Allen-Bradley CX300 User manual

Troubleshooting
Guide
Bulletin 1336 PLUS
Adjustable Frequency
AC Drive
Series A, B, C, D
B150 – B250
C150 – C250
CX300
Allen-Bradley

Important User Information
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
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.
DANGER labels may be located on or inside the drive to alert
people that dangerous voltage may be present.

Summary of Changes
The information below summarizes the changes to the company-wide
templates since the last release.
Updated Information Information has been added to Overtemp Fault 08 in Table 2.A on
page 2-6.
Information has been added to Test 3, Testing the Power Modules,
beginning on page 4-7.

Summary of Changes
This Page Intentionally Left Blank

Table of Contents
i
Preface
Manual Objective P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Who Should Use This Manual P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions P-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1336 PLUS Product Identification P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Nameplate Location P-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Compatibility P-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive and Option Identification P-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1336 PLUS Drive Catalog Numbers P-5. . . . . . . . . . . . . . . . . . . . . . . .
Drive Rating Qualifications P-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Type P-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions P-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications P-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Logic Wiring Chapter 1
and Adapters
Chapter Objectives 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Interface Option. 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Interface Board Jumpers 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available Inputs 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Programming 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Human Interface Module (HIM) 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module Removal 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIM Operation 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents
ii
Troubleshooting and Chapter 2
Error Codes
Chapter Objectives 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Descriptions 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Display 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contact Description 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Procedures by Symptom 2-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Will Not Start 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Display 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Will Not Jog 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Stays at Zero Hertz When Started 2-14. . . . . . . . . . . . . . . . . . . . .
Drive Goes to Max Frequency 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Faults 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Chapter 3
Procedures
Chapter Objectives 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torque Specifications 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Sequence 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Access Procedures 3-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Drive Enclosure 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the High Voltage Shield 3-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Control Interface Board MOD–L4, –L5, or –L6 3-9. . . . . . .
Removing the Main Control Board Mounting Plate 3-11. . . . . . . . . . . .
Removing the Main Control Board from the Mounting Plate 3-13. . . . .
Removing The Gate Driver Board Mounting Plate 3-15. . . . . . . . . . . . .
Removing the Gate Driver Board from the Mounting Plate 3-17. . . . . .
Removing the Precharge Board Mounting Plate 3-19. . . . . . . . . . . . . . .

Table of Contents
iii
Removing the Precharge Board from the Mounting Plate 3-21. . . . . . . .
Removing a Power Module Snubber Board 3-23. . . . . . . . . . . . . . . . . .
Removing the Input Rectifier Snubber Board 3-26. . . . . . . . . . . . . . . . .
Accessing Power Plane Components 3-27. . . . . . . . . . . . . . . . . . . . . . . .
Component Test Procedures Chapter 4
Chapter Objectives 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 Precharge Board 4-5. . . . . . . . . . . . . . . . . . . . . . . . .
Test 3 – Testing the Power Modules 4-7. . . . . . . . . . . . . . . . . . . . . . . . . .
Test 4 – Testing the Bus Capacitors 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Test 5 – Testing the Input Rectifiers 4-13. . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Chapter 5
Procedures
Chapter Objectives 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Replacement Overview 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Discharge Precautions 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Component Replacement 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents
iv
Detailed Product Identification 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Capacitor Bank 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Modules 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Rectifiers 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan and Transformer Assembly 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Bus Inductor L1 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Sense CT 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Fuse 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEMs 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOV Surge Suppressor 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts List Chapter 6
Chapter Objectives 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Replacement Parts 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts Listing 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics
150 – 300 HP 1336 PLUS Drives S-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes N-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary
G-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index
I-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface
P-1
Preface
Manual Objective The information in this manual is designed to help troubleshoot or repair an
Allen-Bradley Bulletin 1336 PLUS Adjustable Frequency AC Drive with
ratings B150 – B250, C150 – C250, and CX300.
Who Should Use This manual is intended for qualified service personnel responsible for
This Manual troubleshooting and repairing the 1336 PLUS 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 troubleshooting 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 +DC and –DC on Terminal Block
TB1. Do not attempt to service the drive until the bus voltage has
discharged to zero volts.
Safety Precautions
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.

Preface
P-2
ATTENTION: Only personnel familiar with the 1336 PLUS
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 Allen-Bradley Publication 8000-4.5.2, Guarding Against
Electrostatic Damage, or any other applicable ESD protection
handbook.
Electrostatic Discharge
Precautions
Electrostatic discharge generated by static electricity can damage the
complimentary metallic oxide semiconductor devices on various drive
boards. It is recommended that you perform these procedures to guard
against this type of damage when circuit boards are removed or installed:
•Wear a wrist type grounding strap that is grounded to the drive chassis.
•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.