Drive Modernization: A Migration Strategy

In a previous post, I looked at converting legacy drives. Legacy drives are in every nook and cranny of our manufacturing facilities. Since the early 1990s, companies have invested in AC drive technology. The applications for AC drives are diverse. Saving energy, matching speeds on lines, and load sharing are just a few places where it makes sense to use drives. Often these drives operate till they fail. Unfortunately, most electrical departments are not prepared for when such an event occurs.

Migrating 1336 PLUS to PowerFlex525

This part of my modernization blog series looks at a migration strategy for the 1336 PLUS and 1336 PLUS II drives that are 30 HP normal duty and below at 480VAC levels as well as 15 HP and below for 230VAC levels. If you are above 30 HP, please go to the blog “How do I convert from a legacy Drive?”.

Step One: Do Your Homework Prior to Legacy Drive Failure

Be prepared to change over the drive efficiently when your old 1336 PLUS drive shows no sign of recovery. Being proficient and prepared when this happens will save hours of time.

  • Save your 1336 PLUS program as soon as possible with DriveTools software
  • Make sure you have an accurate schematic and that the wires are labeled
  • Download the 1336S-UM001-EN-P(1336 PLUS) or 1336F-UM002-EN-P(1336 PLUS II) user manual
  • Purchase a 1203-USB drive cable to retrieve and download drive parameters
  • Prepare a CCW file by correlating the old DriveTools parameters to the new Connected Component Workbench parameters for new PowerFlex® drive

Step Two: Look at The Details Inside and Outside the Drive

  • First, wire up the three phase to the new drive. L1, L2, and L3 are the incoming AC power. T1, T2, and T3 are the motor leads
  • Next, determine the control voltage of the drive. This will be located on the drive as an additional control board:

Termination Block Locations

Step Three: Document Your System

Document which TB3 control card you have:

Control Interface Option

Note: The PowerFlex 525 has 24VDC control voltage. If you have an L6 card it will require interposing relays.

Document which TB2 control terminal you have:

(Analog signals and relay outputs.)

TB2 Connections

1336 PLUS DRIVE TB2

1336 PLUS II DRIVE TB2

1336 PLUS II DRIVE TB2

The 1336 PLUS does not have isolated analog inputs, they were a feature added in the 1336 PLUS II. Small add-in modules were added to the main control board to provide these isolated inputs and outputs. The 1336F-LA1 through 1336F-LA7 add-in modules mount with one-time mounting barbs to the main board; on smaller frames they can be behind the snap in HIM. If you remove the HIM, you will find the modules. They look like the image on the right.

 

1336 PLUS II Example
Document All Wiring

Document all the wiring to the analog I/O and relay outputs for the PowerFlex525 replacement.

  • Take a photograph or find some other way to document the wires going into TB2
  • Plan your strategy to wire new points to the PowerFlex525 I/O terminal strip
  • Analog scaling in the PowerFlex525 should not have to be adjusted to the settings in the 1336 PLUS or 1336 PLUS II
  • If you are using a potentiometer for speed, the 10K pot is the same one used for the PowerFlex525
1336F LA Cards and Terminal Functionality

1336F LA Cards and Terminal Functionality

Note: PowerFlex525 only has one relay output. If the process requires more relays, please consider the PowerFlex 750 series drive.

Digital I/O From 1336 PLUS to PowerFlex525

If there is one takeaway for this blog, let it be this one point as you transition from the 1336 PLUS to the PowerFlex525:

  • Know the input mode of the 1336 PLUS or 1336 PLUS II drive
  • It will tell you if you have two-wire or three-wire control

This parameter is in the setup folder on the 1336 drive. Here is the navigation map and keystrokes to get to the input mode parameter:

input mode parameter

Understanding the Input Mode Function

Go to the input mode parameter and observe the value. It will be numeric if it is a 1336 PLUS, and it will be two wire or three wire if it is a 1336 PLUS II. Below are the different configurations for TB3 digital input card. Here are the charts for the 1336 PLUS drive first generation:

input mode

Please note the input node numeric values and how they equate to two-wire and three-wire control. You will need to know when you wire the PowerFlex525. Input Mode 7 for the 1336 PLUS highlighted above is three-wire control. It is bipolar, meaning it can run in forward or in reverse.

Two Wire Terminology

  • RUN, RUN FWD, RUN REV
  • (OPEN THE RUN CIRCUIT)

Three Wire Terminology

  • START (MOMENTARY)
  • STOP (MOMENTARY)

Typical Parameters to Check

Parameters to Check

The highlighted parameters are the minimal parameters to check with DriveTools software or keypad. Above is the map and keystrokes to retrieve this information.

1336 PLUS Check List

  • Number of digital inputs and their function (TB3)
  • Number of digital outputs and their function (TB2)
  • Number of analog inputs and their function (TB2)
  • Number of analog outputs (TB2)
  • Two-wire or three-wire control, confirm which
  • Full-load amps of motor
  • RPM of motor
  • PWM frequency set for 2 KHZ
  • Set accel and decel time
  • Check and set maximum freq and minimum freq
  • Document speed reference and set PowerFlex525 to the same wiring and programming

PowerFlex 525 Control

Understanding Two-Wire and Three-Wire Concepts

Now that you have all the information needed to program the PowerFlex525, you know all your wiring points and have extracted all the parameters from the 1336 PLUS with DriveTools software (downloaded from Rockwell’s PCDC download center at rockwellautomation.com).

Two-Wire Control

  • Leave the yellow factory jumper in between terminals one and 11
  • Wire the run signal to terminal two
  • Wire the source voltage wire for run signal to terminal 11(24VDC)
  • Press the green start button and start drive turn potentiometer on drive faceplate and change speed after starting
  • Using the integral HIM or software change, 46 to a value of “two DigIN TermBlk.” Now, start the drive from the remote start station away from the drive. Change the speed from the potentiometer on the keypad

Three-Wire Control

  • Remove the yellow factory jumper in between terminals one and 11
  • Install stop wire to terminal one (normally closed momentary)
  • Install start wire to terminal two (normally open momentary)
  • Program T063 to “0” to disable input

Congratulations! You have the drive starting and stopping correctly!

Note: You can only start the drive from one location. To start some place else, you need to point Parameter 46 to another location.

Speed Reference

  • Set parameter 47 to point to where the speed reference is coming from its proper location
  • Check scaling of signal if you have a minimum speed required to run at adjust parameter 43 or adjust minimum frequency
  • Remove signal to drive and make sure it faults out
  • Stop button is the reset for the fault
  • Analog input 4-20MA; 15(+) and 14(com)
  • Analog input 0-10VDC; 13(+) and 14(com)

Analog Outputs

  • Parameter 88 is set to “0” for output frequency change if necessary
  • Jumper J10 is factory default 0-10VDC change to upward position for 4-20MA
  • Relay outputs
  • These are dry contacts AC or DC voltage can be used
  • Default relay one is faulted
  • Default relay two is drive running

Drive Software

  • Connected Components Workbench
  • 9328-S001K-EN

Please consider using CCW software. It’s free, and you can use the Ethernet port on the drive for fast access to the drive.

In Conclusion

The PowerFlex525 is an affordable modernization path from the 1336 PLUS drive. Please keep in mind, this is a V/hz drive with sensorless vector control (autoboost without an encoder). This is not a drive used for torque control applications; this is strictly a velocity regulator. This was exactly what the 1336 PLUS and 1336 PLUS II were, frequency drives. If you have a 1336 impact drive, please consider the PowerFlex750.

We Can Help

If this blog seems like something you don’t want to try to do on your own, please consider our ASP program. A Horizon Solutions factory-authorized engineer will install the drive for you and authorize a two-year warranty instead of the standard one-year warranty. Whether you’re interested in this program or just need to talk through your options, our Automation Specialists are here to help. Contact us today!

All of the figures and images in this post are © Rockwell Automation®

What are your legacy drive challenges? Is it time to modernize? Let us know in the comments.

About the author

Scott Savage
Scott Savage

Scott is an Automation Specialist focusing on drives, motors, and power. He operates out of the state of Maine and brings a combination of experience, expertise, and fast commissioning time. The next time you have a need for AC drives, controllers, and/or network capabilities, Scott is here to assist with your machine design solutions.