Page 1 1336 IMPACT™ Adjustable Frequency AC Drive 519 - 597 kW (700 - 800 HP) Troubleshooting Manual...
Page 2 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.
Page 3: Table Of Contents
Table of Contents Preface Manual Objective ........P–1 Who Should Use This Manual .
Page 4 Table of Contents Troubleshooting and Error Chapter 2 Codes Chapter Objectives ........2–1 Fault/Warning Handling .
Page 5 Table of Contents Component Test Procedures Chapter 4 Chapter Objectives ........4–1 Component Test Overview .
Page 6 Table of Contents Replacing a Power Module ......5–20 Removal ........5–20 Installation .
Page 7 Table of Contents Replacement Parts List Chapter 6 Chapter Objectives ........6–1 Ordering Replacement Parts .
Page 8 Table of Contents This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002...
Page 9: Manual Objective
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.
Page 10: Electrostatic Discharge Precautions
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.
Page 11: 1336 Impact Product Identification
Preface P–3 1336 IMPACT Product Identification Drive Nameplate Location The system nameplate is located on the right side of the Converter Bay. The system nameplate contains the drive’s catalog number and other important drive information. Reference the catalog number when ordering replacement parts. Another nameplate, for the Inverter, is located on the face of the Precharge Board Mounting Frame.
Page 12: 1336 Impact Drive Catalog Numbers
As many valid options as required may be strung together with a dash between each option code number. Drive Rating Qualifications Several factors can affect drive rating. If more than one factor exists, consult Rockwell Automation. Table P.B Drive Rating Code Heat Dissipation...
Page 13: Enclosure Type
Preface P–5 Enclosure Type The first character, A, indicates the Enclosure Code. The second character indicates the type of enclosure shipped from the factory: Table P.C Enclosure Type Code Enclosure Type Code Description NEMA Type 1 (IP 20) HIM and Communication Options Table P.D HIM Code NEMA Type...
Page 14 P–6 Preface Table P.F Configuration Code Configuring Code Combinations Description Circuit Breaker LR or LT Input Line Reactor Drive Output Contactor Drive Output Contactor MK or MT Motor Thermal Overload Relay Circuit Breaker Drive Input Contactor MK or MT Motor Thermal Overload Relay Drive Input Fused Disconnect Switch Drive Output Contactor MK or MT...
Page 15: Other Options
Preface P–7 Figure P.2 Typical Converter Bay Converter Bay Circuit Breaker or Disconnect Switch (Typical) Line Loss Relay Diode Bridge Snubber Board DC Link Choke AB1085 Other Options Table P.G L Option Board Codes L Option Board Options Code Description Contact Closure Contact Closure &...
Page 16: Conventions
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 italicized. Display Text will appear in “quotes”. The following is a list of conventions used throughout this manual, and definitions of the conventions.
Page 17: Default
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 L Option Board. This connection provides an external input to enable or disable the Drive Output section.
Page 18: True
P–10 Preface True True refers to a logical true state. For instance, an L Option signal on TB3 is true when: L4/L7E contact input is closed, L5/L8E input terminal registers 24V, or L6/L9E input terminal registers 115V AC. Related Publications The following lists other Allen-Bradley publications that apply to the 1336 IMPACT Adjustable Frequency AC Drives: Product Pricing Bulletin (1336 IMPACT-3.0)
Page 19: Control Logic Wiring And Adapters
Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Rockwell Automation Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Publication 1336 IMPACT-6.8 – November, 2002...
Page 20 1–2 Control Logic Wiring and Adapters Figure 1.1 TB3 Terminal Block Location Control Board L Option Board TB3 Terminal Block 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.
Page 21: L Option Board
Control Logic Wiring and Adapters 1–3 L Option Board The L Option Board provides a means of interfacing various signals and commands to the 1336 IMPACT drive by using contact closures. Six different versions of the L Option are available: Contact Closure Interface Contact Closure Interface with Encoder Feedback +24V AC/DC Interface...
Page 22 1–4 Control Logic Wiring and Adapters Figure 1.2 Jumper Locations Inverter Bay w/o Cabinet Control Board Jumper Spares Control Board Jumpers on J2 L Option Board AB0979A The available combinations are shown in Figure 1.3. Programming the L Option Mode parameter to one of the L Option Mode numbers listed selects that combination of input functions.
Page 23 Control Logic Wiring and Adapters 1–5 Figure 1.3 L Option Mode Selection and Typical TB3 Connections L Option Mode (parameter 116) = 1 Factory Default Status Not Stop , Clear Fault Momentary Common Maintained Status Status Status Common Status Status Status Common Enable...
Page 24 1–6 Control Logic Wiring and Adapters Momentary Maintained L Option Mode (parameter 116) = 7 – 11, 19 – 22, 28 and 29 Multi-Source, Three-Wire Control Start Not Stop , Clear Fault Mode Common Speed/ Speed/ Reverse Speed/ Reverse Reverse Reverse Digital Reverse...
Page 25: Local Programming
Control Logic Wiring and Adapters 1–7 Local Programming For local programming and control information, refer to the 1336 IMPACT User Manual. Table 1.A L Option Mode Selection Mode(s) Start/Stop Type Direction Control Communication Compatibility to Use Stop & Enable Only None Control must be provided by HIM or Communication Option.
Page 26 1–8 Control Logic Wiring and Adapters Table 1.B defines the input state of the Speed Select inputs for a desired speed reference source. Table 1.B Speed Select/Speed Reference Speed Select 3 Speed Select 2 Speed Select 1 Frequency Source Speed Ref 1 Speed Ref 2 Speed Ref 3 Speed Ref 4...
Page 27: Human Interface Module (Him)
Control Logic Wiring and Adapters 1–9 Human Interface Module (HIM) Description When the drive-mounted HIM is supplied, it will be connected as SCANport 1 (refer to Figure 1.5). 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.
Page 28: Removing The Him
1–10 Control Logic Wiring and Adapters Figure 1.6 SCANport Locations SCANport 1 (Drive Mounted HIM) SCANport 2 SCANport 6 (Remote HIM or PMT) (Gateway) SCANport 0 (L Option) Removing the HIM For handheld operation, you can remove the module and place it up to 10 meters (33 feet) from the 1336 IMPACT drive.
Page 29 Control Logic Wiring and Adapters 1–11 Important: Removing a HIM (or other SCANport device) from a drive while power is applied causes a Serial Fault, except as follows: – Setting bit 1 of SP Enable Mask (parameter 124) to 0 disables the Serial Fault from a HIM on port 1.
Page 30: Him Operation
1–12 Control Logic Wiring and Adapters 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 1.7) will be shown.
Page 31: Troubleshooting And Error Codes
Chapter Troubleshooting and Error Codes Chapter Objectives This chapter provides information to help troubleshoot your 1336 IMPACT drive. ATTENTION: Do not troubleshoot or maintain the 1336 IMPACT drive unless you are familiar with your drive system and the associated machinery. You may be injured and/or the equipment may be damaged if you do not comply.
Page 32: Viewing The Fault And Warning Queues On The Him
2–2 Troubleshooting and Error Codes The LEDs on the Control Board indicate the status of the velocity processor (VP) and current processor (CP): If the VP or CP LED is: Then, for that processor: Solid green No fault occurred. Flashing green A drive warning occurred.
Page 33: Fault Descriptions
Troubleshooting and Error Codes 2–3 4. Use the Increment or Decrement key to scroll through the Control Status options until Fault Queue is displayed. 5. Press the Enter key. 6. Press the Enter key when View Queue is displayed. The fault queue can contain up to 32 faults. The 1336 IMPACT drive reports the faults using the following format: Fault name I n v...
Page 34 2–4 Troubleshooting and Error Codes The fault codes are defined as shown in Table 2.A. Table 2.A Fault Descriptions Fault Code and Fault LED Status Description Suggested Action Text Type The drive encountered a problem while Check Autotune Errors (parameter 176). For running the autotune tests.
Page 35 Troubleshooting and Error Codes 2–5 Fault Code and Fault LED Status Description Suggested Action Text Type Check for possible motor overheating. If the motor temperature is excessive, reduce the accel/decel times (parameters 42–45) or Motor overload tripped. The drive has reduce the load.
Page 36 2–6 Troubleshooting and Error Codes Fault Code and Fault LED Status Description Suggested Action Text Type Check the cabinet filters, drive fans, and heatsinks. Check the thermal sensor and sensor wiring (connector). 02081 An inverter overtemperature is pending. Reduce the load or duty cycle if possible. Inv Overtemp VP, Flashing green Warning...
Page 37 Troubleshooting and Error Codes 2–7 Fault Code and Fault LED Status Description Suggested Action Text Type Initialize parameters or: Perform a Recall Values operation. Perform a Save Values operation. 03014 Verify the parameters. VP, Flashing red Soft The parameter database is corrupt. EE Checksum Reset the drive.
Page 38 2–8 Troubleshooting and Error Codes Fault Code and Fault LED Status Description Suggested Action Text Type Examine the parameter limit testpoints to determine the exact cause. Refer to the Understanding Parameter Limit Faults section in the troubleshooting chapter of the user 03057 VP, Flashing red Soft...
Page 39 Troubleshooting and Error Codes 2–9 Fault Code and Fault LED Status Description Suggested Action Text Type Check the encoder wiring. Verify that the encoder signals are free of 05080 noise. VP, Flashing green Warning A loss of feedback occurred. Spd Fdbk Loss If you do not want this condition to be reported as a warning, change bit 0 in Warning Select 2 (parameter 23) to 0.
Page 40 2–10 Troubleshooting and Error Codes Fault Code and Fault LED Status Description Suggested Action Text Type If the adapter was not intentionally disconnected: Check the wiring to the SCANport adapters. The SCANport adapter at port 5 has Replace wiring, SCANport expander, 06045 VP, Flashing red Soft...
Page 41 Troubleshooting and Error Codes 2–11 Fault Code and Fault LED Status Description Suggested Action Text Type If the adapter was not intentionally disconnected: Check the wiring to the SCANport adapters. The SCANport adapter at port 3 has Replace wiring, SCANport expander, 06075 VP, Flashing green Warning...
Page 42 2–12 Troubleshooting and Error Codes Fault Code and Fault LED Status Description Suggested Action Text Type Monitor the AC line for high line voltage or transient conditions. Increase the deceleration time or install the The DC bus voltage has exceeded the dynamic brake option because motor maximum value.
Page 43 Troubleshooting and Error Codes 2–13 Fault Code and Fault LED Status Description Suggested Action Text Type Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for 12033 The precharge function could not more information.
Page 44 2–14 Troubleshooting and Error Codes Fault Code and Fault LED Status Description Suggested Action Text Type Check the incoming power and fuses. Refer to the Understanding Precharge and Ridethrough Faults section in the 12064 There was a drop of 150V and power did troubleshooting chapter of the user manual for CP, Solid green Warning...
Page 45 Troubleshooting and Error Codes 2–15 Fault Code and Fault LED Status Description Suggested Action Text Type Make sure the motor is properly connected. Refer to the Understanding Precharge and Ridethrough Faults section in the 12069 The fast flux up current is less than 50% troubleshooting chapter of the user manual for CP, Solid green Warning...
Page 46: Diagnostic Procedures By Symptom
2–16 Troubleshooting and Error Codes Diagnostic Procedures by The following charts list drive symptoms, symptom descriptions, and Symptom recommended actions. Drive Will Not Start or Jog Drive will not start or jog. Display on HIM? Refer to No HIM Display. HIM connected properly? Replace HIM, HIM HIM displays “Connecting”?
Page 47: No Him Display
Troubleshooting and Error Codes 2–17 No HIM Display No HIM Display Is HIM backlight lit? Replace the HIM. Is the drive fan running? Is HIM connected properly? Reconnect the HIM. Do +5, +/–15, and 12 Replace HIM, HIM supply voltages on the cable, or Control Board.
Page 48: Him Displays "Running
2–18 Troubleshooting and Error Codes HIM Displays “Running” HIM displays “Running”? Check L Option enable or Green enable light on? jumpers. Check Spd/Trq Mode Sel (par. 68). Incorrect Ref Incorrect Check Command Spd Sts Check bits 12–14 of Speed? Value? Command the correct (par.
Page 49: Motor Response Not As Desired
Troubleshooting and Error Codes 2–19 Motor Response Not As Desired Motor response not as desired. Run the auto-tune Did you run auto-tune? procedure. Adjust Accel Time 1 Need better response (par. 42) and Decel to change in speed? Time 1 (par. 44). Set S-Curve Percent (par.
Page 50: Start Up Troubleshooting Procedures
2–20 Troubleshooting and Error Codes Start Up Troubleshooting If you are having problems with the start up procedure, refer to this Procedures table for possible solutions before calling for help. Then: The start up procedure is not supported on a Series A Human Interface Module (HIM). To You powered up your drive and cannot access the verify that you have a Series A HIM, check the series letter located on the back side of the start up routine.
Page 51 Troubleshooting and Error Codes 2–21 Then you should: Check which speed reference the drive is following in Drive/Inv Status (parameter 21) bits 13–15. The motor does not turn or run at the correct Check if Spd/Trq Mode Sel (parameter 68) is set correctly. speed.
Page 52: Encoderless Troubleshooting Procedures
2–22 Troubleshooting and Error Codes Then you should: Check SP An In1 Scale (parameter 135) or SP An In2Scale (parameter 138) if your speed input is coming from the HIM pot. Check An In 1 Offset (parameter 97), An In 1 Scale (parameter 98), An In 2 Offset (parameter 100), An In 2 Scale (parameter 101), mA Input Offset (parameter 103), and mA Input Scale (parameter 104) if your speed input is coming from the analog inputs.
Page 53: Access Procedures
Chapter Access Procedures Chapter Objectives This chapter describes general disassembly procedures required to access internal drive components for testing or repair. 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.
Page 54: Electrostatic Discharge Precautions
Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Rockwell Automation Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards.
Page 55: Fastener Torque Specifications
Access Procedures 3–3 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.
Page 56: Torque Specifications
3–4 Access Procedures Figure 3.2 Four-Point Mounting Four-Point Mounting Temporary Tighten Final Tighten Figure 3.3 Six-Point Mounting Temporary Tighten to 0.5 N-m (4 in.-lb) Final Tighten to 3 N-m (26 in.-lb) Six-Point Mounting AB0996A Do not exceed 0.4 N-m (3 in.-lb) on initial torque or 3.8 N-m (32 in.-lb) final torque of all six screws.
Page 57 Access Procedures 3–5 Component Fastener Application Torque in.-lb Torque N-m Thermostat Thermostat to heat sink Bus Capacitor Holder Holder to Bus Capacitors Capacitor Bus Bar Assembly Assembly to Bus Capacitors Power Module Gate Interface Board Board to Power Modules Power Module Bus Bar Bus Bar to Power Modules Power Module Module to heat sink...
Page 58: Access Procedures
3–6 Access Procedures Access Procedures Opening the Drive Enclosure Follow all steps in this procedure whenever you open the drive cabinet. Figure 3.4 Drive Enclosure Inverter Bay Door Converter Bay Door 1/4 Turn Door Latches (5) Precharge Board Mounting Frame Latches AB1089 Publication 1336 IMPACT-6.8 –...
Page 59: Opening
Access Procedures 3–7 Opening ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. 1. Remove power from the drive, including all remote power sources.
Page 60 3–8 Access Procedures Figure 3.5 No Voltage Check Inverter Bay w/o Cabinet –DC (Negative Capacitor Bus) Precharge Board Mounting Frame (Shown Unlatched and Swung Open) L Option Board Check All Three TB11 Bus Fuses TB10 6. Typically, the Converter Bay door opens with quarter turn latches. Also, if present, pull the: Circuit breaker handle all the way down Rotary disconnect handle to Off...
Page 61: Closing The Drive Enclosure
Access Procedures 3–9 Figure 3.6 Typical Check for No Incoming Voltage Converter Bay Fuse F1, F1A, F2, F2A, F3, F3A Closing the Drive Enclosure ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury.
Page 62: Removing The Control Board Mounting Plate
3–10 Access Procedures Removing the Control Board Mounting Plate The Control Board Mounting Plate must be removed to access the Gate Driver Board, the Common Bus Precharge Board, and to remove the Precharge Board Mounting Frame. Figure 3.7 Control Board and Mounting Plate Inverter Bay w/o Cabinet Precharge Board Mounting Frame...
Page 63: Installation
Access Procedures 3–11 1. Referring to Opening the Drive Enclosure in this chapter, remove power and check for zero voltage in the drive. 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 64: Removing The Precharge Board Mounting Frame
3–12 Access Procedures Removing the Precharge Board Mounting Frame The Precharge Board Mounting Frame must be removed to access the Capacitor Bank, the Power Modules, and the Current Transducers. And, must be removed before pulling the Inverter Assembly or Capacitor Bank Assembly. Figure 3.8 Precharge Board Mounting Frame Inverter Bay w/o Cabinet...
Page 65: Installation
Access Procedures 3–13 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 66: Removing The Motor Buses
3–14 Access Procedures Access Procedures Removing the Motor Buses The Motor Buses must be removed to access the Bus Capacitor Bank and the Current Transducers (or “LEMs”). Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 67 Access Procedures 3–15 5. Remove the screws and standoffs fastening each Current Transducer to the channels on the bay frame. Figure 3.9 Current Transducers Inverter Motor Bus Flex Cables Top Cover Motor Buses Current Transducer (LEM) Common Mode Choke Channel (Part of Inverter Bay Harness...
Page 68: Installation
3–16 Access Procedures Important: The motor buses include a Common Mode Choke, which can only be replaced as part of the Motor Bus assembly. Installation Install the Motor Bus Bars in reverse order of removal. Refer to Table 3.A – Fastener Torque Specifications in this chapter. ATTENTION: Replace all guards before applying power to the drive.
Page 69: Pulling The Capacitor Bank Assembly
Access Procedures 3–17 Pulling the Capacitor Bank Assembly The Capacitor Bank Assembly must be pulled out to access the Capacitor Bank. The 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.
Page 70 3–18 Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Page 71 Access Procedures 3–19 2. Remove the HV Guard that spans the bottom of the Inverter Bay (held in place with hook-and-loop strips). 3. Remove the incoming motor connections from the Motor Cable Terminals at the bottom right of the Inverter Bay. Refer to Figure 3.10.
Page 72 3–20 Access Procedures 1. Disconnect the Inverter Assembly ground cable from the ground plate at the bottom of the main frame. 2. Remove the 18 nuts fastening the flexible buses to the Spine. 3. Pull all the flexible leads to the right, out of the way. 4.
Page 73 Access Procedures 3–21 3. Remove the capacitor mounting bolt at the top center of the capacitor frame. 4. Remove the wheel chocks at the bottom of the Capacitor Bank Assembly. ATTENTION: Hazard of tipping and severe injury exists. This process requires two people. The platform must be able to support 900 kg (2,000 lbs).
Page 74: Installation
3–22 Access Procedures Installation Install the Capacitor Bank Assembly in reverse order of removal. Refer to Table 3.A – Fastener Torque Specifications in this chapter. 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.
Page 75: Pulling The Inverter Assembly
Access Procedures 3–23 Pulling the Inverter Assembly The Inverter Assembly must be pulled out to access internal components such as Power Modules. The 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.
Page 76 3–24 Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. 1. Perform the following procedures found earlier in this chapter: Opening the Drive Enclosure Removing the Control Board Mounting Plate Removing the Precharge Board Mounting Frame...
Page 77 Access Procedures 3–25 Refer to Figure 3.14 and the following steps, to remove the T bar from the front of the drive: 1. Loosen the lock-down bolt between the inverter and the left arm of the T bar. 2. Remove the T bar mounting bolt at the bottom of the T bar. 3.
Page 78 3–26 Access Procedures 3. Remove the Spine. Push the Spine carefully to the right. Lift it out of the drive without forcing it. 4. Disconnect any remaining wiring between the Inverter Assembly and the Capacitor Bank Assembly. 5. Disconnect the Inverter Assembly ground cable from the ground plate at the bottom of the Capacitor Bank Assembly.
Page 79: Installation
Access Procedures 3–27 ATTENTION: Hazard of tipping and severe injury exists. This process requires two people. The platform must be able to support 900 kg (2,000 lbs). 8. Referring to Figure 3.16, pull the assembly onto a user-supplied platform. Pull using the handle attached to the Fan 2 housing. Installation Install the Inverter Assembly in reverse order of removal.
Page 80: Removing Diode And Scr Heat Sinks
3–28 Access Procedures Removing Diode and SCR Heat Sinks You may need to remove the Diode or SCR Heat Sink Assemblies if you have trouble replacing a Diode, SCR or Thermostat. Access to these components does not require the removal of the Inverter Assembly from the Inverter Bay.
Page 81 Access Procedures 3–29 Removing the Precharge Board Mounting Frame 2. Remove the Lower HV Guard spanning the bottom of the Inverter Bay (held in place with hook-and-loop strips). 3. A harness joins the Thermistor (Power Module) and Thermostat (SCR) to the Control Board. Disconnect the Thermostat leads from this harness.
Page 82: Installation
3–30 Access Procedures 8. Remove the screws that attach the Back-up Plate to the steel frame, four screws for the Diode heat sink, two screws for the SCR heat sink (Figure 3.18). 9. Remove the screws that hold the appropriate heat sink to the Back-up Plate.
Page 83: Component Test Procedures
Chapter Component Test Procedures Chapter Objectives The following tests help you troubleshoot the drive. Component Test Overview The component test procedures in this chapter assume that the drive enclosure is open. For more information on opening the drive enclosure, refer to Chapter 3, Access Procedures. ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels.
Page 84: Electrostatic Discharge Precautions
Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Rockwell Automation Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards.
Page 85: Test 1 - Testing The Gate Driver Board
Component Test Procedures 4–3 Test 1 – Testing the Gate The Gate Driver Board is located behind the Control Board, on the Driver Board Precharge 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.
Page 86 4–4 Component Test Procedures Figure 4.1 Gate Driver Board Test Inverter Assembly w/o Cabinet (Control Board Mounting Plate Removed) Gate Driver Board (Located Behind the Control Board) 6. Check all six reverse-bias Zener diodes: D10, D66, D65, D72, D71, and D78. Table 4.B shows meter connections at the components and ideal meter readings for those connections.
Page 87 Component Test Procedures 4–5 Table 4.A Diode Test Meter (+) Meter (–) Nominal Meter Component Lead Lead Reading* J7-1 J7-2 1.2 +/–5% J7-2 J7-1 0.7 +/–5% J7-3 J7-4 1.2 +/–5% J7-4 J7-3 0.7 +/–5% J7-5 J7-6 1.2 +/–5% J7-6 J7-5 0.7 +/–5% J8-1 J8-2...
Page 88: Test 2 - Testing The Power Modules
4–6 Component Test Procedures Test 2 – Testing the Power The Power Modules are located on three heat sinks in the Inverter Modules 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.
Page 89: Transistor Test
Component Test Procedures 4–7 Figure 4.2 Power Modules Main Heat Sink Preform (only on drives dated before about 2001) Power Module Power Module Gate Interface Board Insulator Power Module Snubber Board Power Module Bus Bar Snubber Bus Bar (+ and –) Inverter Assembly w/o Cabinet AB1096 Transistor Test...
Page 90: Snubber Resister Test
4–8 Component Test Procedures Table 4.C Power Module Transistor Readings Meter (+) Lead Meter (–) Lead Nominal Meter Reading 0.218–0.418 Infinite Infinite Infinite Infinite Infinite Figure 4.3 Power Module Transistor Test Power Module Collector (C) Emitter (E) Gate (G) Emitter Power Tabs (E) Collector Power...
Page 91: Snubber Board Test
Component Test Procedures 4–9 ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Snubber Board Test 1. Set your meter to test diodes. 2. Test D1 to D4. Table 4.D shows meter connections, and nominal meter readings for those connections.
Page 92: Test 3 - Testing The Volt-Sharing Resistors And Dual Diodes
4–10 Component Test Procedures Test 3 – Testing the The Volt-Sharing Resistors and Dual Diodes are mounted on the Volt-Sharing Resistors and Balancer Plate Assembly on the right wall of the Capacitor Bank Dual Diodes Assembly. The wiring of this assembly is illustrated in Figure 4.5. Figure 4.5 Volt-Sharing Resistor Connections to Bus Capacitors C1 C2 C3 C4...
Page 93: Dual Diode Test
Component Test Procedures 4–11 2. Connect a meter lead to the leads from each end of a Volt-Sharing Resistor. Refer to Figure 4.6. Expect a meter reading of 4.3k Ohms +/– 10%. 3. Repeat the above test for each Volt-Sharing Resistor. 4.
Page 94: Capacitor Test
4–12 Component Test Procedures 3. If either diode is out of tolerance, refer to Replacing Volt-Sharing Resistors and Dual Diodes in Chapter 5, Part Replacement Procedures. Table 4.E Dual Diode Test Meter (+) Meter (–) Nominal Meter Component Lead Lead Reading* Bottom Less than 1...
Page 95: Test 4 - Testing The Diode And Scr
Component Test Procedures 4–13 Test 4 – Testing the Diode The Diode and SCR Heat Sink Assemblies are mounted on the front and SCR of the Inverter Assembly. The Diode and SCR Heat Sinks must be electrically isolated from each other and from the rest of the power circuit, to properly test the individual components.
Page 96 4–14 Component Test Procedures Figure 4.7 Diode and SCR Location Diode Heat Sink Test Location (Diode) U-Shaped Bus Bar SCR Heat Sink Precharge to Spine Flex Bus J1 at the Common Test Location Bus Precharge Board (SCR) Black Lead Blue Lead Figure 4.8 Diode and SCR Circuit...
Page 97 Component Test Procedures 4–15 Table 4.F Diode Readings Meter Leads Ohms Reading Diode Scale Volts – 1 to 3 M Ohm (not shorted) Open (not shorted) 0 to 0.4 M Ohm (not shorted) 0.3 to 0.4 V (not shorted) 5. SCR check: Connect the meter leads at the points identified in Figure 4.7 and check for the values indicated in Table 4.G.
Page 98: Test 5 - Testing The Thermistor And Thermostat
4–16 Component Test Procedures Test 5 – Testing the The Thermistor and Thermostat are wired in series on a harness Thermistor and connected to the Control Board. Thermostat Figure 4.9 Thermistor Main Heat Sink Inverter Bay w/o Cabinet Thermistor SCR Heat Sink To Control Board J1 To Thermostat...
Page 99 Component Test Procedures 4–17 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.
Page 100 4–18 Component Test Procedures This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002...
Page 101: Part Replacement Overview
Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Rockwell Automation Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards.
Page 102: Detailed Product Identification
5–2 Part Replacement Procedures 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 Fastener Torque Specifications in Chapter 3, Access Procedures.
Page 103 Part Replacement Procedures 5–3 Figure 5.2 Exploded View of Inverter Bay Ground Power Module Fault CT Snubber Resistor Thermistor Power Module Power Module Gate Diode w/ Interface Board Heat Sink Power Module Snubber Board SCR w/ Heat Sink Capacitors Thermostat Fan 2 Bus Fuse Input Rectifier...
Page 104: Replacing The L Option Board
5–4 Part Replacement Procedures Replacing the L Option Board Figure 5.3 L Option Board Inverter Bay w/o Cabinet Control Board L Option Board Terminal Strip TB3 AB0979A Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 105: Installation
Part Replacement Procedures 5–5 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 106: Replacing The Control Board
5–6 Part Replacement Procedures Replacing the Control Board Figure 5.4 Control Board Inverter Bay w/o Cabinet Mounting Plate Control Board AB1091 Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 107: Installation
Part Replacement Procedures 5–7 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 108: Replacing The Gate Driver Board
5–8 Part Replacement Procedures Replacing the Gate Driver Board Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions in Chapter 3, Access Procedures. ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
Page 109: Installation
Part Replacement Procedures 5–9 Figure 5.5 Gate Driver Board Inverter Bay w/o Cabinet (Control Board Mounting Plate Removed) Gate Driver Board Installation Install the Gate Driver Board in reverse order of removal. Refer to Table 3.A – Fastener Torque Specifications. ATTENTION: When installing the wire harness connecting Gate Driver Board connector J9 to Common Bus Precharge Board connector J3, align the...
Page 110: Replacing The Common Bus Precharge Board
5–10 Part Replacement Procedures Replacing the Common Bus Precharge Board Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions in Chapter 3, Access Procedures. ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
Page 111: Installation
Part Replacement Procedures 5–11 Figure 5.6 Common Bus Precharge Board Inverter Bay w/o Cabinet (Control Board Mounting Not Shown for Clarity) Common Bus Precharge Board High Voltage Guard Precharge Board Mounting Frame Installation ATTENTION: The wrong jumper setting at W1 will either damage the Common Bus Precharge Board, or prevent proper precharge operation.
Page 112 5–12 Part Replacement Procedures 2. Install the Common Bus Precharge Board in reverse order of removal. ATTENTION: When installing the wire harness connecting Gate Driver Board connector J9 to Common Bus Precharge Board connector J3, align the wires on the harness terminals with the pins on the board connectors.
Page 113: Replacing The Power Supply
Part Replacement Procedures 5–13 Replacing the Power Supply Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions in Chapter 3, Access Procedures. Figure 5.7 Power Supply Inverter Bay w/o Cabinet...
Page 114: Installation
5–14 Part Replacement 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 115 Part Replacement Procedures 5–15 Figure 5.8 Power Supply Connections P–A.C.N. PS–V PS–COM PS+V P–GND PS–A.C.L. PS–S PS+S – – Power Supply Connections Front of Drive Adjust to 16V +/– 0.2; Measure from PS–COM to PS+V. AB1093 Publication 1336 IMPACT-6.8 – November, 2002...
Page 116: Replacing An Input Rectifier Snubber Board
5–16 Part Replacement Procedures Replacing an Input Rectifier Snubber Board The Input Rectifier Snubber Boards are located on the Inverter Assembly, under the Guard, between the heat sinks and the vertical bus. Figure 5.9 Input Rectifier Snubber Board Inverter Assembly Copper Plate SCR Heat...
Page 117: Installation
Part Replacement Procedures 5–17 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 118: Replacing A Power Module Snubber Board
5–18 Part Replacement Procedures Part Replacement Procedures Replacing a Power Module Snubber Board The Power Module Snubber Boards are located on the heat sink at the back of the Inverter Assembly. Figure 5.10 Power Module Snubber Board Inverter Assembly Snubber Resistor Power Module Snubber Board...
Page 119 Part Replacement Procedures 5–19 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 120: Replacing A Power Module
5–20 Part Replacement Procedures Replacing a Power Module The Power Modules are located on the heat sink toward the back of the Inverter Assembly. If one or more Power Modules is replaced, you must check the Power Module Snubber Board, the Common Bus Precharge Board, and the Gate Driver Board.
Page 121: Installation
Part Replacement Procedures 5–21 6. Remove the screws fastening the Power Module Gate Interface Board to the Power Modules. 7. Remove the Power Module Gate Interface Boards. 8. Follow the torque sequence, as illustrated in Chapter 3, Access Procedures, Figure 3.3, and remove the screws fastening the Power Module to the heat sink.
Page 122 5–22 Part Replacement Procedures 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.
Page 123: Replacing A Power Module Snubber Resistor
Part Replacement Procedures 5–23 Replacing a Power Module Snubber Resistor The Power Module Snubber Resistors are located on the Main Heat Sink at the back of the Inverter Assembly. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 124: Installation
5–24 Part Replacement Procedures Figure 5.12 Power Module Snubber Resistor Main Heat Sink Power Module Snubber Resistor Screw Screw Inverter Assembly w/o Cabinet AB0642A Installation Install the Power Module Snubber Resistor in reverse order of removal. Important: Install the resistors with the markings to the right (outside) for easier future reference.
Page 125: Replacing A Thermistor
Part Replacement Procedures 5–25 Replacing a Thermistor The Thermistor is located at the top of the Main Heat Sink in the Inverter Assembly. Figure 5.13 Thermistor Main Heat Sink Inverter Bay w/o Cabinet Thermistor Harness To Control Board J1 To Thermostat (SCR Heat Sink) AB1095 Removal...
Page 126: Installation
5–26 Part Replacement 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 127: Replacing A Diode, Scr Or Thermostat
Part Replacement Procedures 5–27 Replacing a Diode, SCR or Thermostat The Diode and SCR Heat Sink Assemblies are mounted on the front of the Inverter Assembly. The SCR Heat Sink Assembly also contains the Thermostat. Access to these components does not require removal of the Inverter Assembly from the Inverter Bay.
Page 128 5–28 Part Replacement Procedures 3. Remove the screws on the HV Guard. 4. Reach behind the HV Guard and remove the leads from the SCR. 5. Pass the leads removed in the above step through the hole in the HV Guard in order to free and remove the guard. 6.
Page 129: Installation
Part Replacement Procedures 5–29 7. With the Clamps removed, it is normally possible to separate the Heat Sink halves enough to remove the SCR and Thermostat, or the Diode. As an alternative, refer to Chapter 3, Access Procedures and perform Removing SCR and Diode Heat Sinks. 8.
Page 130: Replacing Inverter Bay Fan Assemblies
5–30 Part Replacement Procedures Replacing Inverter Bay Fan Assemblies Two fans are located at the bottom of the Inverter Assembly. Both fans can be replaced without pulling out the Inverter Assembly. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 131 Part Replacement Procedures 5–31 7. Pull Fan 1 toward you to remove it. (You may have to also disconnect the connectors for the capacitors in order to get enough clearance to remove the fan.) 8. Remove four bolts on the fan front cover to remove the fan cover. 9.
Page 132: Installation
5–32 Part Replacement Procedures Refer to Figure 5.17, and the following steps to remove Fan 2. Figure 5.17 Fan 2 Assembly Inverter Assembly w/o Cabinet Fan 2 Fan 2 Wiring Fan 2 Cover Harness Capacitors 1. Remove the screws fastening the Fan 2 Cover to Fan 2. 2.
Page 133: Replacing The Ground Fault Ct
Part Replacement Procedures 5–33 Replacing the Ground Fault CT The Ground Fault CT is located at the top of the Inverter Assembly. Figure 5.18 Ground Fault CT DC Input Lines Ground Fault CT Inverter Bay w/o Cabinet (Control Board Not Shown for Clarity) Gate Driver Board Removal...
Page 134: Installation
5–34 Part Replacement 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 135: Replacing Bus Fuses
Part Replacement Procedures 5–35 Part Replacement Procedures Replacing Bus Fuses The Bus Fuses are located on the Transitional Bus Bar Assembly. If just one of the three Bus Fuses fails, suspect a failure in the associated set of Bus Capacitors. Refer to Replacing Bus Capacitors in this chapter.
Page 136: Installation
5–36 Part Replacement 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 zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses.
Page 137: Replacing Current Transducers (Lems)
Part Replacement Procedures 5–37 Replacing Current Transducers (LEMs) The Current Transducers (also known by the supplier’s name, LEM) are located in the Capacitor Bank Assembly above the Motor Terminals. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives. Failure to protect drive components against ESD may damage drive components.
Page 138: Installation
5–38 Part Replacement Procedures Figure 5.20 Current Transducers Motor Buses Terminal Strips Current Transducer Remove the Current Transducer: 1. Remove the Terminal Strip (stairstep shaped bar) from each Motor Bus. 2. Tilt the Motor Buses out at the bottom. (It is not necessary to remove the flex buses from the top of the Motor Buses.) 3.
Page 139: Replacing Bus Capacitors
Part Replacement Procedures 5–39 Replacing Bus Capacitors The Bus Capacitor Bank is located on the right side of the Inverter Bay, in the Capacitor Bank Assembly. Replace any capacitors that show signs of swelling, leaks, or burn marks. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives.
Page 140: Installation
5–40 Part Replacement Procedures 4. Remove the Bus Capacitor Caps at the four corners of each capacitor insulator. 5. Remove the capacitors from the drive. Figure 5.21 Bus Capacitor Bank Bus Capacitor Capacitor Bank Holder Assembly Bus Capacitor Bus Fuse Capacitor Capacitor Insulator...
Page 141 Part Replacement Procedures 5–41 ATTENTION: Capacitors not installed correctly will explode or vent and may cause death or serious injury. Observe correct polarities. Figure 5.23 Volt-Sharing Resistor Connections to Bus Capacitors C1 C2 C3 C4 C1 C2 C3 C4 C9 – C16 C17 –...
Page 142: Replacing Volt-Sharing Resistors And Dual Diodes
5–42 Part Replacement Procedures Replacing Volt-Sharing Resistors and Dual Diodes The Volt-Sharing Resistors and Dual Diodes are mounted on the Balancer Plate Assembly. This assembly is located on the right wall of the Capacitor Bank Assembly. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives.
Page 143: Installation
Part Replacement Procedures 5–43 Figure 5.24 Balancer Plate Assembly Volt-Sharing Resistor and Inverter Bay w/o Cabinet Dual Diode Leads Capacitor Bank Assembly Balancer Plate Assembly Screws Bus Capacitors Volt-Sharing Resistor Balancer Plate Assembly Installation 1. Install the capacitor assembly in reverse order of removal. Refer to Fastener Torque Specifications in Chapter 3, Access Procedures.
Page 144: Replacing The Converter Bay Door Fan
5–44 Part Replacement Procedures Part Replacement Procedures Replacing the Converter Bay Door Fan The Converter Bay is configured to each order. The steps and illustrations in this procedure are typical. Removal 1. Remove power and check for zero voltage in the drive. Refer to Opening the Drive Enclosure in Chapter 3, Access Procedures.
Page 145 Part Replacement Procedures 5–45 Figure 5.25 Converter Bay Door Fan Weld Studs Green White Terminal Block 10-32 Nut, Lock Washer, Flat Washer AB1098 3. Attach the wires to the terminal block located on the side of the fan assembly as follows: The red (or yellow/red) wire goes to terminal 1.
Page 146: Replacing Converter Thermal Switches
5–46 Part Replacement Procedures Replacing Converter Thermal Switches The Converter Bay is configured to each order. The steps and illustrations in this procedure are typical. Three Converter Thermal Switches are mounted on the Bridge Heat Sink located in the Converter Bay. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives.
Page 147 Part Replacement Procedures 5–47 Figure 5.26 Thermal Switches Converter Bay Thermal Switches (3) L-Shaped Bus Bar (3) Flex Bus (3) AB1099 Figure 5.27 Thermal Switches – Side View Front of Cabinet L-Shaped Bus Bar Thermal Switch AB1100 2. Tighten the screw on the thermal switch. 3.
Page 148: Replacing Converter Fans
5–48 Part Replacement Procedures Replacing Converter Fans The Converter Bay is configured to each order. The steps and illustrations in this procedure are typical. Three Converter Fans are located beneath the Bridge Heat Sink in the Converter Bay. Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 IMPACT drives.
Page 149: Installation
Part Replacement Procedures 5–49 Figure 5.28 Converter Fans Converter Bay Bridge Heat Sink Fans (3) AB1101 Figure 5.29 Converter Fans (Bottom and Side Views) Input Power Supply 4 Screws 4 Lockwashers Back of Rack Fan Spacer Bottom View Side View AB1102 Installation Refer to Fastener Torque Specifications in Chapter 3, Access...
Page 150 5–50 Part Replacement Procedures 2. Insert screws and lock washers in the four corners and tighten the screws. 3. Attach the power supply and neutral wires to the fan. ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury.
Page 151 Part Replacement Procedures 5–51 Replacing Converter Diodes The Converter Bay is configured to each order. The steps and illustrations in this procedure are typical. Six Converter Diodes are located on the Bridge Heat Sink in the Converter Bay. Refer to Table 5.B for replacement diode numbers. Table 5.B Diode Numbers Use this catalog number:...
Page 152 5–52 Part Replacement Procedures Figure 5.30 Converter Diodes Converter Bay Bridge Heat Sink Flex Bus Converter Diodes (6) L-Shaped Bus Bar AB1103 Figure 5.31 Bus Bars Converter Diodes Bus Bar Front of Cabinet L-Shaped Bus Bars AB1104 4. Remove the hex head screws that are in the four corners of the Converter Diode.
Page 153 Part Replacement Procedures 5–53 Installation Refer to Fastener Torque Specifications in Chapter 3, Access Procedures. 1. Apply a thin, even coat of Penatrox or equivalent (not supplied) to the base of the new diode. 2. Position the new Converter Diode. Be careful to match the holes for the screws.
Page 154 5–54 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002...
Page 155: Replacement Parts List
A product service report number is required to return any equipment for repair. Your local Rockwell Automation distributor or area sales and support office can provide you with a product service report number.
Page 156: Replacement Parts Listing
6–2 Replacement Parts List Replacement Parts Listing Figure 6.1 Replacement Parts Table 6.A Replacement Parts Symbol on Procedures Callout Callout Job elate Job Related Description escr pt on Access Test Replacement Schematics Fan1 Main Enclosure Fan Does Not Apply (DNA) OL12 Overload Relay F20 –...
Page 157 Replacement Parts List 6–3 Figure 6.2 Inverter Assembly Replacement Parts Table 6.B Inverter Assembly Replacement Parts Procedures Symbol on S mbol on Callout Callout Chapter Chapter 7 Description escr pt on Access Test Replacement Schematics (Ref: Ch. 3) (Ref: Ch. 4) (Ref: Ch.
Page 158 6–4 Replacement Parts List Figure 6.3 Fan Assembly Replacement Parts Table 6.C Fan Assembly Replacement Parts Procedures Symbol on S mbol on Callout Callout Chapter Chapter 7 Description escr pt on Access Test Replacement Schematics (Ref: Ch. 3) (Ref: Ch. 4) (Ref: Ch.
Page 159 Replacement Parts List 6–5 Figure 6.4 Capacitor Assembly Replacement Parts 32, 33 Table 6.D Capacitor Bank Assembly Replacement Parts Procedures Symbol on S mbol on Callout Callout Chapter Chapter 7 Description escr pt on Access Test Replacement Schematics (Ref: Ch. 3) (Ref: Ch.
Page 160: Replacing Converter Diodes
6–6 Replacement Parts List Figure 6.5 Typical Converter Bay Replacement Parts 52, 53 Important: This listing is typical. See the schematics supplied for configured systems for the spare parts list for the Converter Bay and the enclosure fan. Table 6.E Typical Converter Bay Replacement Parts Procedures Symbol on...
Page 161 Chapter Schematics Chapter Objectives This chapter provides: The Inverter Bay schematic for a typical drive. The Control Board layout. Typical Converter Bay and system schematics. Since each drive is configured, the Converter Bay and full schematics for the drive, as configured, are shipped inside the cabinet. Fuse Listings Publication 1336 IMPACT-6.8 –...
Page 162: Inverter Bay Schematic
7–2 Schematics Inverter Bay Schematic Schematic diagram for the 800 horsepower drive. PE PE PE THS1 SCR1 CNV+ INV+ SEE TABLE 7-D 1000:1 105061 CAP BANK SEE DETAIL SHEET 3 –DC INV– 7 10 CUSTOMER’S +SMPS INPUT VOLTAGE 120VAC –SMPS OR 24VDC +15V COMMON BUS PRECHARGE BOARD...
Page 163 Schematics 7–3 U–M1 V–M2 OUTPUT POWER W–M3 CT 1 W_AMPS CT 2 U_AMPS –15 –15 NTC1 FROM SHEET PS+V PSCOM PS–V RL1–5 RL1–9 CONTROL BOARD M1X1 M1X2 CONTACTOR M1K2 INTERFACE M1K1 4 5 6 +SMPS AC FAN1 –SMPS AC FAN2 120VAC +15V 120RTN...
Page 164 7–4 Schematics Fan Circuit Detail JUMPER GRN/Y WHITE 120V CUSTOMER POWER JUMPER GRN/Y 215 OHM TO SHEET 2 PS+V PSCOM PS–V RL1–5 RL1–9 POWER SUPPLY +16V –16V N AC Capacitor Detail 575V 480V SEE TABLE 7–B SEE TABLE 7–B C2 C3 C1 C2 C3 C4 C9 –...
Page 165: Control Board Layout
Schematics 7–5 Control Board Layout Voltage Test Points LEDs Green Jumper Pulse Input Jumper (J4) TB10 TB11 10 11 15 16 18 19 21 22 2 3 4 Publication 1336 IMPACT-6.8 – November, 2002...
Page 166: Typical Converter Bay Schematic
7–6 Schematics Typical Converter Bay Schematic 1011 1021 460 VOLTS 3PH, 60HZ 1031 AC LINES TB11 LINE– 1011 1021 1031 2–11 CCMR –5 600V 1071 1072 1073 4–28 OL12 4–28 1111 1112 1113 FAN1 700A 700V 1201 1202 1203 EA11 PHASE LOSS RELAY EA10...
Page 167 Schematics 7–7 FROM 1–36 FROM 1–04 CHASSIS 1361 1362 – TERMINAL BLOCK TB1 TERMINAL BLOCK TB2 (INTERFACE CONTROL BOARD) FOR DETAILED INFORMATION, REFER TO PAGE 2 TERMINAL BLOCK TB3 (INTERFACE BOARD) FOR DETAILED INFORMATION, REFER TO PAGE 2 BULLETIN 1336 IMPACT DIGITAL AC DRIVE .
Page 168 7–8 Schematics FROM FROM TB10 TB11 3–38 3–38 1336E +10V CONTROL BOARD 3201 4065 AGND PROGRAMMABLE –10V IN1+ COMMON IN1– 0– 10V INPUT IN2+ FAULT IN2– COMMON FAULT IN3+ 4–20mA IN3– INPUT ALARM COMMON OUT1+ ALARM OUT1– 0– 10V OUTPUT OUT2+ TERMINAL BLOCK TB11 OUT2–...
Page 169 Schematics 7–9 115VAC CONTROL FROM CUSTOMER SOURCE 4062 4063 4061 (21–24) FNM–9 250V 4065 CONVERTER BRIDGE FANS (EA10) FAN4 4061 4065 GRAY (1–3) (4–6) FAN5 GRAY FAN6 GRAY FAN2 FAN(TB) FAN(TB) FAN(TB) DRIVE UNIT EA1 BRIDGE FAN1 BRIDGE FAN2 DRIVE UNIT EA1 W1 JUMPER 24VDC 1–2...
Page 170 7–10 Schematics 16.00 2.00 2.00 17.50 FAN SHIPPED SEPARATE TOP HAT REMOVABLE LIFTING ANGLE 2.50 104.88 91.50 30” 20” DRIVE BAY CONTROL BAY 75.0 25.00 4.25 14.00 – AREA AVAILABLE FOR CONDUIT 10.00 21.56 17.50 11.75 3.50 1.69 15.00 25.00 Sheet 5 of 7 0.625 DIA–4 MTG HOLES Publication 1336 IMPACT-6.8 –...
Page 171 Schematics 7–11 110.0 FAN1 100.0 90.0 DEVICE DESCRIPTION DEVICE DESCRIPTION NOT USED NOT USED NOT USED NOT USED 80.0 NOT USED NOT USED TB11 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED 70.0 NOT USED NOT USED NOT USED NOT USED NOT USED...
Page 172 7–12 Schematics MATERIAL LIST – COMPONENTS EXTERNAL INTERCONNECT WIRING REQUIREMENTS A–B POWER SYM. DESCRIPTION MANUFACTURER/PART NO. PART NO. DRIVE UNIT 1336E–R800–AN–EN–L6 SEE INSTRUCTION MANUAL FOR CABLE CLASSES EA10 BRIDGE 177187 EUPEC/2B6U 575/775–800F/ 3KM17L 6DD600N–T INTERCONNECTION INFORMATION EA11 RELAY 128229 TIMEMARK/C263 CURR.
Page 173 Schematics 7–13 Fuse Tables Based on the maximum drive rating the following fuses, or approved equivalents, must be used for the AC input power. Table 7.A AC Input Power, Converter Bay Fuses (F1 – F3 and F1A – F3A) Horsepower AC Input Voltage Fuse Type 700 and 800...
Page 174 7–14 Schematics This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002...
Page 175 Notes Publication 1336 IMPACT-6.8 – November, 2002...
Page 176 N–2 Publication 1336 IMPACT-6.8 – November, 2002...
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Page 188 N–14 Publication 1336 IMPACT-6.8 – November, 2002...
Page 189 Index Index Control Board Mounting Plate Illustration, 3–10 Audience for this Manual, P–1 Installation, 3–11 Auxiliary Input, Definition, P–8 Control Firmware Function, 1–12 Auxiliary Interlock, Definition, P–8 Control Interface L Option Board. See L Option Board Control Logic Wiring and Adapters, 1–1 Conventions, P–8 Balancer Plate, Illustration, 4–11 Converter Bay...
Page 190 Index I–2 Inv Overtemp Pnd, 2–5 Inv Overtemp Trp, 2–5 Electrostatic Discharge, P–2 InvOvld Pend, 2–5 Electrostatic Discharge Precautions, P–2 mA Input, 2–7 Math Limit, 2–8 Enable Input, Definition, P–9 Mtr Stall, 2–4 Enclosure Type, P–5 MtrOvrld Pnd, 2–4 Option Codes, P–5 MtrOvrld Trp, 2–4 ESD, P–2 Open Circuit, 2–13...
Page 191 Index I–3 Removal, 3–14 MOV, Identification, 6–6 Input Rectifier Snubber Board Illustration, 5–16 Installation, 5–17 Removal, 5–16 Nameplate Location, P–3 Inputs, Available for L Option, 1–3 No Voltage Check, Illustration, 3–8, Inverter Assembly 3–9 Installation, 3–27 Part Identification, 5–3, 6–3 Pulling, 3–23 Inverter Bay Option...
Page 192 Index I–4 Bus Fuse Replacement, 5–35 Programming Common Bus Precharge Board L Option Mode, 1–4 Replacement, 5–10 Local, 1–7 Control Board Mounting Plate Removal, 3–10 Control Board Replacement, 5–6 Converter Bay Door Fan Related Publications, P–10 Replacement, 5–44 Replacement Parts Converter Diode Replacement, 5–51 Capacitor Assembly, 6–5 Converter Fan Replacement, 5–48...
Page 193 Index I–5 Thermostat SP 6 Timeout, 2–11 Installation, 5–29 SP Error, 2–11 Removal, 5–27 Spd Fdbk Loss, 2–9 Testing, 4–16 Viewing Queue with HIM, 2–2 Tools Required, 3–2 Torque Four-Point Mounting Sequence, 3–4 Zener Diode, Test, 4–5 Sequence, 3–3 Six-Point Mounting Sequence, 3–4 Specifications, 3–3 Two-Point Mounting Sequence, 3–3 Troubleshooting...
Page 194 Index I–6 This Page Intentionally Left Blank Publication 1336 IMPACT-6.8 – November, 2002...

Rockwell Automation Allen-Bradley IMPACT 1336 Series Troubleshooting Manual

Control Logic Wiring and Adapters

Troubleshooting and Error Codes

Access Procedures

Component Test Procedures

Part Replacement Overview

Replacement Parts List

Quick Links

Troubleshooting

Related Manuals for Rockwell Automation Allen-Bradley IMPACT 1336 Series

Summary of Contents for Rockwell Automation Allen-Bradley IMPACT 1336 Series

Table of Contents