1336 IMPACT™ Adjustable Frequency AC Drive 519 - 597 kW (700 - 800 HP) Troubleshooting Manual Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls” (Publication SGI-1.1 available from your local Allen-Bradley Sales Office or online at http:// www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will the Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company 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. Attentions help you: • identify a hazard • avoid the hazard • recognize the consequences Important:Identifies information that is especially important for successful application and understanding of the product. Shock Hazard labels may be located on or inside the drive to alert people that dangerous voltage may be present. SCANport is a trademark of Rockwell Automation. PLC is a registered trademark of Rockwell Automation. COLOR-KEYED is a registered trademark of Thomas & Betts Corporation. IBM is a registered trademark of International Business Machines Corporation. Windows 95, 98, and NT are registered trademarks of Microsoft Corporation. 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 IMPACT Product Identification . . . . . . . . . . . . . . . . . . . . . . . P–3 Drive Nameplate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–3 Drive and Option Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . P–3 1336 IMPACT Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . . P–4 Drive Rating Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–4 Enclosure Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–5 HIM and Communication Options . . . . . . . . . . . . . . . . . . . . . . . P–5 Configured Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–5 Other Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–7 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Auxiliary Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Auxiliary Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–8 Default . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 False . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 L Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–9 True . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–10 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–10 Control Logic Wiring and Chapter 1 Adapters Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 L Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Control Board Jumpers for L Option . . . . . . . . . . . . . . . . . . . . . 1–3 Available Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Local Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Human Interface Module (HIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 Removing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 HIM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 DriveTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Control Firmware Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 ii Table of Contents Troubleshooting and Error Chapter 2 Codes Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Fault/Warning Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Viewing the Fault and Warning Queues on the HIM . . . . . . . . . . . . 2–2 Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Diagnostic Procedures by Symptom . . . . . . . . . . . . . . . . . . . . . . . 2–16 Drive Will Not Start or Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16 No HIM Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17 HIM Displays “Running” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 Motor Response Not As Desired . . . . . . . . . . . . . . . . . . . . . . . . 2–19 Start Up Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . 2–20 Miscellaneous Troubleshooting Procedures . . . . . . . . . . . . . . . . . . 2–20 Encoderless Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . 2–22 Access Procedures Chapter 3 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Access Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 3–2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Fastener Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Opening the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 Closing the Drive Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 Removing the Control Board Mounting Plate . . . . . . . . . . . . . . . 3–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 Removing the Precharge Board Mounting Frame . . . . . . . . . . . . 3–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 Removing the Motor Buses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Pulling the Capacitor Bank Assembly . . . . . . . . . . . . . . . . . . . . 3–17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22 Pulling the Inverter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 Removing Diode and SCR Heat Sinks . . . . . . . . . . . . . . . . . . . . 3–28 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30 Publication 1336 IMPACT-6.8 – November, 2002 Table of Contents iii Component Test Procedures Chapter 4 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Component Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 4–2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Test 1 – Testing the Gate Driver Board. . . . . . . . . . . . . . . . . . . . . . 4–3 Test 2 – Testing the Power Modules . . . . . . . . . . . . . . . . . . . . . . . 4–6 Transistor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 Snubber Resister Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 Snubber Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 Test 3 – Testing the Volt-Sharing Resistors and Dual Diodes . . . . . . 4–10 Volt-Sharing Resistor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 Dual Diode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 Test 4 – Testing the Diode and SCR . . . . . . . . . . . . . . . . . . . . . . . 4–13 Test 5 – Testing the Thermistor and Thermostat . . . . . . . . . . . . . . . 4–16 Part Replacement Chapter 5 Procedures Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Part Replacement Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . 5–1 Detailed Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Replacing the L Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 Replacing the Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 Replacing the Gate Driver Board . . . . . . . . . . . . . . . . . . . . . . . . 5–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 Replacing the Common Bus Precharge Board . . . . . . . . . . . . . . 5–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 Replacing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 Replacing an Input Rectifier Snubber Board . . . . . . . . . . . . . . . . 5–16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17 Replacing a Power Module Snubber Board . . . . . . . . . . . . . . . . 5–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19 Publication 1336 IMPACT-6.8 – November, 2002 iv Table of Contents Replacing a Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21 Replacing a Power Module Snubber Resistor . . . . . . . . . . . . . . . 5–23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24 Replacing a Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26 Replacing a Diode, SCR or Thermostat . . . . . . . . . . . . . . . . . . . 5–27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29 Replacing Inverter Bay Fan Assemblies . . . . . . . . . . . . . . . . . . . 5–30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32 Replacing the Ground Fault CT . . . . . . . . . . . . . . . . . . . . . . . . . 5–33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–33 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34 Replacing Bus Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–36 Replacing Current Transducers (LEMs) . . . . . . . . . . . . . . . . . . . 5–37 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–37 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–38 Replacing Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–39 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–39 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40 Replacing Volt-Sharing Resistors and Dual Diodes . . . . . . . . . . . 5–42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–42 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–43 Replacing the Converter Bay Door Fan . . . . . . . . . . . . . . . . . . . 5–44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–44 Replacing Converter Thermal Switches . . . . . . . . . . . . . . . . . . . 5–46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46 Replacing Converter Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–48 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49 Replacing Converter Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–53 Publication 1336 IMPACT-6.8 – November, 2002 Table of Contents v Replacement Parts List Chapter 6 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Ordering Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Replacement Parts Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Schematics Chapter 7 Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 Inverter Bay Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 Typical Converter Bay Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 Fuse Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 Index Publication 1336 IMPACT-6.8 – November, 2002 vi Table of Contents This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002 Preface Manual Objective The information in this manual is designed to help troubleshoot or repair an Allen-Bradley 1336 IMPACT Adjustable Frequency AC Drive with ratings B700C – B800C and C700C – C800C. Who Should Use This This manual is intended for qualified service personnel responsible Manual for troubleshooting and repairing the 1336 IMPACT Adjustable Frequency AC Drive. You should: • Read this entire manual before performing maintenance or repairs to drives. • Have previous experience with, and basic understanding of, electrical terminology, procedures, required equipment, equipment protection procedures and methods, and safety precautions. This manual describes equipment, troubleshooting and disassembly procedures. You begin with general illustrations and end with greater detail concerning replacement parts and part locations on the drives. Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement. Safety Precautions ATTENTION: Some printed circuit boards and drive ! components may contain hazardous voltage levels. Remove and lock out power before you disconnect or reconnect wires, and before you remove or replace fuses and circuit boards. Verify bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus 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 3.5. Do not attempt to service the drive until the bus voltage has discharged to zero volts. Publication 1336 IMPACT-6.8 – November, 2002 P–2 Preface ATTENTION: Potentially fatal voltages may result ! from improper usage of oscilloscope and other test equipment. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. If an oscilloscope is used to measure high voltage waveforms, use only a dual channel oscilloscope in the differential mode with X 100 probes. It is recommended that the oscilloscope be used in the A minus B Quasi-differential mode with the oscilloscope chassis correctly grounded to an earth ground. ATTENTION: Only personnel familiar with the ! 1336 IMPACT Adjustable Frequency AC Drive and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. Electrostatic Discharge ATTENTION: This assembly contains parts and Precautions ! sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Rockwell Automation Publication 8000-4.5.2, Guarding Against Electrostatic Damage, or any other applicable ESD protection handbook. Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed: • Wear a wrist-type grounding strap that is grounded to the drive chassis. • Attach the wrist strap before removing the new circuit board from the conductive packet. • Remove boards from the drive and immediately insert them into their conductive packets. Publication 1336 IMPACT-6.8 – November, 2002