spl_en_a.fm5 Page 1 Monday, September 15, 1997 1:31 PM Allen-Bradley 160 SSC™ Variable Speed Controller (Series A) Installation Manual 0.37 – 2.2 kW (1/2 – 3 HP) FRN 4.01, 4.04, 4.
This manual is intended to guide qualified personnel in the installation and operation of this product. Because of the variety of uses for this equipment and because of the differences between this solid-state equipment and electromechanical equipment, the user of and those responsible for applying this equipment must satisfy themselves as to the acceptability of each application and use of the equipment.
$ $# % $ ! $ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . !$ " " $ " %$ # DU–1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 !$ " #$ $ " Installation and Storage . . . . . . . . . . . . . . . . . . . .
Bulletin 160 SSCt Controller For Ratings of 1/2 - 3 HP (0.37 – 2.2kW) This document revises the Bulletin 160 SSC Controller User Manual (Publication 160–5.0, February 1996). Replace pages 2–5, 2–7, and 2–8 of the User Manual with the information on the following pages. ATTENTION: Read the following sections carefully before installing the Bulletin 160 SSC Controller.
Control Wiring Requirements D run all signal wiring in either a shielded cable, or a separate steel conduit. D only connect shield wire at control terminal block common terminals 3 and 7. D do not exceed control wiring length of 15 meters (50 feet). D use Belden 8760 (or equivalent) – 18AWG (0.750mm2), twisted pair, shielded or 3 conductor. À Control signal cable length is highly dependent on electrical environment and installation practices.
Control Wiring (continued) Bulletin 160 Analog Signal Follower models (catalog # 160X–XAXXNSFlXX) can be operated using either a unipolar (frequency control only) or bipolar (frequency and direction control) analog input. Use Parameter 46 – [Input Mode] to select the control method for start, stop, and direction control. There are four settings from which to choose (shown in Table 2.E below).
Figure 2.6 - TB3 Three Wire Control (Setting 0) Figure 2.7a - TB3 Two Wire Run Forward/Run Reverse" Control (Setting 1) &&"! ) *% $ "% ! $ " %""%, ( $ ( ) * & % ") TB3 Terminal Signal Reverse Start ! " !( Common Stop Specification &&"! ) *% ( ) * & % ") $". ! " !( %$*(%" "%)+( !$&+*À %$* * "%)+( !$&+*À %##%$Â %$* * "%)+( !$&+* ( '+!( *% %& ( * %$*(%"" (À Á &&"! ) *% $ "% ! $ " %""%, ( % ") $".
160_5_9DU3.doc 1 Mon Sep 15 11:46:33 1997 Document Update 160 SSC™ Variable Speed Controller (Series B) This publication provides new information for the 160 SSC Variable Speed Controller User Manual, publication 160-5.9, dated December, 1996. Please place this document in your manual for future reference. Important Note Bulletin 160 SSC Controllers with a catalog number suffix of “S01,” (i.e. 160S-AA02NS01) will have the “Motor Stall Fault” (F06, page 6-2) detection feature disabled.
160_5_9DU2.doc 1 Mon Sep 15 11:42:00 1997 Document Update 160 SSC™ Variable Speed Controller (Series B) This publication provides new and updated material for the 160 SSC Variable Speed Controller User Manual, publication 160-5.9, dated December, 1996. Please place this document in your manual for future reference. EMC Directive 89/336/EEC This controller is a component intended for implementation in machines or systems for the industrial environment.
160_5_9DU2.doc 2 2 Mon Sep 15 11:42:00 1997 160 SSC™ Variable Speed Controller (Series B) General Instructions for an EMC Compliant Installation Refer to Figure 1. Shielded Enclosure • Typical NEMA or IEC metal enclosures are adequate. • The ground connection of the shielded enclosure must be solidly connected to the PE terminal of the controller. Good conductivity must be assured – grounding must provide a low impedance path to high frequency signals.
160_5_9DU2.doc 3 Mon Sep 15 11:42:00 1997 160 SSC™ Variable Speed Controller (Series B) 3 Motor Cable • The cable between the controller and motor must be a 4-wire shielded cable (three phases and ground). Refer to Figures 2 & 3. • When using a line filter module as specified in Appendix A, motor cable lengths shall be limited to 75 meters (250 feet) for controllers rated 200-240VAC and 40 meters (133 feet) for controllers rated 380-460VAC.
160_5_9DU2.doc 4 4 Mon Sep 15 11:42:00 1997 160 SSC™ Variable Speed Controller (Series B) Control Cable • Control wiring must use shielded cable, or grounded metal conduit. Refer Figures 3 and 4. • The shield must be connected to signal common at both ends of the cable. • The Common terminals (TB3-3 & 7) must be solidly connected (and as short as possible) to the PE terminal of the controller.
It is your responsibility to thoroughly inspect the equipment before accepting the shipment from the freight company. Check the item(s) received against the purchase order. If any items are obviously damaged, do not accept delivery until the freight agent notes the damage on the freight bill. If you find any concealed damage during unpacking notify the freight agent.
Chapter 1 - Figure 1.1 - Catalog Number Code Explanation 160 - A A04 N SF1 First Position Second Position Third Position Fourth Position Bulletin Number Voltage Rating Current Rating Enclosure Type Motor Rating Current Rating HP kW A02 A03 A04 A08 A12 1/2 3/4 1 2 3 0.37 0.55 0.75 1.50 2.20 CAT I N P U T A01 A02 A03 A04 A06 A08 A12 A 200Ć240V 1∅ 200Ć240V 3∅ An S" in the Bulletin Number denotes a single phase input voltage. Available up to motor ratings of 2 HP (1.
!% # $% % # $% % % # Take these actions to prolong controller life and performance: D store within an ambient temperature range of -40_ to +85_C D store within a relative humidity range of 0% to 95%, non–condensing D protect the cooling fan by avoiding dust or metallic particles D avoid storing or operating the controller where it could be exposed to a corrosive atmosphere D protect from moisture and direct sunlight D operate at an ambient temperature range of 0_ to +50_C
Chapter 2 - Figure 2.2 - Controller Features Ground Tab L1 R L2 S L3 T BR - BR + Ready/Fault Indicating Panel % # !# & % ! %#! #$ FAULT LEDs - % !" # % ! $% %&$ READY 1 2 3 4 5 6 7 8 9 10 11 T1 U T2 V T3 W Terminal Block One (TB1) - !# !' # - DC + DC Terminal Block Three (TB3) - !# ! %#! # Terminal Block Two (TB2) - !# !%!# # Fan DIN Latch Controller Features Figure 2.
Chapter 2 - Motor Cable Recommendations Long Motor Cable Effects A variety of cable types are acceptable for variable speed controller installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 1 meter (3.3 feet) for every 10 meters (33 feet) of unshielded length.
Chapter 2 - Installation/Wiring Power Wiring For Preset Speed and Analog Signal Follower Models Table 2.B Power Terminal Block Specifications Terminal Screw Size Table 2.C Recommended AC Input Line Fuse UL Class J, CC, or BS88 (or equivalent) 3∅ Rating kW (HP) Max/Min Max/Min Wire Size Torque mm2 (AWG) Nm. (lb.in.) 1∅ Rating kW (HP) À Á Figure 2.
"& $ Installation/Wiring ! &$! $ #' $ &% run all signal wiring in either a shielded cable, or a separate steel conduit. only connect shield wire at control terminal block common terminals 3 and 7 do not exceed control wiring length of 15 meters (50 feet). use Belden 8760(or equivalent) – 18AWG (0.750mm 2), twisted pair, shielded or 3 conductor. Control signal cable length is highly dependent on electrical environment and installation practices.
Chapter 2 - Installation/Wiring Control Wiring Figure 2.
Chapter 2 - Installation/Wiring Control Wiring (continued) Use P46 – [Input Mode] to select the control method for start, stop, and direction control. There are four settings from which to choose: Setting 0 – three wire control (this is the factory default setting). Figure 2.6 - TB3 Three Wire control (Setting 0) Setting 1 – two wire “run forward/run reverse”control. Note: The “run” inputs must be maintained. Setting 2 – program keypad module control. See page 3–1.
2–8
3 The program keypad module is located on the front The controller always powers up in the display panel of the controller. It features the following: mode. While in this mode you may view all read only controller parameters, but not modify them.
$ " & " " ' % ATTENTION: Ensure that you disconnect line power and wait one minute before installing or removing the program keypad module. Failure to do so may result in personal injury or death.
$ +/!- / -/ + )"04&2 02/6*%&3 " $/-02&)&.3*6& %&3$2*04*/. /' ",, $/.42/,,&2 0"2"-&4&23 &6*&7 4)& '"$4/29 %&'"5,4 3&44*.(3 ' 9/52 $/.42/,,&2 *3 &15*00&% 7*4) " 2/; (2"- &90"% /%5,& 4)&3& 0"2"-&4&23 $". #& $)".(&% 4/ -&&4 9/52 30&$*'*$ "00,*$"4*/. 2&15*2&; -&.43 . &8"-0,& /' )/7 4/ 02/(2"- " 0"2"-&4&2 *3 3)/7. "4 4)& #&(*..*.( /' )"04&2 / -/ !-! 4 *((*)'4 $ )#! - (!/!-. - (!/! !' %(! ! !' %(! 3%(0( -!,0!) 4 /*+ * ! !'! / .
!% # Start-Up $ 6,2 & 3# ) +( "'0-) 6 - +#) #!,++#!1 1&# -,4#/ 1, 1&# !,+1/,))#/ $ 6,2 & 3# -/,%/ * (#6- " *,"2)# &%!&% # "& ' 4')) "'0-) 6 $ 1&# !,+1/,))#/ & 0 ##+ -/#3',20)6 -,4#/#" 2- "'$$#/#+1 - / *#1#/ +2* #/ * 6 "'0-) 6 % , #+ )# 1&# 01 /1 +" /#3#/0# (#60 $/,* 1&# -/,%/ * (#6- " *,"2)# 0#1 !&% 1, 8 +" !6!)# -,4#/ #$#/ 1, 1&# -/,%/ **'+% #5 *-)# '+ & -1#/ &# %/##+ '+"'! 1,/ 4')) '))2*'+ 1# 0# /#*,1# '+-210 1, !,+1/,)
$' % % ! ' %& " %# % !! " 5 ) %) * # % ! ' %& 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.
$( & '$ , &#)$ & ! ( &' This group of parameters consists of commonly viewed controller operating conditions such as controller output frequency, output voltage, output current and frequency command. All parameters in this group are read only. Display Group "39 1%= *-2( -8 2)')77%6= *36 8,) '3286300)6 83 (-740%= % 74)'-*-' 4%6%1)8)6 )%', 8-1) -8 -7 43;)6)( 94 ,-7 -7 )74)'-%00= 97)*90 ;,)2 8639&0)7,338-2+ %2( 1%/-2+ 7=78)1 %(.
Display Group 10 11 # Parameter Description P# $ ' - !! # & ! - ! ' &* % &'$## ! '%! -' * &' $# $ $#(&$!! & &"+ & ' - )" & !) )" & !) , !) )" & !) ($ # &- )" & ($ & ' !! # & ! - ! ' &* % &'$## ! 12 ! ! '%! -' ( $% # # !$' '( ( $ ( % & !! ! #%)(' # # &- $ $&" ( ( ( (
&* ( Parameters and Programming (% ( # (%+& ( # * () This group contains parameters whose values can be programmed. Refer to the “Programming Example” outlined earlier in this chapter. Unless otherwise stated, parameters that are programmed while the controller is running take immediate effect. Program Group P# 30 Parameter Description " !# !% '* , !$ $ $!*) *%(.
Chapter 5 - Program Groups P# Parameter Description 37 [Maximum Voltage] -, -! !" 38 [Boost Select] -, -! ((,- /(%- Min/Max Range Units Factory Default (%- (%-, (+ .'"-, ' (+ .'"-, -( .& +" %. -( 2 2 -( 2 2 -( (+ .'"-, ' (.-).- -( (+ .'"-, P37 - [Maximum Voltage] &.,- + - + -! ' (+ *.
%( & Program Group P# 41 Parameter Description $($& * &!$ ! ( !'! .- .$! # + # # (' ($&, )!( .* /(!,% '/! .* (+!,!- *" *).,*''!, .%)# .* .* ! *) ! *) - .* *'. *'.- !, .%)# " .*, "*, .$! . *" * &!$ )&& #( !..%)# 42 *" * &!$ )&& #( !..%)# *" * &!$ )&& #( !..%)# *0!,'* "/) .%*).
! (+ ) Parameters and Programming Program Group P# 46 Parameter Description &(,+ ' -,%(&30$1 2'$ $*' ('- ) %,*+ / $ ') +! ! & +' + # + ++"& * 47 +')/ ,$+ 2- 3+$0(" *3$ 2- 3+$0(" *3$ 2- 3+$0(" *3$ 9 5(0$ "-,20-* 9 5(0$ "-,20-* 0-&0 + $7. # -#3*$ "-,20-* -+$,2 07 3, -05 0# 3, $4$01$ -,20-* ,+(,+ '& " ,) -,%(&30$1 2'$ ++"& * 48 &"+* "-,20-* (,.
!% # Program Group P# 49 Parameter Description ( %$ % #) & % 2.0 to 8.0 0.1kHz 4.0 kHz 0 to 9 Numeric Value 0 0.5 to 300 0.1 Seconds 10.0 Seconds 0 to 1 Numeric Value 0 Numeric Value 0 # "& ) Carrier frequency for the PWM output waveform. % Output Current (A) The chart below provides derating guidelines based on the PWM freq. setting.
# *. , Parameters and Programming Program Group P# 54 $( 1 (" ($.- .),2 ! /&. )$ *" ' !* *" ' !* *" ' !* *" ' !* )$ *" ' !* )$ *" ' !* Parameter Description & , /&. )) # ) ( % ' " ) ' )$ 0 % ' $'"( *!) ' ( ) # ) *!) ' ( ) *# ) $# ( $"%! ) ) + !* ( *)$" ) !!. ( ) )$ 0 ). ( % ' " ) ' ##$) %'$ ' "" , ! ) $#)'$!! ' ( '*## # 55 '),2 ,) , -- ( .
#' % Program Group – Preset Speed Model Only P# ! * ! ! '& '"%+ ( ' " " & % # $# $ " !% ( $ $ $ ) ) " " & % # $# $ " !% ( $ $ $ ) ) " " & % # $# $ " !% ( $ $ $ ) ) " " & % # $# $ " !% ( $ $ $ ) ) " " & % # $# $ " !% ( $ $ $ ) ) " " & % # $# $ " !% ( $ $ $ ) )
*(- % +#((,$'" ' -%, '!(*& ,$(' # ), * 6 -%, '!(*& ,$(' $"-* -%, $+)% / +, -%, -%, ( -& *À -%, $,#(-, *("* & /) ( -% Controllers without a program keypad module come equipped with a fault LED. When the fault LED illuminates, a fault condition exists. À ## )# #),4 $,/ $ 2)1 "#0!/'-1',+0 Controllers equipped with a program keypad module will flash the display when a fault is present.
$ *-"+ &" .&&"-%( .&- ", +%*-%)(, )(-%(."! .& .' "+ .& (!% -%)( .
&* ( " (%+ " ) %%*!$ (% " # .3.1 $.%2 -.3 23!13 . .43/43 5.+3!'% 3. ,.3.1 %(( *!, *!%$ (%#* /.6%1 #)1#4)3 D (%#* 24//+8 5.+3!'% D (%#* !++ &42%2 !-$ $)2#.--%#32 (%#* ,.3.1 D %1)&8 3(!3 ,.3.1 )2 #.--%#3%$ /1./%1+8 (%#* #.-31.+ )-/43 2)'-!+2 D %1)&8 3(!3 2)'-!+ )2 /1%2%-3 D %1)&8 3(!3 2)'-!+ )2 /1%2%-3 D %1)&8 3(!3 !-$ 2)'-!+2 !1% ".
Brake Module BR+ F r e q u e n c y DC+ DC- L1/R T1/U L2/S T2/V L3/T T3/W R e f -10 to +10V e or Potentiometer r e n or c 4 - 20 mA e Reverse Start Stop Common 6–4 Capacitor Module BR- GND/PE TB3 - 1 Control Power TB3 - 2 Bus Voltage Circuitry TB3 - 3 (Common) Motor GND/PE Current Circuitry Fault Feedback TB3 - 4 Program Keypad Module CPU TB3 - 5 TB3 - 6 TB3 - 8 TB3 - 7 Opto Isolator
$ " " ! Tables A.1 and A.2 contain information that is unique to each SSC Controller rating. Table A.3 contains information that applies to all Controller ratings. " ! " ! " ! #" ! ! ! ! ! % /# +0+. 0&*$ ' 10,10 1.
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.
PWM Algorithm Sine Weighted PWM with Harmonic Compensation Switching Device (3-Phase Output) IGBT (Intelligent Power Module) V/Hz Ratio Programmable Carrier Frequency Adjustable from 2kHz to 8kHz in 100 Hz Increments (Factory default is 4 kHz) DC Boost Adjustable - Select from a family of Boost Curves Current Limiting Trip Free Operation, CoĆordinated for Cont
% # " ! ! " ! " ! $ À ! ! " ! " ! $ ! !
& ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ
A–6
Index 4 %+.2%/ $ 4 %+.2%/ $ %)+0/ 2%-%)# !' ! !' *)/-*' ( %!)/ /!(+!- /0-! ) '*# %)+0/ /* ( ) '*# . '! /! $ ++-*1 '. 0/* -!./ -/ -!./ -/ /%(! -!./ -/ /-%!. !) '! - &! /* ./*+ $*' '!1!' !" 0'/. -!.!//%)# /* !/!-(%)%)# *)/-*''!- %)"*-( /%*) % #)*./% . %(!).%*). %.+' 3 #-*0+ + - (!/!-. *)/-*''!- "! /0-!. *)/-*''!- .+! %"% /%*).
Index %"& % 0 * )- & 1 %"&"%-% $ * & %','* $ $ & ,!+ ,+ * '%% & ,"'&+ '* '&,*'$$ * "&+, $$ ,"'& * + ,,"& ,' ,'*1 -$,+ * . *+ & % ($ , "& '*% ,"'& '( * ,"& '&,*'$$ * /",!'-, (*' * % # 1( %' -$ '( * ,"& '&,*'$$ * /",!'-, # 1( '-,(-, '&, ,+ '-,(-, "+ '&& ,"'& '-,(-, * ,"& + +"& $ (! + ,!* (! + '.
Attach template to mounting surface and drill four (4) 4.5 mm (0.177 inches) diameter holes. Dimensions are in millimeters [inches].
44.6C :*-4.A * "7,3?.44 *=<75*<276 +=;26.;; 1*; +..6 1.48260 2<; ,=;<75.:; 258:7>. 8:7-=,<2>22,.; 78.:*<7: 26<.:/*,.; ;.6;7:; *6- * >*:2.
