Rockwell Automation Allen-Bradley IMPACT 1336 Series Programmierhandbuch

Troubleshooting Manual

1336 IMPACT™

Adjustable

Frequency AC Drive

519 - 597 kW (700 - 800 HP)

Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. “Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls” (Publication SGI-1.1

available from your local Allen-Bradley Sales Office or online at

http://

www.ab.com/manuals/gi

) describes some important differences between

solid state equipment and hard-wired electromechanical devices. Because of

this difference, and also because of the wide variety of uses for solid state

equipment, all persons responsible for applying this equipment must satisfy

themselves that each intended application of this equipment is acceptable.

In no event will the Allen-Bradley Company be responsible or liable for

indirect or consequential damages resulting from the use or application of

this equipment.

The examples and diagrams in this manual are included solely for

illustrative purposes. Because of the many variables and requirements

associated with any particular installation, the Allen-Bradley Company

cannot assume responsibility or liability for actual use based on the

examples and diagrams.

No patent liability is assumed by Allen-Bradley Company with respect to

use of information, circuits, equipment, or software described in this

manual.

Reproduction of the contents of this manual, in whole or in part, without

written permission of the Allen-Bradley Company is prohibited.

Throughout this manual we use notes to make you aware of safety

considerations.

Attentions help you:

•identify a hazard

•avoid the hazard

•recognize the consequences

Important:Identifies information that is especially important for successful

application and understanding of the product.

SCANport is a trademark of Rockwell Automation.

PLC is a registered trademark of Rockwell Automation.

COLOR-KEYED is a registered trademark of Thomas & Betts Corporation.

IBM is a registered trademark of International Business Machines Corporation.

Windows 95, 98, and NT are registered trademarks of Microsoft Corporation.

!ATTENTION: Identifies information about practices or

circumstances that can lead to personal injury or death, property

damage, or economic loss.

Shock Hazard labels may be located on or inside the drive to

alert people that dangerous voltage may be present.

Manual Objective P–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Who Should Use This Manual P–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SafetyPrecautions P–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions P–2. . . . . . . . . . . . . . . . . . . . . . .

1336 IMPACT Product Identification P–3. . . . . . . . . . . . . . . . . . . . . . .

Drive Nameplate Location P–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive and Option Identification P–3. . . . . . . . . . . . . . . . . . . . . . . . . . .

1336 IMPACT Drive Catalog Numbers P–4. . . . . . . . . . . . . . . . . . . .

Drive Rating Qualifications P–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure Type P–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIM and Communication Options P–5. . . . . . . . . . . . . . . . . . . . . . .

ConfiguredOptions P–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Options P–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventions P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AuxiliaryInput P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Interlock P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bit P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connector P–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Default P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EnableInput P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

False P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jumper P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L Option Board P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Press P–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

True P–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RelatedPublications P–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1

ChapterObjectives 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter Overview 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

L Option Board 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Board Jumpers for L Option 1–3. . . . . . . . . . . . . . . . . . . . .

AvailableInputs 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LocalProgramming 1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Human Interface Module (HIM) 1–9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 1–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the HIM 1–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIM Operation 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DriveTools 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Firmware Function 1–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Preface

Control Logic Wiring and

Adapters

Table of Contentsii

Publication 1336 IMPACT-6.8 – November, 2002

Chapter 2

ChapterObjectives 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault/WarningHandling 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewingthe Fault and Warning Queues on the HIM 2–2. . . . . . . . . . . .

FaultDescriptions 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Procedures by Symptom 2–16. . . . . . . . . . . . . . . . . . . . . . .

Drive Will Not Start or Jog 2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

No HIM Display 2–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIM Displays “Running” 2–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Response Not As Desired 2–19. . . . . . . . . . . . . . . . . . . . . . . .

Start Up TroubleshootingProcedures 2–20. . . . . . . . . . . . . . . . . . . . . .

Miscellaneous Troubleshooting Procedures 2–20. . . . . . . . . . . . . . . . . .

Encoderless Troubleshooting Procedures 2–22. . . . . . . . . . . . . . . . . . .

Chapter 3

ChapterObjectives 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access Overview 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions 3–2. . . . . . . . . . . . . . . . . . . . . . .

Tools 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastener Torque Specifications 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . .

TorqueSequence 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TorqueSpecifications 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access Procedures 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the Drive Enclosure 3–6. . . . . . . . . . . . . . . . . . . . . . . . . .

Opening 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closing the Drive Enclosure 3–9. . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Control Board Mounting Plate 3–10. . . . . . . . . . . . . . .

Removal 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Precharge Board Mounting Frame 3–12. . . . . . . . . . . .

Removal 3–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Motor Buses 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulling the Capacitor Bank Assembly 3–17. . . . . . . . . . . . . . . . . . . .

Removal 3–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulling the Inverter Assembly 3–23. . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 3–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Diode and SCR Heat Sinks 3–28. . . . . . . . . . . . . . . . . . . .

Removal 3–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting and Error

Codes

Access Procedures

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Publication 1336 IMPACT-6.8– November, 2002

Chapter 4

ChapterObjectives 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Test Overview 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions 4–2. . . . . . . . . . . . . . . . . . . . . . .

Tools 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 1 – Testing the Gate Driver Board 4–3. . . . . . . . . . . . . . . . . . . . . .

Test 2 – Testing the Power Modules 4–6. . . . . . . . . . . . . . . . . . . . . . .

Transistor Test 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Snubber Resister Test 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Snubber Board Test 4–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 3 – Testing the Volt-Sharing Resistors and Dual Diodes 4–10. . . . . .

Volt-Sharing Resistor Test 4–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Diode Test 4–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacitor Test 4–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test 4 – Testing the Diode and SCR 4–13. . . . . . . . . . . . . . . . . . . . . . .

Test 5 – Testing the Thermistor and Thermostat 4–16. . . . . . . . . . . . . . .

Chapter 5

ChapterObjectives 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part Replacement Overview 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Discharge Precautions 5–1. . . . . . . . . . . . . . . . . . . . . . .

Detailed Product Identification 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the L Option Board 5–4. . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Control Board 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Gate Driver Board 5–8. . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Common Bus Precharge Board 5–10. . . . . . . . . . . . . .

Removal 5–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Power Supply 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing an Input Rectifier Snubber Board 5–16. . . . . . . . . . . . . . . .

Removal 5–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Power Module Snubber Board 5–18. . . . . . . . . . . . . . . .

Removal 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Test Procedures

Part Replacement

Procedures

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Replacing a Power Module 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Power Module Snubber Resistor 5–23. . . . . . . . . . . . . . .

Removal 5–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Thermistor 5–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Diode, SCR or Thermostat 5–27. . . . . . . . . . . . . . . . . . .

Removal 5–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Inverter Bay Fan Assemblies 5–30. . . . . . . . . . . . . . . . . . .

Removal 5–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Ground Fault CT 5–33. . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Bus Fuses 5–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Current Transducers (LEMs) 5–37. . . . . . . . . . . . . . . . . . .

Removal 5–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Bus Capacitors 5–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Volt-Sharing Resistors and Dual Diodes 5–42. . . . . . . . . . .

Removal 5–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Converter Bay Door Fan 5–44. . . . . . . . . . . . . . . . . . .

Removal 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Converter Thermal Switches 5–46. . . . . . . . . . . . . . . . . . .

Removal 5–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Converter Fans 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Converter Diodes 5–51. . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 5–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents v

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Chapter 6

ChapterObjectives 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordering Replacement Parts 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement Parts Listing 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7

ChapterObjectives 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

Table of Contentsvi

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This Page Intentionally Left Blank

Publication 1336 IMPACT-6.8– November, 2002

Preface

The information in this manual is designed to help troubleshoot or

repair an Allen-Bradley 1336 IMPACT Adjustable Frequency AC

Drive with ratings B700C – B800C and C700C – C800C.

This manual is intended for qualified service personnel responsible

for troubleshooting and repairing the 1336 IMPACT Adjustable

Frequency AC Drive. You should:

•Read this entire manual before performing maintenance or repairs

to drives.

•Have previous experience with, and basic understanding of,

electrical terminology, procedures, required equipment,

equipment protection procedures and methods, and safety

precautions.

This manual describes equipment, troubleshooting and disassembly

procedures. You begin with general illustrations and end with greater

detail concerning replacement parts and part locations on the drives.

Later chapters may refer you back to earlier chapters for information

on basic equipment and steps necessary to perform detailed

diagnostics and part replacement.

!ATTENTION: Some printed circuit boards and drive

components may contain hazardous voltage levels.

Remove and lock out power before you disconnect or

reconnect wires, and before you remove or replace

fuses and circuit boards. Verify bus voltage by

measuring the voltage between the Negative Capacitor

Bus and both ends of all three bus fuses. An open fuse

does not show voltage across both ends of the fuse.

Failure to measure voltage at both ends of the fuses

may result in death or serious injury. Refer to Figure

3.5. Do not attempt to service the drive until the bus

voltage has discharged to zero volts.

Manual Objective

Who Should Use This

Manual

Safety Precautions

PrefaceP–2

Publication 1336 IMPACT-6.8– November, 2002

!ATTENTION: Potentially fatal voltages may result

from improper usage of oscilloscope and other test

equipment. The oscilloscope chassis may be at a

potentially fatal voltage if not properly grounded. If an

oscilloscope is used to measure high voltage

waveforms, use only a dual channel oscilloscope in the

differential mode with X 100 probes. It is

recommended that the oscilloscope be used in the A

minus B Quasi-differential mode with the oscilloscope

chassis correctly grounded to an earth ground.

!ATTENTION: Only personnel familiar with the

1336 IMPACT Adjustable Frequency AC Drive and

associated machinery should plan or implement the

installation, start-up and subsequent maintenance of the

system. Failure to comply may result in personal injury

and/or equipment damage.

!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 Electrostatic Damage, or

any other applicable ESD protection handbook.

Electrostatic discharge generated by static electricity can damage the

complementary metallic oxide semiconductor devices on various

drive boards. It is recommended that you perform these procedures

to guard against this type of damage when circuit boards are

removed or installed:

•Wear a wrist-type grounding strap that is grounded to the drive

chassis.

•Attach the wrist strap before removing the new circuit board from

the conductive packet.

•Remove boards from the drive and immediately insert them into

their conductive packets.

Electrostatic Discharge

Precautions

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