Rockwell Automation 160 AC User Manual

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Allen-Bradley

160 SSC  V ariable 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.

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:

A TTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

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.

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.

This Page Intentionally Left Blank.

Notes

N-1

Notes

This Page Intentionally Left Blank.

N-2

This Page Intentionally Left Blank.

Notes

N-3

Notes

This Page Intentionally Left Blank.

N-4

Attach template to mounting surface

and drill four (4) 4.5mm (0.177 inches) diameter holes.

Dimensions are in millimeters [inches].

Publication 160-5.9 Summary of Changes

D The Firmware Version of the drive was

changed from FRN5.01 to FRN6.0.

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 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

Summary of Changes

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

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. T able 2.C and Table 2.D have also been updated.

D The paragraph titled “Motor Cable

Recommendations” has been updated. T able 2.E was added to provide recommended cable types based on cable distances and environmental conditions.

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 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

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 2-1. . . . . . . . . . . . . . . . . . . .

Installation and Storage 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CE Compliance 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Features 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Wiring For Preset Speed and Analog Signal Follower Models 2-2. . . . . . . . . . . . .

Input Power Conditioning 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Line Side Protection 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Cable Recommendations 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Wiring Requirements 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Wiring – Analog Signal Follower Model 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Wiring – Preset Speed Model 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Wiring Diagrams 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 – Program Keypad Module 3-1. . . . . . . . . . . . . . . . . . .

Features 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Mode 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Mode 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Program Keypad Module 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 – Start-Up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Chapter 5 – Parameters and Programming 5-1. . . . . . . . . . . . . . .

Overview of Parameters 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programming Example 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Group Parameters 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Group Parameters 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 – Troubleshooting and Fault Information 6-1. . . . . . . .

Fault Information 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Block Diagram of Bulletin 160 Analog Signal Follower 6-4. . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Controller Specifications A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Catalog Numbers for Bulletin 160 Accessories A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Dimensions A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Dimensions A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Important Information

Appendix B

CE Compliance B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Essential Requirements for a Conforming EMC Installation B-1. . . . . . . . . . . . . . . . . . . .

General Instructions for an EMC Compliant Installation B-2. . . . . . . . . . . . . . . . . . . . . . .

Low Voltage Directive 73/23/EEC Compliance B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index

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

Information and Precautions

General Information1 Receiving –

thoroughly inspect the equipment before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are obviously damaged, do not accept delivery until the freight agent notes the damage on the freight bill.

If you find any concealed damage during unpacking notify the freight agent. Also, leave the shipping container intact and have the freight agent make a visual inspection of the equipment in order to verify damage.

General Precautions

In addition to the precautions listed throughout this manual, you must read and understand the following statements which are general to the system.

It is your responsibility to

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.).

ATTENTION: The surface temperatures of the controller may become hot, which may cause injury.

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: 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 P1

First Position

Bulletin Number

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

➀ This manual applies only to the open style (IP20) device. Refer to separate instruction sheets for Chassis Mount

and NEMA 4 (IP66) devices.

Second Position

Voltage Rating

A 200 – 240V 1∅

200 – 240V 3∅

B 380 – 460V 3∅

Figure 1.2 – Nameplate Information

CAT160–AA04NSF1P1 SER B

Hz:

VA:

ALLEN-BRADLEY

S/N 32098

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

IP20

WARNING: ! Allow 1 Minute after power is removed before servicing. Accessible surfaces may be hot. Compatible with Type B RCD protection devices only.

200-240

5.4 50/60

2200

Third Position

Current Rating

A01 A02 A03 A04 A06

Fourth Position

Enclosure Type

Letter Type N Open (IP20) P Chassis Mount

(external heatsink)

A08 A12

3∅

U T P U T

4mm Torque 1.35 Nm (12 in.-lbs.)

200-230

4.5

Hz:

0-240

Motor

0.75kW/1HP

Rating:

– .75mm2 (12 – 18 AWG.)

Fifth Position

Control

SF1 = Analog

Signal

➀

Follower

PS1 = Preset

Speed

FRN:

6.xx

3∅

MADE IN U.S.A.

Sixth Position

Programmer (Optional)

Program Keypad Module

Nameplate is located on the side of the unit.

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

Installation and Wiring

Chapter 2

Installation and Storage

Take these actions to prolong controller life and performance:

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

D protect the cooling fan by avoiding dust or

metallic particles

D avoid storing or operating the controller where

it could be exposed to a corrosive atmosphere

D protect from moisture and direct sunlight D operate at an ambient temperature range of 0_

to +50_C

T o 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.

CE Compliance

Refer to Appendix B for detailed information.

Mounting Requirements

Controller Features

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

Important: The features are the same for single and three phase units.

Figure 2.1 – Controller Features

Ground Tab/ Protective Earth

L3L2L1

FAUL T ➁

READY ➂

–

876543219110 1

–

T1T

VDCDC

Terminal Block One (TB1) – For Line

Power. ➀

Ready/Fault Indicating Panel –

Standard for Bulletin 160 controllers. ➃

LEDs – Indicate operational status.

Terminal Block Three (TB3) – For Control

Wiring.

Terminal Block Two (TB2) – For Motor

Wiring. ➀

Description Metric English

Min. Panel Thickness (14 GA) 1.9mm 0.0747 in. Mounting Base Screws m4 x 0.7 # 8–32 Mounting T orque 1.13 to 1.56 Nm. 10–14 lb. in.

D See Appendix A 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. T o ensure proper controller operation, remove cover before applying power.

Fan DIN Latch

➀ Refer to Figure 2.2 ➁ 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.

➂ The READY (green) indicator illuminates when the DC bus is

charged and the controller is ready to run.

➃ Bulletin 160 controllers are fully functional when installed with a

Ready/Fault indicating panel. All control functions can be performed from the control terminal block (TB3). Factory default parameter settings cannot be changed with the Ready/Fault indicating panel.

A Program Keypad Module can be ordered separately, Catalog 160-P1, or as a factory-installed option by adding “P1” to the end of the catalog number. Refer to Chapter 3, Program Keypad Module for a detailed explanation of functionality.

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

➀ For single phase input applications, connect the AC input line to

input terminals (L1) R and (L2) S.

➁ Connection for dynamic brake resistors for all models.

Important: P52 – [DB Enable] must be enabled for proper

operation. See Appendix A for part numbers.

➂ Bulletin 160 controllers are

motor overload protective devices. An external overload relay is not required

➃ Connection for an external capacitor module. Provides extended

ride through capability and improved inherent braking performance. See Appendix A for part number.

L3L2L1

VDCDC

Motor ➂

for single motor applications.

Input Line Protective Device –

See Table 2.C and Table 2.D.

BR BR

–

Capacitor Module Option ➃

Dynamic Brake Module Option ➁

Terminal Block One (TB1) – For

Line Power and Brake Resistor.

Terminal Block Two (TB2) –

For Motor and Capacitor Module.

and listed as

Power Wiring For Preset Speed and Analog Signal Follower Models

Table 2.A – Power Terminal Block Specifications

Terminal

Block

TB1 TB2

➄ The Bulletin 160 SSC is IP20 with wires installed on power

terminal blocks.

Screw

Size

➄ ➄

Max/Min Wire

Size mm

M4 4 – 0.75 (12 – 18) 1.81 – 1.35 (16 – 12) M4 4 – 0.75 (12 – 18) 1.81 – 1.35 (16 – 12)

(AWG)

Max/Min Torque

Nm. (lb.in.)

Input Power Conditioning

The controller is suitable for direct connection to AC power lines within the rated voltage of the controller (see Appendix A). Listed below are

certain power line conditions which may cause component damage or reduction in product life. If any of the conditions exist as described in

the table below, install “one” of the devices listed under the heading “Corrective Action” on the line side of the controller. Important: Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Table 2.B – Power Line Conditions

2-2

A TTENTION: 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.

Power Line Condition Corrective Action

Available short circuit currents (fault currents) greater than 10,000 Amps

Line has power factor correction capacitors

Line has frequent power interruptions

Line has high frequency (>10 Hz) noise spikes in excess of 900V (Induction heaters, RF equipment, choppers)

Line has intermittent noise spikes in excess of 2000V (lightening)

S Check supply voltage. S Line Reactor (See A-4) or S Isolation Transformer

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

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

Chapter 2 –Installation and Wiring

at n

use

)N/A

)

(

)

****

)

(

)

***

)

***

at n

use

)

****

()

***

()

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.

The ratings in T able 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 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”.

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

kW (HP)

.37 (1/2 .55 (3/4)

.55 (3/4

.75 (1)

.75 (1

1.5 (2)

1.5 (2

2.2 (3)

1 ∅ Rating

kW (HP)

.37

.37 (1/2)

1/2

.55

.55 (3/4)

3/4

.75 (1)

.75 (1

1.5 (2)

Fuse

Rating

6 16.37 (1/2

6 6

15 (16

15 (16)

Fuse Types

Class CC Class J Rating Type

KLDR/CCMR

➁

➂

TMR

ATMR

➃

FNQR LPJ 16

FNQR

➇

➁

JDT

➂

AJT

➃

LPJ

Other Protective Devices

16 16

16 16 20

140-MN-****

140-MN-

1492-CB3-H***

1492-CB3-H

HFD ***L

HFD

➆

➄

➅

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

3 ∅ Rating

kW (HP)

.37 (1/2) N/A 3 (4)

.37 (1/2 .55 (3/4)

.55 (3/4

.75 (1)

1.5 (2)

2.2 (3)

➀ Must be dual element time delay. ➁ Littlefuse ➂ Gould Shawmut ➃ Bussman ➄ Allen-Bradley Bulletin 140 manual motor starter. Not recommended

for repetitive application of power to the input of the drive.

Fuse ratings in ( ) denote European size.

1 ∅ Rating

kW (HP)

N/ N/A

N/ N/A N/A N/A 15 (16) 16

Fuse

Rating

3 (4 3 (4)

3 (4

➀

➀ ➀

KLDR/CCMR

ATDR/ATQR

Fuse Types

Class CC Class J Rating Type

➁ ➂

➃

FNQR

➅ Allen-Bradley Bulletin1492 circuit breaker. Not recommended for

➆ Westinghouse type HFD circuit breaker

➇ Controller is also compatible with RK1, RK5, and BS88

➇

➁

JDT

➂

AJT

➃

LPJ

repetitive application of power to the input of the drive.

fuse types.

Other Protective Devices

6.3

6.3 16

140-MN-****

1492-CB3-H***

HFD ***L

➆

➄

➅

2-3

Chapter 2 –

Dry

Motor

Ratings

Insulat on

(3 HP)

(

)

(

)

(

)

(

)

Installation and Wiring

Motor Cable Recommendations

A variety of cable types are acceptable for variable speed controller installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 1 meter (3.3 feet) for every 10 meters (33 feet) of unshielded length. If you cannot

Table 2.E – Recommended Cable Type(s)

Condition Insulation Type(s) Example(s)

Dry

Wet XLPE XHHW-2

➀ For AC line voltages in excess of 264V AC, or motor cable

distances greater than 50 ft (15m), wire with XLPE insulation is recommended.

PVC① THHN

XLPE XHHW-2

separate motor cables from sensitive circuits, or if you must run motor cables from multiple controllers (more than three) in a common conduit or cable trays, shielded motor cable is recommended to reduce system noise.

Motor cables should be four-conductor with the ground lead and shield (if using shielded cable) connected to the controller ground terminal and the motor frame ground terminal.

T able 2.E provides the recommended wire type for both wet and dry installations as defined by NEC 1996 (70-31). These recommendations are based upon a variety of factors such as insulation thickness, susceptibility to moisture and

Long Motor Cable Effects

The controller should be installed as close to the motor whenever possible. Installation with long motor cables may require the addition of external devices to limit voltage reflections at the motor (reflected wave phenomona). See T able 2.F for recommendations.

Important: The use of an external device to limit reflected wave issues may effect the accuracy of the Bulletin 160 current sensing. T able 2.G provides recommended cable length due to Capacitive Current considerations.

susceptibility to nicks and cuts during installation.

Table 2.F – Cable Length Recommendations — Reflected Wave

380 – 460V

Insulation

Rating

2.2 kW

1.5kW 2 HP

0.75 kW 1 HP

0.55 kW

0.75 HP

0.37 kW

0.5 HP

➁ The reflected wave data applies to all PWM frequencies 2 to 8 kHz. For 230V ratings see Table 2.G. ➂ Cable lengths listed are for PWM frequencies of 2 kHz. Refer to publication 1204-5.1 for cable length recommendations at other PWM frequencies. ➃ 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.

1000 Vp-p 1200 Vp-p 1600 Vp-p 500➃152➃500➃152➃360 110 600 183 500➃152➃500➃152

1000 Vp-p 40 12 40 12 300 92 300 92 250 76 250 76 1200 Vp-p 60 18 60 18 300 92 540 165 340 104 340 104 1600 Vp-p 500➃152➃500➃152➃300 92 540 165 500➃152➃500➃152 1000 Vp-p 55 17 40 12 300 92 300 92 325 99 325 99 1200 Vp-p 125 43 60 18 300 92 375 114 500 152 325 99 1600 Vp-p 500➃152➃500➃152➃300 92 375 114 500➃152➃500➃152 1000 Vp-p 45 14 40 12 300 92 300 92 300 92 300 92 1200 Vp-p 125 38 60 18 300 92 375 114 500 152 500 152 1600 Vp-p 500➃152➃500➃152➃300 92 375 114 500➃152➃500➃152 1000 Vp-p 45 14 40 12 300 92 300 92 300 92 300 92 1200 Vp-p 125 38 50 15 300 92 375 114 500 152 500 152 1600 Vp-p 500➃152➃500➃152➃300 92 375 114 500➃152➃500➃152

Motor Cable Only RWR at Drive

Shielded Unshielded Shielded Unshielded Shielded Unshielded

ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.

40 60 18 60 18 360 110 600 183 260 79 260 79

12 40 12 360 110 300 92 210 64 210 64

➁

③

Reactor at Motor

➃

2-4

Chapter 2 –Installation and Wiring

Ratings

(3 HP

(2 HP

(1 HP)

(0.75 HP)

(0.5 HP)

Ratings

Table 2.G – Cable Length Recommendations — Capacitive Current

380 – 460V

2.2 kW

1.5 kW

0.75 kW

0.55 kW

0.37 kW

kHz

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 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 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 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 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

Motor Cable Only RWR at Drive

Shielded

②

Unshielded Shielded

②

ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.

➀ ➀ ➀ ➀

①

Reactor at Motor

Unshielded Shielded

310 94 420 128

300 91 350 107

300 91 300 91

②

Unshielded

200 – 240V

Shielded Unshielded Shielded Unshielded Shielded Unshielded

ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.

0.37 to 2.2 kW

Motor Cable Only RWR at Drive Reactor at Motor

(0.5 to 3 HP) 2 thru 8 kHz

➀ Not recommended for use above 4 kHz PWM frequency. ➁ When using shielded cable at lightly loaded conditions, the 0.75 Kw (1 Hp) and below cable length recommendations are 61m (200 ft.)

➂ Not recommended for 230V applications.

500 152 800 244 ③ ③ ③ ③ 500 152 800 244

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. T o improve noise immunity the control terminal block common must be connected to earth ground.

D use Belden 8760 (or equivalent) — 18AWG

(0.750mm conductor.

Table 2.H – Control Terminal Block Specifications

Terminal

Block

), twisted pair, shielded or 3

Max/Min

Wire Size

(AWG)

TB3 2.5 – 0.5

(14 – 22)

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.

Max/Min

Torque

Nm. (lb.in.)

0.8 – 0.4 (8 – 4)

Control Wiring – Analog Signal Follower Model

You can control the output frequency of the controller via the Control T erminal 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 T erminal 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.

2-6

A TTENTION: 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.

Chapter 2 –Installation and Wiring

Control Wiring

Figure 2.3 – TB3 Control Wiring for Analog Signal Follower Model

Shielded Wire

Signal Specification

+ 10V Pot

Pot Wiper or

+10/–10V DC Input

Common

4–20mA Input

Reverse

Start

Common

Stop

Normally Closed

FAULT READY

Terminal

TB3

➂

Relay Common Normally Open

1101

= N.O. Momentary Contact = N.C. Momentary Contact

Figure 2.4 – TB3 Control Wiring for Preset Speed Model

Shielded Wire

Signal Specification SW1

SW2

2 3

Common

SW3

Reverse

Start Common

Stop

8 9

Normally Closed Relay Common Normally Open

1101

FAULT READY

TerminalTB3

➂

= N.O. Momentary Contact = N.C. Momentary Contact

10 kΩ Potentiometer, 2 Watts

Controller Input Impedance = 100 kΩ

➁

Common Controller Input Impedance = 250 Ω

Contact closure input Contact closure input

➁

Common

➀ ➀

Contact closure input required to operate controller

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

Contact closure input Contact closure input

➁

Common Contact closure input Contact closure input Contact closure input

➁

Common Contact closure input required to operate controller

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.

➀ ➀

➀

= N.O. Maintained Contact

➀

➀ Internal 12V supply. ➁ 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.

➂ This diagram shows “three wire” control. Refer to the following page for diagrams of other control wiring methods.

2-7

Chapter 2 –

Shielded Wire

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 — T wo 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 — T wo Wire “Accel/Decel” control.

Refer to Figure 2.8.

D Setting 5 — T wo Wire “Enable” control.

Refer to Figure 2.9.

D Setting 6 — T wo 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

Signal

TerminalTB3

Reverse

Start

Common

Stop

Specification

Contact closure input Contact closure input

➂

Common Contact closure input required to

operate controller

➀ ➀

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)

➁

Signal Specification

TerminalTB3

Run Reverse

Run Forward

Common

Stop

Contact closure input Contact closure input

➂

Common Contact closure input required to operate controller

➀ ➀

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

Signal Specification

TerminalTB3

Run Reverse

Run Forward

Common

7 8

Stop

Contact closure input Contact closure input

➂

Common Contact closure input required to

operate controller

➀ ➀

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 2.8 – TB3 Two Wire “Accel/Decel” control

Shielded Wire

➁

③

Refer to Figure 2.11.

Figure 2.9 – TB3 Two Wire “Enable” control

Shielded Wire

➁

③

Refer to Figure 2.11.

Figure 2.10 – TB3 Two Wire “Local/Remote” control

Shielded Wire

➁

③

Refer to Figure 2.11.

(Setting 4)

Signal

TerminalTB3

Run Reverse

Run Forward

Common

③

Accel/decel select

(Setting 5)

TerminalTB3

5 6 7

③

(Setting 6)

Signal

TerminalTB3

Run Reverse

Run Forward

Common

③

Local/ Remote

Signal Run Reverse Run Forward Common Enable

Specification

Contact Closure Input

③

Common Contact Closure Input Used to select Accel/Decel.

Specification

Contact Closure Input Contact Closure Input Common

Contact Closure Input required to operate controller

Specification

Contact Closure Input

③

Common

Contact Closure Input

Used to select local (TB3)

Control.

①

① ①

③

①

① ①

①

Figure 2.11

Input Mode

Setting

➃

➃ 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.

➄ When this input is in an open state, P69 – [Accel Time 2] and

P70 – [Decel Time 2] are active.

➅ When this input in in an open state, all power is removed from

the motor and it will “coast to rest”.

➆ 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].

TB3-8

Open

Accel 2

Decel 2

Controller

Disabled

Local (TB3)

Control

TB3-8

Closed

➄

➅

➆

Accel 1 Decel 1

Controller

Enabled

Remote

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

Program Keypad Module

Chapter 3

Features

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

D five keys on the module for display or

programming controller parameters

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

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

SELect

The program mode. It enables the editing of a parameter value. When you press this key the program mode indicator flashes.

disables the editing of a parameter

The

motor rotates in reverse direction.

key is only used while in

The

ESCape

toggle between the display mode

and program mode. When in

program mode, this key also

key allows you to

counter clockwise LED

illuminates constantly when the

manual.

value.

➀

When the

indicator

parameter value. When in display mode, the program indicator does not display.

Display Mode

The controller always powers up in the display mode. While in this mode you may view all read only controller parameters, but not modify them.

Program Mode

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

program mode

flashes, you can edit the

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

up/down

Use the 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 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.

enter

➂

key

Pressing the

motor to ramp down to 0 Hz and then

ramp up to its set speed in the opposite

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.

➁

When the motor is running, pressing this key causes the (currently illuminated) LED to flash indicating motor rotation while

reverse

key causes the

direction.

The

illuminates constantly when

➁

the motor rotates in forward

clockwise LED

direction.

➂

stop

The

start

key initiates a start command when the controller is programmed

➀

for local start/stop control (when P46 – [Input Mode] is set to “2”).

decelerating to zero. The opposite LED will illuminate indicating the commanded direction.

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

The motor to “Coast”, “Ramp” or “DC Brake” to stop depending on the setting of P34 – [Stop Mode].

key initiates the

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.

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.

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

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]

Start-Up

Chapter 4

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

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.

Verify the controller is installed per instructions outlined in Chapter 2 including:

D Minimum clearance distance between controller and other equipment. D Proper grounding practices have been followed. D Proper power and control wiring has been used.

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]

Start-Up Checklist

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.

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.

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.

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.

4-1

Chapter 4 –Start-Up

If you have a blank display panel.

The READY [green] indicator will illuminate. Use remote inputs to TB3 control terminal block to operate the 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.

Reconnect the power to the controller.

Do you have a Analog Signal Follower controller or a Preset Speed controller?

Analog Signal Follower controller Preset Speed 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.

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 STOP command from either the program keypad module or TB3 control block terminal.

Start-Up is complete.

Disconnect and lock out all incoming power to TB1 terminals L1, L2, and L3 [R, S and T].

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

Yes No

4-2

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.

Is the direction of motor rotation correct?

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.

Parameters and Programming

Chapter 5

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

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.

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 Keypad Display

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.

= Parameter applies only to the Analog Signal Follower model

= Parameter applies only to the Preset Speed model

300.

Program Mode Indicator

3. Press the SELect key. The program mode indicator flashes indicating

that you can use the up/down keys to change the parameter value.

4. Change the decel time value from the factory default of 10 seconds to

2.2 seconds by pressing the down key until 2.2 displays.

Important: Continuously holding the up or down key will cause the value to increase or decrease as long as the key is pressed.

5. When the desired value displays, press the ENTER key. This writes

the new value to memory. The program mode indicator will stop flashing and the display will flash once indicating that the new value has been accepted.

Important:

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.

If at any time (while in the program mode) you wish to abort

Program Mode Indicator Flashes

Program Mode Indicator Stops Flashing

1. 2.

1. 1 0.

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

[Output Frequency] Displays the output frequency at TB2 terminals T1, T2 and

T3 (U, V and W).

[Output Voltage] Displays the output voltage present at TB2 terminals T1, T2 and

T3 (U, V and W).

[Output Current] Displays the output current present at TB2 terminals T1, T2 and

T3 (U, V and W).

[Output Power] Displays the output power present at TB2 terminals T1, T2 and T3

(U, V and W).

Parameter Description

05 [Bus Voltage] Displays the DC Bus Voltage level.

[Frequency Command] Displays the frequency that the controller is

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

[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.

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

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

coded format.

Important: A “0” = inactive

and a “1” = active.

Bit 3 Bit 2 Bit 1 Bit 0

Running Forward

Accel Decel

Min/Max

Range

0 to 240 0.1 Hz

0 to [Max Voltage] 1 V olt

0 to 2 Times

Controller Rated

Output Current

0 to 2 Times Rated

Controller Output

Power

0 to 400 – [230V]

0 to 800 – [460V]

0 to 240 0.1 Hz

0 to 49 Numeric Value

0 to 150 1 Degree C

0000 to 1011 Binary Number

Units

0.01Amps

0.01 kW

1 Volt

5-2

[Controller Type] Used by Rockwell Automation field service personnel.

[Control Version] Displays version of controller firmware. Used by Rockwell

Automation field service personnel.

Numeric Value Numeric Value

Fixed Value Numeric Value

Display Group

ÁÁÁÁ

[Input Status] Displays the open (0) and closed (1) state of the

inputs to TB3 in binary coded format as follows:

Parameter Description

Chapter 5 – Parameters and Programming

Min/Max

Range

Bit 3 Bit 2 Bit 1 Bit 0

Units

Input Mode 2 (Keypad)

N/A

Input Mode 3 (Momentary Run FWD/ Run REV)

Run

Reverse

Input Mode 4 (Accel/ Decel)

Reverse

Bit 0 TB3-5

Input Mode 0 (3-Wire)

Reverse

Input Mode 1 (2-Wire)

Run

Reverse

0=Accel 2/

Bit 1 TB3-8

Bit 2 TB3-6

Bit 3 Polarity

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

Stop

Start

Forward

0 = Positive Analog Input 1 = Negative Analog Input

Stop

Run

Stop

N/A

Stop

Run

Forward

Decel 2

1=Accel 1/

Decel 1

Forward

Input Mode 5 (Enable)

Run

Reverse

0=Drive 1=Drive

Run

Forward

Input Mode 6 (Local/ Remote)

Run

0=Local (TB3)

Disable

1=Remote

Enable

Run

voltage and motor current.

14 [Memory Probe Display] Used by Rockwell Automation field service

personnel.

[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 Bit 0

SW1 SW2

SW3 Not Used

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

P60 – [Zero Offset], P75 – [Analog Input Minimum], and P76 – [Analog Input

БББББББББББББББББ

Maximum].

Important: On initial set up of the controller, apply a 0V or 4mA analog command to the

БББББББББББББББББ

controller. Once applied, if the value of this parameter displays something other than zero,

БББББББББББББББББ

program that value into P60 – [Zero Offset]. Important: The value of the [Zero Offset] will

БББББББББББББББББ

be subtracted from the value of this parameter.

= This parameter applies only to the Preset Speed model.

Run

Reverse

Control Control

Run

Forward

0000 to 1111 Binary Number

0.0 to 180.0 0.1 degrees

Numeric Value

ÁÁÁÁ

Numeric Value

ÁÁ

0000 to 0111 Binary Number

–150 to +150.0

ÁÁÁÁ

0.1%

ÁÁ

= 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# Parameter Description

[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

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.

[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.

➀

[Minimum Frequency] Lowest frequency that controller will output

continuously.

➀

[Maximum Frequency] Highest frequency the controller will output.

Important: This parameter can’t be changed while running.

[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)

Max. Frequency

Speed

Accel

Time

'a a

Time

Decel

Time

Min/Max

Range

0.0 to 600 0.1 Seconds

0.1 to 600 0.1 Seconds 10.0

0 to 240 1 Hz 0 Hz

0 to 240 1 Hz 60 Hz

0 to 3 Numeric

Units Factory

Value

Default

10.0

Seconds

Important: DC Injection braking with auto shutoff: works the same as standard

DC injection braking except that it may shut off before the P44 – [DC Hold Time]. This occurs if the controller is out of current limit before the P44 – [DC Hold Time] expires.

35 [Base Frequency] Set value to motor’s rated nameplate frequency. 36 [Base Voltage] Set value to motor’s rated nameplate voltage.

➀ 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].

➁ 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.

10 to 240 1 Hz 60 Hz

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

➁

5-4

Boost Select

Chapter 5 – Parameters and Programming

Program Group

P# Parameter Description

37 [Maximum Voltage] Sets the highest voltage that the controller will

output. P37 – [Maximum Voltage] must be greater than or equal to P36 – [Base Voltage].

[

curve.

See Settings 1

through 8 below

[Skip Frequency] Works in conjunction with P40 – [Skip

Frequency Band] creating a range of frequencies at which the controller will

not operate continuously.

Frequency

Command

Frequency

Skip

Frequency

Setting

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.

] Sets the boost voltage and redefines the Volts per Hz

100

1/2

Base Volts

[Base Voltage], %

[Base Frequency], %

Setting Boost Voltage % of [Base Voltage]

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

Controller Output Frequency

9 10

11 12

Freq.

1/2 Base

50 100

Setting Fan/Pump Curves

45.0

40.0

35.0

30.0

Time

➀

Break Point Voltages

in % of

[Base Voltage]

Two times

P40–[Skip Freq Band]

Setting

Min/Max

Range

20 to 510 for

460V units and

20 to 255 for

230V units

0 to 12 Numeric

0 to 240 1 Hz 240 Hz

0 to 30 1 Hz 0 Hz

Units Factory

1 Volt 460 Volts for

Value

Default

460V units

and 230 for

230V units

5-5

Chapter 5 –Parameters and Programming

DC Injection Braking Mode

amp to Stop Mode

Program Group

P# Parameter Description

41 [Motor Overload Select] Selects the derating factor for the I

load function.

t over-

Min/Max

Range

Units Factory

Default

100

[Overload Current]% of Setting

100

80 60 40 20

[Overload Current]% of Setting

No Derating

80 60 40 20

0 25 50 75100 125150

Max Derating

0 25 50 75100125 150

% Base Speed

175 200

100

[Overload Current]% of Setting

Min Derating

80 60 40 20

0 25 50 75100 125 150

% Base Speed

Settings:

0 = No Derating 1 = Minimum Derating 2 = Maximum Derating

175 200

42 [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.

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 2 Numeric

0.1 to 200%

of controller

rating

1 to 180%

of controller

rating

0 to 25 0.1 Second 0 Seconds

0 to 115 1 Volt 0 Volts

Value

.01 Amperes 115% of

1 % 150%

Controller

Rating

Volts and Speed

5-6

Important: If the current exceeds P43 – [Current Limit] the voltage applied to

the motor will be less than this setting.

Speed

Stop Command

Voltage

[DC Hold Time]

[DC Hold Voltage]

Time

Volts and Speed

Voltage

Speed

Stop Command

[DC Hold Time]

[DC Hold Voltage]

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. the controller is running. Also, power must be cycled or P56 – [Reset Func-

tion] must be set to “2” for the change to take effect.

Settings: 0 = “3 wire” control

See Chapter 2 for wiring diagrams and description of settings.

47 [Output Configure] Configures the TB3 relay output functionality.

Important: This parameter cannot be programmed while

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

Min/Max

Range

0 to 6 Numeric

Units Factory

Value

Default

Settings

0 = Controller

Ready/Faulted

1 = At Frequency 2 = Controller Running 3 = Reverse

4 = Motor Overload 5 = Ramp Regulated

6 = Above Frequency

7= Above Current

8 = Above DC Bus

Voltage

9 = Retries Exhausted the number of retries for P50 – [Restart Tries] is

Output changes state when...

energized and returns to shelf state when power is removed or when a fault occurs.

the controller reaches commanded frequency. the controller is running. the controller is commanded to run in the reverse

direction. when a motor overload condition exists.

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

the controller exceeds the frequency value set in P48 – [Output Threshold].

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. the controller exceeds the DC bus voltage value set

in P48 – [Output Threshold].

exceeded.

0 to 9

Numeric

Value

5-7

Chapter 5 –Parameters and Programming

Program Group

P# Parameter Description

48 [Output Threshold] Determines the on/off point for the TB3

output relay when [P47 – Output Configure] is set to 6, 7, and 8.

49 [PWM Frequency] Carrier frequency for the PWM output waveform.

The chart below provides derating guidelines based on the PWM freq. setting.

100

98 96

94 92 90 88

% Output Current (A)

86 84

Important: Ignoring derating guidelines can cause reduced controller perfor-

mance.

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.

Settings

12345678

Ranges

0 to 240 Hz

0 to 180 %

0 to 815 Volts

Carrier Frequency, kHz

Min/Max

Range

0 to 815 Numeric

2.0 to 8.0 0.1 kHz 4.0 kHz

0 to 9 Numeric

0.5 to 300 0.1 Seconds 10.0

0 to 100 Numeric

Units Factory

Value

Default

Seconds

5-8

Program Group

P# Parameter Description

53 [S-Curve] Enables a fixed shape S-Curve. See formula below:

Formula:

S-Curve Time = Accel or Decel Time x “S-Curve” setting

1/2 S-Curve

Time

1/2 S-Curve

Time

a'a'

(in percent)

Example:

Accel Time = 10 seconds S-Curve Setting = 3

S-Curve Time = 10 x .3

Enabled

Important: Maximum

S-Curve time is 60 seconds.

Disabled

Chapter 5 – Parameters and Programming

➀

= 3 Seconds

Min/Max

Range

S-Curve

Setting

0 = 0% 1 = 10% 2 = 20% 3 = 30% 4 = 40% 5 = 50% 6 = 60% 7 = 70% 8 = 80% 9 = 90%

10 = 100%

Units Factory

Numeric

Value

Default

Accel Time 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.

0 to 1 Numeric

Numeric Value Numeric

Value

Numeric

Value

5-9

Chapter 5 –Parameters and Programming

Program Group

P# Parameter Description

56 [Reset Functions] When using this parameter, the controller’s

parameters and their associated defaults are reset according to the descriptions below:

0 = Idle State 1 = Reset defaults (restores 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 [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].

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.

= This parameter applies only to the Analog Signal Follower model.

Min/Max

Range

0 to 2 Numeric

0 to 1 Numeric

0 to 240 0.1 Hz 60.0 Hz

0 to 1 Numeric

–50.0 to 50.0 Numeric

Units Factory

Value

Default

5-10

Chapter 5 – Parameters and Programming

ccel Time

Decel Time

ccel Time

Decel Time

Program Group

P# Parameter Description

61 [Preset Frequency 0] The programmed value sets the frequency that

the controller outputs when selected.

62 [Preset Frequency 1] The programmed value sets the frequency that

the controller outputs when selected

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

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.

66 [Preset Frequency 5] The programmed value sets the frequency that

the controller outputs when selected.

67 [Preset Frequency 6] The programmed value sets the frequency that

the controller outputs when selected.

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

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

Min/Max

Range

0 to 240 0.1 Hz 3 Hz

0 to 240 0.1 Hz 20 Hz

0 to 240 0.1 Hz 30 Hz

0 to 240 0.1 Hz 40 Hz

0 to 240 0.1 Hz 45Hz

0 to 240 0.1 Hz 50 Hz

0 to 240 0.1 Hz 55 Hz

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.

Units Factory

Default

Preset Accel/Decel Chart For Preset Speed Model Only

TB3-4 (SW3)

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

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.

TB3-2 (SW2)

TB3-1

(SW1) Preset Accel

30 – [A

69 – [A

➀

31 – [

0 – [

Decel

➀

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.

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.

= This parameter applies only to the Analog Signal Follower model.

5-12

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 to 1 Numeric

value

0.0 to 150.0 0.1% 0.0%

0.0 to 150.0 0.1% 100.0%

0 to 1 Numeric

value

Troubleshooting and Fault Information

Fault Information

Figure 6.1 – Fault Display

P07 – [Last Fault] Fault Code Number

➀

047 0

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 T able 6.A.

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.

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

D Set P54 – [Clear Fault] parameter to a “1”.

controller

Chapter 6

Table 6.A – Bulletin 160 Fault Descriptions

Fault

Number

Fault

Indication

Power Loss

ÁÁ

Fault

Under Voltage

Fault

ÁÁ

Over Voltage

ÁÁ

Fault

ÁÁ

Fault Description

DC Bus voltage remains below 85% nominal on

ББББББББББ

power up for longer than 5 seconds. DC Bus voltage fell below the minimum. For

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controllers rated at input voltage 200 – 240V AC, undervoltage trip occurs at 210V DC bus voltage

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(equivalent to 150V AC incoming line voltage).

ББББББББББ

For controllers rated at input voltage

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380 – 460V AC, undervoltage trip occurs at 390V DC bus voltage (equivalent to 275V AC

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incoming line voltage). DC Bus maximum voltage exceeded. For

ББББББББББ

controllers rated at input voltage 200 – 240V AC, overvoltage trip occurs at 410V DC bus voltage

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(equivalent to 290V AC incoming line voltage).

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For controllers rated at input voltage

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380 – 460V AC, overvoltage trip occurs at 815V DC bus voltage (equivalent to 575V AC

ББББББББББ

incoming line voltage).

ББББББББББ

Corrective Action

Monitor incoming AC line for low voltage or line

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power interruption. Monitor incoming AC line for low voltage or line

power interruption.

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Bus overvoltage caused by motor regeneration.

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Monitor incoming AC line for excessive voltage. Extend the decel time or install dynamic brake

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module or external capacitor module. See

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Appendix A.

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6-1

Chapter 6 –Troubleshooting and Fault Information

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

Fault

Number

ÁÁ

32 EEPROM

Fault

Indication

Motor Stall

ÁÁ

Fault

Motor

Overload

ÁÁ

Fault

ÁÁ

Over

Temperature

ÁÁ

Fault

Operator

ÁÁ

Fault

Overcurrent

FauIt

ÁÁ

Fault Description Corrective Action

Motor has stalled. Motor load is excessive.

ББББББББББ

Internal electronic overload trip. Excessive motor load exists.

ББББББББББ

Excessive heat detected.

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Keypad has been removed while controller is

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powered. Overcurrent detected in hardware trip circuit.

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EEPROM has invalid data. Reset EEPROM using P56 – [Reset Functions].

Fault

33 Max Retries

Fault

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

38 Phase U Fault Phase to ground fault detected between

controller and motor in phase U.

39 Phase V Fault Phase to ground fault detected between

controller and motor in phase V.

40 Phase W

Fault

41 UV Short

Fault

42 UW Short

Fault

43 VW Short

Fault

48 Reprogram

Fault

49 Zero

Overload

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

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

Occurs when controller parameters are reset to defaults.

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

Fault

Longer acceleration time or a reduced load

ББББББББББ

required. Reduce motor load until controller output current

does not exceed the current set by P42 – [Motor

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Overload Current]. Reduce P38 – [Boost

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Select]. Clear blocked or dirty heat sink fins. Check

ambient temperature. Check for blocked or

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non-operating fan. Clear fault. Do not remove keypad under power.

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

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Set to 1. Cycle power. Repair system fault.

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

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

Clear fault.

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

6-2

Table 6.B – Troubleshooting

Problem Corrective Action

Motor does not start (No output voltage to motor).

Controller Started but motor NOT rotating. (P01 – [Output Frequency] displays “0.0”).

Motor not accelerating properly.

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

Chapter 6 –

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

1. Check motor.

2. Check frequency source P06 – [Frequency Command].

3. Check control input signals.

4. Check parameter settings.

1. Check motor.

2. Check parameter settings.

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.

P46 – [Input Mode].

S If P46 – [Input Mode] is set to “2”, only the program keypad module Start button will start the

motor.

S Verify that motor is connected properly.

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.

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

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

S Verify that motor is connected properly. S Verify that no mechanical problems exist.

S Verify that S Verify that P43 – [Current Limit] is set properly. S Verify that

P30 – [Accel Time 1] or P69 – [Accel Time 2] is set properly.

P38 – [Boost Volts] is set properly.

Troubleshooting and Fault Information

6-3

Chapter 6 –Troubleshooting and Fault Information

Block Diagram of Bulletin 160 Analog Signal Follower

Capacitor ModuleBrake Module

DC–DC+BR–BR+

F r e q u e n c y

–10 to +10V

f e

Potentiometer r e

or n

4 – 20 mA

L1/R

L2/S

L3/T

Reverse Start

Stop Common

GND/PE

TB3 - 1 TB3 - 2 TB3 - 3

(Common)

TB3 - 4

TB3 - 5 TB3 - 6 TB3 - 8

TB3 - 7

Control Power

Opto Isolator

Bus Voltage Circuitry

C P U

Current Circuitry

Fault Feedback

Relay Circuitry

T1/U T2/V

T3/W

GND/PE

Program Keypad Module

TB3 - 9 TB3 - 10 TB3 - 11

Customer Programmable Output

Motor

6-4

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) Three Phase (input)

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) 180 – 265V Input kVA 1.1 1.4 2.2 3.7 5.7

Environmental Specifications

Cooling Method Convection Cooled Fan Cooled

AC Dynamic Braking Torque

With external Dynamic Brake Module (%) 300 233 200 150 115 Without external Dynamic Brake Module (%) 100 100 100 50 50

➀

160S-AA02 160S-AA03 160S-AA04 160S-AA08

160-AA02 160-AA03 160-AA04 160-AA08 160-AA12

Table A.2 – Specifications for Controllers Rated 380 – 460V Three Phase Input

Controller Catalog Number

Three Phase (input)

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) 340 – 506V Input kVA 1.1 1.6 2.2 3.7 5.7

Environmental Specifications

Cooling Method Convection Cooled Fan Cooled

AC Dynamic Braking Torque

With external Dynamic Brake Module (%) 300 233 200 150 115 Without external Dynamic Brake Module (%) 100 100 100 50 50

➀ Estimated. Actual value depends on motor characteristics.

➀

160-BA01 160-BA02 160-BA03 160-BA04 160-BA06

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 (%) 97.5% (Typical) Transient Protection Standard 2 kV (Optional 6 kV using MOV module). See accessories on page A-5.

Environmental Specifications (All Controller Ratings)

Enclosure IP 20 Ambient T emperature 0_C to 50_C Storage T emperature –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

Also accepts open collector/solid state inputs (sinking) with maximum leakage current of 50 mA.

Start, Stop, Forward/Reverse Configurable inputs for 2 or 3 wire control SW1, SW2, SW3

(Preset Speed Model only)

Programmable Input TB3-8 can be configured to select:

Approvals and Standards Compliance (All Controller Ratings)

Approvals

Optional 24V DC interface allows use of 24V DC sinking inputs.

Configurable Inputs for control of 8 preset speeds and 2 Accel/Decel times

10mA (typical) current flow.

See page A-4 for ordering information.

Accel/Decel Times

Controller Enable/Disable

Local/Remote

UL508C CSA 22.2

Designed to meet these standards IEC 146–1–1

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.

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

FCC Class A➀ and B VDE 0871➀ and 0875

A-2

➀

Appendix A – Specifications and Accessories

Table A.3 – Specifications For All Controller Ratings (continued)

Control Features (All Controller Ratings)

PWM Algorithm Sine Weighted PWM with Harmonic Compensation Switching Device (3-Phase Output) IGBT (Intelligent Power Module) V/Hz Ratio Programmable Carrier Frequency Adjustable from 2 kHz to 8 kHz in 100 Hz Increments (Factory default is 4 kHz) DC Boost Adjustable – Select from a family of Boost Curves Current Limiting Trip Free Operation, Co-ordinated for Controller and Motor Protection – Programmable from

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) 0.1 to 600 Seconds S-Curve Accel/Decel Time(s) 0 to 100% of Accel/Decel time – not to exceed 60 seconds Stopping Modes 3 modes (programmable)

Ramp to stop 0.1 to 600 seconds Coast to stop Stops all PWM Output DC Injection Braking Applies DC Voltage to the Motor for 0 to 25 seconds

Protective Features (All Controller Ratings)

Overcurrent 200% hardware limit, 300% instantaneous fault Excessive Temperature Embedded temperature sensor trips if heatsink temperature exceeds 95°C Over/Under Voltage DC Bus voltage is monitored for safe operation.

For controllers rated at input voltage 200 – 240V AC, overvoltage trip occurs at 410V DC bus

For controllers rated at input voltage 380 – 460V AC, overvoltage trip occurs at 815V DC bus For controllers rated at input voltage 200 – 240V AC, undervoltage trip occurs at 210V DC bus For controllers rated at input voltage 380 – 460V AC, undervoltage trip occurs at 390V DC bus

Control Ride Through Minimum ride through is 0.5 seconds – typical value 2 seconds Ground Short Any output phase to ground, detected at run Faultless Ride Through 100 Milliseconds Output Short Circuit 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

1% to 180% of Controller Output Current

voltage (equivalent to 290V AC incoming line voltage). voltage (equivalent to 575V AC incoming line voltage ). voltage (equivalent to 150V AC incoming line voltage).

voltage (equivalent to 275V AC incoming line voltage).

A-3

Appendix A – Specifications and Accessories

Dr e Mo el

Accessories

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

Rating

200 – 240V

50/60Hz 1 Phase

1 Pha

200 – 230V

50/60Hz 3 Phase

3 Pha

380 – 460V

50/60Hz 3 Phase

3 Pha

Controller

Ratings

1/2 3/4

0.37

0.55

0.75

1.5

0.37

0.55

0.75

1.5

2.2

0.37

0.55

0.75

1.5

2.2

ББББББББ

Input Voltage

Dynamic

ÁÁ

Brake

Module

ÁÁ

Cat. No.

160-BMA1 160-BMA1 160-BMA1 160-BMA2 160-BMA1 160-BMA1 160-BMA1 160-BMA2 160-BMA2 160-BMB1 160-BMB1 160-BMB1 160-BMB2 160-BMB2

MOV

ÁÁ

Module

ÁÁ

Cat. No.

160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMA1 160-MMB1 160-MMB1 160-MMB1 160-MMB1 160-MMB1

3% Line

ÁÁ

Reactors

Open

ÁÁ

➀

Style

Cat. No.

– – –

– 1321-3R4-B 1321-3R4-A 1321-3R4-A 1321-3R8-A 1321-3R12-A 1321-3R2-B 1321-3R2-A 1321-3R2-A 1321-3R4-B 1321-3R8-B

Line

БББББ

Filters

БББББ

②

Cat. No.

160S-LFA1 160S-LFA1 160S-LFA1 160S-LFA1 160-LFA1 160-LFA1 160-LFA1 160-LFA1 160-LFA2 160-LFB1 160-LFB1 160-LFB1 160-LFB1 160-LFB1

Cat. No.

160S-RFA-6-A 160S-RFA-6-A 160S-RFA-10-A 160S-RFA-16-A 160-RFB-3-A 160-RFB-3-A 160-RFB-9-A 160-RFB-9-A

160-RFB-3-A 160-RFB-3-A 160-RFB-3-A 160-RFB-9-A 160-RFB-9-A

Capacitor

ÁÁ

Module

ÁÁ

③

Cat. No.

160-CMA1 160-CMA1 160-CMA1

④

160-CMA1 160-CMA1 160-CMA1 160-CMA1

–

160-CMA1 160-CMB1 160-CMB1 160-CMB1 160-CMB1 160-CMB1

Replacement Parts and Accessories

Fan ➄

ÁÁ

Replacement

Kit

Cat. No. Cat. No. Cat. No. Cat. No.

160-FRK1 160-B1 160-P1 160-DN1

Ready/

ÁÁ

Fault

Panel

Program

ÁÁ

Keypad Module

DeviceNet

ÁÁÁ

Communication

Module

Drive Model

Analog 160-DM-SF1

Preset 160-DM-PS1

➀ 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.

➁ 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.

➂ 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.

➃ Included with controller. ➄ The MTBF for the fan is 40,000 hours at 50_C. ➅ Allows 24V DC sinking inputs.

A-4

24V DC Interface ➅

Cat. No.

Figure A.1 – Controller Dimensions

Controllers Rated 200 – 240V Single Phase

Overall Dimensions

H mm (inches) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) W mm (inches) 72 (2.83) 72 (2.83) 72 (2.83) 72 (2.83) D mm (inches) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4) Weight Kg. (lbs.) 0.8 (1.76) 0.8 (1.76) 0.9 (1.98) 0.9 (1.98)

Overall Dimensions

H mm (inches) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) W mm (inches) 72 (2.83) 72 (2.83) 72 (2.83) 72 (2.83) 130 (5.12) D mm (inches) 136 (5.4) 136 (5.4) 136 (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)

Overall Dimensions

160S AA02

160S AA03

160S AA04

160S AA08

Controllers Rated 200 – 240V 3 Phase

160 AA02

160 AA03

160 AA04

160 AA08

Controllers Rated 380 – 460V 3 Phase

160 BA01

160 BA02

160 BA03

160 BA04

➀

160 AA12

160 BA06

Appendix A – Specifications and Accessories

➀

External capacitor modules are provided with this model and mount separately.

Use the drilling template at the back of the manual for mounting the controller.

Figure A.2 – Mounting Requirements

DIN Mounting

Debris Cover

Dimensions Metric English

Min. Panel Thickness (14 GA) 19mm 0.0747 in. Mounting Base Screws m4 x 0.7 # 8 – 32 Mounting T orque 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. T o 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

72 (2.8)

50 (1.9)

GND BR BR

6,8 (.230) 4 places

8 (.315)

14 (.551)

29 (1.1)

86,4 (3.4)

7,5 (.295)

Cat. No. A B

160-BMA1 & 160-BMB1 245

160-BMA2 & 160-BMB2 334

(9.64)

(13.15)

A-6

225 (8.86)

314 (12.36)

Appendix A – Specifications and Accessories

Approximate Dimensions, Continued

Dimensions are shown in millimeters (inches). Dimensions are not to be used for manufacturing purposes.

Figure A.4 – MOV Module

40,2 (1.6)

L1RL2SL3

71 (2.8)

Figure A.5 – Line Reactor

MODULE

22,7 (.894)

MOV

45,4 (1.8)

5,1 (.199) Pin Extension

0,54 (.021)

Cat. No. BA CD E

102

1321-3R2-A

1321-3R2-B

1321-3R4-A

1321-3R4-B

1321-3R8-A

1321-3R8-B

1321-3R12-A

112 (4.4)

152 (6.0)

(4.0)

102 (4.0)

122 (4.8)

(2.9) 74

(2.9) 79

(3.1) 79

(3.1)

(2.0) 50

(2.0) 54

(2.1) 54

(2.1)

(1.44) 36

(1.44) 50

(2.0) 50

(2.0)

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

mm (in.)

Line Filter

Module

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

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)

A B C D E F G H

182.0 (7.17) 75.0 (2.95) 30.0 (1.18) 167.0 (6.57) 60.0 (2.36)

174.0 (6.85) 75.0 (2.95) 50.0 (1.97) 163.0 (6.41) 60.0 (2.36) 6.9 x 5.25

6.5 x 4.5 (0.26 x 0.18) hole dim.

hole dim. (2 places)

(0.272 x 0.207)

hole dim.

4.2 (0.17) (2 places)

6.9 x 5.25

(0.272 x 0.207)

hole dim.

dia. hole

ia. hol

200

(7.87)

7.87

200

(7.87)

A-8

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

4,5

140 (5.51)

(.177)

Mounting Holes

130 (5.11)

(1.97) 40

(1.5)

254 (10) Approximate Lead Length

110,9 (4.37)

150,9 (5.94)

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

Figure A.9 – 24V DC Interface Module

161,2 (6.35) Overall Height with DeviceNet Module

167,82 (6.61) Overall Height with DeviceNet Connector

A-10

(1.14)

➀

➀ This device does not effect

the overall height of the drive.

Appendix B –

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

General Instructions for an EMC Compliant Installation

Refer to Figure B.1.

Shielded Enclosure

D T ypical NEMA or IEC metal enclosures are

adequate.

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 All wiring, except input power leads, must use

shielded 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

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

Input Line

R (L1) S (L2)

T (L3)

Line

Filter

D Input power, output power and control wiring

outside the enclosure must use separate shielded cables, or separate conduit.

Cable Clamps

D Use suitable EMC-tested cable clamps only . D The connection area must be 360 degrees

around the shielded cable.

D The cable clamps also provide strain-relief for

the 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.

B-2

Ground Tab – PE

Line Power

Control Wiring

Motor Wiring TB2

Shielded Enclosure

= EMC T ested Shielded Cable Clamp (or Metal Conduit)

When the control circuitry is located outside of the 160 enclosure.

TB1

TB3

L2L1 L3 BR BR

–

+ TSR

FAULT READY

1 2 3 4 5 6 7 8 9 10 11

–

T2TI T3 +

DCDCWVU

W (T3) V (T2) U (T1)

to TB3

Control

Cabinet *

Shielded Motor Cable

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

Figure B.2 – Motor Connections

Ground Tab – PE

L2L1 L3 BR BR

–

+TSR

FAUL T READY

1 2 3 4 5 6 7 8 9 10 11

–

Motor Wiring TB2

T2TI T3 +

DCDCWVU

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.

4 Wire

Shielded Motor Cable

Ground to Motor Housing

W (T3) V (T2)

Shielded Enclosure

= EMC T ested Shielded Cable Clamp (or Metal Conduit)

U (T1)

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

L2L1 L3 BR BR

RST +

FAULT READY

1 2 4 5 6 8 9 10 11

Control Wiring

TB3

3 7

T2TI T3 +

UVWDCDC

–

Control

Cabinet *

to TB3

–

Signal Common

Shielded Enclosure

= EMC T ested 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

Shielded Control

Cable

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

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

I-2

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.

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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)

Rockwell Automation 160 AC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

Table of Contents

Information and Precautions

Chapter 1

Installation and Wiring

Chapter 2

Program Keypad Module

Chapter 3

Start-Up

Chapter 4

Parameters and Programming

Chapter 5

Troubleshooting and Fault Information

Chapter 6

Index