Rockwell Automation 161B User Manual

Bulletin 161 AC Drive (Series B)
0.2-3.7kW (0.3 to 5 hp) FRN 2.001
User Manual
Important User Information
Solid State equipment has operational characteristics differing from those of electromechanical equipment. ªSafety Guidelines for the Application, Installation and Maintenance of Solid-State Controlsº (Publication SGI-1.1) describes some important differences between solid-state equipment and hardwired 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: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.
Attention statements help you to:
Identify a hazard
Avoid a hazard
Recognize the consequences
IMPOR TAN T: Identifies information that is especially important for successful application and
understanding of the product.
Shock Hazard labels located on or inside the drive indicate that dangerous voltage may be present.
i
Table of Contents
1. Getting Started ........................................................................................
Important Precautions p.1 Conventions used in this manual p.2 Catalog Number Explanation p.2 Receiving Your New Drive p.3 Nameplate Label p.3 Drive Features p.4
2. Installation & Wiring ...............................................................................
Storage and Operating Conditions p.5 CE Compliance p.5 Installation p.5 Clearances p.5 Terminal Blocks p.6 Power Wiring p.7 Power Terminal Block Wiring Specifications p.8 Branch Circuit Protection Devices p.8 Input Power Conditioning p.8 Grounding p.8 Control Wiring p.9 Control Terminal Descriptions p.10 Programmable Digital Input (Control terminal block inputs 1 through 5) Functions p.12
3. Parameters & Programming ..................................................................
Programming Keypad p.15 Programming Examples p.16 Initial Power Up p.16 Scrolling through parameter groups p.16 Operation of the Drive via the Fixed Keypad p.17 Activating the Speed Pot on the Keypad P.17 Restoring Factory Defaults p.18 Parameter Groups p.19 Parameter Descriptions p.21
d Group - Display and Diagnostic Parameters (Read Only) p.21 F Group – Basic Function Parameters p.22 A Group – Advanced Function Parameters p.22 b Group – Advanced Control and Protection Parameters p.29 C Group – Intelligent I/O and Communication Parameters p.33
4. Faults & Troubleshooting ......................................................................
Fault Information p.35 How to Clear a Fault p.35 Bulletin 161 Fault Descriptions p.35 Possible Problems and Corrective Actions p.36 Other Displays p.37
ii
5. Specifications & Dimensions ................................................................
Technical Data p.39 Dimensions p.40 Accessories p.42
A. CE Conformity ........................................................................................
CE Compliance p.43 General Notes and Instructions p.43 Essential Requirements for a Conforming EMC Installation p.43 Motor Cable p.43 Control Cable p.43
1
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 Bulletin 161 drive contains high voltage DC bus capacitors which take time to discharge after removal of input power. Before working on the drive, wait five minutes for capacitors to discharge to safe voltage levels. Darkened display LEDs are not an indication that capacitors have discharged to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION
This Bulletin 161 drive generates dangerous electrical voltages and controls potentially dangerous rotating mechanical parts. Disregarding the guidelines provided in this manual could result in severe bodily injury or loss of life.
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 could result in bodily injury and/or damage to the equipment.
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. Failure to observe this precaution could result in damage to the equipment.
ATTENTION
The drive is intended to be installed with a fixed ground connection. The protective ground only offers protection for the drive, not against personal injury. According to EN50178 it is not recommended to use the Bulletin 161 drives on protective fault current switches as, due to a possible DC component (rectifier load), the sensitivity of the safety switch will be reduced in the event of a failure. If unavoidable, only type B Residual Current Operated Protective Devices (RCD’s) should be used. As a precautionary measure, the EN50178 regulations should be observed. Failure to observe this precaution could result in severe bodily injury or loss of life.
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. Failure to observe this precaution could result in damage to the equipment.
Getting Started
2
1 Ratings through 3 HP (2.2 KW) are rated for single or three phase input
ATTENTION
To prevent any injuries or damage, do not touch any components located within the housing with your hands or with any other objects while input voltage is applied or if the DC-bus capacitors are not discharged. Do not carry out any work on the wiring or check any signals if input voltage is applied.
ATTENTION
Ensure that the input voltage corresponds to the voltage indicated on the product nameplate. Environmental influences such as high temperatures and high relative humidity are to be avoided as well as dust, dirt and corrosive gases. The mounting location should be well ventilated and not exposed to direct sunlight. Install the device upright on a non-flammable, vertical wall. Failure to observe this precaution could result in damage to the equipment.
ATTENTION
The drive start/stop and enable control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit is required to remove AC input power to the drive.
All the pertinent safety regulations, e.g. accident prevention regulations, professional association regulations, EN, VDE regulations etc. must be observed. As these regulations are implemented differently in different countries, the user must observe the regulations that apply for his particular country. Failure to observe these precautions could result in severe bodily injury or loss of life.
General information
Conventions used in this manual
To help differentiate parameter names and parameter settings from other text the following conventions will be used:
Parameter numbers and names are shown in the following way: Pd01 - [Output Frequency]
Parameter Settings for inputs and outputs are shown with the setting number followed by the alpha description in {Braces} ex: 18{RS}
Catalog Number Explanation
Figure 1.1 below describes the 161 catalog numbering scheme. Please note that not all combinations can be configured as a Drive, refer to Chapter 5 – Specifications & Dimensions.
Figure 1.1Catalog Number
161S
First Position Second Position Third Position Fourth Position Fifth Position Sixth Position
A A01 N P K-
Bulletin Number Voltage Rating Current Rating Enclosure Type Programmer Default Setting
S = Standard
1
A = 200-240V A 01 N = Open (IP20) P = Fixed Keypad K = 50 Hz default settings D = 100-120V A 02
A 03
U = 60 Hz default settings
A 04 A 05 A 07 A 10 A 15
3
Getting Started
Receiving Your New Drive
It is your responsibility to thoroughly inspect the equipment before accepting 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 cover in place on the top of the drive.
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 161 drive was provided in Figure 1.1 as an aide for nameplate interpretation.
IMPORTANT: Before you install and start up your Bulletin 161, inspect for mechanical integrity. Look closely for loose parts, wires and connections.
Nameplate Label
Figure 1.2 depicts a typical Bulletin 161 Nameplate Label.
Figure 1.2Bulletin 161 Nameplate Label
Series
Catalog Number
Letter
161S-AA01NPK SERIES B
FRN: 2.001
NE16452-2
MADE IN JAPAN
I
N
A: 3.1(1.8)
P U
Hz: 50/60
T
VA: 500
S/N:
Allen-Bradley
82TT1362281161
O
V: 200-230 3ØV: 200-240 1Ø (3Ø)
U
A: 1.4
T P
Hz: 0.5-360
U
T
Motor
Rating:
IP20
POWER TERMINAL WIRE
Use 75°C Cu Wire
2.1- 0.75mm2 (14-18 AWG)
Torque 0.9 Nm (8 in.-lbs.)
0.2 kW / 0.3 HP
Date: 9927
Serial Number Enclosure Rating Firmware
Version
Getting Started
4
Drive Features
Fixed keypad
Control terminal block cover
Screw
RS422 serial interface
Enclosure
Heat sink
Front case
Screw
To wire the power terminals and fault relay, loosen the screw and open the front case.
Note that for ratings AA01­AA03 the screw is located under the control terminal block cover.
Debris cover
Control terminal block
Protective earth ground connection
Fault relay terminals
RS422 serial interface
Terminal cover
Power terminal block
Chapter 2 – Installation & Wiring
Storage and Operating Conditions
Follow these recommendations to prolong drive life and performance:
Store within an ambient temperature range of –25
Store within a relative humidity range of 20 to 90%, non-condensing.
Avoid storing or operating the drive where it could be exposed to a corrosive atmosphere.
Protect from moisture and direct sunlight.
Operate within an ambient temperature range of –10 IMPORTANT: To operate the drive between 40
o
Reduce the carrier frequency to 2kHzReduce the output current to 80% of the drives rated currentRemove the debris cover from the top of the drive
CE Compliance
Refer to Appendix A – CE Conformity.
Installation
Mount the drives on a flat, vertical and level surface. Drive orientation must be vertical (top up) for proper heat dissipation.
Install the drive with screws, recommended screw sizes are listed in the table below. Note that ratings AA01-AA03 require screws at the upper left and lower right corners only.
o
C to 70oC.
o
C to 40oC.
C and 50oC, make the following adjustments:
Description Metric English Mounting Torque 1.2 – 1.3 Nm 10.6 – 11.5 lb.in. Mounting Base Screws M4 x 0.7 #8-32
Ensure that debris cover is in place when installing the drive to prevent filings, cable insulation and dust from entering the drive.
Clearances
The drive should be installed using the minimum clearances shown in Figure 2.1.
Figure 2.1 Bulletin 161 Minimum Clearances and Airflow
100 mm (3.94 in)
30 mm (1.18 in)
30 mm (1.18 in)
Air Circulation
100 mm (3.94 in)
5
Installation & Wiring
Terminal Blocks
Figure 2.2 Location of Power, Control, and Fault Relay Terminal Blocks
L
54321
Protective earth
Front cover opened
ground connection
+1 +
P24 AL0
***
L1
L2 N/L3 U/T1 V/T2 W/T3
Power terminal block, AA01 - AA03 ratings only
+1(/) +
terminal block
AL1 AL2
Faul t relay
HO0I LFM
Control terminal block
CM2 12 11
L1 Power terminal block, all ratings except AA01 - AA03 *
Not Used
L2 N/L3 U/T1 V/T2 W/T3
ATTENTION
• The installation, commissioning and maintenance of these drives may only be carried out by experienced personnel who are thoroughly familiar with the functioning of the equipment and the entire machine.
• The devices feature DC-bus capacitors that are energized even when the input supply is switched off. For this reason wait at least 5 minutes after switching off the input supply before you open the device and start working on it. Take care that you do not touch any live parts.
• Do not apply input voltage to the output terminals U/T1, V/T2 and W/T3 as drive damage could occur.
• Contact the motor or machine manufacturers if standard motors with frequencies greater than 60 Hz will be used in your application.
• Failure to follow these precautions could result in severe bodily injury, loss of life or damage to the equipment.
6
Installation & Wiring
Power Wiring
Precautions:
ATTENTION
• Ensure that the input voltage corresponds to the voltage indicated on the product nameplate.
• In normal operation apply the START/STOP commands via the control terminals or the control panel and not by disconnecting and reapplying input power to the drive or motor contactor. If it is necessary to use this method for starting and stopping, or if frequent cycling of power is unavoidable, make certain it does not occur more than once every 5 minutes. Do not install any capacitors or suppressors to the drive output terminals.
• Exercise particular caution if automatic restart is activated. To prevent injuries caused by automatic restarting of the drive following a power failure, install a switching component at the input that is deactivated in the event of a power failure and that may only be manually switched on again on return of the power supply (e.g. contactor etc.).
• Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240V maximum.
Figure 2.3 Power wiring block diagram
Input power supply
Disconnect
Device
Fuses
Optional
Filter
L1
L2
N/L3
U/T1
3
V/T2
Motor
W/T3
Bulletin 161
+
+1
DC Bus Optional
DC Bus Reactor
1
Figure 2.4 Power terminal block descriptions
+1 +
***
L1
L2 N/L3 U/T1 V/T2 W/T3
AA01 - AA03 Power terminal block
Terminal Description L1, L2, N/L3 Connection to incoming power. For single phase input applications, connect the AC input power to
U/T1, V/T2, W/T3 Motor connections
-/+ DC Bus connection +1
+
*
Not Used
input terminals L1 and N/L3
These terminals are connected by a jumper. For applications requiring a DC bus reactor, remove the jumper prior to installing the third party device.
Protective earth ground connection
+1(/) +
L1
All ratings except AA01 - AA03 Power terminal block
L2 N/L3 U/T1 V/T2 W/T3
1 DC Bus Reactor would be used to assist in limiting harmonic distortion from the 161 to the line and reducing capacitive heating due to low impedance lines.
7
Installation & Wiring
Power Terminal Block Wiring Specifications
2
Model Screw Size Max/Min Wire Size mm
AA01-AA02 M3.5 2.1 – .75 (14-18) 0.9-0.8 (8.0-7.0) AA03 M3.5 2.1 – 1.3 (14-16) 0.9-0.8 (8.0-7.0) AA04, DA01 M4 5.3 – 1.3 (10-16) 1.3-1.2 (11.5-10.6) AA05-AA10, DA02-DA03 M4 5.3 – 2.1 (10-14) 1.3-1.2 (11.5-10.6) AA15 M4 5.3 – 3.3 (10-12) 1.3-1.2 (11.5-10.6)
(AWG) Max/Min Torque Nm (lbin)
Power Terminal Connection
IMPORTANT:
Bulletin 161 Drives feature an electronic overload protection to monitor the motor current. In the case of multi-motor operation, thermal contacts or PTC resistors must be used for each motor.
In the case of motor lead lengths greater than 50 meters (165 feet), motor reactors should be used.
Branch Circuit Protection Devices
The following table shows the minimum recommended values for the branch circuit protection devices:
Fuse Rating (Class CC, J) Bulletin 140
Model 1 Ph 3 Ph 1 Ph 3 Ph
AA01 10 10 140M-D8N-C10 140M-D8N-B40 AA02-AA03 10 10 140M-D8N-C10 140M-D8N-B63 AA04-AA05 15 15 140M-D8N-C16 140M-D8N-C10 AA07 20 15 140M-D8N-C16 140M-D8N-C16 AA10 30 20 140M-D8N-C25 140M-D8N-C16 AA15 N/A 30 N/A 140M-D8N-C25 DA01 10 N/A 140M-D8N-C10 N/A DA02 15 N/A 140M-D8N-C10 N/A DA04 20 N/A 140M-D8N-C16 N/A
Input Power Conditioning
The drive is suitable for connection to input power within the rated voltage of the drive (see specifications). The power factor of the input power supply must not exceed .99. Compensation systems must ensure that over compensation does not occur at any time. If the drive must be installed in any of the following conditions, an Input Line Reactor must be used:
Input Power Condition Corrective Action
Line has intermittent noise spikes in excess of 2000V Install 3% impedance Input Line Reactor If frequent voltage dips occur Install 3% impedance Input Line Reactor The drive is operated on a generator Install 3% impedance Input Line Reactor Line has power factor correction capacitors Install 3% impedance Input Line Reactor Several drives are linked via a short common power supply bus bar. Install 3% impedance Input Line Reactor
Grounding
ATTENTION
• The Bulletin 161 has a high leakage current and must be permanently (fixed) hard wired to ground. Failure to observe this precaution could result in severe bodily injury or loss of life.
Ground the drive. Be sure to separate the drive’s grounding pole from those of other electrical machinery. If multiple drives are used, make certain grounding connections do not create a loop as shown in Figure 2.5.
Figure 2.5 Suggested 161 Grounding
Bulletin 161
Protective Earth Ground
8
Bulletin 161 Bulletin 161 Bulletin 161 Bulletin 161 Bulletin 161
Protective Earth Ground
Control Wiring
Requirements
Run all signal wiring in either a shielded cable or separate metal conduit.
Do not exceed control wiring length of 20 meters (65.6 feet).
Use Belden 8760 (or equivalent) –18 AWG (0.750mm
Avoid crossing the power lines or motor lines with the control wires. If they must cross, ensure that they cross at right (90
o
) angles.
If using transistor outputs 11 or 12, with an inductive load such as a relay, install a recovery diode parallel to the relay as shown in Figure 2.6, to prevent damage to the output.
Control Terminal Block Wiring Specifications
2
Max/Min wire size mm
0.750 – 0.14 (18-28) 0.25 - 0.2 (2.21 – 1.77)
Note: 0.75mm2 (18 AWG) wire must be used for the alarm relay. Torque the mounting screw to: 0.5-0.6 Nm (4.4-5.3 in lb).
Figure 2.6 Control Wiring Block Diagram
(AWG) Max/Min Torque Nm (in lb)
2
), twisted pair, shielded or 3 conductor.
Installation & Wiring
24V
External Power
MPORTANT: Only one frequency
ource may be connected at a time.
f more than one reference is
onnected at the same time,
n undetermined frequency
eference will result.
o improve noise immunity, the ommon (terminal L) must be onnected to ground terminal/
protective earth.
1-2k Ohm
P24
1
2
3
4
5 L
Pot.
0-10V
4-20mA
Internal Power
Frequency
Reference
P24
1
2
3
See Note 2
4
5
L
H
O
OI
L
10V
FM
11
CM2
12
CM2
AL0
AL1
AL2
L
0-10V PWM OutPut
V
Parm C01 C02 C03 C04 C05
Parm C01 C02 C03 C04 C05
Notes:
~
Fault Relay
230V AC
Factory Default
Setting & Description
Input
Terminal 1 2 3 4 5
"U"
Default 22 20 21 18 13
2 1
"U" Default
Description 3 wire fwd/rev 3 wire run 3 wire stop reset USP
Factory Default
Setting & Description
Input
Terminal 1 2 3 4 5
1. Parameter C13 is NC. This input must be active (jumpered) for the drive to run. See following pages for description of these settings.
2. A contact closure on terminals 3 and P24 is required for the controller to respond to a Start/Run command.
"K"
"K" Default
Default
Description
0
Run fwd
1
Run rev
2
Preset input 1 (CF1)
3
Preset input 2 (CF2)
13
USP
Figure 2.7 Control terminal block descriptions
ATTENTION
A hazard of electrical shock, death or equipment damage exists. Control terminals are isolated but not tied to earth ground. If terminal (L) on the control terminal block is not grounded, exposed conductors, shields or metal conductors can be at hazardous voltage levels. Failure to observe this precaution could result in severe injury or loss of life.
L
54321P24
HO0ILFM
Control Terminal Block
CM2 12 11
9
Installation & Wiring
Control Terminal Descriptions
ATTENTION
• DO NOT jumper or short circuit terminals H and L or P24 and L or drive damage could occur.
The following table gives a description of each of the terminals on the control terminal block as well as the fault relay:
Control
Terminal
P24 24 V DC 24 V potential for digital inputs 1-5 max. load 30mA 1 Programmable Digital
Inputs.
2
26V max, 5KΩ input impedance.
3
4
5
L 0 V 0 V potential for output FM H 10 V Reference Voltage for
Analog Frequency Command
O Voltage Analog Input
Frequency Command (0-10V)
OI Current Analog Input
Frequency Command (4-20 mA)
L 0 V Reference Potential for
Frequency Command Inputs
FM Programmable Analog
Output
Analog or Pulse Output Frequency or Motor Current
Function Description
Digital inputs 1 – 5 are fully programmable level triggered inputs via parameters C01 thru C05. These inputs are level triggered. An overview of the possible functions can be found in the digital input description table in Chapter 2. The inputs are fully programmable with these exceptions:
1. No two inputs can have the same function
2. Only input 5 can be programmed as PTC.
3. With the exception of the reset setting which must be NO (active high), all of the inputs can be set as NO (active high) or NC (active open) via PC11-[Digital Input 1 Logic] - PC15-[Digital Input 5 Logic].
Note: A signal must be applied to the digital inputs for at least 12 ms
Potentiometer 1 to 2 kOhm
H O
OI
L
PE PE
0-9.6 V nominal 0-10 V
H
+
O
Input impedance
OI
10 kOhm
L
-
Input OI for 4-20mA is activated when one of the digital inputs is set to 16{AT} via PC01-[Digital Input 1] – PC05-[Digital Input 5] The analog input reference can be adjusted using PA11-[Analog Frequency Minimum] – PA16-[Analog Filter Select]. If no digital input is programmed as 16{AT}, the set values are the sum of O and OI.
This output can be used to monitor the output frequency of the drive (either Analog or Pulse) or the motor current. This output is programmable using PC23-[Output FM].
Analog Signal Frequency or Current
t
10 V
+
-
Pulse Signal (50% duty cycle) Frequency only
10 V
4-19.6 mA nominal 0-20 mA
H O
Input impedance
OI
250 Ohm
L
PE
10
s
T
T=4ms (constant) T = (Variable)
T
s
Analog Signal: The relation t/T (duty cycle) changes proportionally with the frequency or current. The maximum voltage of 10V (100% duty cycle) is reached when the maximum frequency or 200% of the rated current is reached. Pb81 ­[Output FM Factor] may be used as a scaling factor.
Accuracy: +/- 5% for frequency , +/- 20% for current
Pulse Signal: Frequency = output frequency x Pb86-[Process Display Scale Factor], but the maximum frequency is 3.6 kHz (ex. Freq = 60Hz x 60 = 3.6kHz).
Installation & Wiring
Control
Function Description
Terminal
CM2 Reference potential for
outputs 11 and 12
12 Programmable Digital
Output
11 Programmable Digital
Output
AL0 Fault Relay
Transistor output, max. 27 Vdc, 50 mA
11,12
CM2
+
24V
The outputs can be programmed as either NO (active high) or NC (active open) contacts using PC31-[Digital Output 11Logic] and PC32-[Digital Output 12 Logic].
The following 6 settings may be programmed using PC21 - [Digital Output 11] and PC22-[Digital Output 12]: 00{RUN} = Motor Running (Signal if output frequency > 0.5 Hz) 01{FA1} = At frequency (Signal when the set frequency is
reached and that frequency is > 0.5Hz)
02{FA2} = Above frequency (Signal if output frequencies >
the
frequencies set under PC42-[Above Frequency Accel Setting] or PC43-[Above Frequency Decel Setting] and >
0.5 Hz).
03{OL} = Motor overload (Signal if the motor current exceeds
the value set under PC41-[Overload Alarm Setting]
04{OD} = PID-deviation (Signal if the deviation between the
set value and the actual value returned is greater than the value set under PC44-[PID Deviation Setting]).
Only available
if the PID control PA71 –[PID Enable] is active.
05{AL} = Fault (Signal if a fault is indicated)
250 VAC, 2.5 A resistive
AL0
230V AC
0.2A inductive
AL1
AL2
AL1
30 VDC, 3.0A resistive
0.7A inductive
min. 100 VAC, 10mA
AL2
5 VDC 100 mA
Faulted / De-energized State
PC33-[Fault Relay AL1 Logic] can be used to invert the operation.
PC33 PC33 = 01 PC33 = 00
AL0 – AL1 Open when Faulted
Open when Power Off
AL0 – AL2 Closed when Faulted
Closed when power off
Closed when faulted
Open when Power Off
Open when Faulted
Closed when Power Off
The fault relay is set with a time delay of approximately 2s after the power is switched on.
11
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