Allen-Bradley Service Bulletin 1336 FORCE Adjustable Frequency Manual AC Drive Series B, C, D B150 – B250 C150 – C250 Important User Because of the variety of uses for the products described in this Information 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-6.14 – August, 1999 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999 Table of Contents Preface Manual Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1 Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . P–2 1336 FORCE Product Identification . . . . . . . . . . . . . . . . . . . . . . . . P–3 Drive Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–3 Software Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–4 Drive and Option Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . P–4 1336 FORCE Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . . P–4 Drive Rating Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–6 Enclosure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–6 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Auxiliary Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Auxiliary Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 False . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Control Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 True . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Control Logic Wiring and Chapter 1 Adapters Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Control Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Control Interface Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Available Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Standard Adapter Local Programming . . . . . . . . . . . . . . . . . . . . . . 1–5 Adapters and Communication Ports . . . . . . . . . . . . . . . . . . . . . . . 1–11 Human Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Standard Adapter Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 PLC Comm Adapter Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 HIM Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 HIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Graphic Programming Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Publication 1336 FORCE-6.14 – August, 1999 ii Table of Contents GPT Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Control Firmware Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Disassembly and Access Chapter 2 Procedures Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Disassembly and Access Overview . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 2–1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Disassembly and Access Procedures . . . . . . . . . . . . . . . . . . . . . . 2–6 Opening the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Removing the High Voltage Guard . . . . . . . . . . . . . . . . . . . . . . 2–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Removing Control Interface L-Option Board MOD–L4, –L5, or –L6 2–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Removing the Main Control Board . . . . . . . . . . . . . . . . . . . . . . . 2–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Removing the Standard Adapter Board . . . . . . . . . . . . . . . . . . . 2–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15 Removing the PLC Comm Adapter Board . . . . . . . . . . . . . . . . . 2–16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17 Removing the Control Board/Adapter Mounting Plate . . . . . . . . . 2–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 Removing The Gate Driver Board Mounting Plate . . . . . . . . . . . . 2–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22 Removing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . . 2–23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24 Removing the Precharge Board Mounting Plate . . . . . . . . . . . . . 2–25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26 Removing the Precharge Board . . . . . . . . . . . . . . . . . . . . . . . . 2–27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 Publication 1336 FORCE-6.14 – August, 1999 Table of Contents iii Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28 Removing a Power Module Snubber Board . . . . . . . . . . . . . . . . 2–29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31 Removing an Input Rectifier Snubber Board . . . . . . . . . . . . . . . . 2–32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33 Accessing Power Plane Components . . . . . . . . . . . . . . . . . . . . 2–33 Component Test Procedures Chapter 3 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Component Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 3–2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Test 1 Testing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Test 2 Testing the Precharge Board . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 Test 3 Testing the Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 Test 4 Testing the Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 Test 5 Testing the Input Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 Part Replacement Chapter 4 Procedures Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 4–1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Major Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 Bus Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6 Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 Input Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13 Fan and Transformer Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4–14 Publication 1336 FORCE-6.14 – August, 1999 iv Table of Contents Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17 DC Bus Inductor L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 Ground Sense CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21 Bus Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–23 LEMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–25 MOV Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27 Replacement Parts List Chapter 5 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Replacement Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Schematics — 150 – 300 HP Chapter 6 1336 FORCE Drives Glossary Index Notes Publication 1336 FORCE-6.14 – August, 1999 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 B150 – B250, C150 – C250, and CX300. Who Should Use This This manual is intended for qualified service personnel responsible Manual for repairing the 1336 FORCE Adjustable Frequency AC Drive. You should: • Read this entire manual before performing maintenance or repairs to drives. • Have previous experience with, and basic understanding of, electrical terminology, procedures, required equipment, equipment protection procedures and methods, and safety precautions. This manual describes equipment and disassembly procedures. You begin with general illustrations and end with greater detail concerning replacement parts and part locations on the drives. Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement. Safety Precautions ATTENTION: Some printed circuit boards and drive ! components may contain hazardous voltage levels. Remove and lock out power before you disconnect or reconnect wires, and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts. Publication 1336 FORCE-6.14 – August, 1999 P–2 Preface ATTENTION: Potentially fatal voltages may result ! from improper usage of oscilloscope and other test equipment. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope be used in the A minus B Quasi-differential mode with the oscilloscope chassis correctly grounded to an earth ground. ATTENTION: Only personnel familiar with the ! 1336 FORCE Adjustable Frequency AC Drive and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. Electrostatic Discharge Precautions 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-6.14 – August, 1999