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.

Rockwell Automation Publication 20P-TG004C-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.
Frame D drives may contain series B fan components. Verify that you are working
on a Frame D, series A or series B drive by checking the data nameplate label on
the lower right side of the drive. The frame size is printed just above the serial
number in the lower right corner of the label. The series letter is printed on the
upper right corner of the label.
Figure 1 - Drive Data Nameplate Label
EXAMPLE ONLY
A0NNN
500HP
3 Phase Original Firmware V. 5.007
Serial Number: D23E0042
Series: B
Frame: D
6.2
8.2
I/O: 24VDC (Standard)
Ind. Cont.
Listed
C
R
US
max. 1 Phase
Hz 1.0/0.5A 1 Phase
Eq. 31KF
N223

12 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021
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.
Phillips® is a registered trademark of Phillips Screw Company.
Software Tools
You can use Connected Components Workbench™ software and DriveExecutive
software for configuring and monitoring drive 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, 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-TG004C-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 16
Troubleshoot a Control Power Supply Failure 17
Troubleshoot an AC Undervoltage Fault 22
Troubleshoot an Armature Bridge Failure 23
Troubleshoot a Field Current Loss Fault 25
Power Component Test Procedures 29
Speed Feedback Device Tests 37
Thermistors and Thermal Switches 40
Relay Outputs 40
Create a Fault Report 41
What You Need When You Call Tech Suppor t 41
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-TG004C-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 Connected Components Workbench™ or
DriveExecutive™ software before performing any service or testing on the drive.
HIM sets are files stored in permanent nonvolatile HIM memory.
Save to a HIM Set
Follow these steps to save the drive and communication 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-TG004C-EN-P - September 2021 15
Component Test Procedures Chapter 2
Save Parameters to a Project File Using Connected Components
Workbench Software
You can save all drive and communication adapter parameters in the drive to a
project file on your computer using Connected Components Workbench
software. A project file (*.ccwsln) contains all information about the node,
including the necessary databases. Follow these steps to save a project file for your
drive.
1. From the Connected Components Workbench software, with the project
for your drive open, click Upload in the toolbar.
•If a communication path has previously been established with the
device, a progress window opens. When the connection is complete, the
Upload window opens. Continue with step 2.
•If a communication path has not previously been established with the
device, the Connection Browser opens. Select the device from which
you want to upload configuration settings and click OK. A progress
window opens. When the connection is complete, the Upload window
opens.
2. In the Upload window, do one of the following:
•If you do not want to change the communication path, continue with
step 3.
•If you want to change the established communication path, click
Change. The Connection Browser opens. Select the device from which
you want to upload configuration settings and click OK. A status
window opens and shows the progress of the connection.
Note: The communication path can only be changed when disconnected
from the device.
3. Click Error Check Upload to upload the configuration settings from the
connected device, parameter-by-parameter, while checking for errors. This
option is only available when a device supports both an optimized (block)
upload and parameter-by-parameter upload.
4. In the Upload window, do one of the following:
•If you want to upload the configuration for all ports for the device, click
Upload Entire Device.
•If you only want to upload the drive configuration, click Upload Port 0.
•If you do not want to upload the configuration for a specific ports for
the device, click Advanced (if available). The Select Ports to Upload
window opens. Select the checkbox of the ports that you do not want to
upload from the drive. Click Upload.
Note: If the device from which you are uploading has a different rating
and/or firmware revision than the device in your project, the Port
Mismatch window opens. Click Details to open the Device Type
Mismatch or Revision Mismatch window and view the rating and/or
revision level differences. Click Continue to complete the upload and
change the rating and/or revision of the device in your project to match
the online device. Click Cancel to cancel the upload.

16 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021
Chapter 2 Component Test Procedures
The Upload status window opens to indicate the progress of the upload
operation.
–Clicking Xwill cancel the upload. When the upload has completed, a
message appears in the window to confirm that the upload completed
successfully.
–Clicking ✔will close the message window, or click Close window when
complete before the upload finishes.
5. From the File menu, choose Save.
Save Parameters to an Offline Node File Using DriveExecutive
Software
You can save all drive and communication adapter parameters in the drive to an
offline database file on your computer using DriveExecutive. software An offline
node file (*.dno) contains all information about the node, including the necessary
databases. Follow these steps to save an offline database file for your drive.
1. From the DriveExecutive software, from the Drive menu, choose Connect
to Drive.
2. From the Connect to Drive dialog box, select the drive for which you want
to save the parameter configuration and click OK.
3. Click (Upload) on the toolbar.
4. A dialog displays the status of the upload operation. Click Cancel to cancel
the operation.
5. From the File menu, click Save.
6. In the Save As dialog box, enter a name for the file and click Save.
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
44.
3. Open the control pan. See Open the Control Panel on page 49.
4. Remove the protective covers from the drive. See Protective Cover
Removal and Installation on page 47.
5. 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.

Rockwell Automation Publication 20P-TG004C-EN-P - September 2021 17
Component Test Procedures Chapter 2
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 bottom control panel and I/O and control terminal covers
from the drive. See Protective Cover Removal and Installation on page 47.
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 132.
Name Testpoint For Testpoint Location
See…
Associated Connector-
Pin
Description
+ 5V XY5 Figure 2 on page 20 XA-1 / XA-3 / XA-5 +5V digital supply
GNDD XY6 Figure 2 on page 20 XA-2 / XA-4 / XA-6 +5V digital supply ground
GNDD XY7 Figure 3 on page 21 XA-2 / XA-4 / XA-6 +5V digital supply ground
+15V XY12 Figure 2 on page 20 XA-9 / XA-10 +15V analog supply
GNDA XY10 Figure 2 on page 20 XA-11 / XA-12 15V analog supply ground
-15 V XY11 Figure 2 on page 20 XA-13 / XA-14 -15V analog supply
+24V XY8 Figure 2 on page 20 XA-16 +24V terminal block
GNDV XY9 Figure 2 on page 20 XA-15 +24V terminal block ground
+5VEXP +5VEXP Figure 3 on page 21 XP3-1 / XP3-2 / XP3-3 +5V for DPI expansion
+12VEXP +12VEXP Figure 3 on page 21 XP3-4 / XP3-5 +12V for DPI expansion
0VEXP 0VEXP Figure 3 on page 21 XP3-7 / XP3-8 / XP3-9 DPI expansion ground

18 Rockwell Automation Publication 20P-TG004C-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 fuse (F1) at the top of the drive. See Switching Power Supply Fuse
Removal and Installation on page 52 for fuse location.
•If the fuse is blown, continue with step 6.
•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 Fuse Removal and Installation on page 52.
7. Disconnect the cable at connector XA on the control board. See Figure 31
on page 128 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 on page 18 below.
•If the fuse does not blow, continue with Testing the Control and Field
Board Connections on page 19.
Testing the Switching Power Supply and Pulse Transformer Boards
1. Remove power from the drive.
2. Replace the fuse on the switching power supply board. See Switching
Power Supply Fuse Removal and Installation on page 52.
3. Remove the switching power supply board from the drive. See Remove the
Pulse Transformer Circuit Board on page 66.
4. Reapply power to the switching power supply board only.
•If the power supply fuse does not blow, continue with step 5 below.
•If the power supply fuse blows, 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-TG004C-EN-P - September 2021 19
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.

20 Rockwell Automation Publication 20P-TG004C-EN-P - September 2021
Chapter 2 Component Test Procedures
Figure 2 - 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