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Rockwell Automation Allen-Bradley IMPACT 1336 Series Troubleshooting Manual Download Page 135

 5–35

Part Replacement Procedures

Publication 1336 IMPACT-6.8 – November, 2002

Part Replacement Procedures

Replacing Bus Fuses

The Bus Fuses are located on the Transitional Bus Bar Assembly.

If just one of the three Bus Fuses fails, suspect a failure in the
associated set of Bus Capacitors. Refer to Replacing Bus Capacitors
in this chapter.

Removal

Figure 5.19
Bus Fuse

Bus Fuse

1/4 Turn 
Latches

Inverter Bay w/o Cabinet

Precharge
Board
Mounting
Frame

!

ATTENTION:   Wear a wrist-type grounding strap
when servicing 1336 IMPACT drives. Failure to
protect drive components against ESD may damage
drive components. Refer to Electrostatic Discharge
Precautions at the beginning of this chapter.

Summary of Contents for Allen-Bradley IMPACT 1336 Series

Page 1: ...Troubleshooting Manual 1336 IMPACT Adjustable Frequency AC Drive 519 597 kW 700 800 HP ...

Page 2: ...dley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout thi...

Page 3: ...ns P 7 Conventions P 8 Auxiliary Input P 8 Auxiliary Interlock P 8 Bit P 8 Check P 8 Connector P 8 Default P 9 Enable Input P 9 False P 9 Jumper P 9 L Option Board P 9 Parameter P 9 Press P 9 True P 10 Related Publications P 10 Chapter 1 Chapter Objectives 1 1 Chapter Overview 1 1 L Option Board 1 3 Control Board Jumpers for L Option 1 3 Available Inputs 1 3 Local Programming 1 7 Human Interface M...

Page 4: ...s Overview 3 1 Electrostatic Discharge Precautions 3 2 Tools 3 2 Fastener Torque Specifications 3 3 Torque Sequence 3 3 Torque Specifications 3 4 Access Procedures 3 6 Opening the Drive Enclosure 3 6 Opening 3 7 Closing the Drive Enclosure 3 9 Removing the Control Board Mounting Plate 3 10 Removal 3 10 Installation 3 11 Removing the Precharge Board Mounting Frame 3 12 Removal 3 12 Installation 3 1...

Page 5: ...stor and Thermostat 4 16 Chapter 5 Chapter Objectives 5 1 Part Replacement Overview 5 1 Safety Precautions 5 1 Electrostatic Discharge Precautions 5 1 Detailed Product Identification 5 2 Replacing the L Option Board 5 4 Removal 5 4 Installation 5 5 Replacing the Control Board 5 6 Removal 5 6 Installation 5 7 Replacing the Gate Driver Board 5 8 Removal 5 8 Installation 5 9 Replacing the Common Bus ...

Page 6: ...Replacing the Ground Fault CT 5 33 Removal 5 33 Installation 5 34 Replacing Bus Fuses 5 35 Removal 5 35 Installation 5 36 Replacing Current Transducers LEMs 5 37 Removal 5 37 Installation 5 38 Replacing Bus Capacitors 5 39 Removal 5 39 Installation 5 40 Replacing Volt Sharing Resistors and Dual Diodes 5 42 Removal 5 42 Installation 5 43 Replacing the Converter Bay Door Fan 5 44 Removal 5 44 Instal...

Page 7: ...ter 6 Chapter Objectives 6 1 Ordering Replacement Parts 6 1 Replacement Parts Listing 6 2 Chapter 7 Chapter Objectives 7 1 Inverter Bay Schematic 7 2 Control Board Layout 7 5 Typical Converter Bay Schematic 7 6 Fuse Tables 7 13 Replacement Parts List Schematics Index ...

Page 8: ...Table of Contents vi Publication 1336 IMPACT 6 8 November 2002 This Page Intentionally Left Blank ...

Page 9: ...ral illustrations and end with greater detail concerning replacement parts and part locations on the drives Later chapters may refer you back to earlier chapters for information on basic equipment and steps necessary to perform detailed diagnostics and part replacement ATTENTION Some printed circuit boards and drive components may contain hazardous voltage levels Remove and lock out power before y...

Page 10: ...mage 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 Rockwell Automation Publication 8000 4 5 2 Guarding Against Electrostati...

Page 11: ...ated on Inside Wall Inverter Bay Converter Bay DATA NAMEPLATE CAT NO SERIAL NO ORDER NO 3 PHASE AC OUTPUT WIRING DIA ENCLOSEMENT TYPE CONSTANT TORQUE VARIABLE TORQUE H P MAXIMUM RMS SHORT CIRCUIT CURRENT AMPS Allen Bradley KVA VOLTS HZ AMPS KVA VOLTS HZ A PH AC INPUT AC OUTPUT DC INPUT KVA VOLTS HZ A PH CONSTANT TORQUE VARIABLE TORQUE CAT Allen Bradley 3 PHASE AC INPUT KVA VOLTS HZ AMPS POWER RATI...

Page 12: ...rate Heat Dissipation Frame Designation Rating Code1 AC Input V AC2 Nominal HP2 Output Amps Derate Base 2 Derate Curve3 4 Drive Watts3 4 Heat Sink Watts3 Converter Watts Choke Watts Total Watts3 H C700C C800C 380 480 380 480 700 800 770 0 800 0 5 5 1700 1900 97004 120004 1750 2000 875 1000 14025 16900 B700C B800C 575 600 575 600 700 800 850 0 983 0 5 5 1800 2000 94004 113004 1750 2000 875 1000 138...

Page 13: ...option refer to Publication 1336 IMPACT 1 0 2 Configured only Table P E Communication Code Communication Options Code Description1 GM1 GM2 GM3 Single Point Remote I O RS 232 422 485 DF1 RS 232 422 485 DH485 1 For a more functionally complete description of each option refer to Publication 1336 IMPACT 1 0 Configured Options All H Frame systems are configured which means that each system is built an...

Page 14: ...ut Fused Disconnect Switch Drive Output Contactor Motor Thermal Overload Relay DT KD KM DS BA or BM FM Non Fused Drive Disconnect Switch Drive Input Contactor Drive Output Contactor Drive Input Fused Disconnect Switch Bypass Bypass Mode Motor Fuse Block CC KD CB BA or BM Bypass Circuit Breaker Drive Input Contactor Drive Circuit Breaker Bypass CC KD CB BS BD BP or BC Bypass Circuit Breaker Drive I...

Page 15: ...ontact Closure 4 L7E 5 o o Contact Closure Encoder Feedback 24V L5 8E 24V AC DC 24V E o F L8E L6 24V AC DC Encoder Feedback 115V AC 6 L9E 115V 115V AC Encoder Feedback 1 For a more functionally complete description of each option refer to Publication 1336 IMPACT 1 0 Table P H Language Module Codes Language Modules Option Code Description EN English English EN FR English English English French F DE...

Page 16: ...iliary Interlock is a user supplied circuit consisting of reset overload or other interlocking circuitry The Interlock is wired to the drive Auxiliary input Bit A bit is a single character or status point used in programmable logic Eight bits form a BYTE 16 bits form a word Drive parameters are actually eight bits or 16 bit words Check To check means to examine either the physical condition of som...

Page 17: ...ircuit between two pins within a male connector on a drive board In the absence of certain optional equipment using female connectors jumpers are applied to certain pins within a male connector to complete specific and necessary circuits L Option Board An L Option Board plugs into connectors J7 and J9 located on the lower portion of the Control Board This board is identified as L4 L5 L6 L7E L8E or...

Page 18: ... Software 9303 2 0 Bulletin 1201 Graphic Programming Terminal User Manual 1201 5 0 1336 5 91 Multipulse Bridge Assembly Parts Kit 1 Current 1336 IMPACT spare parts information including recommended parts catalog numbers and pricing can be obtained from the following sources Allen Bradley home page on the World Wide Web at http www ab com Select Drives and the select Information for Drives Includin...

Page 19: ...tween the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important All printed circuit boards except the Control Board assemb...

Page 20: ...oard TB3 Terminal Block ATTENTION The National Electric Code NEC and local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ...

Page 21: ...ion must be selected through programming as explained later in this section The L7E L8E and L9E options are similar to L4 L5 and L6 with the addition of encoder feedback inputs Control Board Jumpers for L Option Important If the L Option Board is being installed Control Board jumpers at pins 3 4 and 17 18 of J2 must be removed If these jumpers are removed they can be stored on the spares location ...

Page 22: ...owever programming changes will not take effect 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 The programming options of the L Option Board allow you to select an input combination to meet the needs of a specific installation Appropriate selection of a combination may be done by using Table 1 A Firs...

Page 23: ...Enable3 Enable3 Not Stop6 Clear Fault3 5 Speed Select 21 Speed Select 11 Select 31 Select 31 Control2 Single Source Three Wire Control L Option Mode parameter 116 2 6 17 18 and 27 L Option Mode parameter 116 1 Not Stop6 Clear Fault3 5 Rev Fwd4 17 18 Proc Trim Flux En Reset Ramp 4 Bit 11 of Logic Options parameter 17 must be 0 for reverse direction control 5 For soft faults only You need to recycle...

Page 24: ... Torque 210 Speed Torque 110 Speed Process Trim Reverse5 Forward5 Torque 310 Speed Torque 210 Speed Torque 110 Speed Enable Flux Ramp Reset Torque 310 Speed Torque 210 Speed Torque 110 Speed Speed Select 21 Process Trim Reset Flux Enable Process Trim Reset Ramp Run Reverse5 11 Run Forward5 11 Type7 2nd 1st 2nd 1st Precharge Enable Precharge Enable 23 24 25 19 20 21 22 5 6 For soft faults only You ...

Page 25: ... HIM and Communication Options Direction works in parallel with HIM or Communication Options 7 11 19 22 and 28 292 Maintained switches for combined run and direction control 2 wire Run Forward Run Reverse Start works differently than three wire control 1 Direction works differently than three wire control 1 Stop always works 12 16 23 25 and 302 1 Refer to two three wire notes in the user manual 2 ...

Page 26: ...O Speed Ref 5 X O X Speed Ref 6 X X O Speed Ref 7 X X X Last State O Open Removed 0 X Closed Applied 1 Table 1 C defines the input state of the Speed Torque Mode Select inputs for a desired speed torque mode Table 1 C Speed Torque Select Speed Torque Mode Select 3 Speed Torque Mode Select 2 Speed Torque Mode Select 1 Speed Torque Mode O O O Zero Torque O O X Speed Regulate O X O Torque Regulate O ...

Page 27: ...ovides a means of programming the drive and viewing the various operating parameters The Control Panel allows different drive functions to be controlled For HIM operation refer to the 1336 IMPACT User Manual Important The operation of HIM functions depends upon drive parameter settings Default parameter values allow full HIM functionality Figure 1 5 Human Interface Module Inverter Mounted Typical ...

Page 28: ...rive Mounted HIM SCANport 6 Gateway Removing the HIM For handheld operation you can remove the module and place it up to 10 meters 33 feet from the 1336 IMPACT drive You do need a cable to do this 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 ...

Page 29: ...ming device the drive will not fault if you have the SCANport communications fault set to be ignored for that port To remove the HIM you need to 1 Prevent the drive from faulting by either Removing the power or Clearing the appropriate port bit Depending on the port where the HIM is attached either in SP Enable Mask clear parameter 124 or in Fault Select 1 clear parameter 20 2 Remove the front cov...

Page 30: ...Tools Software manual All control functions in the 1336 IMPACT drive are performed through the use of parameters that can be changed with a programming terminal or DriveTools Refer to the overview Block Diagram of the Control Firmware Function in the 1336 IMPACT User Manual Feedback information is derived from hardware devices as part of the process equipment used Analog signals are converted to d...

Page 31: ...not comply During the start up procedure you should have recorded board jumper settings for each board board software version numbers and the drive and motor nameplate data in Table 6 A of the 1336 IMPACT User Manual If this information was not recorded record it before beginning any troubleshooting sequences When a problem occurs with your drive check the VP and CP LEDs on your drive on the Contr...

Page 32: ...he drive Address the condition that caused the warning Faults are annunciated on the Human Interface Module HIM at the time they occur Warnings are not annunciated on the HIM To help troubleshoot your 1336 IMPACT drive the drive logs any faults or warnings in either the fault or warning queue The faults and warnings that are contained in the queues are either configurable or non configurable This ...

Page 33: ...ced in the queue when the first fault occurs after a power up sequence This power up marker is as shown P w r U p M a r k e r F 0 1 1 The 1336 IMPACT drive tracks the time that has elapsed since power up The drive uses this information as a time stamp so that you can tell when a fault occurred in relation to when the drive was powered up To clear the fault queue select Clear Queue from the Fault Q...

Page 34: ...as reached the level of accumulated motor current over time as set by Motor Overload parameter 26 Check for possible motor overheating If the motor temperature is excessive reduce the accel decel times parameters 42 45 or reduce the load If the motor temperature is acceptable increase the value of Motor Overload parameter 26 If you do not want this condition to be reported as a fault change bit 4 ...

Page 35: ... heatsink When this condition occurs the drive coasts to a stop regardless of the selected stop type Check the cabinet filters drive fans and heatsinks Check the thermal sensor and sensor wiring connector Reduce the load or duty cycle if possible Lower the value of PWM Frequency parameter 10 02049 Inv Overtemp Pnd VP Flashing red Soft An inverter overtemperature is pending The inverter heatsink te...

Page 36: ...nt this condition to be reported as a warning change bit 15 in Warning Select 2 parameter 23 to 0 03008 HW Malfunction VP Red 1 blink Hard A hardware malfunction was detected on power up or reset When this condition occurs the drive coasts to a stop regardless of the selected stop type Recycle the power If the fault does not clear replace the Control Board 03009 HW Malfunction VP Red 2 blink Hard ...

Page 37: ...eded the speed limit plus Absolute Overspd parameter 24 settings When this condition occurs the drive coasts to a stop regardless of the selected stop type If operating in torque mode check if the load is allowing excessive motor speed Check if the setting of Absolute Overspd parameter 24 or the speed limits parameters 40 and 41 are too low 03026 Analog Spply Tol VP Flashing red Soft The analog su...

Page 38: ...arameter 21 to 0 03089 Param Limit VP Flashing green Warning A parameter limit has occurred Examine the parameter limit testpoints to determine the exact cause Refer to the Understanding Parameter Limit Faults section in the troubleshooting chapter of the user manual If you do not want this condition to be reported as a warning change bit 9 in Warning Select 2 parameter 23 to 0 03090 Math Limit VP...

Page 39: ...eter 20 to 0 06042 SP 2 Timeout VP Flashing red Soft The SCANport adapter at port 2 has been disconnected and the logic mask bit for port 2 is set 1 If the adapter was not intentionally disconnected Check the wiring to the SCANport adapters Replace wiring SCANport expander SCANport adapters and Control Board Replace drive if required If you do not want this condition to be reported as a fault chan...

Page 40: ...mmunications have been interrupted If the adapter was not intentionally disconnected Check for excessive electrical noise in the system Check the wiring to the SCANport adapters Replace wiring SCANport expander SCANport adapters and Control Board Replace drive if required If you do not want this condition to be reported as a fault change bit 15 in Fault Select 1 parameter 20 to 0 06073 SP 1 Timeou...

Page 41: ...g The SCANport adapter at port 5 has been disconnected and the logic mask bit for port 5 is set 1 If the adapter was not intentionally disconnected Check the wiring to the SCANport adapters Replace wiring SCANport expander SCANport adapters and Control Board Replace drive if required If you do not want this condition to be reported as a warning change bit 13 in Warning Select 1 parameter 21 to 0 0...

Page 42: ...Fault CP Solid red Soft A current path to earth ground in excess of drive rated current has been detected at one or more of the drive output terminals When this condition occurs the drive coasts to a stop regardless of the selected stop type Run the power structure diagnostics Check the motor and external wiring to the drive output terminals for a grounded condition On the Precharge Board Mounting...

Page 43: ... incoming AC line for low voltage or line power interruption Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for more information If you do not want this condition to be reported as a fault change bit 3 in Fault Select 1 parameter 20 to 0 or decrease the bus undervoltage setpoint 12036 Bus Cycle 5 CP Flashing red Soft At least 5...

Page 44: ...w voltage or line power interruption Refer to the Understanding Precharge and Ridethrough Faults section in the troubleshooting chapter of the user manual for more information If you do not want this condition to be reported as a warning change bit 2 in Warning Select 1 parameter 21 to 0 12067 Bus Undervlt CP Solid green Warning The DC bus voltage fell below the minimum value 388V DC at 460V AC in...

Page 45: ...meter 21 to 0 13000 HW Malfunction CP Solid red Hard A hardware malfunction occurred Recycle the power If the fault does not clear replace the Control Board 13001 HW Malfunction CP Solid red Hard A hardware malfunction occurred Recycle the power If the fault does not clear replace the Control Board 13002 HW Malfunction CP Solid red Hard A hardware malfunction occurred Recycle the power If the faul...

Page 46: ...d Jog1 Jog2 Owner par 129 and 130 Check Run Inhibit Sts par 16 HIM displays Running Drive will not start or jog Refer to HIM Displays Running Reconnect the HIM HIM connected properly Refer to No HIM Display Check fault queue Check Stop owner External Fault enabled Fault enabled Stop enabled Not Enabled Replace HIM HIM cable or Control Board Start Jog Ver 2 xx enabled Check Start and Jog owner Chec...

Page 47: ...ct the HIM Is HIM connected properly Replace the HIM DC bus voltage present Replace Gate Driver Board Replace HIM HIM cable or Control Board No Yes Yes No Yes No Yes No Do 5 15 and 12 supply voltages on the Control Board check out Yes Replace Control Board or Gate Driver Board Replace the diode bridge and any other damaged components Replace the fuse the Gate Driver Board or the complete drive as ...

Page 48: ...displays Running No Yes Incorrect Value Check Speed Ref 1 6 Speed Ref 1 Fac par 28 29 31 37 Check Rev Speed Limit and Fwd Speed Limit par 40 and 41 Correct Ref Speed Check L Option enable or jumpers Check Spd Trq Mode Sel par 68 Command the correct reference Check Command Spd Sts par 82 Check Pos Torque Limit and Neg Torque Limit par 74 and 75 Check bits 12 14 of Logic Input Sts par 14 Incorrect R...

Page 49: ...d Need better response to change in speed Did you run auto tune No Yes Run the auto tune procedure Motor response not as desired Adjust the bandwidth Ki Kp and Kf parameters Set S Curve Percent par 47 to zero Adjust Accel Time 1 par 42 and Decel Time 1 par 44 Need better response to change in load Yes No Yes ...

Page 50: ...pm for a 60 Hz 4 pole motor If the motor speed is 0 rpm you should Check the encoder wiring Check the encoder itself If you are having problems with how your 1336 IMPACT drive is operating refer to this table for possible solutions before calling for help If Then you should The drive starts and then stops Check if the mode specified in L Option Mode parameter 116 is 2 or 3 wire Check SP 2 Wire Ena...

Page 51: ...e Check if the port is enabled in SP Enable Mask parameter 124 Check if Reference is enabled in Dir Ref Mask parameter 125 Check if Reference owner in Dir Ref Owner parameter 128 has any bit set If so remove the command reference If bit 0 for the L Option control is set you need to do one of the following to remove ownership Clear bit 0 in Dir Ref Mask parameter 125 If L Option Mode parameter 116 ...

Page 52: ...art smoothly Increase the bandwidth in Spd Desired BW parameter 161 If the bandwidth is too low the motor may not accelerate although the current increases to current limit If the regen power limit is 0 increase it to at least 5 Increase the torque and current limits to the maximum Increase the value of Kp Freq Reg parameter 178 The motor oscillates after it is up to speed Decrease the bandwidth i...

Page 53: ...oth ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equipment can be hazardous Electrical shock burns or unin...

Page 54: ...e the complementary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new circuit board from the conductive packet Remove boards from the drive an...

Page 55: ...edure is not performed to specification The following illustrates temporary and final tightening sequences for components fastened to a heat sink using two four and six screws Temporary torque is 1 3 33 of final torque except six point mountings which require 0 5 N m 4 in lb The numeric illustration labels are for your assistance Drive components do not carry these labels Figure 3 1 Two Point Moun...

Page 56: ...locations by component how the fasteners are used and torque specifications Refer to Torque Sequence in this chapter for fastening two point four point and six point components to the heat sink Table 3 A Fastener Torque Specifications Component Fastener Application Torque in lb Torque N m Fan Motor Motor to Fan Cover Assembly 14 1 6 Snubber Resistor Resistor to heat sink 26 2 9 Snubber Bracket Bra...

Page 57: ...assis 75 8 5 Bus Bar Cable Adaptor Adaptor to Transitional Bus Bar Assembly and DC Bus Inductor right side of Motor Flex Bus 75 8 5 Converter Bus and Motor Bus Bars All connections 240 27 Wires PE Wires to Ground Stud 175 20 Wire TE Wire on Control Board Mounting Plate 26 2 9 Wires Wires to TB1 16 1 8 Wires Wires to TB2 7 0 8 Wires Wires to TB3 8 10 0 9 1 1 Power Cables Cables to terminals 240 27 ...

Page 58: ...er 2002 Opening the Drive Enclosure Follow all steps in this procedure whenever you open the drive cabinet Figure 3 4 Drive Enclosure AB1089 Precharge Board Mounting Frame Latches 1 4 Turn Door Latches 5 Inverter Bay Door Converter Bay Door Access Procedures ...

Page 59: ...ed on the left side of the Precharge Board Mounting frame to open the Precharge Board Mounting Frame Refer to Figure 3 4 4 Check for zero volts between DC and DC Refer to Figure 3 5 ATTENTION Verify zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure volt...

Page 60: ...verter Bay door opens with quarter turn latches Also if present pull the Circuit breaker handle all the way down Rotary disconnect handle to Off 7 Check for zero volts on incoming power lines In particular at the six line fuses check both ends for zero voltage from phase to phase and phase to ground Refer to Figure 3 6 ATTENTION A blown fuse can create a hazard of shock which may result in death o...

Page 61: ...3A Closing the Drive Enclosure ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury 1 If open close and latch the Precharge Board Mounting Frame 2 Close the Inverter Bay door and latch with quarter turn latches 3 Close the Converter Bay door and latch with quarter turn latches ...

Page 62: ...Board Mounting Frame Figure 3 7 Control Board and Mounting Plate AB0977A Control Board Control Board Mounting Plate Terminal Strip TE Inverter Bay w o Cabinet Precharge Board Mounting Frame Chassis Ground Wire Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Disch...

Page 63: ... 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 2 Remove connectors and wires from the Control Board 3 Remove the screws and nuts two each fasteni...

Page 64: ...removed before pulling the Inverter Assembly or Capacitor Bank Assembly Figure 3 8 Precharge Board Mounting Frame AB0987A Precharge Board Mounting Frame Shown Unlatched and Swung Open Inverter Bay w o Cabinet Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discha...

Page 65: ...s 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 Perform the following procedures found earlier in this chapter Opening the Drive Enclosure Removing the Control Board Mounting Plate 2 Disconnect all remaining wires connecting compone...

Page 66: ...lure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 as...

Page 67: ...Connector HV Guard Screws and Standoffs Channel Part of Inverter Bay Frame Motor Bus Flex Cables Common Mode Choke Referring again to Figure 3 9 and to the following steps remove the Motor Buses 1 Disconnect the Motor Buses from the Motor Bus Bottom Support 2 Remove Motor Bus Bottom Support 3 Disconnect the right Motor Bus at its upper end 4 Disconnect Motor Buses from flex cables This step is not...

Page 68: ...hich can only be replaced as part of the Motor Bus assembly Installation Install the Motor Bus Bars in reverse order of removal Refer to Table 3 A Fastener Torque Specifications in this chapter ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 69: ... to hold the assembly You cannot remove the assembly without a platform The top of the platform must be even with the assembly s track The platform must be strong enough to support the assembly and the personnel servicing the drive Refer to Figure 3 16 ATTENTION Do not remove both the Inverter and the Capacitor Bank assemblies at the same time ATTENTION Disconnect and lock out power from the drive...

Page 70: ...s 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 Perform the following procedures found earlier in this chapter Opening the Drive Enclosure Removing the Control Board Mounting Plate Removing the Precharge Board Mounting Frame Figure 3 10 Capacitor Bank Assembly AB0983A Loc...

Page 71: ...emove the T bar from the front of the drive 1 Loosen the lock down bolt between the inverter and the left arm of the T bar 2 Remove the T bar mounting bolt at the bottom of the T bar 3 Remove the bolts fastening each arm of the T bar 4 Release the Snapper Pin at the top of the T bar Refer to Figure 3 11 and the following steps to remove connections and the Spine Figure 3 11 Disconnecting the Spine...

Page 72: ...refully to the right Lift it out of the drive without forcing it 5 Disconnect any remaining wiring between the Inverter Assembly and the Capacitor Bank Assembly Referring to Figure 3 12 perform the following steps Figure 3 12 Disconnecting Ground Cables AB0984 Capacitor Bank Assembly Mounting Bolt Wheel Chocks Capacitor Bank Assembly Ground Cable Inverter Assembly Ground Cable Capacitor Bank Assem...

Page 73: ...mbly ATTENTION Hazard of tipping and severe injury exists This process requires two people The platform must be able to support 900 kg 2 000 lbs 5 Using the Motor Buses as a handle pull the assembly onto a user supplied platform Refer to Figure 3 13 Figure 3 13 Capacitor Bank Assembly on Service Platform AB0986A 46 to 76 cm 18 to 30 in 64 cm 25 in Height to Suit Installation Stop Block User Suppli...

Page 74: ...able 3 A Fastener Torque Specifications in this chapter Important Guide the unit into place so that it mates with the lock down bolt at the top of the capacitor frame Adjust the angle brackets at the ends of the T bar crossbar ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 75: ...ld the assembly You cannot remove the assembly without a platform The top of the platform must be even with the assembly s track The platform must be strong enough to support the assembly and the personnel servicing the drive Refer to Figure 3 16 in this chapter ATTENTION Do not remove both the Inverter and the Capacitor Bank assemblies at the same time ATTENTION Disconnect and lock out power from...

Page 76: ...procedures found earlier in this chapter Opening the Drive Enclosure Removing the Control Board Mounting Plate Removing the Precharge Board Mounting Frame 2 Remove the HV Guard that spans the bottom of the Inverter Bay held in place with hook and loop strips Figure 3 14 Access to the Inverter Assembly AB0983A Lock Down Bolt T Bar Bolts Snapper Pin T Bar Inverter Assembly Inverter Bay w o Cabinet D...

Page 77: ... bar 3 Remove the bolts fastening each arm of the T bar 4 Release the Snapper Pin at the top of the T bar Refer to Figure 3 15 and the following steps to remove connections and the Spine Figure 3 15 Disconnecting the Spine AB0984A Flexible Bus Bars Spine Nuts 18 Inverter Bay w o Cabinet Capacitor Bank Assembly Wheel Chocks Inverter Assembly Ground Cable Inverter Assembly 1 Remove the 18 nuts faste...

Page 78: ...he Inverter Assembly ground cable from the ground plate at the bottom of the Capacitor Bank Assembly 6 Remove the wheel chocks at the bottom of the Inverter Assembly Figure 3 16 Service Platform AB0986A 46 to 76 cm 18 to 30 in 64 cm 25 in Height to Suit Installation Stop Block Fan 2 Housing Handle User Supplied Platform Gate Driver Connector 6 Gate Interface Board 6 Inverter Assembly 7 Remove the ...

Page 79: ...housing Installation Install the Inverter Assembly in reverse order of removal Refer to Table 3 A Fastener Torque Specifications in this chapter Important When pushing the Inverter Assembly into the drive you may need to have someone tip the unit slightly to the left or right to center it between the guides at the back of the Enclosure Adjust the angle brackets at the ends of the T bar crossbar AT...

Page 80: ...Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter Figure 3 17 Diode and SCR Inverter Assembly SCR Heat Sink Diode Heat Sink U Shaped Bus Bar Precharge to Spine Flex Bus SCR HV Guard Lower HV Guard To Control Board J1 To Thermost...

Page 81: ...l Board Disconnect the Thermostat leads from this harness 4 Remove the screws on the SCR HV Guard 5 Reach behind the SCR HV Guard and remove the leads from the SCR 6 Pass the leads removed in the above steps through the hole in the HV Guard in order to free the guard 7 Remove the square shaped bus bar on the left side of the Inverter Assembly refer to Figure 3 18 Figure 3 18 Left Side View Square ...

Page 82: ... Specifications in this chapter 1 Attach the heat sink to the Back up Plate 2 Attach the Back up Plate to the Inverter Assembly 3 Install the square bus bar 4 Route leads from thermostat through the hole in the HV Guard going out of enclosure 5 Route leads for the SCR through the hole in the HV Guard going into the enclosure 6 Re connect the gate and cathode leads to the SCR 7 Reinstall the four s...

Page 83: ... the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts ATTENTION Servicing energized industrial control equi...

Page 84: ...book Electrostatic discharge generated by static electricity can damage the complementary metallic oxide semiconductor devices on various drive boards It is recommended that you perform these procedures to guard against this type of damage when circuit boards are removed or installed Wear a wrist type grounding strap that is grounded to the chassis Attach the wrist strap before removing the new ci...

Page 85: ...of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 w...

Page 86: ...rd D78 D71 D72 D65 D66 D10 J7 J8 6 Check all six reverse bias Zener diodes D10 D66 D65 D72 D71 and D78 Table 4 B shows meter connections at the components and ideal meter readings for those connections Refer to Figure 4 1 for component locations 7 Replace the Gate Driver Board if your readings do not match the table or if any diode is shorted or open in both directions Refer to Replacing the Gate ...

Page 87: ... Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range Table 4 B Zener Diode Test Component Meter Lead Meter Lead Nominal Meter Reading D78 Left Right Right Left less than 1 open D71 Left Right Right Left less than 1 open D72 Left Right Right Left less than 1 open D65 Left Right Right Left less than 1 open D66 Left Right Right Left less than 1 open D10...

Page 88: ...e between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive...

Page 89: ...he screws fastening the positive and negative Snubber Bus Bars to the Power Module Bus Bar 2 Remove the screws fastening the Power Module Bus Bar to the Power Modules 3 Carefully remove the bus bar Do not damage the Insulator 4 Set your meter to test diodes 5 Test the Power Modules Table 4 C shows meter connections and ideal meter readings for those connections Refer to Figure 4 3 for meter connec...

Page 90: ...bber Resistor and Snubber Board associated with the failed Power Module 8 If any Power Module has failed perform the following Replace the Gate Driver Board or at least perform Test 1 Testing the Gate Driver Board Replace the Power Module Snubber Board Snubber Resister Test 1 Set your meter to measure resistance 2 Test the Power Module Snubber Resistors The reading should be 16 ohms each Two 16 oh...

Page 91: ...onnections Refer to Figure 4 4 for component locations Figure 4 4 Power Module Snubber Board Power Module Snubber Board D3 D2 D4 D1 3 Replace the Snubber Board if your readings do not match the table readings Refer to Replacing the Power Module Snubber Board in Chapter 5 Part Replacement Procedures Table 4 D Power Module Snubber Board Test Component Meter Lead Meter Lead Nominal Meter Reading D1 D...

Page 92: ...rounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 3 Access Procedures 1 Referring to Opening the Drive Enclosure in Chapter 3 Access Procedures remove power and check for zero voltage in the drive Important Before you remove connections and wires from the drive compone...

Page 93: ...refer to Removing Volt Sharing Resistors and Dual Diodes in Chapter 5 Part Replacement Procedures Figure 4 6 Balancer Plate Assembly Inverter Bay w o Cabinet Balancer Plate Assembly Capacitor Bank Assembly Volt Sharing Resistor and Dual Diode Leads Volt Sharing Resistor Balancer Plate Assembly Bus Capacitors Fuse Dual Diode Test 1 Set your meter to test diodes 2 Test D1 and D2 Table 4 E shows mete...

Page 94: ...n D2 Top Bottom Bottom Top Less than 1 Open Note Typical malfunction is shorted in both directions Meter Used Fluke Model 87 set to Diode range Important There is no diode on F3 Capacitor Test The only practical test for these capacitors is to look for signs of damage swelling leaking or burn marks To replace the Bus Capacitors refer to Replacing Bus Capacitors in Chapter 5 Part Replacement Proced...

Page 95: ...jury Follow the safety related practices of NFPA 70E Electrical Safety for Employee Workplaces when working on or near energized equipment Do not work alone on energized equipment 2 To isolate the Diode from the rest of the power circuit remove the U shaped bus bar that connects the Diode heat sink to the SCR heat sink refer to Figure 4 7 3 To isolate the SCR from the Capacitor Bank remove the pre...

Page 96: ...cuit 1 2 Diode Upper Heat Sink 3 SCR Lower Heat Sink G C 4 Left Anode Right Cathode Left Cathode Right Anode ATTENTION Resistance or voltage checks made on the Diode or SCR heat sinks must be made to the heat sink aluminum base plate not the aluminum fins refer to Figure 4 7 The heat sinks have an epoxy bonded fin and many of the fins are NOT electrically connected to the aluminum base plate 4 Dio...

Page 97: ...le Volts 3 4 1 to 3 M Ohm not shorted Open not shorted 4 3 1 to 3 M Ohm not shorted Open not shorted G 4 5 to 20 Ohm not open Less than 1 not open 4 G 5 to 20 Ohm not open Less than 1 not open 6 If SCR or Diode test fail refer to Replacing a Diode SCR or Thermostat in Chapter 5 Part Replacement Procedures 7 If SCR and Diode tests pass re install the following bus bars Refer to Table 3 A Fastener T...

Page 98: ...ink To Thermostat SCR Heat Sink SCR Heat Sink Control Board J1 ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 3 Access Procedures 1 Referring to Opening the Drive Enclosure in Chapter 3 Access Procedures remove power and check for zero v...

Page 99: ...rm 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 6 If the test indicates a short or an open break the harness at the in line connectors and test the Thermistor and Thermostat individually Expect the Thermistor to read about 100k Ohms ...

Page 100: ...4 18 Component Test Procedures Publication 1336 IMPACT 6 8 November 2002 This Page Intentionally Left Blank ...

Page 101: ...measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 ignor...

Page 102: ...justable Frequency AC Drives are modular by design to enhance troubleshooting and spare parts replacement thereby helping reduce production down time Figure 5 2 and 5 1 identify the main components of a typical drive Component designs vary slightly among the different drive ratings Also the Converter Bay is configured to each order and can vary considerably For that reason Converter Bay illustrati...

Page 103: ...odule Gate Interface Board Bus Fuse Bus Capacitors L Option Board Control Board Common Bus Precharge Board Gate Driver Board Power Module Snubber Board Thermistor Power Module Snubber Resistor Fan 1 Fan 2 Volt Sharing Resistor and Dual Diodes Diode w Heat Sink SCR w Heat Sink Thermostat Input Rectifier Snubber Board Power Supply Current Transducer LEM ...

Page 104: ...Inverter Bay w o Cabinet Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enclosure in Chapter 3 Access Procedures ...

Page 105: ... not attempt to service the drive until the bus voltage has discharged to zero volts 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 2 Remove all wires from Terminal Strip TB3 3 Loosen the two captive screws fastening the L Option Board...

Page 106: ...y w o Cabinet Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enclosure in Chapter 3 Access Procedures ...

Page 107: ... connections and wires to correspond with their component connections and terminals to prevent incorrect wiring during assembly 2 Remove all wires from Terminal Strip TB3 if an L Option Board is used 3 Disconnect the following from the Control Board All connectors Ground wire at stake on connector All wires from the terminals on TB10 and TB11 4 Remove the screws fastening the Control Board to the ...

Page 108: ... An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their compo...

Page 109: ...le 3 A Fastener Torque Specifications ATTENTION When installing the wire harness connecting Gate Driver Board connector J9 to Common Bus Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the dr...

Page 110: ... ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 incor...

Page 111: ...ng Frame TB1 W1 Installation ATTENTION The wrong jumper setting at W1 will either damage the Common Bus Precharge Board or prevent proper precharge operation 1 The leads attached to TB1 are either at 24VDC or 120VAC Set the jumper position on W1 for the correct TB1 voltage Refer to Table 4 G Table 5 A W1 Jumper Settings Jumper Pos t on olta e etween ea s Attache at T W1 Jumper Position Voltage Bet...

Page 112: ... connecting Gate Driver Board connector J9 to Common Bus Precharge Board connector J3 align the wires on the harness terminals with the pins on the board connectors Incorrect harness connection may result in faulty drive operation and may damage the equipment ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 113: ...rive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 3 Access Procedures Figure 5 7 Power Supply AB1092 Power Supply Inverter Bay w o Cabinet Precharge Board Mounting Frame Shown Unlatched and Swung Open 1 4 Turn Latches Screw 4 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enclosure in Chapter 3 Access ...

Page 114: ... Mounting Frame 3 Swing Precharge Board Mounting Frame away from drive 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 4 Remove the cables from the power supply 5 Remove the four screws fastening the Power Supply to the Precharge Board ...

Page 115: ...ication 1336 IMPACT 6 8 November 2002 Figure 5 8 Power Supply Connections Power Supply Connections L AC N AC S Front of Drive Adjust to 16V 0 2 Measure from PS COM to PS V S COM V PS V PS S PS COM PS V P A C N P GND PS A C L PS S V AB1093 ...

Page 116: ...nks and the vertical bus Figure 5 9 Input Rectifier Snubber Board Input Rectifier Snubber Board Screw 4 Inverter Assembly SCR Heat Sink Copper Plate White Wire Input Rectifier Snubber Board Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in ...

Page 117: ...tage in the drive Refer to Opening the Drive Enclosure in Chapter 3 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 2 Remove the screws fastening the Input Rectifier Snubber Board to the Copper Plate 3 Remove the nut f...

Page 118: ...ink at the back of the Inverter Assembly Figure 5 10 Power Module Snubber Board AB0989A Power Module Snubber Board Screw 8 J1 Inverter Assembly J2 Snubber Resistor Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 3 Access Procedure...

Page 119: ...terminals to prevent incorrect wiring during assembly 1 Perform the following procedures in Chapter 3 Access Procedures Opening the Drive Enclosure Removing the Control Board Mounting Plate Removing the Precharge Board Mounting Frame Pulling the Inverter Assembly 2 Remove the Snubber Resistor connections from the Snubber Board J1 and J2 3 Remove the screws fastening the Power Module Snubber Board ...

Page 120: ...us fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with the...

Page 121: ...esent Figure 5 11 Power Modules Power Module Snubber Bus Bar and Power Module Gate Interface Board Power Module Snubber Board Power Module Bus Bar Preform only on drives dated before about 2001 Insulator Inverter Assembly w o Cabinet Main Heat Sink AB1096 Installation 1 Clean all surfaces between the Power Module and the Main Heat Sink using a soft clean cloth 2 Apply layer of thermal grease suppl...

Page 122: ... when fastening the Power Module components to the Power Modules Use the same size fastener to fasten the components as was originally used Using different fastener lengths will damage the Power Modules ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 123: ...s of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to cor...

Page 124: ...t Sink Screw J1 J2 Screw Inverter Assembly w o Cabinet Installation Install the Power Module Snubber Resistor in reverse order of removal Important Install the resistors with the markings to the right outside for easier future reference ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 125: ...mbly Figure 5 13 Thermistor Thermistor To Control Board J1 Inverter Bay w o Cabinet AB1095 Main Heat Sink To Thermostat SCR Heat Sink Harness Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions in Chapter 3 Access Procedures ...

Page 126: ...the drive until the bus voltage has discharged to zero volts 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enclosure in Chapter 3 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 2 Di...

Page 127: ...ssembly SCR Heat Sink Diode Heat Sink HV Guard To Control Board J1 To Thermostat Through HV Guard To Thermistor Power Module Heat Sink Harness Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter 1 Remove power an...

Page 128: ... Guard and remove the leads from the SCR 5 Pass the leads removed in the above step through the hole in the HV Guard in order to free and remove the guard 6 Remove the heat sink clamp nuts Figure 5 15 Figure 5 15 Heat Sink Detail Clamp SCR or Diode Module Spring Bar Clamp Heat Sink Bolt Bolt Nut AB1097 Thermostat SCR Heat Sink only ...

Page 129: ...ny dirt off of the original heat sink mounting surfaces 4 Install the new Diode or SCR with the same polarity as the original component in the heat sink refer to Figure 5 15 Important A pin on the Heat Sink centers the SCR Verify that the SCR is centered on the pin When properly centered he SCR should rotate freely about the pin 5 Tighten the clamp nuts while holding the heat sinks flat against th...

Page 130: ...both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wire...

Page 131: ... 8 Remove four bolts on the fan front cover to remove the fan cover 9 Remove four bolts on the back cover to release the fan Figure 5 16 Fan 1 Assembly AB0610A Fan 1 Fan 1 Cover Inverter Assembly w o Cabinet Fan 1 Connector Standoffs Spring Pins 2 Fan Cover Screws 4 Fan Mounting Screws 4 Thumb Latch Resistor Assembly Lip Cabinet Bottom Bracket Cabinet Bottom Bracket Capacitors Spring Pins 2 Thumb ...

Page 132: ...ver to Fan 2 2 Remove the standoffs that fasten Fan 2 to the Inverter Assembly 3 Disconnect the Fan 2 wiring harness 4 Remove fan from assembly Installation Install Fan 1 and Fan 2 in reverse order of removal ATTENTION Take care to avoid pinching any wires as the fan assemblies are mounted Also keep wiring clear of the the Resistors in the Resistor Assembly ATTENTION Replace all guards before appl...

Page 133: ...Cabinet Control Board Not Shown for Clarity Ground Fault CT DC Input Lines Removal ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Precautions at the beginning of this chapter 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enc...

Page 134: ...ed to zero volts 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 2 Remove the buses at the DC Input Lines 3 Disconnect the Ground Fault CT harness from the harness that goes to the Gate Driver Board 4 Remove the nut and washer on the le...

Page 135: ...ailure in the associated set of Bus Capacitors Refer to Replacing Bus Capacitors in this chapter Removal Figure 5 19 Bus Fuse Bus Fuse 1 4 Turn Latches Inverter Bay w o Cabinet Precharge Board Mounting Frame ATTENTION Wear a wrist type grounding strap when servicing 1336 IMPACT drives Failure to protect drive components against ESD may damage drive components Refer to Electrostatic Discharge Preca...

Page 136: ...e has discharged to zero volts 1 Remove power and check for zero voltage in the drive Refer to Opening the Drive Enclosure in Chapter 3 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 2 Open the Precharge Board Mountin...

Page 137: ...y Verify zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Befor...

Page 138: ... 2 Tilt the Motor Buses out at the bottom It is not necessary to remove the flex buses from the top of the Motor Buses 3 Slide the Current Transducer off the bottom of the Motor Bus Installation Install the Current Transducers in reverse order of removal Refer to Fastener Torque Specifications in Chapter 3 Access Procedures ATTENTION Replace all guards before applying power to the drive Failure to...

Page 139: ... voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections and termin...

Page 140: ...lator Capacitor Bank Assembly Installation 1 Install the capacitor assembly in reverse order of removal Refer to Fastener Torque Specifications in Chapter 3 Access Procedures Important Position the notch and vent hole on the Bus Capacitors to the top of the drive Refer to Figure 5 22 Figure 5 22 Capacitor Orientation Vent 2 Connect the Volt Sharing Resistors to the Bus Capacitors according to the ...

Page 141: ...ure 5 23 Volt Sharing Resistor Connections to Bus Capacitors AB0625A R4 R6 C13 C24 C25 C36 R7 R9 C5 C9 CAP DETAIL 575V R3 C10 C11 C12 C6 C7 C8 R2 C1 C2 C3 C4 R1 F3 D2 F2 F1 D1 C41 C40 X C1 C2 C3 C4 C8 C7 C6 C5 R1 R2 CAP DETAIL 480V C9 C16 R3 R4 C17 C24 R5 R6 D1 D2 F2 F1 F3 C40 C41 X ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or ser...

Page 142: ...s not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts Important Before you remove connections and wires from the drive components mark the connections and wires to correspond with their component connections ...

Page 143: ...Assembly Volt Sharing Resistor and Dual Diode Leads Volt Sharing Resistor Balancer Plate Assembly Bus Capacitors Installation 1 Install the capacitor assembly in reverse order of removal Refer to Fastener Torque Specifications in Chapter 3 Access Procedures ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 144: ... the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharged to zero volts 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 wir...

Page 145: ...at Washer Red White Green AB1098 3 Attach the wires to the terminal block located on the side of the fan assembly as follows The red or yellow red wire goes to terminal 1 The white or yellow white wire goes to terminal 2 The green wire goes to terminal 3 Refer to Figure 5 25 for the locations of the terminal block and weld studs and for the wiring information ...

Page 146: ...esult in death or serious injury Verify zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to Figure 3 5 Do not attempt to service the drive until the bus voltage has discharge...

Page 147: ... 27 Thermal Switches Side View Thermal Switch L Shaped Bus Bar Front of Cabinet AB1100 2 Tighten the screw on the thermal switch 3 Bolt the L shaped bus bar to the diode with two bolts 4 Connect the power wires to the new thermal switch It is not important which power wire is attached to which end of the thermal switch 5 If not connected connect the flex bus to the L shaped bus bar ...

Page 148: ...er from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fuses may result in death or serious injury Refer to ...

Page 149: ...crews 4 Lockwashers Input Power Supply Back of Rack Bottom View Fan Fan Spacer Side View AB1102 Installation Refer to Fastener Torque Specifications in Chapter 3 Access Procedures 1 Put the new fan in place make sure to align the holes in the bridge with the holes in the four corners of the fan and fan spacer Important Make sure that the arrows on the fan are pointing toward the top of the cabinet...

Page 150: ...ber 2002 2 Insert screws and lock washers in the four corners and tighten the screws 3 Attach the power supply and neutral wires to the fan ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serious injury ...

Page 151: ...ss Procedures ATTENTION Disconnect and lock out power from the drive before disassembling the drive Failure to disconnect power may result in death or serious injury Verify zero bus voltage by measuring the voltage between the Negative Capacitor Bus and both ends of all three bus fuses An open fuse does not show voltage across both ends of the fuse Failure to measure voltage at both ends of the fu...

Page 152: ...erter Diodes Converter Bay Bridge Heat Sink Converter Diodes 6 Flex Bus L Shaped Bus Bar AB1103 Figure 5 31 Bus Bars Converter Diodes Bus Bar L Shaped Bus Bars Front of Cabinet AB1104 4 Remove the hex head screws that are in the four corners of the Converter Diode 5 Remove the Converter Diode ...

Page 153: ...t not supplied to the base of the new diode 2 Position the new Converter Diode Be careful to match the holes for the screws 3 Tighten the four screws 4 Bolt down the L shaped bus bar with two bolts 5 Bolt down the two bus bars with six bolts 6 If not connected connect the Flex bus ATTENTION Replace all guards before applying power to the drive Failure to replace guards may result in death or serio...

Page 154: ...5 54 Part Replacement Procedures Publication 1336 IMPACT 6 8 November 2002 This Page Intentionally Left Blank ...

Page 155: ...l Rockwell Automation 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 Reference the product service report number on the carton and packing slip Include Your company name Your company address The repair purchase order number A brief description of the proble...

Page 156: ...1 Fan12 Main Enclosure Fan Does Not Apply DNA DNA DNA 2 OL12 Overload Relay DNA DNA DNA 3 F20 F22 Fuse DNA DNA DNA 4 Inverter Assembly Refer to Table 6 B and Table 6 C 5 Capacitor Assembly Refer to Table 6 D 6 Converter Bay2 Refer to Table 6 E 1 Access always requires the procedure Opening the Drive Enclosure 2 The schematics supplied for configured systems include the spare parts list for the Con...

Page 157: ...st 5 Replacing a Thermistor 13 R20 R25 Power Module Snubber Resistor Pulling the Inverter Assembly Test 2 Replacing a Power Module 14 Q11 Q12 Q61 Q62 Power Module Transistor Pulling the Inverter Assembly Test 2 15 A23 A28 Power Module Gate IF Board Pulling the Inverter Assembly DNA 16 A20 A22 Power Module Snubber Board Pulling the Inverter Assembly Test 2 Replacing a Power Module Snubber Board 17 ...

Page 158: ...escr pt on Procedures Callout S mbol on Chapter 7 Schematics Description Access1 Ref Ch 3 Test Ref Ch 4 Replacement Ref Ch 5 21 FAN1 Fan DNA DNA Replacing Inverter Bay Fan Assemblies 22 C38 C39 Capacitor DNA DNA DNA 23 R10 R13 Resistor DNA DNA DNA 24 F4 Fuse DNA DNA DNA 25 FAN2 Fan DNA DNA Replacing Inverter Bay Fan Assemblies 1 Access always requires the procedure Opening the Drive Enclosure ...

Page 159: ...Volt Sharing Resistors and Dual Diodes 33 D1 D2 Dual Diode DNA2 DNA 34 F1 F3 Bus Fuse 350 amp DNA DNA Replacing Bus Fuses 35 Power Supply DNA DNA Replacing the Power Supply 36 R1 Relay DNA DNA DNA 37 A1 Gate Driver Board Removing the Control Board M P Test 1 Replacing the Gate Driver Board 38 A10 Common Bus Precharge Board Mounting Plate DNA Replacing the Precharger Board 39 MAIN CTL Control Board...

Page 160: ... on Procedures Callout S mbol on Job Related Schematics Description Access1 Ref Ch 3 Test Ref Ch 4 Replacement Ref Ch 5 51 F1 F3 F1A F3A Fuse DNA DNA DNA 52 EA11 Line Loss Relay DNA DNA DNA 53 MOV MOV DNA DNA DNA 54 EA10 Thermal Switches DNA DNA Replacing Converter Thermal Switches 55 Converter Fans DNA DNA Replacing Converter Fans 56 EA12 DC Snubber Board DNA DNA DNA 57 CH10 DC Bus Inductor DNA D...

Page 161: ...ides The Inverter Bay schematic for a typical drive The Control Board layout Typical Converter Bay and system schematics Since each drive is configured the Converter Bay and full schematics for the drive as configured are shipped inside the cabinet Fuse Listings Chapter Objectives ...

Page 162: ...s Unit Sheet 1 of 3 DC DC THS1 PE PE PE SCR1 CNV R10 R12 R11 R13 D4 F4 INV INV 3 1 3 1 CT3 1000 1 105061 CUSTOMER S INPUT VOLTAGE 120VAC OR 24VDC TB1 1 3 J2 J1 1 4 7 10 1 3 1 4 7 8 9 10 11 12 COMMON BUS PRECHARGE BOARD SEE TABLE 7 C A10 W1 1 2 3 24VDC 120VAC 1 2 2 3 CAP BANK SEE DETAIL SHEET 3 X IN POS BUS IN NEG BUS OUT POS BUS OUT NEG BUS GATE CATHODE W1 J3 SEE TABLE 7 D Inverter Bay Schematic ...

Page 163: ... 38 33 30 29 28 32 31 35 34 37 36 40 39 43 42 41 46 45 44 48 47 A1 8 ACT1 ACT2 J2 1 2 BUS BUS 15 J10 1 4 WN_GATE U_AMPS INTERLOCK W_AMPS 15V 15 15 2 J6 5 6 7 3 4 1 WP_GATE UN_EMIT UN_GATE VN_GATE VN_EMIT WN_EMIT J7 3 2 1 4 5 6 1 EXT RES EXT RES 120VAC TB5 5V 5V TE TB7 50 49 1 2 F1 F3 EXTERNAL DC BUS INPUT CONNECTION HIGH VOLTAGE DC AUX IN HIGH VOLTAGE DC AUX IN 1 TB6 3 J13 1 4 6 4 3 5 24V OUT 120R...

Page 164: ...2 C3 C4 R1 F3 D2 F2 F1 D1 FAN 1 C39 J3 J1 1 2 3 4 Z2 TK U2 GRN Y J4 C38 J2 GRN Y BRN BLK BLU 3 1 2 4 FAN 2 GRN Y RED BLK RED RED GRN Y RED BLK BRN BRN WHITE BLK TB1 JUMPER JUMPER 120V 2 1 1 2 C41 C40 C40 C41 13 X X Capacitor Detail Fan Circuit Detail 575V 480V CUSTOMER POWER GND 16V POWER SUPPLY 16V COM N AC L 14 1 9 5 2 10 6 3 11 7 4 12 8 RL1 215 OHM 1W PS V PSCOM PS V RL1 5 RL1 9 Sheet 3 of 3 SE...

Page 165: ...IMPACT 6 8 November 2002 INV EN VP CP Green Red J2 J3 J6 J5 J8 TB11 TB10 1 2 3 J7 J1 4 5 7 8 10 11 6 9 12 14 13 15 16 18 19 21 22 20 17 1 2 3 4 5 7 8 10 6 9 Voltage Test Points LEDs Pulse Input Jumper EE J4 Jumper Control Board Layout ...

Page 166: ...1361 3383 3384 1113 1111 1112 1201 1202 1203 1031 1011 1021 1072 1071 1073 1011 1021 1031 F2A F2 F1A F1 700A 700V F3A F3 OL12 M12 F21 F20 5 600V F22 AC1 AC2 AC3 1292 1291 SNUBBER BOARD 1 2 3 RELAY PHASE LOSS A B C 2 11 TO 2 10 TO 3 38 10MFD 2000V TO 100W 2 2 100 100W LINE AC LINES 3PH 60HZ FAN1 PE L3 L2 L1 Sheet 1 of 7 Typical Converter Bay Schematic ...

Page 167: ...CATE SHEET AND LINE NUMBERS INDICATES LINE NO 24 INDICATES SHEET NO 1 FROM 1 24 TO 1 24 1 24 A NORMALLY CLOSED CONTACT UNDERSCORED TEXT LINE INDICATES OFF PAGE CROSS REFERENCING NUMBERS ADJACENT TO SOURCE INDICATES SHEET NO 1 INDICATES LINE NO 3 COIL AND UNDER CONTACT INDICATE SHEET AND LINE NUMBERS 4 COIL AND CONTACT CROSS REFERENCING NUMBERS ADJACENT TO 1 3 2 18 1 3 TERMINAL BLOCK TB1 TERMINAL B...

Page 168: ... 18 15 OUTPUT 4 20mA 2 3 X 1 2 J4 OUTPUT 0 10V PLS PLS 13 14 TE 10 9 CONTROL BOARD FAULT COMMON ALARM FAULT COMMON PROGRAMMABLE COMMON 5 SHD IN2 IN2 SHD IN3 SHD IN3 12 11 10 8 9 6 7 INPUT 4 20mA 0 10V INPUT IN1 IN1 TB10 4 1 2 3 AGND 10V 10V 1336E 8 7 6 4 5 RUN 3 2 TB11 1 8 18 INTERLOCK CUSTOMER W7 17 7 W6 CUSTOMER INTERLOCK FROM 6 5 W5 FROM FROM ENABLE 30 29 28 COMMON SPD SEL 1 27 25 26 SPD SEL 2 ...

Page 169: ... 4062 4065 4065 BLU 4061 4282 BRN BLK BRN BLU 4065 4063 F6 FNM 9 250V W1 2 1 21 24 3 4 TO TO COMMON BUS PRECHARGE FAN2 TB1 A10 BLK TB1 GRAY GRAY BLK GRAY BLK TB1 120VAC W1 JUMPER 24VDC 2 3 X 1 2 BRIDGE FAN2 DRIVE UNIT EA1 FAN6 BRN TB1 BRIDGE FAN1 DRIVE UNIT EA1 BLU BRN BLU BLU BRN FAN5 FAN4 CONVERTER BRIDGE FANS EA10 115VAC CONTROL SOURCE FROM CUSTOMER Sheet 4 of 7 ...

Page 170: ...002 75 0 0 0 625 DIA 4 MTG HOLES 17 50 REMOVABLE LIFTING ANGLE 15 00 1 69 25 00 DRIVE BAY 11 75 10 00 21 56 4 25 14 00 3 50 17 50 CONTROL BAY 30 20 104 88 FAN SHIPPED SEPARATE TOP HAT 16 00 2 00 25 00 AREA AVAILABLE FOR CONDUIT 91 50 2 50 2 00 Sheet 5 of 7 ...

Page 171: ... 5 6 7 NOT USED NOT USED DEVICE 1 2 3 4 NOT USED NOT USED NOT USED 1 6 2 3 7 8 NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED 16 17 14 13 15 9 11 10 12 17 11 5 4 10 9 16 P N 162171 REV NOT USED NOT USED NOT USED NOT USED NOT USED U V W NOT USED 1336 MADE IN U S A MAXIMUM RMS SHORT CIRCUIT CURRENT AMPS DATA NAMEPLATE POWER RATINGS 3 PHASE AC INPUT 3 PHASE AC OUTPUT DIA KVA KVA H P WIRING SER...

Page 172: ...WIRING NOTES MATERIAL LIST COMPONENTS DESCRIPTION SYM CONTROL CLASS WIRE SOURCE EXPLANATION TERMINAL CABLE NO NO WIRE RANGE TYPE CLASSES 7 THROUGH 12 ARE SIGNAL WIRES 5 AMPS OR LESS SEE INSTRUCTION MANUAL FOR CABLE CLASSES INTERCONNECTION INFORMATION SIGNAL NO WIRE RANGE CURR WIRE SOURCE EXPLANATION TERMINAL SEE INSTRUCTION MANUAL FOR CABLE CLASSES INTERCONNECTION INFORMATION MANUFACTURER PART NO ...

Page 173: ...the following fuses or approved equivalents must be used for the Inverter DC Bus Table 7 B Inverter DC Bus Fuses F1 F3 Horsepower Input olta e Fuse Information orsepower Input Voltage Rating Type P N ALL SIZES 300A A7OQ 25178 310 14 Table 7 C lists fuse data for all printed circuit assemblies Table 7 C Printed Circuit Fuses Item M Schematic a ram Fuse Information Item B M Schemat c Diagram Designa...

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Page 175: ...Notes Publication 1336 IMPACT 6 8 November 2002 ...

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Page 189: ... System Option Codes P 5 Schematics 7 1 Connector Definition P 8 Control Board Installation 5 7 Removal 5 6 Schematic 7 5 Control Board Mounting Plate Illustration 3 10 Installation 3 11 Control Firmware Function 1 12 Control Interface L Option Board See L Option Board Control Logic Wiring and Adapters 1 1 Conventions P 8 Converter Bay Part Identification 5 2 6 6 Schematics 7 1 Current Transducer ...

Page 190: ...l Board LEDs 2 1 Desaturation 2 12 Descriptions 2 3 Diff Drv Type 2 7 EE Checksum 2 7 External Flt In 2 8 Feedback Loss 2 20 Ground Fault 2 12 HW Malfunction 2 6 2 15 Inv Overload 2 5 Inv Overtemp Pnd 2 5 Inv Overtemp Trp 2 5 InvOvld Pend 2 5 mA Input 2 7 Math Limit 2 8 Mtr Stall 2 4 MtrOvrld Pnd 2 4 MtrOvrld Trp 2 4 Open Circuit 2 13 Overcurrent 2 12 Overvoltage 2 12 Param Limit 2 8 Prechrg Time ...

Page 191: ...ing 1 7 M Main Control Board See Control Board Manual Audience P 1 Objective P 1 Motor Buses Illustration 3 15 Installation 3 16 Removal 3 14 MOV Identification 6 6 N Nameplate Location P 3 No Voltage Check Illustration 3 8 3 9 O Option Identification P 3 L Option Board 1 3 P Parameter Definition P 9 Part Identification 5 2 6 2 Part Replacement Procedures 5 1 Power Module Illustration 4 7 5 21 Ins...

Page 192: ...Precharge Board Mounting Frame Removal 3 12 Pulling the Capacitor Bank Assembly 3 17 Pulling the Inverter Assembly 3 23 Removing SCR and Diode Heat Sinks 3 28 Removing the Motor Buses 3 14 SCR Test 4 13 SCR Diode and Thermostat Replacement 5 27 Thermistor and Thermostat Testing 4 16 Thermistor Replacement 5 25 Volt Sharing Resistor Test 4 10 Volt Sharing Resistors and Dual Diode Replacement 5 42 P...

Page 193: ... 20 True Definition P 10 V Volt Sharing Resistor Connection Diagram 4 10 5 41 Installation 5 43 Removal 5 42 Testing 4 10 W Warnings Bus Cycle 5 2 14 Bus Drop 2 14 Bus Undervlt 2 14 Control Board LEDs 2 1 External Flt In 2 9 Inv Overload 2 6 Inv Overtemp Pnd 2 6 InvOvld Pend 2 6 mA Input 2 8 Math Limit 2 8 Mtr Stall 2 5 MtrOvrld Pend 2 4 MtrOvrld Trp 2 5 Open Circuit 2 15 Param Limit 2 8 Prechrg T...

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Page 196: ...Publication 1336 IMPACT 6 8 November 2002 P N 177811 Copyright 2002 Rockwell Automation Inc All rights reserved Printed in USA ...

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