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1. E SS els e emi e CD PE S PE L1 N M 31 Bulletin 161 General instructions for an EMC compliance installation Enclosure Typical IEC metal enclosures are adequate The ground connection of the enclosure must be solidly connected to the PE terminal of the drive Good conductivity must be assured grounding must provide a low impedance path for high frequency signals All wiring except input power leads must be shielded cable Input power output power and control wiring inside the enclosure must be physically separated Input power output power and control wiring outside the enclosure must use separate shielded cables or separate metal conduit Cable Clamps Use suitable EMC cable clamps The connection area must be 360 degrees around the shielded cables When using conduit the contact point of metal must be free of paint or non conductive surfaces and solidly connected with good conductivity to the enclosure Motor Cable The cable between the drive and motor must be 4 wire shielded cable three phases and ground Do not exceed the maximum motor cable length for the specific line filter module used Inside the enclosure shielded motor cable should be used as close to the drive s output terminals as possible Where the shielded motor cable exits the enclosure an EMC cable clamp or metal conduit must be used to solidly connect the cabl2. coc lt a gt Je NN ttj dj A Ground Terminal 80 lt Ny Main Circuit Terminal x Alarm Terminal 000 000 o 00000000000 1 Control Circuit Terminal CP Bulletin 161S AA05 AA07 140 128 168 sk T 1 Ground Terminal Main Circuit Terminal Alarm Terminal TIT Control Circuit Terminal 153 3 5 28 Bulletin 161S AA03 AA04 98 Ground Terminal Main Circuit Terminal Alarm Terminal Control Circuit Terminal z IO D 180 a Air Ly Ground 00005 000000 Main Circuit Terminal Terminal 010000 ULY Control Circuit Terminal y Bulletin 161 10 Accessories Line Filter Module Specifications Nominal Nominal Leakage Test voltage Input wire Output cable Line Filter Voltage Current Current VDC for 25 max cross cross section dissipation
3. 0 L L ES Q e Wait at least 2s after turning on the power supply before issuing a start command and do not switch off the mains supply during operation of the device e Each signal must be applied to the digital inputs 1 5 for at least 12 ms e f input 5 is programmed as PTC resistor parameter C05 terminal L will be the corresponding reference potential AN ATTENTION Bulletin 161 e If aninput is used as FW or RV and programmed as a Normally Closed NC contact the drive will start as soon as the power supply is switched on without the input being triggered Please note that a start command should not be issued if an input is used as FW or RV when the power is switched on otherwise the motor will start immediately wait at least 2s after switching on the power before issuing a start command Terminal Function Programmable output Output frequency or Motor current Description Analog signal 0 10 V 1 m A The output frequency output is available as a pulse signal In the factory default the frequency is an analog signal 0 10 V corresponding to 0 Hz to the max frequency Match the signal under parameter b81 programming under parameter C23 analog signal pulse signal frequency frequency or current duty cycle approx 5096 t gt 10V 10VL x T T 24 ms const Analog signal The relatio
4. PID act value digital input digital output freq x factor FRS select Display indicator under F1 Remote Keypad only Bulletin 161 Parameter Function Basic number value Digital inputs 1 5 C01 Digital input 1 00 FW Forward 01 RV Reverse 02 CF 1 Preset freq C02 Digital input2 03 CF2 Preset freq 04 Preset freq 05 CF4 Preset freq C03 Digital input 3 06 JG 09 2CH 2 ramp 11 FRS Coast stop C04 Digital input 4 3 12 EXT Ext trip 13 USP unintention start protection 15 SFT Softw lock C05 Digital input 5 16 AT 4 20 mA sel C11 C12 C13 C14 C15 18 RS Reset 19 PTC PTC input Digital input 1 NO NC jo Digital input 2 NO NC o o 00 NO contact Digital input 4 NO NC c5 Digital input 5 NO NC Outputs 11 12 FM ALO AL1 Digital output 11 Digital output 12 2 Output FM Dorao none o o i im oo oo i on C05 only Digital input 3 NO NC 01 NC contact 00 RUN operation 01 FA1 at frequency 02 FA2 above freq 03 OL Motor overload alarm 04 OD PID deviation 05 AL fault 00 A F analog output frequency 01 A Mot Current 02 D F digital output frequenc 00 NO Contact 01 NC Contact 0 0 360 Hz 0 0 360 Hz 0 0 100 Used only by RA field Service personnel Frequency setting for FA2 in acceleration Frequency setting for FA2 in deceleration
5. PID controller deviation 3 C32 Digital output 12 NO NC C C C C Fault indication relay ALO AL 1 C C C C 3 31 32 33 41 Overload alarm setting 42 43 44 91 01 02 18 01 01 100 0 21 Bulletin 161 6 Fault indications The Bulletin 161 drives are provided with protective devices such as protection against excessive current excessive voltage and under voltage When one of the many protection functions is triggered the output voltage will be switched off the motor will freewheel and the device will remain in the fault indication mode until the fault indication has been cleared indication Is the motor rated current larger Select drive with a higher rating Overcurrent than the drive rated current Did a sudden load increase Avoid sudden overloads occur or is the motor blocked Possibly use drive and motor with higher rating Are the motor terminals U T1 Check motor lines and the motor for a V T2 W T3 short circuited short circuit e during deceleration Is the deceleration time setting Set a longer deceleration time too short Fault Description Cause Corrective action e during running Are the motor terminals U T1 Check motor lines and the motor for a V T2 W T3 short circuited short circuit e during acceleration 15 the acceleration time setting Increase the acceleration time too short Are the motor terminals short Check motor lines and the motor for a circuited short cir
6. Terminal Function Description 1 200 240 V 10 50 60 Hz 5 Motor connection Star or delta connection of the motor in accordance with the rated voltage DC bus connection Connection for brake chopper Connection for DC bus If an DC bus reactor is connected remove the copper bridge 41 reactor Ensure that the bridge between the terminals and 1 is installed if there is no DC bus reactor installed Terminal type MinMax Torque Nm 0 8 Nm max 0 9 Nm Fault indication rela Disconnecting or connecting the motor changing the number of poles in pole changing motors or changing the direction of rotation by means of an external device e g contactor is not permitted during operation Connecting capacitive loads is not permitted A variety of cable types are acceptable for the drive installation For many installation unshielded cable is adequate provided it can be separated from sensitive circuits If you cannot separate motor cables from sensitive circuits or if you must run motor cables from multiple drives more than three in a common conduit or cable tray shielded motor cable is recommended to reduce system noise refer to Appendix A In the case of motor lead lengths gt 50 m output reactors should be used Earth the drive carefully in accordance with the instructions Avoid the use of shared protective earth conductors if several Bulletin 161 drives are used The power factor cos of
7. conformity of the drive and filter to any standard does not guarantee that the entire installation or machine will conform Many other factors can influence the total installation and only direct measurements can verify total conformity It is therefore the responsibility of the machine manufacturer or end user to ensure that conformity is met General Notes and Instructions S The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents The cable length increases the capacitive current and electromagnetic emission It is recommended that the motor cable length does not exceed 50 m It is always recommended to install output reactors if the cable length exceeds 50 m S The filters contain capacitors between the phases and the phases to ground as well as suitable discharging resistors But after switching off the line voltage wait a minimum of 60 seconds before removing protective covers or touching terminals to avoid an electric shock Ee The use of ground fault monitoring devices RCD s is not recommended If unavoidable only monitoring devices which are suited for DC AC and HF ground currents type B RCD s should be used It is recommended to use devices which responsiveness and time characteristics are adjustable to avoid nuisance tripping during power up the drive cee The thermal capacity of the line filter is guaranteed up to a maximum motor cable length of 50 m
8. 13 14 15 1___ ON oN fon fon 05 J eN oN oN ON ON ON ON 2CH 2 Accel Decel ramp 2 acceleration deceleration time parameter A92 A93 09 FRS Controller lock The motor voltage will be switched off immediately the motor will coast 11 isolation of motor e g emergency For FRS two operation modes can be selected under parameter b88 1 Synchronisation of the motor speed after the waiting period programmed under parameter 603 is over enter 07 2 0 Hz start after activating FRS enter 00 synchronisation of the motor speed 0 2 start FW RV input FRS motor speed CAP waiting ime yr EXT External fault When this input is addressed a fault indication will be issued E72 e g to 12 be used as the input for thermal contacts The fault indication will be cleared with Reset Attention After reset the drive will start again if a start command has been issued FW or RV FW RV Motor will Input EXT coast Motor speed Input RS Reset Fault indication relay ALO AL2 11 Bulletin 161 Input Function Description Function USP Restart lock The restart lock prevents a uncontrolled restart of the Bulletin 161
9. CERT The line filters have been developed for use in grounded systems Use in ungrounded systems is not recommended Essential requirements for a conforming EMC installation 1 Aninput line filter module see table below must be installed to reduce conducted emissions Line Filter Selection Guide Bulletin 161 Input Voltage Line Filter Module 161S AA01NPK 1 220 V 10 240 V 5 161S RFA 6 A 161S AA02NPK 1 220 V 10 240 V 5 161S RFA 6 A 161S AA03NPK 1 220 V 10 240 V 5 161S RFA 9 B 30 Bulletin 161 Compliance of the Bulletin 161 drive to the conducted emissions levels with appropriate line filter module is as follows PWM Carrier Frequency Motor cable length Limit 16 kHz 10m Class B 5 kHz 20m Class B 16 kHz 50m Class A 2 All motor cables must be shielded cable or be in grounded metal conduit 3 Allcontrol and signal wiring must use shielded cable or be in grounded metal conduit 4 Grounding of equipment and cable shields must be solid with low impedance connections 5 Ensure that the protective conductor terminal PE of the filter is properly connected with the protective conductor terminal of the drive The filter must be solidly and permanently connected with the ground potential to avoid electric shock 7144 NNAL ASSY CULT TAL IS g PE connection UUTEL
10. Module V at 40 at 50 Hz ph ph section mm2 A mA ph ground mm2 161S RFASA 2405 1400 2800 D 4 4 N 161S RFA9 B 240 5 2x10A 1400 72800 44 345 6 1615 22 240 5 2x 23A 1400 7 1400 44 325 9 Current at 40 ambient temperature Dependence of current on ambient temperature Overload 150 IN for 10 min 1 2 0 Frequency 50 60 Hz x Te Material Steel surface refined ME Humidity class C 0 4 Operation height 1000 m without derating 0 2 gt 1000 m 2 for each 1000m 0 0 20 40 60 80 100 Temperature range 25 C to 85 C temperature in Connections Input terminals IP 20 and PE screw M5 Load side cable unshielded Filter Dimensions mm zu mra 7 px 7 i EE r OM GE type 1 DA MP IE d hj a C B Line Filter Module A 161S RFA 6 A 130 161S RFA 9 B ME 11 1615 22 140 29 Bulletin 161 Appendix A CE Conformity The Bulletin 161 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 EEC Electromagnetic Compatibility EMC The standards used are LV EN50178 EN60204 1 EN60950 EMC Emissions EN61800 3 EN55011 Group 1 Class B Immunity EN61800 3 Industrial Environment Important
11. 4 Clearing faults Reset There are three different ways of clearing fault indications e Reset input e Switch off power supply e Press the STOP key 15 Bulletin 161 5 5 Overview of the parameters Parameter Display function Remarks number Display and diagnostic functions Output frequency Hz do3 Direction of rotation F Forward r Reverse 0 Stop Actual value x actual value factor 96 The actual value factor is set in param A75 in the only available if the PID controller is active range from 0 01 99 99 The default setting is 1 0 Status of digital inputs 1 5 Example Inputs 1 3 4 activated Digital inputs 3 BHBB N Signal status of the digital outputs 11 12 Example Output 11 ON no fault and the fault indication relays ALO AL2 Outputs M ON OFF HOH Output frequency x frequency factor The product of frequency factor parameter b86 and output frequency are displayed under this parameter This parameter can be used e g to display the output speed of a drive or the speed of a conveyor 4 position values e g 1500 1500 5 position values e g 15000 1500 Last fault occurred The fault indication last shown as well as the output frequency motor current and DC bus voltage at the time of the fault may be called up using the SEL key The following will be displayed if a fault has not occurred since or if the fault indication has been deleted Fault indication register The 2nd and 3rd f
12. device serviced by customer support External fault External fault indication at the Remove the cause of the fault input EXT indication in the external wiring Fault cause by Has the power supply been Activate the start lock only when the triggering of start lock switched on while the start lock power supply has been switched on was active input USP Has the mains voltage been Check the mains interrupted for a short period of time during operation and while the start lock was activated input USP Earth fault at the motor Is there an earth fault between Remove the earth fault and check the E 14 terminals U T1 V T2 W T3 and earth motor Excess mains voltage If the mains voltage is higher Check the mains voltage than permitted see Technical data the drive will be in fault mode Drive overtemperature Is the drive overloaded Check the motor current Is the ambient temperature too Check the ambient temperature high Are the assembly clearances too Check the assembly clearances small see chapter 3 Assembly Control of the PTC Is the motor overloaded Check the motor load ircuit breaker TP mu Is the self ventilation of the Use an external fan if low speeds are triggering function motor particularly at low often used speeds not sufficient 23 Bulletin 161 Other displays Display Description A reset signal has been issued PU H n gm HH
13. drive 13 when after power off the power supply returns and a start command is issued immediately or straight afterwards In this case the following fault indication will be given E13 Power supply Start command FW RV Input USP Fault indication relay Output frequency min 3 sec A new start command or a reset will clear the fault indication SFT Parameter protection Parameter protection protects parameters entered from being lost by 15 overwriting If the software protection is activated no data can be lost see parameter b31 AT Frequency command In the factory default input 0 10V is active Switching to Ol is effected 16 input Ol active via input AT If there is no digital input programmed as AT the 4 20 mA frequency command values are added to and Ol see parameter 07 RS Clearing a fault indication reset the fault indication relay If a reset 18 command is given during operation the terminal stages are switched off and the motor will coast min 12 ms Input RS I Fault indication relay JG Jog control is used e g to set up a machine manually This is done via the inputs FW or RV if the input JG is controlled When a start command is given the frequency programmed under parameter A38 will be switched directly to the motor the start ramp is not active For the stop command three different modes can be
14. live even when the mains supply is switched off For this reason wait at least 5 minutes after switching off the mains supply before you open the device and start working on it Take care that you do not touch any live parts The drive is intended to be installed with a fix connection to earth The protective earth only offers protection for the drive not against personal injury According to EN 50178 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 RCD s should be used As a precautionary measure the EN 50178 regulations should be observed The stop button on the integrated control panel may not be used for emergency purposes The stop button can be activated via parameter b87 AN ATTENTION Earth the Bulletin 161 drive at the connections intended for this Bulletin 161 AN ATTENTION To prevent any injuries or damage do not touch any components located within the housing either with your hands or with any other objects if mains 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 mains voltage is applied Exercise particular caution if automatic restart is activated To prevent injuries caused by the automatic restarting of the drive following a power
15. mA 1 to 2 kOhm nominal 0 10 V nominal 0 20 mA 5H 5H Eal SE po Input impedance Input impedance 9110 kOhm 2 701250 Ohm 0 0 O OL xr Enc PE PE For analog input reference adjustment see parameters A11 A16 Input OI for 4 20 mA is activated when the digital input is set to AT see parameter C01 C05 If no digital input is programmed as AT switch frequency command 0 10 V 4 20 mA the set values are added to and Ol Transistor output max 27 VDC 50 mA 11 12 vp 2 aC ER CM2 The outputs can be programmed as NC contacts or NO contacts under parameter C31 or C32 factory default NC contact The following functions may be programmed under the parameters C21 and C21 FA1 at frequency Signal when the set value is reached FA2 above frequency Signal if output frequencies gt the frequencies set under parameter C42 or C43 RUN Running Signal if output frequency gt 0 Hz OL Motor overload Signal if the motor current exceeds the value set under parameter C41 OD PID deviation Signal if the deviation between the set value and the actual value returned is greater than the value set under parameter C44 Only available if the PID controller parameter A71 is active AL Fault Signal if a fault is indicated See parameter C21 C22 230VAC 250 VAC 2 5 A resistive 0 2 A cos 0 4 30 VDC 3 0A res
16. selected under parameter A39 1 The motor will coast 2 The motor is slowed down at the deceleration ramp 3 Braking of the motor using the DC brake see parameter A54 A55 Input JG Start command FW RV Motor speed Jog control will not be possible if the jog frequency set is less than the start frequency entered under parameter 682 input Input 5 can be programmed as input under parameter C05 Only in connection In this case terminal L will be the reference potential in all other cases the with input 5 reference potential will be at terminal P24 Reference potential If the PTC resistance exceeds the motor is terminal L will be switched off and the fault indicator E35 ERROR PTC will be issued PLC control Control with internal control voltage Bulletin 161 Control with external control voltage Bulletin 161 Bulletin 161 13 Bulletin 161 5 Programming AN ATTENTION Wait at least 6s after programming the Bulletin 161 before issuing a start or rest command switching off the power supply or pressing any other key on the control panel 5 1 Description of the control panel The Start key will start operation in the direction of rotation defined under parameter F04 not active when control is via the terminal block 4 positio
17. Ng The mains voltage has been switched off 24 The Bulletin 161 drive is in standby mode EE The waiting time before automatic restart has expired see parameter b01 b03 nuu The factory setting has been selected and the drive is in the initialisation phase L EU see parameters b84 b85 The parameters for the European market are loaded display under d04 if the PID controller is not active No data present e g display under d08 d09 if the fault indication register is empty or Bulletin 161 7 Faults and troubleshooting Possible cause Corrective action The motor There is no Is there mains voltage at the input Check connections L1 N and U T1 does not voltage at terminals L1 N V T2 W T3 Switch on the mains start terminals If so is the LED display lit voltage U T1 V T2 PUE EE W T3 Is there a fault indication on the Analyze the cause of the fault indication display Cancel the fault indication with the Reset function Has a start command been issued Press the RUN key or issue the start using the RUN key or via the input command at the relevant input FW RV Has a frequency command been Enter the frequency command under entered using the control panel F01 If the frequency command has been Check that the potentiometer is properly specified via a potentiometer are the connected terminals H O and L wired correctly If
18. ably 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 Rockwell Automation cannot release the user from complying with the latest relevant safety regulations The technical data and descriptions in this user manual have been created to the best of our knowledge and belief Enhancements to products are being made continually Rockwell Automation therefore reserves the right to make modifications without previous notice In spite of the care taken in producing this manual Rockwell Automation cannot be held liable for any errors and damage arising from the use of this manual 1 Checking the scope of supply Type description 1615 First Position Bulletin Number An S in the bulletin Number denotes a single phase input voltage Second Position Voltage Rating A 200 240V 102 A04 Third Position Current Rating A01 A02 A03 A04 A05 A07 A10 1 4A 2 6A 3 0A 4 0A 5 0A 7 1A 10 0A Fourth Position Enclosure Type IP20 Bulletin 161 PK Fifth Position PK Integrated Programmer Keypad Bulletin 161 2 Structure of the device Bulletin 161S AA01 AA02 control panel front cover enclosure RS422 serial interface heat sink PE conne
19. and start working on it Take care that you do not touch any live parts e Do not apply mains voltage to the output terminals U T1 V T2 and W T3 Layout of the power and control terminals control unit control terminals control unit opened Screw PE connection power terminals fault indication relay terminals RS422 serial interface Bulletin 161 4 1 Connection and description of the power terminals The control unit must be open in order to be able to wire the power terminals Do not apply mains voltage to the drive connection terminals U T1 V T2 and W T3 as this will result in damage to equipment The Bulletin 161 drives feature an electronic overload protection to monitor the drive current In the case of multi motor operation thermal contacts or resistors must be used for each motor In the case of motor lead lengths gt 50 m motor reactors should be used Connection example Bulletin 161 Mains power supply L1 Q A 2 a Vee Se Line filter Connection for optional brake chopper E ES AC Line Input fuse ratings or other Line Side Protective Devices Fuse Rating Circuit Breaker Type and Rating Bulletin 161S AA01 AA03 10 A time lag 140 MN 1000 140M D8N C10 Bulletin 161S AA04 AA07 16 A time lag 140 MN 1600 140M D8N C16 Bulletin 1615 10 25 A time lag 140 MN 2500 140M D8N C25 Bulletin 161
20. ault indications last shown can be called up under this parameter by pressing the SEL key ithere is no fault indication stored here Parameter Function Basic Setting range number value Basic parameters Input display frequency command 0 5 360 Hz NEN 1 acceleration time 0 1 3000s 1 deceleration time 0 1 3000s Direction of rotation RUN key ME 00 Forward 01 Reverse b Extended function of A group setting A group regards control setting or parameter Can be entered from A parameter setting Extended function of b group setting b group regards protection setting or others Can be entered from b parameter C Extended function of C group setting C group regards intelligent terminal setting Can be entered from C parameter Parameter Function Basic Setting range number value Basic parameters Frequency command select 01 00 Frequency Pot 01 Input O OI 02 Param F01 A20 A02 Start command select 01 01 Input FWy RV 02 RUN ke A03 Base frequency 50 50 360 Hz A04 Maximum frequency 50 50 360 Hz Analog input reference adjustment Frequency at the minimum set value 0 360 Hz Frequency at the maximum set value 0 360 Hz A1 1 A13 Analog input minimum 0 100 13 Analog input maximum 100 0 100 3 A15 Start condition 01 00 Minimum speed 01 0 Hz start A16 Analog input filter setting 1 max filter slow response to 8 min filter fast respons
21. ction M4 screw control terminals screw To wire the power terminals and fault indication relay loosen the screw and open the control unit fault indication relay terminals RS422 serial interface terminal cover power terminals Bulletin 161 Bulletin 161S 161 AA03 AA04 control unit front cover RS422 serial interface enclosure control terminals To wire the power terminals and fault indication relay loosen the screw and open the control unit PE connection M4 screw fault indication relay terminals RS422 serial interface power terminals Bulletin 161 3 Installation AN ATTENTION e 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 on a non flammable vertical wall that does not transmit any vibrations Attention Do not apply mains voltage to the output terminals U T1 V T2 and W T3 For heat convection reasons the Bulletin 161 drive must be installed vertically Observe the specified minimum distances to the side walls or other devices Objects that come into contact with the inside of the drive may result in the device being damaged If installed in normal environmental conditions max 40 C ambient there must be a minimum of 20 mm clearance around all sides of the drive to enable the user o
22. cuit Is the manual boost parameter Reduce the boost under parameter 42 set too high A42 Is the motor blocked Check the motor load or breakaway torque 04 e ata standstill Is there an earth fault at the Check the output lines or the motor for output terminals or at the motor an earth fault Triggering of internal The internal electronic motor Use a motor and converter with a motor protection protection has been triggered higher rating due to overloading of the connected motor Check the entry under parameter b12 The drive is overloaded The output current is greater Use drive with a higher rating than the drive rated current DC bus overvoltage The motor was operated Set a longer deceleration time h DEC y Inactivate the AVR function for deceleration parameter A81 enter 01 or 02 Enter a higher motor voltage under parameter A82 Use the brake chopper EEPROM error Is the temperature too high or is Check the environmental conditions E 08 the drive exposed to electric Re enter the programmed noise parameters 22 Bulletin 161 Fault Description Corrective action indication DC bus undervoltage Brief voltage dips occur or the Check the input voltage mains voltage is reduced to 150 160V Processor error Possible influence of Examine the environment of the drive electromagnetic fields on the and external wiring for causes of the drive fault e g terminal bar Is the drive defective Have the
23. d for the frequency range in question particularly for the maximum frequency 5 2 Entering the factory defaults initialisation On supply all the Bulletin 161 drives are initialized i e they are programmed with the default factory parameters The devices may however be re programmed to these basic settings at any time e Ensure that the function 01 is stored under parameter b85 01 on initialisation the data of the European defaults are loaded e Enter function 01 under parameter b84 and save this by pressing the ENTER key e Press the A V and SEL key at the same time While you are pressing the keys mentioned above briefly press the STOP key and wait approx 2 3s until the following is flashing d OO e Now release the three keys During initialisation the following will be displayed EU e The end of initialisation will be indicated by 00 5 3 Putting the device into operation via the integrated control panel The integrated control panel enables the Bulletin 161 drive to be controlled without the additional use of the control terminals e Enter function 00 under parameter 07 set frequency command via the integrated potentiometer or 02 enter the frequency under parameter F01 e Program the function 02 under parameter A02 The drive can now be started by pressing the START key e The required direction of rotation can be selected under parameter F04 00 Forward 01 Reverse 5
24. d set points cannot be specified It is not Is parameter protection activated Disable parameter protection possible to set any values The Is the manual boost setting too high Check the boost setting and the setting electronic for the electronic motor protection Is the electronic motor protection motor setting correct protection fault indication E05 is triggered 26 Bulletin 161 8 Technical Data Series Bulletin 161S A aaoi 02 05 AAO7 10 input rated curent a 31 s8 n2 Output rated current A 2 6 3 0 4 0 5 0 7 1 10 0 1 200 V 10 to 240 V 5 50 60 Hz 5 V F characteristics V F characteristics for constant torque and variable torque variable output voltage Base Frequency and Maximum Frequency Type of control Voltage driven PWM sinus coded IGBT Power module Output frequency 0 5 360 Hz Accuracy of frequency Digital 0 0196 of max frequency command Analog 0 296 of max frequency Frequency resolution Digital 0 196 analog max frequency 1000 Overload capacity 15096 for 60 s once in a period of 10 min max 22096 Starting torque min 150 at frequencies gt 3 Hz Braking torque by Bulletin 161S AA01 AA04 10096 feeding back into the Bulletin 161S AA05 AA07 7096 capacitors Bulletin 1615 10 2096 DC brake Starting frequency braking torque running time are variable Analog inputs 0 10V i
25. e Pre set frequencies under parameter 07 A22 2 Preset Frequency A29 9 Preset Frequency A32 12 Preset Frequency Jog Stop Mode 00 Coast 01 Ramp 02 DC brake Bulletin 161 17 Bulletin 161 Parameter Function Basic Setting range number value V F characteristics boost A41 Boost select 00 Man boost 01 Auto boost Manual boost Max boost at of base frequency A44 V F select 00 Constant 01 Variable Maximum output voltage 50 100 DC brake 51 DC Brake active inactive 00 00 inactive 01 active DC Brake Braking torque DC Brake Braking time A53 DC Brake Waiting time Operating frequency range 1 Skip Frequency Band A68 3 Skip Frequency Band Bulletin 161 Parameter Function Basic Setting range number value PID controller PID controller active inactive 00 inactive 01 active PID Proportional Gain 0 2 5 0 PID Integral Gain 0 0 150 5 0 01 99 99 00 01 input 00 active 01 inactive 02 not active in deceleration 00 input set to 2CH 01 Automatic if freq programmed in param A95 A96 is reached 2 acceleration ramp starting frequency 0 0 360 Hz 2 deceleration ramp starting frequency 0 0 360 Hz A97 Acceleration Curve 00 linear 01 S curve A98 Deceleration Curve 00 linear 01 S curve 19 Bulletin 161 Basic value Parameter Function number Automatic start after a fault Restart m
26. e e dei 29 Appendix A GE Gohltormlly oiii decerni Soon esencia adeeb eles deta 30 Bulletin 161 Bulletin 161 Attentions and safety guidelines Before installing the Bulletin 161 drive and putting it into operation please read this user manual carefully and take note of all the Attentions and safety guidelines Always keep this product manual near the Bulletin 161 drive so that it is easily accessible Definition of the guidelines AN ATTENTION Failure to comply with these precautions may result in death serious personal injury or substantial damage to equipment General information Conventions used in this manual To help differentiate parameter names and selection tags from other text the following conventions will be used e parameter names will appear in italic example C22 d07 e selection tags for inputs and outputs will appear in brackets example RS CF1 AN ATTENTION This Bulletin 161 drive generates dangerous electrical voltages and controls potentially dangerous rotating mechanical parts Disregarding the guidelines provided in this manual may result in death serious personal injury or substantial damage to equipment 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
27. e shield to the enclosure The shield on the motor side must be solidly connected to the motor housing with an EMC cable clamp or conduit providing good conductivity from the cable shield to the motor housing Control Wiring 32 Control wiring must use shielded cable or grounded metal conduit The shield must be connected to PE at both ends of the cable Inside the enclosure shielded control wiring should be connected as close to the drive s control terminals as possible Reach us now at www rackwellautomalian com Wherever voa need us Hockwell Autimation brings together kaing brands in industrial automation induding Alen Aradiey controls Reliance Electric power transmission products Dodge mechanical power Transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve competitive advantage is supported by thousands of authorized partners distributors and systgm integrators around the ward Americas Headquarters 1201 out Second Stree Miteaubee WI TIAA Tat 1 414 282 2000 Fae 1 414 392 058 European Headquarters SANV wene Herrmann Debeu 46 11 Bressels Belge 325 2 DE 00 Fo 207 2 DE 40 7 Asia Haadraurtors 77 7 Coma Whifald Road Caussas Bay Hong Tat 2997 4788 Fax E572 2508 1836 Automation Publication 161 5 0EN May 1999 Copyright 1998 Rockwell International Corporation A
28. failure install a switching component at the mains that is deactivated in the event of a power failure and that may only be switched on again on return of the power supply e g contactor etc Earth the drive at the connections intended for this AN 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 on a non flammable vertical wall that does not transmit any vibrations Attention Do not apply mains voltage to the output terminals U T1 V T2 and W T3 Please contact the motor or machine manufacturers if standard motors with frequencies gt 50 Hz are to be used Bulletin 161 drives are checked for dielectric strength and insulation resistance Insulation resistance measurements e g as part of a check may only be taken between the power terminals and earth Do not carry out any measurements at the control terminals In normal operation apply the START STOP commands via the control terminals or the control panel and not by disconnection and reapplying input power to the drive or motor contactor Do not install any capacitors or suppressors to the drive output terminals AN ATTENTION To ensure that your Bulletin 161 drive functions safely and reli
29. istive 0 7 A cos 0 4 min 100 VAC 10 mA 5 VDC 100 mA Operation ALO AL1 closed Fault power off ALO AL2 closed parameter C33 The fault indication relay is set with a time delay of approx 2 s after the power is switched on Bulletin 161 Overview of the functions of the programmable digital inputs 1 5 The digital inputs 1 to 5 can be programmed for 15 different functions With exception of the PTC input programmable on input 5 only every input can be programmed for any function Parameters cannot be programmed for two different inputs at the same time The various functions are listed and described in the table below Programming is done via parameters C01 C15 parameters C01 C05 correspond to inputs 1 to 5 pro gramming for normally closed NC contacts or norm open contacts NO is carried out via parameters C1 1 C15 Input Function Description Function FW Start stop forward see parameter A02 00 RV Start stop reverse see parameter A02 01 CF1 The pre set frequencies may be programmed in two ways 2 0 1 by entering the frequencies under parameter A 1 A35 2 by selecting the corresponding digital input CF 1 CF4 and entering the required frequency under parameter F01 Press the ENTER 03 Preset frequencies key to store the value entered Press the SEL key to check that the value entered has been stored 04 Input Preset Speed 2 4 5 7 10 11 12
30. ll rights reserved NB 571X
31. n LED display to display parameters and operating data Stop Reset key The Stop command see b87 or reset function for clearing fault indications can be used via the control panel or the terminal block The RUN LED will be lit when the drive is in operation i e if a start command has been given The SEL key is used to select and exit input mode The PRG LED will be lit when the drive is programmed The ENTER key is used to save the entered data The Hz and A LED will inform you whether the output frequency or output current is displayed The arrow keys are used to select parameters and enter or modify data The commanded frequency can be set via the speed potentiometer Programming guide Entry of parameters gt 4 HH Saving entered parameters d01 A01 d09 A98 F01 b01 F04 b89 A C01 B C91 C Bulletin 161 A ATTENTION Before switching on the power supply the following points must be observed e Check that the mains lines and motor lines are connected properly e The control wires must be connected at the correct terminals e The drive must be earthed correctly and must be installed vertically on a wall made from non flammable material e All screws and terminals must be tightened e Check that the connected motor is designe
32. n t T changes in proportion to the frequency or to the current The maximum voltage of 10 V is reached with the max frequency or 20096 rated current 100 I 5 V 200 I 10 V accuracy approx 5 for the frequency indicator and 20 for drive current indicator Pulse signal frequency output frequency x factor of the multiplied frequency indicator param b86 factory default 1 max frequency 3 6 kHz 0 V potential for output FM L Programmable digital inputs 24 V potential for digital inputs 1 2 5 max load 30 mA Inputs 1 5 are programmable An overview of the possible functions can be found on pages 11 and 12 This table contains the basic setting for the terminal connections It is not possible to program two inputs with the same function at the same time see parameter 07 05 Inputs 1 5 with the exception of the reset and PTC input may be programmed as either a NC contact or a NO contact see parameter C1 1 C15 Bulletin 161 Terminal Function 10 V reference voltage for frequency command default Analog input Frequency command 0 10 V Analog input Frequency command 4 20 mA 0 V reference potential for frequency command inputs CM2 Reference potential for output 11 12 Programmable Digital output Factory default FA1 Programmable Digital output Factory default RUN Relay output Collective fault Description Potentiometer 0 9 6 V 4 19 6
33. nput impedance 10 4 20 mA input impedance 250 PTC input Digital inputs 5 free programmable inputs 24 V PNP logic NO contacts or NC contacts Analog outputs 1 analog output to either display the output frequency or the motor current For output frequency can be switched as an impulse output Digital outputs 2 open collector outputs for for either operation indication at frequency above frequency overload alarm PID controller deviation exceeded 1 fault indication relay change over contact Protection functions Overcurrent overvoltage under voltage electronic motor protection overtemperature earth fault overload etc Other functions 15 preset speeds PID controller parameter protection restart lock RS422 serial interface skip frequencies etc Ambient temperature 10 40 up to 50 in the case of reduction of reference frequency to 2 kHz restriction of output current to 80 and removal of top cover Relative humidity 20 90 relative humidity no condensation Vibration shock 5 9 m s 0 6 G 10 55 Hz Max installation altitude 1000 m above sea level Standards EN 61800 3 EMC guidelines in connection with optional line filter modules in line with installation guidelines EN 50178 Low Voltage guideline UL 27 Bulletin 161 9 Dimensions Bulletin 161S AA01 AA02 120 0 110
34. ode select Permissible power failure time Waiting time before restart Electronic motor protection Electronic overload setting Electronic overload characteristic Current limit rated current Current limit operation mode rated curr b22 Current limit setting x 1 25 Current limit decel rate 1 0 Parameter protection b31 Selection of Software lock mode Current feedback tuning Reactive current setting rated curr Settings range 00 Fault indication 01 0 Hz start 02 Synchr 03 Synchr stop 00 increased motor protection 01 standard 00 inactive 01 active 02 inactive in accel 50 150 of rated current 00 input SFT active all functions locked 01 input SFT active Speed ref only 02 all functions locked 03 Speed ref only Resolution 196 of inverter rated current Initialisation adjustment parameters Output FM adjustment ___ 0 25 mnt Start frequency 0 5 9 9 Hz s NENNEN PWM carrier frequency 0 5 16 kHz Factory setting basic setting initialisation Pd 00 delete fault oi indic register 01 factory default 01 Frequency scale factor d07 b87 Keypad STOP key select 00 STOP key always active E 01 STOP key inactive if inp FW RV The set value links with the detection current of output current monitor electric thermal protection and overload limit 20 selected 01 synchronisation actual freq motor current dir of rotation
35. otor from accelerating to the commanded frequency 25 Bulletin 161 Possible cause Corrective action The motor Do sudden high load changes occur Choose a drive and motor with a higher runs rating Reduce sudden load changes unstable Resonant frequencies occur in the Blank out the frequencies in question motor with frequency jumps or change the reference frequency The mains voltage is not constant Change PWM carrier frequency The speed Has the maximum frequency been set Check the frequency range entered of the motor correctly eee Has the rated speed of the motor or Check the rated speed of the motor and fr reduction ratio of the gear been the reduction ratio of the gear equency selected correctly The The values The mains voltage has been switched Enter the parameters again and save parameters entered off without storing the values entered by each entry stored do have not pressing the ENTER key not match been the values stored entered When the mains voltage was switched Enter the parameters again and save off the entered and saved values were each entry After setting the parameters transferred to the power failure safe switch the power off for at least 6s EEPROM Power off time must be at least 6s No entries drive Is the control mode been set correctly Check the setting under parameter A01 can be can neither under A01 and 02 and A02 made be started nor stopped an
36. r installer to open the front cover to get access to the terminals The figure below shows the minimum required clearances in case the Bulletin 161 is installed in an IP54 enclosure air circulation Bulletin 161 When carrying out work on the Bulletin 161 drive please ensure that no objects such as cable insulation metal filings or dust get into the enclosure This can be avoided by covering up the non energized AC drive Temperatures may not exceed or go below the permissible temperature range from 10 to 40 C or to 50 C in the following cases reduction of the reference frequency to 2 kHz reduction of the output current to 8096 Bulletin 161 drive rated current removal of the top cover The higher the ambient temperature the shorter the life of the drive Do not install the device in the vicinity of devices that radiate heat If installing the device in a control cabinet pay attention to the size and heat transfer capability of the control cabinet A fan may have to be installed Bulletin 161 4 Wiring AN ATTENTION e 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 mains supply is switched off For this reason wait at least 5 minutes after switching off the mains supply before you open the device
37. ren d Allen Bradley Bulletin 161 Single Phase AC Drive User Manual 1 200 240V 0 2 2 2 kW Bulletin 161 Table of contents 1 Checking the scope of supply oreet petto eek tei wt eect Mosam sdb as 1 2 Structure of the A E ETE 2 3 InstallaHoEi eed fii PIE LEN EIE MEE 4 Lm LII m 5 4 1 Connection and description of the power 1 22 nnne 6 4 2 Connection and description of the control terminals nenne 8 FDA POG ANNAN Pee 14 5 1 Description of the control panel A 14 5 2 Entering the factory defaults initialisation 15 5 3 Putting the device into operation via the integrated control 15 5 4 Clearing faults Rieset css s the Ionen t inb ten poet bte 15 5 5 Overview amp iimis ninaa rinnat aaa aa Ea e E AAE a inns sites sn E sens sinn ns nn tenens 16 6 Fault indlcallofis ie ec ete acetic alee aes 22 7 Faults and troubleshootlng trennen hepate nona ace SERE eausa aS 25 8 T hni cal Data isco secs 27 9 DIMENSIONS cen ee aderat ei eee c Du 28 TU AGCeSSOLGS cioe oe ete tus su
38. the command has been specified externally are inputs or OI properly connected Is the controller lock FRS active Is the input programmed as FRS Has a reset signal been issued Check the signal at input 5 factory default RS Has the drive been programmed under Check the setting under parameter A01 parameter A01 02 in accordance and 02 with the frequency command setting and the start command Check that the cable for the frequency command signal is properly connected Voltage is Is the motor blocked or is the load too Check the motor and the load For test applied to high purposes run the motor without a load terminals U T1 V T2 W T3 The Are the terminals U T1 V T2 W T3 Correct the wiring of the motor direction of connected properly Is the connection rotation of of the terminals U T1 V T2 W T3 set the motor is up properly for the direction of rotation incorrect of the motor Have the control inputs been wired FW Forward correctly RV Reverse The motor A frequency command has not been Check the potentiometer or external does not applied to terminal O or OI frequency command generator and if accelerate necessary replace it Has a Preset Frequency been Observe the priority sequence selected Preset Frequency have priority over the inputs O and OI Is the motor load too high Reduce the motor load If the load is too high the overload restriction function prevents the m
39. the mains power supply must not exceed 0 99 Compensation systems must be tested for reliability to ensure that overcompensation does not occur at any time Attention Input line reactors 396 impedance must be installed under the following conditions The unbalance factor is 2396 High mains voltage dips occur The Bulletin 161 drives is operated on a generator Several Bulletin 161 drives are linked via a short common power supply bus bar Switched power factor correction equipment is installed Input line reactors may also be used to improve the power factor Bulletin 161 4 2 Connection and description of the control terminals When using the transistor outputs 11 12 CM2 install a recovery diode parallel to the relay used Otherwise the switching relay could damage the output Do not short circuit the terminals H and L or P24 and L The control wires must be installed separately from the power lines and motor lines They may not exceed 20 m in length To improve noise immunity the control wires should be screened refer to Appendix A If unavoidable transpositions between the power lines or motor lines and the control wires should be installed at right angles Example of a connection frequency reference c10V fault indication relay pot 1 2kQ 2 230 VAC ZN ua AL 5 Ne Aon
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