Kolego, To jest stary falownik allana-bradleya, którego programować można tylko poprzez ustawianie wartości parametrów zgodnie z instrukcją, lub, jeżeli posiadasz interfejs szeregowy, poprzez kabelek rs232 i program DriveExplorer. Może Instalation Manual będzie pomocny. Jeżeli jeszcze coś z Bradleya potrzebne to proszę o info. pozdrawiam
spl_en_a.fm5 Page 1 Monday, September 15, 1997 1:31 PM
Allen-Bradley
160 SSC™
Variable
Speed
Controller
(Series A)
Installation
Manual
0.37 – 2.2 kW (1/2 – 3 HP)
FRN 4.01, 4.04, 4.07
Table of Contents
Index
Please Read!
This manual is intended to guide qualified
personnel in the installation and operation of this
product.
Because of the variety of uses for this equipment
and because of the differences between this
solid-state equipment and electromechanical
equipment, the user of and those responsible for
applying this equipment must satisfy themselves
as to the acceptability of each application and use
of the equipment. In no event will Allen-Bradley
Company be responsible or liable for indirect or
consequential damages resulting from the use or
application of this equipment.
The illustrations shown in this manual are
intended solely to illustrate the text of this
manual. Because of the many variables and
requirements associated with any particular
installation, the Allen-Bradley Company cannot
assume responsibility or liability for actual use
based upon the illustrative uses and applications.
No patent liability is assumed by Allen-Bradley
Company with respect to use of information,
circuits or equipment described in this text.
SSC is a trademark of Allen-Bradley Company, Inc.
Reproduction of the content of this manual, in
whole or in part, without written permission of
the Allen-Bradley Company is prohibited.
Important User Information
The information in this manual is organized in
numbered chapters. Read each chapter in
sequence and perform procedures when you are
instructed to do so. Do not proceed to the next
chapter until you have completed all procedures.
Throughout this manual we use notes to make you
aware of safety considerations:
ATTENTION: Identifies information
about practices or circumstances that
can lead to personal injury or death,
property damage or economic loss.
Attentions help you:
D identify a hazard
D avoid the hazard
D recognize the consequences
Important: Identifies information that is
especially important for successful application
and understanding of the product.
Table of Contents
Document Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 - Information and Precautions
DU–1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Chapter 2 - Installation and Wiring
Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC Directive 89/336/EEC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Operation Without a Program Keypad Module . . . . . . . . . . . . . . . . . . . .
Motor Cable Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wiring For Preset Speed and Analog Signal Follower Models . . . . . . . . . . . .
Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring – Analog Signal Follower Model . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring – Preset Speed Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
2–1
2–2
2–2
2–3
2–4
2–5
2–5
2–5
2–6
Chapter 3 - Program Keypad Module
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Program Keypad Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–1
3–1
3–1
3–2
Chapter 4 - Start-Up
Start–up Procedure (Analog Signal Follower Model) . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Start–up Procedure (Preset Speed Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Chapter 5 - Parameters and Programming
Overview of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–1
5–1
5–2
5–4
Chapter 6 - Troubleshooting and Fault Information
Fault Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
Block Diagram of Bulletin 160 Analog Signal Follower Model . . . . . . . . . . . . . . . . 6–4
Appendix A
Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–4
Catalog Numbers For Bulletin 160 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5
Index
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I–1
i
Document Update
Bulletin 160 SSCt Controller
For Ratings of 1/2 - 3 HP (0.37 – 2.2kW)
Purpose of this Document
This document revises the Bulletin 160 SSC Controller User
Manual (Publication 160–5.0, February 1996).
Summary of Update
Replace pages 2–5, 2–7, and 2–8 of the User Manual with the
information on the following pages.
ATTENTION: Read the following sections carefully
before installing the Bulletin 160 SSC Controller.
SCC is a trademark of AllenĆBradley Company, Inc.
DU–1
Document Update
Control Wiring Requirements
D run all signal wiring in either a shielded
cable, or a separate steel conduit.
D only connect shield wire at control
terminal block common terminals 3 and 7.
D do not exceed control wiring length of 15
meters (50 feet).
D use Belden 8760 (or equivalent) – 18AWG
(0.750mm2), twisted pair, shielded or 3
conductor.
À
Control signal cable length is highly dependent on
electrical environment and installation practices. To
improve noise immunity the control terminal block
common must be connected to earth ground. Consult
factory for longer control signal cable length applications.
Table 2.DąControl Terminal Block Specifications
Terminal
TB3
Max/Min
Wire Size
mm2 (AWG)
2.5-0.5
(14-22)
Max/Min Wire Torque
Nm. (lb.in.)
0.8-0.4
(8-4)
ATTENTION: The controller is
supplied with an internal 12V
supply. Dry contacts or open
collectors are required for discrete
control inputs. If an external
voltage is applied, component
failure could occur.
ATTENTION: Read the
following sections carefully before
installing the Bulletin 160 SSC.
Control Wiring - Analog Signal Follower
Model
Parameter 59 – [Frequency Source] is used to
select the source of the frequency command.
The frequency source (which controls the
output frequency of the controller) can be
commanded internally using P58 – [Internal
Frequency] or via the Control Terminal Block
(TB3) using a:
D remote potentiometer.
D –10 to +10VDC analog input.
D 4–20mA analog input.
Refer to Chapter 5, parameters 58–60 for
factory default settings.
ATTENTION: Connect and use only
one frequency source at any time. If
more than one frequency source is
connected or in use at the same time,
unintended operation could occur.
If you use P58 – [Internal
Frequency], TB3 – terminal 2 must
be tied to Common (TB3 – terminal 3)
to ensure that unintended operation
does not occur.
Control Wiring - Preset Speed Mode
You can control the output frequency of the
controller via contact closure input to SW1,
SW2, and SW3. A program keypad module is
required to change the factory default settings.
Refer to Chapter 5, parameters 61–70 for the
DU–2
Document Update
Control Wiring (continued)
Bulletin 160 Analog Signal Follower models (catalog # 160X–XAXXNSFlXX) can be operated using
either a unipolar (frequency control only) or bipolar (frequency and direction control) analog input. Use
Parameter 46 – [Input Mode] to select the control method for start, stop, and direction control. There are
four settings from which to choose (shown in Table 2.E below). For all settings, the controller will reverse
when the voltage on the analog input transitions from positive to negative. In two-wire control (Parameter
46 – settings 1 and 3), negative voltage on the analog input will start the controller, which may be
unintended. This applies to both a negative offset in the analog command, or noise which causes the
analog input to go negative. Refer to Table 2.E below for the recommended installation instructions for
all Parameter 46 settings.
ATTENTION: Read the
following sections carefully before
installing the Bulletin 160 SSC.
Table 2.EąRecommended Wiring Instructions
Parameter 46
Setting
0
1
2
3
Direction Control
Forward Only
Forward and
Reverse
Forward Only
Forward and
Reverse
Forward Only
Forward and
Reverse
Forward Only
Forward and
Reverse
Analog Signal Follower Model
UniĆpolar Input
BiĆpolar Input
Preset Speed Model
Refer to Figure 2.6
Refer to Figure 2.6
Refer to Figure 2.6
Refer to Figure 2.7b
Refer to Figure 2.7c or 2.7d
Do not use this setting
Refer to Figure 2.7a
Refer to page 3Ć1
Refer to page 3Ć1
Refer to page 3Ć1
Consult factory for additional
information prior to installation.
Do not use this setting
Refer to Figure 2.8
ATTENTION: When changing the parameter setting for P46 – [Input Mode],
you must cycle power for the change to take effect.
ATTENTION: The program keypad module stop key simulates momentary pushbutton
operation. For “two wire” control schemes (P46 – [Input Mode], setting “1”) the
program keypad module stop button will only provide a “stop” function while the stop
key is depressed.
DU–3
Document Update
Figure 2.6 - TB3 Three Wire Control (Setting 0)
Figure 2.7a - TB3 Two Wire Run Forward/Run
Reverse " Control (Setting 1)
Applies to Analog Signal Follower and Preset Speed Models
TB3 Terminal Signal
1
2
3
4
5
Reverse
6
Start
Common
7
Stop
8
9
10
11
Shielded Wire
Specification
Applies to Preset Speed Models Only
Shielded Wire
Control closure inputÀ
Contact closure inputÀ
CommonÂ
Contact closure input required
to operate controllerÀ
Á
6
7
8
9
10
1
1
Figure 2.7b - TB3 Two Wire Run Forward " Ã ConĆ
trol (Setting 1)
Applies to Analog Signal Follower Models Only
TB3 Terminal Signal
1
2
3
4
5
Run Forward
6
7
Common
Stop
8
9
10
11
Shielded Wire
Á
Á
Type IN4004
6
7
8
9
10
11
Contact closure inputÀ
Á
CommonÂ
Contact closure input required
to operate controller À
Common
Stop
CommonÂ
Contact closure input required
to operate controller À
Figure 2.8 - TB3 Momentary Run Forward/Run
Reverse " Control (Setting 3)
Shielded Wire
Contact closure inputÀ
Run Forward
Contact closure inputÀ
Common
Stop
CommonÂ
Contact Closure input required
to operate controllerÀ
= N.C. Momentary
= N.O. Maintained
Ä
Run Forward Contact closure inputÀ
Applies to Preset Speed Models Only
= N.O. Momentary
Ã
CommonÂ
Contact closure input required
to operate controllerÀ
Specification
TB3 Terminal Signal
1
2
3
4
Run Reverse Contact closure inputÀ
5
6
7
8
9
10
1
1
Specification
Explanation of Symbols
À
Á
Â
Common
Stop
Applies to Analog Signal Follower Models Only
Shielded Wire
Applies to Analog Signal Follower Models Only
TB3 Terminal Signal
1
2
3
4
Run Reverse
5
Run Forward Contact Closure inputÀ
Figure 2.7c - TB3 Two Wire Run Forward/Run
Reverse " Ä Control (Setting 1)
Specification
Figure 2.7d - TB3 Two Wire Run Forward/Run
Reverse " Ä Control (Setting 1)
Shielded Wire
TB3 Terminal
Specification
Signal
1
2
3
4
Run Reverse Contact closure inputÀ
5
Á
Signal
Specification
TB3 Terminal
1
2
3
4
Run Reverse Contact closure inputÀ
5
6
7
8
9
10
11
Run Forward Contact closure inputÀ
Common
Stop
CommonÂ
Contact closure input required
to operate controllerÀ
= N.C. Maintained
Internal 12V supply.
If both Run Forward and Run Reverse inputs are closed at the same time an undetermined state could occur.
Do not exceed control wiring length of 15 meters (50 feet). Control signal cable length is highly dependent on electrical
environment and installation practices. To improve noise immunity the control terminal block common must be connected to
earth ground. Consult factory for longer control signal cable length applications.
Upon power up of the controller, FAULT 22 (stop input not present) will occur. To clear the fault, you must cycle the input to the Run Forward
command.
Upon power up of the controller, FAULT 22 (stop input not present) will occur. To clear the fault, you must cycle the input to the Run Forward or
Run Reverse commands.
DU–4
160_5_9DU3.doc
1 Mon Sep 15 11:46:33 1997
Document Update
160 SSC™ Variable Speed
Controller (Series B)
This publication provides new information for the 160 SSC Variable
Speed Controller User Manual, publication 160-5.9, dated
December, 1996. Please place this document in your manual for
future reference.
Important Note
Bulletin 160 SSC Controllers with a catalog number suffix of “S01,”
(i.e. 160S-AA02NS01) will have the “Motor Stall Fault” (F06, page
6-2) detection feature disabled. All other features specified in the
User Manual will be operational.
SSC is a trademark of Rockwell Automation.
Rockwell Automation helps its customers receive a superior return on their investment by bringing
together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate
products. These are supported by local technical resources available worldwide, a global network
of system solutions providers, and the advanced technology resources of Rockwell.
Worldwide representation.
Argentina • Australia • Austria • Bahrain • Belgium • Bolivia • Brazil • Bulgaria • Canada • Chile • China, People’s Republic of • Colombia • Costa Rica • Croatia • Cyprus
Czech Republic • Denmark • Dominican Republic • Ecuador • Egypt • El Salvador • Finland • France • Germany • Ghana • Greece • Guatemala • Honduras • Hong Kong
Hungary • Iceland • India • Indonesia • Iran • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Macau • Malaysia • Malta • Mexico
Morocco • The Netherlands • New Zealand • Nigeria • Norway • Oman • Pakistan • Panama • Peru • Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia
Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic of • Spain • Sweden • Switzerland • Taiwan • Thailand • Trinidad • Tunisia • Turkey • United Arab Emirates
United Kingdom • United States • Uruguay • Venezuela
Rockwell Automation Headquarters, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414 382-2000, Fax: (1) 414 382-4444
Publication 160-5.9DU3 – April, 1997
P/N 40055-188-01 (A)
Copyright 1997 Rockwell International Corporation. All rights reserved. Printed in USA.
160_5_9DU2.doc
1 Mon Sep 15 11:42:00 1997
Document Update
160 SSC™ Variable Speed
Controller (Series B)
This publication provides new and updated material for the 160 SSC
Variable Speed Controller User Manual, publication 160-5.9, dated
December, 1996. Please place this document in your manual for
future reference.
EMC Directive 89/336/EEC
This controller is a component intended for implementation in
machines or systems for the industrial environment. It has been tested
to meet the Council Directive 89/336 Electromagnetic Compatibility
(EMC) and all applicable standards.
Important: The conformity of the controller and filter to any standard
does not guarantee that the entire installation will conform. Many other factors can influence the total installation and only direct measurements can verify total conformity. It is therefore the responsibility of the machine
manufacturer, to ensure, that the conformity is met.
Essential Requirements for a Conforming EMC Installation
1. An input line filter module (see “Accessories” in Appendix A)
must be installed to reduce conducted emissions. When using the
filters listed in Appendix A, the maximum motor cable lengths
must be 75 meters (250 feet) for controllers rated 200-240VAC,
and 40 meters (133 feet) for controllers rated 380-460VAC.
2. The controller system must be mounted in a shielded enclosure
to reduce radiated emissions.
3. Grounding of equipment and cable shields must be solid, with
low impedance connections.
4. Motor and control cables entering the shielded enclosure must
have EMC-tested shielded cable clamps, or grounded metal
conduit.
5. All motor cables must use shielded cable, or be in grounded metal
conduit.
6. All control and signal wiring must use shielded cable or be in
grounded metal conduit.
7. The Common terminals (TB3-3 & 7) must have a solid connection
to PE (protective earth).
SSC is a trademark of Rockwell Automation.
160_5_9DU2.doc
2
2 Mon Sep 15 11:42:00 1997
160 SSC™ Variable Speed Controller (Series B)
General Instructions for an
EMC Compliant Installation
Refer to Figure 1.
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 controller. Good conductivity
must be assured – grounding must provide a low impedance path
to 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.
Cable Clamps
• 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.
Figure 1 Recommended Grounding Configuration
Enclosure Ground Connection
PE
AC
Input Line
R (L1)
Line
S (L2)
T (L3)
S (L2)
T (L3)
R (L1)
Filter
Ground Tab – PE
Line Power TB1
L1
R
L2
S
L3
T
BR
–
BR
+
FAULT
READY
to TB3
1 2 3 4 5 6 7 8 9 10 11
Control Wiring TB3
Motor Wiring TB2
TI
U
T2
V
T3
W
–
DC
Control
Cabinet *
+
DC
Shielded Motor Cable
W (T3)
V (T2)
U (T1)
Shielded Enclosure
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
* When the control circuitry is located outside of the 160 enclosure.
to Motor
160_5_9DU2.doc
3 Mon Sep 15 11:42:00 1997
160 SSC™ Variable Speed Controller (Series B)
3
Motor Cable
• The cable between the controller and motor must be a 4-wire
shielded cable (three phases and ground). Refer to Figures 2 & 3.
• When using a line filter module as specified in Appendix A, motor
cable lengths shall be limited to 75 meters (250 feet) for controllers
rated 200-240VAC and 40 meters (133 feet) for controllers rated
380-460VAC.
• Inside the shielded enclosure, shielded motor cable must be used
as close to the controller’s output terminals as possible. The shield
must be solidly connected to the PE terminal of the controller.
• 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.
Figure 2 Motor Connections
Ground Tab – PE
L1
R
L2
S
L3
T
BR
–
BR
+
FAULT
READY
4 Wire
Shielded Motor Cable
1 2 3 4 5 6 7 8 9 10 11
Motor Wiring TB2
TI
U
T2
V
T3
W
–
DC
+
DC
Ground to Motor Housing
W (T3)
V (T2)
U (T1)
Shielded Enclosure
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
* When the control circuitry is located outside of the 160 enclosure.
Figure 3 Shielded Motor and Control Cable Example
Stranded Copper Wire
Plastic Insulation
Inner Plastic Sheath
Compact Screen of Galvanized (Tinned) Copper or Steel
Outer Plastic Jacket
160_5_9DU2.doc
4
4 Mon Sep 15 11:42:00 1997
160 SSC™ Variable Speed Controller (Series B)
Control Cable
• Control wiring must use shielded cable, or grounded metal conduit.
Refer Figures 3 and 4.
• 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 controller.
Figure 4 Control Connections
Ground Tab – PE
L1
R
L2
S
L3
T
BR
–
BR
+
FAULT
READY
Control
Cabinet *
1 2 3 4 5 6 7 8 9 10 11
Control Wiring TB3
TI
U
T2
V
T3
W
–
DC
to TB3
+
DC
Signal
Common
Shielded Control
Cable
Shielded Enclosure
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
* When the control circuitry is located outside of the 160 enclosure.
Rockwell Automation helps its customers receive a superior return on their investment by bringing
together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate
products. These are supported by local technical resources available worldwide, a global network
of system solutions providers, and the advanced technology resources of Rockwell.
Worldwide representation.
Argentina • Australia • Austria • Bahrain • Belgium • Bolivia • Brazil • Bulgaria • Canada • Chile • China, People’s Republic of • Colombia • Costa Rica • Croatia • Cyprus
Czech Republic • Denmark • Dominican Republic • Ecuador • Egypt • El Salvador • Finland • France • Germany • Ghana • Greece • Guatemala • Honduras • Hong Kong
Hungary • Iceland • India • Indonesia • Iran • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Macau • Malaysia • Malta • Mexico
Morocco • The Netherlands • New Zealand • Nigeria • Norway • Oman • Pakistan • Panama • Peru • Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia
Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic of • Spain • Sweden • Switzerland • Taiwan • Thailand • Trinidad • Tunisia • Turkey • United Arab Emirates
United Kingdom • United States • Uruguay • Venezuela
Rockwell Automation Headquarters, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414 382-2000, Fax: (1) 414 382-4444
Publication 160-5.9DU2 – May 1997
Copyright 1997 Rockwell International Corporation. All rights reserved. Printed in USA.
Information and Precautions
General Information
Receiving - It is your responsibility to
thoroughly inspect the equipment before
accepting the shipment from the freight company.
Check the item(s) received against the purchase
order. If any items are obviously damaged, do
not accept delivery until the freight agent notes
the damage on the freight bill.
If you find any concealed damage during
unpacking notify the freight agent. Also, leave
the shipping container intact and have the freight
agent make a visual inspection of the equipment
in order to verify damage.
Chapter
1
Unpacking - Remove all packing material,
wedges, or braces from within and around the
controller. Remove all packing material from the
heat sink.
Inspection - After unpacking, check the item(s)
nameplate catalog number against the purchase
order. An explanation of the catalog numbering
system for the Bulletin 160 controller is included
as an aid for nameplate interpretation. Refer to
the following page for complete nomenclature.
IMPORTANT:Before you install and start up the
controller, inspect the mechanical integrity of the
system (e.g., look for loose parts, wires,
connections, etc.).
General Precautions
In addition to the precautions listed throughout
this manual, you must read and understand the
following statements which are general to the
system.
ATTENTION: This controller
contains ESD (Electrostatic
Discharge) sensitive parts and
assemblies. Static control precautions
are required when installing, testing,
servicing or repairing this assembly.
Component damage may result if
ESD control procedures are not
followed. If you are not familiar
with static control procedures,
reference A–B Publication
8000–4.5.2, “Guarding Against
Electrostatic Damage” or any other
applicable ESD protection handbook.
SSC is a trademark of Allen-Bradley Company, Inc.
ATTENTION: An incorrectly
applied or installed controller can
result in component damage or
reduction in product life. Wiring or
application errors such as undersizing
the motor, supplying an incorrect or
an inadequate AC supply, or
excessive ambient temperatures may
result in system malfunction.
ATTENTION: Only personnel
familiar with the controller and
associated machinery should plan or
implement the installation, start–up,
and subsequent maintenance of the
system. Failure to comply may result
in personal injury and/or equipment
damage.
1–1
Chapter 1 - Information and Precautions
Figure 1.1 - Catalog Number Code Explanation
160 - A A04 N SF1
First
Position
Second
Position
Third
Position
Voltage Rating
Current
Rating
Enclosure
Type
Current
Rating HP kW
1/2
3/4
1
2
3
0.37
0.55
0.75
1.50
2.20
CAT
I
N
P
U
T
B 380Ć460V 3∅
2.1A
2.7A
3.6A
6.8A
9.6A
160 – AA04NSF1P1
V: 200-240 3
A: 5.4
Hz: 50/60
VA: 2200
O
U
T
P
U
T
Voltage Rating B
Motor Rating
2.3A
3.0A
3.9A
7.5A
10.6A
Current
Rating HP
2.0A
2.6A
3.4A
6.5A
9.2A
SER
A01
A02
A03
A04
A06
A
200-230 3
4.5
0-240
Motor
Rating: 0.75kW/1HP
V:
A:
Hz:
ALLEN-BRADLEY
Program
Keypad Module
PS1 = Preset
Speed
Output Current Rating
At Listed Voltages - Rating A
180V 200V 208V 230V 240V
2.3A
3.0A
4.1A
7.8A
11A
Programmer
(Optional)
SF1 = Analog
Letter Type
Signal
N Open (IP20)
Follower
Voltage Rating A
2.3A
3.0A
4.5A
8.0A
12A
Sixth
Position
Control
Î
Î
ÎÎ
Î
Motor Rating
A01
A02
A03
A04
A06
A08
A12
A 200Ć240V 1∅
200Ć240V 3∅
An S " in the
Bulletin Number
denotes a single
phase input
voltage.
Available up to
motor ratings of
2 HP (1.5KW)
Max.
A02
A03
A04
A08
A12
Fifth
Position
Fourth
Position
Bulletin
Number
P1
1/2
3/4
1
2
3
kW
Output Current Rating
At Listed Voltages - Rating B
342V 380V 400V 415V 460V
0.37
0.55
0.75
1.50
2.20
1.2A
1.7A
2.3A
4.0A
6.0A
1.2A
1.7A
2.2A
4.0A
5.8A
1.2A
1.6A
2.1A
3.9A
5.5A
1.1 A
1.5A
2.0A
3.7A
5.3A
1.0 A
1.4A
1.8A
3.4A
4.8A
Nameplate Information
Nameplate is located on the
side of the unit.
MADE IN U.S.A.
Conventions Used In This Manual
Parameter numbers and names are shown in bold typeface and follow the format PXX – [*] where P
denotes parameter, XX denotes the two digit parameter number, and * represents the parameter name.
For example, P01 – [Output Frequency].
1–2
Chapter
Installation and Wiring
Installation and Storage
Take these actions to prolong controller life and
performance:
D store within an ambient temperature range of
-40_ to +85_C
D store within a relative humidity range of 0%
to 95%, non–condensing
D protect the cooling fan by avoiding dust or
metallic particles
D avoid storing or operating the controller
where it could be exposed to a corrosive
atmosphere
D protect from moisture and direct sunlight
D operate at an ambient temperature range of
0_ to +50_C
To maintain proper working conditions, install
the controller on a flat, vertical and level
surface. Use mounting screws up to 4.5mm
(0.177 inches) in diameter or mount on 35mm
DIN Rail.
EMC Directive 89/336/EEC Compliance
2
Important: The conformity of this controller and
filter to any standard does not guarantee that the
entire installation will conform. Many factors can
influence the total installation and only direct
measurements can verify total conformity.
A copy of the Declaration of Conformity (DOC) is
available from your local Allen–Bradley sales
office.
Figure 2.1 - Mounting Requirements
Description
Min. Panel Thickness (14 GA)
Mounting Base Screws
Mounting Torque
Metric
1.9 mm
m4 x 0.7
1.13 to 1.56 Nm.
English
.0747 in.
# 8-32
10-14 lb. in.
Note: See Appendix A for details on controller dimensions
and weights.
Note:There must be a minimum of 12.5mm
(0.5 inches) clearance around all sides of the controller. Use
either DIN rail or mounting holes. À
DIN Mounting
Debris Cover Á
This product complies with Electromagnetic
Compatibility (EMC) Directive 89/336/EEC, when
the following requirements for a conforming
installation are applied:
D an input line filter must be installed to reduce
conducted emissions. Refer to the accessory
list in Appendix A.
D the controller system must be mounted in a
shielded enclosure to reduce radiated
emissions. A typical NEMA or IEC metal
enclosure is adequate.
D motor cables must be in conduit, or have
shielding/armor with equivalent attenuation to
reduce radiated emissions.
D motor cable lengths are as specified in table
2.A.
À
D control and signal wiring must be in conduit or
have shielding with equivalent attenuation.
Use the drilling template at the back of the manual for
mounting the controller.
Á
Leave debris cover attached during controller installation to
protect from falling debris. To ensure proper controller
operation, remove cover before applying power.
2–1
Chapter 2 - Installation/Wiring
Figure 2.2 - Controller Features
Ground Tab
L1
R
L2
S
L3
T
BR
-
BR
+
Ready/Fault Indicating
Panel - Standard for
Bulletin 160 controllers.
FAULT
LEDs - Indicate
operational status.
READY
1 2 3 4 5 6 7 8 9 10 11
T1
U
T2
V
T3
W
Terminal Block One
(TB1) - For Line Power.
-
DC
+
DC
Terminal Block Three (TB3)
- For Control Wiring.
Terminal Block Two (TB2)
- For Motor Wiring.
Fan
DIN Latch
Controller Features
Figure 2.2 above details the features of both the
Analog Signal Follower and Preset Speed
models.
Program Keypad Module - This can be
ordered separately, Catalog 160-P1, or
as a factory-installed option by adding
P1 " to the end of the catalog number.
Refer to Chapter 3, Program Keypad
Module for a detailed explanation of
functionality.
Diagnostics For Controllers Without a
Program Keypad Module
There are two indicators provided to display
the controller’s status condition.
Note: The features are the same for single and
three phase units.
The READY (green) indicator illuminates
when the DC bus is charged and the
controller is ready to run.
Controller Operation Without a Program
Keypad Module
The FAULT (red) indicator illuminates
when a controller fault condition exists.
Refer to Chapter 6 for details on how to
clear a fault and general troubleshooting
procedures.
Bulletin 160 controllers are fully functional
without the use of a program keypad module.
All control functions can be performed from the
control terminal block (TB3). A program
keypad module is required to change the factory
default parameter settings.
2–2
Chapter 2 - Installation/Wiring
Motor Cable Recommendations
Long Motor Cable Effects
A variety of cable types are acceptable for
variable speed controller installations. For many
installations, unshielded cable is adequate,
provided it can be separated from sensitive
circuits. As an approximate guide, allow a
spacing of 1 meter (3.3 feet) for every 10 meters
(33 feet) of unshielded length. If you cannot
separate motor cables from sensitive circuits, or if
you must run motor cables from multiple
controllers (more than three) in a common
conduit or cable trays, shielded motor cable is
recommended to reduce system noise.
Installations with long motor cables may require
the addition of output reactors to reduce voltage
reflections at the motor, and reduce cable
charging current. Capacitive charging of long
motor cables may draw current in excess of the
controller rating. The output reactor should be
installed between the controller output terminals
and the motor, and mounted near the controller.
The controller should be installed as close to the
motor as possible.
Motor cables should be four–conductor with the
ground lead and shield (if using shielded cable)
connected to the controller ground terminal and
the motor frame ground terminal.
Note: If your application requires motor cable
lengths exceeding the recommendations listed
below, contact your local Allen–Bradley Sales
Office.
Table 2.A Recommended Shielded Motor Cable Lengths
Recommended Max. Cable Length m (ft.)
Controller Type
kW (HP)
Voltage
Economy Motor
(1000V)
Standard Motor
(1200V)
Inverter Rated Motor
(1600V)
0.37 (0.5)
230
61 (200)
61 (200)
61 (200)
0.56 (0.75)
230
107 (350)
107 (350)
107 (350)
0.75 (1.0)
230
122 (400)
122 (400)
122 (400)
1.5 (2.0)
230
152 (500)
152 (500)
152 (500)
2.2(3.0)
230
152 (500)
152 (500)
152 (500)
460
12 (40)À
20 (60)À
30 (100)
460
12 (40)À
20 (60)À
30 (100)
0.75 (1.0)
460
12 (40)À
20 (60)À
38 (125)
1.5 (2.0)
460
12 (40)À
20 (60)À
46 (150)
2.2(3.0)
460
12 (40)À
20 (60)À
90(275)
0.37 (0.5)
0.56 (0.75)
À
These recommended cable lengths are based on reflected wave limitations, while all other recommended cable lengths listed above are based
on capacitive charging of long, shielded motor cables.
2–3
Chapter 2 - Installation/Wiring
Power Wiring For Preset Speed and
Analog Signal Follower Models
Table 2.B
Power Terminal Block Specifications
Terminal Screw
Size
TB1
M4
TB2
M4
Table 2.C Recommended AC Input Line Fuse
UL Class J, CC, or BS88 (or equivalent)
3∅ Rating
kW (HP)
1∅ Rating
kW (HP)
Fuse
230V Rating
Fuse
460V Rating
.37 (1/2)
.55 (3/4)
.37 (1/2)
6
6
.75 (1)
1.5 (2)
2.2 (3)
Max/Min Max/Min
Wire Size
Torque
mm2 (AWG) Nm. (lb.in.)
4-0.75
1.81-1.35
(12-18)
(16-12)
4-0.75
1.81-1.35
(12-18)
(16-12)
.55 (3/4)
0.75 (1)
1.5 (2)
3(4) À
3(4) À
6Á
10 Á
15(16) Á
( )
À
Á
Figure 2.3 - Power Wiring For Analog
Signal Follower and Preset Speed Models
Denotes European sizes.
Must be dual element time delay, Gould AJT or equivalent.
If blowing fuses is a problem, use dual element type fuses.
Required Branch
Circuit Disconnect Â
Input Line Fuses - See Table 2.C
above. Â
Ground Tab
Dynamic Brake Module
Option Ã
READY
L1
R
L2
S
L3
T
T1
U
FAULT
10
15(16)
25
T2
V
T3
W
BR
-
-
DC
+
Terminal Block One (TB1) - For
Line Power and Brake Resistor.
+
Terminal Block Two (TB2) - For
Motor and Capacitor Module.
DC
Capacitor Module
Option Ä
ATTENTION:
The controller is
Motor Å
intended to be commanded by control input
signals that will start and stop the motor. A
device that routinely disconnects then
reapplies line power to the controller for the
purpose of starting and stopping the motor
should not be used. If it is necessary to use
this method for starting and stopping or if
frequent cycling of power is unavoidable,
make sure that it does not occur more than
once a minute.
BR
Â
Ã
For single phase input applications, connect the AC input line
to input terminals (L1) R and (L2) S.
Connection for dynamic brake resistors for all models. Note:
P52 - [DB Enable] must be enabled for proper operation.
See Appendix A for part numbers.
Do not connect power factor
correction capacitors to controller output terminals
T1, T2, and T3 (U, V, and W).
2–4
Connection for an external capacitor module. Provides
extended ride through capability and improved inherent
braking performance. See Appendix A for part number.
Å
ATTENTION:
Ä
Bulletin 160 controllers are
and
listed as motor overload protective devices. An external
overload relay is not required for single motor applications.
Chapter 2 - Installation/Wiring
Control Wiring Requirements
D run all signal wiring in either a shielded
cable, or a separate steel conduit.
D only connect shield wire at control terminal
block common terminals 3 and 7.
D do not exceed control wiring length of 15
meters (50 feet). À
D use Belden 8760(or equivalent) – 18AWG
(0.750mm 2), twisted pair, shielded or 3
conductor.
À
Control signal cable length is highly dependent on
electrical environment and installation practices. To
improve noise immunity the control terminal block
common must be connected to earth ground.
Consult factory for longer control signal cable length
applications.
Table 2.D Control Terminal Block Specifications
Terminal
TB3
Max/Min
Wire Size
mm2 (AWG)
2.5-0.5
(14-22)
Max/Min
Torque
Nm. (lb.in.)
0.8-0.4
(8-4)
ATTENTION: The controller is
supplied with an internal 12V
supply. Dry contacts or open
collectors are required for discrete
control inputs. If an external
voltage is applied, component
failure could occur.
Control Wiring - Analog Signal Follower
Model
You can control the output frequency of the
controller via the Control Terminal Block (TB3)
using a remote potentiometer, a –10 to +10 VDC
analog input, a 4–20mA analog input, or P58 –
[Internal Frequency]. Note: Only one
frequency source may be connected at a time. If
the frequency reference potentiometer and the
4–20 mA reference are connected at the same
time, an undetermined frequency reference will
result. If the –10 to +10 VDC analog input is not
used, it should be tied to terminal block common
terminal 7 to improve noise immunity. Refer to
Chapter 5, parameters P58–P60 for factory
default settings.
Control Wiring - Preset Speed Model
You can control the output frequency of the
controller via contact closure input to SW1,
SW2, and SW3. A program keypad module is
required to change the factory default settings.
Refer to Chapter 5, parameters 61–70 for the
eight preset frequency factory default settings
and switch configurations.
Wiring Diagrams
Note: Refer to the diagrams on the following
pages for control wiring information.
2–5
Chapter 2 - Installation/Wiring
Control Wiring
Figure 2.4 - TB3 Control Wiring for Analog Signal Follower Model
Shielded Wire
TB3 Terminal
1
2
FAULT
READY
Â
3
4
5
6
7
8
9
10
11
Signal
Specification
+ 10V Pot
Pot Wiper or
+10/-10 VDC Input
Common
4-20mA Input
Reverse
Start
Common
Stop
Normally Closed
10 kΩ Potentiometer, 2 Watts
Relay Common
Normally Open
Controller Input Impedance = 100 kΩ
Controller Input Impedance = 250 Ω
Contact closure input À
Contact closure input À
Common Á
Contact closure input required to operate controller À
Customer-programmable relay outputs.
Resistive load 0.4A at 125 VAC 2A at 30 VDC.
Inductive load 0.2 A at 125 VAC 1A at 30 VDC.
= N.O. Momentary Contact
= N.C. Momentary Contact
= N.O. Maintained Contact
Figure 2.5 - TB3 Control Wiring for Preset Speed Model
Shielded Wire
TB3 Terminal
FAULT
READY
Â
1
2
3
4
5
6
7
8
9
10
11
Signal
Specification
SW1
SW2
Common
SW3
Reverse
Start
Common
Stop
Normally Closed
Relay Common
Normally Open
Contact closure input À
Contact closure input À
Common Á
Contact closure input À
Contact closure input À
Contact closure input À
Common Á
Contact closure input required to operate controller À
Customer-programmable relay outputs.
Resistive load 0.4A at 125 VAC 2A at 30 VDC.
Inductive load 0.2 A at 125 VAC 1A at 30 VDC.
= N.O. Momentary Contact
= N.C. Momentary Contact
= N.O. Maintained Contact
À
Internal 12V supply.
Á
Do not exceed control wiring length of 15 meters (50 feet). Control signal cable length is highly dependent on
electrical environment and installation practices. To improve noise immunity the control terminal block common
must be connected to earth ground. Consult factory for longer control signal cable length applications.
Â
This diagram shows three wire " control. Refer to the following page for diagrams of other control wiring methods.
2–6
Chapter 2 - Installation/Wiring
Control Wiring (continued)
Use P46 – [Input Mode] to select the control
method for start, stop, and direction control.
There are four settings from which to choose:
Figure 2.6 - TB3 Three Wire control (Setting 0)
TB3 Terminal
1
Shielded Wire
2
3
Setting 1 – two wire “run forward/run
4
reverse”control. Note: The “run” inputs must
5
be maintained.
6
Setting 2 – program keypad module control.
7
8
See page 3–1.
9
Setting 3 – momentary “run forward/run
10
reverse” control. Note: The “run” inputs do
1
1
D Setting 0 – three wire control (this is the
factory default setting).
D
D
D
Signal
Specification
Reverse
Start
Common
Stop
Contact closure input À
Contact closure input À
Common Â
Contact closure input required
to operate controller À
not need to be maintained.
ATTENTION: When changing the
parameter setting for P46 – [Input
Mode], you must cycle power for the
change to take effect.
Figure 2.7 - TB3 Two wire Run forward/run reverse
control (Setting 1)
TB3 Terminal
1
Shielded Wire
2
ATTENTION: The program keypad
3
module stop key simulates momentary
Á
4
pushbutton operation. For “two wire”
5
control schemes (P46 – [Input Mode],
6
7
setting “1”) the program keypad module
8
stop button will only provide a “stop”
9
function while the stop key is depressed.
10
1
1
Signal
Specification
Run Reverse
Run Forward
Common
Stop
Contact closure input À
Contact closure input À
Common Â
Contact closure input
required to operate controller À
Explanation of Symbols:
= N.O. Momentary Contact
= N.C. Momentary Contact
= N.O. Maintained Contact
Figure 2.8 - TB3 Momentary Run forward/run
reverse " control (Setting 3)
= N.C. Maintained Contact
À
Internal 12V supply.
Á
If both Run Forward and Run Reverse inputs are closed
at the same time an undetermined state could occur.
Â
Do not exceed control wiring length of 15 meters (50
feet). Control signal cable length is highly dependent
on electrical environment and installation practices.
To improve noise immunity the control terminal block
common must be connected to earth ground.
Consult factory for longer control signal cable length
applications.
Shielded Wire
Á
TB3 Terminal Signal
1
2
3
4
5
Run Reverse
6
Run Forward
7
Common
8
Stop
9
10
1
1
Specification
Contact closure input À
Contact closure input À
Common Â
Contact closure input
required to operate controller À
2–7
Chapter 2 - Installation/Wiring
Notes:
2–8
Chapter
Program Keypad Module
Features
3
Display Mode
The program keypad module is located on the front The controller always powers up in the display
panel of the controller. It features the following: mode. While in this mode you may view all read
only controller parameters, but not modify them.
D five keys on the module for display or
programming controller parameters
Program Mode
D three keys for control inputs to the controller
D directional LEDs
D a 6 digit, seven segment LED display
You enter the program mode by pressing the ESC
key. While in program mode, you can edit any
programmable controller parameters. Refer to
Chapter 5 for programming steps.
Figure 3.1 - Program Keypad Module Features
These two digits display the active
parameter number for both display and
program parameters, which are
designated as P## throughout this
manual.
When the program mode
indicator flashes, you can edit the
parameter value. When in display
mode, the program indicator does not
display.
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.
The SELect key is only used while in
program mode. It enables the editing of
a parameter value. When you press
this key the program mode indicator
flashes.
The ESCape key allows you to
toggle between the display mode
and program mode. When in
program mode, this key also
disables the editing of a parameter
value.
Pressing the enter key
while in programming
mode causes the current
value displayed to be
entered into memory.
When you press this key
the program mode indicator
remains on, but stops
flashing.
The counter clockwise LED
illuminates constantly when the
motor rotates in reverse direction. À
Pressing the reverse key causes the
motor to ramp down to 0 Hz and then
ramp up to its set speed in the opposite
direction. Á
À
These four digits
display the parameter
value or fault code
number.
The clockwise LED
illuminates constantly when
the motor rotates in forward
direction. À
Indicates commanded direction. Actual motor rotation
could be different if motor leads are not connected
properly. See Chapter 4, Startup for details on how to
verify motor rotation.
Á
The start key initiates a
start command when the
controller is programmed
for local start/stop control
(when P46 - [Input Mode]
is set to 2 " ).
The stop key initiates the
motor to Coast " , Ramp " or
DC Brake " to stop dependĆ
ing on the setting of P34[Stop Mode].
When the motor is running, pressing this key causes the (currently
illuminated) LED to flash indicating motor rotation while decelerating to zero.
The opposite LED will illuminate indicating the commanded direction.
The program keypad module stop key simulates
momentary pushbutton operation. For two wire " control schemes
(P46 - [Input Mode], setting 1 " ) the program keypad module stop key will
only provide a stop " function while the stop key is depressed.
ATTENTION:
3–1
Chapter 3 - Program Keypad Module
Removing Program Keypad Module
ATTENTION: Ensure that you
disconnect line power and wait
one minute before installing or
removing the program keypad
module. Failure to do so may
result in personal injury or death.
Figure 3.2 - Removing Program Keypad Module
Insert a small screw driver into
slot, pry back, and pivot module
out. Avoid bending or twisting
the contact pins located
underneath the center portion of
the module.
ATTENTION: This controller
contains ESD (Electrostatic
Discharge) sensitive parts and
assemblies. Static control precautions
are required when installing, testing,
servicing or repairing this assembly.
Component damage may result if
ESD control procedures are not
followed. If you are not familiar
with static control procedures,
reference A–B publication
8000–4.5.2, “Guarding Against
Electrostatic Damage” or any other
applicable ESD protection handbook.
Program Keypad
Module
Dipswitch that changes P35- [Base
Frequency] from 50 to 60 Hertz
when program keypad module is not
installed.
Note: When a program keypad module
is installed, P35 - [Base Frequency]
overrides this switch setting. Once P35
- [Base Frequency] is changed from its
factory default setting, the switch
remains overridden until all parameters
are reset to their factory default settings
using P56- [Reset Defaults].
Installing Program Keypad Module
Insert the module bottom end first and then press on the
symbol at the top of the module until the module is fully
seated. The module is fully seated when its face is flush
with the edges of its surrounding case.
3–2
Chapter
Start-Up
Chapter 5 provides a comprehensive description of
all controller parameters. Review the factory default
settings. If your controller is equipped with a ProĆ
gram Keypad Module these parameters can be
changed to meet your specific application requireĆ
ments. An example of how to program a parameter
is shown at the beginning of Chapter 5.
Start Here
4
Commonly Changed Parameters
Parameter
P30-[Accel Time 1]
P31-[Decel Time 1]
P33-[Maximum Frequency]
P34-[Stop Mode Select]
P35-[Base Frequency]
P36-[Base Voltage]
P42-[Motor Overload Current]
P46-[Input Mode]
P47-[Output Configure]
Preset Speed Model Only
P61-P68-[Preset Frequency 0-7]
Set to...
desired accel time.
desired decel time.
maximum frequency required.
desired stopping mode.
motors rated nameplate frequency.
motors rated nameplate voltage.
motor nameplate Full Load Amps [FLA].
desired control method.
desired output functionality.
desired preset frequencies.
ATTENTION: Power must be applied to the controller to perform the following startĆup procedure. Some of
the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only
qualified service personnel should perform the following procedure. Thoroughly read and understand the
procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed.
Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing.
Start-Up Checklist
Verify the controller is installed per instructions outlined in Chapter 2 including:
D
D
D
Minimum clearance distance between controller and other equipment.
Proper grounding practices have been followed.
Proper power and control wiring has been used.
Verify that AC line power at the
disconnect device is within the rated
value of the controller.
Disconnect and lock out all incoming power to
the controller including incoming AC power to
terminals L1, L2 and L3 (R, S and T) of power
terminal block TB1.
ATTENTION: A DC Bus
voltage may be present at the
power terminal blocks (TB1)
and (TB2) for approximately
one minute after power is
removed from the controller.
Verify that the motor leads are connected to the
power terminal block TB2, terminals T1, T2, T3 (U,
V, W).
Verify that the STOP input is present
at the TB3 control terminal block.
Confirm that all other control inputs are connected to
the correct terminals and are secure. GO TO THE
NEXT PAGE.
A
4–1
Chapter 4 - Start-Up
A
If you have a blank display panel.
Reconnect the power to the
controller.
If you have a program keypad module.
P01- [Output Frequency] will display. If the
controller has been previously powered up, a
different parameter number may display.
Note: To enable the start and reverse keys
from the program keypad module, set P46 [Input Mode] to a 2 " and cycle power. Refer
to the programming example in Chapter 5.
The READY [green] indicator
will illuminate. Use remote
inputs to TB3 control terminal
block to operate the controller.
Do you have a Analog Signal
Follower controller or a Preset Speed
controller?
Analog Signal Follower controller
Check for proper motor rotation by setting the frequency
source to its minimum setting.
If you are using a program keypad module, verify that the
CLOCKWISE LED is illuminated. If you are using a blank
display panel, verify that the REVERSE input to TB3 is in
the OPEN position.
Issue a START command from either the program keypad
module or TB3 control terminal block.
Preset Speed controller
Check for proper motor rotation by selecting P61 [Preset Frequency 0]. This requires removing all inputs
to SW1, SW2, and SW3 on TB3 [see Figure 2.5 in
Chapter 2]. The factory default setting for P61 - [Preset
Frequency 0] is 3 Hz.
If you are using a program keypad module, verify that the
CLOCKWISE LED is illuminated. If you are using a blank
display panel, verify that the REVERSE input to TB3 is in
the OPEN position.
Slowly increase the speed until the motor begins to turn.
Check the direction of the motor.
Issue a START command from either the program
keypad module or TB3 control terminal block. Check the
direction of motor rotation.
Issue a STOP command from either the program
keypad module or TB3 control block terminal.
Issue a STOP command from either the program
keypad module or TB3 control block terminal.
Startup is complete.
Yes
Is the direction of motor
rotation correct?
No
Disconnect and lock out all incoming power to TB1 terminals L1, L2, and L3 [R, S and T].
ATTENTION: A DC Bus voltage may be present at the
power terminal blocks (TB1) and (TB2) for approximately
one minute after power is removed from the controller.
Switch any two of the three motor leads connected to TB2, terminals T1, T2 and T3 [U, V and W].
4–2
Chapter
Parameters and Programming
5
Overview of Parameters
This chapter covers both display and program parameters. Display parameters are read only (they
cannot be programmed), while program parameters can be changed to fit your motor control
requirements. You must have a Program Keypad Module to view/change display and program
parameters. The table below describes which parameters apply to the Preset Speed and Analog Signal
Follower models. Refer to the programming example below for programming instructions.
Parameter Numbers
Parameter Type
Analog Signal Follower Model
Preset Speed Model
Display
1 through 14
1 through 15
Program
30 through 60
30 through 57 and 61 through 70
The following pages contain descriptions of both display and program
parameters. Any parameter description that is shaded pertains only
to the Preset Speed or Analog Signal Follower model. Refer to the
legend to the right.
ÉÉ
= Parameter applies only to the Analog Signal Follower model
= Parameter applies only to the Preset Speed model
Programming Example
The following is an example of the programming steps required to change a program group parameter setting. In this example,
parameter 31 - [Decel Time] is changed from its factory default setting of 10.0 seconds to 2.2 seconds. Refer to Chapter 3, page
NO TAG for an explanation of Program Keypad Module display and programming keys. Note: To reset ALL values to original
factory default settings, refer to P56 - [Reset Defaults].
Action
Description
1. To program the value of a program group parameter, enter the program
group by pressing the ESCape key. The program mode indicator " will
illuminate.
Keypad Display
3 0.
1 0. 0
Program Mode Indicator
2. Press up/down keys until the desired parameter displays. In this case,
3 1.
1 0. 0
3. Press the SELect key. The program mode indicator flashes indicating
3 1.
1 0. 0
press the up key until parameter 31 - [Decel Time] displays.
that you can use the up/down keys to change the parameter value.
4. Change the decel time value from the factory default of 10 seconds to
2.2 seconds by pressing the down key until 2.2 displays.
Note: 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.
Note: If at any time (while in the program mode) you wish to abort the
editing process, press the ESCape key. The original value of the parameter
will remain unchanged and you will be exited from the program mode.
Program Mode Indicator Flashes
3 1.
2. 2
3 1.
2. 2
Program Mode Indicator
Stops Flashing
3 1.
1 0. 0
Program Mode Indicator
Stops Flashing
5–1
Chapter 5 - Parameters and Programming
Display Group Parameters
This group of parameters consists of commonly viewed controller operating conditions such as controller
output frequency, output voltage, output current and frequency command. All parameters in this group
are read only.
Display Group
You may find it necessary for the controller to display a specific parameter each time it is powered up. (This is
especially useful when troubleshooting and making system adjustments). Follow these steps to make the controller
power up at a specific display parameter:
1. While in display mode, increment to the parameter you wish to see when the controller powers up.
2. Press the
key twice. When you cycle power to the controller it will display the parameter that you set.
Note: If you change any program group parameters, the controller (when powered up) will show the last display
parameter that was present before you went into program mode.
01
Min/Max
Range
0 to 240 Hz
0.1 Hz
0 to [Max Voltage]
1 Volt
0 to 2 Times
Controller Rated
Output Current
0.01Amps
0 to 2 Times Rated
Controller Output
Power
0.01 kW
1 Volt
0 to 240
0.1 Hz
0 to 48
Numeric Value
0 to 150
1 Degree C
0000 to 1011
[Output Frequency]Displays the output frequency at TB2 terminals
Units
0 to 400 - [230V]
0 to 800 - [460V]
Parameter Description
P#
Binary Number
T1, T2 and T3 (U, V and W).
02
[Output Voltage]Displays the output voltage present at TB2 terminals
T1, T2 and T3 (U, V and W).
03
[Output Current]Displays the output current present at TB2 terminals
T1, T2 and T3 (U, V and W).
04
[Output Power]Displays the output power present at TB2 terminals T1,
T2 and T3 (U, V and W).
05
[Bus Voltage]
06
[Frequency Command] Displays the frequency that the controller
Displays the DC Bus Voltage level.
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
[Last Fault] Displays the coded last fault number.
If a fault is currently
active (has not been cleared) the display will flash. See Chapter 6 for fault code
descriptions.
08
[Heatsink Temperature]Displays the temperature of the controller
heatsink.
09
[Controller Status]Displays the status of the controller in a binary
coded format.
Note: A 0 " = inactive
and a 1 " = active.
5–2
Bit 3
Bit 2
Bit 1
Bit 0
Running
Forward
Accel
Decel
Chapter 5 - Parameters and Programming
Display Group
10
11
Min/Max
Range
[Controller Type]Used by Allen-Bradley field service personnel.
[Control Version]Displays version of controller firmware. Used by
Units
Numeric Value
Numeric Value
Fixed Value
Numeric Value
0000 to 0111
Parameter Description
P#
Binary Number
0.00 to 90.00
0.01 degrees
Allen-Bradley field service personnel.
12
[Input Status]Displays the open (0) and closed (1) state of the parallel
inputs in binary coded format.
Bit 3
Bit 2
Bit 1
Bit 0
Reverse
Stop
Start
Not Used
13
[Power Factor Angle] Displays the angle in electrical degrees
between motor voltage and motor current.
ÁÁÁ
ÁÁÁ
ÁÁÁ
[Memory Probe Display]Used by Allen-Bradley field service
[Preset Status]Displays the open (0) and closed (1) state of Terminal
Block Three (TB3) inputs SW1, SW2, and SW3 in binary coded format. This
parameter applies to the Preset Speed model only.
Bit 3
Bit 2
Bit 1
Numeric Value
Numeric Value
0000 to 0111
personnel.
15
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Á
Á
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
14
Binary Number
Bit 0
SW1
SW2
SW3
Not Used
=
This parameter applies only to the Preset Speed model.
5–3
Chapter 5 - Parameters and Programming
Program Group Parameters
This group contains parameters whose values can be programmed. Refer to the “Programming Example”
outlined earlier in this chapter. Unless otherwise stated, parameters that are programmed while the
controller is running take immediate effect.
Program Group
P#
30
Min/Max
Range
Units
Factory
Default
0.1 to 600
Parameter Description
0.1 Seconds
10.0
Seconds
0.1 to 600
0.1 Seconds
10.0
Seconds
0 to 240
1 Hz
0 Hz
0 to 240
1 Hz
60 Hz
0 to 2
Numeric
Value
0
10 to 240
1 Hz
60 Hz Á
20 to 460 for
460V units and
20 to 230 for
230V units
1 Volt
460 Volts for
460V units
and 230 for
230V units
[Accel Time 1]Time for the controller to ramp from 0.0 Hz. to P33 [Maximum Frequency]. The rate is linear for any increase in command
frequency unless P53 - [S-Curve] is set to a value other than 0 " .
Max. Frequency '
Speed
0
a Accel '
0
31
Time
Time
a Decel '
Time
[Decel Time 1]Time for the controller to ramp from P33 - [Maximum
Frequency] to 0.0 Hz. The rate is linear for any decrease in command frequency
unless P53 - [S-Curve] is set to a value other than 0 " . See P30-[Accel Time]
figure above.
32À [Minimum Frequency]Lowest frequency that controller will output
continuously.
Note: This parameter cannot be programmed while the controller is running.
33À [Maximum Frequency]Highest frequency the controller will output.
Note: This parameter cannot be programmed while the controller is running.
34
[Stop Mode Select]Determines stopping mode used by the controller
when a stop is initiated. Refer to the P44 - [DC Hold Time] and P45 - [DC Hold
Volts] diagrams. Settings: 0 = Ramp to Stop
1 = Coast to Stop
2 = DC Injection Braking
35
36
[Base Frequency]Set value to motor's rated nameplate frequency.
[Base Voltage]Set value to motor's rated nameplate voltage.
À
The analog inputs to the controller (i.e.,4-20mA, 0 to +10 V, or remote potentiometer) can be scaled to P32 - [Minimum Frequency] and
P33 - [Maximum Frequency] by programming P60 - [Analog Scale Teach].
Á
For controllers without a program keypad module, you can change P35 - [Base Frequency] to 50 Hz via a dipswitch located under the blank
front panel. See the Removing Program Keypad Module section in Chapter 3.
5–4
Chapter 5 - Parameters and Programming
Program Groups
P#
37
Min/Max
Range
Factory
Default
1 Volt
460 Volts for
460V units
and 230 for
230V units
Numeric
Value
4
0 to 240
1 Hz
240 Hz
0 to 30
1 Hz
0 Hz
[Maximum Voltage]Sets the highest voltage that the controller will
38
Units
0 to 12
Parameter Description
[Boost Select]Sets the boost voltage and redefines the Volts per Hz curve.
20 to 460 for
460V units and
output.
20 to 230 for
230V units
P37 - [Maximum Voltage] must be greater than or equal to P36 - [Base Voltage].
[Base Voltage], %
100
1/2
Base
Volts
50
1/2 Base
Freq.
8y
See Settings 1
through 8 below
1b
0
Setting
0
1
2
3
4
5
6
7
8
39
9
10
11
12
50
100
[Base Frequency], %
Boost Voltage % of [Base Voltage]
0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
Setting Fan/Pump Curves À
9
45.0
10
40.0
11
35.0 À Break Point Voltages in %
12
30.0
of [Base Voltage].
[Skip Frequency]Works in conjunction with P40 - [Skip Frequency
Band] creating a range of frequencies at which the controller will not operate
continuously.
Frequency
Controller Output
Command ' a Frequency
Frequency
Skip
Frequency
Setting
y Two times
P40-[Skip Freq Band
b Setting
'
Time
40
[Skip Frequency Band]Determines the band around the P39 - [Skip
Frequency] parameter. The actual band width will be 2 times [Skip Frequency
Band] - 1/2 the band above and 1/2 the band below. A value of zero will disable
the skip frequency.
5–5
Chapter 5 - Parameters and Programming
Program Group
P#
41
Min/Max
Range
Units
Factory
Default
0 to 2
Parameter Description
Numeric
Value
0
25% to 200%
.01 Amperes
115% of
Controller
Rating
20% to 190%
1%
150%
0 to 15
1 Second
0 Seconds
0 to 115
1 Volt
0 Volts
[Motor Overload Select]Selects the derating factor for the I2t
% of [Overload Current] Setting
42
100
80
60
40
20
100
80
60
40
20
No Derating
% of [Overload Current] Setting
% of [Overload Current] Setting
overload function.
Min Derating
100
80
60
40
20
0 25 50 75 100 125 150 175 200
% Base Speed
0 25 50 75100 125 150 175 200
% Base Speed
Max Derating
Settings:
0 25 50 75 100125 150 175 200
% Base Speed
0 = No Derating
1 = Minimum Derating
2 = Maximum Derating
[Motor Overload Current] Set to motor nameplate full load Amps
(FLA).
43
[Current Limit]Maximum output current allowed before current limiting
occurs. Value set in percent of controller rated output current.
44
[DC Hold Time]Time that P45 - [DC Hold Volts] voltage will be applied
to the motor when P34 - [Stop Mode Select] is set to either DC Brake " or
Ramp " mode.
45
[DC Hold Voltage]DC Voltage level applied to the motor during braking
when P34 - [Stop Mode Select] is set to either DC Brake " or Ramp " mode.
Ramp Mode
DC Brake Mode
Voltage
Volts and Speed
Voltage
[DC Hold Time]
Speed
Volts and Speed
[DC Hold Time]
Speed
[DC Hold Voltage]
[DC Hold Voltage]
y
Stop Command
5–6
Time
y
Stop Command
Time
Chapter 5 - Parameters and Programming
Program Group
P#
Parameter Description
46
Min/Max
Range
Units
Factory
Default
0 to 3
Numeric
Value
0
0 to 9
Numeric
Value
0
0 to 815
Numeric
Value
0
[Input Mode]Configures the TB3 control inputs for either 3 wire " or 2 wire
run-fwd/run-rev control " . Also enables/disables the program keypad module input
control. Note: This parameter cannot be programmed while the controller is
running. Also, power must be cycled for the change to take effect.
Settings:
47
0 = 3 wire " control
1 = 2 wire " control
2 = Program Keypad Module control
3 = Momentary ``Run Forward/ Run Reverse " Control
[Output Configure]Configures the TB3 relay output functionality.
Settings
Output changes state when...
0 = Controller
Ready/Faulted
1 = At Frequency
the controller reaches commanded frequency.
2 = Controller Running
the controller is running.
3 = Reverse
the controller is commanded to run in the reverse
direction.
4 = Motor Overload
when a motor overload condition exists.
5 = Ramp Regulated
the ramp regulator is modifying the
programmed accel/decel times to avoid an
overcurrent or overvoltage fault from occurring.
6 = Above Frequency
the controller exceeds the frequency value
set in P48 - [Output Threshold].
7= Above Current
the controller exceeds the value set in P48 [Output Threshold]. Note: Value for P48 [Output Threshold] must be entered in % of
controller rated output current.
8 = Above DC Bus
Voltage
the controller exceeds the DC bus voltage value set
in P48 - [Output Threshold].
9 = Retries Exhausted
48
energized and returns to shelf state when
power is removed or when a fault occurs.
the number of retries for P50 - [Restart Tries] is
exceeded.
[Output Threshold]Determines the on/off point for the TB3
output relay when [P47 - Output Configure] is set to 6, 7, and 8.
Settings
Ranges
6
0 to 240 Hz
7
0 to 150 %
8
0 to 815 Volts
5–7
Chapter 5 - Parameters and Programming
Program Group
49
Min/Max
Range
Factory
Default
0.1kHz
4.0 kHz
0 to 9
Numeric
Value
0
0.5 to 300
Parameter Description
Units
2.0 to 8.0
P#
0.1 Seconds
10.0
Seconds
0 to 1
Numeric
Value
0
Numeric
Value
0
[PWM Frequency]Carrier frequency for the PWM output waveform.
% Output Current (A)
The chart below provides derating guidelines based on the PWM freq. setting.
100
98
96
94
92
90
88
86
84
1
2
6
5
4
Carrier Frequency, kHz
3
7
8
Note: Ignoring derating guidelines can cause reduced controller performance.
50
[Restart Tries]Maximum number of times the controller will attempt to
reset a fault.
51
[Restart Time]Time between restart attempts.
52
[DB Enable]Enables/disables dynamic braking. 0 = Disable, 1 = Enable
Note: This parameter cannot be programmed while the controller 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) À
1/2 SĆCurve
Time
1/2 SĆCurve
Time
'
'
a
'
a
S-Curve Time = 10 x .3
'
a
Example:
Accel Time = 10 seconds
S-Curve Setting = 3
= 3 Seconds
a
S-Curve
Setting
0 = 0%
1 = 10%
2 = 20%
3 = 30%
Enabled
4 = 40%
Note: Maximum
S-Curve time is 60
seconds.
Disabled
5 = 50%
6 = 60%
7 = 70%
8 = 80%
9 = 90%
10 = 100%
'
a
Accel Time
5–8
'
a
Decel Time
À
See values in the Min/Max Range column
Chapter 5 - Parameters and Programming
Program Group
P#
54
Min/Max
Range
Units
Factory
Default
0 to 1
Numeric
Value
0
Numeric Value
Numeric
Value
Numeric
Value
0 to 1
Numeric
Value
0
0 to 1
Numeric
Value
0
Parameter Description
[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 " .
Note: This parameter cannot be programmed while the controller is running.
55
[Memory Probe Address]Used by Allen-Bradley field service
personnel.
56
[Reset Defaults]All parameters and their associated factory defaults are
reset when set to a value of 1 " . When the default function is complete, this
parameter will set itself back to a 0 " . This parameter cannot be programmed
while the controller is running. Note: An F48 - [Reprogram Fault] will occur
and must be cleared by cycling the STOP input to the controller.
Note: P46-[Input Mode Select] factory defaults to 3 wire " control. If using
keypad control, change parameter setting back to a 2 " to regain program keypad
control.
57
[Program Lock]When set to a 1 " , this parameter protects all controller
parameters from being changed by unauthorized personnel.
Program Group – Analog Signal Follower Model Only
P#
Parameter Description
[Internal Frequency]Digital frequency setpoint from the program
ÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
58
Min/Max
Range
Units
Factory
Default
0 to 240
0.1 Hz
60.0
0 to 1
Numeric
Value
0=Analog
0 to 2
Numeric
Value
0
keypad module. Value of frequency command when P59 - [Frequency Select] is
set to a 1 " .
59
[Frequency Select]Selects the source of the frequency command for
the controller.
Settings:
60
0 = frequency source from analog input to TB3 control terminal
block.
1 = frequency source from digital setpoint programmed into
P58 - [Internal Frequency].
[Analog Scale Teach]Scales the 0-10V À ,4-20 mA analog input, or
remote potentiometer input to operate between P32 - [Minimum Frequency] and
P33 - [Maximum Frequency]. To scale to P33 - [Maximum Frequency], set
analog input to maximum value, increment parameter to a 1 " , and then press the
enter key. To scale to P32 - [Minimum Frequency], set analog input to minimum
value, increment parameter to a 2 " , and then press the enter key. Note: The
parameter resets to 0 " after you press the enter key.
À
If you are using a bipolar input (-10 to +10V), do not scale the input to the
minimum frequency setting.
=
This parameter applies only to the Analog Signal Follower model.
5–9
Chapter 5 - Parameters and Programming
Program Group – Preset Speed Model Only
Min/Max
Range
P#
Parameter Description
61
[Preset Frequency 0]The programmed value sets the frequency that
Units
Factory
Default
0 to 240
0.1 Hz
3 Hz
0 to 240
0.1 Hz
20 Hz
0 to 240
0.1 Hz
30 Hz
0 to 240
0.1 Hz
40 Hz
0 to 240
0.1 Hz
45Hz
0 to 240
0.1 Hz
50 Hz
0 to 240
0.1 Hz
55 Hz
0 to 240
0.1 Hz
60 Hz
0.1 to 600
0.1 Sec.
20.0 Sec.
0.1 to 600
0.1 Sec.
20.0 Sec.
the controller outputs when selected.
62
[Preset Frequency 1]The programmed value sets the frequency that
63
[Preset Frequency 2]The programmed value sets the frequency that
the controller outputs when selected
the controller outputs when selected.
[Preset Frequency 3]The programmed value sets the frequency that
64
the controller outputs when selected.
[Preset Frequency 4]The programmed value sets the frequency that
65
the controller outputs when selected.
[Preset Frequency 5]The programmed value sets the frequency that
66
the controller outputs when selected.
[Preset Frequency 6]The programmed value sets the frequency that
67
the controller outputs when selected.
[Preset Frequency 7]The programmed value sets the frequency that
68
the controller outputs when selected.
[Accel Time 2]The programmed value sets the acceleration time for
69
P65
to P68 [Preset Frequencies 4-7]. The rate is linear for any increase in command
frequency unless P53 - [S-Curve] is set to a value other than 0 "
[Decel Time 2]The programmed value sets the deceleration time for P65
70
to P68 [Preset Frequencies 4-7]. The rate is linear for any decrease in command
frequency unless P53 - [S-Curve] is set to a value other than 0 "
=
This parameter applies only to the Preset Speed model
Preset Accel/Decel Chart For Preset Speed Model Only
TB3–
SW3
TB3–
SW2
TB3–
SW1
Preset
0
0
0
Preset 0
0
0
1
Preset 1
0
1
0
Preset 2
0
1
1
Preset 3
1
0
0
Preset 4
1
0
1
Preset 5
1
1
0
Preset 6
1
1
1
Preset 7
Refer to Figure 2.5 for the Preset Speed model control wiring diagram.
5–10
Accel
Decel
P30 -[Accel Time 1]
P31 - [Decel Time 1]
P69 - [Accel Time 2]
P70 - [Decel Time 2]
Troubleshooting and Fault Information
Chapter
6
Fault Information
Figure 6.1 - Fault Display
P07 - [Last Fault]
Fault Code NumberÀ
Fault LED - (Without Program Keypad
Module)
Controllers without a program keypad module
come equipped with a fault LED. When the fault
LED illuminates, a fault condition exists.
0 7
2 2
À See Table 6.A below for fault descriptions.
Controllers equipped with a program keypad
module will flash the display when a fault is
present. If a fault occurs, parameter 07 – [Last
Fault] displays. You can cross reference the
number that appears on the display (e.g., 22) with
the fault numbers listed in Table 6.A.
Tips To Clear a Fault
IMPORTANT:If a fault occurs, it is important to
address and correct the fault as well as the
condition that caused the fault.
To clear a fault, perform one of the following:
D Press the program keypad’s stop button.
D Cycle power to the controller.
D Cycle the TB3 stop input signal to the
controller .
D Set P54 – [Clear Fault] parameter to a “1”.
Table 6.A Bulletin 160 Fault Descriptions
Á
Á
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Á
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Á
Á
Á Á
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
Á Á Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
Á Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
Á
Á Á
ÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
Á Á
Á Á
Á
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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Fault
Number
Fault
Indication
Fault Description
03
Power Loss
Fault
DC Bus voltage remains below 85% nominal on
power up for longer than 5 seconds.
Monitor incoming AC line for low voltage or line power
interruption.
04
Under Voltage DC Bus voltage fell below the minimum. For
Fault
controllers rated at input voltage 200-240 VAC,
undervoltage trip occurs at 210 VDC bus voltage
(equivalent to 150 VAC incoming line voltage).
For controllers rated at input voltage 380-460
VAC, undervoltage trip occurs at 390 VDC bus
voltage (equivalent to 275 VAC incoming line
voltage).
Monitor incoming AC line for low voltage or line power
interruption.
05
Over Voltage
Fault
Bus overvoltage caused by motor regeneration. Monitor
incoming AC line for excessive voltage. Extend the
decel time or install dynamic brake module or external
capacitor module. See Appendix A.
DC Bus maximum voltage exceeded. For
controllers rated at input voltage 200-240 VAC,
overvoltage trip occurs at 410 VDC bus voltage
(equivalent to 290 VAC incoming line voltage).
For controllers rated at input voltage 380-460
VAC, overvoltage trip occurs at 815 VDC bus
voltage (equivalent to 575 VAC incoming line
voltage ).
Corrective Action
6–1
Chapter 6 - Troubleshooting and Fault Information
Table 6.A Bulletin 160 Fault Descriptions
(continued)
Fault
Number
Fault
Indication
Fault Description
Corrective Action
06
Motor Stall
Fault
Motor has stalled. Motor load is excessive.
07
Motor
Overload
Fault
Internal electronic overload trip. Excessive motor Reduce motor load until controller output current
does not exceed the current set by P42 - [Motor
load exists.
Overload Current]. Reduce P38 - [Boost Volts].
08
Over
Temperature
Fault
Excessive heat detected.
Clear blocked or dirty heat sink fins. Check ambient
temperature. Check for blocked or non-operating fan.
12
Overcurrent
FauIt
Overcurrent detected in hardware trip circuit.
Check short circuit at the controller output or excesĆ
sive load conditions at the motor.
22
Controller
Reset FauIt
Stop input not present.
Check stop connection at TB3, terminal 8.
32
EEPROM
Fault
EEPROM has invalid data.
Reset EEPROM using P56 - [Reset Defaults].
33
Max Retries
Fault
Controller failed to reset fault within the number
of retries set in P50 - [Restart Tries].
Repair system fault.
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Longer acceleration time or a reduced load required.
38
Phase U Fault Phase to ground fault detected between
controller and motor in phase U.
Check the wiring between the controller and motor.
Check motor for grounded phase.
39
Phase V Fault Phase to ground fault detected between
controller and motor in phase V.
Check the wiring between the controller and motor.
Check motor for grounded phase.
40
Phase to ground fault detected between
controller and motor in phase W.
Check the wiring between the controller and motor.
Check motor for grounded phase.
41
UV Short
Fault
Excessive current has been detected between
these two controller output terminals.
Check the motor and external wiring to the controller
output terminals for a shorted condition.
42
UW Short
Fault
Excessive current has been detected between
these two controller output terminals.
Check the motor and external wiring to the controller
output terminals for a shorted condition.
43
VW Short
Fault
Excessive current has been detected between
these two controller output terminals.
Check the motor and external wiring to the controller
output terminals for a shorted condition.
46
Power Test
Fault
Fault detected during initial startĆup sequence.
Check controller wiring. Check motor wiring.
48
6–2
Phase W
Fault
Reprogram
Fault
Occurs when controller parameters are reset to
defaults.
Clear fault.
Chapter 6 - Troubleshooting and Fault Information
Table 6.B Troubleshooting
Problem
Motor does not start
(No output voltage to motor).
Corrective Action
1. Check power circuit.
D
Check supply voltage.
D
Check all fuses and disconnects.
2. Check motor.
D
Verify that motor is connected properly.
3. Check control input signals.
D
Verify that START signal is present.
D
Verify that STOP signal is present.
D
Verify that RUN FORWARD and RUN REVERSE signals are NOT both active.
4. Check P46 - [Input Mode Select].
D
Controller Started but motor
NOT rotating.
(P01 - [Output Frequency]
displays 0.0 " ).
If P46 - [Input Mode Select] is set to 2 " , only the program keypad module Start button will start
the motor.
1. Check motor.
D
Verify that motor is connected properly.
2. Check frequency source P06 - [Frequency Command].
D
Verify that frequency signal is present at terminal block TB3.
-10Ć +10V signal
4-20 mA signal
D
Verify that Preset Frequencies are set properly.
3. Check control input signals.
D
Verify that SW1, SW2 and SW3 are correct. (Refer to the chart at the end of Chapter 5).
4. Check parameter settings.
D
Motor not accelerating properly.
Verify that P59 - [Freq Select] is showing desired frequency source.
D
Verify that P58 - [Internal Frequency] is the desired value.
1. Check motor.
D
Verify that motor is connected properly.
D
Verify that no mechanical problems exist.
2. Check parameter settings.
D
D
Verify that P43 - [Current Limit] is set properly.
D
Can not operate in RUN FWD/
RUN REV " mode.
Verify that P30 - [Accel Time 1] or P69 - [Accel Time 2] is set properly.
Verify that P38 - [Boost Volts] is set properly.
1. Verify that P46 - [Input Mode Select] is set to 1 " .
2. Verify that power has been cycled for above change to take effect.
3. Verify that both RUN FORWARD and RUN REVERSE switches are NOT closed simultaneously.
6–3
Chapter 6 - Troubleshooting and Fault Information
Block Diagram of Bulletin 160 Analog
Signal Follower
Brake Module
BR+
Capacitor Module
BR-
DC+
DC-
L1/R
L2/S
T2/V
L3/T
F
r
e
q
u
e
n
c
y
T1/U
T3/W
R
e
f -10 to +10V
e or
Potentiometer
r
e
n or
c
4 - 20 mA
e
Reverse
Start
Stop
Common
6–4
GND/PE
TB3 - 1
Control
Power
TB3 - 2
Bus
Voltage
Circuitry
TB3 - 3
(Common)
Motor
GND/PE
Current
Circuitry
Fault Feedback
TB3 - 4
Program Keypad
Module
CPU
TB3 - 5
TB3 - 6
TB3 - 8
TB3 - 7
Opto
Isolator
Relay
Circuitry
TB3 - 9
Customer
TB3 - 10 Programmable
Output
TB3 - 11
Appendix A - Specifications and Accessories
Controller Specifications
Tables A.1 and A.2 contain information that is unique to each SSC™ Controller rating. Table A.3
contains information that applies to all Controller ratings.
Table A.1 - Specifications for Controllers Rated 200 - 240V Single and Three Phase Input
Controller Catalog Number
Single Phase (input)
160S-AA02
160S-AA03
160S-AA04
160S-AA08
Three Phase (input)
160-AA02
160-AA03
160-AA04
160-AA08
160-AA12
0.37 (1/2)
0.55 (3/4)
0.75 (1)
1.5 (2)
2.2 (3)
Output Current (A) Max
2.3
3.0
4.5
8.0
12.0
Power Dissipation (Watts)
20
25
40
70
105
Output Ratings
3 Phase Motor Rating kW (HP)
Input Ratings
Input Voltage, Frequency
200/240V Single Phase and Three Phase, 50/60 Hz
Operational Range (V)
180Ć265V
Input kVA
1.1
1.4
2.2
3.7
5.7
Environmental Specifications
Cooling Method
AC Dynamic Braking Torque
Convection Cooled
Fan Cooled
À
With external Dynamic Brake Module (%)
300
233
200
150
115
Without external Dynamic Brake Module (%)
100
100
100
50
50
Table A.2 - Specifications for Controllers Rated 380 - 460V Three Phase Input
Controller Catalog Number
Three Phase (input)
160-BA01
160-BA02
160-BA03
160-BA04
160-BA06
0.37 (1/2)
0.55 (3/4)
0.75 (1)
1.5 (2)
2.2 (3)
Output Current (A) Max
1.2
1.7
2.3
4.0
6.0
Power Dissipation (Watts)
25
30
40
65
80
Output Ratings
3 Phase Motor Rating kW (HP)
Input Ratings
Input Voltage, Frequency
380/460V Three Phase, 50/60 Hz
Operational Range (V)
Input kVA
340-506V
1.1
1.6
2.2
3.7
5.7
Environmental Specifications
Cooling Method
Convection Cooled
Fan Cooled
AC Dynamic Braking Torque À
With external Dynamic Brake Module (%)
À
300
233
200
150
115
Without external Dynamic Brake Module (%)
100
100
100
50
50
Estimated. Actual value depends on motor characteristics.
A–1
Appendix A -Specifications and Accessories
Table A.3 - Specifications For All Controller Ratings
Input/Output Ratings (All Controller Ratings)
Output Voltage (V)
Adjustable from 0V to input voltage
Output Frequency (Hz)
0 to 240 Hertz Programmable
Efficiency (%)
Transient Protection
97.5% (Typical)
Standard 2 kV (Optional 6 kV using MOV module). See accessories on page A-5.
Environmental Specifications (All Controller Ratings)
Enclosure
IP 20
Ambient Temperature
0_C to 50_C
Storage Temperature
Ć40_C to 85_C
Relative Humidity
0 to 95% (non condensing)
Vibration
1.0 G Operational - 2.5 G Non-operational
Shock
15 G Operational - 30 G Non-operational
Altitude
1,000 m (3,300 ft.) without derating
Control Inputs (All Controller Ratings)
Control Input Type
For dry contact closure input - the controller has an internal 12V power supply that provides
10-mA (typical) current flow.
Also accepts open collector/solid state input with maximum leakage current of 50 mA
Start, Stop, Forward/Reverse
Configurable inputs for 2 or 3 wire control
SW1, SW2, SW3
(Preset Speed Model only)
Configurable Inputs for control of 8 preset speeds and 2 Accel/Decel times
Approvals and Standards Compliance (All Controller Ratings)
UL508C
Designed to meet these standards
CSA 22.2
ÎÎÎ
ÎÎÎ
Î
ÎÎÎÎ
ÎÎÎÎ
Î
Î
ÎÎÎÎ
ÎÎÎ
Approvals
89/336/EECÀ
IEC 146-1-1
FCC Class AÀ and BÀ
VDE 0871À and 0875À
Control Inputs (Analog Signal Follower only -All Controller Ratings)
External Speed Potentiometer
Analog Input (4 to 20mA)
Analog Input (-10 to +10 V DC)
1K to 10K Ohms, 2 Watts Minimum
Input lmpedance 250 Ohms
Input Impedance 100 K Ohms
Control Output (All Controller Ratings)
Programmable Output
(Form C Relay contact)
À
With external filters.
A–2
Resistive rating: 0.4A @125V AC, 0.2A @ 230 V AC, 2A @ 30V DC
Inductive rating: 0.2A @ 125V AC, 0.1A @ 230V AC, 1A @30V DC
Appendix A - Specifications and Accessories
Table A.3 - Specifications For All Controller Ratings (continued)
Control Features (All Controller Ratings)
PWM Algorithm
Sine Weighted PWM with Harmonic Compensation
Switching Device (3-Phase Output)
IGBT (Intelligent Power Module)
V/Hz Ratio
Programmable
Carrier Frequency
Adjustable from 2kHz to 8kHz in 100 Hz Increments (Factory default is 4 kHz)
DC Boost
Adjustable - Select from a family of Boost Curves
Current Limiting
Trip Free Operation, CoĆordinated for Controller and Motor Protection - Programmable from
20% to 190% of Controller Output Current
Motor Protection
I2t Overload Protection - 150% for 60 seconds, 200% for 30 seconds
Overload Pattern #0
Flat response over speed range (no speed compensation)
Overload Pattern #1
Speed compensation below 25% of Base Speed
Overload Pattern #2
Speed compensation below 100% of Base Speed
Acceleration/Deceleration Time(s)
0.1 to 600 Seconds
S-Curve Accel/Decel Time(s)
0 to 100% of Accel/Decel time - not to exceed 60 seconds
Stopping Modes
3 modes (programmable)
Ramp to stop
0.1 to 600 seconds
Coast
Stops all PWM Output
DC Brake to stop
Applies DC Voltage to the Motor for 0 to 15 seconds
Protective Features (All Controller Ratings)
Overcurrent
Excessive Temperature
Over/Under Voltage
Control Ride Through
Ground Short
Faultless Ride Through
Output Short Circuit
200% hardware limit, 300% instantaneous fault
Embedded temperature sensor trips if heatsink temperature exceeds 95°C
DC Bus voltage is monitored for safe operation.
For controllers rated at input voltage 200-240 VAC, overvoltage trip occurs at 410 VDC bus
voltage (equivalent to 290 VAC incoming line voltage).
For controllers rated at input voltage 380-460 VAC, overvoltage trip occurs at 815 VDC bus
voltage (equivalent to 575 VAC incoming line voltage ).
For controllers rated at input voltage 200-240 VAC, undervoltage trip occurs at 210 VDC bus
voltage (equivalent to 150 VAC incoming line voltage).
For controllers rated at input voltage 380-460 VAC, undervoltage trip occurs at 390 VDC bus
voltage (equivalent to 275 VAC incoming line voltage).
Minimum ride through is 0.5 seconds - typical value 2 seconds
Any output short to ground, detected prior to start
100 Milliseconds
Any output phase to phase short
Programming (All Controller Ratings)
Programmer
Optional, Removable Program Keypad Module
Type of Display
6 character LED - two digit parameter number and four digit value
Local Controls
SPEED, RUN, STOP, and DIRECTION controls
A–3
Appendix A -Specifications and Accessories
Figure A.1 - Controller Dimensions
Controllers Rated 200 - 240V Single Phase
Overall
Dimensions
H mm (inches)
W mm (inches)
D mm (inches)
Weight Kg. (lbs.)
160S
AA02
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160S
AA03
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160S
AA04
152 (6.00)
72 (2.83)
136 (5.4)
0.9 (1.98)
160S
AA08À
152 (6.00)
72 (2.83)
136 (5.4)
0.9 (1.98)
Controllers Rated 200 - 240V 3 Phase
Overall
Dimensions
H mm (inches)
W mm (inches)
D mm (inches)
Weight Kg. (lbs.)
160
AA02
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160
AA03
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160
AA04
152 (6.00)
72 (2.83)
136 (5.4)
0.9 (1.98)
160
AA08
152 (6.00)
72 (2.83)
136 (5.4)
0.9 (1.98)
160
AA12
152 (6.00)
130 (5.12)
136 (5.4)
1.1 (2.46)
H
Controllers Rated 380 - 460V 3 Phase
Overall
Dimensions
H mm (inches)
W mm (inches)
D mm (inches)
Weight Kg. (lbs.)
À
160
BA01
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160
BA02
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.76)
160
BA03
152 (6.00)
72 (2.83)
136 (5.4)
0.8 (1.98)
160
BA04
152 (6.00)
72 (2.83)
136 (5.4)
0.9 (1.98)
160
BA06
152 (6.00)
130 (5.12)
136 (5.4)
1.1 (2.46)
External capacitor modules are provided with this model and mount
separately.
Use the drilling template at the back of the manual for mounting the controller.
A–4
Appendix A - Specifications and Accessories
Accessories
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For All Controller Ratings – 0.37 to 2.2kW (1/2 to 3 HP)
Controller Ratings
Input
Voltage
Rating
200-240V
50/60Hz
1 Phase
200-230V
50/60Hz
3 Phase
380-460V
50/60Hz
3 Phase
À
Dynamic
Brake
Module
MOV
Module
Line Reactors
Open Style
Line Filters
Capacitor
Module
HP
kW
Cat. No.
Cat. No.
Cat. No.
Cat. No.
Cat. No.
1/2
3/4
1
2
1/2
3/4
1
2
3
1/2
3/4
1
2
3
0.37
0.55
0.75
1.5
0.37
0.55
0.75
1.5
2.2
0.37
0.55
0.75
1.5
2.2
160-BMA1
160-BMA1
160-BMA1
160-BMA2
160-BMA1
160-BMA1
160-BMA1
160-BMA2
160-BMA2
160-BMB1
160-BMB1
160-BMB1
160-BMB2
160-BMB2
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMA1
160-MMB1
160-MMB1
160-MMB1
160-MMB1
160-MMB1
1321-3R4-A
1321-3R4-A
1321-3R8-A
1321-3R8-A
1321-3R18-A
1321-3R2-B
1321-3R2-B
1321-3R4-B
1321-3R4-B
1321-3R8-B
160S-LFA1
160S-LFA1
160S-LFA1
160S-LFA1
160-LFA1
160-LFA1
160-LFA1
160-LFA1
160-LFA2
160-LFB1
160-LFB1
160-LFB1
160-LFB1
160-LFB1
160-CMA1
160-CMA1
160-CMA1
À
160-CMA1
160-CMA1
160-CMA1
160-CMA1
160-CMA1
160-CMB1
160-CMB1
160-CMB1
160-CMB1
160-CMB1
Included with controller.
Replacement Parts and Accessories
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
Á
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Á
Á
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
For Controller Ratings – 0.37 to 2.2kW (1/2 to 3 HP)
Fan Replacement Kit
Ready/Fault Panel
Program Keypad Module
DeviceNet Communication
Module
Cat. No.
Cat. No.
Cat. No.
Cat. No.
160-FRK1
160-B1
160-P1
160-DN1
A–5
Appendix A -Specifications and Accessories
Notes:
A–6
Index
Numbers
50 Hz dipswitch, 3-2
60 Hz dipswitch, 3-2
A
AC input wiring, 2-4
accel/decel control, 5-4, 5-10
ambient temperature, A-2
analog input
-10 to +10V, 2-5
0-10V, 2-5
4-20mA, 2-5
analog scale teach, 5-9
approvals, CE, CUL, UL, A-2
auto restart
restart time, 5-8
restart tries, 5-8
D
DB enable, 5-8
DC brake to stop, 5-4, 5-6
DC hold level, 5-6
defaults, resetting to, 5-9
determining controller information, 1-2
diagnostics, 5-2, 6-2, 6-3
dimensions, 2-1
display group, 5-2
parameters, 5-2
controller features, 2-2
controller specifications, A-1
dynamic brake, connection, 2-4
dynamic brake resistor, 2-4
E
effects, long motor cable lengths, 2-3
electrostatic discharge, 1-1, 3-2
F
B
block diagram, 6-4
branch circuit disconnect, 2-4
C
capacitor module, connecting, 2-4
carrier frequency, pwm, 5-8, A-3
catalog number description, 1-2
CE, A-2
changing base frequency, from factory default, 3-2
clearing, fault, 6-1
clearing faults, 5-9
control wiring
Analog Signal Follower model, 2-5
Preset Speed model, 2-5
control wiring requirements
Analog Signal Follower model, 2-5
Preset Speed model, 2-5
CUL, A-2
current limiting, 5-6
current rating, 1-2
fan/pump volts/Hz patterns, 5-5
fault buffer, 5-2
fault information, troubleshooting, 6-1
fault LED, 6-1
faults, clearing, 6-1
frequency dipswitch, 3-2
frequency source selection
Analog Signal Follower model, 2-5, 5-9
Preset Speed Model, 5-10
Preset Speed model, 2-5
fusing, AC Input, 2-4
G
general precautions, 1-1
grounding, 2-5
I
input mode selection, 2-5, 5-7
installation, recommendations, 2-3
installation precautions, 2-1
installing controller, 2-1
installing the controller, 2-1
I–1
Index
M
min/max frequency, 5-4
minimum clearance, 2-1
motor cable lengths, effects, 2-3
R
recommendations, for controller installation, 2-3
resetting, to factory defaults, 5-9
reverse, 2-5, 3-1
S
N
nameplate information, 1-2
O
operating controller, without program keypad module, 2-2
operating controller without keypad, 2-2
output contacts, 2-5, 5-7
output disconnection, 2-4
output ratings, 1-2
200-240V single phase, A-1
380-460V three phase, A-1
overload protection, 2-4, 5-6
P
parameters
display group, 5-2
display only, 5-2
program group, 5-4
potentiometer wiring, 2-5
power, wiring, 2-4
precautions, 1-1
preset frequencies, 2-5
preset frequency, 5-10
program group, parameters, 5-4
program keypad module
description, 3-1
display mode, 3-1
features, 3-1
key descriptions, 3-1
program mode, 3-1
removal, 3-2
program lock, 5-9
program mode, 3-1
programming, 3-1, 5-1
example, 5-1
steps, 5-1
programming parameters, 5-1
I–2
S-curve, 5-8
skip frequency, 5-5
specifications, protection, A-3
specifications 200-240V single phase
environmental, A-1
input/output ratings, A-1
specifications 380 - 460V three phase, input/output ratings,
A-1
specifications 380-460V three phase, environmental, A-1
specifications for all controller ratings, environmental, A-2
standards compliance, CSA, EEC, FCC, IEC, UL, VDE, A-2
start, 2-5, 3-1
stopping, 2-5, 3-1
storage temperature, 2-1, A-2
T
terminal blocks
one and three, 2-4
TB1, 2-2, 2-4
TB2, 2-2, 2-4
TB3, 2-2, 2-4, 2-5
torque ratings, A-1
troubleshooting, 6-3
fault descriptions, 6-1
U
UL, A-2
V
vibration, A-2
voltage rating, 1-2
W
wiring
control and signal, 2-5
fuse requirements, 2-4
input line fuses, 2-4
power, 2-4
terminal blocks, 2-4
Attach template to mounting surface
and drill four (4) 4.5 mm (0.177 inches) diameter holes.
Dimensions are in millimeters [inches].
AllenĆBradley, a Rockwell automation business, has been helping its customers improve productivity and quality for
more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They
include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software.
Rockwell is one of the world's leading technology companies.
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AllenĆBradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382Ć2000 Fax: (1) 414 382Ć4444
Publication 0160-5.0 - July 1997
Supersedes Publication 0160Ć5.0 - February 1996 and 0160-5.0-DU - June, 1996
40055Ć141Ć01(D)
Copyright 1997 AllenĆBradley Company, Inc., a Rockwell International company Printed in USA
I-1