Rockwell Automation Allen-Bradley PowerFlex 4M User manual

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

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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
74
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.

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 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 C 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.
Serial Number: C13D0092
.0/0.5A 1 Phase
Frame: C

12 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021
Chapter 1 BeforeYou BeginTesting, 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.
Phillips®is a registered trademark of Phillips Screw Company.
Software Tools
DriveTools™SP, DriveExecutive, DriveExplorer™and DriveObserver™are software
tools for uploading, downloading and monitoring system parameters.
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 7x2 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-TG003B-EN-P - September 2021 13
Chapter 2
Component Test Procedures
Introduction 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 20
Troubleshoot an Armature Bridge Failure 21
Troubleshoot a Field Current Loss Fault 23
Power ComponentTest Procedures 27
Speed Feedback Device Tests 36
Thermistors andThermal Switches 39
Relay Outputs 39
Create a Fault Report 40
What You Need When You Call Tech Support 40
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 Chapter 4 “Troubleshooting”in the PowerFlex Digital DC Drive
User Manual, publication 20P-UM001.

14 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021
Chapter 2 Component Test Procedures
Save the Parameter
Configuration
It is recommended that you save the drive and communication adapter parameter
configuration to a HIM Set or by up loading the drive and adapter parameters to
an offline node file using DriveExecutive™ before performing any service or
testing on the drive. HIM sets are files stored in permanent nonvolatile HIM
memory.
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.
Download Parameters to an Offline Node File
You can save all drive and adapter parameters in the drive to an offline database
file on your computer using DriveExecutive. An offline node file (*.dno) contains
all information about the node, including the necessary databases.
1. From the Drive menu, select Upload from Drive or click the upload
button on the toolbar.
2. Click Ye s to confirm the operation, which cannot be undone.
3. If you are not connected to a drive, the Connect to Drive dialog displays.
Select the drive to which you want to connect and click OK.
4. A dialog displays the status of the upload operation. Click Cancel to
cancel the operation.

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 15
Component Test Procedures Chapter 2
Visual Component Inspection Visually inspect the drive 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 Remove Power from the Drive on
page 42.
3. Remove the protective covers and lower the control EMI shield when
necessary. See Remove the Protective Covers from the Drive on page 43
and Move the Control EMI Shield on page 58.
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 the protective covers from the drive. See Remove the Protective
Covers from the Drive on page 43.
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 140.
Name Testpoint For Testpoint Location
See…
Associated Connector-
Pin
Description
+ 5V XY5 Figure 1 on page 18 XA-1 / XA-3 / XA-5 +5V digital supply
GNDD XY6 Figure 1 on page 18 XA-2 / XA-4 / XA-6 +5V digital supply ground
GNDD XY7 Figure 2 on page 19 XA-2 / XA-4 / XA-6 +5V digital supply ground
+15V XY12 Figure 1 on page 18 XA-9 / XA-10 +15V analog supply
GNDA XY10 Figure 1 on page 18 XA-11 / XA-12 15V analog supply ground
-15 V XY11 Figure 1 on page 18 XA-13 / XA-14 -15V analog supply
+24V XY8 Figure 1 on page 18 XA-16 +24V terminal block
GNDV XY9 Figure 1 on page 18 XA-15 +24V terminal block ground
+5VEXP +5VEXP Figure 2 on page 19 XP3-1 / XP3-2 / XP3-3 +5V for DPI expansion
+12VEXP +12VEXP Figure 2 on page 19 XP3-4 / XP3-5 +12V for DPI expansion
0VEXP 0VEXP Figure 2 on page 19 XP3-7 / XP3-8 / XP3-9 DPI expansion ground

16 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021
Chapter 2 Component Test Procedures
4. If any of the signals in the table above is incorrect or missing, verify that
either 115 VAC or 230 VAC 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.
5. Remove AC control power from terminals U2 and V2 and remove and test
the fuses (F1 and F2) on the switching power supply board. See Switching
Power Supply Circuit Board Fuse Removal and Installation 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.
6. Replace the fuse on the switching power supply board. See Switching
Power Supply Circuit Board Fuse Removal and Installation on page 60.
7. Disconnect the cable at connector XA on the control board. See Figure 29
on page 136 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 below.
•If the fuse does not blow, continue with Testing the Control and Field
Board Connections on page 17.
Testing the Switching Power Supply and Pulse Transformer Boards
1. Remove power from the drive.
2. Replace the fuses on the switching power supply board. See Switching
Power Supply Circuit Board Fuse Removal and Installation on page 60.
3. Remove the switching power supply board from the drive. See Switching
Power Supply Circuit Board Removal and Installation on page 61.
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.
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.

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 17
Component Test Procedures Chapter 2
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.
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 k. 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 k. If a lower resistance value is measured, replace
field board.

18 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021
Chapter 2 Component Test Procedures
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 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
XY18
XY17
XY19
XY9 XY8 XY12XY10XY11 XY6 XY5
XY21 XY22
XY20

Rockwell Automation Publication 20P-TG003B-EN-P - September 2021 19
Component Test Procedures Chapter 2
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

20 Rockwell Automation Publication 20P-TG003B-EN-P - September 2021
Chapter 2 Component Test Procedures
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 from the drive. See Protective Cover
Removal and Installation on page 43.
3. Using a voltmeter, measure the voltage at terminals U, V, and W of the
drive.
Note: 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 18 and Figure 2 on page 19 for location of the
testpoints. Also, see Figure 16 on page 125 for a schematic diagram.
Table 1 - Combined AC Line Input Signal Testpoints
•If any of the voltage measurements above are incorrect or missing,
continue with step 5 below.
Incoming AC
Line Voltage
Phases Measure From
Testpoint
… To Testpoint Peak to Peak
Measurement
RMS Measurement
240 VAC V and U XY22 … XY18 1.42 VAC 0.500 V
V and W XY21 … XY18
480 VAC V and U XY22 … XY18 2.95 VAC 1.040 V
V and W XY21 … XY18
575 VAC V and U XY22 … XY18 2.85 VAC 1.007 V
V and W XY21 … XY18
690 VAC V and U XY22 … XY18 3.45 VAC 1.220 V
V and W XY21 … XY18