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