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Service Manual, Bulletin 1336 FORCE Adjustable Frequency AC

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2. Figure 1 7 Standard Adapter Board Port Locations 1 Sas EN o Lr Publication 1336 FORCE 6 15 August 1999 p Display Panel Storred 0 00 Hz Control Panel Human Interface Module HIM AB0542A Communications Port for Remote HIM Communication Options Adapter 2 2 3 4 5 or Expansion Options Adapters 2 3 4 5 _ TB10 Encoder Drive Mounted HIM au Adapter Port 1 Control Interface Board Internal Lar TB3 Adapter Port 0 Communication Adapter Port 6 Lc TH Exe r4 TB5 TB6 7 PES Control Logic Wiring and Adapters 1 11 Figure 1 8 PLC Comm Adapter Board Port Locations
3. Main o Control Board 5 Communications Pm Channels Ports 6 7 PLC Comm Board SCAN port 1 m SCAN port 2 nd Ihe TB20 21 Si Tel la mm AB0702B Publication 1336 FORCE 6 15 August 1999 1 12 Control Logic Wiring and Adapters Publication 1336 FORCE 6 15 August 1999 HIM 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 Bit 1 of the Logic Mask parameter must be set to 0 to allow removal of the HIM module without causing a Communication Fault Setting Bit 1 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 Important To remove the module 1 Ensure that power has been removed or Logic Mask has been set to 0 2 Take the drive front cover off and simply slide the module down and out of its cradle Remove cable from module
4. AB0609B Publication 1336 FORCE 6 15 August 1999 4 12 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Removal Important 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero 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 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive
5. gt Vertical Glastic AS s A Insulator im 2 mm i DC Bus Inductor Out Positive Bus Bar AB0639B Remove the connections between assemblies 1 Remove the four connections to the DC Bus Inductor Two connections to the left of the vertical Glastic insulator at the left of the motor leads Two connections to the left of the U phase 350 amp bus fuse capacitor fuse 2 Remove the six nuts fastening the left end of the flex motor buses to the three Power Module Bus Bars 3 Remove the 12 nuts fastening the left side of the capacitor flex bus connections to the spine 4 Pull all the flexible leads to the right out of the way Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 31 Figure 2 15 Removing the Spine Capacitor Flex Bus Connections Spine Motor Bus Bar DC Bus Inductor Out Negative Bus Bar Vertical Glastic Insulator DC Bus Inductor Out Positive Bus Bar
6. LUE 169 A Load Sharing A Resistor A d M Thermal ___ Power Module ESI S KEEK Snubber Board Power Module d m 2 Snubber Resistor DC Bus hi Inductor iL Fan S Capactr gt Fan le Sk Transformer i Ch 2 R lt gt We Fan 1 s 7 Control Board Adapter 8 Mounting Fuse F1 4i ET gt Main Control Board Fuse F3 Standard Adapter Board Adapter Board Control Interface Precharge L Option Board Board Board Fuses AB0707A Publication 1336 FORCE 6 15 August 1999 Part Replacement Procedures 4 5 Bus Capacitor Bank The Bus Capacitor Bank is located in the Capacitor Bank Assembly Figure 4 2 Bus Capacitor Bank Bus Capacitor Holder Bus Capacitor Cap Le gt Ki TE Z4 Ae lt Bus Fuse gt 1 lt gr sl wA ev l P d Capacitor w Laminated Bus Bar f i e9 TL Balancer X Eu Plate Motor 4 Buses Strips Me gt D E bs 7 E wo RR J e AB0608A Motor Bus Bottom Supp
7. Connector J1 ae Standard 16 Adapter Board s Mounting Uu Screw o Terminal A Strip TE AB0705A Publication 1336 FORCE 6 15 August 1999 2 14 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 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 DC and DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts Remove power from the Drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts at between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB5 TB6 and TB7 on the Standard Adapter Board Disconnect the following from the Standard Adapter Board Stake on ground wire connector All wires from TB5 All wires from TB6 All wires from TB7 Remove the Control Interface Board Refer to Removing the Control Interface L Option Board in this chapter Remove the two screws fastening the Standard Adapter Board to the mounting plate Pull the Standard Adapter Board up to release it from the slide mount stand offs and connector J1 Installation Install the Standard Adapte
8. AB0680A 5 Remove the spine Push the spine carefully to the right e Lift it out of the drive without forcing it 6 Remove the six Gate Driver connectors from the Power Module Gate Interface Boards Pinch the sides of the connector body while pulling back 7 Disconnect any remaining wiring between the Inverter Housing Assembly and the Capacitor Bank Assembly 8 Disconnect the Inverter Housing Assembly ground cable from the ground plate at the bottom of the main assembly 9 Remove the wheel chocks at the bottom of the Inverter Housing Assembly 10 Pull the assembly onto a platform Refer to Figure 2 16 for recommendations Use the handle attached to the Fan 2 housing Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 32 ATTENTION Hazard of tipping and severe injury exists This process requires two people The platform must be able to support 909 kg 2 000 Ibs E E o 5 Do wo Fan 2 Handle Stop Block Height to suit installation Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedur
9. o II II AB0766A Publication 1336 FORCE 6 15 August 1999 1 4 Control Logic Wiring and Adapters Standard Adapter Local Programming Publication 1336 FORCE 6 15 August 1999 Available Inputs A variety of combinations made up of the following inputs are available 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 effect 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 you 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 Table 1 A for specific mode selection Recor
10. LEM U Shaped Plate LEM U Shaped Top Plate 614 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 FORCE 6 15 August 1999 Part Replacement Procedures 4 31 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 LEMs Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 o
11. Ml JI NA bp z ava M Op 1 o 68 Mat e 3199 NM 8E Ast 1g Eu 2 SP a us s me z 15 z 06 T SOTERA s ez 1530 ie 82 LHOHS QNO F Sai ko 12 518 504 92 90 Sna Sonar zz SLIOA A E te Sai M Sdv 8 Sd n Sd n s 2 LAM z TOW S 309 93N A 2 L S0d _ SNN 09 ob 93N M d 6 304 M 8 93N L 3808 9 9NN 3041 954 z t H ansa H gt 2 B a 8 B e eesou F 18 0 zE 212 iB 88 Fy zZ Z amp 259 4 2 8 5 726 EXTERNAL DC BUS INPUT CONNECTION Publication 1336 FORCE 6 15 August 1999 6 4 Schematics 300 600 1336 FORCE Drives Fan Circiut Detail FAN 1 FAN 2 aes E Eu 12346 943 2
12. Removal Important Part Replacement Procedures 4 9 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero 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 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 their com
13. Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt El Salvador e Finland e France e Germany Greece e Guatemala e Honduras e Hong Kong e Hungary Iceland India Indonesia e Ireland e Israel e Italy e Jamaica e Japan e Jordan e Korea e Kuwait e Lebanon Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 1336 FORCE 6 15 August 1999 PN 74002 121 01 A Supersedes March 1996 Copyright 1996 Allen Bradley Company Inc Printed in USA
14. Publication 1336 FORCE 6 15 August 1999 1 6 Control Logic Wiring and Adapters o Momentary o o Maintained User Connections 1201 HAP 1201 HA1 1201 HA2 1336 GMI Applies User Connections 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 Publication 1336 FORCE 6 15 August 1999 Figure 1 4 Input Mode Selection and Typical TB3 Connections Status Stop Fault Reset Common Status Status Status Common Status Status Status Common Enable Start Stop Fault Reset Common Reverse Note If this mode is selected the status of all Input Mode 1 Factory Default inputs can be read at the Input Status parameter However only Stop Fault Reset and Enable will have control function Input Mode 2 6 Three Wire Control with Single Source Reversing Auxiliary Common Jog Speed Speed Select 2 Speed Select 1 Common Enable gt Select 3 Stop Type Speed Select 31 1 See Table 1 B Mode 2nd Accel 2nd Decel Digital Pot Up Digital Pot Dn 2 Drive must be stopped to take Local Control Control by all other adapters is disabl
15. 1 14 Publication 1336 FORCE 6 15 August 1999 ii Table of Contents Disassembly and Access Procedures Component Test Procedures Publication 1336 FORCE 6 15 August 1999 Chapter 2 Chapter Objectives Disassembly and Access Electrostatic Discharge Precautions TOOS shave done ea Fastener Torque Specifications Torque Sequence Torque Specifications Disassembly and Access Procedures Opening the Drive Enclosure Openg oc ona nko Closing the Drive Enclosure Removing the Control Interface L Option Board Mod A 5 0 L6 c se eie hace E ERES E Ss Removal EP anette eee kak Installation eR Re Removing the Main Control Removal uso scetur oen etes ow Installation lesse IR Removing the Standard Adapter Board Removal ses PT Installation Removing the PLC Comm Adapter Board Installation II Removing the Control Board Adapter Mount
16. 2 JOG AB0554A Publication 1336 FORCE 6 15 August 1999 1 14 Control Logic Wiring and Adapters Drive Tools Control Firmware Function Publication 1336 FORCE 6 15 August 1999 Drive Tools software is a Windows 3 1 compatible family of application programs allowing the user to perform programming monitoring and diagnostic operations on Allen Bradley AC and DC digital drive products The software consists of five Windows applications For operation refer to the Product Data Drive Tools Software manual control functions in the 1336 FORCE are performed through the use of parameters that can be changed with a programming terminal or Drive Tools Refer to an overview Block Diagram of the Control Firmware Function in the 1336 FORCE Field Oriented Control User Manual Feedback information is derived from hardware devices as part of the process equipment used Analog signals are converted to digital signals for use by the drive Control signals may be provided to the drive by one of two Adapter Boards setup and operation information used by the drive is stored in a system parameter table Every parameter including Setup and Configuration parameters Sources and Sinks has an entry in the parameter table For example parameter 101 is named the Velocity Reference 1 HI whole parameter and contains a number value representing the velocity reference The v
17. 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 external 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
18. 0679 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access Procedures 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 Component Test Procedures 3 13 Access the drive 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 3 4 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Test the Capacitors 1 Set your mete
19. 3 Connect the appropriate cable between the HIM and the Communications Port Adapter 2 3 4 or 5 4 Reverse the above steps to replace the module Apply power or reset Bit 1 of the Logic Mask parameter to 1 to enable HIM control HIM Operation 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 9 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 FORCE Field Oriented Control User Manual Figure 1 9 Status Display Stopped 0 00 Hz Graphic Programming Terminal Control Logic Wiring and Adapters 1 13 GPT Description The optional GPT Figure 1 10 is a remote device with a 1 8 meter 6 foot long cable The GPT offers a 40 by 8 character display that can also be used as a graphics display to show trending graphs For GPT operation refer to the 1336 FORCE Field Oriented Control User Manual See also the 1201 GPT User Manual Important Main Menu screens are dynamic and will change based on functionality provided by adapter and drive status Figure 1 10 Graphic Programming Terminal XREF 1 PRESET 5 eerie PRESET 1 ESC J PRESET 3
20. 5 4 Replacement Parts List This Page Intentionally Left Blank Publication 1336 FORCE 6 15 August 1999 Chapter 6 Schematics 300 600 HP 1336 FORCE Drives Publication 1336 FORCE 6 15 August 1999 INPUT POWER 50 60HZ 6 2 Schematics 300 600 HP 1336 FORCE Drives 06 M 1 PE PE CONV CONV CONV SNUBBER SNUBBER SNUBBER INV 1 TO FAN CIRCUIT CUSTOMER SEE DETAILS FUSING cn CF2 H se BANCA SEE DETAILS 71 3 TABLE 1 PE INV CNV e E gxi 3 5 B S RE did 109 65 21 654321 1 1 4SMPS J2 Jt J4 4 SMPS STANDARD 5 PRECHARGE 2 SV BOARD 9 COMMON SEE TABLE 3 w chance 12 MUNE AB0725A SCHEMATIC DIAGRAM STAND ALONE X250 650 HP Publication 1336 FORCE 6 15 August 1999 6 3 Schematics 300 600 HP 1336 FORCE Drives
21. Thermistor Installation 4 10 Publication 1336 FORCE 6 15 August 1999 Index Publication 1336 FORCE 6 15 August 1999 Thermistor Removal 4 9 Product Identification P 3 Programming Input Mode 1 4 Local 1 4 R Related Publications P 10 Replacement Parts List 5 1 Ordering 5 1 S Safety Precautions P 1 Schematics 6 1 SCRs Heat Sinks 4 18 Illustration 4 16 Installation 4 19 Location 4 16 Removal 4 17 Replacement 4 16 Roll Pins 4 19 Spring Bars 4 19 Testing 3 15 Service Platform 2 32 Software Compatibility P 4 Speed Select Input State 1 8 Spine Disconnecting 2 30 Installation 2 33 Removing 2 31 T TB3 Terminal Designations 1 5 Terminal Block Locations 1 2 Terminal Designations TB3 1 5 Thermal Switch 4 18 Thermistor Illustration 4 8 Installation 4 10 Removal 4 9 Replacement 4 8 Torque Sequence 2 3 Four Point Mounting 2 4 Six Point Mounting 2 4 Two Point Mounting 2 3 Torque Specifications 2 4 Transformer Assembly See Fan and Transformer Assembly True Definition 10 Wire Sizes 1 5 Z Zener Diode Testing 3 5 Notes Publication 1336 FORCE 6 15 August 1999 Publication 1336 FORCE 6 15 August 1999 N 3 Publication 1336 FORCE 6 15 August 1999 Publication 1336 FORCE 6 15 August 1999 N 5 Publication 1336 FORCE 6 15 August 1999 Publication 1336 FORCE 6 15 August 1999
22. less than 1 open 065 less than 1 E open D66 less than 1 B open D10 less than 1 a open 11 Replace the Gate Driver Board if your readings do not match the table or if any diode is shorted or open in both directions Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board 12 Assemble the drive in reverse order of disassembly Publication 1336 FORCE 6 15 August 1999 3 6 Component Test Procedures Publication 1336 FORCE 6 15 August 1999 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 Component Test Procedures 3 7 Test 2 If Power Modules have been replaced you must test the Power Testing the Module Snubber Board the Precharge Board and the Gate Driver Precharge Board Board Figure 3 2 Precharge Board Test D Bi oard N E 2 5 SA r SR F1 AB0605A ATTEN
23. wy Allen Bradley Bulletin 1336 FORCE _ Adjustable Frequency Servi Ce AC Drive Series B C D Manual B300 B600 C300 C650 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 Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley 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 in part without written permission of Allen Bradley Company Inc is
24. Bus Capacitor Bank 9 L1 DC Bus Inductor Capacitor Bank Assembly Chapter 4 DC Bus Inductor 10 CT3 Ground Sense CT Capacitor Bank Assembly Chapter 4 Ground Sense CT 11 CT1 CT2 LEM Capacitor Bank Assembly Chapter 4 LEMs 12 F1 F3 Bus Fuse 350 amp Capacitor Bank Assembly Chapter 4 Bus Fuses 13 THS1 Thermal Switch SW1 Inverter Housing Assembly Chapter 4 SCRs upper SCR heat sink 14 FAN 1 Fan 1 Inverter Housing Assembly Chapter 4 Fan and Transformer Assembly 15 Ti Fan Transformer Inverter Housing Assembly Chapter 4 Fan and Transformer Assembly 16 C38 C39 Fan Capacitor Inverter Housing Assembly Chapter 4 Fan and Transformer Assembly 17 FAN 2 Fan 2 Inverter Housing Assembly Chapter 4 Fan and Transformer Assembly 18 SCR1 SCR6 SCR Inverter Housing Assembly SCR Chapter 4 SCRs heat sinks 19 A11 A13 Input Rectifier Snubber Board Inverter Housing Assembly SCR Chapter 2 Removing the Input heat sinks Rectifier Snubber Board 20 A1 Gate Driver Board PC Board Mounting Frame Chapter 2 Removing the Gate Driver Board 21 A10 Precharge Board PC Board Mounting Frame Chapter 2 Removing the Precharge Board 22 MAIN CTL Main Control Board PC Board Mounting Frame Chapter 2 Removing the Main Control Board 23 GT2 Standard Adapter Board PC Board Mounting Frame Chapter 2 Removing the Standard Adapter Board 24 GT1 PLC Comm Adapter Board PC Board Mounting Frame Chapter 2 Removing the PLC Comm Adapter Board Publication 1336 FORCE 6 15 August 1999
25. 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 uni directional conductor Publication 1336 FORCE 6 15 August 1999 G 4 Glossary Publication 1336 FORCE 6 15 August 1999 Drift A slow change in some characteristic of a device For a drive itis 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
26. Nylon tie wraps Fastener Torque Specifications Disassembly and Access Procedures 2 3 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 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 in Ib The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 2 1 Two Point Mounting HER Two Point Mounting Temporary Tighten 1 Final Tighten ABOO16A c Q Publication 1336 FORCE 6 15 August 1999 2 4 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 Figure 2 2 Four Point Mounting NSF 4 2 Temporary Tighten 3 2 1 Final Tighten AB0017A 9 gt OO Figure 2 3 Six Point Mounting Q SS i M 5 0624 Do not exceed 0 4 Newton meters 3 in Ib on initial torque or 3 8 Newton meters 32 in Ib final torque of all six screws Torque Specifications The following table lists faste
27. 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 their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Part Replacement Procedures 4 13 Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Remove the screws fastening the positive and negative snubber bus bars to the Power Module Bus Bar Remove the screws fastening the Power Module Bus Bar to the Power Modules Carefully remove the bus bar Do not damage the insulation Remove the screws fastening the Power Module Gate Interface Boards to the Power Modules 10 Remove the Power Module Gate Interface Boards 11 Remove the screws fastening the Power Module to the heat sink Refer to Figure 2 3 in Chapter 2 Disassembly and Access Procedures Follow the torque sequence as illustrated for both removal and installation Instal
28. disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Remove the plastic guard by removing the screws fastening the left
29. fuses and circuit boards Verify bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 6 15 August 1999 3 2 Component Test Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 15 August 1999 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 Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Electrostatic discharge generated by static ele
30. 1 Disconnect the Fan wiring harness 2 Remove the screws fastening the fan cover to the fan 3 Turn the standoffs fastening the fan to the Inverter Housing Assembly 1 4 turn counterclockwise to remove the fan Installation Install the Fan and Transformer Assembly 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 Part Replacement Procedures 4 23 DC Bus Inductor The DC Bus Inductor is located in the lower part of the Capacitor Bank Assembly behind the Terminal Strips and Motor Buses Figure 4 10 DC Bus Inductor DC Bus Inductor cee Ground Sense CT Inductor Flex Cable Mounting Plate Inductor Inductor Power TEE Flex Bus Bus Connection Publication 1336 FORCE 6 15 August 1999 4 24 Part Replacement 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the
31. 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB5 TB6 and TB7 on the Standard Adapter Board Remove all wires from Control Interface Board TB3 Loosen the two captive screws fastening the Control Interface Board to the Standard Adapter Board Grip the right and left sides of the Control Interface Board and pull the board straight out from the Standard Adapter 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 2 11 Removing the Main Control Board Figure 2 7 Main Control Board and Mounting Plate Ground Stud _ 4 Control Board Adapter
32. 4 29 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 drive 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board 5 Remove the nuts and washers fastening the Bus Fuse to the drive Installation Install the Bus Fuse in reverse order of removal Refer to Chapter 2 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 FORCE 6 15 August 1999 4 30 Part Replacement Procedures LEMs The LEMs are located in the Capacitor Bank Assembly above the Terminal Strips Figure 4 13 LEMs LEM Mounting Plate B LEM
33. 6 15 August 1999 2 2 Disassembly and Access Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 15 August 1999 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 Allen Bradley 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 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 e 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 e Standard screwdrivers small medium and large Metric socket set up to 19 mm Torque wrench to 34 N m 280 in Ibs Torque screwdriver to 10 N m or 80 in Ibs
34. Board Installation 2 22 Gate Driver Board Removal 2 20 Gate Driver Board Testing 3 3 Ground Sense CT Installation 4 27 Ground Sense CT Replacement 4 26 Input Rectifier Snubber Board Installation 2 44 Input Rectifier Snubber Board Removal Inverter Housing Assembly Access to 2 27 Inverter Housing Assembly Installation 2 33 Inverter Housing Assembly Removal LEM Installation 4 31 LEM Removal 4 30 LEM Replacement 4 30 Main Control Board Installation 2 13 Main Control Board Mounting Plate Installation 2 19 Main Control Board Mounting Plate Removal 2 18 Main Control Board Removal 2 11 Major Component Replacement 4 3 MOV Surge Suppressor Installation 4 34 MOV Surge Suppressor Removal 4 32 MOV Surge Suppressor Replacement 4 32 Opening Drive Enclosure 2 7 PC Board Mounting Frame Installation PC Board Mounting Frame Removal 2 34 Power Module Installation 4 13 Power Module Removal 4 12 Power Module Replacement 3 9 Power Module Snubber Board Installation 2 41 Power Module Snubber Board Removal 2 40 Power Module Snubber Resistor Installation 4 16 Power Module Snubber Resistor Removal 4 15 Power Module Testing 3 9 Precharge Board Installation 2 25 Precharge Board Removal 2 23 Precharge Board Testing 3 7 SCR Installation 4 19 SCR Removal 4 17 SCR Replacement 3 15 SCR Testing 3 15 Spine Disconnecting 2 30 Spine Installation 2 33 Spine Removing 2 31
35. Chapter 2 Disassembly and Access Procedures 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 drive 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Test the SCRs 1 Set your meter to test resistance 2 Measure resistance from AC inputs L1 L2 and L3 to DC Refer to Table 3 F 3 Measure between each pair of gate and cathode terminals on the Precharge Board Refer to Table 3 G Publication 1336 FORCE 6 15 August 1999 3 16 Component Test Procedures Publication 1336 FORCE 6 15 August 1999 The following tables show meter connections and ideal meter readings for those connections Refer to the schematic in this manual for more information Table 3 F SCR Test at AC Input Meter Lead Meter Lead Nominal Meter Reading L1 L2 DC L3 Infinite L1 L2 DC L3 Table 3 G SCR Test at Precharge Board SCR Meter Lead Meter Lead Nominal Meter Reading J1 Connector 10 SCR1 10 10
36. FORCE 6 15 August 1999 iv Table of Contents Replacement Parts List Schematics 300 600 HP 1336 FORCE Drives Glossary Index Publication 1336 FORCE 6 15 August 1999 Detailed Product 4 3 Bus Capacitor 4 5 III 4 8 Power Modules 4 11 Power Module Snubber 4 14 SCRS m vend 4 16 Fan and Transformer Assembly 4 20 DG Bus Inductar 4 x hbo chen pee x de s 4 23 Ground Sense m 4 26 BUS FUSES fU 4 28 LEMS 4 30 MOV Surge Suppressor 4 32 Chapter 5 Chapter Objectives 5 1 Ordering Replacement 5 1 Replacement Parts Listing 5 2 Chapter 6 Preface Manual Objective Who Should Use This Manual Safety Precautions Preface The information in this manual is designed to help repair an Allen Bradley Bulletin 1336 FORCE Adjustable Frequency AC Drive with ratings B300 B600 C300 C600 and BX250 This manual is intended for qualified service personnel responsible for repairing the 1336 FORCE Adjustable Frequency AC Drive You should Read this entire manual before performing maintenance or
37. Ji J2 39 BRN GRNY _ GRNY 2 O98 2 BLK BLK 12 1 me aie BASED ON DRIVE INPUT VOLTAGE EITHER A B WHITE Wu i 380 460 575V FAN AUTOTRANSFORMER WILL BE PROVIDED THE TABLE BELOW DEFINES i THE AUTOTRANSFORMER TAP VOLTAGE 380 460V 575V ee JUMPER JUMPER DEFINITION TRANSFORMER TRANSFORMER Fan NOMINAL 460 575 10 415 500 120V OPTIONAL 380 N A Ti External Fan2 ud du m bs F4 3A F5 542 3 Capacitor Detail 75V 460V SEETABLE2 SEE TABLE 2 D1 D1 D2 re Ee Ee F3 F3 C40 C1 C2 C4 C40 C1 C2 C3 C4 4 4 Ri Ri C9 C16 C17 C24 0000 65 66 7 06 4 613 624 C25 C36 65 C6 C7 C8 R3 R4 R5 R6 R2 R2 R4 R6 R7 R9 eooo o e 000 C9 C10 c11 C12 CAP DETAIL R3 460V e CAP DETAIL 575V ABO723A Publication 1336 FORCE 6 15 August 1999 Schematics 300 600 HP 1336 FORCE Drives TABLE 1 CUSTOMER FUSING BASED ON MAXIMUM DRIVE RATING THE FOLLOWING FUSES OR APPROVED EQUIVALENT MUST BE USED HORSEPOWER 380 460V FUSE 575VAC FUSE CURRENT TYPE X250 450 A70C OR FWH 300 450 A70C OR FWH 400 A70C OR FWH 350 500 A70C OR FWH 450 A70C OR FWH 400 600 A70C OR FWH 500 A70C OR FWH 450 800 A70C OR FWH 600 A70C OR FWH 500 800 A70C OR FWH 800 A70C OR FWH 600 900 A70C OR FWH 800 A70C
38. Mounting Plate oY a le Connector J1 P ze Pd Standard x Adapter Board 64 2 2 9 gt M Connector J5 ER SAN 2 2 Main Control CU p A Board P P Connector J7 TB10 b 4 HIM Standard Adapter Board only 2 vd Zt AB0704A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 2 12 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 termina
39. Optionldentification P 5 1336 FORCE Drive Catalog Numbers P 5 Drive Rating Qualifications P 7 Enclosure 7 Conventions 8 eas eke eee eee es P 8 Auxiliary Interlock P 8 Dil fens EET 8 Plo M MM P 8 suas ure p ol siege pex e eee Ra P 8 pc aep MET rm P 9 Enable NDUT RE RES P 9 El REM P 9 JU m T P 9 Control Interface Board P 9 9 9 tas Seka cee 10 Related Publications 10 Chapter 1 Chapter Objectives 1 1 Chapter Overview 1 1 Control Interface Option 1 3 Control Interface L Option Board Jumpers 1 3 1 4 Standard Adapter Local Programming 1 4 Adapters and Communication Ports 1 9 Human Interface Module 1 9 ada P E 1 12 HIM use ERR keen kn 1 12 Graphic Programming 1 13 GPT DeSCHDDUI 1 18 Dive EE 1 14 Control Firmware Function
40. Publication 1336 FORCE 6 15 August 1999 Publication 1336 FORCE 6 15 August 1999 N 9 Publication 1336 FORCE 6 15 August 1999 Publication 1336 FORCE 6 15 August 1999 CUT ALONG DOTTED LINE lt We Want Our Manuals to be the Best Ty 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 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 PROGRAMMABLE 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 J m AC DC DRIVES d PERSONAL COMPUTERS d Ll NC CONTROLS DATA COMMUNICATIONS LAN m 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
41. 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 equilibrium 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
42. 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 synchronous 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 A 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 curr
43. 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 Standard Adapter Board This board is identified as L4 L5 or L6 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 FORCE 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 FORCE 6 15 August 1999 P 10 Preface Related Publications Publication 1336 FORCE 6 15 August 1999 True True refers to a logical true state For instance a Control Interface signal on TB3 is true when L4 contact input is closed L5 input terminal registers 24V or L6 input terminal registers 115V AC The following lists other Allen Bradley publications that apply to the 1336 FORCE Adjustable Frequency AC Drives Product Data Drive Tools Software 9303 2 0 Bulletin 1201 Graphic Programming Terminal User Manual 1201 5 0 Product Pricing Bulletin 1336 FORCE 3 0 1336 FORCE Field Orient
44. bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 Publication 1336 FORCE 6 15 August 1999 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Access the Capacitor Bank Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Capacitor Bank Assembly Remove the Inductor Flex Cable and the Ground Sense CT Refer to Removing the Ground Sense CT in this chapter Remove the Inductor Flex Bus Remove the two inductor power bus connections Remove the screws fastening the inductor to the Inductor Mounting Plate Part Replacement Procedures 4 25 Important Note the position and orientation of the Ground Sense CT CT3 around the Bus terminal at
45. by measuring the voltage between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access Procedures Important Before you remove connections and wires from the Publication 1336 FORCE 6 15 August 1999 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Remove the Power Module Snubber Board Refer to Chapter 2 Disassembl
46. explanation of the catalog numbering system for Identification 1336 FORCE 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 FORCE Drive Catalog Numbers Table P A 1336T GM1 BULLETIN DRIVE RATING ENCLOSURE STYLE COMMON MODE ADAPTER OPTIONS NO Must be specified CHOKE Must be specified 380 480V AC Input Constant Torque Drive Drive Rating Enclosures Open NEMA Type 1 IP00 IP20 No Enclosure General Purpose Frame Designation Output Amps Nominal HP KW Code Code G 353 6 250 187 BX250 AN BX250A AA 406 4 300 224 B300 AN B300A AA 459 2 350 261 B350 AN B350A AA 505 1 400 298 B400 AN B400A AA 510 2 450 336 B450 AN B450A AA 599 2 500 373 B500 AN B500A AA 673 4 600 448 B600 AN B600A AA Publication 1336 FORCE 6 15 August 1999 P 6 Preface Table P B 1336T C075 AA CM GT2EN L6 BULLETIN DRIVE RATING ENCLOSURE STYLE COMMON MODE ADAPTER OPTION NO Must be specified Must be specified CHOKE Must be specified 500 600V AC Input Constant Torque Drive Enclosures Drive Rating Open NEMA Type 1 IP00 IP20 No Enclosure General Purpose Frame Output Nominal HP KW Code Code Designation Amps G 298 0 300 224 300 C300A AA 353 6 350 261 C350 AN C350A AA 406 4 400 298 C400 AN C400A AA 459 2 45
47. 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 Publication 1336 FORCE 6 15 August 1999 G 6 Glossary Publication 1336 FORCE 6 15 August 1999 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 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 Isolatio
48. repairs to drives Have previous experience with and basic understanding of electrical terminology procedures required equipment equipment protection procedures and methods and safety precautions This manual describes equipment 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts P 2 Preface Electrostatic Discharge Precautions Publication 1336 FORCE 6 15 August 1999 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 gro
49. side of the guard to the SCR heat sink assembly Remove the screws fastening the Input Rectifier Snubber Board to the AC and DC snubber buses Publication 1336 FORCE 6 15 August 1999 2 44 Disassembly and Access Procedures Installation Install the Input Rectifier Snubber Board in reverse order of removal Refer to Table 2 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 FORCE 6 15 August 1999 Chapter Objectives Component Test Overview Chapter 3 Component Test Procedures The following tests help you troubleshoot B300 B600 C300 C600 and BX250 drives In some cases different tests troubleshoot components of the same name 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 The part replacement procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is open For more information on opening the Drive Enclosure refer to Chapter 2 Disassembly and Access Procedures Opening the Drive Enclosure 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
50. 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 develop 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 r
51. the following diagram Refer to the schematic diagrams in this manual for more information on component configurations Figure 4 3 Load Sharing Resistor Connections to Bus Capacitors D1 gt p IFTI 03 F2 e EST y C40 C1 C2 C3 C4 pT IRI 9 9 9 9 9 4 641 C5 C6 7 C8 C13 C24 C25 C36 R4 R6 R7 R9 eooo o C9 C10 11 C12 ooo CAP DETAIL 575V 01 gt pd b Ee 03 F2 e r 9 9 9 9 X C40 C1 C2 C3 C4 m nm mm IR C9 C16 C17 C24 9 9 9 9 9 C41 C5 C6 C7 C8 R3 R4 R5 R6 R EE CAP DETAIL 460V Publication 1336 FORCE 6 15 August 1999 4 8 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 ATTENTION Capacitors not installed correctly will explode or vent and may cause death or serious injury Observe correct polarities ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Thermistor The Thermistor is located at the top of the heat sink in the Inverter Housing Assembly Figure 4 4 Thermistor Thermistor Connector to Main Control Board J1 AB0627A
52. 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 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
53. 0 336 C450 AN C450A AA 505 1 500 373 C500 AN C500A AA 599 2 600 448 C600 AN C600A AA 673 4 650 485 C650 AN C650A AA 1 Refer to the Language Module and Options tables following these Catalog Number tables 2 Drive rating is based on a carrier frequency of 2kHz maximum an altitude of 1 000 meters or less and a maximum ambient temperature of 40 C Refer to Qualifications on page P 7 Table P C Language Modules Description Option Code English E nglish EN English F rench FR English German DE English Italian IT English J apanese JP English S panish ES Publication 1336 FORCE 6 15 August 1999 7 Table P D Options Code Description 2 Code Description Human Interface Modules NEMA Type 1 IP 20 Communication Options b dba a GM1 Single Point Remote HA1 ER LCD Analog Pot GME Rosse ELI HA2 Programmer LCD Digital Pot GNIS Human Interface Modules Type 4 IP 56 Control Interface Options HFB Blank No Functionality HFP Programmer Only HF1 Programmer LCD Analog Pot HF2 Programmer LCD Digital Pot Human Interface Modules NEMA Type 12 IP 54 HJB Blank No Functionality HJP Programmer Only HJ1 Programmer LCD Analog Pot HJ2 Programmer LCD Digital Pot L4 TTL Contacts L5 24V DC L6 115V AC 1 Must be used in conjunction with a standard adapter option GT2EN 21 For a more functionally complet
54. 00 volts Replace it if it is burned expanded or ruptured after a lightening strike or inadvertent connection of the drive input to a voltage source substantially above nameplate voltage Figure 4 14 MOV Surge Suppressor Qe A gt MOV Surge Suppressor i AB0617A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 4 33 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero 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 2 Disassembly and Access Procedures Removing a Po
55. 3 Removing the Precharge Board Figure 2 12 Precharge Board Connector J4 Precharge Connector J3 Board DN Connector J2 S gt Connector J1 High Voltage Guard AB0601A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 2 24 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access Procedures Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component co
56. 336 FORCE 6 15 August 1999 4 Release the snapper pin at the top of the upright Remove the connections between assemblies Important Refer to Figure 2 14 1 Remove the four connections to the DC Bus Inductor Two connections to the left of the vertical Glastic insulator at the left of the motor leads Two connections to the left of the U phase 350 amp bus fuse capacitor fuse 2 Remove the six nuts fastening the left end of the motor flex buses to the three Power Module Bus Bars 3 Remove the 12 nuts fastening the left side of the capacitor flex bus connections to the spine 4 Pull all the flexible leads to the right out of the way 5 Remove the spine Push the spine carefully to the right e Lift it out of the drive without forcing it Access the Capacitor Bank Assembly 1 Disconnect the Inverter Housing Assembly ground cable from the ground plate at the bottom of the main frame 2 Disconnect the Capacitor Bank Assembly ground cable 3 Disconnect any ground wires that obstruct removal of the assembly 4 Remove the capacitor mounting bolt at the top center of the capacitor frame 5 Remove the wheel chocks at the bottom of the Capacitor Bank Assembly 6 Pull the assembly onto a platform Refer to Figure 2 16 ATTENTION Hazard of tipping and severe injury exists This process requires two people The platform must be able to support 909 kg 2 000 Ibs Installation Install the Capacit
57. ATTENTION The National Electric 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 Publication 1336 FORCE 6 15 August 1999 Control Interface Option Control Logic Wiring and Adapters 1 3 The Control Interface L Option Board provides a means of interfacing various signals and commands to the 1336 FORCE by using contact closures Three different versions of the option are available 14 Contact Closure Interface L5 24V AC DC Interface L6 115V AC Interface 1 Uses internal 5V DC supply 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 Control Interface L Option Board Jumpers Important If the Control Interface Board is being installed Standard Adapter Board jumpers at pins 3 amp 4 and 17 amp 18 of 710 must be removed 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 Jumper J10 Located on Standard Adapter Board
58. Board AB0604B 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 3 4 Component Test Procedures ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access Procedures Important Before you remove connections and wires from the Publication 1336 FORCE 6 15 August 1999 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm A
59. FORCE 6 15 August 1999 Index Publication 1336 FORCE 6 15 August 1999 G Gate Driver Board Illustration 2 20 Installation 2 22 Removal 2 20 Testing 3 3 Glossary G 1 Ground Sense CT Illustration 4 26 Installation 4 27 Removal 4 26 Replacement 4 26 H High Voltage Guard 2 24 Illustration 2 23 HIM Removal 1 12 Human Interface Module See Human Interface Module Human Interface Module HIM Illustration 1 10 Operation 1 12 Input Mode 1 5 Factory Default 1 6 Three Wire Control Multi Source Reversing 1 7 Three Wire Control Single Source Reversing 1 6 Two Wire Control Single Source Control 1 7 Input Rectifier Snubber Board Illustration 2 42 Installation 2 44 Removal 2 43 Inputs Available 1 4 Inverter Housing and Capacitor Bank Assemblies Access to 2 25 Inverter Housing Assembly 2 26 Access to 2 27 Installation 2 33 Removal 2 28 J Jumper Definition 9 L Language Modules 6 LEMs Illustration 4 30 Installation 4 31 Removal 4 30 Replacement 4 30 Load Sharing Resistor Connections 4 7 Local Programming 1 4 Main Control Board Illustration 2 11 Installation 2 13 Removal 2 11 Main Control Board Mounting Plate 2 17 Illustration 2 17 Installation 2 19 Removal 2 18 Major Component Replacement See Procedures Manual Audience 1 Objective P 1 Mounting Four Point 2 4 Six Point 2 4 Two Point 2 3 MOV Surge Supp
60. OR FWH 650 900 A70C OR FWH TABLE 2 BASED ON DRIVE HORSEPOWER THE INVERTER DC BUS FUSE WILL CHANGE AMP RATING THE TABLE BELOW DEFINES THE FUSE RATING DRIVE HORSEPOWER INPUT VOLTAGE RATING FUSE INFORMATION TYPE P N HP 380 460VAC HP 575VAC 500HP 380 460VAC 300A A70Q 25178 310 14 600HP 575VAC 300A A70Q 25178 310 14 TABLE 3 THE FOLLOWING IS A LISTING OF ALL PRINTED CIRCUIT ASSEMBLIES VERSUS FUSE amp DOCUMENTATION INFORMATION THE FUSE RATING SCHEMATIC FUSE INFORMATION ITEM BM DIAGRAM DESIGNATOR RATING TYPE P N FA 1 0A 600V KTK R 25172 260 08 ii TIE ud F3 1 5A 600V KTK R 25172 260 09 A10 74101 181 XX 74101 179 F1 F3 1 5A 600V KTK R 25172 260 09 11 13 74101 367 XX 74101 365 NONE A20 22 74101 146 XX 74101 144 NONE A23 28 74101 177 XX 74101 175 NONE 74101 121 F4 F5 3A 600V FNQR 25184 25420 724 6 5 Publication 1336 FORCE 6 15 August 1999 6 6 Schematics 300 600 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE 6 15 August 1999 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
61. SCR3 10 10 SCR5 10 J2 Connector R2G R2K 10 SCR4 R2K R2G 10 S2G S2K 10 SCR6 S2K S2G 10 T2G T2K 10 SCR2 T2K T2G 10 4 Replace the SCR if any meter readings are not as shown Refer to Chapter 4 Part Replacement Procedures SCRs 5 If an SCR requires replacement check the Power Modules for damage Refer to Testing the Power Modules in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Chapter Objective Part Replacement Overview Safety Precautions Chapter 4 Part Replacement Procedures This chapter describes procedures required to replace drive components This chapter references Chapter 2 Disassembly and Access Procedures for basic drive component access The part replacement procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is open For more information on opening the Drive Enclosure refer to Chapter 2 Disassembly and Access Procedures Opening the Drive Enclosure 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 between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across
62. TB7 on drives using a Standard Adapter Board Access the Capacitor Bank Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Capacitor Bank Assembly Remove the Motor Buses 1 3 Remove the screws fastening each motor bus to the top of its Terminal Strip near the bottom of the Capacitor Bank Assembly Remove the screws fastening the motor buses to the Motor Bus Bottom Support Remove the motor buses Access the Capacitors 1 Remove the screws fastening the wires from the Balancer Plate assembly to the capacitors Remove the screws nuts and washers fastening the Capacitor Laminated Bus Bar to the capacitors 5 Part Replacement Procedures 4 7 Remove the Capacitor Laminated Bus Bar and attached components Remove the plastic caps at the four corners of each capacitor insulator Remove the capacitors from the drive Installation 1 Install the capacitor assembly in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important Position 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
63. TENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Chapter 5 Replacement Parts List Chapter Objectives This chapter illustrates and lists replacement parts for the 1336 FORCE Drives rated B300 B600 C300 C600 and BX250 and describes replacement parts ordering procedures The following illustration and table show you parts part names part numbers locations and chapters for replacement procedures Ordering Replacement For your convenience the Allen Bradley Drives Division and the Parts Allen Bradley 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 Allen Bradley 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 e Your company address The repair purchase order number A brief description of the problem Contact your local Allen Bradley 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 Publicati
64. TION 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 3 8 Component Test Procedures ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access Procedures Important Before you remove connections and wires from the Publication 1336 FORCE 6 15 August 1999 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives us
65. 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 Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 15 August 1999 1 2 Control Logic Wiring and Adapters Figure 1 1 Terminal Block Locations Main Control TB10 Encoder Board E 11 zi Standard Adapter Board TB3 Control e 4 L Option Control Interface o L Option Board 1 A TB5 TB6 TB7 Control and Signal Wiring Main Control TB10 Encoder Board E sTeTeTer 5 TB11 PLC Comm Board Communication Channels Geiss EEEBEEE 20 21 Control and Signal Wiring 770
66. 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 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 Allen Bradley Company Inc PLC is a registered trademark of Allen Bradley Company Inc Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve productivity and quality for more than 90 years We design manufacture and support a broad Allen Bradley range of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software Rockwell is one of the world s leading technology companies Worldwide representation
67. 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 radius 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 FORCE 6 15 August 1999 G 12 Glossary This Page Intentionally Left Blank Publication 1336 FORCE 6 15 August 1999 Adapter Locations 1 10 Adapters and Communication Ports Human Interface Module 1 9 Audience for this Manual 1 Auxiliary Input Definition P 8 Auxiliary Interlock Definition P8 Bit Definition P 8 Bus Capacitor Bank Illustration 4 5 Installation 4 7 Load Sharing Resistors 4 7 Removal 4 6 R
68. 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 FORCE 6 15 August 1999 2 26 Disassembly and Access Procedures ATTENTION These assemblies weigh about 500 pounds each Before you pull either one from the drive you must have a platform in place to hold the assembly You cannot remove the assembly without a platform The top of the platform must be even with the assembly s track The platform must be strong enough to support the assembly and the personnel servicing the drive The marketing department at Allen Bradley can provide plans for a suitable platform Refer to the back cover of this manual for the address and telephone number ATTENTION To remove either the Inverter Housing Assembly or the Capacitor Bank Assembly
69. as discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero VDC from Snubber Board terminal TP3 to plus bus before removing connector Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between pins 1 and 2 of connector J1 to discharge any voltage ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board 5 Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Disassembly and Access Procedures 2 41 6 Remove the snubber resistor J1 and J2 connections from
70. assembly by yourself may result in death or serious injury ATTENTION Do not remove both the Inverter Housing and the Capacitor Bank assemblies at the same time Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 29 Access the drive Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Disconnect the AC input lines at the top left of the drive Disconnect the wires to the door mounted external fans at the fan terminal block located on the Inverter Housing Assembly Remove the T Bar from the front of the drive 1 Release the locking nut between the inverter housing and the left side of the T bar Remove the T bar mounting bolt at the bottom of the upright Remove the bolts fastening each end of the crossbar Release the snapper pin at the top of the upright Publication 1336 FORCE 6 15 August 1999 2 30 Disassembly and Access Procedures Figure 2 14 Disconnecting the Spine Capacitor Flex Bus Connections Spine Motor Bus Bar DC Bus Inductor Out Negative Bus Bar
71. both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 4 2 Part Replacement Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 15 August 1999 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 Allen Bradley 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 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 e Remove boards from the drive and immediately insert them into their conductive packets For a list of tools required tightening sequences and fastener torque speci
72. ctricity 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 e Remove boards from the drive and immediately insert them into their conductive packets Tools For a list of tools required tightening sequences and fastener torque specifications refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Component Test Procedures 3 3 Test 1 The Gate Driver Board is located behind the Main Control Board on Testing the Gate the PC Board Mounting Frame If power modules were replaced Driver Board replace the Gate Driver Board If a new Gate Driver Board is not available test the old board using the following procedure Figure 3 1 Gate Driver Board Test oo Oo Korm Gate Driver
73. 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 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
74. d Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Publication 1336 FORCE 6 15 August 1999 4 22 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Remove the Fan Transformer 1 Remove the wiring harness to the Fan Transformer Assembly 2 Turn the thumb latch fastening the Transformer Assembly to Fan 1 1 4 turn counterclockwise 3 Tilt the Transformer Assembly forward and lift it from the mounting bracket Remove Fan 1 1 Disconnect the fan wiring harness 2 Pull down on both spring pins fastening the fan to the Inverter Housing Assembly 3 Pull the fan toward you to remove it Remove Fan 2
75. d capacity is defined by NEMA as 150 of rated full load current for one minute for standard industrial DC motors Publication 1336 FORCE 6 15 August 1999 G 8 Glossary Publication 1336 FORCE 6 15 August 1999 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 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 a Power Factor Distortion 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
76. d the selected mode number below Selected Mode Number For local programming and control information refer to the 1336 FORCE User Manual Control Logic Wiring and Adapters 1 5 Table 1 A Input Mode Selection Start Stop Type Direction Control Communication Compatibility Stop amp Enable None Control must be provided by HIM or Communication Option 1 Only Momentary Maintained Switch Start Stop works in parallel with HIM and Communication Options 2 6 Pushbutton Open Forward Direction Control will not work in parallel with HIM or Communication 8 Wire Closed Reverse Options User must select direction control from either HIM and Communication Options or TB3 input Momentary Momentary Pushbuttons Start Stop works in parallel with HIM and Communication Options Pushbutton Forward and Reverse Direction works in parallel with HIM or Communication Options 7 11 8 Wire Maintained switches for combined run and direction Start Stop not compatible with HIM or Communication Options 12 16 control 2 wire Run Forward Run Reverse Direction not compatible with HIM or Communication Options The maximum and minimum wire sizes accepted by TB3 is 2 1 and 0 30 mm 14 and 22 AWG Maximum torque for all terminals is 0 9 1 13 N m 8 10 in Ib Figure 1 3 TB3 Terminal Designations 20 21 22 23 24 25 26 27 28 29 30 c c Qo 2 5 5 5 Bs 355 g 8 oO E amp B B
77. dapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Control Board Adapter Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Control Board Adapter Mounting Plate Test Gate Driver Board 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 the previous illustration for component locations Component Test Procedures 3 5 Table 3 A Gate Driver Board Test Component Meter Meter Nominal Meter Lead Lead Reading t 1 06 VR1 VR6 Bi 1 8 Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range 9 Replace the Gate Driver Board if your readings do not match the table readings Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board 10 Check all six reverse bias Zener diodes D10 D66 D65 D78 D71 and D72 The following table shows meter connections at the components and ideal meter readings for those connections Refer to the previous illustration for component locations Table 3 B Zener Diode Test Component Meter Meter Nominal Meter Lead Lead Reading D78 t less than 1 open 071 t m less than 1 open D72
78. dapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board 6 Remove the customer supplied wiring from the drive Closing the Drive Enclosure Close the Drive Enclosure in reverse order of opening 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 2 9 Removing the Control Interface L Option Board Mod L4 L5 or L6 Figure 2 6 Control Interface L Option Board Control Interface L Option Board Terminal Strip TB3 AB0759A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 2 10 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August
79. e description of each option refer to Publication 1336 FORCE 1 0 Drive Rating Qualifications Several factors can affect drive rating If more than one factor exists derating percentages must be multiplied For example if a 14 amp drive is installed at a 2km 6 600 ft altitude and has a 2 high input line voltage the actual amp rating is 14 x 94 altitude derating x 96 high input line derating 12 6 amps Enclosure Type The first character A indicates the Enclosure Code The second character indicates the type of enclosure shipped from the factory Table P E Enclosure Type Code Description Enclosure Type Code Description F NEMA Type 1 IP 65 Publication 1336 FORCE 6 15 August 1999 P 8 Preface Conventions Publication 1336 FORCE 6 15 August 1999 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 The following is a list of conventions used throughout this manual and definitions of the conventions For 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
80. eck the following An open condition at an Input Rectifier A voltage drop due to DC Bus Inductor resistance A voltage drop between an Input Rectifier and the bus capacitors due to loose or resistive wires or connections Precharge circuit problems 6 If the above check does not reveal a problem replace the Bus Capacitor Bank and Load Sharing Resistors Refer to Chapter 4 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 Test 5 Testing the SCRs Component Test Procedures 3 15 The SCRs are located in the heat sinks on the Inverter Housing Assembly Important 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in
81. ectors on the Power Module Snubber Board Remove the screws fastening the Power Module Snubber Resistor to the main heat sink Publication 1336 FORCE 6 15 August 1999 4 16 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Installation Install the Power Module Snubber Resistor reverse order of removal Important Install the resistors with the markings to the right ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury SCRs The SCRs are located in the heat sinks on the upper front part of the Inverter Housing Assembly Each of the two heat sinks contains one long and three short sections The cross bars link the sections holding the SCRs in the middle Refer to Figure 4 8 Figure 4 7 SCR Location Converter Back up Cover and Back up Plate Input Rectifier SCR Snubber Board Heat Sink Offset Flex Bus Guard Input Rectifier Horizontal Input Bus Bars Snubber Board lt Oo D Screw Holes 0 SCR Offset Heat Sink Flex Bus NN 9 A 2 i gt AB0603A Removal Important Part Replacement Procedures 4 17 ATTENTION Disconnect and lock out
82. ed except Stop 3 These inputs must be present before drive will start Jog Local Control AB0290B Control Logic Wiring and Adapters 1 7 e y Jog Speed Speed Digital 1st gt Select 3 Select3 PotUp Decel Speed Speed Speed Digital 2nd Select 2 Select 2 Select 2 PotDn Decel oe ossa gne Three Wire Control with Multi Source Reversing Start a Z go 3 22 Be Stop Fault Reset Mode PEX 55 7 8 9 10 11 Bos ZEE Common 2 8S One 252 Reverse Reverse Digital Reverse 1st 224 RA Pot U Accel 2 ot Up cce e g 888 2 gt Foward Forward Digital Forward 2nd 9 oe E ag Pot Dn Accel SgO0 Sz 5 ili z 55 RBZ 3 Auxiliary ue 5 lt 8h 8 sng Wess d EB o 2 Bog DES 52 ae masz ine BES tado of the following 1 05 or earlier Speed Select 11 Common Enable Input Mode 12 16 Two Wire Control Single Source Control Run Forward Stop Fault Reset Common Moge 12 13 14 15 16 Run Reverse Local Stop 2nd Digital Local 5 Control Type Accel PotUp Control Auxiliary 5 9 Speed Speed 2nd Digital Stop Select 3 Select3 Decel PotDn Type Speed Select 2 Speed Select 1 1 See Table 1 B Common 2 Drive mu
83. ed Control User Manual 1336 FORCE 5 12 1336 Force PLC Communications Adapter User Manual 1336 FORCE 5 13 Renewal Parts List 1336 6 5 Options Manuals Instructions Chapter Objectives Chapter Overview Chapter 1 Control Logic Wiring and Adapters This chapter introduces you to terminal block locations and wiring and adapter locations and functions This chapter illustrates and describes Standard Adapter Board Control Logic Interface Options L4 L5 and L6 including Terminal Block TB3 e TB3 input mode selections and functions e TB3 TB5 TB6 TB7 terminal designations This chapter illustrates and describes the following terminal designations for the PLC Comm Adapter Board e TB20 e TB21 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION
84. elocity reference can originate from an external control device such as a potentiometer connected to the analog input of an Adapter board or a signal coming in via RIO from a PLC Refer to the 1336 FORCE User Manual Publication 1336 FORCE 5 12 Chapter 2 Disassembly and Access Procedures Chapter Objectives This chapter describes general disassembly procedures required to access internal drive components Disassembly and Access Overview 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE
85. ent 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 discriminated 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 1 a motor with 1 15 S F can produce 1546 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 FORCE 6 15 August 1999 G 10 Glossary Publication 1336 FORCE 6 15 August 1999 Slip The difference between rotating magnetic field speed synchronous speed and rotor speed
86. eplacement 4 5 Bus Capacitors Testing 3 12 Bus Fuse Illustration 4 28 Installation 4 29 Removal 4 28 Replacement 4 28 C Capacitor Bank Assembly 2 26 Access to 2 36 Installation 2 38 Removal 2 37 Capacitors See Bus Capacitor Bank Check Definition P 8 Component Test 3 1 Component Test Procedures 3 1 Connector Definition P 8 Control Interface Board Installation 2 10 Removal 2 9 Control Interface Board Jumpers 1 3 Jumper Locations 1 3 Control Interface Board Definition P 9 Control Interface Option 1 3 Control Logic Wiring 1 1 Index Control Logic Wiring and Adapters 1 1 Conventions P 8 D DC Bus Inductor Illustration 4 23 Installation 4 25 Removal 4 24 Replacement 4 23 DC Voltage Check Illustration 2 8 Default Definition 9 Detailed Product Identification 4 3 Disassembly and Access Procedures Tools required 2 2 Drive Identification 5 Drive Components Main 4 4 Drive Enclosure Closing 2 8 Illustration 2 6 Opening 2 7 Drive Rating Qualifications 7 E Electrostatic Discharge P 2 Electrostatic Discharge Precautions 2 Enable Input Definition P 9 Enclosure Type P 7 ESD P 2 F False Definition 9 Fan and Transformer Assembly Illustration 4 20 Installation 4 22 Removal 4 21 Replacement 4 20 Fan Capacitors 4 20 Fan Transformer 4 20 Fastener Torque Specifications 2 3 Publication 1336
87. es 2 33 Installation Install the Inverter Housing Assembly in reverse order of removal Important When pushing the Inverter Housing Assembly into the drive you may need to have someone tip the unit slightly to the left or right to center it between the guides at the back of the Enclosure Adjust the angle brackets at the ends of the T bar crossbar ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 15 August 1999 2 34 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 Removing the PC Board Mounting Frame The PC Board Mounting Frame must be removed to pull the Capacitor Bank Assembly from the drive Figure 2 17 PC Board Mounting Frame PC Board Mounting Frame 640 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the
88. esult is a linear braking characteristic ramp that does not diminish with motor speed 3 Regenerative braking A 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 G 2 Glossary Publication 1336 FORCE 6 15 August 1999 4 Motor mounted or separately mounted brake A 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 ap
89. fications refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Major Component Replacement Detailed Product Identification Part Replacement Procedures 4 3 This section explains in detail how to replace the following drive components Bus Capacitor Bank Thermistor Power Modules Power Module Snubber Resistor e SCRs e Fans and Transformer Assembly e DC Bus Inductor Ground Sense CT Bus Fuses e LEMs e MOV Surge Suppressor e Thermal Switch For Gate Driver Board Precharge Board Main Control Board Standard Adapter Board PLC Comm Adapter Board Snubber Board and Control Interface L Option Board installation and removal procedures refer to Chapter 2 Allen Bradley 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 Publication 1336 FORCE 6 15 August 1999 4 4 Part Replacement Procedures Figure 4 1 Main Drive Components MOV Surge Suppressor Thermistor Power Bus Capacitor Module Bank Bus Fuse FI 51 Power Module Power Module Gate Interface Input Rectifier Bus Bar Board Snubber Board
90. fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access 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 Publication 1336 FORCE 6 15 August 1999 2 28 Disassembly and Access Procedures Figure 2 13 Access to the Inverter Housing Assembly AC nput Capacitor Bol oi Mounting Bolt Bolt Bolt Snapper in T Bar Fan Terminal Block Glastic Insulator Wheel Chock 4 2 Mounting Bolt OS Inverter Housing Assembly Ground Cable AB0761A Removal ATTENTION To remove either the Inverter Housing Assembly or the Capacitor Bank Assembly safely requires two persons Attempting to remove either
91. fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Disassembly and Access Procedures 2 35 ATTENTION Wear wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 2 Disassembly and Access 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 Removal 1 2 6 7 Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Disconnect any wires connecting the PC Board Mounting Frame with either main assembly Open the PC Board Mounting Frame all the way to the right Lift the frame straight up to remove it from the hinges Installation Install the PC Board Mounting Frame in reverse order of removal ATTENTION Replace all guards before applying power to the dri
92. g Analog Analog PER Out Out2 Out3 Out4 In In2 In3 In4 Enable Motor Ext er Thermo Fault Publication 1336 FORCE 6 15 August 1999 Adapters and Communication Ports Control Logic Wiring and Adapters 1 9 Table 1 C PLC Comm Adapter Reference Signal Connections Terminal Block Terminal Number s Signal TB20 1 Drive Enable NO 2 Motor Thermoguard NC 3 Normal Stop NC 4 External Fault NC 5 6 Input Common 7 8 Fault Output NC 9 Fault Output COM 10 Fault Output NO TB21 1 OUT 1 2 COM 1 3 COM 2 4 OUT 2 5 OUT 3 6 COM 3 7 OUT 4 8 COM 4 9 IN 1 10 IN 1 11 IN 2 12 IN 2 13 IN 3 14 IN 3 15 IN 4 16 IN 4 17 10 18 19 10V Human Interface Module When the drive mounted HIM is supplied it will be connected as Port 1 refer to Figure 1 7 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 For HIM operation refer to the 1336 FORCE Field Oriented Control User Manual Important The operation of HIM functions depends upon drive parameter settings Default parameter values allow full HIM functionality Publication 1336 FORCE 6 15 August 1999 1 10 Control Logic Wiring and Adapters Figure 1 6 Human Interface Module Standard Adapter Only
93. has dischared to zero volts Remove Power from the drive Turn the enclosure door latches 1 4 turn counterclockwise to open the enclosure door Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts at between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB20 and TB21 on the PLC Comm Adapter Board Disconnect the following from the PLC Comm Adapter Board e Stake on ground wire connector wires from TB20 and TB21 J5 connector J7 connector Communication channel A and B connectors Remove the screws fastening the PLC Comm Adapter Board to the mounting plate Pull the PLC Comm Adapter Board down to release it from the slide mount stand offs and connector J1 Installation Install the PLC Comm Adapter 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 2 17 Removing the Control Board Adapter Mounting Plate Figure 2 10 Control Board Adapter Mounting Plate Mounting Plate p Pd Connector s J2 v Main Control x ooe 8 Pin HIM ie 23 E Connector P E d Terminal ncs Strip TB2 bo lt ae NEN p ag 2 lt Co
94. ing Plate Removal instalation ccna ks ea om REC ecd c ees eg Removing the Gate Driver Chapter 3 Chapter Objectives Component Test Overview Electrostatic Discharge Precautions o berai kee nine ee ese send Test 1 Testing the Gate Driver Board Test 2 Testing the Precharge Test Testing the Power Modules Test 4 Testing the Bus Capacitors Test 5 Testing the SCRS Part Replacement Procedures Table of Contents iii Chapter 4 Chapter saa ek Rex a Rx RE ka 4 1 Part Replacement Overview 4 1 Safety Precautions ous rues aed en ec ebbe DER S Rd 4 1 Electrostatic Discharge Precautions 4 2 Major Component Replacement 4 3 Detailed Product 4 3 Bus Capacitor Bank 4 5 Removal 4 6 instalation as 4 7 ThertfllSlol 4 8 Removal 4 9 liistallatiolt Ye uS 4 10 Power Modules 4 11 Removal a xac hob Ra URS 4 12 Instalatio
95. ing a Standard Adapter Board Set your meter to test resistance Test Precharge Board fuses F1 F2 and F3 for open conditions Replace the Precharge Board if any fuse shows an open condition Refer to Chapter 2 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 3 9 The Power Modules are located on three heat sinks in the Inverter Housing Assembly If Power Modules have been replaced you must check the corresponding Power Module Snubber Board and Snubber Resistor in addition to replacing the Gate Driver Board Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Figure 3 3 Power Module Test Collector C Emitter E Emitter Power 22 1 Tabs E S PF 3 Collector Power Tabs C ey A ES AB0606A Publication 1336 FORCE 6 15 August 1999 3 10 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
96. l connections 240 28 Wires PE Wires to Ground Stud 175 21 Wire TE Wire on Main Control Board Mounting Plate 26 3 Wires Wires to TB1 16 1 8 Wires Wires to TB2 7 0 8 Wires Wires to TB3 8 10 09 1 1 Power Cables Cables to terminals 240 28 Driver Precharge Board Plates to chassis 26 3 Heat Sink Guard Guard to chassis 18 2 T Bar Mounting Bolt T Bar to Main Frame 240 28 8 Capacitor Mounting Bolt Capacitor Bank Assembly to Main Frame 240 28 8 Inverter Housing Assembly Lock Down Bolt Inverter Housing Assembly to Main Frame 240 28 8 Wheel Chock Fasteners Wheel Chocks to tracks 75 9 Ground Cable Bolts Ground Cables from both assemblies to Main Frame 75 9 il Refer to the gauge on the clamp which indicates pounds of force The reading should be 400 Ibs Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 6 Disassembly and Access Procedures Opening the Drive Enclosure C Board Mounting Frame Drive Enclosure Figure 2 4 AB0595B Publication 1336 FORCE 6 15 August 1999 Opening Disassembly and Access Procedures 2 7 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 Negative Capacitor Bus and both ends of all
97. lation 1 Clean all surfaces between the Power Module and the heat sink using a soft clean cloth Replace the preform between the Power Module and the heat sink Install the Power Module in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications 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 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 FORCE 6 15 August 1999 Part Replacement Procedures 4 14 Power Module Snubber Resistor AB0642A The Power Module Snubber Resistors are located on the main heat sink at the back of the Inverter Housing Assembly Power Module Snubber Resistor Power Module Snubber Resistor Figure 4 6 Publication 1336 FORCE 6 15 August 1999 Part Replacement Procedures 4 15 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect
98. ls to prevent incorrect wiring during assembly Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Disconnect the following from the Main Control Board J connector e J5 ribbon cable connector e Stake on ground wire connector All wires from the terminals on TB10 Remove the screws fastening the Main Control Board to the Control Board Adapter Mounting Plate Slide the Main Control Board upward to release it from the slide mount stand offs and connector J7 Store the Main Control Board in an anti static bag Disassembly and Access Procedures 2 13 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 Removing the Standard Adapter Board Figure 2 8 Standard Adapter Board Control Board Adapter Mounting Plate ae Main Control lt Board Slide Mount Stand Off Connector 7 a 2 9 M
99. 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 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 Overloa
100. mer and Fan Capacitors are located in the bottom left corner attached to Fan 1 Both fans and the Transformer Assembly can be replaced without pulling out the Inverter Housing Assembly Figure 4 9 Fan and Transformer Assembly AB0610A Removal Important Part Replacement Procedures 4 21 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero 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 2 Disassembly an
101. moving the Gate Driver Board Gate Driver Board Figure 2 11 Connector J9 7 Connector J7 Gate Driver Connector J13 Connector J2 Connector J6 Connector J10 Connector J8 AB0599A Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 21 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts be
102. n RR 4 13 Power Module Snubber Resistor 4 14 Removal xa 4 15 Installations A 4 16 SORS owe 4 16 Removal e e e t Ee iet Pr e Ss 4 17 Installation x ertt Wie etm 4 19 Fan and Transformer Assembly 4 20 Removal arpes 4 21 Ee EENS 4 22 DC Bus Inductor 4 23 Removal s nakane 4 24 Irstallatiol ELSE 4 25 Ground Sense 4 26 Removal iet t ten erbe deus eS 4 26 sorte ete ete 4 27 BUS FUSES ea hu eM SE 4 28 WR ERE 4 28 Installation 5 decere bane Pe eas 4 29 ES e 4 30 REMOVAL iaces dice oe tnt s don p SED das 4 30 eene 4 31 MOV Surge Suppressor 4 32 TOT TR 4 32 Installation sce a ene 4 34 Chapter Objective 4 1 Part Replacement Overview 4 1 Safety 4 1 Electrostatic Discharge Precautions 4 2 Major Component Replacement 4 3 Publication 1336
103. n 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 generating 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
104. n drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Access the Capacitor Bank Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Capacitor Bank Assembly Remove the LEM Remove the wires from the LEM connectors Remove the two screws fastening the LEM mounting plate to the LEM Remove the LEM U shaped top plate and the LEM U shaped plate Remove the screws and standoffs fastening the LEM to the assembly frame Remove the Terminal Strip from the motor bus Disconnect the motor bus from the Motor Bus Support Disconnect the motor bus at its upper end Remove the motor bus and LEM from the Capacitor Bank Assembly frame Remove the LEM from the motor bus Installation Install the in reverse order of removal Refer to Chapter 2 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 FORCE 6 15 August 1999 4 32 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 MOV Surge Suppressor The MOV Surge Suppressor is located on the left side of the Inverter Housing Assembly in the top left corner at the back of the drive near the vertical bus bars The MOV protects the drive from high voltage surges above approximately 1 0
105. n reverse order of removal inserting the Inductor Flex Cable through the center of the Ground Sense CT Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION possible short circuit hazard exists Position the fuse to inductor wire with the shrink wrapped end of the wire connected to the DC 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 Publication 1336 FORCE 6 15 August 1999 4 28 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Bus Fuses The Bus Fuses are located on the Transitional Bus Bar assembly Figure 4 12 Bus Fuse Bus Fuse Removal p s 3A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures
106. ner 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 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications Component Fastener Application TUE Torque N m Fan Motor Motor to Fan Cover Assembly 14 Fan Transformer Transformer to chassis 75 Fan Capacitor Capacitor to chassis Hand tighten MOV Surge Suppressor MOV to chassis 18 2 Snubber Resistor Resistor to heat sink 26 3 Snubber Bracket Bracket to Power Module Laminated Bus 90 11 Snubber Board Board to Brackets 18 2 Snubber Board Board to Input Rectifier Bracket 18 2 Volt Sharing Resistor Resistor to heat sink 26 3 Volt Sharing Resistor Wires to Capacitor Bus Bar Assembly 50 6 Thermistor Thermistor to heat sink 14 2 Bus Capacitor Holder Holder to Bus Capacitors 26 3 Capacitor Bus Bar Assembly Assembly to Bus Capacitors 50 6 Power Module Gate Interface Board Board to Power Modules 18 2 Power Module Bus Bar Bus Bar to Power Modules 90 11 Power Module Module to heat sink Refer to Figure 2 3 Input Rectifier SCR Rectifier to heat sink 1 Transitional Bus Bar Assembly Assembly to Power Module Bus Bar Assembly 80 9 Bus Fuse F1 Fuse to Transitional Bus Bar Assembly 240 28 DC Bus Inductor L1 Inductor to chassis 75 9 Bus Bar Cable Adaptor DC Bus duct site of ear Fox Bus 75 Converter Bus and Motor Bus Bars Al
107. nnections and terminals to prevent incorrect wiring during assembly Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Turn the four stand offs 1 4 turn counterclockwise to remove the Precharge Board High Voltage Guard Disconnect the following from the Precharge Board J connector J2connector J3 connector J4 connector Turn the six stand offs fastening the Precharge Board to the PC Board Mounting Frame 1 4 turn counterclockwise to remove the board Store the Precharge Board in an anti static bag Disassembly and Access Procedures 2 25 Install the Precharge Board in reverse order of removal ATTENTION When installing the 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 Access to the Inverter Housing and Capacitor Bank Assemblies ATTENTION Disconnect
108. nnector Ji Connector 46 Connector J8 WEAR Terminal Stri ermuna TB3 p Strip TE ABO760A Publication 1336 FORCE 6 15 August 1999 2 18 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 5 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check fo
109. ntil the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Part Replacement Procedures 4 27 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Access the Capacitor Bank Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Capacitor Bank Assembly Remove the Ground Sense CT connector J2 from the Gate Driver Board Remove the nut and washers fastening the end of the Inductor Flexible Cable to the right angled connector on the right side of the DC Bus Inductor Remove the Inductor Flex Cable from the right side inductor power bus connection Slide the Ground Sense CT from the Inductor Flex Cable Installation Install the Ground Sense CT i
110. 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 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
111. on 1336 FORCE 6 15 August 1999 Replacement Parts List 5 2 Replacement Parts Listing Parts for B300 B600 C300 C600 and BX250 Drives Figure 5 1 Publication 1336 FORCE 6 15 August 1999 Replacement Parts List 5 3 Table 5 A Replacement Parts for B300 B600 C300 C600 and BX250 Drives Callout Symbol Description Location Replacement Procedures 1 MOV MOV Surge Suppressor Inverter Housing Assembly Chapter 4 MOV Surge Suppressor 2 011 012 Q21 Q22 Transistor Power Module Inverter Housing Assembly main Chapter 4 Power Modules Q31 Q32 Q41 Q42 heat sink Q51 052 061 Q62 3 R20 R25 Power Module Snubber Inverter Housing Assembly main Chapter 2 Removing a Power Module Resistor heat sink Snubber Board 4 A23 A28 Power Module Gate Interface Power Module Chapter 4 Power Modules Board 5 NTC1 Thermistor Inverter Housing Assembly main Chapter 4 Thermistor heat sink 6 A20 A22 Power Module Snubber Board Power Module Chapter 2 Removing a Power Module Snubber Board 7 R1 R9 Load Sharing Resistor Capacitor Bank Assembly Chapter 4 Bus Capacitor Bank 8 C1 C36 Bus Capacitors Capacitor Bank Assembly Chapter 4
112. onnections 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 Removal ATTENTION To remove either the Inverter Housing Assembly or the Capacitor Bank Assembly safely requires two persons Attempting to remove either assembly by yourself may result in death or serious injury ATTENTION Do not remove both the Inverter Housing and the Capacitor Bank assemblies at the same time Access the drive Remove power from the drive Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in this chapter Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the motor cable connections from the terminal strips at the bottom right of the drive Remove the PC Board Mounting Frame Refer to Removing the PC Board Mounting Frame in this chapter Remove the T Bar Important Refer to Figure 2 13 1 Release the locking nut between the inverter housing and the left side of the T bar 2 Remove the T bar mounting bolt at the bottom of the upright 3 Remove the bolts fastening each end of the crossbar Publication 1336 FORCE 6 15 August 1999 2 38 Disassembly and Access Procedures Publication 1
113. or Bank Assembly in reverse order of removal Important Guide the unit into place so that it mates with the lock down bolt at the top of the capacitor frame Adjust the angle brackets at the ends of the T bar crossbar 2 39 Disassembly and Access Procedures ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury The Power Module Snubber Boards are located on the Inverter Heat Sink assembly Removing a Power Module Snubber Board Power Module Snubber Board Figure 2 19 Publication 1336 FORCE 6 15 August 1999 2 40 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 Removal ATTENTION Disconnect and lock out power from Important 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage h
114. ort Publication 1336 FORCE 6 15 August 1999 4 6 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 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 between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and
115. ponent connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Publication 1336 FORCE 6 15 August 1999 4 10 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 5 Disconnect Main Control Board Connector J1 6 Remove the Thermistor Installation Install the Thermistor in reverse order of removal Refer to Chapter 2 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 4 11 Power Modules The Power Modules are located on the heat sink toward the back of the Inverter Housing Assembly If one or more Power Modules is replaced you must check the Power Module Snubber Board the Precharge Board and the Gate Driver Board Figure 4 5 Power Modules Preform Power Module Power Module Gate Interface Board Insulator Power Module Snubber Bus Bars
116. 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on Power Module Snubber Board Connector J1 if the Snubber Resistor is open Measure for zero 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 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 their component connections and terminals to prevent incorrect wiring during assembly Access the heat sink 1 Remove po
117. power may result in death or serious injury Verify bus voltage by measuring the voltage between between the Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE 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 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Remove the Power Module Snubber Resistor connectors from the J1 and J2 conn
118. 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 Allen Bradley Company Inc Updated Information Summary of Changes Summary of Changes The information below summarizes the changes to the company wide templates since the last release The derating tables in the Preface have been removed Refer to the 1336 FORCE User Manual Publication 1336 FORCE 6 15 August 1999 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE 6 15 August 1999 Preface Control Logic Wiring and Adapters Table of Contents Manual Objective P 1 Who Should UseThis Manual P 1 Safety P 1 Electrostatic DischargePrecautions P 2 1336 FORCE Product Identification P 3 Drive Nameplate Location P 3 Software Compatibility 4 Drive and
119. proximate 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 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
120. r 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 2 15 Removing the PLC Comm Adapter Board Figure 2 9 PLC Comm Adapter Board Control Board Adapter Mounting Plate E gt Main Control DS Slide Mount Stand Off n Ti pd P ae Connector Ji PLC Comm zi Adapter Board PES A vr T Mounting 4 4 Screw TB20 Terminal 21 Connector J5 Strip TE Connector J7 AB0706B Publication 1336 FORCE 6 15 August 1999 2 16 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage
121. r to test voltage 2 Connect the negative lead of the meter to DC and the positive lead to the capacitor terminal called out in Figure 3 4 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 3 Apply power AFTER the meter is connected otherwise your meter will read zero volts Refer to Table 3 D for nominal meter readings Table 3 D Capacitor Test Meter Readings Drive Series Input Volts Meter 380 V 178 V B 415 V 193 V 480 V 218 V 500 V 233 V C 575 V 267 V 600 V 283 V If the capacitors are normal the meter reading should be one third the voltage across the total capacitor bank 4 Using this procedure test each of the three Capacitor Bank sections Table 3 E shows the correct voltage for the total Capacitor Bank Publication 1336 FORCE 6 15 August 1999 3 14 Component Test Procedures Publication 1336 FORCE 6 15 August 1999 Table 3 E Bus Capacitor Bank Test Drive Input Meter Rating Volts Reading 380 535V DC 10 415 580V DC 10 480 650V DC 10 500 700V DC 10 575 800V DC 10 600 850V DC 10 5 If the voltage is out of tolerance ch
122. r zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Standard or PLC Comm Adapter Board The Drive may have either a Standard Adapter Board or a PLC Comm Adapter Board Refer to Removing the Standard Adapter Board or to Removing the PLC Comm Adapter Board in this chapter 6 Remove the wires and connectors from the Main Control Board Refer to Removing the Main Control Board in this chapter Remove the two screws fastening the bottom of the Control Board Adapter Mounting Plate to the PC Board Mounting Frame Disassembly and Access Procedures 2 19 8 Remove the nuts fastening the top of the Main Control Board Mounting Plate to the PC Board Mounting Frame 9 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 2 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 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 20 Re
123. ressor Illustration 4 32 Installation 4 34 Removal 4 32 Replacement 4 32 N Nameplate Location P 3 O Option Control Interface 1 3 Identification 5 Options 7 Parameter Definition P 9 Part Replacement 4 1 Part Replacement Procedures 4 1 PC Board Mounting Frame 2 6 2 26 Illustration 2 34 Installation 2 35 Removal 2 35 Power Module Snubber Board Illustration 2 39 Installation 2 41 Removal 2 40 Power Module Snubber Resistor Illustration 4 14 Installation 4 16 Removal 4 15 Power Modules Illustration 3 9 4 11 Installation 4 13 Removal 4 12 Testing 3 9 Precautions Electrostatic Discharge 2 Safety P 1 Precharge Board Illustration 2 23 Installation 2 25 Removal 2 23 Testing 3 7 Press Definition P 9 Procedures Bus Capacitor Bank Installation 4 7 Bus Capacitor Bank Removal 4 6 Bus Capacitor Replacement 3 12 Bus Capacitor Testing 3 12 Bus Fuse Installation 4 29 Bus Fuse Removal 4 28 Bus Fuse Replacement 4 28 Capacitor Bank Assembly Installation 2 38 Capacitor Bank Assembly Removal Closing Drive Enclosure 2 8 Control Interface Board Installation Control Interface Board Removal 2 9 DC Bus Inductor Installation 4 25 DC Bus Inductor Removal 4 24 DC Bus Inductor Replacement 4 23 DC Voltage Check 2 8 Drive Enclosure Opening and Closing 2 6 Fan Installation 4 22 Fan Removal 4 21 Index 1 3 Gate Driver
124. s 2 Remove the spring bars 3 Remove the short section of the heat sink The long section attached to the Converter Back up Plate remains in place Publication 1336 FORCE 6 15 August 1999 Part Replacement Procedures 4 19 Access the SCRs 1 2 Remove the wires from the SCR Remove the SCR Installation 1 6 Adjust the roll pins in each heat sink half to extend 1 5 mm 0 060 1n toward the inside of the heat sink Apply silicone oil to the heat sink in the areas around the roll pins Clean the surface of the SCR and place it on the roll pin Apply silicone oil to the other side of the SCR Install the SCR Heat Sink in reverse order of removal Allow access to the SCR gate connections Attach the wires to the SCR Important Refer to the torque gauge on the spring bars on the left side of the heat sink Without load the torque gauge should read zero If it does not replace the spring bar assembly Refer to Chapter 2 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 FORCE 6 15 August 1999 4 20 Part Replacement Procedures Fan Cover Publication 1336 FORCE 6 15 August 1999 Fan and Transformer Assembly The two fans are located at the bottom of the Inverter Housing Assembly The Fan Transfor
125. safely requires two persons Attempting to remove either assembly by yourself may result in death or serious injury ATTENTION Do not remove both the Inverter Housing and the Capacitor Bank assemblies at the same time ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury The three main parts of this drive are the PC Board Mounting Frame the Inverter Housing Assembly and the Capacitor Bank Assembly Some procedures in this manual require access to these assemblies and refer to this section Each assembly has wheels that roll in tracks built into the base of the drive Chocks bolted into the tracks prevent assembly movement The drive itself also has wheels built into the main framework of the drive Because of the size weight and physical characteristics of the drive any service procedures requiring removal of either the Inverter Housing Assembly or the Capacitor Bank Assembly requires two people Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 27 Access to the Inverter Housing Assembly 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the
126. st be stopped to take Local Control Control by all other adapters is disabled except Stop Enable 3 These inputs must be present before drive will start AB0291B Publication 1336 FORCE 6 15 August 1999 1 8 Control Logic Wiring and Adapters Table 1 B Speed Select Input State vs Velocity Reference Source Speed Select 3 Speed Select 2 Speed Select 1 Para 52 Bit 14 Bit 13 B12 Velocity Reference TB3 Terminal 26 Terminal 27 Terminal 28 Source Last State X External Reference 1 X O Preset Speed 1 X X Preset Speed 2 X O O Preset Speed 3 X O X Preset Speed 4 X X O Preset Speed 5 X X X External Reference 2 Open Input Removed X Closed Input Present The DIP switches and jumpers on the PLC Communications Board have been preset at the factory Communication is received through Channels A and B This communication protocol is defined through SW U2 US If switches or jumpers require reconfiguration refer to the 1336 FORCE PLC Communications Adapter User Manual Figure 1 5 PLC Comm Adapter Reference Signal Connections 12 34 567 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 TB20 21 3 8 RAE E B d CODO OSOS I S 55 Fault n Common Relay I I I 10 Comm 10 i Analog Analog Analog Analog Analog ena
127. the snubber board 7 Remove the screws fastening the Power Module Snubber Board to the snubber bus bars 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 Using different fastener lengths will damage the Power Modules Install the Power Module Snubber Board in reverse order of removal Refer to Table 2 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 FORCE 6 15 August 1999 2 42 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 Removing an Input Rectifier Snubber Board The Input Rectifier Snubber Boards are located on the Inverter Housing Assembly under the Guard between the heat sinks and the vertical bus Figure 2 20 Input Rectifier Snubber Board Input Rectifier Snubber Board SCRs and Heat Sinks AB0629A Disassembly and Access Procedures 2 43 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to
128. the top of the DC Bus Inductor The Ground Sense CT is removed with the inductor Install the Ground Sense CT in the same position Check that the Bus cable to the fuse passes through the Ground Sense CT during assembly 10 Remove the DC Bus Inductor from the drive Installation Install the DC Bus Inductor in reverse order of removal Refer to Chapter 2 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 FORCE 6 15 August 1999 4 26 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Ground Sense CT The Ground Sense is located between the DC Bus Inductor and the Transitional Bus Bar Assembly Figure 4 11 Ground Sense CT Ground Connector to Gate Sense CT Driver Board J2 2A 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive u
129. three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 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 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter 1 Remove power from the drive 2 Turn the enclosure door latches 90 degrees counterclockwise to open the enclosure door 3 Turn the latches located on the left side of the PC Board Mounting frame to open the PC Board Mounting Frame Refer to Figure 2 4 4 Check for zero volts between DC and DC Refer to Figure 2 5 Publication 1336 FORCE 6 15 August 1999 2 8 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 Figure 2 5 DC Voltage Check DC Negative Sx Capacitor Bus Ul Su Ry Check All Three Bus Fuses AB0637B ATTENTION A blown fuse can create a hazard of shock which may result in death or serious injury Check voltage between the bus bar and both ends of all three fuses 5 Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm A
130. tive packet Remove boards from the drive and immediately insert them into their conductive packets 1336 Product Identification Preface P 3 Drive Nameplate Location The drive nameplate 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 bottom of PC Board i E 2297 7 Mounting Frame o o o AB0541A Publication 1336 FORCE 6 15 August 1999 4 Software Compatibility ATTENTION To guard against machine damage and or personal injury drives with ratings above 45 kW 60 HP must not be used with software versions below 1 07 Refer to the table below Three Phase Drive Rating 380 480V 500 600V Compatible with Frame Version Reference 187 448 kW 224 448 kW 2 01 amp Up 250 600 HP 300 600 HP kW and HP are constant torque CT ratings Publication 1336 FORCE 6 15 August 1999 P 5 Drive and Option The following is an
131. tween DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Remove the Control Board Adapter Mounting Plate Refer to Removing the Control Board Adapter 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 Publication 1336 FORCE 6 15 August 1999 2 22 Disassembly and Access Procedures Publication 1336 FORCE 6 15 August 1999 7 Turn the eight stand offs fastening the Gate Driver Board to the PC Board Mounting Frame 1 4 turn counterclockwise 8 Pull the Gate Driver Board away from the stand offs 9 Store the Gate Driver Board in an anti static bag Installation Install the Gate Driver Board in reverse order of removal Refer to Table 2 A Fastener Torque Specifications ATTENTION When installing the 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 Disassembly and Access Procedures 2 2
132. unded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground ATTENTION Only personnel familiar with the 1336 FORCE 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 Allen Bradley 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 conduc
133. ve Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 15 August 1999 2 36 Disassembly and Access Procedures Access to the Capacitor Bank Assembly Figure 2 18 Capacitor Bank Assembly Capacitor ounting Bolt Motor Cable Terminal Strips Capacitor Bank Assembly Ground Cable Inverter Housing Assembly Ground Cable AB0641B 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 Negative Capacitor Bus and both ends of all three 350 amp fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 2 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 15 August 1999 Disassembly and Access Procedures 2 37 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 c
134. wer Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE 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 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 Check for zero volts between DC and DC Refer to Figure 2 5 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly Remove the MOV wire harness from the vertical bus bars on the left at the back of the Inverter Housing Assembly Remove the screw fastening the MOV to the Inverter weldment Publication 1336 FORCE 6 15 August 1999 4 34 Part Replacement Procedures Publication 1336 FORCE 6 15 August 1999 Installation Install the MOV Surge Suppressor in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications AT
135. wer from the drive 2 Open the PC Board Mounting Frame Refer to Opening the Drive Enclosure in Chapter 2 3 Check for zero volts between DC and DC Refer to Figure 2 5 4 Check for the absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Publication 1336 FORCE 6 15 August 1999 4 18 Part Replacement Procedures 5 Access the Inverter Housing Assembly Refer to Chapter 2 Disassembly and Access Procedures Access to the Inverter Housing Assembly 6 Remove the Input Rectifier Snubber Boards Refer to Chapter 2 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board 7 Remove the snubber insulator and attached snubber buses Figure 4 8 SCR Heat Sinks Converter Converter Back up Plate Back up Cover lt lt SL Cross Bar o Heat Sink Spring Bars AB0628A Remove the short section of the heat sink 1 Remove the nuts from the ends of the cross bar
136. y and Access Procedures Removing a Power Module Snubber Board Set your meter to test diodes Test the Power Modules The following table shows meter connections and ideal meter readings for those connections Refer to the former illustration for meter connection locations Component Test Procedures 3 11 Table 3 C Power Modules Meter Lead Meter Lead Nominal Meter Reading E C 0 318 0 1 E G Infinite C E Infinite G Infinite G E Infinite G C Infinite 9 Replace a Power Module if meter readings are not as shown Refer to Chapter 4 Part Replacement Procedures Power Modules 10 Set your meter to measure resistance 11 Test the Power Module Snubber Resistors The reading should be 16 ohms each If open replace the snubber resistor Two 16 ohm resistors are in parallel when plugged into a snubber board resulting in 8 ohms total 12 Assemble the drive in reverse order of disassembly ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 15 August 1999 3 12 Component Test Procedures Test 4 Testing the Bus Capacitors Publication 1336 FORCE 6 15 August 1999 The Bus Capacitor Bank is located in the Capacitor Bank Assembly Figure 3 4 Bus Capacitor Bank Test Important Meter Lead S Gu Meter Lead

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