Allen-Bradley 160 SSC User manual

160 SSC™
Variable
Speed
Controller
(Series B)
0.37 – 2.2 kW (1/2 – 3 HP)
FRN 5.xx
Allen-Bradley
Installation
Manual
Table of Contents Index
spl_en_b.fm5 Page 1 Monday, September 15, 1997 1:31 PM

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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 dif
ferences 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. In no event will Rockwell
Automation Company be responsible or liable for
indirect or consequential damages resulting from
the use or application of this equipment.
The illustrations shown in this manual are
intended solely to illustrate the text of this
manual. Because of the many variables and
requirements associated with any particular
installation, Rockwell Automation cannot assume
responsibility or liability for actual use based
upon the illustrative uses and applications.
No patent liability is assumed by Rockwell
Automation with respect to use of information,
circuits or equipment described in this text.
Reproduction of the content of this manual, in
whole or in part, without written permission of
the Rockwell Automation Company is prohibited.

The information in this manual is or ganized in
numbered chapters. Read each chapter in
sequence and perform procedures when you are
instructed to do so. Do not proceed to the next
chapter until you have completed all procedures.
Throughout this manual we use notes to make you
aware of safety considerations:
A TTENTION: Identifies information
about practices or circumstances that
can lead to personal injury or death,
property damage or economic loss.
Attentions help you:
Didentify a hazard
Davoid the hazard
D
recognize the consequences
Important: Identifies information that is
especially important for successful application
and understanding of the product.
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160_5_9DU3.doc 1 Mon Sep 15 11:46:33 1997
Thispublicationprovidesnewinformation forthe160SSCVariable
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. All other features specified in the
User Manual will be operational.
Document Update
160 SSC™Variable Speed
Controller (Series B)
Rockwell Automation helps its customers receive a superior return on their investment by bringing
together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate
products. These are supported by local technical resources available worldwide, a global network
of system solutions providers, and the advanced technology resources of Rockwell.
Worldwide representation.
Argentina • Australia • Austria • Bahrain • Belgium • Bolivia • Brazil • Bulgaria • Canada • Chile • China, People’s Republic of • Colombia • Costa Rica • Croatia • Cyprus
Czech Republic • Denmark • Dominican Republic • Ecuador • Egypt • El Salvador • Finland • France • Germany • Ghana • Greece • Guatemala • Honduras • Hong Kong
Hungary • Iceland • India • Indonesia • Iran • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Macau • Malaysia • Malta • Mexico
Morocco • The Netherlands • New Zealand • Nigeria • Norway • Oman • Pakistan • Panama • Peru • Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia
Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic of • Spain • Sweden • Switzerland • Taiwan •Thailand • Trinidad • Tunisia • Turkey • United Arab Emirates
United Kingdom • United States • Uruguay • Venezuela
Rockwell Automation Headquarters, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: [phone], Fax: [phone]
Publication 160-5.9DU3 – April, 1997 P/N 40055-188-01 (A)
Copyright 1997 Rockwell International Corporation. All rights reserved. Printed in USA.
SSC is a trademark of Rockwell Automation.

160_5_9DU2.doc 1 Mon Sep 15 11:42:00 1997
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
machinesorsystemsfortheindustrialenvironment.Ithasbeentested
tomeettheCouncilDirective89/336 ElectromagneticCompatibility
(EMC) and all applicable standards.
Important: Theconformityofthecontrollerandfiltertoanystandard
does not guarantee that the entire installation will con-
form. Many other factors can influence the total installa-
tion and only direct measurements can verify total con-
formity. It is therefore the responsibility of the machine
manufacturer, to ensure, that the conformity is met.
Essential Requirements for a Conforming EMC Installation
1. An input line filter module (see “Accessories” in Appendix A)
mustbeinstalledtoreduceconductedemissions.When using the
filters listed in Appendix A, the maximum motor cable lengths
must be 75 meters (250 feet) for controllers rated 200-240VAC,
and 40 meters (133 feet) for controllers rated 380-460VAC.
2. The controller system must be mounted in a shielded enclosure
to reduce radiated emissions.
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. Allmotorcablesmustuseshieldedcable,orbeingroundedmetal
conduit.
6. All control and signal wiring must use shielded cable or be in
grounded metal conduit.
7. TheCommonterminals(TB3-3&7)musthaveasolidconnection
to PE (protective earth).
Document Update
160 SSC™Variable Speed
Controller (Series B)
SSC is a trademark of Rockwell Automation.

160_5_9DU2.doc 2 Mon Sep 15 11:42:00 1997
2160 SSC™ Variable Speed Controller (Series B)
GeneralInstructionsforan
EMCCompliantInstallation 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.
• All wiring, except input power leads, must use shielded cable.
• Input power, output power and control wiring inside the enclosure
must be physically separated.
• Inputpower,outputpowerandcontrolwiringoutsidetheenclosure
must use separate shielded cables, or separate conduit.
Cable Clamps
• Use suitable EMC-tested cable clamps only.
• Theconnectionareamustbe360degreesaroundtheshieldedcable.
• The cable clamps also provide strain-relief for the cable.
• When using conduit, the contact point of metal entry connections
must be free of paint or non-conductive surfaces and solidly
connected with good conductivity to the enclosure.
Figure 1 Recommended Grounding Configuration
R (L1)
S (L2)
T (L3)
PE
AC
Input Line
Shielded Enclosure
Enclosure Ground Connection
U (T1)
Shielded Motor Cable
to TB3
Control
Cabinet
*
to Motor
V (T2)
W (T3)
R (L1)
S (L2)
T (L3)
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
*When the control circuitry is located outside of the 160 enclosure.
ControlWiring TB3
Motor Wiring TB2
L2
S
L1
RL3 TBR – BR +
1 2 3 4 5 6 7 8 9 10 11
T2
V
TI
UT3 W– DC + DC
GroundTab – PE
Line Power TB1
FAULT
READY
Line
Filter

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
cablelengthsshallbelimitedto75meters(250feet)forcontrollers
rated 200-240VAC and 40 meters (133 feet) for controllers rated
380-460VAC.
• Inside the shielded enclosure, shielded motor cable must be used
as close to the controller’s output terminals as possible. The shield
must be solidly connected to the PE terminal of the controller.
• Wheretheshieldedmotorcableexitstheenclosure,anEMC-tested
cable clamp, or metal conduit must be used to solidly connect the
cable shield to the enclosure.
• Theshieldonthemotorsidemustbesolidlyconnectedtothemotor
housing with an EMC-tested cable clamp, or conduit, providing
good conductivity from the cable shield to the motor housing.
Figure 2 Motor Connections
Figure 3 Shielded Motor and Control Cable Example
Shielded Enclosure U (T1)
V (T2)
W (T3)
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
*When the control circuitry is located outside of the 160 enclosure.
Motor Wiring TB2
L2
S
L1
RL3 TBR – BR +
1 2 3 4 5 6 7 8 9 10 11
T2
V
TI
UT3 W– DC + DC
GroundTab – PE
FAULT
READY
4 Wire
Shielded Motor Cable
Ground to Motor Housing
Stranded Copper Wire
Plastic Insulation
Inner Plastic Sheath
Compact Screen of Galvanized (Tinned) Copper or Steel
Outer Plastic Jacket

160_5_9DU2.doc 4 Mon Sep 15 11:42:00 1997
4160 SSC™ Variable Speed Controller (Series B)
Control Cable
• Controlwiringmustuseshieldedcable,orgroundedmetalconduit.
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.
Figure 4 Control Connections
Shielded Enclosure
= EMC Tested Shielded Cable Clamp (or Metal Conduit)
*When the control circuitry is located outside of the 160 enclosure.
ControlWiring TB3
L2
S
L1
RL3 TBR – BR +
1 2 4 5 6 8 9 10 11
T2
V
TI
UT3 W– DC + DC
GroundTab – PE
FAULT
READY
Shielded Control
Cable
Signal
Common
Control
Cabinet
*
to TB3
3 7
Rockwell Automation helps its customers receive a superior return on their investment by bringing
together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate
products. These are supported by local technical resources available worldwide, a global network
of system solutions providers, and the advanced technology resources of Rockwell.
Worldwide representation.
Argentina • Australia • Austria • Bahrain • Belgium • Bolivia • Brazil • Bulgaria • Canada • Chile • China, People’s Republic of • Colombia • Costa Rica • Croatia • Cyprus
Czech Republic • Denmark • Dominican Republic • Ecuador • Egypt • El Salvador • Finland • France • Germany • Ghana • Greece • Guatemala • Honduras • Hong Kong
Hungary • Iceland • India • Indonesia • Iran • Ireland • Israel • Italy • Jamaica • Japan • Jordan • Korea • Kuwait • Lebanon • Macau • Malaysia • Malta • Mexico
Morocco • The Netherlands • New Zealand • Nigeria • Norway • Oman • Pakistan • Panama • Peru • Philippines • Poland • Portugal • Puerto Rico • Qatar • Romania • Russia
Saudi Arabia • Singapore • Slovakia • Slovenia • South Africa, Republic of • Spain • Sweden • Switzerland • Taiwan • Thailand • Trinidad • Tunisia • Turkey • United Arab Emirates
United Kingdom • United States • Uruguay • Venezuela
Rockwell Automation Headquarters, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: [phone], Fax: [phone]
Publication 160-5.9DU2 – May 1997 Copyright 1997 Rockwell International Corporation. All rights reserved. Printed in USA.

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New features include:
DIncr
eased Low Speed T orque.
The parameter P71 – [IR Compensation]
was
added, allowing adjustment of the amount of
IR compensation desired. This is used to
compensate for stator resistance and allows
much higher levels of starting torque. The
default level of P38 – [Boost Select]
has
changed.
DImproved Acceleration.
The acceleration current ramp regulator has
been retuned and the current feedback filter
time constant was reduced, allowing improved
performance with short acceleration times
under all load conditions. The drive power-up
diagnostics were also shortened considerably ,
which improves response time to a START
signal.
DImproved Current Sensing
The current sense accuracy has been improved
for low speeds and light loads. Capacitive
current cancellation has been added to
eliminate errors due to long shielded cables.
DRobust Current Limit.
A fast frequency foldback was added to
operate with the hardware current limit. This
allows the drive to continue operating under
adverse conditions.
DImproved Speed Regulation.
The parameter P72 – [Slip Compensation]
was added, which compensates for inherent
slip in an induction motor . This assists in
maintaining a constant motor shaft speed
under heavy loading conditions.
DConfigurable Terminal Block Input
The parameter P46 – [Input Mode]
has been
expanded to provide greater flexibility . New
input modes include the ability to select
secondary accel/decel times, switch between
local and remote control or enable/disable of
the controller.
DImproved Drive Functionality.
The “DC Injection Braking” setting for P34 –
[Stop Mode Select] has been improved by
incorporating a current limit function. In
addition, the delay time before applying
voltage has been eliminated.
The parameter P44 – [DC Hold Time] is now
settable up to 25 seconds in 0.1 second
increments and P37 – [Maximum Voltage] is
now settable to 1 10% of the drive rating.
DImproved Analog Input Operation.
The input range and scaling of the analog
inputs has been improved. Refer to P60 –
[Zero Offset], P74 – [Analog Select],
P75 – [Analog Input Minimum]
, and
P76 – [Analog Input Maximum].
DEnhanced Frequency Selection.
P58 – [Internal Frequency] is now controlled
in real time. This means that the output
frequency will change while the parameter is
being adjusted. Pressing the ENTER key will
retain the new frequency
. Pressing the ESCape
key will cause the drive to accel/decel back to
the previous setting.
In addition, P58 – [Internal Frequency] and
P59 – [Frequency Select] are now available
in both the Preset Speed model and the
Analog Signal Follower model.

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ii
This Page Intentionally Blank

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i
 #!!#!$#"
General Information 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions Used In This Manual 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 #!"##!
Installation and Storage 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC Directive Compliance 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Voltage Directive Compliance 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Features 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Wiring For Preset Speed and Analog Signal Follower Models 2–2. . . . . . . . . . . . .
Line Side Protection Recommendations 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Cable Recommendations 2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Requirements 2–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring – Analog Signal Follower Model 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring – Preset Speed Model 2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Diagrams 2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 #!!!& $
Features 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Mode 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Mode 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Program Keypad Module 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 #!#!#
Start–up Procedure (Analog Signal Follower Model) 4–1. . . . . . . . . . . . . . . . . . . . . . . . .
Start–up Procedure (Preset Speed Model) 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 #!!#!"!!
Overview of Parameters 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming Example 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Group Parameters 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program Group Parameters 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 #!!$"#$#!#
Fault Information 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Diagram of Bulletin 160 Analog Signal Follower Model 6–4. . . . . . . . . . . . . . . . .
 %
Controller Specifications A–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Dimensions A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalog Numbers For Bulletin 160 Accessories A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
%
Index I–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .