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Service Manual, Bulletin 1336 FORCE Adjustable Frequency AC

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2. 0529 Publication 1336 FORCE 6 13 August 1999 4 12 Part Replacement Procedures Publication 1336 FORCE 6 13 August 1999 Thermistor The Thermistor is located on the top left corner of the heat sink Figure 4 8 Thermistor Thermistor Connector to Main Control Board J1 0381 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 Part Replacement Procedures 4 13 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum 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 Important
3. dnd PRESET 5 XREF 1 PRESET 1 ESC 9 PRESET 2 3 JOG 0554 Drive Tools Control Firmware Function Control Logic Wiring and Adapters 1 15 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 repr
4. Expansion Options AB0692B Publication 1336 FORCE 6 13 August 1999 1 12 Control Logic Wiring and Adapters Publication 1336 FORCE 6 13 August 1999 PLC Comm Adapter Ports Figure 1 9 PLC Comm Adapter Board Port Locations Main Control Board Communications Channels Ports 6 7 PLC Comm Board SCAN port 1 7 SCAN port 2 dl TB 1 O O O OJ O O O O OJ O O O O OOJ OJO Communications Port Remote HIM Communication Options Adapter 2 or Expansion Options Adapters 2 3 4 5 Expansion Options 0700 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 Control Logic Wiring and Adapters 1 13 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 To r
5. 2 14 Removing the PLC Comm Adapter Board 2 15 IristallatlOri x uero ERROR ERR RR 2 16 Removing the Control Board Adapter Mounting Plate 2 17 Removah carers sur 2 17 Installato DOTT TT 2 18 Removing the Gate Driver Board Mounting Plate 2 19 Removal Gi 2 19 Installation cles IIR 2 21 Removing the Gate Driver 2 22 2 22 s c eta aor rao eR anc aec neas 2 24 Removing the Precharge Board Mounting Plate 2 25 Removal 2 25 2 26 Removing the Precharge Board 2 27 Removal 2 27 Installation oue dt ene pads 2 28 Removing a Power Module Snubber Board 2 29 Publication 1336 FORCE 6 13 August 1999 Component Test Procedures Part Replacement Procedures Table of Contents Removals TOP dud caste ce Removing the Converter Snubber Board Removal RT Installation II Accessing Power Plane Components Chapter 3 Chapter Objectives Component Test Overview Electrostatic Discharge Precautions Tools Test 1 Testing the Gate Driver Board
6. 2 OPTIONAL 380 480V AC Input Constant Torque Drive Open 1 00 No Enclosure Code B060 AN B075 AN B100 AN B125 AN BX150 AN Table P C LANGUAGE MODULE MUST BE SPECIFIED Preface HUMAN INTERFACE OPTIONAL Enclosures NEMA Type 1 IP20 General Purpose B060 AA B075 AA 100 125 150 CONTROL 2 OPTIONAL 500 600V AC Input Constant Torque Drive Open 00 No Enclosure Output Code Code Amps C075 AN 100 C125 AN NEMA Type 1 IP20 General Purpose C075 AA C100 AA C125 AA Refer to the Language Module and Options tables following these Catalog Number tables Enclosures 2 2 NEMA Type 4 IP56 Resist Water Dust Code HUMAN 2 OPTIONAL NEMA Type 4 IP56 Resist Water Dust Code 2 COMMUNICATION CARDB OPTIONAL NEMA Type 12 IP54 Industrial Use Code GM1 COMMUNICATION OPTIONAL NEMA Type 12 IP54 Industrial Use Code Drive rating is based on a carrier frequency of 4kHz maximum an altitude of 1 000 meters or less and a maximum ambient temperature of 40 C Refer to Publication 1336 FORCE 6 13 August 1999
7. 4 Drive and Option Identification P 4 1336 FORCE Drive Catalog Numbers P 4 Drive Rating Qualifications P 6 Enclos te Sess WEE 7 Pup p PTT P 7 Auxiliary Input P 7 Auxiliary Interlock P 7 Bil epen ORT 7 plo P 8 P 8 pU Ar P 8 cuins CPU P 8 RS P 8 METTE P 8 Control Interface Board P 9 Parameter P P 9 gc pvc P 9 e eee P 9 Related Publications P 9 Chapter 1 Chapter Objectives 1 1 Ghapt r OVBIVIBW x Exp Re Rb ei 1 1 Control Interface Option 1 3 Control Interface L Option Board Jumpers 1 3 Available 2 4 52 pr en 1 4 Standard Adapter Local Programming 1 5 Adapters and Communication Ports 1 10 Human Interface Module 1 10 Standard Adapter Ports 1 11 PLC Comm Adapter Ports 1 12 HIM Rx a x DR ER aem axe 1
8. 4 25 4 25 Installation 4 26 Ground Sense GT orbe bide Ries luus 4 27 Removal Shei e ete ED 4 27 PASTA ATION sera cic tee tio tace s Eb E eb 4 28 BUS eU Xo So e Kc anaes 4 29 Removal 4 29 4 30 LEMS a2 HT 4 31 E a E E EIS 4 31 4 33 MOV Surge Suppressor 4 34 Removal 4 35 Installation lle RR 4 35 Chapter 5 Chapter Objectives 5 1 Ordering Replacement 5 1 Replacement Parts Listing 5 2 Chapter 6 Manual Objective Who Should Use This Manual Safety Precautions Preface Preface The information in this manual is designed to help repair an Allen Bradley Bulletin 1336 FORCE Adjustable Frequency AC Drive with ratings A040 A060 B060 B125 BX150 and C075 C125 This manual is intended for qualified service personnel responsible for repairing the 1336 FORCE Adjustable Frequency AC Drive You should e Read this entire manual before performing maintenance or repairs to drives Have previous experience with and basic understanding of electrical terminology procedures required equipment equipment prote
9. Disassembly and Access Procedures 2 19 Removing the Gate Driver Board Mounting Plate Figure 2 9 Gate Driver Board Mounting Plate EN i Gate Driver Board Mounting Plate Gate Driver Connector Board J2 li al UN EN Connector TR LT n 2 Connector y i E 6 TB7 m TB4 Removal EN lt lt S 7 Mounting Screw We CR 0380 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between DC and DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 13 August 1999 2 20 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 ATTENTION Hazard of electric shock exists Up to 1 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 and less than 100 ohm rated for 25 watts minimum 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 compo
10. 93N 1 304 NN 304 sug 0L O3N M 6 09 M 8 93N A aw nm 1 S0d A TIW 9 93 s0d n t z 7 x o Q E wnvoa fa ce 0 Ble EE lt 8 y EE cc 19 EI lt lt HOLSIS3H e ETE Ee zo Lu zz lt C Lr lt c Publication 1336 FORCE 6 13 August 1999 6 4 Schematics 40 150 HP 1336 FORCE Drives Fan Circuit Detail 200 240VAC E AC INPUT POWER P 240 200 115V HEATSINK FAN C HB1 200 240V 415 380 500 575VAC AC INPUT POWER HEATSINK HEATSINK FAN FAN C O mm C HB1 C HB1 re 1 1 380 460V 575 Capacitor Detail 125 HP 575 VAC 73 100 HP 572 VAG 125 HP 380 460 VAC o DC 60 HP 230 VAC 60 75 100 380 460 150 HP 460 VAC R1 40 50 HP 230 VAC ae 9 7564736773 2 DC ee gt R1 A Ciz 34 5 C24 657 C87 R2 C27 657 s e e e o o R1 C24 C4 C6 8 I 2 R2 R2 t t e e e e C34 64 C9 Publication 1336 FORCE 6 13 August 1999
11. 0527 Publication 1336 FORCE 6 13 August 1999 4 10 Part Replacement Procedures Load sharing resistors R1 and R2 have three color coded leads coming out of each resistor body Connect as shown in Figure 4 6 Figure 4 6 Wiring Detail for C075 and C100 Drives DC C1 8 4 e Yellow e 13 6 R1 Black Ohms C2 C5 13 6 Yellow s Ohms R2 Black B Inv gt 0532 R2 YELLOW R1 BLACK R1 YELLOW R1 BLUE R2 BLACK 0528 Publication 1336 FORCE 6 13 August 1999 Part Replacement Procedures 4 11 Load sharing resistors R1 R2 and R3 have two color coded leads coming out of each resistor body Connect as shown in Figure 4 7 Figure 4 7 Wiring Detail for C125 Drives DC Blue a 4 4 3K 1 2 04 cT 07 Black R3 hi hi d e Blue 4 3 202 2 05 2 08 Black RI e Blue m C 2 R2 C3 C6 C9 Black L Ohms Inv R2 BLACK R1 BLACK R3 BLACK BLUE R2 BLUE R1 BLUE e
12. 6 Preface Publication 1336 FORCE 6 13 August 1999 Table P D Language Modules Description English English English French English German English Italian English Japanese English Spanish Table P E Code Human Interface Modules NEMA Type 1 IP 20 HAB HAP HA1 HA2 Human Interface Modules NEMA Type 4 IP 56 HFB HFP 1 2 Options Description Blank No Functionality Programmer Only Programmer LCD Analog Pot Programmer LCD Digital Pot Blank No Functionality Programmer Only Programmer LCD Analog Pot Programmer LCD Digital Pot Option Code EN FR DE IT JP ES Code Description Communication Options Single Point Remote GM1 1 0 GM2 5 232 422 485 DF1 GM3 RS 232 422 485 DH485 Control Interface Options L4 TTL Contacts L5 24V DC L6 115V AC Human Interface Modules NEMA Type 12 IP 54 HJB HJP HJ2 Blank No Functionality Programmer Only Programmer LCD Analog Pot Programmer LCD Digital Pot Drive Rating Qualifications Must be used in conjunction with a standard adapter option GT2EN For a more functionally complete description of each option refer to Publication 1336 FORCE 1 0 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 ha
13. Test 2 Testing the Precharge Board Test 3 Testing the Power Modules Test 4 Testing the Bus Capacitors Test 5 Testing the Input Rectifiers Chapter 4 Chapter Objective Part Replacement Overview Safety Electrostatic Discharge Precautions Tools Major Component Replacement Detailed Product Bus Capacitor Removal 5 ode e tne e ED e iE Poe e s metalation xoc Poe eee iue Vee aes Thermistor Removals aves nee aed wane ood ees P TASTES ece a Power Modules Removal instalation ate ZEE Input Rectifiers Removal Sez et Ub Ur ese bbs ese estos Installation xb eet e Removal e Vor re RR Installation bee tute RIP IRI Publication 1336 FORCE 6 13 August 1999 iv Table of Contents Replacement Parts List Schematics 40 150 HP 1336 FORCE Drives Glossary Index Publication 1336 FORCE 6 13 August 1999 Autotransformer icis 4 23 Removal 4 24 Instalation RR 4 24 DC 1
14. August 1999 Chapter 5 Replacement Parts List Chapter Objectives This chapter illustrates and lists replacement parts for the 1336 FORCE Drives rated A040 A060 B060 B125 150 and C075 C125 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 FORCE Spare Parts Pricing publication included with your drive documentation set Publication 1336 FORCE 6 13 August 1999 Replacement Parts List 5 2 Replacement Parts Listin
15. SCANport is a trademark of Allen Bradley Company Inc PLC is a registered trademark of Allen Bradley Company Inc OY 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 Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC Colombia Costa Rica Croatia e Cyprus e Czech Republic e Denmark e Ecuador Egypt El Salvador e Finland e France Germany Greece e Guatemala e Honduras e Hong Kong Hungary Iceland India Indonesia e Ireland e Israel e Italy e Jamaica 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 Qatar e Romania 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 United Arab Emirates e United Kingdom e United States e Uruguay Venezuela Yugoslavia
16. in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Board Mounting Plate Refer to Removing the Gate Driver Board Mounting Plate in this chapter Remove the wires from Power Module Snubber Board stake on connectors El and E2 Remove J1 and J2 connectors Remove the eight screws fastening the Snubber Board to the Power Module Installation Disassembly and Access Procedures 2 31 ATTENTION Do not substitute longer or shorter hardware when fastening the Power Module Snubber Boards 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 Fastener Torque Specifications in this chapter Important Line up the bottom edge of the Snubber Board with the metal posts on the Power Module Brackets 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 13 August 1999 2 32 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 Removing the Converter Snubber Board Figure 2 14 Converte
17. logic Eight bits form a BYTE 16 bits form a word Drive parameters are actually eight bits or 16 bit words Publication 1336 FORCE 6 13 August 1999 P 8 Preface Publication 1336 FORCE 6 13 August 1999 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 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 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 wi
18. Motor ya Bus Bar Gate Driver 2 Fuse F3 d Connector Main Control J7 Board d Bus Bar c lt 2 Connector 5 onnector J1 Human Interface dule Terminal Strip Hc 4 TB LE Fuse F1 Connector J1 R y Ground y Sense CT Standard 2 PL Adapter Board Bus Inductor a L1 Precharge _ 2977 NON Board Fuses 4 A MOV Surge Suppressor Precharge 2 iA Board Autotransformer C Fan Capacitor Control Interf ontrol Interface C L Option Board PLC Comm 7 NN Adaptet Board 2 Connector J5 Connector J7 Ne 21 20 0698 Publication 1336 FORCE 6 13 August 1999 Part Replacement Procedures 4 5 Bus Capacitor Bank The Bus Capacitor Bank is located on the left side of the Main Chassis Figure 4 2 Bus Capacitor Bank Load Sharing Resistor Bus Fuse Capacitor Ne Bracket lt 9 il ES Capacitor de Capacitor Oo Retainers ro One of two sizes A this bolt only BS NS TN 4 Capacitor 6 DC pn DC L 03820 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result i
19. wy Allen Bradley Bulletin 1336 FORCE _ Adjustable Frequency servi Ce AC Drive Series A B C D Manual A040 A060 B060 B125 BX150 C075 C125 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
20. 11 Installation 2 12 Removal 2 11 Main Control Board Mounting Plate Installation 2 18 Removal 2 17 Major Component Replacement See Procedures Manual Audience 1 Conventions 7 Objective P 1 Related Publications 9 Mounting Four Point 2 4 Two Point 2 3 MOV Surge Suppressor Illustration 4 34 Installation 4 35 Removal 4 35 N Nameplate Location P 3 0 Objective of this Manual 1 Operation Human Interface Module 1 13 Option Control Interface 1 3 Identification 4 P Parameter Definition P 9 PLC COMM Adapter Board Illustration 2 15 Power Module Illustration 4 14 Installation 4 16 Removal 4 15 Test 3 7 Power Module Snubber Board Illustration 2 29 Installation 2 31 Removal 2 29 Precautions Electrostatic Discharge 3 Safety 1 Precharge Board Illustration 2 27 Installation 2 26 2 28 Removal 2 25 2 27 Test 3 5 Precharge Board Mounting Plate Illustration 2 25 Press Definition P 9 Procedures Accessing Internal Drive Components 2 1 Autotransformer Removal 4 21 Bus Capacitor Bank Installation 4 7 Bus Capacitor Bank Removal 4 5 Bus Capacitor Bank Test 3 9 Bus Fuse 4 29 4 30 Component Test 3 1 Control Board Installation 2 12 Control Board Mounting Plate Installation 2 18 Control Board Removal 2 11 Control Board Adapter Mounting Plate Removal 2 17 Control Interface Board Installation
21. 2 10 Control Interface Board Removal 2 9 DC Bus Inductor L1 Installation 4 26 DC Bus Inductor L1 Removal 4 25 Drive Enclosure Installation 2 8 Drive Enclosure Removal 2 7 Fan Capacitor Removal 4 21 Fan Removal 4 21 Gate Driver Board Installation 2 24 Gate Driver Board Removal 2 22 Gate Driver Board Test 3 3 Ground Sense CT 4 27 4 28 Input Rectifier Installation 4 19 Input Rectifier Removal 4 17 Input Rectifier Test 3 12 LEMs Installation 4 33 LEMs Removal 4 31 Major Component Replacement 4 3 MOV Surge Suppressor Installation 4 35 MOV Surge Suppressor Removal 4 35 PLC Comm Adapter Board Removal 2 15 Power Module Installation 4 16 Power Module Removal 4 15 Power Module Snubber Board Installation 2 31 Power Module Snubber Board Removal 2 29 Power Module Test 3 7 Precharge Board Installation 2 26 2 28 Precharge Board Mounting Plate Removal 2 25 Precharge Board Removal 2 27 Precharge Board Test 3 5 Replacement Part 4 1 Standard Adapter Board Removal 2 13 Thermistor Installation 4 14 Thermistor Removal 4 12 Programming Input Mode 1 4 Index 1 3 Local 1 5 R Rating Drive P 6 Related Publications P 9 Removal Procedures See Procedures Removal 1 12 Replacement Part Procedures 4 1 Replacement Parts 5 1 S Safety Precautions 1 Snubber Board Converter Illustration 2 32 Installation 2 33
22. 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 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board 4 Disconnect the MOV wires from TBI terminals L1 L2 and L3 R S and T 5 Disconnect the MOV wire from the ground stud 6 Remove the screw fastening the MOV to the Main Chassis Installation Install the MOV Surge Suppressor in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important Install the MOV using the same M4 or M5 screw as was removed 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 13 August 1999 4 36 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 FORCE 6 13
23. 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 Publication 1336 FORCE 6 13 August 1999 3 6 Component Test Procedures Publication 1336 FORCE 6 13 August 1999 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board 5 TB6 and TB7 on drives using a Standard Adapter Board 4 Set your meter to test resistance 5 Test fuses F1 F2 and for open conditions 6 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 7 The Power Modules are located near the top of the heat sink Figure 3 3 Power Module Test Some drives may not have brackets at E and G AB0390C ATTENTION
24. When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 13 August 1999 2 22 Disassembly and Access Procedures Removing the Gate Driver Board Figure 2 10 Gate Driver Board Removal Publication 1336 FORCE 6 13 August 1999 Gate Driver Board 1 Mounting Plate Connector NUN Connector J1 Pal Connector J6 Connector J10 Gate Driver Board DES Connector J13 Connector J7 Connector J8 Connector 9 0370 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 Disassembly and Access Procedures 2 23 ATTENTION Hazard of electric shock exists Up to 1 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor grea
25. 12 HIM ODOM C 1 13 Graphic Programming 1 14 Publication 1336 FORCE 6 13 August 1999 ii Table of Contents GPT n e seks EX 1 14 Drive n NC T 1 15 Control Firmware Function 1 15 Disassembly and Access Chapter 2 Procedures Chapter Objectives 2 1 Disassembly and Access Overview 2 1 Electrostatic Discharge Precautions 2 2 DRE 2 2 Fastener Torque Specifications 2 3 Torque Sequence 2 3 Two Point Mounting 2 3 Four Point Mounlitig aee eee bow cit 2 4 Torque Specifications 2 4 Disassembly and Access Procedures 2 7 Opening the Drive Enclosure 2 7 Removal ei 22 2 7 ee eee eee E 2 8 Removing Control Interface L Option Board MOD L4 L5 or L6 2 9 Removal 2 9 Installation 2 10 Removing the Main Control Board 2 11 as at RO ON 2 11 Installation lesse II 2 12 Removing the Standard Adapter Board 2 13 Removal 2 13 instalation
26. 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 current Regeneration AC drives When the rotor synchronous frequency is greater than the applied frequency Regenerative Braking Slows or stops a motor through regeneration Refer to Regeneration and Braking Resolution The smallest distinguishable increment into which a quantity can be divided e g position or shaft speed It is also the degree to which nearly equal values of a quantity can be 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
27. 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 13 August 1999 PN 74002 119 01 A Supersedes February 1996 Copyright 1996 Allen Bradley Company Inc Printed in USA
28. Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e TBS TB6 and 7 on drives using a Standard Adapter Board Disconnect the Thermistor connector at J1 on the Main Control Board Remove the Gate Driver Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Cut and remove tie wraps along the wire routing path of the Thermistor Remove the Thermistor from the heat sink Publication 1336 FORCE 6 13 August 1999 4 14 Part Replacement Procedures Installation Install the Thermistor in reverse order of removal replacing tie wraps as needed 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 Power Modules The Power Modules are located near the top of the heat sink Figure 4 9 Power Modules Publication 1336 FORCE 6 13 August 1999 U Phase Module V Pha
29. Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Publication 1336 FORCE 6 13 August 1999 4 2 Part Replacement Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 13 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 e Phillips screwdrivers medium and large Standard screwdrivers small medium and large 10mm socket 13 mm
30. 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 Publication 1336 FORCE 6 13 August 1999 3 8 Component Test Procedures ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 terminals DC and DC 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 Control Board Adapter Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Control Board Adapter Mounting Plate Remove the Gate Driver Board Mounting Plate Refer to Chapt
31. INV eoe AB0636A TABLE 1 CUSTOMER FUSING BASED ON MAXIMUM DRIVE RATING THE FOLLOWING FUSES OR APPROVED EQUIVALENT MUST BE USED Schematics 40 150 HP 1336 FORCE Drives 6 5 HORSEPOWER 230VAC FUSE CURRENT TYPE 380 460VAC FUSE CURRENT TYPE 575VAC FUSE CURRENT TYPE 40 150 AMP CLASS T JJS 50 200 CLASS T JJS 60 250 AMP CLASS T JJS 125 AMP CLASS T JJS 75 150 AMP CLASS T JJS 110 AMP CLASS T JJS 100 200 AMP CLASS T JJS 150 AMP CLASS T JJS 125 250 AMP CLASS T JJS 175 AMP CLASS T JJS 150 250 AMP CLASS T JJS TABLE 2 BASED ON DRIVE HORSEPOWER THE INVERTER DC BUS FUSE WILL CHANGE AMP RATING THE TABLE BELOW DEFINES THE FUSE RATING uos er FUSE INFORMATION INPUT VOLTAGE RATING TYPE PIN 40HP 230VAC 150AMP 700150 4 25178 310 10 50HP 230VAC 200AMP A70Q200 4 25178 310 12 60HP 230 250AMP A70Q250 4 25178 310 13 60HP 380VAC 125AMP 700125 4 25178 310 09 75HP 380 460VAC 150AMP 700150 4 25178 310 10 75HP 575VAC 125 A70Q125 4 25178 310 09 100HP 380 460 VAC 200AMP A70Q200 4 25178 310 12 100HP 575VAC 175AMP 700175 4 25178 310 11 125HP 380 460 VAC 250AMP A70Q250 4 25178 310 13 125HP 575VAC 200AMP 700200 4 25178 310 12 150HP 460VAC 250AMP A70Q250 4 25178 310 13 TABLE 3 THE FOLLOWING 15 A LISTING OF ALL PRINTED CIRCUIT ASSEMBLIES VERSUS FUSE
32. PE CAPACITOR BANK SEE CAPACITOR DETAIL Publication 1336 FORCE 6 13 August 1999 CNV DC 109 65 2 1 554321 LU 4T T m J2 J4 4 SMPS STANDARD n M0 PRECHARGE Fi F2 7 na BOARD 9 COMMON SEE TABLE 3 CHARGE 12 AC LINE 0632 6 3 Schematics 40 150 HP 1336 FORCE Drives TB1 AC OUTPUT POWER INV GATE INTERFACE GATE INTERFACE GATE INTERFACE
33. Removal 2 32 Snubber Board Power Module Illustration 2 29 Installation 2 31 Removal 2 29 Speed Select Input State 1 8 Standard Adapter Board Illustration 2 13 T TB3 Terminal Designations 1 5 Terminal Block Locations PLC Comm Adapter Board 1 2 Standard Adapter Board 1 2 Terminal Designations TB3 1 5 Thermistor Illustration 4 12 Installation 4 14 Removal 4 12 Tools Required for Service 2 2 3 2 4 2 Torque Four Point Mounting Sequence 2 4 Maximum for TB Terminals 1 5 Specifications 2 4 Two Point Mounting Sequence 2 3 Troubleshooting Component Test Procedures 3 1 True Definition P 9 Two Point Mounting 2 3 W Wire Sizes 1 5 Publication 1336 FORCE 6 13 August 1999 Index Publication 1336 FORCE 6 13 August 1999 This Page Intentionally Left Blank 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 RESPONSIB
34. Speed 4 X X Preset Speed 5 X X X External Reference 2 Open Input Removed X Closed Input Present Figure 1 6 PLC Comm Adapter Reference Signal Connections Ta 12 34 5 6 7 8 9 10 12 34 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 TB20 21 E E Fault 10 Comm 10 LILILILIU UU D v e Analog Analog Analog Analog Analog Analog Analog Analog Drive Stop 041 2 043 014 In2 In3 In4 Enable Motor ABO551A Thermo Fault Publication 1336 FORCE 6 13 August 1999 Table 1 C Control Logic Wiring and Adapters PLC Comm Adapter Reference Signal Connections Terminal Block TB20 21 Terminal Number s Signal 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 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 14 10 IN 1 11 IN 24 12 IN 2 13 IN 3 14 IN 3 15 IN 4 16 IN 4 17 10V 18 COM 19 10V Publication 1336 FORCE 6 13 August 1999 1 10 Control Logic Wiring and Adapters Adapters and Communication Ports Publication 1336 FORCE 6 13 August 1999 Human Interface Module When the drive mounted HIM is supplied it will be connected as Adapter 1 ref
35. a device For a drive it is the deviation from the initial set speed with no load change over a specific time period Normally the drive must be operated for a specified warm up time at a specified ambient temperature before drift specifications apply Drift is normally caused by random changes in operating characteristics of various control components Drive Controller Variable Speed Drive Drive An electronic device that can control the speed torque horsepower and direction of an AC or DC motor 1 PWM drive is a motor drive using pulse width modulation techniques to control power to the motor A high efficiency drive used for high response applications 2 SCR drive is a motor drive that uses SCRs as the power control elements Usually used for low bandwidth high power applications 3 Servo drive is a motor drive that uses internal feedback loops for motor current and or velocity 4 Vector drive is an AC static motor drive using power control techniques that produce motor performance similar to DC static drives Duty Cycle 1 The ratio of working time to total time for an intermittently operating device Usually expressed as a percentage 2 The ratio of pulse width to the interval between like portions of successive pulses Usually expressed as a percentage Dynamic Braking Refer to Braking Efficiency Ratio of output to input indicated by a percentage Ina motor it is the effectiveness with wh
36. deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in or N m Nylon tie wraps e Side cutters 17mm socket Major Component Replacement Part Replacement Procedures 4 3 This section explains in detail how to replace the following drive components Bus Capacitors Thermistor Power Modules Input Rectifiers Fan Assembly e Autotransformer e DC Bus Inductor L1 Ground Sense CT Bus Fuse e LEMs Surge Suppressor For Gate Driver Board Precharge Board Main Control Board Standard Adapter Board PLC Comm Adapter Board Snubber Board and Control Interface Board installation and removal procedures refer to Chapter 2 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 4 4 Part Replacement Procedures Detailed Product Allen Bradley Adjustable Frequency AC Drives are modular by Identification design to enhance troubleshooting and spare parts replacement thereby helping reduce production down time The following illustration calls out the main components of a typical drive Component designs vary slightly among the different drive ratings but component locations are identical Figure 4 1 Main Drive Components Load Sharing Resistor Power Module Bus Capacitor Bank Power Module Snubber Resistor pz Bus Fuse SL Inverter p Capacitor Bus Bar Bus Bar Thermistor Power Module Snubber Board
37. explanation of the catalog numbering system for 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 CONTROL INTERFACES OPTIONAL HUMAN INTERFACES OPTIONAL MUST BE SPECIFIED 200 240V AC Input Constant Torque Drive Enclosures NEMA Type 4 GM1 HUMAN COMMUNICATION OPTIONAL NEMA Type 12 Drive Rating Frame Designation 120 3 40 149 2 50 180 4 60 Open 1 00 No Enclosure A040 AN A050 AN A060 AN Publication 1336 FORCE 6 13 August 1999 NEMA Type 1 IP20 General Purpose Amps A040 AA A050 AA A060 AA IP56 Resist Water Dust IP54 Industrial Use 13365 060 BULLETIN RATING ENCLOSURE NO MUST BE SPECIFIED Drive Rating Frame Designation 13365 BULLETIN NO Drive Rating Frame Designation Qualifications on Not available Output Nominal Amps HP C075 AA RATING ENCLOSURE MUST BE SPECIFIED 858 75 1091 100 138 6 125 6 Table LANGUAGE MODULE MUST BE SPECIFIED CONTROL
38. terminal S L2 5 Remove the wire from the Autotransformer stake on connector Note the location of the stake on connector for installation 6 Disconnect the wire harness connecting the Autotransformer to the Fan 7 Remove the screws fastening the Autotransformer to the chassis Installation Install the Autotransformer in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important the replacement Autotransformer connect the wire from Removal Step 5 above to the same stake on connector from which the wire was removed Refer to the Fan wiring diagram in the Schematics section of this manual for correct transformer tap voltage Publication 1336 FORCE 6 13 August 1999 Part Replacement Procedures 4 25 DC Bus Inductor L1 DC Bus Inductor L1 is located on the lower left corner of the Drive Figure 4 13 DC Bus Inductor L1 DC Bus Inductor L1 CNV Connection TB1 DC Connection CNV Connection DC Connection AB0386C 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 Publication 1336 FORCE 6 13
39. their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Remove the Precharge Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Precharge Board Mounting Plate Remove the Converter Snubber Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Converter Snubber Board Remove the Converter Bus Bar Set your meter to test diodes The following table shows meter connections and ideal meter readings for those connections Refer to the former illustration for meter connection locations Publication 1336 FORCE 6 13 August 1999 3 14 Component Test Procedures Table 3 D Input Rectifier Test Meter Lead Meter Lead Nominal Meter Reading AK K Infinite AK A Infinite K A Infinite K AK Infinite A AK Infinite A K Infinite G1 K1 0 008 Ki G1 0 008 G2 K2 0 008 K2 G2 0 008 10 Replace the Input Rectifier if any meter readings are not as shown Refer to Chapter 4 Part Replacement Procedures Input Rec
40. 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e TBS TB6 and 7 on drives using a Standard Adapter Board 4 Disconnect the wiring as follows Wire harness connecting the Fan to the Autotransformer Ground wire from the ground stud e Surge Suppressor wire from the ground stud All wires from TBI Remove the Upper DIN Rail 1 Loosen the screw fastening the Terminal End Stop to the left side of the Upper DIN Rail to remove the end stop exposing a screw on the DIN rail 2 Remove the exposed screw from the DIN rail 3 Slide the terminals to the left to expose the other screw on the Upper DIN Rail 4 Remove the exposed screw from the DIN rail to remove the Upper DIN Rail from the Fan Cover Publication 1336 FORCE 6 13 August 1999 4 22 Part Replacement Procedures Remove the Lower DIN Rail 1 Loosen the screw fastening the Terminal End Stop to the right side of the Lower DIN Rail to remove the end stop 2 Slide TB1 terminal W M3 off the DIN rail to expose a screw on the DIN rail 3 Remove the exposed screw from the DIN rail 4 Slide the TBI terminals to expose the other screw on the lower DIN rail 5 Remove the exposed screw from the DIN rail to remove the lower DIN rail from the Fan Cover 6 Remove the screws fastening the Fan
41. 2 13 Removing the Standard Adapter Board Figure 2 6 Standard Adapter Board Mounting uj Plate Slide Mount Standoff SQ Main Control Mounting Screw M Standard L4 Adapter Board _ Slide Mount Stand Off 0696 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 1 Remove power from the drive 2 Open the Enclosure door 3 Check for zero volts at TB1 Terminals and DC Publication 1336 FORCE 6 13 August 1999 2 14 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 4 Check for the absence of control voltage at TB5 TB6 and TB7 on the Standard Adapter Board 5 Disconnect the following from the Standard Adapter Board Stake on ground wire connector All wires from TB5 TB6 and TB7 6 Remove the Control Interface Board Refer to Removing the Control Interface L Option Board in this chapter 7 Remove the two screws fastening the Standard Adapter Board to the mounting plate 8 Pull the Standard Adapter Board down to release it from the slide mount stand offs and connector J1 Installation Install the Standard A
42. 26 41 MOV Surge Suppressor Surge Suppressor to Chassis M4orM5x10mmScrew 12 16 14 18 Link Inductor L1 Inductor to Chassis M5 x 10 mm Screw 23 26 26 41 Fan Capacitor C HB1 Capacitor to Chassis M8 Nut 32 40 36 45 Autotransformer T1 Autotransformer to Chassis M5 x 10 mm Screw 23 26 26 441 LEM Support Plate Support Plate to Chassis M5 x 10 mm Screw 23 26 26 441 Motor Bus Bar Insulated Standoff Standoff to Chassis M5 x 10 mm Screw 23 36 26 41 Capacitor Bus Bar C1 C9 Bus Bar to Capacitors M6 x 12 mm Screw 55 6 2 IGBT Bus Bar Bus Bar to Motor Bus Bar M5 x 10 mm Screw 23 26 26 441 IGBT Bus Bar Bus Bar to Distribution Bus Bar M5 x 10 mm Screw 23 36 26 441 Motor Bus Bar Bus Bar to Insulated Standoff M5 x 10 mm Screw 23 36 26 41 Distribution Bus Bar Bus Bar to Capacitor Bus Bar M10 x 20 mm Bolt 97 111 11 125 SCR Standoff SCR1 SCR6 Standoff through Converter Bus Bar and Into SCR SCR Standoff 34 3 8 Converter Snubber Board A11 Board to SCR Standoff M4 x 8 mm Screw 12 16 14 18 Power Module Snubber Board A20 A22 Board to IGBT Standoffs M4 x 8 mm Screw 12 16 14 18 Bus Fuse F1 Fuse to Capacitor Bus Bar M10 x 20 mm Bolt 97 111 11 125 Bus Fuse F1 Bus Fuse to Distribution Bus Bar M8 or M10 x 20 mm Bolt 97 111 11 125 TB1 Terminal Block DIN Rail DIN Rail to Chassis M5 x 10 mm Screw 23 36 26 41 Gate Driver Board Mounting Plate Plate to Chassis M5 x 10 mm Screw 23 36 26 41 Main Control Board Board to Mounting Plate M4 x 8 mm Screw 12 16 14 18 Standard
43. 6 13 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 terminals to prevent incorrect wiring during assembly Remove power from the drive Turn the Enclosure door latches located on the right side of the Enclosure door 90 degrees counterclockwise Open the Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the ground wire from the Enclosure door Lift the Enclosure door toward the top of the drive to remove the door from the hinges Remove the customer supplied wiring from the drive Remove the screws from the Enclosure top bottom and side panels to remove the panels Installation Install the Enclosure in reverse order of removal Refer to Fastener Torque Specifications in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result
44. 999 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 Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 Terminals and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and 7 on drives using a Standard Adapter Board Disconnect the following from the Main Control Board e J5 ribbon cable connector Stake on ground wire connector All wires from TB10 Remove the screws fastening the Main Control Board to the Control Board Adapter Mounting Plate Lift the Main Control Board upward to release it from the slide mount stand offs and connector J7 Installation Install the Main Control Board in reverse order of removal Refer to Fastener Torque Specifications in this chapter 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
45. AC to DC to AC e g adjustable frequency drive A frequency converter such as that found in an adjustable frequency drive consists of a rectifier a DC intermediate circuit an inverter and a control unit Counter Electromotive Force CEMF The product of a motor armature rotating in a magnetic field This generating action takes place whenever a motor is rotating Under stable motoring conditions the generated voltage is equal to the voltage supplied to the motor minus small losses However the polarity of the CEMF is opposite to that of the power being supplied to the armature Current Limiting An electronic method of limiting the maximum current available to the motor This is adjustable so that the motor s maximum current can be controlled It can also be preset as a protective device to protect both the motor and the control from extended overloads DC Boost Compensates for the voltage drop across the resistance of an AC motor circuit and the resulting reduction in torque DC Bus drive s power structure that transmits a rectified AC line power from the bridge rectifier to the output transistors DC Hold Describes a holding brake function to stop motor rotation after a ramp to stop function is activated Diode A solid state uni directional conductor Publication 1336 FORCE 6 13 August 1999 G 4 Glossary Publication 1336 FORCE 6 13 August 1999 Drift A slow change in some characteristic of
46. Adapter Board Board to Mounting Plate M4 x 8 mm Screw 12 16 14 18 PLC Comm Adapter Board Board to Mounting Plate M4 x 8 mm Screw 12 16 14 18 TE Ground Block TE Ground Block to Gate Driver Board Sheet Metal M2 5 x 12 mm Screw 6 9 0 7 1 0 Control Board Mounting Plate Plate to Gate Driver Board Mounting Plate M6 Nut 23 36 26 41 Control Board Mounting Plate Plate to Gate Driver Board Mounting Plate M4 x 8 mm Screw 12 16 14 1 8 HIM Holder HIM Holder to Control Board Sheet Metal M4 x 20 mm Screw 12 16 14 18 Capacitor Guard C1 C9 Capacitor Guard to Capacitor Brackets M4 x 20 mm Screw 12 16 14 18 Link Inductor Guard L1 Link Inductor Guard to Link Inductor M6 Nut 23 36 26 441 Enclosure Bottom Top and Side Panels Enclosure Sheet Metal M5 x 10 mm Screw 23 36 26 41 Publication 1336 FORCE 6 13 August 1999 Disassembly and Access Procedures Component IGBT Standoff Power Module Snubber Board A20 A22 Component IGBT Standoff Power Module Snubber Board A20 A22 Present Design Power Module Snubber Board A20 A22 Original Design Gate amp Emitter Terminals Original Design Procedures Component MOV Ground Wire MOV1 Drive Ground Wire Ground Wire TE Gate Driver Board Link Inductor Wires Capacitor Bus Bar Wires Converter Bus Bar Wires Motor Bus Bar Wires TB1 Wires TB20 Wires PLC Comm Adapte r Board TB21 Wires PLC Comm Adapte TB5 Wi Adapte TB6 Wi A
47. August 1999 4 26 Part Replacement 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 at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board 4 Remove the guard 5 Remove the wires from the Bus Inductor terminals 6 Remove the four screws fastening the Bus Inductor to the drive 7 Lift the Bus Inductor out of the drive Installation 1 Lower the inductor into the Main Chassis inserting the inductor into the bottom inductor bracket 2 Install DC Bus Inductor L1 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 13 August 1999 Part Replacement Procedures 4 27 Ground Sense CT
48. Bradley Company Inc is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product ControlNet is a trademark PLC is a registered trademark of 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 13 August 1999 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE 6 13 August 1999 Preface Control Logic Wiring and Adapters Table of Contents Manual Objective P 1 Who Should Use This P 1 Safety P 1 Electrostatic Discharge Precautions P 2 1336 FORCE Product Identification P 3 Drive Nameplate Location P 3 Software Compatibility
49. Cover to the Main Chassis 7 Lift the fan and cover from the Drive 8 Remove the screws fastening the Fan to the Fan Cover to remove the Fan from the cover 9 Remove the nut fastening the Fan Capacitor to the bracket to remove the capacitor Installation 1 Thread the Fan wire through the hole in the Fan Cover 2 Fasten the Fan to the Fan Cover 3 Install the Fan and capacitor 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 13 August 1999 Part Replacement Procedures 4 23 Autotransformer The Autotransformer and Fan Capacitor are located in the bottom left corner of the Main Chassis Figure 4 12 Autotransformer Stake on Connectors Harness xX p Capacitor o 223 Ce SS Se 9e gt MOV Surge Sal Suppressor Sa E Autotransformer AB0619A Publication 1336 FORCE 6 13 August 1999 4 24 Part Replacement Procedures Removal 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board 4 Remove the Autotransformer wire from TBI
50. 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 13 August 1999 G 10 Glossary Publication 1336 FORCE 6 13 August 1999 Slip The difference between rotating magnetic field speed synchronous speed and rotor speed of AC induction motors Usually expressed as a percentage of synchronous speed Slip Compensation Monitors motor current and compensates for speed lost due to increased motor slip The amount of slip is proportional to the motor load Speed Range The speed minimum and maximum at which a motor must operate under constant or variable torque load conditions A 50 1 speed range for a motor with top speed 1800 rpm means the motor must operate as low as 36 rpm and still remain within regulation specification Controllers are capable of wider controllable speed r
51. LE 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 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 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
52. Procedures Publication 1336 FORCE 6 13 August 1999 Load sharing resistor R1 has three color coded leads coming out of the resistor body Connect as shown in Figure 4 4 Figure 4 4 Wiring Detail for A040 A050 B060 B075 and B100 Drives DC Blue 4 C1 C3 C5 l 5 Yellow Ri c2 C4 C6 A l l n Black Inv AB0534A R1 BLACK R1 YELLOW BLUE X TL NE Fr AB0530A ATTENTION The Capacitor Bus must connect a positive capacitor terminal to a negative capacitor terminal Capacitors not connected correctly will explode and cause death or serious injury Part Replacement Procedures 4 9 Load sharing resistors R1 and R2 have two color coded leads coming out of each resistor body Connect as shown in Figure 4 5 Figure 4 5 Wiring Detail for A060 B125 and BX150 Drives Blue DC 43K ohms C1 63 gt C5 C7 Black e e e Blue 4 3K B e Inv Black AB0531A M R1 Blue R1 Black R2 Blue e Q9 R2 Black
53. TB6 and TB7 on drives using a Standard Adapter Board 4 Remove the Control Board Adapter Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Control Board Adapter Mounting Plate 5 Set your meter to test resistance 6 Test Fuses F1 and F3 for an open condition Replace the Gate Driver Board if either fuse shows an open condition 7 Set your meter to test diodes 8 Test VRI VR6 The following table shows meter connections at the components and ideal meter readings for those connections Refer to the former illustration for component locations Table 3 A Gate Driver Board Test Nominal Meter Component Meter Lead Meter Lead Reading 0 9 Note Typical Malfunction is shorted in both directions 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 Assemble the drive in reverse order or disassembly Test 2 Testing the Precharge Board Component Test Procedures 3 5 ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Figure 3 2 Precharge Board Test Precharge Board 0375 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury
54. The Ground Sense is located in the lower left of the Drive Figure 4 14 Ground Sense CT Bus Capacitor Bus Bar 0 Connection Bus Capacitor Bus Bar DC Connection Connector to Gate Driver Board J2 Ground Sense CT 7777 7 i 2555 7 4 UJ 5 5 ic e zs 3 N AB0388D 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 Publication 1336 FORCE 6 13 August 1999 4 28 Part Replacement 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 at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Boar
55. a potentially fatal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended that the oscilloscope be used in the A minus B Quasi differential mode with the oscilloscope chassis correctly grounded to an earth ground ATTENTION 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 1336 FORCE Product Identification Preface P 3 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 e Wear a wrist type grounding strap t
56. al 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 13 August 1999 2 2 Disassembly and Access Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 13 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 Remove boards from the drive and immediately insert t
57. amp DOCUMENTATION INFORMATION ITEM A1 74101 169 SCHEMATIC FUSE INFORMATION DIAGRAM DESIGNATOR RATING 74101 167 1 0A 600V P N 25172 260 08 1 5A 600V 25172 260 09 A10 74101 181 74101 179 1 5A 600V 25172 260 09 11 74101 099 51 74101 077 20 22 74101 032 74101 022 0635 Publication 1336 FORCE 6 13 August 1999 6 6 Schematics 40 150 HP 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE 6 13 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 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 poin
58. anges than motors because there is no thermal limitation only electrical Controllable speed range of a motor is limited by the ability to deliver 10046 torque below base speed without additional cooling Speed Regulation The numerical measure percent of how accurately the motor speed can be maintained It is the percentage of change in speed between full load and no load The ability of a drive to operate a motor at constant speed under varying load without hunting alternately speeding up and slowing down It is related to both the characteristics of the load being driven and electrical time constants in the drive regulator circuits Surge Protection The process of absorbing and clipping voltage transients on an incoming AC power line or control circuit Surge protectors include MOVs Metal Oxide Varistors and specially designed R C networks Synchronous Speed The speed of an AC induction motor s rotating magnetic field It is determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator windings Mathematically it is expressed as Sync Speed rpm 120 x Applied Freq Hz Number of poles per phase Torque A turning force applied to a shaft tending to cause rotation Torque is equal to the force applied times the radius through which it acts Torque is measured in pound feet ounce inches Newton meters or gram centimeters Transducer A device that converts one
59. ard 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 13 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 Check for zero volts at TB1 terminals and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and 7 on drives using a Standard Adapter Board Remove the Precharge Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Precharge Board Mounting Plate Remove Gate Driver Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Disconnect the Inverter output wires running through the LEMs from Motor Bus Bar terminals U MI e V M2 e W M3 Disconnect the J Connector wiring harness from the LEMs Remove the screws fastening the LEM mounting bracket to the heat sink Part Replacement Procedures 4 33 9 Slide the LEM mounting bracket off of Inverter output wires 10 Compress the tabs
60. atus of specified input signals 2 The control element of an SCR GND Sense A current transducer that detects an unequal or imbalanced current in the three phase AC line or DC bus of the drive The imbalance indicates an output ground fault condition Horsepower hp A unit of power 1 hp 33 000 ft Ib min 746 watts IEC International Electrotechnical Commission IGBT Refer to Insulated Gate Bipolar Transistor Induction Motor An induction motor is an alternating current motor in which the primary winding on one member is connected to the power source A secondary winding on the other member carries the induced current There is no physical electrical connection to the secondary winding its current is induced Inertia A measure of a body s resistance to change in velocity whether a body is at rest or moving at a constant velocity The velocity can be either linear or rotational The moment of inertia WK is the product of the weight W of an object and the square of the radius of gyration K The radius of gyration is a measure of how the mass of the object is distributed about the axis of rotation WK is usually expressed in units of Ib ft Insulated Gate Bipolar Transistor IGBT A type of transistor commonly used in drive control devices Publication 1336 FORCE 6 13 August 1999 G 6 Glossary Publication 1336 FORCE 6 13 August 1999 Integral Horsepower Motor A motor that has a continuous rating o
61. ause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference 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 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 medium and large Standard screwdrivers small medium and large e 10 mm socket 13 mm deep well socket e 5 16 inch or 8 mm open end wre
62. ction 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 DC and DC on Terminal Block Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 13 August 1999 P 2 Preface Electrostatic Discharge Precautions Publication 1336 FORCE 6 13 August 1999 ATTENTION Hazard of electric shock exists Up to 1 000 VDC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Potentially fatal voltages may result from improper usage of oscilloscope and other test equipment The oscilloscope chassis may be at
63. ctions and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Remove the Precharge Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Precharge Board Mounting Plate Remove the Converter Snubber Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Converter Snubber Board Remove all cable connections from the Converter Bus Bars Remove the standoffs and the Converter Bus Bar from the rectifiers Remove the screws fastening the Input Rectifier to the drive Part Replacement Procedures 4 19 Installation 1 Clean all surfaces between the Input Rectifier and the heat sink using a soft clean cloth 2 Replace the Preform between the Input Rectifier and the heat sink 3 Install the Input Rectifier 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
64. d e 5 TB6 and TB7 on drives using a Standard Adapter Board 4 Disconnect the Ground Sense CT from Gate Driver Board connector J2 5 Remove the Bus Capacitor Guard 6 Remove the following Bus Capacitor Bus Bar DC wire e Bus Capacitor Bus Bar DC wire Bus Voltage Wire Harness 7 Cut the tie wraps from the Ground Sense CT 8 Slide the Ground Sense CT off the Bus Capacitor wires Installation 1 Place the Bus Capacitor wires through the center of the Ground Sense CT 2 Install the Ground Sense CT 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 13 August 1999 Part Replacement Procedures 4 29 Bus Fuse The Bus Fuse is located at the top center of the Drive Figure 4 15 Bus Fuse Bus Fuse SS LN M10 Bolt Split Washer and f Belville Washer All D Frame LO EN Drives sf Oe Use one of two bolts here Belville M10 on D Frame Drives Belville E QA M8 Belville Spring Washer Split Lock M8 Bolt Early Washer M10 Bolt Later D Frame Drives D Frame Drives 0749 ATTENTION Disconnect and lock power from the drive before disassembling the drive Fa
65. d supply manufacturers Some NEMA motor standards include horsepower hp ratings speeds frame sizes and dimensions torques and drive enclosures NEC Refer to National Electrical Code Negative Slope The location on a V Hz curve where the break voltage exceeds the base voltage NEMA Refer to National Electrical Manufacturer s Association Offset The steady state deviation of a controlled variable from a fixed setpoint Op Amp An operational amplifier A high gain stable linear DC amplifier that is designed to be used with external circuit elements Open Loop System A control system that has no means of comparing the output with the input for control purposes Overload Capacity The ability of the drive to withstand currents beyond the system s continuous rating It is normally specified as a percentage of full load current endured for a specified time period Overload capacity is defined by NEMA as 150 of rated full load current for one minute for standard industrial DC motors Publication 1336 FORCE 6 13 August 1999 G 8 Glossary Publication 1336 FORCE 6 13 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
66. dapte TB7 Wi Adapte r Board res Standard r Board res Standard r Board res Standard r Board Wi res Standard Adapter L Option Board Enclosure Door Ground Wire Table 2 B Fastener Torque Specifications Parts Common to D Frame Drives A040 A050 B060 B100 C075 C100 Fastener Application Fastener Used Standoff Through IGBT Busbar and Into IGBT IGBT Standoff Board to Gate and Emitter Connection on IGBT M4 x 24 mm Screw Table 2 C Fastener Torque Specifications Parts Common to D Frame Drives A060 B125 BX150 C125 Fastener Application Fastener Used Standoff Through IGBT Bus Bar and Into IGBT IGBT Standoff Board to Gate and Emitter Connection on IGBT M4 x 35 mm Screw Board to Gate and Emitter Brackets M4 x 8 mm Screw Gate and Emitter C Brackets to IGBTs M4 x 8 mm Screw Table 2 D Fastener Torque Specifications Wires Common to D Frame Drives Fastener Application Fastener Used Wire to Chassis M6 Nut Wire to Chassis M6 Nut Wire to TB1 Terminal TE Compression Wires to Link Inductor M6 x 12 mm Screw Wires to Capacitor Bus Bar M6 x 12 mm Screw Wires to Converter Bus Bar M6 x 12 mm screw Wires to Motor Bus Bar M6 x 12 mm Screw Wires to TB1 M8 Nut Wires to TB20 Captive Screw Wires to TB21 on Main Control Board Captive Screw Wires to TB5 on Main Control Board Captive Screw Wires to TB6 on Main Control Board Captive Screw Wires to TB7 on Main Control Board Captive Screw Wires t
67. dapter 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 7 PLC Comm Adapter Board Mounting Plate Slide Mount Standoff Main Control Board PLC Comm Adapter Board Connector J5 Connector J7 TB 1 RIO Channel B AB0697B 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 N Open the Enclosure door Refer to Opening the Enclosure Door in this chapter 3 Check for zero volts at TB1 Terminals DC and DC Publication 1336 FORCE 6 13 August 1999 2 16 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 4 Check for the absence of control voltage at TB20 and TB21 on the PLC Comm Adapter Board 5 Disconnect the following from the PLC Comm Adapter Board wires from TB20 and TB21 Stake on ground wire connector J5 connector J7 connector Communication channel A and B connectors 6 Remove the screws fastening the PLC C
68. done per unit of time Measured in horsepower hp or watts W 1 hp 33 000 ft Ib min 746 W Power Factor Displacement A measurement of the time phase difference between the fundamental voltage and fundamental current in an AC circuit It represents the cosine of the phase angle difference cos Power Factor Distortion A measurement of the ratio of the real power kW to the apparent power Distortion power factor takes into account harmonic voltage and current distortion as well as voltage to current displacement Preform A flexible material used between an electronic component and the heat sink to which the component is attached Preform provides maximum heat dissipation from the component to the heat sink Preset Speed Describes one or more fixed speeds at which a drive operates Programmable Controller A solid state control system that has a user programmable memory for storage of instructions to implement specific functions such as I O control logic timing counting report generation communication arithmetic and data file manipulation A controller consists of a central processor input output interface and memory controller is designed as an industrial control system Pull In Torque The maximum constant torque to which a synchronous motor accelerates into synchronism at rated voltage and frequency Pull Out Torque The maximum running torque of a synchronous motor Glossary G
69. drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 13 August 1999 4 20 Part Replacement Procedures Fan Assembly The Fan is located under TB1 at the bottom of the Main Chassis Autotransformer and Fan Capacitor are located in the bottom left corner of the Main Chassis Figure 4 11 Fan Assembly Fan Cover TB1 Terminal Partitions and DIN Rails we End Stop MOV Surge Suppressor Fan Capacitor 0384 Publication 1336 FORCE 6 13 August 1999 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 DC and DC on Terminal Block TB1 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 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
70. drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the 8 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Open the Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and TB21 on drives using a PLC Comm Adapter Board 5 TB6 and 7 on drives using a Standard Adapter Board Remove the wires and connectors from the Standard or PLC Comm Adapter Board This drive may have either a Standard Adapter Board or a PLC Comm Adapter Board Refer to Removing the Standard Adapter Board or Removing the PLC Comm Adapter Board in this chapter Remove the nuts at the top of the Control Board Adapter Mounting Plate Remove the two screws at the bottom of the Control Board Adapter Mounting Plate Lift the Control Board Adapter Mounting Plate out of the drive Installation Install the Control Board Adapter Mounting Plate in reverse order of removal Refer to Fastener Torque Specifications in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury
71. e drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 13 August 1999 2 26 Disassembly and Access Procedures Publication 1336 FORCE 6 13 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 terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Open the Enclosure door Refer to Opening the Drive Enclosure in this chapter 3 Check for zero volts at TB1 terminals DC and DC 4 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board 5 Remove the guard from the Precharge Board 6 Disconnect the following from the Precharge Board Jl connector J2connector J3connector J4 connector 7 Remove the screws fastening the top of the Mounting Plate to the drive 8 Lift the Precharge Board and Mounting Plate out of the enclosure Installation Install the Precharge Board Mounting Plate in reverse order of removal Refer to Fastener Torque Specifications in this chapter ATTENTION Wh
72. e power is removed the brake is set This can be used as a holding brake Note A separately mounted brake is not one which is located on some part of the mechanical drive train other that the motor Breakaway Torque The torque required to start a machine from standstill Breakaway torque is always greater than the torque needed to maintain motion Breakdown Torque The breakdown torque of an AC motor is the maximum torque which it will develop with rated voltage applied at rated frequency Bridge Rectifier Diode SCR A non controlled full wave rectifier that produces a constant rectified DC voltage An SCR bridge rectifier is a full wave rectifier with a DC output that can be controlled by switching on the gate control element Bridge Rectifier A full wave rectifier that conducts current in only one direction of the input current AC applied to the input results in approximate DC at the output British Thermal Unit BTU The quantity of heat required to raise one pound of water by one degree Fahrenheit BTU Refer to British Thermal Unit Bus A single path or multiple parallel paths for power or data signals to which several devices may be connected at the same time A bus may have several sources of supply and or several sources of demand 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 vo
73. e screws fastening the Bus Capacitor Guard to the Capacitor Bank Slide the Capacitor Guard toward the center of the drive to disengage the tabs Lift the Capacitor Guard out of the Drive Remove the Bus Fuse Refer to Bus Fuse in this chapter Remove the Capacitors 1 Remove the bolt and washer assembly fastening the Capacitor Bus Bar to the Transition Bus Bar The Transition Bus Bar assembly is located under and attached to the Bus Fuse Remove the Load sharing Resistor wires and the Capacitor Bus Bar screws Remove the Bus Inductor L1 cables and Bus Voltage wire harness from the Capacitor Bus Bar 7 8 Part Replacement Procedures 4 7 Remove the Capacitor Bus Bar Loosen the screws on the Capacitor Brackets Slide the brackets away from the Capacitor Retainers and down to remove Remove the Capacitor Retainers Lift the Bus Capacitors out of the Drive Installation 1 Fasten the capacitor assembly in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important Refer to Bus Fuse in this chapter for correct Bus Fuse fastener size and type Connect the Load sharing Resistors to the Bus Capacitors according to the following diagrams Figure 4 3 Load Sharing Resistor Connections to Bus Capacitors 0526 Publication 1336 FORCE 6 13 August 1999 4 8 Part Replacement
74. ections 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 Enclosure door Refer to Opening the Drive Enclosure in this chapter 3 Check for zero volts at TB1 terminals DC and DC 4 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board 5 Disconnect the following from the Precharge Board e J connector e J2 connector e J3 connector J4 connector 6 Turn the six stand off screws fastening the Precharge Board to the mounting plate 1 4 turn counterclockwise 7 Remove the Precharge Board from the Mounting Plate Installation Install the Precharge Board in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 29 Removing a Power Module Snubber Board Figure 2 13 Power Module Snubber Board Power Module Snubber Board Cu
75. embly and Access Procedures Publication 1336 FORCE 6 13 August 1999 7 Turn the eight stand off screws fastening the Gate Driver Board to the Mounting Plate 1 4 turn counterclockwise 8 Remove the Gate Driver Board from the enclosure Installation Install the Gate Driver Board in reverse order of removal Refer to Fastener Torque Specifications in this chapter 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 Disassembly and Access Procedures 2 25 Removing the Precharge Board Mounting Plate Figure 2 11 Precharge Board and Mounting Plate Pis VOS N Connector EM J1 Connector Connector Mounting J3 J AA Screw Connector J4 a JR Precharge Mounting Plate and Guard Precharge Board 05190 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 th
76. emove the module 1 Ensure that power has been removed or Logic Mask has been set to 0 2 Open the Enclosure door 3 Slide the module down and out of its cradle 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 see Figure 1 10 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 10 Status Display Publication 1336 FORCE 6 13 August 1999 1 14 Control Logic Wiring and Adapters Graphic Programming Terminal Publication 1336 FORCE 6 13 August 1999 GPT Description The optional GPT Figure 1 11 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 11 Graphic Programming Terminal
77. en Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 13 August 1999 1 2 Control Logic Wiring and Adapters Figure 1 1 Standard Adapter Terminal Block Locations TB10 Encoder Main Control Board S TB11 Standard Adapter Board Control Interface L Option Board 5 6 TB7 E TB3 Control L Option Board Control and Pls Safe E Signal Wiring TB1 Power d Terminal Block Or puo O 0690 Figure 1 2 PLC Comm Adapter Terminal Block Locations Main Control Board TB10 Encoder EJ 11 E PLC Comm Board TB20 21 Communication Control and Channels Signal Wirin TB1 Power Terminal Block 0691 Publication 1336 FORCE 6 13 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 L4 Contact Closure Interface L5 24 AC DC Interface L6 115V AC Interface Uses internal 5 DC supply The us
78. en 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 Disassembly and Access Procedures 2 27 ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Removing the Precharge Board Figure 2 12 Precharge Board Precharge Board Mounting Plate Connector J1 gt Guard Precharge Board AB0371C 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 Publication 1336 FORCE 6 13 August 1999 2 28 Disassembly and Access Procedures Publication 1336 FORCE 6 13 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 conn
79. 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 13 August 1999 G 12 Glossary This Page Intentionally Left Blank Publication 1336 FORCE 6 13 August 1999 A Adapter Locations 1 11 Adapters and Communication Ports Human Interface Module 1 10 Audience for this Manual 1 Autotransformer Illustration 4 20 Auxiliary Input Definition 7 Auxiliary Interlock Definition 7 Bit Definition P 7 Bus Capacitor Bank Illustration 4 5 Installation 4 7 Removal 4 5 Test 3 9 Bus Fuse Illustration 4 29 Installation 4 30 Removal 4 29 C Check Definition P 8 Component Test Procedures 3 1 Connector Definition P 8 Control Board Adapter Mounting Plate Illustration 2 17 Control Interface Board Definition P 9 Illustration 2 9 Installation 2 10 Jumper Locations 1 3 Removal 2 9 Control Interface Option 1 3 Control Logic Wiring 1 1 Conventions in this Manual 7 Converter Snubber Board Illustration 2 32 Installation 2 33 Removal 2 32 Index D DC Bus Inductor L1 I
80. er 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Remove the Power Module Snubber Boards Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Remove the Inverter Bus Bar Refer to Chapter 4 Part Replacement Procedures Power Modules 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 Table 3 B Power Modules Publication 1336 FORCE 6 13 August 1999 Meter Lead Meter Lead Nominal Meter Reading 0 318 Infinite Infinite Infinite Infinite Infinite UJ COO CD CO ITI UJ ITI CB lt gt Test 4 Testing the Bus Capacitors Component Test Procedures 3 9 10 Replace both Power Modules in the same phase if meter readings are not as shown Refer to Chapter 4 Part Replacement Procedures Power Modules 11 If one or more Power Modules is replaced test the Gate Driver Board Refer to Testing the Gate Driver Board in this chapter 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 The Bus Capacitor Bank is located on the left side of the Main Chassis Figure 3 4 Bus Capacitor Bank Test Terminal Bloc
81. er inputs are connected to the option board through TB3 The L5 and L6 options each have nine control inputs The function 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 J10 must be removed If this board is removed these jumpers must be reinstalled and the Input Mode parameter must be programmed to 1 Publication 1336 FORCE 6 13 August 1999 1 4 Control Logic Wiring and Adapters Figure 1 3 Jumper Locations Main Control Board Jumper J10 Located on Standard Standard Adapter Board N Board 5 6 7 AB0365D 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 Publication 1336 FORCE 6 13 August 1999 Standard Adapter Local Programming Control Log
82. er to Figures 1 7 and 1 8 and visible from the front of the drive The HIM can be divided into two sections Display Panel and Control Panel The Display Panel provides a means of programming the drive and viewing the various operating parameters The Control Panel allows different drive functions to be controlled For HIM operation refer to the 1336 FORCE Field Oriented Control User Manual Important operation of HIM functions depends upon drive parameter settings Default parameter values allow full HIM functionality Figure 1 7 Human Interface Module Standard Adapter Only Storred Display Panel 0 00 Hz Control Panel Human Interface Module HIM AB520C Control Logic Wiring and Adapters 1 11 Standard Adapter Ports Figure 1 8 Standard Adapter Board Port Locations TB10 Encoder Internal Communication Adapter Port 6 i E s5008 Drive Mounted HIM Adapter Port 1 0 al Control Interface TB5 TB6 TB7 L Option Board IN TB3 Adapter Port 0 anme o o Communications Port Remote HIM Communication Options Adapter 2 or Expansion Options Adapters 2 3 4 5
83. esenting the velocity reference The velocity 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 Publication 1336 FORCE 6 13 August 1999 1 16 Control Logic Wiring and Adapters This Page Intentionally Left Blank Publication 1336 FORCE 6 13 August 1999 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 DC and DC on Terminal Block 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 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Servicing energized industri
84. f 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 Isolation Transformer 1 A transformer that provides DC isolation from other equipment not connected to that transformer secondary 2 A transformer that provides noise isolation between the primary and secondary by such means as a Faraday shield Jogging 1 In a numerical control system an operator manually generating motion continuously or incrementally by closing a switch 2 An operator 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 curren
85. g Parts for A040 A060 B060 B125 BX150 and C075 C125 Drives Figure 5 1 TM Ne S Na 1 19 7777777 2 gt Publication 1336 FORCE 6 13 August 1999 Table 5 A Replacement Parts List 5 3 Replacement Parts for A040 A060 B060 B125 BX150 and C075 C126 Drives Callout Symbol Description Location Replacement Procedures 1 R1 R3 Load Sharing Resistor Main Chassis Chapter 4 Bus Capacitor Bank 2 Q1 Q6 IGBT Heat Sink Chapter 4 Power Modules 3 F1 Bus Fuse Cap Bus Bar Chapter 4 Bus Fuse F1 4 ST NTCI Thermistor Heat Sink Chapter 4 Thermistor 5 SNUBBER BOARD Inverter Bus Bar and Snubber Heat Sink Chapter 2 Removing a Power Module Board Snubber Board 6 BASEDR PWRSPLY Gate Driver Board Gate Driver Board Chapter 2 Removing the Gate Driver Mounting Plate Board 7 MAIN CTL Main Control Board Control Board Adapter Chapter 2 Removing the Main Control Mounting Plate Board 8 HIM Human Interface Module Control Board Adapter Chapter 1 Module Removal Mounting Plate 9 GT2 Standard Adapter Board Control Board Adapter Chapter 2 Removing the Standard Mounting Plate Adapter Board 10 GT1 PLC Comm Adapter Board Control Board Adapter Chapter 2 Removing the PLC Comm Mounting Plate Adapter Board 11 PRECHARGE Precharge Board Precharge Board Mounting Plate Chapter 2 Removing the Precharge Board 12 R20 R22 Powe
86. hat is grounded to the drive chassis Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Drive Nameplate Location The drive nameplate is located on the face of the Control Board Adapter 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 tab Ld of Control Board Adapter Mounting Plate 0363 Publication 1336 FORCE 6 13 August 1999 P 4 Drive and Op Identification 13365 BULLETIN RATING ENCLOSURE ENCLOSURE LANGUAGE MODULE NO Preface tion MUST BE SPECIFIED 1 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 1 Three Phase Drive Rating 200 240V 380 480V 500 600V 56 93 kW 75 125 HP 30 45 kW 40 60 HP 45 75 94 112 KW 60 100 125 150 HP 81 kW 75 HP kW and HP are constant torque CT ratings Compatible with Version 2 01 amp Up 2 04 amp Up Frame Reference The following is an
87. he Bus Capacitor Guard Refer to Bus Capacitor Bank in this chapter 5 Remove the two bolt and washer assemblies 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 Part Replacement Procedures 4 31 LEMs The LEMs are located near the bottom of the heat sink Figure 4 16 LEMs J6 Connector Nylon Spacers A i i Mounting Screws AB0392C 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 DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 13 August 1999 4 32 Part Replacement Procedures ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Bo
88. hem into their conductive packets Tools You need the following tools to disassemble and assemble the drive Pliers Phillips screwdrivers medium and large Standard screwdrivers small medium and large 10 mm socket 13 mm deep well socket 5 16 inch or 8 mm open end wrench Torque wrench metered in in Ib or N m Nylon tie wraps Side cutters 17 mm socket 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 Two Point Mounting The following illustrates temporary and final tightening sequences for components fastened to a heat sink using two screws Temporary torque is 1 2 50 of final torque The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 2 1 Two Point Mounting 2 Two Point Mounting Temporary Tighten _ Final Tighten ABOO16A Cre Publication 1336 FORCE 6 13 August 1999 2 4 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 Four Point Mounting The following illustrates temporary and final tightening sequences for components fastened to a heat sink using four screws Tempo
89. ic Wiring and Adapters 1 5 Important Input Mode parameter can be changed at any time however programming changes will not take affect until power has been cycled to the drive When changing an input mode it is important to note that the corresponding inputs to TB3 may also change The programming options of the Control Interface Option allow the user to select an input combination to meet the needs of a specific installation Appropriate selection of a combination may be done by using Table 1 A First determine the type of start stop direction control desired Then select the remaining control functions available After selecting a group of Input Modes use Table 1 A for specific mode selection Record the selected mode number below Selected Mode Number For local programming and control information refer to the 1336 FORCE User Manual Table 1 A Input Mode Selection Start Stop Type Direction Control Communication Compatibility E 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 Com
90. ich the motor converts electrical energy into mechanical energy In a power supply it is the effectiveness with which the power supply converts AC power into DC power Electrostatic Discharge ESD A static electricity discharge that may damage drive components Refer to the ESD precautions found in this manual to guard against damage to drive components Enable To activate logic by the removal of a suppression signal Enclosure The housing in which equipment is mounted They are available in designs for various environmental conditions Refer to NEMA standard for specifications of different types of enclosures Glossary G 5 ENUM Enumeration An ANSI C standard extension to the C language An ENUM is a set of named integer constants that specify all the legal values a variable of a given type may have The keyword ENUM signals the start of an enumeration type ESD Refer to Electrostatic Discharge Floating Ground An electrical circuit common which is not at earth ground potential or the same ground potential as circuitry with which it interfaces A voltage difference can exist between the floating ground and earth ground Force The tendency to change the motion of an object with an exertion of energy from a separate source Full Load Torque The full load torque 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 st
91. ilure 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 Publication 1336 FORCE 6 13 August 1999 4 30 Part Replacement Procedures Publication 1336 FORCE 6 13 August 1999 Important ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum 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 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board 4 Remove t
92. in death or serious injury Disassembly and Access Procedures 2 9 Removing Control Interface L Option Board MOD L4 L5 or L6 Figure 2 4 Control Interface L Option Board Control Interface L Option Board Terminal Strip TB3 AB0693A 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 Publication 1336 FORCE 6 13 August 1999 2 10 Disassembly and Access Procedures Publication 1336 FORCE 6 13 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 terminals to prevent incorrect wiring during assembly Remove power from the drive Open the Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB5 TB6 and TB7 on
93. k T 0376 Publication 1336 FORCE 6 13 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 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 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Important Before you remove connections and wires from the Publication 1336 FORCE 6 13 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 Check for zero volts at TB1 terminals and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board 5 TB6 and 7 on drives using a Standard Adapter Board Remove the guard from the bus capacitors Set your meter to test vol
94. llustration 4 25 Installation 4 26 Removal 4 25 Default Definition P 8 Detailed Product Identification 4 4 Drive Enclosure Type P 7 Identification P 4 Illustration 4 4 Nameplate Location 3 Rating 6 Drive Enclosure Illustration 2 7 Installation 2 8 Removal 2 7 E Electrostatic Discharge 3 Enable Input Definition P 8 Enclosure Type 7 ESD P 3 F False Definition P 8 Fan Assembly Illustration 4 20 Removal 4 21 Fan Capacitor Illustration 4 20 Four Point Mounting 2 4 G Gate Driver Board Illustration 2 22 Installation 2 24 Removal 2 22 Test 3 3 Gate Driver Precharge Board Mounting Plate Illustration 2 19 Installation 2 21 Removal 2 19 Publication 1336 FORCE 6 13 August 1999 2 Publication 1336 FORCE 6 13 August 1999 Ground Sense CT Illustration 4 27 Installation 4 28 Removal 4 27 H HIM Removal 1 12 Human Interface Module HIM Adapter Locations 1 11 Illustration 1 10 Operation 1 13 Input Mode Programming 1 4 Selection 1 5 Input Rectifier Illustration 4 17 Installation 4 19 Removal 4 17 Test 3 12 Inputs Available 1 4 Installation Procedures See Procedures J Jumper Definition 8 LEMs Illustration 4 31 Installation 4 33 Removal 4 31 Load Sharing Resistor Connections 4 7 Local Programming 1 5 M Main Control Board Illustration 2
95. ltage Refer to Counter Electromotive Force CMOS Complimentary Metallic Oxide Semiconductor A semiconductor device in which an electric field controls the conductance of a channel under a metal electrode called a gate Cogging A condition in which a motor does not rotate smoothly but steps or jerks from one position to another during shaft revolution Cogging is most pronounced at low motor speeds and can cause objectionable vibrations in the driven machinery Glossary G 3 Constant Torque Range speed range in which a motor is capable of delivering a constant torque subject to cooling limitations of the motor Constant Voltage Range AC Drives The range of motor operation where the drive s output voltage is held constant as output frequency is varied This speed range produces motor performance similar to a DC drive s constant horsepower range Constant Volts per Hertz V Hz The V Hz relationship exists in AC drives where the output voltage is directly proportional to frequency This type of operation produces constant rated torque as the motor s speed varies Continuous Duty CONT A motor that can continue to operate without stopping and remain within the insulation temperature limits after it has reached normal operating 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
96. munication 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 4 TB3 Terminal Designations S iD c O c amp SCS 2B Se BE SS 22 oc c E in AB0550A v 2 2 52 5 gt e e 5 2 Publication 1336 FORCE 6 13 August 1999 1 6 Control Logic Wiring and Adapters Figure 1 5 Input Mode Selection and Typical TB3 Connections 2S o Momentary Maintained Input Mode 1 Factory Default 7 Status Stop Fault Reset Status Note If this mode is selected the status of all inputs can be read at the Input Status parameter Status B aw MP However only Stop Fault Reset and Enable will n have control function o 2 Status i IE 9 Common 5 eal Status Status el Status 3 Common eal Enable Input Mode 2 6 Three Wire Control with Single Source Re
97. n 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 Publication 1336 FORCE 6 13 August 1999 4 6 Part Replacement Procedures Publication 1336 FORCE 6 13 August 1999 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum 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 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 Capacitors 1 2 3 6 7 Remove power from the drive Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove th
98. nch Torque wrench metered in or N m Nylon tie wraps Test 1 Testing the Gate Driver Board Component Test Procedures 3 3 e Side cutters e 17mm socket Gate Driver Board is located between the Main Control Board and the Main Chassis If one or more Power Modules has been replaced you must test the Gate Driver Board Figure 3 1 Gate Driver Board Test VR2 N VR3 VR5 44 VR6 VR1 F1 VR4 Gate Driver Board AB0374B Publication 1336 FORCE 6 13 August 1999 3 4 Component Test Procedures Publication 1336 FORCE 6 13 August 1999 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 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e TBS
99. nents 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 Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board e 5 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 Remove Gate Driver Board connections TB7 ground wire J2 Ground Sense CT connector J13 connector J7 Power Module connector J8 Power Module connector J10 Bus Capacitor Bank connector J6 connector J9 Precharge Board connector TB6 Fan connector if applicable Remove the screws fastening the bottom of the mounting plate to the drive Disassembly and Access Procedures 2 21 8 Slide the plate toward the top of the drive until the tabs disengage from the slots 9 Lift the plate out of the drive Installation Install the Gate Driver Board Mounting Plate in reverse order of removal Refer to Fastener Torque Specifications in this chapter ATTENTION
100. ntionally Left Blank Publication 1336 FORCE 6 13 August 1999 Chapter 1 Control Logic Wiring and Adapters Chapter Objectives This chapter introduces you to terminal block locations and wiring and adapter locations and functions Chapter Overview This chapter illustrates and describes Standard Adapter Board Control Logic Interface Options L4 L5 and L6 including Terminal Block TB3 TB3 input mode selections and functions 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 and DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference All
101. o TB3 on Control Interface Board Captive Screw Wire to Enclosure Door M6 Nut Publication 1336 FORCE 6 13 August 1999 Torque in Ib 36 44 12 16 Torque in Ib 65 79 12 16 12 16 12 16 Torque in Ib 23 36 23 36 6 8 50 72 50 72 50 72 50 72 52 12 16 12 16 12 16 8 10 23 36 Torque N m 2 6 4 1 14 18 Torque N m 7 3 8 9 14 1 8 14 1 8 14 1 8 Parts pertain only to original Snubber Board design which uses shaped Gate and Emitter brackets Refer to Power Modules in Chapter 4 Part Replacement Torque N m 2 6 4 1 2 6 4 1 0 7 0 9 5 6 8 1 5 6 8 1 5 6 8 1 5 6 8 1 5 9 1 4 1 8 1 4 1 8 1 4 1 8 0 9 1 1 2 6 4 1 Disassembly and Access Procedures 2 7 Disassembly and Access Procedures Opening the Drive Enclosure Figure 2 3 Drive Enclosure 4 Q p au L L QN RRS 9 0748 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 Publication 1336 FORCE 6 13 August 1999 2 8 Disassembly and Access Procedures Publication 1336 FORCE
102. omm Adapter Board to the mounting plate 7 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 8 Control Board Adapter Mounting Plate Removal Adapter Board Control Board Mounting Plate Connector J1 TB10 A Main Control x Ss Board Connector J5 lt HM Standard Adapter Board only Connector J7 Connector J1 Standard Adapter E Board S 187 Mounting Xe Plate Screw TB6 Terminal Block TE AB0694B 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 Publication 1336 FORCE 6 13 August 1999 2 18 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage
103. on the nylon spacers to remove the LEM from the mounting bracket Installation Install the LEMs 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 13 August 1999 4 34 Part Replacement Procedures Publication 1336 FORCE 6 13 August 1999 MOV Surge Suppressor The MOV Surge Suppressor is located in the bottom left corner of the Drive near the Autotransformer and Fan Capacitor The MOV protects the drive from high voltage surges above approximately 1 000 volts Replace the MOV if it is burned expanded or ruptured after such events as a lightening strike or inadvertent connection of the drive input to a voltage source substantially above nameplate voltage Figure 4 17 MOV Surge Suppressor Mounting Bracket M4 or M5 Mounting Screw MOV Surge Suppressor 0750 Removal Important Part Replacement Procedures 4 35 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures
104. r Module Main Chassis Chapter 2 Removing a Power Module Snubber Resistor Snubber Board 13 SCR1 SCR3 Input Rectifier Heat Sink Chapter 4 Input Rectifiers 14 CT1 CT2 LEM Main Chassis Chapter 4 LEMs 15 SCR SNUBBER Converter Snubber Board Heat Sink Chapter 2 Removing the Converter BOARD Snubber Board 16 CT3 Ground Sense CT Chapter 4 Ground Sense CT 17 FAN Fan Main Chassis Chapter 4 Fan and Transformer 18 L1 DC Bus Inductor Main Chassis Chapter 4 DC Bus Inductor L1 19 MOV1 MOV Surge Suppressor Main Chassis Chapter 4 Autotransformer 20 1 Autotransformer Main Chassis Chapter 4 Autotransformer 21 C HB1 Fan Capacitor Main Chassis Chapter 4 Autoransformer 22 C1 C6 Bus Capacitors Main Chassis Chapter 4 Bus Capacitor Bank Publication 1336 FORCE 6 13 August 1999 5 4 Replacement Parts List This Page Intentionally Left Blank Publication 1336 FORCE 6 13 August 1999 Chapter 6 Schematics 40 150 HP 1336 FORCE Drives Publication 1336 FORCE 6 13 August 1999 6 2 Schematics 40 150 HP 1336 FORCE Drives TB1 DC CUSTOMER FUSING TB1 1 CONVERTER SNUBBER BOARD F1 2 06 TO FAN CIRCUIT SEE FAN CIRCUIT DETAIL CF1 R L1 AC INPUT POWER 5 12 50 60HZ T L3 SEE TABLE 1
105. r Snubber Board Converter Snubber Board x rt M 9 Screws SS SD N AB0373D 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 Disassembly and Access Procedures 2 33 ATTENTION Hazard of electric shock exists Up to 1 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than lohm and less than 100 ohm rated for 25 watts minimum 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 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 Enclosure door Refer to Opening the Drive Enclousre in this chap
106. rary torque is 1 2 50 of final torque The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 2 2 Four Point Mounting o d Four Point Mounting O O 0 O Temporary Tighten Final Tighten D Torque Specifications AB0017A The following table lists fastener locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point and four point components to the heat sink Disassembly and Access Procedures 2 5 Table 2 A Fastener Torque Specifications Parts Common to D Frame Drives Component Fastener Application Fastener Used Torque Torque in Ib N m Voltage Sharing Resistor R1 Resistor to Heat Sink M5 x 10 mm Screw 23 36 26 441 Snubber Resistor R20 R22 Resistor to Heat Sink M5 x 10 mm Screw 23 36 26 41 Power Modules Q1 Q6 Power Modules to Heat Sink M6 x 16 mm Screw 26 2 9 Input Rectifiers SCR1 SCR6 Rectifiers to Heat Sink M6 x 16 mm Screw 52 5 9 Thermistor Thermister to Heat Sink Thermister 14 1 6 Fan Finger Guard Guard to Chassis M4 x 8 mm Screw 12 16 14 18 Fan Cover Cover to Fan M4 x 8 mm Screw 12 16 14 18 Fan Cover Cover to Chassis M4 x 12 mm Screw 12 16 14 18 Capacitor Retainer C1 C9 Retainer to Chassis 4 x 8 mm Screw 12 16 14 18 Capacitor Bracket C1 C9 Bracket to Capacitor Latch M5 x 10 mm Screw 23 36
107. rs 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 Publication 1336 FORCE 6 13 August 1999 3 12 Component Test Procedures Test 5 The Input Rectifiers are located on the bottom of the heat sink Testing the Input Rectifiers Figure 3 5 Input Rectifier Test Input Rectifier K2 G2 Kt G1 an All C K AK AB0387C 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 Publication 1336 FORCE 6 13 August 1999 Component Test Procedures 3 13 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with
108. rt Replacement Procedures 4 17 Input Rectifiers The Input Rectifiers are located at the bottom of the heat sink Figure 4 10 Input Rectifiers Input Rectifier 9 Standoffs 7 Converter Bus Bar AB0385D 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 Publication 1336 FORCE 6 13 August 1999 4 18 Part Replacement Procedures ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum 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 Important Before you remove connections and wires from the Publication 1336 FORCE 6 13 August 1999 drive components mark the conne
109. s a 296 high input line voltage the actual amp rating is 14 x 94 altitude derating x 96 high input line derating 12 6 amps Calculate the drive rating using the amp rating of your drive Conventions Preface 7 Enclosure Type The first character A indicates the Enclosure Code The second character indicates the type of enclosure shipped from the factory Table P F Enclosure Type Code Description Enclosure Description Type Code i N Open style IP00 A NEMA Type 1 IP20 J NEMA Type 12 IP54 To help differentiate parameter names and display text from other text in this manual the following conventions will be used e Parameter Names will appear in brackets e Display Text will appear in quotes The following is a list of conventions used throughout this manual and definitions of the conventions For a list of terminology and definitions refer to the Glossary in the back of this manual Auxiliary Input The Auxiliary Input is a terminal connection on the Control Interface Board This connection provides an external input for use as an Auxiliary Interlock Unless this interlock is closed the drive will be faulted with an Auxiliary Fault Auxiliary Interlock The Auxiliary Interlock is a user supplied circuit consisting of reset overload or other interlocking circuitry The Interlock is wired to the drive Auxiliary input Bit A bit is a single character or status point used in programmable
110. se Module W Phase Module Inverter 554 ERN gt lt 0 A ay 2 7 G A 2 2 Lower Left Bracket 2 Some Drives may not have brackets 2 at E and G Standoff Ci Se Fs is KO AB0391D Part Replacement Procedures 4 15 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 ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum 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 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 Remo
111. stomer Supplied 100 Ohm 25 Watt Resistor 0372 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 Publication 1336 FORCE 6 13 August 1999 2 30 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1999 ATTENTION Hazard of electric shock exists Up to 1 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 and less than 100 ohm rated for 25 watts minimum 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 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 Enclosure door Refer to Opening the Drive Enclosure
112. t where 60 Hz is applied to the induction motor BR Refer to Bridge Rectifier Braking A method of stopping or reducing the time required to stop an AC motor and can be accomplished in several ways 1 DC Injection braking AC drives A method which produces electromagnetic braking forces in the motor by removing 2 AC motor stator phases and injecting DC current The result is a linear braking characteristic ramp that does not diminish with motor speed Application is normally limited to 10 20 of rated motor speed due to increased heating in the rotor 2 Dynamic braking AC drives A method which produces electromagnetic braking forces in the motor by dissipating generated power into the DC bus through a resistive load Braking force remains constant and is only limited by the thermal capacity of the resistors The result is a linear braking characteristic ramp that does not diminish with motor speed 3 Regenerative braking 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 Publication 1336 FORCE 6 13 August 1999 G 2 Glossary Publication 1336 FORCE 6 13 August 1999 4 Motor mounted or separately mounted brake A positive action mechanical friction device Normal configuration is such that when th
113. t 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 test used to measure an insulation system s resistance This is usually measured in megohms by applying a high voltage MOV Refer to Surge Protection National Electrical Code NEC A set of regulations governing the construction and installation of electrical wiring and apparatus established by the National Fire Protection Association and suitable for mandatory application by governing bodies exercising legal jurisdiction It is widely used by state and local authorities within the United States National Electrical Manufacturer s Association NEMA A non profit organization organized and supported by electrical equipment an
114. tage Connect the negative lead of your meter to the DC Bus terminal on and the positive lead to the DC Bus terminal Refer to the following tables and former illustration for meter readings and terminal locations ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment Component Test Procedures 3 11 7 Apply power AFTER the meter is connected otherwise your meter will read zero volts Expand readings for all input voltage ratings Table 3 C Bus Capacitor Bank Test Drive Input Meter Rating Volts Reading 200 280V DC 10 A 230 322V DC 10 240 336V DC 10 380 535 DC 10 B 415 580V DC 10 480 650V DC 10 500 700V DC 10 C 575 800V DC 10 600 850V DC 10 8 If the voltage is out of tolerance check the following Anopen condition at an Input Rectifier e A voltage drop due to Bus Inductor L1 resistance A voltage drop between an Input Rectifier and the bus capacitors due to loose or resistive wires or connections Precharge circuit problems 9 If the above check does not reveal a problem replace the Bus Capacitor Bank and Load Sharing Resisto
115. ter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Board Mounting Plate Refer to Removing the Gate Driver Board Mounting Plate in this chapter Remove the Precharge Board Mounting Plate Refer to Removing the Precharge Board Mounting Plate in this chapter Remove the nine screws fastening the Converter Snubber Board to the Input Rectifier Installation Install the Converter Snubber Board in reverse order of removal Refer to Fastener Torque Specifications in this chapter 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 13 August 1999 2 34 Disassembly and Access Procedures Accessing Power Plane Components To access the power plane components located on the chassis refer to Removing a Power Module Snubber Board in this chapter Publication 1336 FORCE 6 13 August 1999 Chapter Objectives Component Test Overview Chapter 3 Component Test Procedures The following tests help you troubleshoot A040 A060 B060 B125 BX150 and C075 C125 drives In some cases different tests troubleshoot components of the same name These similar tests vary according to the rating of the drive being
116. ter than lohm and less than 100 ohm rated for 25 watts minimum 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 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 Enclosure door Refer to Opening the Drive Enclosure in this chapter Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at TB20 and 21 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 J9 Precharge Board connector J10 Bus Capacitor Bank connector J2 Ground Sense CT connector J7 Power Module connector J8 Power Module connector J6 LEM harness connector TB6 Fan connector J13 connector Ground wire from TB7 Publication 1336 FORCE 6 13 August 1999 2 24 Disass
117. tested Verify that the rating on the drive matches the rating for the test you are performing The procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is opened 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 fuses and circuit boards Verify bus voltage by measuring the voltage between DC and DC on Terminal Block 1 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 000V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than lohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Publication 1336 FORCE 6 13 August 1999 3 2 Component Test Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 13 August 1999 ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may c
118. the Standard Adapter Board Remove all wires from the terminals on 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 Refer to Fastener Torque Specifications in this chapter 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 5 Main Control Board and Mounting Plate Mounting Plate Slide Mount Standoff HIM Standard Adapter Board only Connector Connector J1 J Main Control Board Connector T SN GS Connector J7 PLC Comm Adapter Board or Standard Adapter Board AB0695A 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 Publication 1336 FORCE 6 13 August 1999 2 12 Disassembly and Access Procedures Publication 1336 FORCE 6 13 August 1
119. thin a male connector to complete specific and necessary circuits Related Publications Preface P 9 Control Interface Board A Control Interface Board plugs into connectors J10 and J12 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 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 Oriented Control User Manual 1336 FORCE 5 12 e 1336 FORCE PLC Communications Adapter User Manual 1336 FORCE 5 13 Renewal Parts List 1336 6 5 Options Manuals Instructions Publication 1336 FORCE 6 13 August 1999 10 Preface This Page Inte
120. tifiers 11 If the Input Rectifier shorted check the Power Modules for damage Refer to Testing the Power Modules in this chapter 12 Assemble the drive in reverse order of disassembly Publication 1336 FORCE 6 13 August 1999 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 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 DC and DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Hazard of electric shock exists Up to 1 000 V DC may be present on Snubber Capacitors Measure for zero V DC across capacitors C2 C3 and C4 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum to discharge any voltage Refer to
121. ve power from the drive Check for zero volts at TB1 terminals DC and DC Check for the absence of control voltage at e TB20 and 21 on drives using a PLC Comm Adapter Board e 5 TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Board Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board Mounting Plate Remove the Power Module Snubber Board Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Remove the three screws located at and on the Inverter Bus Bar Publication 1336 FORCE 6 13 August 1999 4 16 Part Replacement Procedures 7 Remove the four standoffs from the Inverter Bus Bar 8 Remove the four screws fastening the Power Module to the Drive Installation 1 Clean all surfaces between the Power Module and the heat sink using a soft clean cloth 2 Replace the Preform between the Power Module and the heat sink 3 Install the Power Module in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important Slide the MTR tab on the Inverter Bus Bar under the corresponding tab on the Transition Bus Bar 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 13 August 1999 Pa
122. versing Start 2B 28 Stop Fault Reset sz BS TAE 984 ommon X 5 8 E Mode 9 Se Reverse 2 3 4 5 6 c en 1 588 7188 J St 2nd Digital J g58 dos og n gita og m 5 Accel Pot Up 8 5 53 Auxiliary o m aS c 55 8 8 ES E a B Speed Speed 2nd Digital Local ELE SER y gt Select3 Select 3 Decel PotDn Control mH45 badau E OB 5 RES Speed Select 2 TON o C gt 5598 Speed Select 11 1 See Table 1 B 2 Drive must be stopped to take Local Control Common Control by all other adapters is disabled except Stop 3 These inputs must be present before drive will start Enable Publication 1336 FORCE 6 13 August 1999 AB0290C Control Logic Wiring and Adapters 1 7 Figure 1 5 continued Input Mode Selection and Typical TB3 Connections e _ y Jog Speed Speed Digital 1st gt Select 3 Select 3 PotUp Decel Speed Speed Speed Digital 2nd gt Select 2 Select 21 Select 2 Pot Dn Decel o o Maintained i Three Wire Control with Multi Source Reversing Start 25 89 2 E s Stop Fault Reset Mode i E RBS 5 E Common 7 8 9 10 11 ees O 2 8 2 Reverse Reverse Digital Reverse 1st p n 84 Pot Up Accel 5 5 888 458 2 gt Foward Forward Digital For
123. ward 2nd 558 Tae 2 Pot Dn Accel 289 559 9 Auxiliary 92 he 295 53 8 S pz g Z aes 5 25s mos lt 8 5 gt ER 5585 lt 55 of the following 1 05 or earlier Speed Select 1 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 2 Local Stop 2nd Digital Local 5 Control Type Accel PotUp Contro 3 Auxiliary 5 o Common 2 Speed Speed 2nd Digital Stop Select 3 Select 3 Decel PotDn Type Speed Select 2 Speed Select 1 1 See Table 1 B Common 2 Drive must 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 13 August 1999 1 8 Control Logic Wiring and Adapters The following table defines the input state of the Speed Select inputs for a desired frequency source Table 1 B Speed Select Input State vs Frequency Source Speed Select 3 Speed Select 2 Speed Select 1 Para 52 Bit 14 Bit 13 B12 Velocity Reference TB3 Terminal 26 Terminal 27 Terminal 28 Source 0 0 0 Last State 0 X External Reference 1 0 X Preset Speed 1 0 X X Preset Speed 2 X 0 0 Preset Speed 3 X 0 X Preset

Service Manual, Bulletin 1336 FORCE Adjustable Frequency AC

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