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User Manual - Rockwell Automation

1. ES TB3 Terminal Signal Specification Fu y Lal lel el 1 10V Pot 10 KQ Potentiometer 2 Watts amp 2 Pot Wiper or 7 10 10V DC Input_ Controller Input Impedance 100 kQ J 3 Common Common 7 O FAULT 4 4 20mA Input Controller Input Impedance 250 Q READY 5 Reverse Contact closure input 6 Start Contact closure input 7 Common Common 7 FE PPP 8 Stop Contact closure input required to operate controller Ey 9 Normally Closed Customer programmable relay outputs eae 0 Relay Common Resistive load 0 4A at 125V AC 2A at 30V DC Inductive load 0 2 A at 125V AC 1A at 30V DC Normally Open L N 0 Momentary Contact o lt N O Maintained Contact gt o N C Momentary Contact Figure 2 4 TB3 Control Wiring for Preset Speed Model Shielded Wire 5 98g I pecification Fl lal lj lg i SWT Contact closure input T Ts SW2 Contact closure input j Common Common Een e SW3 Contact closure input O READ l Reverse Contact closure input g ans Start Contact closure input Common Common Stop Contact closure input required to operate controller Normally Closed Customer programmable relay outputs Relay Common Resistive load 0 4A at 125V AC 2A at 30V DC Inductive load 0 2 A at 125V AC 1A at 30V DC Normal
2. Motor Cable Only RWR at Drive Reactor at Motor Rangs KHz Shielded Unshielded Shielded Unshielded Shielded Unshielded ft m ft m ft m ft m ft m ft m 2 360 110 750 229 280 85 600 183 410 125 525 160 E 4 335 102 600 183 260 79 600 183 370 113 475 145 8 300 91 410 125 T 310 94 420 128 2 300 91 540 165 430 131 540 165 310 94 425 130 one 4 300 91 425 130 410 125 425 130 300 91 400 122 8 300 91 300 91 300 91 350 107 2 300 91 375 114 250 76 375 114 300 91 300 91 ee 4 300 91 300 91 225 69 375 114 300 91 300 91 8 300 91 300 91 300 91 300 91 2 300 91 375 114 250 76 375 114 300 91 300 91 075 uP 4 300 91 310 94 225 69 375 114 300 91 300 91 8 300 91 300 91 300 91 300 91 2 300 91 375 114 250 76 375 114 300 91 300 91 s qs 4 300 91 325 99 225 69 375 114 300 91 300 91 8 300 91 300 91 300 91 300 91 Motor Cable Only RWR at Drive Reactor at Motor a Shielded Unshielded Shielded Unshielded Shielded Unshielded ft m ft m m 0 37 to 2 2 kW 0 5 to 3 HP 500 152 800 244 244 2 thru 8 kHz Notrecommended for use above 4 kHz PWM fr
3. 5 7 Chapter 5 Parameters and Programming Program Group P Parameter Description Min Max Units Factory Range Default 48 Output Threshold Determines the on off point for the TB3 output relay when P47 Output Configure is set to 6 7 and 8 0 to 815 Numeric 0 Settings Value 6 0 to 240 Hz 7 0 to 180 8 0 to 815 Volts 49 PWM Frequency Carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM freq setting 100 e 98 o 94 3 Y 9 2 0to 8 0 0 1 kHz 4 0 kHz g 90 x 88 86 S 1 2 3 4 5 6 7 8 Carrier Frequency kHz Important Ignoring derating guidelines can cause reduced controller perfor mance 50 Restart Tries maximum number of times the controller will attempt to 0to 3 Numere 0 reset a fault 51 Restart Time Time between restart attempts 0 5t0300 0 1 Seconds RUM 52 DB Enable Enables disables external dynamic braking 0 to 100 Numere 0 5 8 Setting 0 Disable Settings 1 through 100 duty cycle braking Important The Rockwell Automation Bulletin 160 DB Resister package is rated for 5 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 resister must be sized to avoid overheating of the resister package Important This parameter cannot be programmed while the c
4. 5 1 199 Pin Extension Figure A 5 Line Reactor Cat No A B C D E m 112 10 74 50 36 1321 3R2 A 4 4 4 0 2 9 2 0 1 44 men 12 102 74 50 36 ere 271 44 4 0 2 9 2 0 1 44 KD S snisnens s QD Es n2 102 74 50 36 13213844 44 4 0 2 9 2 0 1 44 E 112 102 74 50 136 B 1321 3R4 B 4 4 4 0 2 9 2 0 1 44 ee 152 122 79 54 50 1321 3R8 A 6 0 4 8 3 1 21 2 0 l 152 122 79 54 50 a 1321 6 0 4 8 3 1 21 2 0 B 152 12 79 54 50 1321 3R12 A 6 0 4 8 3 1 2 1 2 0 E S wo Appendix A Specifications and Accessories Approximate Dimensions Continued Dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes Figure A 6 Line Filters C la E RE eodd H J u O O A D O leleleje Line Filter Module A B C D E F G H 1605 RFA 6 A 160S RFA 10 A 182 0 7 17 75 0 2 95 30 0 L18 167 0 6 57 60 0 2 36 PEATA 0 17 2 35 1 18 6 57 2 36 65 45 026x018 4 2 0 17 200 B hole dim dia hole 7 87 160 RFB 3 A 182 0 7 17 75 0 2 95 35 0 1 38 167 0 6 57 60 0 2 36 2 places 2 places 160 RFB 9 A
5. Input Power Conditioning e essc cocos ee e Reb e Re eh pede trs Recommended Line Side Protection e iss e esnie E E EE EEEE Motor Cable Recommendations cx aR Re a R e R 0 R N R 0 R K edirse eA Control Wiring Requirements ss RRR aa RR 9 0 GR R KR eee RRR Control Wiring Analog Signal Follower Model 000000000005 Control Wiring Preset Speed Model 00 0 0c cece eee Control Wiring Diagrams ieran e RTE cent SET Chapter 3 Program Keypad Module Features M PL Display Mode 5t ete tec e Rada IRR ton PRU acr Re Program Mode eit bed ERR eR eR e pRE S ERE TEE EC ERE VIS EE Removing Program Keypad Module 0 0 c eee eee eee eee eee Chapter 4 Start Up eio awe ewe eee eee Start up Procedure ar a sped dpa ERR E ewes PC Rebbe eae Chapter 5 Parameters and Programming Overview of Parameters R Ra K NR a ie isa RN RRR eee ee eee cae are Programming Example etn et RS snd dha ld dk aad SHER aS Gee ERG Display Group Parameters 2 05 socle lr me iem e e pede ee Program Group Parameters rss TR 57 R ERRA E EE R e CEL SG wey ee TRER OEN Chapter 6 Troubleshooting and Fault Information Fault Information 2 2 sc heise head oh hs CERE tee ehewes neers shee Troubleshooting 1 5 reed end eee SPUR we RU wen NAM waa REIR E Block Diagram of Bulletin 160 Analog Signal Follower Appendix A Controller Specifications 680 aa E N esse ed edt eur red RR es Cata
6. Contact closure input required to operate controller Important The Run inputs do not need to be maintained After a stop input either a Run Forward or a Run Reverse input does not need to be toggled to run again ATTENTION Hazard of injury exists due to unintended operation When P46 Input Mode is set to 3 and the Run input is maintained a stop function is provided only when the stop input is AN active open Chapter 2 lt Installation and Wirng 2 Installation and Wiring Control Wiring continued Figure 2 8 TB3 Two Wire Accel Decel control Setting 4 Shielded Wire Signal Specification Run Reverse ContactClosure Input Run Forward Contact Closure Input Common Common Accel decel Contact Closure Input select Used to select Accel Decel Refer to Figure 2 11 Figure 2 9 TB3 Two Wire Enable control Setting 5 Shielded Wire Specification Run Reverse Contact Closure Input 6 Run Forward Contact Closure Input 7 Common Common 8 Enable Contact Closure Input required put req to operate controller Refer to Figure 2 11 Figure 2 10 TB3 Two Wire Local Remote control Setting 6 Shielded Wire Specification 5 Run Reverse Contact Closure Input 6 RunForward Contact Closure Input 7 Common Common 8 Local Contact Closure Input Remote Used to select
7. The clockwise LED illuminates constantly when the motor rotates in forward direction Indicates commanded direction Actual motor rotation could be different if motor leads are not connected properly See Chapter 4 Start up for details on how to verify motor rotation When the motor is running pressing this key causes the currently illuminated LED to flash indicating motor rotation while The start key initiates a start command when the controller is programmed for local start stop control when P46 Input Mode is setto 2 Chapter 5 for programming steps These four digits display the parameter value or fault code number 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 Pressing the enter key while in programming mode causes the current value displayed to be entered into memory When you press this key the program mode indicator remains on but stops flashing The stop key initiates the motor to Coast Ramp or DC Brake to stop depending on the setting of P34 Stop Mode decelerating to zero The opposite LED will illuminate indicating the commanded direction Real time frequency adjustment can be achieved when using P58 Internal Frequency 3 1 Ean E 3 Program Keypad Module Removing Program Keypad Module ATTENTION Ensure t
8. Control Version Displays version of controller firmware Used by Rockwell Fixed Value Numeric Value Automation field service personnel Chapter 5 Parameters and Programming 5 Parameters and Programming Display Group P Parameter Description Nas Units 12 Input Status Displays the open 0 and closed 1 state of the inputs to TB3 in binary coded format as follows Bit3 EVE MS Bito Input Input Input Input Mode 3 Input Input Input Mode 6 Mode 0 Mode1 Mode2 Momentary Mode 4 Mode 5 Local 0000 to 1111 Binary Number 3 Wire 2 Wire Keypad Run FWD Accel Enable Remote Run REV Decel Bit 0 Run Run Run Run Run TB3 5 Reverse Reverse N A Reverse Reverse Reverse Reverse 0 Accel2 0 Drive 0 Local TB3 Bit 1 Decel 2 Disable Control Tasa SP Stop Stop Stop 1 Accel1 1 Drive l Remote Decel 1 Enable Control Bit 2 Run Run Run Run Run TB3 6 one Forward N A Forward Forward Forward Forward Bit3 0 Positive Analog Input Polarity 1 Negative Analog Input 13 Power Factor Angle Displays the angle in electrical degrees between motor 0 0 to 180 0 0 1 degrees voltage and motor current 14 Memory Probe Display used by Rockwell Automation field service Numeric Value Numeric Value personnel 15 Preset Status Displays the open 0 and closed 1 state of Terminal Block Three TB3 inputs SW1 SW2 and SW3 in binary coded format T
9. Seconds with the initial current limit turned off This allows quicker acceleration times for low inertia systems For medium to high inertia 0 systems the minimum value if tine Time N Time Y should be 0 1 sec 31 Decel Time 1 Time forthe controller to ramp from P33 Maximum Frequency to 0 0 Hz The rate is linear for any decrease in command frequency iiaa SSE oe unless P53 S Curve is set to a value other than 0 See P30 Accel Time 1 figure above 32 Minimum Frequency Lowest frequency that controller will output d 0 to 240 1Hz 0 Hz continuously 33 Maximum Frequency Highest frequency the controller will output r i f 0 to 240 1Hz 60 Hz Important This parameter can t be changed while running 34 Stop Mode Select Determines stopping mode used by the controller when a stop is initiated Refer to the P44 DC Hold Time and P45 DC Hold 0103 Numeric 0 Voltage diagrams Settings 0 Ramp to Stop 1 Coast to Stop Value 2 DC Injection Braking 3 DC Injection Braking w Auto Shutoff Important DC Injection braking with 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 controller is out of current limit before the P44 DC Hold Time expires 35 Base Frequency Set value to motor s rated nameplate frequency 10 to 240 1Hz 60 Hz 20 to 460 for 1 Volt 460 Volts for 36 Base Voltage
10. User Manual Important User Information In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we use notes to make you aware of safety considerations The information in this manual is organized in numbered chapters Read each chapter in sequence and perform procedures when you are instructed to do so Do not proceed to the next chapter until you have completed all procedures 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 Attentions help you identify a hazard avoid the hazard recognize the consequences Impo
11. HP 0 37 1 2 0 55 3 4 0 75 1 1 5 2 2 2 3 Output Current A Max 1 2 17 23 4 0 6 0 Power Dissipation Watts 25 30 40 65 80 Input Ratings Input Voltage Frequency 380 460V Three Phase 50 60 Hz Operational Range V 340 506V Input kVA 11 1 6 2 2 3 7 5 7 Environmental Specifications Cooling Method Convection Cooled Fan Cooled AC Dynamic Braking Torque With external Dynamic Brake Module 300 233 200 150 115 Without external Dynamic Brake Module 100 100 100 50 50 Estimated Actual value depends on motor characteristics Appendix A Specifications and Accessories A Specifications and Accessories Table A 3 Specifications For All Controller Ratings Input Output Ratings All Controller Ratings Output Voltage V Adjustable from OV to input voltage Output Frequency Hz 0 to 240 Hertz Programmable Efficiency 97 5 Typical Transient Protection Standard 2 kV Optional 6 kV using MOV module See accessories on page A 5 Environmental Specifications All Controller Ratings Enclosure IP 20 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 All Controller Ratings Control Input Type For dry contact closure input
12. Output Frequency Displays the output frequency at TB2 terminals T1 T2 and 0 to 240 0 1 Hz T3 U V and W 02 Output Voltage Displays the output voltage present at TB2 terminals T1 T2 and 0 to Max Voltage 1Volt T3 U V and W 03 Output Current Displays the output current present at TB2 terminals T1 T2 and LN 0 01Amps 3 U V and W Output Current 04 Output Power Displays the output power present at TB2 terminals T1 T2and T3 0 to 2 Times Rated 0 01 kW U Vand W Controller Output i Power 0 to 400 230V 1 Volt 05 Bus Voltage Displays the DC Bus Voltage level 0 to 800 4601 06 Frequency Command pisplays the frequency that the controller is commanded to output This command may come from any of the frequency sources 0 to 240 0 1 Hz selected by P59 Frequency Select or from a currently selected preset frequency 07 Last Fault Displays the coded last fault number If a fault is currently active has not 0 tp 49 Numeric Val been cleared the display will flash See Chapter 6 for fault code descriptions SIS E 08 Heatsink Temperature Displays the temperature of the controller heatsink 0 to 150 1 Degree C 09 Controller Status pisplays the status of the controller in a binary coded format Important A 0 inactive E 0000 to 1011 Binary Number and a 1 lt active Running Forward Accel Decel 10 Controller Type Used by Rockwell Automation field service personnel Numeric Value Numeric Value 11
13. Set value to motor s rated nameplate voltage 460V units and 460V units 20 to 230 for and 230 for 230V units 230V units The analog inputs to the controller i e 4 20mA 0 to 10V 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 For controllers without a program keypad module you can change P35 Base Frequency to 50 Hz via a dipswitch located under the blank front panel See the Removing Program Keypad Module section in Chapter 3 5 4 Chapter 5 Parameters and Programming 5 Parameters and Programming P 37 Program Group Parameter Description Maximum Voltage Sets the highest voltage that the controller will output P37 Maximum Voltage must be greater than or equal to P36 Base Voltage Min Max Range 20 to 510 for 460V units and 20 to 255 for 230V units Units 1 Volt Factory Default 460 Volts for 460V units and 230 for 230V units 38 Boost Select set the boost voltage and redefines the Volts per Hz cuve ipo 0 50 100 45 0 125 10 40 0 nr D 2 Break Point Voltages 00 in of Base Voltage Oo 1 C Un EJA KA C ei ce c wo 0 to 12 Numeric Value 39 Skip Frequency Works in conjunction with P40 Skip Frequency Band creating a range of frequencies at which the controller will
14. Sto Isolator Mu MM 7 TB3 8 Relay TB3 9 Customer Common Circuitry LQ T83 10 C E TB3 7 T_QO 1B3 l r Appendix A Specifications and Accessories A Specifications and Accessories Controller Specifications Table A 1 and Table A 2 contain information that is unique to each SSC Controller rating Table A 3 contains information that applies to all Controller ratings Table A 1 Specifications for Controllers Rated 200 240V Single and Three Phase Input Controller Catalog Number Single Phase input 160S AA02 160S AA03 160S AA04 160S AA08 Three Phase input 160 AA02 160 AA03 160 AA04 160 AA08 160 AA12 Output Ratings 3 Phase Motor Rating kW HP 0 37 1 2 0 55 3 4 0 75 1 15 2 2 2 3 Output Current A Max 2 3 3 0 45 8 0 12 0 Power Dissipation Watts 20 25 40 70 105 Input Ratings Input Voltage Frequency 200 240V Single Phase and Three Phase 50 60 Hz Operational Range V 180 265V Input kVA 11 14 2 2 3 7 5 1 Environmental Specifications Cooling Method Convection Cooled Fan Cooled AC Dynamic Braking Torque With external Dynamic Brake Module 300 233 200 150 115 Without external Dynamic Brake Module 100 100 100 50 50 Table A 2 Specifications for Controllers Rated 380 460V Three Phase Input Controller Catalog Number Three Phase input 160 BA01 160 BA02 160 BA03 160 BA04 160 BA06 Output Ratings 3 Phase Motor Rating kW
15. not operate continuously er Controller Output Command y 4 Frequency Frequency L Skip Frequency Setting amp Two times P40 Skip Freq Band Setting Time 0 to 240 1Hz 240 Hz 40 Skip Frequency Band Determines the band around the P39 Skip Frequency parameter The actual band width will be 2 times Skip Frequency Band 1 2 the band above and 1 2 the band below A value of zero will disable the skip frequency 0 to 30 1Hz 0 Hz 5 5 Chapter 5 Parameters and Programming 5 Parameters and Programming Program Group P Parameter Description Min Max Units Factory Range Default 41 Motor Overload Select selects the derating factor for the 12t over load function Z p 3 No Derating b Min Derating 100 100 n C C7 E ae L B a 60 C C ius dou dd t G 60 g B AE I UM 7 T a0 tW 5 3 Se x ON MS m Pm uo geo Kr eld ld mo amp 20 s e det bete e ch S 0to2 Numeric 0 a je pe a Sh O pe TEE EOE AS SEN Value amp 0 25 50 75100125150 175 200 0 25 50 75100 125 150 175 200 Base Speed 2 Base Speed g b Max Derating Eao Sg E Settings 9 60 SNL l T us uut T s 0 No Derating E 20 oa dodo od odo od o 1 2 Minimum Derating 9 Lao dod dod od od 2 Maximum Derating 0 25 50 75100125 150175 200 Z Base Speed 0 1 to 200 01 Amperes 115 of 42 Motor Overload Current setto motor nameplate full load Amps obcsnhol
16. reflected wave cable length recommendations replacement parts A 4 resetting mm defaults 5 10 5 10 reverse 2 6 api le reducer 2 4 2 5 RWR r S curve skip reavenoy storage temperature 2 1 T terminal blocks Ta specificatio torque ratings A 1 troubleshooting 6 3 fault descriptions V vibration A 2 fa voltage rating A W wiring control and signal input line fuses motor cable recommendations 2 4 terminal blocks specifications 2 2 2 6 wire size recommendations 2 2 2 6 L Rockwell Automation Rockwell Automation helps its customers receive a Superior return on their investment by bringing together leading brands in industrial automation Allen Bradley creating a broad spectrum of easy to integrate products These are sup ported by local technical resources available worldwide a global network of system solutions providers and the advanced technology resources of Rockwell Worldwide representa tion ae Argentina e Australia e Austria e Bahrain e Belgium e Bolivia e Brazil e Bulgaria e Canada e Chile e China People s Republic of e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Dominican Republic e Ecuador e Egypte El Salvador e F inland e France e Germany e Ghana e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Iran e Ireland e Israele Italy eJ amaica eJ apan eJ ordan e Ko
17. 152 300 92 540 165 500 152 500 152 1000Vp p 55 17 40 12 300 92 300 92 325 99 325 99 ari 1200 Vp p 125 43 60 18 300 92 375 114 500 152 325 99 1600 Vp p 500 1529 500 152 300 92 375 114 500 1529 500 1529 1000 Vp p 45 14 40 12 300 92 300 92 300 92 300 92 gene 1200Vp p 125 38 60 18 300 92 375 114 500 152 500 152 1600 Vp p 500 1529 500 152 300 92 375 114 500 1529 500 1529 1000 Vp p 45 14 40 12 300 92 300 92 300 92 300 92 i EE 1200Vp p 125 38 50 15 300 92 375 114 500 152 500 152 1600 Vp p 500 152 500 152 300 92 375 114 500 152 500 152 Q The reflected wave data applies to all PWM frequencies 2 to 8 kHz For 230V ratings see Table 2 G 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 controller is 1400V due to the minimum on off time software Reflective Wave Testing has been done on cable lengths up to 500 feet See Table 2 G for Capacitive Current Considerations Chapter 2 lt Installation and Wiring 2 Installation and Wiring Table 2 G Cable Length Recommendations Capacitive Current
18. 182 0 7 17 75 0 2 95 47 5 L 87 167 0 6 57 60 0 2 36 160 LF 174 0 6 85 75 0 2 95 50 0 1 97 163 0 6 41 60 0 2 36 6 9x 5 25 6 9 x 525 200 All Types 0 272 x 0 207 0 272 x 0 207 7 87 hole dim hole dim Appendix A Specifications and Accessories A Specifications and Accessories Approximate Dimensions Continued Dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes Figure A 7 Capacitor Module lH 254 10 Approximate Lead Length K 50 1 97 i 17D F sl r 437 Mounting Holes NI 3 5 C T WN H Sura KE Hp aT E T 140 5 51 mm ER 150 9 130 5 94 5 11 GLA Lf gt E mm 4 S N 8 d A 9 Appendix A Specifications and Accessories Approximate Dimensions Continued Dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes Figure A 8 DeviceNet Module Attached to Controller 17 34 161 2 0 68 Required 6 35 Overall Heig
19. 2 for the change to take effect Value Settings 0 3 wire control 1 2 wire control 2 Program Keypad Module control 3 Momentary Run Forward Run Reverse control 4 2 wire Accel Decel control 5 2 wire Enable control 6 2 wire Local R emote control See Chapter 2 for wiring diagrams and description of settings 47 Output Configure Configures the TB3 relay output functionality Settings Output changes state when 0 Controller energized and returns to shelf state when Ready Faulted power is removed or when a fault occurs 1 At Frequency the controller reaches commanded frequency 2 Controller Running the controller is running 3 Reverse the controller is commanded to run in the reverse direction 0 to 9 Numeric 0 4 Motor Overload when a motor overload condition exists Value 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 controller exceeds the frequency value set in P48 Output Threshold 7 Above Current the controller exceeds the value set in P48 Output Threshold Important Value for P48 Output Threshold must be entered in of controller rated output current 8 Above DC Bus the controller exceeds the DC bus voltage value set Voltage in P48 Output Threshold 9 Retries Exhausted the number of retries for P50 Restart Tries is exceeded
20. Block Specifications Terminal Max Min Wire Max Min Torque Block Size mm AWG Nm Ib in TB19 M4 4 0 75 12 18 L81 1 35 16 12 TB29 M4 4 0 75 12 18 L81 1 35 16 12 The Bulletin 160 SSC is IP20 with wires installed on power terminal blocks Input Power Conditioning The controller is suitable for direct connection to AC power lines within the rated voltage of the controller see Appendix A Listed below are certain power line conditions which may cause component damage or reduction in product life If any of the conditions exist as described in the table below install one of the devices listed under the heading Corrective Action on the line side of the controller 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 Table 2 B Power Line Conditions Power Line Condition Corrective Action Available short circuit currents fault currents greater than 10 000 Check supply voltage Line Reactor See A 4 or Amps e Isolation Transformer Line has power factor correction e Line Reactor See A 4 or capacitors e Isolation Transformer Line has frequent power e Line Reactor See A 4 or interruptions e Isolation Transformer Line has high frequency e MOV option See A 4 or gt 10 Hz noise spikes in excess of 900V Induction heaters RF equipment choppers Lin
21. Contact o N C Maintained Contact Internal 12V supply 7 If both Run Forward and Run Reverse inputs are closed at the same time an undetermined state could occur 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 earth ground Factory Default Setting Shielded Wire Y Terminal Specification 0 o1 5 Reverse Contact closure input 6 Start Contact closure input 7 Common Common 8 Stop Contact closure input required to operate controller Important After a Stop input the Start input must be toggled to Run again Figure 2 6 TB3 Two Wire Run Forward Run Reverse control Setting 1 Shielded Wire 5 Run Reverse Contact closure input 6 Run Forward Contact closure input 7 Common Common 8 Stop Contact closure input required to operate controller Important The Run inputs must be maintained After a Stop input either a Run Forward or a Run Reverse input must be toggled to run again Figure 2 7 TB3 Momentary Run Forward Run Reverse control Setting 3 Shielded Wire Signal Run Reverse Specification Contact closure input Run Forward Contact closure input Y Common Common Stop
22. N A 5 4 Ul A 4 5 yee P Hz 50 60 b Hz 0 240 1 07 U VA 2200 U Motor T VA T Paing 0 75KW 1HP C e ALLEN BRADLEY MADE IN U S A S N 32098 E IP20 OPERATING AMBIENT TEMP 0 50 C SHORT CIRCUIT CURRENT 10KA POWER TERMINAL WIRE Use 75 C Cu Wire 4mm 75mm 12 18 AWG Torque 1 35 Nm 12 in lbs WARNING Allow 1 Minute after power is removed before servicing Accessible surfaces may be hot Compatible with Type B RCD protection devices only Nameplate is located on the side of the unit Parameter numbers and names are shown in bold typeface and follow the format PXX where P denotes parameter XX denotes the two digit parameter number and represents the parameter name For example P01 Output Frequency 1 2 Installation and Wiring m3 Installation and Storage Take these actions to prolong controller life and performance store within an ambient temperature range of 40 to 85 C store within a relative humidity range of 096 to 95 non condensing protect the cooling fan by avoiding dust or metallic particles avoid storing or operating the controller 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 To maintain proper working conditions install the controller on a flat vertical and level surface Use mounting screws u
23. at Drive have been added to both Table 2 F and Table 2 G replacing our previous recommendations of a Reactor at Drive The paragraph titled Recommended Line Side Protection has been updated to provide added clarity on the use of devices other than fuses for the purposes of line side protection Table 2 C and Table 2 D have also been updated The paragraph titled Motor Cable Recommendations has been updated Table 2 E was added to provide recommended cable types based on cable distances and environmental conditions Part numbers and dimensional information for the new 24V DC interface module and RF series of line filters have been added to Appendix A Publication 160 5 9DU2 has been incorporated into the manual The contents of the document update can now be found in Appendix B Summary of Changes _ of Changes This Page Intentionally Blank Table of Contents of Contents Chapter 1 Information and Precautions General Information xui eR AS ek Si ATA P Svr ee CSS EX ede General PrecautioOnS 3212 RU Ce ace Sele eee bd PEE Vd S EE Conventions Used In This Manual nee Chapter 2 Installation and Wiring Installation and Storage ee EET eee RP RIPE PR ELE CE Compliance s 6 4 ooo ses beer beat eases TN e Taxe espe Pi Erga Controller Features sx 99 9 KN 0 a eme diet eee eque bee v ED don Power Wiring For Preset Speed and Analog Signal Follower Models
24. occurs at 815V DC bus voltage equivalent to 575V AC incoming line voltage Bus overvoltage caused by motor regeneration Monitor incoming AC line for excessive voltage Extend the decel time or install dynamic brake module or external capacitor module See Appendix A 6 1 Chapter 6 Troubleshooting and Fault Information 6 Troubleshooting and Fault Information Table 6 A Bulletin 160 Fault Descriptions continued Fault Fault Fault Description Corrective Action Number Indication 06 Motor Stall Motor has stalled Motor load is excessive Longer acceleration time or a reduced load Fault required 07 Motor Internal electronic overload trip Excessive Reduce motor load until controller output current Overload motor load exists does not exceed the current set by P42 Motor Fault Overload Current Reduce P38 Boost Select 08 Over Excessive heat detected Clear blocked or dirty heat sink fins Check Temperature ambient temperature Check for blocked or Fault non operating fan 11 Operator Keypad has been removed while controller is Clear fault Do not remove keypad under power Fault powered 12 Overcurrent Overcurrent detected in hardware trip circuit Check short circuit at the controller output or Fault excessive load conditions at the motor 32 EEPROM EEPROM has invalid data Reset EEPROM using P56 Reset Functions Fault Set to 1 Cyc
25. safe operation For controllers rated atinput voltage 200 240V AC overvoltage trip occurs at 410V DC bus voltage equivalent to 290V AC incoming line voltage For controllers rated atinput voltage 380 460V AC overvoltage trip occurs at 815V DC bus voltage equivalent to 575V AC incoming line voltage For controllers rated at input voltage 200 240V AC undervoltage trip occurs at 210V DC bus voltage equivalent to 150V AC incoming line voltage For controllers rated at input voltage 380 460V AC undervoltage trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line voltage Control Ride Through Minimum ride through is 0 5 seconds typical value 2 seconds Ground Short Any output phase to ground detected atrun Faultless Ride Through 100 Milliseconds Output Short Circuit Programming All Controller Ratings Programmer Any output phase to phase short Optional Removable Program Keypad Module Type of Display 6 character LED two digit parameter number and four digit value Local Controls SPEED RUN STOP and DIRECTION controls A 3 Appendix A Specifications and Accessories A Specifications and Accessories Accessories For All Controller Ratings 0 37 to 2 2kW 1 2 to 3 HP Controller Dynamic MOV 3 Line L
26. the branch circuit disconnect device and correct the malfunction before continuing Start Up Checklist Verify the controller is installed per instructions outlined in Chapter 2 including e Minimum clearance distance between controller and other equipment e Proper grounding practices have been followed e Proper power and control wiring has been used Verify that AC line power at the disconnect device is within the rated value of the controller voltage may be present at the power terminal blocks TB1 and TB2 for approximately one minute after power is removed from the controller A ATTENTION A DC Bus Disconnect and lock out all incoming power to the controller including incoming AC power to terminals L1 L2 and L3 R S and T of power terminal block TB1 Verify thatthe motor leads are connected to the power terminal block TB2 terminals T1 T2 T3 U V W Verify thatthe STOP input is present at the TB3 control terminal block See page 2 9 for details on TB3 8 functionality when using P46 Input Mode settings 4 through 6 Confirm that all other control inputs are connected to the correct terminals and are secure GO TO THE NEXT PAGE A aR o 4 Start Up U If you have a blank display panel Reconnect the power to the If you have a program keypad module controller P01 Output Frequency will display If the controller has been previously powered up a different parameter number may d
27. will conform Many factors can influence the total installation and only direct measurements can verify total conformity Numbers 24V DC interface A 10 50 Hz dipswitch 3 2 60 Hz dipswitch 3 2 A AC input wiring 2 accel decel no ea accessories ambient temper A 2 analog input 2 analog scaling analog input zero offset 5 10 analog input maximum 5 12 analog input minimum analog sele t 5 12 approvals A 2 auto restart restart time 5 8 restart tries 5 8 B block diagram 6 4 branch circuit disconnect EES C cable length recommendations capacitive current 2 5 reflected wave 2 4 capacitive current cable length recommendations 2 5 capacitor module A 9 connecting 2 2 carrier frequency pwm 5 8 oe tel mbe a m A 21B 1 nan base DEP from factory default 3 2 Clearing faults Emm compensation control wiring Analog Signal Follower model 2 6 2 6 Preset Speed model control wiring requirements Analog Signal Follower model 6 2 7 Preset Speed mode H Pele controller features 2 1 controller K conventions used in this manua 1 2 2 m LS CUL current limiting current rating D DB enable DC brake Ea e 5 4 5 6 DC hold level 5 6 defaults resetting to 5 10 determining drive information 1 2 DeviceNet module diagnostics 5 2 5 3 6 2 152 6 3 dimensions A 5 SEES display group display group p EE 2 5 3
28. zero hertz or P38 Boost Volts set too high dwell time at zero hertz Reduce P38 Boost Fault Volts Chapter 6 Troubleshooting and Fault Information Table 6 B Troubleshooting Problem Motor does not start No output voltage to motor Corrective Action Check power circuit e Check supply voltage e Check all fuses and disconnects Check motor e Verify that motor is connected properly Check control input signals e Verify that START signal is present e Verify that STOP signal is present e Verify that RUN FORWARD and RUN REVERSE signals are NOT both active Check P46 Input Mode e fP46 Input Mode is set to 2 only the program keypad module Start button will start the motor Controller Started but motor NOT rotating P01 Output Frequency displays 0 0 Check motor e Verify that motor is connected properly Check frequency source P06 Frequency Command e Verify that frequency signal is present at terminal block TB3 e 10 10V signal e 4 20mA signal e Verify that Preset Frequencies are set properly Check control input signals e Verify that SW1 SW2 and SW3 are correct Refer to the chart at the end of Chapter 5 Check parameter settings e Verify that P59 Frequency Select is showing desired frequency source e Verify that P58 Internal Frequency is the desired value Motor not accelerating properly Check mot
29. TB2 For Motor and 1 Capacitor Module 5s Capacitor Module Option For single phase input applications connect the AC input line to input terminals L1 R and L2 S Q Connection for dynamic brake resistors for all models Important P52 DB Enable must be enabled for proper operation See Appendix A for part numbers SE X ED c Bulletin 160 controllers are Z and 959 listed as motor overload protective devices An external overload relay is not required for single motor applications Connection for an external capacitor module Provides extended ride through capability and improved inherent braking performance See Appendix A for part number ATTENTION The controller is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies line power to the controller 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 ATTENTION Do not connect power factor correction capacitors to controller output terminals T1 T2 and T3 U V and W or component damage could occur 2 2 Power Wiring For Preset Speed and Analog Signal Follower Models Table 2 A Power Terminal
30. and for the controller Settings 0 external frequency command 1 internal frequency command from P58 Internal Frequency Otol Numeric Value 60 Zero Offset Used to add or subtract any system offset to the analog input See P16 Analog Input for additional information Important This parameter cannot be programmed while the drive is running 50 0 to 50 0 Numeric Value 0 This parameter applies only to the Analog Signal Follower model Chapter 5 Parameters and Programming 5 Parameters and Programming Program Group P Parameter Description Min Max Units Factory Range Default 61 Preset Frequency 0 The programmed value sets the frequency that 0 to 240 0 1 Hz 3Hz the controller outputs when selected 62 Preset Frequency 1 The programmed value sets the frequency that 0 to 240 0 1 Hz 20 Hz the controller outputs when selected 63 Preset Frequency 2 The programmed value sets the frequency that 0 to 240 0 1 Hz 30 Hz the controller outputs when selected 64 Preset Frequency 3 The programmed value sets the frequency that 0 to 240 0 1 Hz 40 Hz the controller outputs when selected 65 Preset Frequency 4 The programmed value sets the frequency that 0 to 240 0 1 Hz 45Hz the controller outputs when selected 66 Preset Frequency 5 The programmed value sets the frequency that 0 to 240 0 1 Hz 50 Hz the controller outputs when
31. ction of motor rotation Issue a STOP command from either the program keypad module or TB3 control block terminal Issue a STOP command from either the program keypad module or TB3 control block terminal Is the direction of motor No rotation correct Start Up is complete Jk Yes J lt Y Disconnectand lock outall incoming power to TB1 terminals L1 L2 and L3 R S and T ATTENTION A DC Bus voltage may be present at the power terminal blocks TB1 and TB2 for approximately one minute after power is removed from the controller lt Switch any two of the three motor leads connected to TB2 terminals T1 T2 and T3 U V and W 4 2 Parameters and Programming eae Overview of Parameters This chapter covers both display and program parameters Display parameters are read only they cannot be programmed while program parameters can be changed to fit your motor control requirements You must have a Program Keypad Module to view change display and program parameters The table below describes which parameters apply to the Preset Speed and Analog Signal Follower models Refer to the programming example below for programming instructions Parameter Type Parameter Numbers Display Analog Signal Follower Model 1 through 14 and 16 Preset Speed Model 1 through 15 Program 30 through 60 and 69 through 76 78 30 through 59 and 61 through 73 78 The following pages co
32. d for protection of an individual motor within the group and one set of fuses or a UL489 rated circuit breaker serves as the Short Circuit Protective Device for the entire Group Installation Bulletin 1492 circuit breakers are rated as supplementary protective devices When using this device upstream fuses or UL489 rated circuit breakers are required for each motor in the branch circuit regardless if it is a single or group motor installation Table 2 C Minimum Recommended Line Side Protective Devices for 200 240V rated units 3 Rating 1 Rating Fuse Fuse Types Other Protective Devices kW HP kW HP Rating ClassCC Class J Rating Type 31 1 2 N A 6 16 55 3 4 37 1 2 6 KLDR CCMR Jor 16 14 MN 9 9 15 1 55 3 4 10 ATMR AJTE 16 1492 CB3 H 1 5 2 75 1 15 16 FNQR Lp 9 16 HFD L 2 2 3 1 5 2 25 20 Table 2 D Minimum Recommended Line Side Protective Devices for 380 460V rated units 3 Rating 1 Rating Fuse Fuse Types Other Protective Devices kW HP kW HP Rating Class CC Class J Rating Type 37 1 2 N A 3 4 6 3 55 3 4 N A 3 49 KLDR CCMR JDT 6 3 140 MN 75 1 N A KT ATDR ATQR AJTE 6 3 1492 CB3 H 9 15 2 N A 10 FNQR Ley 16 HED co 2 2 3 N A 15 16 16 Must be dual element time delay Allen Bradley Bulletin1492 circuit breaker Not recommended for Liltlefuse repetitive application of power to the input of th
33. 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 Otol Numeric value 7A Analog Select 0 unipolar analog input 0 to 10V 1 bipolar analog input 10 to 10V Important With bipolar analog input selected the reverse inputs keypad terminal block serial are ignored In addition two wire Run Reverse commands P75 Analog Input Minimum and P32 Minimum Frequency settings are ignored Important This parameter cannot be programmed while the drive is running Otol Numeric value 75 Analog Input Minimum 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 Minimum Frequency use P16 Analog Input to adjust the analog input to the desired level 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 0 0 to 150 0 0 1 0 0 76 Analog Input Maximum Important Do not adjust this parameter until setting P60 Zero Offset Sets the percent of analog input used to represent P33 Maximum Frequency If the maxi
34. display mode dynamic brake uea dynamic brake module E oo discharge 1 1 3 2 MC s connections grounding configuration B 2 installation B 1 B 1 motor connections B shielded motor and Tm cable example B 3 F fan pump vos patterns 5 5 fault buffer 5 2 fault information troubleshooting 6 1 fault LED 6 1 faults DB ma frequency dipswitc frequency source se Econ Analog Signal Follower model KAO Preset Speed Model 2 6 7 G general precautions 1 1 grounding 2 6 l input mode selection 2 8 5 7 m input power conditioning L line filters A 4 A 8 line reactor MIR line side protection I 1 low voltage directive compliance B 4 M min max frequency 5 4 minimum clearance 2 1 motor cable lengths effects motor cable recommendations 2 mounting requirements MOV module ja ac N nameplate information 1 2 O operating controller with program keypad module without program keypad module 2 1 output contacts 2 7 5 7 output ratings A 1 overload protection 2 2 5 6 P parameters display osea overview 5 1 program E 54 potentiometer wiring power wiring precautions preset frequencies 2 7 5 11 program group parameters program keypad module description 3 1 display mode 3 1 features 3 1 MEM key descriptions program mode removal program lock 5 10 program mode I 2 programming 3 1 5 1 R
35. 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 press the ENTER key This writes the new value to memory 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 ES Cape key The original value of the parameter will remain unchanged and you will be exited from the program mode Parameter applies only to the Preset Speed model Keypad Display 3o 1 o o N Program Mode Indicator a 1 1 olo a 1 11 olo Program Mode Indicator Flashes 3 1 blo afa lala Program Mode Indicator Stops Flashing ait 1100 Program Mode Indicator Stops Flashing 5 1 Chapter 5 Parameters and Programming 5 Parameters and Programming Display Group Parameters This group of parameters consists of commonly viewed controller operating conditions such as controller 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 will be saved on power down Display Group P Parameter Description Cimen Units 01
36. e drive Gould Shawmut Westinghouse type HFD circuit breaker Bussman Allen Bradley Bulletin 140 manual motor starter Not recommended Controller is also compatible with RK1 RK5 and BS88 for repetitive application of power to the input of the drive Fuse ratings in denote European size fuse types Chapter 2 Installation and Wiring 2 Installation and Wiring Motor Cable Recommendations Table 2 E Recommended Cable Type s A variety of cable types are acceptable for Condition Insulation Type s Example s variable speed controller installations For many Dy Poo mN installations unshielded cable is adequate XLPE XHHW 2 provided it can be separated from sensitive Wet XLPE XHHW 2 circuits As an approximate guide allow a spacing of 1 meter 3 3 feet for every 10 meters For AC line voltages in excess of 264V AC or motor cable distances greater than 50 ft 15m wire with XLPE insulation is 33 feet of unshielded length If you cannot recommended separate motor cables from sensitive circuits or if you must run motor cables from multiple Long Motor Cable Effects controllers more than three ina common _ The controller should be installed as close to the conduit or cable trays shielded motor cable is motor whenever possible Installation with long recommended to reduce system noise motor cables may require the addition of external Motor cables should be four conductor with the devices t
37. e has intermittent noise spikes e in excess of 2000V lightening e Line Reactor See A 4 or e s T n olation Transformer OV option See A 4 or e Line Reactor See A 4 or e Isolation Transformer Chapter 2 lt Installation and Wirng 2 Installation and Wiring Recommended Line Side Protection The Bulletin 160 Smart Speed Controller has been UL tested and approved for use with a fuse circuit breaker or manual motor starter installed on the line side of the controller The maximum branch circuit protective rating is limited to four times the rated output current of the drive or 30 amperes whichever is less The ratings in Table 2 C and Table 2 D are the minimum recommended values for use with each drive rating It should be noted that the products listed under the column heading Other Protective Devices must follow the proper application guidelines stated for those products in order to meet local or national electrical codes When using Bulletin 140 manual motor starters or Bulletin 1492 circuit breakers the following guidelines must be followed in order to meet the NEC requirements for branch circuit protection 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 upstream from the Bulletin 140 manual motor starter In group motor installations the Bulletin 140 can be use
38. ed with a maximum motor cable length of 75 meters 250 feet for controllers rated 200 240V AC and 40 meters 130 feet for controllers rated 380 460V AC RF type Filters These units have been tested with a maximum motor cable length of 25 meters 80 feet for all ratings 2 The controller system must be mounted in a shielded enclosure to reduce radiated emissions 3 Grounding of equipment and cable shields must be solid with low impedance connections 4 Motor and control cables entering the shielded enclosure must have EMC tested shielded cable clamps or grounded metal conduit 5 All motor cables must use shielded cable or be in grounded metal conduit 6 All control and signal wiring must use shielded cable or be in grounded metal conduit 7 The Common terminals TB3 3 amp 7 must have a solid connection to PE protective earth B 1 Appendix B CE Compliance B CE Compliance General Instructions for an EMC Input power output power and control wiring Compliant Installation outside the enclosure must use separate shielded cables or separate conduit Refer to Figure B 1 Shielded Enclosure Cable Clamps Typical NEMA or IEC metal enclosures are adequate Use suitable EMC tested cable clamps only The ground connection of the shielded The connection area must be 360 degrees enclosure must be solidly connected to the PE around the shielded cable terminal of t
39. epairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION Only personnel familiar with the controller 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 SSC is a trademark of Rockwell Automation Unpacking Remove all packing material wedges or braces from within and around the controller Remove all packing material from the heat sink Inspection After unpacking check the item s nameplate catalog number against the purchase order An explanation of the catalog numbering system for the Bulletin 160 controller is included as an aid for nameplate interpretation Refer to the following page for complete nomenclature Important Before you install and start up the controller inspect the mechanical integrity of the system e g look for loose parts wires connections etc ATTENTION The surface temperatures of the controller may become hot which may cause injury ATTENTION An incorrectly applied or installed controller can result in component damage or reduction in product life Wiring or application errors such as undersizing the motor su
40. equency Q When using shielded cable at lightly loaded conditions the 0 75 Kw 1 Hp and below cable length recommendations are 61m 200 ft No recommended for 230V applications 2 5 Chapter 2 Installation and Hing 2 Installation and Wiring Control Wiring Requirements run all signal wiring in either a shielded cable or a separate metal conduit only connect shield wire at control terminal block common terminals TB3 3 and TB3 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 earth ground use Belden 8760 or equivalent I8AWG 0 750mm2 twisted pair shielded or 3 conductor Table 2 H Control Terminal Block Specifications Max Min Max Min ks Wire Size Torque mm AWG Nm Ib in TB3 0 8 0 4 8 4 ATTENTION The controller is supplied with an internal 12V supply Dry contacts or open collectors are required for discrete control inputs If an external voltage is applied component damage could occur ATTENTION The drive start stop 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 line power to the drive W
41. er Ratings continued Control Features All Controller Ratings PWM Algorithm Sine Weighted PWM with Harmonic Compensation Switching Device 3 Phase Output IGBT Intelligent Power Module V Hz Ratio Programmable Carrier Frequency Adjustable from 2 kHz to 8 kHz in 100 Hz Increments Factory default is 4 kHz DC Boost Adjustable Select from a family of Boost Curves Current Limiting Trip Free Operation Co ordinated for Controller and Motor P rotection Programmable from 1 to 180 of Controller Output Current Motor P rotection 12t Overload Protection 150 for 60 seconds 200 for 30 seconds Overload Pattern 0 Flat response over speed range no speed compensation Overload Pattern 1 Speed compensation below 25 of Base Speed Overload Pattern 2 Speed compensation below 100 of Base Speed Acceleration Deceleration Time s 0 1 to 600 Seconds S Curve Accel Decel Time s 0 to 100 of Accel Decel time not to exceed 60 seconds Stopping Modes 3 modes programmable Ramp to stop 0 1 to 600 seconds Coast to stop Stops all PWM Output DC Injection Braking Protective Features All Controller Ratings Overcurrent Applies DC Voltage to the Motor for 0 to 25 seconds 200 hardware limit 300 instantaneous fault Excessive Temperature Embedded temperature sensor trips if heatsink temperature exceeds 95 C Over Under Voltage DC Bus voltage is monitored for
42. f the cable The Common terminals TB3 3 amp 7 must be solidly connected and as short as possible to the PE terminal of the controller Figure B 4 Control Connections Ground Tab PE Control Cabinet Control Wiring TB3 Signal Common Shielded Enclosure Shielded Control Cable E EMC Tested Shielded Cable Clamp or Metal Conduit When the control circuitry is located outside of the 160 enclosure Low Voltage Directive 73 23 EEC Compliance This product complies with Low Voltage Directive 73 23 EEC when conforming with the following installation requirements Review the General Precautions section on page 1 1 inside front cover and other ATTENTION statements throughout this manual prior to installation of the controller B 4 The controller 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 controller should be installed in an appropriate or suitable enclosure Important The conformity of this controller and filter to any standard does not guarantee that the entire installation
43. hat you ATTENTION This controller contains AN disconnect line power and wait A ESD Electrostatic Discharge sensitive one minute before installing or parts and assemblies Static control removing the program keypad precautions are required when installing module Failure to do so may testing servicing or repairing this result in personal injury or death assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B Publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook Figure 3 2 Removing Program Keypad Module Insert a small screw driver into Slot pry back and pivot module out Avoid bending or twisting the contact pins located underneath the center portion of the module Program Keypad Module Dipswitch that changes P35 Base Frequency from 50 to 60 Hertz when program keypad module is not installed Important When a program keypad module is installed P35 Base Frequency overrides this switch setting Once P35 Base Frequency is changed from its factory default setting the switch remains overridden until all parameters are reset to their z factory default settings using XQ P56 Reset Defaults Installing Program Keypad Module Insert the module bottom end first and then press on the symbol atthe top of the
44. he controller Good conductivity must be assured grounding must provide a The cable clamps also provide strain relief for low impedance path to high frequency signals the cable All wiring except input power leads must use When using conduit the contact point of shielded cable metal entry connections must be free of paint Input power output power and control wiring or non conductive surfaces and solidly inside the enclosure must be physically connected with good conductivity to the separated enclosure Figure B 1 Recommended Grounding Configuration PE Enclosure Ground Connection AC Input Line Ground Tab PE Line Power TB1 Control Cabinet Control Wiring TB3 Motor Wiring TB2 Ty Shielded Motor Cable to Motor Shielded Enclosure E EMC Tested Shielded Cable Clamp or Metal Conduit When the control circuitry is located outside of the 160 enclosure Appendix B CE Compliance Motor Cable Figure B 2 Motor Connections The cable between the controller and motor must be a 4 wire shielded cable three phases and ground Refer to Figure B 2 and Figure B 3 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 c
45. hen 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 6 Control Wiring Analog Signal Follower Model You can control the output frequency of the controller via the Control Terminal Block TB3 using a remote potentiometer a 10 to 10V DC analog input a 4 20mA analog input or use P58 Internal Frequency Important Only one frequency source may be connected at a time If the frequency reference potentiometer and the 4 20mA reference are connected at the same time an undetermined frequency reference will result Control Wiring Preset Speed Model You can control the output frequency of the controller via the Control Terminal Block TB3 using dry contacts or open collector inputs to SW1 SW2 and SW3 or use P58 Internal Frequency A program keypad module is required to change the factory default settings Refer to Chapter 5 parameters 61 68 for the eight preset frequency factory default settings and switch configurations Wiring Diagrams Important Refer to the diagrams on the following pages for control wiring information Chapter 2 lt Installation and Wirng 2 Installation and Wiring Control Wiring Figure 2 3 TB3 Control Wiring for Analog Signal Follower Model Shielded Wire
46. his parameter applies to the Preset Speed model only 0000 to 0111 Binary Number SW SW2 SW3 Not Used 16 Analog Input Displays the analog input as a percent of full scale Used in setting 150to 150 0 0 1 P60 Zero Offset P75 Analog Input Minimum and P76 Analog Input Maximum Important On initial set up of the controller apply a OV or 4mA analog command to the controller Once applied if the value of this parameter displays something other than zero program that value into P60 Zero Offset Important The value of the Zero Offset will be subtracted from the value of this parameter This parameter applies only to the Preset Speed model This parameter applies only to the Analog Signal Follower model Chapter 5 Parameters and Programming 5 Parameters and Programming Program Group Parameters This group contains parameters whose values can be programmed Refer to the Programming Example outlined earlier in this chapter Unless otherwise stated parameters that are programmed while the controller is running take immediate effect Program Group P Parameter Description Min Max Units Factory Range Default 30 Accel Time 1 Time forthe controller to ramp from 0 0 Hz to P33 Maximum Frequency The rate is linear for any increase in command frequency unless P53 S Curve is set to a value other than 0 Setting s this to 0 0 sec gives HIM s TE 0 0t0600 0 1Seconds
47. ht for Removal with DeviceNet Module 2 E T K E il LALLY LLL SD LLL L LILI LLL 167 82 6 61 Overall Height with DeviceNet Connector Figure A 9 24V DC Interface Module This device does not effect the overall height of the drive A 10 Appendix B CE Compliance B CE Compliance CE Compliance This controller is a component intended for implementation in machines or systems for the industrial environment It has been tested to meet the Council Directive 89 336 Electromagnetic Compatibility EMC and all applicable standards Important The conformity of the controller and filter to any standard does not guarantee that the entire installation 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 1 An input line filter module see Accessories in Appendix A must be installed to reduce conducted emissions LF type Filters These units have been test
48. ine Capacitor Ratings Brake Module Reactors Filters Module Module Open Style Input Voltage HP kW Cat No Cat No Cat No Cat No Cat No Cat No Rating 12 037 1608MAl 160 MMAl 160S LFA1 160S RFA 6 A 160 CMAl pos 3 4 0 55 160 BMA1 160 MMA1 160S LFAl 160S RFA 6 A 160 CMA1 1 Phase 1 0 75 160 BMA1 160 MMA1 160S LFAl 160S RFA 10 A 160 CMA1 2 15 160 BMA2 160 MMA1 160S LFAl 160S RFA 16 A 1 2 0 37 160 BMA1 160 MMA1 1321 3R4 B 160 LFA1 160 RFB 3 A 160 CMA1 E 3 4 0 55 160 BMA1 160 MMA1 13213R4A 160 LFA1 160 RFB 3 A 160 CMA1 3Phase 1 0 75 160 BMAl 160 MMA1 13213R4A 160 LFA1 160 RFB 9 A 160 CMA1 2 15 160 BMA2 160 MMA1 13213R8A 160 LFA1 160 RFB 9 A 160 CMA1 3 2 2 160 BMA2 160 MMAl 1321 3R12 A 160 LFA2 160 CMA1 1 2 0 37 160 BMB1 160 MMB1 1321 3R2 B 160 LFB1 160 RFB 3 A 160 CMB1 px 3 4 0 55 160 BMB1 160 MMB1 13213R2A 160 LFB1 160 RFB 3 A 160 CMB1 3 Phase 1 0 75 160 BMB1 160 MMB1 13213R2A 160 LFB1 160 RFB 3 A 160 CMB1 2 15 160 BMB2 160 MMBl 13213R4B 160 LFB1 160 RFB 9 A 160 CMB1 3 2 160 BMB2 160 MMBl 13213R8 B 160 LFB1 160 RFB 9 A 160 CMB1 Replacement Parts and Accessories Fan Program DeviceNet Drive Model 24V DC Interface Replacement Keypad Communication Cat No Kit Module Module Cat No Cat No Cat No Analog E 18FRKI T60 DNI Preset 160 DM PS1 Catalog numbers lis
49. ing diagram When using P46 Input Mode setting 4 the Accel and Decel times are selected by providing an input to TB3 8 See page 2 9 for additional information 5 11 Chapter 5 Parameters and Programming 5 Parameters and Programming P 71 Program Group Parameter Description IR Compensation The programmed value adds a voltage to the output based on the torque current An additional 31 volts 150 are 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 Overload fault F 7 or has trouble accelerating to commanded speed this value should be reduced A setting of 0 disables this function Min Max Range 0 to 150 Units 1 Factory Default 50 72 Slip Compensation 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 significantly under heawy loads then this value should be increased A setting of 0 0 Hz disables the function 0 0 to 5 0 0 1 Hz 2 0 Hz 73 Reverse Disable when this parameter is setto a 1 the reverse is disabled The reverse command may come from the analog input the TB3 5 input 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
50. ional status 12345678911 Terminal Block Three TB3 For Control OOo GH RH RH RH GH G Wiring Tian T2 Tb ab ye V wp pc aD 7 Terminal Block Two UU UU ali J TB2 For Motor Wiring Fan lt DIN Latch Refer to Figure 2 2 The FAULT red indicator illuminates when a controller fault condition exists Refer to Chapter 6 for details on how to clear a fault and general troubleshooting procedures The READY green indicator illuminates when the DC bus is charged and the controller is ready to run T Bulletin 160 controllers are fully functional when installed with a Ready Fault indicating panel All control functions can be performed from the control terminal block TB3 Factory default parameter Settings cannot be changed with the Ready Fault indicating panel A Program Keypad Module can be ordered separately Catalog 160 P1 or as a factory installed option by adding P1 to the end of the catalog number Refer to Chapter 3 Program Keypad Module for a detailed explanation of functionality 33 Chapter 2 Installation and Wiring Figure 2 2 Power Wiring For Analog Signal Follower and Preset Speed Models Required Branch Circuit Disconnect Pe Input Line Protective Device See Table 2 C and Table 2 D Dynamic Brake a Module Option 2 Terminal Block One B ER TB1 For Line Power and Brake Resistor Terminal Block SSI Two
51. isplay Important To enable the start and reverse keys from the program keypad module set P46 Input Mode to a 2 and cycle power or set P56 Reset Function to 2 Refer to the programming example in Chapter 5 The READY green indicator will illuminate Use remote inputs to TB3 control terminal block to operate the controller Do you have a Analog Signal Follower controller or a Preset Speed controller Preset Speed controller 1 Check for proper motor rotation by setting the frequency Check for proper motor rotation by selecting P61 source to its minimum setting Preset Frequency 0 This requires removing all inputs to SW1 SW2 and SW3 on TB3 see Figure 2 5 in If you are using a program keypad module verify that the Chapter 2 The factory default setting for P61 Preset CLOCKWISE LED is illuminated If you are using a blank Frequency 0 is 3 Hz display panel verify thatthe REVERSE inputto TB3 is in the OPEN position If you are using a program keypad module verify that the Y CLOCKWISE LED is illuminated If you are using a blank Issue a START command from either the program keypad display panel verify that the REVERSE input to TB3 is in module or TB3 control terminal block the OPEN position Y Y Slowly increase the speed until the motor begins to turn Issue a START command from either the program Check the direction of the motor keypad module or TB3 control terminal block Check the dire
52. le power 33 Max Retries Controller failed to reset fault within the number Repair system fault Fault of retries set in P50 Restart Tries 38 Phase U Fault Phase to ground fault detected between Check the wiring between the controller and controller and motor in phase U motor Check motor for grounded phase 39 Phase V Fault Phase to ground fault detected between Check the wiring between the controller and controller and motor in phase V motor Check motor for grounded phase 40 PhaseW Phase to ground fault detected between Check the wiring between the controller and Fault controller and motor in phase W motor Check motor for grounded phase 41 UV Short Excessive current has been detected between Check the motor and external wiring to the Fault these two controller output terminals controller output terminals for a shorted condition 42 UW Short Excessive current has been detected between Check the motor and external wiring to the Fault these two controller output terminals controller output terminals for a shorted condition 43 VW Short Excessive current has been detected between Check the motor and external wiring to the Fault these two controller output terminals controller output terminals for a shorted condition 48 Reprogram Occurs when controller parameters are resetto Clear fault Fault defaults 49 Zero Occurs when load requires excessive current at Reduce motor load at zero hertz Reduce motor Overload
53. ler Contmller FLA rating Rating 43 Current Limit maximum output current allowed before current limiting s M 1 150 occurs Value set in percent of controller rated output current rating 44 DC Hold Time time that P45 DC Hold Voltage will be applied to the motor when P34 Stop Mode Select is set to either DC Injection Braking or one HEO oS econds Ramp to Stop mode 45 DC Hold Voltage DC Voltage level applied to the motor during braking 0to115 1 Volt 0 Volts when P34 Stop Mode Select is set to either DC Injection Braking or Ramp to Stop mode Important 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 Voltage DC Hold Time Volts and Speed Volts and Speed c DC Hold Time 5p E DC Hold Voltage DC Hold Voltage amp i E Tim Stop Command Time Stop Command e 5 6 Chapter 5 Parameters and Programming 5 Parameters and Programming Program Group P Parameter Description Min Max Units Factory Range Default 46 Input Mode configures the TB3 contro inputs for various 3 wire or 2 wire run fwd run rev control schemes Also enables disables the program keypad module input control Important This parameter cannot be programmed while the controller is running Also power must be cycled or P56 Reset Func 0 to 6 Numeric 0 tion must be set to
54. ll controller parameter settings to factory defaults 2 Update input mode restores the controller 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 controller is running Important For setting 1 only an F48 Reprogram Fault will occur and must be cleared by cycling the STOP input to the controller Important 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 Min Max Range 0to2 Units Numeric Value Factory Default 0 57 Program Lock When setto a 1 this parameter protects all controller parameters from being changed by unauthorized personnel Otol Numeric Value 58 Internal Frequency When P59 Frequency Select is set to a 1 this parameter provides the controller frequency command This parameter will change the frequency command in Real time Important F ollow 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 0 to 240 0 1 Hz 60 0 Hz 59 Frequency Select selects the source of the frequency comm
55. local TB3 Control Refer to Figure 2 11 Figure 2 11 Input Mode TB3 8 TB3 8 Setting Open Closed 42 Accel 2 Accel 1 Decel 2 Decel 1 50 Controller Controller Disabled Enabled e Local TB3 2 Remote Control Control The Run input must be a maintained input After a stop command either a Run Forward or Run Reverse input must be toggled to start the controller When this input is in an open state P69 Accel Time 2 and P70 Decel Time 2 are active When this input in in an open state all power is removed from the motor and it will coast to rest 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 Important In modes 4 through 6 Terminal TB3 8 is also used to clear faults See Figure 2 12 for details Important The system programmer is responsible for returning terminal TB3 8 to its original state if necessary Figure 2 12 TB3 8 CLOSED TB3 8 OPEN i Fault Fault Fault Fault occurs clears occurs clears 2 9 Chapter 2 Installation and Hing 2 Installation and Wiring This Page Intentionally Blank 2 10 Program Keypad Module Chapter 2 Features The program keypad module is located on the front panel of the controller It features the following five keys on the module for display or programming controller paramete
56. log Numbers for Bulletin 160 Accessories esee Controller Dimensions sosire suae t Wrap EEEE EA REPRE eee ee NUS AY LA Accessory Dimensi ns sesi eed eee e E T RER T RET teen doer taeesdade Table of Contents _ of Contents Appendix B CE Compliance us etiem Penes db at eae a og Bee dee RP Essential Requirements for a Conforming EMC Installation General Instructions for an EMC Compliant Installation 0 Low Voltage Directive 73 23 EEC Compliance 0 0 0 0 0 eee eee eee Index Information and Precautions Se MN General Information Receiving It is your responsibility to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against the purchase order If any items are obviously damaged do not accept delivery until the freight agent notes the damage on the freight bill 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 in order to verify damage General Precautions In addition to the precautions listed throughout this manual you must read and understand the following statements which are general to the system ATTENTION This controller contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or r
57. ly Open o 1o zN C Momentary Contact Internal 12V supply Donotexceed 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 earth ground This diagram shows three wire control Refer to the following page for diagrams of other control wiring methods 2 7 Chapter 2 Installation and Wiring 2 Installation and Wiring Figure 2 5 TB3 Three Wire control Setting 0 Control Wiring continued Use P46 Input Mode to select the control method for start stop and direction control Important Settings 4 through 6 provide additional flexibility of TB3 control input terminal 8 Setting 0 Three Wire Control This is the factory default setting Refer to Figure 2 5 Setting 1 Two Wire Run Forward Run Reverse Control Refer to Figure 2 6 Setting 2 Program Keypad Module control See Page 3 1 Setting 3 Momentary Run Forward Run Reverse control Refer to Figure 2 7 Setting 4 Two Wire Accel Decel control Refer to Figure 2 8 Setting 5 Two Wire Enable control Refer to Figure 2 9 Setting 6 Two Wire Local Remote control Refer to Figure 2 10 Explanation of Symbols N 0 Momentary Contact olo N C Momentary Contact o zN O Maintained
58. module until the module is fully seated The module is fully seated when its face is flush with the edges of its surrounding case Start Up Chapter 4 Chapter 5 provides a comprehensive Commonly Changed Parameters description of all controller parameters Review the factory default settings If Parameter Set to your controller is equipped with a P30 Accel Time 1 desired accel time Program Keypad Module these P31 Decel Time 1 desired decel time parameters can be changed to meet P33 Maximum Frequency maximum frequency required your specific application requirements is Sid L P ih a Rd Base Frequen uency RAE prona P36 Base Voltage motors rated E 5 any d parameter is shown at the beginning of P42 Motor Overload Current motor nameplate Full Load Amps FLA Chapter 5 P46 Input Mode desired control method P47 Output Configure desired output functionality Preset Speed Model Only P61 P68 Preset Frequency 0 7 desired preset frequencies ATTENTION Power must be applied to the controller to perform the following start up procedure Some ofthe A 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 and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove Power by opening
59. mum analog input equals maximum frequency no action is needed If itis desired to adjust the analog input to equal Maximum Frequency use P16 Analog Input to adjust the analog input to the desired level 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 0 0 to 150 0 0 1 100 0 78 Compensation some drive motor combinations have inherent instabilities which are exhibited as non sinusoidal motor currents A setting of 1 will enable this parameter and attempt to correct this condition A setting of 0 disables this function Important Available in FRN 6 XX and later Otol Numeric value This parameter applies only to the Analog Signal F ollower model Troubleshooting and Fault Information Fault Information Figure 6 1 Fault Display P07 Last Fault Fault Code Number oj 014 See Table 6 A below for fault descriptions Controllers equipped with a program keypad module will flash the display when a fault is present If a fault occurs parameter 07 Last Fault displays You can cross reference the number that appears on the display e g 04 with the fault numbers listed in Table 6 A Table 6 A Bulletin 160 Fault Descriptions Chapter 6 Fault LED Without Program Keypad Module Controllers without a prog
60. ntain descriptions of both display and program parameters Any parameter description that is shaded pertains only Parameter applies only to the Analog Signal Follower model to the Preset Speed or Analog Signal Follower model Refer to the legend to the right Programming Example The following is an example of the programming steps required to change a program group parameter setting In this example parameter 31 Decel Time is changed from its factory default setting of 10 0 seconds to 2 2 seconds Refer to Chapter 3 Figure 3 1 on page 3 1 for an explanation of Program Keypad Module display and programming keys Important To reset ALL values to original factory default settings refer to P56 Reset Defaults Action SC T gt Cr m m lt m UT e Description 1 To program the value of a program group parameter enter the program group by pressing the ESCape key The program mode indicator will illuminate 2 Press up down keys until the desired parameter displays In this case press the up key until parameter 31 Decel Time displays 3 Press the SELectkey The program mode indicator flashes indicating that you can use the up down keys to change the parameter value 4 Change the decel time value from the factory default of 10 seconds to 2 2 seconds by pressing the down key until 2 2
61. o limit voltage reflections at the motor ground lead and shield if using shielded cable reflected wave phenomona See Table 2 F for connected to the controller ground terminal and recommendations the motor frame ground terminal Important The use of an external device to limit Table 2 E provides the recommended wire type reflected wave issues may effect the accuracy of for both wet and dry installations as defined by the Bulletin 160 current sensing Table 2 G NEC 1996 70 31 These recommendations are provides recommended cable length due to based upon a variety of factors such as insulation thickness susceptibility to moisture and susceptibility to nicks and cuts during installation Table 2 F Cable Length Recommendations Reflected Wave Capacitive Current considerations Motor Motor Cable Only RWR at Drive Reactor at Motor 380 460V l l Ratings Insulation Shielded Unshielded Shielded Unshielded Shielded Unshielded Rating ft m ft m ft m ft m ft m ft m 1000 Vp p 40 12 40 12 360 110 300 92 210 64 210 64 He 1200Vp p 60 18 60 18 360 110 600 183 260 79 260 79 1600 Vp p 500 152 500 152 360 110 600 183 500 152 500 1529 1000 Vp p 40 12 40 12 300 92 300 92 250 76 250 76 1 5kW 1200Vp p 60 18 60 18 300 92 540 165 340 104 340 104 E HE 1600 Vp p 500 152 500
62. ontroller is running Chapter 5 Parameters and Programming 5 Parameters and Programming Program Group P Parameter Description Min Max Units Factory Range Default 53 S Curve Enables a fixed shape S Curve See formula below Formula S Curve Time Accel or Decel Time x S Curve setting in percent S C urve 1 2 S Curve 1 2 S Curve Example setin Time S Time Accel Time 10 seconds 0 0 Pe S Curve Setting 3 S Curve Time 10 x 3 1 10 4 3 Seconds 2 20 i Numeric 0 i 3 30 Value Enabled 4 40 Important Maximum 5 50 i S Curve time is 60 seconds 6 6076 7 21096 Disabled 8 8096 9 90 10 100 Accel Time Decel Time See values in the Min Max Range column 54 Clear Fault setting this parameter to a 1 performs a fault reset When Otol py 0 the fault reset function is complete the value is automatically set back to 0 Important This parameter cannot be programmed while the controller is running 55 Memory Probe Address used by Rockwell Automation field Numeric Value Numeric Numen service personnel 5 9 Chapter 5 Parameters and Programming 5 Parameters and Programming P 56 Program Group Parameter Description Reset Functions when using this parameter the controller s parameters and their associated defaults are reset according to the descriptions below 0 Idle State 1 Reset defaults restores a
63. ontroller s output terminals as possible The shield must Ground Tab PE C FAULT C READY 12345678 9 1011 6690999990 Motor Wiring TB2 TEREORA LU U W T3 V T2 U T1 Shielded Enclosure E EMC Tested Shielded Cable Clamp or Metal Conduit Figure B 3 Shielded Motor and Control Cable Example il be solidly connected to the PE terminal of the controller 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 4 Wire Shielded Motor Cable V Ground to Motor Housing O amm Stranded Copper Wire Plastic Insulation Inner Plastic Sheath Compact Screen of Galvanized Tinned Copper or Steel Outer Plastic Jacket B 3 Appendix B CE Compliance B CE Compliance Control Cable Control wiring must use shielded cable or grounded metal conduit Refer to Figure B 3 and Figure B 4 The shield must be connected to signal common at both ends o
64. or e Verify that motor is connected properly e Verify that no mechanical problems exist Check parameter settings e Verify that P30 Accel Time 1 or P69 Accel Time 2 is set properly e Verify that P43 Current Limit is set properly e Verify that P38 Boost Volts is set properly Can not operate in RUN FWD RUN REV mode E WJ KA Ka Verify that P46 Input Mode is set to 1 Verify that P73 Reverse Disable or P74 Analog Select are not set to 1 Verify that power has been cycled for above change to take effect Verify that both RUN FORWARD and RUN REVERSE switches are NOT closed simultaneously 6 3 Chapter 6 Troubleshooting and Fault Information 6 Troubleshooting and Fault Information Block Diagram of Bulletin 160 Analog Signal Follower coz 0ciouopmn D C do m hD zo n Brake Module Capacitor Module w DC Z U joe TU GTA us VP mo y ooN A lt L Motor oco gt gt Y GND PE m UGND PE Control Bus Cieni O jd ga cain Circuitry H P 64V LT rga 2 Potentiometer 1B3 3 Common or Fault Feedback a ER Program Keypad CPU Module Reverse 97 e TB3 5 Stat Lo 6 4QTB3 6 Opto
65. p to 4 5mm 0 177 inches in diameter or mount on 35mm DIN Rail CE Compliance Refer to Appendix B for detailed information Mounting Requirements Description Metric English Min Panel Thickness 14 GA 1 9mm 0 0747 in Mounting Base Screws m4 x 0 7 18 32 Mounting Torque 1 13 to 1 56 Nm 10 14 Ib in See Appendix A for details on controller dimensions and weights There must be a minimum of 12 5mm 0 5 inches clearance around all sides of the controller Use either DIN rail or mounting holes Use the drilling template at the back of the manual for mounting the controller Leave debris cover attached during controller installation to protect from falling debris To ensure proper controller operation remove cover before applying power Controller Features Figure 2 1 below details the features of both the Analog Signal Follower and Preset Speed models Important The features are the same for single and three phase units Figure 2 1 Controller Features C f Ground Tab O O Protective Earth Je U Leh Terminal Block One Liao L2 ap B3 7C TB1 For Line ROSTO OE Power QB ALLENBRADLEY Ready Fault j p Indicating Panel Standard for Bulletin 160 controllers _ FAULT lt LEDs Indicate C READY operat
66. pplying an incorrect or an inadequate AC supply or excessive ambient temperatures may result in system malfunction ATTENTION The controller contains high voltage capacitors which take time to discharge after removal of mains supply Before working on controller ensure isolation of mains supply from line inputs L1 L2 L3 U V W Wait one minute for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death AN AN 1 1 Chapter 1 Information and Precautions Figure 1 1 Catalog Number Code Explanation First Position Bulletin Number An S in the Bulletin Number denotes a single phase input voltage 160 A A04 N SF1 P1 Second Third Fourth Position Position Position Voltage Rating Current Enclosure Rating Type A 200 240V 1 A01 Letter Type 200 240V 32 A02 N Open IP20 A03 P Chassis Mount B 380 460V 32 A04 extemal A06 heatsink A08 A12 it Fifth Position Control SF1 Analog Signal Follower PS1 zPreset Speed Sixth Position Programmer Optional Program Keypad Module This manual applies only to the open style IP20 device Refer to separate instruction sheets for Chassis Mount and NEMA 4 IP66 devices Figure 1 2 Nameplate Information Conventions Used In This Manual CAT160 AAO4NSF1P1 SERB FRN 1 nni 6 xx yee 1 v 200 240 3 O V 200 230 32 i
67. ram keypad module come equipped with a fault LED When the fault LED illuminates a fault condition exists Tips To Clear a Fault Important If a fault occurs it is important to address and correct the fault as well as the condition that caused the fault To clear a fault perform one of the following Press the program keypad s stop button Cycle power to the controller Cycle the input signal at TB3 8 to the controller Set P54 Clear Fault parameter to a 1 Fault Fault Fault Description Corrective Action Number Indication 03 PowerLoss DC Bus voltage remains below 85 nominal on Monitor incoming AC line for low voltage or line Fault power up for longer than 5 seconds power interruption 04 Under Voltage DC Bus voltage fell below the minimum For Monitor incoming AC line for low voltage or line Fault controllers rated at input voltage 200 240V AC power interruption undervoltage trip occurs at 210V DC bus voltage equivalent to 150V AC incoming line voltage For controllers rated at input voltage 380 460V AC undervoltage trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line voltage 05 Over Voltage Fault DC Bus maximum voltage exceeded For controllers rated at input voltage 200 240V AC overvoltage trip occurs at 410V DC bus voltage equivalent to 290V AC incoming line voltage For controllers rated at input voltage 380 460V AC overvoltage trip
68. rea e Kuwait e Lebanon e Macau e Malaysia e Malta e Mexico e Morocco e The Netherlands e New Zealand e Nigeria e Norway e Oman e Pakistan e Panama e Peru ePhilippines e Poland e Portugal e Puerto Rico e Qatar e R omania e Russia e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic of e Spain e Sweden e Switzerland e Taiwan e Thailand e Trinidad e Tunisia e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela Rockwell Automation Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 0160 5 9 May 1998 40055 180 01 01 Supercedes Publications 0160 5 9 December 1996 0160 5 9DU2 May 1997 0160 5 9DU4 J anuary 1998 Copyright 1996 Allen Bradley Company Inc a Rockwell International company
69. rs three keys for control inputs to the controller directional LEDs a6 digit seven segment LED display Display Mode The controller always powers up in the display mode While in this mode you may view all read only controller parameters but not modify them Program Mode You enter the program mode by pressing the ESC key While in program mode you can edit any programmable controller parameters Refer to Figure 3 1 Program Keypad Module Features These two digits display the active parameter number for both display and program parameters which are designated as P throughout this manual The SELect key is only used while in program mode It enables the editing of a parameter value When you press this key the program mode indicator flashes The ESCape key allows you to toggle between the display mode and program mode When in program mode this key also disables the editing of a parameter value The counter clockwise LED illuminates constantly when the motor rotates in reverse direction Pressing the reverse key causes the motor to ramp down to 0 Hz and then ramp up to its set speed in the opposite direction 9 When the program mode indicator flashes you can edit the parameter value When in display mode the program indicator does not display A EHE esc e JA We Sa
70. rtant Identifies information that is especially important for successful application and understanding of the product ES This Page Intentionally Left Blank N 1 D EE This Page Intentionally Left Blank H Mas This Page Intentionally Left Blank D EE This Page Intentionally Left Blank CE ud Attach template to mounting surface and drill four 4 4 5mm 0 177 inches diameter holes Dimensions are in millimeters inches Summary of Changes of Changes Publication 160 5 9 Summary of Changes The Firmware Version of the drive was changed from FRN5 01 to FRN6 0 The parameter P78 Compensation was added to help eliminate non sinusoidal motor currents that are generated by some motor drive combinations See page 5 12 This information was supplied previously in the form of a Document Update Publication 160 5 9DUA which has been eliminated Firmware version FRN 6 0 includes enhancements made to the current sensing to help filter out capacitive current These enhancements improve the overall accuracy of the drive s displayed output current Due to this improvement the installation of a Reactor at Drive is no longer recommended because it negatively effects the drive s current sensing accuracy If an external device is required to be mounted at the drive for Reflected Wave purposes an RWR protective device is recommended Cable length recommendations for an RWR
71. s 136 5 4 136 5 4 136 54 136 54 136 5 4 Weight Kg bs 0 8 1 76 0 8 1 76 0 9 1 98 0 9 1 98 1 1 2 46 _ Controllers Rated 380 460V 3 Phase Overall 160 160 160 160 160 Dimensions BAO1 BAo2 BA03 BAO4 BAO6 Hmm inches 152 6 00 152 6 00 152 6 00 152 6 00 152 6 00 W mm inches 72 2 83 72 2 83 72 2 83 72 2 83 130 5 12 D mm inches 136 5 4 136 5 4 136 54 136 54 136 5 4 Weight Kg Ibs 0 8 1 76 0 8 1 76 0 8 1 98 0 9 1 98 1 1 2 46 e i GGGGHEGEGGES VEEEEEEEREEEEEEEE S L External capacitor modules are provided with this model and mount separately Use the drilling template at the back of the manual for mounting the controller Figure A 2 Mounting Requirements DIN Mounting A a EE SNS SNS AR SNS SRS SS 130mm E 5 118 in ESESIES eS ss m Jesu Jj Debris Cover T Min Panel Thickness 14 GA Dimensions Metric English 19mm 0 0747 in Mounting Base Screws m4 x 0 7 8 32 Mounting Torque 1 13 to 1 56Nm 10 14 b in See Figure A 1 for details on controller dimensions and weights There must be a minimum of 12 5mm 0 5 inches clearance around all sides of the controller Use either DIN rail or mounting holes U
72. se the drilling template at the back of the manual for mounting the controller Leave debris cover attached during controller installation to protect from falling debris To ensure proper controller operation remove cover before applying power A 5 Appendix A Specifications and Accessories Approximate Dimensions Dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes Figure A 3 Dynamic Brake Module Both Sizes 6 8 EL 72 230 2 8 4 places on m 8 14 al 75 R j um 551 295 F 8 d A B ADANGER DY db ae ge a d hR NW SITAM ec p VEA te L NEN Oo 93922 eJ 1 rol a Cat No A B 160 BMA1 amp 160 BMB1 245 225 9 64 8 86 160 BMA2 amp 160 BMB2 334 314 13 15 12 36 Appendix A Specifications and Accessories Approximate Dimensions Continued Dimensions are shown in millimeters inches Dimensions are not to be used for manufacturing purposes Figure A 4 MOV Module 22 7 894 jetz e puc 0 54 COP 021 71 2 8
73. selected 67 Preset Frequency 6 The programmed value sets the frequency that 0 to 240 0 1 Hz 55 Hz the controller outputs when selected 68 Preset Frequency 7 The programmed value sets the frequency that O to 240 0 1 Hz 60 Hz the controller outputs when selected 69 Accel Time 2 Time forthe controller to ramp from 0 0 Hz to P33 Maximum Frequency The rate is linear for any increase in command frequency 0 0 to 600 0 1 Sec 20 0 Sec 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 70 Decel Time 2 Time forthe controller to ramp from P33 Maximum Frequency to 0 0 Hz The rate is linear for any decrease in command frequency 0 1 to 600 0 1 Sec 20 0 Sec unless P53 S Curve is set to a value other than 0 This parameter applies only to the Preset Speed model Preset Accel Decel Chart For Preset Speed Model Only TB3 4 TB3 2 TB3 1 SW3 SW2 SW1 Preset Accel Decel 0 0 0 Preset 0 0 i pus P30 Accel Time 1 P31 Decel Time 1 0 1 0 Preset2 0 il il Preset 3 il 0 0 Preset 4 l Preset P69 Accel Time 2 P70 Decel Time 2 il 1 0 Preset6 il il il Preset 7 Refer to Figure 2 4 for the Preset Speed model control wir
74. ted are for 3 impedance open style units NEMA 1 and 5 impedance reactor types are also available refer to Publication 1321 2 0 for detailed information Q The 160 LF type filters are designed to meet Class A conducted emissions These units have been tested with a maximum motor cable length of 75m 250 ft for 230V units and 40m 133 ft for 460V units The 160 RF type filters are designed to meet Class A and B conducted emissions These units have been tested with a maximum motor cable length of 25m 80 ft for both 230V and 460V units Included with controller The MTBF for the fan is 40 000 hours at 50 C Allows 24V DC sinking inputs e A 4 Figure A 1 Controller Dimensions Controllers Rated 200 240V Single Phase Appendix A Specifications and Accessories Overall 1605 160S 1605 1808 Dimensions AA02 AA03 AA04 AA08 Hmm inches 152 6 00 152 6 00 152 6 00 152 6 00 W mm inches 72 2 83 72 2 83 72 2 83 72 2 83 D mm inches 136 5 4 136 5 4 136 5 4 136 5 4 Weight Kg lbs 0 8 1 76 0 8 1 76 0 9 1 98 0 9 1 98 _ Controllers Rated 200 240V 3 Phase Overall 160 160 160 160 160 Dimensions AA02 AA03 AA04 AA08 AA12 Hmm inches 152 6 00 152 6 00 152 6 00 152 6 00 152 6 00 W mm inches 72 2 83 72 2 83 72 2 83 72 2 83 130 5 12 D mm inche
75. the controller has an internal 12V power supply that provides 10mA typical current flow Also accepts open collector solid state inputs sinking with maximum leakage current of 50 uA Optional 24V DC interface allows use of 24V DC sinking inputs See page A 4 for ordering information Start Stop Forward Reverse Configurable inputs for 2 or 3 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 Controller Enable Disable Local Remote Approvals and Standards Compliance All Controller Ratings Approvals GERA E WW UL508C UL CSA 222 Kr Cu Boome IEC 146 1 1 Designed to meet these standards FCC Class A and B VDE 08719 and 08759 Control Inputs Analog Signal Follower only All Controller Ratings External Speed Potentiometer 1K to 10K Ohms 2 Watts Minimum Analog Input 4 to 20mA Input Impedance 250 Ohms Analog Input 10 to 10V DC Control Output All Controller Ratings Programmable Output Form C Relay contact With external components A 2 Input Impedance 100K Ohms Resistive rating 0 4A 125V AC 0 2A 230V AC 2A 30V DC Inductive rating 0 2A 125V AC 0 1A 230V AC 1A 30V DC Appendix A Specifications and Accessories A Specifications and Accessories Table A 3 Specifications For All Controll

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