60 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.
Important User Information Solid-State equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid-State Controls” (Publication SGI-1.1) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
S-1 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.
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.
Table of Contents Getting Started Important Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Receiving Your New Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Inspecting . . . . . . . . . . . . . . . . . . .
ii Program Keypad Module Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Key Functions . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1 Getting Started 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. ATTENTION: The drive contains high voltage capacitors which take 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.
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.
Getting Started 1-3 Nameplate The nameplate is located on the side of the drive. Nameplate Information Figure 1.2 Catalog Number 160-AA02NSF1P1 ANALOG S.F. Motor Rating: I N P U T SERIES C FRN: 7.XX Series Letter Firmware Version Drive Model 0.37KW / 0.5 HP V: 200-240 A: 2.8 Hz: 50/60 VA: 1100 3 Ø O V: 200-230 U T A: 2.
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 Hinged Finger Guard R/L1 S/L2 T/L3 BR– BR+ FAULT Ready/Fault Indicating Panel READY Status LEDs 1 2 3 4 5 6 7 8 9 10 11 DC Bus Test Points U/T1 V/T2 W/T3 DC– DC+ Hinged Finger Guard Cooling Fan Cooling Air Flow DIN Latch • Hinged Finger Guard allows easy access to line/load power terminals.
Getting Started 1-5 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.
1-6 Getting Started End of Chapter
Chapter 2 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.
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.
Installation and Wiring 2-3 Terminal Block Wiring Terminal Block Wiring Detail Figure 2.2 Required Branch Circuit Disconnect ➊ Branch Circuit Protective Device ➋ Terminal Block TB1 R/L1 S/L2 T/L3 BR– BR+ Ground Terminal/Protective Earth U/T1 V/T2 W/T3 DC– DC+ Terminal Block TB2 Motor ➌ Specifications Terminal Block TB1 and TB2 Wiring Specifications Model Screw Size 4.0 kW (5 HP) All Other Ratings M4 M4 Max./Min. Wire Size ➍ mm2 (AWG) 5.26 – 3.31 (10 – 12) 3.31 – 0.82 (12 – 18) Table 2.A Max.
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.
Installation and Wiring 2-5 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.
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.
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).
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.
Installation and Wiring 2-9 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.
2-10 Installation and Wiring Control Wiring Considerations Wiring Diagram Key Shielded Wire N.O. Momentary Contact N.C. Momentary Contact N.O. Maintained Contact N.C. Maintained Contact 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. TB3 5 ➊➋➌ 6 ➊➋➌ 7 ➍ 8 ➋ ➊ Run input must be maintained.
Installation and Wiring 2-11 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.
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 5 Reverse 6 Start ➊ 7 Common 8 Stop Note: A contact closure on terminals 7 and 8 is required for the controller to respond to a Start/Run command. ➊ Start input can be a momentary input.
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”.
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.
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.
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 1 +10V 2 SW1 3 Common 4 4 – 20 mA input ➊ 5 Run Reverse 6 Run Forward 7 Common 8 SW2 ➋ TB3-2 and TB3-8 See Table 2.
Installation and Wiring 2-17 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 TB3 TB3 3 Common 4 2 0 – 10V DC 4 – 20 mA 3 Common 5 ➊ 6 Run Forward 7 Common 8 OR PI/Internal Frequency ➋ TB3-8 Open PI TB3-8 Closed Internal Frequency Refer to Chapter 5, 160 PI Control Setup for a detailed PI Control Setup description.
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.
Installation and Wiring ±10V or 0 – 10V DC Frequency Control/Speed Control 2-19 Figure 2.17 TB3 2 ±10V or 0 – 10V DC If calibration is required, use parameters 16, 59, 60, 74, 75, 76 3 Common Controller Input Impedance = 100k Ohms 4 – 20 mA Frequency Control/Speed Control Figure 2.18 TB3 3 Common If calibration is required, use parameters 16, 59, 60, 74, 75, 76 4 4 – 20 mA Controller Input Impedance = 250 Ohms Potentiometer Frequency Control/Speed Control Figure 2.
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 frequency factory default settings and switch configurations. A program keypad module is required to change the factory default settings. TB3 Control Wiring for Preset Speed Model Figure 2.
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.
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.
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.
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.
Chapter 4 Start-Up 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. ATTENTION: Power must be applied to the drive to perform the following start-up procedure.
4-2 Start-Up continued from previous page Program Keypad Module, Remote Keypad Module or CopyCat Keypad Module Procedure Ready/Fault Indicating Panel Procedure The green Ready indicator will illuminate. Use inputs to TB3 to operate the drive. P01- [Output Frequency] will display. If drive has been previously powered up, a different parameter may display.
Chapter 5 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.
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.
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 01 Min./Max. Range 0.0/240.
5-4 Parameters and Programming Display Group (Read Only) No. Parameter Name/Description 12 [Input Status] Min./Max. Range 0000/1111 Units Binary Number 0.0/180.0 0.1 degrees Numeric Value Numeric Value Preset – 0000/0111 Binary Number Displays the open (0) and closed (1) state of the inputs to TB3 in binary coded format as follows: Input Mode 0 (3-Wire) Input Mode 1 (2-Wire) Input Mode 2 (Keypad) Input Mode 3 (Mom. Run Fwd./Rev.
Parameters and Programming Display Group (Read Only) No. Parameter Name/Description 17 5-5 Min./Max. Range Units 0/48 Numeric Value [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].
5-6 Parameters and Programming Program Group No. Parameter Name/Description 31 [Decel Time 1] Min./Max. Range ➊/600.0 Units 0.1 Seconds Factory Default 10.0 Seconds 0/240 1 Hz 0 Hz 0/240 1 Hz 60 Hz 0/3 Numeric Value 0 10/240 1 Hz 60 Hz 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. ➊ Minimum deceleration time must be set based on the applied motor size.
Parameters and Programming 5-7 Program Group No. Parameter Name/Description 38 [Boost Select] Min./Max. Range 0/12 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. Setting 1/2 Base Volts 50 9 10 11 12 1/2 Base Freq.
5-8 Parameters and Programming Program Group No. Parameter Name/Description 41 [Motor Overload Select] Min./Max. Range 0/2 Bulletin 160 provides Class 10 overload protection. Settings 0 – 2 select the derating factor for the I2t overload function. Setting 0 1 2 Derate Level No Derate Min. Derate Max.
Parameters and Programming 5-9 Program Group No. Parameter Name/Description 45 [DC Hold Voltage] Min./Max. Range 0/115 Units 1 Volt Factory Default 0 Volts 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.
5-10 Parameters and Programming Program Group No. Parameter Name/Description 47 [Output Configure] Min./Max. Range 0/10 Configures the TB3 relay output functionality. Setting 0 Drive Ready/Faulted 48 1 2 3 4 5 At Frequency Motor Running Reverse Motor Overload Ramp Regulated 6 Above Frequency 7 Above Current 8 Above DC Bus Voltage 9 10 Retries Exhausted Above Power Factor Angle 0 0/815 Numeric Value 0 2.0/8.0 0.1 kHz 4.
Parameters and Programming 5-11 Program Group No. Parameter Name/Description 51 [Restart Time] Min./Max. Range 0.0/300.0 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.
5-12 Parameters and Programming Program Group No. Parameter Name/Description 54 [Clear Fault] Min./Max. Range 0/1 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 56 Units Numeric Value Factory Default 0 Used by Rockwell Automation field service personnel.
Parameters and Programming 5-13 Program Group No. Min./Max. Range 0.0/240.0 Parameter Name/Description [Preset Frequency 0-7] Units 0.1 Hz Factory Default See Table 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. Preset Speed Model Only Signal Follower Model Only (Input Mode 8) Preset Freq. Default TB3-4 (SW3) TB3-2 (SW2) TB3-1 (SW1) TB3-8 (SW2) TB3-2 (SW1) 61 Preset 0 3.
5-14 Parameters and Programming Program Group No. Parameter Name/Description 71 [IR Compensation] Min./Max. Range 0/150 Units Factory Default 1% 50% 0.0/5.0 0.1 Hz 2.0 Hz 0/1 Numeric value 0 0/1 Numeric value 0 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.
Parameters and Programming 5-15 Program Group No. Parameter Name/Description 75 [Analog Input Minimum] Min./Max. Range 0.0/150.0 Units 0.1% Factory Default 0.0% 0.0/150.0 0.1% 100.0% 0 to 2 Numeric value 0 0/50% 1% 0% 0/5 Numeric Value 0 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.
5-16 Parameters and Programming Program Group No. Parameter Name/Description Min./Max. Range 81 [PI Proportional Gain] 0/10.00 Numeric Value 0.01 0/10.00 Numeric Value 0.01 0/100.0% 0.1% 0.0% 0/10.0% 0.1% 0.0% 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%.
Parameters and Programming 5-17 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).
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.
Parameters and Programming 5-19 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.
5-20 Parameters and Programming End of Chapter
Chapter 6 Troubleshooting 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 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. Ready/Fault Indicating Panel FAULT READY Figure 6.
6-2 Troubleshooting Bulletin 160 Fault Descriptions Fault No. Fault Name 03 Power Loss Fault 04➊ UnderVoltage Fault 05➊ OverVoltage Fault 06➊ Table 6.A Fault Description Corrective Action Monitor the incoming AC line for low voltage or line power interruptions. Monitor the incoming AC line for low voltage or line power interruptions. Motor Stall Fault The DC Bus voltage remains below 85% nominal on power up for longer than 5 seconds. The DC Bus voltage fell below the minimum rated voltage.
Troubleshooting Possible Problems and Corrective Actions Problem The motor does not start — No output voltage to the motor. 6-3 Table 6.B Corrective Action 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.
6-4 Troubleshooting Block Diagram of Bulletin 160 Analog Signal Follower Brake Module BR+ BR- Figure 6.
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 3-Phase Input 160S-AA02 160S-AA03 160S-AA04 160S-AA08 — 160-AA02 160-AA03 160-AA04 160-AA08 160-AA12 — 160-AA18 Output Ratings 3-Phase Motor Rating — kW (HP) Maximum Output Amps Power Dissipation — Watts 0.37 (1/2) 2.3 20 0.
A-2 Specifications All Drive Ratings Table A.3 Input/Output Ratings Output Voltage Output Frequency Efficiency Transient Protection Adjustable from 0 to Input Voltage Programmable from 0 to 240 Hz 97.5% Typical Standard 6 kV Environmental Specifications Enclosure Ambient Temperature Storage Temperature Relative Humidity Vibration Shock Altitude IP20 0°C to 50°C –40°C to 85°C 0 to 95% Non-Condensing 1.0 G Operational — 2.
Specifications Control Features PWM Algorithm Switching Device V/Hz Ratio Carrier Frequency DC Boost Current Limiting A-3 Motor Protection Sine Weighted PWM with Harmonic Compensation IGBT Programmable Adjustable from 2 to 8kHz in 100 Hz Increments (Factory Default is 4kHz) Adjustable — Select from a Family of Boost Curves Software Controlled, Coordinated for Drive and Motor Protection — Programmable from 1 to 180% of Drive Output Current I2t Overload Protection — 150% for 60 Seconds, 200% for 30 Seconds
A-4 Specifications End of Chapter
Appendix B Accessories and Dimensions Accessories for All Drive Ratings Drive Ratings Dynamic Brake Module HP Catalog No. 200-240VAC 0.37 50/60 Hz 0.55 1-Phase 0.75 1.5 1/2 3/4 1 2 — — 200-230VAC 0.37 50/60 Hz 0.55 3-Phase 0.75 1.5 2.2 4.0 1/2 3/4 1 2 3 5 380-460VAC 0.37 50/60 Hz 0.55 3-Phase 0.75 1.5 2.2 4.0 1/2 3/4 1 2 3 5 Input Voltage kW Ready/Fault Panel Catalog No. 160-B1 160-BMA1 160-BMA2 160-BMA2 160-BMA2 ➏ — — 160-BMB1 160-BMB2 160-BMB2 160-BMB2 ➏ Program Keypad Module Catalog No.
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 72 (2.83) 86.4 (3.4) 14 (0.55) 50 (1.97) 7.5 (0.3) WARNING B A DANGER – + GND BR BR DANGER 6.86 (0.27) Mounting Holes – 4 Places – – + GND BR BR 29 (1.14) 8 (0.315) Catalog No. 160-BMA1 & 160-BMB1 160-BMA2 & 160-BMB2 A 245 (9.64) 334 (13.15) B 225 (8.86) 314 (12.36) Bulletin 1321 Line Reactors Figure B.
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 B C E G (2) H A D F (2) Line Filter Module A B C D E F G 160S-RFA-9-A 182.0 (7.17) 75.0 (2.95) 37.5 (1.47) 163.0 (6.42) 60.0 (2.36) 182.0 (7.17) 75.0 (2.95) 47.5 (1.87) 163.0 (6.42) 60.0 (2.36) M4.5 x 6.5 (0.18 x 0.26) obround hole (2 places) M4.5 x 6.5 (0.18 x 0.
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 50 (1.97) 110.9 (4.37) 40 (1.57) 4.5 (0.18) Mounting Holes – 4 Places – 60 (2.36) CAT SER 140 (5.51) 130 (5.12) 150.9 (5.94) MADE IN U.S.A 254 (10) – Approximate Lead Length – CAT MADE IN U.S.
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) 17.34 (0.68) Required for Removal 80 (3.15) Figure B.5 187.1 (7.37) 60 (2.36) TM CONFORMANCE TESTED 150.9 (5.94) 193.69 (7.63) 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 4 Mounting Holes 4.5 (0.18) Figure B.7 W D 60 (2.36) 60 (2.36) 130 (5.12) 83.43 (3.28) H 28.29 (1.11) 60 (2.36) 9.42 (0.37) 101.85 (4.01) Drive Dimensions and Weights Table B.4 200-240VAC — 1-Phase Drive H 160S-AA02 152 (6.00) 160S-AA03 152 (6.00) 160S-AA04 152 (6.00) W 80 (3.15) 80 (3.15) 80 (3.15) D 165 (6.51) 165 (6.51) 165 (6.
Accessories and Dimensions B-7 All dimensions are millimeters and (inches), all weights are kilograms and (pounds). Reference Diagram B 4 Mounting Holes 5.54 (0.22) Figure B.8 W D 81 (3.19) 60 (2.36) 129.74 (5.11) 180 (7.09) 111.43 (4.39) H 39.02 (1.54) 60 (2.36) Drive Dimensions and Weights Table B.5 200-240VAC — 1-Phase Drive H 160S-AA08 193 (7.58) W 92 (3.62) D 193 (7.61) Weight 2.37 (5.23) 200-240VAC — 3-Phase Drive H 160-AA18 193 (7.58) W 92 (3.62) D 193 (7.61) Weight 2.37 (5.
B-8 Accessories and Dimensions Drive Mounting Hole Dimensions Figure B.9 92 (3.62) 81 (3.19) 80 (3.15) 73 (2.87) 60 (2.36) 60 (2.36) 10.5 (0.41) 6.5 (0.26) 5.5 (0.22) Mounting Holes—2 Places 5.5 (0.22) Mounting Holes—2 Places 192.5 (7.58) 143 (5.63) 140 (5.51) 130 (5.12) 4.5 (0.18) 60 (2.36) 180 (7.09) 150.9 (5.94) 171 (6.73) 5 (0.20) 5.5 (0.22) 60 (2.36) 6.3 (0.25) This illustration depicts the mounting hole placements for the drives listed below.
Accessories and Dimensions Drilling Template A B-9 Figure B.
B-10 Accessories and Dimensions Drilling Template B Figure B.
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.
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.
CE Conformity C-3 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. Motor Cable • The cable between the drive and motor must be a 4-wire shielded cable (three phases and ground).
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 Stranded Copper Wire Plastic Insulation Inner Plastic Sheath Compact Screen of Galvanized (Tinned) Copper or Steel Outer Plastic Jacket • 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.
CE Conformity C-5 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.
C-6 CE Conformity End of Chapter
Index Symbols ±10V DC control 2-19 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 Numerics 12V internal power supply 2-9 24V DC interface module B-5 4 – 20 mA control 2-19 A B C 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 freque
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 G I K L M N O 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
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 Frequ
Index-4 W 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 Supersedes 0160-5.15 – January 1999, 0160-5.15DU3 – June 1999, 0160-5.15DU4 – November 1999 P/N 194456 (02) Copyright 2000 Rockwell International Corporation. All rights reserved. Printed in USA.
