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.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 11
Before You Begin Testing, Maintenance or Repairs Chapter 1
Hardware Description The PowerFlex® DC drive contains a power structure that has an armature and
field supply. The armature supply consists of a three–phase, full wave rectified,
dual bridge, capable of two or four quadrant output. 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.
Verify that you are working on a frame B drive by checking the data nameplate
located on the side of the drive. The frame size is printed just above the serial
number in the lower right corner of the label.
.0/0.5A 1 Phase
Frame: B
Serial Number: B23E0042

12 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018
Chapter 1 Before You Begin Testing, Maintenance or Repairs
Commonly Used Tools Service Tools
This list of basic service tools which will cover needs of tools for repair and
maintenance measurements.
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.
Item Details
Digital multimeter Digital multimeter, capable of AC and DC voltage, continuity, resistance, and
forward diode bias tests. Fluke model 87 III or equivalent (recommended).
Oscilloscope Portable, digitizing, dual channel scope, with isolation
Current clamp 3x drive rated armature current output
Soldering station Soldering / de soldering
Torque wrench 1…12 N•m
Torque wrench 6…50 N•m
Box wrench 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm
Socket extension 230 mm
Wrench 7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm
Wire cutter
Nose pliers
Crimping tools For cable terminals 1.5…240
Angle wrench
Screw drivers:
Flat nose 7 x 2 mm
Hexalobular T15, T20, T25
Phillips #1, 2, 3
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-TG002B-EN-P - February 2018 13
Chapter 2
Component Test Procedures
This chapter provides general procedures for inspecting and testing the major
components of the drive and includes recommendations for repairs. Due to the
technical nature of this product and the variety of possible applications, not all
possible fault conditions and troubleshooting solutions can be described in this
manual.
Topic Page
Save the Parameter Configuration 14
Visual Component Inspection 15
Troubleshoot a Control Power Supply Failure 15
Troubleshoot an AC Undervoltage Fault 19
Troubleshoot an Armature Bridge Failure 20
Troubleshoot a Field Current Loss Fault 22
Power Component Test Procedures 26
Speed Feedback Device Tests 34
Thermistors and Thermal Switches 37
Relay Outputs 37
Create a Fault Report 38
What You Need When You Call Tech Support 38
IMPORTANT Using the diagnostic tests in this chapter should only be performed by
qualified personnel and only when other corrective actions have failed. All
tests assume that the control board connections have been properly made.
For common drive symptoms and corrective actions and fault
troubleshooting information, see the Troubleshooting chapter in the
PowerFlex Digital DC Drive User Manual, publication 20P-UM001.

14 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018
Chapter 2 Component Test Procedures
Save the Parameter
Configuration
It is recommended that you save the drive and communication adapter
parameter configuration before performing any service. You can save the drive
configuration in one of these ways:
• Upload the drive configuration to a HIM Set
• Upload the drive configuration to a DriveExecutive file (.dno)
• Export the drive configuration to Connected Components Workbench
file (.iuux)
See the specific software online help for instructions on how to save or export
the drive configuration to an offline file.
Save to a HIM Set
Complete 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 .
3. Select Device -> HIM and press .
4. Do one of the following:
• If there are no existing HIM Sets, enter a name using the and
buttons to select the desired characters and press .
• If there is an existing HIM Set, press to overwrite it, or select
No using the button and use the and buttons to
select the desired characters. Then press .
The HIM Set will be saved to nonvolatile memory.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 15
Component Test Procedures Chapter 2
Visual Component Inspection Visually inspect the circuit boards and power components before energizing
the drive for any of the component test procedures.
1. Read the General Safety Precautions on page 10.
2. Remove power from the drive (see page 42).
3. Remove the protective covers (see page 43) and lower the control EMI
shield (see page 58) when necessary.
4. Check components for burn marks, breakage or foil delamination on all
circuit boards.
Replace any of these components without further testing if they show evidence
of burn marks, breakage, or foil delamination.
Troubleshoot a Control
Power Supply Failure
If a drive Power Failure fault (F3) has occurred and the drive is inoperable via
the HIM or other means of control, compete the steps below to determine
where the control power failure has occurred.
1. Read the General Safety Precautions on page 10.
2. Remove power from the drive (see page 42).
3. Measure the signal voltage at the testpoints on the control board as
indicated in the following table.
Note: For a flow chart version of the steps that follow, see Control Power
Supply Failure on page 122.
4. If any of the signals in the table above is incorrect or missing, verify that
either 115V AC or 230V AC voltage is present at terminals U2 and V2
(control circuit power input).
• If the voltage is present and correct, continue with step 5 below.
• If the voltage is incorrect or missing, remove control power and verify
the wiring and power source to U2, V2 and correct any problems.
Test the voltage level again to verify that it is correct. If the voltage is
correct, but the drive is still inoperable, continue with step 5 below.
Name Testpoint For Testpoint Location
See…
Associated Connector-
Pin
Description
+ 5V XY5 Figure 1 on page 17 XA-1 / XA-3 / XA-5 +5V digital supply
GNDD XY6 Figure 1 on page 17 XA-2 / XA-4 / XA-6 +5V digital supply ground
GNDD XY7 Figure 2 on page 18 XA-2 / XA-4 / XA-6 +5V digital supply ground
+15V XY12 Figure 1 on page 17 XA-9 / XA-10 +15V analog supply
GNDA XY10 Figure 1 on page 17 XA-11 / XA-12 15V analog supply ground
-15 V XY11 Figure 1 on page 17 XA-13 / XA-14 -15V analog supply
+24V XY8 Figure 1 on page 17 XA-16 +24V terminal block
GNDV XY9 Figure 1 on page 17 XA-15 +24V terminal block ground
+5VEXP +5VEXP Figure 2 on page 18 XP3-1 / XP3-2 / XP3-3 +5V for DPI expansion
+12VEXP +12VEXP Figure 2 on page 18 XP3-4 / XP3-5 +12V for DPI expansion
0VEXP 0VEXP Figure 2 on page 18 XP3-7 / XP3-8 / XP3-9 DPI expansion ground

16 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018
Chapter 2 Component Test Procedures
5. Remove AC control power from terminals U2 and V2 and remove and
test the fuse (F1) at the top of the drive. See Remove the Fuses on the
Switching Power Supply Circuit Board on page 60 for fuse location.
• If the fuse is blown, continue with step 6 below.
• If the fuse is not blown, replace the switching power supply board
(see page 62).
6. Replace the fuse on the switching power supply board (see page 61).
7. Disconnect the cable at connector XA on the control board. See
Figure 27 on page 119 for location of connector XA.
8. Apply AC control power to the drive.
• If the fuse blows, continue with Testing the Switching Power Supply
and Pulse Transformer Boards.
• If the fuse does not blow, continue with Testing the Control and
Field Board Connections on page 16.
Testing the Switching Power Supply and Pulse Transformer Boards
1. Remove power from the drive (see page 42).
2. Replace the fuses on the switching power supply board (see page 61).
3. Remove the switching power supply board from the drive (see page 62).
4. Reapply power to the switching power supply board only.
• If the power supply fuses do not blow, continue with step 5 below.
• If the power supply fuses blow, replace the switching power supply
board (see page 62).
5. Remove all incoming AC voltage from the drive.
6. Check all external wiring connected to the pulse transformer board,
including the motor PTC if used, for a possible short circuit condition.
Repair any short circuit conditions if found.
7. If no short circuit conditions exist, replace the pulse transformer board
(see page 62).
Testing the Control and Field Board Connections
1. Using an ohmmeter, check all input and output wiring on terminals
1…40 on terminal blocks TB1 and TB2 on the control board for a
possible short circuit condition. Repair any short circuit conditions if
found.
2. If an encoder and/or tachometer is used, use an ohmmeter to check all
wiring on the respective terminals for a possible short circuit condition.
Repair any short circuit conditions if found.

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 17
Component Test Procedures Chapter 2
3. Remove the cables from connector XR and XFCD on the control board
and use an ohmmeter to check between all voltage test points and
common on the control board for possible short circuit conditions. The
ohmmeter measurements should be greater than 200 kΩ. If any low
resistance measurements are found, replace the control board.
4. Using an ohmmeter, measure between pins 1 and 2 and pins 3 and 2 on
the XFCD cable connector. The resistance measurement for both tests
should be greater than 200 kΩ. If a lower resistance value is measured,
replace field board.
Figure 1 - Control Board Testpoints - Upper Left
- A B C +
A+ A- B+ B- Z+ Z- COM +V
A+A- B+ B- Z+ Z- COM +V
- A B C +
21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10
31 32 33 34 35 36 37 38 39 40
11 12 13 14 15 16 17 18 19 20
2122 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 910 1112 13 14 15 16 17 18 19 20
3132 33 34 35 36 37 38 39 40
DEBUG
S15
S3
S2
S1
S0
RST
ACT
RUN
PWR
1 2 3 4 5 6 7 8
S18
S12
S10
S21
ENC_5
S4
1 2 3 4 5 6 7 8
S14
1 2 3 4 5 6 7 8
S20
S11
S9
ON
ON
XY18
XY17
XY19
XY9
XY8
XY12
XY10
XY11 XY6 XY5
XY21 XY22
XY20
ENC_12

18 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018
Chapter 2 Component Test Procedures
Figure 2 - Control Board Testpoints - Upper Right
- A B C +
A+ A- B+ B- Z+ Z- COM +V
A+ A- B+ B- Z+ Z- COM +V
- A B C +
21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10
31 32 33 34 35 36 37 38 39 40
11 12 13 14 15 16 17 18 19 20
2122 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 910 1112 13 14 15 16 17 18 19 20
3132 33 34 35 36 37 38 39 40
DEBUG
S15
S3
S2
S1
S0
RST
ACT
RUN
PWR
1 2 3 4 5 6 7 8
S18
S12
S10
S21
ENC_5 ENC_12
S4
1 2 3 4 5 6 7 8
S14
1 2 3 4 5 6 7 8
S20
S11
S9
ON
ON
XY7
+12VEXP
0VEXP+5VEXP

Rockwell Automation Publication 20P-TG002B-EN-P - February 2018 19
Component Test Procedures Chapter 2
Troubleshoot an AC
Undervoltage Fault
If the drive faults with an AC Undervoltage Fault (F4), or parameter 466 [AC
Line Voltage] does not equal the expected incoming AC line voltage, measure
the AC line input signals as directed in the steps below.
1. Read the General Safety Precautions on page 10.
2. Remove the protective covers (see page 43).
3. Using a voltmeter, measure the voltage at terminals U, V, and W of the
drive.
If an AC input contactor is used, the voltage must be measured on both
the input and output sides of the contactor.
If any of the voltage measurements is incorrect or missing, remove
incoming AC power and verify the wiring to the drive and the power
supply source and correct any problems.
4. Using a voltmeter, measure the combined voltages of the AC lines on the
following testpoints on the control board (all waveforms have a 2.5V
offset). See Figure 1 on page 17 and Figure 2 on page 18 for location of
the testpoints. Also, see Figure 14 on page 107 for a schematic diagram.
Table 1 - Combined AC Line Input Signal Testpoints
Incoming AC
Line Voltage
Phases Measure from
Testpoint
… To Testpoint Peak to Peak
Measurement
RMS Measurement
240V AC V and U XY22 … XY18 1.42V AC 0.500V
V and W XY21 … XY18
480V AC V and U XY22 … XY18 2.95V AC 1.040V
V and W XY21 … XY18
575V AC V and U XY22 … XY18 2.85V AC 1.007V
V and W XY21 … XY18
690V AC V and U XY22 … XY18 3.45V AC 1.220V
V and W XY21 … XY18

20 Rockwell Automation Publication 20P-TG002B-EN-P - February 2018
Chapter 2 Component Test Procedures
• If any of the voltage measurements above are incorrect or missing,
continue with step 5.
• If the voltage measurements above are correct but the value of
parameter 466 [AC Line Voltage] is incorrect, replace the control
board.
5. Remove the ribbon cable connected to XR on the control board and
pulse transformer board and test the continuity of the cable using the
measurements in Ta ble 2 4 on page 116.
If the measurements on the XR cable are correct, replace the pulse transformer
board.
Troubleshoot an Armature
Bridge Failure
If the drive is running unstable or faults with an Overcurrent Fault (F13) an
armature bridge failure may have occurred. All of the signals going to and
coming from the SCR bridges are transmitted via the ribbon cable connected
to XR on the control board and can be measured at these points. See Figure 27
on page 119 for location of the XR connector on the control board.
Note: If using an AC input contactor, this step requires that the cable remain
connected to the XR connector on the control board and that an adapter be
used to measure these signals.
1. Read the General Safety Precautions on page 10.
2. Remove the protective covers (see page 43).
3. If using a DC output contactor, disconnect the cable from XR on the
control board and measure the signal for each SCR gate as indicated in
this table:
Figure 3 and Figure 4 on page 21, and Figure 5 on page 22 are examples
representing gate pulse, current and voltage signal measurements taken
on an SCR. In the figures below:
– The current signal is taken on the testpoint XY17 (+2.5V offset;
+0.6V=Drive size current).
– The voltage signal is taken on the testpoint XY19 (+2.5V offset).
– The ground signal is taken on either testpoint XY10 or XY18.
Signal Name XR Cable Pin Gate Note
MP MN
IT1 27 G1 G04
IT2 29 G2 G05
IT3 31 G3 G06
IT4 21 G4 G01
IT5 23 G5 G02
IT6 25 G6 G03
MN 33 – – Negative bridge MN - active when high (+5V)
MP 34 – – Positive bridge MP - active when high (+5V)