Allen-Bradley B Series Service Manual
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Allen-Bradley B Series Service Manual

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Allen-Bradley
Bulletin 1336 FORCE
Adjustable Frequency
AC Drive
Series B, C, D
B150 – B250
C150 – C250
Service
Manual

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  • Page 1 Allen-Bradley Service Bulletin 1336 FORCE Adjustable Frequency Manual AC Drive Series B, C, D B150 – B250 C150 – C250...
  • Page 2 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.
  • Page 3 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...
  • Page 4 Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...

  • Page 5: Table Of Contents

    Table of Contents Preface Manual Objective ........P–1 Who Should Use This Manual .
  • Page 6 Table of Contents GPT Description ........1–15 Drive Tools .
  • Page 7 Table of Contents Installation ........2–28 Removing a Power Module Snubber Board .
  • Page 8 Table of Contents Removal ........4–15 Installation .

  • Page 9: 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.

  • 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 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.

  • Page 11: 1336 Force Product Identification

    Preface P–3 1336 FORCE Product Identification Drive Nameplate Location The drive nameplate is located on the face of the Main Control Board Mounting Plate. The drive nameplate contains the drive’s catalog number and other important drive information. Reference the catalog number when ordering replacement parts. Figure P.1 Drive Nameplate Location Nameplate located on...

  • Page 12: Software Compatibility

    P–4 Preface Software Compatibility ATTENTION: To guard against machine damage and/or personal injury, drives with ratings above 45 kW (60 HP) must not be used with software versions below 1.07. Refer to the table below. Three-Phase Drive Rating Compatible with Frame 380 –...
  • Page 13 Preface P–5 Table P.B 1336T – C200-AA – GT2EN – L6 – HA1 – GM1 BULLETIN RATING-ENCLOSURE LANGUAGE MODULE CONTROL HUMAN COMMUNICATION (MUST BE SPECIFIED) (MUST BE SPECIFIED) INTERFACE INTERFACE CARD (OPTIONAL) (OPTIONAL) (OPTIONAL) 500 – 600V AC Input, Constant or Variable Torque Drive Enclosures NEMA Type 4 Open...

  • Page 14: Drive Rating Qualifications

    P–6 Preface Table P.D Options Code Description Code Description Human Interface Modules, NEMA Type 1 (IP20) Communication Options Blank – No Functionality GT1E PLC Communication Programmer Only Adapter, English Programmer/Controller with Analog Pot Standard Adapter, Programmer/Controller with Digital Pot GT2E English No Adapter Human Interface Modules, NEMA Type 4 (IP56)

  • Page 15: Conventions

    Preface P–7 Conventions To help differentiate parameter names and display text from other text in this manual, the following conventions will be used: • Parameter Names will appear in [brackets]. • Display Text will appear in “quotes”. The following is a list of conventions used throughout this manual, and definitions of the conventions.

  • Page 16: Default

    P–8 Preface Default When a drive function defaults, it automatically changes to a pre-programmed setting. Enable Input The Enable Input is a terminal connection on the Control Interface Board. This connection provides an external input to enable or disable the Drive Output section. It must be a logic “true” to permit the drive to operate.

  • Page 17: True

    TB3 is true when: L4 contact input is closed, L5 input terminal registers 24V, or L6 input terminal registers 115V AC. Related Publications The following lists other Allen-Bradley publications that apply to the 1336 FORCE Adjustable Frequency AC Drives: •...
  • Page 18 P–10 Preface This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...

  • Page 19: Control Logic Wiring And Chapter Objectives

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000–4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Publication 1336 FORCE-6.14 – August, 1999...
  • Page 20 1–2 Control Logic Wiring and Adapters Figure 1.1 Standard Adapter Terminal Block Locations Main Control TB10 Encoder Board TB11 Standard Adapter Board TB3 Control L–Option Board Control Interface L-Option Board TB5, TB6, TB7 Control and Signal Wiring TB1 Power Terminal Block AB0564A Figure 1.2 PLC Comm Adapter Terminal Block Locations...

  • Page 21: Control Interface Option

    Control Logic Wiring and Adapters 1–3 ATTENTION: The National Electrical Code (NEC) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

  • Page 22: Control Interface Board Jumpers

    1–4 Control Logic Wiring and Adapters Control Interface Board Jumpers Important: If the Control Interface Board is being installed, Standard Adapter Board jumpers at pins 3 & 4 and 17 & 18 of J10 must be removed. If this board is removed, these jumpers must be reinstalled and the [Input Mode] parameter must be programmed to “1”.

  • Page 23: Available Inputs

    Control Logic Wiring and Adapters 1–5 Available Inputs A variety of combinations made up of the following inputs are available. Start Enable Stop/Clear Fault Auxiliary Reverse 2 Stop Mode Selects Digital Potentiometer (MOP) Run Forward 2 Accel/Decel Rates Run Reverse 3 Speed Selects Local Control The available combinations are shown in Figure 1.4.
  • Page 24 1–6 Control Logic Wiring and Adapters Table 1.A Input Mode Selection Mode(s) Start/Stop Type Direction Control Communication Compatibility to Use Stop & Enable None Control must be provided by HIM or Communication Option. Only Momentary Maintained Switch Start/Stop – works in parallel with HIM and Communication Options. 2 –...
  • Page 25 Control Logic Wiring and Adapters 1–7 Figure 1.5 Input Mode Selection and Typical TB3 Connections Momentary [Input Mode] 1 Factory Default Maintained Status Stop/Fault Reset Common Status Note: If this mode is selected, the status of all inputs can be read at the [Input Status] parameter. Status However, only “Stop/Fault Reset”...
  • Page 26 1–8 Control Logic Wiring and Adapters Momentary [Input Mode] 7 – 11 Maintained Three-Wire Control with Multi-Source Reversing Start Stop/Fault Reset Mode Common Reverse Reverse Digital Reverse Pot Up Accel Forward Forward Digital Forward Pot Dn Accel Auxiliary Common Speed Speed Digital Select 3...
  • Page 27 Control Logic Wiring and Adapters 1–9 The following table defines the input state of the Speed Select inputs for a desired frequency source. Table 1.B Speed Select Input State vs. Velocity Reference Source Speed Select 3 Speed Select 2 Speed Select 1 Para 52 Bit 14 Bit 13...
  • Page 28 1–10 Control Logic Wiring and Adapters Table 1.C PLC Comm Adapter Reference Signal Connections Terminal Block Terminal Number(s) Signal TB20 Drive Enable (NO) Motor Thermoguard (NC) Normal Stop (NC) External Fault (NC) Input Common Fault Output (NC) Fault Output (COM) Fault Output (NO) TB21 OUT 1...

  • Page 29: Adapters And Communication Ports

    Control Logic Wiring and Adapters 1–11 Adapters and Communication Ports Human Interface Module When the drive-mounted HIM is supplied, it will be connected as Port 1 (refer to Figure 1.8) and visible from the front of the drive. The HIM can be divided into two sections; Display Panel and Control Panel.

  • Page 30: Standard Adapter Ports

    1–12 Control Logic Wiring and Adapters Standard Adapter Ports Figure 1.8 Standard Adapter Board Port Locations Main TB10 Encoder Control Board Standard TB11 Drive Mounted HIM Adapter Board (Adapter Port 1) Internal Communication Control Interface (Adapter Port 6) L–Option Board TB3 Control L–Option Board TB5, TB6, TB7...

  • Page 31: Him Removal

    Control Logic Wiring and Adapters 1–13 HIM Removal ATTENTION: Some voltages present behind the drive front cover are at incoming line potential. To avoid an electric shock hazard, use extreme caution when removing/replacing the HIM. For handheld operation, the module can be removed and located up to 10 meters (33 feet) from the drive.

  • Page 32: Him Operation

    1–14 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 1.10) will be shown.

  • Page 33: Graphic Programming Terminal

    Control Logic Wiring and Adapters 1–15 Graphic Programming Terminal GPT Description The optional GPT (Figure 1.11) is a remote device with a 1.8 meter (6 foot) long cable. The GPT offers a 40- by 8-character display that can also be used as a graphics display to show trending graphs. For GPT operation, refer to the 1336 FORCE Field Oriented Control User Manual.

  • Page 34: Drive Tools

    Drive Tools software is a Windows 3.1 compatible family of application programs allowing the user to perform programming, monitoring, and diagnostic operations on Allen-Bradley AC and DC digital drive products. The software consists of five Windows applications. For operation, refer to the Product Data Drive Tools Software manual.

  • Page 35: Disassembly And Access Overview

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000–4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Publication 1336 FORCE-6.14 – August, 1999...

  • Page 36: Tools

    2–2 Disassembly and Access Procedures 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: •...

  • Page 37: Fastener Torque Specifications

    Disassembly and Access Procedures 2–3 Fastener Torque Specifications Torque Sequence When mounting components to a drive’s heat sink, component-fastener torque sequences and tolerances are crucial to component-to-heat sink heat dissipation. ATTENTION: Component can be damaged if temporary tightening procedure is not performed to specification.

  • Page 38: Torque Specifications

    2–4 Disassembly and Access Procedures Figure 2.2 Four-Point Mounting Four–Point Mounting Temporary Tighten Final Tighten AB0017A Figure 2.3 Six-Point Mounting Temporary Tighten to 0.5 N-m (4 lb-in.) Final Tighten to 3 N-m (26 lb-in.) Six Point Mounting AB0433B " Note: Do not exceed 0.5 Newton-meters (4 lb-in.) on initial torque of all six screws.
  • Page 39 Disassembly and Access Procedures 2–5 Table 2.A Fastener Torque Specifications Torque Torque Component Fastener Application lb-in. Fan Motor Motor to Fan Cover Assembly Fan Cover Assembly Assembly to chassis Fan Transformer Transformer to chassis Fan Capacitor Capacitor to chassis Hand-tighten MOV Surge Suppressor MOV to chassis Snubber Resistor...

  • Page 40: Disassembly And Access Procedures

    2–6 Disassembly and Access Procedures Disassembly and Access Procedures Opening the Drive Enclosure Figure 2.4 Drive Enclosure Ground Stud (Behind Cover) Latches 8-Pin HIM Connector (Behind Cover) Hinges AB0769A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.

  • Page 41: Installation

    Disassembly and Access Procedures 2–7 ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. 1. Remove power from the drive. 2.

  • Page 42: Removing The High Voltage Guard

    2–8 Disassembly and Access Procedures Removing the High Voltage Guard The High Voltage Guard is a clear plastic guard covering the LEMs, Bus Capacitor Bank, and DC Bus Inductor. Figure 2.5 High Voltage Guard AB0771A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.

  • Page 43: Installation

    Disassembly and Access Procedures 2–9 ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. 1. Remove power from the drive. 2.

  • Page 44: Removing Control Interface L-Option Board Mod-L4, -L5, Or -L6

    2–10 Disassembly and Access Procedures Removing Control Interface L-Option Board MOD–L4, –L5, or –L6 Figure 2.6 Control Interface Board Main Control Board Standard Adapter Board Control Interface L-Option Board Terminal Strip TB3 AB0567B Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.

  • Page 45: Installation

    Disassembly and Access Procedures 2–11 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 46: Removing The Main Control Board

    2–12 Disassembly and Access Procedures Removing the Main Control Board Figure 2.7 Main Control Board Control Board/Adapter Mounting Plate Ground Stud Main Control Board PLC Comm Connector J1 TB10 Adapter Board HIM (Standard Connector J5 Connector Adapter Board only) Connector J7 Connector J7 Connector J1 TB21...

  • Page 47: Installation

    Disassembly and Access Procedures 2–13 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the Drive. 2.

  • Page 48: Removing The Standard Adapter Board

    2–14 Disassembly and Access Procedures Removing the Standard Adapter Board Figure 2.8 Main Control Board and Standard Adapter Board Control Board/Adapter Mounting Plate Main Control Board Slide-Mount Stand-Off Mounting Screw Standard Connector J1 Adapter Board TB5 TB6 AB0573A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.

  • Page 49: Installation

    Disassembly and Access Procedures 2–15 1. Remove power from the drive. 2. Open the Enclosure cover. Refer to Opening the Drive Enclosure in this chapter. 3. Check for zero volts at TB1 terminals +DC and –DC. 4. Check for the absence of control voltage at TB5, TB6, and TB7 on the Standard Adapter Board.

  • Page 50: Removing The Plc Comm Adapter Board

    2–16 Disassembly and Access Procedures Removing the PLC Comm Adapter Board Figure 2.9 Main Control Board and PLC Comm Adapter Board Control Board/Adapter Mounting Plate Main Control Board Slide-Mount Stand-Off Mounting Connector Screw Connector J5 Connector J7 PLC Comm TB21 Adapter Board TB20 AB0574A...

  • Page 51: Installation

    Disassembly and Access Procedures 2–17 1. Remove power from the drive. 2. Open the Enclosure cover. Refer to Opening the Drive Enclosure in this chapter. 3. Check for zero volts at TB1 terminals +DC and –DC. 4. Check for the absence of control voltage at TB20 and TB21 on the PLC Comm Adapter Board.

  • Page 52: Removing The Control Board/Adapter Mounting Plate

    2–18 Disassembly and Access Procedures Removing the Control Board/Adapter Mounting Plate Figure 2.10 Control Board/Adapter Mounting Plate Connector J1 Control Board/Adapter Mounting Plate PLC Comm Connector J5 Slide-Mount Adapter Board Stand-Off Connector J7 8-Pin HIM Connector TB21 TB20 Main Control Board TB10 Connector HIM (Standard...

  • Page 53: Installation

    Disassembly and Access Procedures 2–19 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 54: Removing The Gate Driver Board Mounting Plate

    2–20 Disassembly and Access Procedures Removing The Gate Driver Board Mounting Plate Figure 2.11 Gate Driver Board Mounting Plate Ground Gate Driver Board Stud Mounting Plate Gate Driver Connector Board Connector J13 Connector J7 Connector J8 Connector J9 Connector Connector AB0439A Removal ATTENTION: Disconnect and lock out power from...
  • Page 55 Disassembly and Access Procedures 2–21 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 56: Installation

    2–22 Disassembly and Access Procedures Installation Install the Gate Driver Board Mounting Plate in reverse order of removal. Refer to Table 2.A – Fastener Torque Specifications. ATTENTION: When removing the entire wire harness connecting Gate Driver Board connector J9 to Precharge Board connector J3, align the wires on the harness terminals with the pins on the board connectors.

  • Page 57: Removing The Gate Driver Board

    Disassembly and Access Procedures 2–23 Removing the Gate Driver Board Figure 2.12 Gate Driver Board and Mounting Plate Gate Driver Board Connector Connector Connector Connector Connector Terminal Strip Connector Connector AB0440A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.

  • Page 58: Installation

    2–24 Disassembly and Access Procedures Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 59: Removing The Precharge Board Mounting Plate

    Disassembly and Access Procedures 2–25 ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Removing the Precharge Board Mounting Plate Figure 2.13 Precharge Board Mounting Plate Precharge Board Precharge Board Mounting Plate Connector...

  • Page 60: Installation

    2–26 Disassembly and Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.

  • Page 61: Removing The Precharge Board

    Disassembly and Access Procedures 2–27 ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Removing the Precharge Board Figure 2.14 Precharge Board Connector Connector Connector Precharge Board Connector High Voltage Guard AB0441B...

  • Page 62: Installation

    2–28 Disassembly and Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.

  • Page 63: Removing A Power Module Snubber Board

    Disassembly and Access Procedures 2–29 ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Removing a Power Module Snubber Board The Power Module Snubber Boards are located under the Motor Bus Bars and LEMs.

  • Page 64: Removal

    2–30 Disassembly and Access Procedures Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.

  • Page 65: Installation

    Disassembly and Access Procedures 2–31 8. Remove the Motor Bus Bars. LEMs are attached to two of these bars. 9. Remove the Motor Bus Bars from TB1 terminals U-M1, V-M2, and W-M3. 10.Slide the notches in the Motor Bus Bars away from the slots in the Motor Bus Bar Support to remove the Motor Bus Bars from the Drive.

  • Page 66: Removing An Input Rectifier Snubber Board

    2–32 Disassembly and Access Procedures Removing an Input Rectifier Snubber Board The Input Rectifier Snubber Boards are located under the Gate Driver Board Mounting Plate. Figure 2.16 Input Rectifier Snubber Board Input Rectifier Snubber Board AB0449A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.

  • Page 67: Installation

    Disassembly and Access Procedures 2–33 ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
  • Page 68 2–34 Disassembly and Access Procedures This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...

  • Page 69: Component Test Procedures Chapter

    Chapter Component Test Procedures Chapter Objectives The following tests help you troubleshoot B150 – B250 and C150 – C250, and CX300 drives. Component Test Overview In some cases, different tests troubleshoot components of the same name. These similar tests vary according to the rating of the drive being tested.

  • Page 70: Electrostatic Discharge Precautions

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000–4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards.

  • Page 71: Test 1

    Component Test Procedures 3–3 Test 1 The Gate Driver Board is located between the Main Control Board Testing the Gate Driver and the Main Chassis. If modules have been replaced, you must test Board the Gate Driver Board. Figure 3.1 Gate Driver Board Test Gate Driver Board...
  • Page 72 3–4 Component Test Procedures Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 73: Test 2

    Component Test Procedures 3–5 Test 2 If modules have been replaced, you must check the Power Module Testing the Precharge Snubber Board and the Precharge Board. Refer to Chapter 2 – Board Disassembly and Access Procedures, Removing a Power Module Snubber Board and Removing the Precharge Board Mounting Plate.
  • Page 74 3–6 Component Test Procedures Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 75: Test 3

    Component Test Procedures 3–7 Test 3 The Power Modules are located near the top of the heat sink. If Testing the Power modules have been replaced, you must check the Power Module Modules Snubber Board. Refer to Chapter 2 – Disassembly and Access Procedures, Removing a Power Module Snubber Board.
  • Page 76 3–8 Component Test Procedures ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
  • Page 77 Component Test Procedures 3–9 Table 3.B Power Modules Meter (+) Lead Meter (–) Lead Nominal Meter Reading 0.318 Infinite Infinite Infinite Infinite Infinite 8. Replace a Power Module if meter readings are not as shown. Refer to Chapter 4 – Part Replacement Procedures, Power Modules.

  • Page 78: Test 4

    3–10 Component Test Procedures Test 4 The Bus Capacitor Bank is located on the left side of the Main Testing the Bus Chassis. Capacitors Figure 3.4 Bus Capacitor Bank Test DC– AB0453B ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
  • Page 79 Component Test Procedures 3–11 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.
  • Page 80 3–12 Component Test Procedures 7. If the voltage is out of tolerance, check the following: • An open condition at an Input Rectifier. • A voltage drop due to Bus Inductor L1 resistance. • A voltage drop between an Input Rectifier and the bus capacitors due to loose or resistive wires or connections.

  • Page 81: Test 5

    Component Test Procedures 3–13 Test 5 The Input Rectifiers are located on the bottom of the heat sink. Testing the Input Rectifiers Figure 3.5 Input Rectifier Test AB0454B ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
  • Page 82 3–14 Component Test Procedures Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.

  • Page 83: Part Replacement Overview

    Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000–4.5.2, Guarding Against Electrostatic Discharge, or any other applicable ESD protection handbook. Publication 1336 FORCE-6.14 – August, 1999...

  • Page 84: Tools

    4–2 Part Replacement Procedures 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: •...
  • Page 85 Part Replacement Procedures 4–3 Detailed Product Allen-Bradley Adjustable Frequency AC Drives are modular by Identification design to enhance troubleshooting and spare parts replacement, thereby helping reduce production down-time. The following illustration calls out the main components of a typical drive. Component designs vary slightly among the different drive ratings, but component locations are identical.

  • Page 86: Removal

    4–4 Part Replacement Procedures Bus Capacitor Bank The Bus Capacitor Bank is located on the left side of the Main Chassis. Figure 4.2 Bus Capacitor Bank Bus Capacitor Holder Bus Capacitor Capacitor Bus Bar Assembly Bus Fuse Fuse Transitional Bus Load Sharing Bar Assembly Resistors...
  • Page 87 Part Replacement Procedures 4–5 ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
  • Page 88 4–6 Part Replacement Procedures 6. Remove the Capacitor Bus Bar Assembly from the drive. 7. Remove the screws fastening the Bus Capacitor Holder to the chassis. Remove the Capacitor Holder and the two Cover Support Brackets at the top of the Bus Capacitor Holder from the drive. 8.
  • Page 89 Part Replacement Procedures 4–7 Thermistor The Thermistor is located on the heat sink at the top-middle of the drive. Figure 4.4 Thermistor Thermistor Connector to Main Control Board J1 AB0458A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
  • Page 90 4–8 Part Replacement Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
  • Page 91 Part Replacement Procedures 4–9 Power Modules The Power Modules are located near the top of the heat sink. If one or more Power Modules is replaced, you must check the Power Module Snubber Board and the Precharge Board. Refer to Chapter 2 –...
  • Page 92 4–10 Part Replacement Procedures ATTENTION: Hazard of electric shock exists. Up to 1,600 VDC will be on J1 if the Snubber Resistor is open. Measure for zero VDC from Snubber Board terminal TP3 to plus (+) bus before removing connector J1. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, between TP3 and plus (+) bus to discharge any voltage.
  • Page 93 Part Replacement Procedures 4–11 Remove the Power Module: 1. Remove the Power Module Snubber Boards. Refer to Chapter 2 – Disassembly and Access Procedures, Removing a Power Module Snubber Board. 2. Remove the screws fastening the Snubber standoffs to the Power Module Bus Bar to remove the standoffs.
  • Page 94 4–12 Part Replacement Procedures Input Rectifiers The Input Rectifiers are located toward the bottom of the heat sink. Figure 4.6 Input Rectifiers Input Preform Rectifier Snubber Board Standoffs Negative Converter Bar Positive Converter Bar AB0460A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
  • Page 95 Part Replacement Procedures 4–13 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. Access the Input Rectifiers: 1. Remove power from the drive. 2.
  • Page 96 4–14 Part Replacement Procedures Important: Install washers on TB1 terminals with the serrated side facing toward you. ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Fan and Transformer Assembly The Fan is located in the chassis and under TB1 at the bottom of the heat sink.
  • Page 97 Part Replacement Procedures 4–15 Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
  • Page 98 4–16 Part Replacement Procedures 6. Remove the Gate Driver Board Mounting Plate. Refer to Chapter 2– Disassembly and Access Procedures, Removing the Gate Driver Board Mounting Plate. 7. Remove the Precharge Board Mounting Plates. Refer to Chapter 2 – Disassembly and Access Procedures, Removing the Precharge Board Mounting Plate.
  • Page 99 Part Replacement Procedures 4–17 7. Disconnect the Fan Transformer from the Fan Wiring Harness and from TB1. 8. Remove the screws fastening the Fan Transformer to the chassis. Installation Install the Fan Assembly in reverse order of removal, with the following exceptions: •...
  • Page 100 4–18 Part Replacement Procedures DC Bus Inductor L1 DC Bus Inductor L1 is located on the lower left corner of the drive. Figure 4.8 DC Bus Inductor L1 DC Bus Inductor L1 Screws (4) AB0462A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
  • Page 101 Part Replacement Procedures 4–19 Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly. 1. Remove power from the drive. 2.
  • Page 102 4–20 Part Replacement Procedures ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Ground Sense CT The Ground Sense CT is located between DC Bus Inductor L1 and the Transitional Bus Bar Assembly.
  • Page 103 Part Replacement Procedures 4–21 ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
  • Page 104 4–22 Part Replacement Procedures ATTENTION: A possible short-circuit hazard exists. Position the fuse-to-inductor wire with the shrink-wrapped end of the wire connected to the Bus Inductor. Failure to position the wire as illustrated may result in serious injury or equipment damage. ATTENTION: Replace all guards before applying power to the drive.

  • Page 105: Installation

    Part Replacement Procedures 4–23 Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
  • Page 106 4–24 Part Replacement Procedures LEMs Figure 4.11 LEMs Motor Bus Mounting Clamp AB0465A Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1.
  • Page 107 Part Replacement Procedures 4–25 ATTENTION: Hazard of electric shock exists. Up to 1,600 VDC will be on J1 if the Snubber Resistor is open. Measure for zero VDC from Snubber Board terminal TP3 to plus (+) bus before removing connector J1. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, between TP3 and plus (+) bus to discharge any voltage.
  • Page 108 4–26 Part Replacement Procedures ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. MOV Surge Suppressor The MOV Surge Suppressor is located in the bottom-left corner of the Drive near the Fan Transformer and Fan Capacitor. The MOV protects the drive from high voltage surges above approximately 1,000 volts.

  • Page 109: Installation

    Part Replacement Procedures 4–27 Removal ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
  • Page 110 4–28 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...

  • Page 111: Replacement Parts List

    A product service report number is required to return any equipment for repair. Your local Allen-Bradley distributor or area sales and support office can provide you with a product service report number. You should return equipment to be repaired to the area sales and support center nearest you.

  • Page 112: Replacement Parts Listing

    5–2 Replacement Parts List Replacement Parts Listing Figure 5.1 Parts for B150 – B250 and C150 – C250 Drives AB0576A Publication 1336 FORCE-6.14 – August, 1999...
  • Page 113 Replacement Parts List 5–3 Table 5.A Replacement Parts for B150–B250 and C150–C250 Drives Callout Symbol Description Location Replacement Procedures Q1 – Q6 Transistor (Power Module) Heat Sink Chapter 4, Power Modules A23 – A28 Power Module Gate Interface Power Module Chapter 4, Power Modules Board R20 –...
  • Page 114 5–4 Replacement Parts List This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...
  • Page 115 Chapter Schematics — 150 – 300 HP 1336 FORCE Drives Publication 1336 FORCE-6.14 – August, 1999...
  • Page 116 6–2 Schematics — 150 – 300 HP 1336 FORCE Drives DC– SEE TABLE 2 CONVERTER CONVERTER CONVERTER SNUBBER SNUBBER SNUBBER CNV+ TO FAN CIRCUIT SEE DETAILS CUSTOMER FUSING R–L1 SCR1 SCR3 SCR5 CAPACITOR BANK INPUT SEE DETAILS POWER S–L2 50/60HZ MOV1 T–L3 TABLE 1...
  • Page 117 Schematics — 150 – 300 HP 1336 FORCE Drives 6–3 U–M1 OUTPUT V–M2 POWER W–M3 U_AMPS W_AMPS 3000:1 3000:1 –15 –15 +INV GATE INTERFACE GATE INTERFACE GATE INTERFACE INVERTER INVERTER INVERTER SNUBBER SNUBBER SNUBBER GATE INTERFACE GATE INTERFACE GATE INTERFACE –INV TO MAIN CONTROL...
  • Page 118 6–4 Schematics — 150 – 300 HP 1336 FORCE Drives Fan Circiut Detail 380/460VAC 575VAC R–L1 AC–INPUT POWER S–L2 R–L1 AC–INPUT POWER S–L2 SEE TABLE 2 SEE TABLE 2 (380) (415) (500) (0V) (575) (0V) (460) 250 VA 250 VA (115V) (115V) HEATSINK...
  • Page 119 Schematics — 150 – 300 HP 1336 FORCE Drives 6–5 TABLE 1: CUSTOMER FUSING BASED ON MAXIMUM DRIVE RATING THE FOLLOWING FUSES OR APPROVED EQUIVALENT MUST BE USED: HORSEPOWER 380/460VAC FUSE CURRENT/TYPE 575VAC FUSE CURRENT/TYPE 300A/UL CLASS CC, T OR J 225A/UL CLASS CC, T OR J 400A/UL CLASS CC, T OR J 350A/UL CLASS CC, T OR J...
  • Page 120 6–6 Schematics — 150 – 300 HP 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...
  • Page 121 Glossary Glossary AC Contactor: An alternating-current (AC) contactor is designed for the specific purpose of establishing or interrupting an AC Power circuit. Adjustable Speed: The concept of varying the speed of a motor, either manually or automatically. The desired operating speed (set speed) is relatively constant regardless of load.
  • Page 122 G–2 Glossary 4. Motor-mounted or separately-mounted brake positive-action, mechanical friction device. Normal configuration is such that when the power is removed, the brake is set. This can be used as a holding brake. (Note: A separately mounted brake is not one which is located on some part of the mechanical drive train other that the motor.) Breakaway Torque: The torque required to start a machine from standstill.
  • Page 123 Glossary G–3 Constant Torque Range: A speed range in which a motor is capable of delivering a constant torque, subject to cooling limitations of the motor. Constant Voltage Range: (AC Drives) The range of motor operation where the drive’s output voltage is held constant as output frequency is varied.
  • Page 124 G–4 Glossary Drift: A slow change in some characteristic of a device. For a drive, it is the deviation from the initial set speed with no load change over a specific time period. Normally the drive must be operated for a specified warm-up time at a specified ambient temperature before drift specifications apply.
  • Page 125 Glossary G–5 ENUM (Enumeration): An ANSI C standard extension to the C language. An ENUM is a set of named integer constants that specify all the legal values a variable of a given type may have. The keyword ENUM signals the start of an enumeration type. ESD: Refer to Electrostatic Discharge.
  • Page 126 G–6 Glossary Integral-Horsepower Motor: A motor that has a continuous rating of 1 hp or more, built into a frame. International Organization for Standards (ISO): An organization established to promote development of international standards. Interposing Relay: An interposing relay is a relay that accepts control signals of one logic level in order to provide isolated contact signals in a circuit operating at a different logic level.
  • Page 127 Glossary G–7 Linearity: A measure of how closely a characteristic follows a straight-line function. Locked-Rotor Current: Steady-state current taken from the line current with the a rotor at standstill (at rated voltage and frequency). This is the current when starting the motor and load. Locked-Rotor Torque: The minimum torque that a motor will develop at rest for all angular positions of the rotor (with rated voltage applied at rated frequency).
  • Page 128 G–8 Glossary 1. Personal Computer. 2. Programmable Controller. 3. Printed Circuit. Plugging: A type of motor braking provided by reversing either line voltage polarity or phase sequence so that the motor develops a counter torque that exerts a retarding force to brake the motor. Pot: A potentiometer, or variable resistor.
  • Page 129 Glossary G–9 Pull-Up Torque: The torque required to accelerate the load from standstill to full speed (where breakdown torque occurs), expressed in percent of running torque. It is the torque required not only to overcome friction, windage, and product loading but also to overcome the inertia of the machine.
  • Page 130 G–10 Glossary Slip: The difference between rotating magnetic field speed (synchronous speed) and rotor speed of AC induction motors. Usually expressed as a percentage of synchronous speed. Slip Compensation: Monitors motor current and compensates for speed lost due to increased motor slip. The amount of slip is proportional to the motor load.
  • Page 131 Glossary G–11 Transistor: An active solid-state semiconductor device. Work: A force moving an object over a distance. (work = force x distance) Publication 1336 FORCE-6.14 – August, 1999...
  • Page 132 G–12 Glossary This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...
  • Page 133 Index Illustration, 4–3 Nameplate Location, P–3 Adapter Locations, 1–12 Rating, P–6 Audience for this Manual, P–1 Drive Enclosure Auxiliary Input, Definition, P–7 Illustration, 2–6 Installation, 2–7 Auxiliary Interlock, Definition, P–7 Removal, 2–6 Bit, Definition, P–7 Electrostatic Discharge, P–2 Bus Capacitor Bank Enable Input, Definition, P–8 Illustration, 4–4 Installation, 4–6...
  • Page 134 Index I–2 Conventions, P–7 See also Human Interface Module Objective, P–1 Removal, 1–13 Related Publications, P–9 Human Interface Module (HIM) Motor Control Board, Removal, 2–14, 2–16 Adapter Locations, 1–12 Description, 1–11 Mounting Illustration, 1–11 Four-Point, 2–4 Operation, 1–14 Six-Point, 2–4 Two-Point, 2–3 Input Mode Programming, 1–5...
  • Page 135 Index I–3 Bus Capacitor Bank Test, 3–10 Related Publications, P–9 Bus Fuse, 4–23 Removal Procedures. See Procedures Component Test, 3–1 Removal, HIM, 1–13 Control Board Installation, 2–13 Replacement Part Procedures, 4–1 Control Board Mounting Plate Installation, 2–19 Replacement Parts, 5–1 Control Board Removal, 2–12 Control Board/Adapter Mounting Plate Removal, 2–18...
  • Page 136 Index I–4 This Page Intentionally Left Blank Publication 1336 FORCE-6.14 – August, 1999...
  • Page 137 Notes Publication 1336 FORCE-6.14 – August, 1999...
  • Page 138 N–2 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 139 N–3 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 140 N–4 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 141 N–5 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 142 N–6 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 143 N–7 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 144 N–8 Publication 1336 FORCE-6.14 – August, 1999...
  • Page 145 By filling out this form you can help us provide the most useful, thorough, and accurate manuals available. Please take a few minutes to tell us what you think. Then mail or FAX this form. FAX: to your local Allen-Bradley Sales Office or 414/512-8579 PUBLICATION NAME PUBLICATION NUMBER, DATE AND PART NUMBER (IF PRESENT) CHECK THE FUNCTION THAT MOST CLEARLY DESCRIBES YOUR JOB.
  • Page 146 FOLD HERE FOLD HERE NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 413 MEQUON, WI POSTAGE WILL BE PAID BY ADDRESSEE ALLEN-BRADLEY Attn: Marketing Communications P.O. Box 760 Mequon, WI 53092-9907...
  • Page 147 SCANport is a trademark of Allen-Bradley Company, Inc. PLC is a registered trademark of Allen-Bradley Company, Inc.
  • Page 148 Sweden • Switzerland • Taiwan • Thailand • Turkey • United Arab Emirates • United Kingdom • United States • Uruguay • Venezuela • Yugoslavia Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444 Publication 1336 FORCE-6.14 –...

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C seriesD seriesB150B250C150C250

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