Rockwell Automation Allen-Bradley PowerFlex 20P User manual

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.