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Service Manual, Bulletin 1336 FORCE Adjustable

1. E Control and B Power Terminal Signal Wiring Block 0547 Figure 1 2 Terminal Block Locations PLC Comm Adapter Main Control TB10 Encoder Board 11 Board Communication TB1 Channels Power Terminal TB20 TB21 Block Control and Im Signal Wiring AB0548B ATTENTION National Electrical Code NEC and local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage Publication 1336 FORCE 6 11 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 24V AC DC Interface L6 115V AC Interface Uses internal 5 DC supply The user inputs are connected to the option board through TB3 The L5 and L6 options each have nine control inputs The function of each input must be selected through programming as explained later in this section Control Interface L Option Board Jumpers Important If the Control Interface L Option Board is b
2. CT2 2000 1 U X TB1 9 V 1 10 2000 1 BANK See Cap 2 Bank Detail 8 1 2 TB7 1 NTC to Main Control Board Q amp 0 o p uc 5 919 D zz al MN ades CONTACTOR 24VDC Fan 9 se SB se T UE TU B amp 020 kt ee m T 24VDC AUX INPUT 1 F1 1 Fant 4 25172 260 08 24VDC AUX INPUT 2 2 600V Fan GATE DRIVER BOARD 1 HIGH VOLT DC AUX IN TB6 2 3 HIGH VOLT DC AUX IN TBI IE TeeseorsoBrSDISSCSTERNERASRSESSSASS SDESSTSQISSUSSS 1 10 OXoc z2200n0uo02zwN 22 IH ARMIN C MIL M gt gt gt gt 25555222 9909 95 2 55 5 gt 22640059 To Main Control Board Series C and D STAND ALONE UNIT BULLETIN 1336 FORC
3. TB1 8 Y U M1 TB1 9 2 1 10 W M3 CT 2000 1 2000 1 CAP BANK See Cap Bi Bank Detail c40 PCB MOUNTED COMPONENT GDB a POWER ARTWORK GDB Els Ej qzzi amp NTC to 2 2 gt o omm Main Control Board PCBARTWORK GDB lo I gg Sey aly 22 58 ss EE DISCRETE WIRING 24VDC Fan POB SCREW TERMINAL CONTACTOR INTERFACE 12 Aita ta 123 123 45 6 J2 TBS J6 F1 24VDC AUX INPUT eer en PEE 4 2 600V 24VDC AUX INPUT 2 Franz GATE DRIVER BOARD HIGH VOLT DC AUX IN TB6 2 3 HIGH VOLT DC AUX IN TB1 J9 1 2 13 14 PH LL ELA AA SSSBSSSSSSSSSIGS LS SSSSB 1 10 onn gt gt gt 29 gt gt gt 292229494808490000 8242450250 452222213125299 8588562642642628 2422222000040605 6 8 711 40689 222922555522 XT 0089595 Q 55 2 gt 2242979 Series A and B STAND ALONE UNIT BULLETIN 1336 FORCE 200 240 Volt 5 5 11 kW 7 5 15 HP 380 480 Volt 5 5 22 kW 7 5 30 HP 500 600 Volt 5 5 15 kW 7 5 20 HP To Main Control Board AB0756A Publication 1336 FORCE 6 11 August 1999 6 4 230V 7 5 10HP 4
4. 230V 230V 7 5 10HP 15HP 460V 460V 7 5 20 25 80HP N 4 LY E4 J2 L f Ci ES J2 E6 J4 E6 js E6 E7 J5 Eg 6 E ALL CAPS ARE CONNECTED TOGETHER BY PCB ARTWORK T MET 1 FS FT CUSTOMER FUSING FUSE AC idi VOLTAGE FR FS FT TYPE JJ 7 5 230 35 10 230 45 15 230 70 7 5CT 10VT 380 460 20 10CT 15VT 380 460 30 15CT 20VT 380 460 35 20CT 25VT 380 460 45 25CT 30VT 380 460 60 30CT 30IEC 380 460 70 7 5 575 15 10 575 20 15 575 25 20 575 35 Series A and B STAND ALONE UNIT BULLETIN 1336 FORCE 200 240 Volt 5 5 11 kW 7 5 15 HP 380 480 Volt 5 5 22 kW 7 5 30 500 600 Volt 5 5 15 kW 7 5 20 HP AB0755A Publication 1336 FORCE 6 11 August 1999 Schematics 7 30 HP 1336 FORCE Drives 10 15 230V 20 575V 20 25 30 380 460V DISCRETE WIRES 6 3
5. 2 9 Installation II 2 10 Removing the Standard Adapter Board 2 11 2 11 Installation 2 12 Removing the PLC Comm Adapter Board 2 13 Removal 2 13 2 14 Removing the Control Board Adapter Mounting Plate 2 15 Removal 2 15 s acia icu eranc a cS a E 2 16 Removing the Gate Driver Power Supply Board Series A and 2 17 Removal Kau EX EXER EX TEARS 2 17 2 18 Removing the Gate Driver Power Supply Board Series CandD 2 19 Removal TP c 2 20 Installation sau ar ok ews dae eek re mae ewe 2 22 Accessing Chassis Power Components 2 22 Component Test Procedures Part Replacement Procedures Table of Contents iii Chapter 3 Chapter Objectives cu i ark Re a Rx RE ym e 3 1 Component Test Overview 3 1 Electrostatic Discharge Precautions 3 2 IG a pL 3 2 Test 1 Testing Bridge RectifierBR1 3 3 Test 2 Testing the Bus Capacitors 3 5 Test 3 Testing Transistor Modules Q1 Q2 3 8 Test 4 Testing the Precharge Module Series 3 11 Test 5 Testin
6. Nameplate Located on Tab of Control Board Adapter Mounting Plate 5 5 22 kW 7 5 30 HP Software Compatibility ATTENTION To guard against machine damage and or personal injury drives with ratings above 45 kW 60 HP must not be used with software versions below 1 07 Refer to the table below Three Phase Drive Rating 200 240V 380 480V 500 600 Compatibiewith Version Reference 55 11kW 55 22kW 55 15kW 105 amp Upor B 75 15HP 75 30HP 75 20HP 1 06 wistd kW and HP are constant torque CT ratings Publication 1336 FORCE 6 11 August 1999 4 Preface Drive and Option Identification 1336T A007 AN BULLETIN RATING ENCLOSURE NO MUST BE SPECIFIED Drive Rating Frame Designation Publication 1336 FORCE 6 11 August 1999 Output Nominal HP Code Amps The following is an 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 LANGUAGE CONTROL INTERFACE OPTIONAL MODULE MUST BE SPECIFIED 200 240V AC Input Constant Torque Drive Open 00 No Enclosure NEMA Type 1 IP20 General Purpose 007 0
7. Enable Input Mode 12 16 Two Wire Control Single Source Control Run Forward Stop Fault Resef Common Mode 12 13 14 15 16 Run Reverse Local Stop 2nd Digital Local 5 Control Type Accel PotUp Control E Auxiliary S 2 Speed Speed 2nd Digital Stop Select 3 Select3 Decel PotDn Type Speed Select 21 Speed Select 1 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 4 Bit 0 of Direction Mask must 1 to allow operation 0291 Publication 1336 FORCE 6 11 August 1999 1 8 Control Logic Wiring and Adapters wan 1 2 3 4 5 6 7 8 9 10 20 Drive Stop Enable Motor Ext Thermo Fault Publication 1336 FORCE 6 11 August 1999 Fault Common Relay 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 Velocity Reference Source Speed Select 3 Speed Select 2 Speed Select 1 Velocity Para 52 Bit 14 Bit 13 B12 Reference TB3 Terminal 26 Terminal 27 Terminal 28 Source 0 0 0 Last State 0 0 X External Reference 1 Preset Speed 1 Preset Speed 2 Preset Speed 3 Preset Speed 4 Preset Speed 5
8. P 3 Drive and Option Identification P 4 1336 FORCE Drive Catalog Numbers P 4 Drive Rating Qualifications P 7 6 sacks Sess seuss 7 E 8 Auxiliary Input P 8 Auxiliary Interlock 8 Bil epen POR LEA 8 CHECK 26 454 P 8 8 Ar P 9 Enable INPUT CPU P 9 c vv P 9 OEE E ES 9 Control Interface L Option Board P 9 9 Press asume haw nea 10 QU PP ETT P 10 Related Publications 10 1 Chapter Objectives 1 1 Ghapt r OVBIVIBW x Exp p 1 1 Control Interface Option 1 3 Control Interface L Option Board Jumpers 1 3 Available INDUS 42222222 teases weds 1 4 Standard Adapter Local Programming 1 4 Adapters and Communication Ports 1 10 Human Interface Module 1 10 Standard Adapter Ports 1 11 PLC Comm Adapter
9. Table of Contents WiSIAIANON s lt 3 a KS 4 17 DC Bus Inductor Series and 0 4 18 Removal 4 19 Installation 4 20 Bus Capacitors ep C m 4 21 Removal kd ee 4 21 4 22 Replacement Parts List Chapter 5 Chapter Objectives 5 1 Ordering Replacement 5 1 Replacement Parts Listing 5 2 Schematics Chapter 6 Glossary Index Notes Publication 1336 FORCE 6 11 August 1999 Manual Objective Who Should Use This Manual Safety Precautions Preface Preface The information in this manual is designed to help troubleshoot or repair an Allen Bradley Bulletin 1336 FORCE Adjustable Frequency AC Drive with ratings A007 A015 B007 B030 and C007 C020 This manual is intended for qualified service personnel responsible for repairing the 1336 FORCE Adjustable Frequency AC Drive You should Read this entire manual before performing maintenance or repairs to drives Have previous experience with and basic understanding of electrical terminology procedures required equipment equipment protection procedures and methods and safety precautions This manual describes equipment and disassembly procedures You begin with general illustrations and end with greater de
10. 10 Preface Related Publications Publication 1336 FORCE 6 11 August 1999 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 1336 FORCE PLC Communications Adapter User Manual 1336 FORCE 5 13 Renewal Parts List 1336 6 5 Options Manuals Instructions Chapter Objectives Chapter Overview Chapter 1 Control Logic Wiring and Adapters This chapter introduces you to terminal block locations and wiring and adapter locations and functions This chapter also illustrates and describes the 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 printe
11. August 1999 Precharge Module Series A and B The Precharge Module is located behind the Gate Driver Power Supply Board to the right of the Bus Capacitor assembly Figure 4 2 Precharge Module Series A and B Preform Precharge Module AN A 0745 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 Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Part Replacement Procedures 4 5 Important Before you remove connections and wires from the 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at 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 TB7 on drives using a Standard Adapter Board Remove the Gate
12. Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 4 8 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 Thermistor The Thermistor is fastened to the upper right corner of the heat sink Figure 4 4 Thermistor Removal MN Thermistor Bw Connector to Main Control Board J1 0306 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 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Part Replacement Procedures 4 9 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
13. Table 5 Replacement Parts for A007 A015 007 030 and C007 C020 Drives Callout Symbol Description Location Replacement Procedures 1 ST Thermistor Main Chassis Chapter 4 Thermistor 2 Q1 3 Transistor Main Chassis Chapter 4 Transistor Modules 3 M1 Precharge Module Main Chassis Chapter 4 Precharge Module 4 BR1 Bridge Rectifier Main Chassis Chapter 4 Bridge Rectifier BR1 5 BASEDR Gate Driver Power Chapter 2 Removing the Gate PWRSPLY Supply PCB Driver Power Supply Board 6 LOCAL DIS Human Interface Control Board Adapter Chapter 2 Module Removal Module Mounting Plate Contro 7 MAIN Main Control PCB Board Adapter Chapter 2 Removing the Main CTL Mounting Plate Control Board 8 GT2 Standard Adapter Board Contro Chapter 2 Removing the Board Adapter Standard Adapter Board Mounting Plate 9 Control Chapter 2 Removing the PLC Comm Adapter Board Board Adapter Adapter Board Mounting Plate 10 FAN Fan Main Chassis Chapter 4 Bus Capacitors 11 L1 DC Bus Main Chassis Chapter 4 DC Bus Inductor L1 Inductor 12 C1 C4 Bus Capacitors Main Chassis Chapter 4 Bus Capacitors Publication 1336 FORCE 6 11 August 1999 5 4 Replacement Parts List This Page Intentionally Left Blank Publication 1336 FORCE 6 11 August 1999 Chapter 6 Schematics 7 30 HP 1336 FORCE Drives Publication 1336 FORCE 6 11 August 1999 6 2 Schematics 7 30 HP 1336 FORCE Drives CAP BANK DETAILS
14. Remove all screws connecting the Gate Driver Power Supply Board to the power components Installation Install the Gate Driver Power Supply Board in reverse order of removal Refer to Table 2 A Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury 2 19 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Series C and D Gate Driver Power Supply Board A010 A015 B020 B030 Figure 2 10 and C020 Drives oS c Kc 82 Em 5 e gt E z 2 KT o NUS T So e Sec qu 3 8 5 S LLI N 7 Supply Board Gate Driver Power Publication 1336 FORCE 6 11 August 1999 2 20 Disassembly and Access Procedures Figure 2 11 Gate Driver Power Supply Board A007 B007 B015 and C007 C015 Drives Gate Driver Power Supply Boaid 18 E22 29 gt nA T TB Precharge Insula tor Stand Alone AB0672B 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 discharge
15. Thermistor Transistor Modules Bridge Rectifier BRI Fan DC Bus Inductor L1 Bus Capacitors For Gate Driver Power Supply Board Main Control Board Standard Adapter Board PLC Comm Adapter Board and Control Interface L Option Board installation and removal procedures refer to Chapter 2 Allen Bradley Adjustable Frequency AC Drives are modular by design to enhance troubleshooting and spare parts replacement thereby helping reduce production down time The following illustration calls out the main components of a typical drive Component designs vary slightly among the different drive ratings but component locations are identical Figure 4 1 Main Drive Comp Heat Sink and Fan Assembly Thermistor Load Sharing Resistor Transistor Module Precharge Module Bus Capacitor Inductor L1 1 Input MOV PLC Comm Adapter Board Part Replacement Procedures 4 3 onents Gate Driver Power Supply Board Control Board Adapter Mounting Plate Human Interface Main Control Module HIM Board J comet J1 Connector Qo 2 1810 2 Connector J7 Connector J1 Standard Connector J5 Connector J7 Control Interface Board AB0561B Publication 1336 FORCE 6 11 August 1999 4 4 Part Replacement Procedures Publication 1336 FORCE 6 11
16. False Definition P 9 Fan Illustration 4 14 Installation 4 15 Removal 4 15 Four Point Mounting 2 3 G Gate Driver Board Illustration 2 17 2 19 Installation 2 18 Removal 2 17 2 20 Gate Driver Power Supply Board Test 3 16 Gate Driver Power Supply Board Series C Illustration 2 20 Installation 2 22 H Human Interface Module HIM Adapter Locations 1 11 Illustration 1 10 Operation 1 12 Removal 1 12 Publication 1336 FORCE 6 11 August 1999 2 Publication 1336 6 11 August 1999 Identification Product 3 Input Mode Factory Default 1 6 Programming 1 4 Selection 1 5 Three Wire Single Source 1 6 Inputs Available 1 4 J Jumper Definition P 9 L Load Sharing Resistor Connections 4 23 Local Programming 1 4 Manual Audience 1 Conventions 8 Objective P 1 Related Publications 10 Motor Control Board Illustration 2 9 Installation 2 10 Removal 2 9 2 11 2 13 Motor Control Board Mounting Plate Illustration 2 15 Installation 2 16 Removal 2 15 Mounting Four Point 2 3 Two Point 2 2 N Nameplate Location 3 0 Objective of this Manual 1 Operation Human Interface Module 1 12 Option Control Interface 1 3 Identification 4 P Parameter Definition P 9 Precautions Electrostatic Discharge 2 Safety 1 Precharge Module Illustration 4 4 Installation 4 5 Removal 4 4
17. wy Allen Bradley Bulletin 1336 FORCE Adjustable Frequency Servi Ce AC Drive Series B C D Manual A007 A015 B001 B030 C001 C020 Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or in part without written permission of Allen Bradley
18. HAP Programmer Only Standard Adapter English HA1 Programmer Controller with Analog Pot GT2EN No Adapter HA2 Programmer Controller with Digital Pot GTO Human Interface Modules NEMA Type 4 56 Control Interface Options HFP Programmer Only L4 Contact Closure HF2 Programmer Controller with Digital Pot L5 24V AC DC L6 115V AC Human Interface Modules NEMA Type 12 54 HJP Programmer Only HA2 Programmer Conroller with Digital Pot 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 Drive Rating Qualifications Several factors can affect drive rating If more than one factor exists derating percentages must be multiplied For example if a 14 amp drive is installed at a 2km 6 600 ft altitude and has a 296 high input line voltage the actual amp rating is 14 x 94 altitude derating x 96 high input line derating 12 6 amps Enclosure Type The first character A indicates the Enclosure Code The second character indicates the type of enclosure shipped from the factory Table P F Enclosure Type Code Descriptions Enclosure Type Code Description N Open style IP 00 A NEMA Type 1 IP 20 E NEMA Type 1 IP 20 CE Metal Cover NEMA Type 4 IP 56 J NEMA Type 12 IP 54 Publication 1336 FORCE 6 11 August 1999 8 Preface Conventions Publication 1336 FORCE 6 11 August 1999 T
19. PZN Wy eX 70 4 GN wD IA WS 0744 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 Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Publication 1336 FORCE 6 11 August 1999 3 12 Component Test Procedures Publication 1336 FORCE 6 11 August 1999 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC before proceeding 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 Remove the Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Series A and B 5 Set your meter to test diodes 6 Test the module The following table shows meter connections at the module and ideal meter readings for those connections Refer to
20. Status Common Status Status Status Common Enable Input Mode 2 6 Three Wire Control with Single Source Reversing Start Stop Fault Reset Common Mode Reverse 2 3 4 5 6 Stop 2nd Digital Jog Type Accel Pot Up Auxiliary Common Speed Speed 2nd Digital Local gt Select3 Select 31 Decel PotDn Control Speed Select 2 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 0290 Control Logic Wiring and Adapters 1 7 o o Momentary Input Mode 7 11 Jog Speed Speed Digital 1st Select 31 Select3 PotUp Decel Speed Speed Speed Digital 2nd Select 21 Select 21 Select2 PotDn Decel Maintain 5 anane Three Wire Control with Multi Source Reversing Start A 88 2 E 3 i 5 Stop Fault Reset Mode Sp 855 2 7 8 9 10 1 223 8 Siz Reverse Reverse Digital Reverse 1st eS gt gt zag Sy Pot Up Accel eS E 883 o Foward Forward Digital Forward 2nd 9 od z Pot Dn Accel 5 5 59 8 2 E 8 Auxiliary ait p a 282 8 T 3 E LE o z285 32s 5 Ozz 2595 52 E 8 o 2 age of the following 1 05 or earlier Speed Select 11 Common
21. Table 3 G Precharge Module Resistance Test Meter Lead Meter Lead Nominal Meter Reading 5 4 20 4 5 20 5 3 500K 5 2 0 00 2 5 0 00 4 2 15 5 1 Infinite 4 3 Infinite 4 1 500K 9 If your readings do not match the table readings replace the Precharge Module Clean the surfaces between the Precharge Module and the heat sink using a soft clean cloth Replace the Preform between the Precharge Module and the heat sink Fasten the Precharge Module to the heat sink using two screws Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications 10 Replace and secure the Gate Driver Power Supply Board and Control Board Adapter Mounting Plate Publication 1336 FORCE 6 11 August 1999 3 16 Component Test Procedures Test 6 Testing the Gate Driver Power Supply Board Publication 1336 FORCE 6 11 August 1999 The Gate Driver Power Supply Board is located between the Main Control Board and the Main Chassis If one or more Transistor Modules Q1 Q2 or Q3 has been replaced you must test the Gate Driver Power Supply Board Figure 3 6 Gate Driver Power Supply Board Test Important Gate Driver Board 0312 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in d
22. and C007 C015 Drive ratings only E25 ground wire J3 connector fan wires IGBT gate connections 12 Precharge Module gate connections 2 incoming power wires at Terminal Block TB1 Publication 1336 FORCE 6 11 August 1999 2 22 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 7 Remove all screws connecting the Gate Driver Power Supply Board to the power components Installation Install the Gate Driver Power Supply Board in reverse order of removal Refer to Table 2 A Fastener Torque Specifications Important Before positioning the Gate Driver Power Supply Board in the drive fold and install the Precharge Insulator through the back of the Gate Driver Power Supply Board Refer to Figures 2 10 and 2 11 ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Accessing Chassis Power Components To access the power components located on the chassis refer to Removing the Gate Driver Power Supply Board in this chapter Chapter Objectives Component Test Overview Chapter 3 Component Test Procedures The following tests help you troubleshoot A007 A015 B007 B030 and C007 C020 drives In some cases different tests troubleshoot components of the same name These similar tests vary according to the rating of the drive being tested Verify that the rating on the drive ma
23. 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 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 Publication 1336 FORCE 6 11 August 1999 G 6 Glossary Publication 1336 FORCE 6 11 August 1999 Gate 1 A logic element that blocks or passes a signal depending on the status of specified input signals 2 The control element of an SCR GND Sense A current transducer that detects an unequal or imbalanced c
24. 015 and C007 C015 drives Remove the nut fastening the inductor bracket to the chassis Remove the bracket from the DC Bus Inductor to remove the inductor Installation 1 2 Publication 1336 FORCE 6 11 August 1999 Lower the DC Bus Inductor into the Main Chassis Align the hole in the bottom inductor bracket with the peg on the chassis Important DC Bus Inductor insulator may shift when the inductor is removed Before installing the inductor check the insulator position Install the DC Bus Inductor in reverse order of removal ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Part Replacement Procedures 4 21 Bus Capacitors The Bus Capacitors are located on the left side of the Main Chassis Bus Capacitor sizes and quantities vary according to drive ratings Figure 4 11 Bus Capacitors Load Sharing Resistors A upper and B lower Smaller drives use only one resistor Bus Capacitor d Bank Tab on Main Chassis fastens through this 0302 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
25. Board 4 Remove the Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board 5 Unscrew the Thermistor from the heat sink Installation Install the Thermistor reverse order of removal Important When fastening the Thermistor to the heat sink hand tighten the Thermistor to avoid damaging the porcelain Thermistor body ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 4 10 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 Transistor Modules Transistor Modules Q1 Q2 and Q3 are located on the center of the heat sink Figure 4 5 Transistor Modules Transistor Module C2E1 B2 4 0307 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 Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to El
26. 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 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 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 Publication 1336 FORCE 6 11 August
27. 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 11 August 1999 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE 6 11 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 3 Drive Nameplate Location P 3 Software Compatibility
28. Connect the Load Sharing Resistors to the Bus Capacitors according to the following diagrams Publication 1336 FORCE 6 11 August 1999 7 5 10 HP 9 200 240V 7 5 20 HP 380 480V lt mT C1 i 5 lt e 7s C2 E6 lt 13 6 Ohms Figure 4 12 Part Replacement Procedures Load Sharing Resistor Connections to Bus Capacitors 7 5 20 HP 500 600V lt C1 e 4 B 13 6K E4 lt Ohms em C2 E5 lt E6 lt H ame C3 e 4 13 6K H i Ohms lt 15 HP 200 240V 25 30 HP 380 480V C1 C3 ere E4 lt E5 ME n C2 C4 E6 lt 4 23 4 3K Ohms 4 3K Ohms 0313 ATTENTION The Capacitor Bus PCB must connect a positive capacitor terminal to a negative capacitor terminal Capacitors not connected correctly will explode and cause death or serious injury Publication 1336 FORCE 6 11 August 1999 4 24 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 FORCE 6 11 August 1999 Chapter 5 Replacement Parts List Chapter Objectives This chapter illustrates and lists replacement parts for the 1336 FORCE Drives rated A007 A015 B007 B030 and C007 C020 and describes replacement parts ordering p
29. Connector J5 lt Connector J7 RIO Channel A RIO Channel B d 21 TB20 0560 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 cover Refer to Opening the Drive Enclosure in this chapter 3 Check for zero volts at TB1 terminals DC and DC Publication 1336 FORCE 6 11 August 1999 2 14 Disassembly and Access Procedures Publication 1336 FORCE 6 11 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 Comm 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 and insulators before applying power to the drive Failure to replace guards may result in death or serious in
30. 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 Glossary G 5 Duty Cycle 1 The ratio of working time to total time for an intermittently operating device Usually expressed as a percentage 2 The ratio of pulse width to the interval between like portions of successive pulses Usually expressed as a percentage Dynamic Braking Refer to Braking Efficiency Ratio of output to input indicated by a percentage In a motor it is the effectiveness with which the motor converts electrical energy into mechanical energy In a power supply it is the effectiveness with which the power supply converts AC power into DC power Electrostatic Discharge ESD A static electricity discharge that
31. Driver Power Supply Board from the drive Refer to Chapter 2 Removing the Gate Driver Power Supply Board Remove the two round head screws fastening the Precharge Module to the heat sink Remove the Precharge Module from the drive Installation 1 Clean the surfaces between the Precharge Module and the heat sink using a soft clean cloth Replace the Preform between the Precharge Module and the heat sink Install the Precharge Module in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 4 6 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 Precharge Module Series C and D The Precharge Module is located near the bottom of the heat sink If one or more Transistor Modules has been replaced you must replace the Precharge Module Figure 4 3 Precharge Module Series C and D Removal Precharge Module AB0305B 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 T
32. Precharge Module Series C Illustration 4 6 Installation 4 7 Removal 4 6 Press Definition P 10 Procedures Accessing Internal Drive Components 2 1 Bridge Rectifier Installation 4 13 Bridge Rectifier Removal 4 12 Bus Capacitor Installation 4 22 Bus Capacitor Removal 4 21 Component Test 3 1 Control Board Installation 2 10 Control Board Mounting Plate Installation 2 16 Control Board Mounting Plate Removal 2 15 Control Board Removal 2 9 Control Interface L Option Board Installation 2 8 Control Interface L Option Board Removal 2 7 DC Bus Inductor Series C Installation 4 20 DC Bus Inductor Series Removal 4 19 DC Bus Inductor Installation 4 17 DC Bus Inductor Removal 4 17 Drive Enclosure Installation 2 6 Drive Enclosure Removal 2 5 Fan Installation 4 15 Fan Removal 4 15 Gate Driver Board Installation 2 18 Gate Driver Board Removal 2 17 2 19 Gate Driver Power Supply Board Series C Installation 2 22 Gate Driver Power Supply Board Test 3 16 Precharge Module Series C 4 6 Precharge Module Series C Installation 4 7 Precharge Module Series C Removal 4 6 Precharge Module Installation 4 5 Precharge Module Removal 4 4 Replacement Part 4 1 Thermistor Installation 4 9 Thermistor Removal 4 8 Transistor Module Installation 4 11 Transistor Module Removal 4 10 Transistor Module Test 3 8 Product Identification 3 Programming Input Mod
33. 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 Publication 1336 FORCE 6 11 August 1999 2 18 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 Remove power from the drive Open the Enclosure cover Refer to Opening the Drive Enclosure in this chapter Check for zero volts at 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 Disconnect the following from the Gate Driver Power Supply Board P13 Stake on connector P14 Stake on connector IGBT gate connections 14 E1 inductor wire E26 inductor wire E25 ground wire J3 fan wires All incoming power wires at TB1
34. 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 Puerto Rico Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 1336 FORCE 6 11 August 1999 Supersedes January 1996 PN 74002 117 01 A Copyright 1996 Allen Bradley Company Printed in USA
35. opportunity to make sure they do just that By filling out this form you can help us provide the most useful thorough and accurate manuals available Please take a few minutes to tell us what you think Then mail or FAX this form FAX to your local Allen Bradley Sales Office or 414 512 8579 PUBLICATION NAME PUBLICATION NUMBER DATE AND PART NUMBER IF PRESENT V CHECK THE FUNCTION THAT MOST CLEARLY DESCRIBES YOUR JOB SUGGEST RESPONSIBLE FOR THE PURCHASE OF EQUIPMENT MAINTAIN OPERATE PROGRAMMABLE MACHINERY DESIGN IMPLEMENT ELECTRICAL SYSTEMS TRAIN EDUCATE MACHINE USERS SUPERVISE FLOOR OPERATIONS V WHAT LEVEL OF EXPERIENCE DO YOU HAVE WITH EACH OF THE FOLLOWING PRODUCTS NONE LITTLE MODERATE EXTENSIVE PROGRAMMABLE CONTROL J Ll 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
36. procedures reference Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 11 August 1999 2 2 Disassembly and Access Procedures Fastener Torque Specifications Publication 1336 FORCE 6 11 August 1999 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 2 Phillips screwdriver e 5 16 inch or 8mm socket Torque wrench metered in 16 1 or N m 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 t
37. 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 Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Component Test Procedures 3 9 Remove power from the drive Check for zero volts at TB1 terminals DC and DC before proceeding 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 Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Set your meter to test diodes The following tables show meter connections and ideal meter readings for those connections Refer to the previous illustration for meter connection locations Table 3 C A007 A005 B007 B015 and C007 C015 01 Q2 and Q3 Test Meter Lead Meter Lead Nominal Meter Reading C2E1 E2 Infinite E2 C2E1 0 36 C1 C2E1 Infinite C2E1 C1 0 36 B1 E1 Infinite capacitive B2 E2 Infinite capacitive Table 3 D B020 B030 and C020 01 02 Q3 Test Meter Meter Nominal Meter Maximum Meter Lead Lead Reading Reading
38. service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 11 August 1999 4 22 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 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 Remove the Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board 5 Remove the Load Sharing Resistor wires from the connectors on the Bus Capacitor Bank 6 Remove the two nuts fastening the Bus Capacitor assembly to the chassis 7 Remove the Bus Capacitor assembly from the Main Chassis Installation 1 Fasten the capacitor assembly to the Main Chassis using the two nuts on the left side Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications 2
39. the previous illustration for meter connection locations Table 3 E Precharge Module Test Meter Lead Meter Lead Nominal Meter Reading 1 0 35 3 Infinite 4 Infinite capacitive 5 Infinite capacitive 7 If your readings do not match the table readings replace the Precharge Module Clean all surfaces between Precharge Module and the heat sink using a soft clean cloth Replace the Preform between the module and the Main Chassis Install the screws Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications 8 Replace and secure the Gate Driver Power Supply Board and Control Board Adapter Mounting Plate Component Test Procedures 3 13 Test 5 The Precharge Module is located near the bottom of the heat sink Testing the Precharge i igure 3 Module Series C and D Precharge Module Test Series C and D Important Precharge Module T SN C S COR GN SN Ey F TY 4 CEN N Yo T AB0299B 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 Before you remo
40. 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 Standard Adapter For local programming and control information refer to the 1336 Local Programming FORCE User Manual Publication 1336 FORCE 6 11 August 1999 Control Logic Wiring and Adapters 1 5 Table 1 A Input Mode Selection Start Stop Type Direction Control Communication Compatibility nen Stop amp Enable None Control must be provided by HIM or Communication Option 1 Only Momentary Maintained Switch Start Stop works in parallel with HIM and Communication Options 2 6 Pushbutton Open Forward Direction Control will not work in parallel with HIM or Communication 8 Wire Closed Reverse Options User must select direction control from either HIM and Communication Options or TB3 input Momentary Momentary Pushbuttons Start Stop works in parallel with HIM and Communication Options Pushbutton Forward and Reverse Direction works in parallel with HIM or Communication Options 7 11 8 Wire Maintained switches for combined run and Start Stop not compatible with HIM or Communication Options 12 16 direction control 2 wire Run Forwa
41. to the front away from DC Bus Inductor L1 Connect the red wire to the positive fan terminal and the black wire to the negative terminal Publication 1336 FORCE 6 11 August 1999 4 16 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury DC Bus Inductor Series A and B DC Bus Inductor is located on the lower left hand corner of the Main Chassis Figure 4 8 DC Bus Inductor 0303 Part Replacement Procedures 4 17 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 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 7 8 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check
42. 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 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 Publication 1336 FORCE 6 11 August 1999 G 8 Glossary Publication 1336 FORCE 6 11 August 1999 Meggar Test A test used to measure an insulation system s resistance This is usually measured in megohms by applying a high voltage MOV Refer to Surge Protection National Electrical Code NEC A set of regulations governing the construction and installation of electrical wiring and apparatus established by the National Fire Protection Association and suitable for mandatory application by governing bodies exercising legal jurisdiction It is widely used by state and local authorities within the United States National Electrical Manufacturer s Association NEMA A non profit organization organized and supported by electrical equipment and supply manufacturers Some NEMA motor standards include horsepower hp ratings speeds frame sizes and dimensions torques and drive enclosur
43. x x x OJ O x x O O x x O x O x O External Reference 2 O Open Input Removed X Closed Input Present The DIP switches and jumpers on the PLC Communications Board have been preset at the factory Communication is received through Channels A and B This communication protocol is defined through SW U2 US If switches or jumpers require reconfiguration refer to the 1336 FORCE PLC Communications Adapter User Manual Figure 1 6 PLC Comm Adapter Reference Signal Connections 1 2 34 56 7 8 9 10 11 12 13 14 15 16 17 18 19 21 P B PB 1 96696996999969960 555 L L L4 Comm 10 Analog Analog Analog Analog Analog Anag Analog Analog 041 042 Out3 044 In2 In3 In4 0551 Table 1 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 11 August 1999 1 10 Control Logic Wiring and Adapters Adapters and C
44. 10 015 007 010 A015 AA AE HUMAN INTERFACE OPTIONAL Enclosures NEMA Type 4 IP65 Resist Water Dust A007 AF A010 AF A015 AF GM1 COMMUNICATION CARD OPTIONAL NEMA Type 12 IP54 Industrial Use A007 AJ A010 AJ A015 AJ 1336 BULLETIN NO Drive Rating Frame Designation 007 RATING ENCLOSURE MUST BE SPECIFIED Constant Torque Output Amps Table P B LANGUAGE MODULE MUST BE SPECIFIED 380 480V AC Input Constant Torque Drive Open 00 No Enclosure B007 AN B010 AN B015 AN B020 AN B025 AN B030 AN CONTROL INTERFACE OPTIONAL NEMA Type 1 IP20 General Purpose B007 AA B010 AA B015 AA 020 025 030 Enclosures Preface HUMAN INTERFACE OPTIONAL NEMA Type 4 IP56 Resist Water Dust B007 AF 010 015 020 025 030 P 5 GM1 COMMUNICATION CARD OPTIONAL NEMA Type 12 IP54 Industrial Use B007 AJ B010 AJ B015 AJ B020 AJ B025 AJ B030 AJ Publication 1336 FORCE 6 11 August 1999 1336 BULLETIN NO Frame Publication 1336 FORCE 6 11 August 1999 Drive Rating Designation Preface 007 RAT
45. 1999 G 4 Glossary Publication 1336 FORCE 6 11 August 1999 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 Drift A slow change in some characteristic of a device For a drive it is the deviation from the initial set speed with no load change over a specific time period Normally the drive must be operated for a specified warm up time at a specified ambient temperature before drift specifications apply
46. 2 30 25 34 Gate Driver Board Module M5 screw 22 30 25 34 Gate Driver Board Module M6 screw 30 39 34 44 Bridge Rectifier BR1 BR1 to Driver board 22 30 25 34 Bridge Rectifier BR1 BR1 to heat sink 25 31 2 8 3 5 Precharge Module M1 to heat sink 22 30 25 34 Precharge Module M1 to Driver board 22 30 25 34 Transistor Modules Q1 Q3 Module to heat sink 25 81 2 8 3 5 Inductor Inductor to chassis 22 30 25 34 TB1 Wires to TB1 16 1 8 TB3 Wires to TB3 8 10 0 9 1 1 Standard Adapter Board Board to Mounting Plate 12 16 1 4 1 8 PLC Comm Adapter Board Board to Mounting Plate 12 16 1 4 1 8 Main Control Board Board to Mounting Plate 12 16 1 4 1 8 TB5 6 7 10 11 20 21 Wires to terminals 8 10 0 9 1 1 Disassembly and Access Procedures Disassembly and Access Procedures 2 5 Opening the Drive Enclosure Figure 2 3 Opening the Drive Enclosure Enclosure Cover 509 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 11 August 1999 2 6 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORC
47. 5 600 850V DC 5 8 If the voltage is out of tolerance check the following Publication 1336 FORCE 6 11 August 1999 An open condition at Bridge Rectifier 1 A voltage drop due to Inductor L1 resistance A voltage drop between Bridge Rectifier BR1 and the bus capacitors due to loose or resistive wires or connections Precharge Circuit problems Component Test Procedures 3 7 9 If the above check did not reveal a problem replace the capacitors and balancing resistors The balancing resistors are located on the top right of the heat sink 10 Install the nuts fastening the capacitor assembly Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 3 8 Component Test Procedures Test 3 Transistor Modules Q1 Q2 and Q3 are located near the center of the Testing Transistor heat sink Modules Q1 Q2 and Q3 Figure 3 3 Transistor Module Test Important Publication 1336 FORCE 6 11 August 1999 Transistor 2 1 Module 0298 ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may
48. 60V 7 5 20 2 T 6 E8 Schematics 7 30 HP 1336 FORCE Drives CAP BANK DETAILS 230V 575V 15HP 7 5 20HP 460V E5 25 30HP gg Jt tk Ges a E E4 2 C2 Cl AN Ee C2 AN J4 gg E7 J5 J6 5 E6 ALL CAPS ARE CONNECTED TOGETHER BY PCB ARTWORK STANDALONE CONFIGURATION SEE TABLE 1 HH FS CUSTOMER FUSING FUSE AC a VOLTAGE FR FS FT TYPE JJ 7 5 230 35 0 230 45 5 230 70 7 5 10 380 460 20 10 15 380 460 30 15 20 380 460 35 20 25VT 380 460 45 25 30 380 460 60 30 380 460 70 7 5 575 15 0 575 20 5 575 25 20 575 35 Series and D STAND ALONE UNIT BULLETIN 1336 FORCE 200 240 Volt 5 5 11 kW 7 5 15 HP 380 480 Volt 5 5 22 kW 7 5 30 500 600 Volt 5 5 15 kW 7 5 20 HP Publication 1336 FORCE 6 11 August 1999 BR1 AB0753A MOUNTED COMPONENT GDB POWER ARTWORK GDB ARTWORK GDB DISCRETE WIRING SCREW TERMINAL Fee TB7 2 Schematics 7 30 HP 1336 FORCE Drives 10 15 230V 20 H P 575V 6 5 DISCRETE WIRES 20 25 30 H P 380 460V TB1 8
49. B1 Do not attempt to service the drive until the bus voltage had discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components For Electrostatic Discharge Precautions refer to Chapter 2 Disassembly and Access Procedures Part Replacement Procedures 4 7 Important Before you remove connections and wires from the 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 Terminals DC and DC before proceeding 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 Remove the Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Remove the two round head screws fastening the Precharge Module to the heat sink Remove the Precharge Module from the drive Installation 1 2 Clean surfaces between the Precharge Module and the heat sink Replace the Preform between the Precharge Module and the heat sink Install the Precharge Module in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Table 2 A
50. C2E1 E2 Infinite E2 C2E1 0 34 0 6 C1 C2E1 Infinite C2E1 C1 0 34 0 6 B1 E1 Infinite Infinite capacitive B2 E2 Infinite Infinite capacitive NOTE Check the Transistor Module casings and replace if deformed Publication 1336 FORCE 6 11 August 1999 3 10 Component Test Procedures 7 If your readings do not match the table readings replace Transistor Module Q1 Q2 or Q3 Clean all surfaces between the transistor and the heat sink using a soft clean cloth Replace the Preform between the transistor and the heat sink Install the screws fastening the Transistor Module to the heat sink Refer to Chapter 2 Disassembly and Access Procedures Table 2 A Fastener Torque Specifications 8 If a Transistor Module is replaced replace the Precharge Module Refer to Test 4 Testing the Precharge Module You must also test the Gate Driver Power Supply Board Refer to Test 5 Testing the Gate Driver Power Supply Board 9 Replace and secure the Gate Driver Power Supply Board and Control Board Adapter Mounting Plate Publication 1336 FORCE 6 11 August 1999 Test 4 Testing the Module Series A and B Component Test Procedures 3 11 The Precharge Module is located near the bottom of the heat sink If one or more Transistor Modules has been replaced you must replace the Precharge Module Figure 3 4 Important Precharge Module Test Series A and B Precharge Module
51. DO YOU HAVE ANY ADDITIONAL COMMENTS V COMPLETE THE FOLLOWING NAME COMPANY TITLE DEPARTMENT STREET CITY STATE ZIP TELEPHONE FAX AND OR E MAIL FOLD HERE FOLD HERE BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 413 MEQUON WI POSTAGE WILL BE PAID BY ADDRESSEE ALLEN BRADLEY Attn Marketing Communications P O Box 760 Mequon WI 53092 9907 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES SCANport is a trademark of Allen Bradley Company Inc PLC is a registered trademark of Allen Bradley Company Inc 6 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 S m A pue 2 9 i M I 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 e Egypt El Salvador e Finland e France Germany e Greece e Guatemala e Honduras e Hong Kong Hungary Iceland e India e Indonesia e Ireland
52. E 200 240 Volt 5 5 11 kW 7 5 15 HP 380 480 Volt 5 5 22 kW 7 5 30 HP 500 600 Volt 5 5 15 kW 7 5 20 HP 0754 Publication 1336 FORCE 6 11 August 1999 6 6 Schematics 7 30 HP 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE 6 11 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 point where 60 Hz is applied to the induction motor BR Refer to Bridge Rectifier Braking A method of stopping or reducing the time required to stop an AC motor and can be accomplished in several ways 1 DC Injection braking AC drives A method w
53. E Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Remove power from the drive Remove the screws fastening the Enclosure cover to the bottom of the Enclosure frame Pull the bottom of the cover outward to clear the Enclosure frame then lift the cover upward to remove the cover 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 TBS TB6 and 7 on drives using a Standard Adapter Board Remove the customer supplied wiring from the drive Remove the screws from the Enclosure frame top and bottom panels to remove the panels Installation Install the Enclosure in reverse order of removal ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 7 Removing the Control Interface L Option Board MOD L4 L5 or L6 Figure 2 4 Control Interface L Option Board Control Interface L Option Board 0556 Terminal Strip TB3 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 measur
54. ING ENCLOSURE MUST BE SPECIFIED Table P C GT2EN LANGUAGE MODULE MUST BE SPECIFIED 500 600V AC Input Constant Torque Drive Open 00 No Enclosure C007 AN C010 AN C015 AN C020 AN Table P D CONTROL INTERFACE OPTIONAL NEMA Type 1 IP20 General Purpose 007 C010 AA C015 AA C020 AA Language Modules Description English English English French English German English Italian English Japanese English Spanish Option Code EN FR DE IT JP ES Enclosures HUMAN INTERFACE OPTIONAL NEMA Type 4 IP65 Resist Water Dust C007 AF C010 AF C015 AF C020 AF Refer to Table 1 1 for explanation of E rating GM1 COMMUNICATION CARD OPTIONAL NEMA Type 12 IP54 Industrial Use C007 AJ 010 015 020 Refer to the Language Module and Options tables following these Catalog Number tables 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 Refer 101336 FORCE User Manual Preface 7 Table Options Code Description Code Description Human Interface Modules NEMA Type 1 IP20 Communication Options HAB Blank No Functionality GT1EN PLC Communication Adapter English
55. Meter Reading VR2 VR7 F 3 12 E 2 5 NOTE Typical malfunction is shorted in both directions 10 If your readings do not match the table readings replace the Gate Driver Power Supply Board 11 Install the Control Board Adapter Mounting Plate in reverse order of removal Publication 1336 FORCE 6 11 August 1999 3 18 Component Test Procedures This Page Intentionally Left Blank Publication 1336 FORCE 6 11 August 1999 Chapter Objective Part Replacement Overview Safety Precautions Electrostatic Discharge Precautions Chapter 4 Part Replacement Procedures This chapter describes procedures required to replace drive components This chapter references Chapter 2 Disassembly and Access Procedures for basic drive component access The part replacement procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is open For more information on opening the Drive Enclosure refer to Chapter 2 Disassembly and Access Procedures Opening the Drive Enclosure ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between DC and DC on Terminal Block TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Thi
56. Ports 1 11 HIM PamoVal E Ea em C axe 1 12 HIM Operation edad 1 12 Publication 1336 FORCE 6 11 August 1999 ii Table of Contents Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 Graphic Programming 1 18 CUN cio M snes 1 13 Drive 05 1 14 Control Firmware Function 1 14 Chapter 2 Chapter Objectives 2 1 Disassembly and Access Overview 2 1 Electrostatic Discharge Precautions 2 1 ID c ET 2 2 Fastener Torque Specifications 2 2 Torque Sequence 2 2 Two Point Mounting decre 2 2 Four Point 0 2 3 Torque Specifications 2 4 Disassembly and Access Procedures 2 5 Opening the Drive Enclosure 2 5 Removal RR RE Ro RW ice Edda 2 5 Installato 2 6 Removing the Control Interface L Option Board MOD 14 15 6 2 7 Removal eT 2 7 instalation Ee cre Y eat 2 8 Removing the Main Control Board 2 9 Fiemoval
57. 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 11 August 1999 2 12 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 Remove power from the drive Open the Enclosure cover 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 the Standard Adapter Board Disconnect the following from the Standard Adapter Board Stake on ground wire connector All wires from TB5 TB6 and TB7 Remove the Control Interface L Option Board Refer to Removing the Control Interface L Option Board in this chapter Remove the two screws fastening the Standard Adapter Board to the mounting plate Pull the Standard Adapter Board down to release it from the slide mount stand offs and connector J1 Installation Install the Standard Adapter Board in reverse order of removal ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 13 Removing the PLC Comm Adapter Board Figure 2 7 Main Control Board and PLC Comm Adapter Board Main Control Board PLC Comm Connector Adapter Board Slide Mount Stand Off
58. cation Options Adapter 2 or 5 AB0552A Expansion Options Adapters 2 3 4 5 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 i Le SCAN port 2 TB20 Publication 1336 FORCE 6 11 August 1999 1 12 Control Logic Wiring and Adapters Publication 1336 FORCE 6 11 August 1999 HIM Removal ATTENTION Some voltages present behind the drive front cover are at incoming line potential To avoid an electric shock hazard use extreme caution when removing replacing the HIM For handheld operation the module can be removed and located up to 10 meters 33 feet from the drive Important Power must be removed to 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 remove the module 1 Assure that power has been removed or Logic Mask has been set to 0 2 Take the drive front cover off and simply slide the module down and out of its cradle Remove cable from module 3 Connect the appropriate cable between the HIM and the Communications Port Adapter 2 3 4 or 5 4 Reverse the above steps to replace the modu
59. ctifier A solid state uni directional latching switch Service Factor When used on a motor nameplate a number that indicates how much above the nameplate rating a motor can be loaded without causing serious degradation i e a motor with 1 15 5 can produce 15 greater torque than one with 1 0 S F Set Speed The desired operating speed Shock Load The load seen by a clutch brake or motor in a system that transmits high peak loads This type of load is present in crushers separators grinders conveyors winches and cranes 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 Glossary G 11 Speed Range The speed minimum and maximum at which a motor must operate under constant or variable torque load conditions A 50 1 speed range for a motor with top speed 1800 rpm means the motor must operate as low as 36 rpm and still remain within regulation specification Controllers are capable of wider controllable speed ranges than motors because there is no thermal limitation only electrical Controllable speed range of a motor is limited by the ability to deliver 10046 torque below base speed without additional cooling Speed Regulation The numerical measu
60. d to zero volts Publication 1336 FORCE 6 11 August 1999 Disassembly and Access Procedures 2 21 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 cover 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 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 Disconnect the following from the Gate Driver Power Supply Board P13 stake on connector P14 stake on connector Bus Inductor wires on Series A and B Drives from E29 DC Bus Inductor wire E22 DC Bus Inductor wire DC Bus Inductor wires on Series C and D Drives from TBI DC and 1 DC A010 A015 and B020 Drive ratings only 7 1 and TB7 2 A007 B007 B015
61. d 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 DC 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 Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 11 August 1999 1 2 Control Logic Wiring and Adapters Figure 1 1 Terminal Block Locations Standard Adapter Main Control TB10 Encoder Board 11 Standard Adapter Board TB3 Control L Option Board Control Interface L Option Board ee TB5 TB6 TB7 1
62. e 1 4 Local 1 4 R Rating Drive P 7 Related Publications 10 Removal Procedures See Procedures Removal Human Interface Module 1 12 Replacement Part Procedures 4 1 Replacement Parts 5 1 S Safety Precautions 1 Schematics 6 1 Speed Select Input State 1 8 Index 1 3 T TB3 Terminal Designations 1 5 Terminal Block Locations 1 2 Terminal Designations TB3 1 5 Thermistor Illustration 4 8 Installation 4 9 Removal 4 8 Tools Required for Service 2 2 3 2 4 2 Torque Four Point Mounting Sequence 2 3 Maximum for TB Terminals 1 5 Specifications 2 4 Two Point Mounting Sequence 2 2 Transistor Module Illustration 4 10 Installation 4 11 Removal 4 10 Test 3 8 Troubleshooting Component Test Procedures 3 1 True Definition 10 Two Point Mounting 2 2 W Wire Sizes 1 5 Publication 1336 FORCE 6 11 August 1999 Publication 1336 6 11 August 1999 This Page Intentionally Left Blank Notes Publication 1336 FORCE 6 11 August 1999 Publication 1336 FORCE 6 11 August 1999 N 3 Publication 1336 FORCE 6 11 August 1999 Publication 1336 FORCE 6 11 August 1999 N 5 Publication 1336 FORCE 6 11 August 1999 Publication 1336 FORCE 6 11 August 1999 CUT ALONG DOTTED LINE lt We Want Our Manuals to be the Best Ty You can help Our manuals must meet the needs of you the user This is your
63. eath 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 Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Component Test Procedures 3 17 1 Remove power from the drive 2 Check for zero volts at TB1 terminals DC and DC before proceeding 3 Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board TBS TB6 and 7 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 Unplug the connectors from the Gate Driver Power Supply Board 6 Set your meter to test resistance 7 Check Fuse F1 located on the lower left side of the Gate Driver Power Supply Board for continuity Replace the fuse if it shows an open condition 8 Set your meter to test diodes 9 Test VR2 through VR7 The following table shows meter connections at the components and ideal meter readings for those connections Refer to the previous illustration for meter connection locations Table 3 H Gate Driver Board Test Component Meter Lead Meter Lead Nominal
64. ectrostatic Discharge Precautions at the beginning of this chapter Part Replacement Procedures 4 11 Important Before you remove connections and wires from the 5 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 Terminals and DC Check for the absence of control voltage at TB20 and 21 on drives using a PLC Comm Adapter Board TBS TB6 and TB7 on drives using a Standard Adapter Board Remove the Gate Driver Power Supply Board from the drive Refer to Chapter 2 Removing the Gate Driver Power Supply Board Remove all wires connected to the transistor module terminals Remove the screws fastening the transistor to the heat sink Installation 1 Clean all surfaces between the transistor and the heat sink using a soft clean cloth Replace the Preform between the transistor and the heat sink Install the transistor modules in reverse order of removal Fasten the mounting screws Refer to Chapter 2 Disassembly and Access procedures Table 2 A Fastener Torque Specifications Fasten the terminal screws Refer to Chapter 2 Disassembly and Access procedures Table 2 A Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace
65. eing 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 Figure 1 3 Jumper Locations Standard Adapter Board Standard ao Jumper J10 Adapter Board oo 5 9 located on Standard Adapter Board ng TB5 TB6 TB7 AB0549B Publication 1336 FORCE 6 11 August 1999 1 4 Control Logic Wiring and Adapters Available Inputs A variety of combinations made up of the following inputs are avallable 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 5 Programming the Input Mode parameter to one of the Input Mode numbers listed selects that combination of input functions Important Input Mode parameter can be changed at any time however programming changes will not take effect until power has been cycled to the drive When changing an input mode it is important to note that the corresponding inputs to TB3 may also change The programming options of the Control Interface Option allow the user to select an input combination
66. es 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 15046 of rated full load current for one minute for standard industrial DC motors 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 Glossary G 9 Pot A potentiometer or variable resistor Power Work done per unit of time Measured in horsepower hp or watts W 1 hp 33 000 ft Ib min 746 W Power Factor Displacement A measurement of the time phase difference between the fundamental voltage and fundamental current in an AC circu
67. 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 TB7 on drives using a Standard Adapter Board Remove the Control Board Adapter Mounting Plate Refer to Chapter 2 Removing the Control Board Adapter Mounting Plate Remove the inductor wires from Gate Driver Power Supply Board terminals and E26 Remove the nut fastening the inductor bracket to the chassis Remove the inductor bracket by swinging it to the side Remove the inductor from the drive Installation 1 2 Lower the inductor into the Main Chassis aligning the hole in the bottom inductor bracket with the peg on the chassis Install DC Bus Inductor L1 in reverse order of removal Publication 1336 FORCE 6 11 August 1999 4 18 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury DC Bus Inductor Series C and D DC Bus Inductor is located on the lower left hand corner of the Main Chassis Figure 4 9 DC Bus Inductor and Gate Driver Power Supply Board A010 A015 B020 B030 and C020 Drives Inductor 0 TB1 DC To TB1 DC DC to Gate Driver Board E22 Pd DC to Gate Driver Board E29 0645 Part Replacement Procedure
68. g a PLC Comm Adapter Board TBS TB6 and 7 on drives using a Standard Adapter Board Remove the Gate Driver Power Supply Board from the drive Refer to Chapter 2 Removing the Gate Driver Power Supply Board Remove the two screws fastening the bridge rectifier to the heat sink Remove the rectifier from the heat sink Installation 1 Clean all surfaces between Bridge Rectifier BR1 and the heat sink using a soft clean cloth Replace the Preform between the rectifier and the heat sink Install the rectifier in reverse order of removal Fasten the mounting screws Refer to Chapter 2 Disassembly and Access Procedrues Table 2 A Fastener Torque Specifications Fasten the terminal screws Refer to Chapter 2 Disassembly and Access Procedrues Table 2 A Fastener Torque Specifications ATTENTION Replace all guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 4 14 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 Fan The Fan is located behind and to the bottom of the heat sink Figure 4 7 Fan Fan a Fan Guard Qw Removal Important Part Replacement Procedures 4 15 ATTENTION Disconnect and lock out power from the dri
69. g the Precharge Module Series C and D 3 13 Test 6 Testing the Gate Driver Power Supply Board 3 16 Chapter 4 Chapter Objective 4 1 Part Replacement Overview 4 1 Safety FIGCQUBONS 522 4 1 Electrostatic Discharge Precautions 4 1 I 4 2 Major Component Replacement 4 2 Detailed Product 4 2 Precharge Module Series 4 4 Removal Haase kad 4 4 4 5 Precharge Module Series C and D 4 6 4 6 4 7 Thi amp rmistor 4 8 Removal ques eae ER ed 4 8 Istallati r 22222 n 4 9 Transistor Modules 4 10 4 10 4 11 Bridge Rectifier 1_ 4 12 as 4 12 Installation IIR 4 13 uM 4 14 REMOVAL x au MO des 4 15 installation EU 4 15 DC Bus Inductor Series 4 16 REMOVA 5 4 17 Publication 1336 FORCE 6 11 August 1999
70. guards and insulators before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 9 Removing the Main Control Board Figure 2 5 Main Control Board and Mounting Plate PLC Comm Adapter Board or Standard Adapter Board Removal HIM Standard Adapter Board only Connector J1 Connector J1 Connector 10 2 p Main Control Connector J7 AB0563B 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 Publication 1336 FORCE 6 11 August 1999 2 10 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 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 Dri
71. guards may result in death or serious injury Publication 1336 FORCE 6 11 August 1999 4 12 Part Replacement Procedures Publication 1336 FORCE 6 11 August 1999 Bridge Rectifier BR1 Bridge Rectifier BRI is located at the bottom of the heat sink Figure 4 6 Bridge Rectifier BR1 Removal Positive Negative Bridge Rectifier 0304 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 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Part Replacement Procedures 4 13 Important Before you remove connections and wires from the 6 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at TB1 Terminals and DC Check for the absence of control voltage at TB20 and 21 on drives usin
72. hich 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 2046 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 Publication 1336 FORCE 6 11 August 1999 G 2 Glossary Publication 1336 FORCE 6 11 August 1999 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 4 Motor mounted or separately mounted brake A positive action mechanical friction device Normal configuration is such that when the power is removed the brake is set This can be used as a holding brake Note A separately mounted brake is not one which is located on some part of the mechanical drive train other that the motor Breakaway Torque The torque required to start a
73. ing 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 11 August 1999 2 8 Disassembly and Access Procedures Publication 1336 FORCE 6 11 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 cover if the drive has an enclosure 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 TB5 TB6 and TB7 on the Standard Adapter Board Remove all wires from the terminals on TB3 Loosen the two captive screws fastening the Control Interface L Option Board to the Standard Adapter Board Grip the right and left sides of the Control Interface L Option Board and pull the board straight outward from the Standard Adapter Board Installation Install the Control Interface L Option Board in reverse order of removal ATTENTION Replace all
74. it It represents the cosine of the phase angle difference Fp cos p 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 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
75. jury Disassembly and Access Procedures 2 15 Removing the Control Board Adapter Mounting Plate Figure 2 8 Control Board Mounting Plate Top corners of Control Board Adapter Mounting Plate hook into Main Chassis N Connector J1 Connector V TB10 J5 uw Main Control Board HIM Standard Adapter Board only Board gE Mounting Plate Ng Screw PLC Comm Adapter Board Nx Connector J5 Connector J7 0557 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 11 August 1999 2 16 Disassembly and Access Procedures Publication 1336 FORCE 6 11 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 Enc
76. le 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 the drive name ID and communication status Upon completion the Status Display refer to 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 For HIM operation refer to the 1336 FORCE Field Oriented Control User Manual Graphic Programming Terminal Control Logic Wiring and Adapters 1 13 Figure 1 10 Status Display Stopped 0 00 2 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 PRESET A PRESET 5 XREF 1 4 PRESET 1 PRESET 2 3 ESC J 0 um x JOG 0554 Publication 1336 6 11 Augus
77. losure cover 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 5 TB6 and TB7 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 wires and connectors from the Main Control Baord Loosen the two captive screws near the bottom of the Control Board Adapter Mounting Plate Pull the Control Board Adapter Mounting Plate out about two inches then slide it downward Installation Install the Control Board Adapter Mounting Plate in reverse order of removal ATTENTION Replace all guards and insulators 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 Gate Driver Power Supply Board Series and Figure 2 9 Removal Important Gate Driver Power Supply Board AB0314C 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
78. lt 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 2 Phillips screwdriver 5 16 inch or 8mm socket Torque wrench metered in lb in or N m Component Test Procedures 3 3 Test 1 Bridge Rectifier BR1 is located on the bottom right of the heat sink Testing Bridge Rectifier BR1 Figure 3 1 Bridge Rectifier Test Positive Bridge Rectifier Negative A X 0 0297 ATTENTION Disconnect and lock power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verif
79. 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 voltage Glossary G 3 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
80. male connectors are at the ends of wires or ribbon cables and plug into male connectors Preface P 9 Default When drive function defaults it automatically changes to pre programmed setting Enable Input The Enable Input is a terminal connection on the Control Interface L Option 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 L Option Board Jumper A jumper completes a circuit between two pins within a male connector on a drive board In the absence of certain optional equipment using female connectors jumpers are applied to certain pins within a male connector to complete specific and necessary circuits Control Interface L Option Board A Control Interface Board plugs into connectors J7 and J9 located on the lower portion of the Standard Adapter Board This board is identified as L4 L5 or L6 and provides optional control wiring configurations for a drive Parameter Parameters are programmable drive functions that define various operating functions or status displays of a drive Refer to Bulletin 1336 FORCE Adjustable Frequency AC Drive User Manual for Parameter details Publication 1336 FORCE 6 11 August 1999
81. move power from the drive 2 Check for zero volts at TB1 terminals DC and DC Publication 1336 FORCE 6 11 August 1999 3 6 Component Test Procedures 3 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 4 Inspect the capacitors for deformation discoloration or other indications of high temperature and replace if damaged Otherwise go to Step 5 5 Set your meter to test voltage 6 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 previous illustration for TB1 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 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment 7 Apply power AFTER the meter is connected otherwise your meter will read zero volts Expand readings for all input voltage ratings Table 3 B Bus Capacitor Group Test Drive Rating Input Volts Meter Reading 200 282V DC 5 A 230 325V DC 5 240 339V DC 5 380 537V DC 5 B 415 586V DC 5 480 478V DC 5 500 707V DC 5 C 575 813V DC
82. nance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the drive Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Preface P 3 1336 FORCE Product Identification Drive Nameplate Location The drive nameplate is located on the face of the Motor 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
83. ne logic level in order to provide isolated contact signals in a circuit operating at a different logic level Glossary G 7 Inverter 1 An AC adjustable frequency drive 2 A particular section of an AC drive This section uses the DC voltage from a previous circuit stage intermediate DC circuit to produce a pulse width modulated or stepped AC current or voltage waveform that has characteristics similar to the desired sine wave frequency 3 A circuit whose output signal is the inverse of its input a positive going pulse is inverted to a negative going pulse and vise versa ISO Refer to International Organization for Standards Isolation Transformer 1 A transformer that provides DC isolation from other equipment not connected to that transformer secondary 2 A transformer that provides noise isolation between the primary and secondary by such means as a Faraday shield Jogging 1 In numerical control system an operator manually generating motion continuously or incrementally by closing a switch 2 An operator generating motion by closing a switch Kinetic Energy The energy of motion of a moving body LAD Refer to Linear Acceleration Deceleration LEM A hall effect current transducer that senses drive output current and generates a signal for the control logic Linear Acceleration Deceleration LAD A circuit that controls the rate at which a motor is allowed to accelerate to a set speed or decelerate
84. o help differentiate parameter names and display text from other text in this manual the following conventions will be used Parameter Names will appear in brackets Display Text will appear in quotes The following is a list of conventions used throughout this manual and definitions of the conventions For a list of terminology and definitions refer to the Glossary in the back of this manual Auxiliary Input The Auxiliary Input is a terminal connection on the Control Interface L Option Board This connection provides an external input for use as an Auxiliary Interlock Unless this interlock is closed the drive will be faulted with an Auxiliary Fault Auxiliary Interlock The Auxiliary Interlock is a user supplied circuit consisting of reset overload or other interlocking circuitry The Interlock is wired to the drive Auxiliary input Bit A bit is a single character or status point used in programmable logic Eight bits form a BYTE 16 bits form a word Drive parameters are actually eight bits or 16 bit words Check To check means to examine either the physical condition of something or the setting of some control such as a Parameter Checking a drive board or component may also require measurements and tests Connector A connector connects one drive board to another Connectors come in two designs male and female Male connectors are stationary and contain pins which are sometimes joined by jumpers Fe
85. ommunication Ports Publication 1336 FORCE 6 11 August 1999 Human Interface Module When the drive mounted HIM is supplied it will be connected as Port 1 refer to Figure 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 P Display Panel Control Panel Human Interface Module HIM AB0268B Control Logic Wiring and Adapters 1 11 Standard Adapter Ports Figure 1 8 Standard Adapter Board Port Locations 5 5 22 kW 7 5 30 HP TB10 Encoder Internal Communication Adapter Port 6 Drive Mounted HIM Adapter Port 1 ae Option Boar TB5 TB6 BEN TB3 Adapter Port 0 Communications Port for Remote Communi
86. or mechanical system Transistor An active solid state semiconductor device Work A force moving an object over a distance work force x distance Publication 1336 FORCE 6 11 August 1999 G 12 Glossary This Page Intentionally Left Blank Publication 1336 FORCE 6 11 August 1999 Adapter Locations 1 11 Adapters and Communication Ports Human Interface Module 1 10 Audience for this Manual 1 Auxiliary Input Definition 8 Auxiliary Interlock Definition P 8 Bit Definition P 8 Bridge Rectifier Illustration 4 12 Installation 4 13 Removal 4 12 Bus Capacitor Illustration 4 21 Installation 4 22 Removal 4 21 C Check Definition P 8 Component Test Procedures 3 1 Connector Definition P 8 Control Interface L Option Board Definition P 9 Illustration 2 7 Installation 2 8 Jumper Locations 1 3 Removal 2 7 Control Interface Option 1 3 Control Logic Wiring 1 1 Conventions in this Manual P 8 D DC Bus Inductor Illustration 4 16 Installation 4 17 Removal 4 17 DC Bus Inductor Series C Illustration 4 18 Installation 4 20 Removal 4 19 Default Definition 9 Index Drive Enclosure Type 7 Identification P 4 Illustration 4 3 Nameplate Location 3 Rating P 7 Drive Enclosure Illustration 2 5 Installation 2 6 Removal 2 5 E Electrostatic Discharge 2 Enable Input Definition P 9 Enclosure Type P 7 ESD 2 F
87. rd Run Direction not compatible with HIM or Communication Options Reverse 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 Ib in Figure 1 4 TB3 Terminal Designations 19 20 21 22 23 24 25 26 27 29 30 co N 2 2 O 5 a6 E amp Ea sgsasts eo 15 0550 e E C Publication 1336 FORCE 6 11 August 1999 o Control Logic Wiring and Adapters o Momentary Maintained ATTENTION The JOG function will not operate properly unless a SCANport option is connected to the PLUS with Language Module 1336S EN firmware FRN 1201 HAP 1201 HA1 1201 HA2 1336 GM1 Applies 1 05 or earlier drive To assure proper JOG function install at least one to 1305 with firmware FRN 2 01 or earlier and 1336 of the following Publication 1336 FORCE 6 11 August 1999 User Connections User Connections Figure 1 5 Input Mode Selection and Typical TB3 Connections Input Mode 1 Factory Default Status Stop Fault Reset Common Status Note If this mode is selected the status of all inputs can be read at the Input Status parameter Status However only Stop Fault Reset and Enable will have control function
88. re 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 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
89. rocedures The following illustration and table show you parts part names 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 11 August 1999 Replacement Parts List 5 2 Replacement Parts Listing Parts for A007 A015 B007 B030 and C007 C020 Drives Figure 5 1 Publication 1336 FORCE 6 11 August 1999 Replacement Parts List 5 3
90. s 4 19 Figure 4 10 DC Bus Inductor and Gate Driver Power Supply Board A007 B007 015 and C007 C015 Drives Inductor DC to Gate Bracket Driver Board E22 p d DC to Gate Driver Board E29 0646 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 1 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 PLUS Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Publication 1336 FORCE 6 11 August 1999 4 20 Part Replacement Procedures Remove power from the drive Check for zero volts at TB1 Terminals DC and DC before proceeding 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 Control Board Adapter Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Control Board Adapter Mounting Plate Remove the DC Bus Inductor wires from DC and DC TB7 1 and TB7 2 on A007 B007
91. s assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Allen Bradley Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 11 August 1999 4 2 Part Replacement Procedures Major Component Replacement Detailed Product Identification Publication 1336 FORCE 6 11 August 1999 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 2 Phillips screwdriver e 5 16 inch or 8mm socket Torque wrench metered in lb in or N m This section explains in detail how to replace the following drive components Precharge Module
92. t 1999 1 14 Control Logic Wiring and Adapters Drive Tools Control Firmware Function Publication 1336 FORCE 6 11 August 1999 Drive Tools software is a Windows 3 1 compatible family of application programs allowing the user to perform programming monitoring and diagnostic operations on Allen Bradley AC and DC digital drive products The software consists of five Windows applications For operation refer to the Product Data Drive Tools Software manual control functions in the 1336 FORCE are performed through the use of parameters that can be changed with a programming terminal or Drive Tools Refer to an overview Block Diagram of the Control Firmware Function in the 1336 FORCE Field Oriented Control User Manual Feedback information is derived from hardware devices as part of the process equipment used Analog signals are converted to digital signals for use by the drive Control signals may be provided to the drive by one of two Adapter Boards setup and operation information used by the drive is stored in a system parameter table Every parameter including Setup and Configuration parameters Sources and Sinks has an entry in the parameter table For example parameter 101 is named the Velocity Reference 1 HI whole parameter and contains a number value representing the velocity reference The velocity reference can originate from an external control device such as a potentiometer connected to the analog inpu
93. t of an Adapter board or a signal coming in via RIO from a PLC Refer to the 1336 FORCE User Manual Publication 1336 FORCE 5 12 Chapter Objectives Disassembly and Access Overview Electrostatic Discharge Precautions Chapter 2 Disassembly and Access Procedures This chapter describes general disassembly procedures required to access internal drive components ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between DC and DC on Terminal Block Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control
94. tail 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 TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 11 August 1999 2 Preface Electrostatic Discharge Precautions Publication 1336 FORCE 6 11 August 1999 ATTENTION Potentially fatal voltages may result from improper usage of oscilloscope and other test equipment The oscilloscope chassis may be at a potentially fatal voltage if not properly 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 mainte
95. tches 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 TB1 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment Publication 1336 FORCE 6 11 August 1999 3 2 Component Test Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 11 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 resu
96. tifier and the heat sink using a soft clean cloth Replace the Preform between the rectifier and the chassis Apply 25 31 Ib in or 2 8 3 5 N m torque to the mounting screws If the rectifier shorted check Transistor Modules for possible damage for an open shorted condition Replace and secure the Gate Driver Power Supply Board and Control Board Adapter Mounting Plate Test 2 Testing the Bus Capacitors Component Test Procedures 3 5 The Bus Capacitors are located on the left side of the Main Chassis Figure 3 2 Bus Capacitor Test Important uv 107 Terminal Block TB1 numm 407 S 9 ec Positive Negative 4 DC DC AB0758A 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 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 Re
97. to overcome the inertia of the machine The torque required by a machine may not be constant after the machine has started to turn This load type is characteristic of fans centrifugal pumps and certain machine tools PWM Pulse width Modulation technique used to eliminate or reduce unwanted harmonic frequencies when inverting DC voltage to sine wave AC Publication 1336 FORCE 6 11 August 1999 G 10 Glossary Publication 1336 FORCE 6 11 August 1999 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 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 Re
98. urrent 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 WK2 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 ft2 Insulated Gate Bipolar Transistor IGBT A type of transistor commonly used in drive control devices Integral Horsepower Motor A motor that has a continuous rating of 1 hp or more built into a frame International Organization for Standards ISO An organization established to promote development of international standards Interposing Relay An interposing relay is a relay that accepts control signals of o
99. ve Open the Enclosure cover 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 5 TB6 and 7 on drives using a Standard Adapter Board Disconnect the following from the Main Control Board J5 ribbon cable connector Stake on ground wire connector All wires from TB10 Jl connector Remove the screws fastening the Main Control Board to the Mounting Plate Lift the Main Control Board upward to release it from the slide mount stand offs and connector J7 Pull the Main Control Board away from the Mounting Plate Installation Install the Main Control Board in reverse order of removal ATTENTION Replace all guards and insulators 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 Standard Adapter Board Figure 2 6 Main Control Board and Standard Adapter Board Main Control Board Mounting Connector J1 Screw Slide Mount Stand Off Standard Adapter Board 0559 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
100. ve 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 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 TBS TB6 and TB7 on drives using a Standard Adapter Board 4 Remove the wire connectors from the terminals on the Fan 5 Remove the four round head screws fastening the top and bottom of the Fan guard to the heat sink 6 Pull the Fan guard and Fan away from the heat sink Installation Install the Fan in reverse order of removal Important When fastening the Fan to the cover plate position the air flow arrow located on the top of the fan near the connectors so it points to the top of the drive Position the Fan connectors
101. ve connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Publication 1336 FORCE 6 11 August 1999 3 14 Component Test Procedures Remove power from the drive Check for zero volts at TB1 Terminals DC and DC before proceeding 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 Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Series C and D Set your meter to test diodes Test the module The following table shows meter connections at the module and ideal meter readings for those connections Refer to the previous illustration for meter connection locations Table 3 F Precharge Module Diode Test 7 Publication 1336 FORCE 6 11 August 1999 Meter Lead Meter Lead Nominal Meter Reading 1 3 Infinite 0 42 Infinite Infinite Infinite Infinite 3 1 2 2 3 Set your meter to test resistance Component Test Procedures 3 15 8 Test the module The following table shows meter connections at the module and ideal meter readings for those connections Refer to the previous illustration for meter connection locations
102. wo screws Temporary torque is 1 3 33 of final torque The numeric illustration labels are for your assistance Drive components do not carry these labels Disassembly and Access Procedures 2 3 Figure 2 1 Two Point Mounting 0 Two Point Mounting po Temporary Tighten Final Tighten ABOO16A Four Point Mounting The following illustrates temporary and final tightening sequences for components fastened to a heat sink using four screws Temporary torque is 1 3 33 of final torque The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 2 2 Four Point Mounting Four Point Mounting Temporary Tighten O Gu O O Final Tighten AB0017A Publication 1336 FORCE 6 11 August 1999 2 4 Disassembly and Access Procedures Publication 1336 FORCE 6 11 August 1999 Torque Specifications The following table lists fastener locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point and four point components to the heat sink Table 2 A Fastener Torque Specifications Component Fastener Torque Torque Application Ib in N m Bus Capacitor Ass y Ass y to chassis 22 30 25 34 Gate Driver Board Driver board to capacitors 22 30 25 34 Gate Driver Board Driver board to inductor 2
103. y 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 TBS TB6 and 7 on drives using a Standard Adapter Board Publication 1336 FORCE 6 11 August 1999 3 4 Component Test Procedures Remove the Gate Driver Power Supply Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Power Supply Board Set your meter to test diodes The following table shows meter connections and ideal meter readings for those connections Refer to the previous illustration for meter connection locations Table 3 A Bridge Rectifier BR1 Test Meter Lead Meter Lead Nominal Meter Reading 0 43 0 43 0 43 Infinite Infinite Infinite 0 43 0 43 0 43 Infinite Infinite Infinite C cx 7 Replace if any readings not as shown above Publication 1336 FORCE 6 11 August 1999 Clean all surfaces between the rec

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