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.

Preface
P-3
1336 PLUS
Product Identification
Drive Nameplate Location
The drive nameplate is located on the face of the Main Control Board
Mounting Plate. The drive nameplate contains the drive’s catalog number
and other important drive information. Reference the catalog number when
ordering replacement parts.
Figure 1.1
Drive Nameplate Location
AB0429A
Nameplate located on
top edge of Main Control
Board Mounting Plate.

Preface
P-4
Software Compatibility
ATTENTION: To guard against machine damage and/or personal
injury, drives with ratings above 45 kW (60 HP) must not be used
with software versions below 1.07. Refer to the table below.
Three-Phase Drive Rating

380 – 480V 500 – 600V Compatible with
Version Frame Reference
112 – 187 kW
150 – 250 HP 112 – 224 kW 150 – 300 HP 2.01 & Up E
kW and HP are constant torque (CT) ratings.

Preface
P-5
Drive and Option The following is an explanation of the catalog numbering system for 1336
Identification PLUS Adjustable Frequency AC Drives and options. The catalog number
is coded to identify the drive power rating and can be found on the drive
shipping carton and nameplate.
1336 PLUS Drive Catalog Numbers
Table 1.A
1336S – B040-AA – EN – L6 – HA1 – GM1
BULLETIN NO. RATING-ENCLOSURE
(MUST BE SPECIFIED) LANGUAGE MODULE

(MUST BE SPECIFIED) CONTROL INTERFACE

(OPTIONAL) HUMAN INTERFACE

(OPTIONAL) COMMUNICATION CARD

(OPTIONAL)
380 – 480V AC Input, Constant or Variable Torque Drive
Enclosures
Drive Rating

Open
IP00
No Enclosure
NEMA Type 1
IP20
General Purpose
NEMA Type 4
IP65
Resist Water, Dust
NEMA Type 12
IP54
Industrial Use
Frame
Constant Torque Variable Torque

Frame
Designation Output
Amps Nominal
HP Output Amps Nominal HP Code Code Code Code
E199.0
263.0
325.0
150
200
250
240.0
292.0
325.0
200
250
250
B150-AN
B200-AN
B250-AN
B150-AA
B200-AA
B250-AA



B150-AJ
B200-AJ
B250-AJ
* 480 volts only

Preface
P-6
Table 1.B
1336S – C025-AA – EN – L6 – HA1 – GM1
BULLETIN NO. RATING-ENCLOSURE
(MUST BE SPECIFIED) LANGUAGE MODULE

(MUST BE SPECIFIED) CONTROL INTERFACE

(OPTIONAL) HUMAN INTERFACE

(OPTIONAL) COMMUNICATION CARD

(OPTIONAL)
500 – 600V AC Input, Constant or Variable Torque Drive
Enclosures
Drive Rating

Open
IP00
No Enclosure
NEMA Type 1
IP20
General Purpose
NEMA Type 4
IP65
Resist Water, Dust
NEMA Type 12
IP54
Industrial Use
Frame
Designation Output
Amps Nominal HP CT Nominal HP VT Code Code Code Code
E158.0
252.0 150 200 150 200 C150-AN C200-AN C150-AA C200-AA


C150-AJ
C200-AJ
284.0 250 250 C250-AN C250-AA

C250-AJ
300.0 300 300 CX300-AN CX300-AA

CX300-AJ

Preface
P-7
Table 1.C
Language Modules
Description Option Code
English/English
EN
English/English
En
g
lish/French
EN
FR
English/French
English/German
FR
DE
g
English/Italian IT
English/Japanese
E lih/S ih
JP
ES
English/Spanish ES
Table 1.D
Options
Code Description Code Description
Human Interface Modules, NEMA Type 1 (IP 20) Communication Options
HAB
HAP
HA1
HA2
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
GM1
GM2
GM3
Single Point Remote I/O
RS-232/422/485, DF1
RS-232/422/485, DH485
Human Interface Modules, NEMA Type 4 (IP 65) Control Interface Options
HFB
HFP
HF1
HF2
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
L4
L4E
L5
L5E
L6
TTL Contacts
Contacts & Encoder Feedback
24V DC
24V DC & Encoder Feedback
115V AC
Human Interface Modules, NEMA Type 12 (IP 54)
L6
L6E
115V
AC
115V AC & Encoder Feedback
HJB
HJP
HJ1
HJ2
Blank – No Functionality
Programmer Only
Programmer, LCD/Analog Pot
Programmer, LCD/Digital Pot
Drive rating is based on a carrier frequency of 2kHz maximum, an altitude of 1,000 meters
or less, and a maximum ambient temperature of 40°C. Refer to Qualifications on pages P-8
and P-9.
Not available.
VT Ratings do not apply to 380V Input.
Refer to the Language Module and Options tables following these Catalog Number tables.
Table 1.E
380 – 480V Drives
Catalog
Number
Maximum
Amp
Rating

Derate
Curve

Heat
Dissipation
Drive
Watts

Heat Sink
Watts Total Watts
B150
B200
B250
199
292
325













Preface
P-8
Table 1.F
500 – 600V Drives
Catalog
Number
Maximum
Amp
Rating

Derate
Curve

Heat
Dissipation
Drive
Watts

Heat Sink
Watts Total Watts
C150
C200
C250
CX300
158
228
284
300
















Amp Rating is at 2kHz. If carrier frequencies above 2kHz are selected, drive Amp Rating
must be derated. Refer to the User Manual for carrier frequency vs. Amp deratings.
Drive Ambient Temperature Rating is 40_C. If ambient exceeds 40_C, the drive must be
derated.
Drive Rating is based on altitudes of 1,000m (3,000 ft) or less. If installed at higher altitude,
drive must be derated.
Refer to the 1336 PLUS User Manual, Appendix A.

Preface
P-9
Drive Rating Qualifications
Several factors can affect drive rating. If more than one factor exists,
consult Allen-Bradley Company.
Enclosure Type
The first character, A, indicates the Enclosure Code.
The second character indicates the type of enclosure shipped from the
factory:
Table 1.G
Enclosure Type Code Description
Enclosure
Type Code Description
N Open style (IP 00)
A NEMA Type 1 (IP 20)
F NEMA Type 4 (IP 65)
J NEMA Type 12 (IP 54)

Preface
P-10
Conventions To help differentiate parameter names and display text from other text in
this manual, the following conventions will be used:
•Parameter Names will appear in [brackets].
•Display Text will appear in “quotes”.
The following is a list of conventions used throughout this manual, and
definitions of the conventions. For a list of terminology and definitions,
refer to the Glossary in the back of this manual.
Auxiliary Input
The Auxiliary Input is a terminal connection on the Control Interface
Board. This connection provides an external input for use as an Auxiliary
Interlock. Unless this interlock is closed, the drive will be faulted with an
Auxiliary Fault.
Auxiliary Interlock
The Auxiliary 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 something or
the setting of some control, such as a Parameter. Checking a drive board or
component may also require measurements and tests.
Connector
A connector connects one drive board to another. Connectors come in two
designs, male and female. Male connectors are stationary and contain pins,
which are sometimes joined by jumpers. Female connectors are at the ends
of wires or ribbon cables and plug into male connectors.

Preface
P-11
Default
When a drive function defaults, it automatically changes to a
pre-programmed setting.
Enable Input
The Enable Input is a terminal connection on the Control Interface Board.
This connection provides an external input to enable or disable the Drive
Output section. It must be true to permit the drive to operate.
False
False refers to a logical false state. For instance, a Control Interface signal
on TB3 is false when the input contact is open or the appropriate voltage is
not applied to the Control Interface Board.
Jumper
A jumper completes a circuit 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.
Control Interface Board
A Control Interface Board plugs into connectors J7 and J9, located on the
lower portion of the Main Control Board. This board is identified as L4/4E,
L5/5E or L6/6E and provides optional control wiring configurations for a
drive.
Parameter
Parameters are programmable drive functions that define various operating
functions or status displays of a drive. Refer to Bulletin 1336 PLUS
Adjustable Frequency AC Drive User Manual for Parameter details.
Press
Press a button on the Human Interface Module to change Parameter
settings and drive functions.

Preface
P-12
True
True refers to a logical true state. For instance, a Control Interface signal
on TB3 is true when: L4/L4E contact input is closed, L5/L5E input
terminal registers 24V, or L6/L6E input terminal registers 115V AC.
Related Publications The following lists other Allen-Bradley publications that apply to the 1336
PLUS Adjustable Frequency AC Drives with ratings B150 – B250, C150 –
C250, and CX300:
•Product Data (1336 PLUS-1.0)
•User Manual (1336 PLUS-5.0)
•Option Manuals/Instructions
•Renewal Parts List (1336-6.5)