User Manual - Rockwell Automation

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Allen-Bradley 160 SSC  Variable Speed Controller (Series B) 0.37 – 2.2 kW (0.5 – 3 HP) FRN 5.xx – 6.xx

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: D identify a hazard D avoid the hazard D recognize the consequences Important: Identifies information that is especially important for successful application and understanding of the product.

Notes

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N-1

Notes

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N-2

Notes

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N-3

Notes

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N-4

Attach template to mounting surface and drill four (4) 4.5mm (0.177 inches) diameter holes. Dimensions are in millimeters [inches].

Summary of Changes Publication 160-5.9 Summary of Changes D The Firmware Version of the drive was changed from FRN5.01 to FRN6.0.

been added to both Table 2.F and Table 2.G replacing our previous recommendations of a “Reactor at Drive”.

D 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 160-5.9DU4, which has been eliminated.

D 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.

D 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 at Drive” have

D Part numbers and dimensional information for the new 24V DC interface module and “RF” series of line filters have been added to Appendix A.

D 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.

D 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 Summary of Change This Page Intentionally Blank

Table of Contents

Chapter 1 – Information and Precautions . . . . . . . . . . . . . . . .

1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 2 – Installation and Wiring . . . . . . . . . . . . . . . . . . . . Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Wiring For Preset Speed and Analog Signal Follower Models . . . . . . . . . . . . . Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Line Side Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Cable Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring – Analog Signal Follower Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring – Preset Speed Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 – Program Keypad Module . . . . . . . . . . . . . . . . . . . Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Program Keypad Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 – Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-1 2-1 2-2 2-2 2-3 2-4 2-6 2-7 2-7 2-8

3-1 3-1 3-1 3-1 3-2

4-1

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Chapter 5 – Parameters and Programming . . . . . . . . . . . . . . . Overview of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Program Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Troubleshooting and Fault Information . . . . . . . .

5-1 5-1 5-1 5-2 5-4

6-1

Fault Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Block Diagram of Bulletin 160 Analog Signal Follower . . . . . . . . . . . . . . . . . . . . . . . 6-4

Appendix A Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalog Numbers for Bulletin 160 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1 A-4 A-5 A-6

i

Table Contents ImportantofInformation

Appendix B CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Essential Requirements for a Conforming EMC Installation . . . . . . . . . . . . . . . . . . . . General Instructions for an EMC Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Directive 73/23/EEC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1 B-1 B-2 B-4

Index Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

ii

Information and Precautions General Information1 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.

Chapter 1

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.).

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 repairing 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

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, supplying 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. 1-1

Chapter 1 – Information and Precautions

Figure 1.1 – Catalog Number Code Explanation 160 – A A04 N SF1

First Position

Second Position

Third Position

Fourth Position

Bulletin Number

Voltage Rating

Current Rating

Enclosure Type

An “S” in the Bulletin Number denotes a single phase input voltage.



A 200 – 240V 1∅ 200 – 240V 3∅ B 380 – 460V 3∅

A01 A02 A03 A04 A06 A08 A12

P1

Fifth Position Control

Sixth Position Programmer (Optional)

SF1 = Analog Letter Type Program Signal N Open (IP20) Keypad Module ➀ Follower P Chassis Mount (external PS1 = Preset heatsink) Speed

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 CAT160–AA04NSF1P1 I N P U T

V: A: Hz: VA:

200-240 3∅ 5.4 50/60 2200

ALLEN-BRADLEY

O U T P U T

SER B

FRN: 6.xx

V: 200-230 3∅ A: 4.5 Hz: 0-240 Motor Rating: 0.75kW/1HP

ÎÎ Î ÎÎ Î

Nameplate is located on the side of the unit.

MADE IN U.S.A.

S/N 32098 OPERATING AMBIENT TEMP: 0 – 50°C SHORT CIRCUIT CURRENT: 10KA POWER TERMINAL WIRE: Use 75°C Cu Wire

IP20

4mm2 – .75mm2 (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.

Conventions Used In This Manual 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

Chapter 2

Installation and Wiring Installation and Storage

Controller Features

Take these actions to prolong controller life and performance:

Figure 2.1 below details the features of both the Analog Signal Follower and Preset Speed models.

D store within an ambient temperature range of –40_ to +85_C D store within a relative humidity range of 0% to 95%, non-condensing

Important: The features are the same for single and three phase units. Figure 2.1 – Controller Features

D protect the cooling fan by avoiding dust or metallic particles

Ground Tab/ Protective Earth

D avoid storing or operating the controller where it could be exposed to a corrosive atmosphere L1 R

D protect from moisture and direct sunlight

L2 S

L3 T

BR



BR

+

D operate at an ambient temperature range of 0_ to +50_C

Ready/Fault Indicating Panel – Standard for Bulletin 160 controllers. ➃

To maintain proper working conditions, install the controller on a flat, vertical and level surface. Use mounting screws up to 4.5mm (0.177 inches) in diameter or mount on 35mm DIN Rail.

FAULT ➁

1 2 3 4 5 6 7 8 9 10 11 T1 U

T2 V

T3 W



+

DC

DC

Mounting Requirements Description

LEDs – Indicate operational status.

READY ➂

CE Compliance Refer to Appendix B for detailed information.

Metric

Terminal Block One (TB1) – For Line Power. ➀

Terminal Block Three (TB3) – For Control Wiring. Terminal Block Two (TB2) – For Motor Wiring. ➀

English

Fan DIN Latch

Min. Panel Thickness (14 GA)

1.9mm

0.0747 in.

Mounting Base Screws

m4 x 0.7

# 8–32

Mounting Torque

1.13 to 1.56 Nm. 10–14 lb. in.



Refer to Figure 2.2

D See Appendix A for details on controller dimensions and weights.



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.

D 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.)



The READY (green) indicator illuminates when the DC bus is charged and the controller is ready to run.



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.

D Leave debris cover attached during controller installation to protect from falling debris. To ensure proper controller operation, remove cover before applying power.

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.

2-1

Chapter 2 – Installation and Wiring

Figure 2.2 – Power Wiring For Analog Signal Follower and Preset Speed Models Required Branch Circuit Disconnect ➀

Input Line Protective Device – See Table 2.C and Table 2.D.

Power Wiring For Preset Speed and Analog Signal Follower Models Table 2.A – Power Terminal Block Specifications

Dynamic Brake Module Option ➁

L1 R

L2 S

L3 T

BR



BR +

T1 U

T2 V

T3 W

– DC

+ DC

Terminal Block One (TB1) – For Line Power and Brake Resistor. Terminal Block Two (TB2) – For Motor and Capacitor Module.

Terminal Block



Screw Max/Min Wire Size Size mm2 (AWG)

Max/Min Torque Nm. (lb.in.)

TB1➄

M4

4 – 0.75 (12 – 18)

1.81 – 1.35 (16 – 12)

TB2➄

M4

4 – 0.75 (12 – 18)

1.81 – 1.35 (16 – 12)

The Bulletin 160 SSC is IP20 with wires installed on power terminal blocks.

Input Power Conditioning Motor ➂ ➀ ➁





Capacitor Module Option ➃

For single phase input applications, connect the AC input line to input terminals (L1) R and (L2) S. Connection for dynamic brake resistors for all models. Important: P52 – [DB Enable] must be enabled for proper operation. See Appendix A for part numbers.

Bulletin 160 controllers are and 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

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 S Check supply voltage. (fault currents) greater than 10,000 S Line Reactor (See A-4) or Amps S Isolation Transformer Line has power factor correction capacitors

S Line Reactor (See A-4) or S Isolation Transformer

Line has frequent power interruptions

S Line Reactor (See A-4) or S Isolation Transformer

Line has high frequency S MOV option (See A-4) or (>10 Hz) noise spikes in excess of S Line Reactor (See A-4) or 900V (Induction heaters, RF S Isolation Transformer equipment, choppers) Line has intermittent noise spikes in excess of 2000V (lightening)

S MOV option (See A-4) or S Line Reactor (See A-4) or S Isolation Transformer

Chapter 2 – Installation and Wiring

Recommended Line Side Protection

guidelines must be followed in order to meet the NEC requirements for branch circuit 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.

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 used 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”.

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

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 at n k (HP) kW ( P)

1 ∅ Rating at n k ((HP) kW P)

Fuse use Rating at n

.37 (1/2) .55 (3/4) .75 (1) 1.5 (2) 2.2 (3)

N/A .37 (1/2) .55 (3/4) .75 (1) 1.5 (2)

6 6 10 15 (16) 25

Fuse Types➇ Class CC Class J KLDR/CCMR➁ ATMR➂ FNQR➃

JDT➁ AJT➂ LPJ➃

Other Protective Devices Rating Type 16 16 16 16 20

140-MN-****➄ 1492-CB3-H***➅ HFD ***L➆

Table 2.D – Minimum Recommended Line Side Protective Devices for 380 – 460V rated units

➀ ➁ ➂ ➃ ➄

3 ∅ Rating at n k (HP) kW ( P)

1 ∅ Rating at n k ((HP) kW P)

Fuse use Rating at n

.37 (1/2) .55 (3/4) .75 ((1)) 1.5 ((2)) 2.2 ((3))

N/A N/A A N/A N/A A A N/A

3 (4)➀ 3 (4)➀ 6➀ 10 ( ) 15 (16)

Fuse Types➇ Class CC Class J KLDR/CCMR➁ ➂ A A ATDR/ATQR ➃ FNQR

Must be dual element time delay. Littlefuse Gould Shawmut Bussman Allen-Bradley Bulletin 140 manual motor starter. Not recommended for repetitive application of power to the input of the drive.

JDT➁ A AJT➂ LPJ➃

Other Protective Devices Rating Type 6.3 6.3 6.3 16 16

140-MN-**** ****➄ ***➅ 1492-CB3-H*** ➆ HFD ***L ***



Allen-Bradley Bulletin1492 circuit breaker. Not recommended for repetitive application of power to the input of the drive.



Westinghouse type HFD circuit breaker



Controller is also compatible with RK1, RK5, and BS88 fuse types.

Fuse ratings in ( ) denote European size.

2-3

Chapter 2 – Installation and Wiring

Table 2.E – Recommended Cable Type(s)

Motor Cable Recommendations

A variety of cable types are acceptable for Condition Insulation Type(s) Example(s) variable speed controller installations. For many Dry PVC① THHN 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 ➀ For AC line voltages in excess of 264V AC, or motor cable spacing of 1 meter (3.3 feet) for every 10 meters 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 Long Motor Cable Effects you must run motor cables from multiple controllers (more than three) in a 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 devices to limit voltage reflections at the motor Motor cables should be four-conductor with the (reflected wave phenomona). See Table 2.F for ground lead and shield (if using shielded cable) recommendations. connected to the controller ground terminal and 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 Capacitive Current considerations. thickness, susceptibility to moisture and susceptibility to nicks and cuts during installation. Table 2.F – Cable Length Recommendations — Reflected Wave➁ 380 – 460V Ratings

2 2 kW 2.2 (3 HP) 1 5kW 1.5kW (2 HP) 0 75 kW 0.75 (1 HP) 0 55 kW 0.55 (0.75 (0 75 HP) 0.37 0 37 kW (0 5 HP) (0.5 ➁ ➂ ➃

2-4

Motor Insulation Insulat on Rating at n

Motor Cable Only Shielded Unshielded ft. m. ft. m.

1000 Vp-p

40

12

40

12

RWR at Drive③ Shielded Unshielded ft. m. ft. m. 360

110

300

92

Reactor at Motor Shielded Unshielded ft. m. ft. m. 210

64

210

64

1200 Vp-p

60

18

60

18

360

110

600

183

260

79

260

79

1600 Vp-p 1000 Vp-p 1200 Vp-p 1600 Vp-p 1000 Vp-p 1200 Vp-p 1600 Vp-p 1000 Vp-p 1200 Vp-p 1600 Vp-p 1000 Vp-p 1200 Vp-p 1600 Vp-p

500➃ 40 60 500➃ 55 125 500➃ 45 125 500➃ 45 125 500➃

152➃ 12 18 152➃ 17 43 152➃ 14 38 152➃ 14 38 152➃

500➃ 40 60 500➃ 40 60 500➃ 40 60 500➃ 40 50 500➃

152➃ 12 18 152➃ 12 18 152➃ 12 18 152➃ 12 15 152➃

360 300 300 300 300 300 300 300 300 300 300 300 300

110 92 92 92 92 92 92 92 92 92 92 92 92

600 300 540 540 300 375 375 300 375 375 300 375 375

183 92 165 165 92 114 114 92 114 114 92 114 114

500➃ 250 340 500➃ 325 500 500➃ 300 500 500➃ 300 500 500➃

152➃ 76 104 152➃ 99 152 152➃ 92 152 152➃ 92 152 152➃

500➃ 250 340 500➃ 325 325 500➃ 300 500 500➃ 300 500 500➃

152➃ 76 104 152➃ 99 99 152➃ 92 152 152➃ 92 152 152➃

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 – Installation and Wiring

Table 2.G – Cable Length Recommendations — Capacitive Current RWR at Drive①

Motor Cable Only 380 – 460V Ratings

kkHzz

Shielded② ft.

2.2 2 2 kW (3 HP

1.5 1 5 kW (2 HP

0 75 kW 0.75 (1 HP)

0.55 0 55 kW (0 75 HP) (0.75

0.37 0 37 kW (0.5 (0 5 HP)

200 – 240V Ratings 0.37 to 2.2 kW (0.5 to 3 HP) 2 thru 8 kHz

m.

Unshielded ft. m.

Shielded② ft. m.

Reactor at Motor

Unshielded ft. m.

Shielded② ft. m.

Unshielded ft. m.

2

360

110

750

229

280

85

600

183

410

125

525

160

4

335

102

600

183

260

79

600

183

370

113

475

145

8

300

91

410

125









310

94

420

128

2

300

91

540

165

430

131

540

165

310

94

425

130

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

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

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

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 Shielded Unshielded ft. m. ft. m. 500

152

800

244

RWR at Drive Shielded Unshielded ft. m. ft. m. ③







Reactor at Motor Shielded Unshielded ft. m. ft. m. 500

152

800



Not recommended for use above 4 kHz PWM frequency.

➁ ➂

When using shielded cable at lightly loaded conditions, the 0.75 Kw (1 Hp) and below cable length recommendations are 61m (200 ft.) Not recommended for 230V applications.

244

2-5

Chapter 2 – Installation and Wiring

Control Wiring Requirements D run all signal wiring in either a shielded cable, or a separate metal conduit. D only connect shield wire at control terminal block common terminals TB3-3 and TB3-7. D 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. D use Belden 8760 (or equivalent) — 18AWG (0.750mm2), twisted pair, shielded or 3 conductor. Table 2.H – Control Terminal Block Specifications Terminal Block TB3

Max/Min Wire Size mm2 (AWG)

Max/Min Torque Nm. (lb.in.)

2.5 – 0.5 (14 – 22)

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. When AC input power is removed, there will be a loss of inherent regenerative braking effect and the motor will coast to a stop. An auxiliary braking method may be required.

2-6

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 – Installation and Wiring

Control Wiring Figure 2.3 – TB3 Control Wiring for Analog Signal Follower Model Shielded Wire TB3 Terminal 1 2 3 4 5 6 7 8 9 10 11

FAULT READY



Signal

Specification

+ 10V Pot Pot Wiper or +10/–10V DC Input Common 4–20mA Input Reverse Start Common Stop Normally Closed

10 kΩ Potentiometer, 2 Watts

Relay Common Normally Open

= N.O. Momentary Contact

Controller Input Impedance = 100 kΩ Common ➁ Controller Input Impedance = 250 Ω Contact closure input ➀ Contact closure input ➀ Common ➁ Contact closure input required to operate controller ➀ Customer-programmable relay outputs. Resistive load 0.4A at 125V AC 2A at 30V DC. Inductive load 0.2 A at 125V AC 1A at 30V DC.

= N.O. Maintained Contact

= N.C. Momentary Contact

Figure 2.4 – TB3 Control Wiring for Preset Speed Model Shielded Wire TB3 Terminal

FAULT READY



Signal

Specification

1 2 3 4 5 6 7

SW1 SW2 Common SW3 Reverse Start Common

Contact closure input ➀ Contact closure input ➀ Common ➁ Contact closure input ➀

8 9

Stop Normally Closed Relay Common Normally Open

10 11

= N.O. Momentary Contact

Contact closure input ➀ Contact closure input ➀ Common ➁ Contact closure input required to operate controller ➀ Customer-programmable relay outputs. Resistive load 0.4A at 125V AC 2A at 30V DC. Inductive load 0.2 A at 125V AC 1A at 30V DC.

= N.O. Maintained Contact

= N.C. Momentary Contact ➀

Internal 12V supply.



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.



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

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. D Setting 0 — Three Wire Control. (This is the factory default setting). Refer to Figure 2.5. D Setting 1 — Two Wire “Run Forward/Run Reverse” Control. Refer to Figure 2.6. D Setting 2 — Program Keypad Module control. See Page 3-1. D Setting 3 — Momentary “Run Forward/Run Reverse” control. Refer to Figure 2.7. D Setting 4 — Two Wire “Accel/Decel” control. Refer to Figure 2.8. D Setting 5 — Two Wire “Enable” control. Refer to Figure 2.9. D Setting 6 — Two Wire “Local/Remote” control. Refer to Figure 2.10. Explanation of Symbols: = N.O. Momentary Contact = N.C. Momentary Contact = N.O. Maintained Contact = N.C. Maintained Contact ➀

Internal 12V supply. ➁ If both Run Forward and Run Reverse inputs are closed at the same time an undetermined state could occur. ➂ 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.

Figure 2.5 – TB3 Three Wire control (Setting 0) ( Factory Default Setting) Shielded Wire TB3 Terminal Signal 5 Reverse 6 Start 7 8

Specification Contact closure input ➀ Contact closure input ➀ ➂ Common Common Contact closure input required to Stop operate controller ➀

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 ➁

TB3 Terminal Signal Specification Run Reverse Contact closure input ➀ 5 6 7 8

Run Forward Contact closure input ➀ Common Common ➂ Contact closure input required to Stop operate controller ➀

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 ➁

TB3 Terminal 5 6 7 8

Signal Run Reverse Run Forward Common Stop

Specification Contact closure input ➀ Contact closure input ➀ Common ➂ Contact closure input required to operate controller ➀

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 active (open).

2-8

Chapter 2 – Installation and Wiring

Control Wiring (continued)

Figure 2.11

Figure 2.8 – TB3 Two Wire “Accel/Decel” control (Setting 4)

Input Mode Setting

TB3-8 Open

TB3-8 Closed

4➃

Accel 2➄ Decel 2

Accel 1 Decel 1

5➃

Controller➅ Disabled

Controller Enabled

6➃

Local (TB3)➆ Control

Remote Control

Shielded Wire ➁

TB3 Terminal 5 6 7 8③

③ Refer

Signal Run Reverse Run Forward Common Accel/decel select

Specification Contact Closure Input① Contact Closure Input① Common③ Contact Closure Input① Used to select Accel/Decel.

to Figure 2.11.

Figure 2.9 – TB3 Two Wire “Enable” control (Setting 5)



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].

Shielded Wire ➁

TB3 Terminal 5 6 7 8③

③ Refer

Signal Run Reverse Run Forward Common

Specification

Enable

Contact Closure Input required to operate controller①

Contact Closure Input① Contact Closure Input① Common③

to Figure 2.11.

Figure 2.10 – TB3 Two Wire “Local/Remote” control (Setting 6) Shielded Wire ➁

③ Refer

TB3 Terminal 5 6 7 8③

to Figure 2.11.

Signal Run Reverse Run Forward Common Local/ Remote

Specification Contact Closure Input① Contact Closure Input① Common③

Contact Closure Input① Used to select local (TB3) Control.

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 Fault occurs

Fault clears

Fault occurs

Fault clears

2-9

Chapter 2 – Installation and Wiring

This Page Intentionally Blank

2-10

Chapter 3

Program Keypad Module Features

Display Mode

The program keypad module is located on the front panel of the controller. It features the following:

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.

D five keys on the module for display or programming controller parameters

Program Mode

D three keys for control inputs to the controller D directional LEDs D a 6 digit, seven segment LED display

You enter the program mode by pressing the ESC key. While in program mode, you can edit any programmable controller parameters. Refer to Chapter 5 for programming steps.

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.

When the program mode indicator flashes, you can edit the parameter value. When in display mode, the program indicator does not display.

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.





Use the up/down➂ 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 counter clockwise LED illuminates constantly when the motor rotates in reverse direction. ➀ 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. ➁

These four digits display the parameter value or fault code number.

The clockwise LED illuminates constantly when the motor rotates in forward direction. ➀

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 set to “2”).

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. ➂

Real time frequency adjustment can be achieved when using P58 – [Internal Frequency].

3-1

Chapter 3 – Program Keypad Module

Removing Program Keypad Module ATTENTION: Ensure that you disconnect line power and wait one minute before installing or removing the program keypad module. Failure to do so may result in personal injury or death.

ATTENTION: This controller contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference 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 factory default settings using P56 – [Reset Defaults]

Installing Program Keypad Module Insert the module bottom end first and then press on the symbol at the top of the module until the module is fully seated. The module is fully seated when its face is flush with the edges of its surrounding case.

3-2

Chapter 4

Start-Up Chapter 5 provides a comprehensive description of all controller parameters. Review the factory default settings. If your controller is equipped with a Program Keypad Module these parameters can be changed to meet your specific application requirements. An example of how to program a parameter is shown at the beginning of Chapter 5. Start Here

Commonly Changed Parameters Parameter P30 – [Accel Time 1] P31 – [Decel Time 1] P33 – [Maximum Frequency] P34 – [Stop Mode Select] P35 – [Base Frequency] P36 – [Base Voltage] P42 – [Motor Overload Current] P46 – [Input Mode] P47 – [Output Configure] Preset Speed Model Only P61 – P68 – [Preset Frequency 0–7]

Set to... desired accel time. desired decel time. maximum frequency required. desired stopping mode. motors rated nameplate frequency. motors rated nameplate voltage. motor nameplate Full Load Amps [FLA]. desired control method. desired output functionality. desired preset frequencies.

ATTENTION: Power must be applied to the controller to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing.

Start-Up Checklist Verify the controller is installed per instructions outlined in Chapter 2 including: D D D

Minimum clearance distance between controller and other equipment. Proper grounding practices have been followed. 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. 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.

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.

Verify that the motor leads are connected to the power terminal block TB2, terminals T1, T2, T3 (U, V, W). Verify that the 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

4-1

Chapter 4 – Start-Up

A If you have a blank display panel.

Reconnect the power to the controller.

If you have a program keypad module. P01– [Output Frequency] will display. If the controller has been previously powered up, a different parameter number may display. 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?

Analog Signal Follower controller Check for proper motor rotation by setting the frequency source to its minimum setting. If you are using a program keypad module, verify that the CLOCKWISE LED is illuminated. If you are using a blank display panel, verify that the REVERSE input to TB3 is in the OPEN position. Issue a START command from either the program keypad module or TB3 control terminal block.

Preset Speed controller Check for proper motor rotation by selecting P61 – [Preset Frequency 0]. This requires removing all inputs to SW1, SW2, and SW3 on TB3 [see Figure 2.5 in Chapter 2]. The factory default setting for P61 – [Preset Frequency 0] is 3 Hz. If you are using a program keypad module, verify that the CLOCKWISE LED is illuminated. If you are using a blank display panel, verify that the REVERSE input to TB3 is in the OPEN position.

Slowly increase the speed until the motor begins to turn. Check the direction of the motor.

Issue a START command from either the program keypad module or TB3 control terminal block. Check the direction 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.

Start-Up is complete.

Yes

Is the direction of motor rotation correct?

No

Disconnect and lock out all 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. Switch any two of the three motor leads connected to TB2, terminals T1, T2 and T3 [U, V and W].

4-2

Chapter 5

Parameters and Programming 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 Analog Signal Follower Model

Preset Speed Model

Display

1 through 14 and 16

1 through 15

Program

30 through 60 and 69 through 76, 78

30 through 59 and 61 through 73, 78

ÉÉ ÉÉ

The following pages contain descriptions of both display and program parameters. Any parameter description that is shaded pertains only to the Preset Speed or Analog Signal Follower model. Refer to the legend to the right.

= Parameter applies only to the Analog Signal Follower model

= Parameter applies only to the Preset Speed model

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

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 SELect key. The program mode indicator flashes indicating that you can use the up/down keys to change the parameter value.

Keypad Display

3 0.

1 0. 0

Program Mode Indicator

3 1.

1 0. 0

3 1.

1 0. 0

Program Mode Indicator Flashes

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 displays.

3 1.

2. 2

3 1.

2. 2

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 ESCape key. The original value of the parameter will remain unchanged and you will be exited from the program mode.

Program Mode Indicator Stops Flashing

3 1.

1 0. 0

Program Mode Indicator Stops Flashing

5-1

Chapter 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 Min/Max Range

Units

0 to 240

0.1 Hz

0 to [Max Voltage]

1 Volt

0 to 2 Times Controller Rated Output Current

0.01Amps

0 to 2 Times Rated Controller Output Power

0.01 kW

0 to 400 – [230V] 0 to 800 – [460V]

1 Volt

commanded to output. This command may come from any of the frequency sources selected by P59 – [Frequency Select] or from a currently selected preset frequency.

0 to 240

0.1 Hz

07

[Last Fault] Displays the coded last fault number. If a fault is currently active (has not been cleared) the display will flash. See Chapter 6 for fault code descriptions.

0 to 49

Numeric Value

08

[Heatsink Temperature] Displays the temperature of the controller heatsink.

0 to 150

1 Degree C

0000 to 1011

Binary Number

Numeric Value

Numeric Value

Fixed Value

Numeric Value

Parameter Description

P# 01

[Output Frequency] Displays the output frequency at TB2 terminals T1, T2 and T3 (U, V and W).

02

[Output Voltage] Displays the output voltage present at TB2 terminals T1, T2 and T3 (U, V and W).

03

[Output Current] Displays the output current present at TB2 terminals T1, T2 and T3 (U, V and W).

04

[Output Power] Displays the output power present at TB2 terminals T1, T2 and T3 (U, V and W).

05

[Bus Voltage] Displays the DC Bus Voltage level.

06

[Frequency Command] Displays the frequency that the controller is

09

[Controller Status] Displays the status of the controller in a binary coded format.

Important: A “0” = inactive and a “1” = active.

10 11

Bit 2

Bit 1

Bit 0 Running Forward Accel Decel

[Controller Type] Used by Rockwell Automation field service personnel. [Control Version] Displays version of controller firmware. Used by Rockwell Automation field service personnel.

5-2

Bit 3

Chapter 5 – Parameters and Programming

Display Group Parameter Description

P# 12

[Input Status] Displays the open (0) and closed (1) state of the inputs to TB3 in binary coded format as follows: Bit 3

Input Input Mode 0 Mode 1 (3-Wire) (2-Wire)

13

Input Input Mode 3 Mode 2 (Momentary (Keypad) Run FWD/ Run REV)

Bit 2

Input Mode 4 (Accel/ Decel)

Input Mode 5 (Enable)

Input Mode 6 (Local/ Remote)

Bit 0 TB3-5

Reverse

Run Reverse

N/A

Run Reverse

Run Reverse

Run Reverse

Run Reverse

Bit 1 TB3-8

Stop

Stop

Stop

Stop

0=Accel 2/ Decel 2 1=Accel 1/ Decel 1

0=Drive Disable 1=Drive Enable

0=Local (TB3) Control 1=Remote Control

Bit 2 TB3-6

Start

Run Forward

N/A

Run Forward

Run Forward

Run Forward

Run Forward

Bit 3 Polarity

0 = Positive Analog Input 1 = Negative Analog Input

[Power Factor Angle] Displays the angle in electrical degrees between motor

ÁÁÁ ÁÁÁ ÁÁÁ

[Memory Probe Display] Used by Rockwell Automation field service

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. This parameter applies to the Preset Speed model only. Bit 3

Bit 2

Bit 1

Units

0000 to 1111

Binary Number

0.0 to 180.0

0.1 degrees

Bit 1 Bit 0

voltage and motor current.

14

Min/Max Range

ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ Numeric Value

Numeric Value

0000 to 0111

Binary Number

Bit 0 SW1 SW2 SW3 Not Used

ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÉÉÉ ÉÉÉ 16

[Analog Input] Displays the analog input as a percent of full scale. Used in setting

–150 to +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 0V 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.

5-3

Chapter 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#

30

Parameter Description

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.

Factory Default

0.0 to 600

0.1 Seconds

10.0 Seconds

0.1 to 600

0.1 Seconds

10.0 Seconds

0 to 240

1 Hz

0 Hz

0 to 240

1 Hz

60 Hz

0 to 3

Numeric Value

0

10 to 240

1 Hz

60 Hz ➁

20 to 460 for 460V units and 20 to 230 for 230V units

1 Volt

460 Volts for 460V units and 230 for 230V units

Speed

0

a Accel '

0

Time

Time

a Decel ' Time

[Decel Time 1] Time for the controller to ramp from P33 – [Maximum Frequency] to 0.0 Hz. The rate is linear for any decrease in command frequency unless P53 – [S-Curve] is set to a value other than “0”. See P30 – [Accel Time 1] figure above.

32➀ [Minimum Frequency] Lowest frequency that controller will output continuously.

33➀ [Maximum Frequency] Highest frequency the controller will output. Important: This parameter can’t be changed while running.

34

Units

[Accel Time 1] Time for the 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 this to 0.0 sec. gives Max. Frequency ' 0.1 sec acceleration

31

Min/Max Range

[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 Voltage] diagrams. Settings: 0 = Ramp to Stop 1 = Coast to Stop 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 36

[Base Frequency] Set value to motor’s rated nameplate frequency. [Base Voltage] Set value to motor’s rated nameplate voltage.



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

Program Group P#

37

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].

38

Units 1 Volt

Factory Default 460 Volts for 460V units and 230 for 230V units

0 to 12

Numeric Value

2

0 to 240

1 Hz

240 Hz

0 to 30

1 Hz

0 Hz

[Boost Select] Sets the boost voltage and redefines the Volts per Hz 100

[Base Voltage], %

curve.

1/2 Base Volts

50

9 10 11 12

1/2 Base Freq.

8y

See Settings 1 through 8 below

1b

0

Setting 0 1 2 3 4 5 6 7 8

39

Min/Max Range 20 to 510 for 460V units and 20 to 255 for 230V units

50 100 [Base Frequency], % Boost Voltage % of [Base Voltage] 0 2.5 5.0 7.5 10.0 12.5 15.0 17.5 20.0

Setting Fan/Pump Curves ➀ 9 45.0 10 40.0 11 35.0 ➀ Break Point Voltages 12 30.0 in % of [Base Voltage].

[Skip Frequency] Works in conjunction with P40 – [Skip Frequency Band] creating a range of frequencies at which the controller will not operate continuously. Frequency

Controller Output

Command Frequency Skip Frequency Setting

'

a Frequency

y Two times P40–[Skip Freq Band] b Setting

'

Time

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.

5-5

Chapter 5 – Parameters and Programming

Program Group P#

Parameter Description

41

[Motor Overload Select] Selects the derating factor for the I2t over-

Min/Max Range

Units

Factory Default

0 to 2

Numeric Value

0

0.1 to 200% of controller rating 1 to 180% of controller rating

.01 Amperes

1%

115% of Controller Rating 150%

% of [Overload Current] Setting

42

100 80 60 40 20

No Derating

0 25 50 75 100 125 150 175 200 % Base Speed

% of [Overload Current] Setting

% of [Overload Current] Setting

load function.

Min Derating 100 80 60 40 20 0 25 50 75100 125 150 175 200 % Base Speed

Max Derating 100 80 60 40 20

Settings: 0 = No Derating 1 = Minimum Derating 2 = Maximum Derating 0 25 50 75 100125 150 175 200 % Base Speed

[Motor Overload Current] Set to motor nameplate full load Amps (FLA).

43

[Current Limit] Maximum output current allowed before current limiting occurs. Value set in percent of controller rated output current.

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 “Ramp to Stop” mode.

0 to 25

0.1 Second

0 Seconds

45

[DC Hold Voltage] DC Voltage level applied to the motor during braking when P34 – [Stop Mode Select] is set to either “DC Injection Braking” or “Ramp to Stop” mode.

0 to 115

1 Volt

0 Volts

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

Volts and Speed

[DC Hold Time]

Voltage [DC Hold Time]

Speed

Volts and Speed Speed [DC Hold Voltage]

[DC Hold Voltage] y Stop Command

5-6

Time

y Stop Command

Time

Chapter 5 – Parameters and Programming

Program Group P#

Parameter Description

46

[Input Mode] Configures the TB3 control 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 Function] must be set to “2” for the change to take effect.

Min/Max Range

Units

Factory Default

0 to 6

Numeric Value

0

0 to 9

Numeric Value

0

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/Remote” 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 Ready/Faulted

energized and returns to shelf state when 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.

4 = Motor Overload

when a motor overload condition exists.

5 = Ramp Regulated

the ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or overvoltage fault from occurring.

6 = Above Frequency

the 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 Voltage

the controller exceeds the DC bus voltage value set in P48 – [Output Threshold].

9 = Retries Exhausted

the number of retries for P50 – [Restart Tries] is exceeded.

5-7

Chapter 5 – Parameters and Programming

Program Group P#

48

Parameter Description

Min/Max Range

Units

Factory Default

0 to 815

Numeric Value

0

2.0 to 8.0

0.1 kHz

4.0 kHz

0 to 9

Numeric Value

0

0.5 to 300

0.1 Seconds

0 to 100

Numeric Value

10.0 Seconds 0

[Output Threshold] Determines the on/off point for the TB3 output relay when [P47 – Output Configure] is set to 6, 7, and 8. Settings

49

Ranges

6

0 to 240 Hz

7

0 to 180 %

8

0 to 815 Volts

[PWM Frequency] Carrier frequency for the PWM output waveform. % Output Current (A)

The chart below provides derating guidelines based on the PWM freq. setting. 100 98 96 94 92 90 88 86 84

1

2

3

4 5 6 Carrier Frequency, kHz

7

8

Important: Ignoring derating guidelines can cause reduced controller performance.

50

[Restart Tries] Maximum number of times the controller will attempt to reset a fault.

51

[Restart Time] Time between restart attempts.

52

[DB Enable] Enables/disables external dynamic braking. 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 controller is running.

5-8

Chapter 5 – Parameters and Programming

Program Group P#

53

Min/Max Range

Parameter Description

Units

Factory Default

Numeric Value

0

0 to 1

Numeric Value

0

Numeric Value

Numeric Value

Numeric Value

[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) ➀

1/2 S-Curve Time

1/2 S-Curve Time

' '

a

'

a

S-Curve Time = 10 x .3

'

a

Example: Accel Time = 10 seconds S-Curve Setting = 3 = 3 Seconds

a

S-Curve Setting 0 = 0% 1 = 10% 2 = 20% 3 = 30%

Enabled

4 = 40% Important: Maximum S-Curve time is 60 seconds.

5 = 50% 6 = 60% 7 = 70%

Disabled

8 = 80% 9 = 90% 10 = 100%

'

a

Accel Time

' a Decel Time ➀ See values in the Min/Max Range column

54

[Clear Fault] Setting this parameter to a “1” performs a fault reset. When 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 service personnel.

5-9

Chapter 5 – Parameters and Programming

Program Group P#

56

Min/Max Range 0 to 2

Parameter Description

[Reset Functions] When using this parameter, the controller’s parameters and their associated defaults are reset according to the descriptions below:

Units Numeric Value

Factory Default 0

0 = Idle State 1 = Reset defaults (restores all 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.

57

0 to 1

Numeric Value

0

0 to 240

0.1 Hz

60.0 Hz

0 to 1

Numeric Value

0

–50.0 to 50.0

Numeric Value

0%

[Program Lock] When set to a “1”, this parameter protects all controller parameters from being changed by unauthorized personnel.

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: Follow normal programming procedures. Once the desired command frequency is reached the ENTER key must be pressed to store this value to EEPROM memory. If the ESC key is used before the ENTER key, the frequency will return to the original value following the normal accel/decel curve.

59

[Frequency Select] Selects the source of the frequency command for the controller.

Settings:

0 = external frequency command 1 = internal frequency command from P58 – [Internal Frequency].

ÉÉÉ ÉÉÉ ÉÉÉÉÉÉ ÉÉÉ 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.

5-10

=

This parameter applies only to the Analog Signal Follower model.

Chapter 5 – Parameters and Programming

Program Group Min/Max Range 0 to 240

0.1 Hz

Factory Default 3 Hz

[Preset Frequency 1] The programmed value sets the frequency that the controller outputs when selected

0 to 240

0.1 Hz

20 Hz

[Preset Frequency 2] The programmed value sets the frequency that

0 to 240

0.1 Hz

30 Hz

0 to 240

0.1 Hz

40 Hz

P#

Parameter Description

61

[Preset Frequency 0] The programmed value sets the frequency that the controller outputs when selected.

62 63

Units

the controller outputs when selected.

64

[Preset Frequency 3] The programmed value sets the frequency that the controller outputs when selected.

65

[Preset Frequency 4] The programmed value sets the frequency that the controller outputs when selected.

0 to 240

0.1 Hz

45Hz

66

[Preset Frequency 5] The programmed value sets the frequency that the controller outputs when selected.

0 to 240

0.1 Hz

50 Hz

67

[Preset Frequency 6] The programmed value sets the frequency that the controller outputs when selected.

0 to 240

0.1 Hz

55 Hz

68

[Preset Frequency 7] The programmed value sets the frequency that

0 to 240

0.1 Hz

60 Hz

0.0 to 600

0.1 Sec.

20.0 Sec.

0.1 to 600

0.1 Sec.

20.0 Sec.

the controller outputs when selected.

69

[Accel Time 2] Time for the 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 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 for the controller to ramp from P33 – [Maximum Frequency] to 0.0 Hz. The rate is linear for any decrease in command frequency 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 (SW3)

TB3-2 (SW2)

TB3-1 (SW1)

Preset

0 0 0 0 1 1 1 1

0 0 1 1 0 0 1 1

0 1 0 1 0 1 0 1

Preset 0 Preset 1 Preset 2 Preset 3 Preset 4 Preset 5 Preset 6 Preset 7

Accel➀

Decel➀

P – [Accel P30 ccel T Time me 1]

P – [Decel P31 Decel T Time me 1]

P – [Accel P69 ccel T Time me 2]

P7 – [Decel P70 Decel T Time me 2]

Refer to Figure 2.4 for the Preset Speed model control wiring diagram. ➀

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

Program Group P#

Parameter Description

71

[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 (F7), or has trouble accelerating to commanded speed, this value should be reduced. A setting of 0% disables this function.

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 heavy loads then this value should be increased. A setting of 0.0 Hz disables the function.

73

[Reverse Disable] When this parameter is set to 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 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.

ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ ÉÉÉ 74

[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.

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.

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 maximum analog input equals maximum frequency no action is needed. If it is 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.

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.

=

5-12

This parameter applies only to the Analog Signal Follower model.

Min/Max Range

Units

Factory Default

0 to 150

1%

50%

0.0 to 5.0

0.1 Hz

2.0 Hz

0 to 1

Numeric value

0

0 to 1

Numeric value

0

0.0 to 150.0

0.1%

0.0%

0.0 to 150.0

0.1%

100.0%

0 to 1

Numeric value

0

Troubleshooting and Fault Information

Chapter 6

Fault Information Figure 6.1 – Fault Display P07 – [Last Fault]

Fault Code

Number➀

Fault LED – (Without Program Keypad Module) Controllers without a program keypad module come equipped with a fault LED. When the fault LED illuminates, a fault condition exists.

0 7

0 4

➀ 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.

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: D Press the program keypad’s stop button. D Cycle power to the controller. D Cycle the input signal at TB3-8 to the controller. D Set P54 – [Clear Fault] parameter to a “1”.

Table 6.A – Bulletin 160 Fault Descriptions

ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Fault Number

Fault Indication

Fault Description

03

Power Loss Fault

DC Bus voltage remains below 85% nominal on power up for longer than 5 seconds.

Corrective Action

Monitor incoming AC line for low voltage or line 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 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

Table 6.A – Bulletin 160 Fault Descriptions (continued)

ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ Fault Number

Fault Indication

06

Motor Stall Fault

Motor has stalled. Motor load is excessive.

Longer acceleration time or a reduced load required.

07

Motor Overload Fault

Internal electronic overload trip. Excessive motor load exists.

Reduce motor load until controller output current does not exceed the current set by P42 – [Motor Overload Current]. Reduce P38 – [Boost Select].

08

Over Temperature Fault

Excessive heat detected.

Clear blocked or dirty heat sink fins. Check ambient temperature. Check for blocked or non-operating fan.

11

Operator Fault

Keypad has been removed while controller is powered.

Clear fault. Do not remove keypad under power.

12

Overcurrent FauIt

Overcurrent detected in hardware trip circuit.

Check short circuit at the controller output or excessive load conditions at the motor.

32

EEPROM Fault

EEPROM has invalid data.

Reset EEPROM using P56 – [Reset Functions]. Set to 1. Cycle power.

33

Max Retries Fault

Controller failed to reset fault within the number of retries set in P50 – [Restart Tries].

Repair system fault.

6-2

Fault Description

Corrective Action

38

Phase U Fault Phase to ground fault detected between controller and motor in phase U.

Check the wiring between the controller and motor. Check motor for grounded phase.

39

Phase V Fault Phase to ground fault detected between controller and motor in phase V.

Check the wiring between the controller and motor. Check motor for grounded phase.

40

Phase W Fault

Phase to ground fault detected between controller and motor in phase W.

Check the wiring between the controller and motor. Check motor for grounded phase.

41

UV Short Fault

Excessive current has been detected between these two controller output terminals.

Check the motor and external wiring to the controller output terminals for a shorted condition.

42

UW Short Fault

Excessive current has been detected between these two controller output terminals.

Check the motor and external wiring to the controller output terminals for a shorted condition.

43

VW Short Fault

Excessive current has been detected between these two controller output terminals.

Check the motor and external wiring to the controller output terminals for a shorted condition.

48

Reprogram Fault

Occurs when controller parameters are reset to defaults.

Clear fault.

49

Zero Overload Fault

Occurs when load requires excessive current at zero hertz, or P38 – [Boost Volts] set too high.

Reduce motor load at zero hertz. Reduce motor dwell time at zero hertz. Reduce P38 – [Boost Volts].

Chapter 6 – Troubleshooting and Fault Information

Table 6.B – Troubleshooting Problem Motor does not start (No output voltage to motor).

Corrective Action 1. Check power circuit. S Check supply voltage. S Check all fuses and disconnects. 2. Check motor. S Verify that motor is connected properly. 3. Check control input signals. S Verify that START signal is present. S Verify that STOP signal is present. S Verify that RUN FORWARD and RUN REVERSE signals are NOT both active. 4. Check P46 – [Input Mode]. S If P46 – [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”).

1. Check motor. S Verify that motor is connected properly. 2. Check frequency source P06 – [Frequency Command]. S Verify that frequency signal is present at terminal block TB3. S –10- +10V signal S 4–20mA signal S Verify that Preset Frequencies are set properly. 3. Check control input signals. S

Verify that SW1, SW2 and SW3 are correct. (Refer to the chart at the end of Chapter 5).

4. Check parameter settings. S Verify that P59 – [Frequency Select] is showing desired frequency source. S Verify that P58 – [Internal Frequency] is the desired value.

Motor not accelerating properly.

1. Check motor. S Verify that motor is connected properly. S Verify that no mechanical problems exist. 2. Check parameter settings. S Verify that P30 – [Accel Time 1] or P69 – [Accel Time 2] is set properly. S Verify that P43 – [Current Limit] is set properly. S Verify that P38 – [Boost Volts] is set properly.

Can not operate in “RUN FWD/ RUN REV” mode.

1. Verify that P46 – [Input Mode] is set to “1”. 2. Verify that P73 – [Reverse Disable] or P74 – [Analog Select] are not set to “1”. 3. Verify that power has been cycled for above change to take effect. 4. Verify that both RUN FORWARD and RUN REVERSE switches are NOT closed simultaneously.

6-3

Chapter 6 – Troubleshooting and Fault Information

Block Diagram of Bulletin 160 Analog Signal Follower

Brake Module BR+

Capacitor Module BR–

DC+

DC–

L1/R

T1/U

L2/S

T2/V

L3/T

T3/W

Motor

GND/PE F r e q u e n c y

R e –10 to +10V or f e Potentiometer r e or n c 4 – 20 mA e Reverse

TB3 - 1

GND/PE Control Power

Bus Voltage Circuitry

Current Circuitry

TB3 - 2 TB3 - 3 (Common) Fault Feedback TB3 - 4

Program Keypad Module

CPU TB3 - 5

Start TB3 - 6 Stop

TB3 - 8

Common TB3 - 7

6-4

Opto Isolator Relay Circuitry

TB3 - 9

Customer TB3 - 10 Programmable Output TB3 - 11

Appendix 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)

1.5 (2)

2.2 (3)

Output Current (A) Max

2.3

3.0

4.5

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) Input kVA

180 – 265V 1.1

1.4

2.2

3.7

5.7

Environmental Specifications Cooling Method

Convection Cooled

Fan Cooled

AC Dynamic Braking Torque ➀ 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 (HP)

0.37 (1/2)

0.55 (3/4)

0.75 (1)

1.5 (2)

2.2 (3)

Output Current (A) Max

1.2

1.7

2.3

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) Input kVA

340 – 506V 1.1

1.6

2.2

3.7

5.7

Environmental Specifications Cooling Method

Convection Cooled

Fan Cooled

AC Dynamic Braking Torque ➀



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.

A-1

Appendix A – Specifications and Accessories

Table A.3 – Specifications For All Controller Ratings Input/Output Ratings (All Controller Ratings) Output Voltage (V)

Adjustable from 0V to input voltage

Output Frequency (Hz)

0 to 240 Hertz Programmable

Efficiency (%) Transient Protection

97.5% (Typical) 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 – 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 mA. 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 UL508C

Designed to meet these standards

CSA 22.2

IEC 146–1–1 FCC Class A➀ and B➀ VDE 0871➀ and 0875➀

ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ ÎÎ

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 lmpedance 250 Ohms

Analog Input (–10 to +10V DC)

Input Impedance 100K Ohms

Control Output (All Controller Ratings) Programmable Output (Form C Relay contact) ➀

With external components.

A-2

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

Table A.3 – Specifications For All Controller Ratings (continued) Control Features (All Controller Ratings) PWM Algorithm Switching Device (3-Phase Output) V/Hz Ratio

Sine Weighted PWM with Harmonic Compensation IGBT (Intelligent Power Module) Programmable

Carrier Frequency DC Boost

Adjustable from 2 kHz to 8 kHz in 100 Hz Increments (Factory default is 4 kHz) Adjustable – Select from a family of Boost Curves

Current Limiting

Trip Free Operation, Co-ordinated for Controller and Motor Protection – Programmable from 1% to 180% of Controller Output Current

Motor Protection

I2t 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) S-Curve Accel/Decel Time(s) Stopping Modes

0.1 to 600 Seconds 0 to 100% of Accel/Decel time – not to exceed 60 seconds 3 modes (programmable)

Ramp to stop

0.1 to 600 seconds

Coast to stop

Stops all PWM Output

DC Injection Braking

Applies DC Voltage to the Motor for 0 to 25 seconds

Protective Features (All Controller Ratings) Overcurrent Excessive Temperature Over/Under Voltage

Control Ride Through Ground Short Faultless Ride Through Output Short Circuit

200% hardware limit, 300% instantaneous fault Embedded temperature sensor trips if heatsink temperature exceeds 95°C DC Bus voltage is monitored for safe operation. 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 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). Minimum ride through is 0.5 seconds – typical value 2 seconds Any output phase to ground, detected at run 100 Milliseconds Any output phase to phase short

Programming (All Controller Ratings) Programmer

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

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ Á ÁÁÁ ÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁÁ Accessories

For All Controller Ratings – 0.37 to 2.2kW (1/2 to 3 HP)

Controller Ratings

Input Voltage Rating

Dynamic Brake Module

MOV Module

3% Line Reactors Open Style➀

Cat. No.

Cat. No.

Cat. No.

Line Filters

Cat. No.②

Capacitor Module

Cat. No.③

HP

kW

1/2

0.37

160-BMA1

160-MMA1



160S-LFA1

160S-RFA-6-A

160-CMA1

3/4

0.55

160-BMA1

160-MMA1



160S-LFA1

160S-RFA-6-A

160-CMA1

1

0.75

160-BMA1

160-MMA1



160S-LFA1

160S-RFA-10-A

160-CMA1

2

1.5

160-BMA2

160-MMA1



160S-LFA1

160S-RFA-16-A



1/2

0.37

160-BMA1

160-MMA1

1321-3R4-B

160-LFA1

160-RFB-3-A

160-CMA1

3/4

0.55

160-BMA1

160-MMA1

1321-3R4-A

160-LFA1

160-RFB-3-A

160-CMA1

1

0.75

160-BMA1

160-MMA1

1321-3R4-A

160-LFA1

160-RFB-9-A

160-CMA1

2

1.5

160-BMA2

160-MMA1

1321-3R8-A

160-LFA1

160-RFB-9-A

160-CMA1

200 – 240V 50/60Hz 1 Phase

200 – 230V 50/60Hz 3 Phase

380 – 460V 50/60Hz 3 Phase



Cat. No.

3

2.2

160-BMA2

160-MMA1

1321-3R12-A

160-LFA2

1/2

0.37

160-BMB1

160-MMB1

1321-3R2-B

160-LFB1

160-RFB-3-A

160-CMA1 160-CMB1

3/4

0.55

160-BMB1

160-MMB1

1321-3R2-A

160-LFB1

160-RFB-3-A

160-CMB1

1

0.75

160-BMB1

160-MMB1

1321-3R2-A

160-LFB1

160-RFB-3-A

160-CMB1

2

1.5

160-BMB2

160-MMB1

1321-3R4-B

160-LFB1

160-RFB-9-A

160-CMB1

3

2.2

160-BMB2

160-MMB1

1321-3R8-B

160-LFB1

160-RFB-9-A

160-CMB1

Replacement Parts and Accessories Fan ➄ Replacement Kit

Ready/ Fault Panel

Program Keypad Module

DeviceNet Communication Module

Cat. No.

Cat. No.

Cat. No.

Cat. No.

160-FRK1

160-B1

160-P1

160-DN1

Drivee Mo Dr Model el

24V DC Interface ➅

Analog

160-DM-SF1

Preset

160-DM-PS1

Cat. No.



Catalog numbers listed 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.



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.

A-4

Appendix A – Specifications and Accessories

Figure A.1 – Controller Dimensions Controllers Rated 200 – 240V Single Phase Overall Dimensions

160S AA02

H mm (inches)

160S AA03

160S AA04

160S AA08➀

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 Dimensions

160 AA02

H mm (inches)

160 AA03

160 AA04

160 AA08

160 AA12

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 (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)

1.1 (2.46)

H

Controllers Rated 380 – 460V 3 Phase Overall Dimensions H mm (inches) W mm (inches)

160 BA01

160 BA02

160 BA03

160 BA04

160 BA06

152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) 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 (5.4)

136 (5.4)

136 (5.4)

Weight Kg. (lbs.)

0.8 (1.76)

0.8 (1.76)

0.8 (1.98)

0.9 (1.98)

1.1 (2.46)



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

Dimensions

DIN Mounting Debris Cover

Metric

English

Min. Panel Thickness (14 GA)

19mm

0.0747 in.

Mounting Base Screws

m4 x 0.7

# 8 – 32

Mounting Torque

1.13 to 1.56 Nm

10 – 14 lb. in.

D See Figure A.1 for details on controller dimensions and weights. D 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.) D 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 (.230) 4 places

72 (2.8) 50 (1.9)

86,4 (3.4)

8 (.315)

B

14 (.551)

A

GND BR BR

29 (1.1)

Cat. No.

A

B

160-BMA1 & 160-BMB1

245 (9.64)

225 (8.86)

160-BMA2 & 160-BMB2

334 (13.15)

314 (12.36)

A-6

7,5 (.295)

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)

40,2 (1.6)

L1 R

L2 S

L3 T

MOV MODULE

45,4 (1.8)

0,54 (.021) 71 (2.8) 5,1 (.199) Pin Extension

Figure A.5 – Line Reactor Cat. No.

A

B

C

D

E

1321-3R2-A

112 (4.4)

102 (4.0)

74 (2.9)

50 (2.0)

36 (1.44)

1321-3R2-B

112 (4.4)

102 (4.0)

74 (2.9)

50 (2.0)

36 (1.44)

1321-3R4-B

112 (4.4) 112 (4.4)

102 (4.0) 102 (4.0)

74 (2.9) 74 (2.9)

50 (2.0) 50 (2.0)

36 (1.44) 36 (1.44)

1321-3R8-A

152 (6.0)

122 (4.8)

79 (3.1)

54 (2.1)

50 (2.0)

1321-3R8-B

152 (6.0)

122 (4.8)

79 (3.1)

54 (2.1)

50 (2.0)

1321-3R12-A

152 (6.0)

122 (4.8)

79 (3.1)

54 (2.1)

50 (2.0)

A

1321-3R4-A B

E

D

C

A-7

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 B mm (in.)

C E

H

F

A

D

G

Line Filter Module

B

C

D

E

182.0 (7.17)

75.0 (2.95)

30.0 (1.18)

167.0 (6.57)

60.0 (2.36)

160-RFB-3-A

182.0 (7.17)

75.0 (2.95)

35.0 (1.38)

167.0 (6.57)

60.0 (2.36)

160-RFB-9-A

182.0 (7.17)

75.0 (2.95)

47.5 (1.87)

167.0 (6.57)

60.0 (2.36)

160-LF (All Types)

174.0 (6.85)

75.0 (2.95)

50.0 (1.97)

163.0 (6.41)

60.0 (2.36)

160S-RFA-6-A 160S-RFA-10-A 160S-RFA-16-A

A-8

A

F

G

H

6.5 x 4.5 (0.26 x 0.18) hole dim. (2 ( places) p ces)

4.2 (0.17) dia. hole ( places) (2 p ces)

200 (7.87)

6.9 x 5.25 (0.272 x 0.207) hole dim.

6.9 x 5.25 (0.272 x 0.207) hole dim.

200 (7.87)

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.7 – Capacitor Module 50 (1.97) 4,5 (.177) Mounting Holes

110,9 (4.37)

40 (1.5)

140 (5.51) 150,9 (5.94)

130 (5.11)

254 (10) Approximate Lead Length

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 (0.68) Required for Removal

161,2 (6.35) Overall Height with DeviceNet Module

167,82 (6.61) Overall Height with DeviceNet Connector

Figure A.9 – 24V DC Interface Module 29 ➀ (1.14)



A-10

This device does not effect the overall height of the drive.

Appendix 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 tested 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 & 7) must have a solid connection to PE (protective earth).

B-1

Appendix B – CE Compliance

D Input power, output power and control wiring outside the enclosure must use separate shielded cables, or separate conduit.

General Instructions for an EMC Compliant Installation Refer to Figure B.1. Shielded Enclosure

Cable Clamps

D Typical NEMA or IEC metal enclosures are adequate.

D Use suitable EMC-tested cable clamps only.

D The ground connection of the shielded enclosure must be solidly connected to the PE terminal of the controller. Good conductivity must be assured – grounding must provide a low impedance path to high frequency signals.

D The connection area must be 360 degrees around the shielded cable.

D All wiring, except input power leads, must use shielded cable.

D When using conduit, the contact point of metal entry connections must be free of paint or non-conductive surfaces and solidly connected with good conductivity to the enclosure.

D The cable clamps also provide strain-relief for the cable.

D Input power, output power and control wiring inside the enclosure must be physically separated. Figure B.1 – Recommended Grounding Configuration

Enclosure Ground Connection

PE AC Input Line

R (L1) Line S (L2) Filter T (L3)

T (L3) S (L2) R (L1)

Ground Tab – PE Line Power TB1

L1 R

L2 S

L3 T

BR –

BR +

FAULT READY

to TB3 1 2 3 4 5 6 7 8 9 10 11

Control Wiring TB3 Motor Wiring TB2

TI U

T2 V

T3 W

– DC

Control Cabinet *

+ DC

Shielded Motor Cable W (T3) V (T2) U (T1) Shielded Enclosure = EMC Tested Shielded Cable Clamp (or Metal Conduit) * When the control circuitry is located outside of the 160 enclosure.

B-2

to Motor

Appendix B –CE Compliance

Motor Cable D 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. D Do not exceed the maximum motor cable length for the specific line filter module used. D Inside the shielded enclosure, shielded motor cable must be used as close to the controller’s output terminals as possible. The shield must

be solidly connected to the PE terminal of the controller. D 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. D 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.

Figure B.2 – Motor Connections Ground Tab – PE

L1 R

L2 S

L3 T

BR –

BR +

FAULT READY

4 Wire Shielded Motor Cable

1 2 3 4 5 6 7 8 9 10 11

Motor Wiring TB2

TI U

T2 V

T3 W

– DC

+ DC

Ground to Motor Housing W (T3) V (T2) U (T1) Shielded Enclosure = EMC Tested Shielded Cable Clamp (or Metal Conduit)

Figure B.3 – Shielded Motor and Control Cable Example 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

Control Cable D Control wiring must use shielded cable, or grounded metal conduit. Refer to Figure B.3 and Figure B.4. D The shield must be connected to signal common at both ends of the cable. D The Common terminals (TB3-3 & 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

L1 R

L2 S

L3 T

BR –

BR +

FAULT READY

Control Cabinet *

1 2 3 4 5 6 7 8 9 10 11

Control Wiring TB3 TI U

T2 V

T3 W

– DC

to TB3 Signal Common

+ DC

Shielded Control Cable Shielded Enclosure = 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: D 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

D 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. D 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 will conform. Many factors can influence the total installation and only direct measurements can verify total conformity.

Index

  24V DC interface, A-10 50 Hz dipswitch, 3-2 60 Hz dipswitch, 3-2

 AC input wiring, 2-2 accel/decel control, 5-4, 5-11 accessories, A-4 ambient temperature, A-2 analog input, 2-6, 2-7 analog scaling analog input, 5-3 zero offset, 5-10 analog input maximum, 5-12 analog input minimum, 5-12 analog select, 5-12 approvals, A-2 auto restart restart time, 5-8 restart tries, 5-8

 block diagram, 6-4 branch circuit disconnect, 2-2, 2-3

 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, A-3 catalog number description, 1-2 CE, 2-1, A-2, B-1 changing base frequency, from factory default, 3-2 clearing faults, 5-9, 6-1 compensation, 5-12 control wiring Analog Signal Follower model, 2-6 Preset Speed model, 2-6 control wiring requirements Analog Signal Follower model, 2-6, 2-7 Preset Speed model, 2-6, 2-7 controller features, 2-1 controller specifications, A-1 conventions used in this manual, 1-2 CSA, A-2 CUL, A-2

current limiting, 5-6 current rating, A-1

 DB enable, 5-8 DC brake to stop, 5-4, 5-6 DC hold level, 5-6 defaults, resetting to, 5-10 determining drive information, 1-2 DeviceNet module, A-10 diagnostics, 5-2, 5-3, 6-2, 6-3 dimensions, A-5 display group, 5-2, 5-3 display group parameters, 5-2, 5-3 display mode, 3-1 dynamic brake, connection, 2-2 dynamic brake module, A-6

 electrostatic discharge, 1-1, 3-2 EMC control connections, B-4 grounding configuration, B-2 installation, B-1 motor connections, B-3 shielded motor and control cable example, B-3

 fan/pump volts/hz patterns, 5-5 fault buffer, 5-2 fault information, troubleshooting, 6-1 fault LED, 6-1 faults, clearing, 5-9, 6-1 frequency dipswitch, 3-2 frequency source selection Analog Signal Follower model, 2-6, 2-7, 5-10 Preset Speed Model, 2-6, 2-7, 5-11

 general precautions, 1-1 grounding, 2-6

 input mode selection, 2-8, 5-7 input power conditioning, 2-2

line filters, A-4, A-8 line reactor, A-4, A-8 line side protection, 2-3

I-1

Index low voltage directive compliance, B-4

 min/max frequency, 5-4 minimum clearance, 2-1 motor cable lengths, effects, 2-4 motor cable recommendations, 2-4 mounting requirements, 2-1, A-5 MOV module, A-4, A-7

 nameplate information, 1-2

 operating controller with program keypad module, 2-1, 3-1 without program keypad module, 2-1 output contacts, 2-7, 5-7 output ratings, A-1 overload protection, 2-2, 5-6

 parameters display group, 5-2 overview, 5-1 program group, 5-4 potentiometer wiring, 2-6 power, wiring, 2-2 precautions, 1-1 preset frequencies, 2-7, 5-11 program group, parameters, 5-4 program keypad module description, 3-1 display mode, 3-1 features, 3-1 installation, 3-2 key descriptions, 3-1 program mode, 3-1 removal, 3-2 program lock, 5-10 program mode, 3-1

I-2

programming, 3-1, 5-1

 reflected wave, cable length recommendations, 2-4 replacement parts, A-4 resetting, to factory defaults, 5-10 reverse, 2-6, 3-1 RWR (reflected wave reducer), 2-4, 2-5

 S-curve, 5-9 skip frequency, 5-5 specifications, A-1, A-2, A-3 standards compliance, A-2 start, 2-7, 2-8, 2-9, 3-1 start-up, 4-1 stopping, 2-7, 2-8, 2-9, 3-1, 5-4 storage temperature, 2-1, A-2

 terminal blocks specifications, 2-2, 2-6 TB1, 2-1, 2-2 TB2, 2-1, 2-2 TB3, 2-1, 2-2, 2-7 torque ratings, A-1 troubleshooting, 6-3 fault descriptions, 6-1

 vibration, A-2 voltage rating, A-1

wiring control and signal, 2-6, 2-7, 2-8, 2-9 input line fuses, 2-3 motor cable recommendations, 2-4 terminal blocks specifications, 2-2, 2-6 wire size recommendations, 2-2, 2-6

Rockwell Automation helps its customers receive a superior return on their investment by bringing together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate products. These are supported by local technical resources available worldwide, a global network of system solutions providers, and the advanced technology resources of Rockwell.

Worldwide representation. Argentina • Australia • Austria • Bahrain • Belgium • Bolivia • Brazil • Bulgaria • Canada • Chile • China, People’s Republic of • Colombia • Costa Rica • Croatia • Cyprus • Czech Republic • Denmark • Dominican Republic • Ecuador • Egypt • El Salvador • Finland • France • Germany • Ghana • Greece • Guatemala • Honduras • Hong Kong • Hungary • Iceland • India • Indonesia • Iran • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Macau • Malaysia • Malta • Mexico • Morocco • The Netherlands • New Zealand • Nigeria • Norway • Oman • Pakistan • Panama • Peru • Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia • Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic of • Spain • Sweden • Switzerland • Taiwan • Thailand • Trinidad • Tunisia • Turkey • United Arab Emirates • United Kingdom • United States • Uruguay • 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 Supercedes Publications 0160-5.9 – December 1996, 0160-5.9DU2 – May 1997, 0160-5.9DU4 – January 1998

40055–180–01(01) Copyright 1996 Allen-Bradley Company, Inc., a Rockwell International company

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User Manual - Rockwell Automation

Allen-Bradley 160 SSC  Variable Speed Controller (Series B) 0.37 – 2.2 kW (0.5 – 3 HP) FRN 5.xx – 6.xx User Manual Important User Information In n...

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