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160 SSC™ Variable Speed Drive (Series C)

1. Reference Diagram B Figure B 8 4 Mounting Holes a W 5 54 0 22 81 D 3 19 2 36 129 74 i 5 11 i a i i 0900098 RILI S L2 1 L3 BR BR li Im i y 180 3m 7 09 6181 IBIBBIB esc sella v oll 111 43 H GE DI id 1 123456789101 69669606606 Y Uoo o o G amp um viz wis 2000 Tc 0 0 009 ad S 1 4 A n gt f Za e 2 36 Drive Dimensions and Weights Table B 5 200 240V AC 1 Phase Drive H Ww D Weight 160S AA08 193 7 58 92 3 62 193 7 61 2 37 5 23 200 240V AC 3 Phase Drive H Ww D Weight 160 AA18 193 7 58 92 3 62 193 7 61 2 37 5 23 380 460V AC 3 Phase Drive H Ww D Weight 160 BA10 193 7 58 92 3 62 193 7 61 2 37 5 23 Important Use Figure B 11 Drilling Template B for mounting a drive listed in the table above B 8 Accessories and Dimensions Drive Mounting Hole Dimensions 80 3 15 2 87 Bl b5 2 36 0 26 e Til 5 5 0 22 Mounting Holes 2 Places 143 5 63 140 5 51 130 150 9 5 12 5 94 J ty Ja A L3 i E 0 18 60 5 2 36 T 0 20 Figure B 9 92 3 62 I 3 19 T Le Le 10 5 2 36 0
2. 456789 SESSI TB3 Terminal Block TB3 Control Wiring amp UTi V T2 WIT3 DC DC E SES MESES El TB2 Terminal Block TB2 ii Ground Motor amp p J Capacitor Module Wiring Installation and Wiring 2 3 Terminal Block Wiring Terminal Block Wiring Detail Figure 2 2 Required Branch Circuit Disconnect O Branch Circuit Protective Device O Terminal Block TB1 R L1 S L2 T L3 BR BR Ground Terminal Protective Earth U T1 V T2 W T3 DC DC COE ale Terminal Block TB2 ale ee Specifications Terminal Block TB1 and TB2 Wiring Specifications Table 2 A Model Screw Size Max Min Wire Size Max Min Torque mm AWG Nm Ib in 4 0 kW 5 HP M4 5 26 3 31 10 12 1 35 0 90 12 8 All Other Ratings M4 3 31 0 82 12 18 1 35 0 90 12 8 O For single phase input applications connect the AC input power to input terminals S L2 andT L3 O See Table 2 B for minimum recommended branch circuit protective devices Bulletin 160 Drives are UL Listed see Appendix A for details as motor overload protective devices
3. V continued on next page 4 2 Start Up continued from previous page E v Ready Fault Indicating Panel Procedure v The green Ready indicator will illuminate Use inputs to TB3 to operate the drive v Program Keypad Module Remote Keypad Module or CopyCat Keypad Module Procedure v P01 Output Frequency will display If drive has been previously powered up a different parameter may display Important To enable the Start and Reverse keys on the Program Keypad Module set P46 Input Mode to 2 and cycle power or set P56 Reset Function to 2 Refer to P56 in Chapter 5 v Analog Signal Follower Model gt v v Preset Speed Model v Set the frequency source to its minimum setting v If you are using a Program Keypad Module verify that the Clockwise LED is illuminated If you are using a Ready Fault Indicating Panel verify that the Reverse input to TB3 is in the Open position v Issue a Start command from the Program Keypad Module or TB3 Drive fan will energize some models v Slowly increase the speed until the motor begins to turn Check the direction of motor rotation v Select P61 Preset Frequency 0 by removing all inputs to SW1 SW2 and SW3 on TB3 see Figure 2 21 The factory default setting for P61 Preset Frequency 0 is 3 Hz lt
4. Allen Bradley 160 SSCTM Variable Speed Drive Series C 0 37 4 0 kW 0 5 5 HP FRN 7 03 FRN 7 04 FRN 7 05 FRN 7 06 User Manual Automation 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 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 Rockwell Automation 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 Rockwell Automation cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation 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 Rockw
5. Approvals and Standards Compliance Approvals KERA CELA UL508C c CSA 22 2 AS NZS 2064 1 1992 Mo conn 0 com gt EMC Directive 89 336 Lv EN 50178 EN 60204 EMC EN 61800 3 EN 50081 1 EN 50082 2 Designed to Meet These Standards FCC Class A O and B IEC 146 1 1 VDE 0871 and VDE 0875 Control Inputs Analog Signal Follo External Speed wer Only 1K to 10K Ohms 2 Watts Minimum Potentiometer 4 20 mA Analog Input 250 Ohms Input Impedance 10 to 10VDC 100K Ohms Input Impedance Analog Input Control Output Programmable Output Form C Relay Contact Resistive Rating 0 4A at 125VAC 0 2A at 230VAC 2A at 30VDC Inductive Rating 0 24 at 125VAC 0 1A at230VAC 1A at 30VDC Analog Signal Follower only With external components Specifications A 3 Control Features PWM Algorithm Sine Weighted PWM with Harmonic Compensation Switching Device IGBT V Hz Ratio Programmable Carrier Frequency Adjustable from 2 to 8kHz in 100 Hz Increments Factory Default is 4kHz DC Boost Adjustable Select from a Family of Boost Curves Current Limiting Software Controlled Coordinated for Drive and Motor Protection Programmable from 1 to 180 of Drive Output Current Motor Protection Overload Pattern 0 Pt Overload Protection 150 for 60 Seconds 200 for 30 Seconds Flat Response Over Speed Range No Speed Compensation Overload Pattern 1 Spee
6. A variety of cable types are acceptable for variable speed drive installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide allow a spacing of 1 meter 3 3 feet for every 10 meters 33 feet of unshielded length If you cannot separate motor cables from sensitive circuits or if you must run motor cables from multiple drives more than three in a common conduit or cable tray shielded motor cable is recommended to reduce system noise Motor cables should be four conductor with the ground lead and shield if using shielded cable connected to the drive ground terminal and the motor frame ground terminal Table 2 D provides the recommended wire type for both wet and dry installations as defined by NEC 1996 70 31 These recommendations are based upon a variety of factors such as insulation thickness susceptibility to moisture and susceptibility to nicks and cuts during installation Recommended Cable Type Table 2 D Condition Insulation Type Example Dry PVC THHN XLPE XHHW 2 Wet XLPE XHHW 2 O For input power voltages in excess of 264V AC or motor cable distances greater than 15 meters 50 feet wire with XLPE insulation is recommended Installation and Wiring 2 7 Long Motor Cable Effects Reflected Wave Protection The drive should be installed as close to the motor as possible Installations with long motor cables may require
7. 1 state of the inputs to TB3 in binary coded format as follows Bit 3 Bit 2 Bit 1 Bit 0 Polarity TB3 6 TB3 8 TB3 5 Input Mode 0 0z Start Stop Reverse 3 Wire Positive Input Mode 1 Analog Run Stop Run 2 Wire Input Forward Reverse Input Mode 2 N A Stop N A Keypad T Input Mode 3 Negative Run Stop Run Mom Run Fwd Rev Analog Forward Reverse Input Mode 4 Input Run 0 Accel 2 Decel 2 Run Accel Decel Forward 1 Accel 1 Decel 1 Reverse Input Mode 5 Run Coast to Rest Stop Run Coast to Rest Forward Reverse Input Mode 6 Run 0 TB3 Control Run TB3 Control Forward 1 Keypad or Comm Reverse Keypad or Comm Input Mode 7 Run 0 Analog Frequency Select Run Frequency Select Forward 1 Internal Frequency Select Reverse Input Mode 8 O Run 0 Open Run SF1 Preset Speed Forward 1 Closed Reverse Input Mode 9 Run 0 Pl Run 2 Wire PI control Forward 1 Internal Frequency Select Reverse O Status of Bit 3 for Input Mode 8 is TB3 2 is 0 Open 1 Closed 13 Power Factor Angle 0 0 180 0 0 1 degrees Displays the angle in electrical degrees between motor voltage and motor current 14 Memory Probe Display Numeric Value Numeric Value Used by Rockwell Automation field service personnel 15 Preset Status Preset Binary Number Displays the open 0 and closed 1 0000 0111 state of TB3 inputs SW1 SW2 and SWS in binary coded format Analog E 0000 0011 SW2 SW3 Not Used 1
8. 5 5 overview 5 1 program group 5 5 5 16 30 Accel Time 1 5 5 31 Decel Time 1 5 6 32 Maximum Frequency 5 6 32 Minimum Frequency 5 6 34 Stop Mode Select 5 6 35 Base Frequency 5 6 36 Base Voltage 5 6 37 Boost Select 5 7 37 Maximum Voltage 5 6 39 Skip Frequency 5 7 Index 3 40 Skip Frequency Band 5 7 41 Motor Overload Select 5 8 42 Motor Overload Current 5 8 43 Current Limit 5 8 44 DC Hold Time 5 8 45 DC Hold Voltage 5 9 46 Input Mode 5 9 47 Output Configure 5 10 48 Output Threshold 5 10 49 PWM Frequency 5 10 50 Restart Tries 5 10 51 Restart Time 5 11 52 DB Enable 5 11 53 S Curve 5 11 54 Clear Fault 5 12 55 Memory Probe Address 5 12 56 Reset Functions 5 12 57 Program Lock 5 12 58 Internal Frequency 5 12 59 Frequency Select 5 12 60 Zero Offset 5 12 61 68 Preset Frequency 0 7 5 13 69 Accel Time 2 5 13 70 Decel Time 2 5 13 71 IR Compensation 5 14 72 Slip Compensation 5 14 73 Reverse Disable 5 14 74 Analog Select 5 14 75 Analog Input Minimum 5 15 76 Analog Input Maximum 5 15 78 Compensation 5 15 79 Software Current Trip 5 15 80 Stall Fault Time 5 15 81 PI Proportional Gain 5 16 82 PI Integral Gain 5 16 83 PI Process Reference 5 16 resetting to factory defaults 5 12 potentiometer wiring 2 19 power wiring 2 2 precautions 2 2 terminal bloc
9. Bulletin 140 manual motor starters can be used in single and group motor applications In single motor applications a fuse or UL489 rated circuit breaker is required ahead of the Bulletin 140 manual motor starter In group motor installations the Bulletin 140 can be used for protection of an individual motor within the group and one set of fuses or a UL489 rated circuit breaker serves as the Branch Circuit Protective Device for the entire Group Installation Bulletin 140M manual motor starters can be used in single and group motor applications without additional short circuit protection Refer to the technical support literature for the 140M for more details Minimum Recommended Branch Circuit Protective Devices O Table 2 B Voltage Rating Drive Rating Fuse Rating UL489 Rated Bulletin 140 140M kW HP Circuit Breaker Manual Motor Starter Amps Amps Single Phase 0 37 0 5 6 16 16 230V 0 55 0 75 10 16 16 0 75 1 15 16 16 15 2 30 20 20 Three Phase 0 37 0 5 6 16 16 230V 0 55 0 75 6 16 16 0 75 1 10 16 16 15 2 15 16 16 22 3 20 20 20 40 5 30 30 30 Three Phase 0 37 0 5 4 6 6 460V 0 55 0 75 4 6 6 0 75 1 5 6 6 15 2 8 16 16 22 3 15 16 16 40 5 20 20 20 O The maximum branch circuit protection rating is limited to four times the rated output current of the drive or 30A whichever is less Fuse class CC J BS88 VDE 06366 gG IEC 269 1 gG EN60269 part 1 and 2
10. IEC Class 10 overload An external overload relay is not required for single motor applications as long as the Drive kW HP rating is less than three times larger than the motor KW HP rating O Each terminal supports up to 2 wires of approved gauge 2 4 Installation and Wiring Motor Branch Circuit Analysis Short circuit and overload protection are requirements of any motor branch circuit Input power conditioning CE conformance reflective wave capacitive current coupling and motor cable type are important considerations of drive applications Branch Circuit Configuration Figure 2 3 2 Branch Circuit Protective Devices See Table 2 B Input Power Conditioning See Table 2 C CE Conformance See Appendix C 160 SSC Motor Cable Types See Table 2 D EN Reflected Wave Protection See Table 2 E Overload Protection Motor Branch Circuit Protective Devices A motor branch circuit requires protection against excessive current This protection can be provided by a fuse circuit breaker or manual motor starter See Table 2 B for a detailed list of these options Input Power Conditioning Certain conditions may exist that could damage a drive in the branch circuit See Table 2 C for an explanation of problems and solutions CE Conformance See Appendix C for information on CE Conformance Motor Cable Types See Table 2 D for recommended cable types Reflected
11. OF y 1 14 5g 0 315 A Catalog No A B 160 BMA1 amp 160 BMB1 245 9 64 225 8 86 160 BMA2 amp 160 BMB2 334 13 15 314 12 36 Bulletin 1321 Line Reactors Figure B 2 Catalog No A B C D E 1321 3R2 A 112 44 104 4 1 74 2 9 50 2 0 37 1 44 1321 3R2 B 112 44 104 4 1 74 2 9 50 2 0 37 1 44 1321 3R4 A 112 44 104 4 1 76 8 0 50 2 0 37 1 44 1321 3R4 B 112 4 4 104 4 1 76 3 0 50 2 0 37 1 44 1321 3R8 A 152 6 0 127 5 0 76 3 0 53 2 1 51 2 0 1321 3R8 B 152 6 0 127 5 0 76 3 0 53 2 1 51 2 0 1321 3R12 A 152 6 0 127 5 0 76 3 0 53 2 1 51 2 0 1321 3R18 A 152 6 0 133 5 3 79 3 1 51 2 0 51 2 0 Accessories and Dimensions B 3 Accessory Dimensions Continued All dimensions are in millimeters and inches Dimensions are not used for manufacturing purposes Line Filters Figure B 3 _ B lt E gt e eg 4 y o O D o o Y O lojojo o cae 2 Line Filter Module A B C D E F G H 160S RFA 9 A 182 0 75 0 37 5 163 0 60 0 M4 5x6 5 M4 5x6 5 160 RFB 5 A 7 17 2 95 1 47 6 42 2 36 0 18 x 0 26 0 18 x 0 26 160 RFB 14 A 182 0 75 0 475 163 0 60 0 prie picis 7 17 2 95 1 87 6 42 2 36 160S RFA 16 B 200 ie Rudd n 227 0 87 0 55 5 212 0 60 0 M4 5 0 18 slot M4 5 0 18 7 87 8 94 3 43 2 18 8 35 2 36 2 places 2 places 160 RFB 14 B 160 L
12. Wiring of Replacement Series A or B Series C U T1 V T2 W T3 U T1 V T2 W T3 e Table of Contents Getting Started Important Precautions xe Oeste aia ad ne Pe eda 1 1 Receiving Your New Drive 0 0 ccc Hm 1 2 UNPACKING sti 1 2 InSpecting acts eee cede be E edt e eec ee ede e ede AA 1 2 Identifying Your DNE insta eon bt e E rnb e e TR b UE PRREN WE 1 2 Catalog Number 5 1 prd ee in Uo Sets 1 2 Nameplates EEUU 1 3 Conventions Used In This Manual sss 1 3 Standard Drive Features 0 cece mmm 1 4 Optional Drive Features 0 Imm 1 5 Installation and Wiring Storage and Operation Conditions issssssssssssssss me 2 1 GE ComplialiCe scorsi eb gad RC RU EUN Qe drei a dedu 2 1 Instala c 2 1 Clearances oa E e dudes E ob de ted o 2 1 pepis Label sacs 2c aat ELA LE Re eoe 2 1 Power Wiring s tas a hr el scat Ad A att es Eds 2 2 Precautions s ete be tene n rette te eec be vete Gb erae 2 2 Terminal Blocks 3 tb tte xev es 2 2 Terminal Block WINING sucios ce o ec ae 2 3 Specifications i ciar e et Een vr eats tee a et tes Yau e en 2 3 Motor Branch Circuit Analysis 0 00 00 ccc cece teen ences 2 4 Branch Circuit Protective Devices 00 0 ccc cette eee eens 2 5 Input Power Conditioning 0 0 0 2 cece cece e 2 6 Motor Cable Types iissssssssssse Ih mn 2 6 Long Motor Cable Effects 0 0 cece cece eee eee ented 2 7 Control Wii a
13. is linear for any decrease in command frequency unless P53 S Curve is set to a value other than 0 O Minimum deceleration time must be set based on the applied motor size To guard against premature drive failure do not set P31 Decel Time 1 or P70 Decel Time 2 below the minimum value listed in the table below 230 and 460V Motor Sizes Minimum Deceleration Settings 4 0 kW 5 HP 0 7 seconds 2 2 kW 3 HP 0 6 seconds 1 5 kW 2 HP 0 2 seconds 0 75 kW 1 HP 0 1 seconds 0 55 kW 0 75 HP 0 1 seconds 0 37 kW 0 5 HP 0 1 seconds 320 Minimum Frequency 0 240 1Hz 0 Hz Lowest frequency that drive will output continuously 33e Maximum Frequency 0 240 1Hz 60 Hz Highest frequency the drive will output This parameter cannot be changed while running The value of this parameter setting must be greater than the value set in P32 Minimum Frequency 34 Stop Mode Select 0 3 Numeric 0 Determines stopping mode used by the drive when a stop is initiated Refer to Value the P44 DC Hold Time and P45 DC Hold Voltage diagrams Settings 0 Ramp to Stop 1 Coast to Stop 2 DC Injection Braking 3 DC Injection Braking w Auto Shutoff works the same as standard DC injection braking except that it may shut off before the P44 DC Hold Time This occurs if the drive is out of current limit before the P44 DC Hold Time expires 35 Base Frequency 10 240 1Hz 60 Hz Set value to rate
14. 1 2 times normal stall time 2 4 times normal stall time 3 6 times normal stall time 4 8 times normal stall time 5 Stall fault disabled ATTENTION Continuous operation at high currents caused by A a stall can cause motor damage This parameter applies only to the Analog Signal Follower model 5 16 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default 81 PI Proportional Gain 0 10 00 Numeric 0 01 Value Proportional gain used by the PI regulator This parameter is scaled so that when itis set to 1 0 the process response is 1 Hz when the process error is 1 The correct value for this parameter depends on the dynamics of the process being controlled as well as the desired response This parameter is active when P46 Input Mode setting 9 is used 82 PI Integral Gain 0 10 00 Numeric 0 01 Integral Gain used by the PI regulator This parameter is scaled so that when it vale is set to 1 0 the process response is 10 Hz sec when the process error is 1 The correct value for this parameter depends on the dynamics of the process being controlled as well as the desired response This parameter is active when P46 Input Mode setting 9 is used 83 PI Process Reference 0 100 0 0 1 0 0 The PI control will regulate to this set point value It represents a percentage of the analog input This parameter is a
15. 60 Hz 0 55 3 4 1321 3R2 A 160 LFB1 160 RFB 5 A 160 CMB1 3 Phase 075 i 160 BMB1 1321 3R2 A 160 LFB1 160 RFB 5 A 160 FRK2 160 CMB1 15 2 160 BMB2 1321 3R4 B 160 LFB1 160 RFB 5 A 160 FRK2 160 CMB1 22 3 160 BMB2 1321 3R8 B 160 LFB1 160 RFB 14 A 160 FRK2 160 CMB1 40 5 160 BMB2 O 1321 3R18 B 160 RFB 14 B 160 FRK3 160 CMB1 Ready Fault Panel Program Keypad Module DeviceNet RS 232 24V DC Interface O Communication Module Catalog No 160 RS1 9 Cable Catalog No Communication Module Catalog No 160 DN2 9 CopyCat Keypad Module Catalog No 160 P3 Catalog No 160 B1 Catalog No 160 P1 Catalog No 160 DM SF1 Analog 160 DM PS1 Preset Remote Programming Adapter Catalog No 160 RPA O Remote Keypad Module Catalog No 160 P2 O 160 C10 1 meter non locking each end 160 C10R 1 meter non locking each end right angle 160 C30 3 meter locking each end 160 C50 5 meter locking each end Bulletin 160 Series C drives with proper filter meet Overall EMC requirements of EN61800 3 for Second Industrial Environments High frequency conducted and radiated emissions of EN61800 3 for First Residential Environments High frequency conducted and radiated emissions of EN55011 for Second Industrial Environments The MTBF for the fan is 40 000 hours at 50 C Catalog numbers listed are for 3 impedance open style units NEMA Type 1 and 5 impedance reactor types are also availa
16. 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION This drive contains ESD Electrostatic Discharge Removal Insert a small screw driver into the slot at top of keypad Carefully pry back and pivot the module out Avoid bending or twisting the contact pins located underneath the center portion of the module Removing Program Keypad Module Figure 3 2 3 4 Program Keypad Module Installation 1 Insert the module bottom end first into the drive 2 Press on the h symbol at the top of the module until it is firmly seated It is critical that the Program Keypad Module is firmly seated to ensure circuit integrity Installing Program Keypad Module Figure 3 3 Chapter 4 Start Up Start Up Procedures This chapter guides you through a basic start up of the drive using factory default parameter settings The objective is to verify power and control wiring set motor direction control motor speed and prepare you for programming parameters tuning if necessary Refer to Chapter 5 for a complete listing and description of parameters and programming information ATTENTION Power must be applied to the drive to perform the following start up procedure Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read
17. Control This input mode activates the Start and Reverse functions from either the Program Keypad Module PKM Remote Keypad Module CopyCat Keypad Module or plug in communication modules and deactivates the Start and Reverse inputs on the control terminal block TB3 Note the frequency reference can be controlled from the keypad modules or communication modules by setting P59 Frequency Select to a setting of 1 The frequency will then be controlled by the value programmed into P58 Internal Frequency Program Keypad Module control Figure 2 6 TB3 oN Q e Reverse Note A contact closure on terminals 7 and 8 is required O Stat for the controller to respond to a Start Run command On Common dp Stop FRA O When performing start and reverse operations from the Program Keypad Module Remote Keypad Module CopyCat Keypad Module or plug in communication modules the Start and Reverse inputs from the Control Terminal Block TB3 are disabled P46 Setting 3 Momentary Run Forward Run Reverse Control This input mode allows the drive to respond to either a momentary or maintained Run Forward or Run Reverse input but requires a stop input to TB3 terminals 7 and 8 to command the drive to stop In addition this is the only input mode that uses level triggered control logic therefore once the stop command is removed or if power is lost and restored the drive will immediately restart if a maintained
18. P33 Maximum Frequency Maximum frequency required 60 Hz P34 Stop Mode Select Desired stopping mode 0 P35 Base Frequency Motor rated nameplate frequency 60 Hz P36 Base Voltage Motor rated nameplate voltage 460V or 230V P38 Boost Select Desired V F boost setting 2 P42 Motor Overload Current Motor nameplate Full Load Amps FLA 11596 P43 Current Limit Desired maximum output current 150 P46 Input Mode Desired control method 0 P47 Output Configure Desired output relay function 0 P56 Reset Functions Desired drive reset description 0 P58 Internal Frequency Desired internal frequency 60 0 Hz P59 Frequency Select Desired frequency source 0 P61 P68 Preset Frequency 0 7 Desired preset frequencies 0 7 P74 P76 Analog Input Desired analog input functionality 0 0 0 100 0 Refer to the Programming Example on the next page for instructions 5 2 Parameters and Programming Important Reset Actions You must set P56 Reset Functions to 2 or cycle power after changing the setting of P46 Input Mode for the change to take effect If you reset to factory defaults you cannot use the Program Keypad Module for start or reverse control until it is selected using P46 setting 2 Note P56 Reset Functions must be set to 2 or power must be cycled for the change to take effect Important If you cycle power you must wait a minimum of one minute for the bus to di
19. Reset Functions if you changed P46 Input Mode Display is dark Verify that the module is firmly seated Remove module and inspect connector pins If pins are not damaged reinstall and firmly seat the module 6 4 Troubleshooting Block Diagram of Bulletin 160 Analog Signal Follower Figure 6 3 Brake Module Capacitor Module s Jp DC DC Lt R T1 U We L2 8 lt T2 V CAO ue Motor L3 T BE T3 W He 1 GND PE GNUEE Control Bus Sine e T Volt z 9783 1 Foner Cicily Circuitry 10 to 10V 1B3 2 or Frequency TB3 3 Reference Potentiometer Common or Fault Feedbac E TB3 4 Program 4 20 mA Keypad Reverse S Module o _ _ _ 1TB3 5 ile Start o ____ _ 1TB3 6 Opto Programable Input J Isolator TB3 9 User p AA TB 8 mu t 19 Programmable ircuitr Common OT83 7 M T 6755 1 Output Appendix A Specifications Tables A A and A B contain information that is unique to each Bulletin 160 Drive rating Table A C contains information that applies to all drive ratings 200 240V AC 1 Phase amp 3 Phase Input Drive Ratings Table A 1 1 Phase Input 160S AA02 160S AA03 160S AA04 160S AA08 3 Phase Input 160 AA02 160 AA03 160 AA04 160 AA08 160 AA12 160 AA18 3 Phase Motor Rating kW HP 0 37 1 2 0 55 3 4 10 75 1 1 5 2 2 2 3
20. Wave Protection The use of a drive may result in increased peak to peak voltage at the motor See Table 2 E for an explanation of motor insulation limitations versus cable lengths Capacitive Current Coupling High speed voltage switching causes AC coupling from motor cables to ground terminal protective earth See Table 2 F for cable length recommendations Overload Protection All motor branch circuits require overload protection The Bulletin 160 Drive is UL listed to provide protection IEC Class 10 overload without an overload relay Separate overload relays are required in multi motor applications or if the drive kW HP rating is more than three times larger than the motor kW HP rating Installation and Wiring 2 5 Branch Circuit Protective Devices Fusing The Bulletin 160 Smart Speed Controller has been UL tested and approved for use with input fuses The ratings in the table below are the minimum recommended values for use with each drive rating The devices listed in this table are provided to serve as a guide Other devices which meet the requirements of UL508C and UL489 with similar trip characteristics may be used in order to meet local or national electrical codes Bulletin 140 Manual Motor Starters UL489 Circuit Breakers When using Bulletin 140 manual motor starters or UL489 rated circuit breakers the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection
21. and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing Start Up Checklist Verify that the drive is installed per the instructions in Chapter 2 including Drive is mounted on a flat vertical and level surface Minimum clearance distance between drive and other equipment Proper grounding practices have been followed Proper power and control wiring has been used No external power applied to control inputs Verify that AC line power at the disconnect device is within the rated value of the drive v Disconnect and lock out all incoming power to the drive including incoming AC power to terminals R S and T L1 L2 and L3 of TB1 v A ATTENTION A DC Bus voltage may be present at TB1 and TB2 for approximately three minutes after power is removed from the drive v Verify that the motor leads are connected to the power terminal block TB2 terminals U V W T1 T2 T3 v IMPORTANT Verify that a closed contact input is present at TB3 8 See Chapter 2 Control Wiring for details onTB3 8 functionality when using P46 Input Mode settings 4 through 9 v Confirm that all other control inputs are connected to the correct terminals and are secure v Remove debris label and reconnect power to drive
22. contains high voltage capacitors which take time to discharge after removal of mains supply Before working on drive ensure isolation of mains supply from line inputs R S T L1 L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels ATTENTION Only personnel familiar with the 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 The surface temperatures of the drive may become hot which may cause injury ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook gt PPP P ATTENTION An incorrectly applied or installed drive can result in component damage or reduction in product life Wiring or application errors such as undersizing the motor supplying an incorrect or an inadequate AC supply
23. current allowed before current limiting occurs Value set in Drive Rating percent of drive rated output current 44 DC Hold Time 0 0 25 0 0 1 0 0 The time that P45 DC Hold Voltage will be applied to the motor when P34 Seconds Seconds Stop Mode Select is set to either DC Injection Braking or Ramp to Stop Parameters and Programming 5 9 Program Group Min Max Factory No Parameter Name Description Range Units Default 45 DC Hold Voltage 0 115 1 Volt 0 Volts DC Voltage level applied to the motor during braking when P34 Stop Mode Select is set to either DC Injection Braking or Ramp to Stop mode If the current exceeds P43 Current Limit the voltage applied to the motor will be less than this setting Ramp to Stop Mode DC Injection Braking Mode Voltage Volts Speed Volts Speed DC Hold Time DC Hold Voltage DC Hold Voltage y ya A Stop Command ine Stop Command om 46 Input Mode 0 9 Numeric 0 Configures the TB3 control inputs for various 3 wire or 2 wire control schemes Value Also enables disables the Program Keypad Module Remote Keypad Module or CopyCat Keypad Module input control See Chapter 2 for wiring diagrams and descriptions of settings Important The method used to activate PI control is dependent upon Firmware Version Refer to 5 17 for PI Control Setup and Activation instructions Important This parameter cannot be programmed while the drive is running In addition po
24. e tenets 5 17 Wire For Pl Control reo EO EE Ee E OC eR vae o 5 17 Program tor Pl Control ous e v ERI IP E E RP eT pel ke eR ERE 5 17 Tune he PIEOOD 1 ne s a RR ENS 5 18 Common Problems with PI Control 0 00 cece cece eee IRI 5 19 Troubleshooting Fault informatione 536 oxi brote sb eo bo eb oe o ee a o ob e A ene Dr RN 6 1 How tO ClO ar a Fault ae am Rr Cor EROR Er Dg De ERROR Een cc s n 6 1 Specifications SS ox tren aa dti uite uc iata foto ua sus A 1 Accessories and Dimensions s sse B 1 Accessory Dimensions c sous id dra bas B 2 Drive DIMENSIONS ae terie eiaa dt t B 6 CE Conformity CE Compliance 4 ev AAA A ee CUR CAT COR Xon da Ed C 1 Essential Requirements for a Conforming EMC Installation ooooooooooooo ooo C 1 General Instructions for an EMC Compliant Installation oooooooooooooomoo C 2 Shielded Enclosure rer iE eR P ERE UE aed anne balan C 2 Cable Clamps coa so Ch exe ROBUR RP Ve pa bd C 3 Motor Cable i tect cinch seduce et cinco VR EY iria EET ous C 3 Control Cable 2 0 s ctvAckenacivathdone sate oe a id C 4 Low Voltage Directive 73 23 EEC Compliance 0 00 cece eee e ete e eee e eee ees C 5 Chapter 1 Getting Started Important Precautions In addition to the precautions listed throughout this manual you must read and understand the following statements which identify hazards associated with AC drives ATTENTION The drive
25. frequency value set in P48 Output Threshold 7 Above Current Drive exceeds the value set in P48 Output Threshold Important Value for P48 Output Threshold must be entered in percent of drive rated output current 8 Above DC Bus Voltage Drive exceeds the DC bus voltage value set in P48 Output Threshold 9 Retries Exhausted Number of retries for P50 Restart Tries is exceeded 10 Above Power Factor Power Factor angle exceeds the value set in Angle P48 Output Threshold 48 Output Threshold 0 815 Numeric 0 Determines the on off point for the TB3 output relay when P47 Output Configure Value is set to 6 7 8 and 10 Setting Ranges 6 0 to 240 Hz 7 0 to 180 8 0 to 815 Volts 10 0 to 180 49 PWM Frequency 2 0 8 0 0 1 kHz 4 0 kHz Carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM frequency setting 100 e e 98 96 94 92 90 88 86 84 Output Current A 1 2 3 4 5 6 7 Carrier Frequency kHz Important Ignoring derating guidelines can cause reduced drive performance 50 Restart Tries 0 9 Numeric 0 Maximum number of times the drive will attempt to reset a fault Value Faults 03 20 will automatically reset according to this parameter setting Parameters and Programming 5 11 Program Group Min Max Factory No Parameter Name Description Range Units Default 51 Restart Time 0 0 300 0 0 1 1
26. g 2 36 amp 8 ALLEN BRADLEY mH ld L DesficeNet Lie i 150 9 UD 00 J 5 94 00000 123 9101 QODowowvOO U T VT2 W T3 DC DC O 60060060 b O IE FC CJ Em a 193 69 7 63 24V DC Interface Module Figure B 6 O This device does not effect the overall height of the drive B 6 Accessories and Dimensions Drive Dimensions All dimensions are in millimeters and inches all weights are in kilograms and pounds Reference Diagram A Figure B 7 4 Mounting Holes 45 a W 9 0 18 60 2 36 000 Ae i coocoo P
27. or Metal Conduit When the control circuitry is located outside of the 160 enclosure CE Conformity C 3 Cable Clamps Motor Cable Use suitable EMC tested cable clamps only The connection area must be 360 degrees around the shielded cable The cable clamps also provide strain relief for the cable When using conduit the contact point of metal entry connections must be free of paint or non conductive surfaces and solidly connected with good conductivity to the enclosure The cable between the drive and motor must be a 4 wire shielded cable three phases and ground Do not exceed the maximum motor cable length for the specific line filter module used Inside the shielded enclosure shielded motor cable must be used as close to the drive s output terminals as possible The shield must be solidly connected to the PE terminal of the drive Where the shielded motor cable exits the enclosure an EMC tested cable clamp or metal conduit must be used to solidly connect the cable shield to the enclosure The shield on the motor side must be solidly connected to the motor housing with an EMC tested cable clamp or conduit providing good conductivity from the cable shield to the motor housing Motor Connections Figure C 2 Ground Terminal PE UMI VIT2 WIT3 DC DC Shielded Enclosure SSS RILI S L2 T L3 BR BR eT ALLEN BRADLEY 4
28. or excessive ambient temperatures may result in system malfunction 1 2 Getting Started Receiving Your New Drive It is your responsibility to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against your purchase order If any items are obviously damaged do not accept delivery until the freight agent notes the damage on the freight bill Unpacking Remove all packing material wedges or braces from within and around the drive Remove all packing material from the heat sink Leave the debris label in place If you find any concealed damage during unpacking notify the freight agent Also leave the shipping container intact and have the freight agent make a visual inspection of the equipment to verify damage Inspecting After unpacking check the item s nameplate catalog number against your purchase order An explanation of the catalog numbering system for the Bulletin 160 drive follows as an aid for nameplate interpretation Refer to Figure 1 1 and Figure 1 2 Important Before you install and start up the drive inspect for mechanical integrity Look for loose parts wires and connections Identifying Your Drive Catalog Number The figure below describes the 160 SSC catalog numbering scheme Catalog Number Explanation Figure 1 1 160 A A02 N SF1 EI First Position Second Position Third Position Fourth Position Fifth Position Sixth Position Bulleti
29. properly Check the frequency source P06 Frequency Command e Verify that a frequency signal is present at terminal block TB3 Either a 10 to 10V signal or a 4 20 mA signal Verify that the Preset Frequencies are set properly Check the control input signals Verify that SW1 SW2 and SW3 are correct Referto the chart in Chapter 5 Check the following parameter settings e Verify that P59 Frequency Select is showing the desired frequency source Verify that P58 Internal Frequency is set to the desired frequency Cycle power or use P56 Reset Functions if you changed P46 Input Mode The motor is not accelerating properly Check the motor e Verify that the motor is connected properly Verify that no mechanical problems exist Check the following parameter settings Verify that P30 Accel Time 1 or P69 Accel Time 2 whichever is currently used is set properly Verify that P43 Current Limit is set properly Verify that P38 Boost Volts is set properly Drive will not operate in the run forward or run reverse modes Boom Verify that P46 Input Mode is set to 1 Verify that neither P73 Reverse Disable nor P74 Analog Select is set to 1 Verify that the power has been cycled for 1and 2 to take effect Verify that both the Run Forward and Run Reverse switches are not closed simultaneously Cycle power or use P56
30. the addition of external devices to limit voltage reflections at the motor reflected wave phenomena See Table 2 E for recommendations Important Both Reflected Wave and Capacitive Current Considerations need to be taken into account when determining motor cable lengths see Table 2 E and Table 2 F The use of an external device to limit reflected wave phenomenon may effect the accuracy of Bulletin 160 current sensing The reflected wave data applies to all frequencies 2 to 8 kHz For 230V ratings the maximum cable length recommendations are the same as the capacitive current recommendations see Table 2 F Cable Length Recommendations Reflected Wave Table 2 E 380 Motor Motor Cable Only RWR at Drive O Reactor at Motor 460V Insulation Shielded Unshielded Shielded Unshielded Shielded Unshielded Ratings Rating feet meters feet meters feet meters feet meters feet meters feet meters 4 0kW 1000Vp p 45 13 7 20 6 1 525 160 600 183 325 991 300 91 5 5HP 1200 Vp p 90 274 40 122 525 160 600 183 525 160 425 130 1600 Vp pO 525 160 475 145 525 160 600 183 525 160 600 183 2 2kW 1000Vp p 40 12 2 40 122 525 160 600 183 225 686 250 76 2 3HP 1200 Vp p 90 274 60 18 3 525 160 600 183 325 991 425 130 1600 Vp p 525 160 500 152 1525 160 600 183 525 160 600 183 15kW 1000Vp p 40 122 40 122 425 130 600 183 325 991 300 91 5 2 HP 1200 V
31. thousands of authorized partners distributors and system integrators around the world Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 European Headquarters SA NV avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Rockwell Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication 0160 5 17ML EN May 2000 P N 194456 02 Supersedes 0160 5 15 January 1999 0160 5 15DU3 June 1999 0160 5 15DU4 November 1999 Copyright 2000 Rockwell International Corporation All rights reserved Printed in USA
32. to Setting 1 except TB3 terminal 8 provides the function of switching the frequency reference from the control terminal block TB3 to the frequency commanded by P58 Internal Frequency For Analog Signal Follower models this provides the ability to switch from analog control to one preset speed For Preset Speed models this provides a ninth preset speed via P58 Internal Frequency Two Wire Frequency Select control Figure 2 11 TB3 TB3 8 Open External TB3 Run Reverse Frequency Command TB3 8 Closed cuneate Internal P58 Common Frequency Command Frequency Select 9 O TB3 terminal 8 can be used to clear faults See Figure 2 14 for details Installation and Wiring P46 Setting 8 Two Wire Preset Speed Control Analog Models Only This input mode is similar to Setting 1 except TB3 terminals 1 2 and 8 provide the function of preset speeds Note All analog functionality is disabled when using this input mode setting Two Wire Preset control TB3 10V Swi Common 4 20 mA input O Run Reverse Run Forward TB3 2 and TB3 8 See Table 2 1 below Figure 2 12 Common sw20 TB3 Terminal 2 and 8 Switch Definitions Table 2 1 SW2 Position SW1 Position TB3 8 TB3 2 Speed Reference Accel Rate Decel Rate Open 0 Open 0 Parameter 61 Parameter 30 Parameter 31 Preset 0 Open 0 Closed 1 Parameter 62 Parameter 30 Parameter 31 Preset 1 Closed 1 Open 0 Parameter 65 Parameter 69
33. will conform Many other factors can influence the total installation and only direct measurements can verify total conformity It is therefore the responsibility of the machine manufacturer to ensure that the conformity is met A copy of the Declaration of Conformity DOC is available from your local Rockwell Automation Sales Office Essential Requirements for a Conforming EMC Installation The following seven items are required for CE Conformance 1 Ow NN An input line filter module see Appendix B Accessories and Dimensions must be installed to reduce conducted emissions 160 LF Filters These units have been tested with a maximum motor cable length of 75 meters 250 feet for drives rated 200 240V AC and 40 meters 133 feet for drives rated 380 460V AC 160S RF Filters These units have been tested with a maximum motor cable length of 25 meters 80 feet for both 230V and 460V units The drive system must be mounted in a shielded enclosure to reduce radiated emissions Grounding of equipment and cable shields must be solid with low impedance connections Motor and control cables entering the shielded enclosure must have EMC tested shielded cable clamps or grounded metal conduit All motor cables must use shielded cable or be in grounded metal conduit All control and signal wiring must use shielded cable or be in grounded metal conduit The Common terminals TB3 3 an
34. 0 0 Time between restart attempts Seconds Seconds If this parameter and P50 Restart Tries are both set to zero and P46 Input Mode is not set to 3 the auto fault clear feature is enabled This feature automatically clears overvoltage undervoltage and overtemperature faults 1 second after the fault condition is removed If this parameter is set to zero and P50 Restart Tries is not zero then the time between restart attempts is 1 second 52 DB Enable 0 100 Numeric 0 Enables disables external dynamic braking Value Setting 0 Disable Settings 1 through 100 duty cycle braking ATTENTION The 160 Dynamic Brake Module is rated for 596 duty cycle Use of this package above 5 should not be used and voids the UL rating of this device When setting this parameter to a value above 5 duty cycle the resistor must be sized to avoid overheating of the resistor package This parameter cannot be programmed while the drive is running 53 S Curve 0 10 Numeric 0 Enables a fixed shape S Curve See formula below Value Formula S Curve Time Accel or Decel Time x S Curve Setting in percent O See values below Example Accel Time 10 Seconds S Curve Setting 3 S Curve Time 10 x 0 3 3 Seconds Important Maximum S Curve time is 60 seconds 1 2 S Curve 1 2 S Curve Time Time y gt I 4 _S Curve Setting 0 096 1 10 2 20 3 30 4 40 5 50 6 7 8 9 1 1 2 S Curve
35. 180 549 350 107 8 180 154 9 1350 107 0 180 54 9 1350 107 037kW 2 100 305 1325 99 1 100 30 5 350 107 100 130 5 1300 91 5 0 5 HP 4 100 30 5 325 991 100 305 350 107 100 30 5 1350 107 8 100 305 1325 99 1 7 100 1305 1350 107 200 240V Ratings No Reactor RWR at Drive O Reactor at Motor 0 37 to 4 0 kW Shielded O Unshielded Shielded Unshielded Shielded O Unshielded 0 5 to 5 HP feet meters feet meters feet meters feet meters feet meters feet meters 2 through 8 kHz 525 160 600 183 e 525 160 600 183 Q Not recommended for use above 4 kHz PWM Frequency When using shielded cable at lightly loaded conditions cable length recommendations for drives rated 0 75 kW 1 HP and below are 61 meters 200 feet Not recommended for 230V applications Installation and Wiring 2 9 Control Wiring Requirements Run all signal wiring in either a shielded cable or separate metal conduit Connect shield wire only at TB3 Common terminals 3 and 7 Do not exceed control wiring length of 15 meters 50 feet Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the control terminal block Common must be connected to ground terminal protective earth Use Belden 8760 or equivalent 18 AWG 0 750 mm twisted pair shielded or 3 conductor Specifications Control Terminal Block TB3 Wiring Spec
36. 3 7 5 Maximum Output Amps 2 3 3 0 4 5 8 0 12 0 18 0 Power Dissipation Watts 20 25 35 74 107 137 Input Voltage Frequency 200 240VAC 1 Phase and 3 Phase 50 60 Hz Operational Input Voltage Range 180 265V AC Input kVA 11 14 2 2 3 7 5 7 8 4 1 Phase Input Current 9 4 8 6 2 9 4 16 3 3 Phase Input Current 9 2 8 3 6 54 94 142 21 1 Environmental Specifications Cooling Method Convection Cooled Fan Cooled Dynamic Braking Torque With External Dynamic Brake Module 200 150 115 100 Without External Dynamic Brake Module 100 100 100 50 50 20 380 460V AC 3 Phase Input Drive Ratings Table A 2 Drive Catalog Number 3 Phase Input 160 BA01 160 BA02 160 BA03 160 BA04 160 BA06 160 BA10 Output Ratings 3 Phase Motor Rating kW HP 0 37 1 2 0 55 3 4 0 75 1 1 5 2 2 2 3 3 7 5 Maximum Output Amps 12 17 2 8 4 0 6 0 10 5 Power Dissipation Watts 25 30 37 50 7T 120 Input Ratings Input Voltage Frequency 380 460V AC 3 Phase 50 60 Hz Operational Input Voltage Range 340 506V AC Input kVA 14 1 6 2 2 3 7 5 6 9 7 Input Current 9 14 2 0 2 8 4 6 7 0 12 2 Environmental Specifications Cooling Method Convection Cooled Fan Cooled Dynamic Braking Torque With External Dynamic Brake Module 200 150 115 100 Without External Dynamic Brake Module 100 100 100 50 50 20 0 Input current ratings are calculated
37. 41 Pa i i X 5 5 0 22 Mounting Holes 2 Places 192 5 7 58 lis E ES A 180 7 09 171 6 73 Y Y Sd i m j s p 0 22 60 _ 6 3 2 36 0 25 This illustration depicts the mounting hole placements for the drives listed below Use the appropriate Drilling Template for your drive 200 240V AC 1 Phase 200 240V AC 3 Phase 380 460V AC 3 Phase 160S AA02 A 160 AA02 A 160 BA01 A 160S AA03 A 160 AA03 A 160 BA02 A 160S AA04 A 160 AA04 A 160 BA03 A 160S AA08 B 160 AA08 A 160 BA04 A 160 AA12 A 160 BA06 A 160 AA18 B 160 AA10 B Accessories and Dimensions B 9 Drilling Template A Figure B 10 ES E B 10 Accessories and Dimensions Drilling Template B Figure B 11 ES CE Compliance Appendix C CE Conformity This drive is a component intended for implementation in machines or systems for the industrial environment Itis CE marked for conformity to the Low Voltage LV Directive 73 23 EEC when installed as described It also has been tested to meet the Council Directive 89 336 Electromagnetic Compatibility EMC The standards used for this testing are LV ENS0178 EN60204 1 EMC EN61800 3 EN5008 1 1 EN50082 2 These tests were conducted with a PWM frequency Parameter 49 of 4 0 kHz Important The conformity of the drive and filter to any standard does not guarantee that the entire installation
38. 6 Analog Input 150 0 150 0 0 1 Displays the analog input as a percent of full scale Used in setting P60 Zero Offset P75 Analog Input Minimum and P76 Analog Input Maximum Important Oninitial set up of the drive apply a OV or 4 mA analog command to the drive Once applied if the value of this parameter displays something other than zero program that value into P60 Zero Offset Please note thatthe value of Zero Offset will be subtracted from the value of this parameter This parameter applies only to the Analog Signal Follower model This TB3 input applies only to the Preset Speed model Parameters and Programming 5 5 Display Group Read Only No Parameter Name Description Min Max Range Units 17 Fault Buffer 0 0 48 Numeric Value This parameter stores the last fault that occurred If the same fault occurs multiple times in a row it will be stored once After a reset defaults P56 this will set this parameter to F48 Reprogram Fault As faults occur the previous value of this parameter is moved to P18 Fault Buffer 1 18 Fault Buffer 1 0 48 Numeric Value This parameter stores the second most recent fault that occurred After a reset defaults P56 this will set this parameter to 0 No active fault As faults occur the value of this parameter will be overwritten by P17 Fault Buffer 0 The previous value of this parameter is moved to P19 Fault Buff
39. EA bak bo ON TES 2 9 Requiremieris ivi 2 9 Specifications i oet tots a rct evi ria Vas are 2 9 Important Precautioris er cel Ate en e ie a areca e a eon 2 9 Control Wiring Considerations ssssssssssses cc 2 10 Control Methods and Selection Guide sessesses esee 2 11 Configurable Relay Output Contacts P47 Settings 0oooocccccoccncccccccnn 2 18 Frequency Source Wiring tco Dent Warne dabei he dre ne ached bones 2 18 Analog Signal Follower Model ssssssssssssee me 2 18 Preset Speed Model uses per E die Yr ER se raids eee eas s 2 20 Analog and Preset Models 2 20 What ToDo Nexura Da veo reeimbesticlbmenosrilqbsitic c ss 2 20 Program Keypad Module A A A O A O TO 3 1 Display Mode viii a AA ian 3 1 Program i Mode sexa e b A Ww Seb SEE 3 1 Key FUNCUONS ii te Aa 3 2 Module Removal and Installation 2 0 0 0 ccc cece eee e en nnaeees 3 3 Removal ici be ue eaten i ta e C worker ee 3 3 ristallatioris zs ss a he ate nds vtt tss Qe hem d alan A mi code 3 4 Start Up Start Up Procedutes nee adorador oda 4 1 Parameters and Programming Overview Of Parameters ics is ia a 5 1 Important Reset Actions oooooooccoocccnccrn or 5 2 Programming Example baii Naud eine e Ee Vote eb e eT le are oe 5 2 Display Group Parameters Read Only 20000 cece eee cc 5 3 Program Group Parameters sssssssssssssssss sse 5 5 PI Control Setup and Activation l isssssssssssssse
40. F AII T 0x5 9x52 SOLF AlITypes 1749 75 0 50 0 163 0 60 0 aa i i suras 2 6 85 2 95 1 97 6 42 2 36 kols dir Sod B 4 Accessories and Dimensions Accessory Dimensions Continued All dimensions are in millimeters and inches Dimensions are not used for manufacturing purposes Capacitor Module Figure B 4 1 97 4 5 0 18 i Ms 110 9 es Mounting Holes 4 Placas N 1 57 4 37 A i Of O A p SM a 60 i u 2 36 ALLEN BRADLEY IT r3 r mA 1 w me R 150 9 130 E gt 5 94 5 12 4 wma gt x 1 yA g y 254 10 A A Approximate Lead Length Accessories and Dimensions B 5 Accessory Dimensions Continued All dimensions are in millimeters and inches Dimensions are not used for manufacturing purposes DeviceNet or RS 232 Module Attached to Drive DeviceNet Shown Figure B 5 17 34 187 1 0 68 7 37 Required for 80 3 15 Removal 6000060 y 60
41. ILI S L2 TL3 BR BR J 60 Susa m 2 36 130 i 5 12 mE 83 43 H Esc set v 3 28 i OF J o 6668668856 S U TI_VT2 WT3 DC DC 28 29 y I Y 0900909 1 11 gt i CARA B 9 42 60 E EM ai 2 36 i Drive Dimensions and Weights Table B 4 200 240VAC 1 Phase Drive H WwW D Weight 160S AA02 152 6 00 80 3 15 165 6 51 0 94 2 07 160S AA03 152 6 00 80 3 15 165 6 51 0 94 2 07 160S AA04 152 6 00 80 3 15 165 6 51 1 02 2 24 200 240VAC 3 Phase Drive H Ww D Weight 160 AA02 152 6 00 80 3 15 165 6 51 0 94 2 07 160 AA03 152 6 00 80 3 15 165 6 51 0 94 2 07 160 AA04 152 6 00 80 3 15 165 6 51 1 02 2 24 160 AA08 152 6 00 80 3 15 165 6 51 1 02 2 24 160 AA12 152 6 00 80 3 15 165 6 51 1 10 2 43 Drive H Ww D Weight 160 BA01 152 6 00 80 3 15 165 6 51 0 94 2 07 160 BA02 152 6 00 80 3 15 165 6 51 0 94 2 07 160 BA03 152 6 00 80 3 15 165 6 51 1 02 2 24 160 BA04 152 6 00 80 3 15 165 6 51 1 02 2 24 160 BA06 152 6 00 80 3 15 165 6 51 1 10 2 43 Important Use Figure B 10 Drilling Template A for mounting a drive listed in the table above Accessories and Dimensions B 7 All dimensions are millimeters and inches all weights are kilograms and pounds
42. O FAULT O READY 1234567891011 0000000000 4 Wire Shielded Motor Cable fc EE Motor Wiring TB2 X Ground to Motor Housing EH EMC Tested Shielded Cable Clamp or Metal Conduit C 4 CE Conformity Control Cable Control wiring must use shielded cable or grounded metal conduit Shielded Motor and Control Cable Example Figure C 3 Stranded Copper Wire Plastic Insulation Inner Plastic Sheath Compact Screen of Galvanized Tinned Copper or Steel Outer Plastic Jacket The shield must be connected to signal common at both ends of the cable The Common terminals TB3 3 amp 7 must be solidly connected and as short as possible to the PE terminal of the drive Control Connections Figure C 4 SESS Ground Terminal PE RILI SIL2 T L3 BR BR O FAUT O READY Control Wiring TB3 Control UT VIT2 WIT3 DC DC Cabinet o alle 8 oe Signal T Common ed Zl Shielded Control Cable Ground Terminal PE AO Shielded Enclosure I EMC Tested Shielded Cable Clamp or Metal Conduit O When the control cir
43. PI Control Setup and Activation instructions Users of Firmware Version FRN 7 05 and earlier can only use P46 Input Mode setting 9 to activate PI control Refer to page 5 17 for PI Control Setup and Activation instructions 2 12 Installation and Wiring P46 Setting 0 Three Wire Control Factory Default This input mode provides a typical three wire control function where a momentary start input will command the drive to start Three Wire control Factory Default Figure 2 4 TB3 Reverse Note A contact closure on Start O terminals 7 and 8 is required a for the controller to respond Common to a Start Run command Stop O Start input can be a momentary input P46 Setting 1 Two Wire Run Forward Run Reverse Control This input mode provides a typical two wire control function where a maintained Run Forward or Run Reverse input will provide both a directional and start command to the drive Opening the Run Forward or Run Reverse input will command the drive to stop in accordance with the P34 Stop Mode setting The stop switch TB3 7 and 8 is not required but can be wired as an Auxiliary Stop if desired Two Wire Run Forward Run Reverse control Figure 2 5 Run Reverse Note A contact closure on terminals 7 and 8 is required Run Forward for the controller to respond Common to a Start Run command Stop Installation and Wiring 2 13 P46 Setting 2 Program Keypad or Communication Module
44. Parameter 70 Preset 4 Closed 1 Closed 1 Parameter 66 Parameter 69 Parameter 70 Preset 5 Q Do not connect to TB3 4 in this mode TB3 terminal 8 can be used to clear faults See Figure 2 14 for details Installation and Wiring 2 17 P46 Setting 9 Two Wire PI Control Analog Models Only This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of PI Control Two Wire Pl control TB3 Figure 2 13 0 10V DC OR Common Common 4 20 mA o TB3 8 Open PI Run Forward TB3 8 Closed Internal Frequency Common Pl Internal Frequency 6 Refer to Chapter 5 160 PI Control Setup for a detailed PI Control Setup description Do not connect to TB3 5 in this mode TB3 terminal 8 can be used to clear faults See Figure 2 14 for details Important TB3 8 Clear Faults TB3 8 Closed TB3 8 Open Important Fault Occurs For P46 Input Mode settings 4 through 9 Terminal TB3 8 is also used to clear faults See figure below for details Figure 2 14 NE Fault Fault Fault Clears Occurs Clears The system programmer is responsible for returning terminal TB3 8 to its original state if necessary 2 18 Installation and Wiring When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives it is important to connect the commons TB3 7 together for all drives If they are to be tied into another com
45. Process Reference to disable PI control while the drive is running Disable PI control only when the drive is stopped Parameters P81 PI Proportional Gain and P82 PI Integral Gain are used to set how the drive will respond to errors fluctuations in feedback P81 PI Proportional Gain corrects output frequency based on the magnitude of the error e P82 PI Integral Gain corrects output frequency based on the length of time an 1 error has been present Set P82 PI Integral Gain to zero and P81 PI Proportional Gain to some low value Apply a step function command via P83 PI Process Reference and monitor the output response Increase P81 PI Proportional Gain until the response of the output is acceptably fast or the output becomes too noisy Reduce P81 PI Proportional Gain back to the highest value at which the response is still clean Set P82 PI Integral Gain to a low value Apply a step function command and monitor the output response Increase P82 PI Integral Gain until the response is acceptably fast without overshoot Important If either the value of P81 or P82 is set too high drive output will oscillate around the set point entered in P83 PI Process Reference due to continually changing loads in the application Use P84 Dead Band to limit the effects of this oscillation by blocking a frequency count to either side of the set point frequency Parameters and P
46. Run command is present Momentary Run Fwd Run Rev control Figure 2 7 Run Reverse O Note A contact closure on terminals 7 and 8 is required Run Forward 9 for the controller to respond Common to a Start Run command Stop O ATTENTION Hazard of injury exists due to unintended operation When P46 Input Mode is set to 3 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop function is provided only when the Stop input is active open O A momentary or maintained input can be used If using maintained inputs please read the Attention statement above A normally closed maintained input is recommended See Attention statement above 2 14 Installation and Wiring Important Settings 4 through 9 provide additional flexibility of TB3 control input terminal 8 P46 Setting 4 Two Wire Accel Decel Control This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of switching from P30 Accel Time 1 and P31 Decel Time 1 to P69 Accel Time 2 and P70 Decel Time 2 for any commanded frequency reference Two Wire Accel Decel control Figure 2 8 TB3 0 2 TB3 8 Open RUDI Te Accel 2 Decel 2 ip pono TB3 8 Closed O Common Accel 1 Decel 1 Accel Decel Select YA O TB3 terminal 8 can be used to clear faults See Figure 2 14 for details P46 Setting 5 Two Wire Enable Control This input
47. Time 1 2 S Curve Time 60 70 80 90 0 100 Enabled Disabled gt 4 4 Accel Time Decel Time 5 12 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default 54 Clear Fault on Numeric 0 Setting this parameter to a 1 performs a fault reset When the fault reset function Value is complete the value is automatically set back to 0 This parameter cannot be programmed while the drive is running 55 Memory Probe Address Numeric Numeric Numeric Used by Rockwell Automation field service personnel Value Value Value 56 Reset Functions 0 2 Numeric 0 Drive parameters and their associated defaults are reset according to the Value following descriptions Settings 0 Idle State 1 Reset defaults restores all parameter settings to factory defaults 2 Update Input Mode restores the drive to most recent programmed P46 Input Mode setting After the reset update function is complete this parameter will set itself back to a 0 This parameter cannot be programmed while the drive is running Important For setting 1 only an F48 Reprogram Fault will occur and must be cleared by cycling the Stop input to the drive P46 Input Mode factory defaults to 3 wire control If using keypad control change parameter setting back to a 2 to regain program keypad control cycle power or use P56 Setting 2 again 57 Pro
48. V DC parameters 16 59 60 74 75 76 Controller Input Impedance 100k Ohms 4 20 mA Frequency Control Speed Control Figure 2 18 If calibration is required use parameters 16 59 60 74 75 76 Controller Input Impedance 250 Ohms Potentiometer Frequency Control Speed Control Figure 2 19 TB3 If calibration is required use parameters 16 59 60 74 75 76 10k Ohms 2 Watt Linear Taper When connecting a single potentiometer to multiple drives itis important to connect commons TB3 3 together for all drives TB3 3 common and TB3 2 potentiometer wiper should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly Predicting actual performance given the variety of installation possibilities is difficult however up to five drives with two meters of cable between have been tested without problems Typical Multiple Drive Analog Connection Figure 2 20 I 1 Optional Ground Connection Preset Frequency Sources The Analog Signal Follower model has a special input mode P46 setting 8 that allows the drive to be operated via preset speed inputs See Figure 2 12 and Table 2 1 for details 2 20 Installation and Wiring Preset Speed Model You can control the output frequency of the drive via the Control Terminal Block TB3 using dry contacts or open collector inputs to SW1 SW2 and SW3 see Figure 2 21 Important Refer to parameters 61 68 in Chapte
49. als U V amp W T1 T2 amp T3 Output Power 05 Bus Voltage 0 400 230V 1 Volt Displays the DC Bus Voltage level 0 800 460V 06 Frequency Command 0 0 240 0 0 1 Hz Displays the frequency that the drive is commanded to output This command may come from any of the frequency sources selected by P59 Frequency Select or from a currently selected preset frequency 07 Active Fault 0 48 Numeric Value Displays the coded active fault number If a fault is currently active has not been cleared the display will flash After fault condition is cleared display will read zero Refer to P17 P18 and P19 for fault history See Chapter 6 for fault code descriptions 08 Heatsink Temperature 69 150 1 Degree C Displays the temperature of the drive heatsink Note A display value of 69 indicates a temperature of less than 70 C 09 Drive Status 0000 1011 Binary Number Displays the status of the drive in a binary coded format f Important isi 0 Inactive 1 Active n Decel 10 Drive Type Numeric Value Numeric Value Used by Rockwell Automation field service personnel 11 Firmware Version Fixed Value Numeric Value Displays version of drive firmware Used by Rockwell Automation field service personnel 5 4 Parameters and Programming Display Group Read Only No Parameter Name Description Min Max Range Units 12 Input Status 0000 1111 Binary Number Displays the open 0 and closed
50. arameters can be changed to fit your motor control requirements A Program Keypad Module Remote Keypad Module or CopyCat Keypad Module allow you to view or change parameters Communication Modules RS1 DN1 or DN2 allow you to view or change parameters with an additional device A Ready Fault Indicating Panel cannot be used to view or change parameters The table below describes which parameters apply to the Preset Speed and Analog Signal Follower models Parameter Type Analog Signal Follower Model Preset Speed Model Parameter Numbers Parameter Numbers Display 1 19 1 15 17 19 Program 30 62 65 66 69 76 78 84 30 59 61 73 78 80 Some parameters pertain only to either the Analog Signal Follower or Preset Speed model not both Indicates that parameter applies only to the Analog Signal Follower Model lt Indicates that parameter applies only to the Preset Speed Model Review the factory default settings These parameters can be changed to meet your specific application requirements with any of the following Program Keypad Module Remote Keypad Module or CopyCat Keypad Module The table below provides a list of parameters that are frequently changed Commonly Changed Parameters Table 5 A Parameter Setting Default Setting P30 Accel Time 1 Desired accel time 10 0 sec P31 Decel Time 1 Desired decel time 10 0 sec
51. based on a nominal input voltage of 230V and 460V respectively O Estimated Actual value depends upon motor characteristics A 2 Specifications All Drive Ratings Input Output Ratings Output Voltage Adjustable from 0 to Input Voltage Output Frequency Programmable from 0 to 240 Hz Efficiency 97 5 Typical Transient Protection Standard 6 kV Environmental Specifications Enclosure IP20 Ambient Temperature 0 C to 50 C Storage Temperature 40 C to 85 C Relative Humidity 0 to 95 Non Condensing Vibration 1 0 G Operational 2 5 G Non Operational Shock 15 G Operational 30 G Non Operational Altitude 1 000 m 3 300 ft without Derating Control Inputs Control Input Type Dry Contact Inputs Drive has an internal 12V power supply that provides 10 mA typical current flow Alternate Inputs Accepts open collector solid state inputs sinking into the drive with maximum leakage current of 50 uA 24V Inputs An optional 24V DC interface module allows use of 24V DC sinking inputs see Start Stop Fwd Rev Configurable Inputs for Two or Three Wire Control SW1 SW2 SW3 Preset Speed Model Only Configurable Inputs for Control of 8 Preset Speeds and 2 Accel Decel Times Programmable Input TB3 8 Can Be Configured to Select Accel Decel Times External Coast to Rest TB3 Control Keypad or Communication Control Frequency Select Preset Speed O
52. ble Refer to publication 1321 2 0 for detailed information O 160 LF type filters have been tested with a maximum motor cable length of 75 meters 250 feet for 230V units and 40 meters 133 feet for 460V units 160 RF type filters have been tested with a maximum motor cable length of 25 meters 80 feet for both 230V and 460V units Listed filters are for Bulletin 160 Series C drives only Q Two in parallel required O Compatible with Bulletin 160 Series A Series B and Series C drives with firmware version FRN 4 07 or later Allows 24VDC sinking inputs Bulletin 160 Series C drives must use a Series B or later 24V DC Interface module Compatible with Bulletin 160 Series C drives with firmware version FRN 7 03 or later B 2 Accessories and Dimensions Accessory Dimensions All dimensions are in millimeters and inches Dimensions are not used for manufacturing purposes Dynamic Brake Modules Figure B 1 72 EM 86 4 me xui 14 3 4 0 55 75 lt Y 0 3 A ON B A A DANGER 3 s E NNUS CEPS Y al F HA 6 86 0 27 jalo sR mm E y exe Mounting Holes 4 Places B toch 29 ET E seses n Y TER Q a O sf do
53. ctive when P46 Input Mode setting 9 is used This parameter along with P72 Slip Compensation also activates Pl control in drives using Firmware Version FRN 7 06 See page 5 17 for PI Control Setup and Activation instructions ATTENTION Hazard of personal injury or equipment damage A exists due to unpredictable changes in motor speed Do not use P72 Slip Compensation and P83 Process Reference to disable PI control while the drive is running Disable PI control only when the drive is stopped 84 PI Dead Band 0 10 0 0 1 0 0 The PI control will ignore errors less than this value This parameter is active when P46 Input Mode setting 9 is used This parameter applies only to the Analog Signal Follower model PI Control Block Diagram Figure 5 1 P83 PI Process Reference P81 P84 TB3 8 Open P01 PI Proportional _ PI Dead Band o q Output Gain 9 TB3 8 Closed Frequency Analog Feedback P82 L PI Integral Gain P58 Internal Frequency Parameters and Programming 5 17 PI Control Setup and Activation The Analog Signal Follower model provides for closed loop process control PI control where PI regulator output is used to drive the process to a desired set point Wire For PI Control 1 Connect input and output power to the drive Follow the instruct
54. cuitry is located outside of the 160 enclosure CE Conformity C 5 Low Voltage Directive 73 23 EEC Compliance This product complies with Low Voltage Directive 72 23 EEC when conforming with the following installation requirements Review Chapter 1 Important Precautions and other ATTENTION statements throughout this manual prior to installation of the drive The drive is intended to be installed with a fixed connection to the earth The use of residual current operated protective devices RCDs or ground fault indicators is not recommended If unavoidable the Bulletin 160 is compatible with type B RCDs only The drive should be installed in an appropriate or suitable enclosure Important The conformity of this drive and filter to any standard does not guarantee that the entire installation will conform Many factors can influence the total installation and only direct measurements can verify total conformity C 6 CE Conformity End of Chapter Symbols 10V DC control 2 19 Numerics 12V internal power supply 2 9 24V DC interface module B 5 4 20 mA control 2 19 AC input wiring 2 3 Accel Decel control 5 5 5 13 accessories see optional accessories B 1 ambient temperature 2 1 A 2 analog input frequency sources 2 18 analog inversion inverting input 5 15 analog scaling analog input min max 5 15 analog select 5 14 zero offset 5 12 analog signal 2 18 approvals CE A 2 C 1 CSA A 2 CUL A 2 arrow k
55. cy Band creating a range of frequencies at which the drive will not operate continuously Frequency v Skip 2x P40 Frequency gt Skip Freq Band Setting Setting Time 0 30 1Hz 0 Hz 40 Skip Frequency Band Determines the band around the P39 Skip Frequency parameter The actual band width will be 2 times P40 Skip Frequency Band 1 2 the band above and 1 2 the band below A value of zero will disable the skip frequency 5 8 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default Motor Overload Select 0 2 des tl 0 Bulletin 160 provides Class 10 overload protection Settings 0 2 select the derating factor for the It overload function Setting Derate Level 0 No Derate 10 1 speed range 1 Min Derate 4 1 speed range derate below 25 of base speed Max Derate 2 1 speed range derate below 50 of base speed No Derate Min Derate 2 100 2100 E E a 80 wn 80 S 60 60 S 40 2 40 3 20 3 20 2 o 2 y x 0 25 50 75 100125 150 175 200 e 0 25 50 75 100 125 150 175 200 of Base Speed of Base Speed Max Derate 2 100 5 Settings 2 80 0 No Derating S 60 1 Minimum Derating 3 2 Maximum Derating w 40 3 20 o s 0 25 50 75 100 125 150 175 200 of Base Speed 42 Motor Overload Current 0 1 200 of 0 01A 115 of Set to motor nameplate Full Load Amps FLA Drive Rating Drive Rating 43 Current Limit 1 180 of 1 150 Maximum output
56. d 7 must have a solid connection to ground terminal protective earth C 2 CE Conformity General Instructions for an EMC Compliant Installation Shielded Enclosure Typical NEMA or IEC metal enclosures are adequate The ground connection of the shielded enclosure must be solidly connected to the PE terminal of the drive Good conductivity must be assured grounding must provide a low impedance path for high frequency signals All wiring except input power leads must use shielded cable Input power output power and control wiring inside the enclosure must be physically separated Input power output power and control wiring outside the enclosure must use separate shielded cables or separate conduit Wires do not touch the heatsink Recommended Grounding Configuration Figure C 1 PE A Enclosure Ground Connection T L3 ma T L3 AC S L2 S L2 Input Line L1 R L1 JA ale El Line Power TB1 Ground Terminal PE G RILI SIL2 T L3 BR BR Li ALLEN BRADLEY 4 O FAULT C READY T Control bs Cabinet o Control Wiring TB3 Ground Terminal PE O UT VIT2 WIT3 DC DC ES ESTE EST Motor Wiring TB2 bonam Motor Cable to Motor Shielded Enclosure fi EMC Tested Shielded Cable Clamp
57. d Compensation Below 25 of Base Speed Overload Pattern 2 Speed Compensation Below 100 of Base Speed Accel Decel Time s S Curve Accel Decel Time s 0 1 to 600 Seconds 0 to 100 of Accel Decel Time Not to Exceed 60 Seconds Stopping Modes 4 Programmable Modes Ramp to Stop 0 1 to 600 Seconds Coast to Stop Stops All PWM Output DC Injection Braking Applies DC Voltage to the Motor for 0 to 25 Seconds DC Injection Braking with Auto Stop Protective Features Overcurrent Programmable limit 200 of Hardware Limit 300 of Instantaneous Fault Excessive Temperature Embedded Temperature Sensor Trips if Heatsink Temperature Exceeds 95 C Over Under Voltage DC bus voltage is monitored for safe operation For200 240V AC input drives the overvoltage trip occurs at a bus voltage of 400V DC equivalent to a 290V AC incoming line voltage For380 460V AC input drives the overvoltage trip occurs at a bus voltage of 800V DC equivalent to a 575V AC incoming line voltage e For 200 240V AC input drives the undervoltage trip occurs at a bus voltage of 210VDC equivalent to a 150V AC incoming line voltage For 380 460V AC input drives the undervoltage trip occurs at a bus voltage of 390VDC equivalent to a 275V AC incoming line voltage Control Ride Through Minimum Ride Through is 0 5 Seconds Typical Value is 2 Seconds Ground Short Any Output Phase to Ground Short Faultless Rid
58. d nameplate frequency of motor A Program Keypad Module Remote Keypad Module or CopyCat Keypad Module is required if P35 must be changed to 50 Hz 36 Base Voltage O 20A60for ivi 460for Set value to rated nameplate voltage of motor Bal ae amp ae 230V units 230V units Sets the highest voltage that the drive will output P37 Maximum Voltage must pad Ns Poe be greater than or equal to P36 Base Voltage 230V units 230V units OThe analog inputs to the drive i e 4 20mA 0 to 10 V or remote potentiometer can be scaled to P32 Minimum Frequency and P33 Maximum Frequency by programming P75 Analog Input Minimum and P76 Analog Input Maximum Parameters and Programming 5 7 Program Group Min Max Factory No Parameter Name Description Range Units Default 38 Boost Select 0 12 Numeric 2 Sets the boost voltage and redefines the Volts per Hz curve Settings 0 8 can Value provide increased torque at low frequency Settings 9 12 are used to reduce energy consumption 199 Setting Boost Voltage of Base Voltage 0 0 1 2 5 gt 2 5 0 5 3 7 5 1 2 Base Volts 4 10 0 go 5 125 a 6 15 0 9s 7 17 5 8 20 0 q Setting Fan Pump CurvesO _ See 9 45 0 Settings 1 8 10 40 0 i i 50 100 i 20 Base Frequency O Break Point Voltages in percent of Base Voltage 39 Skip Frequency 0 240 1 Hz 240 Hz Works in conjunction with P40 Skip Frequen
59. de Indicator will flash see Figure 3 1 indicating the parameter value can be changed The Enter key J must be pressed to write the new value to memory Refer to Chapter 5 for programming steps 3 2 Program Keypad Module Key Functions ESC SEL Escape The ESCape key allows you to toggle between the Display and Program modes When the Program mode is active this key will disable the editing of a parameter value Select The SELect key enables editing of a parameter value when the Program mode is active When you press this key the Program Mode Indicator flashes Up Down Arrow Keys Use the Up Down Arrow keys to scroll through a list of parameters or increase and decrease parameter values Press and hold either key to increase scrolling speed Real time frequency adjustment can be achieved when using P58 Internal Frequency and P59 Frequency Select Refer to Chapter 5 for further information Enter Pressing this key causes the current value displayed to be entered into memory only while in the Program mode When you press this key the Program Mode Indicator remains on but stops flashing Direction LEDs Indicators The appropriate LED will illuminate continuously to indicate the commanded direction of rotation If the second LED is flashing the drive has been commanded to change direction but is still decelerating Important Actual motor rotation could be different if motor leads are not connected properl
60. dule TB3 5 control terminal block or serial communication module are ignored with the exception of when P46 Input Mode is programmed to setting 7 This applies to drives with firmware version FRN 7 03 and later When P46 Input Mode setting 7 is active and TB3 8 is closed the frequency source is P58 Internal Frequency and the direction will be commanded from the control terminal block either terminal TB3 5 or TB3 6 Important This parameter cannot be programmed while the drive is running This parameter applies only to the Analog Signal Follower model Parameters and Programming 5 15 Program Group Min Max Factory No Parameter Name Description Range Units Default 75 Analog Input Minimum 0 0 150 0 0 1 0 0 Important Do not adjust this parameter until setting P60 Zero Offset Sets the percent of analog input used to represent P32 Minimum Frequency If the minimum analog input equals minimum frequency no action is needed If it is desired to adjust the analog input to equal P32 Minimum Frequency use P16 Analog Input to adjust the analog input to the desired level using P60 and then enter this value into P75 Analog inversion can be accomplished by setting this value larger than P76 Important This parameter cannot be programmed while the drive is running 76 Analog Input Maximum 0 0 150 0 0 1 100 0 Important Do not adjust this pa
61. e Through 100 Milliseconds Output Short Circuit Any Output Phase to Phase Short Programmer Optional Removable Program Keypad Module Display Type 6 Character LED Two Digit Parameter Number and Four Digit Value Keypad Controls Speed Run Stop and Direction A 4 Specifications End of Chapter Appendix B Accessories and Dimensions Accessories for All Drive Ratings Drive Ratings Dynamic Brake Module 3 Line Reactors Line Filters 9 Fan Replacement Capacitor Module Open Style Kite Input Voltage kW HP Catalog No Catalog No O Catalog No Catalog No O Catalog No Catalog No 200 240VAC 0 37 1 2 160S LFA1 160S RFA 9 A 160 CMA1 50 60 Hz 0 55 3 4 160S LFA1 160S RFA 9 A 160 CMA1 1 Phase 075 1 160 BMA1 z 1608 LFA1 160S RFA 9 A 160 FRK2 160 CMA1 15 160 BMA2 160S LFA1 160S RFA 16 B 160 FRK3 160 CMA1 200 230VAC 0 37 1 2 1321 3R4 B 160 LFA1 160 RFB 5 A 160 CMA1 50 60 Hz 0 55 34 1321 3R4 A 160 LFA1 160 RFB 5 A 160 CMA1 3 Phase 075 i 160 BMA1 1321 3R4 A 160 LFA1 160 RFB 5 A t60 FRK2 160 CMA1 15 2 160 BMA2 1321 3R8 A 160 LFA1 160 RFB 14 A 160 FRK2 160 CMA1 22 3 160 BMA2 1321 3R12 A 160 LFA2 160 RFB 14 A 160 FRK2 160 CMA1 40 5 160 BMA2 O 1321 3R18 A 160 RFA 22 B 160 FRK3 160 CMA1 380 460VAC 0 37 1 2 1321 3R2 B 160 LFB1 160 RFB 5 A 160 CMB1 50
62. ell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to identify a hazard avoid a hazard recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product Shock Hazard labels located on or inside the drive indicate that dangerous voltage may be present SSC is a trademark of Rockwell Automation Inc S 1 Series C Summary of Changes New Horsepower Ratings 4 kW 5 HP 230V and 460V ratings have been added to the Bulletin 160 family Increased Transient Protection Standard input voltage transient protection has been increased to 6 kV and contained in the drive itself The optional MOV module is no longer required Improved Ground Fault Protection The Bulletin 160 detects phase to phase and phase to ground faults both at start up and while running Reduced 2 2 kW 3 HP Footprint 2 2 kW 3 HP 230V and 460V width has been reduced by more than 45 One Piece 1 5 kW 2 HP 230V Single Phase Unit The external capacitor module has been integrated into the 1 5 kW 2 HP 230V single phase unit The overall width of the unit is reduced however the height depth and mounting hole pa
63. er 2 19 Fault Buffer 2 0 48 Numeric Value This parameter stores the third most recent fault that occurred After a reset defaults P56 this will set this parameter to 0 No active fault As faults occur the value of this parameter will be overwritten by P18 Fault Buffer 1 Program Group Parameters This group contains parameters whose values can be programmed Refer to Programming Example earlier in this chapter Unless otherwise stated parameters that are programmed while the drive is running take immediate effect Program Group Min Max Factory No Parameter Name Description Range Units Default 30 Accel Time 1 0 0 600 0 0 1 10 0 Time for the drive to ramp from 0 0 Hz to P33 Maximum Frequency The rate Seconds Seconds is linear for any increase in command frequency unless P53 S Curve is set to a value other than 0 Setting this to 0 0 sec gives 0 1 sec acceleration with the initial current limit turned off This allows quicker acceleration times for low inertia systems For medium to high inertia systems the minimum value should be 0 1 sec Maximum Frequency Speed 0 bl Accel Time 4 Time p Decel Timel4 0 5 6 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default 31 Decel Time 1 0 600 0 0 1 10 0 Time for the drive to ramp from P33 Maximum Frequency to 0 0 Hz The rate Seconds Seconds
64. eys 3 2 auto restart 5 10 block diagram 6 4 braking DC injection 5 8 enabling dynamic braking 5 11 stop mode 5 6 branch circuit disconnect 2 3 branch circuit protection 2 5 capacitive current cable length recommendations 2 8 capacitor module B 1 B 4 connection 1 5 carrier frequency A 3 PWM 5 10 catalog number explanation 1 2 location 1 3 CE 2 1 A 2 C 1 change direction see also analog inversion 3 2 circuit breaker ratings 2 5 E Index clearing faults 5 12 6 1 compensation 5 15 compliance CE A 2 C 1 CSA A2 CUL A 2 EEC C 5 conditioning input power 2 6 control wiring 2 9 2 17 precautions 2 9 preset speed 2 20 requirements 2 9 CSA A 2 CUL A 2 current limiting 5 8 DeviceNet module 1 5 B 5 diagnostics display group parameters 5 3 5 5 fault descriptions 6 2 dimensions 24V DC interface module B 5 capacitor module B 4 DeviceNet module B 5 drive B 6 B 7 dynamic brake module B 2 line filter module B 3 line reactor B 2 mounting B 8 direction indicators 3 2 display mode 3 1 dynamic brake module B 1 B 2 connection 1 5 dynamic braking 5 11 electrostatic discharge 1 1 3 3 enter key 3 2 escape key 3 2 fan replacement B 1 faults clearing 5 12 6 1 descriptions 6 2 problems and corrective actions 6 3 status LEDs 1 4 Index 2 features optional 1 5 standard 1 4 frequency control min max frequency 5 6 skip frequency 5 7 frequency source 2 18 fuse ratings 2 5 grounding 2 3 2 9 input mode
65. g line voltage For 380 460V AC capacitor module See Appendix A input drives the overvoltage trip occurs at a bus voltage of 800V DC equivalent to a 575V AC incoming line voltage 060 Motor Stall Fault The motor has stalled due to an excessive motor load A longer acceleration time or a reduced load is required 070 Motor Overload An internal electronic overload trip has occurred An Reduce the motor load until the drive output current does Fault excessive motor load exists not exceed the current set by P42 Motor Overload Current Reduce P38 Boost Select 080 OverTemperature Excessive heat has been detected Clear blocked or dirty heat sink fins Check ambient Fault temperature Check for a blocked or non operating fan 11 Operator Fault The keypad has been removed while the drive is Clear the fault Do not remove the keypad under power powered 129 Overcurrent Fault An overcurrent has been detected in the hardware trip Check fora short circuit at the drive output or for excessive circuit load conditions at the motor 130 Software Over Motor current exceeded value set in parameter 79 A longer acceleration time reduced load or removal of Current Fault motor shaft blockage is required 200 Drive Overload An internal electronic overload trip has occurred The Clear blocked or dirty heat sink fins Check ambient Fault drive is over heating temperature Check for blocked or non operating fan Reduce motor load current 32 EEPROM Fau
66. ge Units Default Preset Frequency 0 7 0 0 240 0 0 1 Hz See Table The programmed value sets the frequency that the drive outputs when selected Refer to Chapter2 Figure 2 21 forthe Preset Speed model control wiring diagram Preset Speed Model Only Signal Follower Model Only Input Mode 8 TB3 4 TB3 2 TB3 1 TB3 8 TB3 2 Preset Freq Default SW3 SW2 SW1 SW2 SW1 Accel O Decel O 61 Preset 0 3 0Hz 0 0 0 0 0 P30 P31 Accel Time 1 Decel Time 1 62 Preset 1 20 0Hz 0 0 1 0 1 63 Preset 2 30 0Hz 0 1 0 N A N A 64 Preset 3 40 0Hz 0 1 1 N A N A 65 Preset 4 45 0 Hz 1 0 0 1 0 P69 P70 Accel Time 2 Decel Time 2 66 Preset 5 50 0Hz 1 0 1 1 1 67 Preset 6 550Hz 1 1 0 N A N A 68 Preset 7 60 0Hz 1 1 1 N A N A O When using P46 Input Mode setting 4 the Accel and Decel times are selected by providing an input to TB3 8 See Chapter 2 Figure 2 12 for additional information 69 Accel Time 2 0 0 600 0 0 1 Sec 20 0 Time for the drive to ramp from 0 0 Hz to P33 Maximum Frequency The rate Seconds is linear for any increase in command frequency unless P53 S Curve is set to a value other than 0 Setting this to 0 0 gives 0 1 seconds acceleration with the initial current limit turned off This allows quicker acceleration times for low inertia systems For medium to high inertia systems the minimum value should be 0 1 70 Decel Time 2 600 0 0 1 Sec 20 0 Time for the drive to ramp from P33 Maximum Frequency t
67. gram Lock 0n Numeric 0 When set to 1 all parameters will be protected against change by unauthorized Value personnel 58 Internal Frequency 0 0 240 0 0 1 Hz 60 0 Hz When P59 Frequency Select is set to a 1 this parameter will provide the drive frequency command This parameter will change the frequency command in Real time using the up down arrow keys Maximum value is set in P33 Maximum Frequency Important Follow normal programming procedures Once the desired command frequency is reached the Enter key must be pressed to store this value to EEPROM memory If the ESC key is used before the Enter key the frequency will return to the original value following the normal accel decel curve 59 Frequency Select 0 1 Numeric 0 Selects the source of the frequency command for the drive Value Settings 0 External frequency command from the Control Terminal Block TB3 1 Internal frequency command from P58 Internal Frequency 60 Zero Offset 50 0 50 0 Numeric 0 Used to add or subtract any system offset to the analog input Value See P16 Analog Input for additional information Important This parameter cannot be programmed while the drive is running This parameter applies only to the Analog Signal Follower model Parameters and Programming 5 13 Program Group Min Max Factory No Parameter Name Description Ran
68. he drive current is the combination of capacitive current and motor current Because motor current is monitored for overload protection the table below lists the maximum cable length recommendations that will assure a capacitive current error of less than 15 percent Cable Length Recommendations Capacitive Current Table 2 F 380 460V kHz Motor Cable Only RWR at Drive Reactor at Motor Ratings Shielded O Unshielded Shielded Unshielded Shielded O Unshielded feet meters feet meters feet meters feet meters feet meters feet meters 4 0 kW 2 350 107 600 183 300 91 5 f6eoo 18g 400 122 600 183 5 HP 4 425 130 600 183 350 107 leoo 183 aso 137 600 183 8 475 145 500 152 0 450 137 500 152 2 2 kW 2 360 110 600 183 280 854 600 183 400 122 600 183 3 HP 4 375 114 600 1183 275 1838 600 183 400 122 600 183 8 400 122 500 152 o 400 122 500 152 1 5 KW 2 300 91 5 550 1168 1275 1838 600 183 1300 1915 600 183 2 HP 4 300 1915 550 1168 275 1838 600 1183 1300 1915 500 152 8 325 99 1 500 1152 0 350 107 500 152 075kW 2 200 61 375 114 200 61 425 130 225 686 400 122 1 HP 4 225 68 6 1375 114 200 61 425 130 225 686 375 114 8 250 176 2 375 114 0 225 686 400 122 0 55kW 2 180 154 9 350 107 180 154 9 375 114 180 549 350 107 0 75 HP 4 180 549 1350 107 180 549 375 114
69. ifications Table 2 G Terminal Block Max Min Wire Size Max Min Torque mm AWG Nm Ib in TB3 2 5 0 5 14 22 0 8 0 4 8 4 Important Precautions ATTENTION The drive is supplied with an internal 12V supply Dry contact or open collector inputs are required for discrete control inputs If an external voltage is applied component damage could occur ATTENTION The drive start stop and enable control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit is required to remove AC input power to the drive When AC input power is removed there will be a loss of inherent regenerative braking effect and the motor will coast to a stop An auxiliary braking method may be required 2 10 Installation and Wiring Control Wiring Considerations Wiring Diagram Key A w mS Shielded N O N C N O N C Wire Momentary Momentary Maintained Maintained Contact Contact Contact Contact General Control Wiring Advisories The figure below lists the control wiring requirements for all two wire control input modes P46 Input Mode settings 1 and 4 9 The requirements specific to each input mode are shown separately for that mode Q Run input must be maintained After a stop command either a Run Forward or Run Reverse input must be toggled to sta
70. ions provided in Section 2 Installation and Wiring 2 Connect control wiring see Chapter 2 Figure 2 17 A contact closure on terminals 6 and 7 is required for the drive to respond to a Start Run command 3 Select an external frequency command source See Table 5 B 4 Connect feedback device to TB3 2 and TB3 3 for 0 10V feedback or to TB3 3 and TB3 4 for 4 20 mA feedback 5 Verify polarity of feedback That is increasing feedback signal requires increasing output frequency Program for Pl Control 1 Set P56 Reset Functions to 1 to reset the drive to defaults An F48 Reprogram Fault will occur which must be cleared by cycling the Stop input to the drive 2 Users of Firmware Version 7 06 Set P46 Input Mode to the desired setting Users of Firmware Version 7 05 and earlier Set P46 Input Mode to 9 Table 5 B describes how to reference the external frequency command source for each P46 Input Mode setting Parameter 46 Settings and Frequency Source Selection Table 5 B P46 Setting Reference External Frequency Command Source Firmware Version 0 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 1 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 2 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 3 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 4 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 5 Se
71. k specifications 2 3 precautions 1 1 preset frequencies 5 12 Program Keypad Module 1 5 display mode 3 1 installation 3 4 key descriptions 3 2 program mode 3 1 removal 3 3 program lock 5 12 program mode 3 1 programming 5 1 example 5 2 reset to defaults 5 2 reflected wave protection 2 7 reflective wave cable length 2 7 RWR reflective wave reducer 2 7 resetting default values 5 12 reverse key 3 2 RS 232 module B 5 S Curve 5 11 select key 3 2 specifications A 1 A 3 380 460V AC input ratings A 1 control 2 9 electrical 2 2 environment 2 1 input power protection 2 5 installation 2 1 wiring 2 3 start key 3 2 Start up 4 1 stop key 3 2 storage temperature 2 1 A 2 terminal block control wiring 2 9 specifications 2 9 TB1 2 2 TB2 2 2 TB3 2 2 troubleshooting 6 1 fault descriptions 6 2 problems and corrective actions 6 3 vibration A 2 Index 4 W tor wiring analog input 2 18 cable length 2 7 control signal 2 9 2 17 motor cable specifications 2 6 symbol key 2 10 terminal block specifications 2 3 Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by
72. kW 5 or 75 HP ratings DIN Latch provides an easy means for mounting the drive on standard 35 mm DIN Rail This feature is not available with 4 0 kW 5 HP or 1 5 kW 2 HP single phase units Getting Started 1 5 Optional Drive Features The drive features identified in the figure below are optional See Appendix B for catalog numbers Finger guards omitted for clarity Optional Drive Features E ALLEN BRADLEY Wu 123456789101 OO0000000000 O UTI V T2 W T3 DC DC T RILI S L2 T L3 BR BR EEE Figure 1 4 Dynamic Brake Module Line Filter Module ram Keypad Module DeviceNet Communication Module RS 232 Communication Module Remote Programming Adapter to Remote Keypad Module or CopyCat Keypad Module 24V DC Interface Module Capacitor Module Dynamic Brake Module option allows you to connect dynamic brake resistors Not available on 37 or 55 kW 5 or 75 HP ratings Important P52 DB Enable must be enabled for proper operation Line Filter Module option is available to reduce conductive emissions Program Keypad Module option can be ordered separately and field installed or as a factory installed option by addi
73. ll fault is selectable via P80 Stall Fault Time PI Control Process control is now intergrated in the drive through a PI regulator Users of Firmware Version FRN 7 05 and earlier activate this feature with P46 Input Mode setting 9 Users of Firmware Version FRN 7 06 can activate this feature with P46 Input Mode settings 0 through 7 and 9 PI control is adjusted through parameters P81 PI Proportional Gain P82 PI Integrated Gain P83 PI Process Reference and P84 PI Dead Band Fault Auto Clear Over voltage Under voltage and Over temperature faults are automatically cleared when the fault condition is removed RS 232 Serial Communication An RS 232 serial communication module using a DF protocol is now available See 160 RS1 User Manual for additional information Ground Screw Location Grounding screws are now located on the power connection terminal blocks for easier wiring S 2 Series C Application Installation Considerations Keep the following in mind if you are replacing a Bulletin 160 Series A or B drive with a Series C unit Mounting Dimensions External Braking DeviceNet 24V DC Interface Width has increased by 8 mm for all ratings through 1 5 kW 2 HP Note If proper spacing recommendations were followed for Series A and B drives the increased width should not effect the panel layout because Series C drives of this rating do not require spacing between units Wid
74. lt The EEPROM has invalid data Reset EEPROM using P56 Reset Functions Setto 1 and cycle power 33 Max Retries Fault The drive failed to reset within the number of retries Repair the system fault set in P50 Restart Tries 36 Incompatible Fault Incompatible communication module installed Verify compatibility of communication module 38 Phase U Fault A phase to ground fault has been detected between Check the wiring between the drive and the motor Check the drive and the motor in phase U the motor for a grounded phase Check that ground is not connected to U 39 Phase V Fault A phase to ground fault has been detected between Check the wiring between the drive and the motor Check the drive and the motor in phase V the motor for a grounded phase 40 Phase W Fault A phase to ground fault has been detected between Check the wiring between the drive and the motor Check the drive and the motor in phase W the motor for a grounded phase 41 UV Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output two drive output terminals terminals for a shorted condition 42 UW Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output two drive output terminals terminals for a shorted condition 43 VW Short Fault Excessive current has been detected between these Check the motor and external wiring to the drive output two drive
75. mode is similar to Setting 1 except TB3 terminal 8 provides the function of enable command The enable input is required for the drive to operate and if opened during operation the programmed P34 Stop Mode will be overridden and the motor will coast to rest Two Wire Enable control Figure 2 9 TB3 TB3 8 Open mon maverse Controller Disabled a TB3 8 Closed Common Controller Enabled Enable O TB3 terminal 8 can be used to clear faults See Figure 2 14 for details When this input is in an open state the motor will coast to rest Installation and Wiring 2 15 P46 Setting 6 Two Wire TB3 Control Keypad or Communication Control This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of switching the start reverse and speed reference from the Program Keypad Module Remote Keypad Module CopyCat Keypad Module or Communication Module to the control terminal block TB3 Two Wire TB3 control Keypad or Communication control Figure 2 10 TB3 8 Open Run Reverse TB3 Control Run Forward TB3 8 Closed C Keypad or ommon Communication Control TB3 Keypad or Communication O O TB3 terminal 8 can be used to clear faults See Figure 2 14 for details When this input is in an open state the Frequency source is always from the terminal block regardless of the setting of P59 Frequency Select P46 Setting 7 Two Wire Frequency Select Control This input mode is similar
76. mon such as earth ground or separate apparatus ground only one point of the daisy chain of TB3 7 should be connected Predicting actual performance given the variety of installation possibilities is difficult however up to five drives with two meters of cable between have been tested without problems Typical Multiple Drive Input Connections Figure 2 15 I 1 Optional Ground Customer Inputs N arena Configurable Relay Output Contacts P47 Settings You can configure the drive s dry contact Form C output relay to change state based on P47 Output Configure setting and P48 Output Threshold limits See Chapter 5 for details Configurable Relay Output Contacts Figure 2 16 Normally Closed User Configurable Relay Outputs Form C Relay Resistive Load 0 4A at 125V AC 2A at 30V DC Relay Common Inductive Load 0 2A at 125V AC 1A at 30V DC Normally Open To set up use P47 Output Configure Frequency Source Wiring Analog Signal Follower Model You can control the output frequency of the drive via the Control Terminal Block TB3 using the following methods Analog Frequency Sources Important Only one frequency source may be connected at a time If more than one reference is connected at the same time an undetermined frequency reference will result Installation and Wiring 2 19 10V or 0 10V DC Frequency Control Speed Control Figure 2 17 EE If calibration is required use vnr 10Vor0 10
77. n Number Voltage Rating Current Rating Enclosure Type Model Programmer Optional An S inthe Bulletin A 200 240V 1 Phase A01 N Open IP20 SF1 Analog Signal B1 Ready Fault Number denotes a 200 240V 3 Phase A02 L Low Profile Follower Indicating Panel single phase input B 380 460V 3 Phase 03 P Chassis Mount PS1Preset Speed P1 Program Keypad voltage um external heatsink Module A08 R Chassis Mount A10 Replacement A12 A18 O Amperage ratings vary based on voltage Note Rockwell Automation offers a configured drive program which allows for NEMA rated 4 4x or 12 enclosures Getting Started 1 3 Nameplate The nameplate is located on the side of the drive Nameplate Information Figure 1 2 Catalog Number ln 160 eave P1 SERIES C Series Letter ES Firmwa re Version AO Drive Mode Moor v 200 240 30 0 v 200 230 30 I N U N A 2 8 T A 2 3 y Hz 50 60 5 Hz 0 240 T VA 1100 T S am Bate code XXXXX 4 Date Code OPERATING AMBIENT TEMP 0 50 C SHORT CIRCUIT CURRENT 100 KA POWER TERMINAL WIRE Use 75 C Cu Wire 4 mm 75 mm 12 18 AWG Torque 1 35 Nm 12 in Ibs po De eure CE Allen Bradley MADE IN U S A Enclosure Rating Conventions Used In This Manual Parameter numbers and names are shown in this format P01 Output Frequency P01 denotes the parameter number and the parameter name is enclosed i
78. n square brackets 1 4 Getting Started Standard Drive Features The drive features identified in the figure below apply to all models Standard Drive Features and Mounting Orientation Figure 1 3 EE la Hinged Finger Guard 000000 RI SIL2 TIL3 BR BR e ALLEN BRADLEY hi Ready Fault O FAULT Indicating Panel O READY Status LEDs 1234567891011 00000000000 DC Bus Test Points UIT V T2 W T3 DC DC 00090 r Hinged Finger Guard Cooling Fan FL Cooling Air Flow DIN Latch Hinged Finger Guard allows easy access to line load power terminals Ready Fault Indicating Panel is standard on the Bulletin 160 drive The drive is fully functional with this panel installed All control functions can be performed from TB3 Control Terminal Block Factory default settings cannot be changed with this panel Fault Indicator LED illuminates when a drive fault condition exists Refer to Chapter 6 for details on how to clear a fault and general troubleshooting procedures Ready Indicator LED illuminates when the DC bus is charged and the drive is ready to run DC Bus Test Points provide easy access for test probes when measuring DC Bus voltage Cooling Fan provides air flow across heatsink fins to prevent overheating Not required on 37 or 55
79. nd level surface See Chapter 1 Figure 1 3 for mounting orientation Choose an installation method nstall with screws Recommended screw size is listed in the table below The appropriate drilling template for your drive is provided in Appendix B Install on 35 mm DIN Rail This mounting method is not available on 4 0 kW 5 HP three phase or 1 5 kW 2 HP single phase models Description Metric English Minimum Panel Thickness 14 GA 1 9 mm 0 0747 in Mounting Base Screws m4 x 0 7 8 32 Mounting Torque 1 18 1 56 Nm 10 14 lb in See Appendix B for details on drive dimensions and weights Maintain 12 5 mm 0 5 in clearance at the top bottom and front of all drives Clearance requirements between units varies by model 22 kW 3 HP 230V 460V Drives Provide a minimum of 8 5 mm 0 33 in clearance between units All Other Drive Ratings No clearance is required between units The drive is shipped with a paper debris label attached to the top side of the plastic housing to cover the cooling vents Leave the debris label attached during drive installation to protect against debris falling through the vents of the drive housing To assure proper drive operation you must remove label before applying power ATTENTION After system installation remove the debris label N from unit Failure to remove this label may result in overheating or nuisance tripping 2 2 Installation and Wiring P
80. ng P1 to the end of the catalog number Refer to Chapter 3 Program Keypad Module for a detailed explanation of functionality DeviceNet Communication Module option allows control and monitoring of parameters via a DeviceNet network RS 232 Communication Module option allows control and monitoring of parameters via a RS 232 network Remote Programming Adapter option allows connection to Remote Keypad Module or Copycat Keypad Module via cable 1 to 3 meters 24V DC Interface Module option allows you to command the drive with 24V logic sinking inputs Capacitor Module option allows you to connect an external capacitor module Provides extended ride through capability and improved inherent braking performance 1 6 Getting Started End of Chapter Chapter 2 Installation and Wiring Storage and Operation Conditions Follow these recommendations to prolong drive life and performance Store within an ambient temperature range of 40 to 85 C Store within a relative humidity range of 0 to 95 non condensing Protect the cooling fan by avoiding dust or metallic particles Avoid storing or operating the drive where it could be exposed to a corrosive atmosphere Protect from moisture and direct sunlight Operate at an ambient temperature range of 0 to 50 C CE Compliance Installation Clearances Debris Label Refer to Appendix C Mount the drive on a flat vertical a
81. o 0 0 Hz The rate Seconds is linear for any decrease in command frequency unless P53 S Curve is set to a value other than 0 Minimum deceleration time must be set based on the applied motor size To guard against premature drive failure do not set P31 Decel Time 1 or P70 Decel Time 2 below the minimum value listed in the table below 230 and 460V Motor Sizes Minimum Deceleration Settings 4 0 kW 5 HP 0 7 seconds 2 2 kW 3 HP 0 6 seconds 1 5 kW 2 HP 0 2 seconds 0 75 kW 1 HP 0 1 seconds 0 55 kW 0 75 HP 0 1 seconds 0 37 kW 0 5 HP 0 1 seconds This parameter applies only to the Preset Speed model 5 14 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default 71 IR Compensation 0 150 1 50 The programmed value adds a voltage to the output based on the torque current An additional 31 volts 150 is added to 460 volt units to compensate for stator resistance 15 5 volts 150 is added for 230 volt units If the drive trips on an F07 Motor Overload fault or has trouble accelerating to commanded speed this value should be reduced A setting of 0 disables this function 72 Slip Compensation 0 0 5 0 0 1 Hz 2 0 Hz This parameter compensates for the inherent slip in an induction motor A frequency is added to the commanded output frequency based on torque current If motor shaft speed decreases significantl
82. output terminals terminals for a shorted condition 46 Intermittent Phase An external short occurred while running diagnostics Check wiring between the drive and the motor Check for Fault more than one shorted output 48 Reprogram Fault Occurs when the drive parameters are resetto default Clear the fault O These faults have an auto reset feature This feature automatically clears overvoltage undervotage and overtemperature faults 1 second after the fault condition is removed Refer to P51 Restart Time Troubleshooting 6 3 Possible Problems and Corrective Actions Table 6 B Problem The motor does not start No output voltage to the motor Corrective Action 1 Check the power circuit Check the supply voltage e Check all fuses and disconnects Check the motor e Verify that the motor is connected properly Check the control input signals Verify that the Start signal is present Verify that the contact closure signal is present at TB3 8 Verify that either the Run Forward or Run Reverse signal is active but not both Check P46 Input Mode fP46 Input Mode is set to 2 only the program keypad module Start button will start the motor Cycle power or use P56 Reset Functions if you changed P46 Input Mode The drive is started but the motor is not rotating P01 Output Frequency displays 0 0 1 Check the motor Verify that the motor is connected
83. ower Wiring Precautions Terminal Blocks A ATTENTION Remove and lock out power from the drive before you disconnect or reconnect wires or perform service Verify bus voltage by measuring the voltage between DC and DC on Terminal Block TB2 Do not attempt to service the drive until bus voltage has discharged to zero volts A ATTENTION The drive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies input power to the drive for the purpose of starting and stopping the motor should not be used If it is necessary to use this method for starting and stopping or if frequent cycling of power is unavoidable make sure that it does not occur more than once a minute A ATTENTION Do not connect power factor correction capacitors to drive output terminals U V and W T1 T2 and T3 or component damage could occur Drive Terminal Blocks Terminal R L1 is not present on single phase drives Three phase unit terminal block configuration is depicted in the figure below Figure 2 1 Fi AMINES TB1 Terminal Block TB1 Ground Line Power amp RILI S L2 TIL3 BR BR Dynamic Brake Module Wiring ALLEN BRADLEY e Hazardous Voltages Behind Panel O FAULT C READY
84. p p 90 274 60 18 3 425 130 600 183 425 130 450 137 1600 Vp p8O 500 152 4 500 152 425 130 600 183 540 165 600 183 0 75 KW 1000 Vp p 55 16 8 40 122 325 991 600 183 325 991 350 107 1 HP 1200 Vp p 125 38 1 60 18 3 325 991 600 183 500 152 450 137 1600 Vp p 500 152 4 500 152 325 991 600 183 500 152 600 183 0 55 KW 1000 Vp p 45 13 7 40 122 300 91 5 600 183 300 915 300 915 0 75 HP 1200Vp p 125 138 1 60 18 3 300 915 600 183 500 152 500 152 1600 Vp p 500 152 4 500 1152 300 915 600 183 500 1152 600 183 0 37 kW 1000 Vp p 145 13 7 90 274 300 915 425 130 300 915 425 130 0 5 HP 1200 Vp p 125 381 180 549 300 915 425 130 500 152 500 152 1600 Vp p 500 152 500 152 300 915 425 130 500 152 500 152 O Cable lengths listed are for PWM frequencies of 2 kHz Refer to publication 1204 5 1 for cable length recommendations at other PWM frequencies The maximum peak to peak voltage of the drive is 1400V due to the minimum on off time software Reflective Wave Testing has been done on cable lengths up to 160 meters 600 feet See Table 2 F for capacitive current recommendations 2 8 Installation and Wiring Capacitive Current Coupling AC coupling exists from motor cables to ground terminal protective earth The current produced by this coupling is referred to as capacitive current T
85. press the Enter key This writes the new value to memory MAJA The Program Mode Indicator will stop flashing and the display will flash once indicating that the new value has been accepted Important If at any time while in the program mode you wish to abort the editing process press the ESCape key The original value of the parameter will remain unchanged and you will be exited from the Program mode m 0080 m wm O Parameters and Programming 5 3 Display Group Parameters Read Only This group of parameters consists of commonly viewed drive operating conditions such as output frequency output voltage output current and frequency command All parameters in this group are read only Important The last user selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied Display Group Read Only No Parameter Name Description Min Max Range Units 01 Output Frequency 0 0 240 0 0 1 Hz Displays the output frequency at TB2 terminals U V 8 W T1 T2 amp T3 02 Output Voltage 0 Max Voltage 1 Volt Displays the output voltage present at TB2 terminals U V amp W T1 T2 amp T3 03 Output Current 0 2 x Drive Rated 0 01A Displays the output current present at TB2 terminals U V amp W T1 T2 amp T3 Output Current 04 Output Power 0 2 x Rated Drive 0 01 kW Displays the output power present at TB2 termin
86. q 4 v If you are using a Program Keypad Module verify that the Clockwise LED is illuminated If you are using a Ready Fault Indicating Panel verify that the Reverse input to TB3 is in the Open position v Issue a Start command from the Program Keypad Module or TB3 Check the direction of motor rotation Drive fan will energize some models v Issue a Stop command from the Program Keypad Module or TB3 Issue a Stop command from the Program Keypad Module or TB3 O Start up is complete Direction of Motor Rotation Correct v No v Disconnect and lock out all incoming power to TB1 terminals R S and T L1 L2 and L3 v A ATTENTION A DC Bus voltage may be present at the power terminal blocks TB1 and TB2 for approximately three minutes after power is removed from the drive Y Switch any two of the three motor leads connected to TB2 terminals U V and W T1 T2 and T3 Reconnect power Check rotation ru xa After successfully completing start up proceed to Chapter 5 If you need to change any factory defaults you will need a Program Keypad Module or other type of Communication Module Chapter 5 Parameters and Programming Overview of Parameters This chapter describes both Display and Program parameters Display parameters are read only they cannot be programmed while Program p
87. r 5 for the eight preset frequency factory default settings and switch configurations A program keypad module is required to change the factory default settings TB3 Control Wiring for Preset Speed Model Figure 2 21 TB3 swie Qn sw20 To select program preset speeds e C a use parameters 61 68 c Common O sw30 Internal 12V supply Contact closure or open collector input required Refer to Appendix A for solid state control input specifications 8 Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity TB3 Common must be connected to ground terminal protective earth For control wiring installations greater than 15 meters 50 feet in length an optional 24V DC interface module is recommended See Appendix A for ordering information Analog and Preset Models Internal Frequency Source Both the Analog Signal Follower and Preset Speed models have the provision for frequency control via P58 Internal Frequency This is accomplished by setting P59 Frequency Select to a value of 1 See Chapter 5 for a description of these parameters What To Do Next You should become familiar with the Program Keypad Module operation in Chapter 3 if you need to change any factory default parameter settings for your application Then proceed to Chapter 4 Start Up and follow the flow diagram After applying power you can program parameters if neces
88. rameter until setting P60 Zero Offset Sets the percent of analog input used to represent P33 Maximum Frequency If the maximum analog input equals maximum frequency no action is needed If itis desired to adjust the analog input to equal P33 Maximum Frequency use P16 Analog Input to adjust the analog input to the desired level using P60 and then enter this value into P76 Analog inversion can be accomplished by setting this value smaller than P75 Important This parameter cannot be programmed while the drive is running 78 Compensation Oto2 Numeric 0 Settings value 0 Nocompensation 1 Some drive motor combinations have inherent instabilities which are exhibited as non sinusodial motor currents This setting attempts to correct this condition 2 Some motor load combinations have mechanical resonances which can be excited by the drive current regulator This setting slows down the current regulator response and attempts to correct this condition 79 Software Current Trip 0 50 1 0 This provides a software instantaneous current trip similar to the 300 hardware current trip This value is the percent above the P43 Current Limit at which the drive trips immediately A setting of zero disables the Software Current Trip 80 Stall Fault Time 0 5 Numeric 0 This selects the amount of time the drive must be in a stall condition before it Value causes a stall fault 0 Normal stall time approximately 60 seconds
89. rogramming 5 19 Common Problems with Pl Control 1 Drive direction is incorrectly set for PI control Ensure that the drive is operating with the clockwise direction indicator illuminated Drive oscillates between 0 and 3 Hz Check direction and polarity of analog input signal Ensure that the drive is operating with the clockwise direction indicator illuminated Ensure the 10V DC wire is connected to TB3 2 and that the common is connected to TB3 3 e Check that parameters P81 PI Proportional Gain and P82 PI Integral Gain are set to a value other than 0 00 Drive accelerates too quickly resulting in an F05 OverVoltage Fault Lower P81 PI Proportional Gain below its current value Lower P82 PI Integral Gain below its current value Raise P31 Decel Time 1 above its current value Raise P30 Accel Time 1 above its current value Evaluate the need for a dynamic brake for the application Drive will only run off the internal frequency or does not control with the PI process loop Check that P46 Input Mode is set to 9 Ensure that power was cycled for one minute after changing the P46 setting Ensure that there is not a connection between TB3 7 and 8 Nothing works properly Set P56 Reset Functions to 1 and press the Enter key Press the Stop button to clear the F48 Reprogram Fault Cycle power to the drive Confirm that wiring is correct Reapply po
90. rt the drive 8 Internal 12V supply Contact closure or open collector input required Refer to Appendix A for solid state control input specifications If both Run Forward and Run Reverse inputs are closed at the same time an undetermined state could occur O Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity TB3 Common must be connected to ground terminal protective earth For control wiring installations greater than 15 meters 50 feet in length an optional 24V DC interface module is recommended See Appendix A for ordering information Installation and Wiring 2 11 Control Methods and Selection Guide PI Control You can use P46 Input Mode to select the control method for start stop and direction control Control can be performed from the Control Terminal Block TB3 or the optional Program Keypad Module or the Remote Programming Adapter via cable to either a Remote Keypad or a CopyCat Keypad depending on the P46 Input Mode setting being used The default setting is O which means that only the Control Terminal Block will be active for control If any other input mode is needed 1 9 you must have a device for changing the input mode such as a Program Keypad Module 160 P1 Table 2 H is a guide to wiring diagrams associated with each P46 Input Mode setting Important After a Stop input a Run command either Run Forward Run Reverse or Star
91. sary Refer to Table 5 A for a list of commonly changed parameters Features Chapter 3 Program Keypad Module The Program Keypad Module is located on the front panel of the drive This module is only operational when it is installed directly on the drive The Program Keypad Module provides the following features 6 digit 7 segment LED display Program Mode Indicator Five keys for programming and displaying drive parameters Three keys for control inputs to the drive Two directional LED indicators Program Keypad Module Figure 3 1 Parameter Number Display Indicates which Display or Program Group parameter is active Parameter Value Fault Number Displays the parameter value or fault code number Program Mode Indicator ESC SEL y Y v Flashes when in program mode O M O e Control Inputs and Indicators u m Direction Start Stop Stop is always active Display Mode Program Mode Important To activate Direction and Start inputs P46 Input Mode must be set to 2 Power must be cycled or P56 Reset Functions must be set to 2 for the change to take effect The drive always powers up in the Display mode While in this mode you may view all read only drive parameters but not modify them You enter the Program mode by pressing the ESCape key While in this mode you can edit Program Group parameters by pressing the SELect key The Program Mo
92. scharge to zero to ensure the change has taken effect An F48 Reprogram Fault can be cleared using the Program Keypad Module Remote Keypad Module or CopyCat Keypad Module stop button or by cycling input to TB3 8 Programming Example The following is an example of the programming steps required to change a Program Group parameter setting In this example P31 Decel Time is changed from its factory default setting of 10 0 seconds to 2 2 seconds Refer to Chapter 3 for an explanation of the Program Keypad Module display and programming keys Important To reset ALL values to original factory default settings refer to P56 Reset Defaults Action Description Keypad Display 1 To program the value of a Program Group ESC parameter enter the Program Group by EETEEEE pressing the ESCape key The Program Mode Indicator will illuminate 2 Press the Up Down keys until the desired parameter displays In this case press the Up key until P31 Decel Time displays m LI c Cc 3 Press SELect The Program Mode Indicator flashes indicating that you can usethe Up Down keys to change the parameter value INS 4 Change the decel time value from the factory default of 10 0 seconds to 2 2 seconds by pressing the Down key until 2 2 displays Important Continuously holding the Up or Down key will cause the value to increase or decrease as long as the key is pressed 5 When the desired value displays
93. selection 2 11 5 9 input power conditioning 2 6 protection 2 5 installation clearances 2 1 EMC compliance C 1 C 4 templates B 9 B 10 internal 12V power supply 2 9 keypad display mode 3 1 installation 3 4 key descriptions 3 2 program mode 3 1 removal 3 3 LEDs 1 4 3 2 line filter module 1 5 B 1 B 3 line reactor B 1 B 2 line side protection 2 5 lock protection 5 12 motor cable length recommendations 2 7 2 8 long cable effects 2 7 recommended cable 2 6 reflective wave 2 7 motor starter 2 5 mounting requirements clearances 2 1 mounting templates B 9 B 10 nameplate information 1 3 optional accessories 24V DC interface module 1 5 B 5 capacitor module 1 5 B 4 DeviceNet module 1 5 B 5 dynamic brake module 1 5 B 2 line filters 1 5 B 1 B 3 line reactors B 1 B 2 program keypad module 1 5 output contacts 2 9 5 10 overload protection 2 5 5 8 parameters 5 1 5 16 commonly changed 5 1 display group 5 3 5 5 01 Output Frequency 5 3 02 Output Voltage 5 3 03 Output Current 5 3 04 Output Power 5 3 05 Bus Voltage 5 3 06 Frequency Command 5 3 07 Last Fault 5 3 08 Heatsink Temperature 5 3 09 Controller Status 5 3 10 Controller Type 5 3 11 Control Version 5 3 12 Input Status 5 4 13 Power Factor Angle 5 4 14 Memory Probe Display 5 4 15 Preset Status 5 4 16 Analog Input 5 4 17 Fault Buffer 0 5 5 18 Fault Buffer 1 5 5 19 Fault Buffer 2
94. t must be toggled to run again This is true for all P46 Input Mode settings except setting 3 See the Attention statement below When P46 Input Mode is set to 3 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop function is provided only when the Stop input is active open ATTENTION Hazard of injury exists due to unintended operation Control Selection by Input Mode Table 2 H P46 Setting Description Reference 0 Three Wire control factory default Figure 2 4 1 Two Wire Run Forward Run Reverse control Figure 2 5 20 Program Remote CopyCat Keypad or Communication Figure 2 6 Module control 3 Momentary Run Forward Run Reverse control Figure 2 7 4 Two Wire Accel Decel control Figure 2 8 5 Two Wire Enable control Figure 2 9 60 Two Wire TB3 control Keypad or Communication control Figure 2 10 7 Two Wire Frequency Select control Figure 2 11 8 Two Wire Preset control Analog Signal Follower Models Only Figure 2 12 9 Two Wire PI control Analog Signal Follower Models Only Figure 2 13 When using Firmware Versions FRN 7 05 7 04 amp 7 03 input modes 2 and 6 are the only modes which allow a serial option such as 160 DN2 or 160 RS1 to command the drive to run or stop Firmware Version FRN 7 06 allows activation of PI control in P46 Input Mode settings O through 7 and 9 listed in Table 2 H Refer to page 5 17 for
95. t P59 Frequency Select to 0 Factory Default FRN 7 06 only 6 Set P59 Frequency Select to 0 Factory Default FRN 7 06 only 7 Open the contact at TB3 8 FRN 7 06 only 8 This setting is not used with PI control 9 Open the contact at TB3 8 FRN 7 06 or earlier 3 Cycle power or set P56 Reset Functions to 2 for the change made at Step 2 to take effect 4 Set P72 Slip Compensation to 0 5 18 Parameters and Programming Use P75 Analog Input Minimum and P76 Analog Input Maximum to scale feedback to the process operating range This may also be used to invert the feedback so that increasing feedback signal produces decreasing output frequency Set P83 PI Process Reference to 20 as an initial setting This establishes the set point as 20 of the maximum analog input This setting must be greater than zero to activate PI control in Firmware Version FRN 7 06 except when using input mode 9 Connect TB3 8 with TB3 7 This will disable PI control and force the output frequency to the P58 Internal Frequency setting Connect TB3 6 with TB3 7 to start the drive Verify motor operation and direction Remove the connection between TB3 8 from TB3 7 This will place the drive into PI control mode when using input modes 7 and 9 due to unpredictable changes in motor speed Do not use P72 Slip i ATTENTION Hazard of personal injury or equipment damage exists Tune the PI Loop Compensation and P83
96. th has decreased by 50 mm for the 2 2 kW 3 HP rating Depth has increased by 25 mm for all ratings through 2 2 kW 3 HP Note The drive utilizes the same DIN base and mounting hole pattern for all ratings through 2 2 kW 3 HP The internal brake transistor is not available on 0 37 kW 1 2 HP and 0 55 kW 3 4 HP units If external braking is required a 0 75 kW 1 HP drive must be used DeviceNet modules Catalog No 160 DN1 with Firmware Version FRN 2 0 or earlier are not compatible with the Bulletin 160 Series C drives Series C drives must use DeviceNet modules Catalog No 160 DN2 The 160 DN2 module is also compatible with Series A and B drives with the exception of the Series A Preset Speed model with Firmware Version FRN 4 04 Bulletin 160 Series C drives must use a Series B or later 24V DC Interface module See Appendix B for catalog numbers Terminal Block Wiring The ground terminal is now located on the power terminal block Refer to Figure 2 2 on page 2 3 to avoid incorrect wiring Incorrect Motor Rotation The output phasing of Series C drives is different than the output phasing of Series A and B drives Replacing a Series A or B drive with a Series C drive using the same U V and W T1 T2 and T3 connections will reverse the motor rotation To assure the same direction of rotation switch any 2 of the 3 output wires connected to U V or W T1 T2 or T3 from the motor Example Original Wiring of
97. the fault can be cleared After corrective action has been taken any of the following actions will clear the fault Press the Program Keypad Module s Stop button Disconnect power to the drive wait one minute reapply power Cycle the input signal at TB3 8 to the drive Set P54 Clear Fault to 1 6 2 Troubleshooting Bulletin 160 Fault Descriptions Table 6 A Fault Fault No Name Fault Description Corrective Action 03 Power Loss Fault The DC Bus voltage remains below 85 nominal on Monitor the incoming AC line for low voltage or line power power up for longer than 5 seconds interruptions 040 UnderVoltage The DC Bus voltage fell below the minimum rated Monitor the incoming AC line for low voltage or line power Fault voltage For 200 240V AC input drives the under interruptions voltage trip occurs at a bus voltage of 210V DC equiv alent to a 150VAC incoming line voltage For 380 460V AC rated drives the undervoltage trip occurs at a bus voltage of 390V DC equivalent to a 275V AC incoming line voltage 050 OverVoltage Fault The maximum DC Bus voltage has been exceeded Motor regeneration has caused a bus overvoltage Monitor For 200 240V AC input drives the overvoltage trip the incoming AC line for excessive voltage Extend the occurs at a bus voltage of 400VDC equivalentto a decel time or install a dynamic brake module or external 290V AC incomin
98. ttern has changed Improved Start Stop Overlap Timing The STOP command can be removed up to 20 msec after a START command and the drive will still recognize the START command This allows the drive to respond to a START command occurring concurrently with or slightly after a STOP command is removed Additional Fault History P17 P18 and P19 Fault Buffer 0 1 and 2 have been added to record the last three faults for diagnostic purposes Analog Model with Preset Speed Capability Analog Signal Follower models have an additional input mode With P46 Input Mode setting 8 four preset speeds are available External Frequency Selection P46 Input Mode has an additional setting setting 7 which allows for the frequency source to be switched from the control terminal block TB3 to the P58 Internal Frequency setting New Output Configuration Setting P47 Output Configure has a new setting When setting 10 is selected the output will be active when the Power Factor Angle is above the P48 Output Threshold setting Additional Compensation Mode P78 Compensation has an additional mode that corrects for slow responding systems which can cause current regulator oscillations Software Current Trip P79 Software Current Trip provides an adjustable software current trip with a one second time delay Adjustable Stall Fault Time The time that the drive must be in a stall condition before causing a sta
99. type gG 2 6 Installation and Wiring Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see Appendix A Listed in Table 2 C are certain input power conditions which may cause component damage or reduction in product life If any of the conditions exist as described in Table 2 C install one of the devices listed under the heading Corrective Action on the line side of the drive Important Only one device per branch circuit is required It should be mounted closest to the branch and sized to handle the total current of the branch circuit Input Power Conditions Table 2 C Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance Check Line Impedance Line Reactor See Appendix B or Isolation Transformer Available short circuit currents fault currents greater than Check Supply Transformer 100 000 Amps Line Reactor See Appendix B or Isolation Transformer Greater than 120 kVA supply transformer Line Reactor See Appendix B or Isolation Transformer Line has power factor correction capacitors Line Reactor See Appendix B or Isolation Transformer Line has frequent power interruptions Line Reactor See Appendix B or Isolation Transformer Line has intermittent noise spikes in excess of 6000V Line Reactor See Appendix B lightning or Isolation Transformer Motor Cable Types
100. wer and program according to this procedure PI does not function with DeviceNet Firmware Version 7 05 and earlier only allows one P46 Input Mode setting to be active at one time settings 2 or 6 for DeviceNet or setting 9 for PI tis possible for users of Firmware Version 7 05 and earlier to set up PI control via an external processor such as a SLC500 Consult your processor manual for specific instructions 5 20 Parameters and Programming End of Chapter Chapter 6 Troubleshooting Fault Information This chapter provides information to guide you in troubleshooting the drive Included is a list and description of drive faults and problems that may occur Program Keypad Module Fault Display Figure 6 1 Active Fault If a fault occurs el T PO7 Active Fault is displayed Fault Code Number ESC SEL A V m Controllers equipped with a Program Keypad Module will flash P D O the display when a fault is present Land Ready Fault Indicating Panel Figure 6 2 Fault LED Controllers without a Program el Keypad Module come equipped with a Ready Fault Indicating Panel When the Fault LED is illuminated FAULT a fault exists The optional Remote Programming Adapter is equipped with the same Ready Fault indication READY system How to Clear a Fault When a fault occurs the cause must be corrected before
101. wer must be cycled or P56 Reset Function must be set to 2 for the change to take effect Settings 0 3 wire control 9 1 2 wire control 9 2 Program Keypad Module Remote Keypad Module CopyCat Keypad Module or Communication control 9 3 Momentary Run Forward Run Reverse control 9 4 2 wire Accel Decel control 5 2 wire Coast to Rest control 9 6 2 wire TB3 Control Keypad or Communication control 7 2 wire Frequency Select control 8 2 wire Preset control 9 2 wire PI control A contact closure on TB3 Terminal 7 and 8 is required for the drive to respond to a Run command Only available in Analog Signal Follower model 5 10 Parameters and Programming Program Group Min Max Factory No Parameter Name Description Range Units Default 47 Output Configure 0 10 Numeric 0 Configures the TB3 relay output functionality Value Setting Output Changes State When 0 Drive Ready Faulted Energized and returns to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 Motor Running The motor is receiving power from drive 3 Reverse Drive is commanded to run in the reverse direction 4 Motor Overload A motor overload condition exists 5 Ramp Regulated The ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Frequency The drive exceeds the
102. y Refer to Chapter 4 for details on how to verify correct motor rotation Reverse Change Direction This function is only active when P46 Input Mode is set to 2 When active pressing this key causes the motor to ramp down to 0 Hz and then ramp up to its set speed in the opposite direction When the motor is running pressing this key causes the currently illuminated LED to flash indicating motor rotation while decelerating to zero The other LED will illuminate indicating the commanded direction Start This function is only active when P46 Input Mode is set to 2 When active pressing this key initiates a start command Stop Pressing the Stop key will cause the motor to stop using the selected stop mode Refer to the P34 Stop Mode parameter If the drive has stopped due to a fault pressing this key will clear the fault Important The Stop key is always active in all control modes Program Keypad Module 3 3 Module Removal and Installation ATTENTION Ensure that you disconnect line power and wait three A minutes before installing or removing the Program Keypad Module Failure to do so could result in personal injury or death sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference Publication
103. y under heavy loads then this value should be increased A setting of 0 0 Hz disables the function This parameter along with P83 PI Process Reference also activates PI control in drives using Firmware Version FAN 7 06 See page 5 17 for PI Control Setup and Activation instructions ATTENTION Hazard of personal injury or equipment damage A exists due to unpredictable changes in motor speed Do not use P72 Slip Compensation and P83 Process Reference to disable PIcontrol while the drive is running Disable PI control only when the drive is stopped 73 Reverse Disable 0 1 Numeric 0 When this parameter is set to a 1 reverse is disabled The reverse command value may come from the analog input TB3 5 the keypad or a serial command With a negative analog input and reverse disabled the frequency command will be zero in bipolar mode and minimum frequency in unipolar mode All digital reverse inputs including two wire Run Reverse will be ignored with reverse disabled Important This parameter cannot be programmed while the drive is running 74 Analog Select 0 1 Numeric 0 Settings 0 unipolar analog input 0 to 10V value 1 bipolar analog input 10 to 10V Important With this parameter set to bipolar setting 1 the parameter settings for P75 Analog Input Minimum and P32 Minimum Frequency are ignored In addition all other reverse inputs Program Keypad Module Remote Keypad Module CopyCat Keypad Mo

160 SSC™ Variable Speed Drive (Series C)

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160 SSC&trade; Variable Speed Drive (Series C)

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160 SSC™ Variable Speed Drive (Series C)