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Allen-Bradley

160 SSC  User

Variable Speed
Controller Manual
(Series B)
0.37 – 2.2 kW (0.5 – 3 HP)
FRN 5.xx – 6.xx

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Important User Information The information in this manual is organized in

numbered chapters. Read each chapter in
In no event will the Allen-Bradley Company be sequence and perform procedures when you are
responsible or liable for indirect or consequential instructed to do so. Do not proceed to the next
damages resulting from the use or application of chapter until you have completed all procedures.
this equipment.
Throughout this manual we use notes to make you
The examples and diagrams in this manual are aware of safety considerations:
included solely for illustrative purposes. Because
of the many variables and requirements ATTENTION: Identifies information
associated with any particular installation, the about practices or circumstances that
Allen-Bradley Company cannot assume can lead to personal injury or death,
responsibility or liability for actual use based on property damage or economic loss.
the examples and diagrams.
No patent liability is assumed by Allen-Bradley Attentions help you:
Company with respect to use of information,
circuits, equipment, or software described in this D identify a hazard
manual. D avoid the hazard
Reproduction of the contents of this manual, in D recognize the consequences
whole or in part, without written permission of Important: Identifies information that is
the Allen-Bradley Company is prohibited. especially important for successful application
Throughout this manual we use notes to make you and understanding of the product.
aware of safety considerations.

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Notes

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Notes

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Attach template to mounting surface

and drill four (4) 4.5mm (0.177 inches) diameter holes.
Dimensions are in millimeters [inches].

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Summary of Changes

Publication 160-5.9 Summary of Changes

D The Firmware Version of the drive was been added to both Table 2.F and Table 2.G
changed from FRN5.01 to FRN6.0. replacing our previous recommendations of a
“Reactor at Drive”.
D The parameter P78 – [Compensation] was
added to help eliminate non-sinusoidal motor D The paragraph titled “Recommended Line
currents that are generated by some Side Protection” has been updated to provide
motor/drive combinations. See page 5-12. added clarity on the use of devices other than
This information was supplied previously in fuses for the purposes of line side protection.
the form of a Document Update, Publication Table 2.C and Table 2.D have also been
160-5.9DU4, which has been eliminated. updated.
D The paragraph titled “Motor Cable
D Firmware version FRN 6.0 includes Recommendations” has been updated.
enhancements made to the current sensing to Table 2.E was added to provide recommended
help filter out capacitive current. These cable types based on cable distances and
enhancements improve the overall accuracy of environmental conditions.
the drive’s displayed output current. Due to
this improvement, the installation of a D Part numbers and dimensional information for
“Reactor at Drive” is no longer recommended the new 24V DC interface module and “RF”
because it negatively effects the drive’s series of line filters have been added to
current sensing accuracy. If an external device Appendix A.
is required to be mounted at the drive for D Publication 160-5.9DU2 has been
Reflected Wave purposes, an RWR protective incorporated into the manual. The contents of
device is recommended. Cable length the document update can now be found in
recommendations for an “RWR at Drive” have Appendix B.

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Summary of Changes
Summary of Change

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Table of Contents

Chapter 1 – Information and Precautions . . . . . . . . . . . . . . . . 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Chapter 2 – Installation and Wiring . . . . . . . . . . . . . . . . . . . . 2-1
Installation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power Wiring For Preset Speed and Analog Signal Follower Models . . . . . . . . . . . . . 2-2
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Recommended Line Side Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Motor Cable Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Control Wiring – Analog Signal Follower Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Control Wiring – Preset Speed Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Control Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Chapter 3 – Program Keypad Module . . . . . . . . . . . . . . . . . . . 3-1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removing Program Keypad Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Chapter 4 – Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chapter 5 – Parameters and Programming . . . . . . . . . . . . . . . 5-1
Overview of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Display Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Program Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Chapter 6 – Troubleshooting and Fault Information . . . . . . . . 6-1
Fault Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Block Diagram of Bulletin 160 Analog Signal Follower . . . . . . . . . . . . . . . . . . . . . . . 6-4
Appendix A
Controller Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Catalog Numbers for Bulletin 160 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Accessory Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

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Table
ImportantofInformation
Contents

Appendix B
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Essential Requirements for a Conforming EMC Installation . . . . . . . . . . . . . . . . . . . . B-1
General Instructions for an EMC Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . B-2
Low Voltage Directive 73/23/EEC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Index
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

ii

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Information and Precautions Chapter 1

General Information1
Receiving – It is your responsibility to Unpacking – Remove all packing material,
thoroughly inspect the equipment before wedges, or braces from within and around the
accepting the shipment from the freight company. controller. Remove all packing material from the
Check the item(s) received against the purchase heat sink.
order. If any items are obviously damaged, do not Inspection – After unpacking, check the item(s)
accept delivery until the freight agent notes the nameplate catalog number against the purchase
damage on the freight bill. order. An explanation of the catalog numbering
If you find any concealed damage during system for the Bulletin 160 controller is included
unpacking notify the freight agent. Also, leave the as an aid for nameplate interpretation. Refer to
shipping container intact and have the freight the following page for complete nomenclature.
agent make a visual inspection of the equipment Important: Before you install and start up the
in order to verify damage. 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 ATTENTION: The surface
this manual, you must read and understand the temperatures of the controller may
following statements which are general to the become hot, which may cause injury.
system.

ATTENTION: This controller ATTENTION: An incorrectly

contains ESD (Electrostatic Discharge) applied or installed controller can
sensitive parts and assemblies. Static result in component damage or
control precautions are required when reduction in product life. Wiring or
installing, testing, servicing or application errors such as undersizing
repairing this assembly. Component the motor, supplying an incorrect or
damage may result if ESD control an inadequate AC supply, or
procedures are not followed. If you are excessive ambient temperatures may
not familiar with static control result in system malfunction.
procedures, reference A-B Publication
8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other
ATTENTION: The controller
applicable ESD protection handbook.
contains high voltage capacitors
which take time to discharge after
ATTENTION: Only personnel removal of mains supply. Before
familiar with the controller and working on controller, ensure
associated machinery should plan or isolation of mains supply from line
implement the installation, start-up, inputs [L1, L2, L3 (U, V, W)]. Wait
and subsequent maintenance of the one minute for capacitors to
system. Failure to comply may result discharge to safe voltage levels.
in personal injury and/or equipment Failure to do so may result in
damage. personal injury or death.
SSC is a trademark of Rockwell Automation
1-1

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Chapter 1 – Information and Precautions

Figure 1.1 – Catalog Number Code Explanation

160 – A A04 N SF1 P1

First Second Third Fourth Fifth Sixth

Position Position Position Position Position Position
Bulletin Voltage Rating Current Enclosure Control Programmer
Number Rating Type (Optional)

An “S” in the A 200 – 240V 1∅ A01 Letter Type SF1 = Analog Program
Bulletin Number 200 – 240V 3∅ A02 N Open (IP20) Signal Keypad Module
denotes a single P Chassis Mount ➀ Follower
phase input A03
B 380 – 460V 3∅ (external
voltage. A04 PS1 = Preset
heatsink)
A06 Speed
A08
A12

➀ This manual applies only to the open style (IP20) device. Refer to separate instruction sheets for Chassis Mount
and NEMA 4 (IP66) devices.

Figure 1.2 – Nameplate Information

CAT160–AA04NSF1P1 SER B FRN:

6.xx

I V: 200-240 3∅ O V: 200-230 3∅
N U

ÎÎ
Î
A: 5.4 T A: 4.5 Nameplate is located on the
P side of the unit.
Hz: 50/60 P Hz: 0-240

ÎÎ
Î
U
VA: 2200 U Motor
T T Rating: 0.75kW/1HP

ALLEN-BRADLEY MADE IN U.S.A.

S/N 32098
OPERATING AMBIENT TEMP: 0 – 50°C
SHORT CIRCUIT CURRENT: 10KA
POWER TERMINAL WIRE: Use 75°C Cu Wire
4mm2 – .75mm2 (12 – 18 AWG.)
IP20 Torque 1.35 Nm (12 in.-lbs.)
WARNING: ! Allow 1 Minute after power is removed
before servicing. Accessible surfaces may be hot.
Compatible with Type B RCD protection devices only.

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

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Chapter 2
Installation and Wiring

Installation and Storage Controller Features

Take these actions to prolong controller life and Figure 2.1 below details the features of both the
performance: Analog Signal Follower and Preset Speed models.
D store within an ambient temperature range of
Important: The features are the same for single
–40_ to +85_C
and three phase units.
D store within a relative humidity range of 0%
to 95%, non-condensing Figure 2.1 – Controller Features
D protect the cooling fan by avoiding dust or
metallic particles
Ground Tab/
D avoid storing or operating the controller where Protective Earth
it could be exposed to a corrosive atmosphere Terminal Block One
L1 L2 L3 BR BR (TB1) – For Line
D protect from moisture and direct sunlight R S T – + Power. ➀
D operate at an ambient temperature range of 0_ Ready/Fault
to +50_C Indicating Panel –
Standard for Bulletin
To maintain proper working conditions, install the 160 controllers. ➃
controller on a flat, vertical and level surface. Use FAULT ➁
mounting screws up to 4.5mm (0.177 inches) in LEDs – Indicate
READY ➂ operational status.
diameter or mount on 35mm DIN Rail.

Terminal Block Three

CE Compliance 1 2 3 4 5 6 7 8 9 10 11 (TB3) – For Control
Wiring.
Refer to Appendix B for detailed information. T1 T2 T3 – +
U V W DC DC Terminal Block Two
(TB2) – For Motor
Mounting Requirements Wiring. ➀

Description Metric English Fan

Min. Panel Thickness (14 GA) 1.9mm 0.0747 in. DIN Latch
Mounting Base Screws m4 x 0.7 # 8–32
Mounting Torque 1.13 to 1.56 Nm. 10–14 lb. in.
➀ Refer to Figure 2.2
➁ The FAULT (red) indicator illuminates when a controller fault
D See Appendix A for details on controller condition exists. Refer to Chapter 6 for details on how to clear a fault
dimensions and weights. and general troubleshooting procedures.
D There must be a minimum of 12.5mm ➂ The READY (green) indicator illuminates when the DC bus is
(0.5 inches) clearance around all sides of the charged and the controller is ready to run.
controller. Use either DIN rail or mounting ➃ Bulletin 160 controllers are fully functional when installed with a
holes. (Use the drilling template at the back of Ready/Fault indicating panel. All control functions can be performed
the manual for mounting the controller.) from the control terminal block (TB3). Factory default parameter
settings cannot be changed with the Ready/Fault indicating panel.
D Leave debris cover attached during controller
A Program Keypad Module can be ordered separately, Catalog
installation to protect from falling debris. To 160-P1, or as a factory-installed option by adding “P1” to the end of
ensure proper controller operation, remove the catalog number. Refer to Chapter 3, Program Keypad Module
cover before applying power. for a detailed explanation of functionality.
2-1

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Chapter 2 – Installation and Wiring

Figure 2.2 – Power Wiring For Analog Power Wiring For Preset Speed and Analog
Signal Follower and Preset Speed Models Signal Follower Models
Required Branch Input Line Protective Device –
Circuit Disconnect ➀ See Table 2.C and Table 2.D.
Table 2.A – Power Terminal Block Specifications
Dynamic Brake
Module Option ➁
Terminal Screw Max/Min Wire Max/Min Torque
Block Size Size mm2 (AWG) Nm. (lb.in.)
Terminal
Block One TB1➄ M4 4 – 0.75 (12 – 18) 1.81 – 1.35 (16 – 12)
L1 L2 L3 BR BR (TB1) – For TB2➄ M4 4 – 0.75 (12 – 18) 1.81 – 1.35 (16 – 12)
R S T – + Line Power and
Brake Resistor.
– + Terminal Block ➄ The Bulletin 160 SSC is IP20 with wires installed on power
T1 T2 T3
U V W DC DC Two (TB2) – terminal blocks.
For Motor and
Capacitor
Module.
Input Power Conditioning
Motor ➂ Capacitor Module
Option ➃ The controller is suitable for direct connection to
AC power lines within the rated voltage of the
➀ For single phase input applications, connect the AC input line to controller (see Appendix A). Listed below are
input terminals (L1) R and (L2) S. certain power line conditions which may cause
➁ Connection for dynamic brake resistors for all models. component damage or reduction in product
Important: P52 – [DB Enable] must be enabled for proper life. If any of the conditions exist as described in
operation. See Appendix A for part numbers. the table below, install “one” of the devices listed
under the heading “Corrective Action” on the line
side of the controller. Important: Only one
➂ Bulletin 160 controllers are and listed as
motor overload protective devices. An external overload relay is
device per branch circuit is required. It should be
not required for single motor applications. mounted closest to the branch and sized to handle
➃ Connection for an external capacitor module. Provides extended the total current of the branch circuit.
ride through capability and improved inherent braking
performance. See Appendix A for part number. Table 2.B – Power Line Conditions
ATTENTION: The controller is
intended to be commanded by control Power Line Condition Corrective Action
input signals that will start and stop the Available short circuit currents S Check supply voltage.
motor. A device that routinely disconnects (fault currents) greater than 10,000 S Line Reactor (See A-4) or
then reapplies line power to the controller Amps
S Isolation Transformer
for the purpose of starting and stopping the
motor should not be used. If it is necessary Line has power factor correction S Line Reactor (See A-4) or
capacitors S Isolation Transformer
to use this method for starting and stopping
or if frequent cycling of power is Line has frequent power S Line Reactor (See A-4) or
unavoidable, make sure that it does not interruptions S Isolation Transformer
occur more than once a minute.
Line has high frequency S MOV option (See A-4) or
(>10 Hz) noise spikes in excess of S Line Reactor (See A-4) or
ATTENTION: Do not connect power 900V (Induction heaters, RF
equipment, choppers) S Isolation Transformer
factor correction capacitors to controller
output terminals T1, T2, and T3 (U, V, and Line has intermittent noise spikes S MOV option (See A-4) or
W) or component damage could occur. in excess of 2000V (lightening) S Line Reactor (See A-4) or
S Isolation Transformer
2-2

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Chapter 2 – Installation and Wiring

Recommended Line Side Protection guidelines must be followed in order to meet the
NEC requirements for branch circuit protection:
The Bulletin 160 Smart Speed Controller has
been UL tested and approved for use with a fuse, Bulletin 140 manual motor starters can be used in
circuit breaker or manual motor starter installed single and group motor applications. In single
on the line side of the controller. The maximum motor applications, a fuse or UL489 rated circuit
branch circuit protective rating is limited to four breaker is required upstream from the Bulletin
times the rated output current of the drive or 140 manual motor starter. In group motor
30 amperes, whichever is less. installations, the Bulletin 140 can be used for
protection of an individual motor within the group
The ratings in Table 2.C and Table 2.D are the and “one set” of fuses or a UL489 rated circuit
“minimum” recommended values for use with breaker serves as the Short Circuit Protective
each drive rating. It should be noted that the Device for the entire “Group Installation”.
products listed under the column heading “Other
Protective Devices” must follow the proper Bulletin 1492 circuit breakers are rated as
application guidelines stated for those products in supplementary protective devices. When using
order to meet local or national electrical codes. this device, upstream fuses or UL489 rated circuit
breakers are required for each motor in the branch
When using Bulletin 140 manual motor starters or circuit regardless if it is a single or group motor
Bulletin 1492 circuit breakers the following installation.
Table 2.C – Minimum Recommended Line Side Protective Devices for 200 – 240V rated units

3 ∅ Rating
at n 1 ∅ Rating
at n Fuse
use Fuse Types➇ Other Protective Devices
k (HP)
kW ( P) k ((HP)
kW P) Rating
at n Class CC Class J Rating Type
.37 (1/2) N/A 6 16
.55 (3/4) .37 (1/2) 6 KLDR/CCMR➁ JDT➁ 16 140-MN-****➄
.75 (1) .55 (3/4) 10 ATMR➂ AJT➂ 16 1492-CB3-H***➅
1.5 (2) .75 (1) 15 (16) FNQR➃ LPJ➃ 16 HFD ***L➆
2.2 (3) 1.5 (2) 25 20

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

3 ∅ Rating
at n 1 ∅ Rating
at n Fuse
use Fuse Types➇ Other Protective Devices
k (HP)
kW ( P) k ((HP)
kW P) Rating
at n Class CC Class J Rating Type
.37 (1/2) N/A 3 (4)➀ 6.3
.55 (3/4) N/A 3 (4)➀ KLDR/CCMR➁ JDT➁ 6.3 ****➄
140-MN-****
➂ AJT➂ ***➅
.75 ((1)) A
N/A 6➀ A A
ATDR/ATQR A 6.3 1492-CB3-H***
FNQR ➃ LPJ➃ HFD ***L
*** ➆
1.5 ((2)) N/A
A 10 16
2.2 ((3)) A
N/A ( )
15 (16) 16

➀ Must be dual element time delay. ➅ Allen-Bradley Bulletin1492 circuit breaker. Not recommended for
➁ Littlefuse repetitive application of power to the input of the drive.
➂ Gould Shawmut
➆ Westinghouse type HFD circuit breaker
➃ Bussman
➄ Allen-Bradley Bulletin 140 manual motor starter. Not recommended ➇ Controller is also compatible with RK1, RK5, and BS88
for repetitive application of power to the input of the drive. fuse types.

Fuse ratings in ( ) denote European size.

2-3

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Chapter 2 – Installation and Wiring

Motor Cable Recommendations Table 2.E – Recommended Cable Type(s)

A variety of cable types are acceptable for Condition Insulation Type(s) Example(s)
variable speed controller installations. For many Dry PVC① THHN
installations, unshielded cable is adequate, XLPE XHHW-2
provided it can be separated from sensitive
Wet XLPE XHHW-2
circuits. As an approximate guide, allow a
➀ For AC line voltages in excess of 264V AC, or motor cable
spacing of 1 meter (3.3 feet) for every 10 meters distances greater than 50 ft (15m), wire with XLPE insulation is
(33 feet) of unshielded length. If you cannot recommended.
separate motor cables from sensitive circuits, or if
you must run motor cables from multiple Long Motor Cable Effects
controllers (more than three) in a common The controller should be installed as close to the
conduit or cable trays, shielded motor cable is motor whenever possible. Installation with long
recommended to reduce system noise. motor cables may require the addition of external
Motor cables should be four-conductor with the devices to limit voltage reflections at the motor
ground lead and shield (if using shielded cable) (reflected wave phenomona). See Table 2.F for
connected to the controller ground terminal and recommendations.
the motor frame ground terminal. Important: The use of an external device to limit
Table 2.E provides the recommended wire type reflected wave issues may effect the accuracy of
for both wet and dry installations as defined by the Bulletin 160 current sensing. Table 2.G
NEC 1996 (70-31). These recommendations are provides recommended cable length due to
based upon a variety of factors such as insulation Capacitive Current considerations.
thickness, susceptibility to moisture and
susceptibility to nicks and cuts during installation.
Table 2.F – Cable Length Recommendations — Reflected Wave➁
Motor Motor Cable Only RWR at Drive③ Reactor at Motor
380 – 460V
Ratings Insulation
Insulat on Shielded Unshielded Shielded Unshielded Shielded Unshielded
Rating
at n ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.
1000 Vp-p 40 12 40 12 360 110 300 92 210 64 210 64
2 2 kW
2.2
1200 Vp-p 60 18 60 18 360 110 600 183 260 79 260 79
(3 HP)
1600 Vp-p 500➃ 152➃ 500➃ 152➃ 360 110 600 183 500➃ 152➃ 500➃ 152➃
1000 Vp-p 40 12 40 12 300 92 300 92 250 76 250 76
1 5kW
1.5kW 1200 Vp-p 60 18 60 18 300 92 540 165 340 104 340 104
(2 HP)
1600 Vp-p 500➃ 152➃ 500➃ 152➃ 300 92 540 165 500➃ 152➃ 500➃ 152➃
1000 Vp-p 55 17 40 12 300 92 300 92 325 99 325 99
0 75 kW
0.75 1200 Vp-p 125 43 60 18 300 92 375 114 500 152 325 99
(1 HP)
1600 Vp-p 500➃ 152➃ 500➃ 152➃ 300 92 375 114 500➃ 152➃ 500➃ 152➃
1000 Vp-p 45 14 40 12 300 92 300 92 300 92 300 92
0 55 kW
0.55 1200 Vp-p 125 38 60 18 300 92 375 114 500 152 500 152
(0.75
(0 75 HP)
1600 Vp-p 500➃ 152➃ 500➃ 152➃ 300 92 375 114 500➃ 152➃ 500➃ 152➃
1000 Vp-p 45 14 40 12 300 92 300 92 300 92 300 92
0.37
0 37 kW 1200 Vp-p 125 38 50 15 300 92 375 114 500 152 500 152
(0 5 HP)
(0.5
1600 Vp-p 500➃ 152➃ 500➃ 152➃ 300 92 375 114 500➃ 152➃ 500➃ 152➃
➁ The reflected wave data applies to all PWM frequencies 2 to 8 kHz. For 230V ratings see Table 2.G.
➂ Cable lengths listed are for PWM frequencies of 2 kHz. Refer to publication 1204-5.1 for cable length recommendations at other PWM frequencies.
➃ The maximum peak-to-peak voltage of the controller is 1400V due to the minimum on/off time software. Reflective Wave Testing has been
done on cable lengths up to 500 feet. See Table 2.G for Capacitive Current Considerations.
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Chapter 2 – Installation and Wiring

Table 2.G – Cable Length Recommendations — Capacitive Current

Motor Cable Only RWR at Drive① Reactor at Motor
380 – 460V
Ratings
kkHzz Shielded② Unshielded Shielded② Unshielded Shielded② Unshielded
ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.
2 360 110 750 229 280 85 600 183 410 125 525 160
2.2
2 2 kW 4 335 102 600 183 260 79 600 183 370 113 475 145
(3 HP
8 300 91 410 125 ➀ ➀ ➀ ➀ 310 94 420 128
2 300 91 540 165 430 131 540 165 310 94 425 130
1.5
1 5 kW 4 300 91 425 130 410 125 425 130 300 91 400 122
(2 HP
8 300 91 300 91 ➀ ➀ ➀ ➀ 300 91 350 107
2 300 91 375 114 250 76 375 114 300 91 300 91
0 75 kW
0.75 4 300 91 300 91 225 69 375 114 300 91 300 91
(1 HP)
8 300 91 300 91 ➀ ➀ ➀ ➀ 300 91 300 91
2 300 91 375 114 250 76 375 114 300 91 300 91
0.55
0 55 kW 4 300 91 310 94 225 69 375 114 300 91 300 91
(0 75 HP)
(0.75
8 300 91 300 91 ➀ ➀ ➀ ➀ 300 91 300 91
2 300 91 375 114 250 76 375 114 300 91 300 91
0.37
0 37 kW 4 300 91 325 99 225 69 375 114 300 91 300 91
(0.5
(0 5 HP)
8 300 91 300 91 ➀ ➀ ➀ ➀ 300 91 300 91

Motor Cable Only RWR at Drive Reactor at Motor

200 – 240V
Ratings
Shielded Unshielded Shielded Unshielded Shielded Unshielded
ft. m. ft. m. ft. m. ft. m. ft. m. ft. m.
0.37 to 2.2 kW
(0.5 to 3 HP) 500 152 800 244 ③ ③ ③ ③ 500 152 800 244
2 thru 8 kHz
➀ Not recommended for use above 4 kHz PWM frequency.
➁ When using shielded cable at lightly loaded conditions, the 0.75 Kw (1 Hp) and below cable length recommendations are 61m (200 ft.)
➂ Not recommended for 230V applications.

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Chapter 2 – Installation and Wiring

Control Wiring Requirements Control Wiring – Analog Signal Follower

D run all signal wiring in either a shielded cable, Model
or a separate metal conduit.
You can control the output frequency of the
D only connect shield wire at control terminal controller via the Control Terminal Block (TB3)
block common terminals TB3-3 and TB3-7. using a remote potentiometer, a –10 to +10V DC
D do not exceed control wiring length of 15 analog input, a 4 – 20mA analog input, or use
meters (50 feet). Control signal cable length is P58 – [Internal Frequency]. Important: Only
highly dependent on electrical environment one frequency source may be connected at a time.
and installation practices. To improve noise If the frequency reference potentiometer and the
immunity the control terminal block common 4 – 20mA reference are connected at the same
must be connected to earth ground. time, an undetermined frequency reference will
D use Belden 8760 (or equivalent) — 18AWG result.
(0.750mm2), twisted pair, shielded or 3
conductor. Control Wiring – Preset Speed Model
Table 2.H – Control Terminal Block Specifications You can control the output frequency of the
Max/Min Max/Min controller via the Control Terminal Block (TB3)
Terminal using dry contacts or open collector inputs to
Wire Size Torque
Block SW1, SW2, and SW3 or use P58 – [Internal
mm2 (AWG) Nm. (lb.in.)
Frequency]. A program keypad module is
TB3 2.5 – 0.5 0.8 – 0.4
(14 – 22) (8 – 4) required to change the factory default settings.
Refer to Chapter 5, parameters 61 – 68 for the
ATTENTION: The controller is eight preset frequency factory default settings and
supplied with an internal 12V supply. switch configurations.
Dry contacts or open collectors are
required for discrete control inputs. If Wiring Diagrams
an external voltage is applied, Important: Refer to the diagrams on the
component damage could occur. following pages for control wiring information.

ATTENTION: The drive start/stop

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

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Chapter 2 – Installation and Wiring

Control Wiring
Figure 2.3 – TB3 Control Wiring for Analog Signal Follower Model

Shielded Wire

TB3 Terminal Signal Specification

1 + 10V Pot 10 kΩ Potentiometer, 2 Watts
Pot Wiper or
2 Controller Input Impedance = 100 kΩ
+10/–10V DC Input
3 Common Common ➁
FAULT
4 4–20mA Input Controller Input Impedance = 250 Ω
➂
READY
5 Reverse Contact closure input ➀
6 Start Contact closure input ➀
7 Common Common ➁
8 Stop Contact closure input required to operate controller ➀
9 Normally Closed Customer-programmable relay outputs.
10 Relay Common Resistive load 0.4A at 125V AC 2A at 30V DC.
Inductive load 0.2 A at 125V AC 1A at 30V DC.
11 Normally Open
= N.O. Momentary Contact = N.O. Maintained Contact
= N.C. Momentary Contact

Figure 2.4 – TB3 Control Wiring for Preset Speed Model

Shielded Wire

TB3 Terminal Signal Specification

1 SW1 Contact closure input ➀
2 SW2 Contact closure input ➀
3 Common Common ➁
4 SW3 Contact closure input ➀
FAULT ➂
5 Reverse Contact closure input ➀
READY
6 Start Contact closure input ➀
7 Common Common ➁
8 Stop Contact closure input required to operate controller ➀
9 Normally Closed Customer-programmable relay outputs.
10 Relay Common Resistive load 0.4A at 125V AC 2A at 30V DC.
Inductive load 0.2 A at 125V AC 1A at 30V DC.
11 Normally Open
= N.O. Momentary Contact = N.O. Maintained Contact
= N.C. Momentary Contact

➀ Internal 12V supply.

➁ Do not exceed control wiring length of 15 meters (50 feet). Control signal cable length is highly dependent on
electrical environment and installation practices. To improve noise immunity the control terminal block common
must be connected to earth ground.
➂ This diagram shows “three wire” control. Refer to the following page for diagrams of other control wiring methods.
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Chapter 2 – Installation and Wiring

Control Wiring (continued) Figure 2.5 – TB3 Three Wire control (Setting 0)
( Factory Default Setting)
Use P46 – [Input Mode] to select the control Shielded Wire
method for start, stop, and direction control. TB3 Terminal Signal Specification
Important: Settings 4 through 6 provide 5 Reverse Contact closure input ➀
additional flexibility of TB3 control input 6 Start Contact closure input ➀
➂
terminal 8. 7 Common Common
8 Stop Contact closure input required to
D Setting 0 — Three Wire Control. (This is the operate controller ➀
factory default setting). Refer to Figure 2.5.
Important: After a Stop input, the Start input
D Setting 1 — Two Wire “Run Forward/Run
must be toggled to Run again.
Reverse” Control. Refer to Figure 2.6.
D Setting 2 — Program Keypad Module control. Figure 2.6 – TB3 Two Wire “Run Forward/Run
See Page 3-1. Reverse” control (Setting 1)
Shielded Wire
D Setting 3 — Momentary “Run Forward/Run
Reverse” control. Refer to Figure 2.7. ➁ TB3 Terminal Signal Specification
D Setting 4 — Two Wire “Accel/Decel” control. 5 Run Reverse Contact closure input ➀

Refer to Figure 2.8. 6 Run Forward Contact closure input ➀

7 Common Common ➂
D Setting 5 — Two Wire “Enable” control. 8 Stop Contact closure input required to
Refer to Figure 2.9. operate controller ➀

D Setting 6 — Two Wire “Local/Remote” Important: The “Run” inputs must be

control. Refer to Figure 2.10. maintained. After a Stop input, either a Run
Explanation of Symbols: Forward or a Run Reverse input must be toggled
= N.O. Momentary Contact to run again.

= N.C. Momentary Contact

Figure 2.7 – TB3 Momentary “Run Forward/Run
Reverse” control (Setting 3)
= N.O. Maintained Contact Shielded Wire
= N.C. Maintained Contact
➁
TB3 Terminal Signal Specification
5 Run Reverse Contact closure input ➀
➀ Internal 12V supply.
6 Run Forward Contact closure input ➀
➁ If both Run Forward and Run Reverse inputs are closed at 7 Common Common ➂
the same time an undetermined state could occur. 8 Stop Contact closure input required to
operate controller ➀
➂ Do not exceed control wiring length of 15 meters (50 feet).
Control signal cable length is highly dependent on Important: The “Run” inputs do not need to be
electrical environment and installation practices. To maintained. After a stop input, either a Run
improve noise immunity the control terminal block
Forward or a Run Reverse input does not need to
common must be connected to earth ground.
be toggled to run again.
ATTENTION: Hazard of injury
exists due to unintended operation.
When P46 – [Input Mode] is set to
“3” and the “Run” input is
maintained, a stop function is
provided only when the stop input is
active (open).

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Chapter 2 – Installation and Wiring

Control Wiring (continued) Figure 2.11

Figure 2.8 – TB3 Two Wire “Accel/Decel” control Input Mode TB3-8 TB3-8
(Setting 4) Setting Open Closed
Shielded Wire Accel 2➄ Accel 1
4➃
➁ Decel 2 Decel 1
TB3 Terminal Signal Specification
5 Run Reverse Contact Closure Input① Controller➅ Controller
5➃
6 Run Forward Contact Closure Input① Disabled Enabled
7 Common Common③
8③ Contact Closure Input① Local (TB3)➆ Remote
Accel/decel 6➃
select Used to select Accel/Decel. Control Control

③ Refer to Figure 2.11. ➃ The “Run” input must be a maintained input. After a stop
command, either a “Run Forward” or “Run Reverse” input must
Figure 2.9 – TB3 Two Wire “Enable” control be toggled to start the controller.
(Setting 5) ➄ When this input is in an open state, P69 – [Accel Time 2] and
Shielded Wire P70 – [Decel Time 2] are active.
➁
➅ When this input in in an open state, all power is removed from
TB3 Terminal Signal Specification the motor and it will “coast to rest”.
5 Run Reverse Contact Closure Input①
➆ When this input is in an open state the Frequency source is
6 Run Forward Contact Closure Input①
always from the terminal block regardless of the setting of
7 Common Common③ P59 – [Frequency Select].
8③ Enable Contact Closure Input required
to operate controller① Important: In modes 4 through 6, Terminal
TB3-8 is also used to clear faults. See Figure 2.12
③ Refer to Figure 2.11. for details.
Figure 2.10 – TB3 Two Wire “Local/Remote” control Important: The system programmer is
(Setting 6) responsible for returning terminal TB3-8 to its
Shielded Wire original state if necessary.
➁
TB3 Terminal Signal Specification Figure 2.12
5 Run Reverse Contact Closure Input①
6 Run Forward Contact Closure Input① TB3-8
CLOSED
7 Common Common③
8③ Local/ Contact Closure Input①
Remote Used to select local (TB3) TB3-8
Control. OPEN
Fault Fault Fault Fault
③ Refer to Figure 2.11. occurs clears occurs clears

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Chapter 2 – Installation and Wiring

This Page Intentionally Blank

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Program Keypad Module Chapter 3

Features Display Mode

The program keypad module is located on the The controller always powers up in the display
front panel of the controller. It features the mode. While in this mode you may view all read
following: only controller parameters, but not modify them.
D five keys on the module for display or Program Mode
programming controller parameters
D three keys for control inputs to the controller You enter the program mode by pressing the ESC
key. While in program mode, you can edit any
D directional LEDs programmable controller parameters. Refer to
D a 6 digit, seven segment LED display Chapter 5 for programming steps.

Figure 3.1 – Program Keypad Module Features

These two digits display the active When the program mode These four digits
parameter number for both display and indicator flashes, you can edit the display the parameter
program parameters, which are parameter value. When in display value or fault code
designated as P## throughout this mode, the program indicator does not number.
manual. display.
Use the up/down➂
The SELect key is only used while in arrow keys to scroll
program mode. It enables the editing of through a list of
a parameter value. When you press this parameters, or increase
key the program mode indicator flashes. and decrease parameter
values. Press and hold
either key to increase
The ESCape key allows you to scrolling speed.
toggle between the display mode
and program mode. When in Pressing the enter key
program mode, this key also while in programming
disables the editing of a parameter mode causes the current
value. value displayed to be
entered into memory. When
The counter clockwise LED you press this key the
illuminates constantly when the program mode indicator
motor rotates in reverse direction. ➀ remains on, but stops
flashing.
Pressing the reverse key causes the
motor to ramp down to 0 Hz and then The clockwise LED The start key initiates a The stop key initiates the
ramp up to its set speed in the opposite illuminates constantly when start command when the motor to “Coast”, “Ramp” or
direction. ➁ the motor rotates in forward controller is programmed “DC Brake” to stop
direction. ➀ for local start/stop control depending on the setting of
P34 – [Stop Mode].
(when P46 – [Input Mode]
is set to “2”).

➀ Indicates commanded direction. Actual motor rotation could be decelerating to zero. The opposite LED will illuminate indicating
different if motor leads are not connected properly. See the commanded direction.
Chapter 4, Start-up for details on how to verify motor rotation. ➂ Real time frequency adjustment can be achieved when using
➁ When the motor is running, pressing this key causes the P58 – [Internal Frequency].
(currently illuminated) LED to flash indicating motor rotation while
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Chapter 3 – Program Keypad Module

Removing Program Keypad Module

ATTENTION: Ensure that you ATTENTION: This controller contains

disconnect line power and wait ESD (Electrostatic Discharge) sensitive
one minute before installing or parts and assemblies. Static control
removing the program keypad precautions are required when installing,
module. Failure to do so may testing, servicing or repairing this
result in personal injury or death. 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.

Figure 3.2 – Removing Program Keypad Module

Insert a small screw driver into

slot, pry back, and pivot module Program Keypad
out. Avoid bending or twisting the Module
contact pins located underneath
the center portion of the module.
Dipswitch that changes P35 – [Base
Frequency] from 50 to 60 Hertz
when program keypad module is not
installed.

Important: When a program keypad

module is installed, P35 – [Base
Frequency] overrides this switch
setting. Once P35 – [Base Frequency]
is changed from its factory default
setting, the switch remains overridden
until all parameters are reset to their
factory default settings using
P56 – [Reset Defaults]

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.

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Start-Up Chapter 4

Chapter 5 provides a comprehensive Commonly Changed Parameters

description of all controller parameters. Parameter Set to...
Review the factory default settings. If
your controller is equipped with a P30 – [Accel Time 1] desired accel time.
Program Keypad Module these P31 – [Decel Time 1] desired decel time.
parameters can be changed to meet P33 – [Maximum Frequency] maximum frequency required.
your specific application requirements. P34 – [Stop Mode Select] desired stopping mode.
An example of how to program a P35 – [Base Frequency] motors rated nameplate frequency.
P36 – [Base Voltage] motors rated nameplate voltage.
parameter is shown at the beginning of P42 – [Motor Overload Current] motor nameplate Full Load Amps [FLA].
Chapter 5. P46 – [Input Mode] desired control method.
P47 – [Output Configure] desired output functionality.
Start Here Preset Speed Model Only
P61 – P68 – [Preset Frequency 0–7] desired preset frequencies.

ATTENTION: Power must be applied to the controller to perform the following start-up procedure. Some of the
voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only
qualified service personnel should perform the following procedure. Thoroughly read and understand the
procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed.
Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing.

Start-Up Checklist
Verify the controller is installed per instructions outlined in Chapter 2 including:
D Minimum clearance distance between controller and other equipment.
D Proper grounding practices have been followed.
D Proper power and control wiring has been used.

Verify that AC line power at the

disconnect device is within the rated
value of the controller.
ATTENTION: A DC Bus
Disconnect and lock out all incoming power to voltage may be present at the
the controller including incoming AC power to power terminal blocks (TB1)
terminals L1, L2 and L3 (R, S and T) of power and (TB2) for approximately
terminal block TB1. 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.
See page 2-9 for details on TB3-8 functionality when using P46 – [Input
Mode] settings 4 through 6.

Confirm that all other control inputs are connected to

the correct terminals and are secure. GO TO THE
NEXT PAGE.

A
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Chapter 4 – Start-Up

A
If you have a blank display panel. Reconnect the power to the If you have a program keypad module.
controller.

P01– [Output Frequency] will display. If the

controller has been previously powered up, a
different parameter number may display.
Important: To enable the start and reverse
keys from the program keypad module, set
P46 – [Input Mode] to a “2” and cycle power
or set P56 – [Reset Function] to 2. Refer to
the programming example in Chapter 5.
The READY [green] indicator Do you have a Analog Signal
will illuminate. Use remote Follower controller or a Preset Speed
inputs to TB3 control terminal controller?
block to operate the controller.

Analog Signal Follower controller Preset Speed controller

Check for proper motor rotation by setting the frequency Check for proper motor rotation by selecting P61 –
source to its minimum setting. [Preset Frequency 0]. This requires removing all inputs
to SW1, SW2, and SW3 on TB3 [see Figure 2.5 in
If you are using a program keypad module, verify that the Chapter 2]. The factory default setting for P61 – [Preset
CLOCKWISE LED is illuminated. If you are using a blank Frequency 0] is 3 Hz.
display panel, verify that the REVERSE input to TB3 is in
the OPEN position. If you are using a program keypad module, verify that the
CLOCKWISE LED is illuminated. If you are using a blank
Issue a START command from either the program keypad display panel, verify that the REVERSE input to TB3 is in
module or TB3 control terminal block. the OPEN position.

Slowly increase the speed until the motor begins to turn. Issue a START command from either the program
Check the direction of the motor. keypad module or TB3 control terminal block. Check the
direction of motor rotation.

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

Start-Up is complete. Yes Is the direction of motor No

rotation correct?

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].
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Parameters and Programming Chapter 5

Overview of Parameters
This chapter covers both display and program parameters. Display parameters are read only (they cannot
be programmed), while program parameters can be changed to fit your motor control requirements. You
must have a Program Keypad Module to view/change display and program parameters. The table below
describes which parameters apply to the Preset Speed and Analog Signal Follower models. Refer to the
programming example below for programming instructions.

Parameter Type Parameter Numbers

Analog Signal Follower Model Preset Speed Model
Display 1 through 14 and 16 1 through 15
Program
ÉÉ
30 through 60 and 69 through 76, 78 30 through 59 and 61 through 73, 78

ÉÉ
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.
= 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,
Figure 3.1 on page 3-1 for an explanation of Program Keypad Module display and programming keys.
Important: To reset ALL values to original factory default settings, refer to P56 – [Reset Defaults].
Action Description Keypad Display
1. To program the value of a program group parameter, enter the
program group by pressing the ESCape key. The “program mode 3 0. 1 0. 0
indicator” will illuminate. Program Mode Indicator
2. Press up/down keys until the desired parameter displays. In this case,
press the up key until parameter 31 – [Decel Time] displays.
3 1. 1 0. 0

3. Press the SELect key. The program mode indicator flashes indicating
that you can use the up/down keys to change the parameter
3 1. 1 0. 0
value. Program Mode Indicator Flashes
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. 3 1. 2. 2
Important: Continuously holding the up or down key will cause the value
to increase or decrease as long as the key is pressed.
5. When the desired value displays, press the ENTER key. This writes 3 1. 2. 2
the new value to memory. The program mode indicator will stop Program Mode Indicator
flashing and the display will flash once indicating that the new value Stops Flashing
has been accepted.
3 1. 1 0. 0
Important: If at any time (while in the program mode) you wish to abort
the editing process, press the ESCape key. The original value of the Program Mode Indicator
parameter will remain unchanged and you will be exited from the program Stops Flashing
mode.

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Chapter 5 – Parameters and Programming

Display Group Parameters

This group of parameters consists of commonly viewed controller operating conditions such as controller
output frequency, output voltage, output current and frequency command. All parameters in this group
are read only.
Important: The last user selected Display Group parameter will be saved on power down.

Display Group
P# Parameter Description Min/Max Units
Range
01 [Output Frequency] Displays the output frequency at TB2 terminals T1, T2 and 0 to 240 0.1 Hz
T3 (U, V and W).
02 [Output Voltage] Displays the output voltage present at TB2 terminals T1, T2 and 0 to [Max Voltage] 1 Volt
T3 (U, V and W).
03 [Output Current] Displays the output current present at TB2 terminals T1, T2 and 0 to 2 Times 0.01Amps
Controller Rated
T3 (U, V and W).
Output Current
04 [Output Power] Displays the output power present at TB2 terminals T1, T2 and T3 0 to 2 Times Rated 0.01 kW
Controller Output
(U, V and W).
Power
05 [Bus Voltage] Displays the DC Bus Voltage level. 0 to 400 – [230V] 1 Volt
0 to 800 – [460V]
06 [Frequency Command] Displays the frequency that the controller is
commanded to output. This command may come from any of the frequency sources 0 to 240 0.1 Hz
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 0 to 49 Numeric Value
been cleared) the display will flash. See Chapter 6 for fault code descriptions.
08 [Heatsink Temperature] Displays the temperature of the controller heatsink. 0 to 150 1 Degree C
09 [Controller Status] Displays the status of the controller in a binary
coded format.

Important: A “0” = inactive Bit 3 Bit 2 Bit 1 Bit 0

0000 to 1011 Binary Number
and a “1” = active. Running
Forward
Accel
Decel

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

11 [Control Version] Displays version of controller firmware. Used by Rockwell Fixed Value Numeric Value
Automation field service personnel.

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Chapter 5 – Parameters and Programming

Display Group
P# Parameter Description Min/Max Units
Range
12 [Input Status] Displays the open (0) and closed (1) state of the
inputs to TB3 in binary coded format as follows:
Bit 3 Bit 2 Bit 1 Bit 0

Input Input Input Input Mode 3 Input Input Input Mode 6

Mode 0 Mode 1 Mode 2 (Momentary Mode 4 Mode 5 (Local/ 0000 to 1111 Binary Number
(3-Wire) (2-Wire) (Keypad) Run FWD/ (Accel/ (Enable) Remote)
Run REV) Decel)
Bit 0 Run Run Run Run Run
Reverse N/A
TB3-5 Reverse Reverse Reverse Reverse Reverse
0=Accel 2/ 0=Drive 0=Local (TB3)
Bit 1 Decel 2 Disable Control
Stop Stop Stop Stop
TB3-8 1=Accel 1/ 1=Drive 1=Remote
Decel 1 Enable Control
Bit 2 Run Run Run Run Run
Start N/A
TB3-6 Forward Forward Forward Forward Forward

Bit 3 0 = Positive Analog Input

Polarity 1 = Negative Analog Input

13 [Power Factor Angle] Displays the angle in electrical degrees between motor 0.0 to 180.0 0.1 degrees

ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁ
voltage and motor current.

ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁ
14 [Memory Probe Display] Used by Rockwell Automation field service Numeric Value Numeric Value

ÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁ
personnel.
15 [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.
0000 to 0111 Binary Number

Bit 3 Bit 2 Bit 1 Bit 0

SW1
SW2
SW3

ÉÉÉ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
Not Used

ÉÉÉ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
16 [Analog Input] Displays the analog input as a percent of full scale. Used in setting –150 to +150.0 0.1%

ÉÉÉ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
P60 – [Zero Offset], P75 – [Analog Input Minimum], and P76 – [Analog Input
Maximum].

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

ÉÉÉ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
controller. Once applied, if the value of this parameter displays something other than zero,
program that value into P60 – [Zero Offset]. Important: The value of the [Zero Offset] will

ÉÉÉ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÉÉÉ ÁÁÁÁÁÁ
ÁÁÁÁ
be subtracted from the value of this parameter.
= This parameter applies only to the Preset Speed model.

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

5-3

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Chapter 5 – Parameters and Programming

Program Group Parameters

This group contains parameters whose values can be programmed. Refer to the “Programming Example”
outlined earlier in this chapter. Unless otherwise stated, parameters that are programmed while the
controller is running take immediate effect.

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
30 [Accel Time 1] Time for the controller to ramp from 0.0 Hz. to P33
– [Maximum Frequency]. The rate is linear for any increase in command
frequency unless P53 – [S-Curve] is set to a value other than “0”. Setting
this to 0.0 sec. gives 10.0
0.0 to 600 0.1 Seconds Seconds
0.1 sec acceleration Max. Frequency '
with the initial current
limit turned off. This allows Speed
quicker acceleration times
for low inertia systems. For
medium to high inertia 0
a Accel ' Time a Decel '
systems, the minimum value 0 Time Time
should be 0.1 sec.
31 [Decel Time 1] Time for the controller to ramp from P33 – [Maximum 0.1 to 600 0.1 Seconds 10.0
Frequency] to 0.0 Hz. The rate is linear for any decrease in command frequency Seconds
unless P53 – [S-Curve] is set to a value other than “0”. See P30 – [Accel Time 1]
figure above.
32➀ [Minimum Frequency] Lowest frequency that controller will output 0 to 240 1 Hz 0 Hz
continuously.
33➀ [Maximum Frequency] Highest frequency the controller will output. 0 to 240 1 Hz 60 Hz
Important: This parameter can’t be changed while 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 0 to 3 Numeric 0
Voltage] diagrams. Settings: 0 = Ramp to Stop 1 = Coast to Stop Value
2 = DC Injection Braking 3 = DC Injection Braking (w/Auto Shutoff)
Important: DC Injection braking with auto shutoff: works the same as standard
DC injection braking except that it may shut off before the P44 – [DC Hold Time].
This occurs if the controller is out of current limit before the P44 – [DC Hold
Time] expires.
35 [Base Frequency] Set value to motor’s rated nameplate frequency. 10 to 240 1 Hz 60 Hz ➁

36 [Base Voltage] Set value to motor’s rated nameplate voltage. 20 to 460 for 1 Volt 460 Volts for
460V units and 460V units
20 to 230 for and 230 for
230V units 230V units
➀ The analog inputs to the controller (i.e., 4–20mA, 0 to +10V, or remote potentiometer) can be scaled to P32 – [Minimum Frequency] and
P33 – [Maximum Frequency] by programming P75 – [Analog Input Minimum] and P76 – [Analog Input Maximum].
➁ For controllers without a program keypad module, you can change P35 – [Base Frequency] to 50 Hz via a dipswitch located under the blank
front panel. See the Removing Program Keypad Module section in Chapter 3.

5-4

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
37 [Maximum Voltage] Sets the highest voltage that the controller will 20 to 510 for 1 Volt 460 Volts for
460V units and 460V units
output. 20 to 255 for and 230 for
P37 – [Maximum Voltage] must be greater than or equal to P36 – [Base Voltage]. 230V units 230V units
38 [Boost Select] Sets the boost voltage and redefines the Volts per Hz
curve.
100
[Base Voltage], %

1/2
50 Base 9
Volts 10
11
12
8y
1/2 Base
Freq.

See Settings 1 0 to 12 Numeric 2

through 8 below Value
1b
0
50 100
[Base Frequency], %

Setting Boost Voltage % of [Base Voltage]

0 0
1 2.5
2 5.0
3 7.5 Setting Fan/Pump Curves ➀
4 10.0 9 45.0
5 12.5 10 40.0
6 15.0 11 35.0
7 ➀ Break Point Voltages
17.5 12 30.0
8 20.0 in % of [Base Voltage].

39 [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
a Frequency
Command '
Frequency
y Two times 0 to 240 1 Hz 240 Hz
Skip ' P40–[Skip Freq Band]
Frequency b Setting
Setting

Time
40 [Skip Frequency Band] Determines the band around the P39 –
[Skip Frequency] parameter. The actual band width will be 2 times [Skip 0 to 30 1 Hz 0 Hz
Frequency Band] – 1/2 the band above and 1/2 the band below. A value of zero
will disable the skip frequency.

5-5

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
41 [Motor Overload Select] Selects the derating factor for the I2t over-
load function.

% of [Overload Current] Setting

% of [Overload Current] Setting

No Derating Min Derating
100 100
80 80
60 60
40 40
20 20 0 to 2 Numeric 0
Value
0 25 50 75 100 125 150 175 200 0 25 50 75100 125 150 175 200
% Base Speed % Base Speed
% of [Overload Current] Setting

Max Derating
100
80
Settings:
60
0 = No Derating
40
1 = Minimum Derating
20
2 = Maximum Derating
0 25 50 75 100125 150 175 200
% Base Speed

42 [Motor Overload Current] Set to motor nameplate full load Amps 0.1 to 200% .01 Amperes 115% of
of controller Controller
(FLA). rating Rating
43 [Current Limit] Maximum output current allowed before current limiting 1 to 180% 1% 150%
of controller
occurs. Value set in percent of controller rated output current. rating
44 [DC Hold Time] Time that P45 – [DC Hold Voltage] will be applied to the 0 to 25 0.1 Second 0 Seconds
motor when P34 – [Stop Mode Select] is set to either “DC Injection Braking” or
“Ramp to Stop” mode.
45 [DC Hold Voltage] DC Voltage level applied to the motor during braking 0 to 115 1 Volt 0 Volts
when P34 – [Stop Mode Select] is set to either “DC Injection Braking” or “Ramp
to Stop” mode.

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

Ramp to Stop Mode DC Injection Braking Mode

Voltage

[DC Hold Time]

Voltage
Volts and Speed Volts and Speed
Speed [DC Hold Time] Speed
[DC Hold Voltage]
[DC Hold Voltage]
y y
Time Time
Stop Command Stop Command

5-6

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
46 [Input Mode] Configures the TB3 control inputs for various “3 wire” or “2
wire run-fwd/run-rev control” schemes. Also enables/disables the program keypad
module input control. Important: This parameter cannot be programmed while
the controller is running. Also, power must be cycled or P56 – [Reset Func- 0 to 6 Numeric 0
tion] must be set to “2” for the change to take effect. Value

Settings: 0 = “3 wire” control

1 = “2 wire” control
2 = Program Keypad Module control
3 = Momentary ‘‘Run Forward/ Run Reverse” control
4 = 2 wire “Accel/Decel” control
5 = 2 wire “Enable” control
6 = 2 wire “Local/Remote” control
See Chapter 2 for wiring diagrams and description of settings.
47 [Output Configure] Configures the TB3 relay output functionality.
Settings Output changes state when...
0 = Controller energized and returns to shelf state when
Ready/Faulted power is removed or when a fault occurs.
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. 0 to 9 Numeric 0
4 = Motor Overload when a motor overload condition exists. Value

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]. Important: Value for
P48 – [Output Threshold] must be entered in
% of controller rated output current.
8 = Above DC Bus the controller exceeds the DC bus voltage value set
Voltage in P48 – [Output Threshold].

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

exceeded.

5-7

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
48 [Output Threshold] Determines the on/off point for the TB3
output relay when [P47 – Output Configure] is set to 6, 7, and 8.
0 to 815 Numeric 0
Settings Ranges Value

6 0 to 240 Hz
7 0 to 180 %
8 0 to 815 Volts

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

The chart below provides derating guidelines based on the PWM freq. setting.
100
98
% Output Current (A)

96
94
92
2.0 to 8.0 0.1 kHz 4.0 kHz
90
88
86
84
1 2 3 4 5 6 7 8
Carrier Frequency, kHz
Important: Ignoring derating guidelines can cause reduced controller perfor-
mance.
50 [Restart Tries] Maximum number of times the controller will attempt to 0 to 9 Numeric 0
Value
reset a fault.
51 [Restart Time] Time between restart attempts. 0.5 to 300 0.1 Seconds 10.0
Seconds
52 [DB Enable] Enables/disables external dynamic braking. 0 to 100 Numeric 0
Value
Setting “0” = Disable. Settings 1 through 100 = % duty cycle braking.
Important: The Rockwell Automation Bulletin 160 DB Resister package is rated
for 5% duty cycle. Use of this package above 5% should not be used and voids
the UL rating of this device. When setting this parameter to a value above 5%
duty cycle the resister must be sized to avoid overheating of the resister package.
Important: This parameter cannot be programmed while the controller is
running.

5-8

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
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) ➀ S-Curve
1/2 S-Curve Setting
1/2 S-Curve Example:
Time Time Accel Time = 10 seconds 0 = 0%
S-Curve Setting = 3
' a ' a 1 = 10%
S-Curve Time = 10 x .3

' a = 3 Seconds 2 = 20%

' a
Numeric 0
3 = 30% Value
Enabled
4 = 40%
Important: Maximum 5 = 50%
S-Curve time is 60
seconds. 6 = 60%
7 = 70%
Disabled
8 = 80%
9 = 90%
10 = 100%

' a ' a
Accel Time Decel Time
➀ See values in the Min/Max Range column

54 [Clear Fault] Setting this parameter to a “1” performs a fault reset. When 0 to 1 Numeric 0
Value
the fault reset function is complete, the value is automatically set back to “0”.
Important: This parameter cannot be programmed while the controller is
running.
55 [Memory Probe Address] Used by Rockwell Automation field Numeric Value Numeric Numeric
Value Value
service personnel.

5-9

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
56 [Reset Functions] When using this parameter, the controller’s 0 to 2 Numeric 0
Value
parameters and their associated defaults are reset according to the descriptions
below:

0 = Idle State
1 = Reset defaults (restores all controller parameter settings to factory defaults).
2 = Update input mode (restores the controller to most recent programmed P46 –
[Input Mode] setting).

After the reset/update function is complete, this parameter will set itself back to a
“0”. This parameter cannot be programmed while the controller is running.
Important: For setting “1” only, an F48 – [Reprogram Fault] will occur and must
be cleared by cycling the STOP input to the controller. Important: P46 – [Input
Mode] factory defaults to “3 wire” control. If using keypad control, change
parameter setting back to a “2” to regain program keypad control.
57 [Program Lock] When set to a “1”, this parameter protects all controller 0 to 1 Numeric 0
Value
parameters from being changed by unauthorized personnel.
58 [Internal Frequency] When P59 – [Frequency Select] is set to a “1” 0 to 240 0.1 Hz 60.0 Hz
this parameter provides the controller frequency command. This parameter will
change the frequency command in “Real time”.
Important: Follow normal programming procedures. Once the desired
command frequency is reached the ENTER key must be pressed to store this
value to EEPROM memory. If the ESC key is used before the ENTER key, the
frequency will return to the original value following the normal accel/decel curve.
59 [Frequency Select] Selects the source of the frequency command for
the controller.

Settings: 0 = external frequency command 0 to 1 Numeric 0

ÉÉÉ
1 = internal frequency command from P58 – [Internal Frequency]. Value

ÉÉÉ
60 [Zero Offset] Used to add or subtract any system offset to the analog –50.0 to 50.0 Numeric 0%
Value

ÉÉÉÉÉÉ
input. See P16 – [Analog Input] for additional information.
Important: This parameter cannot be programmed while the drive is running.

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

5-10

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
61 [Preset Frequency 0] The programmed value sets the frequency that 0 to 240 0.1 Hz 3 Hz
the controller outputs when selected.
62 [Preset Frequency 1] The programmed value sets the frequency that 0 to 240 0.1 Hz 20 Hz
the controller outputs when selected
63 [Preset Frequency 2] The programmed value sets the frequency that 0 to 240 0.1 Hz 30 Hz
the controller outputs when selected.
64 [Preset Frequency 3] The programmed value sets the frequency that 0 to 240 0.1 Hz 40 Hz
the controller outputs when selected.
65 [Preset Frequency 4] The programmed value sets the frequency that 0 to 240 0.1 Hz 45Hz
the controller outputs when selected.
66 [Preset Frequency 5] The programmed value sets the frequency that 0 to 240 0.1 Hz 50 Hz
the controller outputs when selected.
67 [Preset Frequency 6] The programmed value sets the frequency that 0 to 240 0.1 Hz 55 Hz
the controller outputs when selected.
68 [Preset Frequency 7] The programmed value sets the frequency that 0 to 240 0.1 Hz 60 Hz
the controller outputs when selected.
69 [Accel Time 2] Time for the controller to ramp from 0.0 Hz. to P33 –
[Maximum Frequency]. The rate is linear for any increase in command frequency 0.0 to 600 0.1 Sec. 20.0 Sec.
unless P53 – [S-Curve] is set to a value other than “0”. Setting this to 0.0 sec.
gives 0.1 sec acceleration with the initial current limit turned off. This allows
quicker acceleration times for low inertia systems. For medium to high inertia
systems, the minimum value should be 0.1 sec.
70 [Decel Time 2] Time for the controller to ramp from P33 – [Maximum
Frequency] to 0.0 Hz. The rate is linear for any decrease in command frequency 0.1 to 600 0.1 Sec. 20.0 Sec.
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

TB3-4 TB3-2 TB3-1
(SW3) (SW2) (SW1) Preset Accel➀ Decel➀
0 0 0 Preset 0
0 0 1 Preset 1
P – [Accel
P30 ccel T
Time
me 1] P – [Decel
P31 Decel T
Time
me 1]
0 1 0 Preset 2
0 1 1 Preset 3
1 0 0 Preset 4
1 0 1 Preset 5
P – [Accel
P69 ccel T
Time
me 2] P7 – [Decel
P70 Decel T
Time
me 2]
1 1 0 Preset 6
1 1 1 Preset 7
Refer to Figure 2.4 for the Preset Speed model control wiring diagram.
➀ When using P46 – [Input Mode] setting “4” the Accel and Decel times are selected by providing an input to TB3-8. See page 2-9 for additional
information.

5-11

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Chapter 5 – Parameters and Programming

Program Group
P# Parameter Description Min/Max Units Factory
Range Default
71 [IR Compensation] The programmed value adds a voltage to the
output based on the torque current. An additional 31 volts (150%) are added to 0 to 150 1% 50%
460 volt units to compensate for stator resistance. 15.5 volts (150%) is added for
230 volt units. If the drive trips on an Overload fault (F7), or has trouble
accelerating to commanded speed, this value should be reduced. A setting of 0%
disables this function.
72 [Slip Compensation] This parameter compensates for the inherent slip in an
induction motor. A frequency is added to the commanded output frequency based on 0.0 to 5.0 0.1 Hz 2.0 Hz
torque current. If motor shaft speed decreases significantly under heavy loads then this
value should be increased. A setting of 0.0 Hz disables the function.
73 [Reverse Disable] When this parameter is set to a 1, the reverse is
disabled. The reverse command may come from the analog input, the TB3-5 input, the 0 to 1 Numeric 0
keypad, or a serial command. With a negative analog input and reverse disabled, the value
frequency command will be zero in bipolar mode and minimum frequency in unipolar
mode. All digital reverse inputs including two-wire “Run Reverse” will be ignored with

ÉÉÉ
reverse disabled.

ÉÉÉ
Important: This parameter cannot be programmed while the drive is running.
74 [Analog Select]
ÉÉÉ
ÉÉÉ
0 = unipolar analog input 0 to +10V
1 = bipolar analog input –10 to +10V
0 to 1 Numeric
value
0

ÉÉÉ
Important: With bipolar analog input selected, the reverse inputs (keypad, terminal
block, serial) are ignored. In addition, two-wire “Run Reverse” commands, P75 –

ÉÉÉ
[Analog Input Minimum] and P32 – [Minimum Frequency] settings are ignored.
Important: This parameter cannot be programmed while the drive is running.

ÉÉÉ
ÉÉÉ
75 [Analog Input Minimum]
Important: Do not adjust this parameter until setting P60 – [Zero Offset].
0.0 to 150.0 0.1% 0.0%

ÉÉÉ
Sets the percent of analog input used to represent P32 – [Minimum Frequency]. If
the minimum analog input equals minimum frequency no action is needed. If it is

ÉÉÉ
desired to adjust the analog input to equal [Minimum Frequency], use

ÉÉÉ
P16 – [Analog Input] to adjust the analog input to the desired level and then enter
this value into P75.

ÉÉÉ
Analog inversion can be accomplished by setting this value larger than P76.
Important: This parameter cannot be programmed while the drive is running.

ÉÉÉ
ÉÉÉ
76 [Analog Input Maximum]
Important: Do not adjust this parameter until setting P60 – [Zero Offset].
0.0 to 150.0 0.1% 100.0%

ÉÉÉ
Sets the percent of analog input used to represent P33 – [Maximum Frequency]. If
the maximum analog input equals maximum frequency no action is needed. If it is

ÉÉÉ
desired to adjust the analog input to equal [Maximum Frequency], use

ÉÉÉ
P16 – [Analog Input] to adjust the analog input to the desired level and then enter
this value into P76.

ÉÉÉ
Analog inversion can be accomplished by setting this value smaller than P75.
Important: This parameter cannot be programmed while the drive is running.
78 [Compensation] Some drive/motor combinations have inherent instabilities
which are exhibited as non-sinusoidal motor currents. A setting of 1 will enable this 0 to 1 Numeric 0
value

ÉÉÉ
parameter and attempt to correct this condition. A setting of 0 disables this function.
Important: Available in FRN 6.XX and later.

ÉÉÉ
5-12
= This parameter applies only to the Analog Signal Follower model.

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Troubleshooting and Fault Information Chapter 6

Fault Information
Figure 6.1 – Fault Display Fault LED – (Without Program Keypad
P07 – [Last Fault] Fault Code Number➀ Module)
Controllers without a program keypad module
come equipped with a fault LED. When the fault
LED illuminates, a fault condition exists.
Tips To Clear a Fault
0 7 0 4 Important: If a fault occurs, it is important to
➀ See Table 6.A below for fault descriptions. address and correct the fault as well as the
condition that caused the fault.
Controllers equipped with a program keypad To clear a fault, perform one of the following:
module will flash the display when a fault is D Press the program keypad’s stop button.
present. If a fault occurs, parameter 07 – [Last
Fault] displays. You can cross reference the D Cycle power to the controller.
number that appears on the display (e.g., 04) with D Cycle the input signal at TB3-8 to the
the fault numbers listed in Table 6.A. controller.
D Set P54 – [Clear Fault] parameter to a “1”.

Table 6.A – Bulletin 160 Fault Descriptions

ÁÁÁ
ÁÁÁÁ
ÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fault Fault Description Corrective Action

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Number Indication

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
03 Power Loss DC Bus voltage remains below 85% nominal on Monitor incoming AC line for low voltage or line
Fault power up for longer than 5 seconds. power interruption.

ÁÁÁ
ÁÁÁÁ
ÁÁÁ
04
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Under Voltage DC Bus voltage fell below the minimum. For

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
Monitor incoming AC line for low voltage or line
controllers rated at input voltage 200 – 240V AC, power interruption.

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
undervoltage trip occurs at 210V DC bus voltage

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
(equivalent to 150V AC incoming line voltage).
For controllers rated at input voltage

ÁÁÁ
ÁÁÁÁ
ÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
380 – 460V AC, undervoltage trip occurs at

ÁÁÁÁÁÁÁÁÁÁÁÁÁ
390V DC bus voltage (equivalent to 275V AC
incoming line voltage).

ÁÁÁ
ÁÁÁÁ
ÁÁÁ
05
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Over Voltage

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
DC Bus maximum voltage exceeded. For
controllers rated at input voltage 200 – 240V AC,
Bus overvoltage caused by motor regeneration.
Monitor incoming AC line for excessive voltage.

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
overvoltage trip occurs at 410V DC bus voltage Extend the decel time or install dynamic brake
module or external capacitor module. See

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
(equivalent to 290V AC incoming line voltage).
Appendix A.
For controllers rated at input voltage

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

ÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
incoming line voltage).

6-1

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Chapter 6 – Troubleshooting and Fault Information

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

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Fault Fault Fault Description Corrective Action
Number Indication

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
06
ÁÁÁÁÁÁÁÁÁÁÁÁ
Motor Stall

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
Motor has stalled. Motor load is excessive. Longer acceleration time or a reduced load
required.

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
07
ÁÁÁÁÁÁÁÁÁÁÁÁ
Motor

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Overload
Fault
Internal electronic overload trip. Excessive
motor load exists.
Reduce motor load until controller output current
does not exceed the current set by P42 – [Motor
Overload Current]. Reduce P38 – [Boost

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
08
ÁÁÁÁÁÁÁÁÁÁÁÁ
Over Excessive heat detected.
Select].
Clear blocked or dirty heat sink fins. Check

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Temperature ambient temperature. Check for blocked or
Fault non-operating fan.

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
11
ÁÁÁÁÁÁÁÁÁÁÁÁ
Operator

ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Fault
Keypad has been removed while controller is
powered.
Clear fault. Do not remove keypad under power.

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
12
ÁÁÁÁÁÁÁÁÁÁÁÁ
Overcurrent

ÁÁÁÁÁÁÁÁÁÁÁÁ
32 ÁÁÁÁÁÁÁÁÁÁÁÁ
FauIt
EEPROM
Overcurrent detected in hardware trip circuit.

EEPROM has invalid data.

Check short circuit at the controller output or
excessive load conditions at the motor.
Reset EEPROM using P56 – [Reset Functions].
Fault Set to 1. Cycle power.
33 Max Retries Controller failed to reset fault within the number Repair system fault.
Fault of retries set in P50 – [Restart Tries].
38 Phase U Fault Phase to ground fault detected between Check the wiring between the controller and
controller and motor in phase U. motor. Check motor for grounded phase.
39 Phase V Fault Phase to ground fault detected between Check the wiring between the controller and
controller and motor in phase V. motor. Check motor for grounded phase.
40 Phase W Phase to ground fault detected between Check the wiring between the controller and
Fault controller and motor in phase W. motor. Check motor for grounded phase.
41 UV Short Excessive current has been detected between Check the motor and external wiring to the
Fault these two controller output terminals. controller output terminals for a shorted condition.
42 UW Short Excessive current has been detected between Check the motor and external wiring to the
Fault these two controller output terminals. controller output terminals for a shorted condition.
43 VW Short Excessive current has been detected between Check the motor and external wiring to the
Fault these two controller output terminals. controller output terminals for a shorted condition.
48 Reprogram Occurs when controller parameters are reset to Clear fault.
Fault defaults.
49 Zero Occurs when load requires excessive current at Reduce motor load at zero hertz. Reduce motor
Overload zero hertz, or P38 – [Boost Volts] set too high. dwell time at zero hertz. Reduce P38 – [Boost
Fault Volts].

6-2

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Chapter 6 – Troubleshooting and Fault Information

Table 6.B – Troubleshooting

Problem Corrective Action

Motor does not start 1. Check power circuit.
(No output voltage to motor). S Check supply voltage.
S Check all fuses and disconnects.
2. Check motor.
S Verify that motor is connected properly.
3. Check control input signals.
S Verify that START signal is present.
S Verify that STOP signal is present.
S Verify that RUN FORWARD and RUN REVERSE signals are NOT both active.
4. Check P46 – [Input Mode].
S If P46 – [Input Mode] is set to “2”, only the program keypad module Start button will start the
motor.
Controller Started but motor 1. Check motor.
NOT rotating. S Verify that motor is connected properly.
(P01 – [Output Frequency]
2. Check frequency source P06 – [Frequency Command].
displays “0.0”).
S Verify that frequency signal is present at terminal block TB3.
S –10- +10V signal
S 4–20mA signal
S Verify that Preset Frequencies are set properly.
3. Check control input signals.
S Verify that SW1, SW2 and SW3 are correct. (Refer to the chart at the end of Chapter 5).
4. Check parameter settings.
S Verify that P59 – [Frequency Select] is showing desired frequency source.
S Verify that P58 – [Internal Frequency] is the desired value.

Motor not accelerating properly. 1. Check motor.

S Verify that motor is connected properly.
S Verify that no mechanical problems exist.
2. Check parameter settings.
S Verify that P30 – [Accel Time 1] or P69 – [Accel Time 2] is set properly.
S Verify that P43 – [Current Limit] is set properly.
S Verify that P38 – [Boost Volts] is set properly.

Can not operate in “RUN FWD/ 1. Verify that P46 – [Input Mode] is set to “1”.
RUN REV” mode. 2. Verify that P73 – [Reverse Disable] or P74 – [Analog Select] are not set to “1”.
3. Verify that power has been cycled for above change to take effect.
4. Verify that both RUN FORWARD and RUN REVERSE switches are NOT closed simultaneously.

6-3

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Chapter 6 – Troubleshooting and Fault Information

Block Diagram of Bulletin 160 Analog

Signal Follower

Brake Module Capacitor Module

BR+ BR– DC+ DC–

L1/R T1/U

L2/S T2/V
Motor
L3/T T3/W

GND/PE
GND/PE Control Bus
Power Voltage Current
TB3 - 1 Circuitry
F R Circuitry
r e –10 to +10V TB3 - 2
e f or
q e Potentiometer TB3 - 3
u r (Common)
e e or Fault Feedback
n n
c c 4 – 20 mA TB3 - 4
y e Program Keypad
CPU Module
Reverse
TB3 - 5
Start
TB3 - 6 Opto
Stop Isolator TB3 - 9
TB3 - 8 Customer
Relay
Common Circuitry TB3 - 10 Programmable
Output
TB3 - 7 TB3 - 11

6-4

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Appendix A – Specifications and Accessories

Controller Specifications
Table A.1 and Table A.2 contain information that is unique to each SSC Controller rating. Table A.3
contains information that applies to all Controller ratings.
Table A.1 – Specifications for Controllers Rated 200 – 240V Single and Three Phase Input
Controller Catalog Number
Single Phase (input) 160S-AA02 160S-AA03 160S-AA04 160S-AA08
Three Phase (input) 160-AA02 160-AA03 160-AA04 160-AA08 160-AA12
Output Ratings
3 Phase Motor Rating kW (HP) 0.37 (1/2) 0.55 (3/4) 0.75 (1) 1.5 (2) 2.2 (3)
Output Current (A) Max 2.3 3.0 4.5 8.0 12.0
Power Dissipation (Watts) 20 25 40 70 105
Input Ratings
Input Voltage, Frequency 200/240V Single Phase and Three Phase, 50/60 Hz
Operational Range (V) 180 – 265V
Input kVA 1.1 1.4 2.2 3.7 5.7
Environmental Specifications
Cooling Method Convection Cooled Fan Cooled
AC Dynamic Braking Torque ➀
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
Output Ratings
3 Phase Motor Rating kW (HP) 0.37 (1/2) 0.55 (3/4) 0.75 (1) 1.5 (2) 2.2 (3)
Output Current (A) Max 1.2 1.7 2.3 4.0 6.0
Power Dissipation (Watts) 25 30 40 65 80
Input Ratings
Input Voltage, Frequency 380/460V Three Phase, 50/60 Hz
Operational Range (V) 340 – 506V
Input kVA 1.1 1.6 2.2 3.7 5.7
Environmental Specifications
Cooling Method Convection Cooled Fan Cooled
AC Dynamic Braking Torque ➀
With external Dynamic Brake Module (%) 300 233 200 150 115
Without external Dynamic Brake Module (%) 100 100 100 50 50
➀ Estimated. Actual value depends on motor characteristics.

A-1

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Appendix A – Specifications and Accessories

Table A.3 – Specifications For All Controller Ratings

Input/Output Ratings (All Controller Ratings)
Output Voltage (V) Adjustable from 0V to input voltage
Output Frequency (Hz) 0 to 240 Hertz Programmable
Efficiency (%) 97.5% (Typical)
Transient Protection Standard 2 kV (Optional 6 kV using MOV module). See accessories on page A-5.
Environmental Specifications (All Controller Ratings)
Enclosure IP 20
Ambient Temperature 0_C to 50_C
Storage Temperature –40_C to 85_C
Relative Humidity 0 to 95% (non condensing)
Vibration 1.0 G Operational – 2.5 G Non-operational
Shock 15 G Operational – 30 G Non-operational
Altitude 1,000 m (3,300 ft.) without derating
Control Inputs (All Controller Ratings)
Control Input Type For dry contact closure input – the controller has an internal 12V power supply that provides
10mA (typical) current flow.
Also accepts open collector/solid state inputs (sinking) with maximum leakage current of 50 mA.
Optional 24V DC interface allows use of 24V DC sinking inputs.
See page A-4 for ordering information.
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
Programmable Input TB3-8 can be configured to select:
Accel/Decel Times
Controller Enable/Disable
Local/Remote

ÎÎ
ÎÎ
ÎÎ
ÎÎ
Approvals and Standards Compliance (All Controller Ratings)
Approvals

ÎÎ
ÎÎ
ÎÎ
ÎÎ
ÎÎ
ÎÎ
ÎÎ
UL508C CSA 22.2

Designed to meet these standards IEC 146–1–1

FCC Class A➀ and B➀
VDE 0871➀ and 0875➀
Control Inputs (Analog Signal Follower only – All Controller Ratings)
External Speed Potentiometer 1K to 10K Ohms, 2 Watts Minimum
Analog Input (4 to 20mA) Input lmpedance 250 Ohms
Analog Input (–10 to +10V DC) Input Impedance 100K Ohms
Control Output (All Controller Ratings)
Programmable Output Resistive rating: 0.4A @125V AC, 0.2A @ 230V AC, 2A @ 30V DC
(Form C Relay contact) Inductive rating: 0.2A @ 125V AC, 0.1A @ 230V AC, 1A @30V DC
➀ With external components.
A-2

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Appendix A – Specifications and Accessories

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

Control Features (All Controller Ratings)
PWM Algorithm Sine Weighted PWM with Harmonic Compensation
Switching Device (3-Phase Output) IGBT (Intelligent Power Module)
V/Hz Ratio Programmable
Carrier Frequency Adjustable from 2 kHz to 8 kHz in 100 Hz Increments (Factory default is 4 kHz)
DC Boost Adjustable – Select from a family of Boost Curves
Current Limiting Trip Free Operation, Co-ordinated for Controller and Motor Protection – Programmable from
1% to 180% 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 to stop Stops all PWM Output
DC Injection Braking Applies DC Voltage to the Motor for 0 to 25 seconds
Protective Features (All Controller Ratings)
Overcurrent 200% hardware limit, 300% instantaneous fault
Excessive Temperature Embedded temperature sensor trips if heatsink temperature exceeds 95°C
Over/Under Voltage DC Bus voltage is monitored for safe operation.
For controllers rated at input voltage 200 – 240V AC, overvoltage trip occurs at 410V DC bus
voltage (equivalent to 290V AC incoming line voltage).
For controllers rated at input voltage 380 – 460V AC, overvoltage trip occurs at 815V DC bus
voltage (equivalent to 575V AC incoming line voltage ).
For controllers rated at input voltage 200 – 240V AC, undervoltage trip occurs at 210V DC bus
voltage (equivalent to 150V AC incoming line voltage).
For controllers rated at input voltage 380 – 460V AC, undervoltage trip occurs at 390V DC bus
voltage (equivalent to 275V AC incoming line voltage).
Control Ride Through Minimum ride through is 0.5 seconds – typical value 2 seconds
Ground Short Any output phase to ground, detected at run
Faultless Ride Through 100 Milliseconds
Output Short Circuit Any output phase to phase short
Programming (All Controller Ratings)
Programmer Optional, Removable Program Keypad Module
Type of Display 6 character LED – two digit parameter number and four digit value
Local Controls SPEED, RUN, STOP, and DIRECTION controls

A-3

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Appendix A – Specifications and Accessories

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Accessories

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁ
Controller
For All Controller Ratings – 0.37 to 2.2kW (1/2 to 3 HP)
Dynamic MOV 3% Line Line Capacitor

ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁ ÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
Ratings

ÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁ
Brake
Module
Module Reactors
Open
Style➀
Filters Module

ÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
Input Voltage

ÁÁÁÁ
Rating
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
HP kW Cat. No. Cat. No. Cat. No. Cat. No.② Cat. No.③ Cat. No.

ÁÁÁÁÁÁ
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ÁÁÁÁ
ÁÁÁÁ
1/2 0.37 160-BMA1 160-MMA1 – 160S-LFA1 160S-RFA-6-A 160-CMA1
200 – 240V
3/4 0.55 160-BMA1 160-MMA1 – 160S-LFA1 160S-RFA-6-A 160-CMA1

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
50/60Hz
1 Phase 1 0.75 160-BMA1 160-MMA1 – 160S-LFA1 160S-RFA-10-A 160-CMA1

ÁÁÁÁÁÁ
Á
ÁÁÁ
ÁÁ
ÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
2 1.5 160-BMA2 160-MMA1 – 160S-LFA1 160S-RFA-16-A ④

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
1/2 0.37 160-BMA1 160-MMA1 1321-3R4-B 160-LFA1 160-RFB-3-A 160-CMA1
200 – 230V

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
3/4 0.55 160-BMA1 160-MMA1 1321-3R4-A 160-LFA1 160-RFB-3-A 160-CMA1
50/60Hz
3 Phase 1 0.75 160-BMA1 160-MMA1 1321-3R4-A 160-LFA1 160-RFB-9-A 160-CMA1

ÁÁÁÁÁÁ
ÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
2
3
1.5
2.2
160-BMA2
160-BMA2
160-MMA1
160-MMA1
1321-3R8-A
1321-3R12-A
160-LFA1
160-LFA2
160-RFB-9-A
–
160-CMA1
160-CMA1

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
1/2 0.37 160-BMB1 160-MMB1 1321-3R2-B 160-LFB1 160-RFB-3-A 160-CMB1
380 – 460V

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
3/4 0.55 160-BMB1 160-MMB1 1321-3R2-A 160-LFB1 160-RFB-3-A 160-CMB1
50/60Hz
1 0.75 160-BMB1 160-MMB1 1321-3R2-A 160-LFB1 160-RFB-3-A 160-CMB1

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
3 Phase
2 1.5 160-BMB2 160-MMB1 1321-3R4-B 160-LFB1 160-RFB-9-A 160-CMB1

ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ 3 2.2 160-BMB2 160-MMB1 1321-3R8-B 160-LFB1 160-RFB-9-A 160-CMB1

ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
Replacement Parts and Accessories

ÁÁÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ ÁÁÁÁ
Fan ➄

ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
Replacement ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Ready/
Fault
Program
Keypad
DeviceNet
Communication
Drivee Mo
Dr Model
el 24V DC Interface ➅
Cat. No.

ÁÁÁÁ ÁÁÁÁÁÁ
Kit Panel Module Module
Analog 160-DM-SF1

ÁÁÁÁ ÁÁÁÁÁÁ
Cat. No. Cat. No. Cat. No. Cat. No.
Preset 160-DM-PS1
160-FRK1 160-B1 160-P1 160-DN1

➀ Catalog numbers listed are for 3% impedance open style units. NEMA 1 and 5% impedance reactor types are also available, refer to
Publication 1321-2.0 for detailed information.
➁ The 160-LF type filters are designed to meet Class A conducted emissions. These units have been tested with a maximum motor cable length of
75m (250 ft.) for 230V units and 40m (133 ft.) for 460V units.
➂ The 160-RF type filters are designed to meet Class A and B conducted emissions. These units have been tested with a maximum motor cable length
of 25m (80 ft.) for both 230V and 460V units.
➃ Included with controller.
➄ The MTBF for the fan is 40,000 hours at 50_C.
➅ Allows 24V DC sinking inputs.

A-4

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Appendix A – Specifications and Accessories

Figure A.1 – Controller Dimensions

Controllers Rated 200 – 240V Single Phase

Overall 160S 160S 160S 160S
Dimensions AA02 AA03 AA04 AA08➀
H mm (inches) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00)
W mm (inches) 72 (2.83) 72 (2.83) 72 (2.83) 72 (2.83)
D mm (inches) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4)
Weight Kg. (lbs.) 0.8 (1.76) 0.8 (1.76) 0.9 (1.98) 0.9 (1.98)

Controllers Rated 200 – 240V 3 Phase

Overall 160 160 160 160 160
Dimensions AA02 AA03 AA04 AA08 AA12
H mm (inches) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00)
W mm (inches) 72 (2.83) 72 (2.83) 72 (2.83) 72 (2.83) 130 (5.12)
D mm (inches) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4)
H
Weight Kg. (lbs.) 0.8 (1.76) 0.8 (1.76) 0.9 (1.98) 0.9 (1.98) 1.1 (2.46)

Controllers Rated 380 – 460V 3 Phase

Overall 160 160 160 160 160
Dimensions BA01 BA02 BA03 BA04 BA06
H mm (inches) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00) 152 (6.00)
W mm (inches) 72 (2.83) 72 (2.83) 72 (2.83) 72 (2.83) 130 (5.12)
D mm (inches) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4) 136 (5.4)
Weight Kg. (lbs.) 0.8 (1.76) 0.8 (1.76) 0.8 (1.98) 0.9 (1.98) 1.1 (2.46)

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

Use the drilling template at the back of the manual for mounting the controller.
Figure A.2 – Mounting Requirements Dimensions Metric English
DIN Mounting Min. Panel Thickness (14 GA) 19mm 0.0747 in.
Mounting Base Screws m4 x 0.7 # 8 – 32
Debris Cover
Mounting Torque 1.13 to 1.56 Nm 10 – 14 lb. in.

D See Figure A.1 for details on controller

dimensions and weights.
D There must be a minimum of 12.5mm
(0.5 inches) clearance around all sides of the
controller. Use either DIN rail or mounting
holes. (Use the drilling template at the back of
the manual for mounting the controller.)
D Leave debris cover attached during controller
installation to protect from falling debris. To
ensure proper controller operation, remove
cover before applying power.
A-5

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Appendix A – Specifications and Accessories

Approximate Dimensions
Dimensions are shown in millimeters (inches). Dimensions are not to be used for manufacturing
purposes.
Figure A.3 – Dynamic Brake Module – Both Sizes
6,8
72
(.230) 86,4
(2.8)
4 places (3.4)
50 8 14 7,5
(1.9) (.315) (.551) (.295)

A
B

GND BR BR

29
(1.1)

Cat. No. A B
160-BMA1 & 160-BMB1 245 225
(9.64) (8.86)
160-BMA2 & 160-BMB2 334 314
(13.15) (12.36)

A-6

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Appendix A – Specifications and Accessories

Approximate Dimensions, Continued

Dimensions are shown in millimeters (inches). Dimensions are not to be used for manufacturing
purposes.
Figure A.4 – MOV Module
22,7
(.894)

MOV
L1 L2 L3 MODULE
40,2 R S T 45,4
(1.6) (1.8)

0,54
(.021)

71
(2.8)
5,1
(.199)
Pin
Extension

Figure A.5 – Line Reactor

Cat. No. A B C D E
112 102 74 50 36
1321-3R2-A (4.4) (4.0) (2.9) (2.0) (1.44)
A
112 102 74 50 36
1321-3R2-B (4.4) (4.0) (2.9) (2.0) (1.44)
112 102 74 50 36
1321-3R4-A (4.4) (4.0) (2.9) (2.0) (1.44)
112 102 74 50 36
B
1321-3R4-B (4.4) (4.0) (2.9) (2.0) (1.44)
152 122 79 54 50
1321-3R8-A (6.0) (4.8) (3.1) (2.1) (2.0)
152 122 79 54 50
1321-3R8-B (6.0) (4.8) (3.1) (2.1) (2.0)
152 122 79 54 50
1321-3R12-A (6.0) (4.8) (3.1) (2.1) (2.0)
E

D C

A-7

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Appendix A – Specifications and Accessories

Approximate Dimensions, Continued

Dimensions are shown in millimeters (inches). Dimensions are not to be used for manufacturing
purposes.
Figure A.6 – Line Filters

B
mm
(in.) C
E

A D

Line Filter
Module A B C D E F G H
160S-RFA-6-A
160S-RFA-10-A 182.0 (7.17) 75.0 (2.95) 30.0 (1.18) 167.0 (6.57) 60.0 (2.36)
6.5 x 4.5 (0.26 x 0.18) 4.2 (0.17) 200
160S-RFA-16-A hole dim. dia. hole (7.87)
160-RFB-3-A 182.0 (7.17) 75.0 (2.95) 35.0 (1.38) 167.0 (6.57) 60.0 (2.36) ( places)
(2 p ces) ( places)
(2 p ces)

160-RFB-9-A 182.0 (7.17) 75.0 (2.95) 47.5 (1.87) 167.0 (6.57) 60.0 (2.36)
160-LF 174.0 (6.85) 75.0 (2.95) 50.0 (1.97) 163.0 (6.41) 60.0 (2.36) 6.9 x 5.25 6.9 x 5.25 200
(All Types) (0.272 x 0.207) (0.272 x 0.207) (7.87)
hole dim. hole dim.

A-8

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Appendix A – Specifications and Accessories

Approximate Dimensions, Continued

Dimensions are shown in millimeters (inches). Dimensions are not to be used for manufacturing
purposes.
Figure A.7 – Capacitor Module

50
(1.97)
4,5 40 110,9
(.177) (1.5) (4.37)
Mounting Holes

140
(5.51)
150,9
130 (5.94)
(5.11)

254 (10) Approximate

Lead Length

A-9

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Appendix A – Specifications and Accessories

Approximate Dimensions, Continued

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

Figure A.8 – DeviceNet Module Attached to Controller

17,34 161,2
(0.68) Required (6.35) Overall Height
for Removal with DeviceNet Module

167,82
(6.61) Overall Height
with DeviceNet Connector

Figure A.9 – 24V DC Interface Module

29 ➀
(1.14)

➀ This device does not effect

the overall height of the drive.

A-10

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Appendix B – CE Compliance

CE Compliance Essential Requirements for a Conforming

This controller is a component intended for EMC Installation
implementation in machines or systems for the 1. An input line filter module (see “Accessories” in
industrial environment. It has been tested to meet Appendix A) must be installed to reduce
the Council Directive 89/336 Electromagnetic conducted emissions.
Compatibility (EMC) and all applicable standards.
“LF type” Filters – These units have been
Important: The conformity of the controller and tested with a maximum motor cable length of
filter to any standard does not guarantee that the 75 meters (250 feet) for controllers rated 200
entire installation will conform. Many other – 240V AC, and 40 meters (130 feet) for
factors can influence the total installation and controllers rated 380 – 460V AC.
only direct measurements can verify total “RF type” Filters – These units have been
conformity. It is therefore the responsibility of the
tested with a maximum motor cable length of
machine manufacturer, to ensure, that the
25 meters (80 feet) for all ratings.
conformity is met.
2. The controller system must be mounted in a
A copy of the Declaration of Conformity (DOC) is shielded enclosure to reduce radiated emissions.
available from your local Rockwell Automation
sales office. 3. Grounding of equipment and cable shields must
be solid, with low impedance connections.
4. Motor and control cables entering the shielded
enclosure must have EMC-tested shielded cable
clamps, or grounded metal conduit.
5. All motor cables must use shielded cable, or be
in grounded metal conduit.
6. All control and signal wiring must use shielded
cable or be in grounded metal conduit.
7. The Common terminals (TB3-3 & 7) must have
a solid connection to PE (protective earth).

B-1

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Appendix B – CE Compliance

General Instructions for an EMC D Input power, output power and control wiring
Compliant Installation outside the enclosure must use separate
shielded cables, or separate conduit.
Refer to Figure B.1.

Shielded Enclosure Cable Clamps

D Typical NEMA or IEC metal enclosures are
adequate. D Use suitable EMC-tested cable clamps only.
D The ground connection of the shielded D The connection area must be 360 degrees
enclosure must be solidly connected to the PE around the shielded cable.
terminal of the controller. Good conductivity
must be assured – grounding must provide a D The cable clamps also provide strain-relief for
low impedance path to high frequency signals. the cable.
D All wiring, except input power leads, must use D When using conduit, the contact point of
shielded cable. metal entry connections must be free of paint
D Input power, output power and control wiring or non-conductive surfaces and solidly
inside the enclosure must be physically connected with good conductivity to the
separated. enclosure.

Figure B.1 – Recommended Grounding Configuration

PE Enclosure Ground Connection

R (L1) T (L3)
Line S (L2)
AC S (L2) Filter
Input Line T (L3) R (L1)

Ground Tab – PE

L1 L2 L3 BR BR
Line Power TB1 R S T – +

FAULT
READY

to TB3 Control
1 2 3 4 5 6 7 8 9 10 11
Cabinet *
Control Wiring TB3
Motor Wiring TB2 TI
U
T2
V
T3
W
–
DC
+
DC

Shielded Motor Cable

W (T3)
V (T2) to Motor
U (T1)
Shielded Enclosure

= EMC Tested Shielded Cable Clamp (or Metal Conduit)

* When the control circuitry is located outside of the 160 enclosure.
B-2

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Appendix B –CE Compliance

Motor Cable be solidly connected to the PE terminal of the

controller.
D The cable between the controller and motor
must be a 4-wire shielded cable (three phases D Where the shielded motor cable exits the
and ground). Refer to Figure B.2 and enclosure, an EMC-tested cable clamp, or
Figure B.3. metal conduit must be used to solidly connect
the cable shield to the enclosure.
D Do not exceed the maximum motor cable
D The shield on the motor side must be solidly
length for the specific line filter module used.
connected to the motor housing with an
D Inside the shielded enclosure, shielded motor EMC-tested cable clamp, or conduit,
cable must be used as close to the controller’s providing good conductivity from the cable
output terminals as possible. The shield must shield to the motor housing.

Figure B.2 – Motor Connections

Ground Tab – PE

L1 L2 L3 BR BR
R S T – +

FAULT
READY

1 2 3 4 5 6 7 8 9 10 11 4 Wire
Shielded Motor Cable
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)

Figure B.3 – Shielded Motor and Control Cable Example

Stranded Copper Wire

Plastic Insulation
Inner Plastic Sheath
Compact Screen of Galvanized (Tinned) Copper or Steel
Outer Plastic Jacket

B-3

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Appendix B – CE Compliance

Control Cable
D Control wiring must use shielded cable, or
grounded metal conduit. Refer to Figure B.3
and Figure B.4.
D The shield must be connected to signal
common at both ends of the cable.
D The Common terminals (TB3-3 & 7) must be
solidly connected (and as short as possible) to
the PE terminal of the controller.

Figure B.4 – Control Connections

Ground Tab – PE

L1 L2 L3 BR BR
R S T – +

FAULT
READY
Control
Cabinet *
Control Wiring TB3 1 2 3 4 5 6 7 8 9 10 11
to TB3
Signal
TI T2 T3 – + Common
U V W DC DC

Shielded Control
Cable
Shielded Enclosure

= EMC Tested Shielded Cable Clamp (or Metal Conduit)

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

Low Voltage Directive 73/23/EEC D The controller is intended to be installed with

Compliance a fixed connection to the earth. The use of
residual-current-operated protective devices
This product complies with Low Voltage Directive (RCDs) or ground fault indicators is not
73/23/EEC when conforming with the following recommended. If unavoidable, the Bulletin
installation requirements: 160 is compatible with type B RCDs only.
D Review the General Precautions section on D The controller should be installed in an
page 1-1, inside front cover, and other appropriate or suitable enclosure.
ATTENTION statements throughout this Important: The conformity of this controller and
manual prior to installation of the controller. 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.

B-4

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Index

  current limiting, 5-6

current rating, A-1
24V DC interface, A-10
50 Hz dipswitch, 3-2 
60 Hz dipswitch, 3-2
DB enable, 5-8

DC brake to stop, 5-4, 5-6
DC hold level, 5-6
AC input wiring, 2-2 defaults, resetting to, 5-10
accel/decel control, 5-4, 5-11 determining drive information, 1-2
accessories, A-4 DeviceNet module, A-10
ambient temperature, A-2 diagnostics, 5-2, 5-3, 6-2, 6-3
analog input, 2-6, 2-7 dimensions, A-5
analog scaling display group, 5-2, 5-3
analog input, 5-3 display group parameters, 5-2, 5-3
zero offset, 5-10 display mode, 3-1
analog input maximum, 5-12 dynamic brake, connection, 2-2
analog input minimum, 5-12 dynamic brake module, A-6
analog select, 5-12
approvals, A-2

auto restart electrostatic discharge, 1-1, 3-2
restart time, 5-8 EMC
restart tries, 5-8 control connections, B-4
grounding configuration, B-2
 installation, B-1
block diagram, 6-4 motor connections, B-3
branch circuit disconnect, 2-2, 2-3 shielded motor and control cable example, B-3

 
fan/pump volts/hz patterns, 5-5
cable length recommendations
fault buffer, 5-2
capacitive current, 2-5 fault information, troubleshooting, 6-1
reflected wave, 2-4 fault LED, 6-1
capacitive current, cable length recommendations, 2-5 faults, clearing, 5-9, 6-1
capacitor module, A-9 frequency dipswitch, 3-2
connecting, 2-2 frequency source selection
carrier frequency, pwm, 5-8, A-3 Analog Signal Follower model, 2-6, 2-7, 5-10
catalog number description, 1-2
Preset Speed Model, 2-6, 2-7, 5-11
CE, 2-1, A-2, B-1
changing base frequency, from factory default, 3-2 
clearing faults, 5-9, 6-1
compensation, 5-12 general precautions, 1-1
control wiring grounding, 2-6
Analog Signal Follower model, 2-6
Preset Speed model, 2-6 
control wiring requirements
input mode selection, 2-8, 5-7
Analog Signal Follower model, 2-6, 2-7
input power conditioning, 2-2
Preset Speed model, 2-6, 2-7
controller features, 2-1
controller specifications, A-1
conventions used in this manual, 1-2 line filters, A-4, A-8
CSA, A-2 line reactor, A-4, A-8
CUL, A-2 line side protection, 2-3
I-1

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Index

low voltage directive compliance, B-4 programming, 3-1, 5-1


min/max frequency, 5-4 reflected wave, cable length recommendations, 2-4
minimum clearance, 2-1 replacement parts, A-4
motor cable lengths, effects, 2-4 resetting, to factory defaults, 5-10
motor cable recommendations, 2-4 reverse, 2-6, 3-1
mounting requirements, 2-1, A-5 RWR (reflected wave reducer), 2-4, 2-5
MOV module, A-4, A-7


S-curve, 5-9
nameplate information, 1-2 skip frequency, 5-5
specifications, A-1, A-2, A-3
 standards compliance, A-2
start, 2-7, 2-8, 2-9, 3-1
operating controller
start-up, 4-1
with program keypad module, 2-1, 3-1
stopping, 2-7, 2-8, 2-9, 3-1, 5-4
without program keypad module, 2-1 storage temperature, 2-1, A-2
output contacts, 2-7, 5-7
output ratings, A-1
overload protection, 2-2, 5-6

terminal blocks
 specifications, 2-2, 2-6
parameters TB1, 2-1, 2-2
display group, 5-2 TB2, 2-1, 2-2
overview, 5-1 TB3, 2-1, 2-2, 2-7
program group, 5-4 torque ratings, A-1
potentiometer wiring, 2-6 troubleshooting, 6-3
power, wiring, 2-2 fault descriptions, 6-1
precautions, 1-1
preset frequencies, 2-7, 5-11 
program group, parameters, 5-4 vibration, A-2
program keypad module voltage rating, A-1
description, 3-1
display mode, 3-1
features, 3-1
installation, 3-2 wiring
key descriptions, 3-1 control and signal, 2-6, 2-7, 2-8, 2-9
program mode, 3-1 input line fuses, 2-3
removal, 3-2 motor cable recommendations, 2-4
program lock, 5-10 terminal blocks specifications, 2-2, 2-6
program mode, 3-1 wire size recommendations, 2-2, 2-6

I-2

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Publication 0160-5.9 – May 1998 40055–180–01(01)

Supercedes Publications 0160-5.9 – December 1996, 0160-5.9DU2 – May 1997, 0160-5.9DU4 – January 1998 Copyright 1996 Allen-Bradley Company, Inc., a Rockwell International company

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