Allen-Bradley A, B, C, D A040 – A060, B060 – B125, BX150, C075 – C125 Adjustable Frequency AC Drive Service Manual

Allen-Bradley
Bulletin 1336 FORCE
Adjustable Frequency
AC Drive
Series A, B, C, D
A040 – A060
B060 – B125, BX150
C075 – C125
Service
Manual
Important User
Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples
shown in this guide are intended solely for purposes of example.
Since there are many variables and requirements associated with any
particular installation, Allen-Bradley does not assume responsibility
or liability (to include intellectual property liability) for actual use
based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation, and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in
whole or in part, without written permission of Allen-Bradley
Company, Inc., is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations:
!
ATTENTION: Identifies information about practices
or circumstances that can lead to personal injury or
death, property damage or economic loss.
Attention statements help you to:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important:
Identifies information that is critical for successful
application and understanding of the product.
ControlNet is a trademark; PLC is a registered trademark of Allen-Bradley Company, Inc.
Summary of Changes
Summary of Changes
The information below summarizes the changes to the
company-wide templates since the last release.
Updated Information
The derating tables in the Preface have been removed. Refer to the
1336 FORCE User Manual.
Publication 1336 FORCE-6.13 – August, 1999
Summary of Changes
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
Table of Contents
Preface
Manual Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
1336 FORCE Product Identification . . . . . . . . . . . . . . . . . . . . . . . .
Drive Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive and Option Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .
1336 FORCE Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . .
Drive Rating Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
False . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
True . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Logic Wiring and
Adapters
P–1
P–1
P–1
P–2
P–3
P–3
P–4
P–4
P–4
P–6
P–7
P–7
P–7
P–7
P–7
P–8
P–8
P–8
P–8
P–8
P–8
P–9
P–9
P–9
P–9
P–9
Chapter 1
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Interface L-Option Board Jumpers . . . . . . . . . . . . . . . . .
Available Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Adapter Local Programming . . . . . . . . . . . . . . . . . . . . . .
Adapters and Communication Ports . . . . . . . . . . . . . . . . . . . . . . .
Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Adapter Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLC Comm Adapter Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphic Programming Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–1
1–1
1–3
1–3
1–4
1–5
1–10
1–10
1–11
1–12
1–12
1–13
1–14
Publication 1336 FORCE-6.13 – August, 1999
ii
Table of Contents
GPT Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Firmware Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access
Procedures
Publication 1336 FORCE-6.13 – August, 1999
1–14
1–15
1–15
Chapter 2
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 Control Interface L-Option Board MOD-L4, -L5, or -L6 .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Main Control Board . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Standard Adapter Board . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the PLC Comm Adapter Board . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Control Board/Adapter Mounting Plate . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Gate Driver Board Mounting Plate . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Precharge Board Mounting Plate . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Precharge Board . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a Power Module Snubber Board . . . . . . . . . . . . . . . .
2–1
2–1
2–2
2–2
2–3
2–3
2–3
2–4
2–4
2–7
2–7
2–7
2–8
2–9
2–9
2–10
2–11
2–11
2–12
2–13
2–13
2–14
2–15
2–16
2–17
2–17
2–18
2–19
2–19
2–21
2–22
2–22
2–24
2–25
2–25
2–26
2–27
2–27
2–28
2–29
Table of Contents
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Converter Snubber Board . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessing Power Plane Components . . . . . . . . . . . . . . . . . . . .
Component Test Procedures
2–29
2–31
2–32
2–32
2–33
2–34
Chapter 3
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 1
Testing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . . .
Test 2
Testing the Precharge Board . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 3
Testing the Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 4
Testing the Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 5
Testing the Input Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement
Procedures
iii
3–1
3–1
3–2
3–2
3–3
3–5
3–7
3–9
3–12
Chapter 4
Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–1
4–1
4–2
4–2
4–3
4–4
4–5
4–5
4–7
4–12
4–12
4–14
4–14
4–15
4–16
4–17
4–17
4–19
4–20
4–21
4–22
Publication 1336 FORCE-6.13 – August, 1999
iv
Table of Contents
Autotransformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Bus Inductor L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Sense CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOV Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts List
Chapter 5
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics — 40 – 150 HP
1336 FORCE Drives
Glossary
Index
Publication 1336 FORCE-6.13 – August, 1999
4–23
4–24
4–24
4–25
4–25
4–26
4–27
4–27
4–28
4–29
4–29
4–30
4–31
4–31
4–33
4–34
4–35
4–35
Chapter 6
5–1
5–1
5–2
Preface
Preface
Manual Objective
The information in this manual is designed to help repair an
Allen-Bradley Bulletin 1336 FORCE Adjustable Frequency AC
Drive with ratings A040 – A060, B060 – B125, BX150, and
C075 – C125.
Who Should Use This
Manual
This manual is intended for qualified service personnel responsible
for repairing the 1336 FORCE Adjustable Frequency AC Drive. You
should:
• Read this entire manual before performing maintenance or repairs
to drives.
• Have previous experience with, and basic understanding of,
electrical terminology, procedures, required equipment,
equipment protection procedures and methods, and safety
precautions.
This manual describes equipment and disassembly procedures. You
begin with general illustrations and end with greater 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 FORCE-6.13 – August, 1999
P–2
Preface
!
!
!
ATTENTION: Hazard of electric shock exists. Up to
1,000 VDC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Potentially fatal voltages may result
from improper usage of oscilloscope and other test
equipment. The oscilloscope chassis may be at a
potentially fatal voltage if not properly grounded. If an
oscilloscope is used to measure high voltage
waveforms, use only a dual channel oscilloscope in the
differential mode with X 100 probes. It is
recommended that the oscilloscope be used in the A
minus B Quasi-differential mode with the oscilloscope
chassis correctly grounded to an earth ground.
ATTENTION: Only personnel familiar with the
1336 FORCE Adjustable Frequency AC Drive and
associated machinery should plan or implement the
installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury
and/or equipment damage.
Electrostatic Discharge
Precautions
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: This assembly contains parts and
sub-assemblies that are sensitive to electrostatic
discharge. Static control precautions are required when
servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures,
reference Allen-Bradley Publication 8000–4.5.2,
Guarding Against Electrostatic Damage, or any other
applicable ESD protection handbook.
Preface
P–3
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various
drive boards. It is recommended that you perform these procedures
to guard against this type of damage when circuit boards are
removed or installed:
• 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.
1336 FORCE Product
Identification
Drive Nameplate Location
The drive nameplate is located on the face of the Control
Board/Adapter Mounting Plate. The drive nameplate contains the
drive’s catalog number and other important drive information.
Reference the catalog number when ordering replacement parts.
Figure P.1
Drive Nameplate Location
Nameplate located on tab
of Control Board/Adapter
Mounting Plate.
AB0363B
Publication 1336 FORCE-6.13 – August, 1999
P–4
Preface
Software Compatibility
!
ATTENTION: To guard against machine damage
and/or personal injury, drives with ratings above 45 kW
(60 HP) must not be used with software versions below
1.07. Refer to the table below.
Three-Phase Drive Rating
Compatible with
Version
Frame
Reference
200 – 240V
380 – 480V
500 – 600V
30 – 45 kW
40 – 60 HP
45, 75, 94, 112 kW
60, 100, 125, 150 HP
56 – 93 kW
75 – 125 HP
2.01 & Up
D
—
81 kW
75 HP
—
2.04 & Up
D
kW and HP are constant torque (CT) ratings.
Drive and Option
Identification
The following is an explanation of the catalog numbering system for
1336 FORCE Adjustable Frequency AC Drives and options. The
catalog number is coded to identify the drive power rating and can be
found on the drive shipping carton and nameplate.
1336 FORCE Drive Catalog Numbers
Table P.A
– A040-AA
1336S
BULLETIN
NO.
– EN
RATING-ENCLOSURE LANGUAGE MODULE
(MUST BE
(MUST BE SPECIFIED)
SPECIFIED)
– L6
– HA1
– GM1
CONTROL INTERFACE
(OPTIONAL)
HUMAN
INTERFACE
(OPTIONAL)
COMMUNICATION
CARD
(OPTIONAL)
200 – 240V AC Input, Constant Torque Drive
Enclosures
Drive Rating
Frame
Designation
D
Output
Amps
120.3
149 2
149.2
180.4
Open
IP00
No Enclosure
NEMA Type 1
IP20
General Purpose
NEMA Type 4
IP56
Resist Water, Dust
NEMA Type 12
IP54
Industrial Use
Code
Code
Code
Code
Nominal
HP
40
50
60
A040-AN
A050 AN
A050-AN
A060-AN
Publication 1336 FORCE-6.13 – August, 1999
A040-AA
A050 AA
A050-AA
A060-AA
Preface
P–5
Table P.B
1336S
– B060-AA
– EN
– L6
– HA1
– GM1
BULLETIN
NO.
RATING-ENCLOSURE
(MUST BE
SPECIFIED)
LANGUAGE
MODULE
(MUST BE
SPECIFIED)
CONTROL
INTERFACE
(OPTIONAL)
HUMAN
INTERFACE
(OPTIONAL)
COMMUNICATION
CARD
(OPTIONAL)
380 – 480V AC Input, Constant Torque Drive
Enclosures
Drive Rating
Frame
Designation
D
Output
Amps
Nominal
HP
96.9
120.3
149.2
180.4
180.4
60
75
100
125
150
Open
IP00
NEMA Type 1
IP20
NEMA Type 4
IP56
NEMA Type 12
IP54
No Enclosure
General Purpose
Resist Water, Dust
Industrial Use
Code
Code
Code
Code
B060–AN
B075–AN
B100–AN
B125–AN
BX150–AN
B060–AA
B075–AA
B100–AA
B125–AA
BX150–AA
Table P.C
1336S
– C075-AA
– EN
– L6
– HA1
– GM1
BULLETIN
NO.
RATING-ENCLOSURE
(MUST BE SPECIFIED)
LANGUAGE
MODULE
(MUST BE
SPECIFIED)
CONTROL
INTERFACE
(OPTIONAL)
HUMAN
INTERFACE
(OPTIONAL)
COMMUNICATION
CARD
(OPTIONAL)
500 – 600V AC Input, Constant Torque Drive
Enclosures
Drive Rating
Frame
Designation
Output
Amps
D
85.8
109.1
138.6
Nominal
HP
75
100
125
Open
IP00
No Enclosure
NEMA Type 1
IP20
General Purpose
NEMA Type 4
IP56
Resist Water, Dust
NEMA Type 12
IP54
Industrial Use
Code
Code
Code
Code
C075–AN
C100–AN
C125–AN
C075–AA
C100–AA
C125–AA
Drive rating is based on a carrier frequency of 4kHz maximum, an altitude of 1,000 meters or less, and a maximum ambient temperature of 40_C. Refer to
Qualifications on page P–6.
Not available.
Refer to the Language Module and Options tables following these Catalog Number tables.
Publication 1336 FORCE-6.13 – August, 1999
P–6
Preface
Table P.D
Language Modules
Description
Option Code
English/English
English/French
g
English/German
g
English/Italian
English/Japanese
English/Spanish
/S
EN
FR
DE
IT
JP
ES
S
Table P.E
Options
Code
Description
Code
Description
Human Interface Modules, NEMA Type 1 (IP 20)
Communication Options
HAB
HAP
HA1
HA2
GM1
GM2
GM3
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
Single Point Remote
I/O
RS-232/422/485, DF1
RS-232/422/485,
DH485
Human Interface Modules, NEMA Type 4 (IP 56)
Control Interface Options
HFB
HFP
HF1
HF2
L4
L5
L6
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
TTL Contacts
24V DC
115V AC
Human Interface Modules, NEMA Type 12 (IP 54)
HJB
HJP
HJ1
HJ2
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
Must be used in conjunction with a standard adapter option –GT2EN
For a more functionally complete description of each option refer to Publication 1336 FORCE-1.0.
Drive Rating Qualifications
Several factors can affect drive rating. If more than one factor exists,
derating percentages must be multiplied. For example, if a 14-amp
drive is installed at a 2km (6,600 ft.) altitude and has a 2%
high-input line voltage, the actual amp rating is:14 x 94% altitude
derating x 96% high-input line derating = 12.6 amps
"
Publication 1336 FORCE-6.13 – August, 1999
Calculate the drive rating using the amp rating of your drive.
Preface
P–7
Enclosure Type
The first character, A, indicates the Enclosure Code.
The second character indicates the type of enclosure shipped from
the factory:
Table P.F
Enclosure Type Code Description
Enclosure
Type Code
N
A
J
Conventions
Description
Open style
y (IP00)
(
)
NEMA Type
y 1 (IP20)
(
)
NEMA Type 12 (IP54)
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 [brackets].
• Display Text will appear in “quotes”.
The following is a list of conventions used throughout this manual,
and definitions of the conventions. For a list of terminology and
definitions, refer to the Glossary in the back of this manual.
Auxiliary Input
The Auxiliary Input is a terminal connection on the Control Interface
Board. This connection provides an external input for use as an
Auxiliary Interlock. Unless this interlock is closed, the drive will be
faulted with an Auxiliary Fault.
Auxiliary Interlock
The Auxiliary Interlock is a user supplied circuit consisting of reset,
overload, or other interlocking circuitry. The Interlock is wired to the
drive Auxiliary input.
Bit
A bit is a single character or status point used in programmable
logic. Eight bits form a BYTE, 16 bits form a word. Drive
parameters are actually eight bits or 16 bit words.
Publication 1336 FORCE-6.13 – August, 1999
P–8
Preface
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.
Enable Input
The Enable Input is a terminal connection on the Control Interface
Board. This connection provides an external input to enable or
disable the Drive Output section. It must be true to permit the drive
to operate.
False
False refers to a logical false state. For instance, a Control Interface
signal on TB3 is false when the input contact is open or the
appropriate voltage is not applied to the Control Interface Board.
Jumper
A jumper completes a circuit between two pins within a male
connector on a drive board. In the absence of certain optional
equipment using female connectors, jumpers are applied to certain
pins within a male connector to complete specific and necessary
circuits.
Publication 1336 FORCE-6.13 – August, 1999
Preface
P–9
Control Interface Board
A Control Interface Board plugs into connectors J10 and J12, located
on the lower portion of the Standard Adapter Board. This board is
identified as L4, L5 or L6 and provides optional control wiring
configurations for a drive.
Parameter
Parameters are programmable drive functions that define various
operating functions or status displays of a drive. Refer to Bulletin
1336 FORCE Adjustable Frequency AC Drive User Manual for
Parameter details.
Press
Press a button on the Human Interface Module to change Parameter
settings and drive functions.
True
True refers to a logical true state. For instance, a Control Interface
signal on TB3 is true when: L4 contact input is closed, L5 input
terminal registers 24V, or L6 input terminal registers 115V AC.
Related Publications
The following lists other Allen-Bradley publications that apply to the
1336 FORCE Adjustable Frequency AC Drives.
• Product Data Drive Tools Software (9303-2.0)
• Bulletin 1201 Graphic Programming Terminal User Manual
(1201-5.0)
• Product Pricing Bulletin (1336 FORCE-3.0)
• 1336 FORCE Field Oriented Control User Manual (1336
FORCE-5.12)
• 1336 FORCE PLC Communications Adapter User Manual
(1336 FORCE-5.13)
• Renewal Parts List (1336-6.5)
• Options Manuals/Instructions
Publication 1336 FORCE-6.13 – August, 1999
P–10
Preface
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
Chapter
1
Control Logic Wiring and Adapters
Chapter Objectives
This chapter introduces you to terminal block locations and wiring,
and adapter locations and functions.
Chapter Overview
This chapter illustrates and describes Standard Adapter Board:
• Control Logic Interface Options L4, L5, and L6, including
Terminal Block TB3
• TB3 input mode selections and functions
• TB3, TB5, TB6, TB7 terminal designations
This chapter illustrates and describes the following terminal
designations for the PLC Comm Adapter Board:
• TB20
• TB21
Important:
!
!
All printed circuit boards, except the Main Control
Board assembly, are referenced to negative ground
(–bus).
ATTENTION: Some printed circuit boards and drive
components may contain hazardous voltage levels.
Remove power before you disconnect or reconnect
wires, and before you remove or replace fuses and
circuit boards. Verify bus voltage by measuring the
voltage between +DC and –DC on Terminal Block
TB1. Do not attempt to service the drive until the bus
voltage has discharged to zero volts.
ATTENTION: This assembly contains parts and
sub-assemblies that are sensitive to electrostatic
discharge. Static control precautions are required when
servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures,
reference Allen-Bradley Publication 8000-4.5.2,
Guarding Against Electrostatic Discharge, or any other
applicable ESD protection handbook.
Publication 1336 FORCE-6.13 – August, 1999
1–2
Control Logic Wiring and Adapters
Figure 1.1
Standard Adapter Terminal Block Locations
Main Control
Board
TB10 Encoder
TB11
ESC
SEL
Standard
Adapter Board
TB5, TB6, TB7
Control and
Signal Wiring
JOG
Control Interface
L-Option Board
TB3 Control
L–Option Board
TB1 Power
Terminal Block
AB0690B
Figure 1.2
PLC Comm Adapter Terminal Block Locations
Main Control Board
TB10 Encoder
TB11
PLC Comm
Board
TB20, TB21
Control and
Signal Wiring
Communication
Channels
TB1 Power
Terminal Block
AB0691B
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
Control Interface Option
1–3
The Control Interface L-Option Board provides a means of
interfacing various signals and commands to the 1336 FORCE by
using contact closures.
Three different versions of the option are available:
L4
Contact Closure Interface1
L5
+24V AC/DC Interface
L6
115V AC Interface
1 Uses internal +5V DC supply.
The user inputs are connected to the option board through TB3. The
L4, L5 and L6 options each have nine control inputs. The function
each input must be selected through programming as explained later
in this section.
Control Interface L-Option Board Jumpers
Important:
If the Control Interface Board is being installed,
Standard Adapter Board jumpers at pins 3 & 4 and 17
& 18 of J10 must be removed. If this board is removed,
these jumpers must be reinstalled and the [Input Mode]
parameter must be programmed to “1”.
Publication 1336 FORCE-6.13 – August, 1999
1–4
Control Logic Wiring and Adapters
Figure 1.3
Jumper Locations
Main Control
Board
ESC
Jumper J10
(Located on Standard
Adapter Board)
SEL
Standard
Adapter Board
JOG
TB5, TB6, TB7
AB0365D
Available Inputs
A variety of combinations made up of the following inputs are
available.
Start
Enable
Stop/Clear Fault
Auxiliary
Reverse
2 Stop Mode Selects
Digital Potentiometer (MOP)
Run Forward
2 Accel/Decel Rates
Run Reverse
3 Speed Selects
Local Control
The available combinations are shown in Figure 1.4. Programming
the [Input Mode] parameter to one of the Input Mode numbers listed
selects that combination of input functions.
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
Important:
1–5
The [Input Mode] parameter can be changed at any
time; however, programming changes will not take
affect until power has been cycled to the drive. When
changing an input mode, it is important to note that the
corresponding inputs to TB3 may also change.
The programming options of the Control Interface Option allow the
user to select an input combination to meet the needs of a specific
installation. Appropriate selection of a combination may be done by
using Table 1.A. First determine the type of start/stop/direction
control desired. Then select the remaining control functions
available. After selecting a group of Input Modes use Table 1.A for
specific mode selection. Record the selected mode number below.
Selected Mode Number:
Standard Adapter Local
Programming
For local programming and control information, refer to the 1336
FORCE User Manual.
Table 1.A
Input Mode Selection
Direction Control
Start/Stop Type
Mode(s)
to Use
Communication Compatibility
Stop & Enable
Only
None
Control must be provided by HIM or Communication Option.
1
Momentary
Pushbutton
(3 Wire)
Maintained Switch
(Open-Forward,
Closed-Reverse)
Start/Stop – works in parallel with HIM and Communication Options.
Direction Control will not work in parallel with HIM or Communication
Options. User must select direction control from either HIM and
Communication Options or TB3 input.
2–6
Momentary
Pushbutton
(3 Wire)
Momentary Pushbuttons
(Forward and Reverse)
Start/Stop – works in parallel with HIM and Communication Options.
Direction – works in parallel with HIM or Communication Options.
Start/Stop – not compatible with HIM or Communication Options.
Direction – not compatible with HIM or Communication Options.
12–16
The maximum and minimum wire sizes accepted by TB3 is 2.1 and
0.30 mm2 (14 and 22 AWG). Maximum torque for all terminals is
0.9 – 1.13 N-m (8 – 10 in.-lb).
19
20
21
22
23
24
25
26
27
28
29
30
Input 2 (Stop)
Common
Input 3
Input 4
Input 5
Common
Input 6
Input 7
Input 8
Common
Enable
Figure 1.4
TB3 Terminal Designations
Input 1
Maintained switches for combined run and direction
control (2 wire, Run Forward, Run Reverse)
7–11
AB0550A
Publication 1336 FORCE-6.13 – August, 1999
1–6
Control Logic Wiring and Adapters
Figure 1.5
Input Mode Selection and Typical TB3 Connections
Momentary
[Input Mode] 1
Factory Default
User Connections
Maintained
19
Status
20
Stop/Fault Reset3
21
Common
22
Status
23
Status
24
Status
25
Common
26
Status
27
Status
28
Status
29
Common
30
Enable3
Note: If this mode is selected, the status of all
inputs can be read at the [Input Status] parameter.
However, only “Stop/Fault Reset” and “Enable” will
have control function.
User Connections
ATTENTION: The JOG function will not operate
properly unless a SCANport option is connected to the
drive. To assure proper JOG function, install at least one
of the following:
1201-HAP, 1201-HA1, 1201-HA2, 1336-GM1. Applies
to 1305 with firmware FRN 2.01 or earlier and 1336
PLUS with Language Module 1336S-EN firmware FRN
1.05 or earlier.
[Input Mode] 2 – 6
Three-Wire Control with Single-Source Reversing
19
Start
20
Stop/Fault Reset3
21
Common
22
Reverse
23
24
Auxiliary3
25
Common
2
3
Mode
4
Jog
Stop
Type
2nd
Accel
Digital
Pot Up
Jog
2nd
Decel
Digital
Pot Dn
Local
Control2
Speed
Speed
Select 31 Select 31
26
27
Speed Select 21
28
Speed Select 11
29
Common
30
Enable3
5
6
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.
AB0290C
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
1–7
Figure 1.5 (continued)
Input Mode Selection and Typical TB3 Connections
Momentary
[Input Mode] 7 – 11
Three-Wire Control with Multi-Source Reversing
19
Start
20
Stop/Fault Reset3
User Connections
Mode
9
7
8
22
Reverse
Reverse
23
Forward
Jog
21
Common
24
Auxiliary3
25
Common
26
27
Speed
Select 21
28
Speed Select 11
29
Common
30
Enable3
10
11
Digital
Pot Up
Reverse
1st
Accel
Forward
Digital
Pot Dn
Forward
2nd
Accel
Speed
Select 31
Speed
Select 31
Digital
Pot Up
1st
Decel
Speed
Speed
Select 21 Select 21
Digital
Pot Dn
2nd
Decel
[Input Mode] 12 – 16
Two-Wire Control, Single-Source Control
19
Run Forward
20
Stop/Fault Reset3
21
22
User Connections
ATTENTION: The JOG function will not operate
properly unless a SCANport option is connected to the
drive. To assure proper JOG function, install at least one
of the following:
1201-HAP, 1201-HA1, 1201-HA2, 1336-GM1. Applies
to 1305 with firmware FRN 2.01 or earlier and 1336
PLUS with Language Module 1336S-EN firmware FRN
1.05 or earlier.
Maintained
Common
25
28
29
30
Mode
14
Local
Control2
Stop
Type
2nd
Accel
Digital
Pot Up
Local
Control2
Speed
Select 31
Speed
Select 31
2nd
Decel
Digital
Pot Dn
Stop
Type
15
16
Auxiliary3
Common
26
27
13
Run Reverse
23
24
12
Speed Select 21
Speed Select 11
1 See Table 1.B.
Common
2 Drive must be stopped to take Local Control.
Control by all other adapters is disabled (except Stop).
Enable3
3 These inputs must be present before drive will start.
AB0291B
Publication 1336 FORCE-6.13 – August, 1999
1–8
Control Logic Wiring and Adapters
The following table defines the input state of the Speed Select inputs
for a desired frequency source.
Table 1.B
Speed Select Input State vs. Frequency Source
Speed Select 3 Speed Select 2 Speed Select 1
Bit 14
Bit 13
B12
Terminal 26
Terminal 27
Terminal 28
Para 52
TB3
Velocity Reference
Source
O
O
O
Last State
O
O
X
External Reference 1
O
X
O
Preset Speed 1
O
X
X
Preset Speed 2
X
O
O
Preset Speed 3
X
O
X
Preset Speed 4
X
X
O
Preset Speed 5
X
X
X
External Reference 2
O = Open — Input Removed
X = Closed — Input Present
Figure 1.6
PLC Comm Adapter Reference Signal Connections
1
2
3
4
5
6
7
8
9 10
1
2
3
4
TB20
Common
Drive
Enable
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19
TB21
Fault
Relay
Stop
Motor
Ext
Thermo Fault
Publication 1336 FORCE-6.13 – August, 1999
+10 Comm –10
Analog Analog
Out 1 Out 2
Analog Analog Analog Analog Analog Analog
Out 3 Out 4
In1
In2
In3
In4
AB0551A
Control Logic Wiring and Adapters
1–9
Table 1.C
PLC Comm Adapter Reference Signal Connections
Terminal Block
Terminal Number(s)
Signal
TB20
1
Drive Enable (NO)
2
Motor Thermoguard (NC)
3
Normal Stop (NC)
4
External Fault (NC)
5
6
Input Common
7
TB21
8
Fault Output (NC)
9
Fault Output (COM)
10
Fault Output (NO)
1
OUT 1
2
COM 1
3
COM 2
4
OUT 2
5
OUT 3
6
COM 3
7
OUT 4
8
COM 4
9
IN 1+
10
IN 1–
11
IN 2+
12
IN 2–
13
IN 3+
14
IN 3–
15
IN 4+
16
IN 4–
17
+10V
18
COM
19
–10V
Publication 1336 FORCE-6.13 – August, 1999
1–10
Control Logic Wiring and Adapters
Adapters and
Communication Ports
Human Interface Module
When the drive-mounted HIM is supplied, it will be connected as
Adapter 1 (refer to Figures 1.7 and 1.8) and visible from the front of
the drive. The HIM can be divided into two sections; Display Panel
and Control Panel. The Display Panel provides a means of
programming the drive and viewing the various operating
parameters. The Control Panel allows different drive functions to be
controlled. For HIM operation, refer to the 1336 FORCE Field
Oriented Control User Manual.
Important:
The operation of HIM functions depends upon drive
parameter settings. Default parameter values allow full
HIM functionality.
Figure 1.7
Human Interface Module, Standard Adapter Only
Display Panel
Control Panel
Human Interface Module
(HIM)
AB520C
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
1–11
Standard Adapter Ports
Figure 1.8
Standard Adapter Board Port Locations
TB10 Encoder
Internal Communication
(Adapter Port 6)
ESC
Drive Mounted HIM
(Adapter Port 1)
SEL
JOG
Control Interface
L-Option Board
(TB3 Adapter Port 0)
TB5, TB6, TB7
Communications Port Remote HIM/
Communication Options (Adapter 2) or
Expansion Options (Adapters 2, 3, 4, 5)
2
2
3
3
4
5
Expansion Options
AB0692B
Publication 1336 FORCE-6.13 – August, 1999
1–12
Control Logic Wiring and Adapters
PLC Comm Adapter Ports
Figure 1.9
PLC Comm Adapter Board Port Locations
Main Control
Board
Communications
Channels Ports 6,7
PLC Comm
Board
SCAN port 1
SCAN port 2
TB21
TB20
Communications Port Remote HIM/
Communication Options (Adapter 2) or
Expansion Options (Adapters 2, 3, 4, 5)
2
2
3
3
4
5
Expansion Options
AB0700A
HIM Removal
!
ATTENTION: Some voltages present behind the
drive front cover are at incoming line potential. To
avoid an electric shock hazard, use extreme caution
when removing/replacing the HIM.
For handheld operation, the module can be removed and located up
to 10 meters (33 feet) from the drive.
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
Important:
1–13
Power must be removed from the drive or Bit 1 of the
[Logic Mask] parameter must be set to “0” to allow
removal of the HIM module without causing a
Communication Fault. Setting Bit 1 of the [Logic
Mask] parameter to “0” allows HIM removal while
power is applied to the drive. Note that this also
disables all HIM control functions except Stop.
To remove the module:
1. Ensure that power has been removed or [Logic Mask] has been
set to “0”.
2. Open the Enclosure door.
3. Slide the module down and out of its cradle.
4. Reverse the above steps to replace the module. Apply power or
reset Bit 1 of the [Logic Mask] parameter to “1” to enable HIM
control.
HIM Operation
When power is first applied to the drive, the HIM will cycle through
a series of displays. These displays will show drive ID and
communication status. Upon completion, the Status Display (see
Figure 1.10) will be shown. This display shows the current status of
the drive (i.e. Stopped, Running, etc.) or any faults that may be
present (Not Enabled, etc.). Refer to the 1336 FORCE Field Oriented
Control User Manual.
Figure 1.10
Status Display
Stopped
+0.00 Hz
Publication 1336 FORCE-6.13 – August, 1999
1–14
Control Logic Wiring and Adapters
Graphic Programming
Terminal
GPT Description
The optional GPT (Figure 1.11) is a remote device with a 1.8 meter
(6 foot) long cable. The GPT offers a 40-by-8 character display that
can also be used as a graphics display to show trending graphs. For
GPT operation, refer to the 1336 FORCE Field Oriented Control
User Manual. See also the 1201 GPT User Manual.
Important:
Main Menu screens are dynamic and will change based
on functionality provided by adapter and drive status.
Figure 1.11
Graphic Programming Terminal
F1
F2
D
7
4
ALT
8
F
9
5
6
PRESET 4
PRESET 5
XREF 1
PRESET 1
PRESET 2
PRESET 3
0
+/–
1
ESC
E
F3
.
2
F4
+
–
3
JOG
AB0554A
Publication 1336 FORCE-6.13 – August, 1999
Control Logic Wiring and Adapters
1–15
Drive Tools
Drive Tools software is a Windows 3.1 compatible family of
application programs allowing the user to perform programming,
monitoring, and diagnostic operations on Allen-Bradley AC and DC
digital drive products. The software consists of five Windows
applications. For operation, refer to the Product Data Drive Tools
Software manual.
Control Firmware Function
All control functions in the 1336 FORCE are performed through the
use of parameters that can be changed with a programming terminal
or Drive Tools. Refer to an overview Block Diagram of the Control
Firmware Function in the 1336 FORCE Field Oriented Control User
Manual.
Feedback information is derived from hardware devices as part of
the process equipment used. Analog signals are converted to digital
signals for use by the drive. Control signals may be provided to the
drive by one of two Adapter Boards.
All setup and operation information used by the drive is stored in a
system parameter table. Every parameter, including Setup and
Configuration parameters (Sources and Sinks), has an entry in the
parameter table. For example, parameter 101 is named the “Velocity
Reference 1 HI (whole)” parameter and contains a number value
representing the velocity reference. The velocity reference can
originate from an external control device such as a potentiometer
connected to the analog input of an Adapter board or a signal coming
in via RIO from a PLC. Refer to the 1336 FORCE User Manual,
Publication 1336 FORCE-5.12.
Publication 1336 FORCE-6.13 – August, 1999
1–16
Control Logic Wiring and Adapters
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
Chapter
2
Disassembly and Access
Procedures
Chapter Objectives
This chapter describes general disassembly procedures required to
access internal drive components.
Disassembly and Access
Overview
!
!
!
ATTENTION: Some printed circuit boards and drive
components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or
reconnect wires, and before you remove or replace
fuses and circuit boards. Verify bus voltage by
measuring the voltage between +DC and –DC on
Terminal Block TB1. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Servicing energized industrial control
equipment can be hazardous. Electrical shock, burns,
or unintentional actuation of controlled industrial
equipment may cause death or serious injury. Follow
the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or
near energized equipment. Do not work alone on
energized equipment.
Publication 1336 FORCE-6.13 – August, 1999
2–2
Disassembly and Access 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 Allen-Bradley Publication 8000-4.5.2,
Guarding Against Electrostatic Discharge, or any other
applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various
drive boards. It is recommended that you perform these procedures
to guard against this type of damage when circuit boards are
removed or installed:
• Wear a wrist-type grounding strap that is grounded to the chassis.
• Attach the wrist strap before removing the new circuit board from
the conductive packet.
• Remove boards from the drive and immediately insert them into
their conductive packets.
Tools
You need the following tools to disassemble and assemble the drive:
• Pliers
• Phillips screwdrivers (medium and large)
• Standard screwdrivers (small, medium, and large)
• 10 mm socket
• 13 mm deep-well socket
• 5/16-inch or 8 mm open-end wrench
• Torque wrench, metered in in.-lb or N-m
• Nylon tie wraps
• Side cutters
• 17 mm socket
Publication 1336 FORCE-6.13 – August, 1999
Disassembly and Access Procedures
2–3
Fastener Torque
Specifications
Torque Sequence
When mounting components to a drive’s heat sink,
component-fastener torque sequences and tolerances are crucial to
component-to-heat sink heat dissipation.
!
ATTENTION: Component can be damaged if
temporary tightening procedure is not performed to
specification.
Two-Point Mounting
The following illustrates temporary and final tightening sequences
for components fastened to a heat sink using two screws. Temporary
torque is 1/2 (50%) of final torque. The numeric illustration labels
are for your assistance. Drive components do not carry these labels.
Figure 2.1
Two-Point Mounting
1
2
Two–Point Mounting
1
2
Temporary Tighten
2
1
Final Tighten
AB0016A
Publication 1336 FORCE-6.13 – August, 1999
2–4
Disassembly and Access Procedures
Four-Point Mounting
The following illustrates temporary and final tightening sequences
for components fastened to a heat sink using four screws. Temporary
torque is 1/2 (50%) of final torque. The numeric illustration labels
are for your assistance. Drive components do not carry these labels.
Figure 2.2
Four-Point Mounting
1
3
4
2
Four–Point Mounting
1
2
3
4
2
1
Temporary Tighten
4
3
Final Tighten
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.
Publication 1336 FORCE-6.13 – August, 1999
Disassembly and Access Procedures
2–5
Table 2.A
Fastener Torque Specifications — Parts Common to “D”
Frame Drives
Component
Fastener Application
Fastener Used
Torque
in.-lb
Torque
N-m
Voltage Sharing Resistor (R1 – R3)
Snubber Resistor (R20 – R22)
Power Modules (Q1 – Q6)
Input Rectifiers (SCR1 – SCR6)
Thermistor
Resistor to Heat Sink
Resistor to Heat Sink
Power Modules to Heat Sink
Rectifiers to Heat Sink
Thermister to Heat Sink
M5 x 10 mm Screw
M5 x 10 mm Screw
M6 x 16 mm Screw
M6 x 16 mm Screw
Thermister
23 – 36
23 – 36
26
52
14
2.6 – 4.1
2.6 – 4.1
2.9
5.9
1.6
Fan Finger Guard
Fan Cover
Fan Cover
Capacitor Retainer (C1 – C9)
Capacitor Bracket (C1 – C9)
Guard to Chassis
Cover to Fan
Cover to Chassis
Retainer to Chassis
Bracket to Capacitor Latch
M4 x 8 mm Screw
M4 x 8 mm Screw
M4 x 12 mm Screw
M4 x 8 mm Screw
M5 x 10 mm Screw
12 – 16
12 – 16
12 – 16
12 – 16
23 – 36
1.4 – 1.8
1.4 – 1.8
1.4 – 1.8
1.4 – 1.8
2.6 – 4.1
MOV Surge Suppressor
Link Inductor (L1)
Fan Capacitor (C-HB1)
Autotransformer (T1)
LEM Support Plate
Surge Suppressor to Chassis
Inductor to Chassis
Capacitor to Chassis
Autotransformer to Chassis
Support Plate to Chassis
M4 or M5 x 10 mm Screw
M5 x 10 mm Screw
M8 Nut
M5 x 10 mm Screw
M5 x 10 mm Screw
12 – 16
23 – 26
32 – 40
23 – 26
23 – 26
1.4 – 1.8
2.6 – 4.1
3.6 – 4.5
2.6 – 4.1
2.6 – 4.1
Motor Bus Bar Insulated Standoff
Capacitor Bus Bar (C1 – C9)
IGBT Bus Bar
IGBT Bus Bar
Motor Bus Bar
Standoff to Chassis
Bus Bar to Capacitors
Bus Bar to Motor Bus Bar
Bus Bar to Distribution Bus Bar
Bus Bar to Insulated Standoff
M5 x 10 mm Screw
M6 x 12 mm Screw
M5 x 10 mm Screw
M5 x 10 mm Screw
M5 x 10 mm Screw
23 – 36
55
23 – 26
23 – 36
23 – 36
2.6 – 4.1
6.2
2.6 – 4.1
2.6 – 4.1
2.6 – 4.1
Distribution Bus Bar
SCR Standoff (SCR1 – SCR6)
Converter Snubber Board (A11)
Power Module Snubber Board
(A20 – A22)
Bus Fuse (F1)
Bus Bar to Capacitor Bus Bar
Standoff through Converter Bus Bar and Into SCR
Board to SCR Standoff
M10 x 20 mm Bolt
SCR Standoff
M4 x 8 mm Screw
97 – 111
34
12 – 16
11 – 12.5
3.8
1.4 – 1.8
Board to IGBT Standoffs
Fuse to Capacitor Bus Bar
M4 x 8 mm Screw
M10 x 20 mm Bolt
12 – 16
97 – 111
1.4 – 1.8
11 – 12.5
Bus Fuse (F1)
TB1 Terminal Block DIN Rail
Gate Driver Board Mounting Plate
Main Control Board
Standard Adapter Board
PLC Comm Adapter Board
TE Ground Block
Bus Fuse to Distribution Bus Bar
DIN Rail to Chassis
Plate to Chassis
Board to Mounting Plate
Board to Mounting Plate
Board to Mounting Plate
TE Ground Block to Gate Driver Board Sheet Metal
M8 or M10 x 20 mm Bolt
M5 x 10 mm Screw
M5 x 10 mm Screw
M4 x 8 mm Screw
M4 x 8 mm Screw
M4 x 8 mm Screw
M2.5 x 12 mm Screw
97 – 111
23 – 36
23 – 36
12 – 16
12 – 16
12 – 16
6–9
11 – 12.5
2.6 – 4.1
2.6 – 4.1
1.4 – 1.8
1.4 – 1.8
1.4 – 1.8
0.7 – 1.0
Control Board Mounting Plate
Control Board Mounting Plate
HIM Holder
Capacitor Guard (C1 – C9)
Link Inductor Guard (L1)
Enclosure Bottom, Top, and
Side Panels
Plate to Gate Driver Board Mounting Plate
Plate to Gate Driver Board Mounting Plate
HIM Holder to Control Board Sheet Metal
Capacitor Guard to Capacitor Brackets
Link Inductor Guard to Link Inductor
M6 Nut
M4 x 8 mm Screw
M4 x 20 mm Screw
M4 x 20 mm Screw
M6 Nut
23 – 36
12 – 16
12 – 16
12 – 16
23 – 36
2.6 – 4.1
1.4 – 1.8
1.4 – 1.8
1.4 – 1.8
2.6 – 4.1
Enclosure Sheet Metal
M5 x 10 mm Screw
23 – 36
2.6 – 4.1
Publication 1336 FORCE-6.13 – August, 1999
2–6
Disassembly and Access Procedures
Table 2.B
Fastener Torque Specifications — Parts Common to “D”
Frame Drives A040, A050, B060 – B100, C075, C100
Fastener Application
Component
IGBT Standoff
Power Module Snubber Board
(A20 – A22)
Fastener Used
Torque
in.-lb
Torque
N-m
Standoff Through IGBT Busbar and Into IGBT
IGBT Standoff
36 – 44
2.6 – 4.1
Board to Gate and Emitter Connection on IGBT
M4 x 24 mm Screw
12 – 16
1.4 – 1.8
Table 2.C
Fastener Torque Specifications — Parts Common to “D”
Frame Drives A060, B125, BX150, C125
Component
IGBT Standoff
Power Module Snubber Board
(A20 – A22) (Present Design)
*Power Module Snubber Board
(A20 – A22) (Original Design)
*Gate & Emitter Terminals
(Original Design)
*
Fastener Application
Fastener Used
Torque
in.-lb
Torque
N-m
Standoff Through IGBT Bus Bar and Into IGBT
IGBT Standoff
65 – 79
7.3 – 8.9
Board to Gate and Emitter Connection on IGBT
M4 x 35 mm Screw
12 – 16
1.4 – 1.8
Board to Gate and Emitter “C” Brackets
M4 x 8 mm Screw
12 – 16
1.4 – 1.8
Gate and Emitter “C” Brackets to IGBTs
M4 x 8 mm Screw
12 – 16
1.4 – 1.8
Parts pertain only to original Snubber Board design which uses “C” shaped Gate and Emitter brackets. Refer to Power Modules in Chapter 4 – Part Replacement
Procedures.
Table 2.D
Fastener Torque Specifications — Wires Common to “D”
Frame Drives
Fastener Application
Component
Fastener Used
Torque
in.-lb
Torque
N-m
MOV Ground Wire (MOV1)
Wire to Chassis
M6 Nut
23 – 36
2.6 – 4.1
Drive Ground Wire
Ground Wire TE (Gate
Driver Board)
Link Inductor Wires
Capacitor Bus Bar Wires
Converter Bus Bar Wires
Motor Bus Bar Wires
Wire to Chassis
M6 Nut
23 – 36
2.6 – 4.1
Wire to TB1 Terminal TE
Wires to Link Inductor
Wires to Capacitor Bus Bar
Wires to Converter Bus Bar
Wires to Motor Bus Bar
Compression
M6 x 12 mm Screw
M6 x 12 mm Screw
M6 x 12 mm screw
M6 x 12 mm Screw
6–8
50 – 72
50 – 72
50 – 72
50 – 72
0.7 – 0.9
5.6 – 8.1
5.6 – 8.1
5.6 – 8.1
5.6 – 8.1
Wires to TB1
M8 Nut
52
5.9
Wires to TB20
Captive Screw
–
–
Wires to TB21 on Main Control Board
Captive Screw
–
–
Wires to TB5 on Main Control Board
Captive Screw
12 – 16
1.4 – 1.8
Wires to TB6 on Main Control Board
Captive Screw
12 – 16
1.4 – 1.8
Wires to TB7 on Main Control Board
Captive Screw
12 – 16
1.4 – 1.8
Wires to TB3 on Control Interface Board
Wire to Enclosure Door
Captive Screw
M6 Nut
8 – 10
23 – 36
0.9 – 1.1
2.6 – 4.1
TB1 Wires
TB20 Wires, PLC Comm
Adapter Board
TB21 Wires, PLC Comm
Adapter Board
TB5 Wires, Standard
Adapter Board
TB6 Wires, Standard
Adapter Board
TB7 Wires, Standard
Adapter Board
TB3 Wires, Standard Adapter
L–Option Board
Enclosure Door Ground Wire
Publication 1336 FORCE-6.13 – August, 1999
Disassembly and Access Procedures
2–7
Disassembly and Access
Procedures
Opening the Drive Enclosure
Figure 2.3
Drive Enclosure
Latches
Hinges
AB0748A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–8
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Turn the Enclosure door latches, located on the right side of the
Enclosure door, 90 degrees counterclockwise.
3. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
4. Check for zero volts at TB1 terminals +DC and –DC.
5. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
6. Remove the ground wire from the Enclosure door.
7. Lift the Enclosure door toward the top of the drive to remove the
door from the hinges.
8. Remove the customer-supplied wiring from the drive.
9. Remove the screws from the Enclosure top, bottom, and side
panels to remove the panels.
Installation
Install the Enclosure in reverse order of removal. Refer to Fastener
Torque Specifications in this chapter.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–9
Removing Control Interface L-Option Board MOD-L4, -L5, or -L6
Figure 2.4
Control Interface L-Option Board
Control Interface
L-Option Board
Terminal
Strip TB3
AB0693A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–10
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at TB5, TB6, and TB7
on the Standard Adapter Board.
5. Remove all wires from the terminals on TB3.
6. Loosen the two captive screws fastening the Control Interface
Board to the Standard Adapter Board.
7. Grip the right and left sides of the Control Interface Board and
pull the board straight out from the Standard Adapter Board.
Installation
Install the Control Interface Board in reverse order of removal. Refer
to Fastener Torque Specifications in this chapter.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–11
Removing the Main Control Board
Figure 2.5
Main Control Board and Mounting Plate
Mounting Plate
Connector
J1
Slide-Mount
Standoff
HIM (Standard Adapter
Board only)
Connector J1
Connector
J5
TB10
Main Control
Board
Connector
J7
PLC Comm Adapter
Board or Standard
Adapter Board
AB0695A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–12
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 Terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Disconnect the following from the Main Control Board:
• J5 ribbon cable connector
• Stake-on ground wire connector
• All wires from TB10
6. Remove the screws fastening the Main Control Board to the
Control Board/Adapter Mounting Plate.
7. Lift the Main Control Board upward to release it from the
slide-mount stand-offs and connector J7.
Installation
Install the Main Control Board in reverse order of removal. Refer to
Fastener Torque Specifications in this chapter.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–13
Removing the Standard Adapter Board
Figure 2.6
Standard Adapter Board
Mounting
Plate
Slide-Mount
Standoff
Main Control
Board
Connector
J1
Mounting
Screw
Standard
Adapter Board
TB7
Slide-Mount
Stand-Off
TB6
TB5
AB0696A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
1. Remove power from the drive.
2. Open the Enclosure door.
3. Check for zero volts at TB1 Terminals +DC and –DC.
Publication 1336 FORCE-6.13 – August, 1999
2–14
Disassembly and Access Procedures
4. Check for the absence of control voltage at TB5, TB6, and TB7
on the Standard Adapter Board.
5. Disconnect the following from the Standard Adapter Board:
• Stake-on ground wire connector
• All wires from TB5, TB6, and TB7
6. Remove the Control Interface Board. Refer to Removing the
Control Interface L-Option Board in this chapter.
7. Remove the two screws fastening the Standard Adapter Board to
the mounting plate.
8. Pull the Standard Adapter Board down to release it from the
slide-mount stand-offs and connector J1.
Installation
Install the Standard Adapter Board in reverse order of removal.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–15
Removing the PLC Comm Adapter Board
Figure 2.7
PLC Comm Adapter Board
Mounting
Plate
Slide-Mount
Standoff
Main Control
Board
Connector
J1
PLC Comm
Adapter Board
Connector J5
Connector J7
RIO
Channel A
TB21
TB20
RIO
Channel B
AB0697B
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Enclosure Door in
this chapter.
3. Check for zero volts at TB1 Terminals +DC and –DC.
Publication 1336 FORCE-6.13 – August, 1999
2–16
Disassembly and Access Procedures
4. Check for the absence of control voltage at TB20 and TB21 on
the PLC Comm Adapter Board.
5. Disconnect the following from the PLC Comm Adapter Board:
• All wires from TB20 and TB21
• Stake-on ground wire connector
• J5 connector
• J7 connector
• Communication channel A and B connectors
6. Remove the screws fastening the PLC Comm Adapter Board to
the mounting plate.
7. Pull the PLC Comm Adapter Board down to release it from the
slide-mount stand-offs and connector J1.
Installation
Install the PLC Comm Adapter Board in reverse order of removal.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–17
Removing the Control Board/Adapter Mounting Plate
Figure 2.8
Control Board/Adapter Mounting Plate
Control Board
Mounting Plate
Connector J1
TB10
Main Control
Board
Connector
J5
HIM (Standard
Adapter Board only)
Connector J7
Connector J1
Standard Adapter
Board
Connector
J1
TB7
TB6
TB5
PLC Comm
Adapter Board
TB21
TB20
Mounting
Plate Screw
Terminal
Block TE
Connector
J5
Connector
J7
AB0694B
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–18
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the wires and connectors from the Standard or PLC
Comm Adapter Board.
This drive may have either a Standard Adapter Board or a PLC
Comm Adapter Board. Refer to Removing the Standard Adapter
Board or Removing the PLC Comm Adapter Board in this
chapter.
6. Remove the nuts at the top of the Control Board/Adapter
Mounting Plate.
7. Remove the two screws at the bottom of the Control
Board/Adapter Mounting Plate.
8. Lift the Control Board/Adapter Mounting Plate out of the drive.
Installation
Install the Control Board/Adapter Mounting Plate in reverse order of
removal. Refer to Fastener Torque Specifications in this chapter.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–19
Removing the Gate Driver Board Mounting Plate
Figure 2.9
Gate Driver Board Mounting Plate
Gate Driver Board
Mounting Plate
Gate Driver
Board
Connector
J2
Connector
J1
Connector
J13
Connector
J7
Connector
J6
Connector
J8
TB7
TB4
Connector
J10
TB5
Connector
TB6
J9
Mounting
Screw
AB0380E
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–20
Disassembly and Access Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the Control Board/Adapter Mounting Plate. Refer to
Removing the Control Board/Adapter Mounting Plate in this
chapter.
6. Remove Gate Driver Board connections:
• TB7 ground wire
• J2 Ground Sense CT connector
• J13 connector
• J7 Power Module connector
• J8 Power Module connector
• J10 Bus Capacitor Bank connector
• J6 connector
• J9 Precharge Board connector
• TB6 Fan connector if applicable
7. Remove the screws fastening the bottom of the mounting plate to
the drive.
Publication 1336 FORCE-6.13 – August, 1999
Disassembly and Access Procedures
2–21
8. Slide the plate toward the top of the drive until the tabs disengage
from the slots.
9. Lift the plate out of the drive.
Installation
Install the Gate Driver Board Mounting Plate in reverse order of
removal. Refer to Fastener Torque Specifications in this chapter.
!
!
ATTENTION: When removing the entire wire
harness connecting Gate Driver Board connector J9 to
Precharge Board connector J3, align the wires on the
harness terminals with the pins on the board
connectors. Incorrect harness connection may result in
faulty drive operation and may damage the equipment.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
2–22
Disassembly and Access Procedures
Removing the Gate Driver Board
Figure 2.10
Gate Driver Board
Gate Driver
Board
Gate Driver Board
Mounting Plate
Connector J13
Connector J7
Connector
J2
Connector J8
Connector
J1
TB7
TB4
Connector
J6
TB5
TB6
Connector
J10
Connector
J9
AB0370E
Removal
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Disassembly and Access Procedures
!
!
Important:
2–23
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the Control Board/Adapter Mounting Plate. Refer to
Removing the Control Board/Adapter 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 Power Module connector
• J8 Power Module connector
• J6 LEM harness connector
• TB6 Fan connector
• J13 connector
• Ground wire from TB7.
Publication 1336 FORCE-6.13 – August, 1999
2–24
Disassembly and Access Procedures
7. Turn the eight stand-off screws, fastening the Gate Driver Board
to the Mounting Plate, 1/4 turn counterclockwise.
8. Remove the Gate Driver Board from the enclosure.
Installation
Install the Gate Driver Board in reverse order of removal. Refer to
Fastener Torque Specifications in this chapter.
!
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: When removing the entire wire
harness connecting Gate Driver Board connector J9 to
Precharge Board connector J3, align the wires on the
harness terminals with the pins on the board
connectors. Incorrect harness connection may result in
faulty drive operation and may damage the equipment.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–25
Removing the Precharge Board Mounting Plate
Figure 2.11
Precharge Board and Mounting Plate
Connector
J1
Connector Connector
J3
J2
Mounting
Screw
Connector
J4
Mounting Plate and
Precharge Board
Precharge
Guard
AB0519D
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–26
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the guard from the Precharge Board.
6. Disconnect the following from the Precharge Board:
• J1 connector
• J2 connector
• J3 connector
• J4 connector
7. Remove the screws fastening the top of the Mounting Plate to the
drive.
8. Lift the Precharge Board and Mounting Plate out of the enclosure.
Installation
Install the Precharge Board Mounting Plate in reverse order of
removal. Refer to Fastener Torque Specifications in this chapter.
!
Publication 1336 FORCE-6.13 – August, 1999
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.
Disassembly and Access Procedures
!
2–27
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Removing the Precharge Board
Figure 2.12
Precharge Board
Precharge Board
Mounting Plate
Connector J1
Connector J2
Guard
Connector J3
Connector J4
Precharge
Board
AB0371C
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–28
Disassembly and Access Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Disconnect the following from the Precharge Board:
• J1 connector
• J2 connector
• J3 connector
• J4 connector
6. Turn the six stand-off screws, fastening the Precharge Board to
the mounting plate, 1/4 turn counterclockwise.
7. Remove the Precharge Board from the Mounting Plate.
Installation
Install the Precharge Board in reverse order of removal.
!
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: When removing the entire wire
harness connecting Gate Driver Board connector J9 to
Precharge Board connector J3, align the wires on the
harness terminals with the pins on the board
connectors. Incorrect harness connection may result in
faulty drive operation and may damage the equipment.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Disassembly and Access Procedures
2–29
Removing a Power Module Snubber Board
Figure 2.13
Power Module Snubber Board
Power Module
Snubber Board
E2
E1
C2
C3
C4
J2
J1
Customer-Supplied
100 Ohm, 25 Watt
Resistor
AB0372F
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
2–30
Disassembly and Access Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclosure
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the Gate Driver Board Mounting Plate. Refer to
Removing the Gate Driver Board Mounting Plate in this chapter.
6. Remove the wires from Power Module Snubber Board stake-on
connectors E1 and E2.
7. Remove J1 and J2 connectors.
8. Remove the eight screws fastening the Snubber Board to the
Power Module.
Publication 1336 FORCE-6.13 – August, 1999
Disassembly and Access Procedures
2–31
Installation
!
ATTENTION: Do not substitute longer or shorter
hardware when fastening the Power Module Snubber
Boards to the Power Modules. Use the same size
fastener to fasten the components as was originally
used. Using different fastener lengths will damage the
Power Modules.
Install the Power Module Snubber Board in reverse order of
removal. Refer to Fastener Torque Specifications in this chapter.
Important:
!
Line up the bottom edge of the Snubber Board with the
metal posts on the Power Module Brackets.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
2–32
Disassembly and Access Procedures
Removing the Converter Snubber Board
Figure 2.14
Converter Snubber Board
Converter
Snubber Board
9 Screws
AB0373D
Removal
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Disassembly and Access Procedures
!
!
Important:
2–33
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the Enclosure door. Refer to Opening the Drive Enclousre
in this chapter.
3. Check for zero volts at TB1 terminals +DC and –DC.
4. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
5. Remove the Gate Driver Board Mounting Plate. Refer to
Removing the Gate Driver Board Mounting Plate in this chapter.
6. Remove the Precharge Board Mounting Plate. Refer to Removing
the Precharge Board Mounting Plate in this chapter.
7. Remove the nine screws fastening the Converter Snubber Board
to the Input Rectifier.
Installation
Install the Converter Snubber Board in reverse order of removal.
Refer to Fastener Torque Specifications in this chapter.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
2–34
Disassembly and Access Procedures
Accessing Power Plane Components
To access the power plane components located on the chassis, refer
to Removing a Power Module Snubber Board in this chapter.
Publication 1336 FORCE-6.13 – August, 1999
Chapter
3
Component Test Procedures
Chapter Objectives
The following tests help you troubleshoot A040 – A060, B060 –
B125, BX150, and C075 – C125 drives.
Component Test Overview
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 opened. For
more information on opening the Drive Enclosure, refer to Chapter 2
– Disassembly and Access Procedures, Opening the Drive Enclosure.
!
!
ATTENTION: Some printed circuit boards and drive
components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or
reconnect wires, and before you remove or replace
fuses and circuit boards. Verify bus voltage by
measuring the voltage between +DC and –DC on
Terminal Block TB1. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,000V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
Publication 1336 FORCE-6.13 – August, 1999
3–2
Component Test Procedures
!
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 Allen-Bradley Publication 8000-4.5.2,
Guarding Against Electrostatic Discharge, or any other
applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various
drive boards. It is recommended that you perform these procedures
to guard against this type of damage when circuit boards are
removed or installed:
• Wear a wrist-type grounding strap that is grounded to the chassis.
• Attach the wrist strap before removing the new circuit board from
the conductive packet.
• Remove boards from the drive and immediately insert them into
their conductive packets.
Tools
You need the following tools to disassemble and assemble the drive:
• Pliers
• Phillips screwdrivers (medium and large)
• Standard screwdrivers (small, medium, and large)
• 10 mm socket
• 13 mm deep-well socket
• 5/16-inch or 8 mm open-end wrench
• Torque wrench, metered in in.-lb or N-m
• Nylon tie wraps
Publication 1336 FORCE-6.13 – August, 1999
Component Test Procedures
3–3
• Side cutters
• 17 mm socket
Test 1
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 3.1
Gate Driver Board Test
F3
VR2
VR3
VR5
VR6
VR1
F1
VR4
Gate Driver
Board
AB0374B
Publication 1336 FORCE-6.13 – August, 1999
3–4
Component Test Procedures
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Important:
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Control Board/Adapter Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Control Board/Adapter Mounting Plate.
5. Set your meter to test resistance.
6. Test Fuses F1 and F3 for an open condition. Replace the Gate
Driver Board if either fuse shows an open condition.
7. Set your meter to test diodes.
8. Test VR1 – VR6. The following table shows meter connections at
the components and ideal meter readings for those connections.
Refer to the former illustration for component locations.
Table 3.A
Gate Driver Board Test
Component
Meter (+) Lead
Meter (–) Lead
Nominal Meter
Reading
VR1 – VR6
+
–
–
+
0.9
1.5
Note: Typical Malfunction is shorted in both directions.
9. Replace the Gate Driver Board if your readings do not match the
table readings. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing the Gate Driver Board.
10.Assemble the drive in reverse order or disassembly.
Publication 1336 FORCE-6.13 – August, 1999
Component Test Procedures
!
Test 2
Testing the Precharge
Board
3–5
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Figure 3.2
Precharge Board Test
F3
F2
F1
Precharge
Board
AB0375B
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
3–6
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 the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Set your meter to test resistance.
5. Test fuses F1, F2, and F3 for open conditions.
6. Replace the Precharge Board if any fuse shows an open
condition. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing the Precharge Board.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Component Test Procedures
Test 3
Testing the Power
Modules
3–7
The Power Modules are located near the top of the heat sink.
Figure 3.3
Power Module Test
C
E
G
E
Power
Module
(Some drives may
not have brackets
at E and G)
AB0390C
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
3–8
Component Test Procedures
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
!
Important:
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Control Board/Adapter Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Control Board/Adapter Mounting Plate.
5. Remove the Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
6. Remove the Power Module Snubber Boards. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
7. Remove the Inverter Bus Bar. Refer to Chapter 4 – Part
Replacement Procedures, Power Modules.
8. Set your meter to test diodes.
9. Test the Power Modules. The following table shows meter
connections and ideal meter readings for those connections. Refer
to the former illustration for meter connection locations.
Table 3.B
Power Modules
Publication 1336 FORCE-6.13 – August, 1999
Meter (+) Lead
Meter (–) Lead
Nominal Meter Reading
E
E
C
C
B
B
C
B
E
B
E
C
0.318
Infinite
Infinite
Infinite
Infinite
Infinite
Component Test Procedures
3–9
10.Replace both Power Modules in the same phase if meter readings
are not as shown. Refer to Chapter 4 – Part Replacement
Procedures, Power Modules.
11. If one or more Power Modules is replaced, test the Gate Driver
Board. Refer to Testing the Gate Driver Board in this chapter.
12.Assemble the drive in reverse order of disassembly.
!
Test 4
Testing the Bus
Capacitors
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
The Bus Capacitor Bank is located on the left side of the Main
Chassis.
Figure 3.4
Bus Capacitor Bank Test
Terminal Block
TB1
DC+
DC–
AB0376B
Publication 1336 FORCE-6.13 – August, 1999
3–10
Component Test Procedures
!
!
Important:
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the guard from the bus capacitors.
5. Set your meter to test voltage.
6. 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.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Servicing energized industrial control
equipment can be hazardous. Electrical shock, burns,
or unintentional actuation of controlled industrial
equipment may cause death or serious injury. Follow
the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or
near energized equipment. Do not work alone on
energized equipment.
Component Test Procedures
3–11
7. Apply power AFTER the meter is connected, otherwise your
meter will read zero volts. Expand readings for all input voltage
ratings.
Table 3.C
Bus Capacitor Bank Test
Drive
Rating
A
B
C
Input
Volts
Meter
Reading
200
230
240
380
415
480
500
575
600
280V DC +/–10%
322V DC +/–10%
336V DC +/–10%
535V DC +/–10%
580V DC +/–10%
650V DC +/–10%
700V DC +/–10%
800V DC +/–10%
850V DC+/–10%
8. If the voltage is out of tolerance, check the following:
• An open condition at an Input Rectifier.
• A voltage drop due to Bus Inductor L1 resistance.
• A voltage drop between an Input Rectifier and the bus
capacitors due to loose or resistive wires or connections.
• Precharge circuit problems.
9. If the above check does not reveal a problem, replace the Bus
Capacitor Bank and Load-Sharing Resistors. Refer to Chapter 4 –
Part Replacement Procedures, Bus Capacitor Bank.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
3–12
Component Test Procedures
Test 5
Testing the Input Rectifiers
The Input Rectifiers are located on the bottom of the heat sink.
Figure 3.5
Input Rectifier Test
Input
Rectifier
K2/G2
K1/G1
A
K
AK
AB0387C
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Component Test Procedures
!
Important:
3–13
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
5. Remove the Precharge Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Precharge Board Mounting Plate.
6. Remove the Converter Snubber Board. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Converter Snubber Board.
7. Remove the Converter Bus Bar.
8. Set your meter to test diodes.
9. The following table shows meter connections and ideal meter
readings for those connections. Refer to the former illustration for
meter connection locations.
Publication 1336 FORCE-6.13 – August, 1999
3–14
Component Test Procedures
Table 3.D
Input Rectifier Test
Meter (+) Lead
Meter (–) Lead
Nominal Meter Reading
AK
K
Infinite
AK
A
Infinite
K
A
Infinite
K
AK
Infinite
A
AK
Infinite
A
K
Infinite
G1
K1
0.008
K1
G1
0.008
G2
K2
0.008
K2
G2
0.008
10.Replace the Input Rectifier if any meter readings are not as
shown. Refer to Chapter 4 – Part Replacement Procedures, Input
Rectifiers.
11. If the Input Rectifier shorted, check the Power Modules for
damage. Refer to Testing the Power Modules in this chapter.
12.Assemble the drive in reverse order of disassembly.
Publication 1336 FORCE-6.13 – August, 1999
Chapter
4
Part Replacement Procedures
Chapter Objective
This chapter describes procedures required to replace drive
components. This chapter references Chapter 2 – Disassembly and
Access Procedures for basic drive component access.
Part Replacement
Overview
The part replacement procedures in this chapter assume that the drive
you are servicing either has no enclosure or that the enclosure is
open. For more information on opening the Drive Enclosure, refer to
Chapter 2 – Disassembly and Access Procedures, Opening the Drive
Enclosure.
Safety Precautions
!
!
ATTENTION: Some printed circuit boards and drive
components may contain hazardous voltage levels.
Remove power before you disconnect or reconnect
wires, and before you remove or replace fuses and
circuit boards. Verify bus voltage by measuring the
voltage between +DC and –DC on Terminal Block
TB1. Do not attempt to service the drive until the bus
voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
Publication 1336 FORCE-6.13 – August, 1999
4–2
Part Replacement Procedures
Electrostatic Discharge
Precautions
!
ATTENTION: This assembly contains parts and
sub-assemblies that are sensitive to electrostatic
discharge. Static control precautions are required when
servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures,
reference Allen-Bradley Publication 8000-4.5.2,
Guarding Against Electrostatic Discharge, or any other
applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various
drive boards. It is recommended that you perform these procedures
to guard against this type of damage when circuit boards are
removed or installed:
• Wear a wrist-type grounding strap that is grounded to the chassis.
• Attach the wrist strap before removing the new circuit board from
the conductive packet.
• Remove boards from the drive and immediately insert them into
their conductive packets.
Tools
• You need the following tools to disassemble and assemble the
•
•
•
•
•
•
•
•
•
•
Publication 1336 FORCE-6.13 – August, 1999
drive:
Pliers
Phillips screwdrivers (medium and large)
Standard screwdrivers (small, medium, and large)
10 mm socket
13 mm deep-well socket
5/16-inch or 8 mm open-end wrench
Torque wrench, metered in in.-lb or N-m
Nylon tie wraps
Side cutters
17 mm socket
Part Replacement Procedures
Major Component
Replacement
4–3
This section explains in detail how to replace the following drive
components:
• Bus Capacitors
• Thermistor
• Power Modules
• Input Rectifiers
• Fan Assembly
• Autotransformer
• DC Bus Inductor L1
• Ground Sense CT
• Bus Fuse
• LEMs
• MOV Surge Suppressor
For Gate Driver Board, Precharge Board, Main Control Board,
Standard Adapter Board, PLC Comm Adapter Board, Snubber
Board, and Control Interface Board installation and removal
procedures, refer to Chapter 2 – Disassembly and Access Procedures.
Publication 1336 FORCE-6.13 – August, 1999
4–4
Part Replacement Procedures
Detailed Product
Identification
Allen-Bradley Adjustable Frequency AC Drives are modular by
design to enhance troubleshooting and spare parts replacement,
thereby helping reduce production down-time.
The following illustration calls out the main components of a typical
drive. Component designs vary slightly among the different drive
ratings, but component locations are identical.
Figure 4.1
Main Drive Components
Load Sharing
Resistor
Bus Capacitor
Bank
Power
Module
Power Module
Snubber Resistor
Bus Fuse
Capacitor
Bus Bar
Thermistor
Inverter
Bus Bar
Power Module
Snubber Board
Motor
Bus Bar
Gate Driver
Board
Input
Rectifier
LEM
Fuse F3
Connector
J7
Connector
J5
Converter
Bus Bar
Main Control
Board
Connector J1
TB10
Converter
Snubber Board
Human Interface
Module
Terminal Strip
TB1
Fuse F1
Ground
Sense CT
Bus Inductor
L1
MOV Surge
Suppressor
Fan Capacitor
Autotransformer
Connector J1
Standard
Adapter Board
Precharge
Board Fuses
TB7
Precharge
Board
TB6
TB5
Connector J1
Control Interface
L-Option Board
PLC Comm
Adapter Board
Connector J5
Connector J7
TB21
TB20
Publication 1336 FORCE-6.13 – August, 1999
AB0698B
Part Replacement Procedures
4–5
Bus Capacitor Bank
The Bus Capacitor Bank is located on the left side of the Main
Chassis.
Figure 4.2
Bus Capacitor Bank
Load-Sharing
Resistor
Bus Fuse
Capacitor
Bracket
Capacitor
Capacitor
Retainers
One of two sizes,
this bolt only
Capacitor
Bus Bar
DC–
DC+
AB0382D
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–6
Part Replacement Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Access the Capacitors:
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the screws fastening the Bus Capacitor Guard to the
Capacitor Bank.
5. Slide the Capacitor Guard toward the center of the drive to
disengage the tabs.
6. Lift the Capacitor Guard out of the Drive.
7. Remove the Bus Fuse. Refer to Bus Fuse in this chapter.
Remove the Capacitors:
1. Remove the bolt and washer assembly fastening the Capacitor
Bus Bar to the Transition Bus Bar. The Transition Bus Bar
assembly is located under, and attached to, the Bus Fuse.
2. Remove the Load-sharing Resistor wires and the Capacitor Bus
Bar screws.
3. Remove the Bus Inductor L1 cables and Bus Voltage wire harness
from the Capacitor Bus Bar.
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–7
4. Remove the Capacitor Bus Bar.
5. Loosen the screws on the Capacitor Brackets.
6. Slide the brackets away from the Capacitor Retainers and down
to remove.
7. Remove the Capacitor Retainers.
8. Lift the Bus Capacitors out of the Drive.
Installation
1. Fasten the capacitor assembly in reverse order of removal. Refer
to Chapter 2 – Disassembly and Access Procedures, Fastener
Torque Specifications.
Important:
Refer to Bus Fuse in this chapter for correct Bus
Fuse fastener size and type.
2. Connect the Load-sharing Resistors to the Bus Capacitors
according to the following diagrams.
Figure 4.3
Load-Sharing Resistor Connections to Bus Capacitors
R2
R1
R3
C1
C2
C3
C4
C5
C6
C7
C8
C9
AB0526A
Publication 1336 FORCE-6.13 – August, 1999
4–8
Part Replacement Procedures
Load-sharing resistor R1 has three color coded leads coming out of
the resistor body. Connect as shown in Figure 4.4.
Figure 4.4
Wiring Detail for A040, A050, B060, B075, and B100 Drives
DC+
+
Blue
+
C1
+
C3
C5
Yellow
+
+
C2
13.6K
Ohms R1
+
C4
A
C6
Black
Inv–
AB0534A
R1 (BLACK)
R1 (YELLOW)
C2
(–)
R1 (BLUE)
C1
(+)
(–)
(+)
AB0530A
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: The Capacitor Bus must connect a
positive (+) capacitor terminal to a negative (–)
capacitor terminal. Capacitors not connected correctly
will explode and cause death or serious injury.
Part Replacement Procedures
4–9
Load-sharing resistors R1 and R2 have two color coded leads
coming out of each resistor body. Connect as shown in Figure 4.5.
Figure 4.5
Wiring Detail for A060, B125, and BX150 Drives
Blue
DC+
+
+
C1
+
+
C3
+
C2
+
C5
+
C4
C7
Blue
+
C6
Black
A 4.3K R1
Ohms
C8
B
Inv–
4.3K R2
Ohms
Black
C2
(+)
R2 (Blue)
R2 (Black)
(+)
(–)
R1 (Black)
(–)
R1 (Blue)
C1
AB0531A
AB0527B
Publication 1336 FORCE-6.13 – August, 1999
4–10
Part Replacement Procedures
Load sharing resistors R1 and R2 have three color coded leads
coming out of each resistor body. Connect as shown in Figure 4.6.
Figure 4.6
Wiring Detail for C075 and C100 Drives
DC+
Blue
+
+
C1
C4
Yellow
+
+
C2
+
C5
Blue
13.6K R2
Ohms
B
Yellow
+
C3
13.6K R1
Ohms
A
Black
C6
Black
AB0532A
Inv–
R2 (YELLOW)
R2 (BLACK)
R1 (BLACK)
R1 (BLUE)
R2 (BLUE)
C3
(–)
R1 (YELLOW)
C2
(+)
(–)
C1
(+)
(–)
(+)
AB0528A
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–11
Load-sharing resistors R1, R2, and R3 have two color coded leads
coming out of each resistor body. Connect as shown in Figure 4.7.
Figure 4.7
Wiring Detail for C125 Drives
DC+
Blue
+
+
C1
+
+
C4
+
C2
+
C7
C5
C3
A 4.3K R3
Ohms
Blue
+
+
Black
C8
Black
Blue
+
C6
C9
Black
B 4.3K R1
Ohms
C 4.3K R2
Ohms
Inv–
AB0533A
R2 (BLACK)
C3
C2
(+)
R3 (BLUE)
R1 (BLUE)
R2 (BLUE)
(–)
R3 (BLACK)
R1 (BLACK)
(–)
C1
(+)
(–)
(+)
AB0529A
Publication 1336 FORCE-6.13 – August, 1999
4–12
Part Replacement Procedures
Thermistor
The Thermistor is located on the top-left corner of the heat sink.
Figure 4.8
Thermistor
Thermistor
Connector to Main
Control Board J1
AB0381B
Removal
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Part Replacement Procedures
!
!
Important:
4–13
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Disconnect the Thermistor connector at J1 on the Main Control
Board.
5. Remove the Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
6. Cut and remove tie wraps along the wire routing path of the
Thermistor.
7. Remove the Thermistor from the heat sink.
Publication 1336 FORCE-6.13 – August, 1999
4–14
Part Replacement Procedures
Installation
Install the Thermistor in reverse order of removal, replacing tie
wraps as needed. Refer to Chapter 2 – Disassembly and Access
Procedures, Fastener Torque Specifications.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Power Modules
The Power Modules are located near the top of the heat sink.
Figure 4.9
Power Modules
U-Phase Module
V-Phase Module
W-Phase Module
Power
Module
Preform
C
E
E
Inverter
Bus Bar
G
Lower-Left Bracket
(Some Drives may
not have brackets
at E and G)
Standoff
AB0391D
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–15
Removal
!
!
!
Important:
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
5. Remove the Power Module Snubber Board. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
6. Remove the three screws located at (+), (–), and MTR on the
Inverter Bus Bar.
Publication 1336 FORCE-6.13 – August, 1999
4–16
Part Replacement Procedures
7. Remove the four standoffs from the Inverter Bus Bar.
8. Remove the four screws fastening the Power Module to the
Drive.
Installation
1. Clean all surfaces between the Power Module and the heat sink
using a soft, clean cloth.
2. Replace the Preform between the Power Module and the heat
sink.
3. Install the Power Module in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
Important:
!
Publication 1336 FORCE-6.13 – August, 1999
Slide the MTR tab on the Inverter Bus Bar under the
corresponding tab on the Transition Bus Bar.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Part Replacement Procedures
4–17
Input Rectifiers
The Input Rectifiers are located at the bottom of the heat sink.
Figure 4.10
Input Rectifiers
Input
Rectifier
9 Standoffs
Converter
Bus Bar
CNV –
T-L3
CNV +
S-L2
R-L1
AB0385D
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–18
Part Replacement Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
5. Remove the Precharge Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Precharge Board Mounting Plate.
6. Remove the Converter Snubber Board. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Converter Snubber Board.
7. Remove all cable connections from the Converter Bus Bars.
8. Remove the standoffs and the Converter Bus Bar from the
rectifiers.
9. Remove the screws fastening the Input Rectifier to the drive.
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–19
Installation
1. Clean all surfaces between the Input Rectifier and the heat sink
using a soft, clean cloth.
2. Replace the Preform between the Input Rectifier and the heat
sink.
3. Install the Input Rectifier in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
4–20
Part Replacement Procedures
Fan Assembly
The Fan is located under TB1 at the bottom of the Main Chassis. The
Autotransformer and Fan Capacitor are located in the bottom left
corner of the Main Chassis.
Figure 4.11
Fan Assembly
Fan
Fan Cover
TB1 Terminal Partitions
and DIN Rails
Terminal
End Stop
MOV Surge
Suppressor
Fan
Capacitor
Autotransformer
Publication 1336 FORCE-6.13 – August, 1999
Terminal
End Stop
AB0384E
Part Replacement Procedures
4–21
Removal
!
!
Important:
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Access the Drive:
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Disconnect the wiring as follows:
• Wire harness connecting the Fan to the Autotransformer
• Ground wire from the ground stud
• MOV Surge Suppressor wire from the ground stud
• All wires from TB1
Remove the Upper DIN Rail:
1. Loosen the screw fastening the Terminal End Stop to the left side
of the Upper DIN Rail to remove the end stop, exposing a screw
on the DIN rail.
2. Remove the exposed screw from the DIN rail.
3. Slide the TB1 terminals to the left to expose the other screw on
the Upper DIN Rail.
4. Remove the exposed screw from the DIN rail to remove the
Upper DIN Rail from the Fan Cover.
Publication 1336 FORCE-6.13 – August, 1999
4–22
Part Replacement Procedures
Remove the Lower DIN Rail:
1. Loosen the screw fastening the Terminal End Stop to the right
side of the Lower DIN Rail to remove the end stop.
2. Slide TB1 terminal W-M3 off the DIN rail to expose a screw on
the DIN rail.
3. Remove the exposed screw from the DIN rail.
4. Slide the TB1 terminals to expose the other screw on the lower
DIN rail.
5. Remove the exposed screw from the DIN rail to remove the lower
DIN rail from the Fan Cover.
6. Remove the screws fastening the Fan Cover to the Main Chassis.
7. Lift the fan and cover from the Drive.
8. Remove the screws fastening the Fan to the Fan Cover to remove
the Fan from the cover.
9. Remove the nut fastening the Fan Capacitor to the bracket to
remove the capacitor.
Installation
1. Thread the Fan wire through the hole in the Fan Cover.
2. Fasten the Fan to the Fan Cover.
3. Install the Fan and capacitor in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Part Replacement Procedures
4–23
Autotransformer
The Autotransformer and Fan Capacitor are located in the bottom
left corner of the Main Chassis.
Figure 4.12
Autotransformer
Stake-on
Connectors
Wire
Harness
Fan
Capacitor
MOV Surge
Suppressor
Autotransformer
AB0619A
Publication 1336 FORCE-6.13 – August, 1999
4–24
Part Replacement Procedures
Removal
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Autotransformer wire from TB1 terminal S-L2.
5. Remove the wire from the Autotransformer stake-on connector.
Note the location of the stake-on connector for installation.
6. Disconnect the wire harness connecting the Autotransformer to
the Fan.
7. Remove the screws fastening the Autotransformer to the chassis.
Installation
Install the Autotransformer in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
Important:
Publication 1336 FORCE-6.13 – August, 1999
On the replacement Autotransformer, connect the wire
from Removal Step 5, above, to the same stake-on
connector from which the wire was removed. Refer to
the Fan wiring diagram in the Schematics section of this
manual for correct transformer-tap voltage.
Part Replacement Procedures
4–25
DC Bus Inductor L1
DC Bus Inductor L1 is located on the lower left corner of the Drive.
Figure 4.13
DC Bus Inductor L1
DC Bus
Inductor L1
CNV – Connection
TB1 DC–
Connection
CNV + Connection
TB1 DC+
Connection
AB0386C
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–26
Part Replacement Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the guard.
5. Remove the wires from the Bus Inductor terminals.
6. Remove the four screws fastening the Bus Inductor to the drive.
7. Lift the Bus Inductor out of the drive.
Installation
1. Lower the inductor into the Main Chassis, inserting the inductor
into the bottom inductor bracket.
2. Install DC Bus Inductor L1 in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Part Replacement Procedures
4–27
Ground Sense CT
The Ground Sense CT is located in the lower left of the Drive.
Figure 4.14
Ground Sense CT
Bus Capacitor Bus Bar
+DC Connection
Bus Capacitor Bus Bar
–DC Connection
Connector to Gate
Driver Board J2
Ground
Sense CT
Tie Wraps
Bus Inductor L1
–DC Connection
Bus Inductor L1
+DC Connection
AB0388D
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–28
Part Replacement Procedures
!
Important:
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Disconnect the Ground Sense CT from Gate Driver Board
connector J2.
5. Remove the Bus Capacitor Guard.
6. Remove the following:
• Bus Capacitor Bus Bar DC+ wire.
• Bus Capacitor Bus Bar DC– wire.
• Bus Voltage Wire Harness
7. Cut the tie wraps from the Ground Sense CT.
8. Slide the Ground Sense CT off the Bus Capacitor wires.
Installation
1. Place the Bus Capacitor wires through the center of the Ground
Sense CT.
2. Install the Ground Sense CT in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Part Replacement Procedures
4–29
Bus Fuse
The Bus Fuse is located at the top-center of the Drive.
Figure 4.15
Bus Fuse
Bus Fuse
M10 Bolt, Split Washer and
Belville Washer, All D-Frame
Drives
M10
Belville
Use one of two bolts here
on D-Frame Drives
M10 Belville
M8 Belville
Spring Washer
Split Lock
Washer
M10 Bolt, Later
D-Frame Drives
M8 Bolt, Early
D-Frame Drives
AB0749A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–30
Part Replacement Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Bus Capacitor Guard. Refer to Bus Capacitor Bank
in this chapter.
5. Remove the two bolt-and-washer assemblies fastening the Bus
Fuse to the drive.
Installation
Install the Bus Fuse in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.13 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Part Replacement Procedures
4–31
LEMs
The LEMs are located near the bottom of the heat sink.
Figure 4.16
LEMs
W-M3
V-M2
U-M1
J6
Connector
Nylon
Spacers
Mounting
Bracket
Mounting
Screws
AB0392C
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt
to service the drive until the bus voltage has discharged
to zero volts.
Publication 1336 FORCE-6.13 – August, 1999
4–32
Part Replacement Procedures
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Remove the Precharge Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Precharge Board Mounting Plate.
5. Remove Gate Driver Board Mounting Plate. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board Mounting Plate.
6. Disconnect the Inverter output wires, running through the LEMs,
from Motor Bus Bar terminals:
• U-M1
• V-M2
• W-M3
7. Disconnect the J6 Connector wiring harness from the LEMs.
8. Remove the screws fastening the LEM mounting bracket to the
heat sink.
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–33
9. Slide the LEM mounting bracket off of Inverter output wires.
10.Compress the tabs on the nylon spacers to remove the LEM from
the mounting bracket.
Installation
Install the LEMs in reverse order of removal. Refer to
Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
4–34
Part Replacement Procedures
MOV Surge Suppressor
The MOV Surge Suppressor is located in the bottom-left corner of
the Drive near the Autotransformer and Fan Capacitor.
The MOV protects the drive from high voltage surges above
approximately 1,000 volts. Replace the MOV if it is burned,
expanded, or ruptured after such events as a lightening strike or
inadvertent connection of the drive input to a voltage source
substantially above nameplate voltage.
Figure 4.17
MOV Surge Suppressor
Mounting
Bracket
M4 or M5
Mounting Screw
MOV Surge
Suppressor
AB0750A
Publication 1336 FORCE-6.13 – August, 1999
Part Replacement Procedures
4–35
Removal
!
!
Important:
ATTENTION: Hazard of electric shock exists. Up to
1,000 V DC may be present on Snubber Capacitors.
Measure for zero V DC across capacitors C2, C3, and
C4. Use a resistor greater than 1 ohm and less than 100
ohm, rated for 25 watts minimum, to discharge any
voltage. Refer to Chapter 2 – Disassembly and Access
Procedures, Removing a Power Module Snubber
Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Check for zero volts at TB1 terminals +DC and –DC.
3. Check for the absence of control voltage at:
• TB20 and TB21 on drives using a PLC Comm Adapter Board
• TB5, TB6, and TB7 on drives using a Standard Adapter Board
4. Disconnect the MOV wires from TB1 terminals L1, L2, and L3
(R, S, and T).
5. Disconnect the MOV wire from the ground stud.
6. Remove the screw fastening the MOV to the Main Chassis.
Installation
Install the MOV Surge Suppressor in reverse order of removal. Refer
to Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
Important:
!
Install the MOV using the same M4 or M5 screw as
was removed.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.13 – August, 1999
4–36
Part Replacement Procedures
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
Chapter
5
Replacement Parts List
Chapter Objectives
This chapter illustrates and lists replacement parts for the 1336
FORCE Drives rated A040 – A060, B060 – B125, BX150, and
C075 – C125 and describes replacement parts ordering procedures.
The following illustration and table show you parts, part names, part
numbers, locations, and chapters for replacement procedures.
Ordering Replacement
Parts
For your convenience, the Allen-Bradley Drives Division and the
Allen-Bradley Support Division provide efficient and convenient
repair and exchange for eligible equipment.
A product service report number is required to return any equipment
for repair. Your local Allen-Bradley distributor or area sales and
support office can provide you with a product service report number.
You should return equipment to be repaired to the area sales and
support center nearest you. Reference the product service report
number on the carton and packing slip. Include:
• Your company name
• Your company address
• The repair purchase order number
• A brief description of the problem
Contact your local Allen-Bradley distributor or sales office for a
complete listing of area sales and support centers near you.
For parts catalog numbers, refer to the 1336 FORCE Spare Parts
Pricing publication included with your drive documentation set.
Publication 1336 FORCE-6.13 – August, 1999
5–2
Replacement Parts List
Replacement Parts Listing
Figure 5.1
Parts for A040 – A060, B060 – B125, BX150, and
C075 – C125 Drives
22
1
2
3
5
4
6
12
13
14
7
15
8
9
16
17
21
20
19
18
11
10
Publication 1336 FORCE-6.13 – August, 1999
AB0699A
Replacement Parts List
5–3
Table 5.A
Replacement Parts for A040 – A060, B060 – B125, BX150,
and C075 – C126 Drives
Callout
Symbol
Description
Location
Replacement Procedures
1
R1 – R3
Load-Sharing Resistor
Main Chassis
Chapter 4, Bus Capacitor Bank
2
Q1 – Q6
IGBT
Heat Sink
Chapter 4, Power Modules
3
F1
Bus Fuse
Cap Bus Bar
Chapter 4, Bus Fuse F1
4
ST NTCI
Thermistor
Heat Sink
Chapter 4, Thermistor
5
SNUBBER BOARD
Inverter Bus Bar and Snubber
Board
Heat Sink
Chapter 2, Removing a Power Module
Snubber Board
6
BASEDR/PWRSPLY
Gate Driver Board
Gate Driver Board
Mounting Plate
Chapter 2, Removing the Gate Driver
Board
7
MAIN CTL
Main Control Board
Control Board/Adapter
Mounting Plate
Chapter 2, Removing the Main Control
Board
8
HIM
Human Interface Module
Control Board/Adapter
Mounting Plate
Chapter 1, Module Removal
9
GT2
Standard Adapter Board
Control Board/Adapter
Mounting Plate
Chapter 2, Removing the Standard
Adapter Board
10
GT1
PLC Comm Adapter Board
Control Board/Adapter
Mounting Plate
Chapter 2, Removing the PLC Comm
Adapter Board
11
PRECHARGE
Precharge Board
Precharge Board Mounting Plate
Chapter 2, Removing the Precharge
Board
12
R20 – R22
Power Module
Snubber Resistor
Main Chassis
Chapter 2, Removing a Power Module
Snubber Board
13
SCR1 – SCR3
Input Rectifier
Heat Sink
Chapter 4, Input Rectifiers
14
CT1, CT2
LEM
Main Chassis
Chapter 4, LEMs
15
SCR SNUBBER
BOARD
Converter Snubber Board
Heat Sink
Chapter 2, Removing the Converter
Snubber Board
16
CT3
Ground Sense CT
—
Chapter 4, Ground Sense CT
17
FAN
Fan
Main Chassis
Chapter 4, Fan and Transformer
18
L1
DC Bus Inductor
Main Chassis
Chapter 4, DC Bus Inductor L1
19
MOV1
MOV Surge Suppressor
Main Chassis
Chapter 4, Autotransformer
20
T1
Autotransformer
Main Chassis
Chapter 4, Autotransformer
21
C-HB1
Fan Capacitor
Main Chassis
Chapter 4, Autoransformer
22
C1 – C6
Bus Capacitors
Main Chassis
Chapter 4, Bus Capacitor Bank
Publication 1336 FORCE-6.13 – August, 1999
5–4
Replacement Parts List
This Page Intentionally Left Blank.
Publication 1336 FORCE-6.13 – August, 1999
Chapter
6
Schematics — 40 – 150 HP 1336
FORCE Drives
Publication 1336 FORCE-6.13 – August, 1999
6–2
Schematics — 40 – 150 HP 1336 FORCE Drives
TE
PE
TB1
DC+
DC–
CONVERTER SNUBBER BOARD
A11
F1
SEE TABLE 2
L1
CNV+
DC+
PM1
PM2
PM3
TO FAN CIRCUIT
SEE FAN CIRCUIT
DETAIL
CUSTOMER
FUSING
TB1
CF1
K1
K1
K1
G1
G1
G1
R–L1
SCR1
AC
INPUT
POWER
50/60HZ
SCR3
CT3
1000:1
SCR5
CF2
CM1
S–L2
PE
CF3
T–L3
MOV1
SEE
TABLE 1
K2
K2
K2
G2
G2
G2
SCR4
PE
SCR6
CAPACITOR
BANK
SEE CAPACITOR
DETAIL
CM2
SCR2
PE
CNV–
6 5 4 3 2 1
1
J2
A10
J1
STANDARD
PRECHARGE
BOARD
–BUS
T2G
T2K
2 1
+BUS
6 5
R1G
R1K
S1G
S1K
T1G
T1K
10 9
S2G
S2K
R2G
R2K
DC–
4
1
+SMPS
4
–SMPS
7
8
9
10
11
12
+15V
–15V
COMMON
+5V
/CHARGE
AC LINE
J4
J3
F1
F2
F3
SEE TABLE 3
AB0632A
Publication 1336 FORCE-6.13 – August, 1999
Schematics — 40 – 150 HP 1336 FORCE Drives
6–3
TB1
U–M1
AC
OUTPUT
POWER
V–M2
W–M3
+15
U_AMPS
3
–15
+15
CT1
2000:1
2
3
W_AMPS
1
CT2
2000:1
2
–15
PE
1
+INV
GATE INTERFACE
GATE INTERFACE
1 C
J1
C0
G1
5 G
E1
4 E
1 C
J1
C0
5 G
GATE INTERFACE
1 C
J1
C0
G1
5 G
G1
E1
4 E
Q1
E1
A20
R20
E0
E1
A21
R21
E2
C0
5 G
A22
R22
E2
1 C
J2
C0
G1
5 G
E1
4 E
1 C
J2
C0
G1
5 G
G1
E1
4 E
Q4
4 E
E1
E2
1 C
J2
E1
E0
CLAMP
RESISTOR
CLAMP
RESISTOR
E0
Q5
CLAMP
RESISTOR
4 E
Q3
Q6
E0
Q2
E1
E0
E0
–INV
TO
MAIN
CONTROL
BOARD
VP_GATE
VP_EMIT
VN_COL
1 2 3
6 7 8
WP_COL
VP_COL
UP_COL
1 2 3 4 5 6
J6
WP_GATE
WP_EMIT
WN_COL
WN_GATE
WN_EMIT
VN_GATE
VN_EMIT
UN_GATE
UN_EMIT
8 7 6 5 4 3 2 1
UP_GATE
UP_EMIT
UN_COL
4
J10
+15
U_AMPS
–15V
1
J2
+15
W_AMPS
–15
INTERLOCK
1 2
+BUS
–BUS
12
ACT1
ACT2
NTC1
11 12 13
16 17 18
M1X1
M1X2
M1K2
M1K1
1 2
J8
J7
4
6
J5
9
F1
F3
1
2
3
4
5
6
SEE TABLE 3
1
TB7
J1
SCHEMATIC DIAGRAM
STAND ALONE 40 – 150 HP
TO MAIN CONTROL BOARD
1
J13
TB6
2
TE
4
1
3
HIGH VOLTAGE
–DC AUX IN
TB4
1
2
GATE
DRIVER
BOARD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
–24V DC AUX INPUT
A1
J9
DGND
DGND
DGND
DGND
U_POS+
U_NEG+
V_POS+
V_NEG+
W_POS+
W_NEG+
U_POS–
U_NEG–
V_POS–
V_NEG–
W_POS–
W_NEG–
U_AMPS+
U_AMPS–
W_AMPS+
W_AMPS–
U_VOLTS
V_VOLTS
W_VOLTS
V_COM NC
NEG_BUS
NEG_CAP
POS_BUS
GND_SHORT
DESAT
AC LINE
/CHARGE
EE_IO
EE_SK
EE_CS
PILOT
CVERIFY
+5V
+5V
+5V
+15V
+15V
–15V
–15V
+24V
ISO12V
ISO12RTN
DGND
DGND
+5V
+5V
+24V DC AUX INPUT
TB5
HIGH VOLTAGE
+DC AUX IN
6
5
4
3
2
1
CONTACTOR
INTERFACE
EXTERNAL DC BUS
INPUT CONNECTION
AC FAN1
AC FAN2
120VAC
120RTN
24V+ OUT
24V– OUT
EXTERNAL
+EXT. RES. BUS
–EXT. RES.
DISCHARGE
RESISTOR
AB0633A
Publication 1336 FORCE-6.13 – August, 1999
6–4
Schematics — 40 – 150 HP 1336 FORCE Drives
Fan Circuit Detail
200/240VAC
AC–INPUT POWER
R–L1
S–L2
(240) (200)
(0V)
T1 (240)
250 VA
(115V)
HEATSINK
FAN
C–HB1
200/240V
380/460VAC
AC–INPUT POWER
R–L1
575VAC
AC–INPUT POWER
R–L1
S–L2
(415) (380)
S–L2
(500)
(0V)
T1 (460)
250 VA
(0V)
T1 (575)
250 VA
(115V)
(115V)
HEATSINK
FAN
HEATSINK
FAN
C–HB1
C–HB1
380/460V
575V
Capacitor Detail
125 HP
575 VAC
75/100 HP 575 VAC
125 HP 380/460 VAC
60 HP 230 VAC
150 HP 460 VAC
DC+
60/75/100 HP 380/460 VAC
40/50 HP 230 VAC
+
C1
+
C4
+
C2
+
C5
DC+
DC+
R1
+
C1
+
C3
+
C5
+
C2
+
C4
+
C6
DC+
R1
+
C1
+
C3
+
C5
+
C7
+
C2
+
C4
+
C6
+
C8
R1
INV–
+
C6
+
C4
+
C7
+
C2
+
C5
+
C8
+
C3
+
C6
+
C9
R2
R2
+
C3
+
C1
INV–
R1
R2
R3
INV–
INV–
Publication 1336 FORCE-6.13 – August, 1999
AB0636A
Schematics — 40 – 150 HP 1336 FORCE Drives
6–5
TABLE 1: CUSTOMER FUSING
BASED ON MAXIMUM DRIVE RATING THE FOLLOWING FUSES OR
APPROVED EQUIVALENT MUST BE USED:
HORSEPOWER
230VAC FUSE CURRENT/TYPE
40
150 AMP, CLASS T, JJS
–
–
50
200 AMP, CLASS T, JJS
–
–
60
250 AMP, CLASS T, JJS
380/460VAC FUSE CURRENT/TYPE
575VAC FUSE CURRENT/TYPE
125 AMP, CLASS T, JJS
–
75
–
150 AMP, CLASS T, JJS
110 AMP, CLASS T, JJS
100
–
200 AMP, CLASS T, JJS
150 AMP, CLASS T, JJS
125
–
250 AMP, CLASS T, JJS
175 AMP, CLASS T, JJS
150
–
250 AMP, CLASS T, JJS
TABLE 2: BASED ON DRIVE HORSEPOWER, THE INVERTER DC + BUS
FUSE WILL CHANGE AMP RATING. THE TABLE BELOW DEFINES
THE FUSE RATING.
DRIVE
HORSEPOWER,
INPUT VOLTAGE
40HP, 230VAC
RATING
150 AMP
FUSE INFORMATION
TYPE
P/N
A70Q150–4
25178–310–10
50HP, 230VAC
200 AMP
A70Q200–4
25178–310–12
60HP, 230VAC
250 AMP
A70Q250–4
25178–310–13
60HP, 380VAC
125 AMP
A70Q125–4
25178–310–09
75HP, 380/460VAC
150 AMP
A70Q150–4
25178–310–10
75HP, 575VAC
125 AMP
A70Q125–4
25178–310–09
100HP, 380/460VAC
200 AMP
A70Q200–4
25178–310–12
100HP, 575VAC
175 AMP
A70Q175–4
25178–310–11
125HP, 380/460VAC
250 AMP
A70Q250–4
25178–310–13
125HP, 575VAC
200 AMP
A70Q200–4
25178–310–12
150HP, 460VAC
250 AMP
A70Q250–4
25178–310–13
TABLE 3: THE FOLLOWING IS A LISTING OF ALL PRINTED CIRCUIT
ASSEMBLIES VERSUS FUSE & DOCUMENTATION INFORMATION.
ITEM
A1
A10
A11
A20–22
B/M
SCHEMATIC
DIAGRAM
74101–169–XX
74101–167
74101–181–XX
74101–099–51
74101–032–XX
74101–179
74101–077
74101–022
FUSE INFORMATION
DESIGNATOR
F1
F3
F1–F3
NONE
NONE
RATING
TYPE
1.0A/600V
1.5A/600V
1.5A/600V
–
–
KTK–R
KTK–R
KTK–R
–
–
P/N
25172–260–08
25172–260–09
25172–260–09
–
–
AB0635A
Publication 1336 FORCE-6.13 – August, 1999
6–6
Schematics — 40 – 150 HP 1336 FORCE Drives
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
Glossary
Glossary
AC Contactor: An alternating-current (AC) contactor is designed
for the specific purpose of establishing or interrupting an AC Power
circuit.
Adjustable Speed: The concept of varying the speed of a motor,
either manually or automatically. The desired operating speed (set
speed) is relatively constant regardless of load.
Adjustable Speed Drive (Electrical): The adjustable speed drive is
comprised of the motor, drive controller and operator’s controls
(either manual or automatic).
Ambient Temperature: The temperature of the medium (air, water,
earth) into which the heat of the equipment is dissipated.
Base Speed: The manufacturer’s nameplate rating where the motor
will develop rated power at rated load and voltage. With DC drives,
it is commonly the point where full armature voltage is applied with
full-rated field excitation. With AC systems, it is commonly the point
where 60 Hz is applied to the induction motor.
BR: Refer to Bridge Rectifier.
Braking: A method of stopping or reducing the time required to
stop an AC motor, and can be accomplished in several ways:
1. DC-Injection braking (AC drives) Ċ A method which produces
electromagnetic braking forces in the motor by removing 2 AC
motor (stator) phases and injecting DC current. The result is a
linear braking characteristic (ramp) that does not diminish with
motor speed. Application is normally limited to 10–20% of rated
motor speed due to increased heating in the rotor.
2. Dynamic braking (AC drives) Ċ A method which produces
electromagnetic braking forces in the motor by dissipating
generated power into the DC bus through a resistive load.
Braking force remains constant and is only limited by the thermal
capacity of the resistors. The result is a linear braking
characteristic (ramp) that does not diminish with motor speed.
3. Regenerative braking Ċ A method which produces
electromagnetic braking forces in the motor by electronically
controlling the return of generated power to the AC supply. The
result is a controllable linear braking characteristic (ramp) that
does not diminish with motor speed.
Publication 1336 FORCE-6.13 – August, 1999
G–2
Glossary
4. Motor-mounted or separately-mounted brake Ċ A
positive-action, mechanical friction device. Normal configuration
is such that when the power is removed, the brake is set. This can
be used as a holding brake. (Note: A separately mounted brake is
not one which is located on some part of the mechanical drive
train other that the motor.)
Breakaway Torque: The torque required to start a machine from
standstill. Breakaway torque is always greater than the torque needed
to maintain motion.
Breakdown Torque: The breakdown torque of an AC motor is the
maximum torque which it will develop with rated voltage applied at
rated frequency.
Bridge Rectifier (Diode, SCR): A non-controlled, full-wave
rectifier that produces a constant, rectified, DC voltage. An SCR
bridge rectifier is a full-wave rectifier with a DC output that can be
controlled by switching on the gate control element.
Bridge Rectifier: A full-wave rectifier that conducts current in only
one direction of the input current. AC applied to the input results in
approximate DC at the output.
British Thermal Unit (BTU): The quantity of heat required to raise
one pound of water by one degree Fahrenheit.
BTU: Refer to British Thermal Unit.
Bus: A single path or multiple parallel paths for power or data
signals to which several devices may be connected at the same time.
A bus may have several sources of supply and/or several sources of
demand.
Bus Sense: A signal transducer that generates a signal proportional
to the current in the drive’s DC bus. The control logic uses this signal
to sense the presence or absence of bus voltage.
CEMF: Refer to Counter Electromotive Force.
CMOS: Complimentary Metallic Oxide Semiconductor. A
semiconductor device in which an electric field controls the
conductance of a channel under a metal electrode called a gate.
Cogging: A condition in which a motor does not rotate smoothly but
steps or jerks from one position to another during shaft revolution.
Cogging is most pronounced at low motor speeds and can cause
objectionable vibrations in the driven machinery.
Publication 1336 FORCE-6.13 – August, 1999
Glossary
G–3
Constant Torque Range: A speed range in which a motor is
capable of delivering a constant torque, subject to cooling limitations
of the motor.
Constant Voltage Range: (AC Drives) The range of motor
operation where the drive’s output voltage is held constant as output
frequency is varied. This speed range produces motor performance
similar to a DC drive’s constant horsepower range.
Constant Volts per Hertz (V/Hz): The V/Hz relationship exists in
AC drives where the output voltage is directly proportional to
frequency. This type of operation produces constant rated torque as
the motor’s speed varies.
Continuous Duty (CONT): A motor that can continue to operate
without stopping and remain within the insulation temperature limits
after it has reached normal operating (equilibrium) temperature.
Converter:
1. A device for changing AC to DC. This is accomplished through
use of a diode rectifier or thyristor rectifier circuit.
2. A device for changing AC to DC to AC (e.g., adjustable
frequency drive). A frequency converter, such as that found in an
adjustable frequency drive, consists of a rectifier, a DC
intermediate circuit, an inverter, and a control unit.
Counter Electromotive Force (CEMF): The product of a motor
armature rotating in a magnetic field. This generating action takes
place whenever a motor is rotating. Under stable motoring conditions
the generated voltage (CEMF) is equal to the voltage supplied to the
motor minus small losses. However, the polarity of the CEMF is
opposite to that of the power being supplied to the armature.
Current Limiting: An electronic method of limiting the maximum
current available to the motor. This is adjustable so that the motor’s
maximum current can be controlled. It can also be preset as a
protective device to protect both the motor and the control from
extended overloads.
DC Boost: Compensates for the voltage drop across the resistance
of an AC motor circuit and the resulting reduction in torque.
DC Bus: A drive’s power structure that transmits a rectified AC line
power from the bridge rectifier to the output transistors.
DC Hold: Describes a “holding brake” function to stop motor
rotation after a ramp-to-stop function is activated.
Diode: A solid-state uni-directional conductor.
Publication 1336 FORCE-6.13 – August, 1999
G–4
Glossary
Drift: A slow change in some characteristic of a device. For a drive,
it is the deviation from the initial set speed with no load change over
a specific time period. Normally the drive must be operated for a
specified warm-up time at a specified ambient temperature before
drift specifications apply. Drift is normally caused by random
changes in operating characteristics of various control components.
Drive Controller (Variable Speed Drive) (Drive): An electronic
device that can control the speed, torque, horsepower, and direction
of an AC or DC motor.
1. PWM drive Ċ is a motor drive using pulse-width modulation
techniques to control power to the motor. A high-efficiency drive
used for high-response applications.
2. SCR drive Ċ is a motor drive that uses SCRs as the power
control elements. Usually used for low-bandwidth high-power
applications.
3. Servo drive Ċ is a motor drive that uses internal feedback loops
for motor current and/or velocity.
4. Vector drive Ċ is an AC static motor drive using power-control
techniques that produce motor performance similar to DC static
drives.
Duty Cycle:
1. The ratio of working time to total time for an intermittently
operating device. Usually expressed as a percentage.
2. The ratio of pulse width to the interval between like portions of
successive pulses. Usually expressed as a percentage.
Dynamic Braking: Refer to Braking.
Efficiency: Ratio of output to input, indicated by a percentage. In a
motor, it is the effectiveness with which the motor converts electrical
energy into mechanical energy. In a power supply, it is the
effectiveness with which the power supply converts AC power into
DC power.
Electrostatic Discharge (ESD): A static-electricity discharge that
may damage drive components. Refer to the ESD precautions found
in this manual to guard against damage to drive components.
Enable: To activate logic by the removal of a suppression signal.
Enclosure: The housing in which equipment is mounted. They are
available in designs for various environmental conditions. Refer to
NEMA standard for specifications of different types of enclosures.
Publication 1336 FORCE-6.13 – August, 1999
Glossary
G–5
ENUM (Enumeration): An ANSI C standard extension to the C
language. An ENUM is a set of named integer constants that specify
all the legal values a variable of a given type may have. The keyword
ENUM signals the start of an enumeration type.
ESD: Refer to Electrostatic Discharge.
Floating Ground: An electrical circuit common which is not at
earth ground potential or the same ground potential as circuitry with
which it interfaces. A voltage difference can exist between the
floating ground and earth ground.
Force: The tendency to change the motion of an object with an
exertion of energy from a separate source.
Full Load Torque: The full-load torque of a motor is the torque
necessary to produce rated horsepower at full-load speed.
Gate:
1. A logic element that blocks or passes a signal, depending on the
status of specified input signals.
2. The control element of an SCR.
GND Sense: A current transducer that detects an unequal or
imbalanced current in the three-phase AC line or DC bus of the
drive. The imbalance indicates an output ground fault condition.
Horsepower (hp): A unit of power: 1 hp = 33,000 ft-lb/min. = 746
watts.
IEC: International Electrotechnical Commission.
IGBT: Refer to Insulated Gate Bipolar Transistor.
Induction Motor: An induction motor is an alternating-current
motor in which the primary winding on one member is connected to
the power source. A secondary winding on the other member carries
the induced current. There is no physical electrical connection to the
secondary winding; its current is induced.
Inertia: A measure of a body’s resistance to change in velocity,
whether a body is at rest or moving at a constant velocity. The
velocity can be either linear or rotational. The moment of inertia
(WK2) is the product of the weight (W) of an object and the square
of the radius of gyration (K2). The radius of gyration is a measure of
how the mass of the object is distributed about the axis of rotation.
WK2 is usually expressed in units of lb-ft2.
Insulated Gate Bipolar Transistor (IGBT): A type of transistor
commonly used in drive-control devices.
Publication 1336 FORCE-6.13 – August, 1999
G–6
Glossary
Integral-Horsepower Motor: A motor that has a continuous rating
of 1 hp or more, built into a frame.
International Organization for Standards (ISO): An organization
established to promote development of international standards.
Interposing Relay: An interposing relay is a relay that accepts
control signals of one logic level in order to provide isolated contact
signals in a circuit operating at a different logic level.
Inverter:
1. An AC adjustable frequency drive.
2. A particular section of an AC drive. This section uses the DC
voltage from a previous circuit stage (intermediate DC circuit) to
produce a pulse-width-modulated or stepped AC current or
voltage waveform that has characteristics similar to the desired
sine-wave frequency.
3. A circuit whose output signal is the inverse of its input (a
positive-going pulse is inverted to a negative-going pulse, and
vise versa).
ISO: Refer to International Organization for Standards.
Isolation Transformer:
1. A transformer that provides DC isolation from other equipment
not connected to that transformer secondary.
2. A transformer that provides noise isolation between the primary
and secondary by such means as a Faraday shield.
Jogging:
1. In a numerical control system, an operator manually generating
motion (continuously or incrementally) by closing a switch.
2. An operator generating motion by closing a switch.
Kinetic Energy: The energy of motion of a moving body.
LAD: Refer to Linear Acceleration/Deceleration.
LEM: A hall-effect current transducer that senses drive output
current and generates a signal for the control logic.
Linear Acceleration/Deceleration (LAD): A circuit that controls
the rate at which a motor is allowed to accelerate to a set speed or
decelerate to zero speed. On most drives, this circuit is adjustable
and can be set to accommodate a particular application.
Linearity: A measure of how closely a characteristic follows a
straight-line function.
Publication 1336 FORCE-6.13 – August, 1999
Glossary
G–7
Locked-Rotor Current: Steady-state current taken from the line
current with the a rotor at standstill (at rated voltage and frequency).
This is the current when starting the motor and load.
Locked-Rotor Torque: The minimum torque that a motor will
develop at rest for all angular positions of the rotor (with rated
voltage applied at rated frequency).
Meggar Test: A test used to measure an insulation system’s
resistance. This is usually measured in megohms by applying a high
voltage.
MOV: Refer to Surge Protection.
National Electrical Code (NEC): A set of regulations governing
the construction and installation of electrical wiring and apparatus,
established by the National Fire Protection Association and suitable
for mandatory application by governing bodies exercising legal
jurisdiction. It is widely used by state and local authorities within the
United States.
National Electrical Manufacturer’s Association (NEMA): A
non-profit organization organized and supported by electrical
equipment and supply manufacturers. Some NEMA motor standards
include horsepower (hp) ratings, speeds, frame sizes and dimensions,
torques, and drive enclosures.
NEC: Refer to National Electrical Code.
Negative Slope: The location on a V/Hz curve where the break
voltage exceeds the base voltage.
NEMA: Refer to National Electrical Manufacturer’s Association.
Offset: The steady-state deviation of a controlled variable from a
fixed setpoint.
Op Amp: An operational amplifier. A high-gain stable linear DC
amplifier that is designed to be used with external circuit elements.
Open Loop System: A control system that has no means of
comparing the output with the input for control purposes.
Overload Capacity: The ability of the drive to withstand currents
beyond the system’s continuous rating. It is normally specified as a
percentage of full-load current endured for a specified time period.
Overload capacity is defined by NEMA as 150% of rated full load
current for one minute for “standard industrial DC motors.”
Publication 1336 FORCE-6.13 – August, 1999
G–8
Glossary
PC:
1. Personal Computer.
2. Programmable Controller.
3. Printed Circuit.
Plugging: A type of motor braking provided by reversing either line
voltage polarity or phase sequence so that the motor develops a
counter torque that exerts a retarding force to brake the motor.
Pot: A potentiometer, or variable resistor.
Power: Work done per unit of time. Measured in horsepower (hp) or
watts (W): 1 hp = 33,000 ft-lb/min. = 746 W.
Power Factor (Displacement): A measurement of the time phase
difference between the fundamental voltage and fundamental current
in an AC circuit. It represents the cosine of the phase angle
difference.
Fp = cos (α– β)
Power Factor (Distortion): A measurement of the ratio of the real
power (kW) to the apparent power (kVA). Distortion power factor
takes into account harmonic voltage and current distortion as well as
voltage-to-current displacement.
Preform: A flexible material used between an electronic component
and the heat sink to which the component is attached. Preform
provides maximum heat dissipation from the component to the heat
sink.
Preset Speed: Describes one or more fixed speeds at which a drive
operates.
Programmable Controller: A solid-state control system that has a
user-programmable memory for storage of instructions to implement
specific functions such as I/O control, logic, timing, counting, report
generation, communication, arithmetic, and data file manipulation. A
controller consists of a central processor, input/output interface, and
memory. A controller is designed as an industrial control system.
Pull-In Torque: The maximum constant torque to which a
synchronous motor accelerates into synchronism at rated voltage and
frequency.
Pull-Out Torque: The maximum running torque of a synchronous
motor.
Publication 1336 FORCE-6.13 – August, 1999
Glossary
G–9
Pull-Up Torque: The torque required to accelerate the load from
standstill to full speed (where breakdown torque occurs), expressed
in percent of running torque. It is the torque required not only to
overcome friction, windage, and product loading but also to
overcome the inertia of the machine. The torque required by a
machine may not be constant after the machine has started to turn.
This load type is characteristic of fans, centrifugal pumps, and
certain machine tools.
PWM: Pulse-width Modulation. A technique used to eliminate or
reduce unwanted harmonic frequencies when inverting DC voltage
to sine wave AC.
Reactance: Pure inductance or capacitance, expressed in ohms, in a
circuit. It is the component of impedance to alternating current that is
not resistance.
Rectifier: A device that conducts current in only one direction,
thereby transforming alternating current to direct current.
Regeneration: (AC drives) When the rotor synchronous frequency
is greater than the applied frequency.
Regenerative Braking: Slows or stops a motor through
regeneration. Refer to Regeneration and Braking.
Resolution: The smallest distinguishable increment into which a
quantity can be divided (e.g., position or shaft speed). It is also the
degree to which nearly equal values of a quantity can be
discriminated. For rotary encoders, it is the number of unique
electrically identified positions occurring in 360 degrees of input
shaft rotation. For D/A or A/D conversion, may be expressed as the
number of bits in the digital value that corresponds to a full-scale
analog value.
SCR: Silicon Controlled Rectifier. A solid-state uni-directional
latching switch.
Service Factor: When used on a motor nameplate, a number that
indicates how much above the nameplate rating a motor can be
loaded without causing serious degradation (i.e., a motor with 1.15
S-F can produce 15% greater torque than one with 1.0 S-F).
Set Speed: The desired operating speed.
Shock Load: The load seen by a clutch, brake, or motor in a system
that transmits high peak loads. This type of load is present in
crushers, separators, grinders, conveyors, winches, and cranes.
Publication 1336 FORCE-6.13 – August, 1999
G–10
Glossary
Slip: The difference between rotating magnetic field speed
(synchronous speed) and rotor speed of AC induction motors.
Usually expressed as a percentage of synchronous speed.
Slip Compensation: Monitors motor current and compensates for
speed lost due to increased motor slip. The amount of slip is
proportional to the motor load.
Speed Range: The speed minimum and maximum at which a motor
must operate under constant or variable torque load conditions. A
50:1 speed range for a motor with top speed 1800 rpm means the
motor must operate as low as 36 rpm and still remain within
regulation specification. Controllers are capable of wider
controllable speed ranges than motors because there is no thermal
limitation, only electrical. Controllable speed range of a motor is
limited by the ability to deliver 100% torque below base speed
without additional cooling.
Speed Regulation: The numerical measure (percent) of how
accurately the motor speed can be maintained. It is the percentage of
change in speed between full load and no load. The ability of a drive
to operate a motor at constant speed (under varying load), without
“hunting” (alternately speeding up and slowing down). It is related to
both the characteristics of the load being driven and electrical time
constants in the drive regulator circuits.
Surge Protection: The process of absorbing and clipping voltage
transients on an incoming AC power line or control circuit. Surge
protectors include MOVs (Metal Oxide Varistors) and specially
designed R-C networks.
Synchronous Speed: The speed of an AC induction motor’s
rotating magnetic field. It is determined by the frequency applied to
the stator and the number of magnetic poles present in each phase of
the stator windings. Mathematically, it is expressed as: Sync Speed
(rpm) = 120 x Applied Freq. (Hz) / Number of poles per phase.
Torque: A turning force applied to a shaft, tending to cause rotation.
Torque is equal to the force applied, times the radius through which
it acts. Torque is measured in pound-feet, ounce-inches,
Newton-meters, or gram-centimeters.
Transducer: A device that converts one energy form to another
(e.g., mechanical to electrical). When a transducer is actuated by
signals from one system or medium, it can supply a related signal to
the other system or medium.
Transient: A momentary power deviation in an electrical or
mechanical system.
Publication 1336 FORCE-6.13 – August, 1999
Glossary
G–11
Transistor: An active solid-state semiconductor device.
Work: A force moving an object over a distance.
(work = force x distance)
Publication 1336 FORCE-6.13 – August, 1999
G–12
Glossary
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Publication 1336 FORCE-6.13 – August, 1999
Index
A
Adapter Locations, 1–11
Adapters and Communication Ports, Human
Interface Module, 1–10
Audience for this Manual, P–1
Autotransformer, Illustration, 4–20
Auxiliary Input, Definition, P–7
Auxiliary Interlock, Definition, P–7
B
Bit, Definition, P–7
Bus Capacitor Bank
Illustration, 4–5
Installation, 4–7
Removal, 4–5
Test, 3–9
Bus Fuse
Illustration, 4–29
Installation, 4–30
Removal, 4–29
D
DC Bus Inductor L1
Illustration, 4–25
Installation, 4–26
Removal, 4–25
Default, Definition, P–8
Detailed Product Identification, 4–4
Drive
Enclosure Type, P–7
Identification, P–4
Illustration, 4–4
Nameplate Location, P–3
Rating, P–6
Drive Enclosure
Illustration, 2–7
Installation, 2–8
Removal, 2–7
E
Electrostatic Discharge, P–3
Enable Input, Definition, P–8
Enclosure Type, P–7
C
ESD, P–3
Check, Definition, P–8
Component Test Procedures, 3–1
Connector, Definition, P–8
Control Board/Adapter Mounting Plate,
Illustration, 2–17
Control Interface Board
Definition, P–9
Illustration, 2–9
Installation, 2–10
Jumper Locations, 1–3
Removal, 2–9
Control Interface Option, 1–3
Control Logic Wiring, 1–1
Conventions in this Manual, P–7
Converter Snubber Board
Illustration, 2–32
Installation, 2–33
Removal, 2–32
F
False, Definition, P–8
Fan Assembly
Illustration, 4–20
Removal, 4–21
Fan Capacitor, Illustration, 4–20
Four-Point Mounting, 2–4
G
Gate Driver Board
Illustration, 2–22
Installation, 2–24
Removal, 2–22
Test, 3–3
Gate Driver/Precharge Board Mounting
Plate
Illustration, 2–19
Installation, 2–21
Removal, 2–19
Publication 1336 FORCE-6.13 – August, 1999
I–2
Index
Ground Sense CT
Illustration, 4–27
Installation, 4–28
Removal, 4–27
Manual
Audience, P–1
Conventions, P–7
Objective, P–1
Related Publications, P–9
HIM, Removal, 1–12
Mounting
Four-Point, 2–4
Two-Point, 2–3
Human Interface Module (HIM)
Adapter Locations, 1–11
Illustration, 1–10
Operation, 1–13
MOV Surge Suppressor
Illustration, 4–34
Installation, 4–35
Removal, 4–35
H
I
Input Mode
Programming, 1–4
Selection, 1–5
Input Rectifier
Illustration, 4–17
Installation, 4–19
Removal, 4–17
Test, 3–12
Inputs, Available, 1–4
N
Nameplate Location, P–3
O
Objective of this Manual, P–1
Operation, Human Interface Module, 1–13
Option
Control Interface, 1–3
Identification, P–4
Installation Procedures. See Procedures
P
J
Jumper, Definition, P–8
L
LEMs
Illustration, 4–31
Installation, 4–33
Removal, 4–31
Load Sharing Resistor Connections, 4–7
Local Programming, 1–5
M
Main Control Board
Illustration, 2–11
Installation, 2–12
Removal, 2–11
Main Control Board Mounting Plate
Installation, 2–18
Removal, 2–17
Major Component Replacement. See
Procedures
Publication 1336 FORCE-6.13 – August, 1999
Parameter, Definition, P–9
PLC COMM Adapter Board, Illustration,
2–15
Power Module
Illustration, 4–14
Installation, 4–16
Removal, 4–15
Test, 3–7
Power Module Snubber Board
Illustration, 2–29
Installation, 2–31
Removal, 2–29
Precautions
Electrostatic Discharge, P–3
Safety, P–1
Precharge Board
Illustration, 2–27
Installation, 2–26, 2–28
Removal, 2–25, 2–27
Test, 3–5
Precharge Board Mounting Plate,
Illustration, 2–25
Press, Definition, P–9
Index
Procedures
Accessing Internal Drive Components,
2–1
Autotransformer Removal, 4–21
Bus Capacitor Bank Installation, 4–7
Bus Capacitor Bank Removal, 4–5
Bus Capacitor Bank Test, 3–9
Bus Fuse, 4–29, 4–30
Component Test, 3–1
Control Board Installation, 2–12
Control Board Mounting Plate
Installation, 2–18
Control Board Removal, 2–11
Control Board/Adapter Mounting Plate
Removal, 2–17
Control Interface Board Installation,
2–10
Control Interface Board Removal, 2–9
DC Bus Inductor L1 Installation, 4–26
DC Bus Inductor L1 Removal, 4–25
Drive Enclosure Installation, 2–8
Drive Enclosure Removal, 2–7
Fan Capacitor Removal, 4–21
Fan Removal, 4–21
Gate Driver Board Installation, 2–24
Gate Driver Board Removal, 2–22
Gate Driver Board Test, 3–3
Ground Sense CT, 4–27, 4–28
Input Rectifier Installation, 4–19
Input Rectifier Removal, 4–17
Input Rectifier Test, 3–12
LEMs Installation, 4–33
LEMs Removal, 4–31
Major Component Replacement, 4–3
MOV Surge Suppressor Installation,
4–35
MOV Surge Suppressor Removal, 4–35
PLC Comm Adapter Board Removal,
2–15
Power Module Installation, 4–16
Power Module Removal, 4–15
Power Module Snubber Board
Installation, 2–31
Power Module Snubber Board Removal,
2–29
Power Module Test, 3–7
Precharge Board Installation, 2–26,
2–28
Precharge Board Mounting Plate
Removal, 2–25
Precharge Board Removal, 2–27
Precharge Board Test, 3–5
Replacement Part, 4–1
Standard Adapter Board Removal, 2–13
Thermistor Installation, 4–14
Thermistor Removal, 4–12
Programming
Input Mode, 1–4
I–3
Local, 1–5
R
Rating, Drive, P–6
Related Publications, P–9
Removal Procedures. See Procedures
Removal, HIM, 1–12
Replacement Part Procedures, 4–1
Replacement Parts, 5–1
S
Safety Precautions, P–1
Snubber Board, Converter
Illustration, 2–32
Installation, 2–33
Removal, 2–32
Snubber Board, Power Module
Illustration, 2–29
Installation, 2–31
Removal, 2–29
Speed Select, Input State, 1–8
Standard Adapter Board, Illustration, 2–13
T
TB3 Terminal Designations, 1–5
Terminal Block Locations
PLC Comm Adapter Board, 1–2
Standard Adapter Board, 1–2
Terminal Designations, TB3, 1–5
Thermistor
Illustration, 4–12
Installation, 4–14
Removal, 4–12
Tools, Required for Service, 2–2, 3–2, 4–2
Torque
Four-Point Mounting Sequence, 2–4
Maximum for TB Terminals, 1–5
Specifications, 2–4
Two-Point Mounting Sequence, 2–3
Troubleshooting, Component Test
Procedures, 3–1
True, Definition, P–9
Two-Point Mounting, 2–3
W
Wire Sizes, 1–5
Publication 1336 FORCE-6.13 – August, 1999
I–4
Index
This Page Intentionally Left Blank
Publication 1336 FORCE-6.13 – August, 1999
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