Rockwell Automation Allen-Bradley PowerFlex 20P User manual

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.
7
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.