Rockwell Automation 160 SSC User Manual

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160 SSC™ Variable Speed Drive (Series C)

0.37–4.0 kW (0.5–5 HP) FRN 7.03 FRN 7.04 FRN 7.05 FRN 7.06

User Manual

Important User Information

Solid-State equipment has operational characteristics differing from those of electromechanical equipment.

and Maintenance of Solid-State Controls”

important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation is prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

“Safety Guidelines for the Application, Installation

(Publication SGI-1.1) describes some

ATTENTION:

circumstances that can lead to personal injury or death, property damage or economic loss.

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Important:

SSC is a trademark of Rockwell Automation, Inc.

Identiﬁes information that is especially important for successful application and understanding of the product.

Shock Hazard

dangerous voltage may be present.

Identiﬁes information about practices or

labels located on or inside the drive indicate that

Series C Summary of Changes

•

New Horsepower Ratings

4 kW (5 HP), 230V and 460V ratings have been added to the Bulletin 160 family.

•

Increased Transient Protection

Standard input voltage transient protection has been increased to 6 kV and contained in the drive itself. The optional MOV module is no longer required.

•

Improved Ground Fault Protection

The Bulletin 160 detects phase-to-phase and phase-to-ground faults both at start-up and while running.

•

Reduced 2.2 kW (3 HP) Footprint

2.2 kW (3 HP), 230V and 460V width has been reduced by more than 45%.

•

One Piece, 1.5 kW (2 HP) 230V Single Phase Unit

The external capacitor module has been integrated into the 1.5 kW (2 HP), 230V single phase unit. The overall width of the unit is reduced, however, the height, depth, and mounting hole pattern has changed.

•

Improved Start/Stop Overlap Timing

The STOP command can be removed up to 20 msec after a START command and the drive will still recognize the START command. This allows the drive to respond to a START command occurring concurrently with or slightly after a STOP command is removed.

•

Additional Fault History

P17, P18

have been added to record the last three faults for diagnostic purposes.

•

Analog Model with Preset Speed Capability

Analog Signal Follower models have an additional input mode. With

Mode]

available.

•

External Frequency Selection

P46 - [Input Mode]

(setting 7) which allows for the frequency source to be switched from the control terminal block (TB3) to the

Frequency]

, and

P19 - [Fault Buffer 0, 1 and 2]

P46 - [Input

setting 8, four preset speeds are

has an additional setting

P58 - [Internal

setting.

•

New Output Conﬁguration Setting

P47 - [Output Conﬁgure]

When setting 10 is selected, the output will be active when the Power Factor Angle is above the setting.

•

Additional Compensation Mode

P78 - [Compensation]

mode that corrects for slow responding systems which can cause current regulator oscillations.

•

Software Current Trip

P79 - [Software Current Trip]

adjustable software current trip with a one second time delay.

•

Adjustable Stall Fault Time

The time that the drive must be in a stall condition before causing a stall fault is selectable via

•

PI Control

Process control is now intergrated in the drive through a PI regulator. Users of Firmware Version FRN 7.05 and earlier activate this feature with setting 9. Users of Firmware Version FRN

7.06 can activate this feature with

[Input Mode]

PI control is adjusted through parameters

P81 - [PI Proportional Gain], P82 - [PI Integrated Gain], P83 - [PI Process Reference]

•

Fault Auto Clear

Over voltage, Under voltage, and Over temperature faults are automatically cleared when the fault condition is removed.

•

RS-232 Serial Communication

An RS-232 serial communication module using a DF1 protocol is now available. See 160-RS1 User Manual for additional information.

•

Ground Screw Location

Grounding screws are now located on the power connection terminal blocks for easier wiring.

P80 - [Stall Fault Time]

settings 0 through 7 and 9.

, and

has a new setting.

P48 - [Output Threshold]

has an additional

provides an

P46 - [Input Mode]

P84 - [PI Dead Band].

S-1

P46 -

S-2

Series C Application/Installation Considerations

Keep the following in mind if you are replacing a Bulletin 160 Series A or B drive with a Series C unit.

Mounting Dimensions

• Width has increased by 8 mm for all ratings through 1.5 kW (2 HP).

Note:

If proper spacing recommendations were followed for Series A and B drives, the increased width should not effect the panel layout because Series C drives of this rating do not require spacing between units.

• Width has decreased by 50 mm for the 2.2 kW (3 HP) rating.

• Depth has increased by 25 mm for all ratings through 2.2 kW (3 HP).

Note:

The drive utilizes the same DIN base and mounting hole pattern for all ratings through 2.2 kW (3 HP).

External Braking

• The internal brake transistor is (3/4 HP) units. If external braking is required, a 0.75 kW (1 HP) drive must be used.

DeviceNet

• DeviceNet modules (Catalog No.160-DN1) with Firmware Version FRN 2.0 or earlier are not compatible with the Bulletin 160 Series C drives. Series C drives must use DeviceNet modules (Catalog No. 160-DN2). The 160-DN2 module is also compatible with Series A and B drives with the exception of the Series A Preset Speed model with Firmware Version FRN 4.04.

not

available on 0.37 kW (1/2 HP) and 0.55 kW

24V DC Interface

• Bulletin 160 Series C drives must use a Series B, or later, 24V DC Interface module. See Appendix B for catalog numbers.

Terminal Block Wiring

• The ground terminal is now located on the power terminal block. Refer to Figure 2.2 on page 2-3 to avoid incorrect wiring.

Incorrect Motor Rotation

• The output phasing of Series C drives is different than the output phasing of Series A and B drives. Replacing a Series A or B drive with a Series C drive using the same U, V and W (T1, T2 and T3) connections will reverse the motor rotation. To assure the same direction of rotation, switch any 2 of the 3 output wires connected to U, V or W (T1, T2 or T3) from the motor.

Example:

Original

Wiring of

Series A or B

U/T1 V/T2 W/T3

V/T2

U/T1

W/T3

Motor

Wiring of

Replacement

Series C

U/T1 V/T2 W/T3

V/T2

U/T1

W/T3

Motor

Getting Started

Important Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Receiving Your New Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Identifying Your Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Standard Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Optional Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Installation and Wiring

Storage and Operation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

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

Debris Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Terminal Block Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Motor Branch Circuit Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Branch Circuit Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Motor Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Long Motor Cable Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Important Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Control Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Control Methods and Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Configurable Relay Output Contacts (P47 Settings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Frequency Source Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

Analog Signal Follower Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Preset Speed Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Analog and Preset Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

What To Do Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Program Keypad Module

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

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

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

Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Module Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Start-Up

Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Parameters and Programming

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

Important Reset Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Display Group Parameters (Read Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

PI Control Setup and Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Wire For PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

Program for PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Tune the PI Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Common Problems with PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Troubleshooting

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

How to Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Accessories and Dimensions

Accessory Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6

CE Conformity

CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

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

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

Shielded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Low Voltage Directive 73/23/EEC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Important Precautions

In addition to the precautions listed throughout this manual, you must read and understand the following statements which identify hazards associated with AC drives.

Chapter

Getting Started

ATTENTION:

time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death.

Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels.

ATTENTION:

machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION:

hot, which may cause injury.

ATTENTION:

sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

The drive contains high voltage capacitors which take

Only personnel familiar with the drive and associated

The surface temperatures of the drive may become

This drive contains ESD (Electrostatic Discharge)

ATTENTION:

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.

An incorrectly applied or installed drive can result in

1-2

Getting Started

Receiving Your New Drive

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

Unpacking

Remove all packing material, wedges, or braces from within and around the drive. Remove all packing material from the heat sink. Leave the debris label in place.

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

Inspecting

After unpacking, check the item(s) nameplate catalog number against your purchase order. An explanation of the catalog numbering system for the Bulletin 160 drive follows as an aid for nameplate interpretation. Refer to Figure 1.1 and Figure 1.2.

Important:

Before you install and start up the drive, inspect for mechanical integrity. Look for loose parts, wires, and connections.

Identifying Your Drive

Catalog Number

The ﬁgure below describes the 160 SSC catalog numbering scheme.

Catalog Number Explanation Figure 1.1

160 -AA02 N SF1 P1

First Position Second Position Third Position Fourth Position Sixth Position

Bulletin Number Current Rating➊ Enclosure TypeVoltage Rating

An “S” in the Bulletin

Number denotes a

single-phase input

voltage.

A 200-240V, 1-Phase

200-240V, 3-Phase

B 380-460V, 3-Phase

A01

A02

A03

A04

A06

A08

A10

A12

A18

N Open (IP20)

L Low Profile

P Chassis Mount

(external heatsink)

R Chassis Mount

Replacement

Fifth Position

Model

SF1 Analog Signal

Follower

PS1 Preset Speed

Programmer

(Optional)

B1 Ready/Fault

Indicating Panel

P1 Program Keypad

Module

➊

Amperage ratings vary based on voltage.

Note: Rockwell Automation offers a conﬁgured drive program which allows for NEMA rated 4, 4x, or 12 enclosures.

Nameplate

Getting Started

1-3

The nameplate is located on the side of the drive.

Nameplate Information Figure 1.2

Catalog Number

160-AA02NSF1P1 SERIES C

ANALOG S.F.

Motor

Rating:

V: 200-240 3 Ø

A: 2.8

Hz: 50/60

VA: 1100

OPERATING AMBIENT TEMP: 0 - 50° C SHORT CIRCUIT CURRENT: 100 KA POWER TERMINAL WIRE : Use 75° C Cu Wire: 4 mm Torque 1.35 Nm (12 in.- lbs.)

0.37KW / 0.5 HP

- .75 mm2 (12-18 AWG.)

IP20

CUS

Allen-Bradley

FRN: 7.XX

V: 200-230 3 Ø

A: 2.3

Hz: 0-240

S/N: XXXXXXXX XXXXX

LISTED

IND. CONT. EQ.



966X

MADE IN U.S.A.

Series Letter Firmware Version Drive Model

Serial Number Date Code

Enclosure Rating

Conventions Used In This Manual

Parameter numbers and names are shown in this format:

P01

denotes the parameter number and the parameter name is enclosed in square

brackets.

P01 - [Output Frequency]

1-4

Getting Started

Standard Drive Features

The drive features identiﬁed in the ﬁgure below apply to all models.

Standard Drive Features and Mounting Orientation Figure 1.3

R/L1

FAULT

READY

U/T1

S/L2

45678 910112

V/T2

T/L3

W/T3

BR–

DC–

BR+

DC+

Hinged Finger Guard

Ready/Fault Indicating Panel

Status LEDs

DC Bus Test Points

Hinged Finger Guard

Cooling Fan

Cooling

DIN Latch

Air Flow

•

Hinged Finger Guard

•

Ready/Fault Indicating Panel

allows easy access to line/load power terminals.

is standard on the Bulletin 160 drive. The drive is fully functional with this panel installed. All control functions can be performed from TB3 (Control Terminal Block). Factory default settings cannot be changed with this panel.

•

Fault Indicator LED

illuminates when a drive fault condition exists. Refer to Chapter 6 for details on how to clear a fault and general troubleshooting procedures.

•

Ready Indicator LED illuminates when the DC bus is charged and the drive is

ready to run.

•

DC Bus Test Points

provide easy access for test probes when measuring DC

Bus voltage.

•

Cooling Fan

provides air ﬂow across heatsink ﬁns to prevent overheating. Not

required on .37 or .55 kW (.5 or .75 HP) ratings.

•

DIN Latch

provides an easy means for mounting the drive on standard 35 mm DIN Rail. This feature is not available with 4.0 kW (5 HP) or 1.5 kW (2 HP) single phase units.

Optional Drive Features

The drive features identiﬁed in the ﬁgure below are optional. See Appendix B for catalog numbers. (Finger guards omitted for clarity.)

Optional Drive Features Figure 1.4

Dynamic Brake Module

Getting Started

1-5

R/L1

S/L2

T/L3

BR–

BR+

Line Filter Module

Program Keypad Module or DeviceNet Communication Module or RS-232 Communication Module or Remote Programming Adapter to: Remote Keypad Module

45678 910112

V/T2

U/T1

W/T3

DC–

DC+

or CopyCat Keypad Module

24V DC Interface Module

Capacitor Module

• Dynamic Brake Module option allows you to connect dynamic brake

resistors. Not available on .37 or .55 kW (.5 or .75 HP) ratings. Important: P52 - [DB Enable] must be enabled for proper operation.

• Line Filter Module option is available to reduce conductive emissions.

• Program Keypad Module option can be ordered separately and ﬁeld installed,

or as a factory installed option by adding “P1” to the end of the catalog number. Refer to Chapter 3, Program Keypad Module for a detailed explanation of functionality.

• DeviceNet Communication Module option allows control and monitoring of

parameters via a DeviceNet network.

• RS-232 Communication Module option allows control and monitoring of

parameters via a RS-232 network.

• Remote Programming Adapter option allows connection to Remote Keypad

Module or Copycat Keypad Module via cable (1 to 3 meters).

• 24V DC Interface Module option allows you to command the drive with 24V

logic (sinking inputs).

• Capacitor Module option allows you to connect an external capacitor module.

Provides extended ride through capability and improved inherent braking performance.

1-6 Getting Started

End of Chapter

Installation and Wiring

Storage and Operation Conditions

Follow these recommendations to prolong drive life and performance:

• Store within an ambient temperature range of –40° to +85°C.

• Store within a relative humidity range of 0% to 95%, non-condensing.

• Protect the cooling fan by avoiding dust or metallic particles.

• Avoid storing or operating the drive where it could be exposed to a corrosive atmosphere.

• Protect from moisture and direct sunlight.

• Operate at an ambient temperature range of 0° to +50°C.

CE Compliance

Refer to Appendix C.

Installation

Mount the drive on a ﬂat, vertical and level surface. See Chapter 1, Figure 1.3 for mounting orientation.

Choose an installation method:

• Install with screws. Recommended screw size is listed in the table below. The appropriate drilling template for your drive is provided in Appendix B.

• Install on 35 mm DIN Rail. This mounting method is not available on

4.0 kW (5 HP) three phase or 1.5 kW (2 HP) single phase models.

Description Metric English

Minimum Panel Thickness (14 GA) 1.9 mm 0.0747 in.

Mounting Base Screws m4 x 0.7 # 8-32

Mounting Torque 1.13 – 1.56 Nm 10 – 14 lb.-in.

See Appendix B for details on drive dimensions and weights.

Chapter 2

Clearances

Debris Label

Maintain 12.5 mm (0.5 in.) clearance at the top, bottom, and front of all drives. Clearance requirements between units varies by model.

• 2.2 kW (3 HP) 230V/460V Drives Provide a minimum of 8.5 mm (0.33 in.) clearance between units.

• All Other Drive Ratings No clearance is required between units.

The drive is shipped with a paper debris label attached to the top side of the plastic housing to cover the cooling vents. Leave the debris label attached during drive installation to protect against debris falling through the vents of the drive housing. To assure proper drive operation, you must remove label before applying power.

ATTENTION: After system installation, remove the debris label from unit. Failure to remove this label may result in overheating or nuisance tripping.

2-2 Installation and Wiring

Power Wiring

Precautions

ATTENTION: Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Verify bus voltage by measuring the voltage between DC- and DC+ on Terminal Block TB2. Do not attempt to service the drive until bus voltage has discharged to zero volts.

ATTENTION: The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies input power to the drive for the purpose of starting and stopping the motor should not be used. If it is necessary to use this method for starting and stopping, or if frequent cycling of power is unavoidable, make sure that it does not occur more than once a minute.

ATTENTION: Do not connect power factor correction capacitors to drive output terminals U, V and W (T1, T2 and T3) or component damage could occur.

Terminal Blocks

Terminal R (L1) is not present on single phase drives. Three phase unit terminal block conﬁguration is depicted in the ﬁgure below.

Drive Terminal Blocks Figure 2.1

Terminal Block TB1

TB1

R/L1

S/L2

T/L3

BR–

BR+

Ground, Line Power Dynamic Brake Module Wiring

Hazardous Voltages Behind Panel

FAULT

READY

45678 910112

Terminal Block TB3

TB3

Control Wiring

V/T2

U/T1

W/T3

DC–

DC+

Terminal Block TB2

TB2

Ground, Motor Capacitor Module Wiring

Terminal Block Wiring

Terminal Block Wiring Detail Figure 2.2

Ground Terminal/Protective Earth

Terminal Block TB1

Terminal Block TB2

Installation and Wiring 2-3

Required Branch

Circuit Disconnect ➊

Branch Circuit Protective Device ➋

S/L2

R/L1

U/T1

Motor ➌

V/T2

T/L3

W/T3

BR–

DC–

BR+

DC+

Speciﬁcations

Terminal Block TB1 and TB2 Wiring Speciﬁcations Table 2.A

Model Screw Size Max./Min. Wire Size ➍

4.0 kW (5 HP) M4 5.26 – 3.31 (10 – 12) 1.35 – 0.90 (12 – 8)

All Other Ratings M4 3.31 – 0.82 (12 – 18) 1.35 – 0.90 (12 – 8)

➊ For single phase input applications, connect the AC input power to input terminals S (L2) and T (L3).

➋ See Table 2.B for minimum recommended branch circuit protective devices.

➌ Bulletin 160 Drives are UL Listed (see Appendix A for details) as motor overload protective devices

(IEC Class 10 overload). An external overload relay is not required as long as the Drive kW (HP) rating is less than three times larger than the motor kW (HP) rating.

➍ Each terminal supports up to 2 wires of approved gauge.

(AWG)

Max./Min. Torque

Nm (lb.-in.)

for single motor applications

2-4 Installation and Wiring

Motor Branch Circuit Analysis

Short circuit and overload protection are requirements of any motor branch circuit. Input power conditioning, CE conformance, reﬂective wave, capacitive current coupling, and motor cable type are important considerations of drive applications.

Branch Circuit Conﬁguration Figure 2.3

Branch Circuit Protective Devices – See Table 2.B

Input Power Conditioning – See Table 2.C

CE Conformance – See Appendix C

160 SSC™

Motor Cable Types – See Table 2.D

Reflected Wave Protection – See Table 2.E

Capacitive Current Coupling – See Table 2.F

Overload Protection

Motor

• Branch Circuit Protective Devices

A motor branch circuit requires protection against excessive current. This protection can be provided by a fuse, circuit breaker, or manual motor starter. See Table 2.B for a detailed list of these options.

• Input Power Conditioning

Certain conditions may exist that could damage a drive in the branch circuit. See Table 2.C for an explanation of problems and solutions.

• CE Conformance

See Appendix C for information on CE Conformance.

• Motor Cable Types

See Table 2.D for recommended cable types.

• Reﬂected Wave Protection

The use of a drive may result in increased peak-to-peak voltage at the motor. See Table 2.E for an explanation of motor insulation limitations versus cable lengths.

• Capacitive Current Coupling

High speed voltage switching causes AC coupling from motor cables to ground terminal/protective earth. See Table 2.F for cable length recommendations.

• Overload Protection

All motor branch circuits require overload protection. The Bulletin 160 Drive is UL listed to provide protection (IEC Class 10 overload) without an overload relay. Separate overload relays are required in multi-motor applications or if the drive kW (HP) rating is more than three times larger than the motor kW (HP) rating.

Branch Circuit Protective Devices

Fusing

The Bulletin 160 Smart Speed Controller has been UL tested and approved for use with input fuses. The ratings in the table below are the minimum recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide. Other devices which meet the requirements of UL508C and UL489 with similar trip characteristics may be used in order to meet local or national electrical codes.

Bulletin 140 Manual Motor Starters/UL489 Circuit Breakers

When using Bulletin 140 manual motor starters or UL489 rated circuit breakers, the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection.

• Bulletin 140 manual motor starters can be used in single and group motor applications.

• In single motor applications, a fuse or UL489 rated circuit breaker is required ahead of the Bulletin 140 manual motor starter.

• In group motor installations, the Bulletin 140 can be used for protection of an individual motor within the group and “one set” of fuses or a UL489 rated circuit breaker serves as the Branch Circuit Protective Device for the entire “Group Installation”.

• Bulletin 140M manual motor starters can be used in single and group motor applications without additional short circuit protection. Refer to the technical support literature for the 140M for more details.

Installation and Wiring 2-5

Minimum Recommended Branch Circuit Protective Devices ➊ Table 2.B

Voltage Rating Drive Rating

Single Phase 230V

Three Phase 230V

Three Phase 460V

➊ The maximum branch circuit protection rating is limited to four times the rated output current of

the drive or 30A, whichever is less.

➋ Fuse class CC, J, BS88, VDE 06366/gG, IEC 269-1/gG, EN60269 part 1 and 2 type gG

kW (HP)

0.37 (0.5)

0.55 (0.75)

0.75 (1)

1.5 (2)

0.37 (0.5)

0.55 (0.75)

0.75 (1)

1.5 (2)

2.2 (3)

4.0 (5)

0.37 (0.5)

0.55 (0.75)

0.75 (1)

1.5 (2)

2.2 (3)

4.0 (5)

Fuse Rating ➋ UL489 Rated

6 10 15 30

6 6 10 15 20 30

4 4 5 8 15 20

Circuit Breaker Amps

16 16 16 20

16 16 16 16 20 30

6 6 6 16 16 20

Bulletin 140/140M Manual Motor Starter Amps

16 16 16 20

16 16 16 16 20 30

6 6 6 16 16 20

2-6 Installation and Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix A). Listed in Table 2.C are certain input power conditions which may cause component damage or reduction in product life. If any of the conditions exist, as described in Table 2.C, install one of the devices listed under the heading Corrective Action on the line side of the drive.

Important: Only one device per branch circuit is required. It should be

Input Power Conditions Table 2.C

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) • Check Line Impedance

Available short circuit currents (fault currents) greater than 100,000 Amps

Greater than 120 kVA supply transformer • Line Reactor (See Appendix B)

Line has power factor correction capacitors • Line Reactor (See Appendix B)

Line has frequent power interruptions • Line Reactor (See Appendix B)

Line has intermittent noise spikes in excess of 6000V (lightning)

mounted closest to the branch and sized to handle the total current of the branch circuit.

• Line Reactor (See Appendix B)

• or Isolation Transformer

• Check Supply Transformer

• Line Reactor (See Appendix B)

• or Isolation Transformer

• Line Reactor (See Appendix B)

• or Isolation Transformer

Motor Cable Types

A variety of cable types are acceptable for variable speed drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 1 meter (3.3 feet) for every 10 meters (33 feet) of unshielded length. If you cannot separate motor cables from sensitive circuits, or if you must run motor cables from multiple drives (more than three) in a common conduit or cable tray, shielded motor cable is recommended to reduce system noise.

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

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

Recommended Cable Type Table 2.D

Condition Insulation Type Example Dry PVC ➊ THHN

XLPE XHHW-2

Wet XLPE XHHW-2

➊ For input power voltages in excess of 264V AC, or motor cable distances greater than 15 meters

(50 feet), wire with XLPE insulation is recommended.

Installation and Wiring 2-7

Long Motor Cable Effects

Reﬂected Wave Protection

The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition of external devices to limit voltage reﬂections at the motor (reﬂected wave phenomena). See Table 2.E for recommendations.

Important: Both Reﬂected Wave and Capacitive Current Considerations need

to be taken into account when determining motor cable lengths (see Table 2.E and Table 2.F). The use of an external device to limit reﬂected wave phenomenon may effect the accuracy of Bulletin 160 current sensing.

The reﬂected wave data applies to all frequencies 2 to 8 kHz. For 230V ratings, the maximum cable length recommendations are the same as the capacitive current recommendations (see Table 2.F).

Cable Length Recommendations – Reﬂected Wave Table 2.E

380460V Ratings

4.0 kW (5 HP)

2.2 kW (3 HP)

1.5 kW (2 HP)

0.75 kW (1 HP)

0.55 kW (0.75 HP)

0.37 kW (0.5 HP)

Motor Insulation Rating

1000 Vp-p 45 13.7 20 6.1 525 160 600 183 325 99.1 300 91.5

1200 Vp-p 90 27.4 40 12.2 525 160 600 183 525 160 425 130 1600 Vp-p ➋ 525 160 475 145 525 160 600 183 525 160 600 183

1000 Vp-p 40 12.2 40 12.2 525 160 600 183 225 68.6 250 76.2

1200 Vp-p 90 27.4 60 18.3 525 160 600 183 325 99.1 425 130 1600 Vp-p ➋ 525 160 500 152 525 160 600 183 525 160 600 183

1000 Vp-p 40 12.2 40 12.2 425 130 600 183 325 99.1 300 91.5

1200 Vp-p 90 27.4 60 18.3 425 130 600 183 425 130 450 137 1600 Vp-p ➋ 500 152 500 152 425 130 600 183 540 165 600 183

1000 Vp-p 55 16.8 40 12.2 325 99.1 600 183 325 99.1 350 107

1200 Vp-p 125 38.1 60 18.3 325 99.1 600 183 500 152 450 137 1600 Vp-p ➋ 500 152 500 152 325 99.1 600 183 500 152 600 183

1000 Vp-p 45 13.7 40 12.2 300 91.5 600 183 300 91.5 300 91.5

1200 Vp-p 125 38.1 60 18.3 300 91.5 600 183 500 152 500 152 1600 Vp-p ➋ 500 152 500 152 300 91.5 600 183 500 152 600 183

1000 Vp-p 45 13.7 90 27.4 300 91.5 425 130 300 91.5 425 130

1200 Vp-p 125 38.1 180 54.9 300 91.5 425 130 500 152 500 152 1600 Vp-p ➋ 500 152 500 152 300 91.5 425 130 500 152 500 152

Motor Cable Only RWR at Drive ➊ Reactor at Motor

Shielded Unshielded Shielded Unshielded Shielded Unshielded

feet meters feet meters feet meters feet meters feet meters feet meters

➊ Cable lengths listed are for PWM frequencies of 2 kHz. Refer to publication 1204-5.1 for cable length recommendations at

other PWM frequencies.

➋ The maximum peak-to-peak voltage of the drive is 1400V due to the minimum on/off time software.

Reﬂective Wave Testing has been done on cable lengths up to 160 meters (600 feet). See Table 2.F for capacitive current recommendations.

2-8 Installation and Wiring

Capacitive Current Coupling

AC coupling exists from motor cables to ground terminal/protective earth. The current produced by this coupling is referred to as capacitive current. The drive current is the combination of capacitive current and motor current. Because motor current is monitored for overload protection, the table below lists the maximum cable length recommendations that will assure a capacitive current error of less than 15 percent.

Cable Length Recommendations — Capacitive Current Table 2.F

380-460V Ratings

4.0 kW (5 HP)

2.2 kW (3 HP)

1.5 kW (2 HP)

0.75 kW (1 HP)

0.55 kW (0.75 HP)

0.37 kW (0.5 HP)

200-240V Ratings No Reactor RWR at Drive ➊ Reactor at Motor

0.37 to 4.0 kW (0.5 to 5 HP) 2 through 8 kHz

kHz Motor Cable Only RWR at Drive ➊ Reactor at Motor

Shielded ➋ Unshielded Shielded ➋ Unshielded Shielded ➋ Unshielded

feet meters feet meters feet meters feet meters feet meters feet meters

2 350 107 600 183 300 91.5 600 183 400 122 600 183

4 425 130 600 183 350 107 600 183 450 137 600 183 8 475 145 500 152 ➊ 450 137 500 152

2 360 110 600 183 280 85.4 600 183 400 122 600 183

4 375 114 600 183 275 83.8 600 183 400 122 600 183 8 400 122 500 152 ➊ 400 122 500 152

2 300 91.5 550 168 275 83.8 600 183 300 91.5 600 183

4 300 91.5 550 168 275 83.8 600 183 300 91.5 500 152 8 325 99.1 500 152 ➊ 350 107 500 152

2 200 61 375 114 200 61 425 130 225 68.6 400 122

4 225 68.6 375 114 200 61 425 130 225 68.6 375 114 8 250 76.2 375 114 ➊ 225 68.6 400 122

2 180 54.9 350 107 180 54.9 375 114 180 54.9 350 107

4 180 54.9 350 107 180 54.9 375 114 180 54.9 350 107 8 180 54.9 350 107 ➊ 180 54.9 350 107

2 100 30.5 325 99.1 100 30.5 350 107 100 30.5 300 91.5

4 100 30.5 325 99.1 100 30.5 350 107 100 30.5 350 107 8 100 30.5 325 99.1 ➊ 100 30.5 350 107

Shielded ➋ Unshielded Shielded ➋ Unshielded Shielded ➋ Unshielded

feet meters feet meters feet meters feet meters feet meters feet meters

525 160 600 183 ➌ 525 160 600 183

➊ Not recommended for use above 4 kHz PWM Frequency.

➋ When using shielded cable at lightly loaded conditions, cable length recommendations for drives rated 0.75 kW (1 HP) and

below are 61 meters (200 feet).

➌ Not recommended for 230V applications.

Control Wiring

Requirements

• Run all signal wiring in either a shielded cable or separate metal conduit.

• Connect shield wire only at TB3 Common terminals (3 and 7).

• Do not exceed control wiring length of 15 meters (50 feet). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the control terminal block Common must be connected to ground terminal/protective earth.

• Use Belden 8760 (or equivalent) — 18 AWG (0.750 mm2), twisted pair, shielded or 3 conductor.

Speciﬁcations

Control Terminal Block TB3 Wiring Speciﬁcations Table 2.G

Terminal Block Max./Min. Wire Size

TB3 2.5 – 0.5 (14 – 22) 0.8 – 0.4 (8 – 4)

Important Precautions

Installation and Wiring 2-9

(AWG)

Max./Min. Torque

Nm (lb.-in.)

ATTENTION: The drive is supplied with an internal 12V supply. Dry contact or open collector inputs are required for discrete control inputs. If an external voltage is applied, component damage could occur.

TB3

567

External

Power

Supply

NO!

ATTENTION: The drive start/stop and enable control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional ﬂow of liquid, gas or solids exist, an additional hardwired stop circuit is required to remove AC input power to the drive. When AC input power is removed, there will be a loss of inherent regenerative braking effect and the motor will coast to a stop. An auxiliary braking method may be required.

2-10 Installation and Wiring

Control Wiring Considerations

Wiring Diagram Key

Shielded Wire

General Control Wiring Advisories

The ﬁgure below lists the control wiring requirements for all two wire control input modes (P46 - [Input Mode] settings 1 and 4 – 9). The requirements speciﬁc to each input mode are shown separately for that mode.

➊ Run input must be maintained. After a stop command, either a Run Forward or Run Reverse input

must be toggled to start the drive.

➋ Internal 12V supply. Contact closure or open collector input required. Refer to Appendix A for solid

state control input speciﬁcations.

➌ If both Run Forward and Run Reverse inputs are closed at the same time, an undetermined state

could occur.

➍ Control signal cable length is highly dependent on electrical environment and installation practices.

To improve noise immunity, TB3 Common must be connected to ground terminal/protective earth. For control wiring installations greater than 15 meters (50 feet) in length, an optional 24V DC interface module is recommended. See Appendix A for ordering information.

N.O. Momentary Contact

TB3

567

➊➋➌

➍

➋

N.C. Momentary Contact

N.O. Maintained Contact

N.C. Maintained Contact

Control Methods and Selection Guide

You can use P46 - [Input Mode] to select the control method for start, stop, and direction control. Control can be performed from the Control Terminal Block (TB3) or the optional Program Keypad Module or the Remote Programming Adapter via cable to either a Remote Keypad or a CopyCat Keypad depending on the P46 - [Input Mode] setting being used. The default setting is 0 which means that only the Control Terminal Block will be active for control. If any other input mode is needed (1-9) you must have a device for changing the input mode such as a Program Keypad Module (160-P1). Table 2.H is a guide to wiring diagrams associated with each P46 - [Input Mode] setting.

Important: After a Stop input, a Run command (either Run Forward, Run

Reverse or Start) must be toggled to run again. This is true for all P46 - [Input Mode] settings except setting 3. See the Attention statement below.

ATTENTION: Hazard of injury exists due to unintended operation. When P46 - [Input Mode] is set to 3, and the Run input is maintained, the Run inputs do not need to be toggled after a Stop input for the drive to run again. A Stop function is provided only when the Stop input is active (open).

Control Selection by Input Mode Table 2.H

Installation and Wiring 2-11

PI Control

P46 Setting Description Reference

0 Three-Wire control (factory default) Figure 2.4

1 Two-Wire Run Forward/Run Reverse control Figure 2.5

2 ➊ Program, Remote, CopyCat Keypad or Communication

Module control

3 Momentary Run Forward/Run Reverse control Figure 2.7

4 Two-Wire Accel/Decel control Figure 2.8

5 Two-Wire Enable control Figure 2.9

6 ➊ Two-Wire TB3 control/Keypad or Communication control Figure 2.10

7 Two-Wire Frequency Select control Figure 2.11

8 Two-Wire Preset control (Analog Signal Follower Models Only) Figure 2.12

9 Two-Wire PI control (Analog Signal Follower Models Only) Figure 2.13

➊ When using Firmware Versions FRN 7.05, 7.04 & 7.03, input modes 2 and 6 are the only modes

which allow a serial option, such as 160-DN2 or 160 RS1, to command the drive to run or stop.

Figure 2.6

Firmware Version FRN 7.06 allows activation of PI control in P46 - [Input Mode] settings 0 through 7 and 9 listed in Table 2.H. Refer to page 5-17 for PI Control Setup and Activation instructions.

Users of Firmware Version FRN 7.05 and earlier can only use P46 - [Input Mode] setting 9 to activate PI control. Refer to page 5-17 for PI Control Setup and Activation instructions.

2-12 Installation and Wiring

P46 Setting 0 - Three-Wire Control (Factory Default)

This input mode provides a typical three wire control function where a momentary start input will command the drive to start.

Three-Wire control – Factory Default Figure 2.4

TB3

567

Reverse

Start

➊

Common

Stop

➊ Start input can be a momentary input.

P46 Setting 1 - Two-Wire Run Forward/Run Reverse Control

This input mode provides a typical two wire control function where a maintained Run Forward or Run Reverse input will provide both a directional and start command to the drive. Opening the Run Forward or Run Reverse input will command the drive to stop in accordance with the P34 - [Stop Mode] setting. The stop switch (TB3-7 and 8) is not required but can be wired as an Auxiliary Stop if desired.

Note: A contact closure on terminals 7 and 8 is required for the controller to respond to a Start/Run command.

Two-Wire Run Forward/Run Reverse control Figure 2.5

TB3

567

Run Reverse

Run Forward

Common

Stop

Note: A contact closure on terminals 7 and 8 is required for the controller to respond to a Start/Run command.

Installation and Wiring 2-13

P46 Setting 2 - Program Keypad or Communication Module Control

This input mode activates the Start and Reverse functions from either the Program Keypad Module (PKM), Remote Keypad Module, CopyCat Keypad Module or plug in communication modules and deactivates the Start and Reverse inputs on the control terminal block (TB3). Note: the frequency reference can be controlled from the keypad modules or communication modules by setting P59 - [Frequency Select] to a setting of “1”. The frequency will then be controlled by the value programmed into P58 - [Internal Frequency].

Program Keypad Module control Figure 2.6

TB3

567

Reverse

Start

Common

Stop

➊ When performing start and reverse operations from the Program Keypad Module, Remote Keypad

Module, CopyCat Keypad Module or plug-in communication modules, the Start and Reverse inputs from the Control Terminal Block (TB3) are disabled.

➊

Note: A contact closure on terminals 7 and 8 is required for the controller to respond to a Start/Run command.

P46 Setting 3 - Momentary Run Forward/Run Reverse Control

This input mode allows the drive to respond to either a momentary or maintained Run Forward or Run Reverse input, but requires a stop input to TB3 terminals 7 and 8 to command the drive to stop. In addition, this is the only input mode that uses “level triggered” control logic, therefore once the stop command is removed or if power is lost and restored, the drive will immediately restart if a maintained Run command is present.

Momentary Run Fwd/Run Rev control Figure 2.7

TB3

567

Run Reverse

Run Forward

Common

Stop

➋

➊

Note: A contact closure on terminals 7 and 8 is required for the controller to respond to a Start/Run command.

➊ A momentary or maintained input can be used. If using maintained inputs, please read the

Attention statement above.

➋ A normally closed maintained input is recommended. See Attention statement above.

2-14 Installation and Wiring

Important: Settings 4 through 9 provide additional ﬂexibility of TB3 control

input terminal 8.

P46 Setting 4 - Two-Wire Accel/Decel Control

This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of switching from P30 - [Accel Time 1] and P31 - [Decel Time 1] to P69 - [Accel Time 2] and P70 - [Decel Time 2] for any commanded frequency reference.

Two-Wire Accel/Decel control Figure 2.8

TB3

567

Run Reverse

Run Forward

Common

Accel/Decel Select

➊ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details.

P46 Setting 5 - Two-Wire Enable Control

This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of “enable” command. The “enable” input is required for the drive to operate and if opened during operation the programmed P34 - [Stop Mode] will be overridden and the motor will coast to rest.

TB3-8 Open

Accel 2, Decel 2

TB3-8 Closed

Accel 1, Decel 1

➊

Two-Wire Enable control Figure 2.9

TB3

567

Run Reverse

Run Forward

Common

Enable

➊

➊ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details.

➋ When this input is in an open state, the motor will coast to rest.

TB3-8 Open

Controller Disabled

➋

TB3-8 Closed

Controller Enabled

Installation and Wiring 2-15

P46 Setting 6 - Two-Wire TB3 Control/Keypad or Communication Control

This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of switching the start, reverse and speed reference from the Program Keypad Module, Remote Keypad Module, CopyCat Keypad Module, or Communication Module to the control terminal block (TB3).

Two-Wire TB3 control/Keypad or Communication control Figure 2.10

TB3

567

Run Reverse

Run Forward

Common

TB3/Keypad or Communication

➊ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details.

➋ 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].

➊

TB3-8 Open

TB3 Control

TB3-8 Closed

Keypad or Communication Control

P46 Setting 7 - Two-Wire Frequency Select Control

This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of switching the frequency reference from the control terminal block (TB3) to the frequency commanded by P58 - [Internal Frequency]. For Analog Signal Follower models this provides the ability to switch from analog control to one preset speed. For Preset Speed models this provides a ninth preset speed via P58 - [Internal Frequency].

➋

Two-Wire Frequency Select control Figure 2.11

TB3

567

Run Reverse

Run Forward

Common

Frequency Select

➊ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details.

➊

TB3-8 Open

External (TB3) Frequency Command

TB3-8 Closed

Internal (P58) Frequency Command

2-16 Installation and Wiring

P46 Setting 8 - Two Wire Preset Speed Control (Analog Models Only)

This input mode is similar to Setting 1 except TB3 terminals 1, 2 and 8 provide the function of preset speeds. Note: All analog functionality is disabled when using this input mode setting.

Two-Wire Preset control Figure 2.12

TB3

+10V

SW1

Common

4 – 20 mA input

567

Run Reverse

➊

TB3-2 and TB3-8

See Table 2.I below

Run Forward

Common

SW2

➋

TB3 Terminal 2 and 8 Switch Deﬁnitions Table 2.I

SW2 Position TB3-8

Open (0) Open (0) Parameter 61

Open (0) Closed (1) Parameter 62

Closed (1) Open (0) Parameter 65

Closed (1) Closed (1) Parameter 66

SW1 Position TB3-2

Speed Reference Accel Rate Decel Rate

Parameter 30 Parameter 31

(Preset 0)

Parameter 30 Parameter 31

(Preset 1)

Parameter 69 Parameter 70

(Preset 4)

Parameter 69 Parameter 70

(Preset 5)

➊ Do not connect to TB3-4 in this mode.

➋ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details.

P46 Setting 9 - Two-Wire PI Control (Analog Models Only)

This input mode is similar to Setting 1 except TB3 terminal 8 provides the function of PI Control.

Two-Wire PI control Figure 2.13

0 – 10V DC

Common

Installation and Wiring 2-17

TB3TB3

Common

4 – 20 mA

567

➊

Run Forward

Common

PI/Internal Frequency

➋

TB3-8 Open

TB3-8 Closed

Internal Frequency

Refer to Chapter 5, 160 PI Control Setup for a detailed PI Control Setup description.

➊ Do not connect to TB3-5 in this mode.

➋ TB3 terminal 8 can be used to clear faults. See Figure 2.14 for details

Important: For P46 - [Input Mode] settings 4 through 9, Terminal TB3-8 is also

used to clear faults. See ﬁgure below for details.

TB3-8 – Clear Faults Figure 2.14

TB3-8 Closed

TB3-8 Open

Fault Occurs

Fault Clears

Fault Occurs

Fault Clears

Important: The system programmer is responsible for returning terminal

TB3-8 to its original state if necessary.

2-18 Installation and Wiring

When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect the commons (TB3-7) together for all drives. If they are to be tied into another common (such as earth ground or separate apparatus ground) only one point of the daisy chain of TB3-7 should be connected. Predicting actual performance given the variety of installation possibilities is difﬁcult, however, up to ﬁve drives with two meters of cable between have been tested without problems.

Typical Multiple Drive Input Connections Figure 2.15

TB3

567 567 567 567

Customer Inputs

Optional Ground Connection

Conﬁgurable Relay Output Contacts (P47 Settings)

You can conﬁgure the drive’s dry contact Form C output relay to change state based on P47 - [Output Conﬁgure] setting and P48 - [Output Threshold] limits. See Chapter 5 for details.

Conﬁgurable Relay Output Contacts Figure 2.16

TB3

Normally Closed

Relay Common

Normally Open

User Configurable Relay Outputs (Form C Relay) Resistive Load = 0.4A at 125V AC, 2A at 30V DC Inductive Load = 0.2A at 125V AC, 1A at 30V DC To set up, use P47 - [Output Configure]

Frequency Source Wiring

Analog Signal Follower Model

You can control the output frequency of the drive via the Control Terminal Block (TB3) using the following methods.

Analog Frequency Sources

Important: Only one frequency source may be connected at a time. If more

than one reference is connected at the same time, an undetermined frequency reference will result.

Installation and Wiring 2-19

±10V or 0 – 10V DC Frequency Control/Speed Control Figure 2.17

TB3

10V or 0 – 10V DC

Common Controller Input Impedance = 100k Ohms

4 – 20 mA Frequency Control/Speed Control Figure 2.18

TB3

Common parameters 16, 59, 60, 74, 75, 76

4 – 20 mA Controller Input Impedance = 250 Ohms

Potentiometer Frequency Control/Speed Control Figure 2.19

TB3

10V DC Supply

Wiper

Common

If calibration is required, use parameters 16, 59, 60, 74, 75, 76

If calibration is required, use

If calibration is required, use parameters 16, 59, 60, 74, 75, 76

10k Ohms, 2 Watt Linear Taper

When connecting a single potentiometer to multiple drives it is important to connect commons (TB3-3) together for all drives. TB3-3 (common) and TB3-2 (potentiometer wiper) should be daisy-chained to each drive. All drives must be powered up for the analog signal to be read correctly. Predicting actual performance given the variety of installation possibilities is difﬁcult, however, up to ﬁve drives with two meters of cable between have been tested without problems.

Typical Multiple Drive Analog Connection Figure 2.20

TB3

Preset Frequency Sources

The Analog Signal Follower model has a special input mode, P46 setting 8 that allows the drive to be operated via preset speed inputs. See Figure 2.12 and Table

2.I for details.

Optional Ground Connection

2-20 Installation and Wiring

Preset Speed Model

You can control the output frequency of the drive via the Control Terminal Block (TB3) using dry contacts or open collector inputs to SW1, SW2, and SW3 (see Figure 2.21).

Important: Refer to parameters 61 – 68 in Chapter 5 for the eight preset

TB3 Control Wiring for Preset Speed Model Figure 2.21

➊ Internal 12V supply. Contact closure or open collector input required. Refer to Appendix A for solid

state control input speciﬁcations.

➋ Control signal cable length is highly dependent on electrical environment and installation practices.

frequency factory default settings and switch conﬁgurations. A program keypad module is required to change the factory default settings.

TB3

SW1

➊

SW2

➊

Common

SW3

➊

➋

To select/program preset speeds, use parameters 61 – 68

Analog and Preset Models

Internal Frequency Source

Both the Analog Signal Follower and Preset Speed models have the provision for frequency control via P58 - [Internal Frequency]. This is accomplished by setting P59 - [Frequency Select] to a value of 1. See Chapter 5 for a description of these parameters.

What To Do Next

You should become familiar with the Program Keypad Module operation in Chapter 3 if you need to change any factory default parameter settings for your application.

Then proceed to Chapter 4, Start-Up and follow the ﬂow diagram. After applying power, you can program parameters if necessary. Refer to Table 5.A for a list of commonly changed parameters.

Chapter 3

Program Keypad Module

The Program Keypad Module is located on the front panel of the drive. This module is only operational when it is installed directly on the drive.

Features

The Program Keypad Module provides the following features:

• 6-digit, 7-segment LED display

• Program Mode Indicator

• Five keys for programming and displaying drive parameters

• Three keys for control inputs to the drive

• Two directional LED indicators

Program Keypad Module Figure 3.1

Parameter Number Display

Indicates which Display or Program Group parameter is active.

Parameter Value/Fault Number

Displays the parameter value or fault code number.

Display Mode

Program Mode

Program Mode Indicator

Flashes when in program mode.

Control Inputs and Indicators

Direction, Start, Stop (Stop is always active).

Important:

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

You enter the Program mode by pressing the ESCape key. While in this mode, you can edit Program Group parameters by pressing the SELect key. The Program Mode Indicator will ﬂash (see Figure 3.1) indicating the parameter value can be changed. The Enter key (↵) must be pressed to write the new value to memory. Refer to Chapter 5 for programming steps.

To activate Direction and Start inputs, must be set to 2. Power must be cycled or

Functions]

must be set to 2 for the change to take effect.

P46 - [Input Mode]

P56 - [Reset

3-2 Program Keypad Module

Key Functions

Escape

The ESCape key allows you to toggle between the Display and Program modes. When the Program mode is active, this key will disable the editing of a parameter value.

Select

The SELect key enables editing of a parameter value when the Program mode is active. When you press this key, the Program Mode Indicator ﬂashes.

Up/Down Arrow Keys

Use the Up/Down Arrow keys to scroll through a list of parameters, or increase and decrease parameter values. Press and hold either key to increase scrolling speed. Real time frequency adjustment can be achieved when using P58 - [Internal Frequency] and P59 - [Frequency Select]. Refer to Chapter 5 for further information.

Enter

Pressing this key causes the current value displayed to be entered into memory (only while in the Program mode). When you press this key, the Program Mode Indicator remains on, but stops ﬂashing.

Direction LEDs (Indicators)

The appropriate LED will illuminate continuously to indicate the commanded direction of rotation. If the second LED is ﬂashing, the drive has been commanded to change direction, but is still decelerating.

Important: Actual motor rotation could be different if motor leads are not

connected properly. Refer to Chapter 4 for details on how to verify correct motor rotation.

Reverse (Change Direction)

This function is only active when P46 - [Input Mode] is set to 2. When active, pressing this key causes the motor to ramp down to 0 Hz and then ramp up to its set speed in the opposite direction. When the motor is running, pressing this key causes the (currently illuminated) LED to ﬂash, indicating motor rotation while decelerating to zero. The other LED will illuminate indicating the commanded direction.

Start

This function is only active when P46 - [Input Mode] is set to 2. When active, pressing this key initiates a start command.

Stop

Pressing the Stop key will cause the motor to stop, using the selected stop mode. Refer to the P34 - [Stop Mode] parameter. If the drive has stopped due to a fault, pressing this key will clear the fault.

Important: The Stop key is always active in all control modes.

Program Keypad Module 3-3

Module Removal and Installation

ATTENTION: Ensure that you disconnect line power and wait three minutes before installing or removing the Program Keypad Module. Failure to do so could result in personal injury or death.

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

Removal

Insert a small screw driver into the slot at top of keypad. Carefully pry back and pivot the module out. Avoid bending or twisting the contact pins located underneath the center portion of the module.

Removing Program Keypad Module Figure 3.2

3-4 Program Keypad Module

Installation

1. Insert the module, bottom end ﬁrst, into the drive.

2. Press on the symbol at the top of the module until it is ﬁrmly seated.

It is critical that the Program Keypad Module is ﬁrmly seated to ensure circuit integrity.

Installing Program Keypad Module Figure 3.3

Start-Up Procedures

This chapter guides you through a basic start-up of the drive using factory default parameter settings. The objective is to verify power and control wiring, set motor direction, control motor speed and prepare you for programming parameters (tuning) if necessary. Refer to Chapter 5 for a complete listing and description of parameters and programming information.

Chapter 4

Start-Up

ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualiﬁed service personnel should perform the following procedure. Thoroughly read 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 that the drive is installed per the instructions in Chapter 2, including…

• Drive is mounted on a ﬂat, vertical and level surface.

• Minimum clearance distance between drive and other equipment.

• Proper grounding practices have been followed.

• Proper power and control wiring has been used.

• No external power applied to control inputs.

Verify that AC line power at the disconnect device is within the rated value of the drive.

Disconnect and lock out all incoming power to the drive including incoming

AC power to terminals R, S and T (L1, L2 and L3) of TB1.

ATTENTION: A DC Bus voltage may be present at TB1 and TB2 for approximately three minutes after power is removed from the drive.

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

IMPORTANT: Verify that a closed contact input is present at TB3-8. See Chapter 2, Control Wiring for details

onTB3-8 functionality when using P46 - [Input Mode] settings 4 through 9.

Conﬁrm that all other control inputs are connected to the correct terminals and are secure.

Remove debris label and reconnect power to drive.

Start-Up Checklist

continued on next page

4-2 Start-Up

continued from previous page

Ready/Fault Indicating Panel Procedure

The green Ready indicator will illuminate.

Use inputs to TB3 to operate the drive.

Analog Signal Follower Model Preset Speed Model

Set 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

Ready/Fault Indicating Panel, verify that the Reverse input to

TB3 is in the Open position.

Issue a Start command from the Program Keypad Module or

TB3. Drive fan will energize (some models).

Slowly increase the speed until the motor begins to turn.

Check the direction of motor rotation.

Program Keypad Module, Remote Keypad Module or

CopyCat Keypad Module Procedure

P01- [Output Frequency] will display. If drive has been previously powered up, a different parameter may display. Important: To enable the Start and Reverse keys on the Program Keypad Module, set P46 - [Input Mode] to 2 and cycle power (or set P56 - [Reset Function] to 2). Refer to P56 in Chapter 5.

Select P61 - [Preset Frequency 0] by removing all inputs to SW1,

SW2, and SW3 on TB3 (see Figure 2.21). The factory default

setting for P61 - [Preset Frequency 0] is 3 Hz.

If you are using a Program Keypad Module, verify that the

Clockwise LED is illuminated. If you are using a Ready/Fault

Indicating Panel, verify that the Reverse input to TB3 is in the

Open position.

Issue a Start command from the Program Keypad Module

or TB3. Check the direction of motor rotation.

Drive fan will energize (some models).

Issue a Stop command from the Program Keypad Module or TB3.

Ye s

❶ Start-up is complete!

Switch any two of the three motor leads connected to TB2, terminals U, V and W (T1, T2 and T3). Reconnect power. Check rotation.

❶ After successfully completing start-up, proceed to Chapter 5. If you need to change any factory

defaults, you will need a Program Keypad Module or other type of Communication Module.

Direction of Motor Rotation Correct?

Disconnect and lock out all incoming power to

TB1 terminals R, S and T (L1, L2, and L3).

ATTENTION: A DC Bus voltage may be present at the power terminal blocks TB1 and TB2 for approximately three minutes after power is removed from the drive.

Issue a Stop command from the Program Keypad Module or TB3.

Parameters and Programming

Overview of Parameters

This chapter describes both Display and Program parameters. Display parameters are read only (they cannot be programmed), while Program parameters can be changed to ﬁt your motor control requirements. A Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module allow you to view or change parameters. Communication Modules (RS1, DN1 or DN2) allow you to view or change parameters with an additional device. A Ready/Fault Indicating Panel cannot be used to view or change parameters. The table below describes which parameters apply to the Preset Speed and Analog Signal Follower models.

Chapter 5

Parameter Type Analog Signal Follower Model

Parameter Numbers

Display 1 – 19 1 – 15, 17 – 19

Program 30 – 62, 65, 66, 69 – 76, 78 – 84 30 – 59, 61 – 73, 78 – 80

Preset Speed Model Parameter Numbers

Some parameters pertain only to either the Analog Signal Follower or Preset Speed model, not both.

⇐ Indicates that parameter applies only to the Analog Signal Follower Model

⇐ Indicates that parameter applies only to the Preset Speed Model

Review the factory default settings. These parameters can be changed to meet your speciﬁc application requirements with any of the following: Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module. The table below provides a list of parameters that are frequently changed.

Commonly Changed Parameters Table 5.A

Parameter Setting Default Setting

P30 - [Accel Time 1] Desired accel time. 10.0 sec

P31 - [Decel Time 1] Desired decel time. 10.0 sec

P33 - [Maximum Frequency] Maximum frequency required. 60 Hz

P34 - [Stop Mode Select] Desired stopping mode. 0

P35 - [Base Frequency] Motor rated nameplate frequency. 60 Hz

P36 - [Base Voltage] Motor rated nameplate voltage. 460V or 230V

P38 - [Boost Select] Desired V/F boost setting. 2

P42 - [Motor Overload Current] Motor nameplate Full Load Amps (FLA). 115%

P43 - [Current Limit] Desired maximum output current. 150%

P46 - [Input Mode] Desired control method. 0

P47 - [Output Conﬁgure] Desired output relay function. 0

P56 - [Reset Functions] Desired drive reset description. 0

P58 - [Internal Frequency] Desired internal frequency. 60.0 Hz

P59 - [Frequency Select] Desired frequency source. 0

P61 – P68 - [Preset Frequency 0-7] Desired preset frequencies. 0-7

P74 – P76 - [Analog Input] Desired analog input functionality. 0, 0.0, 100.0%

Refer to the Programming Example on the next page for instructions.

5-2 Parameters and Programming

Important Reset Actions

You must set P56 - [Reset Functions] to 2 or cycle power after changing the setting of P46 - [Input Mode] for the change to take effect.

If you reset to factory defaults, you cannot use the Program Keypad Module for start or reverse control until it is selected using P46 setting 2. Note: P56 - [Reset Functions] must be set to 2 or power must be cycled for the change to take effect.

Important: If you cycle power, you must wait a minimum of one minute for

the bus to discharge to zero to ensure the change has taken effect.

An F48 - Reprogram Fault can be cleared using the Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module stop button or by cycling input to TB3-8.

Programming Example

The following is an example of the programming steps required to change a Program Group parameter setting. In this example, P31 - [Decel Time] is changed from its factory default setting of 10.0 seconds to 2.2 seconds. Refer to Chapter 3 for an explanation of the Program Keypad Module display and programming keys.

Important: To reset ALL values to original factory default settings, refer to

P56 - [Reset Defaults].

Action Description Keypad Display

1. To program the value of a Program Group

parameter, enter the Program Group by pressing the ESCape key. The Program Mode Indicator will illuminate.

2. Press the Up/Down keys until the desired parameter displays. In this case, press the Up key until P31 - [Decel Time] displays.

3. Press SELect. 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 10.0 seconds to 2.2 seconds by pressing the Down key until 2.2 displays.

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

5. When the desired value displays, press the Enter key. This writes the new value to memory. The Program Mode Indicator will stop ﬂashing and the display will ﬂash once indicating that the new value has been accepted.

Important: If at any time (while in the program mode) you wish to abort the editing process, press the ESCape key. The original value of the parameter will remain unchanged and you will be exited from the Program mode.

Parameters and Programming 5-3

Display Group Parameters (Read Only)

This group of parameters consists of commonly viewed drive operating conditions such as output frequency, output voltage, output current and frequency command. All parameters in this group are read only.

Important: The last user-selected Display Group parameter is saved when

power is removed and is displayed by default when power is reapplied.

Display Group (Read Only)

No. Parameter Name/Description Min./Max. Range Units

01 [Output Frequency]

Displays the output frequency at TB2 terminals U, V & W (T1, T2 & T3).

02 [Output Voltage]

Displays the output voltage present at TB2 terminals U, V & W (T1, T2 & T3).

03 [Output Current]

Displays the output current present at TB2 terminals U, V & W (T1, T2 & T3).

04 [Output Power]

Displays the output power present at TB2 terminals U, V & W (T1, T2 & T3).

05 [Bus Voltage]

Displays the DC Bus Voltage level.

06 [Frequency Command]

Displays the frequency that the drive is commanded to output. This command may come from any of the frequency sources selected by P59 - [Frequency Select]

or from a currently selected preset frequency.

07 [Active Fault]

Displays the coded active fault number. If a fault is currently active (has not been cleared) the display will ﬂash. After fault condition is cleared, display will read zero. Refer to P17, P18, and P19 for fault history. See Chapter 6 for fault code descriptions.

08 [Heatsink Temperature]

Displays the temperature of the drive heatsink. Note: A display value of 69 indicates a temperature of less than 70°C.

09 [Drive Status]

Displays the status of the drive in a binary coded format.

Important:

0 = Inactive, 1 = Active.

Bit 3 Bit 2 Bit 1 Bit 0

10 [Drive Type]

Used by Rockwell Automation ﬁeld service personnel.

11 [Firmware Version]

Displays version of drive ﬁrmware. Used by Rockwell Automation ﬁeld service personnel.

Running

Forward

Accel

Decel

0.0/240.0 0.1 Hz

0/Max Voltage 1 Volt

0/2 x Drive Rated Output Current

0/2 x Rated Drive Output Power

0/400 - 230V 0/800 - 460V

0.0/240.0 0.1 Hz

0/48 Numeric Value

69/150 1 Degree C

0000/1011 Binary Number

Numeric Value Numeric Value

Fixed Value Numeric Value

0.01A

0.01 kW

1 Volt

5-4 Parameters and Programming

Display Group (Read Only)

No. Parameter Name/Description Min./Max. Range Units

12 [Input Status]

0000/1111 Binary Number

Displays the open (0) and closed (1) state of the inputs to TB3 in binary coded format as follows:

Bit 3

Input Mode 0

(3-Wire)

Input Mode 1

(2-Wire)

Input Mode 2

(Keypad)

Input Mode 3

(Mom. Run Fwd./Rev.)

Input Mode 4

(Accel/Decel)

Input Mode 5

(Coast to Rest)

Input Mode 6

(TB3 Control/ Keypad or Comm.)

Input Mode 7

(Frequency Select)

Input Mode 8 ➊

(SF1 Preset Speed)

Input Mode 9

(2-Wire PI control)

➊ Status of Bit 3 for Input Mode 8 is TB3-2 is: 0 = Open, 1 = Closed.

Polarity

0 = Positive Analog Input

1 = Negative Analog Input

Bit 2 TB3-6

Start Stop Reverse

Run Forward

N/A Stop N/A

Run Forward

Bit 1 TB3-8

Stop Run

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

Coast to Rest Stop Run

0 = TB3 Control 1 = Keypad or Comm.

0 = Analog Frequency Select 1 = Internal Frequency Select

0 = Open 1 = Closed

0 = PI 1 = Internal Frequency Select

Bit 0 TB3-5

Reverse

Run Reverse

Reverse

Run Reverse

13 [Power Factor Angle]

Displays the angle in electrical degrees between motor voltage and motor current.

14 [Memory Probe Display]

Used by Rockwell Automation ﬁeld service personnel.

15 [Preset Status]

Displays the open (0) and closed (1) state of TB3 inputs SW1, SW2 and

Bit 3 Bit 2 Bit 1 Bit 0

SW3 in binary coded format.

16 [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 Maximum].

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

the drive. Once applied, if the value of this parameter displays something other than zero, program that value into P60 - [Zero Offset]. Please note that the value of [Zero Offset] will be subtracted from the value of this parameter.

This parameter applies only to the Analog Signal Follower model.

This TB3 input applies only to the Preset Speed model.

SW1

SW2

SW3

Not Used

0.0/180.0 0.1 degrees

Numeric Value Numeric Value

Preset –

Binary Number

0000/0111

Analog –

0000/0011

–150.0/+150.0 0.1%

Parameters and Programming 5-5

Display Group (Read Only)

No. Parameter Name/Description Min./Max. Range Units

17 [Fault Buffer 0]

This parameter stores the last fault that occurred. If the same fault occurs multiple times in a row, it will be stored once. After a “reset defaults” (P56) this will set this parameter to F48 - Reprogram Fault. As faults occur, the previous value of this parameter is moved to P18 - [Fault Buffer 1].

18 [Fault Buffer 1]

This parameter stores the second most recent fault that occurred. After a “reset defaults” (P56) this will set this parameter to 0 (No active fault). As faults occur, the value of this parameter will be overwritten by P17 - [Fault Buffer 0]. The previous value of this parameter is moved to P19 - [Fault Buffer 2].

19 [Fault Buffer 2]

This parameter stores the third most recent fault that occurred. After a “reset defaults” (P56) this will set this parameter to 0 (No active fault). As faults occur, the value of this parameter will be overwritten by P18 - [Fault Buffer 1].

0/48 Numeric Value

0/48

Numeric Value

Program Group Parameters

This group contains parameters whose values can be programmed. Refer to Programming Example earlier in this chapter. Unless otherwise stated, parameters

that are programmed while the drive is running take immediate effect.

Program Group

No. Parameter Name/Description

30 [Accel Time 1]

Time for the drive 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.

Maximum

Frequency

Deceleration

Min./Max. Range

Units

0.0/600.0 0.1 Seconds

Factory Default

10.0 Seconds

Speed

Acceleration

Accel Time Decel Time

Time

5-6 Parameters and Programming

Program Group

No. Parameter Name/Description

31 [Decel Time 1]

Time for the drive to ramp from P33 - [Maximum Frequency] to 0.0 Hz. The rate

Min./Max. Range

➊/600.0 0.1

Units

Seconds

Factory Default

10.0 Seconds

is linear for any decrease in command frequency unless P53 - [S-Curve] is set to a value other than 0.

➊ Minimum deceleration time must be set based on the applied motor size.

To guard against premature drive failure, do not set P31 - [Decel Time 1] or P70 - [Decel Time 2] below the minimum value listed in the table below.

230 and 460V Motor Sizes

4.0 kW (5 HP) 0.7 seconds

2.2 kW (3 HP) 0.6 seconds

1.5 kW (2 HP) 0.2 seconds

0.75 kW (1 HP) 0.1 seconds

0.55 kW (0.75 HP) 0.1 seconds

0.37 kW (0.5 HP) 0.1 seconds

32➋ [Minimum Frequency]

Minimum Deceleration Settings

0/240 1 Hz 0 Hz

Lowest frequency that drive will output continuously.

33➋ [Maximum Frequency]

0/240 1 Hz 60 Hz

Highest frequency the drive will output.

This parameter cannot be changed while running. The value of this parameter setting must be greater than the value set in P32 - [Minimum Frequency].

34 [Stop Mode Select]

Determines stopping mode used by the drive when a stop is initiated. Refer to

0/3 Numeric

Value

the P44 - [DC Hold Time] and P45 - [DC Hold Voltage] diagrams.

Settings: 0 Ramp to Stop 1 Coast to Stop 2 DC Injection Braking 3 DC Injection Braking (w/Auto Shutoff) – works the same as standard DC injection

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

35 [Base Frequency]

10/240 1 Hz 60 Hz

Set value to rated nameplate frequency of motor. A Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module is required if P35 must be changed to 50 Hz.

36 [Base Voltage]

Set value to rated nameplate voltage of motor.

37 [Maximum Voltage]

Sets the highest voltage that the drive will output. P37 - [Maximum Voltage] must be greater than or equal to P36 - [Base Voltage].

20/460 for 460V units 20/230 for 230V units

20/510 for 460V units 20/255 for 230V units

1 Volt

460 for 460V units 230 for 230V units

➋The analog inputs to the drive (i.e. 4-20mA, 0 to +10 V, or remote potentiometer) can be scaled to P32 - [Minimum Frequency] and

P33 - [Maximum Frequency] by programming P75 - [Analog Input Minimum] and P76 - [Analog Input Maximum].

Program Group

No. Parameter Name/Description

38 [Boost Select]

Sets the boost voltage and redeﬁnes the Volts per Hz curve. Settings 0 – 8 can provide increased torque at low frequency. Settings 9 – 12 are used to reduce energy consumption.

Parameters and Programming 5-7

Min./Max. Range

Units

0/12 Numeric

Factory Default

Value

100

1/2 Base Volts

% [Base Voltage]

8 See

ettings 1-8

0 50 100

➊ Break Point Voltages in percent of [Base Voltage]

% [Base Frequency]

9 10 11 12

1/2

Base Freq.

Setting Boost Voltage

0 1 2 3 4 5 6 7 8

Setting Fan/Pump Curves➊

9 10 11 12

39 [Skip Frequency]

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

Frequency

rellortnoC

Skip

Frequency

Setting

Command

Frequency

tuptuO

ycneuqerF

(% of [Base Voltage]) 0

2.5

5.0

7.5

10.0

12.5

15.0

17.5

20.0

45.0

40.0

35.0

30.0

2 x P40

[Skip Freq Band]

Setting

0/240 1 Hz 240 Hz

Time

40 [Skip Frequency Band]

Determines the band around the P39 - [Skip Frequency] parameter. The actual band width will be 2 times P40 - [Skip Frequency Band] - 1/2 the band above and 1/2 the band below. A value of zero will disable the skip frequency.

0/30 1 Hz 0 Hz

5-8 Parameters and Programming

Program Group

No. Parameter Name/Description

[Motor Overload Select]

Bulletin 160 provides Class 10 overload protection. Settings 0 – 2 select the

derating factor for the I

Setting Derate Level

0 No Derate 10:1 speed range

1 Min. Derate 4:1 speed range, derate below 25% of base speed

2 Max. Derate 2:1 speed range, derate below 50% of base speed

t overload function.

Min./Max. Range

Units

0/2 Numeric

Value

Factory Default

100

% of [Overload Curent] Setting% of [Overload Curent] Setting

100

No Derate

150

125100755025 0

% of Base Speed % of Base Speed

Max Derate

150

125100755025

% of Base Speed

175

100

200

% of [Overload Curent] Setting

Settings

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

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 drive rated output current.

44 [DC Hold Time]

The 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.”

Min Derate

125100755025

150

175

200

0.1/200% of Drive Rating

1/180% of Drive Rating

0.0/25.0 0.1

0.01A 115% of Drive Rating

1% 150%

0.0

Seconds

Program Group

No. Parameter Name/Description

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.

If the current exceeds P43 - [Current Limit] the voltage applied to the motor will be less than this setting.

Parameters and Programming 5-9

Min./Max. Range

Units

Factory Default

0/115 1 Volt 0 Volts

Ramp-to-Stop Mode

Volts/Speed

Stop Command

Voltage

[DC Hold Time]

deepS

[DC Hold Voltage]

Time

46 [Input Mode]

Conﬁgures the TB3 control inputs for various 3-wire or 2-wire control schemes. Also enables/disables the Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module input control. See Chapter 2 for wiring diagrams and descriptions of settings.

Important: The method used to activate PI control is dependent upon Fir mware

Version. Refer to 5-17 for PI Control Setup and Activation instructions.

Important: This parameter cannot be programmed while the drive is running.

In addition, power must be cycled or P56 - [Reset Function] must be set to 2 for the change to take effect.

Settings: 0 = 3-wire control ➊

1 = 2-wire control ➊ 2 = Program Keypad Module, Remote Keypad Module,

CopyCat Keypad Module, or Communication control

3 = Momentary Run Forward/ Run Reverse control ➊ 4 = 2-wire Accel/Decel control 5 = 2-wire Coast to Rest control 6 = 2-wire TB3 Control/Keypad or Communication control 7 = 2-wire Frequency Select control 8 = 2-wire Preset control 9 = 2-wire PI control ➋

➊

A contact closure on TB3 Terminal 7 and 8 is required for the drive

➊

➋

to respond to a Run command.

➋ Only available in Analog Signal Follower model.

➊

Voltage

Volts/Speed

DC Injection Braking Mode

[DC Hold Time]

Speed

Stop Command

Time

0/9 Numeric

Value

[DC Hold Voltage]

5-10 Parameters and Programming

Program Group

No. Parameter Name/Description

47 [Output Conﬁgure]

Conﬁgures the TB3 relay output functionality.

Setting Output Changes State When . . .

0 Drive Ready/Faulted Energized and returns to shelf state when power is

1 At Frequency Drive reaches commanded frequency.

2 Motor Running The motor is receiving power from drive.

3 Reverse Drive is commanded to run in the reverse direction.

4 Motor Overload A motor overload condition exists.

5 Ramp Regulated The ramp regulator is modifying the programmed accel/

6 Above Frequency The drive exceeds the frequency value set in

7 Above Current Dr ive exceeds the value set in P48 - [Output Threshold].

8 Above DC Bus Voltage Drive exceeds the DC bus voltage value set in

9 Retries Exhausted Number of retries for P50 - [Restart Tries] is exceeded.

10 Above Power Factor

Angle

removed or a fault occurs.

decel times to avoid an overcurrent or overvoltage fault from occurring.

P48 - [Output Threshold].

Important: Value for P48 - [Output Threshold] must be entered in percent of drive rated output current.

P48 - [Output Threshold].

Power Factor angle exceeds the value set in P48 - [Output Threshold].

Min./Max. Range

Units

0/10 Numeric

Value

Factory Default

48 [Output Threshold]

Determines the on/off point for the TB3 output relay when P47 - [Output Conﬁgure] is set to 6, 7, 8, and 10.

Setting Ranges 6 0 to 240 Hz 7 0 to 180% 8 0 to 815 Volts 10 0 to 180˚

49 [PWM Frequency]

Carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting.

100

98 96 94 92 90 88

% Output Current (A)

86 84

2345678

Carrier Frequency (kHz)

Important: Ignoring derating guidelines can cause reduced drive performance.

50 [Restart Tries]

Maximum number of times the drive will attempt to reset a fault. Faults 03 – 20 will automatically reset according to this parameter setting.

0/815 Numeric

Value

2.0/8.0 0.1 kHz 4.0 kHz

0/9 Numeric

Value

Program Group

No. Parameter Name/Description

51 [Restart Time]

Time between restart attempts.

If this parameter and P50 - [Restart Tries] are both set to zero, and P46 - [Input Mode] is not set to 3, the auto fault clear feature is enabled. This feature automatically clears overvoltage, undervoltage, and overtemperature faults 1 second after the fault condition is removed.

If this parameter is set to zero and P50 - [Restart Tries] is not zero, then the time between restart attempts is 1 second.

Parameters and Programming 5-11

Min./Max. Range

Units

0.0/300.0 0.1 Seconds

Factory Default

10.0 Seconds

52 [DB Enable]

Enables/disables external dynamic braking. Setting “0” = Disable. Settings 1 through 100 = % duty cycle braking.

ATTENTION: The 160 Dynamic Brake Module 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 resistor must be sized to avoid overheating of the resistor package.

This parameter cannot be programmed while the drive is running.

53 [S-Curve]

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

Formula: S-Curve Time = Accel or Decel Time x S-Curve Setting (in percent)➊

➊ See values below.

Example: Accel Time = 10 Seconds

S-Curve Setting = 3 S-Curve Time = 10 x 0.3 = 3 Seconds

Important: Maximum S-Curve time is 60 seconds.

S-Curve

Time

S-Curve

Time

Enabled

S-Curve

Time

S-Curve

Time

S-Curve Setting

= 0%

= 10%

= 20%

= 30%

= 40%

= 50%

= 60%

= 70%

= 80%

= 90%

= 100%

0/100 Numeric

Value

0/10 Numeric

Value

Accel Time

Disabled

Decel Time

5-12 Parameters and Programming

Program Group

No. Parameter Name/Description

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.

This parameter cannot be programmed while the drive is running.

55 [Memory Probe Address]

Used by Rockwell Automation ﬁeld service personnel.

56 [Reset Functions]

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

Settings:

0 Idle State 1 Reset defaults (restores all parameter settings to factory defaults). 2 Update Input Mode (restores the drive to most recent programmed

P46 - [Input Mode] setting).

After the reset/update function is complete, this parameter will set itself back to a “0.” This parameter cannot be programmed while the drive is running.

Important: For setting 1 only, an F48 - Reprogram Fault will occur and must be

cleared by cycling the Stop input to the drive. P46 - [Input Mode] factory defaults to 3-wire control. If using keypad control, change parameter setting back to a 2 to regain program keypad control, cycle power or use P56 Setting 2 again.

57 [Program Lock]

When set to 1, all parameters will be protected against change by unauthorized personnel.

58 [Internal Frequency]

When P59 - [Frequency Select] is set to a 1, this parameter will provide the drive frequency command. This parameter will change the frequency command in “Real time” using the up/down arrow keys. Maximum value is set in P33 - [Maximum Frequency].

Important: Follow normal programming procedures. Once the desired

command frequency is reached, the Enter key must be pressed to store this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return to the original value following the normal accel/decel curve.

59 [Frequency Select]

Selects the source of the frequency command for the drive.

Settings: 0 = External frequency command from the Control Ter minal Block (TB3)

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.

Min./Max. Range

Units

0/1 Numeric

Factory Default

Value

Numeric Value

0/2 Numeric

Numeric Value

Value

0/1 Numeric

Value

0.0/240.0 0.1 Hz 60.0 Hz

0/1

Numeric

Value

–50.0/+ 50.0 Numeric

Value

This parameter applies only to the Analog Signal Follower model.

Program Group

No. Parameter Name/Description

[Preset Frequency 0-7]

The programmed value sets the frequency that the drive outputs when selected. Refer to Chapter 2, Figure 2.21 for the Preset Speed model control wiring diagram.

Parameters and Programming 5-13

Min./Max. Range

Units

Factory Default

0.0/240.0 0.1 Hz See Table

TB3-1

(SW1)

Signal Follower Model Only

(Input Mode 8)

TB3-8

(SW2)

TB3-2 (SW1) Accel

➊ Decel ➊

P30 [Accel Time 1]

P69 [Accel Time 2]

Preset Speed Model Only

TB3-4

TB3-2

(SW3)

Preset Freq. Default

Preset 0 3.0 Hz 0 0 0 0 0

Preset 1 20.0 Hz 0 0 1 0 1

Preset 2 30.0 Hz 0 1 0 N/A N/A

Preset 3 40.0 Hz 0 1 1 N/A N/A

Preset 4 45.0 Hz 1 0 0 1 0

Preset 5 50.0 Hz 1 0 1 1 1

Preset 6 55.0 Hz 1 1 0 N/A N/A

Preset 7 60.0 Hz 1 1 1 N/A N/A

➊ When using P46 - [Input Mode] setting 4, the Accel and Decel times are selected by providing an input to TB3-8.

See Chapter 2, Figure 2.12 for additional information.

(SW2)

69 [Accel Time 2]

Time for the drive 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 gives 0.1 seconds acceleration with the initial current limit turned off. This allows quicker acceleration times for low inertia systems. For medium to high inertia systems, the minimum value should be 0.1.

70 [Decel Time 2]

Time for the drive 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.

➋ Minimum deceleration time must be set based on the applied motor size.

To guard against premature drive failure, do not set P31 - [Decel Time 1] or P70 - [Decel Time 2] below the minimum value listed in the table below.

230 and 460V Motor Sizes

4.0 kW (5 HP) 0.7 seconds

2.2 kW (3 HP) 0.6 seconds

1.5 kW (2 HP) 0.2 seconds

0.75 kW (1 HP) 0.1 seconds

0.55 kW (0.75 HP) 0.1 seconds

0.37 kW (0.5 HP) 0.1 seconds

Minimum Deceleration Settings

P31 [Decel Time 1]

P70 [Decel Time 2]

0.0/600.0 0.1 Sec. 20.0 Seconds

➋/600.0 0.1 Sec. 20.0

Seconds

This parameter applies only to the Preset Speed model.

5-14 Parameters and Programming

Program Group

No. Parameter Name/Description

71 [IR Compensation]

The programmed value adds a voltage to the output based on the torque current. An additional 31 volts (150%) is added to 460 volt units to compensate for stator resistance. 15.5 volts (150%) is added for 230 volt units. If the drive trips on an F07 - Motor Overload fault, or has trouble accelerating to commanded speed, this value should be reduced. A setting of 0% disables this function.

72 [Slip Compensation]

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. This parameter along with P83 - [PI Process Reference] also activates PI control in drives using Firmware Version FRN 7.06. See page 5-17 for PI Control Setup and Activation instructions.

ATTENTION: Hazard of personal injury or equipment damage

exists due to unpredictable changes in motor speed. Do not use

P72 - [Slip Compensation] and P83 - [Process Reference] to disable PI control while the drive is running. Disable PI control only when the drive is stopped.

73 [Reverse Disable]

When this parameter is set to a 1, reverse is disabled. The reverse command may come from the analog input, TB3-5, the keypad or a serial command. With a negative analog input and reverse disabled, the frequency command will be zero in bipolar mode and minimum frequency in unipolar mode. All digital reverse inputs including two-wire Run Reverse will be ignored with reverse disabled.

Important: This parameter cannot be programmed while the drive is running.

74 [Analog Select]

Settings: 0 = unipolar analog input 0 to +10V

1 = bipolar analog input -10 to +10V

Important: With this parameter set to bipolar (setting 1), the parameter settings

for P75 - [Analog Input Minimum] and P32 - [Minimum Frequency] are ignored. In addition, all other reverse inputs (Program Keypad Module, Remote Keypad Module, CopyCat Keypad Module, TB3-5 control terminal block, or serial communication module) are ignored with the exception of when P46 - [Input Mode] is programmed to setting 7. (This applies to drives with ﬁrmware version FRN 7.03 and later.) When P46 - [Input Mode] setting 7 is active, and TB3-8 is closed, the frequency source is P58 - [Internal Frequency] and the direction will be commanded from the control terminal block (either terminal TB3-5 or TB3-6).

Important: This parameter cannot be programmed while the drive is running.

Min./Max. Range

0/150

Units

1% 50%

Factory Default

0.0/5.0 0.1 Hz 2.0 Hz

0/1

Numeric

value

0/1 Numeric

value

This parameter applies only to the Analog Signal Follower model.

Program Group

No. Parameter Name/Description

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 P32 - [Minimum Frequency], use P16 - [Analog Input] to adjust the analog input to the desired level using P60 and then enter this value into P75.

Analog inversion can be accomplished by setting this value larger than P76.

Important: This parameter cannot be programmed while the drive is running.

76 [Analog Input Maximum]

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 P33 - [Maximum Frequency], use P16 - [Analog Input] to adjust the analog input to the desired level using P60 and then enter this value into P76.

Analog inversion can be accomplished by setting this value smaller than P75.

Important: This parameter cannot be programmed while the drive is running.

78 [Compensation]

Settings:

0 No compensation.

1 Some drive/motor combinations have inherent instabilities which are exhibited

as non-sinusodial motor currents. This setting attempts to correct this condition.

2 Some motor/load combinations have mechanical resonances which can be

excited by the drive current regulator. This setting slows down the current regulator response and attempts to correct this condition.

79 [Software Current Trip]

This provides a software instantaneous current trip similar to the 300% hardware current trip. This value is the percent above the P43 - [Current Limit] at which the drive trips immediately. A setting of zero disables the Software Current Trip.

80 [Stall Fault Time]

This selects the amount of time the drive must be in a stall condition before it causes a stall fault.

0 = Normal stall time, approximately 60 seconds 1 = 2 times normal stall time 2 = 4 times normal stall time 3 = 6 times normal stall time 4 = 8 times normal stall time 5 = Stall fault disabled

ATTENTION: Continuous operation at high currents caused by a stall can cause motor damage.

Parameters and Programming 5-15

Min./Max. Range

Units

Factory Default

0.0/150.0 0.1% 0.0%

0.0/150.0

0 to 2 Numeric

0.1% 100.0%

value

0/50% 1% 0%

0/5 Numeric

Value

This parameter applies only to the Analog Signal Follower model.

5-16 Parameters and Programming

Program Group

No. Parameter Name/Description

81 [PI Proportional Gain]

Proportional gain used by the PI regulator. This parameter is scaled so that when it is set to 1.0, the process response is 1 Hz when the process error is 1%. The correct value for this parameter depends on the dynamics of the process being controlled, as well as the desired response. This parameter is active when P46 - [Input Mode] setting 9 is used.

82 [PI Integral Gain]

Integral Gain used by the PI regulator. This parameter is scaled so that when it is set to 1.0, the process response is 10 Hz/sec when the process error is 1%. The correct value for this parameter depends on the dynamics of the process being controlled, as well as the desired response. This parameter is active when P46 - [Input Mode] setting 9 is used.

83 [PI Process Reference]

The PI control will regulate to this set point value. It represents a percentage of the analog input. This parameter is active when P46 - [Input Mode] setting 9 is used. This parameter along with P72 - [Slip Compensation] also activates PI control in drives using Firmware Version FRN 7.06. See page 5-17 for PI Control Setup and Activation instructions.

ATTENTION: Hazard of personal injury or equipment damage

exists due to unpredictable changes in motor speed. Do not use

P72 - [Slip Compensation] and P83 - [Process Reference] to disable PI control while the drive is running. Disable PI control only when the drive is stopped.

84 [PI Dead Band]

The PI control will ignore errors less than this value. This parameter is active when P46 - [Input Mode] setting 9 is used.

Min./Max. Range

0/10.00 Numeric

0/100.0% 0.1% 0.0%

0/10.0% 0.1% 0.0%

Units

Value

Factory Default

0.01

This parameter applies only to the Analog Signal Follower model.

PI Control Block Diagram Figure 5.1

P83 [PI Process Reference]

Analog Feedback

P58 [Internal Frequency]

P81 [PI Proportional Gain]

P82 [PI Integral Gain]

P84 [PI Dead Band]

TB3-8 Open

TB3-8 Closed

P01 [Output Frequency]

PI Control Setup and Activation

The Analog Signal Follower model provides for closed loop process control (PI control) where PI regulator output is used to drive the process to a desired set point.

Wire For PI Control

1. Connect input and output power to the drive. Follow the instructions provided in Section 2, Installation and Wiring.

2. Connect control wiring (see Chapter 2, Figure 2.17). A contact closure on terminals 6 and 7 is required for the drive to respond to a Start/Run command.

3. Select an external frequency command source. See Table 5.B.

4. Connect feedback device to TB3-2 and TB3-3 for 0 – 10V feedback or to TB3-3 and TB3-4 for 4 – 20 mA feedback.

5. Verify polarity of feedback. That is, increasing feedback signal requires increasing output frequency.

Program for PI Control

1. Set P56 - [Reset Functions] to 1 to reset the drive to defaults. An F48 - Reprogram Fault will occur which must be cleared by cycling the Stop input to the drive.

2. Users of Firmware Version 7.06: Set P46 - [Input Mode] to the desired setting. Users of Firmware Version 7.05 and earlier: Set P46 - [Input Mode] to 9.

Table 5.B describes how to reference the external frequency command source for each P46 - [Input Mode] setting.

Parameter 46 Settings and Frequency Source Selection Table 5.B

Parameters and Programming 5-17

P46 Setting Reference External Frequency Command Source Firmware Version

0 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

1 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

2 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

3 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

4 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

5 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

6 Set P59 - [Frequency Select] to 0 (Factory Default) FRN 7.06 only

7 Open the contact at TB3-8 FRN 7.06 only

8 This setting is not used with PI control.

9 Open the contact at TB3-8 FRN 7.06 or earlier

3. Cycle power or set P56 - [Reset Functions] to 2 for the change made at Step 2 to take effect.

4. Set P72 - [Slip Compensation] to 0.

5-18 Parameters and Programming

5. Use P75 - [Analog Input Minimum] and P76 - [Analog Input Maximum] to scale feedback to the process operating range. This may also be used to invert the feedback so that increasing feedback signal produces decreasing output frequency.

6. Set P83 - [PI Process Reference] to 20 as an initial setting. This establishes the set point as 20% of the maximum analog input. (This setting must be greater than zero to activate PI control in Firmware Version FRN 7.06 except when using input mode 9.)

7. Connect TB3-8 with TB3-7. This will disable PI control and force the output frequency to the P58 - [Internal Frequency] setting.

8. Connect TB3-6 with TB3-7 to start the drive. Verify motor operation and direction.

9. Remove the connection between TB3-8 from TB3-7. This will place the drive into PI control mode when using input modes 7 and 9.

ATTENTION: Hazard of personal injury or equipment damage exists due to unpredictable changes in motor speed. Do not use P72 - [Slip Compensation] and P83 - [Process Reference] to disable PI control while the drive is running. Disable PI control only when the drive is stopped.

Tune the PI Loop

Parameters P81 - [PI Proportional Gain] and P82 - [PI Integral Gain] are used to set how the drive will respond to errors (ﬂuctuations) in feedback.

• P81 - [PI Proportional Gain] corrects output frequency based on the magnitude of

the error.

• P82 - [PI Integral Gain] corrects output frequency based on the length of time an

error has been present.

1. Set P82 - [PI Integral Gain] to zero and P81 - [PI Proportional Gain] to some low value.

2. Apply a step function command via P83 - [PI Process Reference] and monitor the output response.

3. Increase P81 - [PI Proportional Gain] until the response of the output is acceptably fast or the output becomes too noisy.

4. Reduce P81 - [PI Proportional Gain] back to the highest value at which the response is still clean.

5. Set P82 - [PI Integral Gain] to a low value.

6. Apply a step function command and monitor the output response.

7. Increase P82 - [PI Integral Gain] until the response is acceptably fast without overshoot.

Important: If either the value of P81 or P82 is set too high, drive output will

oscillate around the set point entered in P83 - [PI Process Reference] due to continually changing loads in the application. Use P84 - [Dead Band] to limit the effects of this oscillation by blocking a frequency count to either side of the set point frequency.

Common Problems with PI Control

1. Drive direction is incorrectly set for PI control.

Ensure that the drive is operating with the clockwise direction indicator illuminated.

2. Drive oscillates between 0 and 3 Hz.

• Check direction and polarity of analog input signal.

• Ensure that the drive is operating with the clockwise direction indicator

illuminated.

• Ensure the +10V DC wire is connected to TB3-2 and that the common is connected to TB3-3.

• Check that parameters P81 - [PI Proportional Gain] and P82 - [PI Integral Gain] are set to a value other than 0.00.

3. Drive accelerates too quickly resulting in an F05 - OverVoltage Fault.

• Lower P81 - [PI Proportional Gain] below its current value.

• Lower P82 - [PI Integral Gain] below its current value.

• Raise P31 - [Decel Time 1] above its current value.

• Raise P30 - [Accel Time 1] above its current value.

• Evaluate the need for a dynamic brake for the application.

4. Drive will only run off the internal frequency or does not control with the PI process loop.

• Check that P46 - [Input Mode] is set to 9.

• Ensure that power was cycled for one minute after changing the P46 setting.

• Ensure that there is not a connection between TB3-7 and 8.

5. Nothing works properly.

• Set P56 - [Reset Functions] to 1 and press the Enter key.

• Press the Stop button to clear the F48 - Reprogram Fault.

• Cycle power to the drive.

• Conﬁrm that wiring is correct.

• Reapply power and program according to this procedure.

6. PI does not function with DeviceNet.

• Firmware Version 7.05 and earlier only allows one P46 - [Input Mode] setting

to be active at one time (settings 2 or 6 for DeviceNet or setting 9 for PI).

• It is possible for users of Firmware Version 7.05 and earlier to set up PI

control via an external processor, such as a SLC500. Consult your processor manual for speciﬁc instructions.

Parameters and Programming 5-19

5-20 Parameters and Programming

End of Chapter

Fault Information

This chapter provides information to guide you in troubleshooting the drive. Included is a list and description of drive faults and problems that may occur.

Program Keypad Module Fault Display Figure 6.1

Ready/Fault Indicating Panel Figure 6.2

Chapter 6

Troubleshooting

Active Fault

If a fault occurs, P07 - [Active Fault] is displayed.

Fault Code Number

Controllers equipped with a Program Keypad Module will flash the display when a fault is present.

FAULT

READY

How to Clear a Fault

When a fault occurs, the cause must be corrected before the fault can be cleared. After corrective action has been taken, any of the following actions will clear the fault.

• Press the Program Keypad Module’s Stop button.

• Disconnect power to the drive, wait one minute, reapply power.

• Cycle the input signal at TB3-8 to the drive.

• Set P54 - [Clear Fault] to 1.

Fault LED

Controllers without a Program Keypad Module come equipped with a Ready/Fault Indicating Panel. When the Fault LED is illuminated, a fault exists. The optional Remote Programming Adapter is equipped with the same Ready/Fault indication system.

6-2 Troubleshooting

Bulletin 160 Fault Descriptions Table 6.A

Fault

No.

Name

Power Loss Fault The DC Bus voltage remains below 85% nominal on

UnderVoltage

04➊

Fault

OverVoltage Fault The maximum DC Bus voltage has been exceeded.

05➊

Motor Stall Fault The motor has stalled due to an excessive motor load. A longer acceleration time or a reduced load is required.

06➊

Motor Overload

07➊

Fault

Over Temperature

08➊

Fault

Operator Fault The keypad has been removed while the drive is

Overcurrent Fault An overcurrent has been detected in the hardware trip

12➊

Software Over

13➊

Current Fault

Drive Overload

20➊

Fault

EEPROM Fault The EEPROM has invalid data. Reset EEPROM using P56 - [Reset Functions] — Set to

Max Retries Fault The drive failed to reset within the number of retries

Incompatible Fault Incompatible communication module installed. Verify compatibility of communication module.

Phase U Fault A phase to ground fault has been detected between

Phase V Fault A phase to ground fault has been detected between

Phase W Fault A phase to ground fault has been detected between

UV Short Fault Excessive current has been detected between these

UW Short Fault Excessive current has been detected between these

VW Short Fault Excessive current has been detected between these

Intermittent Phase

Fault

Reprogram Fault Occurs when the drive parameters are reset to default. Clear the fault.

➊ These faults have an auto reset feature. This feature automatically clears overvoltage, undervotage, and overtemperature faults

1 second after the fault condition is removed. Refer to P51 - [Restart Time].

Fault Description Corrective Action

power up for longer than 5 seconds.

The DC Bus voltage fell below the minimum rated voltage. For 200-240V AC input drives, the undervoltage trip occurs at a bus voltage of 210VDC (equivalent to a 150VAC incoming line voltage). For 380460VAC rated drives, the undervoltage trip occurs at a bus voltage of 390VDC (equivalent to a 275V AC incoming line voltage).

For 200-240VAC input drives, the overvoltage trip occurs at a bus voltage of 400VDC (equivalent to a 290VAC incoming line voltage). For 380-460VAC input drives, the overvoltage trip occurs at a bus voltage of 800VDC (equivalent to a 575V AC incoming line voltage).

An internal electronic overload trip has occurred. An excessive motor load exists.

Excessive heat has been detected. Clear blocked or dirty heat sink ﬁns. Check ambient

powered.

circuit.

Motor current exceeded value set in parameter 79. A longer acceleration time, reduced load, or removal of

An internal electronic overload trip has occurred. The drive is over heating.

set in P50 - [Restart Tries].

the drive and the motor in phase U.

the drive and the motor in phase V.

the drive and the motor in phase W.

two drive output terminals.

An external short occurred while running diagnostics. Check wiring between the drive and the motor. Check for

Monitor the incoming AC line for low voltage or line power interruptions.

Motor regeneration has caused a bus overvoltage. Monitor the incoming AC line for excessive voltage. Extend the decel time or install a dynamic brake module or external capacitor module (See Appendix A).

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

temperature. Check for a blocked or non-operating fan.

Clear the fault. Do not remove the keypad under power.

Check for a short circuit at the drive output or for excessive load conditions at the motor.

motor shaft blockage is required.

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

1 and cycle power.

Repair the system fault.

Check the wiring between the drive and the motor. Check the motor for a grounded phase. Check that ground is not connected to U.

Check the wiring between the drive and the motor. Check the motor for a grounded phase.

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

more than one shorted output.

Troubleshooting 6-3

Possible Problems and Corrective Actions Table 6.B

Problem Corrective Action

The motor does not start — No output voltage to the motor.

The drive is started but the motor is not rotating. P01 - [Output Frequency] displays 0.0.

The motor is not accelerating properly. 1. Check the motor.

Drive will not operate in the run/forward or run reverse modes.

Display is dark. 1. Verify that the module is ﬁrmly seated.

1. Check the power circuit.

• Check the supply voltage.

• Check all fuses and disconnects.

2. Check the motor.

• Verify that the motor is connected properly.

3. Check the control input signals.

• Verify that the Start signal is present.

• Verify that the contact closure signal is present at TB3-8.

• Verify that either the Run Forward or Run Reverse signal is both.

4. Check P46 - [Input Mode].

• If P46 - [Input Mode] is set to 2, only the program keypad module Start button will start the motor.

5. Cycle power or use P56 - [Reset Functions] if you changed P46 - [Input Mode].

1. Check the motor.

• Verify that the motor is connected properly.

2. Check the frequency source P06 - [Frequency Command].

• Verify that a frequency signal is present at terminal block TB3 — Either a

-10 to +10V signal or a 4-20 mA signal.

• Verify that the Preset Frequencies are set properly.

3. Check the control input signals.

• Verify that SW1, SW2 and SW3 are correct. (Refer to the chart in Chapter 5.)

4. Check the following parameter settings.

• Verify that P59 - [Frequency Select] is showing the desired frequency source.

• Verify that P58 - [Internal Frequency] is set to the desired frequency.

5. Cycle power or use P56 - [Reset Functions] if you changed P46 - [Input Mode].

• Verify that the motor is connected properly.

• Verify that no mechanical problems exist.

2. Check the following parameter settings.

• Verify that P30 - [Accel Time 1] or P69 - [Accel Time 2]

— whichever is currently used — is set properly.

• Verify that P43 - [Current Limit] is set properly.

• Verify that P38 - [Boost Volts] is set properly.

1. Verify that P46 - [Input Mode] is set to 1.

2. Verify that neither P73 - [Reverse Disable] nor P74 - [Analog Select] is set to 1.

3. Verify that the power has been cycled for 1and 2 to take effect.

4. Verify that both the Run Forward and Run Reverse switches are not closed simultaneously.

5. Cycle power or use P56 - [Reset Functions] if you changed P46 - [Input Mode].

2. Remove module and inspect connector pins. If pins are not damaged, reinstall and ﬁrmly seat the module.

active, but not

6-4 Troubleshooting

Block Diagram of Bulletin 160 Analog Signal Follower Figure 6.3

Capacitor ModuleBrake Module

DC-DC+BR-BR+

Frequency Reference

L1/R

L2/S

L3/T

-10 to +10V or

Potentiometer

4 - 20 mA

Reverse

Start

Programable Input

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

Motor

User Programmable Output

Appendix A

Speciﬁcations

Tables A.A and A.B contain information that is unique to each Bulletin 160 Drive rating. Table A.C contains information that applies to all drive ratings.

200-240VAC – 1-Phase & 3-Phase Input Drive Ratings Table A.1

Drive Catalog Number

1-Phase Input 160S-AA02 160S-AA03 160S-AA04 160S-AA08 ——

3-Phase Input 160-AA02 160-AA03 160-AA04 160-AA08 160-AA12 160-AA18

Output Ratings

3-Phase Motor Rating — kW (HP) 0.37 (1/2) 0.55 (3/4) 0.75 (1) 1.5 (2) 2.2 (3) 3.7 (5)

Maximum Output Amps 2.3 3.0 4.5 8.0 12.0 18.0

Power Dissipation — Watts 20 25 35 74 107 137

Input Ratings

Input Voltage, Frequency 200/240VAC, 1-Phase and 3-Phase, 50/60 Hz

Operational Input Voltage Range 180-265VAC

Input kVA 1.1 1.4 2.2 3.7 5.7 8.4

1-Phase Input Current ➊ 4.8 6.2 9.4 16.3 — —

3-Phase Input Current ➊ 2.8 3.6 5.4 9.4 14.2 21.1

Environmental Speciﬁcations

Cooling Method Convection Cooled Fan Cooled

Dynamic Braking Torque ➋

With External Dynamic Brake Module ——200 150 115 100

Without External Dynamic Brake Module 100 100 100 50 50 20

380-460VAC – 3-Phase Input Drive Ratings Table A.2

Drive Catalog Number

3-Phase Input 160-BA01 160-BA02 160-BA03 160-BA04 160-BA06 160-BA10

Output Ratings

3-Phase Motor Rating — kW (HP) 0.37 (1/2) 0.55 (3/4) 0.75 (1) 1.5 (2) 2.2 (3) 3.7 (5)

Maximum Output Amps 1.2 1.7 2.3 4.0 6.0 10.5

Power Dissipation — Watts 25 30 37 50 77 120

Input Ratings

Input Voltage, Frequency 380/460VAC, 3-Phase, 50/60 Hz

Operational Input Voltage Range 340-506VAC

Input kVA 1.1 1.6 2.2 3.7 5.6 9.7

Input Current ➊ 1.4 2.0 2.8 4.6 7.0 12.2

Environmental Speciﬁcations

Cooling Method Convection Cooled Fan Cooled

Dynamic Braking Torque ➋

With External Dynamic Brake Module — — 200 150 115 100

Without External Dynamic Brake Module 100 100 100 50 50 20

➊ Input current ratings are calculated based on a nominal input voltage of 230V and 460V respectively.

➋ Estimated – Actual value depends upon motor characteristics.

A-2 Specifications

All Drive Ratings Table A.3

Input/Output Ratings

Output Voltage Adjustable from 0 to Input Voltage

Output Frequency Programmable from 0 to 240 Hz

Efﬁciency 97.5% Typical

Transient Protection Standard 6 kV

Environmental Speciﬁcations

Enclosure IP20

Ambient Temperature 0°C to 50°C

Storage Temperature

Relative Humidity 0 to 95% Non-Condensing

Vibration 1.0 G Operational — 2.5 G Non-Operational

Shock 15 G Operational — 30 G Non-Operational

Altitude 1,000 m (3,300 ft) without Derating

Control Inputs

Control Input Type Dry Contact Inputs — Drive has an internal 12V power supply that provides 10

Start, Stop, Fwd/Rev

SW1, SW2, SW3

Preset Speed Model Only

Programmable Input

–40°C to 85°C

mA typical current ﬂow.

Alternate Inputs — Accepts open collector/solid state inputs (sinking into the

drive) with maximum leakage current of 50 µA.

24V Inputs — An optional 24V DC interface module allows use of 24V DC

sinking inputs (see ).

Conﬁgurable Inputs for Two- or Three-Wire Control

Conﬁgurable Inputs for Control of 8 Preset Speeds and 2 Accel/Decel Times

TB3-8 Can Be Conﬁgured to Select:

• Accel/Decel Times

• External Coast to Rest

• Frequency Select

• Preset Speed ➊

• TB3 Control/Keypad or Communication Control

Approvals and Standards Compliance

Approvals

UL508C

CSA 22.2 AS/NZS 2064.1:1992

EMC Directive 89/336

LV: EN 50178, EN 60204 EMC: EN 61800-3, EN 50081-1, EN 50082-2

Designed to Meet These Standards FCC Class A ➋ and B ➋, IEC 146-1-1, VDE 0871 and VDE 0875

Control Inputs — Analog Signal Follower Only

External Speed

1K to 10K Ohms, 2 Watts Minimum

Potentiometer

4 – 20 mA Analog Input

–10 to +10V DC

250 Ohms Input Impedance

100K Ohms Input Impedance

Analog Input

Control Output

Programmable Output

(Form C Relay Contact)

Resistive Rating: 0.4A at 125VAC — 0.2A at 230V AC — 2A at 30VDC

Inductive Rating: 0.2A at 125VAC — 0.1A at 230V AC — 1A at 30V DC

➊ Analog Signal Follower only.

➋ With external components.

Specifications A-3

Control Features

PWM Algorithm Sine Weighted PWM with Harmonic Compensation

Switching Device IGBT

V/Hz Ratio Programmable

Carrier Frequency Adjustable from 2 to 8kHz in 100 Hz Increments (Factory Default is 4kHz)

DC Boost Adjustable — Select from a Family of Boost Curves

Current Limiting Software Controlled, Coordinated for Drive and Motor Protection — Programmable

Motor Protection I

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

Accel/Decel 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 4 Programmable Modes:

Protective Features

Overcurrent Programmable limit, 200% of Hardware Limit, 300% of Instantaneous Fault

Excessive Temperature Embedded Temperature Sensor Trips if Heatsink Temperature Exceeds 95°C

Over/Under Voltage DC bus voltage is monitored for safe operation.

Control Ride Through

Ground Short Any Output Phase to Ground Short

Faultless Ride Through 100 Milliseconds

Output Short Circuit Any Output Phase to Phase Shor t

from 1 to 180% of Drive Output Current

t Overload Protection — 150% for 60 Seconds, 200% for 30 Seconds

Ramp to Stop — 0.1 to 600 Seconds

Coast to Stop — Stops All PWM Output

DC Injection Braking — Applies DC Voltage to the Motor for 0 to 25 Seconds

DC Injection Braking with Auto Stop

• For 200-240V AC input drives, the overvoltage trip occurs at a bus voltage of 400V DC

(equivalent to a 290VAC incoming line voltage).

• For 380-460V AC input drives, the overvoltage trip occurs at a bus voltage of 800V DC

(equivalent to a 575VAC incoming line voltage).

• For 200-240V AC input drives, the undervoltage trip occurs at a bus voltage of

210VDC (equivalent to a 150V AC incoming line voltage).

• For 380-460V AC input drives, the undervoltage trip occurs at a bus voltage of

390VDC (equivalent to a 275V AC incoming line voltage).

Minimum Ride Through is 0.5 Seconds — Typical Value is 2 Seconds

Programming

Programmer Optional — Removable Program Keypad Module

Display Type 6 Character LED — Two Digit Parameter Number and Four Digit Value

Keypad Controls Speed, Run, Stop and Direction

A-4 Specifications

End of Chapter

Accessories and Dimensions

Accessories for All Drive Ratings

Drive Ratings Dynamic Brake Module 3% Line Reactors

Input Voltage kW HP

Catalog No.

Open Style

Catalog No. ➌

Appendix B

Line Filters ➊ Fan Replacement

Kit

Catalog No. ➍ Catalog No. ➎ Catalog No. Catalog No.

Capacitor Module

➋

200-240VAC

50/60 Hz

1-Phase

200-230VAC

50/60 Hz

3-Phase

380-460VAC

50/60 Hz

3-Phase

Ready/Fault Panel

Catalog No. 160-B1

Remote Programming

Adapter

Catalog No. 160-RPA

0.37 1/2 ——160S-LFA1 160S-RFA-9-A — 160-CMA1

0.55 3/4 ——160S-LFA1 160S-RFA-9-A — 160-CMA1

0.75 1 160-BMA1 — 160S-LFA1 160S-RFA-9-A 160-FRK2 160-CMA1

1.5 2 160-BMA2 — 160S-LFA1 160S-RFA-16-B 160-FRK3 160-CMA1

0.37 1/2 — 1321-3R4-B 160-LFA1 160-RFB-5-A — 160-CMA1

0.55 3/4 — 1321-3R4-A 160-LFA1 160-RFB-5-A — 160-CMA1

0.75 1 160-BMA1 1321-3R4-A 160-LFA1 160-RFB-5-A 160-FRK2 160-CMA1

1.5 2 160-BMA2 1321-3R8-A 160-LFA1 160-RFB-14-A 160-FRK2 160-CMA1

2.2 3 160-BMA2 1321-3R12-A 160-LFA2 160-RFB-14-A 160-FRK2 160-CMA1

4.0 5 160-BMA2

0.37 1/2 — 1321-3R2-B 160-LFB1 160-RFB-5-A — 160-CMB1

0.55 3/4 — 1321-3R2-A 160-LFB1 160-RFB-5-A — 160-CMB1

0.75 1 160-BMB1 1321-3R2-A 160-LFB1 160-RFB-5-A 160-FRK2 160-CMB1

1.5 2 160-BMB2 1321-3R4-B 160-LFB1 160-RFB-5-A 160-FRK2 160-CMB1

2.2 3 160-BMB2 1321-3R8-B 160-LFB1 160-RFB-14-A 160-FRK2 160-CMB1

4.0 5 160-BMB2 ➏ 1321-3R18-B — 160-RFB-14-B 160-FRK3 160-CMB1

Program Keypad Module

Catalog No. 160-P1

Remote Keypad Module

Catalog No. 160-P2

➒

➏ 1321-3R18-A — 160-RFA-22-B 160-FRK3 160-CMA1

DeviceNet

Communication Module

Catalog No. 160-DN2

CopyCat Keypad Module

Catalog No. 160-P3

➒

RS-232

Communication Module

Catalog No. 160-RS1

➐

Cable

Catalog No. 160-C10 (1 meter, non-locking each end)

➒

160-C10R (1 meter, non-locking each end, right angle)

160-C30 (3 meter, locking each end)

160-C50 (5 meter, locking each end)

24V DC Interface ➑

Catalog No. 160-DM-SF1 (Analog)

➐

160-DM-PS1 (Preset)

➊ Bulletin 160 Series C drives (with proper ﬁlter) meet:

– Overall EMC requirements of EN61800-3 for Second (Industrial) Environments – High frequency conducted and radiated emissions of EN61800-3 for (First) Residential Environments – High frequency conducted and radiated emissions of EN55011 for (Second) Industrial Environments

➋ The MTBF for the fan is 40,000 hours at 50°C.

➌ Catalog numbers listed are for 3% impedance open style units. NEMA Type 1 and 5% impedance reactor types are also

available. Refer to publication 1321-2.0 for detailed information.

➍ 160-LF type ﬁlters have been tested with a maximum motor cable length of 75 meters (250 feet) for 230V units and 40 meters

(133 feet) for 460V units.

➎ 160-RF type ﬁlters have been tested with a maximum motor cable length of 25 meters (80 feet) for both 230V and 460V units.

Listed ﬁlters are for Bulletin 160 Series C drives only.

➏ Two in parallel required.

➐ Compatible with Bulletin 160 Series A, Series B and Series C drives with ﬁrmware version FRN 4.07 or later.

➑ Allows 24VDC sinking inputs. Bulletin 160 Series C drives must use a Series B, or later, 24V DC Interface module.

➒ Compatible with Bulletin 160 Series C drives with ﬁrmware version FRN 7.03 or later.

B-2 Accessories and Dimensions

Accessory Dimensions

All dimensions are in millimeters and (inches). Dimensions are not used for manufacturing purposes.

Dynamic Brake Modules Figure B.1

(2.83)

(1.97)

WARNING

(0.55)

86.4

(3.4)

7.5

(0.3)

Mounting Holes – 4 Places –

6.86 (0.27)

GND

DANGER

–

(1.14)

DANGER

–

GND

8 (0.315)

Catalog No. A B

160-BMA1 & 160-BMB1 245 (9.64) 225 (8.86)

160-BMA2 & 160-BMB2 334 (13.15) 314 (12.36)

Bulletin 1321 Line Reactors Figure B.2

Catalog No. A B C D E

1321-3R2-A 112 (4.4) 104 (4.1) 74 (2.9) 50 (2.0) 37 (1.44)

1321-3R2-B 112 (4.4) 104 (4.1) 74 (2.9) 50 (2.0) 37 (1.44)

1321-3R4-A 112 (4.4) 104 (4.1) 76 (3.0) 50 (2.0) 37 (1.44)

1321-3R4-B 112 (4.4) 104 (4.1) 76 (3.0) 50 (2.0) 37 (1.44)

1321-3R8-A 152 (6.0) 127 (5.0) 76 (3.0) 53 (2.1) 51 (2.0)

1321-3R8-B 152 (6.0) 127 (5.0) 76 (3.0) 53 (2.1) 51 (2.0)

1321-3R12-A 152 (6.0) 127 (5.0) 76 (3.0) 53 (2.1) 51 (2.0)

1321-3R18-A 152 (6.0) 133 (5.3) 79 (3.1) 51 (2.0) 51 (2.0)

Accessories and Dimensions B-3

Accessory Dimensions, Continued

All dimensions are in millimeters and (inches). Dimensions are not used for manufacturing purposes.

Line Filters Figure B.3

G (2)

F (2)

Line Filter Module ABCDE F G H

160S-RFA-9-A

160-RFB-5-A

160-RFB-14-A 182.0

160S-RFA-16-B

160-RFA-22-B

160-RFB-14-B

160 LF (All Types)

182.0

(7.17)

227.0

(8.94)

174.0

(6.85)

75.0

(2.95)

75.0

(2.95)

87.0

(3.43)

75.0

(2.95)

37.5

(1.47)

47.5

(1.87)

55.5

(2.18)

50.0

(1.97)

163.0

(6.42)

163.0

(6.42)

212.0

(8.35)

163.0

(6.42)

60.0

(2.36)

60.0

(2.36)

60.0

(2.36)

60.0

(2.36)

M4.5 x 6.5

(0.18 x 0.26)

obround hole

(2 places)

M4.5 (0.18) slot

(2 places)

7.0 x 5.3

(0.28 x 0.21)

hole dim.

M4.5 x 6.5

(0.18 x 0.26)

obround hole

(2 places)

M4.5 (0.18)

(2 places)

6.9 x 5.25

(0.272 x 0.207)

hole dim.

200

(7.87)

B-4 Accessories and Dimensions

Accessory Dimensions, Continued

All dimensions are in millimeters and (inches). Dimensions are not used for manufacturing purposes.

Capacitor Module Figure B.4

Mounting Holes – 4 Places –

4.5 (0.18)

140

(5.51)

130

(5.12)

(1.97)

CAT

(1.57)

MADE IN U.S.A

SER

254 (10) – Approximate Lead Length –

110.9

(4.37)

(2.36)

150.9

(5.94)

CAT

MADE IN U.S.A

-DC

SER

+DC

Accessories and Dimensions B-5

Accessory Dimensions, Continued

All dimensions are in millimeters and (inches). Dimensions are not used for manufacturing purposes.

DeviceNet or RS-232 Module Attached to Drive (DeviceNet Shown) Figure B.5

80 (3.15)

17.34 (0.68)

Required for Removal

CONFORMANCE TESTED

187.1 (7.37)

193.69 (7.63)

(2.36)

150.9

(5.94)

24V DC Interface Module Figure B.6

29 ➊

(1.14)

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

B-6 Accessories and Dimensions

Drive Dimensions

All dimensions are in millimeters and (inches), all weights are in kilograms and (pounds).

Reference Diagram A Figure B.7

4 Mounting Holes

4.5

(0.18)

130

(5.12)

(2.36)

9.42

(0.37)

83.43 (3.28)

28.29

(1.11)

(2.36)

101.85 (4.01)

Drive Dimensions and Weights Table B.4

200-240VAC — 1-Phase

Drive H W D Weight

160S-AA02 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160S-AA03 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160S-AA04 152 (6.00) 80 (3.15) 165 (6.51) 1.02 (2.24)

200-240VAC — 3-Phase

Drive H W D Weight

160-AA02 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160-AA03 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160-AA04 152 (6.00) 80 (3.15) 165 (6.51) 1.02 (2.24)

160-AA08 152 (6.00) 80 (3.15) 165 (6.51) 1.02 (2.24)

160-AA12 152 (6.00) 80 (3.15) 165 (6.51) 1.10 (2.43)

380-460VAC — 3-Phase

Drive H W D Weight

160-BA01 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160-BA02 152 (6.00) 80 (3.15) 165 (6.51) 0.94 (2.07)

160-BA03 152 (6.00) 80 (3.15) 165 (6.51) 1.02 (2.24)

160-BA04 152 (6.00) 80 (3.15) 165 (6.51) 1.02 (2.24)

160-BA06 152 (6.00) 80 (3.15) 165 (6.51) 1.10 (2.43)

Important: Use Figure B.10: Drilling Template A for mounting a drive listed

in the table above.

Accessories and Dimensions B-7

All dimensions are millimeters and (inches), all weights are kilograms and (pounds).

Reference Diagram B Figure B.8

4 Mounting Holes

5.54

(0.22)

180

(7.09)

(3.19)

(2.36)

111.43 (4.39)

39.02 (1.54)

129.74 (5.11)

(2.36)

Drive Dimensions and Weights Table B.5

200-240VAC — 1-Phase

Drive H W D Weight

160S-AA08 193 (7.58) 92 (3.62) 193 (7.61) 2.37 (5.23)

200-240VAC — 3-Phase

Drive H W D Weight

160-AA18 193 (7.58) 92 (3.62) 193 (7.61) 2.37 (5.23)

380-460VAC — 3-Phase

Drive H W D Weight

160-BA10 193 (7.58) 92 (3.62) 193 (7.61) 2.37 (5.23)

Important: Use Figure B.11: Drilling Template B for mounting a drive listed

in the table above.

B-8 Accessories and Dimensions

Drive Mounting Hole Dimensions Figure B.9

(3.62)

(3.19)

(3.15)

(2.87)

(2.36)

5.5 (0.22) Mounting Holes—2 Places

6.5

(0.26)

(2.36)

5.5 (0.22) Mounting Holes—2 Places

10.5

(0.41)

4.5

(0.18)

143

(5.63)

140

(5.51)

(2.36)

130

(5.12)

(0.20)

150.9 (5.94)

5.5

(0.22)

(2.36)

This illustration depicts the mounting hole placements for the drives listed below. Use the appropriate Drilling Template for your drive.

200-240V AC — 1-Phase 200-240V AC — 3-Phase 380-460V AC — 3-Phase

160S-AA02 A 160-AA02 A 160-BA01 A

160S-AA03 A 160-AA03 A 160-BA02 A

160S-AA04 A 160-AA04 A 160-BA03 A

160S-AA08 B 160-AA08 A 160-BA04 A

160-AA12 A 160-BA06 A

160-AA18 B 160-AA10 B

171

(6.73)

180

(7.09)

6.3

(0.25)

192.5 (7.58)

Accessories and Dimensions B-9

Drilling Template A Figure B.10

B-10 Accessories and Dimensions

Drilling Template B Figure B.11

Appendix C

CE Conformity

CE Compliance

This drive is a component intended for implementation in machines or systems for the industrial environment. It is CE marked for conformity to the Low Voltage (LV) Directive 73/23/EEC when installed as described. It also has been tested to meet the Council Directive 89/336 Electromagnetic Compatibility (EMC). The standards used for this testing are, LV: EN50178, EN60204-1, EMC EN61800-3, EN50081-1, EN50082-2. These tests were conducted with a PWM frequency (Parameter 49) of 4.0 kHz.

Important: The conformity of the drive and ﬁlter to any standard does not

guarantee that the entire installation will conform. Many other factors can inﬂuence the total installation and only direct measurements can verify total conformity. It is therefore the responsibility of the machine manufacturer, to ensure, that the conformity is met.

A copy of the Declaration of Conformity (DOC) is available from your local Rockwell Automation Sales Ofﬁce.

Essential Requirements for a Conforming EMC Installation

The following seven items are required for CE Conformance:

1. An input line ﬁlter module (see Appendix B, Accessories and Dimensions) must be installed to reduce conducted emissions.

160-LF Filters

These units have been tested with a maximum motor cable length of 75 meters (250 feet) for drives rated 200 – 240VAC, and 40 meters (133 feet) for drives rated 380 – 460VAC.

160S-RF Filters

These units have been tested with a maximum motor cable length of 25 meters (80 feet) for both 230V and 460V units.

2. The drive 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 EMCtested 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 and 7) must have a solid connection to ground terminal/protective earth.

C-2 CE Conformity

General Instructions for an EMC Compliant Installation

Shielded Enclosure

• Typical NEMA or IEC metal enclosures are adequate.

• The ground connection of the shielded enclosure must be solidly connected to

the PE terminal of the drive. Good conductivity must be assured – grounding must provide a low impedance path for high frequency signals.

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

• Input power, output power and control wiring inside the enclosure must be

physically separated.

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

• Wires do not touch the heatsink.

Recommended Grounding Conﬁguration Figure C.1

Enclosure Ground Connection

T/L3

S/L2

R/L1

Input Line

T (L3)

S (L2)

R (L1)

Line

Filter

Ground Terminal – PE

Shielded Enclosure

= EMC Tested Shielded Cable Clamp (or Metal Conduit)

➊

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

R/L1

FAULT

READY

U/T1

45678910112

S/L2

V/T2

BR–

DC–

BR+

DC+

Line Power TB1

to TB3

Control Wiring TB3

Motor Wiring TB2

W/T3

V/T2

U/T1

Control Cabinet

➊

Shielded Motor Cable

to Motor

T/L3

W/T3

Cable Clamps

Motor Cable

CE Conformity C-3

• Use suitable EMC-tested cable clamps only.

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

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

• When using conduit, the contact point of metal entry connections must be free

of paint or non-conductive surfaces and solidly connected with good conductivity to the enclosure.

• The cable between the drive and motor must be a 4-wire shielded cable (three phases and ground).

• Do not exceed the maximum motor cable length for the speciﬁc line ﬁlter module used.

• Inside the shielded enclosure, shielded motor cable must be used as close to the drive’s output terminals as possible. The shield must be solidly connected to the PE terminal of the drive.

• Where the shielded motor cable exits the enclosure, an EMC-tested cable clamp, or metal conduit must be used to solidly connect the cable shield to the enclosure.

• The shield on the motor side must be solidly connected to the motor housing with an EMC-tested cable clamp, or conduit, providing good conductivity from the cable shield to the motor housing.

Motor Connections Figure C.2

Ground Terminal – PE

Shielded Enclosure

S/L2

R/L1

T/L3

BR–

BR+

FAULT

READY

45678910112

V/T2

U/T1

W/T3

DC–

DC+

Motor Wiring TB2

W/T3

V/T2 U/T1

= EMC Tested Shielded Cable Clamp (or Metal Conduit)

4 Wire Shielded Motor Cable

Ground to Motor Housing

C-4 CE Conformity

Control Cable

• Control wiring must use shielded cable, or grounded metal conduit.

Shielded Motor and Control Cable Example Figure C.3

• The shield must be connected to signal common at both ends of the cable.

• The Common terminals (TB3-3 & 7) must be solidly connected (and as short as

possible) to the PE terminal of the drive.

Control Connections Figure C.4

Ground Terminal – PE

Stranded Copper Wire

Plastic Insulation

Inner Plastic Sheath

Compact Screen of Galvanized (Tinned) Copper or Steel

Outer Plastic Jacket

S/L2

R/L1

T/L3

BR–

BR+

Ground Terminal – PE

Shielded Enclosure

➊

FAULT

READY

45678910112

U/T1

V/T2

W/T3

DC–

DC+

Control Wiring TB3

to TB3

Control Cabinet

Signal Common

Shielded Control Cable

= EMC Tested Shielded Cable Clamp (or Metal Conduit)

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

➊

Low Voltage Directive 73/23/EEC Compliance

This product complies with Low Voltage Directive 72/23/EEC when conforming with the following installation requirements:

• Review Chapter 1, Important Precautions and other ATTENTION statements throughout this manual prior to installation of the drive.

• The drive is intended to be installed with a ﬁxed connection to the earth. The use of residual-current-operated protective devices (RCDs) or ground fault indicators is not recommended. If unavoidable, the Bulletin 160 is compatible with type B RCDs only.

• The drive should be installed in an appropriate or suitable enclosure.

Important: The conformity of this drive and ﬁlter to any standard does not

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

CE Conformity C-5

C-6 CE Conformity

End of Chapter

Symbols

±10V DC control 2-19

Numerics

12V internal power supply 2-9 24V DC interface module B-5 4 – 20 mA control 2-19

AC input wiring 2-3 Accel/Decel control 5-5, 5-13 accessories (see optional accessories) B-1 ambient temperature 2-1, A-2 analog input

frequency sources 2-18

analog inversion

inverting input 5-15

analog scaling

analog input min/max 5-15 analog select 5-14

zero offset 5-12 analog signal 2-18 approvals

CE A-2, C-1

CSA A-2

CUL A-2 arrow keys 3-2 auto restart 5-10

block diagram 6-4 braking

DC injection 5-8

enabling dynamic braking 5-11

stop mode 5-6 branch circuit disconnect 2-3 branch circuit protection 2-5

capacitive current cable length recommendations

2-8

capacitor module B-1, B-4

connection 1-5 carrier frequency A-3

PWM 5-10 catalog number

explanation 1-2

location 1-3 CE 2-1, A-2, C-1 change direction (see also analog inversion) 3-2 circuit breaker ratings 2-5

Index

clearing faults 5-12, 6-1 compensation 5-15 compliance

CE A-2, C-1 CSA A-2 CUL A-2

EEC C-5 conditioning input power 2-6 control wiring 2-9–2-17

precautions 2-9

preset speed 2-20

requirements 2-9 CSA A-2 CUL A-2 current limiting 5-8

DeviceNet module 1-5, B-5 diagnostics

display group parameters 5-3–5-5

fault descriptions 6-2 dimensions

24V DC interface module B-5

capacitor module B-4

DeviceNet module B-5

drive B-6, B-7

dynamic brake module B-2

line filter module B-3

line reactor B-2

mounting B-8 direction indicators 3-2 display mode 3-1 dynamic brake module B-1, B-2

connection 1-5 dynamic braking 5-11

electrostatic discharge 1-1, 3-3 enter key 3-2 escape key 3-2

fan replacement B-1 faults

clearing 5-12, 6-1

descriptions 6-2

problems and corrective actions 6-3

status LEDs 1-4

Index-2

features

optional 1-5 standard 1-4

frequency control

min/max frequency 5-6

skip frequency 5-7 frequency source 2-18 fuse ratings 2-5

grounding 2-3, 2-9

input mode selection 2-11, 5-9 input power

conditioning 2-6

protection 2-5 installation

clearances 2-1

EMC compliance C-1–C-4

templates B-9, B-10 internal 12V power supply 2-9

keypad

display mode 3-1

installation 3-4

key descriptions 3-2

program mode 3-1

removal 3-3

LEDs 1-4, 3-2 line filter module 1-5, B-1, B-3 line reactor B-1, B-2 line side protection 2-5 lock protection 5-12

motor cable

length recommendations 2-7–2-8

long cable effects 2-7

recommended cable 2-6

reflective wave 2-7 motor starter 2-5 mounting requirements

clearances 2-1 mounting templates B-9, B-10

nameplate information 1-3

optional accessories

24V DC interface module 1-5, B-5 capacitor module 1-5, B-4 DeviceNet module 1-5, B-5 dynamic brake module 1-5, B-2 line filters 1-5, B-1, B-3 line reactors B-1, B-2

program keypad module 1-5 output contacts 2-9, 5-10 overload protection 2-5, 5-8

parameters 5-1–5-16

commonly changed 5-1

display group 5-3–5-5

01 - [Output Frequency] 5-3 02 - [Output Voltage] 5-3 03 - [Output Current] 5-3 04 - [Output Power] 5-3 05 - [Bus Voltage] 5-3 06 - [Frequency Command] 5-3 07 - [Last Fault] 5-3 08 - [Heatsink Temperature] 5-3 09 - [Controller Status] 5-3 10 - [Controller Type] 5-3 11 - [Control Version] 5-3 12 - [Input Status] 5-4 13 - [Power Factor Angle] 5-4 14 - [Memory Probe Display] 5-4 15 - [Preset Status] 5-4 16 - [Analog Input] 5-4 17 - [Fault Buffer 0] 5-5 18 - [Fault Buffer 1] 5-5

19 - [Fault Buffer 2] 5-5 overview 5-1 program group 5-5–5-16

30 - [Accel Time 1] 5-5

31 - [Decel Time 1] 5-6

32 - [Maximum Frequency] 5-6

32 - [Minimum Frequency] 5-6

34 - [Stop Mode Select] 5-6

35 - [Base Frequency] 5-6

36 - [Base Voltage] 5-6

37 - [Boost Select] 5-7

37 - [Maximum Voltage] 5-6

39 - [Skip Frequency] 5-7

Index-3

40 - [Skip Frequency Band] 5-7 41 - [Motor Overload Select] 5-8 42 - [Motor Overload Current] 5-8 43 - [Current Limit] 5-8 44 - [DC Hold Time] 5-8 45 - [DC Hold Voltage] 5-9 46 - [Input Mode] 5-9 47 - [Output Configure] 5-10 48 - [Output Threshold] 5-10 49 - [PWM Frequency] 5-10 50 - [Restart Tries] 5-10 51 - [Restart Time] 5-11 52 - [DB Enable] 5-11 53 - [S-Curve] 5-11 54 - [Clear Fault] 5-12 55 - [Memory Probe Address] 5-12 56 - [Reset Functions] 5-12 57 - [Program Lock] 5-12 58 - [Internal Frequency] 5-12 59 - [Frequency Select] 5-12 60 - [Zero Offset] 5-12 61 – 68 - [Preset Frequency 0-7] 5-13 69 - [Accel Time 2] 5-13 70 - [Decel Time 2] 5-13 71 - [IR Compensation] 5-14 72 - [Slip Compensation] 5-14 73 - [Reverse Disable] 5-14 74 - [Analog Select] 5-14 75 - [Analog Input Minimum] 5-15 76 - [Analog Input Maximum] 5-15 78 - [Compensation] 5-15 79 - [Software Current Trip] 5-15 80 - [Stall Fault Time] 5-15 81 - [PI Proportional Gain] 5-16 82 - [PI Integral Gain] 5-16 83 - [PI Process Reference] 5-16

resetting to factory defaults 5-12 potentiometer wiring 2-19 power wiring 2-2

precautions 2-2

terminal block specifications 2-3 precautions 1-1 preset frequencies 5-12

Program Keypad Module 1-5

display mode 3-1 installation 3-4 key descriptions 3-2 program mode 3-1

removal 3-3 program lock 5-12 program mode 3-1 programming 5-1

example 5-2

reset to defaults 5-2

reflected wave protection 2-7 reflective wave

cable length 2-7

RWR (reflective wave reducer) 2-7 resetting default values 5-12 reverse key 3-2 RS-232 module B-5

S-Curve 5-11 select key 3-2 specifications A-1–A-3

380-460V AC input ratings A-1

control 2-9

electrical 2-2

environment 2-1

input power protection 2-5

installation 2-1

wiring 2-3 start key 3-2 start-up 4-1 stop key 3-2 storage temperature 2-1, A-2

terminal block

control wiring 2-9

specifications 2-9

TB1 2-2

TB2 2-2

TB3 2-2 troubleshooting 6-1

fault descriptions 6-2

problems and corrective actions 6-3

vibration A-2

Index-4

wiring

analog input 2-18 cable length 2-7 control/signal 2-9–2-17 motor cable specifications 2-6 symbol key 2-10 terminal block specifications 2-3

Publication 0160-5.17ML-EN — May 2000 P/N 194456 (02)

Rockwell Automation 160 SSC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Series C Summary of Changes

Series C Application/Installation Considerations

Mounting Dimensions

External Braking

DeviceNet

24V DC Interface

Terminal Block Wiring

Incorrect Motor Rotation

Table of Contents

Important Precautions

Receiving Your New Drive

Unpacking

Inspecting

Identifying Your Drive

Catalog Number

Nameplate

Conventions Used In This Manual

Standard Drive Features

Optional Drive Features

Storage and Operation Conditions

CE Compliance

Installation

Chapter 2

Clearances

Debris Label

Power Wiring

Precautions

Terminal Blocks

Terminal Block Wiring

Motor Branch Circuit Analysis

Branch Circuit Protective Devices

Input Power Conditioning

Motor Cable Types

Long Motor Cable Effects

Control Wiring

Requirements

Important Precautions

Control Wiring Considerations

Control Methods and Selection Guide

Frequency Source Wiring

Analog Signal Follower Model

Preset Speed Model

Analog and Preset Models

What To Do Next

Chapter 3

Features

Display Mode

Program Mode

Key Functions

Module Removal and Installation

Removal

Installation

Start-Up Procedures

Chapter 4

Overview of Parameters

Chapter 5

Important Reset Actions

Programming Example

Display Group Parameters (Read Only)

Program Group Parameters

PI Control Setup and Activation

Wire For PI Control

Program for PI Control

Tune the PI Loop

Common Problems with PI Control

Fault Information

Chapter 6

How to Clear a Fault

Appendix A

Appendix B

Accessory Dimensions

Accessory Dimensions, Continued

Accessory Dimensions, Continued

Accessory Dimensions, Continued

Drive Dimensions