Allen-Bradley 161S-AA04NPU User Manual
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Allen-Bradley 161S-AA04NPU User Manual

Allen-Bradley 161S-AA04NPU User Manual

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  • Page 1 (217) 352-9330 | Click HERE Find the Rockwell / Allen-Bradley 161S-AA04NPU at our website:...
  • Page 2 Allen-Bradley Bulletin 161 AC Drive User (Series B) Manual 0.2-3.7kW (0.3 to 5 hp) FRN 2.001 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 3 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.

  • Page 4: Table Of Contents

    Table of Contents 1. Getting Started ..................Important Precautions Conventions used in this manual Catalog Number Explanation Receiving Your New Drive Nameplate Label Drive Features 2. Installation & Wiring ................Storage and Operating Conditions CE Compliance Installation Clearances Terminal Blocks Power Wiring Power Terminal Block Wiring Specifications Branch Circuit Protection Devices...
  • Page 5 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 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 6: Getting Started

    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.

  • Page 7: Conventions Used In This Manual

    Getting Started 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.

  • Page 8: Receiving Your New Drive

    0.2 kW / 0.3 HP Motor V A: 500 Rating: 82TT1362281161 9927 NE16452-2 S/N: Date: IP20 Allen-Bradley MADE IN J AP AN Serial Number Enclosure Rating Firmware Version Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 9: Drive Features

    Getting Started Drive Features Fixed keypad Control terminal block cover Screw RS422 serial interface Enclosure Heat sink Front case Control terminal block Screw To wire the power terminals and fault relay, loosen the screw and open the front case. Note that for ratings AA01- AA03 the screw is located under the control terminal block cover.

  • Page 10: Installation & Wiring

    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 C to 70 • Store within a relative humidity range of 20 to 90%, non-condensing. •...

  • Page 11: Terminal Blocks

    Installation & Wiring Terminal Blocks Figure 2.2 Location of Power, Control, and Fault Relay Terminal Blocks Front cover opened Protective earth ground connection – AL1 AL2 L2 N/L3 U/T1 V/T2 W/T3 Power terminal block, AA01 - AA03 ratings only – Fault relay terminal block O 0I...

  • Page 12: Power Wiring

    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.

  • Page 13: Power Terminal Block Wiring Specifications

    Installation & Wiring Power Terminal Block Wiring Specifications Model Screw Size Max/Min Wire Size mm (AWG) Max/Min Torque Nm (lbin) 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 5.3 – 1.3 (10-16) 1.3-1.2 (11.5-10.6) AA05-AA10, DA02-DA03 M4 5.3 –...

  • Page 14: Control Wiring

    Installation & Wiring 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 ), twisted pair, shielded or 3 conductor.

  • Page 15: Control Terminal Descriptions

    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 Function...
  • Page 16 Installation & Wiring Control Function Description Terminal Reference potential for Transistor output, max. 27 Vdc, 50 mA outputs 11 and 12 11,12 – The outputs can be programmed as either NO (active high) or NC (active open) contacts using PC31-[Digital Output 11Logic] Programmable Digital and PC32-[Digital Output 12 Logic].

  • Page 17: Programmable Digital Input (Control Terminal Block Inputs 1 Through 5) Functions

    Installation & Wiring Programmable Digital Input (Control terminal block inputs 1 through 5) Functions The function of the digital inputs 1 through 5 are programmed via the corresponding PC01 [Digital Input 1] through PC05 - [Digital Input 5]. The following programming guidelines must be followed: •...
  • Page 18 Installation & Wiring C01 - C05 Alpha Function Description Setting Setting {FRS} Coast to Stop The motor voltage will be switched off immediately and the motor will coast. This function can be programmed to operate in two different modes via Pb88-[FRS Select]. Run (NO) Input 11 {FRS} (NO) Motor speed...
  • Page 19 Installation & Wiring C01 - C05 Alpha Function Description Setting Setting {RS} Reset Used to clear a fault condition. If a 18 {RS} command is given during operation, the output IGBT’s are switched off and the motor will coast. min 12 ms 18 {RS} (NO) ca.

  • Page 20: Parameters & Programming

    Chapter 3 – Parameters & Programming ATTENTION Wait at least 6 seconds after programming the Bulletin 161 before issuing a start, reset command, or switching off the power supply. Failure to wait 6 seconds, could result in failure to recognize programming changes, which could lead to bodily injury or damage to the equipment.

  • Page 21: Programming Examples

    Parameters & Programming Figure 3.2 Programming Guide A .. View Save B .. Parameter Change Entered Value Parameter Parameter Value Value C .. Press SEL to enter Scroll Thru Scroll Thru parameter group. Parameter Groups Parameter Numbers Programming Examples In this section you will find four different programming examples to help you program the 161 drive. Initial Power Up This example shows you how to proceed from the power up parameter value to the actual parameter number.

  • Page 22: Operation Of The Drive Via The Fixed Keypad

    Parameters & Programming Action Description Display Press the SELect Key to view the parameter value stored in PC21 - [Digital 01 01 01 01 Output 11]. Press the SELect Key again to exit from the parameter value back to the C 21 C 21 C 21...

  • Page 23: Restoring Factory Defaults

    Parameters & Programming Restoring Factory Defaults This example will show you how to reset the factory defaults of the drive. Action Description Display 20. Press the Down Key to advance to the b parameter group. b - - 21. Press the SELect key to enter into the b parameter group. b 01 22.

  • Page 24: Parameter Groups

    Parameters & Programming Figure 3.3 Parameter Groups Parameter Tree d group - Display and Diagnostic Parameters (Read only) Display & Diagnostic Functions d01 Output Frequency d02 Output Current d03 Direction d04 PID Process Display d05 Digital Input Status d06 Output Status d07 Process Display d08 Last Fault d09 Fault Register...
  • Page 25 Parameters & Programming Parameter Tree cont. b Group - Advanced Control and Protection Automatic Start After a Fault b01 Restart Mode Select b02 Power Loss Time b03 Restart Time Electronic Motor Protection b12 Motor Overload Current b13 Motor Overload Select Current Limit b21 Current Limit Select b22 Current Limit...

  • Page 26: Parameter Descriptions

    Parameters & Programming Parameter Descriptions D Group - Display and Diagnostic Parameters (Read Only) This group of parameters consists of commonly viewed drive operation conditions such as output frequency. All parameters in this group are Read Only. Parameter Parameter Name / Description Min./Max Units Number...

  • Page 27: F Group - Basic Function Parameters

    Parameters & Programming F Group – Basic Function Parameters Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Basic Functions [Frequency Command] 0.0/360.0 0.1 Hz When parameter A01- [Frequency Command Select] is set to 00 or 01, this parameter will display the commanded frequency.
  • Page 28 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Basic Functions [Base Frequency] 50/360 1 Hz Set value to rated nameplate frequency of motor Upper Command Voltage Frequency Limit Frequency 100% Frequency Start Base Maximum Minimum Frequency Frequency...
  • Page 29 Parameters & Programming U = 50Hz default settings, K = 50 Hz default settings. Settable using Pb85 – [Factory Default Select] Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Pre-Set Frequencies [Internal Frequency] 0.0/360.0 0.1 Hz 60.0 When PA01-[Frequency Command Select] is set to 02, this parameter will provide the drives frequency command.
  • Page 30 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults V/F Characteristics / Boost [Boost Select] 00/01 Numeric Used to select auto or manual boost Value Settings: 00=Manual Boost 01=Auto Boost [Manual Boost Voltage] 0/99 Numeric Sets the boost level as a percent of PA82 - [Base Value Voltage].
  • Page 31 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults DC Brake [DC Brake Enable] 00/01 Numeric Value Used to enable/disable DC injection braking Settings: 00=Disabled 01=Enabled [DC Brake Start Frequency] 0.5/10.0 0.1Hz 10.0 10.0 Sets the frequency at which the DC brake will become active.
  • Page 32 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Operating Frequency Range cont. [Skip Frequency 3] 0.0/360.0 0.1Hz Sets a frequency at which the drive will not output continuously. [Skip Frequency Band 3] 0.0/10.0 0.1 Hz Sets the bandwidth around PA67 - [Skip Frequency 3].
  • Page 33 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Operating Frequency Range cont. [Accel / Decel 2 Select] 00/01 Numeric Used to determine when the PA92 – [Accel Value Time 2] and PA93 - [Decel Time 2] are used. Settings: 00=Digital inputs (C01-C05) set to 09{2CH} 01=Automatic if frequency...

  • Page 34: Group - Advanced Control And Protection Parameters

    Parameters & Programming b Group – Advanced Control and Protection Parameters Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Automatic Start After a Fault [Restart Mode Select] 00/03 Numeric Value Selects the restart mode for the drive Settings: 00=Fault indication 01=0 Hz start...
  • Page 35 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Current Limit [Current Limit Select] 00/02 Numeric Selects the mode for current limit. Value Settings: 00=Inactive 01=Active 02=Inactive in acceleration [Current Limit] 50/150% of 0.01 A 150% of 150% of Sets the maximum output current allowed before...
  • Page 36 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Initialization / Adjustment Function [Output FM Adjustment] 0/255 Sets the multiplier applied to output duty cycle for the FM analog signal. This Parameter can be changed while motor is running. [Start Frequency] 0.5/9.9 0.1 Hz...
  • Page 37 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Initialization / Adjustment Function [FRS Select] 00/01 Numeric Value Selects operation of the drive after a digital input (C01 – C05) setting 11{FRS} input is removed. Settings: 00=0 Hz start 01=Synchronization of motor speed...

  • Page 38: C Group - Intelligent I/O And Communication Parameters

    Parameters & Programming C Group – Intelligent I/O and Communication Parameters This parameter group is used to program the functions of the digital and analog I/O. ATTENTION • All digital inputs respond to level sensitive commands. • Inputs do not require a voltage transition (cycle) after a fault condition is cleared, after input power cycling or after programming the logic of the digital input.
  • Page 39 Parameters & Programming Parameter Parameter Name / Description Min./Max Units Factory Number Range Defaults Outputs 11, 12, FM, AL0-AI1 [Output FM Select] 00/02 Numeric Value Sets the operation of the output FM. Settings: 00={A-F} (Analog Output Frequency) 01={A} (Motor Current) 02={D-F} (Digital Output Frequency) Refer to control inputs table in Chapter 2 for setting descriptions.

  • Page 40: Faults & Troubleshooting

    Chapter 4 – Faults & Troubleshooting Fault Information This chapter provides information to guide you in troubleshooting the drive. Included is a list and description of drive faults and problems that may occur. How to Clear a Fault When a fault occurs, the cause must be corrected before the fault can be cleared. After corrective action has been taken, any of the following actions will clear the fault.

  • Page 41: Possible Problems And Corrective Actions

    Faults & Troubleshooting Fault Fault Name Fault Description Corrective Action Number Ground Fault There was a ground fault at the Check for a ground fault at the output terminals. E 14 motor output terminals. Excess Input The input voltage is higher than Check the incoming AC line.

  • Page 42: Other Displays

    Faults & Troubleshooting Problem Corrective Action The motor does not accelerate properly. Check to see that a frequency has been commanded. Check to see if a preset frequency has been selected. Check to see if the motor load is too high. Check to see if the acceleration time is too long.
  • Page 43 Faults & Troubleshooting This Page Intentionally Blank Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 44: Specifications & Dimensions

    Chapter 5 – Specifications & Dimensions Technical Data Series Bulletin 161 Type 0.2 (0.3) 0.4 (0.5) .55 (.75) 0.75 (1) 1.1 (1.5) 1.5 (2) 2.2 (3) 3.7 (5) Drive rating kW (HP) 115V Input rated current (A) 10.0 16.0 230V 1F Input rated current (A) 11.2 16.0 22.5...

  • Page 45: Dimensions

    Specifications & Dimensions Figure 5.1 Bulletin 161 Dimensions (All dimensions are in millimeters and (inches). AA04 / AA05 AA01 / AA02 / AA03 Mass Kg (lb) Mass Kg (lb) AA04/AA05 AA01 1.3 (2.87) 0.7 (1.54) AA02/AA03 0.85 (1.87) AA07 AA10/AA15 Mass Kg (lb) Mass Kg (lb) AA10/AA15...
  • Page 46 Specifications & Dimensions DA04 DA01 / DA02 Mass Kg (lb) Mass Kg (lb) DA01 DA04 1.1 (2.42) 1.5 (3.31) DA02 1.2 (2.64) Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 47: Accessories

    Specifications & Dimensions Accessories Line Filter Module Specifications Test voltage Input wire Nominal Nominal [VDC for 2s] max. cross Output cable Heat Line Filter Voltage Current Leakage Current ph. to ph; section cross section dissipation Module at 40°C [A] at 50 Hz (mA) ph.

  • Page 48: Ce Conformity

    Appendix A – CE Conformity CE Compliance This drive is a component intended for implementation in machines or systems for the industrial environment. It is CE marked for conformity to the Low Voltage (LV) directive 73/23/EEC when installed as described. It also has been tested to meet the Council Directive 89/336 Electromagnetic Compatibility (EMC).
  • Page 49 CE Conformity This Page Intentionally Blank Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 50 CE Conformity Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 51 Publication 0161-5.0MU – March, 2001 NB591XA Supersedes 161-5.0MU dated September, 2000 Copyright 2001 Rockwell International Corporation. All rights reserved. Printed in USA Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

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