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



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:

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

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: (1) 414 382-2000, Fax: (1) 414 382-4444

Publication 160-5.9DU3 – April, 1997 P/N 40055-188-01 (A)

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)

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

RL3

TBR

– BR

1 2 3 4 5 6 7 8 9 10 11

UT3

W–

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

RL3

TBR

– BR

1 2 3 4 5 6 7 8 9 10 11

UT3

W–

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

RL3

TBR

– BR

1 2 4 5 6 8 9 10 11

UT3

W–

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.

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: (1) 414 382-2000, Fax: (1) 414 382-4444



t

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]

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.





This Page Intentionally Blank

##"

 #!!#!$#"

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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