Publication 1336 PLUS-6.5 August, 1999

TroubleshootingGuide

Bulletin 1336 PLUSAdjustable FrequencyAC Drive Series A, B, C, DB300 – B600BX250C300 – C600

Allen-Bradley

Important User Information

ATTENTION: Identifies information about practices orcircumstances that can lead to personal injury or death, propertydamage or economic loss.

Attentions help you:

• Identify a hazard.

• Avoid the hazard.

• Recognize the consequences.

IMPORTANT: Identifies information that is especially important forsuccessful application and understanding of the product.

DANGER labels may be located on or inside the drive to alertpeople that dangerous voltage may be present.

Summary of Changes

The information below summarizes the changes to the company-widetemplates since the last release.

Updated Information Information has been added to Overtemp Fault 08 in Table 2.A on page 2-6.

An illustration has been added on page 4-11.

Table 4.F on page 4-16 has been changed.

Summary of Changes

This Page Intentionally Left Blank

Table of Contents

i

Preface

Manual Objective P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Who Should Use This Manual P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions P-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1336 PLUS Product Identification P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Nameplate Location P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Software Compatibility P-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive and Option Identification P-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1336 PLUS Drive Catalog Numbers P-5. . . . . . . . . . . . . . . . . . . . . . . .

Drive Rating Qualifications P-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure Type P-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventions P-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Publications P-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Logic Wiring Chapter 1and Adapters

Chapter Objectives 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Interface Option 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Interface Board Jumpers 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Available Inputs 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Programming 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Human Interface Module (HIM) 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module Removal 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIM Operation 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

ii

Troubleshooting and Chapter 2Error Codes


Troubleshooting Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Descriptions 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Display 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact Description 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Procedures by Symptom 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Will Not Start 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Display 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Will Not Jog 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive Stays at Zero Hertz When Started 2-14. . . . . . . . . . . . . . . . . . . . .

Drive Goes to Max Frequency 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearing Faults 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly and Chapter 3Access Procedures


Disassembly and Access Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Tools 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastener Torque Specifications 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Sequence 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly and Access Procedures 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the Drive Enclosure 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Control Interface Board 3-9. . . . . . . . . . . . . . . . . . . . . . .

Removing the Main Control Board Mounting Plate 3-11. . . . . . . . . . . .

Removing the Main Control Board 3-14. . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Gate Driver Board 3-16. . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Precharge Board 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access to the Inverter Housing and Capacitor Bank Assemblies 3-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access to the Inverter Housing Assembly 3-23. . . . . . . . . . . . . . . . . . . .

Table of Contents

iii

Removing the PC Board Mounting Frame 3-30. . . . . . . . . . . . . . . . . . .

Access to the Capacitor Bank Assembly 3-32. . . . . . . . . . . . . . . . . . . . .

Removing a Power Module Snubber Board 3-35. . . . . . . . . . . . . . . . . .

Removing an Input Rectifier Snubber Board 3-38. . . . . . . . . . . . . . . . .

Component Test Procedures Chapter 4


Component Test Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Tools 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 1 Testing the Gate Driver Board 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 2 Testing the Precharge Board 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 3 Testing the Power Modules 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 4 Testing the Bus Capacitors 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 5 Testing the SCRs 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part Replacement Procedures Chapter 5

Chapter Objective 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part Replacement Overview 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Major Component Replacement 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Detailed Product Identification 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bus Capacitor Bank 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermistor 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Modules 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Module Snubber Resistor 5-14. . . . . . . . . . . . . . . . . . . . . . . . . . .

SCRs 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan and Transformer Assembly 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

DC Bus Inductor 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ground Sense CT 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bus Fuses 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LEMs 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOV Surge Suppressor 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

iv

Replacement Parts List Chapter 6


Ordering Replacement Parts 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Parts Listing 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematics

150 – 300 HP 1336 PLUS Drives S-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary G-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index I-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface

P-1

Preface

Manual Objective The information in this manual is designed to help troubleshoot or repair anAllen-Bradley Bulletin 1336 PLUS Adjustable Frequency AC Drive withratings B300 – B600, C300 – C600, and BX250.

Who Should Use This manual is intended for qualified service personnel responsible for

This Manual troubleshooting and repairing the 1336 PLUS Adjustable Frequency ACDrive. You should:

Read this entire manual before performing maintenance or repairs todrives.

Have previous experience with, and basic understanding of, electricalterminology, procedures, required troubleshooting equipment, equipmentprotection procedures and methods, and safety precautions.

This manual describes equipment, troubleshooting, and disassemblyprocedures. You begin with general illustrations and end with greater detailconcerning replacement parts and part locations on the drives. Laterchapters may refer you back to earlier chapters for information on basicequipment and steps necessary to perform detailed diagnostics and partreplacement.

ATTENTION: Some printed circuit boards and drive componentsmay contain hazardous voltage levels. Remove and lock out powerbefore you disconnect or reconnect wires, and before you removeor replace fuses and circuit boards. Verify bus voltage bymeasuring the voltage between the Negative Capacitor Bus andboth ends of all three 350 amp fuses. An open fuse does not showvoltage across both ends of the fuse. Failure to measure voltage atboth ends of the fuses may result in death or serious injury. Refer toFigure 3.5. Do not attempt to service the drive until the bus voltagehas discharged to zero volts.

Safety Precautions

Preface

P-2

ATTENTION: Potentially fatal voltages may result from improperusage of oscilloscope and other test equipment. The oscilloscopechassis may be at a potentially fatal voltage if not properlygrounded. If an oscilloscope is used to measure high voltagewaveforms, use only a dual channel oscilloscope in the differentialmode with X 100 probes. It is recommended that the oscilloscopebe used in the A minus B Quasi-differential mode with theoscilloscope chassis correctly grounded to an earth ground.

ATTENTION: Only personnel familiar with the 1336 PLUSAdjustable Frequency AC Drive and associated machinery shouldplan or implement the installation, start-up and subsequentmaintenance of the system. Failure to comply may result inpersonal injury and/or equipment damage.

ATTENTION: This assembly contains parts and sub-assembliesthat are sensitive to electrostatic discharge. Static controlprecautions are required when servicing this assembly. Componentdamage may result if you ignore electrostatic discharge controlprocedures. If you are not familiar with static control procedures,reference Allen-Bradley Publication 8000-4.5.2, Guarding AgainstElectrostatic Damage, or any other applicable ESD protectionhandbook.

Electrostatic DischargePrecautions

Electrostatic discharge generated by static electricity can damage thecomplimentary metallic oxide semiconductor devices on various driveboards. It is recommended that you perform these procedures to guardagainst this type of damage when circuit boards are removed or installed:

Wear a wrist type grounding strap that is grounded to the drive chassis.

Attach the wrist strap before removing the new circuit board from theconductive packet.

Remove boards from the drive and immediately insert them into theirconductive packets.

Preface

P-3

1336 PLUSProduct Identification

Drive Nameplate Location

The drive nameplate is located on the face of the Main Control Boardmounting plate. The drive nameplate contains the drive’s catalog numberand other important drive information. Reference the catalog number whenordering replacement parts.

Figure 1.1Drive Nameplate Location

AB0541A

Nameplate locatedon botttom of PCBoard Mounting

Frame

Preface

P-4

Software Compatibility

ATTENTION: To guard against machine damage and/or personalinjury, drives with ratings above 45 kW (60 HP) must not be usedwith software versions below 1.07. Refer to the table below.

Three-Phase Drive Rating

380 – 480V 500 – 600VCompatible with

VersionFrame

Reference

187 – 448 kW250 – 600 HP

224 – 448 kW300 – 600 HP

2.01 & Up G

kW and HP are constant torque (CT) ratings.

Preface

P-5

Drive and Option The following is an explanation of the catalog numbering system for 1336

Identification PLUS Adjustable Frequency AC Drives and options. The catalog numberis coded to identify the drive power rating and can be found on the driveshipping carton and nameplate.

1336 PLUS Drive Catalog Numbers

Table 1.A

1336S – B600-AA – EN – L6 – HA1 – GM1

BULLETIN NO. RATING-ENCLOSURE(MUST BE SPECIFIED)

LANGUAGE MODULE

(MUST BE SPECIFIED)CONTROL INTERFACE

(OPTIONAL)HUMAN INTERFACE

(OPTIONAL)COMMUNICATION CARD

(OPTIONAL)

380 – 480V AC Input, Constant or Variable Torque Drive

Drive Rating Enclosures

OpenIP00

No Enclosure

NEMA Type 1IP20

General Purpose

FrameDesignation

Constant Torque Variable Torque

OutputAmps

NominalHP

OutputAmps

NominalHP

Code Code

G 325.0 250 360.0 300 BX250*-AN BX250*-AA

360.0425.0475.0525.0590.0670.0

300350400450500600

425.0475.0525.0590.0670.0670.0

350400450500600600

B300-ANB350-ANB400-ANB450-ANB500-ANB600-AN

B300-AAB350-AAB400-AAB450-ANB500-ANB600-AN

* 480 volts only

Preface

P-6

Table 1.B

1336S – C600-AA – EN – L6 – HA1 – GM1

BULLETIN NO. RATING-ENCLOSURE(MUST BE SPECIFIED)

LANGUAGE MODULE

(MUST BE SPECIFIED)CONTROL INTERFACE

(OPTIONAL)HUMAN INTERFACE

(OPTIONAL)COMMUNICATION CARD

(OPTIONAL)

500 – 600V AC Input, Constant or Variable Torque Drive

Enclosures

Drive Rating OpenIP00

No Enclosure

NEMA Type 1IP20

General Purpose

FrameDesignation

OutputAmps

Nominal HP CT

Nominal HPVT

Code Code

G 300.0350.0

300550

300350

C300-ANC350-AN

C300-AAC350-AA

400.0450.0

400450

400450

C400-ANC450-AN

C400-AAC450-AA

500.0600.0

500600

500600

CX500-ANCX600-AN

CX500-AACX600-AA

Preface

P-7

Table 1.C

Language Modules

Description Option Code

English/English ENEnglish/EnglishEnglish/French

ENFREnglish/French

English/GermanFRDEg

English/Italian ITEnglish/JapaneseE li h/S i h

JPESEnglish/Spanish ES

Table 1.D

OptionsCode Description Code Description

Human Interface Modules, NEMA Type 1 (IP 20) Communication Options

HABHAPHA1HA2

Blank – No FunctionalityProgrammer OnlyProgrammer, LCD/Analog PotProgrammer, LCD/Digital Pot

GM1GM2GM3

Single Point Remote I/ORS-232/422/485, DF1RS-232/422/485, DH485

Human Interface Modules, NEMA Type 4 (IP 65) Control Interface Options

HFBHFPHF1HF2


L4L4EL5L5EL6

TTL ContactsContacts & Encoder Feedback24V DC24V DC & Encoder Feedback115V AC

Human Interface Modules, NEMA Type 12 (IP 54)L6L6E

115V AC115V AC & Encoder Feedback

HJBHJPHJ1HJ2


Drive rating is based on a carrier frequency of 2kHz maximum, an altitude of 1,000 metersor less, and a maximum ambient temperature of 40°C. Refer to Qualifications on pages P-8and P-9.

Not available. VT Ratings do not apply to 380V Input. Refer to the Language Module and Options tables following these Catalog Number tables.

Preface

P-8

Table 1.E380 – 480V Drives

CatalogNumber

MaximumAmp

Rating

DerateCurve

HeatDissipation

DriveWatts

Heat SinkWatts

TotalWatts

BX250B300B350B400B450B500B600

325360425475525590670

NoneNoneNoneNoneNone

90299310551132120712941485

4100344041254865540059857367

5810443351805997660772798852

Table 1.F500 – 600V Drives

CatalogNumber

MaximumAmp

Rating

DerateCurve

HeatDissipation

DriveWatts

Heat SinkWatts

TotalWatts

C300C350C400C500C600

300350400500600

10501110120513801610

43755195601576759185

542563057220905510795

Amp Rating is at 2kHz. If carrier frequencies above 2kHz are selected, drive Amp Ratingmust be derated. Refer to the User Manual for carrier frequency vs. Amp deratings.

Drive Ambient Temperature Rating is 40C. If ambient exceeds 40C, the drive must bederated.

Drive Rating is based on altitudes of 1,000m (3,000 ft) or less. If installed at higher altitude,drive must be derated.

Refer to 1336 Plus User Manual.

Preface

P-9

Drive Rating Qualifications

Several factors can affect drive rating. If more than one factor exists,consult Allen-Bradley Company.

Enclosure Type

The first character, A, indicates the Enclosure Code.

The second character indicates the type of enclosure shipped from thefactory:

Table 1.GEnclosure Type Code Description

EnclosureType Code Description

F NEMA Type 1 (IP 65)

Preface

P-10

Conventions To help differentiate parameter names and display text from other text inthis 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, anddefinitions 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 InterfaceBoard. This connection provides an external input for use as an AuxiliaryInterlock. Unless this interlock is closed, the drive will be faulted with anAuxiliary 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 driveAuxiliary input.

Bit

A bit is a single character or status point used in programmable logic. Eightbits form a BYTE, 16 bits form a word. Drive parameters are actually eightbits or 16 bit words.

Check

To check means to examine either the physical condition of something orthe setting of some control, such as a Parameter. Checking a drive board orcomponent may also require measurements and tests.

Connector

A connector connects one drive board to another. Connectors come in twodesigns, male and female. Male connectors are stationary and contain pins,which are sometimes joined by jumpers. Female connectors are at the endsof wires or ribbon cables and plug into male connectors.

Preface

P-11

Default

When a drive function defaults, it automatically changes to apre-programmed setting.

Enable Input

The Enable Input is a terminal connection on the Control Interface Board.This connection provides an external input to enable or disable the DriveOutput section. It must be true to permit the drive to operate.

False

False refers to a logical false state. For instance, a Control Interface signalon TB3 is false when the input contact is open or the appropriate voltage isnot applied to the Control Interface Board.

Jumper

A jumper completes a circuit between two pins within a male connector ona drive board. In the absence of certain optional equipment using femaleconnectors, jumpers are applied to certain pins within a male connector tocomplete specific and necessary circuits.

Control Interface Board

A Control Interface Board plugs into connectors J7 and J9, located on thelower 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 adrive.

Parameter

Parameters are programmable drive functions that define various operatingfunctions or status displays of a drive. Refer to Bulletin 1336 PLUSAdjustable Frequency AC Drive User Manual for Parameter details.

Press

Press a button on the Human Interface Module to change Parametersettings and drive functions.

Preface

P-12

True

True refers to a logical true state. For instance, a Control Interface signalon TB3 is true when: L4/L4E contact input is closed, L5/L5E inputterminal registers 24V, or L6/L6E input terminal registers 115V AC.

Related Publications The following lists other Allen-Bradley publications that apply to the 1336PLUS Adjustable Frequency AC Drives with ratings B300 – B600, C300 –C600, and BX250:

Product Data (1336 PLUS-1.0)

User Manual (1336 PLUS-5.0)

Option Manuals/Instructions

Renewal Parts List (1336-6.5)

Chapter

1-1

Control Logic Wiring and Adapters

Chapter Objectives This chapter introduces you to terminal block locations and wiring, andadapter locations and functions.

Chapter Overview This chapter illustrates and describes:

Control Logic Interface Options L4, L5, and L6, including TerminalBlock TB3

TB3 input mode selections and functions

TB3 terminal designations

IMPORTANT: All printed circuit boards, except the Main Control Boardassembly, are referenced to negative ground (–bus).

ATTENTION: Some printed circuit boards and drive componentsmay contain hazardous voltage levels. Remove power before youdisconnect or reconnect wires, and before you remove or replacefuses and circuit boards. Verify bus voltage by measuring thevoltage between the Negative Capacitor Bus and both ends of allthree 350 amp fuses. An open fuse does not show voltage acrossboth ends of the fuse. Failure to measure voltage at both ends of thefuses may result in death or serious injury. Refer to Figure 3.5. Donot attempt to service the drive until the bus voltage has dischargedto zero volts.

ATTENTION: This assembly contains parts and sub-assembliesthat are sensitive to electrostatic discharge. Static controlprecautions are required when servicing this assembly. Componentdamage may result if you ignore electrostatic discharge controlprocedures. If you are not familiar with static control procedures,reference Allen-Bradley Publication 8000–4.5.2, Guarding AgainstElectrostatic Discharge, or any other applicable ESD protectionhandbook.

Chapter 1Control Logic Wiring and HIM Fundamentals

1-2

Figure 1.1Terminal Block Locations

AB0539A

TB3 ControlInterface Option

TB2 Control andSignal Wiring

AC LineInput

Motor BusOutput

ATTENTION: The National Electrical Code (NEC) and localcodes 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 equipmentdamage.

Control Interface The Control Interface Option provides a means of interfacing various

Option signals and commands to the 1336 PLUS by using contact closures.

Six different versions of the option are available:

L4 Contact Closure Interface1

L4E Contact Closure Interface with Encoder Feedback Inputs1

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.


1-3

The user inputs are connected to the option board through TB3. The L4, L5and L6 options each have nine control inputs. The function of each inputmust be selected through programming as explained later in this section.The L4E, L5E and L6E options are similar to L4, L5 and L6 with theaddition of encoder feedback inputs.

Control Interface Board Jumpers

IMPORTANT: If the Control Interface Board is being installed, MainControl Board jumpers at pins 3 & 4 and 17 & 18 of J4 must be removed.If removed, these jumpers can be stored on the spares location on the MainControl Board. If this board is removed, these jumpers must be reinstalledand the [Input Mode] parameter must be programmed to “1”.

Figure 1.2Jumper Locations

AB0540A

JumperSpares

Jumper J7 (Located onMain Control Board)


1-4

Available Inputs

A variety of combinations made up of the following inputs are available.

Start Enable

Stop/Clear Fault Auxiliary

Reverse 2 Stop Mode Selects

Digital Potentiometer (MOP) Run Forward

2 Accel/Decel Rates Run Reverse

3 Speed Selects Local Control

The available combinations are shown in Figure 1.4. Programming the[Input Mode] parameter to one of the Input Mode numbers listed selectsthat 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 beencycled to the drive. When changing an input mode, it is important to notethat the corresponding inputs to TB3 may also change.

The programming options of the Control Interface Option allow you toselect 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 selectthe remaining control functions available. After selecting a group of InputModes use Figure 1.2 for specific mode selection. Record the selectedmode number below.

Selected Mode Number:

Local Programming For local programming and control information, refer to the 1336 PLUSUser Manual.


1-5

Table 1.AInput Mode Selection

Start/Stop Type Direction Control Communication CompatibilityMode(s)to Use

Stop & EnableOnly

None Control must be provided by HIM or Communication Option. 1

MomentaryPushbutton(3 Wire)

Maintained Switch(Open-Forward, Closed-Reverse)

Start/Stop – works in parallel with HIM and Communication Options.Direction Control will not work in parallel with HIM or CommunicationOptions. User must select direction control from either HIM andCommunication Options or TB3 input.

2 – 6

MomentaryPushbutton(3 Wire)

Momentary Pushbuttons(Forward and Reverse)

Start/Stop – works in parallel with HIM and Communication Options.Direction – works in parallel with HIM or Communication Options. 7 – 11

Maintained switches for combined run and directioncontrol (2 wire, Run Forward, Run Reverse)

Start/Stop – not compatible with HIM or Communication Options.Direction – not compatible with HIM or Communication Options.

12 – 16

The maximum and minimum wire sizes accepted by TB3 is 2.1 and0.30 mm2 (14 and 22 AWG). Maximum torque for all terminals is0.9 – 1.13 N-m (8 – 10 in.-lb).

Figure 1.3TB3 Terminal Designations L4E, L5E, and L6E Only

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Inpu

t 1

Inpu

t 2 (S

top)

Com

mon

Inpu

t 3

Inpu

t 4

Inpu

t 5

Com

mon

Inpu

t 6

Inpu

t 7

Inpu

t 8

Com

mon

Enab

le

Enco

der B

Enco

der N

OT

A

Enco

der N

OT

B

Enco

der A

+12V

(200

mA

max

.)

Enco

der C

omm

on

AB0293A


1-6

Figure 1.4Input Mode Selection and Typical TB3 Connections

19

20

21

22

23

24

25

26

27

28

29

30

Status

Common

Status

Status

Status

Common

Status

Status

Status

Common

[Input Mode] 1Factory Default

19

20

21

22

23

24

25

26

27

28

29

30

Start

Common

Reverse

Common

Common

Jog StopType

2ndAccel

DigitalPot Up

Jog

Speed Speed 2ndDecel

DigitalPot Dn

Local

2 3 4 5 6

Mode

[Input Mode] 2 – 6

See Table 1.B. 1

Drive must be stopped to take Local Control.Control by all other adapters is disabled (except Stop).

2

These inputs must be present before drive will start. 3

User

Con

nect

ions

User

Con

nect

ions

AB0290B

Momentary

Maintained

AT

TE

NT

ION

:pr

oper

ly u

nles

s a

SC

AN

port

opt

ion

is c

onne

cted

to

the

driv

e. T

o as

sure

pro

per

JOG

fun

ctio

n, in

stal

l at

leas

t on

eof

the

fol

low

ing:

1201

-HA

P,

1201

-HA

1, 1

201-

HA

2, 1

336-

GM

1. A

pplie

sto

130

5 w

ith f

irmw

are

FR

N 2

.01

or e

arlie

r an

d 13

36

PLU

S w

ith L

angu

age

Mod

ule

1336

S-E

N f

irmw

are

FR

N1.

05 o

r ea

rlier

.The

JO

G f

unct

ion

will

not

ope

rate

Enable3

Enable3

Stop/Fault Reset3

Stop/Fault Reset3

Auxiliary3

Speed Select 21

Speed Select 11

Select 31 Select 31 Control2

Note: If this mode is selected, the status of allinputs can be read at the [Input Status] parameter.However, only “Stop/Fault Reset” and “Enable” willhave control function.

Three-Wire Control with Single-Source Reversing


1-7

Momentary

Maintained

Run Forward

Common

Run Reverse

Common

Common

Local StopType

2ndAccel

DigitalPot Up

Local

Speed Speed 2ndDecel

DigitalPot Dn

StopType

12 13 14 15 16Mode

[Input Mode] 12 – 16Two-Wire Control, Single-Source Control

19

20

21

22

23

24

25

26

27

28

29

30

Start

Common

Common

Common

Forward Forward DigitalPot Dn

Forward 2ndAccel

Jog Speed Speed DigitalPot Up

1stDecel

[Input Mode] 7 – 11Three-Wire Control with Multi-Source Reversing

Reverse Reverse DigitalPot Up

Reverse 1stAccel

7 8 9 10 11Mode

Speed Speed Speed DigitalPot Dn

2ndDecel

19

20

21

22

23

24

25

26

27

28

29

30

User

Con

nect

ions

User

Con

nect

ions

See Table 1.B. 1

Drive must be stopped to take Local Control.Control by all other adapters is disabled (except Stop).

2

AB0291B

These inputs must be present before drive will start. 3

AT

TE

NT

ION

:pr

oper

ly u

nles

s a

SC

AN

port

opt

ion

is c

onne

cted

to

the

driv

e. T

o as

sure

pro

per

JOG

fun

ctio

n, in

stal

l at

leas

t on

eof

the

fol

low

ing:

1201

-HA

P,

1201

-HA

1, 1

201-

HA

2, 1

336-

GM

1. A

pplie

sto

130

5 w

ith f

irmw

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N 2

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arlie

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36

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05 o

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rlier

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JO

G f

unct

ion

will

not

ope

rate Stop/Fault Reset3

Auxiliary3

Speed Select 11

Enable3

Stop/Fault Reset3

Auxiliary3

Speed Select 21

Speed Select 11

Enable3

Select 21 Select 21 Select 21

Select 31 Select 31

Control2 Control2

Select 31 Select 31


1-8

The following table defines the input state of the Speed Select inputs foreach frequency source.

Table 1.BSpeed Select Input State vs. Frequency Source

Speed Select 3 Speed Select 2 Speed Select 1 Frequency Source

O O O [Freq Select 1]

O O X [Freq Select 2]

O X O [Preset Freq 2]

O X X [Preset Freq 3]

X O O [Preset Freq 4]

X O X [Preset Freq 5]

X X O [Preset Freq 6]

X X X [Preset Freq 7]

O = OpenX = Closed

Human InterfaceModule (HIM)

Description

When the drive mounted HIM is supplied, it will be connected as Adapter1 (refer to Figure 1.6). The HIM can be divided into two sections; DisplayPanel and Control Panel. The Display Panel provides a means ofprogramming the drive and viewing the various operating parameters. TheControl Panel allows different drive functions to be controlled. Refer to the1336 PLUS User Manual for HIM operation.

IMPORTANT: The operation of HIM functions depends upon driveparameter settings. Default parameter values allow full HIM functionality.


1-9

Figure 1.5Human Interface Module

AB0542A

Display Panel

Control Panel

Human Interface Module(HIM)

Figure 1.6Adapter Locations

AB0594A

CommunicationsPort RemoteHIM or PMT

Control InterfaceOption

(TB3 Adapter 0)

Drive MountedHIM (Adapter 1)Open Style Only

InternalCommunication

(Adapter 6)


1-10

Module Removal

ATTENTION: Some voltages present behind the drive front coverare at incoming line potential. To avoid an electric shock hazard,use extreme caution when removing/replacing the HIM.

For handheld operation, the module can be removed and located up to 10meters (33 feet) from the drive.

IMPORTANT: Power must be removed from the drive or Bit 1 of the[Logic Mask] parameter must be set to “0” to allow removal of the HIMmodule without causing a Communication Fault. Setting Bit 1 of the[Logic Mask] parameter to “0” allows HIM removal while power isapplied to the drive. Note that this also disables all HIM control functionsexcept Stop.

IMPORTANT: To remove the module:

1. Ensure that power has been removed or [Logic Mask] has been set to“0”.

2. Take the drive front cover off and simply slide the module down and outof its cradle. Remove cable from module.

3. Connect the appropriate cable between the HIM and theCommunications Port (Adaptor 2, 3, 4, or 5).

4. Reverse the above steps to replace the module. Apply power or resetBit 1 of the [Logic Mask] parameter to “1” to enable HIM control.

HIM Operation

When power is first applied to the drive, the HIM will cycle through aseries of displays. These displays will show drive ID and communicationstatus. Upon completion, the Status Display (refer to Figure 1.7) will beshown. This display shows the current status of the drive (i.e. Stopped,Running, etc.) or any faults that may be present (Not Enabled, etc.).Refer to the 1336 PLUS User Manual for HIM operation.

Figure 1.7Status Display

Stopped+0.00 Hz

ChapterChapter

2-1

Troubleshooting and Error Codes

Chapter Objectives This chapter helps you trace faults to field-replaceable components.

Troubleshooting To troubleshoot a 1336 PLUS Adjustable Frequency AC Drive, you need

Overview a Range DVM, DMM, or VOM with a range capacity of at least 1000 V.

IMPORTANT: All printed circuit boards are referenced to “common” perthe schematic diagrams.

ATTENTION: Power circuits are optically isolated from controldriver circuits. Power circuit components are floating with respectto ground. Use only approved methods of isolating test equipmentwhen making measurements in power circuits.

ATTENTION: Some printed circuit boards and drive componentsmay contain hazardous voltage levels. Remove power before youdisconnect or reconnect wires, and before you remove or replacefuses and circuit boards. Verify bus voltage by measuring thevoltage between the Negative Capacitor Bus and both ends of allthree 350 amp fuses. An open fuse does not show voltage acrossboth ends of the fuse. Failure to measure voltage at both ends of thefuses may result in death or serious injury. Refer to Figure 3.5. Donot attempt to service the drive until the bus voltage has dischargedto zero volts.

ATTENTION: Potentially fatal voltages may result from improperusage of oscilloscope and other test equipment. The oscilloscopechassis may be at a potentially fatal voltage if not properlygrounded. We do not recommend use of an oscilloscope to directlymeasure high voltages. Use an isolated measuring device with ahigh voltage probe. Contact Allen-Bradley for recommendations.

Chapter 2Troubleshooting and Error Codes

2-2

ATTENTION: To guard against equipment damage whentroubleshooting the drive, always check the following beforeissuing a Start command:

• Set the Speed Reference to minimum.• Select the proper motor-rotation direction.• Disconnect the motor from its mechanical load.


Electrostatic Discharge Electrostatic Discharge generated by static electricity can damage the

Precautions complimentary metallic oxide semiconductor devices on various driveboards. It is recommended that you perform these procedures to guardagainst this type of damage when circuit boards are removed or installed:

Wear a wrist type grounding strap that is grounded to the chassis.




2-3

Fault Descriptions

Fault Display

The LCD display is used to indicate a fault by showing a brief textstatement relating to the fault (refer to figure below). The fault will bedisplayed until a drive reset is initiated. Refer to Table 2.A for a listing anddescription of the various faults. Table 2.B provides a listing of faults bynumber.

Overvolt FaultF 5

IMPORTANT: Before clearing a fault, refer to the Fault Descriptionstable and Diagnostic Procedures by Symptom flowcharts in this chapter toisolate and correct faults.

To help differentiate parameter names and display text from other text inthis manual, the following conventions will be used:Parameter Names will appear in [brackets]Display Text will appear in “quotes”

Contact Description

During normal operating conditions (no faults present, drive running) theCR3 fault contacts at TB2–13 & 14 are open, and the contacts at TB2–14& 15 are closed. When a fault occurs, the state of these contacts changes.


2-4

Table 2.A1336 PLUS Fault Descriptions

Name & Fault # Description Action

Adptr Freq Err65

The SCANport adapter that was the selected frequencyreference sent a frequency greater than 32767 to thedrive.

Correct the problem that is causing the SCANportadapter to send the illegal frequency reference to thedrive.

Auxiliary Fault02

The auxiliary input interlock is open. If Control Interface option is installed, check connec-tions at TB3-24. If option is not installed, set [InputMode] to “1”.

BGND 10ms Over51

Microprocessor loop fault. Occurs if the 10msbackground task hasn’t been run in 15 ms.

Replace Main Control Board or complete drive asrequired.

Blwn Fuse Flt58

If the difference between the commanded voltage andthe measured voltage is greater than 1/8 of ratedvoltage for 0.5 seconds, then a fault will be issuedindicating that the bus fuse in 30 kW (40 HP) and updrives has blown.

Locate cause, replace Fuse.

Diag C Lim Flt36

The drive output current has exceeded the hardwarecurrent limit and the [Cur Lim Trip En] parameter wasenabled.

Check programming of [Cur Lim Trip En] parameter.Check for excess load, improper DC boost setting, DCbrake volts set too high or other causes of excesscurrent.

Drive Fault Reset22

Power-up has been attempted with an Open Stopcontact or Closed Start contact.

Check/verify wiring and contact operation.

Drive –> HIM Error 1 – The checksum read from the EEPROM doesnot match the checksum calculated from the EEPROMdata.

Repeat operation. Replace HIM.

EE Init Read53

1. Gate Driver Board replacement (requires re-initialization).

2. Trouble reading EEPROM during initialization.

1. Reset to factory defaults & cycle input power.2. Check all connections to the Power/Driver Board.

Replace the board or complete drive as needed.

EE Init Value54

Stored parameter value is out of range on initialization. 1. Reset to factory defaults & cycle input power.2. Check all connections to the Power/Driver Board.

Replace the board or complete drive as needed.

EEprom Checksum66

The checksum read from the EEPROM does not matchthe checksum calculated from the EEPROM data.

1. Reset to factory defaults & cycle input power.2. Check all wire and cable connections to the

Power/Driver Board. Replace the Power/DriverBoard or complete drive as required.

EEprom Fault32

EEPROM is being programmed and will not write a newvalue.

Check all wire and cable connections to the MainControl Board. Replace Main Control Board or completedrive as required.

FGND 10ms Over52

Microprocessor loop fault. Occurs if a 10ms interrupt ispending before the current interrupt is complete.

Replace Main Control Board or complete drive asrequired.

Ground Fault13

A current path to earth ground in excess of 100A hasbeen detected at one or more of the drive outputterminals. NOTE: If ground current exceeds 220% ofdrive rated current, “Overcurrent Flt” may occur insteadof Ground Fault.

Check the motor and external wiring to the drive outputterminals for a grounded condition.


2-5

Table 2.A (continued)1336 PLUS Fault Descriptions


Ground Warning57

A current path to earth ground in excess of 2A has beendetected at one or more of the drive output terminals.See [Ground Warning].

Check the motor and external wiring to the drive outputterminals for a grounded condition.

Hertz Err Fault29

This fault indicates that there is not a valid operatingfrequency. It can be caused by any of the following:1. [Maximum Freq] is less than [Minimum Freq].2. Skip frequencies and skip bandwidth eliminate all

operating frequencies.3. 4–20mA input signal speed reference has been lost

and [4–20mA Loss Sel] is set for “Stop-Fault.”

1. Check [Minimum Freq] and [Maximum Freq]parameters.

2. Check [Skip Freq 1], [Skip Freq 2], [Skip Freq 3] and[Skip Freq Band] parameters.

3. Check for broken wires, loose connections ortransducer loss at 4–20mA input, TB2.

Hertz Sel Fault30

A frequency select parameter has been programmedwith an out of range value.

Reprogram [Freq Select 1] and/or [Freq Select 2] with acorrect value. If problem persists, replace Main ControlBoard or complete drive.

HIM –> Drive Error 1 – The checksum read from the EEPROM doesnot match the checksum calculated from the EEPROMdata.Error 2 – Number of parameters in saved profile doesnot equal master.Error 3 – Download was attempted to a different typedrive (i.e. 1336 –> 1305).Error 4 – Saved data not correct for new drive.

Error 5 – Drive is running while attempting download.

Retry download. Replace HIM.

Retry download. Replace HIM.

Download can only take place with same type drive.

Capabilities of drive different than master drive.Reprogram param.Stop drive, then perform download.

Loop Overrn Flt23

An overrun of the 2.5ms control loop has occurred. Check all connections to the Power/Driver Board.Replace the board or complete drive as required.

Max Retries Fault33

Drive unsuccessfully attempted to reset a fault andresume running for the programmed number of[Reset/Run Tries].

Check fault buffer for fault code requiring reset. Correctthe cause of the fault and manually clear by pressingthe local Stop key or cycling the TB3 Stop input.

Motor Mode Flt24

A fault has been detected originating from the ControlBoard.

Check all connections to the Control Board. Replacethe board, Language Module, or complete drive asrequired.

Motor Stall Fault06

Current remained over 150% for more than 4 seconds. If the motor is drawing excessive current (over 150%),the motor load is excessive and will not allow the driveto accelerate to set speed. A longer accel time or areduced load may be required.


2-6



Neg Slope Fault35

Drive software detected a portion of the volts/hertzcurve with a negative slope.

Check drive programming:1. [Maximum Voltage] parameter must be greater than

[Base Voltage].2. [Maximum Freq] parameter must be greater than

[Base Frequency].3. [Base Voltage] parameter must be greater than

[Start Boost].4. If the [DC Boost Select] parameter is set to “Custom”

[Base Voltage] must be greater than [Break Voltage]and [Break Voltage] must be greater than [StartBoost].

Open Pot Fault09

An external pot is connected and the common side ofthe pot is open. The drive generates this fault when thevoltage between TB2-2 and TB2-3 exceeds 3.9V DC.

Check the external potentiometer circuit at TB2,terminals 1, 2 and 3 for an open circuit.

Op Error Fault11

A SCANport device requests a Read or Write of adata type not supported. This will also occur if:1. [Motor Type] is set to “Sync PM” and [Stop Mode

Used] is set to “DC Brake”, or2. [Motor Type] is set to “Sync Reluc” or “Sync PM” and

[Speed Control] is set to “Slip Comp”.

Check programming.

Overcurrent Flt12

Overcurrent is detected in overcurrent hardware tripcircuit.

Check for a short circuit at the drive output or excessiveload conditions at the motor.

Overload Fault07

Internal electronic overload trip. An excessive motor load exists. It must be reducedsuch that drive output current does not exceed thecurrent set by the [Overload Amps] parameter.

Overtemp Fault08

Heat sink temperature exceeds a predefined value of90C (195F).

Check for blocked or dirty heat sink fins. Check that theambient temperature has not exceeded 40C (104F).Check fan.Check thermistor. Thermistor should register 100kΩ atroom temperature.

Overvolt Fault05

DC bus voltage exceeded maximum value. Monitor the AC line for high line voltage or transientconditions.Bus overvoltage can also be caused by motorregeneration. Extend the decel time or install dynamicbrake option.

Phase U Fault38

A phase to ground fault has been detected between thedrive and motor in this phase.

Check the wiring between the drive and motor. Checkmotor for grounded phase.

Phase V Fault39



Phase W Fault40



P Jump Err Flt37

Reserved for future use.


2-7



Pole Calc Fault50

Generated if the calculated value of [Motor Poles] isless than 2 or greater than 32.

Check [Motor NP RPM] and [Motor NP Hertz]programming.

Power Loss Fault03

DC bus voltage remained below 85% of nominal forlonger than 0.500ms. [Line Loss Fault] parameter is setto “enabled.”

Monitor the incoming AC line for low voltage or linepower interruption.

Power Mode Fault26

The internal power mode variable received an incorrectvalue.

Check all connections to the Control Board. Replacethe board, Language Module, or complete drive asrequired.

Power Overload64

The drive rating of 150% for 1 minute has beenexceeded.

Reduce load.

Power Test Flt46

The internal power mode variable received an incorrectvalue.

Check all connections to the Power/Driver Board.Replace the board or complete drive as required.

Precharge Fault19

Occurs if precharge device is open 20ms after the endof a line loss condition or if the bus charging alarmremains on for 20 seconds (precharge did notcomplete).

All larger frames – Check the precharge circuit. Replacethe input SCRs, SCR Firing Board, Power Driver Boardor complete drive as needed.

Precharge Open56

The precharge circuit was commanded to close, butwas detected to be open.

All larger frames – Check the precharge circuit. Replacethe input SCRs, SCR Firing Board, Power Driver Boardor complete drive as needed.

Reprogram Fault48

The drive was commanded to write default values toEEPROM.

1. Clear the fault or cycle power to the drive.2. Program the drive parameters as needed.Important: If [Input Mode] has been changed from itsoriginal value, power must be cycled before the newvalue will take affect.

ROM or RAM Flt68

Internal power-up ROM or RAM tests have notexecuted properly.

Check Language Module. Replace Control Board orcomplete drive as required.

Run Boost Fault34

An attempt has been made to set the [Run Boost]parameter to a value greater than the [Start Boost]parameter.

Verify that parameter has been programmed correctly.

Serial Fault10

A SCANport adapter has been disconnected and the[Logic Mask] bit for that adapter is set to “1.”

1. If no adapter was intentionally disconnected, checkwiring to the SCANport adapters. Replace wiring,SCANport expander, SCANport adapters, MainControl Board or complete drive as required.

2. If an adapter was intentionally disconnected and the[Logic Mask] bit for that adapter is set to “1”, thisfault will occur. To guard against this fault occurring,set the [Logic Mask] bit for the adapter to “0.”

Shear Pin Fault63

Programmed [Current Limit] amps has been exceededand [Shear Pin Fault] is enabled.

Check load requirements and [Current Limit] setting.


2-8



Temp Sense Open55

Heat sink thermistor is open or malfunctioning. Check thermistor and connections.

Undervolt Fault04

DC Bus voltage fell below the minimum value (388V DCat 460V AC input). [Line Loss Fault] and [Low BusFault] set to “enabled.”

Monitor the incoming AC line for low voltage or linepower interruption.

UV Short Fault41

Excessive current has been detected between thesetwo output terminals.

Check the motor and external wiring to the drive outputterminals for a shorted condition.

UW Short Fault42



VW Short Fault43



Xsistr Desat Flt47

One or more of the output transistors were operating inthe active region instead of desaturation. This can becaused by excessive transistor current or insufficientbase drive voltage.

Check for damaged output transistors. Replace outputtransistors, Power Driver Board or complete drive asneeded.


2-9

Table 2.BFault Code Cross Reference

Fault # Display Name Reset/Run

02 Auxiliary Fault Yes

03 Power Loss Fault Yes

04 Undervolt Fault Yes

05 Overvolt Fault Yes

06 Motor Stall Fault Yes

07 Overload Fault Yes

08 Overtemp Fault Yes

09 Open Pot Fault No

10 Serial Fault No

11 Op Error Fault No

12 Overcurrent Flt Yes

13 Ground Fault No

19 Precharge Fault No

22 Drive Fault Reset Yes

23 Loop Overrn Flt Yes

24 Motor Mode Flt Yes

26 Power Mode Fault Yes

28 Timeout Fault No

29 Hertz Err Fault No

30 Hertz Set Fault No

31 Timeout Fault No

32 EEprom Fault No

33 Max Retries Fault No

34 Run Boost Fault No

35 Neg Slope Fault No


2-10

Table 2.B (continued)Fault Code Cross Reference

Fault # Display Name Reset/Run

36 Diag C Lim Flt No

37 P Jump Err Flt No

38 Phase U Fault No

39 Phase V Fault No

40 Phase W Fault No

41 UV Short Fault No

42 UW Short Fault No

43 VW Short Fault No

46 Power Test Flt No

47 Xsistr Desat Flt No

48 Reprogram Fault No

50 Pole Calc Fault No

51 BGND 10ms Over Yes

52 FGND 10ms Over Yes

53 EE Init Read No

54 EE Init Value No

55 Temp Sense Open No

56 Precharge Open No

57 Ground Warning No

58 Blwn Fuse Flt No

63 Shear Pin Fault No

64 Power Overload No

65 Adptr Freq Err No

66 EEprom Checksum No

68 ROM or RAM Flt No


2-11

Diagnostic Procedures These charts list drive symptoms, symptom descriptions, and

by Symptom recommended actions to remedy the symptoms.

Drive Will Not Start

AB0416B

Yes

Drive will not start.

HIM displays“Auxiliary Fault”?

No

Display on HIM?

Yes

NoRefer to “No Display”.

Drive equippedwith L Option?

Yes Auxiliary Input True? Correct AuxiliaryCircuit and clear fault.

Program [InputMode] to “1” and

cycle input power.

No

Replace L Option orMain Control Board.

Yes

YesHIM displays“Not Enabled”?

No

Drive equippedwith L Option?

Yes Enable Input True? No Correct Enable Circuit.

Add a jumper to J7between pins 3 and 4

or replace Main ControlBoard as needed.

No

Yes

YesHIM displaysfault message?

Follow instructionsgiven in Table 2.A.

NoHIM displays“Stopped”?

Drive running atzero Hertz?

No

Yes

Yes Refer to: “DriveStays at Zero Hertz

When Started”.

NoAre any bits in[Stop Owner] set to

“1”?

Find and correct sourceof STOP command.

No

NoDoes [Start Owner]show a bit set to “1”

when STARTcommanded?

Correct Start Inputcircuit or replace

Main Control Boardas needed.

Yes

Drive Starts?

Yes

No Replace MainControl Board.

End of troubleshooting.

No


2-12

No Display

AB0417A

No

No HIM display.

Is the drive’s fanrunning?

Yes

Is the HIM backlight lit?Yes

No

Replace the HIM,Main Control Board,

Language Module, orcomplete drive as

needed.

Voltage present atTB1-R, -S, -T?

No Restore incomingpower to drive.

HIM connectedproperly?

Yes

Replace HIM, MainControl Board, orGate Driver Board

as needed.

NoRe-connect HIM. Is the fuse blown

on the GateDriver Board?

Replace the fuse,Gate Driver Board,

or complete drive asneeded.

Yes

No

DC bus voltagepresent?

Replace GateDriver Board.

Yes

No

Replace the DiodeBridge and any other

damaged components.

Yes


2-13

Drive Will Not Jog

Local Human Interface Module used to control drive.

JOG is not active if a START command is present. START commandalways overrides a JOG command.

AB0418A

Drive will not Jog.

Is drive running?Yes

No

Drive must bestopped before

attempting to Jog.

Will drive run ifcommanded to Start?

No Refer to “Drive WillNot Start”.

Does a [Jog Owner]bit go to 1 when Jog

is commanded?

Yes

No Is the [Jog Mask] bitfor the adapter being

used set to 1?

Yes Is the Jog Input truewhen Jog is

commanded?

Yes Replace the Adapter,L Option, or Main

Control Board.

Set the [Jog Mask]bit for the adapterbeing used to 1.

External wiring problem.

No NoYes

HIM displays“Stopped” when Jog

is commanded?

No Drive running atincorrect frequency?

No Replace MainControl Board.

Yes

Is a [Stop Owner] bitset to 1?

Yes Find and correct thesource of the Stop

command.

No

Is Logic Mask bit setto 0?

Reprogram [JogFrequency].

Yes

No

Replace MainControl Board

Yes Change Logic Maskbit to 1.


2-14

Drive Stays at Zero Hertz When Started

IMPORTANT: [Command Frequency] parameter in the Metering Groupcan be checked using the HIM.

AB0419A

Drive stays at ZeroHertz when Started.

No[Drive Status]Running Bit(Bit 1) = 1?

Refer to “DriveWill Not Start”.

Yes

HIM displays “At Speed”or [Drive Status] At

Speed Bit (Bit 8) = 1?

No HIM displays“Accelerating” or

[Drive Status] AccelBit (Bit 4) = 1?

Yes Are [Accel Time 1] or[Accel Time 2] set to

very long times?

Yes Set [Accel Time 1] or[Accel Time 2] to correct

application values.

Yes

[Command Freq]greater than zero?

Yes Replace MainControl Board, Gate

Driver Board, ordrive as needed.

No [Drive Alarm] MotorLimit or Regen LimitBits (Bits 2 & 3) = 1?

Yes Correct excessivemotor load condition.

No No

No

Is [Freq Source]correct?

No Is [Input Mode] setto a mode with L

Option TB3 SpeedSelect inputs?

No SCANport adapter has selectedan incorrect reference. Correct

the problem with, or replace, theSCANport adapter.

Yes

Is the frequencyreference input to the

drive at zero?

Yes Correct problem withfrequency reference.

Replace Main ControlBoard or completedrive as needed.

No

Check state of SpeedSelect inputs on TB3.Check programmingof [Reference Mask]

and [Input Mode].

Yes


2-15

Drive Goes to Max Frequency

IMPORTANT: [Command Frequency] parameter in the Metering Groupcan be checked using the HIM.

Does the meteringparameter for the

frequency referenceequal [Maximum Freq]?

AB0420B

Drive goes to[Maximum Freq].

YesIs [Command Freq] =[Maximum Freq]?

No

[Freq Source]correct?

Yes

NoIs Scanport Adapter orL Option set to selectthe correct reference?

Yes

Replace Main ControlBoard.

Skip Frequencyfunction interfering

with reference?

Yes Reprogram the SkipFrequency function.

Correct the SpeedSelect inputs.

No

No

[Freq source] =Adapter 1–6?

Yes Replace the Adapterproviding the reference.

No

[Freq source] =Preset 1–7?

Yes Is the Preset usedprogrammed to

[Maximum Freq]?

Yes Reprogram to correctvalue.

No

No

No

Yes

Input signal at TB2normal?

Yes[Analog Invert] correct?

No Reprogram[Analog Invert].

No

Correct input signalproblem.

Yes

Drive is correctlyfollowing Freq

Reference

Clearing Faults After correcting a fault, you can clear a fault from the drive in one of threeways:

1. Cycle the input power to the drive.

2. Press the Stop button. This works only if [Fault Clear Mode] is set to“Enabled”.

3. Issue a reset command from a serial device.


2-16


Chapter

3-1

Disassembly and Access Procedures

Chapter Objectives This chapter describes general disassembly procedures required to accessinternal drive components.

Disassembly and Access Overview


ATTENTION: Servicing energized industrial control equipmentcan be hazardous. Electrical shock, burns, or unintentionalactuation of controlled industrial equipment may cause death orserious injury. Follow the safety-related practices of NFPA 70E,Electrical Safety for Employee Workplaces, when working on ornear energized equipment. Do not work alone on energizedequipment.

Electrostatic Discharge Precautions


Chapter 3Disassembly and Access Procedures

3-2


Wear a wrist-type grounding strap that is grounded to the chassis.



Tools

You need the following tools to disassemble and assemble the drive: Pliers

Phillips screwdrivers (small, medium, and large)

Standard screwdrivers (small, medium, and large)

Metric socket set up to 19 mm

Torque wrench to 34 N-m or 280 in.-lbs

Torque screwdriver to 10 N-m or 80 in.-lbs

Nylon tie wraps


3-3

Fastener Torque Specifications

Torque Sequence

When mounting components to a drive’s heat sink, component-fastenertorque sequences and tolerances are crucial to component-to-heat sink heatdissipation.

ATTENTION: Component can be damaged if temporarytightening procedure is not performed to specification.

The following illustrates temporary and final tightening sequences forcomponents fastened to a heat sink using two, four, and six screws.Temporary torque is 1/3 (33%) of final torque, except six-point mountings,which require 0.5 N-m (4 in.-lb). The numeric illustration labels are foryour assistance. Drive components do not carry these labels.

Figure 3.1Two-Point Mounting

21

AB0016A

12

21

Temporary Tighten

Final Tighten

Two–Point Mounting


3-4

Figure 3.2Four-Point Mounting

AB0017A

1

2

3

4

1 32 4

4 123

Temporary Tighten

Final Tighten

Four–Point Mounting

Figure 3.3Six-Point Mounting

AB0624B

6

3

2

1

4

5

Note: Do not exceed 0.4 Newton-meters (3 in.-lb) on initial torque or 3.8Newton-meters (32 in.-lb) final torque of all six screws.

Torque Specifications

The following table lists fastener locations by component, how thefasteners are used, and torque specifications. Refer to Torque Sequence inthis chapter for fastening two-point, four-point and six-point components tothe heat sink.


3-5

Table 3.AFastener Torque Specifications

Component Fastener Application Torquein.-lb

TorqueN-m

Fan Motor Motor to Fan Cover Assembly 14 2

Fan Transformer Transformer to chassis 75 9

Fan Capacitor Capacitor to chassis Hand-tighten

MOV Surge Suppressor MOV to chassis 18 2

Snubber Resistor Resistor to heat sink 26 3

Snubber Bracket Bracket to Power Module Laminated Bus 90 11

Snubber Board Board to Brackets 18 2

Snubber Board Board to Input Rectifier Bracket 18 2

Volt Sharing Resistor Resistor to heat sink 26 3

Volt Sharing Resistor Wires to Capacitor Bus Bar Assembly 50 6

Thermistor Thermistor to heat sink 14 2

Bus Capacitor Holder Holder to Bus Capacitors 26 3

Capacitor Bus Bar Assembly Assembly to Bus Capacitors 50 6

Power Module Gate Interface Board Board to Power Modules 18 2

Power Module Bus Bar Bus Bar to Power Modules 90 11

Power Module Module to heat sink Refer to Figure 3.3

Input Rectifier (SCR) Rectifier to heat sink

Transitional Bus Bar Assembly Assembly to Power Module Bus Bar Assembly 80 9

Bus Fuse F1 – F3 Fuse to Transitional Bus Bar Assembly 240 28

DC Bus Inductor L1 Inductor to chassis 75 9

Bus Bar Cable AdaptorAdaptor to Transitional Bus Bar Assembly and DC Bus Inductor, right side of Motor Flex Bus

75 9

Converter Bus and Motor Bus Bars All connections 240 28

Wires (PE) Wires to Ground Stud 175 21

Wire (TE) Wire on Main Control Board Mounting Plate 26 3

Wires Wires to TB2 7 0.8

Wires Wires to TB3 8 – 10 09 – 1.1

Power Cables Cables to terminals 240 28

Main Control, Gate Driver, PrechargeBoard Mounting Plates

Plates to chassis 26 3

Heat Sink Guard Guard to chassis 18 2

T-Bar Mounting Bolt T-Bar to Main Frame 240 28.8

Capacitor Mounting Bolt Capacitor Bank Assembly to Main Frame 240 28.8

Inverter Housing Assembly Lock-DownBolt

Inverter Housing Assembly to Main Frame 240 28.8

Wheel Chock Fasteners Wheel Chocks to tracks 75 9

Ground Cable Bolts Ground Cables from both assemblies to Main Frame 75 9

Refer to the gauge on the clamp, which indicates pounds of force. The reading should be 400 lbs.


3-6

Disassembly and Access Procedures

Opening the Drive Enclosure

Figure 3.4Drive Enclosure

AB0595A

PC BoardMounting Frame


3-7

Opening

ATTENTION: Disconnect and lock out power from the drivebefore disassembling the drive. Failure to disconnect power mayresult in death or serious injury. Verify bus voltage by measuringthe voltage between the Negative Capacitor Bus and both ends ofall three 350 amp fuses. An open fuse does not show voltage acrossboth ends of the fuse. Failure to measure voltage at both ends of thefuses may result in death or serious injury. Refer to Figure 3.5. Donot attempt to service the drive until the bus voltage has dischargedto zero volts.

ATTENTION: Wear a wrist-type grounding strap when servicing1336 PLUS Drives. Failure to protect drive components againstESD may damage drive components. Refer to ElectrostaticDischarge Precautions at the beginning of this chapter.

1. Remove power from the drive.

2. Turn the enclosure door latches 1/4 turn counterclockwise to open theenclosure door.

3. Turn the latches, located on the left side of the PC Board Mountingframe, to open the PC Board Mounting Frame. Refer to Figure 3.6.

4. Check for zero volts between +DC and –DC. Refer to Figure 3.5.


3-8

Figure 3.5DC Voltage Check

AB0637B

–DC (NegativeCapacitor Bus)

+DC

Check All ThreeBus Fuses

ATTENTION: A blown fuse can create a hazard of shock whichmay result in death or serious injury. Check voltage between thebus bar and both ends of all three fuses.

5. Check for the absence of control voltage at the points marked on theMain Control Board.

Closing

Close the Drive Enclosure in reverse order of opening.

ATTENTION: Replace all guards before applying power to thedrive. Failure to replace guards may result in death or seriousinjury.


3-9

Removing the Control Interface Board

Figure 3.6Control Interface Board

AB0596A

Control InterfaceBoard

Terminal StripTB3

Main ControlBoard

Removal



3-10


IMPORTANT: Before you remove connections and wires from the drivecomponents, mark the connections and wires to correspond with theircomponent connections and terminals to prevent incorrect wiring duringassembly.



3. Open the PC Board Mounting Frame.



6. Remove all wires from Control Interface Board TB3.

7. Loosen the two captive screws fastening the Control Interface Board tothe Main Control Board.

8. Grip the right and left sides of the Control Interface Board and pull theboard straight out from the Main Control Board.

Installation

Install the Control Interface Board in reverse order of removal.



3-11

Removing the Main Control Board Mounting Plate

Figure 3.7Main Control Board Mounting Plate

AB0597A

Main ControlBoard

ConnectorJ1

ConnectorJ6

ConnectorJ8

TerminalStrip TB2

MountingPlate

ConnectorJ2

Terminal StripTB3

TerminalStrip TE

8-Pin HIMConnector


3-12

Removal









6. Disconnect the following from the Main Control Board:

J1 connector

J2 ribbon cable connector

J8 connector

8-pin HIM connector

Ground wires from Terminal Strip TE.

Chassis ground wire at the top-right corner of the Main Control BoardMounting Plate.

7. Remove the two screws fastening the bottom of the Main Control BoardMounting Plate to the PC Board Mounting Frame.


3-13

8. Remove the nuts fastening the top of the Main Control Board MountingPlate to the PC Board Mounting Frame.

9. Lift the Main Control Board Mounting Plate out of the drive.

Installation

Install the Main Control Board Mounting Plate in reverse order of removal.Refer to Table 3.A – Fastener Torque Specifications.



3-14

Removing the Main Control Board

Figure 3.8Main Control Board and Mounting Plate

AB0598A

MainControlBoard

TerminalStrip TB2

MountingPlate

ConnectorJ2

8-Pin HIMConnector

ConnectorJ1

ConnectorJ6

ConnectorJ8

Slide-MountStand-Off

MountingScrew

Ground WireStake-OnConnector

J10

Removal

ATTENTION: Disconnect and lock out power from the drivebefore disassembling the drive. Failure to disconnect power mayresult in death or serious injury. Verify bus voltage by measuringthe voltage between the Negative Capacitor Bus and both ends ofall three 350 amp fuses. An open fuse does not show voltage acrossboth ends of the fuse. Refer to Figure 3.5. Do not attempt to servicethe drive until the bus voltage has discharged to zero volts.


3-15








6. Remove all wires from Terminal Strip TB3 if a Control Interface Boardis used.

7. Disconnect the following from the Main Control Board:

J1 connector

J2 ribbon cable connector

J6 connector

J8 connector

8-pin HIM connector

Ground wire at stake-on connector J10

All wires from the terminals on TB2

8. Remove the five screws fastening the Main Control Board to themounting plate.

9. Slide the Main Control Board toward the top of the drive to release itfrom the slide-mount stand-offs.

10. Store the Main Control Board in an anti-static bag.


3-16

InstallationInstall the Main Control Board in reverse order of removal.


Removing the Gate Driver Board

Figure 3.9Gate Driver Board

AB0599A

ConnectorJ6

Gate DriverBoard

ConnectorJ2

ConnectorJ13

ConnectorJ7 Connector

J8

ConnectorJ10

ConnectorJ9


3-17

Removal









6. Remove the Main Control Board Mounting Plate. Refer to Removingthe Main Control Board Mounting Plate in this chapter.

7. Disconnect the following from the Gate Driver Board:

J2 connector

J6 connector

J7 connector

J8 connector

J9 connector

J10 connector

J13 connector


3-18

8. Turn the eight standoffs, fastening the Gate Driver Board to the PCBoard Mounting Frame, 1/4 turn counterclockwise to remove the board.

9. Store the Gate Driver Board in an anti-static bag.

InstallationInstall the Gate Driver Board in reverse order of removal. Refer toTable 3.A – Fastener Torque Specifications.

ATTENTION: When installing the wire harness connecting GateDriver Board connector J9 to Precharge Board connector J3, alignthe wires on the harness terminals with the pins on the boardconnectors. Incorrect harness connection may result in faulty driveoperation and may damage the equipment.



3-19

Removing the Precharge Board

Figure 3.10Precharge Board

AB0601A

PrechargeBoard

ConnectorJ1

ConnectorJ2

ConnectorJ4

ConnectorJ3

High VoltageGuard

Removal



3-20

ATTENTION: Wear a wrist-type grounding strap when servicing1336 PLUS Drives. Failure to protect drive components againstESD may damage drive components. Refer to ElectrostaticDischarge Precautions in Chapter 3 – Disassembly and AccessProcedures.







6. Remove the High Voltage Guard

7. Disconnect the following from the Precharge Board:

J1 connector

J2 connector

J3 connector

J4 connector

8. Turn the four standoffs 1/4 turn counterclockwise to remove the HighVoltage Guard.

9. Turn the six standoff screws, fastening the Precharge Board to the PCBoard Mounting Frame, 1/4 turn counterclockwise to remove the board.

10. Store the Precharge Board in an anti-static bag.


3-21

InstallationInstall the Precharge Board in reverse order of removal.

ATTENTION: When installing the wire harness connecting GateDriver Board connector J9 to Precharge Board connector J3, alignthe wires on the harness terminals with the pins on the boardconnectors. Incorrect harness connection may result in faulty driveoperation and may damage the equipment.


Access to the Inverter Housing and Capacitor Bank Assemblies




3-22

ATTENTION: These assemblies weigh about 500 pounds each.Before you pull either one from the drive, you must have aplatform in place to hold the assembly. You cannot remove theassembly without a platform. The top of the platform must be evenwith the assembly’s track. The platform must be strong enough tosupport the assembly and the personnel servicing the drive. Themarketing department at Allen-Bradley can provide plans for asuitable platform. Refer to the back cover of this manual for theaddress and telephone number.

ATTENTION: To remove either the Inverter Housing Assemblyor the Capacitor Bank Assembly safely requires two persons.Attempting to remove either assembly by yourself may result indeath or serious injury.

ATTENTION: Do not remove both the Inverter Housing and theCapacitor Bank assemblies at the same time.


The three main parts of this drive are the PC Board Mounting Frame, theInverter Housing Assembly, and the Capacitor Bank Assembly. Someprocedures in this manual require access to these assemblies and refer tothis section.

Each assembly has wheels that roll in tracks built into the base of the drive.Chocks bolted into the tracks prevent assembly movement. The drive itselfalso has wheels, built into the main framework of the drive. Because of thesize, weight, and physical characteristics of the drive, any serviceprocedures requiring removal of either the Inverter Housing Assembly orthe Capacitor Bank Assembly requires two people.


3-23

Access to the Inverter Housing Assembly





3-24

Figure 3.11Access to the Inverter Housing Assembly

AB0638B

AC Input

Lock–DownBolt

Bolt

BoltSnapper

Pin

Fan TerminalBlock

Wheel Chock

T-Bar

Glastic

Insulator

T-BarMounting Bolt

Inverter HousingAssembly Ground Cable

CapacitorMounting Bolt

Removal




3-25

Access the drive:






6. Disconnect the AC input lines at the top left of the drive.

7. Disconnect the wires to the door-mounted external fans at the fanterminal block located on the Inverter Housing Assembly.

Remove the T-Bar from the front of the drive:

1. Release the locking nut between the inverter housing and the left side ofthe T-bar.

2. Remove the T-bar mounting bolt at the bottom of the upright.

3. Remove the bolts fastening each end of the crossbar.

4. Release the snapper pin at the top of the upright.


3-26

Figure 3.12Disconnecting the Spine

AB0639B

Capacitor FlexBus Connections

Spine

MotorBus Bar

DC Bus Inductor OutNegative Bus Bar

DC Bus Inductor OutPositive Bus Bar

Vertical Glastic

Insulator

Remove the connections between assemblies:

1. Remove the four connections to the DC Bus Inductor.

Two connections to the left of the vertical Glastic insulator at the leftof the motor leads.

Two just to the left of the U-phase 350 amp bus fuse (capacitor fuse).

2. Remove the six nuts fastening the left end of the flex motor buses to thethree Power Module Bus Bars.

3. Remove the 12 nuts fastening the left side of the capacitor flex busconnections to the spine.

4. Pull all the flexible leads to the right, out of the way.


3-27

Figure 3.13Removing the Spine

AB0680A

Capacitor FlexBus Connections

Spine

MotorBus Bar

DC Bus Inductor OutNegative Bus Bar

DC Bus Inductor OutPositive Bus Bar

Vertical Glastic

Insulator

1. Remove the spine.

Push the spine carefully to the right.

Lift it out of the drive without forcing it.

2. Remove the six Gate Driver connectors from the Power Module GateInterface Boards. Pinch the sides of the connector body while pullingback.

3. Disconnect any remaining wiring between the Inverter HousingAssembly and the Capacitor Bank Assembly.

4. Disconnect the Inverter Housing Assembly ground cable from theground plate at the bottom of the main assembly.

5. Remove the wheel chocks at the bottom of the Inverter HousingAssembly.

6. Pull the assembly onto a platform (see Figure 3.14 forrecommendations). Use the handle attached to the Fan 2 housing.


3-28

ATTENTION: Hazard of tipping and severe injury exists. Thisprocess requires two people. The platform must be able to suppor909 kg (2,000 lbs).

Installation

Install the Inverter Housing Assembly in reverse order of removal.

IMPORTANT: When pushing the Inverter Housing Assembly into thedrive, you may need to have someone tip the unit slightly to the left orright to center it between the guides at the back of the Enclosure. Adjustthe angle brackets at the ends of the T-bar crossbar.



3-29

Figure 3.14Service Platform

AB0681A

30”25”

Height tosuit

installation

Stop Block

Fan 2 Handle


3-30

Removing the PC Board Mounting Frame

The PC Board Mounting Frame must be removed to pull the CapacitorBank Assembly from the drive.

Figure 3.15Removing the PC Board Mounting Frame

AB0640A

PC BoardMounting Frame



3-31



Removal



3. Turn the latches, located on the left side of the PC Board MountingFrame, to open the PC Board Mounting Frame.



6. Disconnect any wires connecting the PC Board Mounting Frame witheither main assembly.

7. Open the PC Board Mounting Frame all the way to the right.

8. Lift the frame straight up to remove it from the hinges.

Installation

Install the PC Board Mounting Frame in reverse order of removal.



3-32

Access to the Capacitor Bank Assembly

Figure 3.16Capacitor Bank Assembly

AB0641B

CapacitorMounting Bolt

T-Bar

Motor CableTerminal Strips

Capacitor BankAssembly Ground Cable

Inverter HousingAssembly Ground Cable



3-33



Removal



Access the drive:





5. Check for the absence of control voltage at the points marked on theMain Control Board

6. Remove the motor cable connections from the terminal strips at thebottom right of the drive.

7. Remove the PC Board Mounting Frame. Refer to Removing the PCBoard Mounting Frame in this chapter.

Remove the T-Bar:

IMPORTANT: Refer to Figure 3.11.





3-34


Remove the connections between assemblies:

IMPORTANT: Refer to Figure 3.12.

1. Remove the four connections to the DC Bus Inductor.

Two connections to the left of the vertical Glastic insulator at the leftof the motor leads.

Two just to the left of the U-phase 350 amp bus fuse (capacitor fuse).

2. Remove the six nuts fastening the left end of the motor flex buses to thethree Power Module Bus Bars.

3. Remove the 12 nuts fastening the left side of the capacitor flex busconnections to the spine.

4. Pull all the flexible leads to the right, out of the way.

5. Remove the spine.

Push the spine carefully to the right.

Lift it out of the drive without forcing it.

Access the Capacitor Bank Assembly:

1. Disconnect the Inverter Housing Assembly ground cable from theground plate at the bottom of the main frame.

2. Disconnect the Capacitor Bank Assembly ground cable.

3. Disconnect any ground wires that obstruct removal of the assembly.

4. Remove the capacitor mounting bolt at the top center of the capacitorframe.

5. Remove the wheel chocks at the bottom of the Capacitor BankAssembly.

6. Pull the assembly onto a platform. Refer to Figure 3.14.

ATTENTION: Hazard of tipping and severe injury exists. Thisprocess requires two people. The platform must be able to support909 kg (2,000 lbs).

Installation

Install the Capacitor Bank Assembly in reverse order of removal.

IMPORTANT: Guide the unit into place so that it mates with thelock-down bolt at the top of the capacitor frame. Adjust the angle bracketsat the ends of the T-bar crossbar.


3-35


Removing a Power Module Snubber Board

The Power Module Snubber Boards are located on the Inverter Heat Sinkassembly.

Figure 3.17Power Module Snubber Board

AB0602A

Power ModuleSnubber Board

SnubberResistor

Screw (2)

Preform

Screw (8)


3-36

Removal


ATTENTION: Hazard of electric shock exists. Up to 1,600 VDCwill be on Power Module Snubber Board Connector J1 if theSnubber Resistor is open. Measure for zero (0) VDC from SnubberBoard terminal TP3 to plus (+) bus before removing connector J1.Use a resistor greater than 1 ohm and less than 100 ohm, rated for25 watts minimum, between pins 1 and 2 of connector J1 todischarge any voltage.



1. Access the Inverter Housing Assembly. Refer to Chapter 3 –Disassembly and Access Procedures, Access to the Inverter HousingAssembly.

2. Remove the snubber resistor J1 and J2 connections from the snubberboard.

3. Remove the screws fastening the Power Module Snubber Board to thesnubber bus bars.


3-37

Installation

ATTENTION: Do not substitute longer or shorter hardware whenfastening the Power Module components to the Power Modules.Use the same size fastener to fasten the components as wasoriginally used. Using different fastener lengths will damage thePower Modules.

Install the Power Module Snubber Board in reverse order of removal. Referto Table 3.A – Fastener Torque Specifications.



3-38

Removing an Input Rectifier Snubber Board

The Input Rectifier Snubber Boards are located on the Inverter HousingAssembly, under the Guard, between the heat sinks and the vertical bus.

Figure 3.18Input Rectifier Snubber Board

AB0629A

Input RectifierSnubber Board

Guard

SCRs andHeat Sinks


3-39

Removal





2. Remove the plastic guard by removing the screws fastening the left sideof the guard to the SCR-heat sink assembly.

3. Remove the screws fastening the Input Rectifier Snubber Board to theAC and DC snubber buses.

4. Remove the snubber board.

InstallationInstall the Input Rectifier Snubber Board in reverse order of removal. Referto Table 3.A – Fastener Torque Specifications.



3-40

This Page Intentionally Left Blank.

Chapter

4-1

Component Test Procedures

Chapter Objectives The following tests help you troubleshoot B300 – B600, C300 – C600, andBX250 drives.

Component Test In some cases, different tests troubleshoot components of the same name.

Overview 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 areperforming.



Chapter 4Component Test Procedures

4-2


ATTENTION: This assembly contains parts and sub-assembliesthat are sensitive to electrostatic discharge. Static controlprecautions are required when servicing this assembly. Componentdamage may result if you ignore electrostatic discharge controlprocedures. If you are not familiar with static control procedures,reference Allen-Bradley Publication 8000-4.5.2, Guarding AgainstElectrostatic Discharge, or any other applicable ESD protectionhandbook.





Tools

For a list of tools required, tightening sequences, and fastener torquespecifications, refer to Chapter 3 – Disassembly and Access Procedures,Fastener Torque Specifications.


4-3

Test 1 The Gate Driver Board is located behind the Main Control Board, on the

Testing the Gate PC Board Mounting Frame. If you have replaced power modules, you

Driver Board should also replace the Gate Driver Board. If a new Gate Driver Board isnot available, you must test the old board, using the following procedure.

Figure 4.1Gate Driver Board Test

AB0604B

F3

VR2VR3VR5

VR6

VR1

VR4F1

Gate DriverBoard

D78

D71

D72

D65

D66

D10



4-4








6. Remove the Main Control Board Mounting Plate. Refer to Chapter 3 –Disassembly and Access Procedures, Removing the Main Control BoardMounting Plate.

7. Test Gate Driver Board fuses F1 and F3 for an open condition. Replacethe Gate Driver Board if either fuse shows an open condition.

8. Set your meter to test diodes.

9. Test VR1 – VR6. The following table shows meter connections at thecomponents and ideal meter readings for those connections. Refer to theprevious illustration for component locations.


4-5

Component Meter (+) Lead Meter (–) Lead Nominal Meter Reading*

+ – 1.06– + 1.8+ – 1.06– + 1.8+ – 1.06– + 1.8+ – 1.06– + 1.8+ – 1.06– + 1.8+ – 1.06– + 1.8

Note: Typical malfunction is shorted in both directions.* Meter Used: Fluke Model 87, set to “Diode” range.

Table 4.AGate Driver Board Test

VR1

VR2

VR3

VR4

VR5

VR6

10. Replace the Gate Driver Board if your readings do not match the tablereadings. Refer to Chapter 3 – Disassembly and Access Procedures,Removing the Gate Driver Board.

11. Check all six reverse-bias Zener diodes: D10, D66, D65, D78, D71, andD72. The following table shows meter connections at the componentsand ideal meter readings for those connections. Refer to the previousillustration for component locations.

Table 4.BZener Diode Test

Component Meter (+) Lead

Meter (–) Lead

Nominal MeterReading

D78 +–

–+

less than 1open

D71 +–

–+

less than 1open

D72 +–

–+

less than 1open

D65 +–

–+

less than 1open

D66 +–

–+

less than 1open

D10 +–

–+

less than 1open

12. Replace the Gate Driver Board if your readings do not match the table,or if any diode is shorted or open in both directions. Refer to Chapter3 – Disassembly and Access Procedures, Removing the Gate DriverBoard.


4-6

ATTENTION: When removing the entire wire harness connectingGate Driver Board connector J9 to Precharge Board connector J3,align the wires on the harness terminals with the pins on the boardconnectors. Incorrect harness connection may result in faulty driveoperation and may damage the equipment.



4-7

Test 2 If Power Modules have been replaced, you must test the Power Module

Testing the Snubber Board, the Precharge Board, and the Gate Driver Board.

Precharge Board

Figure 4.2Precharge Board Test

AB0605A

PrechargeBoard F3

F2F1



4-8








6. Set your meter to test resistance.

7. Test Precharge Board fuses F1, F2, and F3 for open conditions.

8. Replace the Precharge Board if any fuse shows an open condition. Referto Chapter 3 – Disassembly and Access Procedures, Removing thePrecharge Board.



4-9

Test 3 The Power Modules are located on three heat sinks in the Inverter Housing

Testing the Power Assembly. If Power Modules have been replaced, you must check the

Modules corresponding Snubber Resistor in addition to replacing the Gate DriverBoard and the corresponding Power Module Snubber Board. Refer toChapter 3 – Disassembly and Access Procedures, Removing a PowerModule Snubber Board.

Figure 4.3Power Module Test

AB0606A

Gate (G)

Collector (C)Emitter (E)

Emitter PowerTabs (E)

Collector PowerTabs (C)


4-10





2. Remove the Power Module Snubber Board. Refer to Chapter 3 –Disassembly and Access Procedures, Removing a Power ModuleSnubber Board.

3. Set your meter to test diodes.

4. Test the Power Modules. The following table shows meter connectionsand ideal meter readings for those connections. Refer to the formerillustration for meter connection locations.

Meter (+) Lead Meter (–) Lead Nominal Meter Reading

E C 0.218 – 0.418E G InfiniteC E InfiniteC G InfiniteG E InfiniteG C Infinite

Table 4.CPower Modules


4-11

5. Replace a Power Module if meter readings are not as shown. Refer toChapter 5 – Part Replacement Procedures, Power Modules.

6. Set your meter to measure resistance.

7. Test the Power Module Snubber Resistors. The reading should be 16ohms each. If open, replace the snubber resistor.

Figure 4.4Power Module Snubber Resistors

AB0998A

SnubberResistor

Note: Two 16 ohm resistors are in parallel when plugged into a snubber board,resulting in 8 ohms total.



4-12

Test 4 The Bus Capacitor Bank is located in the Capacitor Bank Assembly.

Testing the Bus Capacitors

Figure 4.5Bus Capacitor Bank Test

AB0679A

Meter (–) Lead

Meter (+) Lead





4-13

Access the drive:






Test the Capacitors:

1. Set your meter to test voltage.

2. Connect the negative lead of the meter to –DC and the positive lead tothe capacitor terminal called out in Figure 4.5.


3. Apply power AFTER the meter is connected, otherwise your meter willread zero volts.

Refer to Table 4.D for nominal meter readings.

Table 4.DCapacitor Test Meter Readings

Drive Series Input Volts Meter

380 V 178 V

B 415 V 193 V

480 V 218 V

500 V 233 V

C 575 V 267 V

600 V 283 V

If the capacitors are normal, the meter reading should be one third the voltage across thetotal capacitor bank.

4. Using this procedure, test each of the three Capacitor Bank sections.Table 4.E shows the correct voltage for the total Capacitor Bank.


4-14

Table 4.EBus Capacitor Bank Test

DriveRating

InputVolts

Meter Reading

B380415480

535V DC +/–10%580V DC +/–10%650V DC +/–10%

C500575600

700V DC +/–10%800V DC +/–10%850V DC +/–10%

5. If the voltage is out of tolerance, check the following:

An open condition at an Input Rectifier.

A voltage drop due to DC Bus Inductor resistance.

A voltage drop between an Input Rectifier and the bus capacitors dueto loose or resistive wires or connections.

Precharge circuit problems.

6. If the above check does not reveal a problem, replace the Bus CapacitorBank and Load-Sharing Resistors. Refer to Chapter 5 – PartReplacement Procedures, Bus Capacitor Bank.



4-15

Test 5 The SCRs are located in the heat sinks on the Inverter Housing

Testing the SCRs Assembly.




Access the drive:






6. Set your meter to test resistance.

7. Measure resistance from AC inputs L1, L2, and L3 to +DC. Refer toTable 4.F.

8. Measure between each pair of gate and cathode terminals on thePrecharge Board. Refer to Table 4.G.

The following tables show meter connections and ideal meter readings forthose connections. Refer to the schematic in this manual for moreinformation.


4-16

Table 4.FSCR Test at AC Input

Meter (+) Lead Meter (–) Lead Nominal Meter Reading

L1

L2 +DC

L3> 10kΩ

L1> 10kΩ

L2 –DC

L3

Table 4.GSCR Test at Precharge Board

SCR Meter (+) Lead Meter (–) Lead Nominal MeterReading

J1 Connector

SCR1R1G R1K 10

SCR1R1K R1G 10

SCR3S1G S1K 10

SCR3S1G S1G 10

SCR5T1G T1K 10

SCR5T1K T1G 10

J2 Connector

SCR4R2G R2K 10

SCR4R2K R2G 10

SCR6S2G S2K 10

SCR6S2K S2G 10

SCR2T2G T2K 10

SCR2T2K T2G 10

9. Replace the SCR if any meter readings are not as shown. Refer toChapter 5 – Part Replacement Procedures, SCRs.

10. If an SCR requires replacement, check the Power Modules for damage.Refer to Testing the Power Modules in this chapter.


Chapter

5-1

Part Replacement Procedures

Chapter Objective This chapter describes procedures required to replace drive components.This chapter references Chapter 3 – Disassembly and Access Proceduresfor basic drive component access.

Part Replacement The part replacement procedures in this chapter assume that the drive you

Overview are servicing either has no enclosure or that the enclosure is open. For moreinformation on opening the Drive Enclosure, refer to Chapter 3 –Disassembly and Access Procedures, Opening the Drive Enclosure.

Safety Precautions

ATTENTION: Some printed circuit boards and drive componentsmay contain hazardous voltage levels. Remove power before youdisconnect or reconnect wires, and before you remove or replacefuses and circuit boards. Verify bus voltage by measuring thevoltage between between the Negative Capacitor Bus and bothends of all three 350 amp fuses. An open fuse does not showvoltage across both ends of the fuse. Failure to measure voltage atboth ends of the fuses may result in death or serious injury. Refer toFigure 3.5. Do not attempt to service the drive until the bus voltagehas discharged to zero volts.

Chapter 5Part Replacement Procedures

5-2







For a list of tools required, tightening sequences, and fastener torquespecifications, refer to Chapter 3 – Disassembly and Access Procedures,Fastener Torque Specifications.


5-3

Major Component This section explains in detail how to replace the following drive

Replacement components:

Bus Capacitor Bank

Thermistor

Power Modules

Power Module Snubber Resistor

SCRs

Fans and Transformer Assembly

DC Bus Inductor

Ground Sense CT

Bus Fuses

LEMs

MOV Surge Suppressor

Thermal Switch

For Gate Driver Board, Precharge Board, Main Control Board, SnubberBoard, and Control Interface Board installation and removal procedures,refer to Chapter 3.

Detailed Product Allen-Bradley Adjustable Frequency AC Drives are modular by design to

Identification enhance troubleshooting and spare parts replacement, thereby helpingreduce production down-time.

The following illustration calls out the main components of a typical drive.Component designs vary slightly among the different drive ratings, butcomponent locations are identical.


5-4

Figure 5.1Main Drive Components

AB0618A

PowerModule

GroundSense CT


Power ModuleBus Bar

Power ModuleGate Interface

Board

LEM

FanTransformer

FanCapacitor

DC BusInductor

MOV SurgeSuppressor

Bus FuseF1

Bus CapacitorBank

ControlInterface Board

Main ControlBoard

Main Control BoardMounting Plate

PrechargeBoard

PrechargeBoard Fuses

Gate DriverBoard

Fuse F3

Fuse F1

Power ModuleSnubber Board

Thermistor

Power ModuleSnubber Resistor

Fan 1

Fan 2

ThermalSwitch

SCR

Load SharingResistor


5-5

Bus Capacitor Bank

The Bus Capacitor Bank is located in the Capacitor Bank Assembly.

Figure 5.2Bus Capacitor Bank

AB0608A

Bus CapacitorCap

Bus CapacitorHolder

CapacitorLaminated Bus Bar

Bus FuseF1

TerminalStrips

Motor BusBottom Support

CapacitorInsulator

BalancerPlate

MotorBuses


5-6

Removal

ATTENTION: Disconnect and lock out power from the drivebefore disassembling the drive. Failure to disconnect power mayresult in death or serious injury. Verify bus voltage by measuringthe voltage between between the Negative Capacitor Bus and bothends of all three 350 amp fuses. An open fuse does not showvoltage across both ends of the fuse. Failure to measure voltage atboth ends of the fuses may result in death or serious injury. Refer toFigure 3.5. Do not attempt to service the drive until the bus voltagehas discharged to zero volts.


IMPORTANT: Before you remove connections and wires from drivecomponents, mark the connections and wires to correspond with theircomponent connections and terminals to prevent incorrect wiring duringassembly.





5. Access the Capacitor Bank Assembly. Refer to Chapter 3 – Disassemblyand Access Procedures, Access to the Capacitor Bank Assembly.

Remove the Motor Buses:

1. Remove the screws fastening each motor bus to the top of its TerminalStrip near the bottom of the Capacitor Bank Assembly.

2. Remove the screws fastening the motor buses to the Motor Bus BottomSupport.

3. Remove the motor buses.

Access the Capacitors:

1. Remove the screws fastening the wires from the Balancer Plateassembly to the capacitors.

2. Remove the screws, nuts, and washers fastening the CapacitorLaminated Bus Bar to the capacitors.

3. Remove the Capacitor Laminated Bus Bar and attached components.

4. Remove the plastic caps at the four corners of each capacitor insulator.

5. Remove the capacitors from the drive.


5-7

Installation

1. Install the capacitor assembly in reverse order of removal. Refer toChapter 3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.

IMPORTANT: Position the notch and vent hole on the Bus Capacitors tothe top of the drive.

2. Connect the Load-Sharing Resistors to the Bus Capacitors according tothe following diagram. Refer to the schematic diagrams in this manualfor more information on component configurations.

Figure 5.3Load-Sharing Resistor Connections to Bus Capacitors

AB0625A

R4 – R6

C13 – C24 C25 – C36

R7 – R9

C5

C9

–

CAP DETAIL575V

R3C10 C11 C12

C6 C7 C8R2

C1 C2 C3 C4R1

+ D3

F3

D2

F2

F1

D1

C41

C40

X

C1 C2 C3 C4

C8C7C6C5

R1

R2

CAP DETAIL460V

C9 – C16

R3 – R4

C17 – C24

R5 – R6

D1

D2

D3F2

F1

F3

+

–

C40

C41

X

ATTENTION: Capacitors not installed correctly will explode orvent and may cause death or serious injury. Observe correctpolarities.


5-8


Thermistor

The Thermistor is located at the top of the heat sink in the Inverter HousingAssembly.

Figure 5.4Thermistor

AB0627A

Thermistor

Connector to MainControl Board J1


5-9

Removal


ATTENTION: Hazard of electric shock exists. Up to 1,600 VDCwill be on Power Module Snubber Board Connector J1 if theSnubber Resistor is open. Measure for zero (0) VDC from SnubberBoard terminal TP3 to plus (+) bus before removing Connector J1.Use a resistor greater than 1 ohm and less than 100 ohm, rated for25 watts minimum, between TP3 and plus (+) bus to discharge anyvoltage. Refer to Chapter 3 – Disassembly and Access Procedures,Removing a Power Module Snubber Board.







5. Disconnect Main Control Board Connector J1.

6. Remove the Thermistor.


5-10

Installation

Install the Thermistor in reverse order of removal. Refer to Chapter 3 –Disassembly and Access Procedures, Fastener Torque Specifications.



5-11

Power Modules

The Power Modules are located on the heat sink toward the back of theInverter Housing Assembly. If one or more Power Modules is replaced,you must check the Power Module Snubber Board, the Precharge Board,and the Gate Driver Board.

Figure 5.5Power Modules

AB0609B

Power ModulePreform

Power Module GateInterface Board

Power ModuleBus Bar Snubber

Bus Bars

Insulator


5-12

Removal


ATTENTION: Hazard of electric shock exists. Up to 1,600 VDCwill be on Power Module Snubber Board Connector J1 if theSnubber Resistor is open. Measure for zero (0) VDC from SnubberBoard terminal TP3 to plus (+) bus before removing connector J1.Use a resistor greater than 1 ohm and less than 100 ohm, rated for25 watts minimum, between TP3 and plus (+) bus to discharge anyvoltage. Refer to Chapter 3 – Disassembly and Access Procedures,Removing a Power Module Snubber Board.








6. Remove the screws fastening the positive and negative snubber bus barsto the Power Module Bus Bar.

7. Remove the screws fastening the Power Module Bus Bar to the PowerModules.


5-13

8. Carefully remove the bus bar. Do not damage the insulation.

9. Remove the screws fastening the Power Module Gate Interface Boardsto the Power Modules.

10. Remove the Power Module Gate Interface Boards.

11. Remove the Power Module by removing the screws fastening it to theheat sink. Refer to Figure 3.3 in Chapter 3 – Disassembly and AccessProcedures. Follow the torque sequence, as illustrated, both for removaland for installation.

Installation

1. Clean all surfaces between the Power Module and the heat sink using asoft, 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 Chapter3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.

ATTENTION: Do not substitute longer or shorter hardware whenfastening the Power Module components to the Power Modules.Use the same size fastener to fasten the components as wasoriginally used. Using different fastener lengths will damage thePower Modules.



5-14

Power Module Snubber Resistor

The Power Module Snubber Resistors are located on the main heat sink atthe back of the Inverter Housing Assembly.

Figure 5.6Power Module Snubber Resistor

AB0642A

Power ModuleSnubber Resistor


5-15

Removal

ATTENTION: Disconnect and lock out power from the drivebefore disassembling the drive. Failure to disconnect power mayresult in death or serious injury. Verify bus voltage by measuringthe voltage between between the Negative Capacitor Bus and bothends of all three 350 amp fuses. An open fuse does not showvoltage across both ends of the fuse. Failure to measure voltage atboth ends of the fuses may result in death or serious injury. Refer toFigure 3.5. Do not attempt to service the drive until the bus voltagehas discharged to zero volts.


IMPORTANT: Before you remove connections and wires from drivecomponents, mark the connections and wires to correspond with theircomponent connections and terminals to prevent incorrect wiring duringassembly.






6. Remove the Power Module Snubber Resistor connectors from the J1and J2 connectors on the Power Module Snubber Board.

7. Remove the screws fastening the Power Module Snubber Resistor to themain heat sink.

Installation

Install the Power Module Snubber Resistor in reverse order of removal.

IMPORTANT: Install the resistors with the markings to the right.


5-16


SCRs

The SCRs are located in the heat sinks on the upper front part of theInverter Housing Assembly. Each of the two heat sinks contains one longand three short sections. The cross bars link the sections, holding the SCRsin the middle. Refer to Figure 5.8.

Figure 5.7SCR Location

AB0603A


Guard

Horizontal InputBus Bars

OffsetFlex Bus

OffsetFlex Bus


Converter Back-up Coverand Back-up Plate

ScrewHoles

SCRHeat Sink

SCRHeat Sink


5-17

Removal





Access the heat sink:






6. Remove the Input Rectifier Snubber Boards. Refer to Chapter 3 –Disassembly and Access Procedures, Removing an Input RectifierSnubber Board.


5-18

7. Remove the snubber insulator and attached snubber buses.

Figure 5.8SCR Heat Sinks

AB0628A

Thermal SwitchSW1

Cross Bar

Roll Pin

SCR

Spring BarsHeat Sink

Converter Back-up Plate

Nut Bar

ConverterBack-up Cover

Remove the short section of the heat sink:

1. Remove the nuts from the ends of the cross bars.

2. Remove the spring bars.

3. Remove ths short section of the heat sink. The long section, attached tothe Converter Back-up Plate, remains in place.

Access the SCRs:

1. Remove the wires from the SCR.

2. Remove the SCR.


5-19

Installation

1. Adjust the roll pins in each heat sink half to protrude 1.5 mm (0.060 in)toward the inside of the heat sink.

2. Apply silicone oil to the heat sink in the areas around the roll pins.

3. Clean the surface of the SCR and place it on the roll pin.

4. Apply silicone oil to the other side of the SCR.

5. Install the SCR Heat Sink in reverse order of removal. Leave access tothe SCR gate connections.

6. Attach the wires to the SCR.

IMPORTANT: Refer to the torque gauge on the spring bars on the leftside of the heat sink. Without load, the torque gauge should read zero. If itdoes not, replace the spring bar assembly. Refer to Chapter 3 –Disassembly and Access Procedures, Fastener Torque Specifications.



5-20

Fan and Transformer Assembly

The two fans are located at the bottom of the Inverter Housing Assembly.The Fan Transformer and Fan Capacitors are located in the bottom leftcorner, attached to Fan 1. Both fans and the Transformer Assembly can bereplaced without pulling out the Inverter Housing Assembly.

Figure 5.9Fan and Transformer Assembly

AB0610A

Fan 1

Fan Cover

FanTransformer

FanCapacitor

Fan 2

Fan Cover


5-21

Removal










5-22

Remove the Fan Transformer:

1. Remove the wiring harness to the Fan Transformer Assembly.

2. Turn the thumb latch, fastening the Transformer Assembly to Fan 1, 1/4turn counterclockwise.

3. Tilt the Transformer Assembly forward and lift it from the mountingbracket.

Remove Fan 1:

1. Disconnect the fan wiring harness.

2. Pull down on both spring pins fastening the fan to the Inverter HousingAssembly to remove the fan. Pull the fan toward you to remove it.

Remove Fan 2:

1. Disconnect the Fan wiring harness.

2. Remove the screws fastening the fan cover to the fan.

3. Turn the standoffs, fastening the fan to the Inverter Housing Assembly,1/4 turn counterclockwise to remove the fan.

InstallationInstall the Fan and Transformer Assembly in reverse order of removal.



5-23

DC Bus Inductor

The DC Bus Inductor is located in the lower part of the Capacitor BankAssembly, behind the Terminal Strips and Motor Buses.

Figure 5.10DC Bus Inductor

AB0611B

DC BusInductor

InductorMounting Plate

Inductor PowerBus Connection

InductorFlex Cable

InductorFlex Bus

GroungSense CT


5-24

Removal









6. Remove the Inductor Flex Cable and the Ground Sense CT. Refer toRemoving the Ground Sense CT in this chapter.

7. Remove the Inductor Flex Bus.

8. Remove the two inductor power bus connections.

9. Remove the screws fastening the inductor to the Inductor MountingPlate.


5-25

IMPORTANT: Note the position and orientation of the Ground Sense CT(CT3) around the (–)Bus terminal at the top of the DC Bus Inductor. TheGround Sense CT is removed with the inductor. Install the Ground SenseCT in the same position. Check that the (+)Bus cable to the fuse passesthrough the Ground Sense CT during assembly.

10. Remove the DC Bus Inductor from the drive.

Installation

Install the DC Bus Inductor in reverse order of removal. Refer toChapter 3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.



5-26

Ground Sense CT

The Ground Sense CT is located between the DC Bus Inductor and theTransitional Bus Bar Assembly.

Figure 5.11Ground Sense CT

AB0612A

GroundSense CTConnector to Gate

Driver Board J2

Removal




5-27







6. Remove the Ground Sense CT connector J2 from the Gate DriverBoard.

7. Remove the nut and washers fastening the end of the Inductor FlexibleCable to the right-angled connector on the right side of the DC BusInductor.

8. Remove the Inductor Flex Cable from the right side inductor power busconnection.

9. Slide the Ground Sense CT from the Inductor Flex Cable.

InstallationInstall the Ground Sense CT in reverse order of removal, inserting theInductor Flex Cable through the center of the Ground Sense CT. Refer toChapter 3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.

ATTENTION: A possible short-circuit hazard exists. Position thefuse-to-inductor wire with the shrink-wrapped end of the wireconnected to the DC Bus Inductor. Failure to position the wire asillustrated may result in serious injury or equipment damage.



5-28

Bus Fuses

The Bus Fuses are located on the Transitional Bus Bar assembly.

Figure 5.12Bus Fuse

AB0613A

Bus Fuse

Removal




5-29


Access the drive:





5. Remove the nuts and washers fastening the Bus Fuse to the drive.

Installation

Install the Bus Fuse in reverse order of removal. Refer toChapter 3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.



5-30

LEMs

The LEMs are located in the Capacitor Bank Assembly, above theTerminal Strips.

Figure 5.13LEMs

AB0614A

LEM U-ShapedTop Plate

LEM U-ShapedPlate

LEM MountingPlate

LEM

Removal




5-31



2. Remove the wires from the LEM connectors.

3. Remove the two screws fastening the LEM mounting plate to the LEM.

4. Remove the LEM U-shaped top plate and the LEM U-shaped plate.

5. Remove the screws and standoffs fastening the LEM to the assemblyframe.

6. Remove the Terminal Strip from the motor bus.

7. Disconnect the motor bus from the Motor Bus Support.

8. Disconnect the motor bus at its upper end.

9. Remove the motor bus and LEM from the Capacitor Bank Assemblyframe.

10. Remove the LEM from the motor bus.

Installation

Install the LEMs in reverse order of removal. Refer to Chapter 3 –Disassembly and Access Procedures, Fastener Torque Specifications.



5-32

MOV Surge Suppressor

The MOV Surge Suppressor is located on the left side of the InverterHousing Assembly in the top-left corner at the back of the drive near thevertical bus bars.

The MOV protects the drive from high voltage surges above approximately1,000 volts. Replace it if it is burned, expanded, or ruptured after suchevents as a lightening strike, or inadvertent connection of the drive input toa voltage source substantially above nameplate voltage.

Figure 5.14MOV Surge Suppressor

AB0617A

MOV SurgeSuppressor

Removal

ATTENTION: Disconnect and lock out power from the drivebefore disassembling the drive. Failure to disconnect power mayresult in death or serious injury. Verify bus voltage by measuringthe voltage between the +DC and –DC on Terminal Block TB1. Donot attempt to service the drive until the bus voltage has dischargedto zero volts.


5-33

ATTENTION: Hazard of electric shock exists. Up to 1,600 VDCwill be on Power Module Snubber Board Connector J1 if theSnubber Resistor is open. Measure for zero (0) VDC from SnubberBoard terminal TP3 to plus (+) bus before removing connector J1.Use a resistor greater than 1 ohm and less than 100 ohm, rated for25 watts minimum, between TP3 and plus (+) bus to discharge anyvoltage. Refer to Chapter 3 – Disassembly and Access Procedures,Removing a Power Module Snubber Board.




2. Remove the MOV wire harness from the vertical bus bars on the left atthe back of the Inverter Housing Assembly.

3. Remove the screw fastening the MOV to the Inverter weldment.

InstallationInstall the MOV Surge Suppressor in reverse order of removal. Refer toChapter 3 – Disassembly and Access Procedures, Fastener TorqueSpecifications.



5-34


Chapter

6-1

Replacement Parts List

Chapter Objectives This chapter illustrates and lists replacement parts for the 1336 PLUSDrives rated B300 – B600, C300 – C600, and BX250, and describesreplacement parts ordering procedures.

The following illustration and table show you parts, part names, partnumbers, locations, and chapters for replacement procedures.

Ordering Replacement For your convenience, the Allen-Bradley Drives Division and the

Parts Allen-Bradley Support Division provide efficient and convenient repairand exchange for eligible equipment.

A product service report number is required to return any equipment forrepair. Your local Allen-Bradley distributor or area sales and support officecan provide you with a product service report number.

You should return equipment to be repaired to the area sales and supportcenter nearest you. Reference the product service report number on thecarton and packing slip. Include:

Your company name

Your company address

The repair purchase order number

A brief description of the problem

Contact your local Allen-Bradley distributor or sales office for a completelisting of area sales and support centers near you.

For parts catalog numbers, refer to the 1336 PLUS Spare Parts Pricingpublication included with your drive documentation set.

Chapter 6Replacement Parts List

6-2

Replacement Parts Listing

Figure 6.1Parts for B300 – B600, C300 – C600, and BX250 Drives

AB0626A

12

5

3

46 7

8

9

10

11

1213

14

15

16

17

18

19

20

21

22

Chapter 6Replacement Parts List

6-3

Table 6.AReplacement Parts for B300 – B600, C300 – C600, and BX250 Drives

Callout Symbol Description Location Replacement Procedures

1 MOV MOV Surge Suppressor Inverter Housing Assembly Chapter 5, MOV Surge Suppressor

2 Q11, Q12, Q21, Q22Q31, Q32, Q41, Q42Q51, Q52, Q61, Q62

Transistor (Power Module) Inverter Housing Assembly mainheat sink

Chapter 5, Power Modules

3 R20 – R25 Power Module Snubber Resistor Inverter Housing Assembly mainheat sink

Chapter 3, Removing a Power ModuleSnubber Board

4 A23 – A28 Power Module Gate InterfaceBoard

Power Module Chapter 5, Power Modules

5 NTC1 Thermistor Inverter Housing Assembly mainheat sink

Chapter 5, Thermistor

6 A20 – A22 Power Module Snubber Board Power Module Chapter 3, Removing a Power ModuleSnubber Board

7 R1 – R9 Load-Sharing Resistor Capacitor Bank Assembly Chapter 5, Bus Capacitor Bank

8 C1 – C36 Bus Capacitors Capacitor Bank Assembly Chapter 5, Bus Capacitor Bank

9 L1 DC Bus Inductor Capacitor Bank Assembly Chapter 5, DC Bus Inductor

10 CT3 Ground Sense CT Capacitor Bank Assembly Chapter 5, Ground Sense CT

11 CT1, CT2 LEM Capacitor Bank Assembly Chapter 5, LEMs

12 F1 – F3 Bus Fuse, 350 amp Capacitor Bank Assembly Chapter 5, Bus Fuses

13 THS1 Thermal Switch SW1 Inverter Housing Assembly,upper SCR heat sink

Chapter 5, SCRs

14 FAN 1 Fan 1 Inverter Housing Assembly Chapter 5, Fan and Transformer Assembly

15 T1 Fan Transformer Inverter Housing Assembly Chapter 5, Fan and Transformer Assembly

16 C38, C39 Fan Capacitor Inverter Housing Assembly Chapter 5, Fan and Transformer Assembly

17 FAN 2 Fan 2 Inverter Housing Assembly Chapter 5, Fan and Transformer Assembly

18 SCR1 – SCR6 SCR Inverter Housing Assembly, SCRheat sinks

Chapter 5, SCRs

19 A11 – A13 Input Rectifier Snubber Board Inverter Housing Assembly, SCRheat sinks

Chapter 3, Removing the Input RectifierSnubber Board

20 A1 Gate Driver Board PC Board Mounting Frame Chapter 3, Removing the Gate Driver Board

21 A10 Precharge Board PC Board Mounting Frame Chapter 3, Removing the Precharge Board

22 MAIN CTL Main Control Board PC Board Mounting Frame Chapter 3, Removing the Main ControlBoard

Chapter 6

Spare Parts Information

1336 PLUSSpare Parts Information

Current 1336 PLUS spare parts information including recommended parts, catalog numbers and pricing can be obtrained from the following sources:

• Allen-Bradley home page on the World Wide Web at:http://www.ab.comthen select . . .“Drives” followed by . . .“Product Information” and . . .“Service Information . . .”Select document 1060.pdf

• Standard Drives “AutoFax” service — An automated system that you can call to request a “faxed” copy of the spare parts information (or other technical document).

Simply call 440-646-6701 and follow the phone prompts to request document 1060.

C300 – 600B300 – B6001336 PLUS Schematics

BX250

S-1

300 – 600 HP 1336 PLUS Drives

C300 – C600B300 – B6001336 PLUS Schematics

BX250

S-6

Current and Voltage Processing PWM Algorithm Analog I/O Fault Protection and Monitoring

Main Control Board

TB21

Analog Out

Contacts Shownin Unpowered State

10k Ohm

4–20mAtoTE or PE

0–10VPulse

SourceAuxiliary Output

forDynamic BrakeSlave Operation

CR2

TETE

CR1ChassisCommon

Only Presenton 5.5–22 kW(7.5–30 HP)

Only Presenton 5.5–22 kW(7.5–30 HP)

CR3CR3 CR4CR4

2 3 4 5 6 9 10 11 12 13 14 15 16 17 18 A1 A287

User SuppliedAnalog Device

++ + +

36 18 1213 101617 141527 22 19202526 232430 29 283435 323345 3840 39 37

44 43 42474849 4650 41 31 1121 89 57 6 134 2

J6

J8

J9Optional SCANportCommunicationsAdapter Ports

J2

J7

J10

J1

20

20

AB0735A

From NTCFrom Gate Driver BoardConnector J1

Glossary

G-1

Glossary

AC Contactor: An alternating-current (AC) contactor is designed for thespecific purpose of establishing or interrupting an AC Power circuit.

Adjustable Speed: The concept of varying the speed of a motor, eithermanually or automatically. The desired operating speed (set speed) isrelatively constant regardless of load.

Adjustable Speed Drive (Electrical): The adjustable speed drive iscomprised of the motor, drive controller and operator’s controls (eithermanual or automatic).

Ambient Temperature: The temperature of the medium (air, water, earth)into which the heat of the equipment is dissipated.

Base Speed:The manufacturer’s nameplate rating where the motor willdevelop rated power at rated load and voltage. With DC drives, it iscommonly the point where full armature voltage is applied with full-ratedfield excitation. With AC systems, it is commonly the point where 60 Hz isapplied to the induction motor.

BR: Refer to Bridge Rectifier.

Braking: A method of stopping or reducing the time required to stop anAC motor, and can be accomplished in several ways:

1. DC-Injection braking (AC drives) A method which produceselectromagnetic braking forces in the motor by removing 2 AC motor(stator) phases and injecting DC current. The result is a linear brakingcharacteristic (ramp) that does not diminish with motor speed.Application is normally limited to 10–20% of rated motor speed due toincreased heating in the rotor.

2. Dynamic braking (AC drives) A method which produceselectromagnetic braking forces in the motor by dissipating generatedpower into the DC bus through a resistive load. Braking force remainsconstant and is only limited by the thermal capacity of the resistors. Theresult is a linear braking characteristic (ramp) that does not diminishwith motor speed.

3. Regenerative braking A method which produces electromagneticbraking forces in the motor by electronically controlling the return ofgenerated power to the AC supply. The result is a controllable linearbraking characteristic (ramp) that does not diminish with motor speed.

Glossary

G-2

4. Motor-mounted or separately-mounted brake A positive-action,mechanical friction device. Normal configuration is such that when thepower is removed, the brake is set. This can be used as a holding brake.(Note: A separately mounted brake is not one which is located on somepart of the mechanical drive train other that the motor.)

Breakaway Torque: The torque required to start a machine fromstandstill. Breakaway torque is always greater than the torque needed tomaintain motion.

Breakdown Torque: The breakdown torque of an AC motor is themaximum torque which it will develop with rated voltage applied at ratedfrequency.

Bridge Rectifier (Diode, SCR): A non-controlled, full-wave rectifier thatproduces a constant, rectified, DC voltage. An SCR bridge rectifier is afull-wave rectifier with a DC output that can be controlled by switching onthe gate control element.

Bridge Rectifier: A full-wave rectifier that conducts current in only onedirection of the input current. AC applied to the input results inapproximate DC at the output.

British Thermal Unit (BTU): The quantity of heat required to raise onepound of water by one degree Fahrenheit.

BTU: Refer to British Thermal Unit.

Bus: A single path or multiple parallel paths for power or data signals towhich several devices may be connected at the same time. A bus may haveseveral sources of supply and/or several sources of demand.

Bus Sense:A signal transducer that generates a signal proportional to thecurrent in the drive’s DC bus. The control logic uses this signal to sense thepresence or absence of bus voltage.

CEMF: Refer to Counter Electromotive Force.

CMOS: Complimentary Metallic Oxide Semiconductor. A semiconductordevice in which an electric field controls the conductance of a channelunder a metal electrode called a gate.

Cogging: A condition in which a motor does not rotate smoothly but stepsor jerks from one position to another during shaft revolution. Cogging is

Glossary

G-3

most pronounced at low motor speeds and can cause objectionablevibrations in the driven machinery.

Constant Torque Range: A speed range in which a motor is capable ofdelivering a constant torque, subject to cooling limitations of the motor.

Constant Voltage Range:(AC Drives) The range of motor operationwhere the drive’s output voltage is held constant as output frequency isvaried. This speed range produces motor performance similar to a DCdrive’s constant horsepower range.

Constant Volts per Hertz (V/Hz): The V/Hz relationship exists in ACdrives where the output voltage is directly proportional to frequency. Thistype of operation produces constant rated torque as the motor’s speedvaries.

Continuous Duty (CONT): A motor that can continue to operate withoutstopping and remain within the insulation temperature limits after it hasreached normal operating (equilibrium) temperature.

Converter:

1. A device for changing AC to DC. This is accomplished through use of adiode rectifier or thyristor rectifier circuit.

2. A device for changing AC to DC to AC (e.g., adjustable frequencydrive). A frequency converter, such as that found in an adjustablefrequency drive, consists of a rectifier, a DC intermediate circuit, aninverter, and a control unit.

Counter Electromotive Force (CEMF): The product of a motor armaturerotating in a magnetic field. This generating action takes place whenever amotor is rotating. Under stable motoring conditions the generated voltage(CEMF) is equal to the voltage supplied to the motor minus small losses.However, the polarity of the CEMF is opposite to that of the power beingsupplied to the armature.

Current Limiting: An electronic method of limiting the maximumcurrent available to the motor. This is adjustable so that the motor’smaximum current can be controlled. It can also be preset as a protectivedevice to protect both the motor and the control from extended overloads.

DC Boost: Compensates for the voltage drop across the resistance of anAC motor circuit and the resulting reduction in torque.

DC Bus: A drive’s power structure that transmits a rectified AC linepower from the bridge rectifier to the output transistors.

Glossary

G-4

DC Hold: Describes a “holding brake” function to stop motor rotationafter a ramp-to-stop function is activated.

Diode: A solid-state uni-directional conductor.

Drift: A slow change in some characteristic of a device. For a drive, it isthe deviation from the initial set speed with no load change over a specifictime period. Normally the drive must be operated for a specified warm-uptime at a specified ambient temperature before drift specifications apply.Drift is normally caused by random changes in operating characteristics ofvarious control components.

Drive Controller (Variable Speed Drive) (Drive): An electronic devicethat can control the speed, torque, horsepower, and direction of an AC orDC motor.

1. PWM drive is a motor drive using pulse-width modulationtechniques to control power to the motor. A high-efficiency drive usedfor high-response applications.

2. SCR drive is a motor drive that uses SCRs as the power controlelements. Usually used for low-bandwidth high-power applications.

3. Servo drive is a motor drive that uses internal feedback loops formotor current and/or velocity.

4. Vector drive is an AC static motor drive using power-controltechniques that produce motor performance similar to DC static drives.

Duty Cycle:

1. The ratio of working time to total time for an intermittently operatingdevice. Usually expressed as a percentage.

2. The ratio of pulse width to the interval between like portions ofsuccessive pulses. Usually expressed as a percentage.

Dynamic Braking: Refer to Braking.

Efficiency: Ratio of output to input, indicated by a percentage. In amotor, it is the effectiveness with which the motor converts electricalenergy into mechanical energy. In a power supply, it is the effectivenesswith which the power supply converts AC power into DC power.

Electrostatic Discharge (ESD):A static-electricity discharge that maydamage drive components. Refer to the ESD precautions found in thismanual to guard against damage to drive components.

Glossary

G-5

Enable: To activate logic by the removal of a suppression signal.

Enclosure: The housing in which equipment is mounted. They areavailable in designs for various environmental conditions. Refer to NEMAstandard for specifications of different types of enclosures.

ENUM (Enumeration): An ANSI C standard extension to the C language.An ENUM is a set of named integer constants that specify all the legalvalues a variable of a given type may have. The keyword ENUM signalsthe start of an enumeration type.

ESD: Refer to Electrostatic Discharge.

Floating Ground: An electrical circuit common which is not at earthground potential or the same ground potential as circuitry with which itinterfaces. A voltage difference can exist between the floating ground andearth ground.

Force: The tendency to change the motion of an object with an exertion ofenergy from a separate source.

Full Load Torque: The full-load torque of a motor is the torque necessaryto produce rated horsepower at full-load speed.

Gate:

1. A logic element that blocks or passes a signal, depending on the statusof specified input signals.

2. The control element of an SCR.

GND Sense:A current transducer that detects an unequal or imbalancedcurrent in the three-phase AC line or DC bus of the drive. The imbalanceindicates an output ground fault condition.

Horsepower (hp): A unit of power: 1 hp = 33,000 ft-lb/min. = 746 watts.

IEC: International Electrotechnical Commission.

IGBT: Refer to Insulated Gate Bipolar Transistor.

Induction Motor: An induction motor is an alternating-current motor inwhich the primary winding on one member is connected to the powersource. A secondary winding on the other member carries the inducedcurrent. There is no physical electrical connection to the secondarywinding; its current is induced.

Glossary

G-6

Inertia: A measure of a body’s resistance to change in velocity, whether abody is at rest or moving at a constant velocity. The velocity can be eitherlinear or rotational. The moment of inertia (WK2) is the product of theweight (W) of an object and the square of the radius of gyration (K2). Theradius of gyration is a measure of how the mass of the object is distributedabout the axis of rotation. WK2 is usually expressed in units of lb-ft2.

Insulated Gate Bipolar Transistor (IGBT): A type of transistorcommonly used in drive-control devices.

Integral-Horsepower Motor: A motor that has a continuous rating of1 hp or more, built into a frame.

International Organization for Standards (ISO): An organizationestablished to promote development of international standards.

Interposing Relay: An interposing relay is a relay that accepts controlsignals of one logic level in order to provide isolated contact signals in acircuit operating at a different logic level.

Inverter:

1. An AC adjustable frequency drive.

2. A particular section of an AC drive. This section uses the DC voltagefrom a previous circuit stage (intermediate DC circuit) to produce apulse-width-modulated or stepped AC current or voltage waveform thathas characteristics similar to the desired sine-wave frequency.

3. A circuit whose output signal is the inverse of its input (a positive-goingpulse is inverted to a negative-going pulse, and vise versa).

ISO: Refer to International Organization for Standards.

Isolation Transformer:

1. A transformer that provides DC isolation from other equipment notconnected to that transformer secondary.

2. A transformer that provides noise isolation between the primary andsecondary by such means as a Faraday shield.

Jogging:

1. In a numerical control system, an operator manually generating motion(continuously or incrementally) by closing a switch.

2. An operator generating motion by closing a switch.

Kinetic Energy: The energy of motion of a moving body.

Glossary

G-7

LAD: Refer to Linear Acceleration/Deceleration.

LEM: A hall-effect current transducer that senses drive output current andgenerates a signal for the control logic.

Linear Acceleration/Deceleration (LAD): A circuit that controls the rateat which a motor is allowed to accelerate to a set speed or decelerate tozero speed. On most drives, this circuit is adjustable and can be set toaccommodate a particular application.

Linearity: A measure of how closely a characteristic follows astraight-line function.

Locked-Rotor Current: Steady-state current taken from the line currentwith the a rotor at standstill (at rated voltage and frequency). This is thecurrent when starting the motor and load.

Locked-Rotor Torque: The minimum torque that a motor will develop atrest for all angular positions of the rotor (with rated voltage applied at ratedfrequency).

Meggar Test: A test used to measure an insulation system’s resistance.This is usually measured in megohms by applying a high voltage.

MOV: Refer to Surge Protection.

National Electrical Code (NEC): A set of regulations governing theconstruction and installation of electrical wiring and apparatus, establishedby the National Fire Protection Association and suitable for mandatoryapplication by governing bodies exercising legal jurisdiction. It is widelyused by state and local authorities within the United States.

National Electrical Manufacturer’s Association (NEMA): A non-profitorganization organized and supported by electrical equipment and supplymanufacturers. Some NEMA motor standards include horsepower (hp)ratings, speeds, frame sizes and dimensions, torques, and drive enclosures.

NEC: Refer to National Electrical Code.

Negative Slope: The location on a V/Hz curve where the break voltageexceeds the base voltage.

NEMA: Refer to National Electrical Manufacturer’s Association.

Glossary

G-8

Offset: The steady-state deviation of a controlled variable from a fixedsetpoint.

Op Amp: An operational amplifier. A high-gain stable linear DCamplifier that is designed to be used with external circuit elements.

Open Loop System:A control system that has no means of comparing theoutput with the input for control purposes.

Overload Capacity: The ability of the drive to withstand currents beyondthe system’s continuous rating. It is normally specified as a percentage offull-load current endured for a specified time period. Overload capacity isdefined by NEMA as 150% of rated full load current for one minute for“standard industrial DC motors.”

PC:

1. Personal Computer.

2. Programmable Controller.

3. Printed Circuit.

Plugging: A type of motor braking provided by reversing either linevoltage polarity or phase sequence so that the motor develops a countertorque that exerts a retarding force to brake the motor.

Pot: A potentiometer, or variable resistor.

Power: Work done per unit of time. Measured in horsepower (hp) orwatts (W): 1 hp = 33,000 ft-lb/min. = 746 W.

Power Factor (Displacement):A measurement of the time phasedifference between the fundamental voltage and fundamental current in anAC circuit. It represents the cosine of the phase angle difference. Fp = cos (α– β)

Power Factor (Distortion): A measurement of the ratio of the real power(kW) to the apparent power (kVA). Distortion power factor takes intoaccount harmonic voltage and current distortion as well asvoltage-to-current displacement.

Preform: A flexible material used between an electronic component andthe heat sink to which the component is attached. Preform providesmaximum heat dissipation from the component to the heat sink.

Glossary

G-9

Preset Speed:Describes one or more fixed speeds at which a driveoperates.

Programmable Controller: A solid-state control system that has auser-programmable memory for storage of instructions to implementspecific functions such as I/O control, logic, timing, counting, reportgeneration, communication, arithmetic, and data file manipulation. Acontroller consists of a central processor, input/output interface, andmemory. A controller is designed as an industrial control system.

Pull-In Torque: The maximum constant torque to which a synchronousmotor accelerates into synchronism at rated voltage and frequency.

Pull-Out Torque: The maximum running torque of a synchronous motor.

Pull-Up Torque: The torque required to accelerate the load from standstillto full speed (where breakdown torque occurs), expressed in percent ofrunning torque. It is the torque required not only to overcome friction,windage, and product loading but also to overcome the inertia of themachine. The torque required by a machine may not be constant after themachine has started to turn. This load type is characteristic of fans,centrifugal pumps, and certain machine tools.

PWM: Pulse-width Modulation. A technique used to eliminate or reduceunwanted harmonic frequencies when inverting DC voltage to sine waveAC.

Reactance: Pure inductance or capacitance, expressed in ohms, in acircuit. It is the component of impedance to alternating current that is notresistance.

Rectifier: A device that conducts current in only one direction, therebytransforming alternating current to direct current.

Regeneration: (AC drives) When the rotor synchronous frequency isgreater than the applied frequency.

Regenerative Braking: Slows or stops a motor through regeneration.Refer to Regeneration and Braking.

Glossary

G-10

Resolution: The smallest distinguishable increment into which a quantitycan be divided (e.g., position or shaft speed). It is also the degree to whichnearly equal values of a quantity can be discriminated. For rotary encoders,it is the number of unique electrically identified positions occurring in 360degrees of input shaft rotation. For D/A or A/D conversion, may beexpressed as the number of bits in the digital value that corresponds to afull-scale analog value.

SCR: Silicon Controlled Rectifier. A solid-state uni-directional latchingswitch.

Service Factor: When used on a motor nameplate, a number that indicateshow much above the nameplate rating a motor can be loaded withoutcausing serious degradation (i.e., a motor with 1.15 S-F can produce 15%greater torque than one with 1.0 S-F).

Set Speed:The desired operating speed.

Shock Load: The load seen by a clutch, brake, or motor in a system thattransmits high peak loads. This type of load is present in crushers,separators, grinders, conveyors, winches, and cranes.

Slip: The difference between rotating magnetic field speed (synchronousspeed) and rotor speed of AC induction motors. Usually expressed as apercentage of synchronous speed.

Slip Compensation: Monitors motor current and compensates for speedlost due to increased motor slip. The amount of slip is proportional to themotor load.

Speed Range:The speed minimum and maximum at which a motor mustoperate under constant or variable torque load conditions. A 50:1 speedrange for a motor with top speed 1800 rpm means the motor must operateas low as 36 rpm and still remain within regulation specification.Controllers are capable of wider controllable speed ranges than motorsbecause there is no thermal limitation, only electrical. Controllable speedrange of a motor is limited by the ability to deliver 100% torque belowbase speed without additional cooling.

Glossary

G-11

Speed Regulation:The numerical measure (percent) of how accuratelythe motor speed can be maintained. It is the percentage of change in speedbetween full load and no load. The ability of a drive to operate a motor atconstant speed (under varying load), without “hunting” (alternatelyspeeding up and slowing down). It is related to both the characteristics ofthe load being driven and electrical time constants in the drive regulatorcircuits.

Surge Protection: The process of absorbing and clipping voltagetransients on an incoming AC power line or control circuit. Surgeprotectors include MOVs (Metal Oxide Varistors) and specially designedR-C networks.

Synchronous Speed:The speed of an AC induction motor’s rotatingmagnetic field. It is determined by the frequency applied to the stator andthe number of magnetic poles present in each phase of the stator windings.Mathematically, it is expressed as: Sync Speed (rpm) = 120 x AppliedFreq. (Hz) / Number of poles per phase.

Torque: A turning force applied to a shaft, tending to cause rotation.Torque is equal to the force applied, times the radius through which it acts.Torque is measured in pound-feet, ounce-inches, Newton-meters, orgram-centimeters.

Transducer: A device that converts one energy form to another (e.g.,mechanical to electrical). When a transducer is actuated by signals fromone system or medium, it can supply a related signal to the other system ormedium.

Transient: A momentary power deviation in an electrical or mechanicalsystem.

Transistor: An active solid-state semiconductor device.

Work: A force moving an object over a distance. (work = force x distance)

Glossary

G-12


Index

I-1

IndexA

Adapter Locations, 1-9

Adptr Freq Err, 2-4

Audience for this Manual, P-1

Auxiliary Fault, 2-4

Auxiliary Input, Definition, P-10

Auxiliary Interlock, Definition, P-10

BBGND 10ms Over, 2-4

Bit, Definition, P-10

Blwn Fuse Flt, 2-4

Bus Capacitor BankIllustration, 5-5Installation, 5-7Load-Sharing Resistors, 5-7Removal, 5-6Replacement, 5-5

Bus Capacitors, Testing, 4-12

Bus FuseIllustration, 5-28Installation, 5-29Removal, 5-28Replacement, 5-28

CCapacitor Bank Assembly, 3-22

Access to, 3-32Installation, 3-34Removal, 3-33

Capacitors. See Bus Capacitor Bank

Check, Definition, P-10

Clearing Faults, 2-15

Component Test Procedures, 4-1

Connector, Definition, P-10

Contact Description, 2-3

Control Interface BoardInstallation, 3-10

Removal, 3-9

Control Interface Board Jumpers, 1-3Jumper Locations, 1-3

Control Interface Board, Definition, P-11

Control Interface Option, 1-2

Control Logic Wiring, 1-1

Control Logic Wiring and Adapters, 1-1

Conventions, P-10

DDC Bus Inductor

Illustration, 5-23Installation, 5-25Removal, 5-24Replacement, 5-23

DC Voltage Check, Illustration, 3-8

Default, Definition, P-11

Detailed Product Identification, 5-3

Diag C Lim Flt, 2-4

Diagnostic ProceduresClearing Faults, 2-15Drive Goes to Max Frequency, 2-15Drive Stays at Zero Hertz, 2-14Drive Will Not Jog, 2-13Drive Will Not Start, 2-11No Display, 2-12

Disassembly and Access Procedures, 3-1Tools required, 3-2

Drive, Identification, P-5

Drive –> HIM, 2-4

Drive Components, Main, 5-4

Drive EnclosureClosing, 3-8Illustration, 3-6Opening, 3-7

Drive Fault Reset, 2-4

Drive Goes to Max Frequency, 2-15

Drive Rating Qualifications, P-9

Drive Stays at Zero Hertz, 2-14

Drive Will Not Jog, 2-13

Drive Will Not Start, 2-11

Index

I-2

EEE Init Read, 2-4

EE Init Value, 2-4

EEprom Checksum, 2-4

EEProm Fault, 2-4

Electrostatic Discharge, P-2

Electrostatic Discharge Precautions, P-2, 2-2

Enable Input, Definition, P-11

Enclosure Type, P-9

Error Codes, 2-4

ESD, P-2

FFalse, Definition, P-11

Fan and Transformer AssemblyIllustration, 5-20Installation, 5-22Removal, 5-21Replacement, 5-20

Fan Capacitors, 5-20

Fan Transformer, 5-20

Fastener Torque Specifications, 3-3

Fault Descriptions, 2-4

Fault Display, Illustration, 2-3

FaultsClearing, 2-15Cross Reference, 2-9Descriptions, 2-4

Fgnd 10ms Over, 2-4

GGate Driver Board

Illustration, 3-16Installation, 3-18Removal, 3-16Testing, 4-3

Ground Fault, 2-4

Ground Sense CTIllustration, 5-26Installation, 5-27Removal, 5-26Replacement, 5-26

Ground Warning, 2-5

HHertz Err Fault, 2-5

Hertz Sel Fault, 2-5

High Voltage Guard, 3-20Illustration, 3-19

HIM. See Human Interface Module

HIM –> Drive, 2-5

Human Interface Module (HIM)Description, 1-8Illustration, 1-9Operation, 1-10Removal, 1-10

IInput Mode, 1-5

Factory Default, 1-6Three-Wire Control, Multi-Source Reversing, 1-7Three-Wire Control, Single-Source Reversing, 1-6Two-Wire Control, Single-Source Control, 1-7

Input Rectifier Snubber BoardIllustration, 3-38Installation, 3-39Removal, 3-39

Inputs, Available, 1-4

Inverter Housing and Capacitor Bank Assemblies, Accessto, 3-21

Inverter Housing Assembly, 3-22Access to, 3-23Installation, 3-28Removal, 3-24

JJumper, Definition, P-11

LLanguage Modules, P-7

LEMsIllustration, 5-30Installation, 5-31

Index

I-3

Removal, 5-30Replacement, 5-30

Load Sharing Resistor Connections, 5-7

Local Programming, 1-4

Loop Overrn Flt, 2-5

MMain Control Board

Illustration, 3-14Installation, 3-16Removal, 3-14

Main Control Board Mounting Plate, 3-11Illustration, 3-11Installation, 3-13Removal, 3-12

Major Component Replacement. See Procedures

ManualAudience, P-1Objective, P-1

Max Retries Fault, 2-5

Motor Mode Flt, 2-5

Motor Stall Fault, 2-5

MountingFour-Point, 3-4Six-Point, 3-4Two-Point, 3-3

MOV Surge SuppressorIllustration, 5-32Installation, 5-33Removal, 5-32Replacement, 5-32

NNameplate Location, P-3

Neg Slope Fault, 2-6

No Display, 2-12

OOp Error Fault, 2-6

Open Pot Fault, 2-6

OptionControl Interface, 1-2

Identification, P-5

Options, P-7

Overcurrent Flt, 2-6

Overload Fault, 2-6

Overtemp Fault, 2-6

Overvolt Fault, 2-6

PP Jump Err Flt, 2-6

Parameter, Definition, P-11

Part Replacement Procedures, 5-1

PC Board Mounting Frame, 3-6, 3-22Illustration, 3-30Installation, 3-31Removal, 3-31

Phase U Fault, 2-6

Phase V Fault, 2-6

Phase W Fault, 2-6

Pole Calc Fault, 2-7

Power Loss Fault, 2-7

Power Mode Fault, 2-7

Power Module Snubber BoardIllustration, 3-35Installation, 3-37Removal, 3-36

Power Module Snubber ResistorIllustration, 5-14Installation, 5-15Removal, 5-15

Power ModulesIllustration, 4-9, 5-11Installation, 5-13Removal, 5-12Testing, 4-9

Power Overload, 2-7

Power Test Flt, 2-7

PrecautionsElectrostatic Discharge, P-2Safety, P-1

Precharge BoardIllustration, 3-19Installation, 3-21Removal, 3-19Testing, 4-7

Precharge Fault, 2-7

Index

I-4

Precharge Open, 2-7

Press, Definition, P-11

ProceduresBus Capacitor Bank Installation, 5-7Bus Capacitor Bank Removal, 5-6Bus Capacitor Replacement, 4-12Bus Capacitor Testing, 4-12Bus Fuse Installation, 5-29Bus Fuse Removal, 5-28Bus Fuse Replacement, 5-28Capacitor Bank Assembly Installation, 3-34Capacitor Bank Assembly Removal, 3-33Closing Drive Enclosure, 3-8Component Test, 4-1Control Interface Board Installation, 3-10Control Interface Board Removal, 3-9DC Bus Inductor Installation, 5-25DC Bus Inductor Removal, 5-24DC Bus Inductor Replacement, 5-23DC Voltage Check, 3-8Diagnostic, 2-11Drive Enclosure, Opening and Closing, 3-6Fan Installation, 5-22Fan Removal, 5-21Gate Driver Board Installation, 3-18Gate Driver Board Removal, 3-16Gate Driver Board Testing, 4-3Ground Sense CT Installation, 5-27Ground Sense CT Replacement, 5-26Input Rectifier Snubber Board Installation, 3-39Input Rectifier Snubber Board Removal, 3-39Inverter Housing Assembly, Access to, 3-23Inverter Housing Assembly, Installation, 3-28Inverter Housing Assembly, Removal, 3-24LEM Installation, 5-31LEM Removal, 5-30LEM Replacement, 5-30Main Control Board Installation, 3-16Main Control Board Mounting Plate Installation, 3-13Main Control Board Mounting Plate Removal, 3-12Main Control Board Removal, 3-14Major Component Replacement, 5-3MOV Surge Suppressor Installation, 5-33MOV Surge Suppressor Removal, 5-32MOV Surge Suppressor Replacement, 5-32Opening Drive Enclosure, 3-7Part Replacement, 5-1PC Board Mounting Frame Installation, 3-31PC Board Mounting Frame Removal, 3-30Power Module Installation, 5-13Power Module Removal, 5-12Power Module Replacement, 4-9Power Module Snubber Board Installation, 3-37Power Module Snubber Board Removal, 3-36

Power Module Snubber Resistor Installation, 5-15Power Module Snubber Resistor Removal, 5-15Power Module Testing, 4-9Precharge Board Installation, 3-21Precharge Board Removal, 3-19Precharge Board Testing, 4-7SCR Installation, 5-19SCR Removal, 5-17SCR Replacement, 4-15SCR Testing, 4-15Spine, Disconnecting, 3-26Spine, Installation, 3-28Spine, Removing, 3-27Thermistor Installation, 5-10Thermistor Removal, 5-9

Product Identification, P-3

ProgrammingInput Mode, 1-4Local, 1-4

RRelated Publications, P-12

Replacement PartsList, 6-1Ordering, 6-1

Reprogram Fault, 2-7

ROM or RAM Flt, 2-7

Run Boost Fault, 2-7

SSafety Precautions, P-1

Schematics, S-1

SCRsHeat Sinks, 5-18Illustration, 5-16Installation, 5-19Location, 5-16Removal, 5-17Replacement, 5-16Roll Pins, 5-19Spring Bars, 5-19Testing, 4-15

Serial Fault, 2-7

Service Platform, 3-29

Shear Pin Fault, 2-7

Software Compatibility, P-4

Speed Select, Input State, 1-8

Index

I-5

SpineDisconnecting, 3-26Installation, 3-28Removing, 3-27

TTB3 Terminal Designations, 1-5

Temp Sense Open, 2-8

Terminal Block Locations, 1-2

Terminal Designations, TB3, 1-5

Thermal Switch, 5-18

ThermistorIllustration, 5-8Installation, 5-10Removal, 5-9Replacement, 5-8

Torque Sequence, 3-3Four-Point Mounting, 3-4Six-Point Mounting, 3-4Two-Point Mounting, 3-3

Torque Specifications, 3-4

Transformer Assembly. See Fan and Transformer Assembly

TroubleshootingFault Code Cross Reference, 2-9Fault Descriptions, 2-4Fault Display Illustration, 2-3

Meter for, 2-1Overview, 2-1

Troubleshooting and Error Codes, 2-1

True, Definition, P-12

UUndervolt Fault, 2-8

UV Short Fault, 2-8

UW Short Fault, 2-8

VVW Short Fault, 2-8

WWire Sizes, 1-5

XXsistr Desat Flt, 2-8

ZZener Diode Testing, 4-5

Index

I-6


Notes

N-1

Notes

N-2

Notes

N-3

Notes

N-4

Notes

N-5

Notes

N-6

Notes

N-7

Notes

N-8

Notes

N-9

Notes

N-10

Notes

N-11

Notes

N-12

CU

T AL

ON

G D

OTT

ED L

INE

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Publication 1336 PLUS-6.5 – August, 1999

Allen-Bradley, a Rockwell Automation Business, has been helping its customers improveproductivity and quality for more than 90 years. We design, manufacture and support a broadrange of automation products worldwide. They include logic processors, power and motioncontrol devices, operator interfaces, sensors and a variety of software. Rockwell is one of theworld’s leading technology companies.

Worldwide representation.Argentina • Australia • Austria • Bahrain • Belgium • Brazil • Bulgaria • Canada • Chile • China, PRC • Colombia • Costa Rica • Croatia • Cyprus • Czech Republic •Denmark • Ecuador • Egypt • El Salvador • Finland • France • Germany • Greece • Guatemala • Honduras • Hong Kong • Hungary • Iceland • India • Indonesia • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Malaysia • Mexico • Netherlands • New Zealand • Norway • Pakistan • Peru •Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia–CIS • Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic • Spain •Sweden • Switzerland • Taiwan • Thailand • Turkey • United Arab Emirates • United Kingdom • United States • Uruguay • Venezuela • Yugoslavia

Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

Publication 1336 PLUS-6.5 – August, 1999Supersedes August, 1997

P/N 74002-136-01(D)Copyright 1997 Allen-Bradley Company, Inc. Printed in USA

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Publication 1336 PLUS-6.5 August, 1999

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