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1336 PLUS Adjustable Frequency AC Drive with Sensorless Vector

1. DC L4 L3 CF4 crs HNV o _ SEE NOTE 2 2 3 D1 CAP BANK CNV DC 88 du mx E EEEE E 109 65 2 1 654321 1 1 4SMPS J2 jl 4 5 5 BRECHARGE ay BOARD 5 SEE NOTE 5 SEE NOTE 3 i 12 AC LINE Publication 1336 PLUS 6 6 February 2002 AB0813A 7 3 Schematics BP250 450 and CP350 450 74103 281 AB0812A Publication 1336 PLUS 6 6 February 2002 TO MAIN CONT
2. HEATSINK BLOWER 4 C HB1 Ce e e lt lt gt lt gt C326 Sl Cao i R1 C8 e 5 e e DETAIL 1 380 460 VAC DETAIL 2 500 600 VAC NOTES DETAIL 1 1 C1 THRU 18 400 VDC CAPACITORS NOTES DETAIL 2 1 C1 THRU C18 ARE 500 VDC CAPACITORS NOTE 4 COMMON MODE CHOKE OPTIONAL EQUIPMENT PER APPLICATION U M1 AC V M2 OUTPUT W M3 POWER PE 74103 281 AB0814A Publication 1336 PLUS 6 6 February 2002 Vote 1 The Input Line Fuses for this product are supplied in the unit as follows Schematics BP250 BP450 and CP350 CP450 380 460VAC FUSE CURRENT TYPE 500V 600VAC FUSE CURRENT TYPE FUSE INFORMATION FUSE INFORMATION HORSEPOWER TE aTING TYPE PIN HORSEPOWER RATING TYPE PIN 250 450A 7005 25178 315 18 300 5004 7005 25178 315 19 3
3. Storred p Display Panel Hz Control Panel P Human Interface Module HIM AB0816A Publication 1336 PLUS 6 6 February 2002 1 10 Control Logic Wiring and Adapters Publication 1336 PLUS 6 6 February 2002 HIM Module Removal ATTENTION Some voltages present behind the drive front cover are at incoming line potential To avoid an electric shock hazard use extreme caution when removing replacing the HIM For handheld operation the module can be removed and located up to 10 meters 33 feet from the drive Important Power must be removed from the drive or the appropriate bit of the Logic Mask parameter must be set to 0 to allow removal of the HIM module without causing a Communication Fault Setting the appropriate bit of the Logic Mask parameter to 0 allows HIM removal while power is applied to the drive Note that this also disables all HIM control functions except Stop To remove the module 1 Assure that power has been removed or the appropriate Logic Mask bit has been set to 0 2 Take the drive front cover off and slide the module down and out of its cradle Otherwise unplug the cable between the HIM and the Communications Port Adaptor 2 3 4 or 5 3 Reverse the above steps to replace the module Apply power or reset the appropriate bit of the Logic Mask parameter to 1 to enable HIM control HIM Operati
4. W M3 V M2 U M1 799 4DC DC Brake Brake Publication 1336 PLUS 6 6 February 2002 4 8 Component Test Procedures ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to Zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the motor leads from TB1 U V and W terminals of the drive 4 Set your meter to test diodes 5 Test the output sections of the drive This should idicate if any of the drive s output phases has a problem Table 4 B shows meter connections and ideal meter readings for those connections Refer to Figure 4 3 for meter connection locations Table 4 B Output Sections Nominal Meter Phase with Meter Lead Meter Lead Reading Problem DC Brake U M1 Infinite U DC Brake V M2 Infinite V DC Brake W M3 Infinite W U M1 DC Brake 0 318 U V M2 DC Brake 0 318 W M3 DC Brake 0 318 W DC Brake U
5. 5 22 LEMS cse acia ese 5 23 RR ER 5 23 Iistallatiorl Ji ose re er kc 5 25 MOM ACC Ed ra barra beens 5 26 5 26 5 27 Fan and Transformer Assembly 5 28 Removal is oda n Ctr ra e d eine ai ite GEN UD As ds 5 28 hr PPP TH 5 30 DC Bus Inductor Ll iussa ebbe ERR EY 5 31 Peal ous sers 5 31 5 33 6 Chapter ODIGCUVES oan eater dex eh sas Eater as 6 1 Ordering Replacement P arts 6 1 Replacement Parts Listing 6 2 Chapter 7 Manual Objective Who Should Use This Manual Safety Precautions Preface Preface The information in this manual is designed to help troubleshoot or repair an Rockwell Automation Bulletin 1336 PLUS Adjustable Frequency AC Drive with ratings BP250 BP450 This manual is intended for qualified service personnel responsible for troubleshooting and repairing the 1336 PLUS Adjustable Frequency AC Drive You should Read this entire manual before performing maintenance or repairs to drives Have previous experience with and basic understanding of
6. T 3 15 Removing the Gate Driver Board from the Mounting Plate 3 16 Fab au ed ues d tee Pardo ETEN 3 16 hzc RR TU 3 17 Removing the Precharge Board from the Mounting Plate 3 18 3 18 Installation MTM 3 19 Component Test Procedures Part Replacement Procedures Table of Contents iii Removing a Power Module Snubber Board 3 20 METTUS 3 20 eh E Race RIDERE o aac cd 3 22 Removing an Input Rectifier 5 Board 3 23 UEM 3 23 Mr 3 24 Accessing Power Plane Components 3 24 Chapter 4 Chapter Objectives 4 1 Component Test Overview 4 Electrostatic Discharge Precautions 4 2 TOO delet end ander ana 4 2 Test 1 Testing the Gate 4 3 Test 2 Testing the Precharge Board 4 5 Test 3 Testing the Power Modules 4 7 Test 4 Testing the Bus 5 4 11 Test 5 Testing the Input Rectifiers 4 14 Chapter 5 Chapter ur PT 5 1 Saleh wicker d que dut Sew aud Pere ie qE 5 1 Electrostatic Discharge Precautions
7. E P 9 1 x watt P 9 vr Geka dae dow ade ba cel soo Rees oe P 10 Related Publications P 10 Chapter 1 Chapter Objectives 1 1 Chapter OQVEIMIOW AE 1 1 Control Interface Option 1 2 Control Interface Board Jumpers 1 3 Available Inputs 1 4 Local Programming 1 4 Human Interface Module 1 8 D SCIDUOI xad YR da ERR 1 8 HIM Module 1 10 HIM D BER UOI dac ER pr eeu 1 10 Publication 1336 PLUS 6 6 February 2002 ii Table of Contents Troubleshooting and Error Codes Disassembly and Access Procedures Publication 1336 P LUS 6 6 February 2002 Chapter 2 Chapter Objectives 2 1 Troubleshooting Overview 2 1 Electrostatic Discharge Precautions 2 2 Descriptions Vespa RSV x Syd 2 3 24 ed acp idera CUR VER ROCA 2 3 Contact Description cia 2 3 Diagnostic Procedures bySymptom 2 11 Drive WILNOESIBIU 2 11 ops A PP 2 12 Drive
8. 5 1 io er DIT 5 2 Major Component Replacement 5 3 Detailed 5 4 Bus 5 5 nm 5 5 rh Ra we eee RR E ERR 5 7 TROTIWSIDE dead acus ded 5 9 Gad spi tune Leaded Ebates oom ed 5 9 Meta DID ct Pieter aden odit 5 10 Power MOQUIBS EROR 5 11 REMOVAL doh m 5 11 rri eae d bs ae ase os 5 13 BUS FUSES FI uasa ies eerte oid rrt erba ted 5 14 REMOVE qa swa d d 5 14 5 5 15 Input Fuses 5 16 Lo vexdrRPSEPPaObreiEPUSCPRP 5 16 E ya eed Rh DRE cR CAR 5 17 Ground Faull GT i e iR KR Re tini 5 18 ad 5 18 RE EROR 5 20 hia AT T 5 21 Publication 1336 PLUS 6 6 February 2002 iv Table of Contents Replacement Parts List Schematics CP350 CP450 250 450 HP 1336 PLUS Drives Glossary Index Publication 1336 P LUS 6 6 February 2002 5 21
9. 2 13 Drive Stays at Zero Herz When Started 2 14 Drive Goes to Max 2 15 Clearing Raed 2 15 Chapter 3 Chapter Objectives 3 1 Disassembly and Access Overview 3 1 Electrostatic Discharge Precautions 3 1 iste rea beatae wees 3 2 Fastener Torque Specifications 3 2 Torque Sequence 3 2 Torque Specifications 3 3 Disassembly and Access Procedures 3 5 Removing the High Voltage Guard 3 5 Removal bacs a p act Dau dd 3 6 Installation T TI 3 6 Removing Control Interface Board MOD L4 L5 or L6 3 7 ic MERERI 3 7 3 8 Removing the Circuit Board Platform 3 9 Removal PEN 3 9 INStallatiON vues hk Rak seed 3 11 Removing the Main Control Board Mounting Plate 3 12 Removal assess su e 3 12 Iistallatiofl jii aka aaa ed Gack wand ea aw BA 3 13 Removing the Main Control Board from the Mounting Plate 3 14 nc per a 3 14
10. Enclosures Drive Rating Open NEMA Type1 NEMA Type4 NEMA Type 12 IP00 IP20 IP65 IP54 No Enclosure General Purpose Resist Water Dust Industrial Use Constant Torque Variable Torque Frame Designation Output Nominal Output Nominal Code Code Code Code Amps HP Amps HP F 325 0 250 360 0 300 BP250 AN BP250 AA 4 360 0 300 425 0 350 BP300 AN BP300 AA 4 425 0 350 475 0 400 BP350 AN BP350 AA 4 475 0 400 532 0 450 BP400 AN BP400 AA 4 532 0 450 532 0 450 450 450 4 Drive rating is based on a carrier frequency of 4kHz maximum an altitude of 1 000 meters or less and a maximum ambient temperature of 40 m VT Ratings do not apply to 380V Input Refer to the Language Module and Options tables following these Catalog Number tables 5 Not available in this rating Publication 1336 PLUS 6 6 February 2002 P 5 1336 PLUS Drive Catalog Numbers Table P B BULLETIN RATING ENCLOSURE LANGUAGE CONTROL HUMAN COMMUNICATION CARD NO MUST BE SPECIFIED MODULE INTERFACE INTERFACES OPTIONAL MUST BE SPECIFIED OPTIONAL OPTIONAL 575V AC Input Constant or Variable Torque Drive Enclosures Drive Rating Open NEMA Type1 NEMA Type4 NEMA Type 12 IP00 IP20 IP65 IP54 No Enclosure General Purpose Resist Water
11. Restore incoming power to drive Yes HIM connected properly Re connect HIM Replace HIM Main Control Board or Gate Driver Board as needed Publication 1336 PLUS 6 6 February 2002 s the fuse blown on the Gate Driver Board DC bus voltage present Replace the Diode Bridge and any other damaged components Replace the fuse Gate Driver Board or complete drive as needed Replace Gate Driver Board AB0417B Drive will not J og Is drive running Will drive run if commanded to Start Yes y Does a J og Owner bit go to 1 when J og is commanded HIM displays Stopped when J 00 is commanded Is a Stop Owner bit setto 1 Is Logic Mask bit set to 0 Replace Main Control Board Troubleshooting and Error Codes 2 13 Drive Will Not Jog Local Human Interface Module used to control drive JOG is not active if a START command is present START command always overrides a JOG command Drive must be stopped before attempting to J og Refer to Drive Will Not Start Is the J og Mask bit Is the J og Input true Replace the Adapter for the adapter being when J og is L Option or Main used setto 1 commanded Control Board Set the J og Mask bit for the adapter being used to 1 External wiring problem Drive running at Replace Main incorrect frequency Control Board Find and correct the Reprogram sourc
12. 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Set your meter to test resistance 4 Test fuses F1 F2 and F3 through the access holes in the Precharge Board High Voltage Guard and check for open conditions 5 Replace the Precharge Board if any fuse shows an open condition Refer to Chapter 3 Disassembly and Access Procedures Removing the Precharge Board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Test 3 Testing the Power Modules Component Test Procedures 4 7 The Power Modules are located on the upper right side of the heat sink If modules have been replaced you must check the Power Module Snubber Board Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board Figure 4 3 Power Module Test 00000 000 V Phase W Phase
13. 3 Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Disconnect the Thermistor connector at J1 on the Main Control Board 5 Unscrew the Thermistor from the heat sink Installation Install the Thermistor in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Part Replacement Procedures 5 11 Power Modules The Power Modules are located near the top of the heat sink If one or more Power Modules is replaced you must check the Power Module Snubber Board and the Precharge Board Refer to Chapter 3 Disassembly and Access Procedures Removing the Precharge Board Figure 5 5 Power Modules Power Module Preform Power Interface Board Module A Power Module Bus Bar S AN Standoffs Ca ae Screw S 8 PLA Bn Output Bus EC Bar ET SE uu 0789 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until th
14. Allen Bradley 1336 PLUS Adjustable Frequency AC Drive with WS SENSORLESS VECTOR Wy BP250 BP450 CP350 CP450 ED SENSORLESS VECTOR Troubleshooting Guide Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or
15. Disconnect the following from the Precharge Board J connector J2connector J4 connector Disconnect the two LEM wire harness plugs 10 Remove the four nuts fastening the Circuit Board Platform to the drive 11 Pull the Circuit Board Platform straight out and remove the platform from the drive Disassembly and Access Procedures 3 11 Installation Install the Circuit Board Platform in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 3 12 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Removing the Main Control Board Mounting Plate Figure 3 7 Main Control Board Mounting Plate Removal Mounting Plate Connector 2 Connector J 1 Connector J 6 Connector J 8 inal Strip TB2 Terminal Strip TE Main Control Board 0781 ATTENTION Disconnect and lock out power from the drive before disassembling t
16. Publication 1336 PLUS 6 6 February 2002 table readings Refer to Chapter 3 Disassembly and Access Procedures Removing the Gate Driver Board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Test 2 Testing the Precharge Board Component Test Procedures 4 5 If Input Rectifier modules have been replaced you must check the Input Rectifier Snubber Board and the Precharge Board Refer to Chapter 3 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board and Removing the Precharge Board Figure 4 2 Precharge Board Test Precharge Board n ABO798B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 4 6 Component Test Procedures Publication 1336 PLUS 6 6 February 2002 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly
17. 4 2 450 450 0 450 0 n 3 Gi 1 Rating is at 4kHz If carrier frequencies above 4kHz are selected drive rating must be derated 21 Drive Ambient Temperature Rating is 40 C If ambient exceeds 40 C the drive must be derated Drive Rating is based on altitudes of 1 000m 3 000 ft or less If installed at higher altitude drive must be derated Refer to the 1336 PLUS User Manual Appendix A CT Constant Torque VT Variable Torque Drive Rating Qualifications Several factors can affect drive rating If more than one factor exists consult Rockwell Automation Encl osure Type The first character A indicates the Enclosure Code The second character indicates the type of enclosure shipped from the factory Table P G Enclosure Type Code Description Enclosure Type Code Description N Open style IP 00 A NEMA Type 1 IP 20 F NEMA Type 4 IP 65 J NEMA Type 12 IP 54 Publication 1336 PLUS 6 6 February 2002 P 8 Preface Conventions Publication 1336 PLUS 6 6 February 2002 To help differentiate parameter names and display text from other text in this manual the following conventions will be used Parameter Names will appear in brackets e Display Text will appear in quotes The following is a list of conventions used throughout this manual and definitions of the conventions For
18. Publication 1336 P LUS 6 6 February 2002 4 Motor mounted or separately mounted brake positive action mechanical friction device Normal configuration is such that when the power is removed the brake is set This can be used as a holding brake Note A separately mounted brake is not one which is located on some part of the mechanical drive train other that the motor Breakaway Torque The torque required to start a machine from standstill Breakaway torque is always greater than the torque needed to maintain motion Breakdown Torque The breakdown torque of an AC motor is the maximum torque which it will develop with rated voltage applied at rated frequency Bridge Rectifier Diode SCR A non controlled full wave rectifier that produces a constant rectified DC voltage An SCR bridge rectifier is a full wave rectifier with a DC output that can be controlled by switching on the gate control element Bridge Rectifier A full wave rectifier that conducts current in only one direction of the input current AC applied to the input results in approximate DC at the output British Thermal Unit BTU The quantity of heat required to raise one pound of water by one degree Fahrenheit BTU Refer to British Thermal Unit Bus A single path or multiple parallel paths for power or data signals to which several devices may be connected at the same time A bus may have several sources of supply and or several sources of demand
19. Reverse Reverse Digital Reverse 1st Reverse Reverse4 PotUp Accel gt Forward Forward Digital Forward 2nd Forward Forward p PotDn Accel Auxiliary Common Jog Speed Speed Digital Ist Integrator Integrator gt Select 3 Select3 PotUp Decel Reset Reset Speed Speed Speed Digital 2nd Speed PI Select 2 Select2 Select21 PotDn Decel Select3 Output Speed Select 1 Common Enable Input Mode 12 16 20 21 24 Rn Two Wire Control Single Source Control Stop F ault Reset Common Mora 12 13 14 15 16 200 218 248 Run Reverse Local Stop 2nd Digital Local Local PI Control Type Accel PotUp Contro Control Output Auxiliary Common Speed Speed 2nd Digital Stop Integrator Speed Integrator 5 3 3 PotDn Type ResetS Select3 Reset 0291 Publication 1336 PLUS 6 6 February 2002 1 8 Control Logic Wiring and Adapters Human Interface Module HIM Publication 1336 PLUS 6 6 February 2002 Table 1 B defines the input state of the Speed Select inputs for a desired frequency source Table 1 B Speed Select Input State vs Frequency Source Speed Select 3 Speed Select 2 Speed Select 1 Frequency Source 0 0 0 Freq Select 1 0 0 X Freq Select 2 0 X 0 Preset Freq 2 0 X X Preset Freq 3 X 0 0 Preset Freq 4 X 0 Preset Freq 5 X X 0 Preset Freq 6
20. T TB3 Terminal Designations 1 5 Temp Sense Open 2 8 Terminal Block Locations 1 2 Terminal Designations TB3 1 5 Thermistor Illustration 5 9 Installation 5 10 Removal 5 9 Tools Required for Service 3 2 4 2 5 2 Torque Four Point Mounting Sequence 3 3 Maximum for TB Terminals 1 5 Six Point Mounting Sequence 3 3 Specifications 3 3 Two P oint Mounting Sequence 3 3 Troubleshooting Component Test P rocedures 4 1 Fault Code Cross Reference 2 9 Fault Contact Description 2 3 Fault Descriptions 2 3 2 4 Fault Display Illustration 2 3 Overview 2 1 True Definition P 10 Two Point Mounting 3 3 U Undervolt Fault 2 8 UV Short Fault 2 8 UW ShortFault 2 8 V VW Short Fault 2 8 W Wire Sizes 1 5 X Xsistr Desat Fit 2 8 CUT ALONG DOTTED LINE ov We Want Our Manuals to be the Best NZD You can help Our manuals must meet the needs of you the user This is your opportunity to make sure they do just that By filling out this form you can help us provide the most useful thorough and accurate manuals available Please take a few minutes to tell us what you think Then mail or FAX this form FAX to your local Rockwell Automation Allen Bradley Sales Office or 414 512 8579 PUBLICATION NAME PUBLICATION NUMBER DATE AND PART NUMBER IF PRESENT V CHECK THE FUNCTION THAT MOST CLEARLY DESCRIBES YOUR JOB SUGGEST RESPONSIBLE FOR THE PURCHASE OF EQUIPMENT MAINTAIN OPERATE PROGRA
21. Using different fastener lengths will damage the Power Modules Install the Snubber Board in reverse order of removal Refer to Table 3 A Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 3 23 Removing an Input Rectifier Snubber Board The Input Rectifier Snubber Boards are located under the Circuit Board Platform Figure 3 12 Input Rectifier Snubber Board Input Rectifier Snubber Board AB0785B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 3 24 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Important ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Before you remove connections and wires from the drive components mark the connections and wires to correspond with th
22. X X X Preset Freq 7 0 Open X Closed Description When the drive mounted HIM is supplied it will be connected as Adapter 1 refer to Figure 1 6 and will be visible from the front of the drive The HIM can be divided into two sections Display Panel and Control Panel The Display Panel provides a means of programming the drive and viewing the various operating parameters The Control Panel allows different drive functions to be controlled Refer to the 1336 PLUS User Manual for HIM operation Important The operation of HIM functions depends upon drive parameter settings Default parameter values allow full HIM functionality Control Logic Wiring and Adapters Figure 1 5 Adapter Locations ALLEN BRADLEY Internal Communication Adapter 6 Drive Mounted HIM Eu Adapter 1 Open Style Only Communications Port Remote HIM or GPT Control Interface Option TB3 Adapter 0 AB0817A Door Mounted HIM NEMA 1 Figure 1 6 Human Interface Module
23. electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions This manual describes equipment troubleshooting and disassembly procedures You begin with general illustrations and end with greater detail concerning replacement parts and part locations on the drives Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 P 2 Preface Electrostatic Discharge Precautions Publication 1336 PLUS 6 6 February 2002 ATTENTION Potentially fatal voltages may result from improper usage of oscilloscope and other test equip ment The oscilloscope chassis may be at a potentially fa tal 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 Qua
24. power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 3 20 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Removing a Power Module Snubber Board The Power Module Snubber Boards are located on the upper right side of the chassis Figure 3 11 Power Module Snubber Board Heat Transfer Snubber Pad Resistor 22 a 27 Screw 2 S lt a Ww Power Module Stake On Snubber Board Connector J 1 Stake On Connector J 2 7 Screw 12 no gt 0784 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Disassembly and Access Procedures 3 21 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives F
25. specification The following illustrates temporary and final tightening sequences for components fastened to a heat sink using two four and six screws Temporary torque is 1 3 33 of final torque except six point mountings which require 0 5 N m 4 Ib in The numeric illustration labels are for your assistance Drive components do not carry these labels Disassembly and Access Procedures 3 3 Figure 3 1 Two Point Mounting rdi Two P oint Mounting Temporary Tighten 3 Final Tighten ABOQ16A Figure 3 2 Four Point Mounting LG O O Temporary Tighten O 9 O Final Tighten Figure 3 3 Six Point Mounting D D 0 0 05 Temporary Tighten to 0 5 N m 4 Ib in o Final Tighten to 3 N m 26 Ib in Six Point Mounting AB04338 Important Do not exceed 0 5 Newton meters 4 Ib in on initial torque of all six screws O AB0017A Torque Specifications The following table lists fastener locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point four point and six point components to the heat sink Publication 1336 PLUS 6 6 February 2002 3 4 Disassembly and Access Procedures Component Fan Motor Fan Cover Assembly Fan Transformer Fan Capacitor MOV Surge Sup
26. 2 4 Troubleshooting and Error Codes Name amp Fault Adptr Freq Err 65 Auxiliary Fault 02 Table 2 A 1336 PLUS Fault Descriptions The SCANport adapter that was the selected frequency reference sent a frequency greater than 32167 to the drive The auxiliary input interlock is open Action Correct the problem that is causing the S CAN port adapter to send the illegal frequency reference to the drive If Control Interface option is installed check connections at TB3 24 If option is not installed set Input Mode to 1 BGND 10ms Over Microprocessor loop fault Occurs if the 10ms Replace Main Control Board or complete drive as 51 background task hasn t been run in 15 ms required Blwn Fuse Flt If the difference between the commanded voltage Locate cause replace fuse 58 and the measured voltage is greater than 1 8 of ated voltage for 0 5 seconds then a fault will be issued indicating that the bus fuse in 30 kW 40 HP and up drives has blown Diag C Lim The drive output current has exceeded the hardware Check programming of Cur Lim Trip En parameter 36 current limit and the Cur Lim Trip En parameter was Check for excess load improper DC boost setting Drive Fault Reset 22 enabled Power up has been attempted with an Open Stop contact or Closed Start contact DC brake volts set too high or other causes of excess Current Check verify wiring and contact operation Drive gt
27. Bus Sense A signal transducer that generates a signal proportional to the current in the drive s DC bus The control logic uses this signal to sense the presence or absence of bus voltage Refer to Counter Electromotive Force CMOS Complimentary Metallic Oxide Semiconductor A semiconductor device in which an electric field controls the conductance of a channel under a metal electrode called a gate Cogging A condition in which a motor does not rotate smoothly but steps or jerks from one position to another during shaft revolution Cogging is most pronounced at low motor speeds and can cause objectionable vibrations in the driven machinery Glossary G 3 Constant Torque Range speed range in which a motor is capable of delivering a constant torque subject to cooling limitations of the motor Constant Voltage Range AC Drives The range of motor operation where the drive s output voltage is held constant as output frequency is varied This speed range produces motor performance similar to a DC drive s constant horsepower range Constant Volts per Hertz V Hz The V Hz relationship exists in AC drives where the output voltage is directly proportional to frequency This type of operation produces constant rated torque as the motor s speed varies Continuous Duty CONT A motor that can continue to operate without stopping and remain within the insulation temperature limits after it has reached normal operating equilib
28. Connector B 13 Connector Connector 7 S 6 41 Terminal Strip 7 Terminal Strip Connector TB6 J9 Connector li Terminal Strip 10 4 0783 ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important 6 Installation Disassembly and Access Procedures 3 17 Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the Main Control Board Mounting Plate Refer to Removing the Main Control Board Mounting Plate in this chapter Disconnect the following from the Gate Driver Board J2 connector J6 connector J7 connector J8 connector J9 connector J10 connector J13 connector
29. February 2002 10 Remove the MOV Surge Suppressor Refer to the removal instructions for the MOV Surge Suppressor in this chapter Remove TBI 1 Remove the nut located on the lowest stud on Terminal PE 2 Remove the four screws fastening the TB1 Assembly to the drive 3 Pull the complete TB1 Assembly with the shield and LEMS attached away from the drive Access the Fan 1 Disconnect the Fan Wiring Harness 2 Remove the screws fastening the Fan Cover to the chassis 3 Pull the Fan Cover assembly away from the drive 4 Remove the screws fastening the fan to the Fan Cover to remove the fan 5 Disconnect the Fan Capacitor from the Fan Wiring Harness 6 Unscrew the Fan Capacitor from the chassis by hand 7 Disconnect the Fan Transformer from the Fan Wiring Harness 8 Remove the screws fastening the Fan Transformer to the chassis Installation Install the Fan Assembly in reverse order of removal with the following exceptions Thread the fan wiring connector through the hole in the Fan Cover Referto Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications Install the Fan Capacitor to the chassis with M8 split washer and hand tighten Connect the Fan Transformer red wire to terminal S L2 and the black wire to terminal R L 1 Important Install washers on TBI terminals with the serrated side ATTENTION Replace all guards before applying power to the d
30. HIM Error 1 The checksum read from the EEPROM Repeat operation Replace HIM does not match the checksum calculated from the EEPROM data EE Init Read 1 Gate Driver Board replacement requires 1 Reset to factory defaults amp reset fault 53 re initialization 2 Check all connections to the Power Driver Board 2 Trouble reading EEPROM during initialization Replace the board or complete drive as needed EE Init Value Stored parameter value is out of range on Check all connections to the Power Driver Board 54 initialization Replace the board or complete drive as needed EEprom Checksum 66 EEprom Fault 32 FGND 10ms Over 52 Ground Fault 13 Ground Warning 57 The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data EEPROM is being programmed and will not write a new value Microprocessor loop fault Occurs if a 10ms interrupt is pending before the current interrupt is complete A current path to earth ground in excess of 100A has been detected at one or more of the drive output terminals NOTE If ground current exceeds 220 of drive rated current Overcurrent F It may occur instead of Ground Fault A current path to earth ground in excess of 2A has been detected at one or more of the drive output terminals See Ground Warning Check all wire and cable connections to the Power Driver Board Replace Power Driver Board or complete drive as required Check all
31. Inc www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1336 PLUS 6 6 February 2002 P N 74002 223 01 B Supersedes August 1999 Copyright 2002 Rockwell Automation All rights reserved Printed in USA
32. Inductor enclosure ATTENTION The DC Bus Inductor weighs 100 165 Failure to use extreme caution in handling this part may result in serious injury 4 Remove the eight bolts fastening the Bus Bar Cables to the DC Bus Inductor terminals 5 Remove the four bolts fastening the DC Bus Inductor to the back panel of the chassis 6 Remove the Bus Inductor from the drive Part Replacement Procedures 5 33 Installation Install DC Bus Inductor 1 1 in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION If you mount the inductor remotely verify the connections between the Bus Inductor the Input Rectifier Bus Bars and the DC Brake Terminals L1 of inductor should connect to the Input Rectifier Bus Bar L2 to the DC Brake Terminal L3 to the DC Brake Terminal and L4 to the Input Rectifier Bus Bar Refer to Chapter 4 Component Test Procedures Test 5 Testing the Input Rectifiers ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 34 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Chapter Objectives Ordering Replacement Parts Chapter 6 Replacement Parts List This chapter illustrates and lists replacement parts for the 1336 PLUS Drives rate
33. Mode AB0419A Drive goes to Maximum F req Is Yes Troubleshooting and Error Codes 2 15 Drive Goes to Max Frequency Important Command Frequency parameter in the Metering Group can be checked using the HIM Drive is correctly following Freq Reference Command Freq Maximum Freq No Freq Source No correct Yes Skip Frequency function interfering ves with reference Freq source Yes Adapter 1 6 Freg 5 Yes Preset 1 7 Does the metering parameter for the No frequency reference Is Scanport Adapter or L Option setto select the correct reference Correct the Speed Select inputs Reprogram the Skip Frequency function Replace Main Control Replace the Adapter Board providing the reference 15 the Preset used programmed to Maximum Freq Yes Reprogram to correct value equal Maximum Freq Yes Input signal at TB2 normal Y Analog Invert correct Yes Correct input signal problem Reprogram Analog Invert Clearing Faults AB0420B After correcting a fault you can clear a fault from the drive in one of three ways 1 Cycle the input power to the drive 2 Press the Stop button This works only if Fault Clear Mode is set to Enabled 3 Issue a reset command from a serial device Publication 1336 PLUS 6 6 February 2002 2 16 Troubleshooting and Error Codes Thi
34. TB4 24 VDC Auxiliary Input Ground wire from TB7 on the Gate Driver Board Turn the eight standoff screws fastening the Gate Driver Board to the mounting plate 1 4 turn counterclockwise Pull the Gate Driver Board away from the mounting plate Install the Gate Driver Board in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 3 18 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Removing the Precharge Board from the Mounting Plate Figure 3 10 Precharge Board no Removal Connector Connector J4 3 Connector 2 A ector Precharge Board High Voltage Guard AB0780B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until t
35. VDC ATTENTION Capacitors not installed correctly will erupt or vent and could cause injury and equipment damage Observe correct polarities Part Replacement Procedures 5 9 Thermistor The Thermistor is located on the heat sink at the top middle of the drive Figure 5 4 Thermistor Thermistor Connector to Main Control Board J 1 AB0788B Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 5 10 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage
36. as a percentage Dynamic Braking Refer to Braking Efficiency Ratio of output to input indicated by a percentage In a motor it is the effectiveness with which the motor converts electrical energy into mechanical energy In a power supply it is the effectiveness with which the power supply converts AC power into DC power Electrostatic Discharge ESD A static electricity discharge that may damage drive components Refer to the ESD precautions found in this manual to guard against damage to drive components Enable To activate logic by the removal of a suppression signal Enclosure The housing in which equipment is mounted They are available in designs for various environmental conditions Refer to NEMA standard for specifications of different types of enclosures Glossary G 5 ENUM Enumeration An ANSI C standard extension to the C language An ENUM is a set of named integer constants that specify all the legal values a variable of a given type may have The keyword ENUM signals the start of an enumeration type ESD Refer to Electrostatic Discharge Floating Ground An electrical circuit common which is not at earth ground potential or the same ground potential as circuitry with which it interfaces A voltage difference can exist between the floating ground and earth ground Force The tendency to change the motion of an object with an exertion of energy from a separate source Full Load Torque The full load torque
37. in part without written permission of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product ControlNet is a trademark PLC is a registered trademark of Rockwell Automation Updated Information August 1999 February 2002 Summary of Changes Summary of Changes The information below summarizes the changes since the last release 575 AC information CP350 CP450 has been added to this manual The following pages contain this new information Table has been added on page 5 Table has been added on page 7 IMPORTANT statements have been added to Figure 5 3 on page 5 8 e Ratings have been added to pages 6 1 and 6 3 Ratings have been added to pages 7 1 through 7 5 Information has been added to Overtemp Fault 08 in Table 2 A on page 2 6 Information has been added to Test 3 Testing the Power Modules beginning on page 4 9 illustrations have been changed to depict the new style Bus Fuse Diode F1 assembly with horizontal terminal block orientation P
38. of a motor is the torque necessary to produce rated horsepower at full load speed Gate 1 A logic element that blocks or passes a signal depending on the status of specified input signals 2 The control element of an SCR GND Sense A current transducer that detects an unequal or imbalanced current in the three phase AC line or DC bus of the drive The imbalance indicates an output ground fault condition Horsepower hp A unit of power 1 hp 33 000 ft Ib min 746 watts IEC International Electrotechnical Commission IGBT Refer to Insulated Gate Bipolar Transistor Induction Motor An induction motor is an alternating current motor in which the primary winding on one member is connected to the power source A secondary winding on the other member carries the induced current There is no physical electrical connection to the secondary winding its current is induced Inertia A measure of a body s resistance to change in velocity whether a body is at rest or moving at a constant velocity The velocity can be either linear or rotational The moment of inertia WK is the product of the weight W of an object and the square of the radius of gyration K The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation WK is usually expressed in units of Ib ft Insulated Gate Bipolar Transistor IGBT A type of transistor commonly used in drive control devices Publicatio
39. of this chapter m Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the four nuts fastening the High Voltage Guard to the standoffs 4 Pull the guard away from the drive Installation Install the High Voltage Guard in reverse order of removal Refer to Table 3 A Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 Disassembly and Access Procedures 3 7 Removing Control Interface Board MOD L4 1 5 or L6 Figure 3 5 Control Interface Board Removal Main Control Board Control Interface Board Terminal Strip TB3 AB0803B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Publication 1336 PLUS 6 6 Febr
40. on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis e Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Tools You need the following tools to disassemble and assemble the drive Pliers e Phillips screwdrivers medium and large Standard screwdrivers small medium and large e 25 64 inch or 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m Nylon tie wraps Component Test Procedures 4 3 Test 1 Testing the Gate The Gate Driver Board is located beneath the Main Control Board If Driver Board modules have been replaced you must test the Gate Driver Board Figure 4 1 Gate Driver Board Test VR2 VR3 VR5 1 VR4 Gate Driver Board AB0804B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to
41. six bolts fastening the Input Bus Bars to the Input Rectifier Assembly and the Input Fuse Assembly Slide the Input Bus Bars to the right to remove the bus bars and the Ground Fault CT which encircles the bus bars from the drive Slide the Ground Fault CT off the bus bars Publication 1336 PLUS 6 6 February 2002 5 20 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 Installation Install the Ground Fault CT in reverse order of removal inserting the Input Bus Bars through the center of the Ground Fault CT Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION A possible short circuit hazard exists Position the fuse to inductor wire with the shrink wrapped end of the wire connected to the Bus Inductor Failure to position the wire as illustrated may result in serious injury or equipment damage ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Part Replacement Procedures 5 21 Input Rectifiers The Input Rectifiers are located toward the bottom of the heat sink Figure 5 9 Input Rectifiers n gt Removal Preform Input Rectifier Negative Converter Bar Snubber Board Standoffs Positive Converter Bar AB0790B ATTENTION Disconnect and lock out power from the drive bef
42. so that the motor develops a counter torque that exerts a retarding force to brake the motor Pot A potentiometer or variable resistor Power Work done per unit of time Measured in horsepower hp or watts W 1 hp 33 000 ft Ib min 746 W Power Factor Displacement A measurement of the time phase difference between the fundamental voltage and fundamental current in an AC circuit It represents the cosine of the phase angle difference cos Power Factor Distortion A measurement of the ratio of the real power kW to the apparent power Distortion power factor takes into account harmonic voltage and current distortion as well as voltage to current displacement Preform A flexible material used between an electronic component and the heat sink to which the component is attached Preform provides maximum heat dissipation from the component to the heat sink Preset Speed Describes one or more fixed speeds at which a drive operates Programmable Controller A solid state control system that has a user programmable memory for storage of instructions to implement specific functions such as I O control logic timing counting report generation communication arithmetic and data file manipulation A controller consists of a central processor input output interface and memory controller is designed as an industrial control system Pull In Torque The maximum constant torque to which a synchr
43. will damage the Power Modules ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 14 Part Replacement Procedures Bus Fuses F1 The Bus Fuses are located on the Bus Capacitor Bank Assembly Figure 5 6 Bus Fuses F1 Bus Fuses Fa Diode Terminals Early Model Verticle lt B m 2 5 Later Model Horizontal S Jele AB0794B Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to Zero volts Publication 1336 PLUS 6 6 February 2002 Part Replacement Procedures 5 15 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring durin
44. wire and cable connections to the Main Control Board Replace Main Control Board or complete drive as required Replace Main Control Board or complete drive as required Check the motor and external wiring to the drive output terminals for a grounded condition Check the motor and external wiring to the drive output terminals for a grounded condition Publication 1336 PLUS 6 6 February 2002 Name amp Fault Hertz Err Fault 29 Troubleshooting and Error Codes 2 5 Table 2 A continued 1336 PLUS Fault Descriptions This fault indicates that there is not a valid operating frequency It can be caused by any of the following 1 Maximum Freq is less than Minimum Freq 2 Skip frequencies and skip bandwidth eliminate all operating frequencies 3 4 20mA input signal speed reference has been lost and 4 20mA Loss Sel is set for Stop F ault Action 1 Check Minimum Freq and Maximum Freq parameters 2 Check Skip Freq 1 Skip Freq 2 Skip Freq 3 and Skip Freq Band parameters 3 Check for broken wires loose connections or transducer loss at 4 20mA input TB2 Hertz Sel Fault 30 A frequency select parameter has been programmed with an out of range value Reprogram Freq Select 1 and or F req Select 2 with a correct value If problem persists replace Main Control Board or complete drive HIM Drive Loop Overrn Fit 23 Max Retries Fault 33 Motor Mode FIt 24
45. within the United States National Electrical Manufacturer s Association NEMA A non profit organization organized and supported by electrical equipment and supply manufacturers Some NEMA motor standards include horsepower hp ratings speeds frame sizes and dimensions torques and drive enclosures NEC Refer to National Electrical Code Negative Slope The location on a V Hz curve where the break voltage exceeds the base voltage NEMA Refer to National Electrical Manufacturer s Association Offset The steady state deviation of a controlled variable from a fixed setpoint Op Amp An operational amplifier A high gain stable linear DC amplifier that is designed to be used with external circuit elements Open Loop System A control system that has no means of comparing the output with the input for control purposes Overload Capacity The ability of the drive to withstand currents beyond the system s continuous rating It is normally specified as a percentage of full load current endured for a specified time period Overload capacity is defined by NEMA as 150 of rated full load current for one minute for standard industrial DC motors Publication 1336 PLUS 6 6 February 2002 G 8 Glossary Publication 1336 P LUS 6 6 February 2002 PC 1 Personal Computer 2 Programmable Controller 3 Printed Circuit Plugging A type of motor braking provided by reversing either line voltage polarity or phase sequence
46. 00 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 PLUS 6 6 February 2002 3 2 Disassembly and Access Procedures Fastener Torque Specifications Publication 1336 PLUS 6 6 February 2002 Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Tools You need the following tools to disassemble and assemble the drive Pliers e Phillips screwdrivers small medium and large e Standard screwdrivers small medium and large e 25 64 inch or 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m Nylon tie wraps Torque Sequence When mounting components to a drive s heat sink component fastener torque sequences and tolerances are crucial to component to heat sink heat dissipation ATTENTION Component can be damaged if temporary tightening procedure is not performed to
47. 5 No Display 2 12 Objective of this Manual P 1 Op Error Fault 2 6 Open PotFault 2 6 Operation Human Interface Module 1 10 Option Control Interface 1 2 Identification P 4 Overcurrent Flt 2 6 Overload Fault 2 6 Overtemp Fault 2 6 Overvolt Fault 2 6 P P Jump Err Fit 2 6 Parameter Definition P 9 Phase U Fault 2 6 Phase V Fault 2 6 Phase W Fault 2 6 Pole Calc Fault 2 6 Power Loss Fault 2 6 Power Mode Fault 2 6 Power Module Illustration 5 11 Installation 5 13 Removal 5 11 Test 4 7 Power Module Snubber Board Illustration 3 20 Installation 3 22 Removal 3 20 Power Overload 2 7 Power Test Fit 2 7 Precautions Electrostatic Discharge P 2 Safety P 1 Precharge Board Illustration 3 18 Index 1 3 Installation 3 19 Removal 3 9 3 18 Test 4 5 Precharge Fault 2 7 Precharge Open 2 7 Press Definition P 9 Procedures Accessing Internal Drive Components 3 1 Bus Capacitor Bank Installation 5 7 Bus Capacitor Bank Removal 5 5 Bus Capacitor Bank Test 4 11 Bus Fuse 5 14 5 15 Circuit Board Platform Installation 3 11 Circuit Board Platform Removal 3 9 Component Test 4 1 Control Board Installation 3 15 Control Board Mounting Plate Installation 3 13 Control Board Mounting Plate Removal 3 12 Control Board Removal 3 14 Control Interface Board Installation 3 8 Control Interface Board Removal 3 7 DC Bus Inductor L1 Installation 5 33 DC Bus Inductor L1 Removal
48. 5 31 Diagnostic 2 11 Fan Installation 5 30 Fan Removal 5 28 Gate Driver Board Installation 3 17 Gate Driver Board Removal 3 16 Gate Driver Board Test 4 3 Ground Fault CT 5 18 5 20 High Voltage Shield 3 6 Input Fuses 5 16 5 17 Input Rectifier Installation 5 22 Input Rectifier Removal 5 21 Input Rectifier Test 4 14 Major Component Replacement 5 3 Power Module Installation 5 13 Power Module Removal 5 11 Power Module Snubber Board Installation 3 22 Power Module Snubber Board Removal 3 20 Power Module Test 4 7 Precharge Board Installation 3 19 Precharge Board Removal 3 18 Precharge Board Test 4 5 Replacement Part 5 1 Thermistor Installation 5 10 Thermistor Removal 5 9 Product Identification P 3 Programming Input Mode 1 4 Publication 1336 PLUS 6 6 February 2002 Index Publication 1336 PLUS 6 6 February 2002 Local 1 4 R Rating Drive P 7 Related P ublications P 10 Removal Procedures See Procedures Removal Human Interface Module 1 10 Replacement Part Procedures 5 1 Replacement Parts 6 1 Reprogram Fault 2 7 ROM or RAM Fit 2 7 Run BoostFault 2 7 S Safety Precautions P 1 Schematics 7 1 Serial Fault 2 7 Shear Pin Fault 2 7 Six Point Mounting 3 3 Snubber Board Input R ectifier Illustration 3 23 Installation 3 24 Removal 3 23 Snubber Board Power Module Illustration 3 20 Installation 3 22 Removal 3 20 Speed Select InputState 1 8
49. 50 600A A70QS 25178 315 20 350 400A 7005 25178 315 18 400 600A A70QS 25178 315 20 400 500A 7005 25178 315 19 450 700A 7005 25178 315 21 400 600A 7005 25178 315 20 Note 2 The Inverter Bus Fuse for this product is as follows HORSEPOWER 380 460VAC FUSE CURRENT TYPE 500V 600VAC FUSE CURRENT TYPE FUSE INFORMATION FUSE INFORMATION RATING CATALOG P N RATING CATALOG P N ALL 2x450A A65C450 4AB 25178 254 01 2 4504 A070URC33TT10450 188956 001 Note 3 The following is a listing of all printed circuit assemblies versus fuse and documentation information SCHEMATIC FUSE INFORMATION ITEM B M DIAGRAM DESIGNATOR RATING TYPE P N 200 101 F1 1 0A 600V_ KTK R 1 25172 260 08 AL L5A 600V_ KTK R 1 5 25172 260 09 10 74101 181 51 14101 179 F1 F3 1 5A 600V KTK R 1 5 25172 260 09 All 13 74103 867 51 74103 866 NONE A20 22 74103 784 51 14103 783 NONE A23 28 74103 845 51 14103 844 NONE Note 5 The Output Terminal Block TB9 is only available on F Frame Terminal Blk TB9 drives This terminal block provides a three phase high voltage connection from the load side of the AC Input Line Fuses Normally this connection is used to power an external control transformer user OUTI 480V 600V supplied or other auxiliary circuit Refer to Figure 1 1 for location OUT2 480V 600V Important Depending on the circuitry connected additional fusing may be required OUT3 480V 600V Attention The installation of auxiliar
50. Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 5 17 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the nuts fastening the Input Fuse to the Input Bus Bar and TBI 4 Pull the blown fuse out from the drive Installation Install the Input Fuse in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 18 Part Replacement Procedures Ground Fault CT The Ground Fault CT encircles the Input Bus Bars and is located between the Input Fuse Assembly and the Input Rectifier Assembly Figure 5 8 Ground Fault CT Ground Fault CT Input Bus Bars Con
51. Dust Industrial Use Constant Torque Variable Torque Frame Designation Output Nominal Output Nominal Code Code Code Code Amps HP Amps HP F 350 0 350 350 0 350 CP350 4 400 0 400 400 0 400 400 4 450 0 450 450 0 450 450 4 Drive rating is based on a carrier frequency of 4kHz maximum an altitude of 1 000 meters or less and a maximum ambient temperature of 40 C VT Ratings do not apply to 380V Input Refer to the Language Module and Options tables following these Catalog Number tables Not available in this rating Publication 1336 PLUS 6 6 February 2002 Table P C Language Modules Description Option Code English English EN4 English French FR4 English German DE4 English Italian IT4 English Japanese JP4 English Spanish ES4 Table P D Options Code Description Human Interface Module NEMA Type 1 IP 20 Code Communication Options Description din ste No GM1 Single Point Remote 1 0 rogrammer Sny GM2 RS 232 422 485 amp DH485 HA1 Programmer Controller w Analog Pot GM3 DeviceNet HA2 Programmer Controller w Digital Pot Human Interface Module NEMA Type 4 IP 65 Control Interface Options HJP Programmer Only L4 TTL Contact HF1 Programmer LCD Analog Pot L4
52. E TTL Contact amp Encoder Feedback HJ2 Programmer Controller w Digital Pot L5 24V AC DC L5E 24V AC DC amp Encoder Feedback Human Interface Module NEMA Type 12 L6 115V AC IP 54 L6E 115V AC amp Encoder Feedback HJP Programmer Only HJ2 Programmer Controller w Digital Pot Table P E 380 480V Drives Maximum Derat Heat Heat Total Catalog Output Amp Rating in Dissipation Sink Watts Number l 7 Drive Watts 1 CT VT Watts 25 1 250 325 0 360 0 4 4 4 4 BP300 360 0 425 0 4 4 4 4 BP350 425 0 475 0 4 400 475 0 532 0 4 4 BP450 532 0 532 0 4 4 4 must be derated CT Constant Torque VT Variable Torque Publication 1336 PLUS 6 6 February 2002 1 Rating is at 4kHz If carrier frequencies above 4kHz are selected drive rating must be derated 2 Drive Ambient Temperature Rating is 40 C If ambient exceeds 40 C the drive must be derated 3 Drive Rating is based on altitudes of 1 000m 3 000 ft or less If installed at higher altitude drive 8 Refer to the 1336 PLUS User Manual Appendix A 7 Table 575V Drives Maximam Derate neat Total Catalog Output Amp Rating Dissipation Sink Curve Watts Number m Drive Watts 1 CT VT Watts 43 1 CP350 350 0 350 0 4 4 4 4 CP400 400 0 400 0
53. M1 0 318 U DC Brake V M2 0 318 DC Brake W M3 0 318 W U M1 DC Brake Infinite U V M2 DC Brake Infinite V W M3 DC Brake Infinite W Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 setto Diode range 6 If the readings are not approximately the same as in Table 4 B Publication 1336 PLUS 6 6 February 2002 the last column identifies the phase with a potential problem If the readings are not correct continue with the test procedure to check the individual phase or phases in question Component Test Procedures 4 9 7 Remove the High Voltage Guard Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 8 Remove the Power Module Snubber Boards Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board 9 Test the Power Module Snubber Resistor The Snubber Resistor will read 8 0 ohm with meter on resistance Refer to Figure 4 4 10 Test the Power Module phases that did not pass the Table 4 B tests Table 4 C shows meter connections and ideal meter readings for those connections Refer to Figure 4 3 for meter connection locations Table 4 C Power Modules Upper Phase Meter Lead Meter Lead IMS Type of Reading Motor NV 0 289v Diode HNV Motor Infinite Diode E TP1 0 289v Diode TP1 E Infinite Diode E Motor 0 ohms Resistance TP1 HNV 0 ohms Resistance E R2 10k ohms Resistance Lower Phase Meter L
54. MMABLE MACHINERY DESIGN IMPLEMENT ELECTRICAL SYSTEMS TRAIN EDUCATE MACHINE USERS SUPERVISE FLOOR OPERATIONS V WHAT LEVEL OF EXPERIENCE DO YOU HAVE WITH EACH OF THE FOLLOWING PRODUCTS NONE LITTLE MODERATE EXTENSIVE PROGRAMMABLE CONTROL AC DC DRIVES PERSONAL COMPUTERS NC CNC CONTROLS DATA COMMUNICATIONS LAN V THE OVERALL QUALITY OF THIS MANUAL BY CIRCLING YOUR RESPONSE BELOW 1 POOR 5 EXCELLENT HELPFULNESS OF INDEX TABLE OF CONTENTS 1 2 3 4 5 CLARITY 1 2 3 4 5 EASE OF USE 1 2 3 4 5 ACCURACY AND COMPLETENESS 1 2 3 4 5 QUALITY COMPARED TO OTHER COMPANIES MANUALS 1 2 3 4 5 QUALITY COMPARED TO OTHER ALLEN BRADLEY MANUALS 1 2 3 4 5 V WHAT DID YOU LIKE MOST ABOUT THIS MANUAL V WHAT DID YOU LIKE LEAST ABOUT THIS MANUAL V PLEASE LIST ANY ERRORS YOU FOUND IN THIS MANUAL REFERENCE PAGE TABLE OR FIGURE NUMBERS V DO YOU HAVE ANY ADDITIONAL COMMENTS V COMPLETE THE FOLLOWING NAME COMPANY TITLE DEPARTMENT STREET CITY STATE ZIP TELEPHONE FAX AND OR E MAIL FOLD HERE FOLD HERE BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 413 MEQUON WI POSTAGE WILL BE PAID BY ADDRESSEE ROCKWELL AUTOMATION ALLEN BRADLEY Attn Marketing Communications P O Box 760 Mequon WI 53092 9907 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES SCANport is a trademark of Rockwell Automation Company Inc PLC is a registered trademark of Rockwell Automation Company
55. Motor Stall Fault 06 Error 1 The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data Error 2 Number of parameters in saved profile does not equal master Error 3 Download was attempted to a different type drive i e 1336 gt 1305 Error 4 Saved data not correct for new drive Error 5 Drive is running while attempting download An overrun of the 2 5ms control loop has occurred Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of Reset Run Tries A fault has been detected originating from the Control Board Current remained over 150 of Rated Amps for more than 4 seconds Retry download Replace HIM Retry download Replace HIM Download can only take place with same type drive Capabilities of drive different than master drive Reprogram param Stop drive then perform download Check all connections to the Power Driver Board Replace the board or complete drive as required Check fault buffer for fault code requiring reset Correct the cause of the fault and manually clear by pressing the local Stop key or cycling the TB3 Stop input Check all connections to the Control Board Replace the board Language Module or complete drive as required If the motor is drawing excessive current over 150 the motor load is excessive and will not allow the drive to accelerate to set speed A longer accel time or a redu
56. ROL BOARD ES c QO tu E a m o 2 p E o NS wn KS a 9 Oost gt E e a E coa z O3 d 5 CO p w qon 2 E u amo an m u 2 TOO NA a lt lt d HEB EE lt oz ui ac OS ja SE ER x TOO NM co Twa nn RS Nn lt WdalnNS wam HADHZQANI lt gt or JA NA ec P lt m ve saw ze E Te Lomm ae ao ez sawm _ 235 x MP E L pu XE n 5 qz es oz al oz Di sma 6t at a 15 SU vt a YALYAANI 5 5 z Ste a Q m oe wneman x x uc uc Eu pu lt E xt oz oz non USE TUS 5 7 4 Schematics BP250 BP450 and CP350 CP450 380 460VAC AC INPUT POWER e 5 12 SEE TABLE 2 415 380
57. a list of terminology and definitions refer to the Glossary in the back of this manual Auxiliary Input The Auxiliary Input is a terminal connection on the Control Interface Board This connection provides an external input for use as an Auxiliary Interlock Unless this interlock is closed the drive will be faulted with an Auxiliary Fault Auxiliary Interlock The Auxiliary Interlock is a user supplied circuit consisting of reset overload or other interlocking circuitry The Interlock is wired to the drive Auxiliary input Bit A bit is a single character or status point used in programmable logic Eight bits form a BYTE 16 bits form a word Drive parameters are actually eight bits or 16 bit words Check To check means to examine either the physical condition of something or the setting of some control such as a Parameter Checking a drive board or component may also require measurements and tests Connector A connector connects one drive board to another Connectors come in two designs male and female Male connectors are stationary and contain pins which are sometimes joined by jumpers Female connectors are at the ends of wires or ribbon cables and plug into male connectors P 9 Default When drive function defaults it automatically changes to a pre programmed setting Enable Input The Enable Input is a terminal connection on the Control Interface Board This connection provides an extern
58. ailure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the High Voltage Guard Refer to Removing the High Voltage Guard in this chapter Measure the DC voltage from TP5 on the Power Module Snubber Board to TP2 DC Bus If voltage greater than 50 VDC is still present follow the directions in the Electric Shock Hazard Attention shown above Remove the Snubber Resistor wire from the Power Module Snubber Board stake on connectors J1 and J2 Remove the twelve screws fastening the Power Module Snubber Board to the snubber bracket to remove the snubber boards Check Snubber Resistor with VOM The reading should be 8 ohms If open replace resistor Publication 1336 PLUS 6 6 February 2002 3 22 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Installation ATTENTION Do not substitute longer or shorter hardware when fastening the Power Module components to the Power Modules Use the same size fastener to fasten the components as was originally used
59. ainst this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Publication 1336 PLUS 6 6 February 2002 Fault Descriptions Troubleshooting and Error Codes 2 3 Fault Display The LCD display is used to indicate a fault by showing a brief text statement relating to the fault see figure below The fault will be displayed until a drive reset is initiated Refer to Table 2 A for a listing and description of the various faults Table 2 B provides a listing of faults by number Overvolt Fault HERS Important Before clearing a fault refer to the Fault Descriptions table and Diagnostic Procedures by Symptom flowcharts in this chapter to isolate and correct faults To help differentiate parameter names and display text from other text in this manual the following conventions will be used Parameter Names will appear in brackets Display Text will appear in quotes Contact Description During normal operating conditions no faults present drive running the CR3 fault contacts at TB2 13 amp 14 are open and the contacts at TB2 14 amp 15 are closed When a fault occurs the state of these contacts changes Publication 1336 PLUS 6 6 February 2002
60. al input to enable or disable the Drive Output section It must be true to permit the drive to operate False False refers to a logical false state For instance a Control Interface signal on TB3 is false when the input contact is open or the appropriate voltage is not applied to the Control Interface Board Jumper A jumper completes a circuit between two pins within a male connector on a drive board In the absence of certain optional equipment using female connectors jumpers are applied to certain pins within a male connector to complete specific and necessary circuits Control Interface Board A Control Interface Board plugs into connectors J7 and J9 located on the lower portion of the Main Control Board This board is identified as L4 4E L5 5E or L6 6E and provides optional control wiring configurations for a drive Parameter Parameters are programmable drive functions that define various operating functions or status displays of a drive Refer to Bulletin 1336 PLUS Adjustable Frequency AC Drive User Manual for Parameter details Press Press a button on the Human Interface Module to change Parameter settings and drive functions Publication 1336 PLUS 6 6 February 2002 10 Related Publications Publication 1336 PLUS 6 6 February 2002 True True refers to a logical true state For instance a Control Interface signal on TB3 is true when LA LAE contact input is closed L5 L5E input term
61. allable Start Enable Stop Clear Fault Auxiliary Reverse 2 Stop Mode Selects Digital Potentiometer MOP Run Forward 2 Accel Decel Rates Run Reverse 3 Speed Selects Local Control The available combinations are shown in Figure 1 4 Programming the Input Mode parameter to one of the Input Mode numbers listed selects that combination of input functions Important The Input Mode parameter can be changed at any time however programming changes will not take affect until power has been cycled to the drive When changing an input mode it is important to note that the corresponding inputs to TB3 may also change The programming options of the Control Interface Option allow the user to select an input combination to meet the needs of a specific installation Appropriate selection of a combination may be done by using Table 1 A First determine the type of start stop direction control desired Then select the remaining control functions available After selecting a group of Input Modes use Figure 1 4 for specific mode selection Record the selected mode number below Selected Mode Number Local Programming For local programming and control information refer to the 1336 PLUS User Manual Publication 1336 PLUS 6 6 February 2002 Start Stop Stop amp Enable Only Momentary Pushbutton 3 Wire Momentary Pushbutton 3 Wire Maintained switches for combined run and direction Direction Control C
62. ary 2002 2 8 Name amp Fault Temp Sense Open 55 Troubleshooting and Error Codes Table 2 A continued 1336 PLUS Fault Descriptions Description Heat sink thermistor is open or malfunctioning Action Check thermistor and connections Undervolt Fault 04 DC Bus voltage fell below the minimum value 388V DC at 460V AC input Line Loss Fault and Low Bus Fault set to enabled Monitor the incoming AC line for low voltage or line power interruption UV Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output 41 two output terminals terminals for a shorted condition UW Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output 42 two output terminals terminals for a shorted condition VW Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output 43 two output terminals terminals for a shorted condition Xsistr Desat Flt One or more of the output transistors were operating in Check for damaged output transistors Replace output 47 the active region instead of desaturation This can be transistors Power Driver Board or complete drive as caused by excessive transistor current or insufficient base drive voltage Publication 1336 PLUS 6 6 February 2002 needed Troubleshoo
63. ber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Access the Main Chassis 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform 5 Remove the nine bolts fastening the Output Bus Bars to the Power Module Assembly and TB1 6 Pull the Output Bus Bars away from the drive 7 Remove the Input Fuses Refer to the removal instructions for Input Fuses in this chapter 8 Remove the three bolts fastening the Input Bus Bars to the Input Rectifier and remove the six screws on the Input Bus Bars 9 Remove the Input Bus Bars with the Ground Fault CT encircling the bars from the drive Publication 1336 PLUS 6 6 February 2002 5 30 Part Replacement Procedures Publication 1336 PLUS 6 6
64. ced load may be required Neg Slope Fault 35 Drive software detected a portion of the volts hertz curve with a negative slope Check drive programming 1 Maximum Voltage parameter must be greater than Base Voltage 2 Maximum Freq parameter must be greater than Base Frequency 3 Base Voltage parameter must be greater than Start Boost 4 If the DC Boost Select parameter is set to Full Custom Base Voltage must be greater than Break Voltage and Break Voltage must be greater than Start Boost Publication 1336 PLUS 6 6 February 2002 2 6 Troubleshooting and Error Codes Name amp Fault Open Pot Fault 09 Table 2 A continued 1336 PLUS Fault Descriptions An external pot is connected and the common side ofthe pot is open The drive generates this fault when the voltage between TB2 2 and TB2 3 exceeds 3 9V DC Check the external potentiometer circuit at TB2 terminals 1 2 and 3 for an open circuit Op Error Fault 11 A SCANport device requests a Read or Write of a data type not supported This will also occur if 1 Motor Type is set to Sync PM and Stop Mode Used is setto DC Brake or 2 Motor Type is set to Sync Reluc or Sync PM and S peed Control is setto Slip Comp Check programming Overcurrent Fit 12 Overload Fault 07 Overtemp Fault 08 Overvolt Fault 05 Phase U Fault 38 Overcurrent is detected in instantaneous overcurren
65. d BP250 BP450 or CP350 CP450 and describes replacement parts ordering procedures The following illustration and table show you parts part names part numbers locations and chapters for replacement procedures For your convenience the Rockwell Automation Drives Division and the Rockwell Automation Support Division provide efficient and convenient repair and exchange for eligible equipment A product service report number is required to return any equipment for repair Your local Rockwell Automation distributor or area sales and support office can provide you with a product service report number You should return equipment to be repaired to the area sales and support center nearest you Reference the product service report number on the carton and packing slip Include Yourcompany name Your company address The repair purchase order number A brief description of the problem Contact your local Rockwell Automation distributor or sales office for a complete listing of area sales and support centers near you For parts catalog numbers refer to the 1336 PLUS Spare Parts Pricing publication included with your drive documentation set Publication 1336 P LUS 6 6 February 2002 Replacement Parts List 6 2 Replacement Parts Listing Figure 6 1 Parts for BP250 BP450 Drives 0805 Publ
66. dius through which it acts Torque is measured in pound feet ounce inches Newton meters or gram centimeters Transducer A device that converts one energy form to another e g mechanical to electrical When a transducer is actuated by signals from one system or medium it can supply a related signal to the other system or medium Transient A momentary power deviation in an electrical or mechanical system Glossary G 11 Transistor An active solid state semiconductor device Work A force moving an object over a distance work force x distance Publication 1336 PLUS 6 6 February 2002 G 12 Glossary This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Adapter Locations 1 9 Adptr Freq Err 2 4 Audience for this Manual P 1 Auxiliary Fault 2 4 Auxiliary Input Definition P 8 Auxiliary Interlock Definition P 8 BGND 10ms Over 2 4 Bit Definition P 8 Blwn Fuse Flt 2 4 Bus Capacitor Bank Illustration 5 5 Installation 5 7 Removal 5 5 Test 4 11 Bus Fuse Illustration 5 14 Installation 5 15 Removal 5 14 Check Definition P 8 Circuit Board Platform Illustration 3 9 Installation 3 11 Removal 3 9 Clearing Faults 2 15 Component Test Procedures 4 1 Connector Definition P 8 Control Interface Board Definition P 9 Illustration 3 7 Installation 3 8 Jumper Locations 1 3 Removal 3 7 Control Interface Option 1 2 Control Logic Wiri
67. e bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 5 12 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Plat
68. e of the Stop command Frequency Change Logic Mask bit to 1 AB0418A Publication 1336 PLUS 6 6 February 2002 2 14 Troubleshooting and Error Codes Drive stays at Zero Hertz when Started Drive Status Running Bit Bit1 1 HIM displays At Speed or Drive Status At Speed Bit Bit 8 2 1 Command req greater than zero 15 Freq Source correct Is the frequency reference input to the drive at zero Replace Main Control Board or complete drive as needed Publication 1336 PLUS 6 6 February 2002 Drive Stays at Zero Hertz When Started Important Command Frequency parameter in the Metering Group can be checked using the HIM Refer to Drive Will Not Start HIM displays Accelerating or Drive Status Accel Bit Bit 4 2 1 Replace Main Control Board Gate Driver Board or drive as needed Is Input Mode set to a mode with L Option TB3 Speed Select inputs Are Accel Time 1 or Accel Time 2 set to very long times Drive Alarm Motor Limit or Regen Limit Set Accel Time 1 or Accel Time 2 to correct application values Correct excessive motor load condition Bits Bits 2 amp 3 1 SCANport adapter has selected an incorrect reference Correct the problem with or replace the SCANport adapter Correct problem with frequency reference Check state of Speed Select inputs on TB3 Check programmin of Reference Mask and Input
69. ead Meter Lead giat Type of Reading Reading INV Motor 0 289v Diode Motor INV Infinite Diode E TP1 0 289v Diode TP1 E Infinite Diode E INV 0 ohms Resistance TP1 Motor 0 ohms Resistance E R2 10k ohms Resistance Note Typical malfunction for diode test is shorted in both directions Note Select meter to read appropriate type of measurement where needed Meter Used Fluke Model 87 set to Diode range Publication 1336 PLUS 6 6 February 2002 4 10 Component Test Procedures Publication 1336 PLUS 6 6 February 2002 Figure 4 4 Power Module Snubber Resistors Snubber Resistor AB0999A 11 Replace the Power Module phase if the meter readings are not approximately as shown Refer to Chapter 5 Part Replacement Procedures Power Modules 12 If one or more Power Modules is replaced test the Gate Driver Board Refer to Testing the Gate Driver Board in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Component Test Procedures 4 11 Test 4 Testing the Bus The Bus Capacitor Bank is located on the upper left side of the Main Capacitors Chassis Figure 4 5 Bus Capacitor Bank Test DC Brake Terminal DC Brake GSP md Terminal adi Ld Q Sa X 0801 ATTENTION Disco
70. eir component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the Circuit Board Platform Refer to Removing the Circuit Board Platform in this chapter 4 Remove the wire from Input Rectifier Snubber Board stake on connectors J1 AC1 and J2 AC2 5 Remove the two screws fastening the Snubber Board to the Converter Bus Bar Installation Install the Snubber Board in reverse order of removal Refer to Table 3 A Fastener Torque Specifications Important Verify that the snubber resistor wiring is reconnected to the proper phase snubber board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Accessing Power Plane Components To access the power plane components located on the chassis refer to Removing a Power Module Snubber Board in this chapter Chapter Objectives Component Test Overview Chapter 4 Component Test Procedures The following tests help you troubleshoot BP250 BP450 drives In some cases different tests troubleshoot components of the same These similar tests vary according to the rating of the drive being tested Verify that the rating on the drive matches the rating for the test you are performing ATTENTION Some printed circuit boards and drive compone
71. emove connections and wires from the 7 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove all wires from terminal strip TB3 if a Control Interface Board is used Disconnect the following from the Main Control Board J1 connector J2 ribbon cable connector J6 connector J8 connector 8 pin connector from HIM Mounting Plate Ground wire at stake on connector J10 wires from terminals on TB2 Remove the five screws fastening the Main Control Board to the mounting plate Slide the Main Control Board toward the top of the drive to release it from the slide mount stand offs Lift the Main Control Board away from the mounting plate Installation Install the Main Control Board in reverse order of removal ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 3 16 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Removing the Gate Driver Board from the Mounting Plate Figure 3 9 Gate Driver Board and Mounting Plate no Removal Gate Driver Board Connector 2 b
72. evelop rated power at rated load and voltage With DC drives itis commonly the point where full armature voltage is applied with full rated field excitation With AC systems it is commonly the point where 60 Hz is applied to the induction motor BR Refer to Bridge Rectifier Braking A method of stopping or reducing the time required to stop an AC motor and can be accomplished in several ways 1 DC Injection braking AC drives A method which produces electromagnetic braking forces in the motor by removing 2 AC motor stator phases and injecting DC current The result is a linear braking characteristic ramp that does not diminish with motor speed Application is normally limited to 10 20 of rated motor speed due to increased heating in the rotor 2 Dynamic braking AC drives A method which produces electromagnetic braking forces in the motor by dissipating generated power into the DC bus through a resistive load Braking force remains constant and is only limited by the thermal capacity of the resistors The result is a linear braking characteristic ramp that does not diminish with motor speed 3 Regenerative braking method which produces electromagnetic braking forces in the motor by electronically controlling the return of generated power to the AC supply The result is a controllable linear braking characteristic ramp that does not diminish with motor speed Publication 1336 PLUS 6 6 February 2002 G 2 Glossary
73. form 5 Remove the six bolts fastening the three Output Bus Bars to the Power Module Assembly and 1 6 Remove the Power Module Snubber Boards Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board 7 Remove the bolts fastening the Power Module Bus Bar to the Bus Capacitor Bank 8 Remove the eight screws fastening the Snubber Standoffs to the Power Module Bus Bar Remove the standoffs 9 Slide the Power Module Bus Bar to the right and remove the bus bar from the drive Part Replacement Procedures 5 13 10 Remove the three screws fastening the Power Module Interface Board to the Power Module 11 Remove the six screws fastening the Power Module to the heat sink 12 Pull the Power Module away from the heat sink Installation 1 Clean all surfaces between the Power Module and the heat sink using a soft clean cloth 2 Replace the Preform between the Power Module and the heat sink 3 Install the Power Module in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications Important Remove the copper shorting strip from the Power Module before replacing the Power Module Interface Board ATTENTION Do not substitute longer or shorter hardware when fastening the Power Module components to the Power Modules Use the same size fastener to fasten the components as was originally used Using different fastener lengths
74. g assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Remove the screws fastening the two Bus Fuses to the drive 5 Pull the fuses out from the drive Important When one fuse blows you must replace both fuses Also replace the Bus Fuse Diode Module in parallel Bus Fuse Diode Conversion kits also include new style Bus Bar Installation Install the Bus Fuses in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 16 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 Input Fuses The Input Fuses are located on the bottom left hand side of the chassis above TB1 Figure 5 7 Input Fuses n Removal 795 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals
75. g motion by closing a switch Kinetic Energy The energy of motion of a moving body LAD Refer to Linear Acceleration Deceleration LEM A hall effect current transducer that senses drive output current and generates a signal for the control logic Linear Acceleration Deceleration LAD A circuit that controls the rate at which a motor is allowed to accelerate to a set speed or decelerate to zero speed On most drives this circuit is adjustable and can be set to accommodate a particular application Linearity A measure of how closely a characteristic follows a straight line function Glossary G 7 Locked Rotor Current Steady state current taken from the line current with the a rotor at standstill at rated voltage and frequency This is the current when starting the motor and load Locked Rotor Torque The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency Meggar Test A test used to measure an insulation system s resistance This is usually measured in megohms by applying a high voltage MOV Refer to Surge Protection National Electrical Code NEC A set of regulations governing the construction and installation of electrical wiring and apparatus established by the National Fire Protection Association and suitable for mandatory application by governing bodies exercising legal jurisdiction It is widely used by state and local authorities
76. he bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Disassembly and Access Procedures 3 19 Important Before you remove connections and wires from the 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Disconnect the following from the Precharge Board Jl connector J2connector J3 connector J4 connector Pull the Precharge High Voltage Guard away from the four nylon spacers Turn the six standoff screws fastening the Precharge Board to the mounting plate 1 4 turn counterclockwise Pull the Precharge Board away from the mounting plate Installation Install the Precharge Board in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying
77. he drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Disassembly and Access Procedures 3 13 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Disconnect the following from the Main Control Board J connector J2 ribbon cable connector J8 connector Ground wires from terminal strip TE Remove the two screws fastening the bottom of the Main Control Board Mounting Plate to the Circuit Board Platform Remove the nuts fastening the top of the Main Control Board Mounting Plate to the Circuit Board Platform Lift the Main Control Board Mounting Plate out of the drive Installation Install the Main Control Board Mounting Plate in reverse order of removal Refer to Table 3 A Fastener Torque S
78. her adapters is disabled except Stop inputs must be present before drive will start 4 of Direction Mask must 1 to allow TB3 direction change 5 Firmware version 3 01 and Up Only 6 Inverted function voltage resets integrator to zero 7 See ATTENTION statement on this page 8 Firmware version 4 01 and Up Only 02908 a Momentary o o Maintained 1201 1201 HAI 1201 HA2 1336 GMI Applies to 1305 with firmware FRN 2 01 or earlier and 1336 PLUS with Language Module 1336S EN firmware FRN drive To assure proper JOG function install at least one 1 05 or earlier properly unless a SCANport option is connected to the of the following ATTENTION The JOG function will not operate Speed 5 2 Speed Select 1 Common Enable 1 See Table 1 B 2 Drive must be stopped to take Local Control Control by all other adapters is disabled except Stop 3 These inputs must be present before drive will start 4 of Direction Mask must 1 to allow TB3 direction change 5 Firmware version 3 01 and Up Only 6 Inverted function voltage resets integrator to zero 7 See ATTENTION statement on this page 8 Firmware version 4 01 and Up Only Control Logic Wiring and Adapters 1 7 Input Mode 7 11 19 23 Start Three Wire Control with Multi Source Reversing 3 Stop F ault Reset Mode 7 8 9 10 11 195 238
79. i directional conductor Publication 1336 PLUS 6 6 February 2002 G 4 Glossary Publication 1336 PLUS 6 6 February 2002 Drift A slow change in some characteristic of a device For a drive it is the deviation from the initial set speed with no load change over a specific time period Normally the drive must be operated for a specified warm up time at a specified ambient temperature before drift specifications apply Drift is normally caused by random changes in operating characteristics of various control components Drive Controller Variable Speed Drive Drive An electronic device that can control the speed torque horsepower and direction of an AC or DC motor 1 PWM drive is a motor drive using pulse width modulation techniques to control power to the motor A high efficiency drive used for high response applications 2 SCR drive is a motor drive that uses SCRs as the power control elements Usually used for low bandwidth high power applications 3 Servo drive is a motor drive that uses internal feedback loops for motor current and or velocity 4 Vector drive is an AC static motor drive using power control techniques that produce motor performance similar to DC static drives Duty Cycle 1 The ratio of working time to total time for an intermittently operating device Usually expressed as a percentage 2 The ratio of pulse width to the interval between like portions of successive pulses Usually expressed
80. ication 1336 PLUS 6 6 February 2002 Replacement Parts List Table 6 A Replacement Parts for BP250 BP450 CP350 CP450 Drives Callout Symbol Description Location Replacement Procedures 1 01 06 Transistor Power Module Heat Sink Chapter 5 Power Modules 2 A23 A28 Power Module Gate Interface Power Module Chapter 5 Power Modules Board 3 R20 R22 Power Module Heat Sink Chapter 3 Removing a Power Module Snubber Resistor Snubber Board 4 NTC1 Thermistor Heat Sink Chapter 5 Thermistor 5 SCR1 SCR3 Input R ectifier Heat Sink Chapter 5 Input Rectifiers 6 A20 A22 Power Module Bus Bar and Power Module Chapter 3 Removing a Power Module Snubber Board Snubber Board 7 R1 Load Sharing Resistor Heat Sink Chapter 5 Bus Capacitor Bank 8 CT1 CT2 LEM 1 Chapter 5 LEMs 9 All A13 Input Rectifier 5 nubber Board Input Rectifier Chapter 3 Removing the Input Rectifier 5 nubber Board 10 Al Gate Driver Board Circuit Board P latform Chapter 3 Removing the Gate Driver Board from the Mounting Plate 11 MAIN CONTROL Main Control Board Main Control Board Chapter 3 Removing the Main Control BOARD Mounting P late Board from the Mounting Plate 12 HIM Human Interface Module Enclosure Cover Chapter 1 Module R emoval 13 A10 Precharge Board Circuit Board P latform Chapter 3 Removing the Precharge Board from the Mounting Plate 14 FAN Fan ain Chassis Chapter 5 Fan and Transformer 15 MOVI MOV Surge Suppressor Fan Cover P
81. inal registers 24V or L6 L6E input terminal registers 115V AC The following lists other Rockwell Automation publications that apply to the 1336 PLUS Adjustable Frequency AC Drives with ratings BP250 BP450 Product Data 1336 PLUS 1 0 User Manual 1336 PLUS 5 0 Option Manuals Instructions Renewal Parts List 1336 6 5 Chapter 1 Control Logic Wiring and Adapters Chapter Objectives This chapter introduces you to terminal block locations and wiring and adapter locations and functions Chapter Overview This chapter illustrates and describes Control Logic Interface Options L4 L5 and L6 including Terminal Block TB3 TB3 input mode selections and functions TB3 terminal designations Important All printed circuit boards except the Main Control Board assembly are referenced to negative ground bus ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electro
82. late Chapter 5 MOV Surge Suppressor 16 1 Fan Transformer ain Chassis Chapter 5 Fan and Transformer 17 1 Fan Capacitor ain Chassis Chapter 5 Fan and Transformer 18 L1 DC Bus Inductor ain Chassis Chapter 5 DC Bus Inductor L1 19 CT3 Ground Sense CT nput Bus Bar Chapter 5 Ground Sense CT 20 F1 Bus Fuses Diode Assembly Capacitor Bus Bank Chapter 5 Bus Fuses F1 21 C1 Bus Capacitors ain Chassis Chapter 5 Bus Capacitor Bank 22 1 Input Fuses nput Bus Bars Chapter 5 Input Fuses Publication 1336 PLUS 6 6 February 2002 6 4 Replacement Parts List This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Chapter 7 Schematics BP250 BP450 and CP350 CP450 250 450 HP 1336 PLUS Drives Publication 1336 P LUS 6 6 February 2002 JUMPER PE CONV SNUBBER All R1 Schematics BP250 BP450 and CP350 CP450 DC USER BRAKE POWER DC CONV CONV SNUBBER SNUBBER Al2 1 R12 H R13 H CT3 7 2 TO BLOWER INPU POWER CIRCUIT 50 60HZ CFI R L1 CH CF2 5 12 CH CF3 T L3 CH MOV Y I l 480V OUT1 i 480V PE OUT2 v 480V OUT 3 AUX AC POWER OUTPUT TB9 SEE NOTE 5
83. late to LEM Clamping Plate Cables to terminals Plates to chassis Guard to chassis Torque Torque Ib in N m 14 2 26 3 26 3 Hand tighten 14 2 26 3 50 6 80 9 50 6 50 6 26 3 50 6 14 2 26 3 50 6 14 2 80 9 Refer to Figure 3 3 50 6 80 9 50 6 208 23 208 23 80 9 50 6 208 23 208 23 80 9 80 9 50 6 7 0 8 8 10 09 11 14 2 208 23 26 3 26 3 Publication 1336 PLUS 6 6 February 2002 Disassembly and Access Procedures Disassembly and Access Procedures 3 5 Removing the High Voltage Guard The High Voltage Guard is a clear plastic guard covering the Bus Capacitor Bank and the Power Module Assembly Figure 3 4 High Voltage Guard High Voltage vos Guard AB0779B Publication 1336 PLUS 6 6 February 2002 3 6 Disassembly and Access Procedures Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning
84. le 1336S EN firmware FRN 1 05 or earlier drive To assure proper JOG function install at least one properly unless a SCANport option is connected to the of the following ATTENTION The JOG function will not operate Publication 1336 PLUS 6 6 February 2002 Figure 1 4 Input Mode Selection and Typical TB3 Connections 19 el Status 20 Stop F ault Reset 21 IES Common 22 IES Status 23 Status 24 IES Status 25 IED Common 26 eal Status 2 Status 28 el Status 2 Common 2 Enable el Start eal Stop F ault Reset eal Common Jog eal Auxiliary el Common uem el Speed Select 2 Speed Select 1 Common Enable Input Mode 1 Factory Default Note If this mode is selected the status of all inputs can be read atthe Input Status parameter However only Stop Fault Reset and Enable will have control function Input Mode 2 6 17 18 22 Three Wire Control with Single Source Reversing 3 Reverse4 Stop Type Speed Select 31 4 Reverse4 2nd Accel 2nd Decel 1 See Table 1 2 Drive must be stopped to take Local Control Contro 3 These Mode 5 Reverse Digital PotUp Digital PotDn 6 Reverse4 Local Control 17 Reverse 2nd Decel 18 22 Integrator Integrator Reset Reset Output Speed Local Select 31 Contro by all ot
85. moval Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 28 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 Fan and Transformer Assembly The Fan is located in the chassis and under TB1 at the bottom of the heat sink The Fan Transformer and Fan Capacitor are located in the bottom left corner of the chassis Figure 5 12 Fan and Transformer TB1 Label Plate 0791 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 5 29 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snub
86. n 1336 PLUS 6 6 February 2002 G 6 Glossary Publication 1336 P LUS 6 6 February 2002 Integral Horsepower Motor A motor that has a continuous rating of 1 hp or more built into a frame International Organization for Standards ISO An organization established to promote development of international standards Interposing Relay An interposing relay is a relay that accepts control signals of one logic level in order to provide isolated contact signals in a circuit operating at a different logic level Inverter 1 An AC adjustable frequency drive 2 A particular section of an AC drive This section uses the DC voltage from a previous circuit stage intermediate DC circuit to produce a pulse width modulated or stepped AC current or voltage waveform that has characteristics similar to the desired sine wave frequency 3 A circuit whose output signal is the inverse of its input a positive going pulse is inverted to a negative going pulse and vise versa ISO Refer to International Organization for Standards Isolation Transformer 1 A transformer that provides DC isolation from other equipment not connected to that transformer secondary 2 A transformer that provides noise isolation between the primary and secondary by such means as a Faraday shield Jogging 1 In a numerical control system an operator manually generating motion continuously or incrementally by closing a switch 2 An operator generatin
87. nector to Gate Driver Board J 2 n7 AB0793B Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 Part Replacement Procedures 5 19 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the six screws fastening the Input Rectifier wiring to the Input Bus Bars Remove the
88. ng 1 1 Conventions in this Manual P 8 D DC Brake Terminals 4 7 4 11 5 4 Index DC Bus Inductor L1 Illustration 5 31 Installation 5 33 Removal 5 31 Default Definition P 9 Diag C Lim Flt 2 4 Diagnostic Procedures Clearing Faults 2 15 Drive Goes to Max Frequency 2 15 Drive Stays at Zero Hertz 2 14 Drive Will Not og 2 13 Drive Will Not Start 2 11 No Display 2 12 Drive Enclosure Type P 7 Identification P 4 Illustration 5 4 Nameplate Location P 3 Rating P 7 Drive HIM 2 4 Drive Fault Reset 2 4 Drive Goes to Max Frequency 2 15 Drive Stays at Zero Hertz 2 14 Drive Will Not og 2 13 Drive Will Not Start 2 11 E EE InitRead 2 4 EE Init Value 2 4 EEprom Checksum 2 4 EEprom Fault 2 4 Electrostatic Discharge P 2 Enable Input Definition P 9 Enclosure Type P 7 Error Codes 2 4 ESD P 2 F False Definition P 9 Fan and Transformer Illustration 5 28 Installation 5 30 Removal 5 28 Fastener Torque Specifications 3 2 Publication 1336 PLUS 6 6 February 2002 Index Publication 1336 PLUS 6 6 February 2002 Fault Contacts 2 3 Fault Descriptions 2 3 2 4 Fault Display Illustration 2 3 Faults Clearing 2 15 Cross Reference 2 9 Descriptions 2 4 FGND 10ms Over 2 4 Four Point Mounting 3 3 G Gate Driver Board Illustration 3 16 Installation 3 17 Removal 3 16 Test 4 3 Ground Fault 2 4 Ground Fault CT Illustration 5 18 Installati
89. nk is located on the upper left side of the Main Chassis Figure 5 2 Bus Capacitor Bank Bus Capacitor Bar a Snubber mM Resistors Capacitor PIN Standoffs ss D Bus Capacitor RR Bar On w 6 o Converter S Fuse Support ss Te 9 Bus Fuses Bus Capacitor Diode Assembly Bracket PM Snubber Resistors 2 0787 ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 5 6 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Access the Main Chassis 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and f
90. nnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 4 12 Component Test Procedures Publication 1336 PLUS 6 6 February 2002 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Set your meter to test DC voltage 4 Connect the negative lead of your meter to the DC Brake Terminal on 1 and the positive lead to the DC Brake Terminal Refer to the following tables and Figure 4 5 for meter readings and terminal locations ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment 5 Apply power AFTER the meter is connected otherwi
91. nts may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment Publication 1336 P LUS 6 6 February 2002 4 2 Component Test Procedures Electrostatic Discharge Precautions Publication 1336 PLUS 6 6 February 2002 ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices
92. on When power is first applied to the drive the HIM will cycle through a series of displays These displays will show drive ID and communication status Upon completion the Status Display refer to Figure 1 7 will be shown This display shows the current status of the drive i e Stopped Running etc or any faults that may be present Not Enabled etc Refer to the 1336 PLUS User Manual for HIM operation Figure 1 7 Status Display Chapter 2 Troubleshooting and Error Codes Chapter Objectives This chapter helps you trace faults to field replaceable components Trou bleshooting Overview To troubleshoot a 1336 PLUS Adjustable Frequency AC Drive you need a Range DVM DMM or VOM with a range capacity of at least 1000 V Important printed circuit boards are referenced to common per the schematic diagrams ATTENTION Power circuits are optically isolated from control driver circuits Power circuit components are floating with respect to ground Use only approved methods of isolating test equipment when making measurements in power circuits ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to ze
93. on 5 20 Removal 5 18 Ground Warning 2 4 H Hertz Err Fault 2 5 Hertz Sel Fault 2 5 High Voltage Shield Illustration 3 5 Installation 3 6 Removal 3 6 HIM See Human Interface Module HIM gt Drive 2 5 Human Interface Module HIM Adapter Locations 1 9 Description 1 8 Illustration 1 9 Operation 1 10 Removal 1 10 Identification Product P 3 Input Fuses Illustration 5 16 Installation 5 17 Removal 5 16 Input Mode Programming 1 4 Selection 1 5 Three Wire Multi Source 1 6 Two Wire Single Source 1 6 Input R ectifier Illustration 5 21 Installation 5 22 Removal 5 21 Test 4 14 Input Snubber Board Illustration 3 23 Installation 3 24 Removal 3 23 Inputs Available 1 4 Installation Procedures See Procedures J J umper Definition P 9 LEMs Illustration 5 23 5 26 Installation 5 25 Removal 5 23 Load Sharing Resistor Connections 5 8 Local Programming 1 4 Loop Overrn Flt 2 5 Main Control Board Illustration 3 14 Installation 3 15 Removal 3 14 Main Control Board Mounting Plate Illustration 3 12 Installation 3 13 Removal 3 12 Major Component Replacement See Procedures Manual Audience P 1 Conventions P 8 Objective P 1 Related Publications 10 Max Retries Fault 2 5 Motor Mode Flt 2 5 Motor Stall Fault 2 5 Mounting Four Point 3 3 Six Point 3 3 Two Point 3 3 N Nameplate Location P 3 Neg Slope Fault 2
94. on handbook Publication 1336 PLUS 6 6 February 2002 5 2 Part Replacement Procedures Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Tools You need the following tools to disassemble and assemble the drive Pliers Phillips screwdrivers small medium and large Standard screwdrivers small medium and large e 25 64 inch 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m Nylon tie wraps Publication 1336 PLUS 6 6 February 2002 Major Component Replacement Part Replacement Procedures 5 3 This section explains in detail how to replace the following drive components Bus Capacitor Bank Thermistor Power Modules Bus Fuses Fl Input Fuses Ground Fault CT Input Rectifiers e LEMs MOV Surge Suppressor Fan and Transformer Assembly e DC Bus Inductor L1 For Main Control Board Ga
95. onous motor accelerates into synchronism at rated voltage and frequency Pull Out Torque The maximum running torque of a synchronous motor Glossary G 9 Pull Up Torque The torque required to accelerate the load from standstill to full speed where breakdown torque occurs expressed in percent of running torque It is the torque required not only to overcome friction windage and product loading but also to overcome the inertia of the machine The torque required by a machine may not be constant after the machine has started to turn This load type is characteristic of fans centrifugal pumps and certain machine tools PWM Pulse width Modulation technique used to eliminate or reduce unwanted harmonic frequencies when inverting DC voltage to sine wave AC Reactance Pure inductance or capacitance expressed in ohms in a circuit It is the component of impedance to alternating current that is not resistance Rectifier A device that conducts current in only one direction thereby transforming alternating current to direct current Regeneration AC drives When the rotor synchronous frequency is greater than the applied frequency Regenerative Braking Slows or stops a motor through regeneration Refer to Regeneration and Braking Resolution The smallest distinguishable increment into which a quantity can be divided e g position or shaft speed It is also the degree to which nearly equal values of a quantity can be di
96. ontrol Logic Wiring and Adapters 1 5 Table 1 A Input Mode Selection Mode s Communication Compatibility to Use None Control must be provided by HIM or Communication Option 1 Maintained Switch Open F orward Closed Reverse Momentary Pushbuttons Forward and Reverse control 2 wire Run Forward Run Reverse Start Stop works in parallel with HIM and Communication Options 2 6 17 Direction Control will not work in parallel with HIM or Communication 18 amp 22 Options User must select direction control from either HIM and Communication Options or TB3 input Start Stop works in parallel with HIM and Communication Options Direction works in parallel with HIM or Communication Options Start Stop not compatible with HIM or Communication Options 12 16 Direction not compatible with HIM or Communication Options 20 21 amp 24 Figure 1 3 provides the terminal designations for TB3 The maximum and minimum wire sizes accepted by TB3 are 2 1 and 0 30 mm 14 and 22 AWG Recommended torque for all terminals is 0 9 1 13 N m 8 10 Ib in Use Copper wire only Figure 1 3 TB3 Terminal Designations AB0293B Publication 1336 PLUS 6 6 February 2002 1 6 Control Logic Wiring and Adapters M A omentary o o Maintained User Connections 1201 1201 HAI 1201 HA2 1336 Applies to 1305 with firmware FRN 2 01 or earlier and 1336 PLUS with Language Modu
97. or absence of control voltage 3 Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform Access the Bus Capacitor Bank 1 Remove the Bus Capacitor Bar A Remove the two sets of bolts fastening the power cables to the top and bottom of the Bus Capacitor Bank Remove the four bolts fastening the Converter Fuse Support to the 4 Bus Capacitor Bar and Power Module Bus Bar Pull the Converter Fuse Support with bus fuses attached from the drive Remove the six bolts 2 per phase fastening the Bus Capacitor Bar to the Power Module Bus Bar Remove the two bolts fastening the Bus Capacitor Bar to the Bus Capacitor Inverter Standoffs Remove the three screws fastening the Bus Capacitor Bar to the Power Module Snubber Resistors Pull the 4 Bus Capacitor Bar from the drive Part Replacement Procedures 5 7 2 Remove the Power Module Bus Bar A D E Remove the six screws fastening the Power Module Bus Bar to the Bus Capacitor Bar Remove the eighteen nuts fastening the Power Module Bus Bars to the Bus Capacitor Bar Remove the five screws fastening the Power Module Bus Bar to the Snubber Resistors Remove the two bolts fastening the Power Module Bu
98. or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Component Test Procedures 4 15 3 Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform 4 Remove the Input Rectifier Snubber Board Refer to Chapter 3 Disassembly and Access Procedures Removing the Input Rectifier Snubber Board 5 Set your meter to test diodes 6 The following table shows meter connections and ideal meter readings for those connections Refer to Figure 4 6 for meter connection locations Table 4 E Input Rectifier Test Meter Lead Meter Lead Nominal Meter Reading AK K nfinite AK nfinite nfinite AK nfinite AK nfinite nfinite G1 K1 0 011 K1 G1 0 011 G2 K2 0 011 K2 G2 0 011 Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range 7 Replace the Input Rectifier if any meter readings are not as shown Refer to Chapter 5 Part Re
99. ore disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Publication 1336 PLUS 6 6 February 2002 5 22 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the Input Rectifier Snubber Boards Refer to Chapter 3 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board Remove the three bolts fastening the Input Bus Bars to the Inpu
100. pecifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 3 14 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Removing the Main Control Board from the Mounting Plate Figure 3 8 Main Control Board and Mounting Plate no Removal ANS Slide Mount gt 20 IZ Stand Off V S 8 Pin HIM t EN Connector BED e Main Control Board b Connector J 1 D a Connector 6 E Connector 2 Mounting Screw Connector J 8 Mounting Terminal Strip Plate Ground Wire TB2 Stake On Connector J10 AB0782B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Disassembly and Access Procedures 3 15 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you r
101. placement Procedures Input Rectifiers 8 If the Input Rectifier shorted check the Power Modules for damage Refer to Testing the Power Modules in this chapter Publication 1336 PLUS 6 6 February 2002 4 16 Component Test Procedures This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Chapter Objective Safety Precautions Electrostatic Discharge Precautions Chapter 5 Part Replacement Procedures This chapter describes procedures required to replace drive components This chapter references Chapter 3 Disassembly and Access Procedures for basic drive component access ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protecti
102. pressor Snubber Resistor Snubber Resistor Snubber Bracket Snubber Board Snubber Board Volt Sharing Resistor Volt Sharing Resistor Thermistor Bus Capacitor Holder Capacitor Bus Bar Assembly Power Module Gate Interface Board Power Module Bus Bar Power Module DIN Rail TB1 PE Shortening Bar Input Rectifier Input Fuse Transitional Bus Bar Assembly Bus Fuse F1 DC Bus Inductor L1 Bus Bar Cable Adaptor Converter Bus and Motor Bus Bars Wires PE Wires Wire TE Wires Wires LEM Mounting Plate Power Cables Control Board Platform High Voltage Guard Table 3 A Fastener Torque Specifications Fastener Application Motor to Fan Cover Assembly Assembly to chassis Transformer to chassis Capacitor to chassis MOV to chassis Resistor to heat sink Wires to Capacitor Bus Bar Assembly Bracketto Power Module Board to Brackets Board to Input Rectifier Resistor to heat sink Wires to Capacitor Bus Bar Assembly Thermistor to heatsink Holder to Bus Capacitors Assembly to Bus Capacitors Board to Power Modules Bus Bar to Power Modules Module to heat sink Rail to chassis Barto TB1 Rectifier to heat sink Fuse to Input Bus Bar Assembly to Power Module Bus Bar Assembly Fuse to Transitional Bus Bar Assembly Inductor to chassis Adaptor to Transitional Bus Bar Assembly and DC Bus Inductor Bus Bars to all connections Wires to Ground Stud Wires to TB1 Wire to TB1 Wires to TB2 Wires to TB3 Mounting P
103. r greater than 32 Check Motor NP RPM and Motor NP Hertz programming Power Loss Fault 03 DC bus voltage remained below 8596 of nominal for longer than 0 500ms Line Loss Fault parameter is set to enabled Monitor the incoming AC line for low voltage or line power interruption Power Mode Fault 26 The internal power mode variable received an incorrect value Publication 1336 PLUS 6 6 February 2002 Check all connections to the Control Board Replace the board Language Module or complete drive as required Name amp Fault Power Overload 64 Troubleshooting and Error Codes 2 7 Table 2 A continued 1336 PLUS Fault Descriptions The drive rating of 15096 for 1 minute has been exceeded Reduce load Power Test 46 The internal power mode variable received an incorrect value Check all connections to the Power Driver Board Replace the board or complete drive as required Precharge Fault 19 Occurs if precharge device is open 20ms after the end of a line loss condition or if the bus charging alarm remains on for 20 seconds precharge did not complete All larger frames Check the precharge circuit Replace the input SCRs SCR Firing Board Power Driver Board or complete drive as needed Precharge Open 56 Reprogram Fault 48 ROM or RAM Fit 68 Run Boost Fault 34 Serial Fault 10 Shear Pin Fault 63 The precharge circuit was commanded to close b
104. rium temperature Converter 1 A device for changing AC to DC This is accomplished through use of a diode rectifier or thyristor rectifier circuit 2 A device for changing AC to DC to AC e g adjustable frequency drive A frequency converter such as that found in an adjustable frequency drive consists of a rectifier a DC intermediate circuit an inverter and a control unit Counter Electromotive Force CEMF The product of a motor armature rotating in a magnetic field This generating action takes place whenever a motor is rotating Under stable motoring conditions the generated voltage is equal to the voltage supplied to the motor minus small losses However the polarity of the CEMF is opposite to that of the power being supplied to the armature Current Limiting An electronic method of limiting the maximum current available to the motor This is adjustable so that the motor s maximum current can be controlled It can also be preset as a protective device to protect both the motor and the control from extended overloads DC Boost Compensates for the voltage drop across the resistance of an AC motor circuit and the resulting reduction in torque DC Bus drive s power structure that transmits a rectified AC line power from the bridge rectifier to the output transistors DC Hold Describes a holding brake function to stop motor rotation after a ramp to stop function is activated Diode A solid state un
105. rive Failure to replace guards may result in death or serious injury Part Replacement Procedures 5 31 DC Bus Inductor L1 DC Bus Inductor L1 is located at the bottom of the drive Figure 5 13 DC Bus Inductor L1 DC Bus Inductor L1 DC Bus Inductor Terminals AB0792B Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 5 32 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Disconnect AC input and motor output wiring from TBI to provide easy access to the DC Bus
106. ro volts ATTENTION Potentially fatal voltages may result from improper usage of oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded We do not recommend use of an oscilloscope to directly measure high voltages Use an isolated measuring device with a high voltage probe Contact Rockwell Automation for recommendations Publication 1336 P LUS 6 6 February 2002 2 2 Troubleshooting and Error Codes ATTENTION To guard against equipment damage when troubleshooting the drive always check the following before issuing a Start command e Set the Speed Reference to minimum Select the proper motor rotation direction Disconnect the motor from its mechanical load ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Electrostatic Discharge Electrostatic Discharge generated by static electricity can damage Precautions thecomplimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard ag
107. rpm means the motor must operate as low as 36 rpm and still remain within regulation specification Controllers are capable of wider controllable speed ranges than motors because there is no thermal limitation only electrical Controllable speed range of a motor is limited by the ability to deliver 10046 torque below base speed without additional cooling Speed Regulation The numerical measure percent of how accurately the motor speed can be maintained It is the percentage of change in speed between full load and no load The ability of a drive to operate a motor at constant speed under varying load without hunting alternately speeding up and slowing down It is related to both the characteristics of the load being driven and electrical time constants in the drive regulator circuits Surge Protection The process of absorbing and clipping voltage transients on an incoming AC power line or control circuit Surge protectors include MOVs Metal Oxide Varistors and specially designed R C networks Synchronous Speed The speed of an AC induction motor s rotating magnetic field It is determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator windings Mathematically it is expressed as Sync Speed rpm 120 x Applied Freq Hz Number of poles per phase Torque A turning force applied to a shaft tending to cause rotation Torque is equal to the force applied times the ra
108. s Bar to the drive Pull the Power Module Bus Bar from the drive 3 Remove the Bus Capacitors A Remove the eighteen nuts fastening the Bus Capacitor Bar to the Bus Capacitors Pull the Bus Capacitor Bar from the drive C Remove the Bus Capacitors from the drive Installation 1 Fasten the capacitor assembly in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications Important Orient the notch and vent hole on the Bus Capacitors to the top of the drive 2 Connect the Load Sharing Resistors to the Bus Capacitors according to the diagram in Figure 5 3 Refer to the schematic diagrams in this manual for more information on component configurations Important Check the Load Sharing Resistors for an open condition and replace any open resistors Important If the drive is equipped with PEM nuts on the Cap Bus bar use them instead of capacitor studs to make the electrical connection Publication 1336 PLUS 6 6 February 2002 5 8 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 Figure 5 3 Load Sharing Resistor Connections to Bus Capacitors Cla 23 CIL CIL C15 CIR 0820 Important 380 460 AC C1 C18 400 VDC Important 500 600 AC C1 C18 are 500
109. s Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Chapter Objectives Disassembly and Access Overview Electrostatic Discharge Precautions Chapter 3 Disassembly and Access Procedures This chapter describes general disassembly procedures required to access internal drive components ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 80
110. scriminated For rotary encoders it is the number of unique electrically identified positions occurring in 360 degrees of input shaft rotation For D A or A D conversion may be expressed as the number of bits in the digital value that corresponds to a full scale analog value SCR Silicon Controlled Rectifier A solid state uni directional latching switch Service Factor When used on a motor nameplate a number that indicates how much above the nameplate rating a motor can be loaded without causing serious degradation i e a motor with 1 15 S F can produce 15 greater torque than one with 1 0 S F Set Speed The desired operating speed Shock Load The load seen by a clutch brake or motor in a system that transmits high peak loads This type of load is present in crushers separators grinders conveyors winches and cranes Publication 1336 PLUS 6 6 February 2002 G 10 Glossary Publication 1336 P LUS 6 6 February 2002 Slip The difference between rotating magnetic field speed synchronous speed and rotor speed of AC induction motors Usually expressed as a percentage of synchronous speed Slip Compensation Monitors motor current and compensates for speed lost due to increased motor slip The amount of slip is proportional to the motor load Speed Range The speed minimum and maximum at which a motor must operate under constant or variable torque load conditions A 50 1 speed range for a motor with top speed 1800
111. se your meter will read zero volts Expand readings for all input voltage ratings Table 4 D Bus Capacitor Bank Test Drive Rating Input Volts Meter Reading 200 283V DC 10 230 325V DC 10 240 339V DC 10 380 537V DC 10 415 587V DC 10 480 679V DC 10 500 707V DC 10 575 813V DC 10 600 848V DC 10 Component Test Procedures 4 13 6 If the voltage is out of tolerance check the following An open condition at an Input Rectifier e A voltage drop due to Bus Inductor L1 resistance A voltage drop between an Input Rectifier and the bus capacitors due to loose or resistive wires or connections Precharge circuit problems 7 If the above check does not reveal a problem replace the Bus Capacitor Bank and Load Sharing Resistors Refer to Chapter 5 Part Replacement Procedures Bus Capacitor Bank ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 4 14 Component Test Procedures Test 5 Testing the Input Rectifiers Publication 1336 PLUS 6 6 February 2002 The Input Rectifiers are located on the bottom of the heat sink Figure 4 6 Input Rectifier Test Important AB0802B ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death
112. service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 4 4 Component Test Procedures Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the Main Control Board Mounting Plate Refer to Chapter 3 Disassembly and Access Procedures Removing the Main Control Board Mounting Plate Unplug the connectors from the Gate Driver Board Set your meter to test resistance Test Fuses F1 and F3 for an open condition Replace the Gate Driver Board if either fuse shows an open condition Set your meter to test diodes Test VR1 VR6 The following table shows meter connections at the components and ideal meter readings for those connections Refer to Figure 4 1 for component locations Table 4 A Gate Driver Board Test Component Meter Lead Meter Lead Nominal Meter Reading 1 06 1 8 VR2 t 1 06 t 1 8 VR3 t 1 06 1 8 VR4 1 06 1 8 VR5 1 06 1 8 VR6 1 06 1 8 Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 setto Diode range 9 Replace the Gate Driver Board if your readings do not match the
113. si differential mode with the oscillo scope chassis correctly grounded to an earth ground ATTENTION Only personnel familiar with the 1336 PLUS Adjustable Frequency AC Drive and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the drive Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets P 3 1336 PLUS Product Identification Drive Nameplate Location The drive namepla
114. splays fault message HIM displays Stopped Are any bits in Stop Owner Set to 1 Does Start Owner show a bit setto 1 when START commanded Drive Starts Troubleshooting and Error Codes 2 11 These charts list drive symptoms symptom descriptions and recommended actions to remedy the symptoms Drive Will Not Start Refer to No Display Drive equipped Yes No Correct Auxiliary with L Option Auxiliary Input True Circuit and clear fault Yes Program Input Mode to 1 and cycle input power Replace L Option or Main Control Board Yes Drive equipped Yes No n with L Option Enable Input True Correct Enable Circuit Add a jumper to J 7 between pins 3 and 4 or replace Main Control Board as needed Follow instructions given in Table 2 A Refer to Drive Drive running at Stays at Zero Hertz zero Hertz When Started Find and correct source of STOP command Correct Start Input circuit or replace Main Control Board as needed Check Bit 12 in Parameter 60 if this bit is 1 connect a Motor to Drive End of troubleshooting AB0416C Publication 1336 PLUS 6 6 February 2002 2 12 Troubleshooting and Error Codes No Display No HIM display Replace the HIM Main Control Board Language Module or complete drive as needed Is the HIM backlight lit 15 the drive s fan Voltage present at running 5
115. static discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 PLUS 6 6 February 2002 1 2 Control Logic Wiring and Adapters Control Interface Option Publication 1336 PLUS 6 6 February 2002 Figure 1 1 Terminal Block Locations TB3 Control 789 7 Interface Option zi TB2 Control and Signal Wiring TB1 Power D Terminal Block E 15 0818 ATTENTION The National Electrical Code NEC and local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage The Control Interface Option provides a means of interfacing various signals and commands to the 1336 PLUS by using contact closures Six different versions of the option are available L4 Contact Closure Interface L4E Contact Closure Interface with Encoder Feedback Inp
116. stening the Output Bus Bars to the Power Module Assembly and TB1 6 Pull the Output Bus Bars out from the drive 7 Remove the two screws fastening the TB1 shield to the TB1 Assembly 8 Pull the shield away from the drive 9 Remove the four screws fastening the LEM Interface Board to the standoffs 10 Lift the LEM up and away from the drive Part Replacement Procedures 5 25 Installation Install the LEMs in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 PLUS 6 6 February 2002 5 26 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 MOV Surge Suppressor The MOV Surge Suppressor is located on top of the Fan Cover Plate The MOV protects the drive from high voltage surges above approximately 1 000 volts Replace it if it is burned expanded or ruptured after such events as a lightning strike or inadvertent connection of the drive input to a voltage source substantially above nameplate voltage Figure 5 11 MOV Surge Suppressor MOV Surge Suppressor n gt 0797 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in dea
117. suring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 PLUS 6 6 February 2002 3 10 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the 9 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Disconnect both ground wires from TBS located in the lower right hand corner of the the Main Control Board Mounting Plate Disconnect the following from the Main Control Board J connector J2connector TB3 if Control Interface Board is used any optional boards Remove the two nuts from the top and the bottom of the Main Control Board Mounting Plate Pull the Main Control Board Mounting Plate straight out and remove the plate from the drive Disconnect the following from the Gate Driver Board J2connector J7 connector J8 connector J10 connector
118. t Rectifiers Remove the six Allen head screws fastening the positive and negative Converter Bus Bars to the Input Rectifiers Remove the Precharge Wiring Harness from the top of the rectifiers Remove the four screws fastening the Input Rectifier to the heat sink 10 Pull the Input Rectifier away from the heat sink Installation 1 Clean all surfaces between the Input Rectifier and the heat sink using a soft clean cloth Replace the Preform between the Input Rectifier and the heat sink Install the Input Rectifier in reverse order of removal Refer to Chapter 3 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury LEMs Part Replacement Procedures 5 23 The two LEMs are located above 1 on the right side of the chassis Figure 5 10 LEMs Output Bus Bar Removal Uu Uy Uy Screws 2 TB1 Shield ARS 796 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero
119. t trip circuit Internal electronic overload trip Heat sink temperature exceeds a predefined value of 90 C 195 DC bus voltage exceeded maximum value A phase to ground fault has been detected between the drive and motor in this phase Check for a short circuit at the drive output or excessive load conditions at the motor An excessive motor load exists It must be reduced such that drive output current does not exceed the current set by the Overload Amps parameter Check for blocked or dirty heat sink fins Check that the ambient temperature has not exceeded 40 C 104 F Check fan Check thermistor Thermistor should register 100kQ atroom temperature Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option Check the wiring between the drive and motor Check motor for grounded phase Phase V Fault A phase to ground fault has been detected between Check the wiring between the drive and motor 39 the drive and motor in this phase Check motor for grounded phase Phase W Fault A phase to ground fault has been detected between Check the wiring between the drive and motor 40 the drive and motor in this phase Check motor for grounded phase P Jump Err Fit Reserved for future use 37 Pole Calc Fault 50 Generated if the calculated value of Motor Poles is less than 2 o
120. te Driver Board Precharge Board Snubber Boards and Control Interface Board installation and removal procedures refer to Chapter 3 Publication 1336 PLUS 6 6 February 2002 5 4 Part Replacement Procedures Detailed Product Identification Bus Capacitor Bank Bus Fuses F1 2 Diode 1 S A Input N Fuses 3 DC DC Bus Bar Assembly Rockwell Automation Adjustable Frequency AC Drives are modular by design to enhance troubleshooting and spare parts replacement thereby helping reduce production down time The following illustration calls out the main components of a typical drive Component designs vary slightly among the different drive ratings but component locations are identical Figure 5 1 Main Drive Components Power Module B 4 Power Module Gate Qa Interface Board V ER a _ lg Power Module Bus hermistor x d Bar FN Power Module ense Snubber Board Input Rectifier Snubber Board TS 4 Load Sharing Mounting Resistor Plate Gate Driver LEM Board recharge MOV Surge Board Mounting Suppressor Pa Fuse P late y pos F2 Main Control Board Fan Capacitor Precharge Board Fuses Inductor L1 Transformer AB0786B Publication 1336 PLUS 6 6 February 2002 Part Replacement Procedures 5 5 Bus Capacitor Bank The Bus Capacitor Ba
121. te is located on the face of the Main Control Board Mounting Plate The drive nameplate contains the drive s catalog number and other important drive information Reference the catalog number when ordering replacement parts Figure P 1 Drive Nameplate Location Nameplate located on top edge of Control Board Adapter Mounting Plate Precharge Board l ABO806A Software Compatibility Three Phase Drive Rating 380 480V Compatible with Version Frame Reference 187 336 kW 4 01 amp Up F 250 450 HP 1 KW and HP are constant torque CT ratings Publication 1336 PLUS 6 6 February 2002 4 Drive and Option The following is an explanation of the catalog numbering system for Identification 1336 PLUS Adjustable Frequency AC Drives and options The catalog number is coded to identify the drive power rating and can be found on the drive shipping carton and nameplate 1336 PLUS Drive Catalog Numbers Table P A 1336S AQF15 AA EN L6 HA1 GM1 BULLETIN RATING ENCLOSURE LANGUAGE CONTROL HUMAN COMMUNICATION CARD NO MUST BE SPECIFIED MODULE INTERFACE INTERFACE OPTIONAL MUST BE SPECIFIED OPTIONAL OPTIONAL 380 480V AC Input Constant or Variable Torque Drive
122. th or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 5 27 ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the 8 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the three screws fastening the MOV Surge Suppressor wires to the Input Bus Bars Remove the screw fastening the MOV Surge Suppressor wire to terminal PE Remove the screw fastening the MOV Surge Suppressor to the chassis Pull the MOV Surge Suppressor from the drive Installation Install the MOV Surge Suppressor in reverse order of re
123. ting and Error Codes 2 9 Table 2 B Fault Code Cross Reference Fault Display Name Reset Run 02 Auxiliary Fault Yes 03 Power Loss Fault Yes 04 Undervolt Fault Yes 05 Overvolt Fault Yes 06 Motor Stall Fault Yes 07 Overload Fault Yes 08 Overtemp Fault Yes 09 Open Pot Fault No 10 Serial Fault No 1 Op Error Fault No 12 Overcurrent F It Yes 13 Ground Fault No 19 Precharge Fault No 22 Drive Fault Reset Yes 23 Loop Overrn Yes 24 Motor Mode Fit Yes 26 Power Mode Fault Yes 28 Timeout Fault No 29 Hertz Err Fault No 30 Hertz Set Fault No 31 Timeout Fault No 32 EEprom Fault No 33 Max Retries Fault 0 34 Run Boost Fault No 35 Neg Slope Fault 0 Publication 1336 PLUS 6 6 February 2002 2 10 Troubleshooting and Error Codes Table 2 B continued Fault Code Cross Reference Fault Display Name Reset Run 36 Diag C Lim Flt 0 37 P Jump Err Fit 0 38 Phase U Fault 0 39 Phase V Fault 0 40 Phase W Fault 0 41 UV Short Fault 0 42 UW Short Fault 0 43 VW Short Fault 0 46 Power Test Flt 0 47 Xsistr Desat Flt 0 58 Blwn Fuse 0 63 Shear Pin Fault 0 64 Power Overload 0 65 Adptr Freq Err 0 66 EEprom Checksum No 68 ROM or RAM No Publication 1336 PLUS 6 6 February 2002 Diagnostic Procedures by Symptom Drive will not start Display on HIM Yes HIM displays Auxiliary Fault HIM displays Not Enabled HIM di
124. uary 2002 3 8 Disassembly and Access Procedures Publication 1336 PLUS 6 6 February 2002 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove all wires from the terminals on TB3 4 Loosen the two captive screws fastening the Control Interface Board to the Main Control Board 5 Grip the right and left sides of the Control Interface Board and pull the board straight outward from the Main Control Board Installation Install the Control Interface Board in reverse order of removal ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 3 9 Removing the Circuit Board Platform The Circuit Board Platform contains the Main Control Board the Gate Driver Board and the Precharge Board Figure 3 6 Circuit Board Platform Circuit Board Platform 0800 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by mea
125. ublication 1336 PLUS 6 6 February 2002 Summary of Changes This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Preface Control Logic Wiring and Adapters Table of Contents Manual Objective P 1 Who Should Use This P 1 Safety 5 P 1 Electrostatic Discharge Precautions P 2 1336 PLUS Product Identification P 3 Drive Nameplate Location P 3 Software Compatibility P 3 Drive and Option Identification P 4 1336 PLUS Drive Catalog Numbers P 4 1336 PLUS Drive Catalog Numbers 5 Drive Rating Qualifications P 7 Enclosure Type duran diets P 7 Conventions P 8 Auxiliary Input P 8 Auxiliary Interlock P 8 8 M ere P 8 Sm PEE P 8 Default P 9 hri PERPE T P 9 Ic NP P 9 P 9 Control Interface Board P 9 Paramete Coa voca
126. ut was detected to be open The drive was commanded to write default values to EEPROM Internal power up ROM or RAM tests have not executed properly An attempt has been made to set the Run Boost parameter to a value greater than the Start Boost parameter A SCANport adapter has been disconnected and the Logic Mask bit for that adapter is set to 1 Programmed Current Limit amps has been exceeded and Shear Pin Fault is enabled All larger frames Check the precharge circuit Replace the input SCRs SCR Firing Board Power Driver Board or complete drive as needed 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Important If Input Mode has been changed from its original value power must be cycled before the new value will take affect Check Language Module Replace Control Board or complete drive as required Verify that parameter has been programmed correctly 1 If no adapter was intentionally disconnected check wiring to the SCANport adapters Replace wiring SCANport expander SCANport adapters Main Control Board or complete drive as required 2 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 1 this fault will occur To guard against this fault occurring set the Logic Mask bit for the adapter to 0 Check load requirements and Current Limit setting Publication 1336 PLUS 6 6 Febru
127. uts L5 24V AC DC Interface L5E 24V AC DC Interface with Encoder Feedback Inputs L6 115V AC Interface L6E 115V AC Interface with Encoder Feedback Inputs 1 Uses internal 5V DC supply Control Logic Wiring and Adapters 1 3 The user inputs are connected to the option board through TB3 The L4 L5 and L6 options each have nine control inputs The function of each input must be selected through programming as explained later in this section The LAE L5E and L6E options are similar to L4 L5 and L6 with the addition of encoder feedback inputs Control Interface Board Jumpers Important If the Control Interface Board is being installed Main Control Board jumpers at pins 3 amp 4 and 17 amp 18 of J4 J7 on 7 5 30 HP drives must be removed If removed these jumpers can be stored on the spares location on the Main Control Board If this board is removed these jumpers must be reinstalled and the Input Mode parameter must be programmed to 1 Figure 1 2 Jumper Locations umper Spares Jumper J 7 Located on Main Control Board MI SU lU E i Wm Ww 1 o fo 7 AB0819A Publication 1336 PLUS 6 6 February 2002 1 4 Control Logic Wiring and Adapters Available Inputs A variety of combinations made up of the following inputs are av
128. volts Publication 1336 PLUS 6 6 February 2002 5 24 Part Replacement Procedures Publication 1336 PLUS 6 6 February 2002 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 3 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at the DC DC Brake Terminals and for absence of control voltage 3 Remove the High Voltage Guard from the drive Refer to Chapter 3 Disassembly and Access Procedures Removing the High Voltage Guard 4 Remove the Circuit Board Platform Refer to Chapter 3 Disassembly and Access Procedures Removing the Circuit Board Platform 5 Remove the nine bolts fa
129. y circuits must comply with the national codes and standards NEC VDE BSA etc and local codes regarding wire type conductor size branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage The auxiliary circuit can be utilized to a maximum current capacity of 8 amperes RMS The maximum and minimum wire size accepted by TB9 is 4 0 and 0 8 mm 12 and 18 AWG Use copper wire only with a minimum temperature rating of 75 C Maximum Torque is 0 90 1 81 N m 8 16 Ib in AB0815A 7 5 Publication 1336 PLUS 6 6 February 2002 7 6 Schematics BP250 BP450 and CP350 CP450 This Page Intentionally Left Blank Publication 1336 PLUS 6 6 February 2002 Glossary Glossary AC Contactor An alternating current AC contactor is designed for the specific purpose of establishing or interrupting an AC Power circuit Adjustable Speed The concept of varying the speed of a motor either manually or automatically The desired operating speed set speed is relatively constant regardless of load Adjustable Speed Drive Electrical The adjustable speed drive is comprised of the motor drive controller and operator s controls either manual or automatic Ambient Temperature The temperature of the medium air water earth into which the heat of the equipment is dissipated Base Speed The manufacturer s nameplate rating where the motor will d

1336 PLUS Adjustable Frequency AC Drive with Sensorless Vector

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