Allen-Bradley B 300 - B600, C 300 - C650, BX 250 Adjustable Frequency AC Drive Service Manual

Allen-Bradley
Bulletin 1336 FORCE
Adjustable Frequency
AC Drive
Series B, C, D
B300 – B600
C300 – C650
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-6.15 – August, 1999
Summary of Changes
This Page Intentionally Left Blank
Publication 1336 FORCE-6.15 – August, 1999
Table of Contents
Preface
Manual Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should UseThis Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic DischargePrecautions . . . . . . . . . . . . . . . . . . . . . . . .
1336 FORCE Product Identification . . . . . . . . . . . . . . . . . . . . . . . .
Drive Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive and OptionIdentification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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–5
P–5
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
P–9
P–9
P–10
P–10
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphic Programming Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . .
GPT Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Firmware Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–1
1–1
1–3
1–3
1–4
1–4
1–9
1–9
1–12
1–12
1–13
1–13
1–14
1–14
Publication 1336 FORCE-6.15 – August, 1999
ii
Table of Contents
Disassembly and Access
Procedures
Component Test Procedures
Chapter 2
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Overview . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Procedures . . . . . . . . . . . . . . . . . . . . . .
Opening the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . .
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closing the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the 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 . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Control Board/Adapter Mounting Plate . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . .
2–9
2–9
2–10
2–11
2–11
2–13
2–13
2–14
2–14
2–15
2–16
2–16
2–17
2–18
2–19
2–20
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 SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Publication 1336 FORCE-6.15 – August, 1999
2–1
2–1
2–2
2–2
2–3
2–3
2–4
2–6
2–6
2–7
2–8
3–1
3–1
3–2
3–2
3–3
3–7
3–9
3–12
3–15
Table of Contents
Part Replacement
Procedures
iii
Chapter 4
Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Major Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module Snubber Resistor . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan and Transformer Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Bus Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Sense CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOV Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . .
Major Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
4–1
4–1
4–2
4–3
4–3
4–5
4–6
4–7
4–8
4–9
4–10
4–11
4–12
4–13
4–14
4–15
4–16
4–16
4–17
4–19
4–20
4–21
4–22
4–23
4–24
4–25
4–26
4–26
4–27
4–28
4–28
4–29
4–30
4–30
4–31
4–32
4–32
4–34
4–1
4–1
4–1
4–2
4–3
Publication 1336 FORCE-6.15 – August, 1999
iv
Table of Contents
Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module Snubber Resistor . . . . . . . . . . . . . . . . . . . . . . . .
SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan and Transformer Assembly . . . . . . . . . . . . . . . . . . . . . . . .
DC Bus Inductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Sense CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOV Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts List
Chapter 5
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics — 300 – 600 HP
1336 FORCE Drives
Glossary
Index
Publication 1336 FORCE-6.15 – August, 1999
4–3
4–5
4–8
4–11
4–14
4–16
4–20
4–23
4–26
4–28
4–30
4–32
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 B300 – B600, C300 – C600, and BX250.
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 the Negative Capacitor
Bus and both ends of all three 350 amp fuses. An open
fuse does not show voltage across both ends of the
fuse. Failure to measure voltage at both ends of the
fuses may result in death or serious injury. Refer to
Figure 2.5. Do not attempt to service the drive until the
bus voltage has discharged to zero volts.
P–1
P–2
Preface
!
!
Electrostatic Discharge
Precautions
!
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.
ATTENTION: This assembly contains parts and
sub-assemblies that are sensitive to electrostatic
discharge. Static control precautions are required when
servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures,
reference Allen-Bradley Publication 8000-4.5.2,
Guarding Against Electrostatic Damage, or any other
applicable ESD protection handbook.
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various
drive boards. It is recommended that you perform these procedures
to guard against this type of damage when circuit boards are
removed or installed:
• Wear a wrist-type grounding strap that is grounded to the drive
chassis.
• Attach the wrist strap before removing the new circuit board from
the conductive packet.
• Remove boards from the drive and immediately insert them into
their conductive packets.
Publication 1336 FORCE-6.15 – August, 1999
Preface
P–3
1336 FORCE
Product Identification
Drive Nameplate Location
The drive nameplate is located on the face of the Main Control
Board mounting plate. The drive nameplate contains the drive’s
catalog number and other important drive information. Reference the
catalog number when ordering replacement parts.
Figure P.1
Drive Nameplate Location
Nameplate located on
bottom of PC Board
Mounting Frame
AB0541A
Publication 1336 FORCE-6.15 – 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
380 – 480V
500 – 600V
187 – 448 kW
250 – 600 HP
224 – 448 kW
300 – 600 HP
Compatible with
Version
2.01 & Up
kW and HP are constant torque (CT) ratings.
Publication 1336 FORCE-6.15 – August, 1999
Frame
Reference
G
Preface
Drive and Option
Identification
P–5
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
1336T
– B007
– AA
– CM
– GT2EN
– GM1
BULLETIN
NO.
DRIVE RATING
ENCLOSURE STYLE
(Must be specified)
COMMON MODE
CHOKE
ADAPTER
(Must be specified)
OPTIONS
380 – 480V AC Input, Constant Torque Drive
Drive Rating
Enclosures
Open
IP00
NEMA Type 1
IP20
No Enclosure
General Purpose
Code
Code
Frame
Designation
Output Amps
G
Nominal HP (KW)
353.6
250 (187)
BX250-AN
BX250A-AA
406.4
459.2
505.1
570.2
599.2
673.4
300 (224)
350 (261)
400 (298)
450 (336)
500 (373)
600 (448)
B300-AN
B350-AN
B400-AN
B450-AN
B500-AN
B600-AN
B300A-AA
B350A-AA
B400A-AA
B450A-AA
B500A-AA
B600A-AA
Publication 1336 FORCE-6.15 – August, 1999
P–6
Preface
Table P.B
1336T
– C075
– AA
– CM
– GT2EN
– L6
BULLETIN
NO.
DRIVE RATING
(Must be specified)
ENCLOSURE STYLE
(Must be specified)
COMMON MODE CHOKE
ADAPTER
(Must be specified)
OPTION
500 – 600V AC Input, Constant Torque Drive
Enclosures
Drive Rating
Frame
Designation
G
Output
Amps
Nominal HP (KW)
NEMA Type 1
IP20
No Enclosure
General Purpose
Code
Code
298.0
353.6
300 (224)
350 (261)
C300-AN
C350-AN
C300A-AA
C350A-AA
406.4
459.2
400 (298)
450 (336)
C400-AN
C450-AN
C400A-AA
C450A-AA
505.1
599.2
673.4
500 (373)
600 (448)
650 (485)
C500-AN
C600-AN
C650-AN
C500A-AA
C600A-AA
C650A-AA
Refer to the Language Module and Options tables following these Catalog Number tables.
Drive rating is based on a carrier frequency of 2kHz maximum, an altitude of 1,000 meters or less,
and a maximum ambient temperature of 40°C. Refer to Qualifications on page P-7.
Table P.C
Language Modules
Description
English/English
English/French
English/German
English/Italian
n li /Italian
English/Japanese
n li /Ja an
English/Spanish
n li / ani
Publication 1336 FORCE-6.15 – August, 1999
Open
IP00
Option Code
EN
FR
DE
IT
JP
ES
Preface
P–7
Table P.D
Options
Code
Description
Description
Code
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
Enclosure Type
The first character, A, indicates the Enclosure Code.
The second character indicates the type of enclosure shipped from
the factory:
Table P.E
Enclosure Type Code Description
Enclosure
Type Code
Description
F
NEMA Type 1 (IP 65)
Publication 1336 FORCE-6.15 – August, 1999
P–8
Preface
Conventions
To help differentiate parameter names and display text from other
text in this manual, the following conventions will be used:
• Parameter Names will appear in [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.
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.
Publication 1336 FORCE-6.15 – August, 1999
Preface
P–9
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.
Control Interface Board
A Control Interface Board plugs into connectors J7 and J9, located
on the lower portion of the Standard Adapter Board. This board is
identified as L4, L5, or L6 and provides optional control wiring
configurations for a drive.
Parameter
Parameters are programmable drive functions that define various
operating functions or status displays of a drive. Refer to Bulletin
1336 FORCE Adjustable Frequency AC Drive User Manual for
Parameter details.
Press
Press a button on the Human Interface Module to change Parameter
settings and drive functions.
Publication 1336 FORCE-6.15 – August, 1999
P–10
Preface
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
Publication 1336 FORCE-6.15 – August, 1999
The following lists other Allen-Bradley publications that apply to the
1336 FORCE Adjustable Frequency AC Drives:
• Product Data Drive Tools Software (9303-2.0)
• Bulletin 1201 Graphic Programming Terminal User Manual
(1201-5.0)
• Product Pricing Bulletin (1336 FORCE-3.0)
• 1336 FORCE Field Oriented Control User Manual (1336
FORCE-5.12)
• 1336 Force PLC Communications Adapter User Manual
(1336 FORCE-5.13)
• Renewal Parts List (1336-6.5)
• Options Manuals/Instructions
Chapter
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 the Negative Capacitor Bus and both
ends of all three 350 amp fuses. An open fuse does not
show voltage across both ends of the fuse. Failure to
measure voltage at both ends of the fuses may result in
death or serious injury. Refer to Figure 2.5. 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-6.15 – August, 1999
1–2
Control Logic Wiring and Adapters
Figure 1.1
Terminal Block Locations
TB10 Encoder
Main Control
Board
TB11
ESC
Standard
Adapter
Board
Control Interface
L-Option Board
SEL
JOG
TB3 Control
L–Option Board
TB5, TB6, TB7
Control and
Signal Wiring
Main Control
Board
TB11
TB10 Encoder
PLC Comm
Board
Communication
Channels
TB20, TB21
Control and
Signal Wiring
!
Publication 1336 FORCE-6.15 – August, 1999
AB0770A
ATTENTION: The National Electric Code (NEC)
and local codes outline provisions for safely installing
electrical equipment. Installation must comply with
specifications regarding wire types, conductor sizes,
branch circuit protection and disconnect devices.
Failure to do so may result in personal injury and/or
equipment damage.
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 of
each input must be selected through programming as explained later
in this section.
Control Interface L-Option Board Jumpers
Important: If the Control Interface 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”.
Figure 1.2
Jumper Locations
Jumper J10 (Located on
Standard Adapter Board)
AB0766A
Publication 1336 FORCE-6.15 – August, 1999
1–4
Control Logic Wiring and Adapters
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.
Important: The [Input Mode] parameter can be changed at any
time; however, programming changes will not take
effect until power has been cycled to the drive. When
changing an input mode, it is important to note that the
corresponding inputs to TB3 may also change.
The programming options of the Control Interface Option allow you
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
Publication 1336 FORCE-6.15 – August, 1999
For local programming and control information, refer to the 1336
FORCE User Manual.
Control Logic Wiring and Adapters
1–5
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 Pushbuttons
(Forward and Reverse)
Start/Stop – works in parallel with HIM and Communication Options.
Direction – works in parallel with HIM or Communication Options.
Momentary
Pushbutton
(3 Wire)
Maintained switches for combined run and direction
control (2 wire, Run Forward, Run Reverse)
Start/Stop – not compatible with HIM or Communication Options.
Direction – not compatible with HIM or Communication Options.
7 – 11
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 1
Input 2 (Stop)
Common
Input 3
Input 4
Input 5
Common
Input 6
Input 7
Input 8
Common
Enable
Figure 1.3
TB3 Terminal Designations
AB0550A
Publication 1336 FORCE-6.15 – August, 1999
1–6
Control Logic Wiring and Adapters
Figure 1.4
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
5
6
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
1 See Table 1.B.
29
Common
30
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.
Enable3
AB0290B
Publication 1336 FORCE-6.15 – August, 1999
Control Logic Wiring and Adapters
1–7
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-6.15 – August, 1999
1–8
Control Logic Wiring and Adapters
Table 1.B
Speed Select Input State vs. Velocity Reference Source
Para 52
TB3
Speed Select 3 Speed Select 2 Speed Select 1
Bit 14
Bit 13
B12
Terminal 26
Terminal 27
Terminal 28
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
The DIP switches and jumpers on the PLC Communications Board
have been preset at the factory. Communication is received through
Channels A and B. This communication protocol is defined through
SW U2 – U5. If switches or jumpers require reconfiguration, refer to
the 1336 FORCE PLC Communications Adapter User Manual.
Figure 1.5
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-6.15 – 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
TB20
TB21
Terminal Number(s)
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Signal
Drive Enable (NO)
Motor Thermoguard (NC)
Normal Stop (NC)
External Fault (NC)
Input Common
Fault Output (NC)
Fault Output (COM)
Fault Output (NO)
OUT 1
COM 1
COM 2
OUT 2
OUT 3
COM 3
OUT 4
COM 4
IN 1+
IN 1–
IN 2+
IN 2–
IN 3+
IN 3–
IN 4+
IN 4–
+10V
COM
–10V
Adapters and
Communication Ports
Human Interface Module
When the drive-mounted HIM is supplied, it will be connected as
Port 1 (refer to Figure 1.7). 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.
Publication 1336 FORCE-6.15 – August, 1999
1–10
Control Logic Wiring and Adapters
Figure 1.6
Human Interface Module, Standard Adapter Only
Display Panel
Control Panel
Human Interface Module
(HIM)
AB0542A
Figure 1.7
Standard Adapter Board Port Locations
2
2
3
3
4
5
Communications Port for Remote HIM/
Communication Options (Adapter 2)
or
Expansion Options (Adapters 2, 3, 4, 5)
TB10 Encoder
ESC
SEL
JOG
Control Interface Board
(TB3 Adapter Port 0)
Internal
Communication
(Adapter Port 6)
TB5
Publication 1336 FORCE-6.15 – August, 1999
Drive Mounted HIM
(Adapter Port 1)
TB6
TB7
AB0701B
Control Logic Wiring and Adapters
1–11
Figure 1.8
PLC Comm Adapter Board Port Locations
Main
Control
Board
PLC Comm
Board
TB20
Communications
Channels Ports 6, 7
SCAN port 1
SCAN port 2
TB21
AB0702B
Publication 1336 FORCE-6.15 – August, 1999
1–12
Control Logic Wiring and Adapters
HIM Removal
!
ATTENTION: Some voltages present behind the
drive front cover are at incoming line potential. To
avoid an electric shock hazard, use extreme caution
when removing/replacing the HIM.
For handheld operation, the module can be removed and located up
to 10 meters (33 feet) from the drive.
Important: Power must be removed 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.
Important: To remove the module:
1. Ensure that power has been removed or [Logic Mask] has been
set to “0”.
2. Take the drive front cover off and simply slide the module down
and out of its cradle. Remove cable from module.
3. Connect the appropriate cable between the HIM and the
Communications Port (Adapter 2, 3, 4, or 5).
4. Reverse the above steps to replace the module. Apply power or reset
Bit 1 of the [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 (refer to
Figure 1.9) 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 1.9
Status Display
Stopped
+0.00 Hz
Publication 1336 FORCE-6.15 – August, 1999
Control Logic Wiring and Adapters
1–13
Graphic Programming
Terminal
GPT Description
The optional GPT (Figure 1.10) 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 1.10
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-6.15 – August, 1999
1–14
Control Logic Wiring and Adapters
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-6.15 – 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 the Negative Capacitor
Bus and both ends of all three 350 amp fuses. An open
fuse does not show voltage across both ends of the
fuse. Failure to measure voltage at both ends of the
fuses may result in death or serious injury. Refer to
Figure 2.5. Do not attempt to service the drive until the
bus voltage has discharged to zero volts.
ATTENTION: Servicing energized industrial control
equipment can be hazardous. Electrical shock, burns,
or unintentional actuation of controlled industrial
equipment may cause death or serious injury. Follow
the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or
near energized equipment. Do not work alone on
energized equipment.
Publication 1336 FORCE-6.15 – 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 (small, medium, and large)
• Standard screwdrivers (small, medium, and large)
• Metric socket set up to 19 mm
• Torque wrench to 34 N-m or 280 in.-lbs
• Torque screwdriver to 10 N-m or 80 in.-lbs
• Nylon tie wraps
Publication 1336 FORCE-6.15 – 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.
The following illustrates temporary and final tightening sequences
for components fastened to a heat sink using two, four, and six
screws. Temporary torque is 1/3 (33%) of final torque, except
six-point mountings, which require 0.5 N-m (4 in.-lb). 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-6.15 – August, 1999
2–4
Disassembly and Access Procedures
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
Figure 2.3
Six-Point Mounting
3
1
5
6
2
4
AB0624B
"
Do not exceed 0.4 Newton-meters (3 in.-lb) on initial torque or 3.8
Newton-meters (32 in.-lb) final torque of all six screws.
Torque Specifications
The following table lists fastener locations by component, how the
fasteners are used, and torque specifications. Refer to Torque
Sequence in this chapter for fastening two-point, four-point and
six-point components to the heat sink.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–5
Table 2.A
Fastener Torque Specifications
Torque
in.-lb
Fastener Application
Component
Fan Motor
Motor to Fan Cover Assembly
Fan Transformer
Fan Capacitor
Torque N-m
14
2
Transformer to chassis
75
9
Capacitor to chassis
Hand-tighten
MOV Surge Suppressor
MOV to chassis
18
2
Snubber Resistor
Resistor to heat sink
26
3
Snubber Bracket
Bracket to Power Module Laminated Bus
90
11
Snubber Board
Board to Brackets
18
2
Snubber Board
Board to Input Rectifier Bracket
18
2
Volt Sharing Resistor
Resistor to heat sink
26
3
Volt Sharing Resistor
Wires to Capacitor Bus Bar Assembly
50
6
Thermistor
Thermistor to heat sink
14
2
Bus Capacitor Holder
Holder to Bus Capacitors
26
3
Capacitor Bus Bar Assembly
Assembly to Bus Capacitors
50
6
Power Module Gate Interface Board
Board to Power Modules
18
2
Power Module Bus Bar
Bus Bar to Power Modules
90
11
Power Module
Module to heat sink
Refer to Figure 2.3
Input Rectifier (SCR)
Rectifier to heat sink
Transitional Bus Bar Assembly
Assembly to Power Module Bus Bar Assembly
80
9
Bus Fuse F1 – F3
Fuse to Transitional Bus Bar Assembly
240
28
DC Bus Inductor L1
Inductor to chassis
75
9
Bus Bar Cable Adaptor
Adaptor to Transitional Bus Bar Assembly and
DC Bus Inductor, right side of Motor Flex Bus
75
9
Converter Bus and Motor Bus Bars
All connections
240
28
Wires (PE)
Wires to Ground Stud
175
21
Wire (TE)
Wire on Main Control Board Mounting Plate
26
3
Wires
Wires to TB1
16
1.8
Wires
Wires to TB2
7
0.8
Wires
Wires to TB3
8 – 10
09 – 1.1
Power Cables
Cables to terminals
240
28
Main Control, Gate Driver, Precharge Board
Mounting Plates
Plates to chassis
26
3
Heat Sink Guard
Guard to chassis
18
2
T-Bar Mounting Bolt
T-Bar to Main Frame
240
28.8
Capacitor Mounting Bolt
Capacitor Bank Assembly to Main Frame
240
28.8
Inverter Housing Assembly Lock-Down Bolt
Inverter Housing Assembly to Main Frame
240
28.8
Wheel Chock Fasteners
Wheel Chocks to tracks
75
9
Ground Cable Bolts
Ground Cables from both assemblies to Main Frame
75
9
Refer to the gauge on the clamp, which indicates pounds of force. The reading should be 400 lbs.
Publication 1336 FORCE-6.15 – August, 1999
2–6
Disassembly and Access Procedures
Disassembly and
Access Procedures
Opening the Drive Enclosure
Figure 2.4
Drive Enclosure
PC Board
Mounting Frame
AB0595B
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–7
Opening
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between the
Negative Capacitor Bus and both ends of all three 350
amp fuses. An open fuse does not show voltage across
both ends of the fuse. Failure to measure voltage at both
ends of the fuses may result in death or serious injury.
Refer to Figure 2.5. 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.
1. Remove power from the drive.
2. Turn the enclosure door latches 90 degrees counterclockwise to
open the enclosure door.
3. Turn the latches, located on the left side of the PC Board
Mounting frame, to open the PC Board Mounting Frame. Refer to
Figure 2.4.
4. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
Publication 1336 FORCE-6.15 – August, 1999
2–8
Disassembly and Access Procedures
Figure 2.5
DC Voltage Check
–DC (Negative
Capacitor Bus)
+DC
Check All Three
Bus Fuses
AB0637B
!
ATTENTION: A blown fuse can create a hazard of
shock which may result in death or serious injury.
Check voltage between the bus bar and both ends of all
three fuses.
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 customer-supplied wiring from the drive.
Closing the Drive Enclosure
Close the Drive Enclosure in reverse order of opening.
!
Publication 1336 FORCE-6.15 – 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 the Control Interface L-Option Board Mod –L4, –L5, or
–L6
Figure 2.6
Control Interface L-Option Board
Main Control Board
Control Interface
L-Option Board
Terminal Strip TB3
AB0759A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Publication 1336 FORCE-6.15 – August, 1999
2–10
Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
4. Check for the absence of control voltage at TB5, TB6, and TB7
on the Standard Adapter Board.
5. Remove all wires from Control Interface Board 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.
!
Publication 1336 FORCE-6.15 – 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 2.7
Main Control Board and Mounting Plate
Ground Stud
Control Board/Adapter
Mounting Plate
Connector J1
Standard
Adapter Board
Connector J5
Main Control
Board
Connector J7
TB10
HIM (Standard
Adapter Board only)
AB0704A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Refer to Figure 2.5. Do
not attempt to service the drive until the bus voltage
has discharged to zero volts.
Publication 1336 FORCE-6.15 – August, 1999
2–12
Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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:
• J1 connector
• J5 ribbon cable connector
• Stake-on ground wire connector
• All wires from the terminals on TB10
6. Remove the screws fastening the Main Control Board to the
Control Board/Adapter Mounting Plate.
7. Slide the Main Control Board upward to release it from the
slide-mount stand-offs and connector J7.
8. Store the Main Control Board in an anti-static bag.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–13
Installation
Install the Main Control Board in reverse order of removal.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
!
Removing the Standard Adapter Board
Figure 2.8
Standard Adapter Board
Control Board/Adapter
Mounting Plate
Main Control
Board
Slide-Mount
Stand-Off
Connector J7
Connector J1
Standard
Adapter Board
Mounting
Screw
TB5
TB6 TB7
Terminal
Strip TE
AB0705A
Publication 1336 FORCE-6.15 – August, 1999
2–14
Disassembly and Access Procedures
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
+DC and –DC on Terminal Block TB1. Do not attempt to
service the drive until the bus voltage has discharged to
zero volts.
1. Remove power from the Drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts at between +DC and –DC. Refer to Figure 2.5.
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
• All wires from TB6
• All wires from 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 up 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-6.15 – 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 2.9
PLC Comm Adapter Board
Control Board/Adapter
Mounting Plate
Main Control
Board
Slide-Mount
Stand-Off
Connector
J1
PLC Comm
Adapter Board
Mounting
Screw
TB20
TB21
Connector J5
Terminal
Strip TE
Connector J7
AB0706B
Publication 1336 FORCE-6.15 – August, 1999
2–16
Disassembly and Access Procedures
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between the
Negative Capacitor Bus and both ends of all three 350
amp fuses. An open fuse does not show voltage across
both ends of the fuse. Failure to measure voltage at both
ends of the fuses may result in death or serious injury.
Refer to Figure 2.5. Do not attempt to service the drive
until the bus voltage has dischared to zero volts.
1. Remove Power from the drive.
2. Turn the enclosure door latches 1/4 turn counterclockwise to open
the enclosure door.
3. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
4. Check for zero volts at between +DC and –DC. Refer to Figure 2.5.
5. Check for the absence of control voltage at TB20 and TB21 on
the PLC Comm Adapter Board.
6. Disconnect the following from the PLC Comm Adapter Board:
• Stake-on ground wire connector
• All wires from TB20 and TB21
• J5 connector
• J7 connector
• Communication channel A and B connectors
7. Remove the screws fastening the PLC Comm Adapter Board to
the mounting plate.
8. 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-6.15 – 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 2.10
Control Board Adapter Mounting Plate
Mounting
Plate
Connector
J2
Main Control
Board
8-Pin HIM
Connector
Terminal
Strip TB2
Terminal Strip
TB3
Terminal
Strip TE
Connector
J1
Connector
J6
AB0760A
Connector
J8
Publication 1336 FORCE-6.15 – August, 1999
2–18
Disassembly and Access Procedures
Removal
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service
the drive until the bus voltage has discharged to zero
volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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 Standard or PLC Comm Adapter Board.
"
The Drive may have either a Standard Adapter Board or a PLC
Comm Adapter Board. Refer to Removing the Standard Adapter
Board or to Removing the PLC Comm Adapter Board in this chapter.
6. Remove the wires and connectors from the Main Control Board.
Refer to Removing the Main Control Board in this chapter.
7. Remove the two screws fastening the bottom of the Control
Board Adapter Mounting Plate to the PC Board Mounting Frame.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–19
8. Remove the nuts fastening the top of the Main Control Board
Mounting Plate to the PC Board Mounting Frame.
9. Lift the Main Control Board Mounting Plate out of the drive.
Installation
Install the Main Control Board Mounting Plate in reverse order of
removal. Refer to Table 2.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
2–20
Disassembly and Access Procedures
Removing the Gate Driver Board
Figure 2.11
Gate Driver Board
Gate Driver Connector J13
Board
Connector J2
Connector J6
Connector J10
Connector J9
Connector J7
Connector J8
AB0599A
Disassembly and Access
Procedures
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–21
Removal
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between the
Negative Capacitor Bus and both ends of all three 350
amp fuses. An open fuse does not show voltage across
both ends of the fuse. Failure to measure voltage at both
ends of the fuses may result in death or serious injury.
Refer to Figure 2.5. Do not attempt to service the drive
until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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:
• J2 connector
• J6 connector
• J7 connector
• J8 connector
• J9 connector
• J10 connector
• J13 connector
Publication 1336 FORCE-6.15 – August, 1999
2–22
Disassembly and Access Procedures
7. Turn the eight stand-offs, fastening the Gate Driver Board to the
PC Board Mounting Frame, 1/4 turn counterclockwise.
8. Pull the Gate Driver Board away from the stand-offs.
9. Store the Gate Driver Board in an anti-static bag.
Installation
Install the Gate Driver Board in reverse order of removal. Refer to
Table 2.A – Fastener Torque Specifications.
!
!
Publication 1336 FORCE-6.15 – August, 1999
ATTENTION: When installing the 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
2–23
Removing the Precharge Board
Figure 2.12
Precharge Board
Connector J4
Precharge
Connector J3
Board
Connector J2
Connector J1
High Voltage
Guard
AB0601A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Publication 1336 FORCE-6.15 – August, 1999
2–24
Disassembly and Access Procedures
!
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions in Chapter 2 – Disassembly and Access
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. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Turn the four stand-offs 1/4 turn counterclockwise to remove the
Precharge Board High Voltage Guard.
6. Disconnect the following from the Precharge Board:
• J1 connector
• J2 connector
• J3 connector
• J4 connector
7. Turn the six stand-offs, fastening the Precharge Board to the PC
Board Mounting Frame, 1/4 turn counterclockwise to remove the
board.
8. Store the Precharge Board in an anti-static bag.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–25
Installation
Install the Precharge Board in reverse order of removal.
!
!
ATTENTION: When installing the 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.
Access to the Inverter Housing and Capacitor Bank Assemblies
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Publication 1336 FORCE-6.15 – August, 1999
2–26
Disassembly and Access Procedures
!
!
ATTENTION: These assemblies weigh about 500
pounds each. Before you pull either one from the drive,
you must have a platform in place to hold the assembly.
You cannot remove the assembly without a platform. The
top of the platform must be even with the assembly’s
track. The platform must be strong enough to support the
assembly and the personnel servicing the drive. The
marketing department at Allen-Bradley can provide plans
for a suitable platform. Refer to the back cover of this
manual for the address and telephone number.
ATTENTION: To remove either the Inverter
Housing Assembly or the Capacitor Bank Assembly
safely requires two persons. Attempting to remove
either assembly by yourself may result in death or
serious injury.
!
ATTENTION: Do not remove both the Inverter
Housing and the Capacitor Bank assemblies at the
same time.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
The three main parts of this drive are the PC Board Mounting Frame,
the Inverter Housing Assembly, and the Capacitor Bank Assembly.
Some procedures in this manual require access to these assemblies
and refer to this section.
Each assembly has wheels that roll in tracks built into the base of the
drive. Chocks bolted into the tracks prevent assembly movement. The
drive itself also has wheels, built into the main framework of the drive.
Because of the size, weight, and physical characteristics of the drive,
any service procedures requiring removal of either the Inverter Housing
Assembly or the Capacitor Bank Assembly requires two people.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–27
Access to the Inverter Housing Assembly
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. 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
in Chapter 2 – Disassembly and Access 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.
Publication 1336 FORCE-6.15 – August, 1999
2–28
Disassembly and Access Procedures
Figure 2.13
Access to the Inverter Housing Assembly
AC Input
Capacitor
Mounting Bolt
Bolt
Lock-Down
Bolt
Bolt
Snapper
Pin
T-Bar
Fan Terminal
Block
Glastic
Insulator
Wheel Chock
T-Bar
Mounting Bolt
Inverter Housing
Assembly Ground Cable
AB0761A
Removal
!
!
Publication 1336 FORCE-6.15 – August, 1999
ATTENTION: To remove either the Inverter
Housing Assembly or the Capacitor Bank Assembly
safely requires two persons. Attempting to remove
either assembly by yourself may result in death or
serious injury.
ATTENTION: Do not remove both the Inverter
Housing and the Capacitor Bank assemblies at the
same time.
Disassembly and Access Procedures
2–29
Access the drive:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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 AC input lines at the top left of the drive.
6. Disconnect the wires to the door-mounted external fans at the fan
terminal block located on the Inverter Housing Assembly.
Remove the T-Bar from the front of the drive:
1. Release the locking nut between the inverter housing and the left
side of the T-bar.
2. Remove the T-bar mounting bolt at the bottom of the upright.
3. Remove the bolts fastening each end of the crossbar.
4. Release the snapper pin at the top of the upright.
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2–30
Disassembly and Access Procedures
Figure 2.14
Disconnecting the Spine
Capacitor Flex
Bus Connections
Spine
Motor
Bus Bar
DC Bus Inductor Out
Negative Bus Bar
Vertical Glastic
Insulator
DC Bus Inductor Out
Positive Bus Bar
AB0639B
Remove the connections between assemblies:
1. Remove the four connections to the DC Bus Inductor.
• Two connections to the left of the vertical Glastic insulator at
the left of the motor leads.
• Two connections to the left of the U-phase 350 amp bus fuse
(capacitor fuse).
2. Remove the six nuts fastening the left end of the flex motor buses
to the three Power Module Bus Bars.
3. Remove the 12 nuts fastening the left side of the capacitor flex
bus connections to the spine.
4. Pull all the flexible leads to the right, out of the way.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–31
Figure 2.15
Removing the Spine
Capacitor Flex
Bus Connections
Spine
Motor
Bus Bar
DC Bus Inductor Out
Negative Bus Bar
Vertical Glastic
Insulator
DC Bus Inductor Out
Positive Bus Bar
AB0680A
5. Remove the spine.
• Push the spine carefully to the right.
• Lift it out of the drive without forcing it.
6. Remove the six Gate Driver connectors from the Power Module
Gate Interface Boards. Pinch the sides of the connector body
while pulling back.
7. Disconnect any remaining wiring between the Inverter Housing
Assembly and the Capacitor Bank Assembly.
8. Disconnect the Inverter Housing Assembly ground cable from the
ground plate at the bottom of the main assembly.
9. Remove the wheel chocks at the bottom of the Inverter Housing
Assembly.
10.Pull the assembly onto a platform. Refer to Figure 2.16 for
recommendations. Use the handle attached to the Fan 2 housing.
Publication 1336 FORCE-6.15 – August, 1999
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Disassembly and Access Procedures
!
ATTENTION: Hazard of tipping and severe injury
exists. This process requires two people. The platform
must be able to support 909 kg (2,000 lbs).
Figure 2.16
Service Platform
Fan 2 Handle
Stop Block
Height to
suit
installation
30″
25″
AB0681A
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–33
Installation
Install the Inverter Housing Assembly in reverse order of removal.
Important: When pushing the Inverter Housing Assembly into the
drive, you may need to have someone tip the unit
slightly to the left or right to center it between the
guides at the back of the Enclosure. Adjust the angle
brackets at the ends of the T-bar crossbar.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
2–34
Disassembly and Access Procedures
Removing the PC Board Mounting Frame
The PC Board Mounting Frame must be removed to pull the
Capacitor Bank Assembly from the drive.
Figure 2.17
PC Board Mounting Frame
PC
Board
Mounting
Frame
AB0640A
!
Publication 1336 FORCE-6.15 – 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
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Disassembly and Access Procedures
!
2–35
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 in Chapter 2 – Disassembly and Access
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.
Removal
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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 any wires connecting the PC Board Mounting Frame
with either main assembly.
6. Open the PC Board Mounting Frame all the way to the right.
7. Lift the frame straight up to remove it from the hinges.
Installation
Install the PC Board Mounting Frame in reverse order of removal.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
2–36
Disassembly and Access Procedures
Access to the Capacitor Bank Assembly
Figure 2.18
Capacitor Bank Assembly
Capacitor
Mounting Bolt
T-Bar
Motor Cable
Terminal Strips
Capacitor Bank
Assembly Ground Cable
Inverter Housing
Assembly Ground Cable
!
Publication 1336 FORCE-6.15 – August, 1999
AB0641B
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Disassembly and Access Procedures
!
2–37
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Removal
!
!
ATTENTION: To remove either the Inverter
Housing Assembly or the Capacitor Bank Assembly
safely requires two persons. Attempting to remove
either assembly by yourself may result in death or
serious injury.
ATTENTION: Do not remove both the Inverter
Housing and the Capacitor Bank assemblies at the
same time.
Access the drive:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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 motor cable connections from the terminal strips at
the bottom right of the drive.
6. Remove the PC Board Mounting Frame. Refer to Removing the
PC Board Mounting Frame in this chapter.
Remove the T-Bar:
Important: Refer to Figure 2.13.
1. Release the locking nut between the inverter housing and the left
side of the T-bar.
2. Remove the T-bar mounting bolt at the bottom of the upright.
3. Remove the bolts fastening each end of the crossbar.
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2–38
Disassembly and Access Procedures
4. Release the snapper pin at the top of the upright.
Remove the connections between assemblies:
Important: Refer to Figure 2.14.
1. Remove the four connections to the DC Bus Inductor.
• Two connections to the left of the vertical Glastic insulator at
the left of the motor leads.
• Two connections to the left of the U-phase 350 amp bus fuse
(capacitor fuse).
2. Remove the six nuts fastening the left end of the motor flex buses
to the three Power Module Bus Bars.
3. Remove the 12 nuts fastening the left side of the capacitor flex
bus connections to the spine.
4. Pull all the flexible leads to the right, out of the way.
5. Remove the spine.
• Push the spine carefully to the right.
• Lift it out of the drive without forcing it.
Access the Capacitor Bank Assembly:
1. Disconnect the Inverter Housing Assembly ground cable from the
ground plate at the bottom of the main frame.
2. Disconnect the Capacitor Bank Assembly ground cable.
3. Disconnect any ground wires that obstruct removal of the assembly.
4. Remove the capacitor mounting bolt at the top center of the
capacitor frame.
5. Remove the wheel chocks at the bottom of the Capacitor Bank
Assembly.
6. Pull the assembly onto a platform. Refer to Figure 2.16.
!
ATTENTION: Hazard of tipping and severe injury
exists. This process requires two people. The platform
must be able to support 909 kg (2,000 lbs).
Installation
Install the Capacitor Bank Assembly in reverse order of removal.
Important: Guide the unit into place so that it mates with the
lock-down bolt at the top of the capacitor frame. Adjust
the angle brackets at the ends of the T-bar crossbar.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
!
2–39
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Removing a Power Module Snubber Board
The Power Module Snubber Boards are located on the Inverter Heat
Sink assembly.
Figure 2.19
Power Module Snubber Board
Screw
(8)
Power
Module
Snubber
Board
AB0762A
Publication 1336 FORCE-6.15 – August, 1999
2–40
Disassembly and Access Procedures
Removal
!
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between pins 1 and 2 of
connector J1 to discharge any voltage.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–41
6. Remove the snubber resistor J1 and J2 connections from the
snubber board.
7. Remove the screws fastening the Power Module Snubber Board
to the snubber bus bars.
Installation
!
ATTENTION: Do not substitute longer or shorter
hardware when fastening the Power Module
components to the Power Modules. Use the same size
fastener to fasten the components as was originally
used. Using different fastener lengths will damage the
Power Modules.
Install the Power Module Snubber Board in reverse order of
removal. Refer to Table 2.A – Fastener Torque Specifications.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
2–42
Disassembly and Access Procedures
Removing an Input Rectifier Snubber Board
The Input Rectifier Snubber Boards are located on the Inverter
Housing Assembly, under the Guard, between the heat sinks and the
vertical bus.
Figure 2.20
Input Rectifier Snubber Board
Guard
Input Rectifier
Snubber Board
SCRs and
Heat Sinks
AB0629A
Publication 1336 FORCE-6.15 – August, 1999
Disassembly and Access Procedures
2–43
Removal
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in this chapter.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the plastic guard by removing the screws fastening the
left side of the guard to the SCR-heat sink assembly.
7. Remove the screws fastening the Input Rectifier Snubber Board
to the AC and DC snubber buses.
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Disassembly and Access Procedures
Installation
Install the Input Rectifier Snubber Board in reverse order of removal.
Refer to Table 2.A – Fastener Torque Specifications.
!
Publication 1336 FORCE-6.15 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Chapter
3
Component Test Procedures
Chapter Objectives
The following tests help you troubleshoot B300 – B600, C300 –
C600, and BX250 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 part replacement procedures in this chapter assume that the drive
you are servicing either has no enclosure or that the enclosure is
open. For more information on opening the Drive Enclosure, refer to
Chapter 2 – Disassembly and Access Procedures, Opening the Drive
Enclosure.
!
!
ATTENTION: Some printed circuit boards and drive
components may contain hazardous voltage levels.
Remove and lock out power before you disconnect or
reconnect wires, and before you remove or replace
fuses and circuit boards. Verify bus voltage by
measuring the voltage between the Negative Capacitor
Bus and both ends of all three 350 amp fuses. An open
fuse does not show voltage across both ends of the
fuse. Failure to measure voltage at both ends of the
fuses may result in death or serious injury. Refer to
Figure 2.5. Do not attempt to service the drive until the
bus voltage has discharged to zero volts.
ATTENTION: Servicing energized industrial control
equipment can be hazardous. Electrical shock, burns,
or unintentional actuation of controlled industrial
equipment may cause death or serious injury. Follow
the safety-related practices of NFPA 70E, Electrical
Safety for Employee Workplaces, when working on or
near energized equipment. Do not work alone on
energized equipment.
Publication 1336 FORCE-6.15 – August, 1999
3–2
Component Test Procedures
Electrostatic Discharge
Precautions
!
ATTENTION: This assembly contains parts and
sub-assemblies that are sensitive to electrostatic
discharge. Static control precautions are required when
servicing this assembly. Component damage may result
if you ignore electrostatic discharge control procedures.
If you are not familiar with static control procedures,
reference 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
For a list of tools required, tightening sequences, and fastener torque
specifications, refer to Chapter 2 – Disassembly and Access
Procedures, Fastener Torque Specifications.
Publication 1336 FORCE-6.15 – August, 1999
Component Test Procedures
Test 1
Testing the Gate
Driver Board
3–3
The Gate Driver Board is located behind the Main Control Board, on
the PC Board Mounting Frame. If power modules were replaced,
replace the Gate Driver Board. If a new Gate Driver Board is not
available, test the old board using the following procedure.
Figure 3.1
Gate Driver Board Test
F3
D78
D71
VR2
VR3
VR5
D72
VR6
D65
D66
F1
VR1
VR4
D10
Gate Driver
Board
AB0604B
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Publication 1336 FORCE-6.15 – August, 1999
3–4
Component Test Procedures
!
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions in Chapter 2 – Disassembly and Access
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. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Chapter 2 – Disassembly and Access Procedures, Removing the
Control Board/Adapter Mounting Plate.
6. Test Gate Driver Board 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 previous illustration for component locations.
Publication 1336 FORCE-6.15 – August, 1999
Component Test Procedures
3–5
Table 3.A
Gate Driver Board Test
Component
VR1 – VR6
Meter (+)
Lead
Meter (–)
Lead
Nominal Meter
Reading*
+
–
1.06
–
+
1.8
Note: Typical malfunction is shorted in both directions.
* Meter Used: Fluke Model 87, set to “Diode” range.
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.Check all six reverse-bias Zener diodes: D10, D66, D65, D78,
D71, and D72. The following table shows meter connections at
the components and ideal meter readings for those connections.
Refer to the previous illustration for component locations.
Table 3.B
Zener Diode Test
Component
Meter
(+) Lead
Meter
(–) Lead
Nominal Meter
Reading
D78
+
–
–
+
less than 1
open
D71
+
–
–
+
less than 1
open
D72
+
–
–
+
less than 1
open
D65
+
–
–
+
less than 1
open
D66
+
–
–
+
less than 1
open
D10
+
–
–
+
less than 1
open
11. Replace the Gate Driver Board if your readings do not match the
table, or if any diode is shorted or open in both directions. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing the
Gate Driver Board.
12.Assemble the drive in reverse order of disassembly.
Publication 1336 FORCE-6.15 – August, 1999
3–6
Component Test Procedures
!
!
Publication 1336 FORCE-6.15 – 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.
Component Test Procedures
Test 2
Testing the
Precharge Board
3–7
If Power Modules have been replaced, you must test the Power
Module Snubber Board, the Precharge Board, and the Gate Driver
Board.
Figure 3.2
Precharge Board Test
Precharge
Board
F3
F2
F1
AB0605A
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Publication 1336 FORCE-6.15 – August, 1999
3–8
Component Test Procedures
!
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge Precautions
in Chapter 2 – Disassembly and Access 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. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Set your meter to test resistance.
6. Test Precharge Board fuses F1, F2, and F3 for open conditions.
7. 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-6.15 – 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
3–9
The Power Modules are located on three heat sinks in the Inverter
Housing Assembly. If Power Modules have been replaced, you must
check the corresponding Power Module Snubber Board and Snubber
Resistor in addition to replacing the Gate Driver Board. Refer to
Chapter 2 – Disassembly and Access Procedures, Removing a Power
Module Snubber Board.
Figure 3.3
Power Module Test
Collector (C)
Gate (G)
Emitter (E)
Emitter Power
Tabs (E)
Collector Power
Tabs (C)
AB0606A
Publication 1336 FORCE-6.15 – August, 1999
3–10
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
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. 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 in Chapter 2 – Disassembly and Access
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. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the Power Module Snubber Board. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a Power Module
Snubber Board.
7. Set your meter to test diodes.
8. 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.
Publication 1336 FORCE-6.15 – August, 1999
Component Test Procedures
3–11
Table 3.C
Power Modules
Meter (+) Lead
Meter (–) Lead
Nominal Meter Reading
E
C
0.318 ± 0.1
E
G
Infinite
C
E
Infinite
C
G
Infinite
G
E
Infinite
G
C
Infinite
9. Replace a Power Module if meter readings are not as shown.
Refer to Chapter 4 – Part Replacement Procedures, Power
Modules.
10.Set your meter to measure resistance.
11. Test the Power Module Snubber Resistors. The reading should be
16 ohms each. If open, replace the snubber resistor.
"
Two 16-ohm resistors are in parallel when plugged into a snubber
board, resulting in 8 ohms total.
12.Assemble the drive in reverse order of disassembly.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
3–12
Component Test Procedures
Test 4
Testing the
Bus Capacitors
The Bus Capacitor Bank is located in the Capacitor Bank Assembly.
Figure 3.4
Bus Capacitor Bank Test
Meter (+) Lead
Meter (–) Lead
AB0679A
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. 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 in Chapter 2 – Disassembly and Access
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.
Publication 1336 FORCE-6.15 – August, 1999
Component Test Procedures
3–13
Access the drive:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 3.4.
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
Test the Capacitors:
1. Set your meter to test voltage.
2. Connect the negative lead of the meter to –DC and the positive
lead to the capacitor terminal called out in Figure 3.4.
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.
!
3. Apply power AFTER the meter is connected, otherwise your
meter will read zero volts.
Refer to Table 3.D for nominal meter readings.
Table 3.D
Capacitor Test Meter Readings
Drive Series
B
C
Input Volts
Meter
380 V
178 V
415 V
193 V
480 V
218 V
500 V
233 V
575 V
267 V
600 V
283 V
If the capacitors are normal, the meter reading should be one third the voltage across the total
capacitor bank.
4. Using this procedure, test each of the three Capacitor Bank
sections. Table 3.E shows the correct voltage for the total
Capacitor Bank.
Publication 1336 FORCE-6.15 – August, 1999
3–14
Component Test Procedures
Table 3.E
Bus Capacitor Bank Test
Drive
Rating
Input
Volts
Meter
Reading
B
380
415
480
535V DC +/–10%
580V DC +/–10%
650V DC +/–10%
C
500
575
600
700V DC +/–10%
800V DC +/–10%
850V DC +/–10%
5. If the voltage is out of tolerance, check the following:
• An open condition at an Input Rectifier.
• A voltage drop due to DC Bus Inductor resistance.
• A voltage drop between an Input Rectifier and the bus
capacitors due to loose or resistive wires or connections.
• Precharge circuit problems.
6. 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.
!
Publication 1336 FORCE-6.15 – 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 5
Testing the SCRs
3–15
The SCRs are located in the heat sinks on the Inverter Housing
Assembly.
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. 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 in Chapter 2 – Disassembly and Access
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.
Access the drive:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Test the SCRs:
1. Set your meter to test resistance.
2. Measure resistance from AC inputs L1, L2, and L3 to +DC. Refer
to Table 3.F.
3. Measure between each pair of gate and cathode terminals on the
Precharge Board. Refer to Table 3.G.
Publication 1336 FORCE-6.15 – August, 1999
3–16
Component Test Procedures
The following tables show meter connections and ideal meter
readings for those connections. Refer to the schematic in this manual
for more information.
Table 3.F
SCR Test at AC Input
Meter (–) Lead
Meter (+) Lead
Nominal Meter Reading
L1
L2
+DC
L3
Infinite
L1
L2
–DC
L3
Table 3.G
SCR Test at Precharge Board
SCR
Meter (–) Lead
Nominal Meter
Reading
R1G
R1K
10
R1K
R1G
10
S1G
S1K
10
S1G
S1G
10
T1G
T1K
10
T1K
T1G
10
R2G
R2K
10
R2K
R2G
10
S2G
S2K
10
S2K
S2G
10
T2G
T2K
10
T2K
T2G
10
Meter (+) Lead
J1 Connector
SCR1
SCR3
SCR5
J2 Connector
SCR4
SCR6
SCR2
4. Replace the SCR if any meter readings are not as shown. Refer to
Chapter 4 – Part Replacement Procedures, SCRs.
5. If an SCR requires replacement, check the Power Modules for
damage. Refer to Testing the Power Modules in this chapter.
!
Publication 1336 FORCE-6.15 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
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 between the Negative Capacitor Bus
and both ends of all three 350 amp fuses. An open fuse
does not show voltage across both ends of the fuse.
Failure to measure voltage at both ends of the fuses may
result in death or serious injury. Refer to Figure 2.5. Do
not attempt to service the drive until the bus voltage has
discharged to zero volts.
Publication 1336 FORCE-6.15 – 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.
For a list of tools required, tightening sequences, and fastener torque
specifications, refer to Chapter 2 – Disassembly and Access
Procedures, Fastener Torque Specifications.
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
Major Component
Replacement
4–3
This section explains in detail how to replace the following drive
components:
• Bus Capacitor Bank
• Thermistor
• Power Modules
• Power Module Snubber Resistor
• SCRs
• Fans and Transformer Assembly
• DC Bus Inductor
• Ground Sense CT
• Bus Fuses
• LEMs
• MOV Surge Suppressor
• Thermal Switch
For Gate Driver Board, Precharge Board, Main Control Board,
Standard Adapter Board, PLC Comm Adapter Board, Snubber
Board, and Control Interface L-Option Board installation and
removal procedures, refer to Chapter 2.
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.
Publication 1336 FORCE-6.15 – August, 1999
4–4
Part Replacement Procedures
Figure 4.1
Main Drive Components
MOV Surge
Suppressor
Thermistor
Power
Module
Power Module
Bus Bar
Input Rectifier
Snubber Board
Bus Capacitor
Bank
Bus Fuse
F1
Power Module
Gate Interface
Board
Load Sharing
Resistor
Thermal
Switch
Power Module
Snubber Board
SCR
Power Module
Snubber Resistor
Fan 2
DC Bus
Inductor
Fan
Capacitor
LEM
Fan
Transformer
Fan 1
Control Board/Adapter
Mounting Plate
Gate Driver
Board
Fuse F1
Main Control
Board
PLC Comm
Adapter Board
Ground
Sense CT
Fuse F3
Standard
Adapter Board
Control Interface
L-Option Board
Publication 1336 FORCE-6.15 – August, 1999
Precharge
Board
Precharge
Board Fuses
AB0707A
Part Replacement Procedures
4–5
Bus Capacitor Bank
The Bus Capacitor Bank is located in the Capacitor Bank Assembly.
Figure 4.2
Bus Capacitor Bank
Bus Capacitor
Holder
Bus Capacitor
Cap
Capacitor
Insulator
Bus Fuse
F1
Capacitor
Laminated Bus Bar
Balancer
Plate
Motor
Buses
Terminal
Strips
AB0608A
Motor Bus
Bottom Support
Publication 1336 FORCE-6.15 – August, 1999
4–6
Part Replacement Procedures
Removal
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
between the Negative Capacitor Bus and both ends of all
three 350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage at
both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from 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 PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Capacitor Bank Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Capacitor
Bank Assembly.
Remove the Motor Buses:
1. Remove the screws fastening each motor bus to the top of its
Terminal Strip near the bottom of the Capacitor Bank Assembly.
2. Remove the screws fastening the motor buses to the Motor Bus
Bottom Support.
3. Remove the motor buses.
Access the Capacitors:
1. Remove the screws fastening the wires from the Balancer Plate
assembly to the capacitors.
2. Remove the screws, nuts, and washers fastening the Capacitor
Laminated Bus Bar to the capacitors.
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–7
3. Remove the Capacitor Laminated Bus Bar and attached
components.
4. Remove the plastic caps at the four corners of each capacitor
insulator.
5. Remove the capacitors from the drive.
Installation
1. Install the capacitor assembly in reverse order of removal. Refer
to Chapter 2 – Disassembly and Access Procedures, Fastener
Torque Specifications.
Important: Position the notch and vent hole on the Bus Capacitors
to the top of the drive.
2. Connect the Load-Sharing Resistors to the Bus Capacitors
according to the following diagram. Refer to the schematic
diagrams in this manual for more information on component
configurations.
Figure 4.3
Load-Sharing Resistor Connections to Bus Capacitors
D1
+
D2
D3
F1
F2
F3
X
C1 C2 C3 C4
C40
R1
C5 C6 C7 C8
C41
C13 – C24
C25 – C36
R4 – R6
R7 – R9
R2
C9 C10 C11 C12
R3
–
CAP DETAIL
575V
D1
D2
+
D3
F1
F2
F3
X
C40
C1 C2 C3 C4
R1
C41
C5 C6 C7 C8
C9 – C16
C17 – C24
R3 – R4
R5 – R6
R2
–
CAP DETAIL
460V
Publication 1336 FORCE-6.15 – August, 1999
4–8
Part Replacement Procedures
!
ATTENTION: Capacitors not installed correctly will
explode or vent and may cause death or serious injury.
Observe correct polarities.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Thermistor
The Thermistor is located at the top of the heat sink in the Inverter
Housing Assembly.
Figure 4.4
Thermistor
Thermistor
Connector to Main
Control Board J1
AB0627A
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–9
Removal
!
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing Connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between TP3 and plus (+)
bus to discharge any voltage. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Publication 1336 FORCE-6.15 – August, 1999
4–10
Part Replacement Procedures
5. Disconnect Main Control Board Connector J1.
6. Remove the Thermistor.
Installation
Install the Thermistor in reverse order of removal. Refer to Chapter 2
– Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.15 – 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
4–11
Power Modules
The Power Modules are located on the heat sink toward the back of
the Inverter Housing Assembly. If one or more Power Modules is
replaced, you must check the Power Module Snubber Board, the
Precharge Board, and the Gate Driver Board.
Figure 4.5
Power Modules
Preform
Power Module
Power Module Gate
Interface Board
Insulator
Power Module
Bus Bar
Snubber
Bus Bars
AB0609B
Publication 1336 FORCE-6.15 – August, 1999
4–12
Part Replacement Procedures
Removal
!
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between TP3 and plus (+)
bus to discharge any voltage. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–13
5. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the screws fastening the positive and negative snubber
bus bars to the Power Module Bus Bar.
7. Remove the screws fastening the Power Module Bus Bar to the
Power Modules.
8. Carefully remove the bus bar. Do not damage the insulation.
9. Remove the screws fastening the Power Module Gate Interface
Boards to the Power Modules.
10.Remove the Power Module Gate Interface Boards.
11. Remove the screws fastening the Power Module to the heat sink.
Refer to Figure 2.3 in Chapter 2 – Disassembly and Access
Procedures. Follow the torque sequence, as illustrated, for both
removal and installation.
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.
!
!
ATTENTION: Do not substitute longer or shorter
hardware when fastening the Power Module
components to the Power Modules. Use the same size
fastener to fasten the components as was originally
used. Using different fastener lengths will damage the
Power Modules.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
4–14
Part Replacement Procedures
Power Module Snubber Resistor
The Power Module Snubber Resistors are located on the main heat
sink at the back of the Inverter Housing Assembly.
Figure 4.6
Power Module Snubber Resistor
Power Module
Snubber Resistor
AB0642A
Part Replacement Procedures
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–15
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
between the Negative Capacitor Bus and both ends of
all three 350 amp fuses. An open fuse does not show
voltage across both ends of the fuse. Failure to measure
voltage at both ends of the fuses may result in death or
serious injury. Refer to Figure 2.5. Do not attempt to
service the drive until the bus voltage has discharged to
zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from 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 PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the Power Module Snubber Resistor connectors from the
J1 and J2 connectors on the Power Module Snubber Board.
7. Remove the screws fastening the Power Module Snubber Resistor
to the main heat sink.
Publication 1336 FORCE-6.15 – August, 1999
4–16
Part Replacement Procedures
Installation
Install the Power Module Snubber Resistor in reverse order of
removal.
Important: Install the resistors with the markings to the right.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
!
SCRs
The SCRs are located in the heat sinks on the upper front part of the
Inverter Housing Assembly. Each of the two heat sinks contains one
long and three short sections. The cross bars link the sections,
holding the SCRs in the middle. Refer to Figure 4.8.
Figure 4.7
SCR Location
Converter Back-up Cover
and Back-up Plate
SCR
Heat Sink
Input Rectifier
Snubber Board
Offset
Flex Bus
Guard
Horizontal Input
Bus Bars
Input Rectifier
Snubber Board
Screw
Holes
SCR
Heat Sink
Offset
Flex Bus
AB0603A
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–17
Removal
!
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing Connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between TP3 and plus (+)
bus to discharge any voltage. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Access the heat sink:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Publication 1336 FORCE-6.15 – August, 1999
4–18
Part Replacement Procedures
5. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the Input Rectifier Snubber Boards. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing an Input
Rectifier Snubber Board.
7. Remove the snubber insulator and attached snubber buses.
Figure 4.8
SCR Heat Sinks
Converter
Back-up Cover
Converter Back-up Plate
Nut Bar
Cross Bar
Thermal Switch
SW1
Roll Pin
SCR
Heat Sink
Spring Bars
AB0628A
Remove the short section of the heat sink:
1. Remove the nuts from the ends of the cross bars.
2. Remove the spring bars.
3. Remove the short section of the heat sink. The long section,
attached to the Converter Back-up Plate, remains in place.
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–19
Access the SCRs:
1. Remove the wires from the SCR.
2. Remove the SCR.
Installation
1. Adjust the roll pins in each heat sink half to extend 1.5 mm
(0.060 in) toward the inside of the heat sink.
2. Apply silicone oil to the heat sink in the areas around the roll
pins.
3. Clean the surface of the SCR and place it on the roll pin.
4. Apply silicone oil to the other side of the SCR.
5. Install the SCR Heat Sink in reverse order of removal. Allow
access to the SCR gate connections.
6. Attach the wires to the SCR.
Important: Refer to the torque gauge on the spring bars on the left
side of the heat sink. Without load, the torque gauge
should read zero. If it does not, replace the spring bar
assembly. 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-6.15 – August, 1999
4–20
Part Replacement Procedures
Fan and Transformer Assembly
The two fans are located at the bottom of the Inverter Housing
Assembly. The Fan Transformer and Fan Capacitors are located in
the bottom left corner, attached to Fan 1. Both fans and the
Transformer Assembly can be replaced without pulling out the
Inverter Housing Assembly.
Figure 4.9
Fan and Transformer Assembly
Fan Cover
Fan 1
Fan 2
Fan Cover
Fan
Capacitor
Fan
Transformer
Publication 1336 FORCE-6.15 – August, 1999
AB0610A
Part Replacement Procedures
4–21
Removal
!
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing Connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between TP3 and plus (+)
bus to discharge any voltage. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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
Publication 1336 FORCE-6.15 – August, 1999
4–22
Part Replacement Procedures
Remove the Fan Transformer:
1. Remove the wiring harness to the Fan Transformer Assembly.
2. Turn the thumb latch, fastening the Transformer Assembly to Fan
1, 1/4 turn counterclockwise.
3. Tilt the Transformer Assembly forward and lift it from the
mounting bracket.
Remove Fan 1:
1. Disconnect the fan wiring harness.
2. Pull down on both spring pins fastening the fan to the Inverter
Housing Assembly.
3. Pull the fan toward you to remove it.
Remove Fan 2:
1. Disconnect the Fan wiring harness.
2. Remove the screws fastening the fan cover to the fan.
3. Turn the standoffs, fastening the fan to the Inverter Housing
Assembly, 1/4 turn counterclockwise to remove the fan.
Installation
Install the Fan and Transformer Assembly in reverse order of removal.
!
Publication 1336 FORCE-6.15 – 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
DC Bus Inductor
The DC Bus Inductor is located in the lower part of the Capacitor
Bank Assembly, behind the Terminal Strips and Motor Buses.
Figure 4.10
DC Bus Inductor
DC Bus
Inductor
Ground
Sense CT
Inductor
Flex Cable
Inductor
Mounting Plate
Inductor
Flex Bus
Inductor Power
Bus Connection
AB0611B
Publication 1336 FORCE-6.15 – August, 1999
4–24
Part Replacement Procedures
Removal
!
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Capacitor Bank Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Capacitor
Bank Assembly.
6. Remove the Inductor Flex Cable and the Ground Sense CT. Refer
to Removing the Ground Sense CT in this chapter.
7. Remove the Inductor Flex Bus.
8. Remove the two inductor power bus connections.
9. Remove the screws fastening the inductor to the Inductor
Mounting Plate.
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
4–25
Important: Note the position and orientation of the Ground Sense
CT (CT3) around the (–)Bus terminal at the top of the
DC Bus Inductor. The Ground Sense CT is removed
with the inductor. Install the Ground Sense CT in the
same position. Check that the (+)Bus cable to the fuse
passes through the Ground Sense CT during assembly.
10.Remove the DC Bus Inductor from the drive.
Installation
Install the DC Bus Inductor in reverse order of removal. Refer 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-6.15 – August, 1999
4–26
Part Replacement Procedures
Ground Sense CT
The Ground Sense CT is located between the DC Bus Inductor and
the Transitional Bus Bar Assembly.
Figure 4.11
Ground Sense CT
Connector to Gate
Driver Board J2
Ground
Sense CT
AB0612A
Removal
!
!
Publication 1336 FORCE-6.15 – 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
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Part Replacement Procedures
4–27
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Capacitor Bank Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Capacitor
Bank Assembly.
6. Remove the Ground Sense CT connector J2 from the Gate Driver
Board.
7. Remove the nut and washers fastening the end of the Inductor
Flexible Cable to the right-angled connector on the right side of
the DC Bus Inductor.
8. Remove the Inductor Flex Cable from the right side inductor
power bus connection.
9. Slide the Ground Sense CT from the Inductor Flex Cable.
Installation
Install the Ground Sense CT in reverse order of removal, inserting
the Inductor Flex Cable through the center of the Ground Sense CT.
Refer to Chapter 2 – Disassembly and Access Procedures, Fastener
Torque Specifications.
!
!
ATTENTION: A possible short-circuit hazard exists.
Position the fuse-to-inductor wire with the
shrink-wrapped end of the wire connected to the DC
Bus Inductor. Failure to position the wire as illustrated
may result in serious injury or equipment damage.
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
4–28
Part Replacement Procedures
Bus Fuses
The Bus Fuses are located on the Transitional Bus Bar assembly.
Figure 4.12
Bus Fuse
Bus Fuse
AB0613A
Removal
!
ATTENTION: Disconnect and lock out power from
the drive before disassembling the drive. Failure to
disconnect power may result in death or serious injury.
Verify bus voltage by measuring the voltage between
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Part Replacement Procedures
Publication 1336 FORCE-6.15 – August, 1999
Part Replacement Procedures
!
4–29
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Access the drive:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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 nuts and washers 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.
!
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Publication 1336 FORCE-6.15 – August, 1999
4–30
Part Replacement Procedures
LEMs
The LEMs are located in the Capacitor Bank Assembly, above the
Terminal Strips.
Figure 4.13
LEMs
LEM Mounting
Plate
LEM
LEM U-Shaped
Plate
LEM U-Shaped
Top Plate
AB0614A
Removal
!
!
Publication 1336 FORCE-6.15 – 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
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Part Replacement Procedures
4–31
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
Access the LEMs:
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Capacitor Bank Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Capacitor
Bank Assembly.
Remove the LEM:
1. Remove the wires from the LEM connectors.
2. Remove the two screws fastening the LEM mounting plate to
the LEM.
3. Remove the LEM U-shaped top plate and the LEM U-shaped plate.
4. Remove the screws and standoffs fastening the LEM to the
assembly frame.
5. Remove the Terminal Strip from the motor bus.
6. Disconnect the motor bus from the Motor Bus Support.
7. Disconnect the motor bus at its upper end.
8. Remove the motor bus and LEM from the Capacitor Bank
Assembly frame.
9. Remove the LEM from the motor bus.
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-6.15 – August, 1999
4–32
Part Replacement Procedures
MOV Surge Suppressor
The MOV Surge Suppressor is located on the left side of the Inverter
Housing Assembly in the top-left corner at the back of the drive near
the vertical bus bars.
The MOV protects the drive from high voltage surges above
approximately 1,000 volts. Replace it if it is burned, expanded, or
ruptured after a lightening strike, or inadvertent connection of the
drive input to a voltage source substantially above nameplate
voltage.
Figure 4.14
MOV Surge Suppressor
MOV Surge
Suppressor
AB0617A
Removal
!
Publication 1336 FORCE-6.15 – 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
the Negative Capacitor Bus and both ends of all three
350 amp fuses. An open fuse does not show voltage
across both ends of the fuse. Failure to measure voltage
at both ends of the fuses may result in death or serious
injury. Refer to Figure 2.5. Do not attempt to service the
drive until the bus voltage has discharged to zero volts.
Part Replacement Procedures
!
!
4–33
ATTENTION: Hazard of electric shock exists. Up to
1,600 VDC will be on Power Module Snubber Board
Connector J1 if the Snubber Resistor is open. Measure
for zero VDC from Snubber Board terminal TP3 to
plus (+) bus before removing connector J1. Use a
resistor greater than 1 ohm and less than 100 ohm,
rated for 25 watts minimum, between TP3 and plus (+)
bus to discharge any voltage. Refer to Chapter 2 –
Disassembly and Access Procedures, Removing a
Power Module Snubber Board.
ATTENTION: Wear a wrist-type grounding strap
when servicing 1336 FORCE Drives. Failure to protect
drive components against ESD may damage drive
components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.
Important: Before you remove connections and wires from the
drive components, mark the connections and wires to
correspond with their component connections and
terminals to prevent incorrect wiring during assembly.
1. Remove power from the drive.
2. Open the PC Board Mounting Frame. Refer to Opening the Drive
Enclosure in Chapter 2.
3. Check for zero volts between +DC and –DC. Refer to Figure 2.5.
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. Access the Inverter Housing Assembly. Refer to Chapter 2 –
Disassembly and Access Procedures, Access to the Inverter
Housing Assembly.
6. Remove the MOV wire harness from the vertical bus bars on the
left at the back of the Inverter Housing Assembly.
7. Remove the screw fastening the MOV to the Inverter weldment.
Publication 1336 FORCE-6.15 – August, 1999
4–34
Part Replacement Procedures
Installation
Install the MOV Surge Suppressor in reverse order of removal. Refer
to Chapter 2 – Disassembly and Access Procedures, Fastener Torque
Specifications.
!
Publication 1336 FORCE-6.15 – August, 1999
ATTENTION: Replace all guards before applying
power to the drive. Failure to replace guards may result
in death or serious injury.
Chapter
5
Replacement Parts List
Chapter Objectives
This chapter illustrates and lists replacement parts for the 1336
FORCE Drives rated B300 – B600, C300 – C600, and BX250, 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 PLUS Spare Parts
Pricing publication included with your drive documentation set.
Publication 1336 FORCE-6.15 – August, 1999
5–2
Replacement Parts List
Replacement Parts Listing
Figure 5.1
Parts for B300 – B600, C300 – C600, and BX250 Drives
1
2
3
4
6
5
7
19
8
13
12
18
17
9
14
16
11
15
20
10
24
22
23
21
AB0708A
Publication 1336 FORCE-6.15 – August, 1999
Replacement Parts List
5–3
Table 5.A
Replacement Parts for B300 – B600, C300 – C600, and BX250 Drives
Callout
Symbol
Description
Location
Replacement Procedures
1
MOV
MOV Surge Suppressor
Inverter Housing Assembly
Chapter 4, MOV Surge Suppressor
2
Q11, Q12, Q21, Q22
Q31, Q32, Q41, Q42
Q51, Q52, Q61, Q62
Transistor (Power Module)
Inverter Housing Assembly main
heat sink
Chapter 4, Power Modules
3
R20 – R25
Power Module Snubber
Resistor
Inverter Housing Assembly main
heat sink
Chapter 2, Removing a Power Module
Snubber Board
4
A23 – A28
Power Module Gate Interface
Board
Power Module
Chapter 4, Power Modules
5
NTC1
Thermistor
Inverter Housing Assembly main
heat sink
Chapter 4, Thermistor
6
A20 – A22
Power Module Snubber Board
Power Module
Chapter 2, Removing a Power Module
Snubber Board
7
R1 – R9
Load-Sharing Resistor
Capacitor Bank Assembly
Chapter 4, Bus Capacitor Bank
8
C1 – C36
Bus Capacitors
Capacitor Bank Assembly
Chapter 4, Bus Capacitor Bank
9
L1
DC Bus Inductor
Capacitor Bank Assembly
Chapter 4, DC Bus Inductor
10
CT3
Ground Sense CT
Capacitor Bank Assembly
Chapter 4, Ground Sense CT
11
CT1, CT2
LEM
Capacitor Bank Assembly
Chapter 4, LEMs
12
F1 – F3
Bus Fuse, 350 amp
Capacitor Bank Assembly
Chapter 4, Bus Fuses
13
THS1
Thermal Switch SW1
Inverter Housing Assembly,
upper SCR heat sink
Chapter 4, SCRs
14
FAN 1
Fan 1
Inverter Housing Assembly
Chapter 4, Fan and Transformer
Assembly
15
T1
Fan Transformer
Inverter Housing Assembly
Chapter 4, Fan and Transformer
Assembly
16
C38, C39
Fan Capacitor
Inverter Housing Assembly
Chapter 4, Fan and Transformer
Assembly
17
FAN 2
Fan 2
Inverter Housing Assembly
Chapter 4, Fan and Transformer
Assembly
18
SCR1 – SCR6
SCR
Inverter Housing Assembly, SCR
heat sinks
Chapter 4, SCRs
19
A11 – A13
Input Rectifier Snubber Board
Inverter Housing Assembly, SCR
heat sinks
Chapter 2, Removing the Input
Rectifier Snubber Board
20
A1
Gate Driver Board
PC Board Mounting Frame
Chapter 2, Removing the Gate Driver
Board
21
A10
Precharge Board
PC Board Mounting Frame
Chapter 2, Removing the Precharge
Board
22
MAIN CTL
Main Control Board
PC Board Mounting Frame
Chapter 2, Removing the Main Control
Board
23
GT2
Standard Adapter Board
PC Board Mounting Frame
Chapter 2, Removing the Standard
Adapter Board
24
GT1
PLC Comm Adapter Board
PC Board Mounting Frame
Chapter 2, Removing the PLC Comm
Adapter Board
Publication 1336 FORCE-6.15 – August, 1999
5–4
Replacement Parts List
This Page Intentionally Left Blank.
Publication 1336 FORCE-6.15 – August, 1999
Chapter
6
Schematics — 300 – 600 HP 1336
FORCE Drives
Publication 1336 FORCE-6.15 – August, 1999
6–2
Schematics — 300 – 600 HP 1336 FORCE Drives
TB1
DC+
DC–
PE
CONV
SNUBBER
A11
CONV
SNUBBER
CONV
SNUBBER
A12
A13
L1
PE
PE
THS1
CNV+
INV+
DC+
PM1
PM2
PM3
(1)
(2)
TO FAN CIRCUIT
CUSTOMER
FUSING
SEE DETAILS
TB1
CF1
K1
K1
K1
G1
G1
G1
SCR1
SCR3
SCR5
C40
R–L1
AC
INPUT
POWER
50/60HZ
105061
X
CF2
CAPACITOR
BANK
SEE DETAILS
S–L2
CF3
MOV1
T–L3
K2
K2
K2
G2
G2
G2
SCR4
SCR6
SCR2
C41
SEE
TABLE 1
CT3
PE
INV–
PE
DC–
CNV–
A10
+ BUS
2 1
6 5 4 3 2 1
J1
1
STANDARD
PRECHARGE
BOARD
F1
4
J4
F2
F3
SEE TABLE 3
SCHEMATIC DIAGRAM
STAND ALONE
X250 – 650 HP
Publication 1336 FORCE-6.15 – August, 1999
(3)
– BUS
6 5
J2
R1G
R1K
S1G
S1K
T1G
T1K
S2G
S2K
10 9
T2G
T2K
R2G
R2K
(4)
1
+SMPS
4
–SMPS
J3 7
8
9
10
11
12
+15V
–15V
COMMON
+5V
/CHARGE
AC LINE
AB0725A
Schematics — 300 – 600 HP 1336 FORCE Drives
6–3
TB1
U–M1
AC
OUTPUT
POWER
V–M2
W–M3
+15
U_AMPS
–15
3
2
1
+15
W_AMPS
–15
CT 1
R20
Q11
R21
R22
Q12
Q31
C1
C1
1
J1
C1
B1
3
1
J2
B1
B1
E1
E1
3
1
J2
3
E1
A20
CT 2
R23
PE
R24
Q32
Q51
C1
C1
1
J1
3
2
1
B1
B1
E1
E1
R25
Q52
1
J1
C1
3
B1
1
J2
3
3
E1
A21
A22
Q41
Q42
Q61
Q62
Q21
Q22
C1
C1
C1
C1
C1
C1
B1
B1
B1
B1
B1
B1
E1
E1
E1
E1
E1
E1
A23
1
5
1
4
1
5
4
1
4
1
5
E2
E1
G2
G1
C1
E2
E1
G2
A27
A26
5
G1
C1
E2
E1
G2
G1
C1
E2
E1
G2
A25
A24
4
G1
C1
G2
E1
G2
G1
C1
E2
E1
B2
B1
C1
NTC1
A28
4
5
1
4
5
NTC
4
J10
87 6 5 432 1
J6
WP_COL
VP_COL
UP_COL
6 7 8
UP_GATE
UP_EMIT
UN_COL
WN_GATE
WN_EMIT
VN_GATE
VN_EMIT
UN_GATE
UN_EMIT
1 2 3
A1
11 12 13
J8
GATE
DRIVER
BOARD
16 17 18
1 2
4
F1
CONTACTOR
INTERFACE
6
J5
F3
1
2
3
4
5
6
AC FAN1
AC FAN2
120VAC
120RTN
24V+ OUT
24V– OUT
SEE TABLE 3
1
TB7
TO MAIN CONTROL BOARD
1
J13
TB6
2
TE
1
4
+EXT. RES.
–EXT. RES.
EXTERNAL
BUS
DISCHARGE
RESISTOR
3
HIGH VOLTAGE
–DC AUX IN
J1
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
TB4
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
1
2
1 2 3 4 5 6
J7
TB5
6
5 J9
4
3
2
1
+24V DC AUX INPUT
–24V DC AUX INPUT
+15
U_AMPS
–15V
+15
W_AMPS
–15
INTERLOCK
+BUS
1
M1X1
M1X2
M1K2
M1K1
HIGH VOLTAGE
+DC AUX IN
+15V
–15V
COMMON
+5V
/CHARGE
AC LINE
1 2
J2
VP_GATE
VP_EMIT
VN_COL
9
WP_GATE
WP_EMIT
WN_COL
12
–SMPS
–BUS
+SMPS
ACT1
ACT2
TO
MAIN
CONTROL
BOARD
EXTERNAL DC BUS
INPUT CONNECTION
AB0726A
Publication 1336 FORCE-6.15 – August, 1999
6–4
Schematics — 300 – 600 HP 1336 FORCE Drives
Fan Circiut Detail
FAN 2
BRN
BLK
BLU
GRN/Y
1 2 3 4
GRN/Y
Z2
TK
U2
FAN 1
4 3 2 1
J1
C39
J2
GRN/Y
BRN
2
1
GRN/Y
BLK
WHITE
WHITE
J3
2
1
BRN
BLK
WHITE
WHITE
C38
BASED ON DRIVE INPUT VOLTAGE, EITHER A
380/460V OR A 575V FAN AUTOTRANSFORMER
WILL BE PROVIDED. THE TABLE BELOW DEFINES
THE AUTOTRANSFORMER TAP VOLTAGE.
J4
TB1
TAP
DEFINITION
NOMINAL
–10%
OPTIONAL
JUMPER
WHITE
BLK
JUMPER
External
Fan 1
120V
380/460V
TRANSFORMER
460
415
380
575V
TRANSFORMER
575
500
N/A
T1
External
Fan 2
575
415
460
F4
380
3A
F5
R–L1
S–L2
SEE TABLE 3
Capacitor Detail
575V
460V
SEE TABLE 2
SEE TABLE 2
D1
D2
+
D3
D1
F1
D2
+
F2
D3
F3
F1
F2
F3
X
C40
C1
C2
C3
X
C4
R1
C41
C5
C6
C7
C8
R2
R3
C2
C3
C4
R1
C13 – C24
C25 – C36
C5
C41
C6
C7
C8
C9 – C16
C17 – C24
R3 – R4
R5 – R6
R2
R4 – R6
C9 C10 C11 C12
C1
C40
R7 – R9
–
CAP DETAIL
460V
–
CAP DETAIL
575V
Publication 1336 FORCE-6.15 – August, 1999
AB0723A
Schematics — 300 – 600 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
380/460V FUSE I/TYPE
X250
450 A70C OR FWH
575VAC FUSE CURRENT/TYPE
300
450 A70C OR FWH
400 A70C OR FWH
350
500 A70C OR FWH
450 A70C OR FWH
400
600 A70C OR FWH
500 A70C OR FWH
450
800 A70C OR FWH
600 A70C OR FWH
500
800 A70C OR FWH
800 A70C OR FWH
600
900 A70C OR FWH
800 A70C OR FWH
650
900 A70C OR FWH
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
HP, 380/460VAC
FUSE INFORMATION
RATING
TYPE
P/N
500HP, 380/460VAC
300A
A70Q
25178–310–14
600HP, 575VAC
300A
A70Q
25178–310–14
HP, 575VAC
TABLE 3: THE FOLLOWING IS A LISTING OF ALL PRINTED CIRCUIT
ASSEMBLIES VERSUS FUSE & DOCUMENTATION INFORMATION.
THE FUSE RATING.
ITEM
B/M
SCHEMATIC
DIAGRAM
A1
74101–163–XX
74101–167
A10
A11–13
A20–22
A23–28
74101–181–XX
74101–367–XX
74101–146–XX
74101–177–XX
74101–179
74101–365
74101–144
74101–175
74101–121
FUSE INFORMATION
DESIGNATOR
RATING
TYPE
F1
F3
F1–F3
NONE
NONE
NONE
F4–F5
1.0A/600V
1.5A/600V
1.5A/600V
KTK–R
KTK–R
KTK–R
25172–260–08
25172–260–09
25172–260–09
P/N
3A/600V
FNQR
25184–254–20
AB0724A
Publication 1336 FORCE-6.15 – August, 1999
6–6
Schematics — 300 – 600 HP 1336 FORCE Drives
This Page Intentionally Left Blank.
Publication 1336 FORCE-6.15 – 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.
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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – 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-6.15 – August, 1999
G–12
Glossary
This Page Intentionally Left Blank.
Publication 1336 FORCE-6.15 – August, 1999
Index
A
Adapter Locations, 1–10
Control Logic Wiring and Adapters, 1–1
Conventions, P–8
Adapters and Communication Ports, Human
Interface Module, 1–9
Audience for this Manual, P–1
Auxiliary Input, Definition, P–8
Auxiliary Interlock, Definition, P–8
B
D
DC Bus Inductor
Illustration, 4–23
Installation, 4–25
Removal, 4–24
Replacement, 4–23
DC Voltage Check, Illustration, 2–8
Bit, Definition, P–8
Default, Definition, P–9
Bus Capacitor Bank
Illustration, 4–5
Installation, 4–7
Load-Sharing Resistors, 4–7
Removal, 4–6
Replacement, 4–5
Detailed Product Identification, 4–3
Bus Capacitors, Testing, 3–12
Drive Enclosure
Closing, 2–8
Illustration, 2–6
Opening, 2–7
Bus Fuse
Illustration, 4–28
Installation, 4–29
Removal, 4–28
Replacement, 4–28
Disassembly and Access Procedures, Tools
required, 2–2
Drive, Identification, P–5
Drive Components, Main, 4–4
Drive Rating Qualifications, P–7
E
C
Electrostatic Discharge, P–2
Capacitor Bank Assembly, 2–26
Access to, 2–36
Installation, 2–38
Removal, 2–37
Electrostatic Discharge Precautions, P–2
Capacitors. See Bus Capacitor Bank
ESD, P–2
Enable Input, Definition, P–9
Enclosure Type, P–7
Check, Definition, P–8
Component Test, 3–1
F
Component Test Procedures, 3–1
False, Definition, P–9
Connector, Definition, P–8
Fan and Transformer Assembly
Illustration, 4–20
Installation, 4–22
Removal, 4–21
Replacement, 4–20
Control Interface Board
Installation, 2–10
Removal, 2–9
Control Interface Board Jumpers, 1–3
Jumper Locations, 1–3
Fan Capacitors, 4–20
Control Interface Board, Definition, P–9
Fan Transformer, 4–20
Control Interface Option, 1–3
Fastener Torque Specifications, 2–3
Control Logic Wiring, 1–1
Publication 1336 FORCE-6.15 – August, 1999
I–2
Index
G
Gate Driver Board
Illustration, 2–20
Installation, 2–22
Removal, 2–20
Testing, 3–3
Glossary, G–1
Ground Sense CT
Illustration, 4–26
Installation, 4–27
Removal, 4–26
Replacement, 4–26
H
High Voltage Guard, 2–24
Illustration, 2–23
HIM, Removal, 1–12
Human Interface Module. See Human
Interface Module
Human Interface Module (HIM)
Illustration, 1–10
Operation, 1–12
I
Input Mode, 1–5
Factory Default, 1–6
Three-Wire Control, Multi-Source
Reversing, 1–7
Three-Wire Control, Single-Source
Reversing, 1–6
Two-Wire Control, Single-Source Control,
1–7
Input Rectifier Snubber Board
Illustration, 2–42
Installation, 2–44
Removal, 2–43
Inputs, Available, 1–4
Inverter Housing and Capacitor Bank
Assemblies, Access to, 2–25
Inverter Housing Assembly, 2–26
Access to, 2–27
Installation, 2–33
Removal, 2–28
J
Jumper, Definition, P–9
Publication 1336 FORCE-6.15 – August, 1999
L
Language Modules, P–6
LEMs
Illustration, 4–30
Installation, 4–31
Removal, 4–30
Replacement, 4–30
Load Sharing Resistor Connections, 4–7
Local Programming, 1–4
M
Main Control Board
Illustration, 2–11
Installation, 2–13
Removal, 2–11
Main Control Board Mounting Plate, 2–17
Illustration, 2–17
Installation, 2–19
Removal, 2–18
Major Component Replacement. See
Procedures
Manual
Audience, P–1
Objective, P–1
Mounting
Four-Point, 2–4
Six-Point, 2–4
Two-Point, 2–3
MOV Surge Suppressor
Illustration, 4–32
Installation, 4–34
Removal, 4–32
Replacement, 4–32
N
Nameplate Location, P–3
O
Option
Control Interface, 1–3
Identification, P–5
Options, P–7
Index
P
Parameter, Definition, P–9
Part Replacement, 4–1
Part Replacement Procedures, 4–1
PC Board Mounting Frame, 2–6, 2–26
Illustration, 2–34
Installation, 2–35
Removal, 2–35
Power Module Snubber Board
Illustration, 2–39
Installation, 2–41
Removal, 2–40
Power Module Snubber Resistor
Illustration, 4–14
Installation, 4–16
Removal, 4–15
Power Modules
Illustration, 3–9, 4–11
Installation, 4–13
Removal, 4–12
Testing, 3–9
Precautions
Electrostatic Discharge, P–2
Safety, P–1
Precharge Board
Illustration, 2–23
Installation, 2–25
Removal, 2–23
Testing, 3–7
Press, Definition, P–9
Procedures
Bus Capacitor Bank Installation, 4–7
Bus Capacitor Bank Removal, 4–6
Bus Capacitor Replacement, 3–12
Bus Capacitor Testing, 3–12
Bus Fuse Installation, 4–29
Bus Fuse Removal, 4–28
Bus Fuse Replacement, 4–28
Capacitor Bank Assembly Installation,
2–38
Capacitor Bank Assembly Removal,
2–37
Closing Drive Enclosure, 2–8
Control Interface Board Installation,
2–10
Control Interface Board Removal, 2–9
DC Bus Inductor Installation, 4–25
DC Bus Inductor Removal, 4–24
DC Bus Inductor Replacement, 4–23
DC Voltage Check, 2–8
Drive Enclosure, Opening and Closing,
2–6
Fan Installation, 4–22
Fan Removal, 4–21
I–3
Gate Driver Board Installation, 2–22
Gate Driver Board Removal, 2–20
Gate Driver Board Testing, 3–3
Ground Sense CT Installation, 4–27
Ground Sense CT Replacement, 4–26
Input Rectifier Snubber Board
Installation, 2–44
Input Rectifier Snubber Board Removal,
2–43
Inverter Housing Assembly, Access to,
2–27
Inverter Housing Assembly, Installation,
2–33
Inverter Housing Assembly, Removal,
2–28
LEM Installation, 4–31
LEM Removal, 4–30
LEM Replacement, 4–30
Main Control Board Installation, 2–13
Main Control Board Mounting Plate
Installation, 2–19
Main Control Board Mounting Plate
Removal, 2–18
Main Control Board Removal, 2–11
Major Component Replacement, 4–3
MOV Surge Suppressor Installation,
4–34
MOV Surge Suppressor Removal, 4–32
MOV Surge Suppressor Replacement,
4–32
Opening Drive Enclosure, 2–7
PC Board Mounting Frame Installation,
2–35
PC Board Mounting Frame Removal,
2–34
Power Module Installation, 4–13
Power Module Removal, 4–12
Power Module Replacement, 3–9
Power Module Snubber Board
Installation, 2–41
Power Module Snubber Board Removal,
2–40
Power Module Snubber Resistor
Installation, 4–16
Power Module Snubber Resistor
Removal, 4–15
Power Module Testing, 3–9
Precharge Board Installation, 2–25
Precharge Board Removal, 2–23
Precharge Board Testing, 3–7
SCR Installation, 4–19
SCR Removal, 4–17
SCR Replacement, 3–15
SCR Testing, 3–15
Spine, Disconnecting, 2–30
Spine, Installation, 2–33
Spine, Removing, 2–31
Thermistor Installation, 4–10
Publication 1336 FORCE-6.15 – August, 1999
I–4
Index
Thermistor Removal, 4–9
Product Identification, P–3
Programming
Input Mode, 1–4
Local, 1–4
Disconnecting, 2–30
Installation, 2–33
Removing, 2–31
T
TB3 Terminal Designations, 1–5
R
Terminal Block Locations, 1–2
Related Publications, P–10
Terminal Designations, TB3, 1–5
Replacement Parts
List, 5–1
Ordering, 5–1
Thermal Switch, 4–18
S
Safety Precautions, P–1
Schematics, 6–1
SCRs
Heat Sinks, 4–18
Illustration, 4–16
Installation, 4–19
Location, 4–16
Removal, 4–17
Replacement, 4–16
Roll Pins, 4–19
Spring Bars, 4–19
Testing, 3–15
Service Platform, 2–32
Thermistor
Illustration, 4–8
Installation, 4–10
Removal, 4–9
Replacement, 4–8
Torque Sequence, 2–3
Four-Point Mounting, 2–4
Six-Point Mounting, 2–4
Two-Point Mounting, 2–3
Torque Specifications, 2–4
Transformer Assembly. See Fan and
Transformer Assembly
True, Definition, P–10
W
Wire Sizes, 1–5
Software Compatibility, P–4
Speed Select, Input State, 1–8
Spine
Publication 1336 FORCE-6.15 – August, 1999
Z
Zener Diode Testing, 3–5
Notes
Publication 1336 FORCE-6.15 – August, 1999
N–2
Publication 1336 FORCE-6.15 – August, 1999
N–3
Publication 1336 FORCE-6.15 – August, 1999
N–4
Publication 1336 FORCE-6.15 – August, 1999
N–5
Publication 1336 FORCE-6.15 – August, 1999
N–6
Publication 1336 FORCE-6.15 – August, 1999
N–7
Publication 1336 FORCE-6.15 – August, 1999
N–8
Publication 1336 FORCE-6.15 – August, 1999
N–9
Publication 1336 FORCE-6.15 – August, 1999
N–10
Publication 1336 FORCE-6.15 – August, 1999
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