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
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 KeypadP.17
Restoring Factory Defaultsp.18
Parameter Groupsp.19
Parameter Descriptionsp.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
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
Technical Data p.39
Dimensionsp.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 PositionSecond Position Third PositionFourth PositionFifth PositionSixth Position
A A01 N P K-
Bulletin Number Voltage RatingCurrent RatingEnclosure TypeProgrammerDefault Setting
S = Standard
1
A = 200-240VA 01N = Open (IP20)P = Fixed Keypad K = 50 Hz default settings
D = 100-120VA 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-AA01NPKSERIES 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 NumberEnclosure RatingFirmware
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 2kHz
➢ Reduce the output current to 80% of the drives rated current
➢ Remove 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:
DescriptionMetricEnglish
Mounting Torque1.2 – 1.3 Nm10.6 – 11.5 lb.in.
Mounting Base ScrewsM4 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–+
P24AL0
***
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
TerminalDescription
L1, L2, N/L3Connection to incoming power. For single phase input applications, connect the AC input power to
U/T1, V/T2, W/T3Motor 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.
•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:
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 ConditionCorrective Action
Line has intermittent noise spikes in excess of 2000VInstall 3% impedance Input Line Reactor
If frequent voltage dips occurInstall 3% impedance Input Line Reactor
The drive is operated on a generatorInstall 3% impedance Input Line Reactor
Line has power factor correction capacitorsInstall 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.
•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/
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
P2424 V DC24 V potential for digital inputs 1-5 max. load 30mA
1Programmable Digital
Inputs.
2
26V max, 5KΩ input
impedance.
3
4
5
L0 V0 V potential for output FM
H10 V Reference Voltage for
Analog Frequency
Command
OVoltage Analog Input
Frequency Command
(0-10V)
OICurrent Analog Input
Frequency Command
(4-20 mA)
L0 V Reference Potential for
Frequency Command Inputs
FMProgrammable Analog
Output
Analog or Pulse Output
Frequency or Motor Current
FunctionDescription
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
PEPE
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
FunctionDescription
Terminal
CM2Reference potential for
outputs 11 and 12
12Programmable Digital
Output
11Programmable Digital
Output
AL0Fault 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.
PC33PC33 = 01PC33 = 00
AL0 – AL1Open 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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