Rockwell Automation Allen-Bradley 160 SSC Series Bedienungsanleitung

160 SSC™

Variable Speed

Drive

(Series C)

0.37–4.0 kW (0.5–5 HP)

FRN 7.03

FRN 7.04

FRN 7.05

FRN 7.06

User Manual

Important User Information

Solid-State equipment has operational characteristics differing from those of

electromechanical equipment.

“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. Because of this difference, and also because of the wide

variety of uses for solid-state equipment, all persons responsible for applying this

equipment must satisfy themselves that each intended application of this equipment

is acceptable.

In no event will Rockwell Automation be responsible or liable for indirect or

consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative

purposes. Because of the many variables and requirements associated with any

particular installation, Rockwell Automation cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation with respect to use of

information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written

permission of Rockwell Automation is prohibited.

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

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Important:

Identiﬁes information that is especially important for successful

application and understanding of the product.

SSC is a trademark of Rockwell Automation, Inc.

ATTENTION:

Identiﬁes information about practices or

circumstances that can lead to personal injury or death, property

damage or economic loss.

Shock Hazard

labels located on or inside the drive indicate that

dangerous voltage may be present.

S-1

•

New Horsepower Ratings

4 kW (5 HP), 230V and 460V ratings have

been added to the Bulletin 160 family.

•

Increased Transient Protection

Standard input voltage transient protection

has been increased to 6 kV and contained

in the drive itself. The optional MOV

module is no longer required.

•

Improved Ground Fault Protection

The Bulletin 160 detects phase-to-phase

and phase-to-ground faults both at start-up

and while running.

•

Reduced 2.2 kW (3 HP) Footprint

2.2 kW (3 HP), 230V and 460V width has

been reduced by more than 45%.

•

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

Unit

The external capacitor module has been

integrated into the 1.5 kW (2 HP), 230V

single phase unit. The overall width of the

unit is reduced, however, the height,

depth, and mounting hole pattern has

changed.

•

Improved Start/Stop Overlap Timing

The STOP command can be removed up

to 20 msec after a START command and

the drive will still recognize the START

command. This allows the drive to

respond to a START command occurring

concurrently with or slightly after a STOP

command is removed.

•

Additional Fault History

P17

P18

, and

P19 - [Fault Buffer 0, 1 and 2]

have been added to record the last three

faults for diagnostic purposes.

•

Analog Model with Preset Speed Capability

Analog Signal Follower models have an

additional input mode. With

P46 - [Input

Mode]

setting 8, four preset speeds are

available.

•

External Frequency Selection

P46 - [Input Mode]

has an additional setting

(setting 7) which allows for the frequency

source to be switched from the control

terminal block (TB3) to the

P58 - [Internal

Frequency]

setting.

•

New Output Conﬁguration Setting

P47 - [Output Conﬁgure]

has a new setting.

When setting 10 is selected, the output

will be active when the Power Factor

Angle is above the

P48 - [Output Threshold]

setting.

•

Additional Compensation Mode

P78 - [Compensation]

has an additional

mode that corrects for slow responding

systems which can cause current regulator

oscillations.

•

Software Current Trip

P79 - [Software Current Trip]

provides an

adjustable software current trip with a one

second time delay.

•

Adjustable Stall Fault Time

The time that the drive must be in a stall

condition before causing a stall fault is

selectable via

P80 - [Stall Fault Time]

•

PI Control

Process control is now intergrated in the

drive through a PI regulator. Users of

Firmware Version FRN 7.05 and earlier

activate this feature with

P46 - [Input Mode]

setting 9. Users of Firmware Version FRN

7.06 can activate this feature with

P46 -

[Input Mode]

settings 0 through 7 and 9.

PI control is adjusted through parameters

P81 - [PI Proportional Gain]

P82 - [PI

Integrated Gain]

P83 - [PI Process

Reference]

, and

P84 - [PI Dead Band].

•

Fault Auto Clear

Over voltage, Under voltage, and Over

temperature faults are automatically

cleared when the fault condition is

removed.

•

RS-232 Serial Communication

An RS-232 serial communication module

using a DF1 protocol is now available. See

160-RS1 User Manual for additional

information.

•

Ground Screw Location

Grounding screws are now located on the

power connection terminal blocks for

easier wiring.

Series C Summary of Changes

S-2

Series C Application/Installation Considerations

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

with a Series C unit.

Mounting Dimensions

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

Note:

If proper spacing recommendations were followed for Series A and B

drives, the increased width should not effect the panel layout because Series C

drives of this rating do not require spacing between units.

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

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

Note:

The drive utilizes the same DIN base and mounting hole pattern for all

ratings through 2.2 kW (3 HP).

External Braking

• The internal brake transistor is

not

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

(3/4 HP) units. If external braking is required, a 0.75 kW (1 HP) drive must be

used.

DeviceNet

• DeviceNet modules (Catalog No.160-DN1) with Firmware Version FRN 2.0 or

earlier are not compatible with the Bulletin 160 Series C drives. Series C drives

must use DeviceNet modules (Catalog No. 160-DN2). The 160-DN2 module is

also compatible with Series A and B drives with the exception of the Series A

Preset Speed model with Firmware Version FRN 4.04.

24V DC Interface

• Bulletin 160 Series C drives must use a Series B, or later, 24V DC Interface

module. See Appendix B for catalog numbers.

Terminal Block Wiring

• The ground terminal is now located on the power terminal block. Refer to

Figure 2.2 on page 2-3 to avoid incorrect wiring.

Incorrect Motor Rotation

• The output phasing of Series C drives is different than the output phasing of

Series A and B drives. Replacing a Series A or B drive with a Series C drive

using the same U, V and W (T1, T2 and T3) connections will reverse the motor

rotation. To assure the same direction of rotation, switch any 2 of the 3 output

wires connected to U, V or W (T1, T2 or T3) from the motor.

Example:

U/T1 V/T2 W/T3

U/T1

V/T2

Motor

W/T3

U/T1 V/T2 W/T3

U/T1

V/T2

Motor

W/T3

Original

Wiring of

Series A or B

Wiring of

Replacement

Series C

Table of Contents

Getting Started

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

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

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

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

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

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

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

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

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

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

Installation and Wiring

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Program Keypad Module

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

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

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

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

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

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

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

Start-Up

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

Parameters and Programming

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

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

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

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

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

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

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

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

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

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

Troubleshooting

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

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

Specifications

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

Accessories and Dimensions

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

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

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

CE Conformity

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

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

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

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

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

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

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

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

Chapter

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. Failure to do so may result in personal injury

or death.

Darkened display LEDs is not an indication that capacitors have

discharged to safe voltage levels.

ATTENTION:

Only personnel familiar with the drive 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.

ATTENTION:

The surface temperatures of the drive may become

hot, which may cause injury.

ATTENTION:

This drive contains ESD (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly.

Component damage may result if ESD control procedures are not

followed. If you are not familiar with static control procedures,

reference Publication 8000-4.5.2, “Guarding Against Electrostatic

Damage” or any other applicable ESD protection handbook.

ATTENTION:

An incorrectly applied or installed drive 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.

1-2

Getting Started

Receiving Your New Drive

It is your responsibility to thoroughly inspect the equipment before accepting the

shipment from the freight company. Check the item(s) received against your

purchase order. If any items are obviously damaged, do not accept delivery until

the freight agent notes the damage on the freight bill.

Unpacking

Remove all packing material, wedges, or braces from within and around the drive.

Remove all packing material from the heat sink. Leave the debris label in place.

If you ﬁnd any concealed damage during unpacking notify the freight agent. Also,

leave the shipping container intact and have the freight agent make a visual

inspection of the equipment to verify damage.

Inspecting

After unpacking, check the item(s) nameplate catalog number against your

purchase order. An explanation of the catalog numbering system for the Bulletin

160 drive follows as an aid for nameplate interpretation. Refer to Figure 1.1 and

Figure 1.2.

Important:

Before you install and start up the drive, inspect for mechanical

integrity. Look for loose parts, wires, and connections.

Identifying Your Drive

Catalog Number

The ﬁgure below describes the 160 SSC catalog numbering scheme.

Catalog Number Explanation Figure 1.1

➊

Amperage ratings vary based on voltage.

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

160 -AA02 N SF1 P1

Bulletin Number Current Rating➊Enclosure TypeVoltage Rating

A01

A02

A03

A04

A06

A08

A10

A12

A18

N Open (IP20)

L Low Profile

P Chassis Mount

(external heatsink)

R Chassis Mount

Replacement

A 200-240V, 1-Phase

200-240V, 3-Phase

B 380-460V, 3-Phase

First Position Second Position Third Position Fourth Position Sixth Position

Model

Fifth Position

Programmer

(Optional)

SF1 Analog Signal

Follower

PS1 Preset Speed

B1 Ready/Fault

Indicating Panel

P1 Program Keypad

Module

An “S” in the Bulletin

Number denotes a

single-phase input

voltage.

Getting Started

1-3

Nameplate

The nameplate is located on the side of the drive.

Nameplate Information Figure 1.2

Conventions Used In This Manual

Parameter numbers and names are shown in this format:

P01 - [Output Frequency]

P01

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

brackets.

160-AA02NSF1P1 SERIES C

ANALOG S.F.

FRN: 7.XX

IP20

Allen-Bradley MADE IN U.S.A.

0.37KW / 0.5 HP

Motor

Rating:

V: 200-240 3 Ø

A: 2.8

Hz: 50/60

VA: 1100

V: 200-230 3 Ø

A: 2.3

Hz: 0-240

S/N: XXXXXXXX

XXXXX

OPERATING AMBIENT TEMP: 0 - 50°C

SHORT CIRCUIT CURRENT: 100 KA

POWER TERMINAL WIRE :

Use 75°C Cu Wire:

4 mm2- .75 mm2(12-18 AWG.)

Torque 1.35 Nm (12 in.- lbs.)

CUS



LISTED

IND. CONT. EQ.

966X

Catalog Number

Series Letter

Firmware Version

Drive Model

Serial Number

Date Code

Enclosure Rating

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

allows easy access to line/load power terminals.

•

Ready/Fault Indicating Panel

is standard on the Bulletin 160 drive. The drive

is fully functional with this panel installed. All control functions can be

performed from TB3 (Control Terminal Block). Factory default settings cannot

be changed with this panel.

•

Fault Indicator LED

illuminates when a drive fault condition exists. Refer to

Chapter 6 for details on how to clear a fault and general troubleshooting

procedures.

•

Ready Indicator LED

illuminates when the DC bus is charged and the drive is

ready to run.

•

DC Bus Test Points

provide easy access for test probes when measuring DC

Bus voltage.

•

Cooling Fan

provides air ﬂow across heatsink ﬁns to prevent overheating. Not

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

•

DIN Latch

provides an easy means for mounting the drive on standard 35 mm

DIN Rail. This feature is not available with 4.0 kW (5 HP) or 1.5 kW (2 HP)

single phase units.

Cooling Fan

DIN Latch

Status LEDs

DC+

W/T3

1345678910112

V/T2

U/T1 DC–

BR+

T/L3

S/L2

R/L1 BR–

FAULT

READY

Hinged Finger Guard

Cooling

Air Flow

Ready/Fault

Indicating Panel

DC Bus Test Points

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