Allen-Bradley 160-RS1 User manual

FAULT READY
RS232
Serial Comm
COMM
CAT
160-RS1
SER
MADE IN U.S.A.
160-RS1
Serial
Communication
Module
FRN 1.xx
User Manual

Important User Information Solid state equipment has operational characteristics differing from
those of electromechanical equipment. “Safety Guidelines for the
Application, Installation and Maintenance of Solid State Controls”
(Publication SGI-1.1) describes some important differences between
solid state equipment and hard-wired 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 the Allen-Bradley Company 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, the Allen-Bradley
Company cannot assume responsibility or liability for actual use
based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is
prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is especially important for
successful application and understanding of the product.
DriveExplorer, DriveTools, DriveTools32, MicroLogix and SLC are trademarks of Rockwell Automation.
PLC and PLC-5 are registered trademarks of Rockwell Automation.
RSLinx and RSLogix 500 are trademarks of Rockwell Software, Inc.
Windows and Windows NT are registered trademarks of Microsoft Corporation
!ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death,
property damage, or economic loss.
Shock Hazard labels may be located on or inside the drive
to alert people that dangerous voltage may be present.

Table of Contents
Preface
Using This Manual Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–i
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–i
RS1 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–i
Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–ii
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p–ii
Chapter 1
Product Overview Module Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Configuration DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Chapter 2
Quick Start for Experienced
Users
Required Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Chapter 3
Installation and Wiring EMC Directive 89/336/EEC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
Low Voltage Directive 73/23/EEC Compliance . . . . . . . . . . . . . . . . . . . . . 3–1
Module Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Setting the Baud Rate – SW1 & SW2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
Setting the Protocol – SW3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Selecting the Checksum Mode – SW4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Module Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Keypad or Ready/Fault Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Installing the RS1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Removing the RS1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
Wiring the Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Connecting the Communication Cable to the Module. . . . . . . . . . . . . . . . 3–8
Chapter 4
Modes of Operation Powering Up the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Power-up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Error Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Chapter 5
RS1 Data Table Interface Supported PCCC Command List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Data Table Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
Chapter 6
Parameter Descriptions RS1 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

toc–ii Table of Contents
Chapter 7
Using the RS1 Module with
DriveExplorer™ Software
Required Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Example Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
Setting Baud Rates and Configuring the Communications Port . . . . . . . 7–2
Monitoring and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Monitoring Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Uploading Editable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Downloading Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
Chapter 8
Using the RS1 Module with a
Programmable Controller
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Example Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Setting the Drive to Enable Network Control . . . . . . . . . . . . . . . . . . . . . . 8–2
Setting the Baud Rate and Checksum Mode . . . . . . . . . . . . . . . . . . . . . . 8–2
Connecting the Drive to the Programmable Controller. . . . . . . . . . . . . . . 8–2
Controlling the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Program the Ladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Reading and Writing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Program the Ladder for Parameter Reads and Writes . . . . . . . . . . . . . . . 8–5
Chapter 9
Troubleshooting LED Indicators and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
READY LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
COMM LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
FAULT LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2
RS1/DF1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Appendix A
Specifications Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
Appendix B
RS1 Module Compatibility

Preface
Using This Manual
The purpose of this manual is to provide you with the necessary
information to apply the Bulletin 160-RS1 Communication Module.
Described in this manual are methods for installing, configuring, and
troubleshooting the RS1 Communication Module.
For information on specific drive features, refer to the Bulletin 160
User Manual.
Important: Read this manual in its entirety before installing, operating,
servicing, or initializing the RS1 Module.
Who Should Use This Manual? This manual is intended for qualified personnel. To make efficient use
of the Communication Module, you must be able to program and
operate serial communications devices, as well as have an
understanding of the parameter settings and functions of the 160
Drive.
Conventions In this manual we refer to the:
•160 RS1 Communication Module as Communication Module,
RS1 Module or Module.
•160 SSC Adjustable Frequency AC Drive as the 160 Drive or
drive.
In addition, parameter numbers and names (both 160 Drive and RS1
Module) are shown in bold typeface and follow the format PXX - [*]
where P denotes parameter, XX denotes the two digit parameter
number, and * represents the parameter name.
For example, P01 - [Output Frequency].
RS1 Compatibility The RS1 Module is compatible with all series of 160 Drives. When
properly connected, the module communicates via RS-232 using the
Allen-Bradley DF1 protocol.

p–ii Preface
Reference Manuals The following documents contain additional information concerning
Allen-Bradley products. To obtain a copy, contact your local Allen-
Bradley Sales Office or visit the “On-Line Publications” area of the
Allen-Bradley home page on the World Wide Web at:
www.ab.com .
Safety Precautions
For Read This Document
Publication
Number
Information about the DF1 protocol DF1 Protocol and Command Set Reference Manual 1770-6.5.16
Additional information about networking and the SLC™ 500 SLC 500 Modular Hardware Style Manual 1747-6.2
Information about the AIC+ AIC+ Advanced Interface Converter User Manual 1761-6.4
Instruction set information for the SLC 500 and MicroLogix™
1000
SLC 500 and MicroLogix 1000 Instruction Set
Reference Manual
1747-6.15
For general MicroLogix 1000 information MicroLogix 1000 User Manual 1761-6.3
For DriveExplorer™ information DriveExplorer User Manual 9306-5.0
For 160 SSC Drive Information: 160 SSC User Manual Series A
160 SSC User Manual Series B
160 SSC User Manual Series C
0160-5.0
0160-5.9
0160-5.15
A complete listing of current Allen-Bradley documentation,
including ordering instructions. Also indicates whether the
documents are available on CD-ROM or in multi-languages.
Allen-Bradley Publication Index SD499
A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1
!
ATTENTION: Only personnel familiar with 160 Drives,
Communication Modules and associated machinery should
plan or implement the installation, start-up, configuration
and subsequent maintenance of this module. Failure to com-
ply may result in personal injury and/or equipment damage.
!
ATTENTION: This module 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. If you are not
familiar with static control procedures, reference Allen-
Bradley Publication 8000-4.5.2, Guarding Against Electro-
static Damage or any other applicable ESD protection
handbook.
!
ATTENTION: The drive contains high voltage capacitors
which take time to discharge after removal of AC line power.
Before installing or removing the Communication Module,
ensure isolation of mains supply from line inputs L1, L2,
L3 (R, S, T). Wait the recommended amount of time for the
capacitors to discharge to safe voltage levels (refer to the
160 User Manual for recommended time). Failure to do so
may result in personal injury or death.
!
ATTENTION: When a system is configured for the first
time, the motor must be disconnected from the machine or
process during initial system testing. Hazard of injury or
equipment damage may occur due to unintended or incor-
rect machine motion.

Chapter 1
Product Overview
This chapter contains the following information:
•The physical layout of the module.
•Location of configuration switches.
•Overview and components.
Module Description The RS1 Module is an optional interface device designed to provide a
direct, digital link between RS-232 devices and the 160 Drive. The
module connects to the drive through the expansion/keypad port on
the front of the drive. Refer to the figures 1.1 and 1.2 for general
layout of the module and Chapters 4 or 9 for details on the LED
indicators.
Figure 1.1
Module Front View
FAULT READY
RS232
Serial Comm
COMM
CAT
160-RS1
SER
MADE IN U.S.A.
9 Pin, Female D-Shell Connector
Refer to Chapter 3 for Details
Module Installation Latch
Status LEDs
Refer to Chapters 4 & 9
for Further Information
Nameplate
Provides Firmware Version
and Series Letter

1–2 Product Overview
Configuration DIP Switches
The Communication Module has one four position DIP switch for
setting the baud rate, protocol and checksum type. DIP switches are
located on the rear of the module (see below) and are only accessible
when the module is removed from the 160 Drive. Refer to Chapter 3
for switch configuration information.
Figure 1.2
Module Rear View
1234
ON
SW1 - SW4
DIP Switches
Expansion/Keypad Port
Connector
D-Shell Connector
Module Latch

Chapter 2
Quick Start for Experienced Users
This chapter can help you start using the RS1 Communication
Module. If you have installed or configured a network previously and
are familiar with Allen-Bradley communication modules and drives,
this information can help reduce the time of installation. If you are
uncertain, use the full installation/configuration information
beginning in Chapter 3.
We base the procedures here on the assumption that you understand
the basic concepts and know how to program the 160 Drive. In
addition, you should understand electronic process control and be
able to interpret the ladder logic instructions required to generate the
electronic signals that control your application.
Because it is a start-up guide for experienced users, this chapter does
not contain detailed explanations about the procedures listed. It does,
however, reference other chapters in this book where you can get
more information.
If you have any questions or are unfamiliar with the terms used or
concepts presented in the procedural steps, always read the
referenced chapters and other recommended documentation before
trying to apply the information.
This chapter contains the following information:
•What tools and equipment you need.
•When to address, configure and program the module.
•How to install and wire the Communication Module.
•System power-up procedures.
Required Tools and Equipment Have the following tools and equipment ready:
•1/8 in. (3.2 mm) flat blade screwdriver.
•Blunt, pointed instrument (not pen or pencil) for setting the DIP
switches.

2–2 Quick Start for Experienced Users
Procedures
Step Action
For Further Information
Refer to . . .
1. Review Attention statements in the Preface.
2. Ensure that power has been removed to the 160 Drive. 160 Drive
User Manual
3.
Verify that the 160 Drive is correctly installed and
wired. Stop Input (TB3-7, TB3-8) must be jumpered
together to start drive.
160 Drive
User Manual
4. Remove Program Keypad Module or Ready/Fault
Indicating Panel from the drive.
Chapter 3
(Installation)
5. Set the RS1 Module’s baud rate, protocol and check-
sum type DIP switches.
Chapter 3
(Installation)
6. Install the RS1 Module. Chapter 3
(Installation)
7. Connect communication cable. Chapter 3
(Installation)
8. Power up the drive and the network. Chapter 3
(Installation)
9.
Configure the 160 Drive for the RS1 Module so the
drive can accept control logic and speed reference via
the network.
Chapter 8
(Using the RS1 Module
with a Programmable
Controller)
or
Chapter 7
(Using the RS1 Module
with DriveExplorer
Software)
Set P46 - [Input Mode] to a value of “2.” This will configure
the drive to accept the logic commands from the network.
Set P59 - [Frequency Select] to “1.” This will configure the
drive to accept speed commands from the network.
10.
Configure the RS1 Module parameters for your
application. For Example: P103 - [Fault Mode],
P114 - [Application Timeout], etc.
Chapter 6
(Parameter Descriptions)
11. Check for proper operation.