Important User Because of the variety of uses for the products described in this Information publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
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-6.13 – August, 1999...
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Summary of Changes This Page Intentionally Left Blank Publication 1336 FORCE-6.13 – August, 1999...
Preface Preface Manual Objective The information in this manual is designed to help repair an Allen-Bradley Bulletin 1336 FORCE Adjustable Frequency AC Drive with ratings A040 – A060, B060 – B125, BX150, and C075 – C125. Who Should Use This This manual is intended for qualified service personnel responsible Manual for repairing the 1336 FORCE Adjustable Frequency AC Drive.
P–2 Preface ATTENTION: Hazard of electric shock exists. Up to 1,000 VDC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum to discharge any voltage.
Preface P–3 Electrostatic discharge generated by static electricity can damage the complimentary metallic oxide semiconductor devices on various drive boards. It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed: Wear a wrist-type grounding strap that is grounded to the drive chassis.
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 200 –...
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Preface P–5 Table P.B 1336S – B060-AA – EN – L6 – HA1 – GM1 BULLETIN RATING-ENCLOSURE LANGUAGE CONTROL HUMAN COMMUNICATION (MUST BE MODULE INTERFACE INTERFACE CARD SPECIFIED) (MUST BE (OPTIONAL) (OPTIONAL) (OPTIONAL) SPECIFIED) 380 – 480V AC Input, Constant Torque Drive Enclosures Open NEMA Type 1...
Preface P–7 Enclosure Type The first character, A, indicates the Enclosure Code. The second character indicates the type of enclosure shipped from the factory: Table P.F Enclosure Type Code Description Enclosure Description Type Code Open style (IP00) NEMA Type 1 (IP20) NEMA Type 12 (IP54) Conventions To help differentiate parameter names and display text from other...
P–8 Preface Check To check means to examine either the physical condition of something or the setting of some control, such as a Parameter. Checking a drive board or component may also require measurements and tests. Connector A connector connects one drive board to another. Connectors come in two designs, male and female.
Preface P–9 Control Interface Board A Control Interface Board plugs into connectors J10 and J12, located on the lower portion of the Standard Adapter Board. This board is identified as L4, L5 or L6 and provides optional control wiring configurations for a drive. Parameter Parameters are programmable drive functions that define various operating functions or status displays of a drive.
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Chapter Control Logic Wiring and Adapters Chapter Objectives This chapter introduces you to terminal block locations and wiring, and adapter locations and functions. Chapter Overview This chapter illustrates and describes Standard Adapter Board: Control Logic Interface Options L4, L5, and L6, including Terminal Block TB3 TB3 input mode selections and functions TB3, TB5, TB6, TB7 terminal designations...
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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 AB0690B Figure 1.2 PLC Comm Adapter Terminal Block Locations...
Control Logic Wiring and Adapters 1–3 Control Interface Option The Control Interface L-Option Board provides a means of interfacing various signals and commands to the 1336 FORCE by using contact closures. Three different versions of the option are available: Contact Closure Interface +24V AC/DC Interface 115V AC Interface Uses internal +5V DC supply.
1–4 Control Logic Wiring and Adapters Figure 1.3 Jumper Locations Main Control Board Jumper J10 Standard (Located on Standard Adapter Board Adapter Board) TB5, TB6, TB7 AB0365D Available Inputs A variety of combinations made up of the following inputs are available.
Control Logic Wiring and Adapters 1–5 Important: The [Input Mode] parameter can be changed at any time; however, programming changes will not take affect until power has been cycled to the drive. When changing an input mode, it is important to note that the corresponding inputs to TB3 may also change.
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1–6 Control Logic Wiring and Adapters 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”...
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Control Logic Wiring and Adapters 1–7 Figure 1.5 ( continued) Input Mode Selection and Typical TB3 Connections 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...
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1–8 Control Logic Wiring and Adapters 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. Frequency Source Speed Select 3 Speed Select 2 Speed Select 1 Para 52 Bit 14 Bit 13...
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Control Logic Wiring and Adapters 1–9 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...
1–10 Control Logic Wiring and Adapters Adapters and Communication Ports Human Interface Module When the drive-mounted HIM is supplied, it will be connected as Adapter 1 (refer to Figures 1.7 and 1.8) and visible from the front of the drive. The HIM can be divided into two sections; Display Panel and Control Panel.
Control Logic Wiring and Adapters 1–11 Standard Adapter Ports Figure 1.8 Standard Adapter Board Port Locations TB10 Encoder Internal Communication (Adapter Port 6) Drive Mounted HIM (Adapter Port 1) Control Interface L-Option Board TB5, TB6, TB7 (TB3 Adapter Port 0) Communications Port Remote HIM/ Communication Options (Adapter 2) or Expansion Options (Adapters 2, 3, 4, 5)
1–12 Control Logic Wiring and Adapters PLC Comm Adapter Ports Figure 1.9 PLC Comm Adapter Board Port Locations Main Control Board Communications Channels Ports 6,7 PLC Comm Board SCAN port 1 SCAN port 2 TB21 TB20 Communications Port Remote HIM/ Communication Options (Adapter 2) or Expansion Options (Adapters 2, 3, 4, 5) Expansion Options...
Control Logic Wiring and Adapters 1–13 Important: Power must be removed from the drive or Bit 1 of the [Logic Mask] parameter must be set to “0” to allow removal of the HIM module without causing a Communication Fault. Setting Bit 1 of the [Logic Mask] parameter to “0”...
1–14 Control Logic Wiring and Adapters 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.
Control Logic Wiring and Adapters 1–15 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.
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Chapter Disassembly and Access Procedures Chapter Objectives This chapter describes general disassembly procedures required to access internal drive components. Disassembly and Access Overview ATTENTION: Some printed circuit boards and drive components may contain hazardous voltage levels. Remove and lock out power before you disconnect or reconnect wires, and before you remove or replace fuses and circuit boards.
2–2 Disassembly and Access Procedures Electrostatic Discharge Precautions ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other...
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.
2–4 Disassembly and Access Procedures Four-Point Mounting The following illustrates temporary and final tightening sequences for components fastened to a heat sink using four screws. Temporary torque is 1/2 (50%) of final torque. The numeric illustration labels are for your assistance. Drive components do not carry these labels. Figure 2.2 Four-Point Mounting Four–Point Mounting...
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Disassembly and Access Procedures 2–5 Table 2.A Fastener Torque Specifications — Parts Common to “D” Frame Drives Torque Torque Component Fastener Application Fastener Used in.-lb Voltage Sharing Resistor (R1 – R3) Resistor to Heat Sink M5 x 10 mm Screw 23 –...
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2–6 Disassembly and Access Procedures Table 2.B Fastener Torque Specifications — Parts Common to “D” Frame Drives A040, A050, B060 – B100, C075, C100 Torque Torque Component Fastener Application Fastener Used in.-lb IGBT Standoff Standoff Through IGBT Busbar and Into IGBT IGBT Standoff 36 –...
Disassembly and Access Procedures 2–7 Disassembly and Access Procedures Opening the Drive Enclosure Figure 2.3 Drive Enclosure Latches Hinges AB0748A 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.
2–8 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.
Disassembly and Access Procedures 2–9 Removing Control Interface L-Option Board MOD-L4, -L5, or -L6 Figure 2.4 Control Interface L-Option Board Control Interface L-Option Board Terminal Strip TB3 AB0693A 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.
2–10 Disassembly and Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Disassembly and Access Procedures 2–11 Removing the Main Control Board Figure 2.5 Main Control Board and Mounting Plate Mounting Plate Slide-Mount Connector Standoff HIM (Standard Adapter Board only) Connector J1 Connector TB10 Main Control Board Connector PLC Comm Adapter Board or Standard Adapter Board AB0695A Removal...
2–12 Disassembly and Access Procedures ATTENTION: Wear a wrist-type grounding strap when servicing 1336 FORCE Drives. Failure to protect drive components against ESD may damage drive components. Refer to Electrostatic Discharge Precautions at the beginning of this chapter. Important: Before you remove connections and wires from the drive components, mark the connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly.
Disassembly and Access Procedures 2–13 Removing the Standard Adapter Board Figure 2.6 Standard Adapter Board Mounting Plate Slide-Mount Standoff Main Control Board Connector Mounting Screw Standard Adapter Board Slide-Mount Stand-Off AB0696A 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.
2–14 Disassembly and Access Procedures 4. Check for the absence of control voltage at TB5, TB6, and TB7 on the Standard Adapter Board. 5. Disconnect the following from the Standard Adapter Board: Stake-on ground wire connector All wires from TB5, TB6, and TB7 6.
Disassembly and Access Procedures 2–15 Removing the PLC Comm Adapter Board Figure 2.7 PLC Comm Adapter Board Mounting Plate Slide-Mount Standoff Main Control Board PLC Comm Connector Adapter Board Connector J5 Connector J7 TB21 Channel A TB20 Channel B AB0697B ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
2–16 Disassembly and Access Procedures 4. Check for the absence of control voltage at TB20 and TB21 on the PLC Comm Adapter Board. 5. Disconnect the following from the PLC Comm Adapter Board: All wires from TB20 and TB21 Stake-on ground wire connector J5 connector J7 connector Communication channel A and B connectors...
Disassembly and Access Procedures 2–17 Removing the Control Board/Adapter Mounting Plate Figure 2.8 Control Board/Adapter Mounting Plate Control Board Mounting Plate Connector J1 TB10 Main Control Board Connector HIM (Standard Adapter Board only) Connector J7 Connector J1 Connector Standard Adapter Board Mounting Plate Screw...
2–18 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.
Disassembly and Access Procedures 2–19 Removing the Gate Driver Board Mounting Plate Figure 2.9 Gate Driver Board Mounting Plate Gate Driver Board Mounting Plate Gate Driver Board Connector Connector Connector Connector Connector Connector Connector Connector Mounting Screw AB0380E Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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2–20 Disassembly and Access Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Disassembly and Access Procedures 2–21 8. Slide the plate toward the top of the drive until the tabs disengage from the slots. 9. Lift the plate out of the drive. Installation Install the Gate Driver Board Mounting Plate in reverse order of removal.
2–22 Disassembly and Access Procedures Removing the Gate Driver Board Figure 2.10 Gate Driver Board Gate Driver Board Gate Driver Board Mounting Plate Connector J13 Connector J7 Connector Connector J8 Connector Connector Connector Connector AB0370E Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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Disassembly and Access Procedures 2–23 ATTENTION: Hazard of electric shock exists. Up to 1,000V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
2–24 Disassembly and Access Procedures 7. Turn the eight stand-off screws, fastening the Gate Driver Board to the Mounting Plate, 1/4 turn counterclockwise. 8. Remove the Gate Driver Board from the enclosure. Installation Install the Gate Driver Board in reverse order of removal. Refer to Fastener Torque Specifications in this chapter.
Disassembly and Access Procedures 2–25 Removing the Precharge Board Mounting Plate Figure 2.11 Precharge Board and Mounting Plate Connector Connector Connector Mounting Screw Connector Precharge Mounting Plate and Guard Precharge Board AB0519D Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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.
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 2.12 Precharge Board Precharge Board Mounting Plate Connector J1 Connector J2 Guard Connector J3...
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.
Disassembly and Access Procedures 2–29 Removing a Power Module Snubber Board Figure 2.13 Power Module Snubber Board Power Module Snubber Board Customer-Supplied 100 Ohm, 25 Watt Resistor AB0372F 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.
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2–30 Disassembly and Access Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Disassembly and Access Procedures 2–31 Installation ATTENTION: Do not substitute longer or shorter hardware when fastening the Power Module Snubber Boards 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.
2–32 Disassembly and Access Procedures Removing the Converter Snubber Board Figure 2.14 Converter Snubber Board Converter Snubber Board 9 Screws AB0373D 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.
Disassembly and Access Procedures 2–33 ATTENTION: Hazard of electric shock exists. Up to 1,000V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
2–34 Disassembly and Access Procedures Accessing Power Plane Components To access the power plane components located on the chassis, refer to Removing a Power Module Snubber Board in this chapter. Publication 1336 FORCE-6.13 – August, 1999...
Chapter Component Test Procedures Chapter Objectives The following tests help you troubleshoot A040 – A060, B060 – B125, BX150, and C075 – C125 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.
3–2 Component Test Procedures 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.
Component Test Procedures 3–3 Side cutters 17 mm socket Test 1 The Gate Driver Board is located between the Main Control Board Testing the Gate Driver and the Main Chassis. If one or more Power Modules has been Board replaced, you must test the Gate Driver Board. Figure 3.1 Gate Driver Board Test Gate Driver...
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3–4 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.
Component Test Procedures 3–5 ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury. Test 2 Testing the Precharge Figure 3.2 Board Precharge Board Test Precharge Board AB0375B ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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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.
Component Test Procedures 3–7 Test 3 The Power Modules are located near the top of the heat sink. Testing the Power Figure 3.3 Modules Power Module Test Power Module (Some drives may not have brackets at E and G) AB0390C ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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3–8 Component Test Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Component Test Procedures 3–9 10.Replace both Power Modules in the same phase if meter readings are not as shown. Refer to Chapter 4 – Part Replacement Procedures, Power Modules. 11. If one or more Power Modules is replaced, test the Gate Driver Board.
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3–10 Component Test Procedures ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
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Component Test Procedures 3–11 7. Apply power AFTER the meter is connected, otherwise your meter will read zero volts. Expand readings for all input voltage ratings. Table 3.C Bus Capacitor Bank Test Drive Input Meter Rating Volts Reading 280V DC +/–10% 322V DC +/–10% 336V DC +/–10% 535V DC +/–10%...
3–12 Component Test Procedures Test 5 The Input Rectifiers are located on the bottom of the heat sink. Testing the Input Rectifiers Figure 3.5 Input Rectifier Test Input Rectifier K2/G2 K1/G1 AB0387C ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury.
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Component Test Procedures 3–13 ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
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3–14 Component Test Procedures Table 3.D Input Rectifier Test Meter (+) Lead Meter (–) Lead Nominal Meter Reading Infinite Infinite Infinite Infinite Infinite Infinite 0.008 0.008 0.008 0.008 10.Replace the Input Rectifier if any meter readings are not as shown. Refer to Chapter 4 – Part Replacement Procedures, Input Rectifiers.
Chapter Part Replacement Procedures Chapter Objective This chapter describes procedures required to replace drive components. This chapter references Chapter 2 – Disassembly and Access Procedures for basic drive component access. Part Replacement The part replacement procedures in this chapter assume that the drive Overview you are servicing either has no enclosure or that the enclosure is open.
4–2 Part Replacement Procedures Electrostatic Discharge Precautions ATTENTION: This assembly contains parts and sub-assemblies that are sensitive to electrostatic discharge. Static control precautions are required when servicing this assembly. Component damage may result if you ignore electrostatic discharge control procedures. If you are not familiar with static control procedures, reference Allen-Bradley Publication 8000-4.5.2, Guarding Against Electrostatic Discharge, or any other...
Part Replacement Procedures 4–3 Major Component This section explains in detail how to replace the following drive Replacement components: Bus Capacitors Thermistor Power Modules Input Rectifiers Fan Assembly Autotransformer DC Bus Inductor L1 Ground Sense CT Bus Fuse LEMs MOV Surge Suppressor For Gate Driver Board, Precharge Board, Main Control Board, Standard Adapter Board, PLC Comm Adapter Board, Snubber Board, and Control Interface Board installation and removal...
4–4 Part Replacement Procedures 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.
Part Replacement Procedures 4–5 Bus Capacitor Bank The Bus Capacitor Bank is located on the left side of the Main Chassis. Figure 4.2 Bus Capacitor Bank Load-Sharing Resistor Bus Fuse Capacitor Bracket Capacitor Capacitor Retainers One of two sizes, this bolt only Capacitor Bus Bar DC–...
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4–6 Part Replacement Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Part Replacement Procedures 4–7 4. Remove the Capacitor Bus Bar. 5. Loosen the screws on the Capacitor Brackets. 6. Slide the brackets away from the Capacitor Retainers and down to remove. 7. Remove the Capacitor Retainers. 8. Lift the Bus Capacitors out of the Drive. Installation 1.
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4–8 Part Replacement Procedures Load-sharing resistor R1 has three color coded leads coming out of the resistor body. Connect as shown in Figure 4.4. Figure 4.4 Wiring Detail for A040, A050, B060, B075, and B100 Drives Blue Yellow 13.6K Ohms Black Inv–...
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Part Replacement Procedures 4–9 Load-sharing resistors R1 and R2 have two color coded leads coming out of each resistor body. Connect as shown in Figure 4.5. Figure 4.5 Wiring Detail for A060, B125, and BX150 Drives Blue 4.3K Ohms Black Blue 4.3K Ohms...
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4–10 Part Replacement Procedures Load sharing resistors R1 and R2 have three color coded leads coming out of each resistor body. Connect as shown in Figure 4.6. Figure 4.6 Wiring Detail for C075 and C100 Drives Blue Yellow 13.6K Ohms Black Blue 13.6K...
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Part Replacement Procedures 4–11 Load-sharing resistors R1, R2, and R3 have two color coded leads coming out of each resistor body. Connect as shown in Figure 4.7. Figure 4.7 Wiring Detail for C125 Drives Blue 4.3K Black Ohms Blue 4.3K Black Ohms Blue...
4–12 Part Replacement Procedures Thermistor The Thermistor is located on the top-left corner of the heat sink. Figure 4.8 Thermistor Thermistor Connector to Main Control Board J1 AB0381B 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.
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Part Replacement Procedures 4–13 ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
4–14 Part Replacement Procedures Installation Install the Thermistor in reverse order of removal, replacing tie wraps as needed. Refer to Chapter 2 – Disassembly and Access Procedures, Fastener Torque Specifications. ATTENTION: Replace all guards before applying power to the drive. Failure to replace guards may result in death or serious injury.
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.
4–16 Part Replacement Procedures 7. Remove the four standoffs from the Inverter Bus Bar. 8. Remove the four screws fastening the Power Module to the Drive. Installation 1. Clean all surfaces between the Power Module and the heat sink using a soft, clean cloth. 2.
Part Replacement Procedures 4–17 Input Rectifiers The Input Rectifiers are located at the bottom of the heat sink. Figure 4.10 Input Rectifiers Input Rectifier 9 Standoffs Converter Bus Bar CNV – T-L3 CNV + S-L2 R-L1 AB0385D Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive.
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4–18 Part Replacement Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Part Replacement Procedures 4–19 Installation 1. Clean all surfaces between the Input Rectifier and the heat sink using a soft, clean cloth. 2. Replace the Preform between the Input Rectifier and the heat sink. 3. Install the Input Rectifier in reverse order of removal. Refer to Chapter 2 –...
4–20 Part Replacement Procedures Fan Assembly The Fan is located under TB1 at the bottom of the Main Chassis. The Autotransformer and Fan Capacitor are located in the bottom left corner of the Main Chassis. Figure 4.11 Fan Assembly Fan Cover TB1 Terminal Partitions and DIN Rails Terminal...
Part Replacement Procedures 4–21 Removal ATTENTION: Disconnect and lock out power from the drive before disassembling the drive. Failure to disconnect power may result in death or serious injury. Verify bus voltage by measuring the voltage between +DC and –DC on Terminal Block TB1. Do not attempt to service the drive until the bus voltage has discharged to zero volts.
4–22 Part Replacement Procedures Remove the Lower DIN Rail: 1. Loosen the screw fastening the Terminal End Stop to the right side of the Lower DIN Rail to remove the end stop. 2. Slide TB1 terminal W-M3 off the DIN rail to expose a screw on the DIN rail.
Part Replacement Procedures 4–23 Autotransformer The Autotransformer and Fan Capacitor are located in the bottom left corner of the Main Chassis. Figure 4.12 Autotransformer Stake-on Connectors Wire Harness Capacitor MOV Surge Suppressor Autotransformer AB0619A Publication 1336 FORCE-6.13 – August, 1999...
4–24 Part Replacement Procedures Removal 1. Remove power from the drive. 2. Check for zero volts at TB1 terminals +DC and –DC. 3. Check for the absence of control voltage at: TB20 and TB21 on drives using a PLC Comm Adapter Board TB5, TB6, and TB7 on drives using a Standard Adapter Board 4.
Part Replacement Procedures 4–25 DC Bus Inductor L1 DC Bus Inductor L1 is located on the lower left corner of the Drive. Figure 4.13 DC Bus Inductor L1 DC Bus Inductor L1 CNV – Connection TB1 DC– Connection CNV + Connection TB1 DC+ Connection AB0386C...
4–26 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.
Part Replacement Procedures 4–27 Ground Sense CT The Ground Sense CT is located in the lower left of the Drive. Figure 4.14 Ground Sense CT Bus Capacitor Bus Bar Bus Capacitor Bus Bar +DC Connection –DC Connection Connector to Gate Driver Board J2 Ground Sense CT...
4–28 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.
Part Replacement Procedures 4–29 Bus Fuse The Bus Fuse is located at the top-center of the Drive. Figure 4.15 Bus Fuse Bus Fuse M10 Bolt, Split Washer and Belville Washer, All D-Frame Drives Use one of two bolts here M10 Belville on D-Frame Drives Belville M8 Belville...
4–30 Part Replacement Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Part Replacement Procedures 4–31 LEMs The LEMs are located near the bottom of the heat sink. Figure 4.16 LEMs W-M3 V-M2 U-M1 Connector Nylon Spacers Mounting Mounting Screws Bracket AB0392C 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.
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4–32 Part Replacement Procedures ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
Part Replacement Procedures 4–33 9. Slide the LEM mounting bracket off of Inverter output wires. 10.Compress the tabs on the nylon spacers to remove the LEM from the mounting bracket. Installation Install the LEMs in reverse order of removal. Refer to Chapter 2 –...
4–34 Part Replacement Procedures MOV Surge Suppressor The MOV Surge Suppressor is located in the bottom-left corner of the Drive near the Autotransformer and Fan Capacitor. The MOV protects the drive from high voltage surges above approximately 1,000 volts. Replace the MOV if it is burned, expanded, or ruptured after such events as a lightening strike or inadvertent connection of the drive input to a voltage source substantially above nameplate voltage.
Part Replacement Procedures 4–35 Removal ATTENTION: Hazard of electric shock exists. Up to 1,000 V DC may be present on Snubber Capacitors. Measure for zero V DC across capacitors C2, C3, and C4. Use a resistor greater than 1 ohm and less than 100 ohm, rated for 25 watts minimum, to discharge any voltage.
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4–36 Part Replacement Procedures This Page Intentionally Left Blank Publication 1336 FORCE-6.13 – August, 1999...
Chapter Replacement Parts List Chapter Objectives This chapter illustrates and lists replacement parts for the 1336 FORCE Drives rated A040 – A060, B060 – B125, BX150, and C075 – C125 and describes replacement parts ordering procedures. The following illustration and table show you parts, part names, part numbers, locations, and chapters for replacement procedures.
5–2 Replacement Parts List Replacement Parts Listing Figure 5.1 Parts for A040 – A060, B060 – B125, BX150, and C075 – C125 Drives AB0699A Publication 1336 FORCE-6.13 – August, 1999...
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Replacement Parts List 5–3 Table 5.A Replacement Parts for A040 – A060, B060 – B125, BX150, and C075 – C126 Drives Callout Symbol Description Location Replacement Procedures R1 – R3 Load-Sharing Resistor Main Chassis Chapter 4, Bus Capacitor Bank Q1 – Q6 IGBT Heat Sink Chapter 4, Power Modules...
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5–4 Replacement Parts List This Page Intentionally Left Blank. Publication 1336 FORCE-6.13 – August, 1999...
Chapter Schematics — 40 – 150 HP 1336 FORCE Drives Publication 1336 FORCE-6.13 – August, 1999...
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6–2 Schematics — 40 – 150 HP 1336 FORCE Drives DC– CONVERTER SNUBBER BOARD SEE TABLE 2 CNV+ TO FAN CIRCUIT SEE FAN CIRCUIT DETAIL CUSTOMER FUSING R–L1 SCR1 SCR3 SCR5 1000:1 CAPACITOR BANK INPUT S–L2 POWER SEE CAPACITOR 50/60HZ DETAIL MOV1 T–L3...
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Schematics — 40 – 150 HP 1336 FORCE Drives 6–3 U–M1 OUTPUT V–M2 POWER W–M3 U_AMPS W_AMPS 2000:1 2000:1 –15 –15 +INV GATE INTERFACE GATE INTERFACE GATE INTERFACE –INV MAIN NTC1 CONTROL BOARD M1X1 M1X2 CONTACTOR M1K2 INTERFACE M1K1 8 7 6 5 4 3 2 1 1 2 3 16 17 18 AC FAN1...
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6–4 Schematics — 40 – 150 HP 1336 FORCE Drives Fan Circuit Detail 200/240VAC R–L1 S–L2 AC–INPUT POWER (240) (200) (240) (0V) 250 VA (115V) HEATSINK C–HB1 200/240V 380/460VAC 575VAC R–L1 S–L2 R–L1 S–L2 AC–INPUT POWER AC–INPUT POWER (415) (380) (500) (0V) (575)
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Schematics — 40 – 150 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 230VAC FUSE CURRENT/TYPE 380/460VAC FUSE CURRENT/TYPE 575VAC FUSE CURRENT/TYPE 150 AMP, CLASS T, JJS –...
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6–6 Schematics — 40 – 150 HP 1336 FORCE Drives This Page Intentionally Left Blank Publication 1336 FORCE-6.13 – August, 1999...
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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.
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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.
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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.
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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.
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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.
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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.
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Glossary G–7 Locked-Rotor Current: Steady-state current taken from the line current with the a rotor at standstill (at rated voltage and frequency). This is the current when starting the motor and load. Locked-Rotor Torque: The minimum torque that a motor will develop at rest for all angular positions of the rotor (with rated voltage applied at rated frequency).
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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.
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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.
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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.
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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-6.13 – August, 1999...
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G–12 Glossary This Page Intentionally Left Blank Publication 1336 FORCE-6.13 – August, 1999...
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Index Adapter Locations, 1–11 DC Bus Inductor L1 Illustration, 4–25 Adapters and Communication Ports, Human Installation, 4–26 Interface Module, 1–10 Removal, 4–25 Audience for this Manual, P–1 Default, Definition, P–8 Autotransformer, Illustration, 4–20 Detailed Product Identification, 4–4 Auxiliary Input, Definition, P–7 Drive Auxiliary Interlock, Definition, P–7 Enclosure Type, P–7...
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Index I–3 Procedures Local, 1–5 Accessing Internal Drive Components, 2–1 Autotransformer Removal, 4–21 Bus Capacitor Bank Installation, 4–7 Rating, Drive, P–6 Bus Capacitor Bank Removal, 4–5 Related Publications, P–9 Bus Capacitor Bank Test, 3–9 Bus Fuse, 4–29, 4–30 Removal Procedures. See Procedures Component Test, 3–1 Removal, HIM, 1–12 Control Board Installation, 2–12...
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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...
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SCANport is a trademark of Allen-Bradley Company, Inc. PLC is a registered trademark of Allen-Bradley Company, Inc.
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Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software. Rockwell is one of the world’s leading technology companies.
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