Allen-Bradley A020, A025, A030, C025, C040, C050 Troubleshooting Manual
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Allen-Bradley
1336 IMPACT
t
Adjustable Frequency
AC Drive
(Series A)
A020 – A030
B040 – B050
BX040, BX060
C025 – C060
Troubleshooting
Guide
AB Spares
Important User
Information
Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example.
Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the
Application, Installation, and Maintenance of Solid-State Control
(available from your local Rockwell Automation office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Rockwell
International Corporation, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
!
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.
Attention statements help you to:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is critical for successful application and understanding of the product.
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Updated Information
Summary of Changes
Summary of Changes
The information below summarizes the changes to the company-wide templates since the last release.
No changes have been made to this manual.
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
Table of Contents
Preface
Control Logic Wiring and
Adapters
Manual Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions
1336 IMPACT Product Identification
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Drive Nameplate Location
Drive and Option Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
1336 IMPACT Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . .
Drive Rating Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Type
Conventions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Interlock
Bit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
False . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not External Fault Input
Parameter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press
True
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P–4
P–9
P–9
P–10
P–10
P–10
P–10
P–10
P–10
P–11
P–11
P–1
P–1
P–1
P–2
P–3
P–3
P–4
P–11
P–11
P–11
P–11
P–12
P–12
P–12
Chapter 1
Chapter Objectives
Chapter Overview
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L Option Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Human Interface Module (HIM) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphic Programming Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . .
GPT Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DriveTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Firmware Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–9
1–10
1–12
1–12
1–12
1–13
1–13
1–1
1–1
1–2
1–3
1–4
1–5
1–9
Publication 1336 IMPACT-6.2 – March 1998
ii Table of Contents
Troubshooting and Error
Codes
Chapter 2
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault/Warning Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing the Fault and Warning Queues on the HIM . . . . . . . . . . . .
What Are the Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . .
Start Up Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Troubleshooting Procedures . . . . . . . . . . . . . . . . . .
Encoderless Troubleshooting Procedures . . . . . . . . . . . . . . . . . . .
2–1
2–1
2–3
2–4
2–14
2–18
2–18
2–20
Disassembly and Access
Procedures
Chapter 3
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Overview
Electrostatic Discharge Precautions
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-Point Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Four-Point Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Procedures
Opening the Drive Enclosure
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing L Option Board
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Main Control Board Mounting Plate
Removal
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Main Control Board . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Precharge Board
Removal
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Snubber Board . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing Chassis Power Components . . . . . . . . . . . . . . . . . . .
3–15
3–16
3–17
3–17
3–19
3–19
3–10
3–11
3–11
3–12
3–13
3–13
3–14
3–15
3–3
3–4
3–5
3–5
3–6
3–6
3–7
3–8
3–8
3–9
3–9
3–1
3–1
3–1
3–2
3–3
3–3
3–3
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
Table of Contents iii
Component Test Procedures Chapter 4
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 1 – Testing Input Rectifier SCR1 . . . . . . . . . . . . . . . . . . . . . . .
Test 2 – Testing the Bus Capacitor Bank . . . . . . . . . . . . . . . . . . . .
Test 3 – Testing Power Modules PM1 – PM3 . . . . . . . . . . . . . . . . .
Test 4 – Testing Bus Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 5 – Testing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . .
Test 6 – Testing the Precharge Board
Test 7 – Testing the Thermistor
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–1
4–2
4–2
4–3
4–5
4–8
4–10
4–12
4–14
4–16
Part Replacement
Procedures
Chapter 5
Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Sense CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Fuse F1
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Modules PM1 – PM3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Rectifier SCR1
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Bus Inductor L1
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–10
5–11
5–11
5–12
5–13
5–13
5–14
5–15
5–16
5–17
5–18
5–19
5–20
5–4
5–6
5–7
5–8
5–8
5–9
5–9
5–1
5–1
5–1
5–1
5–2
5–2
5–2
5–4
Publication 1336 IMPACT-6.2 – March 1998
iv Table of Contents
Replacement Parts List
Schematics — 20 – 60 HP
1336 IMPACT Drives
Index
Bus Capacitor Bank
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–21
5–21
5–23
5–15
Chapter 6
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–1
6–1
6–2
Chapter 7
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
P–1
Manual Objective
Who Should Use This
Manual
Preface
Preface
The information in this manual is designed to help troubleshoot or repair an Allen-Bradley Bulletin 1336 IMPACT Adjustable
Frequency AC Drive with ratings A020 – A030, B040, B050,
BX040, BX060, and C025 – C060.
This manual is intended for qualified service personnel responsible for troubleshooting and repairing the 1336 IMPACT Adjustable
Frequency AC Drive. You should:
•
Read this entire manual before performing maintenance or repairs to drives.
•
Have previous experience with, and basic understanding of, electrical terminology, procedures, required troubleshooting equipment, equipment protection procedures and methods, and safety precautions.
This manual describes equipment, troubleshooting, and disassembly procedures. You begin with general illustrations and end with greater detail concerning replacement parts and part locations on the drives.
Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement.
Safety Precautions
!
ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
P–2 Preface
!
ATTENTION: Potentially fatal voltages may result from improper usage of oscilloscope and other test equipment. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope be used in the A minus B Quasi-differential mode with the oscilloscope chassis correctly grounded to an earth ground.
!
ATTENTION: Only personnel familiar with the
1336 IMPACT Adjustable Frequency AC Drive and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
Electrostatic Discharge
Precautions
!
ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures, reference Rockwell Automation Publication
8000-4.5.2, Guarding Against Electrostatic Damage, or any other applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed:
•
Wear a wrist-type grounding strap that is grounded to the drive chassis.
•
Attach the wrist strap before removing the new circuit board from the conductive packet.
•
Remove boards from the drive and immediately insert them into their conductive packets.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
1336 IMPACT Product
Identification
Preface P–3
Drive Nameplate Location
The drive nameplate is located on the face of the Main Control
Board Mounting Plate. The drive nameplate contains the drive’s catalog number and other important drive information. Reference the catalog number when ordering replacement parts.
Figure P.1
Drive Nameplate Location
Nameplate located on tab of Main Control Board
Mounting Plate
AB0334B
Publication 1336 IMPACT-6.2 – March 1998
P–4 Preface
Drive and Option
Identification
The following is an explanation of the catalog numbering system for
1336 IMPACT Adjustable Frequency AC Drives and options. The catalog number is coded to identify the drive power rating and can be found on the drive shipping carton and nameplate.
1336E
Bulletin No.
– A020-AN
Rating-Enclosure
(Must Be Specified)
1336 IMPACT Drive Catalog Numbers
Table P.A
200 – 240V AC Input
– EN
Language Module
(Must Be Specified)
– L6
L Option
(Optional)
– HA1
Human
Interface
(Optional)
– GM1
Communication Card
(Optional)
Drive Rating
Open IP00
No Enclosure
Enclosures
NEMA Type 1 IP20
General Purpose
NEMA Type 4
IP65
Resist Water, Dust
NEMA Type 12
IP54
Industrial Use
Frame
Designation
Output
Amps
64.5
78.2
80.0
20
25
30
Nominal
HP
Code
A
A
A030–AN
Code
AA
AA
A
A
A030–AA, –AE
Code
A
A
A030–AF
A
A
A030–AJ
Code
Refer to the Language Module and Options tables following these Catalog Number tables.
200 – 240V AC drive rating is based on nominal voltage of 240V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. 380 – 480VAC drive rating is based on nominal voltage of 480V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz
(75HP/55kW and above) at altitudes of 1,000 meters or less. 500 – 600V AC drive rating is based on nominal voltage of 600v and carrier frequency of 4kHz
(60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. Refer to Drive Rating Qualifications on page P–9.
Refer to Table P.I for explanation of “E” rating.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Preface P–5
1336E
Bulletin No.
– B040-AN
Rating-Enclosure
(Must Be Specified)
Table P.B
380 – 480V AC Input
– EN
Language Module
(Must Be Specified)
– L6
L Option
(Optional)
– HA1
Human Interface
(Optional)
– GM1
Communication Card
(Optional)
Drive Rating
Open
IP00
No Enclosure
Code
General Purpose
Enclosures
NEMA Type 1 IP20 NEMA Type 4 IP56
Resist Water, Dust
NEMA Type 12 IP54
Industrial Use
Frame
Designation
C
Output
Amps
58.7
64.5
78.2
78.2
40
40
50
60
Nominal
HP
Code Code Code
BX040–AN
B040–AN
B050–AN
BX060–AN
BX040–AA, –AE
B040–AA, –AE
B050–AA, –AE
BX060–AA, –AE
BX040–AF
B040–AF
B050–AF
BX060–AF
BX040–AJ
B040–AJ
B050–AJ
BX060–AJ
Refer to the Language Module and Options tables following these Catalog Number tables.
200 – 240V AC drive rating is based on nominal voltage of 240V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. 380 – 480VAC drive rating is based on nominal voltage of 480V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz
(75HP/55kW and above) at altitudes of 1,000 meters or less. 500 – 600V AC drive rating is based on nominal voltage of 600v and carrier frequency of 4kHz
(60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. Refer to Drive Rating Qualifications on page P–9.
Refer to Table P.I for explanation of “E” rating.
Publication 1336 IMPACT-6.2 – March 1998
P–6 Preface
1336E
Bulletin No.
– C025-AN
Rating Enclosure
(Must Be Specified)
Table P.C
500 – 600V AC Input
– EN
Language Module
(Must Be Specified)
– L6
L Option
(Optional)
– HA1
Human Interface
(Optional)
– GM1
Communication
Card
(Optional)
Drive Rating
Open
IP00
No Enclosure
Code
NEMA Type 1
IP20
General Purpose
Code
Enclosures
NEMA Type 4
IP56
Resist Water, Dust
Code
NEMA Type 12
IP54
Industrial Use
Code Frame
Designation
C
Output
Amps
30.0
34.6
45.1
57.2
61.6
25
30
40
50
60
Nominal
HP
C025–AN
C A
C040–AN
C A
C060–AN
C025–AA
AA
C040–AA
AA
C060–AA
C025–AF
A
C040–AF
A
C060–AF
C025–AJ
A
C040–AJ
A
C060–AJ
Refer to the Language Module and Options tables following these Catalog Number tables.
200 – 240V AC drive rating is based on nominal voltage of 240V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. 380 – 480VAC drive rating is based on nominal voltage of 480V and carrier frequency of 4kHz (60HP/45kW and below) or 2kHz
(75HP/55kW and above) at altitudes of 1,000 meters or less. 500 – 600V AC drive rating is based on nominal voltage of 600v and carrier frequency of 4kHz
(60HP/45kW and below) or 2kHz (75HP/55kW and above) at altitudes of 1,000 meters or less. Refer to Drive Rating Qualifications on page P–9.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Preface
Table P.E
Options
Code Description
Human Interface Modules, NEMA Type 1 (IP20)
HAB
HAP
HA1
HA2
Blank – No Functionality
Programmer Only
Programmer/Controller with Analog Pot
Programmer/Controller with Digital Pot
Human Interface Modules, NEMA Type 4/12 (IP65/54)
HJP
HJ2
Programmer Only
Programmer/Controller with Digital Pot
Table P.D
Language Modules
Description
English/English
English/French
English/German
English/Italian
English/Japanese
English/Spanish
Not available at time of printing.
Option Code
EN
FR
DE
IT
JP
ES
Code
Communication Options
Description
GM1
GM2
GM5
Single Point Remote I/O
RS-232/422/485, DF1, & DH485 Protocol
DeviceNet ™
L Option Boards
L4
L7E
L5
L8E
L6
L9E
Contact Closure
Contact Closure & Encoder Feedback
+24V AC/DC
+24V AC/DC & Encoder Feedback
115V AC
115V AC & Encoder Feedback
For a more functionally complete description of each option, refer to Publication 1336 IMPACT-1.0.
P–7
Publication 1336 IMPACT-6.2 – March 1998
P–8 Preface
Table P.F
200 – 240V Drives
Catalog
Number
Maximum
A020
A025
A030
65
78
80
Table P.G
380 – 480V Drives
Amp
Rating
Derate
Curve
None
Heat
Dissipation
Drive
Watts
210
215
220
Heat Sink
Watts
933
1110
1110
Total Watts
1143
1325
1330
Catalog
Number
B040
B050
BX040
BX060
65
78
59
78
Maximum
Amp
Rating
Derate
Curve
175
193
175
193
Heat
Dissipation
Drive
Watts
Heat Sink
Watts
933
1110
933
1110
Total Watts
1108
1303
1108
1303
Table P.H
500 – 600V Drives
Catalog
Number
Maximum
Amp
Rating
Derate
Curve
Heat
Dissipation
Drive
Watts
Heat Sink
Watts
Total Watts
C025
C030
C040
C050
C060
30
35
45
57
62
None
None
None
None
None
141
141
175
193
193
492
526
678
899
981
633
667
853
1092
1174
Amp Rating is at 4kHz. If carrier frequencies above 4kHz are selected, drive Amp Rating must be derated.
Drive Rating is based on nominal voltage (240, 480, or 600V). If input voltage exceeds Drive
Rating, Drive Output must be derated.
Drive Ambient Temperature Rating is 40
_
C. If ambient exceeds 40
_
C, the drive must be derated.
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 the 1336 IMPACT User Manual.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Preface P–9
Drive Rating Qualifications
Several factors can affect drive rating. If more than one factor exists, derating percentages must be multiplied. For example, if a 14-amp drive is installed at a 2km (6,600 ft.) altitude and has a 2% high-input line voltage, the actual amp rating is: 14 x 94% altitude derating x 96% high-input line derating = 12.6 amps
Enclosure Type
The first character, A, indicates the Enclosure Code.
The second character indicates the type of enclosure shipped from the factory:
Table P.I
Enclosure Type Code Description
Enclosure
Type Code
N
A
E
F
J
Description
Open style (IP00)
NEMA Type 1 (IP20)
NEMA Type 1 (IP20) “CE” Metal Cover
NEMA Type 4 (IP65)
NEMA Type 12 (IP54)
Publication 1336 IMPACT-6.2 – March 1998
P–10 Preface
Conventions
To help differentiate parameter names and display text from other text in this manual, the following conventions will be used:
•
Parameter Names will appear in italics .
•
Display Text will appear in “quotes”.
The following is a list of conventions used throughout this manual, and definitions of the conventions. For a list of terminology and definitions, refer to the Glossary in the back of this manual.
Auxiliary Interlock
The Auxiliary Interlock is a user supplied circuit consisting of reset, overload, or other interlocking circuitry. The Interlock is wired to the drive Not External Fault Input.
Bit
A bit is a single character or status point used in programmable logic. Eight bits form a BYTE, 16 bits form a word. Drive parameters are actually eight bits or 16 bit words.
Check
To check means to examine either the physical condition of something or the setting of some control, such as a Parameter.
Checking a drive board or component may also require measurements and tests.
Connector
A connector connects one drive board to another. Connectors come in two designs, male and female. Male connectors are stationary and contain pins, which are sometimes joined by jumpers. Female connectors are at the ends of wires or ribbon cables and plug into male connectors.
Default
When a drive function defaults, it automatically changes to a pre-programmed setting.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Preface P–11
Enable Input
The Enable Input is a terminal connection on the L Option Board.
This connection provides an external input to enable or disable the
Drive Output section. It must be true to permit the drive to operate.
False
False refers to a logical false state. For instance, an L Option signal on TB3 is false when the input contact is open or the appropriate voltage is not applied to the L Option Board.
Jumper
A jumper completes a circuit between two pins within a male connector on a drive board. In the absence of certain optional equipment using female connectors, jumpers are applied to certain pins within a male connector to complete specific and necessary circuits.
L Option Board
An L Option Board plugs into connectors J7 and J9, located on the lower portion of the Main Control Board. This board is identified as
L4, L5, L6, L7E, L8E, and L9E and provides optional control wiring configurations for a drive.
Not External Fault Input
The Not External Fault Input is a terminal connection on the L
Option Board. This connection provides an external input for use as an Auxiliary Interlock. Unless this interlock is closed, the drive will be faulted with an External Fault.
Parameter
Parameters are programmable drive functions that define various operating functions or status displays of a drive. Refer to Bulletin
1336 IMPACT Adjustable Frequency AC Drive User Manual for parameter details.
Publication 1336 IMPACT-6.2 – March 1998
P–12 Preface
Related Publications
Press
Press a button on the Human Interface Module to change parameter settings and drive functions.
True
True refers to a logical true state. For instance, an L Option signal on
TB3 is true when: L4 contact input is closed, L5 input terminal registers 24V, or L6 input terminal registers 115V AC.
The following lists other Allen-Bradley publications that apply to the
1336 IMPACT Adjustable Frequency AC Drives with ratings A020 –
A030, B040, B050, BX040, BX060, and
C025 – C060:
•
Product Pricing Bulletin (1336 IMPACT-3.0)
•
User Manual (1336 IMPACT-5.0)
•
Renewal Parts List
•
Options Manuals/Instructions
•
Product Data DriveTools Software (9303-2.0)
•
User Manual Bulletin 1201 Graphic Programming Terminal
(1201-5.0)
Current 1336 IMPACT spare parts information, including recommended parts, catalog numbers, and pricing, can be obtained from the following sources.
•
Allen–Bradley home page on the World Wide Web at: http://www.ab.com
Select Drives , and the select Information for Drives, Including Part Lists . . .
Select documents
1060.pdf
(230V drives) and/or 1070.pdf
(460 & 575V drives).
•
Standard Drives “AutoFax” service–an automated system that you can call to request a “faxed” copy of the spare parts information (or other technical documentation).
Simply call 444–646–6701 and follow the phone prompts to request document(s) 1060 (230V drives) and/or 1070 (460 &575V drives).
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
1–1
Chapter Objectives
Chapter Overview
Chapter 1
Control Logic Wiring and Adapters
This chapter introduces you to terminal block locations and wiring and adapter locations and functions.
This chapter illustrates and describes:
•
L Option boards L4, L5, L6, L7E, L8E, and L9E including terminal block TB3.
•
TB3 L Option mode selections and functions
•
TB3 terminal designations
Important: All printed circuit boards, except the Main Control
Board assembly, are referenced to negative ground
(–bus).
!
ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on terminal block TB1.
Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures, reference Rockwell Automation Publication
8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook.
Publication 1336 IMPACT-6.2 – March 1998
1–2 Control Logic Wiring and Adapters
Figure 1.1
Terminal Block Locations
TB3
TB2
TB1
AB0335A
L Option Board
!
ATTENTION: The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices.
Failure to do so may result in personal injury and/or equipment damage.
The L Option Board provides a means of interfacing various signals and commands to the 1336 IMPACT by using contact closures.
Six different versions of the L Option are available:
L4
L7E
L5
L8E
Contact Closure Interface
1
Contact Closure Interface with Encoder Feedback
+24V AC/DC Interface
+24V AC/DC Interface with Encoder Feedback
L6 115V AC Interface
L9E
1
115V AC Interface with Encoder Feedback
Uses internal +5V DC supply.
1
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Control Logic Wiring and Adapters 1–3
The user inputs are connected to the L Option Board through TB3.
The L4, L5, and L6 options each have nine inputs: seven user-configurable inputs and two factory-defined control inputs. The function of each L Option must be selected through programming as explained later in this section. The L7E, L8E, and L9E options are similar to L4, L5, and L6 with the addition of encoder feedback L
Options.
L Option Board Jumpers
Important: If the L Option Board is being installed, Main Control
Board jumpers at pins 3 & 4 and 17 & 18 of J2 (J7 on
7.5 – 30 HP drives) must be removed. If these jumpers are removed, they can be stored on the “spaces” location on the Main Control Board. If this board is removed, these jumpers must be reinstalled and the
L Option Mode parameter must be programmed to “1”.
Figure 1.2
Jumper Locations
Jumper J10 (Located on Main Board)
AB0763A
Publication 1336 IMPACT-6.2 – March 1998
1–4 Control Logic Wiring and Adapters
Available Inputs
A variety of combinations made up of the following L Options are available.
Accel/Decel Rate
Digital Potentiometer (MOP)
Enable
Flux Enable
Forward/Reverse
Jog
Local Control
Not Ext Flt
Not Stop, Clear Fault
Process Trim
Ramp
Reset
Run Forward
Run Reverse
Speed Selects
Speed Torque Selections
Start
Stop Mode Selects
The available combinations are shown in Figure 1.4. Programming the L Option Mode parameter to one of the L Option Mode numbers listed selects that combination of L Option functions.
Important: The L Option Mode parameter can be changed at any time; however, programming changes will not take affect until power has been cycled to the drive. When changing an L Option mode, it is important to note that the corresponding L Options to TB3 may also change.
The programming options of the L Option Board allow the user to select an L Option combination to meet the needs of a specific installation. Appropriate selection of a combination may be done by using Table 1.A. First determine the type of start/stop/direction control desired. Then select the remaining control functions available. After selecting a group of L Option Modes, use Table 1.A
for specific mode selection. Record the selected mode number below.
Selected Mode Number:
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Control Logic Wiring and Adapters 1–5
Local Programming
For local programming and control information, refer to the
1336 IMPACT User Manual .
Table 1.A
L Option Mode Selection
Start/Stop
Type
Stop & Enable
Only
Momentary
Pushbutton
(3 Wire)
Momentary
Pushbutton
(3 Wire)
None
Direction Control
Maintained Switch
(Open-Forward,
Closed-Reverse)
Single-Source
Momentary Pushbuttons
(Forward and Reverse)
Multi-Source
Communication Compatibility
Control must be provided by HIM or Communication Option.
Start/Stop – works like HIM and Communication Options. Direction
Control will not work in parallel with HIM or Communication Options.
User must select direction control from either HIM and
Communication Options or TB3 L Option.
Start/Stop – works in parallel with HIM and Communication Options.
Direction – works in parallel with HIM or Communication Options.
Mode(s) to Use
1
Maintained switches for combined run and direction control (2 wire, Run Forward, Run Reverse)
Start – works differently than three-wire control.
Direction – works differently than three-wire control.
Stop – always works.
Refer to two-, three-wire notes in the user manual.
Diodes 27 – 30 are available with versions 2.02 and later.
Figure 1.3 provides the terminal designations for TB3. The maximum and minimum wire sizes accepted by TB3 is 2.1 and
0.30 mm 2 (14 and 22 AWG). Maximum torque for all terminals is
1.36 N-m (12 lb-in.). Use copper wire only.
Figure 1.3
TB3 Terminal Designations
19 20 21 22 23 24 25 26 27 28 29
Included on L7E, L8E, & L9E Only
30 31 32 33 34 35 36
2 – 6, 17,
18, and
27
7 – 11,
19 – 22, and 28,
29
12 – 16,
23 – 26, and 30
AB0293B
Publication 1336 IMPACT-6.2 – March 1998
1–6
25
26
27
28
29
30
19
20
21
22
23
24
28
29
26
27
30
22
23
24
25
19
20
21
Control Logic Wiring and Adapters
Figure 1.4
L Option Mode Selection and Typical TB3 Connections
Momentary
Maintained
AB0290B
L Option Mode (parameter 116) = 1
Factory Default
Status
Not Stop 7 , Clear Fault 3,6
Common
Status
Status
Status
Common
Status
Status
Status
Common
Enable 3
Start 9
Not Stop
7
, Clear Fault
3,6
L Option Mode (parameter 116) = 2 – 6, 17, 18, and 27
Single-Source, Three-Wire Control
Common
Rev/Fwd
5
2
Jog
3
Stop
Type 7
4 5
11
2nd/1st
Accel
Digital
Pot Up
Mode
6
Jog
17
Proc
Trim
18 27
11, 12
Flux En Digital
Pot Up
Not Ext Fault 4,8,10
Common
Speed Speed 2nd/1st
Select 3 1 Select 3 1 Decel
Digital
Pot Dn
Local
Control 2
Ramp Reset Digital
Pot Dn
Speed Select 2 1
Speed Select 1 1
1 See Table 1.B.
2 Drive must be stopped to take Local Control.
Control by all other adapters is disabled (except Stop).
Common
Enable 3
3 These inputs must be present before drive will start.
4 For Common Bus, this becomes Precharge Enable.
5 Bit 11 of Logic Options (parameter 17) must be 0 for reverse direction control.
6 For soft faults only. You need to recycle power to the drive or reset to clear. For hard faults, refer to the troubleshooting chapter.
7 To configure the stop type, refer to Logic Options (parameter 17).
8 This L Option must be present before the fault can be cleared and the drive will start. This can be disabled through Fault Select 2 (parameter 22) and Warning Select 2 (parameter 23).
9 Latched starts require a stop to stop the drive.
10 This input must be present or masked out before drive will start.
11 In mode 5, the MOP value is not reset to 0 when you stop. In mode 27, the MOP value is reset when you stop.
Available in versions 2.02 and later.
Publication 1336 IMPACT-6.2 – March 1998
Control Logic Wiring and Adapters 1–7
Momentary
Maintained
25
28
29
26
27
30
19
20
21
22
23
24
25
28
29
26
27
22
23
24
19
20
21
30
Start 9
Not Stop 7 , Clear Fault 3,6
L Option Mode (parameter 116) = 7 – 11, 19 – 22, 28, and 29
Multi-Source, Three-Wire Control
Common 7 8 9
12
10
12
Mode
11 19 20 21 22 28
12,13
29
12,13
Reverse 5 Reverse
5
Digital
Pot Up
Not Ext Fault 4,8
Forward
5
Forward
5 Digital
Pot Dn
Reverse 5
1st
Accel
Speed/
Torque 3
10
Speed/
Torque 3
10
Reverse
5
Speed/
Torque 3
10
Digital
Pot Up
Forward
5 2nd
Accel
Speed/
Torque 2
10
Speed/
Torque 2
10
Forward
5
Speed/
Torque 2
10
Digital
Pot Dn
Reverse 5
Forward
5
Common
Speed Select 1
1
Jog Speed Speed
Select 3
1
Select 3
1
Digital
Pot Up
1st
Decel
Speed/
Torque 1 10
Speed/
Torque 1 10
Ramp Speed/
Torque 1 10
Speed
Select 3
1
Digital
Pot Up
Speed Speed Speed
Select 2 1 Select 2 1 Select 2 1
Digital
Pot Dn
2nd
Decel
Process
Trim
Flux
Enable
Reset Speed
Select 2 1
Speed
Select 2 1
Digital
Pot Dn
Common
Enable
3
L Option Mode (parameter 116) = 12 – 16, 23 – 26, and 30
Run Forward 5,11
Not Stop 7 , Clear Fault 3,6
Single-Source, Two-Wire Control
Common
Run Reverse 5,11
12 13 14 15
12
Mode
16 23 24 25 26
Local
Control 2
Stop
Type 7
2nd/1st
Accel
Digital
Pot Up
Local
Control 2
Process
Trim
Flux
Enable
Process
Trim
Jog
Not Ext Fault
4,8
30
12,13
Digital
Pot Up
Common
Speed Speed
Select 3 1
Select 3 1
2nd/1st
Decel
Digital
Pot Dn
Stop
Type
Reset Reset Ramp Speed
Select 3 1
Digital
Pot Dn
Speed Select 2 1
Speed Select 1
Common
Enable 3
1
1 See Table 1.B.
2 Drive must be stopped to take Local Control.
Control by all other adapters is disabled (except Stop).
3 These inputs must be present before drive will start.
4 For Common Bus, this becomes Precharge Enable.
5 Bit 11 of Logic Options (parameter 17) must be 0 for reverse direction control.
6 For soft faults only. You need to recycle power to the drive to clear. For hard faults, refer to the troubleshooting chapter.
7 To configure the stop type, refer to Logic Options (parameter 17).
8 This L Option must be present before the fault can be cleared and the drive will start. This can be disabled through Fault Select 2 (parameter 22) and
Warning Select 2 (parameter 23).
9 Latched starts require a stop to stop the drive.
10 See Speed/Torque Select table.
11 Unlatched start.
12 In modes 9, 10, and 15, the MOP value is not reset to 0 when you stop. In modes 28, 29, and
13
30, the MOP value is reset when you stop.
Available in versions 2.02 and later.
AB0291B
Publication 1336 IMPACT-6.2 – March 1998
1–8 Control Logic Wiring and Adapters
Table 1.B defines the input state of the Speed Select inputs for a desired frequency source.
Table 1.B
Speed Select/Speed Reference
Speed Select 3 Speed Select 2 Speed Select 1 Frequency Source
O O O Speed Ref 1
O
O
O
X
X
O
Speed Ref 2
Speed Ref 3
X
X
O
X
X
X
O
O
X
X
X
O
X
O
X
Speed Ref 4
Speed Ref 5
Speed Ref 6
Speed Ref 7
Last State
O = Open = Removed = 0
X = Closed = Applied = 1
Table 1.C defines the input state of the Speed/Torque Mode Select inputs for a desired speed/torque mode.
Table 1.D
Speed/Torque Select
Speed/
Torque Mode
Select 3
O
O
X
X
O
O
X
X
O = Open = Removed = 0
X = Closed = Applied = 1
Speed/
Torque Mode
Select 2
O
O
O
O
X
X
X
X
Speed/
Torque Mode
Select 2
O
X
O
X
O
X
O
X
Speed/Torque Mode
Zero torque
Speed regulate
Torque regulate
Minimum torque/speed
Maximum torque/speed
Sum of the torque and speed
Zero torque
Zero torque
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Control Logic Wiring and Adapters 1–9
Human Interface Module
(HIM)
Description
When the drive-mounted HIM is supplied, it will be connected as
SCANport Adapter 1 (refer to Figure 1.6) and visible from the front of the drive. The HIM can be divided into two sections: Display
Panel and Control Panel. The Display Panel provides a means of programming the drive and viewing the various operating parameters. The Control Panel allows different drive functions to be controlled. Refer to the 1336 IMPACT User Manual for HIM operation.
Important: The operation of HIM functions depends upon drive parameter settings. Default parameter values allow full
HIM functionality.
Figure 1.5
Human Interface Module
Display Panel
ESC SEL
Control Panel
ESC SEL
JOG
JOG
Human Interface Module
(HIM)
AB0268B
Publication 1336 IMPACT-6.2 – March 1998
1–10 Control Logic Wiring and Adapters
Figure 1.6
Adapter Locations
Internal
Communication
(Adapter 6)
Drive Mounted
HIM (Adapter 1)
L Option
(TB3 Adapter 0)
Communications Port Remote HIM/
Communication Options (Adapter 2) or
Expansion Options (Adapters 2, 3, 4, 5)
2 3
2 3 4 5
Expansion Options
AB0337B
Removing the HIM
For handheld operation, you can remove the module and place it up to 10 meters (33 feet) from the 1336 IMPACT drive. (You do need a cable to do this.)
!
ATTENTION: Some voltages present behind the drive front cover are at incoming line potential. To avoid an electrical shock hazard, use extreme caution when removing/replacing the HIM.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Control Logic Wiring and Adapters 1–11
Important: Removing a HIM (or other SCANport device) from a drive while power is applied causes a Serial Fault, unless SP Enable Mask (parameter 124) or Fault Select
1 (parameter 20) have been set to disable this fault or
Control Logic (from the Control Status menu) has been disabled (only available on a Series A, version 3.0 or
Series B HIM). Setting bit 1 of SP Enable Mask to 0 disables Serial Fault from a HIM on port 1. It also disables all HIM control functions except Stop. Setting bit 9 of Fault Select 1 to 0 disables the serial fault from the HIM on port 1 but still allows HIM control.
!
ATTENTION: Hazard of personal injury or equipment damage exist. If you initiate a command to start motor rotation (command a start or jog) and then disconnect the programming device, the drive will not fault if you have the SCANport communications fault set to be ignored for that port.
To remove the HIM, you need to:
1.
Either remove the power or clear the port bit, which corresponds to the port the HIM is attached to, in SP Enable Mask (parameter
124) or Fault Select 1 (parameter 20) to prevent the drive from faulting.
2.
Remove the front cover of the drive.
3.
Push the release at the bottom of the HIM cradle and slide the module down out of its cradle.
To use the module from anywhere up to 10 meters (33 feet) from your drive, you need to:
1.
Connect the appropriate cable between the HIM and the communications port (adapter 2, 3, 4, or 5) or adapter 1 (the HIM cradle).
2.
Set SP Enable Mask (parameter 124) and/or Fault Select 1
(parameter 20) to enable the port into which you plugged the
HIM.
Publication 1336 IMPACT-6.2 – March 1998
1–12 Control Logic Wiring and Adapters
To replace the module, follow these steps:
1.
Slide the module up into its cradle.
2.
Replace the front cover of the drive.
3.
Apply power, set SP Enable Mask or set Fault Select 1.
HIM Operation
When power is first applied to the drive, the HIM will cycle through a series of displays. These displays will show drive ID and communication status. Upon completion, the Status Display (see
Figure 1.7) will be shown. This display shows the current status of the drive (i.e. Stopped, Running, etc.) or any faults that may be present (Not Enabled, etc.).
Refer to the 1336 IMPACT User Manual for HIM operation.
Figure 1.7
Status Display
Stopped
+0.00 RPM
Graphic Programming
Terminal
GPT Description
The optional GPT (Figure 1.8) is a remote device with a 1.8 meter (6 foot) long cable. The GPT offers a 40-by-8 character display that can also be used as a graphics display. For GPT operation, refer to the
1201 GPT User Manual.
Important: Main Menu screens are dynamic and will change based on functionality provided by adapter and drive status.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Control Logic Wiring and Adapters
Figure 1.8
Graphic Programming Terminal
1–13
F1 F2 F3
D
7
E
8
F
9
ALT
ESC
4
PRESET 4
1
PRESET 1 .
JOG
5
PRESET 5
2
PRESET 2
0
6
XREF 1
3
PRESET 3
+/–
+
–
F4
DriveTools
Control Firmware Function
AB0554A
DriveTools software is a Windows 3.1 compatible family of application programs allowing the user to perform programming, monitoring, and diagnostic operations on Rockwell Automation AC and DC digital drive products. The software consists of five
Windows applications. For operation, refer to the Product Data
DriveTools Software manual.
All control functions in the 1336 IMPACT drive are performed through the use of parameters that can be changed with a programming terminal or DriveTools. Refer to an overview Block
Diagram of the Control Firmware Function in the 1336 IMPACT
User Manual.
Feedback information is derived from hardware devices as part of the process equipment used. Analog signals are converted to digital signals for use by the drive. Control signals may be provided to the drive by the Main Control Board.
Publication 1336 IMPACT-6.2 – March 1998
1–14 Control Logic Wiring and Adapters
All setup and operation information used by the drive is stored in a system parameter table. Every parameter, including Setup and
Configuration parameters (Sources and Destinations), has an entry in the parameter table. For example, parameter 29 is named the Speed
Ref 1 parameter and contains a number value representing the speed reference. The speed reference can originate from an external control device such as a potentiometer connected to the analog input of the
Main Control Board. Refer to the 1336 IMPACT User Manual,
Publication 1336 IMPACT-5.0.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
2–1
Chapter Objectives
Fault/Warning Handling
Chapter 2
Troubleshooting and Error Codes
This chapter provides information to help troubleshoot your 1336
IMPACT drive.
!
ATTENTION: Do not troubleshoot or maintain the
1336 IMPACT drive unless you are familiar with your drive system and the associated machinery. You may be injured and/or the equipment may be damaged if you do not comply.
During the start-up procedure, you should have recorded board jumper settings for each board, board software version numbers, and the drive and motor nameplate data in Table 6.A of the 1336
IMPACT t
Adjustable Frequency AC Drive User Manual . If this information was not recorded, record it before beginning any troubleshooting sequences.
When a problem occurs with your drive, check the VP and CP lights on your drive on the main control board. Figure 2.1 shows the location of the VP and CP lights.
Figure 2.1
VP and CP LED Locations
Frames B – H
The lights on the motor control board indicate the status of the velocity processor (VP) and current processor (CP):
Publication 1336 IMPACT-6.2 – March 1998
2–2 Troubleshooting and Error Codes
"
Table 2.A
If the VP or CP LED is:
Solid green
Flashing green
Flashing red
Solid red
Then, for that processor:
No fault occurred.
A drive warning occurred.
A drive soft fault occurred.
A drive hard fault occurred.
Faults fall into three basic categories:
Table 2.B
This type of fault:
Hard
Soft
Warning
Has the following definition:
To remove this fault, you need to:
Trips the drive causing it to stop.
You cannot regain control until you reset the drive.
Perform a Drive Reset or cycle drive power.
command
Trips the drive causing it to stop.
1 Address the condition that caused the fault.
2 Perform a Clear Faults command.
Indicates an undesirable condition.
The drive will not stop, but the condition may lead to a fault that will stop the drive.
Address the condition that caused the warning.
Faults are annunciated on the Human Interface Module (HIM) at the time they occur. Warnings are not annunciated on the HIM.
To help troubleshoot your 1336 IMPACT drive, the drive logs any faults or warnings in either the fault or warning queue. The faults and warnings that are contained in the queues are either configurable or non-configurable.
Table 2.C
This fault type:
Configurable
Non-configurable
Refers to faults that you:
Can set up to either trip the drive or provide only a visual warning while the drive continues to operate.
Cannot disable. These faults are the result of a condition that could damage the drive if allowed to persist.
You can reset the soft faults by pressing the stop button on the HIM.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Viewing the Fault and
Warning Queues on the
HIM
Troubleshooting and Error Codes 2–3
You can use the HIM to view the fault and warning queues. To view the fault queue, you need to:
1.
Press the Escape key until you reach the Choose Mode level.
2.
Use the Increment or Decrement key to scroll through the Choose
Mode options until Control Status is displayed.
3.
Press the Enter key.
4.
Use the Increment or Decrement key to scroll through the Control
Status options until Fault Queue is displayed.
5.
Press the Enter key.
6.
Press the Enter key when View Queue is displayed.
The fault queue can contain up to 32 faults. The 1336 IMPACT drive reports the faults using the following format:
Figure 2.2
Fault name
F
I n v O v e r T e m p
2 0 2 8 T r i p
T r p
1
Fault queue indicator
Fault code number
Trip indicator Position in fault queue
The trip indicator is only present if this fault caused the drive to trip.
The last number (1) indicates the position of this fault within the fault queue.
A marker is placed in the queue when the first fault occurs after a power up sequence. This power up marker is as shown.
Figure 2.3
P w r
F
U p
0
M a r k e r
1 1
The 1336 IMPACT drive tracks the time that has elapsed since power up. The drive uses this information as a time stamp so that you can tell when a fault occurred in relation to when the drive was powered up.
To clear the fault queue, select Clear Queue from the Fault Queue options.
Publication 1336 IMPACT-6.2 – March 1998
2–4 Troubleshooting and Error Codes
To view the warning queue, select Warning Queue from the Control
Status options. The remaining steps are the same as for the fault queue.
What Are the Fault
Descriptions
Fault Code and
Text
01027
Autotune Diag
01051
MtrOvrld Pnd
01052
MtrOvrld Trp
01053
Mtr Stall
LED Information
VP, Flashing red
VP, Flashing red
VP, Flashing red
VP, Flashing red
Fault
Type
Soft
Soft
Soft
Soft
When a fault occurs, the fault is displayed until you initiate a Drive
Reset or a Clear Faults command. A Drive Reset clears all faults, while a Clear Faults command only clears soft and warning faults.
You can perform a Drive Reset and Clear Faults either through bits in Logic Input Sts (parameter 14) or with a terminal.
The fault codes are defined as shown in Table 2.D.
Table 2.D
Fault Descriptions
Description
The drive encountered a problem while running the autotune tests.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A motor overload is pending. The drive has reached 95% of the level required for a motor overload trip (see fault 01052).
Motor overload tripped. The drive has reached the level of accumulated motor current over time as set by Motor Overload
% (parameter 26).
The drive is in a limit condition for a period of time in excess of the value specified in
Motor Stall Time (parameter 25) with the motor at zero speed.
Suggested Action
Check Autotune Errors (parameter 176).
For additional information about Autotune
Errors , refer to Chapter 13, Understanding the Autotuning Procedure , in the user manual.
Check for possible motor overheating.
•
If the motor temperature is excessive, reduce the accel/decel times (parameters 42 – 45) or reduce the load.
•
If the motor temperature is acceptable, increase the value of Motor Overload %
(parameter 26).
If you do not want this condition to be reported as a fault, change bit 3 in Fault
Select 2 (parameter 22) to 0.
Check for possible motor overheating.
•
If the motor temperature is excessive, reduce the accel/decel times (parameters 42 – 45) or reduce the load.
•
If the motor temperature is acceptable, increase the value of Motor Overload %
(parameter 26).
If you do not want this condition to be reported as a fault, change bit 4 in Fault
Select 2 (parameter 22) to 0.
Check Torque Limit Sts (parameter 87) to see which limit has occurred. Increase the appropriate limit parameter or reduce the load.
If you do not want this condition to be reported as a fault, change bit 5 in Fault
Select 2 (parameter 22) to 0.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Troubleshooting and Error Codes 2–5
Fault Code and
01083
MtrOvrld Pend
01084
MtrOvrld Trp
01085
Mtr Stall
02028
Inv Overtemp Trp
02049
Inv Overtemp Pnd
02061
InvOvld Pend
02063
Text
Inv Overload
LED Information
VP, Flashing red
Fault
Type
VP, Flashing green Warning
VP, Flashing green Warning
VP, Flashing green Warning
VP, Flashing red
VP, Flashing red
VP, Flashing red
Soft
Soft
Soft
Soft
Description Suggested Action
Motor overload pending. The drive has reached 95% of the level required for a motor overload trip (see fault 01084).
Motor overload tripped. The drive has reached the level of accumulated motor current over time as set by
% (parameter 26).
Inverter overtemperature trip. There is excessive temperature at the heatsink.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
Motor Overload
The drive is in a limit condition for a period of time in excess of the value specified in
Motor Stall Time (parameter 25) with the motor at zero speed.
An inverter overtemperature is pending.
The inverter heatsink temperature is approaching the trip level.
Inverter (IT) overload. The inverter current has been in excess of 105% of Inverter
Amps (parameter 11) too long.
Check for possible motor overheating.
•
If the motor temperature is excessive, reduce the accel/decel times (parameters 42 – 45) or reduce the load.
•
If the motor temperature is acceptable, increase the value of Motor Overload %
(parameter 26).
If you do not want this condition to be reported as a warning, change bit 3 in
Warning Select 2 (parameter 23) to 0.
Check for possible motor overheating.
•
If the motor temperature is excessive, reduce the accel/decel times (parameters 42 – 45) or reduce the load.
•
If the motor temperature is acceptable, increase the value of Motor Overload %
(parameter 26).
If you do not want this condition to be reported as a warning, change bit 4 in
Warning Select 2 (parameter 23) to 0.
Check Torque Limit Sts (parameter 87) to see which limit has occurred. Increase the appropriate limit parameter or reduce the load.
If you do not want this condition to be reported as a warning, change bit 5 in
Warning Select 2 (parameter 23) to 0.
Check the cabinet filters, drive fans, and heatsinks.
Check the thermal sensor and sensor wiring (connector).
Reduce the load or duty cycle if possible.
Lower the value of PWM Frequency
(parameter 10).
Check the cabinet filters, drive fans, and heatsinks.
Check the thermal sensor and sensor wiring (connector).
Reduce the load or duty cycle if possible.
Lower the value of PWM Frequency
(parameter 10).
If you do not want this condition to be reported as a fault, change bit 1 in Fault
Select 2 (parameter 22) to 0.
An inverter (IT) overload is pending. The inverter current has been in excess of
105% of Inverter Amps (parameter 11) too long. Continued operation at this load level will cause an overload.
Reduce the load or duty cycle if possible.
If you do not want this condition to be reported as a fault, change bit 13 in Fault
Select 2 (parameter 22) to 0.
Reduce the load or duty cycle if possible.
If you do not want this condition to be reported as a fault, change bit 15 in Fault
Select 2 (parameter 22) to 0.
Publication 1336 IMPACT-6.2 – March 1998
2–6 Troubleshooting and Error Codes
Fault Code and
Text
02081
Inv Overtemp Pnd
02093
InvOvld Pend
02095
Inv Overload
03008
HW Malfunction
03009
HW Malfunction
03010
HW Malfunction
03011
HW Malfunction
03012
HW Malfunction
03014
EE Checksum
03015
HW Malfunction
LED Information Description Suggested Action
Fault
Type
VP, Flashing green Warning
An inverter overtemperature is pending.
The inverter heatsink temperature is approaching the trip level.
Check the cabinet filters, drive fans, and heatsinks.
Check the thermal sensor and sensor wiring (connector).
Reduce the load or duty cycle if possible.
Lower the value of PWM Frequency
(parameter 10).
If you do not want this condition to be reported as a warning, change bit 1 in
Warning Select 2 (parameter 23) to 0.
VP, Flashing green Warning
An inverter (IT) overload is pending. The inverter current has been in excess of
105% of Inverter Amps (parameter 11) too long. Continued operation at this load level will cause an overload.
Reduce the load or duty cycle if possible.
If you do not want this condition to be reported as a warning, change bit 13 in
Warning Select 2 (parameter 23) to 0.
VP, Flashing green Warning
VP, Red 1 blink
VP, Red 2 blink
VP, Red 3 blink
VP, Red 4 blink
VP, Red 5 blink
VP, Flashing red
VP, Flashing red
Inverter (IT) overload. The inverter current has been in excess of 105% of Inverter
Amps (parameter 11) too long.
Reduce the load or duty cycle if possible.
If you do not want this condition to be reported as a warning, change bit 15 in
Warning Select 2 (parameter 23) to 0.
Hard
Hard
Hard
Hard
Hard
A hardware malfunction was detected on power up or reset.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A hardware malfunction was detected on power up or reset.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A hardware malfunction was detected on power up or reset.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A hardware malfunction was detected on power up or reset.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A hardware malfunction was detected on power up or reset.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Soft The parameter database is corrupt.
Initialize parameters or:
• Perform a Recall Values operation.
•
Perform a Save Values operation.
•
Verify the parameters.
•
Reset the drive.
If the fault still occurs, replace the main control board.
Recycle the power. If the fault does not
Soft A hardware malfunction has occurred.
AB Spares clear, replace the main control board.
Publication 1336 IMPACT-6.2 – March 1998
Troubleshooting and Error Codes 2–7
Fault Code and
Text
03022
Diff Drv Type
LED Information
VP, Flashing red
Fault
Type
Soft
03023
SW Malfunction
03024
SW Malfunction
03025
Absolute Overspd
03026
Analog Spply Tol
03029
SW Malfunction
03030
SW Malfunction
03031
SW Malfunction
03040 mA Input
03057
Param Limit
03058
Math Limit
VP, Solid red
VP, Solid red
VP, Flashing red
VP, Flashing red
VP, Solid red
VP, Solid red
VP, Solid red
VP, Flashing red
VP, Flashing red
VP, Flashing red
Hard
Hard
Soft
Soft
Hard
Hard
Hard
Soft
Soft
Soft
Description Suggested Action
The main control board has been initialized on a different size drive.
A software malfunction has occurred.
Issue a Reset Defaults command to set the drive parameters back to the default values.
Recycle the power. If the fault does not clear, replace the main control board. If the fault still occurs, replace the gate driver board.
A software malfunction has occurred.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
The motor speed has exceeded the speed limit plus Absolute Overspd (parameter 24) settings.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
The analog supply tolerance voltage is outside of the 13V to 18V range.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
Recycle the power. If the fault does not clear, replace the main control board.
If operating in torque mode, check if the load is allowing excessive motor speed.
Check if the setting of Absolute Overspd
(parameter 24) or the speed limits
(parameters 40 and 41) are too low.
Possible faulty analog 15V power supply.
The gate driver board or the main control board may require replacement.
A software malfunction has occurred.
Recycle the power. If the fault does not clear, replace the main control board.
A software malfunction has occurred.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
Recycle the power. If the fault does not clear, replace the main control board.
A software malfunction has occurred.
A loss of 4 – 20mA input has occurred.
A parameter limit has occurred.
A math limit has occurred.
Recycle the power. If the fault does not clear, replace the main control board.
Check your wiring and connections.
If the fault does not clear, replace the main control board.
If you do not want this condition to be reported as a fault, change bit 8 in Fault
Select 1 (parameter 20) to 0.
Examine the parameter limit testpoints to determine the exact cause. Refer to the
Understanding Parameter Limit Faults section in the troubleshooting chapter of the user manual.
If you do not want this condition to be reported as a fault, change bit 9 in Fault
Select 2 (parameter 22) to 0.
Examine the math limit testpoints to determine the exact cause. Refer to the
Understanding Math Limit Faults section in the troubleshooting chapter of the user manual.
If you do not want this condition to be reported as a fault, change bit 10 in Fault
Select 2 (parameter 22) to 0.
Publication 1336 IMPACT-6.2 – March 1998
2–8 Troubleshooting and Error Codes
Fault Code and
Text
03072 mA Input
03089
Param Limit
03090
Math Limit
05048
Spd Fdbk Loss
05054
External Flt In
05080
Spd Fdbk Loss
05086
External Flt In
06041
SP 1 Timeout
LED Information
VP, Flashing green
VP, Flashing green
VP, Flashing green
VP, Flashing red
VP, Flashing red
VP, Flashing green
VP, Flashing green
VP, Flashing red
Fault
Type
Warning
Warning
Warning
Soft
Soft
Warning
Warning
Soft
The external fault input from the L Option board is open.
The external fault input from the L Option board is open.
Description
A loss of 4 – 20mA input has occurred.
A parameter limit has occurred.
A math limit has occurred.
A loss of feedback occurred.
A loss of feedback occurred.
The SCANport adapter at port 1 has been disconnected and the logic mask bit for port 1 is set (1).
Suggested Action
Check your wiring and connections.
If you do not want this condition to be reported as a warning, change bit 8 in
Warning Select 1 (parameter 21) to 0.
Examine the parameter limit testpoints to determine the exact cause. Refer to the
Understanding Parameter Limit Faults section in the troubleshooting chapter of the user manual.
If you do not want this condition to be reported as a warning, change bit 9 in
Warning Select 2 (parameter 23) to 0.
Examine the math limit testpoints to determine the exact cause. Refer to the
Understanding Math Limit Faults section in the troubleshooting chapter of the user manual.
If you do not want this condition to be reported as a warning, change bit 10 in
Warning Select 2 (parameter 23) to 0.
Check the encoder wiring.
Verify that the encoder signals are free of noise.
If you do not want this condition to be reported as a fault, change bit 0 in Fault
Select 2 (parameter 22) to 0.
Check the external circuit for cause of an open input signal.
If you do not want this condition to be reported as a fault, change bit 6 in Fault
Select 2 (parameter 22) to 0.
Check the encoder wiring.
Verify that the encoder signals are free of noise.
If you do not want this condition to be reported as a warning, change bit 0 in
Warning Select 2 (parameter 23) to 0.
Check the external circuit for cause of an open input signal.
If you do not want this condition to be reported as a warning, change bit 6 in
Warning Select 2 (parameter 23) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 9 in Fault
Select 1 (parameter 20) to 0.
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
Troubleshooting and Error Codes 2–9
Fault Code and
Text
06042
SP 2 Timeout
06043
SP 3 Timeout
06044
SP 4 Timeout
06045
SP 5 Timeout
06046
SP 6 Timeout
06047
SP Error
LED Information
VP, Flashing red
VP, Flashing red
VP, Flashing red
VP, Flashing red
VP, Flashing red
VP, Flashing red
Fault
Type
Soft
Soft
Soft
Soft
Soft
Soft
SCANport communications have been interrupted.
Description
The SCANport adapter at port 2 has been disconnected and the logic mask bit for port 2 is set (1).
The SCANport adapter at port 3 has been disconnected and the logic mask bit for port 3 is set (1).
The SCANport adapter at port 4 has been disconnected and the logic mask bit for port 4 is set (1).
The SCANport adapter at port 5 has been disconnected and the logic mask bit for port 5 is set (1).
The SCANport adapter at port 6 has been disconnected and the logic mask bit for port 6 is set (1).
Suggested Action
If the adapter was not intentionally disconnected:
• Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 10 in Fault
Select 1 (parameter 20) to 0.
If the adapter was not intentionally disconnected:
• Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
• Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 11 in Fault
Select 1 (parameter 20) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
• Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 12 in Fault
Select 1 (parameter 20) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 13 in Fault
Select 1 (parameter 20) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 14 in Fault
Select 1 (parameter 20) to 0.
If the adapter was not intentionally disconnected:
•
Check the amount of noise on the system.
• Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
• Replace drive, if required.
If you do not want this condition to be reported as a fault, change bit 15 in Fault
Select 1 (parameter 20) to 0.
Publication 1336 IMPACT-6.2 – March 1998
2–10 Troubleshooting and Error Codes
Fault Code and
Text
06073
SP 1 Timeout
06074
SP 2 Timeout
06075
SP 3 Timeout
06076
SP 4 Timeout
06077
SP 5 Timeout
06078
SP 6 Timeout
LED Information
VP, Flashing green Warning
The SCANport adapter at port 1 has been disconnected and the logic mask bit for port 1 is set (1).
VP, Flashing green
VP, Flashing green
VP, Flashing green
VP, Flashing green
VP, Flashing green
Fault
Type
Warning
Warning
Warning
Warning
Warning
The SCANport adapter at port 5 has been disconnected and the logic mask bit for port 5 is set (1).
The SCANport adapter at port 6 has been disconnected and the logic mask bit for port 6 is set (1).
Description
The SCANport adapter at port 2 has been disconnected and the logic mask bit for port 2 is set (1).
The SCANport adapter at port 3 has been disconnected and the logic mask bit for port 3 is set (1).
The SCANport adapter at port 4 has been disconnected and the logic mask bit for port 4 is set (1).
Suggested Action
If the adapter was not intentionally disconnected:
• Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 9 in
Warning Select 1 (parameter 21) to 0.
If the adapter was not intentionally disconnected:
• Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
• Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 10 in
Warning Select 1 (parameter 21) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
•
Replace wiring, SCANport expander,
SCANport adapters, and main control board.
• Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 11 in
Warning Select 1 (parameter 21) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 12 in
Warning Select 1 (parameter 21) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 13 in
Warning Select 1 (parameter 21) to 0.
If the adapter was not intentionally disconnected:
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 14 in
Warning Select 1 (parameter 21) to 0.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Troubleshooting and Error Codes 2–11
Fault Code and
Text
06079
SP Error
12016
Overvoltage
12017
Desaturation
12018
Ground Fault
12019
Overcurrent
12032
RidethruTime
12033
Prechrg Time
LED Information
Fault
Type
VP, Flashing green Warning
CP, Solid red
CP, Solid red
CP, Solid red
CP, Solid red
CP, Flashing red
CP, Flashing red
Soft
Soft
Soft
Soft
Soft
Soft
Description Suggested Action
SCANport communications have been interrupted.
The DC bus voltage has exceeded the maximum value.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
If the adapter was not intentionally disconnected:
• Check the amount of noise on the system.
•
Check the wiring to the SCANport adapters.
• Replace wiring, SCANport expander,
SCANport adapters, and main control board.
•
Replace drive, if required.
If you do not want this condition to be reported as a warning, change bit 15 in
Warning Select 1 (parameter 21) to 0.
Monitor the AC line for high line voltage or transient conditions.
Increase the deceleration time or install the dynamic brake option because motor regeneration can also cause bus overvoltages. Refer to the user manual for a description of Bus Options (parameter
13) for additional information about bus overvoltages.
If you are using flux braking, refer to
Chapter 9, Applications , in the user manual for information about flux braking.
There was too much current in the system.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
A current path to earth ground in excess of drive rated current has been detected at one or more of the drive output terminals.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
There was too much current in the system.
When this condition occurs, the drive coasts to a stop regardless of the selected stop type.
Run the power structure diagnostics.
Check for a shorted motor or motor wiring.
Replace the drive.
Run the power structure diagnostics.
Check the motor and external wiring to the drive output terminals for a grounded condition.
Replace the drive.
Run the power structure diagnostics.
Check for shorted motor or motor wiring.
Replace drive.
There was a bus voltage drop of 150V and power did not return within 2 seconds.
The precharge function could not complete within 30 seconds.
Check the incoming power and fuses.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 0 in Fault
Select 1 (parameter 20) to 0.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 1 in Fault
Select 1 (parameter 20) to 0.
Publication 1336 IMPACT-6.2 – March 1998
2–12 Troubleshooting and Error Codes
Fault Code and
Text
12034
Bus Drop
12035
Bus Undervlt
12036
Bus Cycle>5
12037
Open Circuit
12064
RidethruTime
12065
Prechrg Time
LED Information
CP, Flashing red
CP, Flashing red
CP, Flashing red
CP, Flashing red
CP, Solid green
CP, Solid green
Description Suggested Action
Fault
Type
Soft
Soft
Soft
Soft
The bus voltage dropped 150V below the bus tracker voltage.
The DC bus voltage fell below the trip value (388V DC at 460V AC input).
At least 5 ridethrough cycles have occurred within a 20 second period. This indicates a converter problem or a problem with the incoming power.
The fast flux up current is less than 50% of commanded.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 2 in Fault
Select 1 (parameter 20) to 0.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 3 in Fault
Select 1 (parameter 20) to 0 or decrease the bus undervoltage setpoint.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 4 in Fault
Select 1 (parameter 20) to 0.
Make sure the motor is properly connected.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a fault, change bit 5 in Fault
Select 1 (parameter 20) to 0.
Warning
There was a drop of 150V and power did not return within 2 seconds.
Check the incoming power and fuses.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 0 in
Warning Select 1 (parameter 21) to 0.
Warning
The precharge function could not complete within 30 seconds.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 1 in
AB Spares
Warning Select 1 (parameter 21) to 0.
Publication 1336 IMPACT-6.2 – March 1998
Troubleshooting and Error Codes 2–13
Fault Code and
Text
12066
Bus Drop
12067
Bus Undervlt
12068
Bus Cycle>5
12069
Open Circuit
13000
HW Malfunction
13001
HW Malfunction
13002
HW Malfunction
13003
HW Malfunction
13004
HW Malfunction
LED Information
CP, Solid green
CP, Solid green
CP, Solid green
CP, Solid green
CP, Solid red
CP, Solid red
CP, Solid red
CP, Solid red
CP, Solid red
Fault
Type
Warning
Warning
Warning
Warning
Hard
Hard
Hard
Hard
Hard
Description Suggested Action
The bus voltage dropped 150V below the bus tracker voltage.
The DC bus voltage fell below the minimum value (388V DC at 460V AC input).
At least 5 ridethrough cycles have occurred within a 20 second period. This indicates a converter problem or a problem with the incoming power.
The fast flux up current is less than 50% of commanded.
A hardware malfunction occurred.
A hardware malfunction occurred.
A hardware malfunction occurred.
A hardware malfunction occurred.
A hardware malfunction occurred.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 2 in
Warning Select 1 (parameter 21) to 0.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 3 in
Warning Select 1 (parameter 21) to 0.
Monitor the incoming AC line for low voltage or line power interruption.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 4 in
Warning Select 1 (parameter 21) to 0.
Make sure the motor is properly connected.
Refer to the Understanding Precharge and
Ridethrough Faults section in the troubleshooting chapter of the user manual for more information.
If you do not want this condition to be reported as a warning, change bit 5 in
Warning Select 1 (parameter 21) to 0.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Recycle the power. If the fault does not clear, replace the main control board.
Publication 1336 IMPACT-6.2 – March 1998
2–14 Troubleshooting and Error Codes
Diagnostic Procedures by
Symptom
The following charts list drive symptoms, symptom descriptions, and recommended actions.
Figure 2.4
Drive Will Not Start or Jog
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Figure 2.5
No HIM Display
Troubleshooting and Error Codes 2–15
Publication 1336 IMPACT-6.2 – March 1998
2–16 Troubleshooting and Error Codes
Figure 2.6
HIM Displays “Running”
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Troubleshooting and Error Codes
Figure 2.7
Motor Response Not Where You Want It
2–17
Publication 1336 IMPACT-6.2 – March 1998
2–18 Troubleshooting and Error Codes
Start Up Troubleshooting
Procedures
If you are having problems with the start up procedure, refer to this table for possible solutions before calling for help.
Table 2.E
You powered up your drive and cannot access the start up routine.
You got a
If:
Feedback Loss Fault .
The motor does not turn during the phase rotation test.
During the phase rotation test you were asked to swap the encoder leads. You changed the leads and ran start up again. You were asked to swap the leads again.
Then:
The start up procedure is not supported on a Series A Human Interface
Module (HIM). To verify that you have a Series A HIM, check the series letter located on the back side of the HIM or check the HIM version when you first power up your drive.
You have specified that an encoder is on the system but it has been disconnected.
Remove the load from the motor and try running the autotune tests again.
Afterwards, you will need to attach the load again and run the inertia test manually.
The drive is not getting any speed feedback information. You need to:
•
•
Check the connection between the encoder and the motor.
Run the phase rotation test again and escape out to the status display at the first question. Check the motor speed. It should ramp to 3 Hz (90
•
• rpm) for a 60 Hz 4 pole motor. If the motor speed is 0 rpm, you should:
Check the encoder wiring.
Check the encoder itself.
Miscellaneous
Troubleshooting
Procedures
If you are having problems with how your 1336 IMPACT drive is operating, refer to this table for possible solutions before calling for help.
Table 2.F
If:
The drive starts and then stops.
There is a delay before the stop command takes effect.
The motor waits before starting.
The drive coasts on stop.
You cannot clear faults.
The motor does not turn or run at the correct speed.
Then you should:
• Check if the mode specified in L Option Mode (parameter 116) is 2 or 3 wire.
•
Check SP 2 Wire Enable (parameter 181).
•
Check to see if the HIM displays a fault message.
•
Check the L Option Board wiring.
•
Check the settings on your gateway (communications module).
•
Check the value of Stop Dwell Time (parameter 18).
•
Check Start Dwell Time (parameter 194).
• Check Pos Torque Lim (parameter 74) and Neg Torque Lim (parameter 75).
•
Check Fast Flux Level (parameter 78) and bit 8 of Bus/Brake Opts (parameter 13).
•
Check S-Curve Percent (parameter 47).
• Check the stop type bits in Logic Options (parameter 17).
•
Check Zero Speed Tol (parameter 19).
•
Check if the port is enabled in SP Enable Mask (parameter 124).
•
Check if clear faults is enabled in Clr Flt/Res Mask (parameter 127).
•
Check if clear fault owners in Ramp/ClFlt Owner (parameter 131) is set. If set, check stop owners in Start/Stop Owner (parameter 129) and remove stop conditions.
• The fault is a hard fault which requires a power cycle or drive reset.
•
Check which speed reference the drive is following in Drive/Inv Status (parameter
15) bits 13 – 15.
•
Check if Spd/Trq Mode Sel (parameter 68) is set correctly.
•
Check if Spd Desired BW (parameter 161) is non-zero.
•
Set the drive defaults and run start up again to tune the drive.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Troubleshooting and Error Codes 2–19
The HIM pot does not control motor speed.
The drive will not change direction.
You cannot change the speed reference.
The external fault does not work.
You keep getting motor overload trips.
The motor reduced the speed range.
If:
The drive does not run correct torque.
The drive cannot control current and trips on an overcurrent fault.
The MOP does not work.
The pulse input does not work.
Then you should:
•
Check if SP An In1 Select (parameter 133) or SP An In2 Select (parameter 136) is set to the HIM port number.
• Check if SP An In1 Scale (parameter 135) or SP An In2 Scale (parameter 138) is
0.125.
•
Check if a Speed Ref 1 – 7 (parameters 29 through 36) is linked to SP An In1 Value
(parameter 134) or SP An In2 Value (parameter 137).
•
Check which speed reference the drive is following in Drive/Inv Status (parameter
15) bits 13 – 15. The speed reference should be set to the speed reference that SP
An In1 Value (parameter 134) or SP An In2 Value (parameter 137) is linked to.
• Check if the port is enabled in SP Enable Mask (parameter 124).
•
Check if Direction is enabled in Dir/Ref Mask (parameter 125).
•
Check if Direction owner in Dir/Ref Owner (parameter 128) has any bit set. If so, remove the command direction.
•
Check to make sure that bit 11 in Logic Options (parameter 17) is clear (0).
•
Check if the port is enabled in SP Enable Mask (parameter 124).
•
Check if Reference is enabled in Dir/Ref Mask (parameter 125).
•
Check if Reference owner in Dir/Ref Owner (parameter 128) has any bit set. If so, remove the command reference. If bit 0 (for the L Option control) is set, you need to do one of the following to remove ownership:
•
Clear bit 0 in Dir/Ref Mask (parameter 125).
• If L Option Mode (parameter 116) is 2, 3, 8, 9, 23, 24, or 26, close the L Option inputs for speed references 1, 2, and 3.
•
Set the drive defaults and run start up again to tune the drive.
• Check Spd/Trq Mode Sel (parameter 68) and Slave Torque % (parameter 70).
• If you are using an encoder, check that you have entered the correct PPR into
Encoder PPR (parameter 8).
•
Check L Option Mode (parameter 116).
•
Make sure that Mop Value (parameter 119) is linked to a speed reference.
•
Make sure that the pulse input jumper is set correctly.
•
Make sure that the input is differential and not single ended.
•
Check the values of Pulse In PPR (parameter 120), Pulse In Scale (parameter 121), and Pulse In Offset (parameter 122).
•
Check the link on Pulse In Value (parameter 123).
•
Check the mode in L Option Mode (parameter 116).
• Check bit 6 in Fault Select 2 (parameter 22) and Warning Select 2 (parameter 23).
•
Reduce the load.
•
Check bits 3 and 4 in Fault Select 2 (parameter 22) and Warning Select 2 (parameter
23).
•
Check Motor Overload % (parameter 26).
•
Check SP An In1 Scale (parameter 135) or SP An In2Scale (parameter 138) if your speed input is coming from the HIM pot.
•
Check An In 1 Offset (parameter 97), An In 1 Scale (parameter 98), An In 2 Offset
(parameter 100), An In 2 Scale (parameter 101), mA Input Offset (parameter 103), and mA Input Scale (parameter 104) if your speed input is coming from the analog inputs.
•
Check Speed Scale 1 (parameter 30) or Speed Scale 7 (parameter 37).
• Check Absolute Overspd (parameter 24).
•
Check Min Speed Limit (parameter 215).
Publication 1336 IMPACT-6.2 – March 1998
2–20 Troubleshooting and Error Codes
Encoderless
Troubleshooting
Procedures
If you are having problems with encoderless mode, refer to this table for possible solutions before calling for help.
Table 2.G
If:
The motor will not accelerate or does not start smoothly
The motor oscillates after it is up to speed
The inverter trips on absolute overspeed during starting
Then you should:
•
Increase the bandwidth in Spd Desired BW (parameter 161). If the bandwidth is too low, the motor may not accelerate, although the current increases to current limit.
• If the regen power limit is 0, increase it to at least –5%.
•
Increase the torque and current limits to the maximum.
•
Increase the value of Kp Freq Reg (parameter 178).
•
Decrease the bandwidth in Spd Desired BW (parameter 161) if the process will allow.
If this does not help, depending on your application, you need to either increase or decrease the value of Error Filter BW (parameter 162).
•
Increase the acceleration time.
• If the overspeed occurs during a fast acceleration, increase the value of Kp Freq Reg
(parameter 178) until the trip stops occurring.
•
Increase the bandwidth in Spd Desired BW (parameter 161).
•
If the overspeed occurs during a reversal, increase the deceleration time (slower deceleration).shippshippy
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
3–1
Chapter Objectives
Disassembly and Access
Overview
Chapter 3
Disassembly and Access
Procedures
This chapter describes general disassembly procedures required to access internal drive components.
!
ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Servicing energized industrial control equipment can be hazardous. Electrical shock, burns, or unintentional actuation of controlled industrial equipment may cause death or serious injury. Follow the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or near energized equipment. Do not work alone on energized equipment.
Electrostatic Discharge
Precautions
!
ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures, reference Rockwell Automation Publication
8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook.
Publication 1336 IMPACT-6.2 – March 1998
3–2 Disassembly and Access Procedures
Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed:
•
Wear a wrist type grounding strap that is grounded to the chassis.
•
Attach the wrist strap before removing the new circuit board from the conductive packet.
•
Remove boards from the drive and immediately insert them into their conductive packets.
Tools
You need the following tools to disassemble and assemble the drive:
•
Pliers
•
Phillips screwdriver
•
Standard screwdriver
•
5/16-inch or 8 mm socket
•
11/16-inch or 17 mm socket
•
5/16-inch or 8 mm open-end wrench
•
Torque wrench, metered in lb-in. or N-m
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Fastener Torque
Specifications
Disassembly and Access Procedures 3–3
Torque Sequence
When mounting components to a drive’s heat sink, component-fastener torque sequences and tolerances are crucial to component-to-heat sink heat dissipation.
!
ATTENTION: Component can be damaged if temporary tightening procedure is not performed to specification.
Two-Point Mounting
The following illustrates temporary and final tightening sequences for components fastened to a heat sink using two screws. Temporary torque is 1/3 (33%) of final torque. The numeric illustration labels are for your assistance. Drive components do not carry these labels.
Figure 3.1
Two-Point Mounting
1 2
Two-Point Mounting
1
2
Temporary Tighten
2
1
Final Tighten
AB0016A
Four-Point Mounting
The following illustrates temporary and final tightening sequences for components fastened to a heat sink using four screws. Temporary torque is 1/3 (33%) of final torque. The numeric illustration labels are for your assistance. Drive components do not carry these labels.
Publication 1336 IMPACT-6.2 – March 1998
3–4 Disassembly and Access Procedures
Figure 3.2
Four-Point Mounting
1 3
4
1
4 2
2
3
Four-Point Mounting
Temporary Tighten
3
2
Final Tighten
4
1
AB0017A
Torque Specifications
The following table lists fastener locations by component, how the fasteners are used, and torque specifications. Refer to Torque
Sequence in this chapter for fastening two-point and four-point components to the heat sink.
Table 3.A
Fastener Torque Specifications
Component
Bus Capacitor Bank
DC Bus Inductor
DC Bus Inductor
Snubber Board
Snubber Board
Snubber Board
Power Modules PM1 – PM3
Input Rectifier
Bus Fuse F1
Thermistor
TB1
TB2
TB3
Ground Sense CT
Ground Sense CT
Ground Sense CT
Main Control Board
Fastener Application
Bank to chassis
Wires to bus bars
TB1 mounting plate to chassis
Bus bars to capacitor bank
Board to SCR1
Board to PM1 – PM3
Module to heat sink
Rectifier to heat sink
Fuse to chassis
Thermistor to heat sink
Wires to terminals
Wires to terminals
Wires to terminals
Bracket to chassis
Positive bus bar junction
Bus bars to capacitor bank
Board to Mounting Plate
Torque lb-in.
Torque
N-m
25 – 31
25 – 31
25 – 31
25 – 31
25 – 31
30 – 39
25 – 31
25 – 31
200 – 220
2.8 – 3.5
2.8 – 3.5
2.8 – 3.5
2.8 – 3.5
2.8 – 3.5
3.4 – 4.4
2.8 – 3.5
2.8 – 3.5
22.6 – 24.8
Hand tighten only
25 – 31
8
8
25 – 31
25 – 31
2.8 – 3.5
0.9
0.9
2.8 – 3.5
2.8 – 3.5
25 – 31
12 – 16
2.8 – 3.5
1.4 – 1.8
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Disassembly and Access Procedures 3–5
Disassembly and Access
Procedures
Opening the Drive Enclosure
Figure 3.3
Drive Enclosure
Enclosure
Cover
Captive
Thumbscrew
AB0852A
Publication 1336 IMPACT-6.2 – March 1998
3–6 Disassembly and Access Procedures
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
1.
Remove power from the drive.
2.
Loosen the captive thumb screw fastening the Enclosure cover to the bottom of the Enclosure frame.
3.
Pull the bottom of the Enclosure cover outward to clear the frame and then lift the cover upward to remove the cover.
4.
Check for zero volts at TB1 terminals +DC and –DC.
5.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
6.
Remove the customer-supplied wiring from the drive.
7.
Remove the screws from the Enclosure top panel. Note the tab slots in the top panel holding the side panels into place.
8.
Lift the Enclosure side panels out of the Enclosure bottom-panel tab slots to remove the side panels.
Installation
Install the Enclosure in reverse order of removal.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Disassembly and Access Procedures
Removing L Option Board
Figure 3.4
L Option Board
3–7
Control Interface
Board
Terminal Strip
TB3
AB0853A
Publication 1336 IMPACT-6.2 – March 1998
3–8 Disassembly and Access Procedures
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Open the Enclosure cover. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
5.
Remove all wires from the terminals on TB3.
6.
Loosen the two captive screws fastening the L Option Board to the Main Control Board.
7.
Grip the right and left sides of the L Option Board and pull the board straight outward from the Main Control Board.
Installation
Install the L Option Board in reverse order of removal.
Publication 1336 IMPACT-6.2 – March 1998
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
AB Spares
Disassembly and Access Procedures
Removing the Main Control Board Mounting Plate
Figure 3.5
Main Control Board Mounting Plate
3–9
Top corners of Control Board/
Adapter Mounting Plate hook into Main Chassis.
Main Control
Board
Connector J1
Connector
J5
Connector J7
L Option
Board
Terminal Strip
TB3
AB0855A
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
3–10 Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Open the Enclosure Cover. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
5.
Disconnect the following from the Main Control Board:
•
J1 connector
•
J5 ribbon cable connector
•
J7 connector
•
Ground wires from terminal strip TE
•
Chassis ground wire at the top-right corner of the Main
Control Board Mounting Plate
6.
Loosen the two captive screws near the bottom of the Main
Control Board.
7.
Pull the Main Control Board Mounting Plate out about two inches, then slide it downward.
Installation
Install the Main Control Board Mounting Plate in reverse order of removal.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Disassembly and Access Procedures
Removing the Main Control Board
Figure 3.6
Main Control Board
3–11
Main Control Board
Mounting Plate
Connector
J5
Main Control
Board
Connector J1
Connector J6
Connector J7
TB11
L Option
Board
TB10
AB0854A
Terminal Strip
TB3
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
3–12 Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the Drive.
2.
Open the Enclosure Cover. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 Terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10 and TB11
•
L Option Board (if used)
5.
Remove all wires from Terminal Strip TB3 if an L Option Board is used.
6.
Disconnect the following from the Main Control Board:
•
J1 connector
•
J5 ribbon cable connector
•
J6 connector
•
J7 connector
•
Ground wire at stake-on connector
•
All wires from the terminals on TB10 and TB11
7.
Remove the screws fastening the Main Control Board to the mounting plate.
8.
Lift the Main Control Board upward to release it from the slide-mount stand-offs.
9.
Pull the Main Control Board away from the mounting plate.
Installation
Install the Main Control Board in reverse order of removal.
Publication 1336 IMPACT-6.2 – March 1998
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace
!
guards may result in death or serious injury.
AB Spares
Disassembly and Access Procedures
Removing the Precharge Board
Figure 3.7
Precharge Board
3–13
Connector
J4
Connector
J3
Connector
J2
Connector
J1
Precharge
Board
Washer
Nut
Mounting
Brackets
AB0327A
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
3–14 Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Open the Enclosure. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10 and TB11
•
L Option Board (if used)
5.
Disconnect the following from the Precharge Board:
•
J1 connector
•
J2 connector
•
J3 connector
•
J4 connector
6.
Remove the nuts and brackets fastening the sides of the Precharge
Board to the drive.
Installation
Install the Precharge Board in reverse order of removal.
!
ATTENTION: When removing the entire wire harness connecting Gate Driver Board connector J9 to
Precharge Board connector J3, align the wires on the harness terminals with the pins on the board connectors. Incorrect harness connection may result in faulty drive operation and may damage the equipment.
Publication 1336 IMPACT-6.2 – March 1998
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
AB Spares
Disassembly and Access Procedures
Removing the Gate Driver Board
Figure 3.8
Gate Driver Board
3–15
Connector
J1
Connector J7
Connector J8
Connector
J6
Connector
J2
Stake-On
Connector
Connector
J10
Connector
J9
Terminal Strip
TB6
Removal
!
AB0341A
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
3–16 Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Open the Enclosure. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10 and TB11
•
L Option Board (if used)
5.
Remove the Main Control Board Mounting Plate. Refer to
Removing the Main Control Board Mounting Plate in this chapter.
6.
Disconnect the following from the Gate Driver Board:
•
J9 Precharge Board connector
•
J10 Bus Capacitor Bank connector
•
J2 Ground Sense CT connector
•
J7 Transistor Module connector
•
J8 Transistor Module connector
•
J6 Snubber Board connector
•
TB6 Fan connector
7.
Remove the screws, fastening the Gate Driver Board to the drive to remove the board from the drive.
Installation
Install the Gate Driver Board in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
Publication 1336 IMPACT-6.2 – March 1998
ATTENTION: Replace all guards and insulators
!
before applying power to the drive. Failure to replace guards may result in death or serious injury.
AB Spares
Disassembly and Access Procedures
Removing the Snubber Board
Figure 3.9
Snubber Board
3–17
Snubber
Board
15 Screws
Connects to Gate
Driver Board
Connector J6
AB0343A
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
3–18 Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Open the Enclosure. Refer to Opening the Drive Enclosure in this chapter.
3.
Check for zero volts at TB1 terminals +DC and –DC.
4.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
5.
Remove the Main Control Board Mounting Plate. Refer to
Removing the Main Control Board Mounting Plate.
6.
Remove the Gate Driver Board. Refer to Removing the Gate
Driver Board in this chapter.
7.
Remove the Precharge Board. Refer to Removing the Precharge
Board in this chapter.
8.
Remove the screws fastening the Snubber Board bus bar to the
Bus Capacitor Bank.
9.
Remove the wires from the Snubber Board stake-on connectors.
10.
Remove the 15 screws fastening the Snubber Board to the
Transistor Modules and Input Rectifier.
!
ATTENTION: The wire from TB1 terminal T3 (W) passes through the lower LEM located on the back of the Snubber Board. The wire from TB1 terminal T1
(U) passes through the upper LEM located on the back of the Snubber Board. During assembly, pass these wires through their respective LEMs to prevent damage to the equipment.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Disassembly and Access Procedures 3–19
Installation
1.
Remove the screws and nuts fastening the negative (–) bus bar to the old Snubber Board.
2.
Fasten the bus bar to the new Snubber Board.
3.
Pass the wires from TB1 terminals T3 (W) and T1 (U) through their respective LEMs.
!
ATTENTION: The wire from TB1 terminal T3 (W) passes through the lower LEM located on the back of the Snubber Board. The wire from TB1 terminal T1
(U) passes through the upper LEM located on the back of the Snubber Board. During assembly, pass these wires through their respective LEMs to prevent damage to the equipment.
4.
Align the screw holes in the Snubber Board with the holes on the
Transistor Modules and Input Rectifier.
5.
Install the Snubber Board in reverse order of removal.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Accessing Chassis Power Components
To access the power components located on the chassis, refer to
Removing the Gate Driver Board in this chapter.
Publication 1336 IMPACT-6.2 – March 1998
3–20 Disassembly and Access Procedures
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Publication 1336 IMPACT-6.2 – March 1998
AB Spares
4–1
Chapter 4
Component Test Procedures
Chapter Objectives
Component Test Overview
The following tests help you troubleshoot A020 – A030, B040,
B050, BX040, BX060, and C025 – C060 drives.
In some cases, different tests troubleshoot components of the same name. These similar tests vary according to the rating of the drive being tested. Verify that the rating on the drive matches the rating for the test you are performing.
The procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is open. For more information on opening the Drive Enclosure, refer to
Chapter 3 – Disassembly and Access Procedures, Opening the Drive
Enclosure.
!
ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Servicing energized industrial control equipment can be hazardous. Electrical shock, burns, or unintentional actuation of controlled industrial equipment may cause death or serious injury. Follow the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or near energized equipment. Do not work alone on energized equipment.
Publication 1336 IMPACT-6.2 – March 1998
4–2 Component Test Procedures
Electrostatic Discharge
Precautions
!
ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures, reference Rockwell Automation Publication
8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed:
•
Wear a wrist-type grounding strap that is grounded to the chassis.
•
Attach the wrist strap before removing the new circuit board from the conductive packet.
•
Remove boards from the drive and immediately insert them into their conductive packets.
Tools
You need the following tools to disassemble and assemble the drive:
•
Pliers
•
Phillips screwdriver
•
Standard screwdriver
•
5/16-inch or 8 mm socket
•
11/16-inch or 17 mm socket
•
5/16-inch or 8 mm open-end wrench
•
Torque wrench, metered in lb-in. or N-m
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Test 1 – Testing Input
Rectifier SCR1
Component Test Procedures
Input Rectifier SCR1 is located on the bottom of the heat sink.
Figure 4.1
Input Rectifier Test
4–3
11
13
C
B
A
23
21
3
2
1
22
12
AB0328B
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Publication 1336 IMPACT-6.2 – March 1998
4–4 Component Test Procedures
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Snubber Board. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Snubber Board.
5.
Set your meter to test diodes.
6.
The following table shows meter connections and ideal meter readings for those connections. Refer to the former illustration for meter connection locations.
Table 4.A
Input Rectifier SCR1 Test
Meter (+) Lead Meter (–) Lead
3
21
21
3
3
1
2
1
1
2
2
22
23
11
12
13
A
B
C
22
23
C
A
A
B
B
C
1
2
21
21
3
Nominal Diode
Reading
Infinite
Infinite
Infinite
Infinite
Infinite
Infinite
Infinite
Infinite
Infinite
0.035
0.035
0.035
0.035
0.035
0.035
0.035
7.
Replace the Input Rectifier if any meter readings are not as shown. Refer to Chapter 5 – Part Replacement Procedures, Input
Rectifier SCR1.
Nominal Ohm
Reading
8 Meg
8 Meg
8 Meg
8.5 Meg
8.5 Meg
8.5 Meg
7 Meg
7 Meg
7 Meg
30
30
30
30
15
15
15
8.
If the Input Rectifier requires replacement, check the Power
Modules for damage. Refer to Testing the Power Modules in this chapter.
9.
Assemble the drive in reverse order of disassembly.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Test 2 – Testing the Bus
Capacitor Bank
Component Test Procedures
The Bus Capacitor Bank is located on the left side of the Main
Chassis.
Figure 4.2
Bus Capacitor Bank Test
4–5 terminal block TB1
Positive (+)
DC
Negative (–)
DC
AB0340A
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
4–6 Component Test Procedures
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Set your meter to test voltage.
5.
Connect the negative (–) lead of your meter to the (–) DC Bus terminal on TB1 and the positive lead to the (+) DC Bus terminal.
Refer to the following tables and former illustration for meter readings and terminal locations.
!
ATTENTION: Servicing energized industrial control equipment can be hazardous. Electrical shock, burns, or unintentional actuation of controlled industrial equipment may cause death or serious injury. Follow the safety-related practices of
NFPA 70E, Electrical Safety for Employee
Workplaces, when working on or near energized equipment. Do not work alone on energized equipment.
6.
Apply power AFTER the meter is connected; otherwise, your meter will read zero volts. Expand readings for all input voltage ratings.
Table 4.B
Bus Capacitor Bank Test
Drive
Rating
A
B
C
380
415
480
500
575
600
Input
Volts
200
230
240
Meter
Reading
280V DC +/–5%
322V DC +/–5%
336V DC +/–5%
535V DC +/–5%
580V DC +/–5%
675V DC +/–5%
700V DC +/–5%
810V DC +/–5%
850V DC +/–5%
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Component Test Procedures 4–7
7.
If the voltage is out of tolerance, check the following:
•
An open condition at Input Rectifier SCR1
•
A voltage drop due to Bus Inductor L1 resistance
•
A voltage drop between Input Rectifier SCR1 and the bus capacitors due to loose or resistive wires or connections
•
Precharge circuit problems
8.
If the above check does not reveal a problem, replace the Bus
Capacitor Bank and Load-Sharing Resistors. Refer to
Chapter 5 – Part Replacement Procedures, Bus Capacitor Bank.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
4–8 Component Test Procedures
Test 3 – Testing Power
Modules PM1 – PM3
Power Modules PM1 – PM3 are located near the center of the heat sink.
Figure 4.3
Power Module Test
C2E1
E2
C1
B2
E2
E1
B1
AB0330A
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
AB Spares
Component Test Procedures 4–9
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Snubber Board. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Snubber Board.
5.
Set your meter to test diodes.
6.
Test Power Modules PM1, PM2, and PM3. The following table shows meter connections and ideal meter readings for those connections. Refer to the former illustration for meter connection locations.
Table 4.C
Power Modules PM1 – PM3
Motor (+) Lead
C2E1
E2
C1
C2E1
B1
B2
Meter (–) Lead
E2
C2E1
C2E1
C1
E1
E2
Nominal Meter Reading
Infinite
0.36
Infinite
0.36
Infinite
Infinite
7.
Replace Power Module PM1, PM2, or PM3 if meter readings are not as shown. Refer to Chapter 5 – Part Replacement Procedures,
Power Modules PM1 – PM3.
8.
If one or more Power Modules is replaced, test the Gate Driver
Board. Refer to Testing the Gate Driver Board in this chapter.
9.
Assemble the drive in reverse order of disassembly.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
4–10 Component Test Procedures
Test 4 – Testing Bus
Fuse F1
Bus Fuse F1 is located at the top of the heat sink.
Figure 4.4
Bus Fuse F1 Test
Bus Fuse
AB0331A
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Component Test Procedures 4–11
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Gate Driver Board. Refer to Chapter 3 –
Disassembly and Access Procedures, Removing the Gate Driver
Board.
5.
Set your meter to test resistance.
6.
Check for an open condition across Bus Fuse F1.
7.
If the fuse shows an open condition, replace the fuse. Refer to
Chapter 5 – Part Replacement Procedures, Bus Fuse F1.
8.
Assemble the drive in reverse order of disassembly.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
4–12 Component Test Procedures
Test 5 – Testing the Gate
Driver Board
The Gate Driver Board is located between the Main Control Board and the Main Chassis. If one or more Power Modules has been replaced, you must test the Gate Driver Board.
Figure 4.5
Gate Driver Board Test
F1
VR2
VR3
VR5
VR6
VR1
VR4
F3
AB0339A
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Component Test Procedures 4–13
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Main Control Board Mounting Plate. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Main Control Board Mounting Plate.
5.
Unplug the connectors from the Gate Driver Board.
6.
Set your meter to test resistance.
7.
Test Fuses F1 and F3 for an open condition. Replace the 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 the components and ideal meter readings for those connections.
Refer to the former illustration for meter connection locations.
Table 4.D
Gate Driver Board Test
Component Meter (+) Lead Meter (–) Lead
VR1 – VR6 +
–
–
+
Important: Typical malfunction is shorted in both directions.
Nominal Meter
Reading
1.06
1.8
10.
Replace the Gate Driver Board if your readings do not match the table readings. Refer to Chapter 3 – Disassembly and Access
Procedures, Removing the Gate Driver Board.
11.
Assemble the drive in reverse order of disassembly.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
4–14 Component Test Procedures
Test 6 – Testing the
Precharge Board
Figure 4.6
Precharge Board Test
Precharge
Board
Fuses F1, F2, and F3
AB0342A
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Component Test Procedures 4–15
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Set your meter to measure resistance.
5.
Test fuses F1, F2, and F3 for open conditions.
6.
Replace the Precharge Board if any fuse shows an open condition.
Publication 1336 IMPACT-6.2 – March 1998
4–16 Component Test Procedures
Test 7 – Testing the
Thermistor
Figure 4.7
Thermistor Test
Connector J1
!
AB0856A
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Component Test Procedures 4–17
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Disconnect the Thermistor from Connector J1 on the Main
Control Board.
5.
Allow the drive to cool down to room temperature.
6.
Set your meter to test resistance.
7.
Measure the resistance across the Thermistor wires. Nominal meter reading should be 100K ohms at room temperature.
8.
If the Thermistor reading measures other than the nominal value, replace the Thermistor. Refer to Chapter 5 – Part Replacement
Procedures, Thermistor.
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4–18 Component Test Procedures
This Page Intentionally Left Blank
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
5–1
Chapter Objective
Part Replacement
Overview
Safety Precautions
Electrostatic Discharge
Precautions
Chapter 5
Part Replacement Procedures
This chapter describes procedures required to replace drive components. This chapter references Chapter 3 – Disassembly and
Access Procedures for basic drive component access.
The part replacement procedures in this chapter assume that the drive you are servicing either has no enclosure or that the enclosure is open. For more information on opening the Drive Enclosure, refer to
Chapter 3 – Disassembly and Access Procedures, Opening the Drive
Enclosure.
!
ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Remove power before you disconnect or reconnect wires and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on terminal block TB1.
Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures, reference Rockwell Automation Publication
8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook.
Publication 1336 IMPACT-6.2 – March 1998
5–2 Part Replacement Procedures
Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed:
•
Wear a wrist-type grounding strap that is grounded to the chassis.
•
Attach the wrist strap before removing the new circuit board from the conductive packet.
•
Remove boards from the drive and immediately insert them into their conductive packets.
Major Component
Replacement
Tools
You need the following tools to disassemble and assemble the drive:
•
Pliers
•
Phillips screwdriver
•
Standard screwdriver
•
5/16-inch or 8 mm socket
•
11/16-inch or 17 mm socket
•
5/16-inch or 8 mm open-end wrench
•
Torque wrench, metered in lb-in. or N-m
This section explains in detail how to replace the following drive components:
•
Ground Sense CT
•
Bus Fuse F1
•
Thermistor
•
Power Modules PM1 – PM3
•
Input Rectifier SCR1
•
Fan
•
DC Bus Inductor L1
•
Bus Capacitors
For Gate Driver Board, Main Control Board, Precharge Board, and
L Option Board installation and removal procedures, refer to
Chapter 3.
Detailed Product
Identification
Publication 1336 IMPACT-6.2 – March 1998
Rockwell Automation Adjustable Frequency AC Drives are modular by design to enhance troubleshooting and spare parts replacement, thereby helping reduce production down-time.
AB Spares
Heat Sink and
Fan Assembly
Part Replacement Procedures 5–3
The following illustration calls out the main components of a typical drive. Component designs vary slightly among the different drive ratings, but component locations are identical.
Figure 5.1
Main Drive Components
Load-Sharing
Resistor
Bus Fuse
Power
Module
Thermistor
Snubber Board and LEMs
Snubber Board
Connector
Ground Sense
CT Connector
Fuse F3
Power Module
Connectors
Control Board
Mounting Plate
Human Interface
Module (HIM)
Gate Driver Board
Ribbon Cable
Connector
Main Control
Board
Bus Capacitor
Bank
Terminal Strip
TB1 Fuse F1
DC Bus Inductor
(Behind Ground
Sense CT) Bus Cap
Connectors
Ground Sense
CT
Snubber Board/SCR
Connector
Precharge Board
Connector
Fuses
SCR
Control
Interface
Board
Connectors
TB5
TB6
TB7
Terminal
Strip TB3
Control
Interface
Board
AB0857A
Publication 1336 IMPACT-6.2 – March 1998
5–4 Part Replacement Procedures
Ground Sense CT
The Ground Sense CT is located in the lower left corner of the drive.
Figure 5.2
Ground Sense CT
Bus Bars fasten to
Bus Capacitor Bank
Negative(–) Bus
To Bus Inductor wire L2(–)
To TB1 Terminal
DC–
Ground Sense
CT
Connector to
Gate Driver
Board J2
Positive(+) Bus
To TB1 Terminal
DC+ and Bus
Inductor Wire
L3(+)
Screw fastens Bus
Bar to Standoff on
TB1 Mounting Plate
AB0348A
Publication 1336 IMPACT-6.2 – March 1998
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
AB Spares
Part Replacement Procedures 5–5
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Main Control Board Mounting Plate. Refer to
Chapter 3 – Disassembly and Access Procedures, Removing the
Main Control Board Mounting Plate.
5.
Remove the Precharge Board. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Precharge Board.
6.
Disconnect the Ground Sense CT from Gate Driver Board connector J2.
7.
Remove the following from the Ground Sense CT Bus Bars:
•
DC Bus Inductor wire L3
•
DC Bus Inductor wire L2. Note that the positive (+) and negative (–) DC wires from TB1 do not need to be removed from the bus bars.
•
The screw fastening the positive (+) bus bar to the standoff
•
The screw and nut assembly fastening the positive (+) bus bar to the bus bar extension from Bus Capacitor Bank terminal E1
•
The two screws fastening the negative (–) bus bar to the Bus
Capacitor Bank terminal E2
8.
Remove the nut fastening the Ground Sense CT to the Main
Chassis.
9.
Remove the screw fastening the Ground Sense CT to the TB1
Mounting Plate.
Publication 1336 IMPACT-6.2 – March 1998
5–6 Part Replacement Procedures
Installation
1.
Place the bus bars through the center of the Ground Sense CT.
Refer to Figure 5.2.
2.
Install the Ground Sense CT in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures
Bus Fuse F1
Bus Fuse F1 is located at the top of the heat sink.
Figure 5.3
Bus Fuse F1
5–7
AB0332A
Publication 1336 IMPACT-6.2 – March 1998
5–8 Part Replacement Procedures
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Gate Driver Board. Refer to Chapter 3 –
Disassembly and Access Procedures, Removing the Gate Driver
Board.
5.
Remove the two bolts fastening the fuse to the drive.
Installation
Install Fuse F1 in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures
Thermistor
The Thermistor is located on the heat sink, between the Power
Modules and the Input Rectifier.
Figure 5.4
Thermistor
5–9
Thermistor
Connector to Main
Control Board J1
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
5–10 Part Replacement Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Snubber Board from the drive. Refer to
Chapter 3 – Disassembly and Access Procedures, Removing the
Snubber Board.
5.
Unscrew the Thermistor from the heat sink.
Installation
Install the Thermistor in reverse order of removal.
Important: When fastening the Thermistor to the heat sink, hand-tighten the Thermistor to avoid damaging the porcelain Thermistor body.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures 5–11
Power Modules PM1 – PM3
Power Modules PM1 – PM3 are located on the heat sink, behind the
Snubber Board.
Figure 5.5
Power Modules
Power
Module
Preform
B2
E2
E1
C1
B1
C2E1
E2
AB0350A
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
5–12 Part Replacement Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Snubber Board from the drive. Refer to
Chapter 3 – Disassembly and Access Procedures, Removing the
Snubber Board.
5.
Remove all wires connected to the Power Module terminals.
6.
Remove the screws fastening the Power Module to the heat sink.
Installation
1.
Clean all surfaces between the Power Module and the heat sink using a soft, clean cloth.
2.
Replace the Preform between the Power Module and the heat sink.
3.
Install the Power Module in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures
Input Rectifier SCR1
The Input Rectifier SCR1 is located on the heat sink, behind the
Snubber Board.
Figure 5.6
Input Rectifier SCR1
5–13
C
B
A
Preform
23
Input Rectifier
SCR1
21
3
2
1
22
AB0349B
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
5–14 Part Replacement Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Snubber Board from the drive. Refer to
Chapter 3 – Disassembly and Access Procedures, Removing the
Snubber Board.
5.
Remove all wires from the Input Rectifier.
6.
Remove the screws fastening the Input Rectifier to the heat sink.
Installation
1.
Clean all surfaces between the Input Rectifier and the heat sink using a soft, clean cloth.
2.
Replace the Preform between the Input Rectifier and the heat sink.
3.
Install the Input Rectifier in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures
Fan
The Fan is located behind and on the bottom of the heat sink.
Figure 5.7
Fan
5–15
Air
Flow
Fan Wire
Stake-On
Connectors
Fan
Fan Guard
AB0323A
Publication 1336 IMPACT-6.2 – March 1998
5–16 Part Replacement Procedures
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the four screws fastening the Fan assembly to the bottom of the Drive.
5.
Remove the wires from the Fan stake-on connectors.
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Part Replacement Procedures 5–17
Installation
Install the fan in reverse order of removal.
Important: When fastening the Fan to the cover plate, position the air flow arrow, located on the top of the fan near the connectors, so it points to the top of the drive. Position the Fan connectors to the front, away from DC Bus
Inductor L1. Connect the red wire to the positive fan terminal and the black wire to the negative terminal.
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
5–18 Part Replacement Procedures
DC Bus Inductor L1
The DC Bus Inductor L1 is located on the lower left corner of the drive, behind the Ground Sense CT.
Figure 5.8
DC Bus Inductor L1
L2 wire to DC–
Inductor bracket holes align with studs on
Main Chassis
DC Bus
Inductor
L3 wire to DC+
L1 wire to SCR1
Terminal C (–)
L4 wire to SCR1
Terminal A (+)
TB1 and Mounting
Plate
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
AB0347A
Part Replacement Procedures 5–19
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Access the Main Chassis:
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Precharge Board. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Precharge Board.
5.
Remove the Gate Driver Board. Refer to Chapter 3 –
Disassembly and Access Procedures, Removing the Gate Driver
Board.
6.
Remove the Bus Capacitor Bank. Refer to Bus Capacitor Bank in this chapter.
Remove the TB1 Mounting Plate and DC Bus Inductor L1:
1.
Remove the following from the drive-connection side of TB1:
•
Ground wires
•
Wires at terminals U, V, and W (T1, T2, and T3)
Publication 1336 IMPACT-6.2 – March 1998
5–20 Part Replacement Procedures
2.
Remove the following from the Ground Sense CT Bus Bars:
•
L3 wire from DC Bus Inductor L1.
•
L2 wire from DC Bus Inductor L1. Note that the positive (+) and negative (–) DC wires from TB1 may remain connected to the bus bars.
3.
Remove the following from the Snubber Board:
•
DC Bus Inductor wire L1 from SCR1 terminal C (–).
•
DC Bus Inductor wire L4 from SCR1 terminal A (+).
•
TB1 terminal wire R from SCR1 terminal 3.
•
TB1 terminal wire S from SCR1 terminal 2.
•
TB1 terminal wire T from SCR1 terminal 1.
4.
Remove the nuts fastening the TB1 Mounting Plate to the drive to remove the plate from the drive.
5.
Pull the Bus Inductor straight out of the drive to remove the inductor from the drive.
!
ATTENTION: Note the position of the bracket toward the lower end of the inductor. The tab on the bottom right of the inductor bracket fits into a hole on the TB1 mounting plate. Correctly position the replacement inductor brackets to prevent damage to the equipment.
!
ATTENTION: Holes in the inductor bracket align with pins located on the inside-back of the Main
Chassis. Correctly align the holes on the replacement inductor bracket with the chassis pins to prevent damage to the equipment.
Installation
1.
Lower the inductor into the Main Chassis, aligning the hole in the bottom inductor bracket with the peg on the chassis.
2.
Install DC Bus Inductor L1 in reverse order of removal. Refer to
Table 3.A – Fastener Torque Specifications.
Publication 1336 IMPACT-6.2 – March 1998
!
ATTENTION: Replace all guards and insulators before applying power to the drive. Failure to replace guards may result in death or serious injury.
AB Spares
Part Replacement Procedures
Bus Capacitor Bank
The Bus Capacitor Bank is located on the left side of the Main
Chassis.
Figure 5.9
Bus Capacitor Bank
Load-Sharing Resistor
Stake-On Connectors
5–21
E10 (+)
E11 (–)
Tabs on Main Chassis lock into slots.
E1 (+)
E2 (–)
AB0329A
Removal
!
ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on terminal block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
Publication 1336 IMPACT-6.2 – March 1998
5–22 Part Replacement Procedures
!
ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Access the Main Chassis:
1.
Remove power from the drive.
2.
Check for zero volts at TB1 terminals +DC and –DC.
3.
Check for absence of control voltage at:
•
TB10
•
TB11
•
L Option Board (if used)
4.
Remove the Precharge Board. Refer to Chapter 3 – Disassembly and Access Procedures, Removing the Precharge Board.
5.
Remove the Gate Driver Board. Refer to
Chapter 3 – Disassembly and Access Procedures, Removing the
Gate Driver Board.
Remove the Bus Capacitor Bank:
1.
Remove the Load-Sharing Resistor wires from the Bus Capacitor
Bank stake-on connectors.
2.
Remove the four screws fastening the Snubber Board Bus Bars to the Bus Capacitor Bank terminals E10 (+) and E11 (–).
3.
Loosen the screws fastening the Snubber Board negative Bus Bar to the Snubber Board.
!
ATTENTION: These screws are fastened with nuts located under the Snubber Board. Removing the screws requires removing the Snubber Board to fasten the bus bar to the Snubber Board.
Publication 1336 IMPACT-6.2 – March 1998
4.
Remove the four screws fastening the Ground Sense CT Bus Bars to Bus Capacitor Bank terminals E1 (+) and E2 (–).
5.
Remove the three nuts and washers fastening the left side of the
Bus Capacitor Bank to the Main Chassis.
AB Spares
Part Replacement Procedures 5–23
E1+
E2–
+
C5
20–25 HP @ 230V
40–50 HP @ 380/460V
60 HP @ 460V
E3
+ +
C3 C1
+
C6
+
C4
+
C2
E4
E6
6.
Slide the Bus Capacitor Bank to the right to unlock the right side of the capacitor frame from the tabs located on the Main Chassis.
7.
Pull the Bus Capacitor Bank away from the drive to remove the capacitors from the drive.
Installation
1.
Fasten the capacitor assembly in reverse order of removal. Refer to Table 3.A – Fastener Torque Specifications.
2.
Connect the Load-Sharing Resistors to the Bus Capacitors according to the following diagram.
Figure 5.10
Load-Sharing Resistor Connections to Bus Capacitors
13.6K
Ohms
E1+
+
25–60 HP @ 575V
E3
+
C2 C1
+
C4
+
C3
E4
+
C6
+
C5
E5
E14
E6
A
13.6K
Ohms
B 13.6K
Ohms
E2– E15
AB0326A
!
ATTENTION: The Capacitor Bus PCB must connect a positive (+) capacitor terminal to a negative (–) capacitor terminal. Capacitors not connected correctly will explode and cause death or serious injury.
Publication 1336 IMPACT-6.2 – March 1998
5–24 Part Replacement Procedures
This Page Intentionally Left Blank
Publication 1336 IMPACT-6.2 – March 1998
AB Spares
Chapter 6
6–1
Replacement Parts List
Chapter Objectives
This chapter illustrates and lists replacement parts for the 1336
IMPACT Drives rated A020 – A030, B040, B050, BX040, BX060, and C025 – C060 and describes replacement parts ordering procedures.
The following illustration and table show you parts, part names, locations, and chapters for replacement procedures.
Ordering Replacement
Parts
For your convenience, the Rockwell Automation Drives Division and the Rockwell Automation Support Division provide efficient and convenient repair and exchange for eligible equipment.
A product service report number is required to return any equipment for repair. Your local Rockwell Automation distributor or area sales and support office can provide you with a product service report number.
You should return equipment to be repaired to the area sales and support center nearest you. Reference the product service report number on the carton and packing slip. Include:
•
Your company name
•
Your company address
•
The repair purchase order number
•
A brief description of the problem
Contact your local Rockwell Automation distributor or sales office for a complete listing of area sales and support centers near you.
For parts catalog numbers, refer to the 1336 IMPACT Spare Parts Pricing publication included with your drive documentation set. See next page for more information.
Publication 1336 IMPACT-6.2 – March 1998
Spare Parts Information
Current 1336 IMPACT drive spare parts information including recommended parts, catalog numbers and pricing can be obtained from the following sources:
Allen-Bradley home page on the World Wide Web at http://www.ab.com
then select . . .
“ Drives and Motors ” followed by . . .
“ 1336 IMPACT ” from the Product Directory and . . .
“ T e chn ic al Supp o r t . . .
”
Select "Parts List"
AB Spares
6–2 Replacement Parts List
Replacement Parts Listing
Figure 6.1
Parts for A020 – A030, B040, B050, BX040, BX060, and
C025 – C060 Drives
1
2
3 4
5
14
12
10
11 (bottom back side)
13 (behind 12)
9
AB0858A
6
7
8
Publication 1336 IMPACT-6.2 – March 1998
Replacement Parts List 6–3
9
10
11
12
13
Callout
3
4
1
2
5
6
7
Symbol
F1
Q1–3
ST Thermistor
SNUBBER BOARD Snubber Board
BASEDR/PWRSPLY
LOCAL DIS
MAIN CTL
Description
Bus Fuse
Transistor
Main Control PCB
Table 6.A
Replacement Parts for A020 – A030, B040, B050, BX040,
BX060, and C025 – C060 Drives
Location
Heat Sink
Heat Sink
Heat Sink
—
Gate Driver/Power Supply PCB
Human Interface Module
—
Main Control Board
Mounting Plate
Main Control Board
Replacement Procedures
Chapter 5, Bus Fuse F1
Chapter 5, Transistor Modules
Chapter 5, Thermistor
Chapter 3, Removing the Snubber
Board
Chapter 3, Removing the Gate Driver
Board
Chapter 1, Removing the HIM
8 PRECHARGE
SCR1
FAN
GND SENSE
L1
C1–C6
Precharge Board
Input Rectifier
Fan
Ground Sense CT
DC Bus Inductor
Bus Capacitors
—
Heat Sink
Main Chassis
—
Main Chassis
Main Chassis
Chapter 3, Removing the Main Control
Board from the Mounting Plate
Chapter 3, Removing the Precharge
Board
Chapter 5, Input Rectifier SCR1
Chapter 5, Fan
Chapter 5, Ground Sense CT
Chapter 5, DC Bus Inductor L1
Chapter 5, Bus Capacitors
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
6–4 Replacement Parts List
This Page Intentionally Left Blank
Publication 1336 IMPACT-6.2 – March 1998
7–1
Chapter 7
Schematics — 20 – 60 HP 1336 IMPACT
Drives
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
7–2 Schematics — 20 – 60 HP 1336 IMPACT Drives
HIGH VOLT +DC AUX IN
HIGH VOLT –DC AUX
+15V
+15V
–15V
–15V
+24V
IOS12
ISORTN
DGND
DGND
+5V
+5V
GND_SHRT
DESAT
AC_LINE
/CHARGE
EE_IO
EE_SK
EE_CS
PILOT
CVERIFY
+5V
+5V
+5V
V_POS–
V_NEG–
W_POS–
W_NEG–
U_AMPS+
U_AMPS–
W_AMPS+
W_AMPS–
U_VOLTS
V_VOLTS
W_VOLTS
DGND
NEG_BUS
NEG_CAP
POS_BUS
DGND
DGND
DGND
DGND
U_POS+
U_NEG+
V_POS+
V_NEG+
W_POS+
W_NEG+
U_POS–
U_NEG–
46
47
48
43
44
45
49
50
40
41
42
37
38
39
34
35
36
31
32
33
28
29
30
25
26
27
22
23
24
19
20
21
16
17
18
13
14
15
10
11
12
7
8
9
4
5
6
2
1
3
ACT1
ACT2
+BUS
–BUS
+15
W_AMPS
–15
GND_SHORT
+15
U_AMPS
–15V
WN_GATE
WN_EMIT
VN_GATE
VN_EMIT
UN_GATE
UN_EMIT
WP_GATE
WP_EMIT
VP_GATE
VP_EMIT
UP_GATE
UP_EMIT
WP_COL
VP_COL
UP_COL
PHASE L1, R
PHASE L2, S
PHASE L3, T
DC+
1 /
3 /
3 /
/ 2
Publication 1336 IMPACT-6.2 – March 1998
AB0734A
Schematics — 20 – 60 HP 1336 IMPACT Drives
TABLE 1 – FUSES
DC FUSE
INVERTER
F1
A70Q TYPE HP RATING
230VAC
20
25
30
100A,700V
125A,700V
125A,700V
380/460VAC
40CT 50VT
50CT 60VT
60 460V ONLY
575VAC
100A,700V
125A,700V
125A,700V
25
30
40
50
60
50A,700V
60A,700V
70A,700V
90A,700V
100A,700V
LINE FUSE
(AC)
FR,FS,FT
TYPE JJ
100A
100A
100A
90A
100A
100A
40A
50A
60A
80A
90A
7–3
Schematic Diagram
Stand Alone Unit
Bulletin 1336 IMPACT
200-240 Volt: 15-22 kW (20-30 HP)
380-480 Volt: 30-44 kW (40-60 HP)
500-600 Volt: 18.5-44 kW (25-60 HP)
+
+
230V
20–30HP
460V
40–60HP
+
+
E3
+
E4
+
CAP BANK DETAILS
+
+
575V
25–30HP
E3
+
E4
+
E5
E14
+ +
A
B
E6
E6
E15
AB0757A
AB Spares
Publication 1336 IMPACT-6.2 – March 1998
7–4 Schematics — 20 – 60 HP 1336 IMPACT Drives
Main Control Board
Publication 1336 IMPACT-6.2 – March 1998
Index
A
Adapter Locations, 1–10
Adapters and Communication Ports, Human
Interface Module, 1–9
Audience for this Manual, P–1
Auxiliary Interlock, Definition, P–10
B
Bit, Definition, P–10
Bus Capacitor Bank
Illustration, 5–21
Installation, 5–23
Removal, 5–21
Test, 4–5
Bus Fuse F1
Illustration, 5–7
Installation, 5–8
Test, 4–10
C
Check, Definition, P–10
Component Test Procedures, 4–1
Connector, Definition, P–10
Control Firmware Function, 1–13
Control Interface L-Option. See L Option
Board
Control Logic Wiring, 1–1
Conventions in this Manual, P–10
D
DC Bus Inductor
Illustration, 5–18
Installation, 5–20
Removal, 5–19
Default, Definition, P–10
Drive
Enclosure Type, P–9
Identification, P–4
Illustration, 5–3
Nameplate Location, P–3
Rating, P–9
AB Spares
Drive Enclosure
Illustration, 3–5
Installation, 3–6
Removal, 3–6
DriveTools, 1–13
E
Electrostatic Discharge, P–2
Enable Input, Definition, P–11
Enclosure Type, P–9
Encoderless, 2–20
ESD, P–2
F
False, Definition, P–11
Fan
Illustration, 5–15
Installation, 5–17
Removal, 5–16
Faults, 2–1
Absolute Overspd, 2–7
Analog Spply Tol, 2–7
Autotune Diag, 2–4
Bus Cycle >5, 2–12
Bus Drop, 2–12
Bus Undervlt, 2–12
Clear Queue, 2–3
Desaturation, 2–11
Diff Drv Type, 2–6
EE Checksum, 2–6
External Flt In, 2–8
Feedback Loss, 2–18
Ground Fault, 2–11
HW Malfunction, 2–6, 2–13
Inv Overload, 2–5
Inv Overtemp Pnd, 2–5
Inv Overtemp Trp, 2–5
InvOvld Pend, 2–5 mA Input, 2–7
Math Limit, 2–7
Mtr Stall, 2–4
MtrOvrld Pnd, 2–4
MtrOvrld Trp, 2–4
Open Circuit, 2–12
Overcurrent, 2–11
Overvoltage, 2–11
Param Limit, 2–7
Prechrg Time, 2–11
Publication 1336 IMPACT-6.2 – March 1998
I–2 Index
Publication 1336 IMPACT-6.2 – March 1998
Ridethru Time, 2–11
SP 1 Timeout, 2–8
SP 2 Timeout, 2–9
SP 3 Timeout, 2–9
SP 4 Timeout, 2–9
SP 5 Timeout, 2–9
SP 6 Timeout, 2–9
SP Error, 2–9
Spd Fdbk Loss, 2–8
SW Malfunction, 2–6
Viewing Queue with HIM, 2–3
Feedback Loss Fault, 2–18
Four-Point Mounting, 3–3
G
Gate Driver Board
Illustration, 3–15
Installation, 3–16
Removal, 3–15
Test, 4–12
GPT. See Graphic Programming Terminal
Graphic Programming Terminal
Description, 1–12
Illustration, 1–13
Ground Sense CT
Illustration, 5–4
Installation, 5–6
Removal, 5–4
H
HIM.
See Human Interface Module
Human Interface Module
Adapter Locations, 1–10
Description, 1–9
Illustration, 1–9
Operation, 1–12
Human Interface Module (HIM), Viewing
Fault/Warning Queues, 2–3
I
Input Mode. See L Option Mode
Input Rectifier
Illustration, 5–13
Installation, 5–14
Removal, 5–13
Test, 4–3
Inputs, Available, 1–4
J
Jumper, Definition, P–11
L
L Option, 1–2
Inputs, 1–4
Options, 1–2
L Option Board
Definition, P–11
Illustration, 3–7
Installation, 3–8
Jumper Locations, 1–3
Removal, 3–8
L Option Mode, 1–4
Programming, 1–4
Selection, 1–5
Three-Wire, Multi-Source, 1–6
Three-Wire Control, Multi-Source
Reversing, 1–7
Two-Wire, Single-Source, 1–6
Two-Wire Control, Single-Source Control,
1–7
Load-Sharing Resistor Connections, 5–23
Local Programming, 1–5
M
Main Control Board
Illustration, 3–11
Installation, 3–12
Removal, 3–11
Main Control Board Mounting Plate
Illustration, 3–9
Installation, 3–10
Removal, 3–9
Major Component Replacement. See
Procedures
Manual
Audience, P–1
Conventions, P–10
Objective, P–1
Related Publications, P–12
Mounting
Four-Point, 3–3
Two-Point, 3–3
Index
N
Nameplate Location, P–3
Not External Fault Input, Definition, P–11
O
Objective of this Manual, P–1
Operation, Human Interface Module, 1–12
Option
Identification, P–4
L Option Board, 1–2
P
Parameter, Definition, P–11
Power Module
Illustration, 5–11
Installation, 5–12
Removal, 5–11
Test, 4–8
Precautions
Electrostatic Discharge, P–2
Safety, P–1
Precharge Board
Illustration, 3–13
Installation, 3–14
Removal, 3–13
Test, 4–14
Press, Definition, P–12
Procedures
Bus Capacitor Bank Installation, 5–23
Bus Capacitor Bank Removal, 5–21
Bus Capacitor Bank Test, 4–5
Bus Fuse F1 Installation, 5–8
Bus Fuse F1 Removal, 5–8
Bus Fuse F1 Test, 4–10
Component Test, 4–1
Control Interface L-Option Board
Installation, 3–8
Control Interface L-Option Board
Removal, 3–7
DC Bus Inductor Installation, 5–20
DC Bus Inductor Removal, 5–19
Drive Enclosure Installation, 3–6
Drive Enclosure Removal, 3–6
Fan Installation, 5–17
Fan Removal, 5–16
Gate Driver Board Installation, 3–16
Gate Driver Board Removal, 3–15
Gate Driver Board Test, 4–12
Ground Sense CT Installation, 5–6 AB Spares
Input Rectifier Installation, 5–14
Input Rectifier Removal, 5–13
Input Rectifier Test, 4–3
Main Control Board Installation, 3–12
Main Control Board Mounting Plate
Installation, 3–10
Main Control Board Mounting Plate
Removal, 3–9
Main Control Board Removal, 3–11
Major Component Replacement, 5–2
Power Module Installation, 5–12
Power Module Removal, 5–11
Power Module Test, 4–8
Precharge Board Installation, 3–14
Precharge Board Removal, 3–13
Precharge Board Test, 4–14
Replacement Part, 5–1
Snubber Board Installation, 3–19
Snubber Board Removal, 3–17
Thermistor Installation, 5–10
Thermistor Removal, 5–9
Thermistor Test, 4–16
Programming
L Option Mode, 1–4
Local, 1–5
R
Rating, Drive, P–9
Related Publications, P–12
Replacement Part Procedures, 5–1
Replacement Parts, 6–1
S
Safety Precautions, P–1
Schematics, 7–1
Snubber Board
Illustration, 3–17
Installation, 3–19
Removal, 3–17
Speed Select, Input State, 1–8
T
TB3 Terminal Designations, 1–5
Terminal Block Locations, 1–2
Terminal Designations, TB3, 1–5
Termistor, Test, 4–16
Thermistor
Illustration, 5–9
Installation, 5–10
Removal, 5–9
Publication 1336 IMPACT-6.2 – March 1998
I–3
I–4 Index
Tools, Required for Service, 3–2, 4–2, 5–2
Torque
Four-Point Mounting Sequence, 3–3
Maximum for TB Terminals, 1–5
Specifications, 3–4
Two-Point Mounting Sequence, 3–3
Troubleshooting
Component Test Procedures, 4–1
Encoderless, 2–20
Start Up, 2–14, 2–18
True, Definition, P–12
Two-Point Mounting, 3–3
W
Warnings, 2–1
Bus Cycle>5, 2–13
Bus Drop, 2–13
Bus Undervlt, 2–13
External Flt In, 2–8
Inv Overload, 2–6
Inv Overtemp Pnd, 2–5
InvOvld Pend, 2–6 mA Input, 2–7
Math Limit, 2–8
Mtr Stall, 2–5
MtrOvrld Pend, 2–4
MtrOvrld Trp, 2–5
Open Circuit, 2–13
Param Limit, 2–8
Prechrg Time, 2–12
Ridethru Time, 2–12
SP 1 Timeout, 2–10
SP 2 Timeout, 2–10
SP 3 Timeout, 2–10
SP 4 Timeout, 2–10
SP 5 Timeout, 2–10
SP 6 Timeout, 2–10
SP Error, 2–11
Spd Fdbk Loss, 2–8
Viewing Queue with HIM, 2–3
Wire Sizes, 1–5
Publication 1336 IMPACT-6.2 – March 1998
1336 IMPACT, ControlNet, and SCANport are trademarks of Rockwell Automation Company, Inc.
PLC is a registered trademark of Rockwell Automation.
AB Spares
Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the world’s leading technology companies.
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Publication 1336 IMPACT-6.2 – March 1998
Publication 1336 IMPACT-6.2 – March 1998
PN 74103-724-01
Copyright 1998 Allen-Bradley Company, Inc., a Rockwell International Company. Printed in USA

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