cooling Fans Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 115

Remove the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Install the Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Chapter 4

Start Up After Repair Test With the Motor, Without a Mechanical Load . . . . . . . . . . . . . 119

Appendix A

Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Appendix B

Board Layouts and Connections List of Board Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Switching Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Field Power Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

Table of Contents

Appendix C

Flow Charts List of Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Control Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Field Current Loss Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 7

Preface

This manual contains component test and hardware replacement information

for PowerFlex® DC frame C drives, 150…500 Hp (112…373 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 147 for

information on related publications and how to obtain manuals.

Summary of Changes This manual contains new and updated information.

Topic Page

Added a note to the procedure Troubleshoot an Armature Bridge Failure. 21

Changed values in the table Armature Pulse/Snubber Circuit Measurements for Non-Regenerative Drives. 32

Changed the procedure Check the Field SCR/Dual Diode Module. 33

Added the Non-regenerative Drive Power Module Diagram. 123

Added the Regenerative Drive Power Module Diagram. 124

8Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

Preface

Notes:

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 9

Chapter 1

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 10

Hardware Description 11

Commonly Used Tools 12

10 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021

Chapter 1 BeforeYou BeginTesting, 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, startup, and subsequent

maintenance of the system. Failure to comply may result in personal injury and/

or equipment damage.

ATTENTION: This drive contains ESD (Electrostatic Discharge) 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

EmployeeWorkplaces, 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: Removepower 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 during operation of the drive. After disconnecting power allow time for

cooling.

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