Rockwell Automation Allen-Bradley PowerFlex 20P Bedienungsanleitung

PowerFlex Digital DC Drive -

Frame D

Bulletin Number: 20P

Hardware Service Manual Original Instructions

2Rockwell Automation Publication 20P-TG004C-EN-P - September 2021

PowerFlex Digital DC Drive - Frame D 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-TG004C-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

Save Parameters to a Project File Using Connected

Components Workbench Software . . . . . . . . . . . . . . . . . . . . . . . . . 15

Save Parameters to an Offline Node File Using DriveExecutive

Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Visual Component Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Troubleshoot a Control Power Supply Failure . . . . . . . . . . . . . . . . . . . 17

Testing the Switching Power Supply and Pulse Transformer

Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Testing the Control and Field Board Connections . . . . . . . . . . . 19

Troubleshoot an AC Undervoltage Fault. . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshoot an Armature Bridge Failure . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshoot a Field Current Loss Fault . . . . . . . . . . . . . . . . . . . . . . . . 25

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Power Component Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Check the Armature SCR Modules . . . . . . . . . . . . . . . . . . . . . . . . . 29

Check the Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . 33

Check the Field SCR/Dual Diode Module . . . . . . . . . . . . . . . . . . 34

Speed Feedback Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check the Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check the DC Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check the Resolver Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermistors and Thermal Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Create a Fault Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

What You Need When You Call Tech Support. . . . . . . . . . . . . . . . . . 41

Chapter 3

Access Procedures Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Remove Power from the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Field Circuit Fuse Removal and Installation . . . . . . . . . . . . . . . . . . . . . 45

4Rockwell Automation Publication 20P-TG004C-EN-P - September 2021

Table of Contents

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

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

DPI / HIM Assembly Removal and Installation . . . . . . . . . . . . . . . . . 46

Remove the DPI / HIM Assembly from the Protective Cover . 46

Install the DPI / HIM Assembly on the Protective Cover . . . . . 46

Protective Cover Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 47

Remove the Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Install the Protective Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Open and Close the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Open the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Close the Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Communication Adapter and EMI Shield Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Remove the Communication Adapter and EMI Shield . . . . . . . 50

Install the Communication Adapter and EMI Shield . . . . . . . . . 51

Switching Power Supply Fuse Removal and Installation . . . . . . . . . . 52

Remove the Fuse on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Install the Fuse on the Switching Power Supply Circuit

Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Resolver Feedback and Interface Circuit Board Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Remove the Resolver Feedback and Interface Circuit Boards . . 54

Install the Resolver Feedback and Interface Circuit Boards . . . . 57

I/O Expansion Circuit Board Removal and Installation . . . . . . . . . . 58

Remove the I/O Expansion Circuit Board . . . . . . . . . . . . . . . . . . . 58

Install the I/O Expansion Circuit Board. . . . . . . . . . . . . . . . . . . . . 59

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

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

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

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

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

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

Control Circuit Board Removal and Installation. . . . . . . . . . . . . . . . . 61

Remove the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . 61

Install the Control Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Switching Power Supply Circuit Board Removal and Installation. . 65

Remove the Switching Power Supply Circuit Board . . . . . . . . . . 65

Install the Switching Power Supply Circuit Board . . . . . . . . . . . . 66

Pulse Transformer Circuit Board Removal and Installation . . . . . . . 66

Remove the Pulse Transformer Circuit Board. . . . . . . . . . . . . . . . 66

Install the Pulse Transformer Board. . . . . . . . . . . . . . . . . . . . . . . . . 69

Field Circuit Board Removal and Installation. . . . . . . . . . . . . . . . . . . . 70

Remove the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Install the Field Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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

Remove the Field SCR and Dual Diode Modules. . . . . . . . . . . . . 72

Rockwell Automation Publication 20P-TG004C-EN-P - September 2021 5

Table of Contents

Install the Field SCR and Dual Diode Modules . . . . . . . . . . . . . . 73

Field Fuse Holder Removal and Installation . . . . . . . . . . . . . . . . . . . . . 74

Remove the Field Fuse Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Install the Field Fuse Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Fan Starting Capacitor Removal and Installation. . . . . . . . . . . . . . . . . 76

Remove the Fan Starting Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . 76

Install the Fan Starting Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Series A Fan Circuit Board Removal and Installation . . . . . . . . . . . . . 78

Remove the Series A Fan Circuit Board. . . . . . . . . . . . . . . . . . . . . . 78

Install the Series A Fan Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 78

Series B Fan Circuit Board Removal and Installation . . . . . . . . . . . . . 79

Remove the Series B Fan Circuit Board. . . . . . . . . . . . . . . . . . . . . . 79

Install the Series B Fan Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 79

Series A Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . . 80

Remove the Series A Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 80

Install the Series A Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Series B Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . . 82

Remove the Series B Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Install the Series B Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Series C Fan Assembly Removal and Installation . . . . . . . . . . . . . . . . . 84

Remove the Series C Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 84

Install the Series C Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

AC Current Transducers Removal and Installation . . . . . . . . . . . . . . 86

Remove the AC Current Transducers . . . . . . . . . . . . . . . . . . . . . . . 86

Install the AC Current Transducers. . . . . . . . . . . . . . . . . . . . . . . . . 89

Overvoltage Clipping Circuit Board Fuse Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Remove the Overvoltage Clipping Circuit Board Fuses . . . . . . . 90

Install the Overvoltage Clipping Circuit Board Fuses . . . . . . . . . 90

Overvoltage Clipping Circuit Board Removal and Installation . . . . 91

Remove the Overvoltage Clipping Circuit Board. . . . . . . . . . . . . 91

Install the Overvoltage Clipping Circuit Board. . . . . . . . . . . . . . . 92

Armature Leg Fuse Removal and Installation . . . . . . . . . . . . . . . . . . . . 92

Remove the Armature Leg Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Install the Armature Leg Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

SCR Module Leg Assembly Removal and Installation . . . . . . . . . . . . 94

Remove the SCR Module Leg Assembly . . . . . . . . . . . . . . . . . . . . . 94

Install the SCR Module Leg Assembly. . . . . . . . . . . . . . . . . . . . . . . 99

Bimetal Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . 100

Remove the Bimetal Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Install the Bimetal Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Discharge Resistors Removal and Installation . . . . . . . . . . . . . . . . . . . 100

Remove the Discharge Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Install the Discharge Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Inrush Limiting Resistor Removal and Installation . . . . . . . . . . . . . . 102

Remove the Inrush Limiting Resistor. . . . . . . . . . . . . . . . . . . . . . . 102

Install the Inrush Limiting Resistor . . . . . . . . . . . . . . . . . . . . . . . . 104

6Rockwell Automation Publication 20P-TG004C-EN-P - September 2021

Table of Contents

Snubber Capacitors Removal and Installation . . . . . . . . . . . . . . . . . . 104

Remove the Snubber Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Install the Snubber Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Snubber Resistors Removal and Installation . . . . . . . . . . . . . . . . . . . . 106

Remove the Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Install the Snubber Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Chapter 4

Start Up After Repair Test With the Motor, Without a Mechanical Load . . . . . . . . . . . . . 109

Appendix A

Schematics List of Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Appendix B

Circuit Board Layouts and

Connections

List of Circuit Board Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Pulse Transformer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Switching Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Field Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Overvoltage Clipping Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Appendix C

Flow Charts List of Flow Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Control Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Field Current Loss Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

No Field Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Low or Incorrect Field Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Appendix D

History of Changes 20P-TG004C-EN-P, September 2021 . . . . . . . . . . . . . . . . . . . . . . . . . 135

20P-TG004B-EN-P, October 2013. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Rockwell Automation Publication 20P-TG004C-EN-P - September 2021 7

Preface

This manual contains component test and hardware replacement information

for PowerFlex® DC frame D drives, 250…1400 Hp (186…1044 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 141 for

information on related publications and how to obtain manuals.

Summary of Changes This manual contains new and updated information in the following sections.

Topic Page

Added a note to the procedure Troubleshoot an Armature Bridge Failure. 23

Changed values in the table Armature Pulse/Snubber Circuit Measurements for Non-Regenerative Drives. 33

Changed the procedure Check the Field SCR/Dual Diode Module. 34

Changed figure in the procedure Remove the Field Circuit Fuses. 45

Changed figure in the procedure Remove the Fuse on the Switching Power Supply Circuit Board. 52

Changed figure in the procedure Remove the Switching Power Supply Circuit Board. 65

Changed figure in the procedure Remove the Pulse Transformer Circuit Board. 66

Changed figure in the procedure Remove the Field Circuit Board. 70

Changed figure in the procedure Remove the Field Fuse Holder. 74

Added the section Series C Fan Assembly Removal and Installation. 84

Added the Block Diagram of Non-regenerative Drive Power Module with Six Fuses. 113

Added the Block Diagram of Non-regenerative Drive Power Module with 12 Fuses. 114

Added the Block Diagram of Regenerative Drive Power Module with Six Fuses. 115

Added the Series C Fan Circuit Diagram. 122

8Rockwell Automation Publication 20P-TG004C-EN-P - September 2021

Preface

Notes:

Rockwell Automation Publication 20P-TG004C-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-TG004C-EN-P - September 2021

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, 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

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 during operation of the drive. After disconnecting power allow time for

cooling.

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