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Service Manual, 1336 FORCE, Adjustable Frequency AC Drive

1. AB0564A Figure 2 2 PLC Comm Adapter Terminal Block Locations Main Control TB10 Encoder Board x PLC Comm Board Communication Channels TB20 TB21 Tris TB1 Power Control and Terminal Block Signal Wiring ABOS65C Publication 1336 FORCE 6 16 August 1999 Control Interface Option Control Logic Wiring and Adapters 1 3 ATTENTION The National Electrical Code NEC and local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage The Control Interface L Option Board provides a means of interfacing various signals and commands to the 1336 FORCE by using contact closures Six different versions of the option are available L4 Contact Closure Interface L4E Contact Closure Interface with Encoder Feedback Inputs L5 24V AC DC Interface L5E 24V AC DC Interface with Encoder Feedback Inputs L6 115V AC Interface L6E 115V AC Interface with Encoder Feedback Inputs 1 Uses internal 5V DC supply The user inputs a
2. 0005 3 3 Test 2 Testing the Precharge Board 0005 3 6 Test 3 Testing the Power Modules 0 00005 3 8 Test 4 Testing the Bus Capacitors 00 00 eee 3 12 Test 5 Testing the Input Rectifiers 0 00 ea ue 3 15 Chapter 4 Chapter Objective ics rx n n sue es 4 1 Safety Precautions essi soertar tnni te peen OER 4 1 Electrostatic Discharge Precautions 0 0005 4 1 Inc 4 2 Major Component Replacement 000 cece ee eae 4 2 Detailed Product Identification 0 0 0 cc eee ee 4 3 Bus Capacitor Bank 222 ssceuxe cue obese s hades veka sees 4 4 Removal xc reeestlctuthrodhencr coe ENS HEU 4 5 Irstallatiors co ese rerenueetenexerk me rnerEwentus 4 7 Thermistor 0 ccc RII 4 8 acu s dirsas ae a a E O EE E EES 4 8 Installation anae a AE GY 4 9 Power Modules is mcn eese erbe ia a a 4 10 RemoVval ose ese rx Exe ru EE 4 10 NST ATP scs eccesso dae eerie ears 4 12 Bus FUSES F1 oiii ure deserve ces eA dass ees 4 13 Removal 4 ice 2 retro a Le os eae eye aes 4 13 Installation oe eee eR ie he ese al ee 4 14 LI Plo 4 15 Removal occ scatman e rere HERE EMT 4 15 Iristallatigni eeu ict ae he ee de Mee eee ne EE E 4 16 Ground Fault GT ios svezec ee Rer RR ER 4 17 Removal veste EMO DeEd re S RS aon ae 4 17 Instalation llle RR 4 19 Input Rectifiers od exon RR QRee Ax RR Ea orm E A 4 20 Remova asni era itte te
3. A DC Brake P K DC Brake ig E AK AC Input o AB0802A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 16 August 1999 3 16 Component Test Procedures 1 Remove power from the drive 2 Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board TB3 on drives using a Control Interface L Option Board 4 Check for absence of control voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board 5 Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform 6 Remove the Input Rectifier Snubber Board
4. T 3 BRRR Disassembly and Access Procedures Removing the Main Control Board Figure 3 7 Main Control Board Slide Mount Stand Off HIM Standard Adapter Board only i d a FON gt T ins KNE NY S E i TB7 Mounting TB6 Plate TB5 Connector J7 Standard Adapter Board Main Control Mounting Screw AB0827A Disassembly and Access Procedures 2 13 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 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 e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at
5. Have previous experience with and basic understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions This manual describes equipment and disassembly procedures You begin with general illustrations and end with greater detail concerning replacement parts and part locations on the drives Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 P 2 Preface Electrostatic Discharge Precautions Publication 1336 FORCE 6 16 August 1999 ATTENTION Potentially fatal voltages may result from improper usage of oscilloscope and other test equip ment The oscilloscope chassis may be at a potentially fa tal voltage if not properly grounded If an oscilloscope is used to measure high voltage waveforms use only a dual channel oscilloscope in the differential mode with X 100 probes It is recommended t
6. 1 12 Control Logic Wiring and Adapters Standard Adapter Ports Figure 2 8 Standard Adapter Board Port Locations Main TB10 E Control E Pr di VISUM Board 5 re e TB11 Standard a Adapter Board T Drive Mounted HIM Adapter Port 1 Internal Communication Control Interface N Adapter Port 6 L Option Board ML CHEER KW Scanport 1 7 Scanport 2 Communications TB5 TB6 TB7 TB3 Control Port Remote Control and L Option Board HIM or PMT Signal Wiring Door Mounted HIM NEMA Type1 ABO767A PLC Comm Adapter Ports Figure 2 9 PLC Comm Adapter Board Port Locations Main Control TB10 Board B gt Encoder eis Communications Channels Ports 6 7 PLC Comm Board SCAN port 1 le SCAN port 2 TB20 AB0768A Publication 1336 FORCE 6 16 August 1999 Control Logic Wiring and Adapters 1 13 HIM Removal ATTENTION Some voltages present behind the drive front cover are at incoming line potential To avoid
7. OUTPUT wm POWER CT2 PE 4000 1 GATE INTERFACE q C Ck 4 un A23 4G Gc R22 BE Ek 74103 281 AB0814A Publication 1336 FORCE 6 16 August 1999 Note 1 The Input Line Fuses for this product are supplied in the unit as follows HORSEPOWER 380 460VAC FUSE CURRENT TYPE FUSE INFORMATION RATING TYPE P N 250 450A A70QS 25178 315 18 300 500A A70QS 25178 315 19 350 600A A70QS 25178 315 20 400 600A A70QS 25178 315 20 450 700A A70QS 25178 315 21 Note2 The Inv erter Bus Fuse for this product is as follows HORSEPOWER 380 460VAC FUSE CURRENT TYPE FUSE INFORMATION RATING CATALOG P N ALL 2x450A A65C450 4AB 25178 254 01 Schematics 250 450 HP 1336 FORCE Drives Note 3 The following is a listing of all printed circuit assemblies versus fuse and documentation information FUSE INFORMATION SCHEMATIC ITEM B M DIAGRAM DESIGNATOR RATING TYPE P N FA 1 04 600V KTK R 1 25172 260 08 B AIOS AA a F3 1 5A 600V KTK R 1 5 25172 260 09 A10 74101 181 51 74101 179 F1 F3 1 5A 600V KTK R 1 5 25172 260 09 A11 13 74103 867 51 74103 866 NONE A20 22 74103 784 51 74103 783 NONE A23 28 74103 845 51 74103 844 NONE Note 5 The Output Terminal Block TB9 is only available on F Frame drives This termi nal block provides a three phase high voltage connection from the load s
8. Remove the six bolts fastening the three Output Bus Bars to the Power Module Assembly and TB1 Remove the Power Module Snubber Boards Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Publication 1336 FORCE 6 16 August 1999 4 12 Part Replacement Procedures 8 Remove the bolts fastening the Power Module Bus Bar to the Bus Capacitor Bank 9 Remove the eight screws fastening the Snubber Standoffs to the Power Module Bus Bar Remove the standoffs 10 Slide the Power Module Bus Bar to the right and remove the bus bar from the drive 11 Remove the three screws fastening the Power Module Interface Board to the Power Module 12 Remove the six screws fastening the Power Module to the heat sink 13 Pull the Power Module away from the heat sink Installation 1 Clean all surfaces between the Power Module and the heat sink using a soft clean cloth 2 Replace the Preform between the Power Module and the heat sink 3 Install the Power Module in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Important Remove the copper shorting strip from the Power Module before replacing the Power Module Interface Board ATTENTION Do not substitute longer or shorter hardware when fastening the Power Module components to the Power Modules Use the same size fastener to fasten the components as was originally us
9. ATTENTION If you mount the inductor remotely verify the connections between the Bus Inductor the Input Rectifier Bus Bars and the DC Brake Terminals L1 of inductor should connect to the Input Rectifier Bus Bar L2 to the DC Brake Terminal L3 to the DC Brake Terminal and L4 to the Input Rectifier Bus Bar Refer to Chapter 3 Component Test Procedures Test 5 Testing the Input Rectifiers ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Chapter Objectives Ordering Replacement Parts Chapter 5 Replacement Parts List This chapter illustrates and lists replacement parts for the 1336 FORCE Drives rated BP300 BP450 and describes replacement parts ordering procedures The following illustration and table show you parts part names part numbers locations and chapters for replacement procedures For your convenience the Rockwell Automation Drives Division and the Rockwell Automation Support Division provide efficient and convenient repair and exchange for eligible equipment A product service report number is required to return any equipment for repair Your local Rockwell Automation distributor or area sales and support office can provide you with a product service report number You should return equipment to be repaired to the area sales and support center nearest you Reference the product service report number on th
10. Important Before you remove connections and wires from the 7 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Disconnect the following from the Precharge Board J connector e J2 connector J3 connector J4 connector Pull the Precharge High Voltage Guard away from the four nylon spacers Turn the six standoff screws fastening the Precharge Board to the mounting plate 1 4 turn counterclockwise Pull the Precharge Board away from the mounting plate Installation Install the Precharge Board in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to repla
11. wy Allen Bradley 1336 FORCE Adjustable Frequency AC Drive BP300 BP450 Service Manual Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or in part without written permission of Rockwell Automation is prohibited Through
12. 1999 Supersedes March 1998 PN 184163 A Copyright 1998 Allen Bradley Company Inc a Rockwell International Company Printed in USA
13. Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 16 August 1999 2 2 Disassembly and Access Procedures Fastener Torque Specifications Publication 1336 FORCE 6 16 August 1999 Electrostatic discharge generated by static electricity can damage t
14. and V on TB11 on the Main Control Board TB20 and TB21 on the PLC Comm Adapter Board Disconnect the following from the PLC Comm Adapter Board All wires from TB20 and TB21 by separating the mated connectors with wires from the adapter board Stake on ground wire connector J5 connector J7 connector Communication channel A and B connectors Remove the screws fastening the PLC Comm Adapter Board to the Control Board Adapter Mounting Plate Pull the PLC Comm Adapter Board down to release it from the slide mount stand offs and connector J1 Installation Install the PLC Comm Adapter Board in reverse order of removal ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 19 Removing the Control Board Adapter Mounting Plate Figure 3 10 Control Board Adapter Mounting Plate Control Board Adapter Ground Mounting Plate Stud ae Main Control Board PLCC EN omm Se N TB10 Connector J1 Adapter Board p HIM Standard 5 EC Connector J5 Adapter Board only A gt A s 7 Connector J7 gt DEORE Connector J1 S TB21 E 2 Tr M ae Standard Adapter Board TB20 E E i e ant Terminal Strip TE l EP s E E TB5 tge 187 Terminal E E Strip TB3 S SN Q f AB0828A R
15. e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board 4 Remove all wires from terminal strip TB3 if a Control Interface Board is used 5 Disconnect the following from the Main Control Board J1 connector J2 ribbon cable connector J6 connector J8 connector 8 pin connector from HIM Mounting Plate Ground wire at stake on connector J10 All wires from terminals on TB2 Publication 1336 FORCE 6 16 August 1999 2 14 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 6 Remove the five screws fastening the Main Control Board to the mounting plate 7 Slide the Main Control Board toward the top of the drive to release it from the slide mount stand offs 8 Lift the Main Control Board away from the mounting plate Installation Install the Main Control Board in reverse order of removal ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 15 Removing the Standard Adapter Board Figure 3 8 Main Control Board and Standard Adapter Board Control Board Adapter Mounting Plate X Lay Main Co
16. gt K AB0826A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 2 10 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board 4 Disconnect both ground wires from TBS located in the lower right hand corner of the the Main Control Boar
17. 14 Stop 1st 2nd Type Accel Speed 1st 2nd 1 Select 3 Decel 1 See Table 2 B 2 Drive must be stopped to take Local Control Control by all other adapters is disabled except Stop 15 Digital Pot Up Digital Pot Dn 16 Local Control Stop Type 23 Proc Trim Reset 24 Flux En Reset 3 These inputs must be present before drive will start 4 Bit 0 of Direction Mask must 1 to allow operation 5 For Common Bus Precharge Enable 21 Rev Fwd Ramp Dis Reset 25 Proc Trim Ramp Dis 9910 Spd Tq3 Spd Tq2 Spd Tq1 Spd Sel 2 26 Jog Speed Sel 3 6 Bit 12 of Para 59 Logic Options must 0 reverse direction control 7 Soft Fault Reset Only Must cycle power to drive to clear Hard Fault see Troubleshooting 8 Refer to Para 59 to configure Start amp Stop type 9 Can be masked out 10 Parameter 53 Spd Tq Mode Sel becomes read only AB0291B Control Logic Wiring and Adapters 1 9 The following table defines the input state of the Speed Select inputs for a desired frequency source Table 2 B Speed Select Input State vs Velocity Reference Source Speed Select 3 Speed Select 2 Speed Select 1 Velocity Reference Source T3 Temina26 Terminal27 Terminal28 Interface Option MOD L4 L5 L6 O O O Ext Ref 1 Para 101 Oo O X Preset Speed Ref 1 P 119 O X O Preset Speed Ref 2 P120 O X X Preset Speed
18. 4 25 9 Pull the TB1 shield away from the drive 10 Remove the four screws fastening the LEM Interface Board to the standoffs 11 Lift the LEM up and away from the drive Installation Install the LEMs in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 4 26 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 MOV Surge Suppressor The MOV Surge Suppressor is located on top of the Fan Cover Plate The MOV protects the drive from high voltage surges above approximately 1 000 volts Replace it if it is burned expanded or ruptured after such events as a lightning strike or inadvertent connection of the drive input to a voltage source substantially above nameplate voltage Figure 5 11 MOV Surge Suppressor MOV Surge Suppressor Tg BR AB0797A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Proc
19. 50 6 7 0 8 8 10 0 9 1 1 14 2 208 23 26 3 26 3 Disassembly and Access Procedures Disassembly and Access Procedures 2 5 Removing the High Voltage Guard The High Voltage Guard is a clear plastic guard covering the Bus Capacitor Bank and the Power Module Assembly Figure 3 4 High Voltage Guard E High Voltage d Guard AB0824A Publication 1336 FORCE 6 16 August 1999 2 6 Disassembly and Access Procedures Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter m Remove power from the drive 2 Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives
20. 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 m L Ll m AC DC DRIVES m d E E PERSONAL COMPUTERS d Lj c n NC CNC CONTROLS d m m m DATA COMMUNICATIONS LAN m L Ll B V RATE THE OVERALL QUALITY OF THIS MANUAL BY CIRCLING YOUR RESPONSE BELOW 1 POOR 5 EXCELLENT HELPFULNESS OF INDEX TABLE OF CONTENTS 1 2 3 4 5 CLARITY 1 2 3 4 5 EASE OF USE 1 2 3 4 5 ACCURACY AND COMPLETENESS 1 2 3 4 5 QUALITY COMPARED TO OTHER COMPANIES MANUALS 1 2 3 4 5 QUALITY COMPARED TO OTHER ALLEN BRADLEY MANUALS 1 2 3 4 5 V WHAT DID YOU LIKE MOST ABOUT THIS MANUAL V WHAT DID YOU LIKE LEAST ABOUT THIS MANUAL V PLEASE LIST ANY ERRORS YOU FOUND IN THIS MANUAL REFERENCE PAGE TABLE OR FIGURE NUMBERS V DO YOU HAVE ANY ADDITIONAL COMMENTS V COMPLETE THE FOLLOWING NAME COMPANY TITLE DEPARTMENT STREET CITY STATE ZIP TELEPHONE DATE 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 Rockwell Automation Company Inc PLC is a registered trademark of Rockwell Automation Company Inc OY Rockwell Automatio
21. FORCE 6 16 August 1999 Installation ATTENTION Do not substitute longer or shorter hardware when fastening the Power Module components to the Power Modules Use the same size fastener to fasten the components as was originally used Using different fastener lengths will damage the Power Modules Install the Snubber Board in reverse order of removal Refer to Table 3 A Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 29 Removing an Input Rectifier Snubber Board The Input Rectifier Snubber Boards are located under the Circuit Board Platform Figure 3 14 Input Rectifier Snubber Board Input Rectifier Snubber Board AB0785A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 2 30 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive compone
22. NO x 3lvo Nn Y3g9NNS z 1W3NA lt x INIM U3183ANI SM TS avo NM a er eg RE AaluaA9 101d aes 80 38 sd Git E Dioses 2m s iil SdWV M jn S LHOHS QNO o uI oF S Zi sna sod o dVO 53N E sS EE x INNOD A Lut z wi eT lO SLIOAM E oz o w e oz nF Sdv M T E Sdv M SaN n zv S C 182v f HOW u38gnNS g U3l1H3ANI lt 6 L 9 S v z an9a 2 co a an9a i E S o envear Fa Lu Lu e e E am gu gui lt E lt E oF oF 6 18 zo 8 z TO MAIN CONTROL BOARD Publication 1336 FORCE 6 16 August 1999 6 4 Schematics 250 450 HP 1336 FORCE Drives 380 460VAC R L1 __ _ _4H4H _ AC INPUTPOWER_ S l2 SEE TABLE 2 415 880 HEATSINK BLOWER d 4 4 E 4 R1 Cl G3 C5 C7 C9 Z7 Clis C137 C157 C17 3 C27 C4 C67 C8 T C10 2 C12 Z4 C14 Z C16 AY C18 74 DETAIL 1 380 460 VAC NOTES DETAIL 1 1 C1 THRU C18 ARE 400 VDC CAPACITORS NOTE 4 COMMON MODE CHOKE OPTIONAL EQUIPMENT PER APPLICATION U Mt AC V M2
23. an electric shock hazard use extreme caution when removing replacing the HIM For handheld operation the module can be removed and located up to 10 meters 33 feet from the drive Important Power must be removed from the drive or Bit 1 of the SCANport Port Enable Mask 330 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 Ensure that power has been removed or SCANport Port Enable Mask 330 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 module Apply power or reset Bit 1 of the SCANport Port Enable Mask 330 parameter to 1 to enable HIM control Publication 1336 FORCE 6 16 August 1999 1 14 Control Logic Wiring and Adapters Publication 1336 FORCE 6 16 August 1999 HIM Operation When power is first applied to the drive the HIM will cycle through a series of displays These displays will show drive ID and communication status Upon completion the Status Display refer to Figure 2 10 will be shown This display
24. damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard Refer to Removing the High Voltage Guard in this chapter Measure the DC voltage from TP5 on the Power Module Snubber Board to TP2 DC Bus If voltage greater than 50 VDC is still present follow the directions in the Electric Shock Hazard Attention shown above Remove the Snubber Resistor wire from the Power Module Snubber Board stake on connectors J1 and J2 Remove the twelve screws fastening the Power Module Snubber Board to the snubber bracket to remove the snubber boards Check Snubber Resistor with VOM The reading should be 8 ohms If open replace resistor Publication 1336 FORCE 6 16 August 1999 2 28 Disassembly and Access Procedures Publication 1336
25. i Z ec um nterface Boar P4 MS ON E J Power Module Bus Thermistor x Bar Aid RS Power Module ense Snubber Board Input Rectifier Snubber Board g Jn PLC Comm j Load Sharing Mounting Adapter Board Resistor Plate Gate Driver LEM Practt recharge MOV Surge ET Suppressor Standard Adapter Board K Fan Inductor L1 Capacitor Precharge Fan Board Fuses Transformer Control Board Adapter Control Interface Mounting Plate DC Brake L Option Board Terminal AB0822A Publication 1336 FORCE 6 16 August 1999 4 4 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Bus Capacitor Bank The Bus Capacitor Bank is located on the upper left side of the Main Chassis Figure 5 2 Bus Capacitor Bank iT qu Bus ADN Capacitor Bar AVA EN nubber Ke Sy Resistors Bus Capacitor N 3 PIN Standoffs ISS 4 Bus y SA Capacitor Bar dA p 5 2 zt V Converter yi os Fuse Support gt LIN ER ES EE y Bus EE Power Module Fuses BE i Bus Bar p SS PM Snubber Q Resistors AB0787A Part Replacement Procedures 4 5 Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until t
26. ideal meter readings for those connections Refer to Figure 4 3 for meter connection locations Table 4 B Output Sections Meter Lead Meter Lead pec EIS DC Brake U M1 Infinite U DC Brake V M2 Infinite V DC Brake W M3 Infinite W U M1 DC Brake 0 318 U V M2 DC Brake 0 318 V W M3 DC Brake 0 318 W DC Brake U M1 0 318 U DC Brake V M2 0 318 V DC Brake W M3 0 318 W U M1 DC Brake Infinite U V M2 DC Brake Infinite V W M3 DC Brake Infinite W Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range 7 If the readings are not approximately the same as in Table 4 B Publication 1336 FORCE 6 16 August 1999 the last column identifies the phase with a potential problem If the readings are not correct continue with the test procedure to check the individual phase or phases in question Remove the High Voltage Guard Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Power Module Snubber Boards Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Component Test Procedures 3 11 10 Test the Power Module phases that did not pass the Table 4 B tests Table 4 C shows meter connections and ideal meter readings for those connections Refer to Figure 4 3 for meter connection locations Table 4 C Power Modules Upper Phase Meter Lead Meter Lead nnn Typ
27. the power cables to the top and bottom of the Bus Capacitor Bank Remove the four bolts fastening the Converter Fuse Support to the Bus Capacitor Bar and Power Module Bus Bar Pull the Converter Fuse Support with bus fuses attached from the drive Remove the six bolts 2 per phase fastening the Bus Capacitor Bar to the Power Module Bus Bar Remove the two bolts fastening the Bus Capacitor Bar to the Bus Capacitor Inverter Standoffs Remove the three screws fastening the Bus Capacitor Bar to the Power Module Snubber Resistors Pull the Bus Capacitor Bar from the drive 2 Remove the Power Module Bus Bar A D E Remove the six screws fastening the Power Module Bus Bar to the Bus Capacitor Bar Remove the eighteen nuts fastening the Power Module Bus Bars to the Bus Capacitor Bar Remove the five screws fastening the Power Module Bus Bar to the Snubber Resistors Remove the two bolts fastening the Power Module Bus Bar to the drive Pull the Power Module Bus Bar from the drive 3 Remove the Bus Capacitors A Remove the eighteen nuts fastening the Bus Capacitor Bar to the Bus Capacitors Pull the Bus Capacitor Bar from the drive C Remove the Bus Capacitors from the drive Part Replacement Procedures 4 7 Installation 1 Fasten the capacitor assembly in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fas
28. this chapter Publication 1336 FORCE 6 16 August 1999 2 22 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 Important Before you remove connections and wires from the 1 2 7 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the Control Board Adapter Mounting Plate Refer to Removing the Control Board Adapter Mounting Plate in this chapter Disconnect the following from the Gate Driver Board J2 connector J6 connector J7 connector J8 connector J9 connector J10 connector J13 connector TB4 24 VDC Auxiliary Input Ground wire from TB7 on the Gate Driver Board Turn the eight standoff screws fastening the Gate Driver Board to the mounting plate 1 4 turn counterclockwise Pull the Gate Driver Board away from the mounting plate Disassembly and Access Procedures 2 23 Installation Install the Gate Driver Board in reverse order of removal ATTEN
29. to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 Important Component Test Procedures 3 13 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 e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board 4 Set your meter to test DC voltage 5 Connect the negative lead of your meter to the DC Brake Terminal on TBI and the positive lead to the DC Brake Terminal Refer to the following tables and Figure 4 4 for meter readings and terminal locations ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for E
30. to the Circuit Board Platform Remove the nuts fastening the top of the Main Control Board Mounting Plate to the Circuit Board Platform Lift the Main Control Board Mounting Plate out of the drive Installation Install the Main Control Board Mounting Plate in reverse order of removal Refer to Table 3 A Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 21 Removing the Gate Driver Board from the Mounting Plate Figure 3 11 Gate Driver Board and Mounting Plate Removal Gate Driver Board Connector J2 Connector J13 Connector Terminal Strip Sp TB7 A Connector d Terminal Strip Jo X TB4 Terminal Strip Connector TB6 J9 AB0783A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of
31. up 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 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 PLC Comm Adapter Board Figure 3 9 Main Control Board and PLC Comm Adapter Board nv gt AREE Removal Control Board Adapter Mounting Plate Main Control gt po Board 4 Slide Mount x Stand Off RN Mounting TS Screw is ul 4 places Bo ae Connector J5 7 Connector J7 Connector L TB21 Ji i TB20 PLC Comm Adapter Board AB0895A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminal Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 2 18 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at terminals V
32. using a Control Interface L Option Board 4 Remove the four nuts fastening the High Voltage Guard to the standoffs 5 Pull the guard away from the drive Installation Install the High Voltage Guard in reverse order of removal Refer to Table 3 A Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 Disassembly and Access Procedures 2 7 Removing Control Interface L Option Board MOD L4 L5 or L6 Figure 3 5 Control Interface L Option Board Removal Main Control Board Standard Adapter Board Control Interface y L Option Board Terminal Strip TB3 AB0825A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 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 16 August 1999 2 8 Disassembly and Access
33. voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 4 16 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for absence of control voltage at terminals V and V on TB11 on the Main Control Board TB20 and TB21 on drives using a PLC Comm Adapter Board TB5 TB6 and TB7 on drives using a Standard Adapter Board TB3 on drives using a Control Interface L Option Board 4 Remove the nuts fastening the Input Fuse to the Input Bus Bar and TBI 5 Pull the blown fuse out from the drive Installation Install the Input Fuse in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applyi
34. 1336 FORCE Drive Catalog Numbers 00 P 4 Adapter Options Factory Installed Select One P 4 Drive Rating Qualifications 6 cee eee eee P 5 Enclosure Type eco cust her riden EC EE EE EESTE P 5 Conventions PP P 6 Auxiliary TOL 5a ages oe pa Re ae IDERRERERERC teke E ES P 6 Auxiliary Interlock oce e e n P 6 Bii cS P 6 Plo P P 6 CONNGCION iue tuas Rue devas Exc ek e E e P 6 Control Interface L Option Board 0 cee eee P 7 D 8laull 1 eaae ORE EC n RO PO RO d P 7 Enable INput sisesta NT E P 7 FalS6 e de pest trate e E E ata el cun P 7 JI o eo P 7 Parameter eeina op the nepal Rana ane shave P 7 dr cm TTL mm P 7 TIUS oca sex ohne ave ogee POLE Ee a EK PERS EUM P 8 Related Publications 2 cicer Er Re RR Rh P 8 Chapter 1 Chapter ODISCIINES cusceutueed eor bre b REPRE CEP REESE 1 1 Chapter Overview iusso xou hr eR bac bens eeu 1 1 Control Interface Option 0 eee eee eee 1 3 Control Interface Board Jumpers 00 eee aee 1 4 Available Inputs 0 0 2 e eee 1 5 Local Progtamimil widen vista Boer RA CC IERRRT RN a eed 1 5 Adapters and Communication Ports 0 0eeaeee 1 11 Human Interface Module 0 cece eee eee 1 11 Standard Adapter Ports 20 cscs ie cks tate nseraeaeas eae 1 12 PLC Comm Adapter Ports 0 0 0c eee eee eee 1 12 rdum rU 1 13 AIM ORSON Deve o Pene chee E ES 1 14 Publicat
35. 6 FORCE 6 16 August 1999 1 8 Control Logic Wiring and Adapters 2E o o Momentary o o Maintained PLUS with Language Module 1336S EN firmware FRN User Connections 1201 HAP 1201 HAI 1201 HA2 1336 GMI 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 properly unless a SCANport option is connected to the of the following ATTENTION The JOG function will not operate A User Connections Publication 1336 FORCE 6 16 August 1999 Start Common gt Ext Fault35 9 Common S K eal Speed Select 1 IES Common Enable Run Forward 6 Common Run Reverset6 gt Ext Fault3 9 Common Speed Select 21 Speed Select 1 Common Enable Stop Clear Fault 7 8 Rev 9 Rev46 Fwd Fwd Jog Spd Sel 3 Spd Spd Sel 2 Sel Stop Clear Fault3 78 12 Local Control Speed Select 3 Input Mode 7 11 Three Wire Control with Multi Source Reversing 9 10 Digital Rev 6 Pot Up Digital Fwa Pot Dn Spd Digital Sel 3 PotUp Spd Digital Sel 2 PotDn Mode 11 19 0 200 tst Spd Tq3 Spd Tq3 Accel 2nd Spd Ta2 Spd Tq2 Accel 1st Spd Tq1 Spd Tq1 Decel 2nd Proc Flux Decel Trim En Input Mode 12 16 Two Wire Control Single Source Control Mode 13
36. ARGE AC LINE Publication 1336 FORCE 6 16 August 1999 AB0813A 6 3 Schematics 250 450 HP 1336 FORCE Drives l go E x Eon passes ox M B s 9 FSoa gt j 2 Es e I mE LL a N Ss o z s e N E N g U38gniNS x ES U31H3ANI lt 5 eo 2 E o EET 300 d z 39d u 100 dM D e Too Nn rg B ungan S uw co alva dn 99 E E 5 d a 9 TOON u ES wo LNs dA wi z pu 3IVO dA Eu TE ra xz o w coz um oz oan D lt L joo Nm lt O Age NM oy H ASt Jd dM canam ae 31 9 dM an9a Nis LOSI ING
37. CT2 LEM TB1 Chapter 4 LEMs 9 A11 A13 Input Rectifier Snubber Board Input Rectifier Chapter 2 Removing the Input Rectifier Snubber Board 10 A1 Gate Driver Board Circuit Board Platform Chapter 2 Removing the Gate Driver Board from the Mounting Plate 11 MAIN CONTROL Main Control Board Main Control Board Chapter 2 Removing the Main Control BOARD Mounting Plate Board 12 GT2 Standard Adapter Board Control Board Adapter Mounting Chapter 2 Removing the Standard Plate Adapter Board 13 GT1 PLC Comm Adapter Board Control Board Adapter Mounting Chapter 2 Removing the PLC Comm Plate Adapter Board 14 FAN Fan Main Chassis Chapter 4 Fan and Transformer 15 MOV1 MOV Surge Suppressor Fan Cover Plate Chapter 4 MOV Surge Suppressor 16 Ti Fan Transformer Main Chassis Chapter 4 Fan and Transformer 17 C HB1 Fan Capacitor Main Chassis Chapter 4 Fan and Transformer 18 L1 DC Bus Inductor Main Chassis Chapter 4 DC Bus Inductor L1 19 CT3 Ground Sense CT Input Bus Bar Chapter 4 Ground Fault CT 20 CF4 CF5 Bus Fuses Capacitor Bus Bank Chapter 4 Bus Fuses F1 21 C1 C10 Bus Capacitors Main Chassis Chapter 4 Bus Capacitor Bank 22 CF1 CF3 Input Fuses Input Bus Bars Chapter 4 Input Fuses 23 HIM Human Interface Module Enclosure Cover Chapter 1 Module Removal 24 A10 Precharge Board Circuit Board Platform Chapter 2 Removing the Precharge Board from the Mounting Plate Publication 1336 FORCE 6 16 August 1999 5 4 Replacement Parts List This Page Intentionall
38. If Driver Board modules have been replaced you must test the Gate Driver Board Figure 4 1 Gate Driver Board Test VR2 VR3 VR5 VR6 VR1 VR4 Gate Driver Board AB0804A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 3 4 Component Test Procedures Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Check for zero volts at the DC DC Brake Terminals and for absence of control voltage Check for absence of con
39. Illustration 2 9 Installation 2 11 Removal 2 9 Component Test Procedures 3 1 Connector Definition P 6 Control Board Adapter Mounting Plate Illustration 2 19 Installation 2 20 Removal 2 19 Control Interface L Option Board Available Inputs 1 5 Definition P 7 Illustration 2 7 Installation 2 8 Jumper Locations 1 4 Options 1 3 Removal 2 7 Control Interface Option 1 3 Control Logic Wiring and Adapters 1 1 Conventions in this Manual P 6 Index D DC 4 Brake Terminals 3 8 3 12 4 3 DC Bus Inductor L1 Illustration 4 32 Installation 4 34 Removal 4 32 Default Definition P 7 Disassembly and Access Procedures 2 1 Drive Enclosure Type P 5 Identification P 4 Illustration 4 3 Nameplate Location P 3 Rating P 5 Drive Tools 1 16 E Electrostatic Discharge P 2 Enable Input Definition P 7 Enclosure Type P 5 ESD P 2 F False Definition P 7 Fan and Transformer Illustration 4 28 Installation 4 30 Removal 4 28 Fastener Torque Specifications 2 2 Firmware Function 1 16 Four Point Mounting 2 3 G Gate Driver Board Illustration 2 21 Installation 2 23 Removal 2 21 Test 3 3 Graphic Programming Terminal GPT Description 1 15 Publication 1336 FORCE 6 16 August 1999 l 2 Index Publication 1336 FORCE 6 16 August 1999 Ground Fault CT Illustration 4 17 Installation 4 19 H High Voltage Guard Illustration 2 5 Installation 2 6
40. L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board TB3 on drives using a Control Interface L Option Board Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the six screws fastening the Input Rectifier wiring to the Input Bus Bars Remove the six bolts fastening the Input Bus Bars to the Input Rectifier Assembly and the Input Fuse Assembly Slide the Input Bus Bars to the right to remove the bus bars and the Ground Fault CT which encircles the bus bars from the drive Slide the Ground Fault CT off the bus bars Part Replacement Procedures 4 19 Installation Install the Ground Fault CT in reverse order of removal inserting the Input Bus Bars through the center of the Ground Fault CT Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION A possible short circuit hazard exists Position the fuse to inductor wire with the shrink wrapped end of the wire connected to the Bus Inductor Failure to position the wire as illustrated may r
41. Module Snubber Board AB0799A DC Brake DC Brake Terminal Terminal Important Component Test Procedures 3 9 ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 1 Remove power from the drive 2 Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board 4 Remove the motor leads from TB1 U V and W terminals of the drive 5 Set your meter to test diodes Publication 1336 FORCE 6 16 August 1999 3 10 Component Test Procedures 6 Test the output sections of the drive This should indicate if any of the drive s output phases has a problem Table 4 B shows meter connections and
42. Procedures Publication 1336 FORCE 6 16 August 1999 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at terminals V and V on TB11 on the Main Control Board e TB5 TB6 and TB7 on the Standard Adapter Board TB3on the Control Interface L Option 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 guards before applying power to the drive Failure to replace guards may result in death or serious injury Disassembly and Access Procedures 2 9 Removing the Circuit Board Platform The Circuit Board Platform contains the Main Control Board the Gate Driver Board and the Precharge Board Figure 3 6 Circuit Board Platform Circuit Board Platform n
43. Rectifier Snubber Board Removal 2 29 Input Rectifier Test 3 15 LEM Installation 4 25 LEM Removal 4 23 Index I 3 Main Control Board Installation 2 14 Main Control Board Removal 2 13 Major Component Replacement 4 2 MOV Surge Suppressor Installation 4 27 MOV Surge Suppressor Removal 4 26 PLC Comm Adapter Board Installation 2 18 PLC Comm Adapter Board Removal 2 17 Power Module Installation 4 12 Power Module Removal 4 10 Power Module Snubber Board Installation Power Module Snubber Board Removal 2 26 Power Module Test 3 8 Precharge Board Installation 2 25 Precharge Board Removal 2 24 Precharge Board Test 3 6 Replacement Part 4 1 Standard Adapter Board Installation 2 16 Standard Adapter Board Removal 2 15 Thermistor Installation 4 9 Thermistor Removal 4 8 Product Identification P 3 4 3 Programming Input Mode 1 5 Local 1 5 R Rating Drive P 5 Related Publications P 8 Removal Procedures See Procedures Removal HIM 1 13 Replacement Part Procedures 4 1 Replacement Parts List 5 1 S Safety Precautions P 1 Schematics 6 1 Six Point Mounting 2 3 Snubber Board Input Rectifier Illustration 2 29 Installation 2 30 Removal 2 29 Snubber Board Power Module Illustration 2 26 Installation 2 28 Removal 2 26 Publication 1336 FORCE 6 16 August 1999 Publication 1336 FORCE 6 16 August 1999 Speed Select Input State 1 9 Standard Adapte
44. Ref 3 P 121 X 0 O Preset Speed Ref 4 P 122 X O X Preset Speed Ref 5 P 123 X X O External Reference 2 P 104 X X X Last State Equivalent truth table implemented in Parameter 52 Logic Command Word Oo Oo X Ext Ref 1 P 101 O X O Preset Speed Ref 1 P 119 O X X Preset Speed Ref 2 P120 X 0 O Preset Speed Ref 3 P 121 X O X Preset Speed Ref 4 P 122 X X O Preset Speed Ref 5 P 123 X X X External Reference 2 P 104 Oo Oo Oo No Reference or Last State O Open Input Removed X Closed Input Present 1 Unless otherwise configured this will default to the HIM speed reference input Figure 2 6 PLC Comm Adapter Reference Signal Connections 1234 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 TB20 TB21 E EH BH EH ee NH BJ ee ee E BH EH EH JH HB BH eee eee B BJ J B i DO DDODBOOSTS DpQDOOGOIOIDUOEO SOQOoDOOOouge ra ii Faut EJ LT E E LT st0comm t0 f Common Relay Analog Analog Analog Analog Analog Analog Analog Analog an Stop Out Out2 Out3 Out4 Int In2 In3 In4 nable Motor Ext AB0551A Thermo Fault Publication 1336 FORCE 6 16 August 1999 1 10 Control Logic Wiring and Adapters Table 2 C PLC Comm Adapter Reference Signal Connections Terminal Block Terminal Number s Signal TB20 Drive Enable NO Motor Thermoguard NC Normal Stop NC External Fault NC Input Com
45. Refer to Chapter 2 Disassembly and Access Procedures Removing the Input Rectifier Snubber Board 7 Set your meter to test diodes 8 The following table shows meter connections and ideal meter readings for those connections Refer to Figure 4 5 for meter connection locations Table 4 E Input Rectifier Test Meter Lead Meter Lead Nominal Meter Reading AK K Infinite AK A Infinite K A Infinite K AK Infinite A AK Infinite A K Infinite G1 Ki 0 011 K1 G1 0 011 G2 K2 0 011 K2 G2 0 011 Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range 9 Replace the Input Rectifier if any meter readings are not as shown Refer to Chapter 4 Part Replacement Procedures Input Rectifiers 10 If the Input Rectifier shorted check the Power Modules for damage Refer to Testing the Power Modules in this chapter Publication 1336 FORCE 6 16 August 1999 Chapter Objective 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 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 v
46. Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Disconnect AC input and motor output wiring from TBI to provide easy access to the DC Bus Inductor enclosure ATTENTION The DC Bus Inductor weighs 100 lbs Failure to use extreme caution in handling this part may result in serious injury Remove the eight bolts fastening the Bus Bar Cables to the DC Bus Inductor terminals Remove the four bolts fastening the DC Bus Inductor to the back panel of the chassis Remove the Bus Inductor from the drive Publication 1336 FORCE 6 16 August 1999 4 34 Part Replacement Procedures Installation Install DC Bus Inductor L1 in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Publication 1336 FORCE 6 16 August 1999
47. Removal 2 6 HIM See Human Interface Module Human Interface Module HIM Adapter Locations 1 12 Description 1 11 Illustration 1 11 Operation 1 14 Removal 1 13 Identification Product P 3 Input Fuses Illustration 4 15 Installation 4 16 Input Mode Programming 1 5 Selection 1 6 Three Wire Multi Source 1 7 Two Wire Single Source 1 7 Input Rectifier Illustration 4 20 Installation 4 22 Removal 4 20 Test 3 15 Input Rectifier Snubber Board Illustration 2 29 Installation 2 30 Removal 2 29 Inputs Available 1 5 Installation Procedures See Procedures J Jumper Locations 1 4 Jumper Definition P 7 LEMs Illustration 4 23 Installation 4 25 Removal 4 23 Load Sharing Resistor Connections 4 7 Local Programming 1 5 L Option Board See Control Interface L Option Board Main Control Board Illustration 2 12 Installation 2 14 Removal 2 13 Major Component Replacement See Procedures Manual Audience P 1 Conventions P 6 Objective P 1 Related Publications P 8 Mounting Four Point 2 3 Six Point 2 3 Two Point 2 3 MOV Surge Suppressor Illustration 4 26 Installation 4 27 Removal 4 26 N Nameplate Location P 3 O Objective of this Manual P 1 Operation Human Interface Module 1 14 Option Control Interface 1 3 Identification P 4 P Parameter Definition P 7 PLC Comm Adapter Board Illustration 2 17 Installation 2 18 Reference Signal Conn
48. TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Set your meter to test resistance Test fuses F1 F2 and F3 through the access holes in the Precharge Board High Voltage Guard and check for open conditions Replace the Precharge Board if any fuse shows an open condition Refer to Chapter 2 Disassembly and Access Procedures Removing the Precharge Board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 3 8 Component Test Procedures Test 3 Testing the Power Modules Publication 1336 FORCE 6 16 August 1999 The Power Modules are located on the upper right side of the heat sink If modules have been replaced you must check the Power Module Snubber Board Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board Figure 4 3 Power Module Test n gt B ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power
49. TION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 2 24 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 Removing the Precharge Board from the Mounting Plate Figure 3 12 Precharge Board Ty Mana Removal Connector Connector 7 J4 Connector J2 val Connector J1 Precharge Board High Voltage Guard AB0780A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to Zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Disassembly and Access Procedures 2 25
50. a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the Publication 1336 FORCE 6 16 August 1999 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the nine bolts fastening the Output Bus Bars to the Power Module Assembly and TB1 Pull the Output Bus Bars out from the drive Remove the two screws fastening the TB1 shield to the TBI Assembly Part Replacement Procedures
51. and the heat sink 3 Install the Input Rectifier in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 Part Replacement Procedures 4 23 LEMs The two LEMs are located above TB1 on the right side of the chassis Figure 5 10 LEMs Screws 9 d Screws 2 Output TB1 Shield Bus Bars AB0796A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 4 24 Part Replacement Procedures ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing
52. at the ends of wires or ribbon cables and plug into male connectors Preface P 7 Control Interface L Option Board A Control Interface L Option Board plugs into connectors J7 and J9 located on the lower portion of the Main Control Board This board is identified as L4 4E L5 5E or L6 6E and provides optional control wiring configurations for a drive Default When a drive function defaults it automatically changes to a 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 Parameter Parameters are programmable drive functions that define various operating functions or status displays of a drive Refer to Bulletin 1336 FORCE Adjustable Frequency AC Drive User Manual for Parameter details Press Press a button on the Human Interface Module
53. ce dee EE RR WERE CENE MS 2 16 Removing the PLC Comm Adapter Board 2 17 Removal uua ouai e xa ex red dox opened Skene ER 2 17 Installation Loren ad 6 COD EORR EUR FUROR RR wo OE RR 2 18 Removing the Control Board Adapter Mounting Plate 2 19 REMOVA sata enter eode kan cari adhe E ONU EORR 2 19 Installation cesses II 2 20 Removing the Gate Driver Board from the Mounting Plate 2 21 Removal es ponnien eda e kaa ke nel 2 21 instalation caw cease dvd dens ka Cea e koe ER n RR es 2 23 Removing the Precharge Board from the Mounting Plate 2 24 Removal ose ch unco et ique dice Ea e OUR c CE da 2 24 WSTAN AMON a nese ione oce e rs ie te e aoe 2 25 Removing a Power Module Snubber Board 2 26 Removal os ttt aati hed ddan elect thee ned 2 26 Installation 23 2459 Su EREEREREREWGECEPRS AE Peg P 2 28 Publication 1336 FORCE 6 16 August 1999 Table of Contents iii Component Test Procedures Part Replacement Procedures Removing an Input Rectifier Snubber Board 2 29 REMOVAL sie oxide i o c CROACIE ERE Y 2 29 IMStallatiOns lt v4 sue eos asset teet des qd icem 2 30 Accessing Power Plane Components 00 05 2 30 Chapter 3 Chapter Objectives cencecsdeeaces RR E RR on wes 3 1 Component Test Overview 0 0 c eee eee eee ee 3 1 Electrostatic Discharge Precautions lslseussn 3 2 loo PPP 3 2 Test 1 Testing the Gate Driver Board
54. ce guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 2 26 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 Removing a Power Module Snubber Board The Power Module Snubber Boards are located on the upper right side of the chassis Figure 3 13 Power Module Snubber Board Heat Transfer Snubber Pad N N GEE Screw 2 LN wy Power Module Stake On Snubber Board Connector J1 Stake On Connector J2 x Come TP2 Screw 12 Tg B AB0830A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to Zero volts Disassembly and Access Procedures 2 27 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to FORCE bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and FORCE bus to discharge any voltage ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may
55. d sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new circuit board from the conductive packet e Remove boards from the drive and immediately insert them into their conductive packets Tools You need the following tools to disassemble and assemble the drive e Pliers Phillips screwdrivers medium and large e Standard screwdrivers small medium and large e 25 64 inch or 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m Nylon tie wraps Component Test Procedures 3 3 Test 1 Testing the Gate The Gate Driver Board is located beneath the Main Control Board
56. d Mounting Plate 5 Disconnect the following from the Main Control Board e J connector e J2 connector e TB3 if Control Interface L Option Board is used any optional boards 6 Remove the two nuts from the top and the bottom of the Main Control Board Mounting Plate 7 Pull the Main Control Board Mounting Plate straight out and remove the plate from the drive 8 Disconnect the following from the Gate Driver Board J2 connector J7 connector J8 connector e J10 connector 9 Disconnect the following from the Precharge Board J connector e J2 connector J4 connector 10 Disconnect the two LEM wire harness plugs Disassembly and Access Procedures 2 11 11 Remove the four nuts fastening the Circuit Board Platform to the drive 12 Pull the Circuit Board Platform straight out and remove the platform from the drive Installation Install the Circuit Board Platform in reverse order of removal ATTENTION When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 2 12 Publication 1336 FORCE 6 16 August 1999
57. dard screwdrivers small medium and large e 25 64 inch or 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m e Nylon tie wraps This section explains in detail how to replace the following drive components Bus Capacitor Bank Thermistor Power Modules Bus Fuses Fl Input Fuses Ground Fault CT Input Rectifiers e LEMs MOV Surge Suppressor Fan and Transformer Assembly e DC Bus Inductor L1 For Main Control Board PLC Comm Adapter Board Standard Adapter Board Gate Driver Board Precharge Board Snubber Boards and Control Interface Board installation and removal procedures refer to Chapter 2 Detailed Product Identification Capacitor Bank Bus Fuse F1 G 7 T i Ss Input N Fuses 3 DC Brake Terminal Part Replacement Procedures 4 3 Rockwell Automation Adjustable Frequency AC Drives are modular by design to enhance troubleshooting and spare parts replacement thereby helping reduce production down time The following illustration calls out the main components of a typical drive Component designs vary slightly among the different drive ratings but component locations are identical Figure 5 1 Main Drive Components Power Module it
58. e carton and packing slip Include Your company name Your company address The repair purchase order number A brief description of the problem Contact your local Rockwell Automation distributor or sales office for a complete listing of area sales and support centers near you For parts catalog numbers refer to the 1336 FORCE Spare Parts Pricing publication included with your drive documentation set Publication 1336 FORCE 6 16 August 1999 Replacement Parts List 5 2 Replacement Parts Listing Parts for BP300 BP450 Drives Figure 6 1 22 AB0823A Publication 1336 FORCE 6 16 August 1999 Table 6 A Replacement Parts List 5 3 Replacement Parts for BP300 BP450 Drives Callout Symbol Description Location Replacement Procedures 1 Q1 Q6 Transistor Power Module Heat Sink Chapter 4 Power Modules 2 A23 A28 Power Module Gate Interface Power Module Chapter 4 Power Modules Board 3 R20 R22 Power Module Heat Sink Chapter 2 Removing a Power Module Snubber Resistor Snubber Board 4 NTC1 Thermistor Heat Sink Chapter 4 Thermistor 5 SCR1 SCR3 Input Rectifier Heat Sink Chapter 4 Input Rectifiers 6 A20 A22 Power Module Bus Bar and Power Module Chapter 2 Removing a Power Module Snubber Board Snubber Board 7 R1 R3 Load Sharing Resistor Heat Sink Chapter 4 Bus Capacitor Bank 8 CT1
59. e drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 4 9 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 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 e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Disconnect the Thermistor connector at J1 on the Main Control Board Unscrew the Thermistor from the heat sink Installation Install the The
60. e of Reading Motor INV 0 289v Diode INV Motor Infinite Diode E TP1 0 289v Diode TP1 E Infinite Diode E Motor 0 ohms Resistance TP1 INV 0 ohms Resistance E R2 10k ohms Resistance Lower Phase Meter Lead Meter Lead Nominal meter Type of Reading Reading INV Motor 0 289v Diode Motor INV Infinite Diode E TP1 0 289v Diode TP1 E Infinite Diode E INV 0 ohms Resistance TP1 Motor 0 ohms Resistance E R2 10k ohms Resistance Note Typical malfunction for diode test is shorted in both directions Note Select meter to read appropriate type of measurement where needed Meter Used Fluke Model 87 set to Diode range 11 Replace the Power Module phase if the meter readings are not approximately as shown Refer to Chapter 4 Part Replacement Procedures Power Modules 12 If one or more Power Modules is replaced test the Gate Driver Board Refer to Testing the Gate Driver Board in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 3 12 Component Test Procedures Test 4 Testing the Bus The Bus Capacitor Bank is located on the upper left side of the Main Capacitors Chassis Figure 4 4 Bus Capacitor Bank Test n 2 7j AB0832A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure
61. ections 1 9 Removal 2 17 Terminal Block Locations 1 2 Power Module Illustration 4 10 Installation 4 12 Removal 4 10 Test 3 8 Power Module Snubber Board Illustration 2 26 Installation 2 28 Removal 2 26 Precautions Electrostatic Discharge P 2 Safety P 1 Precharge Board Illustration 2 24 Installation 2 25 Removal 2 24 Test 3 6 Press Definition P 7 Procedures Accessing Internal Drive Components 2 1 Bus Capacitor Bank Installation 4 7 Bus Capacitor Bank Removal 4 5 Bus Capacitor Bank Test 3 12 Bus Fuse Installation 4 14 Bus Fuse Removal 4 13 Circuit Board Platform Installation 2 11 Circuit Board Platform Removal 2 9 Component Test 3 1 Control Board Adapter Mounting Plate Installation 2 20 Control Board Adapter Mounting Plate Removal 2 19 Control Interface L Option Board Installation 2 8 Control Interface L Option Board Removal 2 7 DC Bus Inductor L1 Installation 4 34 DC Bus Inductor L1 Removal 4 32 Fan Installation 4 30 Fan Removal 4 28 Gate Driver Board Installation 2 23 Gate Driver Board Removal 2 21 Gate Driver Board Test 3 3 Ground Fault CT Installation 4 19 Ground Fault CT Removal 4 17 High Voltage Guard Installation 2 6 High Voltage Guard Removal 2 6 Input Fuse Installation 4 16 Input Fuse Removal 4 15 Input Rectifier Installation 4 22 Input Rectifier Removal 4 20 Input Rectifier Snubber Board Installation 2 30 Input
62. ed Using different fastener lengths will damage the Power Modules ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 Part Replacement Procedures 4 13 Bus Fuses F1 The Bus Fuses are located on the Bus Capacitor Bank Assembly Figure 5 6 Bus Fuses F1 Bus Fuses n gt AER AB0834A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 4 14 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 e DC DC Brake Terminals ter
63. edures 4 27 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 9 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the three screws fastening the MOV Surge Suppressor wires to the Input Bus Bars Remove the screw fastening the MOV Surge Suppressor wire to TB1 terminal PE Remove the screw fastening the MOV Surge Suppressor to the chassis Pull the MOV Surge Suppressor from the drive Ins
64. emoval ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 2 20 Disassembly and Access Procedures Publication 1336 FORCE 6 16 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 7 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at terminals V and V on TB11 on the Main Control Board TB20 and TB21 on the PLC Comm Adapter Board Disconnect the following from the Main Control Board J connector e J5 ribbon cable connector Stake on ground wire connector All wire from TB10 Remove the two screws fastening the bottom of the Main Control Board Mounting Plate
65. ents located on the chassis refer to Removing a Power Module Snubber Board in this chapter Chapter Objectives Component Test Overview Chapter 3 Component Test Procedures The following tests help you troubleshoot BP300 BP450 drives In some cases different tests troubleshoot components of the same These similar tests vary according to the rating of the drive being tested Verify that the rating on the drive matches the rating for the test you are performing ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unintentional actuation of controlled industrial equipment may cause death or serious injury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment Publication 1336 FORCE 6 16 August 1999 3 2 Component Test Procedures Electrostatic Discharge Precautions Publication 1336 FORCE 6 16 August 1999 ATTENTION This assembly contains parts an
66. esult in serious injury or equipment damage ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 4 20 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Input Rectifiers The Input Rectifiers are located toward the bottom of the heat sink Figure 5 9 Input Rectifiers ay Preform Input Rectifier SAIDA Pia 1 Snubber Board P Standoffs L Bar Converter CANA Bar no lt LA AB0790A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to Zero volts Part Replacement Procedures 4 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 fr
67. et se Re 4 20 Iristallationi xe Er ez a teer aae Rs 4 22 Publication 1336 FORCE 6 16 August 1999 iv Table of Contents Replacement Parts List Schematics 250 450 HP 1336 FORCE Drives Index Publication 1336 FORCE 6 16 August 1999 LEMS veer knee capenpea ceeoneeseonc sed bene aomaces 4 23 FiemoVall eee e tu an eaten cy Pn CHR UR RR A OR 4 23 Installation IR 4 25 MOV Surge Suppressor 000 eee e eee ee eee 4 26 Removal v ETC cx Mt 4 26 instalation aci aeo aeta ri pe e RR i e ees 4 27 Fan and Transformer Assembly 00 eee eens 4 28 Removal scatet atem a e E atl bate ales 4 28 Installation IR 4 30 DC SUS Inducto El assu 2d ashen hee e X ale okies 4 32 oir Mc P L M 4 32 Instalati ess e yk xRERRORCRRKSXRRREFREK AZGueens 4 34 Chapter 5 Chapter Objectives csse edes ehh Rm rmm eee 5 1 Ordering Replacement Parts 00 esses 5 1 Replacement Parts Listing llle 5 2 Chapter 6 Manual Objective Who Should Use This Manual Safety Precautions Preface Preface The information in this manual is designed to help repair a Rockwell Automation Bulletin 1336 FORCE Adjustable Frequency AC Drive with ratings BP300 BP450 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
68. hat the oscilloscope be used in the A minus B Quasi differential mode with the oscillo scope chassis correctly grounded to an earth ground ATTENTION Only personnel familiar with the 1336 FORCE Adjustable Frequency AC Drive and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the drive Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Preface P 3 1336 FORCE Product Identification Dri
69. he complimentary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis e Attach the wrist strap before removing the new circuit board from the conductive packet 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 e Pliers e Phillips screwdrivers small medium and large e Standard screwdrivers small medium and large e 25 64 inch or 10 mm socket e 7 16 inch or 11 mm socket e 33 64 inch or 13 mm deep well socket e 5 16 inch or 8 mm open end wrench Torque wrench metered in lb in or N m e Nylon tie wraps Torque Sequence When mounting components to a drive s heat sink component fastener torque sequences and tolerances are crucial to component to heat sink heat dissipation ATTENTION Component can be damaged if temporary tightening procedure is not performed to specification The following illustrates temporary and final tightening sequences for components fastened to a heat sink using two four and six screws Temporary torque is 1 3 33 of final torque except six point mountings which require 0 5 N m 4 Ib in The numeric illustration labels are for your assistance Drive components d
70. he Fan Cover e Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications Install the Fan Capacitor to the chassis with M8 split washer and hand tighten Connect the Fan Transformer red wire to TB1 terminal S L2 and the black wire to TB1 terminal R L1 Part Replacement Procedures 4 31 Important Install washers on TB1 terminals with the serrated side up ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 4 32 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 DC Bus Inductor L1 DC Bus Inductor L1 is located at the bottom of the drive Figure 5 13 DC Bus Inductor L1 no lt ABER DC Bus Inductor L1 DC Brake Terminal DC Brake Terminal Removal L3 AB0792A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 4 33 ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components
71. he bus voltage has discharged to zero volts ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Access the Main Chassis Remove power from the drive Check for zero volts at e DC DC Brake Terminals e terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Publication 1336 FORCE 6 16 August 1999 4 6 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Access the Bus Capacitor Bank 1 Remove the Bus Capacitor Bar A G Remove the two sets of bolts fastening
72. ide of the AC Input Line Fuses Normally this connection is used to power an external control transformer user supplied or other auxiliary circuit Refer to Figure 1 1 for location Important Depending on the circuitry connected additional fusing may be required Attention The installation of auxiliary circuits must comply with the national codes and standards NEC VDE BSA etc and local codes regarding wire type conductor size branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage The auxiliary circuit can be utilized to a maximum current capacity of 8 amperes RMS The maximum and minimum wire size accepted by TB9 is 4 0 and 0 8 mm 12 and 18 AWG Use copper wire only with a minimum temperature rating of 75 C Maximum Torque is 0 90 1 81 N m 8 16 lb in AB0815A 6 5 Publication 1336 FORCE 6 16 August 1999 6 6 Schematics 250 450 HP 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE 6 16 August 1999 A Adapter Locations 1 12 Audience for this Manual P 1 Auxiliary Input Definition P 6 Auxiliary Interlock Definition P 6 Bit Definition P 6 Bus Capacitor Bank Illustration 4 4 Installation 4 7 Removal 4 5 Test 3 12 Bus Fuse Illustration 4 13 Installation 4 14 Removal 4 13 Bus Inductor See DC Bus Inductor L1 C Check Definition P 6 Circuit Board Platform
73. ion 1336 FORCE 6 16 August 1999 ii Table of Contents Graphic Programming Terminal sisse 1 15 GPT Description adoors ene ux het ENT Rar RE HR ERR Seen 1 15 DriveTools lssssssssssesses eI 1 16 Control Firmware Function 00 00 cece cece eens 1 16 Disassembly and Access Chapter 2 Procedures Chapter Objectives 2 1 Disassembly and Access Overview 0000 eee eee eee 2 1 Electrostatic Discharge Precautions 0005 2 1 JOOS oi eenaa EEn A a E E O E OEE EEA 2 2 Fastener Torque Specifications nusas 2 2 Torque Sequence asse ses cer eR Renner 2 2 Torque Specifications c cec rm oen e 2 3 Disassembly and Access Procedures 000s eae 2 5 Removing the High Voltage Guard 0 00 eee 2 5 Removah osuere Ea metti 2 6 WiStAIANON 2 oro citar esa cans ve ineens henes iett 2 6 Removing Control Interface L Option Board MOD L4 L5 or L6 2 7 Removal seserys ereta eoa i eE nEn E ETES P 2 7 Installation as ca xx xeu aaa 2 8 Removing the Circuit Board Platform 005 2 9 Removal 0 0 0 ccc cette e 2 9 ASTANA OI sx ce pcs stn sea Been te ic ec aite Cet anata Oh 2 11 Removing the Main Control Board 0 cee eee 2 12 Removal EET 2 13 WriStallallOTE aid oci ea e Com CoD Gees tera OT e ER ede 2 14 Removing the Standard Adapter Board 05 2 15 REMOVAll sti cs siete guter ir sepe E Demi tape Pa i 2 15 Irnistallatorizs vi
74. lects Local Control The available combinations are shown in Figure 2 5 Programming the Input Mode parameter to one of the Input Mode numbers listed selects that combination of input functions Important The Input Mode parameter can be changed at any time however programming changes will not take affect until power has been cycled to the drive When changing an input mode it is important to note that the corresponding inputs to TB3 may also change The programming options of the Control Interface Option allow the user to select an input combination to meet the needs of a specific installation Appropriate selection of a combination may be done by using Table 1 A First determine the type of start stop direction control desired Then select the remaining control functions available After selecting a group of Input Modes use Table 1 A for specific mode selection Record the selected mode number below Selected Mode Number For local programming and control information refer to the 1336 FORCE User Manual Publication 1336 FORCE 6 16 August 1999 1 6 Control Logic Wiring and Adapters Table 2 A Input Mode Selection Start Stop Type Direction Control Communication Compatibility nee 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 For
75. lus bus to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Access the Main Chassis 1 2 Remove power from the drive Check for zero volts at DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the nine bolts fastening the Output Bus Bars to the Power Module Assembly and TB1 Pull the Output Bus Bars away from the drive Remove
76. ly Bus Fuse F1 DC Bus Inductor L1 Bus Bar Cable Adaptor Converter Bus and Motor Bus Bars Wires PE Wires Wire TE Wires Wires LEM Mounting Plate Power Cables Control Board Platform High Voltage Guard Publication 1336 FORCE 6 16 August 1999 Table 3 A Fastener Torque Specifications Fastener Application Motor to Fan Cover Assembly Assembly to chassis Transformer to chassis Capacitor to chassis MOV to chassis Resistor to heat sink Wires to Capacitor Bus Bar Assembly Bracket to Power Module Board to Brackets Board to Input Rectifier Resistor to heat sink Wires to Capacitor Bus Bar Assembly Thermistor to heatsink Holder to Bus Capacitors Assembly to Bus Capacitors Board to Power Modules Bus Bar to Power Modules Module to heat sink Rail to chassis Bar to TB1 Rectifier to heat sink Fuse to Input Bus Bar Assembly to Power Module Bus Bar Assembly Fuse to Transitional Bus Bar Assembly Inductor to chassis Adaptor to Transitional Bus Bar Assembly and DC Bus Inductor Bus Bars to all connections Wires to Ground Stud Wires to TB1 Wire to TB1 Wires to TB2 Wires to TB3 Mounting Plate to LEM Clamping Plate Cables to terminals Plates to chassis Guard to chassis Torque Torque Ib in N m 14 2 26 3 26 3 Hand tighten 14 2 26 3 50 6 80 9 50 6 50 6 26 3 50 6 14 2 26 3 50 6 14 2 80 9 Refer to Figure 3 3 50 6 80 9 50 6 208 23 208 23 80 9 50 6 208 23 208 23 80 9 80 9
77. minals R L1 S L2 and T L3 on TBI 3 Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board TB3 on drives using a Control Interface L Option Board 4 Remove the screws fastening the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard 5 Remove the screws fastening the two Bus Fuses to the drive 6 Pull the fuses out from the drive Important When one fuse blows you must replace both fuses Also replace the Bus Fuse Diode Module in parallel Installation Install the Bus Fuses in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 Part Replacement Procedures 4 15 Input Fuses The Input Fuses are located on the bottom left hand side of the chassis above TB1 Figure 5 7 Input Fuses AB0795A 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
78. mon Fault Output NC Fault Output COM Fault Output NO OUT 1 COM 1 COM 2 OUT 2 OUT 3 COM 3 OUT 4 COM 4 N 1 N1 N 2 N 2 N 3 N 3 N 4 N 4 TB21 10V COM o CO N 10V Publication 1336 FORCE 6 16 August 1999 Adapters and Communication Ports Control Logic Wiring and Adapters 1 11 Human Interface Module When the drive mounted HIM is supplied it will be connected as Port 1 refer to Figure 2 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 Refer to the 1336 FORCE User Manual for HIM operation Important The operation of HIM functions depends upon drive parameter settings Default parameter values allow full HIM functionality Figure 2 7 Human Interface Module Standard Adapter Only Display Panel Storred ve wae 0 00 RPM al E CH A Eu Control Panel Human Interface Module HIM Door Mounted Board Mounted HIM HIM NEMA Type1 ABO751B Publication 1336 FORCE 6 16 August 1999
79. mployee Workplaces when working on or near energized equipment Do not work alone on energized equipment 6 Apply power AFTER the meter is connected otherwise your meter will read zero volts Expand readings for all input voltage ratings Table 4 D Bus Capacitor Bank Test Drive Rating Input Volts Meter Reading 200 283V DC 10 230 325V DC 10 240 339V DC 10 380 537V DC 10 415 587V DC 10 480 679V DC 10 500 707V DC 10 575 813V DC 10 600 848V DC 10 Publication 1336 FORCE 6 16 August 1999 3 14 Component Test Procedures 7 If the voltage is out of tolerance check the following e An open condition at an Input Rectifier e A voltage drop due to Bus Inductor L1 resistance e A voltage drop between an Input Rectifier and the bus capacitors due to loose or resistive wires or connections Precharge circuit problems 8 If the above check does not reveal a problem replace the Bus Capacitor Bank and Load Sharing Resistors Refer to Chapter 4 Part Replacement Procedures Bus Capacitor Bank ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 Test 5 Testing the Input Rectifiers Component Test Procedures 3 15 The Input Rectifiers are located on the bottom of the heat sink Figure 4 5 Input Rectifier Test Important
80. n Allen Bradley a Rockwell Automation Business has been helping its customers improve pro ductivity and quality for more than 90 years We design manufacture and support a broad range Allen Bradley 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 Ig EE Worldwide representation sss Usa il Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Ireland e Israel e Italy e Jamaica e Japan e Jordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 1336 FORCE 6 16 August
81. ng power to the drive Failure to replace guards may result in death or serious injury Part Replacement Procedures 4 17 Ground Fault CT The Ground Fault CT encircles the Input Bus Bars and is located between the Input Fuse Assembly and the Input Rectifier Assembly Figure 5 8 Ground Fault CT Ground Fault CT Input Bus Bars Connector to Gate Driver Board J2 AB0793A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 4 18 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 Publication 1336 FORCE 6 16 August 1999 drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S
82. ntrol K D pe Board 2E Slide Mount 0r Stand Off A Dm Mounting SS vA Screw Nx ON jd LB ae ere NN J onnector T w AA ay EE tandari TB7 E Adapter Board g5 TB6 CS Q AB0894A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Publication 1336 FORCE 6 16 August 1999 2 16 Disassembly and Access Procedures Publication 1336 FORCE 6 16 August 1999 Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at terminals V and V on TB11 on the Main Control Board e TB5 TB6 and TB7 on the Standard Adapter Board TB3 the Control Interface L Option Board Disconnect the following from the Standard Adapter Board e Stake on ground wire connector All wires from TB5 TB6 and TB7 by separating the mating connectors with wires from the Adapter Board 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 Control Board Adapter Mounting Plate Pull the Standard Adapter Board
83. nts 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 e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI 3 Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board 4 Remove the Circuit Board Platform Refer to Removing the Circuit Board Platform in this chapter 5 Remove the wire from Input Rectifier Snubber Board stake on connectors J1 AC1 and J2 AC2 6 Remove the two screws fastening the Snubber Board to the Converter Bus Bar Installation Install the Snubber Board in reverse order of removal Refer to Table 3 A Fastener Torque Specifications Important Verify that the snubber resistor wiring is reconnected to the proper phase snubber board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Accessing Power Plane Components To access the power plane compon
84. o not carry these labels Disassembly and Access Procedures 2 3 Figure 3 1 Two Point Mounting Two Point Mounting Temporary Tighten o ae 4 Final Tighten ABOO16A x UG S d O O O Temporary Tighten O Om O 0 Final Tighten Figure 3 3 Six Point Mounting 0 49 9 D 9 O o o oO Temporary Tighten to 0 5 N m 4 Ib in 8 2 D DOO O Final Tighten to 3 N m 26 Ib in Six Point Mounting AB0433B Important Do not exceed 0 5 Newton meters 4 Ib in on initial torque of all six screws O Figure 3 2 Four Point Mounting AB0017A Torque Specifications The following table lists fastener locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point four point and six point components to the heat sink Publication 1336 FORCE 6 16 August 1999 2 4 Disassembly and Access Procedures Component Fan Motor Fan Cover Assembly Fan Transformer Fan Capacitor MOV Surge Suppressor Snubber Resistor Snubber Resistor Snubber Bracket Snubber Board Snubber Board Volt Sharing Resistor Volt Sharing Resistor Thermistor Bus Capacitor Holder Capacitor Bus Bar Assembly Power Module Gate Interface Board Power Module Bus Bar Power Module DIN Rail TB1 PE Shortening Bar Input Rectifier Input Fuse Transitional Bus Bar Assemb
85. ode Description Human Interface Module NEMA Type 1 IP 20 Communication Options GM1 Single Point Remote I O GM2 RS 232 422 485 DF1 amp DH485 GM3 DeviceNet Human Interface Module NEMA Type 12 IP 54 Control Interface Options Programmer Only L4 TTL Contact Programmer Controller w Digital Pot L4E TTL Contact amp Encoder Feedback L5 24V AC DC L5E 24V AC DC amp Encoder Feedback L6 115V AC L6E 115V AC amp Encoder Feedback 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 2 high input line voltage the actual amp rating is 14 x 94 altitude derating x 96 high input line derating 12 6 amps Enclosure Type The first character A indicates the Enclosure Code The second character indicates the type of enclosure shipped from the factory Table P C Enclosure Type Code Description Enclosure Type Code Description N Open style IP 00 A NEMA Type 1 IP 20 F NEMA Type 4 IP 65 J NEMA Type 12 IP 54 Publication 1336 FORCE 6 16 August 1999 P 6 Preface Conventions Publication 1336 FORCE 6 16 August 1999 To help differentiate
86. oltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 16 August 1999 4 2 Part Replacement Procedures Major Component Replacement Publication 1336 FORCE 6 16 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 e Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive and immediately insert them into their conductive packets Tools You need the following tools to disassemble and assemble the drive e Pliers e Phillips screwdrivers small medium and large e Stan
87. om the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform Remove the Input Rectifier Snubber Boards Refer to Chapter 2 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board Remove the three bolts fastening the Input Bus Bars to the Input Rectifiers Remove the six Allen head screws fastening the positive and negative Converter Bus Bars to the Input Rectifiers Remove the Precharge Wiring Harness from the top of the rectifiers 10 Remove the four screws fastening the Input Rectifier to the heat sink 11 Pull the Input Rectifier away from the heat sink Publication 1336 FORCE 6 16 August 1999 4 22 Part Replacement Procedures Installation 1 Clean all surfaces between the Input Rectifier and the heat sink using a soft clean cloth 2 Replace the Preform between the Input Rectifier
88. out this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product ControlNet is a trademark PLC is a registered trademark of Rockwell Automation Updated Information 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 16 August 1999 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE 6 16 August 1999 Preface Control Logic Wiring and Adapters Table of Contents Manual ODIBCINB 6rd sce ark wee RE n EE RE TES P 1 Who Should Use This Manual 000 0 cece eee P 1 Safety Precautions iua zx E hee ER EORR bade ens Ron d P 1 Electrostatic Discharge Precautions susunanana P 2 1336 FORCE Product Identification 0 2 cee eee P 3 Drive Nameplate Location 0 cee e eee eee P 3 Software Compatibility cles P 3 Drive and Option Identification 0 eee eee P 4
89. 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 Female connectors are
90. r Board Illustration 2 15 Installation 2 16 Removal 2 15 Terminal Block Locations 1 2 T TB3 Terminal Designations 1 6 Terminal Block Locations 1 2 Terminal Designations TB3 1 6 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 6 Six Point Mounting Sequence 2 3 Specifications 2 3 Two Point Mounting Sequence 2 3 Troubleshooting Component Test Procedures 3 1 True Definition P 8 Two Point Mounting 2 3 W Wire Sizes 1 6 Notes Publication 1336 FORCE 6 16 August 1999 Publication 1336 FORCE 6 16 August 1999 CUT ALONG DOTTED LINE We Want Our Manuals to be the Best Ty You can help Our manuals must meet the needs of you the user This is your opportunity to make sure they do just that By filling out this form you can help us provide the most useful thorough and accurate manuals available Please take a few minutes to tell us what you think Then mail or FAX this form FAX to your local Rockwell Automation Allen Bradley Sales Office or 414 512 8579 PUBLICATION NAME PUBLICATION NUMBER DATE AND PART NUMBER IF PRESENT V CHECK THE FUNCTION THAT MOST CLEARLY DESCRIBES YOUR JOB SUGGEST RESPONSIBLE FOR THE PURCHASE OF EQUIPMENT MAINTAIN OPERATE PROGRAMMABLE MACHINERY DESIGN IMPLEMENT ELECTRICAL SYSTEMS TRAIN
91. re connected to the Control Interface L Option Board through TB3 The L4 L5 and L6 options each have nine control inputs The function of each input must be selected through programming as explained later in this section The LAE L5E and L6E options are similar to L4 L5 and L6 with the addition of encoder feedback inputs Publication 1336 FORCE 6 16 August 1999 Control Logic Wiring and Adapters Publication 1336 FORCE 6 16 August 1999 Control Interface Board Jumpers Important If the Control Interface L Option Board is being installed Standard Adapter Board jumpers at pins 3 amp 4 and 17 amp 18 of J10 must be removed If this board is removed these jumpers must be reinstalled and the Input Mode parameter must be programmed to 1 Figure 2 3 Jumper Locations LE ea MI Rr snm elle T eTeT Eele d Jumper J10 Located on Standard Adapter Board AB0819A Local Programming Control Logic Wiring and Adapters 1 5 Available Inputs A variety of combinations made up of the following inputs are available Start Enable Stop Clear Fault Auxiliary Reverse 2 Stop Mode Selects Digital Potentiometer MOP Run Forward 2 Accel Decel Rates Run Reverse 3 Speed Se
92. rmistor in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 4 10 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Power Modules The Power Modules are located near the top of the heat sink If one or more Power Modules is replaced you must check the Power Module Snubber Board and the Precharge Board Refer to Chapter 2 Disassembly and Access Procedures Removing the Precharge Board Figure 5 5 Power Modules Power Module Preform Power Gate Interface Module y Board EK Screw e Pd 3 Power Module Bus Bar PE oor Snubber SEX Standoffs Saw Screw ac Ree Bn N T l Output Bus EC Bar ER S D AB0789A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 4 11 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for ze
93. ro 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and plus bus to discharge any voltage Refer to Chapter 2 Disassembly and Access Procedures Removing a Power Module Snubber Board ATTENTION Wear a wrist type grounding strap when servicing 1336 FORCE Drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals terminals R L1 S L2 and T L3 on TBI Check for absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board e TB3 on drives using a Control Interface L Option Board Remove the High Voltage Guard from the drive Refer to Chapter 2 Disassembly and Access Procedures Removing the High Voltage Guard Remove the Circuit Board Platform Refer to Chapter 2 Disassembly and Access Procedures Removing the Circuit Board Platform
94. s applications For operation refer to the Product Data Drive Tools Software manual All 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 All 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 input of an Adapter board or a signal coming in via RIO from a PLC Refer to the 1336 FORCE User Manual Publication 1336 FORCE 5 12 Chapter 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
95. sh GT1EN Standard Adapter English GT2EN No Adapter GTO 380 480V AC Input Constant Drive Enclosures Drive Rating Open NEMA Type 1 NEMA Type 4 NEMA Type 12 IP00 IP20 IP65 IP54 No Enclosure General Purpose Resist Water Dust Industrial Use T Frame Constant Torque Designation Output Nominal HP Code Amps F BP300 AN BP300 AA 3 BP350 AN BP350 AA 3 BP400 AN BP400 AA 3 531 7 450 BP450 AN BP450 AA 3 1 Drive rating is based on a carrier frequency of 4kHz maximum an altitude of 1 000 meters or less and a maximum ambient temperature of 40 C 2 Refer to the Language Module and Options tables following these Catalog Number tables Not available in this rating 4l An adapter Board see Adapter Options Factory Installed table is required to make the drive functional If the GTO option no adapter is chosen then the Adapter Kit must be added after shipment 5 A Common Mode Choke option CM or No Common Mode Choke option NCM must be specified with each F Frame Drive Publication 1336 FORCE 6 16 August 1999 1 Blank No Functionality Programmer Only Programmer Controller w Analog Pot Programmer Controller w Digital Pot Preface P 5 Table P B Options Description C
96. shows the current status of the drive i e Stopped Running etc or any faults that may be present Not Enabled etc Refer to the 1336 FORCE Field Oriented Control User Manual for HIM operation Figure 2 10 Status Display Stopped ORO Rew Graphic Programming Terminal Control Logic Wiring and Adapters 1 15 GPT Description The optional GPT Figure 2 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 2 11 Graphic Programming Terminal 4 5 PRESET 4 PRESET 5 PRESET 1 PRESET 2 PRESET 3 AB0554A Publication 1336 FORCE 6 16 August 1999 1 16 Control Logic Wiring and Adapters Drive Tools Control Firmware Function Publication 1336 FORCE 6 16 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 Rockwell Automation AC and DC digital drive products The software consists of five Window
97. tallation Install the MOV Surge Suppressor in reverse order of removal Refer to Chapter 2 Disassembly and Access Procedures Fastener Torque Specifications ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury Publication 1336 FORCE 6 16 August 1999 4 28 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Fan and Transformer Assembly The Fan is located in the chassis and under TB1 at the bottom of the heat sink The Fan Transformer and Fan Capacitor are located in the bottom left corner of the chassis Figure 5 12 Fan and Transformer MOV Surge Suppressor n ABER TB1 Label Plate AB0791A Removal ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Part Replacement Procedures 4 29 ATTENTION Hazard of electric shock exists Up to 1 600 VDC will be on J1 if the Snubber Resistor is open Measure for zero 0 VDC from Snubber Board terminal TP3 to plus bus before removing connector J1 Use a resistor greater than 1 ohm and less than 100 ohm rated for 25 watts minimum between TP3 and p
98. ted circuit boards except the Main Control Board assembly are referenced to negative ground bus ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION This assembly contains parts and sub assemblies that are sensitive to electrostatic discharge Static control precautions are required when servicing this assembly Component damage may result if you ignore electrostatic discharge control procedures If you are not familiar with static control procedures reference Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostatic Discharge or any other applicable ESD protection handbook Publication 1336 FORCE 6 16 August 1999 1 2 Control Logic Wiring and Adapters Figure 2 1 Standard Adapter Terminal Block Locations Main Control TB10 Encoder Board eI ee Standard Adapter Board TB3 Control L Option Board Control Interface L Option Board Le TB5 TB6 TB7 s Control and ac Signal Wiring 4 f K Mae TBI Power TB5 TB6 En Terminal Block Control and Signal Wiring
99. tener Torque Specifications Important Orient the notch and vent hole on the Bus Capacitors to the top of the drive 2 Connect the Load Sharing Resistors to the Bus Capacitors according to the diagram in Figure 5 3 Refer to the schematic diagrams in this manual for more information on component configurations Important Check the Load Sharing Resistors for an open condition and replace any open resistors Important If the drive is equipped with PEM nuts on the Cap Bus bar use them instead of capacitor studs to make the electrical connection Figure 5 3 Load Sharing Resistor Connections to Bus Capacitors me C37 C57 Fa C98 LZ CH LZ C137 C15 2 C17 7 4 e o e R1 hd C27 Amn 067 Ba C10 BN C12 FY C14 7 O16 L C18 7 AB0820A ATTENTION Capacitors not installed correctly will erupt or vent and could cause injury and equipment damage Observe correct polarities Publication 1336 FORCE 6 16 August 1999 4 8 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 Thermistor The Thermistor is located on the heat sink at the top middle of the drive Figure 5 4 Thermistor Thermistor Connector to Main Control Board J1 Tg gt B AB0833A Removal ATTENTION Disconnect and lock out power from the drive before disassembling th
100. the Input Fuses Refer to the removal instructions for Input Fuses in this chapter Publication 1336 FORCE 6 16 August 1999 4 30 Part Replacement Procedures Publication 1336 FORCE 6 16 August 1999 9 Remove the three bolts fastening the Input Bus Bars to the Input Rectifier and remove the six screws on the Input Bus Bars 10 Remove the Input Bus Bars with the Ground Fault CT encircling the bars from the drive 11 Remove the MOV Surge Suppressor Refer to the removal instructions for the MOV Surge Suppressor in this chapter Remove TBI 1 Remove the nut located on the lowest stud on Terminal PE 2 Remove the four screws fastening the TB1 Assembly to the drive 3 Pull the complete TB1 Assembly with the shield and LEMS attached away from the drive Access the Fan 1 Disconnect the Fan Wiring Harness Remove the screws fastening the Fan Cover to the chassis Pull the Fan Cover assembly away from the drive gt WwW N Remove the screws fastening the fan to the Fan Cover to remove the fan Disconnect the Fan Capacitor from the Fan Wiring Harness Unscrew the Fan Capacitor from the chassis by hand Disconnect the Fan Transformer from the Fan Wiring Harness oc Nl A Un Remove the screws fastening the Fan Transformer to the chassis Installation Install the Fan Assembly in reverse order of removal with the following exceptions Thread the fan wiring connector through the hole in t
101. to change Parameter settings and drive functions Publication 1336 FORCE 6 16 August 1999 P 8 Preface Related Publications Publication 1336 FORCE 6 16 August 1999 True True refers to a logical true state For instance a Control Interface signal on TB3 is true when L4 L4E contact input is closed L5 L5E input terminal registers 24V or L6 L6E input terminal registers 115V AC The following lists other Rockwell Automation 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 FORCE 6 0 Options Manuals Instructions Chapter 1 Control Logic Wiring and Adapters Chapter Objectives This chapter introduces you to terminal block locations and wiring and to adapter locations and functions Chapter Overview This chapter illustrates and describes the Standard Adapter Board Control Logic Interface Options L4 L5 and L6 including terminal block TB3 e TB3 input mode selections and functions e TB3 TB5 TB6 TB7 terminal designations This chapter illustrates and describes the following terminal designations for the PLC Comm Adapter Board e TB20 e TB21 Important All prin
102. trol voltage at e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS TB6 and TB7 on drives using a Standard Adapter Board Remove the Control Board Adapter Mounting Plate Refer to Chapter 2 Disassembly and Access Procedures Removing the Main Control Board Mounting Plate Unplug the connectors from the Gate Driver Board Set your meter to test resistance Test Fuses F1 and F3 for an open condition Replace the Gate Driver Board if either fuse shows an open condition 10 Set your meter to test diodes 11 Test VR1 VR6 The following table shows meter connections at Publication 1336 FORCE 6 16 August 1999 the components and ideal meter readings for those connections Refer to Figure 4 1 for component locations Component Test Procedures 3 5 Table 4 A Gate Driver Board Test Component Meter Lead Meter Lead Nominal Meter Reading VR1 1 06 1 8 VR2 1 06 i 1 8 VR3 1 06 1 8 VR4 1 06 1 8 VR5 1 06 1 8 VR6 1 06 1 8 Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range 12 Replace the Gate Driver Board if your readings do not match the table readings Refer to Chapter 2 Disassembly and Access Procedures Removing the Gate Driver Board ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury P
103. ublication 1336 FORCE 6 16 August 1999 3 6 Component Test Procedures Test 2 Testing the Precharge Board Publication 1336 FORCE 6 16 August 1999 If Input Rectifier modules have been replaced you must check the Input Rectifier Snubber Board and the Precharge Board Refer to Chapter 2 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board and Removing the Precharge Board Figure 4 2 Precharge Board Test Precharge Board n gt ARR AB0831A ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify bus voltage by measuring the voltage between the DC DC Brake Terminals Do not attempt to service the drive until the bus voltage has discharged to zero volts Component Test Procedures 3 7 Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly Remove power from the drive Check for zero volts at e DC DC Brake Terminals e terminals R L1 S L2 and T L3 on TBI Check for the absence of control voltage at e terminals V and V on TB11 on the Main Control Board e TB20 and TB21 on drives using a PLC Comm Adapter Board e TBS
104. us parameter alle However only Stop Fault Reset and Enable will E Status have control function 8 Common 8 2 Status Status Status Common Enable Input Mode 2 6 Three Wire Control with Single Source Reversing Start 2 a Z gs 3 ok Stop Clear Fault 8 28 E Es g Mode m SBE SEA Common 2 3 4 5 6 17 18 oon Sok 88 E qu Rev Fwd 9 Rev Fwd 6 Rev Fwd 6 Rev Fwd 6 Rev Fwd 6 Rev Fwd 6 Rev Fwd 6 son REN LT E a 5 Jog Stop ist2nd Digital Jog Proc Flux En S28 Ea o Type Accel PotUp Trim Jog o og cd 2 Sto 293 5 Ext Fault 59 856 a 5 z o Q F i E O45 Sas v5 Q Common Oa lt 5 amp o ZEO T SB Er Speed Speed isU2nd Digital Local Ramp Reset ZLE RSS Select3 Select3 Decel PotDn Control ORE sia pa o luu I CERE Speed Select 21 1 See Table 1 B ET o i Sag 2 Drive must be stopped to take Local Control E e so Hd 2 Speed Select 11 Control by all other adapters is disabled except Stop 4 amp 8855 898R 3 These inputs must be present before drive will start 4 Bit 0 of Direction Mask must 1 5 For Common Bus Precharge Enable 6 Bit 12 of Para 59 Logic Options must 0 for Reverse Direction Control Enable 7 Soft Fault Reset Only Must Cycle Power to Drive to Clear Hard Fault Hard Fault See Troubleshooting Section 8 Soft Fault Refer to Para 59 to Configure Start amp Stop Type AB0290B 9 Can be masked out Common A Publication 133
105. ve Nameplate Location The drive nameplate is located on the face of the Main Control Board Mounting Plate The drive nameplate contains the drive s catalog number and other important drive information Reference the catalog number when ordering replacement parts Figure P 1 Drive Nameplate Location Nameplate located on top edge of Control Board Adapter Mounting Plate Precharge Board ABO0806A Software Compatibility Three Phase Drive Rating 380 480V Compatible with Version Frame Reference 187 336 kW Standard Adapter Board 4 xx amp Up F 250 450 HP PLC Comm Adapter Board 3 02 amp Up 1 kW and HP are constant torque CT ratings Publication 1336 FORCE 6 16 August 1999 P 4 Preface Drive and Option The following is an explanation of the catalog numbering system for Identification 1336 FORCE Adjustable Frequency AC Drives and options The catalog number is coded to identify the drive power rating and can be found on the drive shipping carton and nameplate 1336 FORCE Drive Catalog Numbers Table P A BULLETIN NO DRIVE RATING ENCLOSURE STYLE ADAPTER OPTIONS MUST BE SPECIFIED MUST BE SPECIFIED MUST BE SPECIFIED AS REQUIRED Adapter Options Factory Installed Select One Description Option Code PLC Communication Adapter Engli
106. ward Direction Control will not work in parallel with HIM or Communication 8 Wire Closed Reverse Options User must select direction control from either HIM and Communication Options or TB3 input Momentary Momentary Pushbuttons Start Stop works in parallel with HIM and Communication Options Pushbutton Forward and Reverse Direction works in parallel with HIM or Communication Options 7 11 8 Wire Maintained switches for combined run and direction Start works differently than three wire control 12 16 control 2 wire Run Forward Run Reverse Direction works differently than three wire control Stop always works Refer to two three wire notes in the user manual Figure 2 4 provides the terminal designations for TB3 The maximum and minimum wire sizes accepted by TB3 are 2 1 and 0 30 mm 14 and 22 AWG Recommended torque for all terminals is 0 9 1 13 N m 8 10 Ib in Use Copper wire only Figure 2 4 TB3 Terminal Designations Publication 1336 FORCE 6 16 August 1999 Input 2 Stop Common Common AB0293B Control Logic Wiring and Adapters 1 7 Figure 2 5 Input Mode Selection and Typical TB3 Connections eil gt o Momentary Input Mode 1 o o Maintained Factory Default Status Stop Fault Reset Common Status Note If this mode is selected the status of all Stat inputs can be read at the Input Stat
107. y Left Blank Publication 1336 FORCE 6 16 August 1999 Chapter 6 Schematics 250 450 HP 1336 FORCE Drives Publication 1336 FORCE 6 16 August 1999 6 2 Schematics 250 450 HP 1336 FORCE Drives TE AC TO BLOWER INPU POWER CIRCUIT Z 50 60H CF1 R L1 CF2 CF3 CH S L2 CH CH MOV1 Y I Y 480V OUT 1 1 O 480V y PE OUT 2 Oo 480V OUT3 AUX AC POWER OUTPUT TB9 SEE NOTE 5 CT3 TE JUMPER PE CONV SNUBBER Atl La DC USER BRAKE POWER DC CONV CONV SNUBBER SNUBBER A12 A13 L Ria H F RI3 H CNV CH1 e DC DC CF4 CF5 4INV P SEE NOTE 2 2 3 Di CAP BANK R2G R2K T2G TK DC DC s 4SMPS STANDARD PRECHARGE Fi F2 F3 BOARD J4 J3 SEE NOTE 3 SMPS 15V common SEE NOTE 5 5V CH

Service Manual, 1336 FORCE, Adjustable Frequency AC Drive

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