Rockwell Automation Allen-Bradley 160 SSC Series User manual

160 SSC™
Variable Speed
Drive
(Series C)
0.37–4.0 kW (0.5–5 HP)
FRN 7.03
FRN 7.04
FRN 7.05
FRN 7.06
User Manual

Important User Information
Solid-State equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Controls” (Publication SGI-1.1) describes some
important differences between solid-state equipment and hard-wired
electromechanical devices. Because of this difference, and also because of the wide
variety of uses for solid-state equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended application of this equipment
is acceptable.
In no event will Rockwell Automation be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
Attention statements help you to:
• identify a hazard
• avoid a hazard
• recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
SSC is a trademark of Rockwell Automation, Inc.
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage or economic loss.
Shock Hazard labels located on or inside the drive indicate that
dangerous voltage may be present.

S-1
• New Horsepower Ratings
4 kW (5 HP), 230V and 460V ratings have
been added to the Bulletin 160 family.
• Increased Transient Protection
Standard input voltage transient protection
has been increased to 6 kV and contained
in the drive itself. The optional MOV
module is no longer required.
• Improved Ground Fault Protection
The Bulletin 160 detects phase-to-phase
and phase-to-ground faults both at start-up
and while running.
• Reduced 2.2 kW (3 HP) Footprint
2.2 kW (3 HP), 230V and 460V width has
been reduced by more than 45%.
• One Piece, 1.5 kW (2 HP) 230V Single Phase
Unit
The external capacitor module has been
integrated into the 1.5 kW (2 HP), 230V
single phase unit. The overall width of the
unit is reduced, however, the height,
depth, and mounting hole pattern has
changed.
• Improved Start/Stop Overlap Timing
The STOP command can be removed up
to 20 msec after a START command and
the drive will still recognize the START
command. This allows the drive to
respond to a START command occurring
concurrently with or slightly after a STOP
command is removed.
• Additional Fault History
P17 , P18 , and P19 - [Fault Buffer 0, 1 and 2]
have been added to record the last three
faults for diagnostic purposes.
• Analog Model with Preset Speed Capability
Analog Signal Follower models have an
additional input mode. With P46 - [Input
Mode] setting 8, four preset speeds are
available.
• External Frequency Selection
P46 - [Input Mode] has an additional setting
(setting 7) which allows for the frequency
source to be switched from the control
terminal block (TB3) to the P58 - [Internal
Frequency] setting.
• New Output Configuration Setting
P47 - [Output Configure] has a new setting.
When setting 10 is selected, the output
will be active when the Power Factor
Angle is above the P48 - [Output Threshold]
setting.
• Additional Compensation Mode
P78 - [Compensation] has an additional
mode that corrects for slow responding
systems which can cause current regulator
oscillations.
• Software Current Trip
P79 - [Software Current Trip] provides an
adjustable software current trip with a one
second time delay.
• Adjustable Stall Fault Time
The time that the drive must be in a stall
condition before causing a stall fault is
selectable via P80 - [Stall Fault Time] .
• PI Control
Process control is now intergrated in the
drive through a PI regulator. Users of
Firmware Version FRN 7.05 and earlier
activate this feature with P46 - [Input Mode]
setting 9. Users of Firmware Version FRN
7.06 can activate this feature with P46 -
[Input Mode] settings 0 through 7 and 9.
PI control is adjusted through parameters
P81 - [PI Proportional Gain] , P82 - [PI
Integrated Gain] , P83 - [PI Process
Reference] , and P84 - [PI Dead Band].
• Fault Auto Clear
Over voltage, Under voltage, and Over
temperature faults are automatically
cleared when the fault condition is
removed.
• RS-232 Serial Communication
An RS-232 serial communication module
using a DF1 protocol is now available. See
160-RS1 User Manual for additional
information.
• Ground Screw Location
Grounding screws are now located on the
power connection terminal blocks for
easier wiring.
Series C Summary of Changes

S-2
Series C Application/Installation Considerations
Keep the following in mind if you are replacing a Bulletin 160 Series A or B drive
with a Series C unit.
Mounting Dimensions
• Width has increased by 8 mm for all ratings through 1.5 kW (2 HP).
Note: If proper spacing recommendations were followed for Series A and B
drives, the increased width should not effect the panel layout because Series C
drives of this rating do not require spacing between units.
• Width has decreased by 50 mm for the 2.2 kW (3 HP) rating.
• Depth has increased by 25 mm for all ratings through 2.2 kW (3 HP).
Note: The drive utilizes the same DIN base and mounting hole pattern for all
ratings through 2.2 kW (3 HP).
External Braking
• The internal brake transistor is not available on 0.37 kW (1/2 HP) and 0.55 kW
(3/4 HP) units. If external braking is required, a 0.75 kW (1 HP) drive must be
used.
DeviceNet
• DeviceNet modules (Catalog No.160-DN1) with Firmware Version FRN 2.0 or
earlier are not compatible with the Bulletin 160 Series C drives. Series C drives
must use DeviceNet modules (Catalog No. 160-DN2). The 160-DN2 module is
also compatible with Series A and B drives with the exception of the Series A
Preset Speed model with Firmware Version FRN 4.04.
24V DC Interface
• Bulletin 160 Series C drives must use a Series B, or later, 24V DC Interface
module. See Appendix B for catalog numbers.
Terminal Block Wiring
• The ground terminal is now located on the power terminal block. Refer to
Figure 2.2 on page 2-3 to avoid incorrect wiring.
Incorrect Motor Rotation
• The output phasing of Series C drives is different than the output phasing of
Series A and B drives. Replacing a Series A or B drive with a Series C drive
using the same U, V and W (T1, T2 and T3) connections will reverse the motor
rotation. To assure the same direction of rotation, switch any 2 of the 3 output
wires connected to U, V or W (T1, T2 or T3) from the motor.
Example:
U/T1 V/T2 W/T3
U/T1
V/T2
Motor
W/T3
U/T1 V/T2 W/T3
U/T1
V/T2
Motor
W/T3
Original
Wiring of
Series A or B
Wiring of
Replacement
Series C

Table of Contents
Getting Started
Important Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receiving Your New Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Identifying Your Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Standard Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Optional Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Installation and Wiring
Storage and Operation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Debris Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Terminal Block Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Motor Branch Circuit Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Branch Circuit Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Motor Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Long Motor Cable Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Important Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Control Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Control Methods and Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Configurable Relay Output Contacts (P47 Settings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Frequency Source Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Analog Signal Follower Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Preset Speed Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Analog and Preset Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
What To Do Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

ii
Program Keypad Module
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Module Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Start-Up
Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Parameters and Programming
Overview of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Important Reset Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Programming Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Display Group Parameters (Read Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Program Group Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
PI Control Setup and Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Wire For PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Program for PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tune the PI Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Common Problems with PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Troubleshooting
Fault Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
How to Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Accessories and Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Accessory Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
CE Conformity
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Essential Requirements for a Conforming EMC Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
General Instructions for an EMC Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Shielded Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Cable Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Low Voltage Directive 73/23/EEC Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Chapter 1
Getting Started
Important Precautions
In addition to the precautions listed throughout this manual, you must read and
understand the following statements which identify hazards associated with AC
drives.
ATTENTION: The drive contains high voltage capacitors which take
time to discharge after removal of mains supply. Before working on
drive, ensure isolation of mains supply from line inputs
[R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge
to safe voltage levels. Failure to do so may result in personal injury
or death.
Darkened display LEDs is not an indication that capacitors have
discharged to safe voltage levels.
ATTENTION: Only personnel familiar with the drive and associated
machinery should plan or implement the installation, start-up, and
subsequent maintenance of the system. Failure to comply may result
in personal injury and/or equipment damage.
ATTENTION: The surface temperatures of the drive may become
hot, which may cause injury.
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference Publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or reduction in product life. Wiring or application
errors such as undersizing the motor, supplying an incorrect or an
inadequate AC supply, or excessive ambient temperatures may result
in system malfunction.

1-2 Getting Started
Receiving Your New Drive
It is your responsibility to thoroughly inspect the equipment before accepting the
shipment from the freight company. Check the item(s) received against your
purchase order. If any items are obviously damaged, do not accept delivery until
the freight agent notes the damage on the freight bill.
Unpacking
Remove all packing material, wedges, or braces from within and around the drive.
Remove all packing material from the heat sink. Leave the debris label in place.
If you find any concealed damage during unpacking notify the freight agent. Also,
leave the shipping container intact and have the freight agent make a visual
inspection of the equipment to verify damage.
Inspecting
After unpacking, check the item(s) nameplate catalog number against your
purchase order. An explanation of the catalog numbering system for the Bulletin
160 drive follows as an aid for nameplate interpretation. Refer to Figure 1.1 and
Figure 1.2.
Important: Before you install and start up the drive, inspect for mechanical
integrity. Look for loose parts, wires, and connections.
Identifying Your Drive
Catalog Number
The figure below describes the 160 SSC catalog numbering scheme.
Catalog Number Explanation Figure 1.1
➊ Amperage ratings vary based on voltage.
Note: Rockwell Automation offers a configured drive program which allows for NEMA rated 4, 4x, or 12 enclosures.
160 -AA02 N SF1 P1
Bulletin Number Current Rating➊Enclosure TypeVoltage Rating
A01
A02
A03
A04
A06
A08
A10
A12
A18
N Open (IP20)
L Low Profile
P Chassis Mount
(external heatsink)
R Chassis Mount
Replacement
A 200-240V, 1-Phase
200-240V, 3-Phase
B 380-460V, 3-Phase
First Position Second Position Third Position Fourth Position Sixth Position
Model
Fifth Position
Programmer
(Optional)
SF1 Analog Signal
Follower
PS1 Preset Speed
B1 Ready/Fault
Indicating Panel
P1 Program Keypad
Module
An “S” in the Bulletin
Number denotes a
single-phase input
voltage.

Getting Started 1-3
Nameplate
The nameplate is located on the side of the drive.
Nameplate Information Figure 1.2
Conventions Used In This Manual
Parameter numbers and names are shown in this format: P01 - [Output Frequency] .
P01 denotes the parameter number and the parameter name is enclosed in square
brackets.
160-AA02NSF1P1 SERIES C
ANALOG S.F. FRN: 7.XX
IP20
Allen-Bradley MADE IN U.S.A.
0.37KW / 0.5 HP
Motor
Rating:
I
N
P
U
T
O
U
T
P
U
T
V: 200-240 3 Ø
A: 2.8
Hz: 50/60
VA: 1100
V: 200-230 3 Ø
A: 2.3
Hz: 0-240
S/N: XXXXXXXX
XXXXX
OPERATING AMBIENT TEMP: 0 - 50°C
SHORT CIRCUIT CURRENT: 100 KA
POWER TERMINAL WIRE :
Use 75°C Cu Wire:
4 mm2- .75 mm2(12-18 AWG.)
Torque 1.35 Nm (12 in.- lbs.)
CUS

U
L
LISTED
IND. CONT. EQ.
966X
Catalog Number
Series Letter
Firmware Version
Drive Model
Serial Number
Date Code
Enclosure Rating

1-4 Getting Started
Standard Drive Features
The drive features identified in the figure below apply to all models.
Standard Drive Features and Mounting Orientation Figure 1.3
• Hinged Finger Guard allows easy access to line/load power terminals.
• Ready/Fault Indicating Panel is standard on the Bulletin 160 drive. The drive
is fully functional with this panel installed. All control functions can be
performed from TB3 (Control Terminal Block). Factory default settings cannot
be changed with this panel.
• Fault Indicator LED illuminates when a drive fault condition exists. Refer to
Chapter 6 for details on how to clear a fault and general troubleshooting
procedures.
• Ready Indicator LED illuminates when the DC bus is charged and the drive is
ready to run.
• DC Bus Test Points provide easy access for test probes when measuring DC
Bus voltage.
• Cooling Fan provides air flow across heatsink fins to prevent overheating. Not
required on .37 or .55 kW (.5 or .75 HP) ratings.
• DIN Latch provides an easy means for mounting the drive on standard 35 mm
DIN Rail. This feature is not available with 4.0 kW (5 HP) or 1.5 kW (2 HP)
single phase units.
Cooling Fan
DIN Latch
Status LEDs
DC+
W/T3
1345678910112
V/T2
U/T1 DC–
BR+
T/L3
S/L2
R/L1 BR–
FAULT
READY
Hinged Finger Guard
Hinged Finger Guard
Cooling
Air Flow
Ready/Fault
Indicating Panel
DC Bus Test Points

Getting Started 1-5
Optional Drive Features
The drive features identified in the figure below are optional. See Appendix B for
catalog numbers. (Finger guards omitted for clarity.)
Optional Drive Features Figure 1.4
•Dynamic Brake Module option allows you to connect dynamic brake
resistors. Not available on .37 or .55 kW (.5 or .75 HP) ratings.
Important: P52 - [DB Enable] must be enabled for proper operation.
•Line Filter Module option is available to reduce conductive emissions.
•Program Keypad Module option can be ordered separately and field installed,
or as a factory installed option by adding “P1” to the end of the catalog number.
Refer to Chapter 3, Program Keypad Module for a detailed explanation of
functionality.
•DeviceNet Communication Module option allows control and monitoring of
parameters via a DeviceNet network.
•RS-232 Communication Module option allows control and monitoring of
parameters via a RS-232 network.
•Remote Programming Adapter option allows connection to Remote Keypad
Module or Copycat Keypad Module via cable (1 to 3 meters).
•24V DC Interface Module option allows you to command the drive with 24V
logic (sinking inputs).
•Capacitor Module option allows you to connect an external capacitor module.
Provides extended ride through capability and improved inherent braking
performance.
Dynamic Brake
Module
Line Filter Module
Program Keypad Module
or
DeviceNet Communication Module
or
RS-232 Communication Module
or
Remote Programming Adapter to:
Remote Keypad Module
or
CopyCat Keypad Module
24V DC Interface Module
Capacitor
Module
DC+
W/T3
1345678910112
V/T2
U/T1 DC–
BR+
T/L3
S/L2
R/L1 BR–

1-6 Getting Started
End of Chapter

Chapter 2
Installation and Wiring
Storage and Operation Conditions
Follow these recommendations to prolong drive life and performance:
• Store within an ambient temperature range of –40°to +85°C.
• Store within a relative humidity range of 0% to 95%, non-condensing.
• Protect the cooling fan by avoiding dust or metallic particles.
• Avoid storing or operating the drive where it could be exposed to a corrosive
atmosphere.
• Protect from moisture and direct sunlight.
• Operate at an ambient temperature range of 0°to +50°C.
CE Compliance
Refer to Appendix C.
Installation
Mount the drive on a flat, vertical and level surface. See Chapter 1, Figure 1.3 for
mounting orientation.
Choose an installation method:
• Install with screws. Recommended screw size is listed in the table below.
The appropriate drilling template for your drive is provided in Appendix B.
• Install on 35 mm DIN Rail. This mounting method is not available on
4.0 kW (5 HP) three phase or 1.5 kW (2 HP) single phase models.
See Appendix B for details on drive dimensions and weights.
Clearances
Maintain 12.5 mm (0.5 in.) clearance at the top, bottom, and front of all drives.
Clearance requirements between units varies by model.
• 2.2 kW (3 HP) 230V/460V Drives
Provide a minimum of 8.5 mm (0.33 in.) clearance between units.
• All Other Drive Ratings
No clearance is required between units.
Debris Label
The drive is shipped with a paper debris label attached to the top side of the plastic
housing to cover the cooling vents. Leave the debris label attached during drive
installation to protect against debris falling through the vents of the drive housing.
To assure proper drive operation, you must remove label before applying power.
Description Metric English
Minimum Panel Thickness (14 GA) 1.9 mm 0.0747 in.
Mounting Base Screws m4 x 0.7 # 8-32
Mounting Torque 1.13 –1.56 Nm 10 –14 lb.-in.
ATTENTION: After system installation, remove the debris label
from unit. Failure to remove this label may result in overheating or
nuisance tripping.

2-2 Installation and Wiring
Power Wiring
Precautions
Terminal Blocks
Terminal R (L1) is not present on single phase drives. Three phase unit terminal
block configuration is depicted in the figure below.
Drive Terminal Blocks Figure 2.1
ATTENTION: Remove and lock out power from the drive before
you disconnect or reconnect wires or perform service. Verify bus
voltage by measuring the voltage between DC- and DC+ on Terminal
Block TB2. Do not attempt to service the drive until bus voltage has
discharged to zero volts.
ATTENTION: The drive is intended to be commanded by control
input signals that will start and stop the motor. A device that routinely
disconnects then reapplies input power to the drive for the purpose of
starting and stopping the motor should not be used. If it is necessary
to use this method for starting and stopping, or if frequent cycling of
power is unavoidable, make sure that it does not occur more than once
a minute.
ATTENTION: Do not connect power factor correction capacitors to
drive output terminals U, V and W (T1, T2 and T3) or component
damage could occur.
Terminal Block TB3
Control Wiring
TB3
Terminal Block TB2
Ground, Motor &
Capacitor Module Wiring
TB2
Terminal Block TB1
Ground, Line Power &
Dynamic Brake Module Wiring
TB1
DC+
W/T3
1345678910112
V/T2
U/T1 DC–
BR+
T/L3
S/L2
R/L1 BR–
FAULT
READY
Hazardous Voltages
Behind Panel

Installation and Wiring 2-3
Terminal Block Wiring
Terminal Block Wiring Detail Figure 2.2
Specifications
Terminal Block TB1 and TB2 Wiring Specifications Table 2.A
➊For single phase input applications, connect the AC input power to input terminals S (L2) and T (L3).
➋See Table 2.B for minimum recommended branch circuit protective devices.
➌Bulletin 160 Drives are UL Listed (see Appendix A for details) as motor overload protective devices
(IEC Class 10 overload). An external overload relay is not required for single motor applications
as long as the Drive kW (HP) rating is less than three times larger than the motor kW (HP) rating.
➍Each terminal supports up to 2 wires of approved gauge.
Model Screw Size Max./Min. Wire Size ➍
mm2(AWG)
Max./Min. Torque
Nm (lb.-in.)
4.0 kW (5 HP) M4 5.26 –3.31 (10 –12) 1.35 –0.90 (12 –8)
All Other Ratings M4 3.31 –0.82 (12 –18) 1.35 –0.90 (12 –8)
Required Branch
Circuit Disconnect ➊
Branch Circuit
Protective Device ➋
BR+
T/L3
S/L2
R/L1 BR–
DC+
W/T3
V/T2
U/T1 DC–
Ground Terminal/Protective Earth
Terminal Block TB1
Terminal Block TB2
Motor ➌

2-4 Installation and Wiring
Motor Branch Circuit Analysis
Short circuit and overload protection are requirements of any motor branch circuit.
Input power conditioning, CE conformance, reflective wave, capacitive current
coupling, and motor cable type are important considerations of drive applications.
Branch Circuit Configuration Figure 2.3
•Branch Circuit Protective Devices
A motor branch circuit requires protection against excessive current. This
protection can be provided by a fuse, circuit breaker, or manual motor starter.
See Table 2.B for a detailed list of these options.
•Input Power Conditioning
Certain conditions may exist that could damage a drive in the branch circuit.
See Table 2.C for an explanation of problems and solutions.
•CE Conformance
See Appendix C for information on CE Conformance.
•Motor Cable Types
See Table 2.D for recommended cable types.
•Reflected Wave Protection
The use of a drive may result in increased peak-to-peak voltage at the motor.
See Table 2.E for an explanation of motor insulation limitations versus cable
lengths.
•Capacitive Current Coupling
High speed voltage switching causes AC coupling from motor cables to ground
terminal/protective earth. See Table 2.F for cable length recommendations.
•Overload Protection
All motor branch circuits require overload protection. The Bulletin 160 Drive is
UL listed to provide protection (IEC Class 10 overload) without an overload
relay. Separate overload relays are required in multi-motor applications or if the
drive kW (HP) rating is more than three times larger than the motor kW (HP)
rating.
Branch Circuit Protective Devices –See Table 2.B
Input Power Conditioning –See Table 2.C
160 SSC™
Motor Cable Types –See Table 2.D
Reflected Wave Protection –See Table 2.E
Overload Protection
CE Conformance –See Appendix C
Capacitive Current Coupling –See Table 2.F
Motor

Installation and Wiring 2-5
Branch Circuit Protective Devices
Fusing
The Bulletin 160 Smart Speed Controller has been UL tested and approved for use
with input fuses. The ratings in the table below are the minimum recommended
values for use with each drive rating. The devices listed in this table are provided
to serve as a guide. Other devices which meet the requirements of UL508C and
UL489 with similar trip characteristics may be used in order to meet local or
national electrical codes.
Bulletin 140 Manual Motor Starters/UL489 Circuit Breakers
When using Bulletin 140 manual motor starters or UL489 rated circuit breakers,
the guidelines listed below must be followed in order to meet the NEC requirements
for branch circuit protection.
• Bulletin 140 manual motor starters can be used in single and group motor
applications.
• In single motor applications, a fuse or UL489 rated circuit breaker is required
ahead of the Bulletin 140 manual motor starter.
• In group motor installations, the Bulletin 140 can be used for protection of an
individual motor within the group and “one set” of fuses or a UL489 rated
circuit breaker serves as the Branch Circuit Protective Device for the entire
“Group Installation”.
• Bulletin 140M manual motor starters can be used in single and group motor
applications without additional short circuit protection. Refer to the technical
support literature for the 140M for more details.
Minimum Recommended Branch Circuit Protective Devices ➊Table 2.B
➊The maximum branch circuit protection rating is limited to four times the rated output current of
the drive or 30A, whichever is less.
➋Fuse class CC, J, BS88, VDE 06366/gG, IEC 269-1/gG, EN60269 part 1 and 2 type gG
Voltage Rating Drive Rating
kW (HP)
Fuse Rating ➋UL489 Rated
Circuit Breaker
Amps
Bulletin 140/140M
Manual Motor Starter
Amps
Single Phase
230V
0.37 (0.5)
0.55 (0.75)
0.75 (1)
1.5 (2)
6
10
15
30
16
16
16
20
16
16
16
20
Three Phase
230V
0.37 (0.5)
0.55 (0.75)
0.75 (1)
1.5 (2)
2.2 (3)
4.0 (5)
6
6
10
15
20
30
16
16
16
16
20
30
16
16
16
16
20
30
Three Phase
460V
0.37 (0.5)
0.55 (0.75)
0.75 (1)
1.5 (2)
2.2 (3)
4.0 (5)
4
4
5
8
15
20
6
6
6
16
16
20
6
6
6
16
16
20

2-6 Installation and Wiring
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated voltage
of the drive (seeAppendixA). Listed in Table 2.C are certain input power conditions
which may cause component damage or reduction in product life. If any of the
conditions exist, as described in Table 2.C, install one of the devices listed under
the heading Corrective Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be
mounted closest to the branch and sized to handle the total current
of the branch circuit.
Input Power Conditions Table 2.C
Motor Cable Types
A variety of cable types are acceptable for variable speed drive installations. For
many installations, unshielded cable is adequate, provided it can be separated from
sensitive circuits. As an approximate guide, allow a spacing of 1 meter (3.3 feet)
for every 10 meters (33 feet) of unshielded length. If you cannot separate motor
cables from sensitive circuits, or if you must run motor cables from multiple drives
(more than three) in a common conduit or cable tray, shielded motor cable is
recommended to reduce system noise.
Motor cables should be four-conductor with the ground lead and shield (if using
shielded cable) connected to the drive ground terminal and the motor frame ground
terminal.
Table 2.D provides the recommended wire type for both wet and dry installations
as defined by NEC 1996 (70-31). These recommendations are based upon a variety
of factors such as insulation thickness, susceptibility to moisture and susceptibility
to nicks and cuts during installation.
Recommended Cable Type Table 2.D
➊For input power voltages in excess of 264VAC, or motor cable distances greater than 15 meters
(50 feet), wire with XLPE insulation is recommended.
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Check Line Impedance
•Line Reactor (See Appendix B)
•or Isolation Transformer
Available short circuit currents (fault currents) greater than
100,000 Amps
•Check Supply Transformer
•Line Reactor (See Appendix B)
•or Isolation Transformer
Greater than 120 kVA supply transformer •Line Reactor (See Appendix B)
•or Isolation Transformer
Line has power factor correction capacitors •Line Reactor (See Appendix B)
•or Isolation Transformer
Line has frequent power interruptions •Line Reactor (See Appendix B)
•or Isolation Transformer
Line has intermittent noise spikes in excess of 6000V
(lightning)
•Line Reactor (See Appendix B)
•or Isolation Transformer
Condition Insulation Type Example
Dry PVC ➊THHN
XLPE XHHW-2
Wet XLPE XHHW-2

Installation and Wiring 2-7
Long Motor Cable Effects
Reflected Wave Protection
The drive should be installed as close to the motor as possible. Installations with
long motor cables may require the addition of external devices to limit voltage
reflections at the motor (reflected wave phenomena). See Table 2.E for
recommendations.
Important: Both Reflected Wave and Capacitive Current Considerations need
to be taken into account when determining motor cable lengths
(see Table 2.E and Table 2.F). The use of an external device to
limit reflected wave phenomenon may effect the accuracy of
Bulletin 160 current sensing.
The reflected wave data applies to all frequencies 2 to 8 kHz. For 230V ratings,
the maximum cable length recommendations are the same as the capacitive current
recommendations (see Table 2.F).
Cable Length Recommendations –Reflected Wave Table 2.E
➊Cable lengths listed are for PWM frequencies of 2 kHz. Refer to publication 1204-5.1 for cable length recommendations at
other PWM frequencies.
➋The maximum peak-to-peak voltage of the drive is 1400V due to the minimum on/off time software.
Reflective Wave Testing has been done on cable lengths up to 160 meters (600 feet). See Table 2.F for capacitive current
recommendations.
380-
460V
Ratings
Motor
Insulation
Rating
Motor Cable Only RWR at Drive ➊Reactor at Motor
Shielded Unshielded Shielded Unshielded Shielded Unshielded
feet meters feet meters feet meters feet meters feet meters feet meters
4.0 kW
(5 HP)
1000 Vp-p 45 13.7 20 6.1 525 160 600 183 325 99.1 300 91.5
1200 Vp-p 90 27.4 40 12.2 525 160 600 183 525 160 425 130
1600 Vp-p ➋525 160 475 145 525 160 600 183 525 160 600 183
2.2 kW
(3 HP)
1000 Vp-p 40 12.2 40 12.2 525 160 600 183 225 68.6 250 76.2
1200 Vp-p 90 27.4 60 18.3 525 160 600 183 325 99.1 425 130
1600 Vp-p ➋525 160 500 152 525 160 600 183 525 160 600 183
1.5 kW
(2 HP)
1000 Vp-p 40 12.2 40 12.2 425 130 600 183 325 99.1 300 91.5
1200 Vp-p 90 27.4 60 18.3 425 130 600 183 425 130 450 137
1600 Vp-p ➋500 152 500 152 425 130 600 183 540 165 600 183
0.75 kW
(1 HP)
1000 Vp-p 55 16.8 40 12.2 325 99.1 600 183 325 99.1 350 107
1200 Vp-p 125 38.1 60 18.3 325 99.1 600 183 500 152 450 137
1600 Vp-p ➋500 152 500 152 325 99.1 600 183 500 152 600 183
0.55 kW
(0.75 HP)
1000 Vp-p 45 13.7 40 12.2 300 91.5 600 183 300 91.5 300 91.5
1200 Vp-p 125 38.1 60 18.3 300 91.5 600 183 500 152 500 152
1600 Vp-p ➋500 152 500 152 300 91.5 600 183 500 152 600 183
0.37 kW
(0.5 HP)
1000 Vp-p 45 13.7 90 27.4 300 91.5 425 130 300 91.5 425 130
1200 Vp-p 125 38.1 180 54.9 300 91.5 425 130 500 152 500 152
1600 Vp-p ➋500 152 500 152 300 91.5 425 130 500 152 500 152

2-8 Installation and Wiring
Capacitive Current Coupling
AC coupling exists from motor cables to ground terminal/protective earth. The
current produced by this coupling is referred to as capacitive current. The drive
current is the combination of capacitive current and motor current. Because motor
current is monitored for overload protection, the table below lists the maximum
cable length recommendations that will assure a capacitive current error of less
than 15 percent.
Cable Length Recommendations —Capacitive Current Table 2.F
➊Not recommended for use above 4 kHz PWM Frequency.
➋When using shielded cable at lightly loaded conditions, cable length recommendations for drives rated 0.75 kW (1 HP) and
below are 61 meters (200 feet).
➌Not recommended for 230V applications.
380-460V
Ratings
kHz Motor Cable Only RWR at Drive ➊Reactor at Motor
Shielded ➋Unshielded Shielded ➋Unshielded Shielded ➋Unshielded
feet meters feet meters feet meters feet meters feet meters feet meters
4.0 kW
(5 HP)
2350 107 600 183 300 91.5 600 183 400 122 600 183
4425 130 600 183 350 107 600 183 450 137 600 183
8475 145 500 152 ➊450 137 500 152
2.2 kW
(3 HP)
2360 110 600 183 280 85.4 600 183 400 122 600 183
4375 114 600 183 275 83.8 600 183 400 122 600 183
8400 122 500 152 ➊400 122 500 152
1.5 kW
(2 HP)
2300 91.5 550 168 275 83.8 600 183 300 91.5 600 183
4300 91.5 550 168 275 83.8 600 183 300 91.5 500 152
8325 99.1 500 152 ➊350 107 500 152
0.75 kW
(1 HP)
2200 61 375 114 200 61 425 130 225 68.6 400 122
4225 68.6 375 114 200 61 425 130 225 68.6 375 114
8250 76.2 375 114 ➊225 68.6 400 122
0.55 kW
(0.75 HP)
2180 54.9 350 107 180 54.9 375 114 180 54.9 350 107
4180 54.9 350 107 180 54.9 375 114 180 54.9 350 107
8180 54.9 350 107 ➊180 54.9 350 107
0.37 kW
(0.5 HP)
2100 30.5 325 99.1 100 30.5 350 107 100 30.5 300 91.5
4100 30.5 325 99.1 100 30.5 350 107 100 30.5 350 107
8100 30.5 325 99.1 ➊100 30.5 350 107
200-240V Ratings No Reactor RWR at Drive ➊Reactor at Motor
0.37 to 4.0 kW
(0.5 to 5 HP)
2 through 8 kHz
Shielded ➋Unshielded Shielded ➋Unshielded Shielded ➋Unshielded
feet meters feet meters feet meters feet meters feet meters feet meters
525 160 600 183 ➌525 160 600 183