User manual | drives-ap005 - Rockwell Automation

160 SSC Variable Speed Drive to PowerFlex 4/4M/40 Drives

Conversion Guide

Table of Contents

TABLE OF CONTENTS.................................................................................................................. 2

REFERENCE INFORMATION ........................................................................................................ 3

INTRODUCTION ............................................................................................................................. 3

DRIVE SELECTION CONSIDERATIONS ...................................................................................... 4

ONVERSION

UIDE

...................................................................................................................... 5

Specifications and Features ................................................................................................... 5

Dimensions ........................................................................................................................... 10

Terminal Comparison............................................................................................................ 11

Communications ................................................................................................................... 13

Software................................................................................................................................ 14

RIVE

ATALOG

UMBERS

.......................................................................................................... 15

DRIVE CONFIGURATION ............................................................................................................ 19

ENERAL

OTES

......................................................................................................................... 19

ANALOG SPEED FOLLOWER .................................................................................................... 20

3 W

IRE

ONTROL

, P

PEED

EFERENCE

................................................................................. 21

Wiring Examples ................................................................................................................... 21

Parameter Comparison......................................................................................................... 22

2 W

IRE

ONTROL

, A

NALOG

NPUT

PEED

EFERENCE

.................................................................. 23

Wiring Examples ................................................................................................................... 23

Parameter Comparison......................................................................................................... 24

PRESET SPEED ........................................................................................................................... 25

Wiring Examples ................................................................................................................... 25

Parameter Comparison......................................................................................................... 26

DEVICENET .................................................................................................................................. 27

ENERAL

.................................................................................................................................... 27

OFTWARE

ERSIONS

................................................................................................................. 27

ARDWIRED

RIVE

NABLE

......................................................................................................... 28

AVE

XISTING

ETWORK

........................................................................................................... 28

ONFIGURE

OWER

LEX

RIVE

................................................................................................... 35

ONFIGURE

EVICE

CANNER

............................................................................................... 44

XAMPLE

ADDER

OGIC

............................................................................................................. 54

ControlLogix I/O Messaging Examples................................................................................. 57

ControlLogix Explicit Messaging Examples .......................................................................... 67

SLC 500 I/O Messaging Examples....................................................................................... 72

SLC 500 Explicit Messaging Examples ................................................................................ 84

PARAMETER CROSS REFERENCE........................................................................................... 93

Reference Information

22A-UM001

22B-UM001

22F-UM001

22COMM-UM003

22COMM-IN001

160-UM002

160-UM009

DNET-UM004P

PowerFlex 4 User Manual

PowerFlex 40 User Manual

PowerFlex 4M User Manual

22-COMM-D DeviceNet Adapter User Manual

22-XCOMM External Comms Installation Manual

160-DN2 Device Net Comms Module User Manual

160-SSC Variable Speed Drive User Manual

DeviceNet Modules in Logix5000 User Manual

Introduction

The purpose of this document is to assist in the retrofit of existing 160 SSC drives to PowerFlex

4-Class drives. The document is broken into four major sections:

Drive Selection

The features of the PowerFlex 4M, 4, and 40 are compared to the 160 SSC. Major differences and in-depth comparison table listed.

Analog Speed Follower

An example of a 160 SSC analog speed follower model is show. Control wiring and parameter comparisons are show for the PowerFlex 4-Class used in this configuration.

Preset

An example of a 160 SSC preset speed model is show. Control wiring and parameter comparisons are show for the PowerFlex 4-Class used in this configuration

DeviceNet

Included in this section are:

- Examples of 160 SSC and PowerFlex 4-Class DeviceNet configurations.

- Procedures to configure the PowerFlex 4-Class drive.

- Procedures configure the DeviceNet scanner are described.

- Examples of ControlLogix and SLC PLC logic.

- Examples of Explicit Messaging in ControlLogix and SLC.

Drive Selection Considerations

Selecting a PowerFlex to use as a replacement in a 160 SSC application needs to take into account some of the differences and features between the PowerFlex 4M, 4, and 40. Listed here are some of the major differences in the PowerFlex 4-Class compared to the 160 SSC. The next section has an in-depth comparison of the PowerFlex 4-Class.

Feed through wiring

The 160 SSC has feed through wiring. The line is connected to the top of the drive and motor is connected to the bottom of the drive. The PowerFlex 4M has feed through wiring. The PowerFlex

4 and 40 terminate the line and motor to the bottom of the drive.

DeviceNet

The 160 SSC could have an optional 160-DNx DeviceNet communication module. This enables the 160 SSC to be controlled and monitored on DeviceNet. The PowerFlex 40 accepts an optional 22COMM-D DeviceNet communication module mounted directly in the drive. For the

PowerFlex 4 and 4M to communicate on DeviceNet, a 22COMM-D module is mounted in an external 22XCOMM module and connected to the drives DSI port.

The 160 SSC has configurable Input and Output Assemblies for DeviceNet control of drive. The

PowerFlex has fixed Input and Output Assemblies. Logic changes may have to be made to control the PowerFlex in the same manner.

Speed Presets

The 160 SSC Preset Speed model has eight preset speeds set by three digital inputs. The

PowerFlex 40 has eight preset speeds and the PowerFlex 4 and 4M have four preset speeds.

Sensorless Vector Control

The 160 SSC is a Volts per Hertz drive with adjustments for Boost and Slip Compensation. The

PowerFlex 4 and 4M are Volts per Hertz drives as well. The PowerFlex 40 by default is in

Sensorless Vector control, which achieves a higher level of torque response and speed accuracy.

The PowerFlex 40 can be changed to Volts per Hertz control if need be.

Bipolar Speed Reference

The 160 SSC can accept a Bipolar (+/-10VDC) speed reference. The direction is set by the polarity of the speed reference. This feature is available on the PowerFlex 40 but not the

PowerFlex 4 and 4M.

Circuit Protection

When selecting a PowerFlex replacement for a 160 SSC, pay attention to the recommendations for fusing and circuit breakers. Protective device sizing may be different between equivalent 160

SSC and PowerFlex drives.

More information on the PowerFlex fuse and circuit breaker recommended sizes in the following publications at:

http://literature.rockwellautomation.com

22A-UM001

22B-UM001

PowerFlex 4 User Manual

PowerFlex 40 User Manual

22F-UM001

PowerFlex 4M User Manual

Conversion Guide

Specifications and Features

Drive Model 160 SSC

Catalog Number

160-AAxxxx

120V N/A

240V, 1-Phase

240V, 3-Phase

480V

0.5…2 HP

(0.37…1.5 kW)

0.5…5 HP

(0.37…4.0 kW)

0.5…5 HP

(0.37…4.0 kW)

PowerFlex 4M

22F-xxxxxxxx

(0.2…1.1 kW)

0.25…3 HP

(0.2…2.2 kW)

0.25…10 HP

(0.2…7.5 kW)

0.5…15 HP

(0.4…11 kW)

PowerFlex 4

22A-xxxxxxxx

(0.2…1.1 kW)

0.25…3 HP

(0.2…2.2 kW)

0.25…5 HP

(0.2…3.7 kW)

0.5…5 HP

(0.4…3.7 kW)

PowerFlex 40

22B-xxxxxxx

0.5…1.5 HP

(0.4…1.1 kW)

0.5…3 HP

(0.4…2.2 kW)

0.5…10 HP

(0.4…7.5 kW)

0.5…15 HP

(0.4…11 kW)

(0.75…11 kW)

Normal Duty Overload

1 N/A N/A N/A N/A

3 N/A N/A N/A N/A

Heavy Duty Overload

3 Seconds

Power Wiring

200% for 30 Sec.

Feed through

200% for 3 Sec.

Feed through

200% for 3 Sec.

Bottom Fed

200%

Bottom Fed

Specifications and Features

(continued)

Drive Model

Catalog Number

160 SSC

160-AAxxxx

PowerFlex 4M

22F-xxxxxxxx

Frequency Control 240 Hz Max.

PWM Frequency 2…8 kHz

Enclosures Types

400 Hz Max

2…10 kHz

Open, Type IP20, Type

12/4/4X IP40/54/65 all

Frames Heatsink Out the Back

Open, Type IP20

PowerFlex 4

22A-xxxxxxxx

240 Hz Max.

2…16 kHz

PowerFlex 40

22B-xxxxxxx

400 Hz Max.

2…16 kHz

Open, Type IP20, Type

1 IP30 (with kit), Type

1/12/4/4X IP40/54/65 all

Frames Heatsink Out the Back

Open, Type IP20, Type

1 IP30 (with kit), Type

1/12/4/4X IP40/54/65 C

Frame Heatsink Out the

Back

Ambient Temp 0

…

C Open

…

C IP66 (NEMA

12/4/4X)

Torque Control

Open Loop Accuracy N/A

Closed Loop

Accuracy

N/A

Speed Control

Open Loop Accuracy 1% - 40:1

–10

…

C –10

…

C –10

…

±2% across 40:1 Speed

Range, with Slip Comp.

±2% across 40:1 Speed

Range, with Slip Comp.

1% across 80:1 Speed

Range, with Slip Comp.

Closed Loop

Accuracy

N/A N/A N/A N/A

HP w/DC Link Choke N/A

HP w/AC line Choke N/A

Volt Tolerance ±10%

Frequency Tolerance 47…63 Hz

N/A

15 Hp

N/A

Compliance Marks CE, UL, cUL, C-Tick

Maximum Altitude 1000 m

Specifications and Features

(continued)

Drive Model

Catalog Number

EMC Filtering

Heatsink Out the

Back

160 SSC

160-AAxxxx

External - 1ø,

External - 3ø

Yes, All Frames

PowerFlex 4M

22F-xxxxxxxx

Internal - 1ø & 3ø,

External - 3ø

PowerFlex 4

22A-xxxxxxxx

Internal - 1ø,

External - 3ø

Yes, All Frames

PowerFlex 40

22B-xxxxxxx

Internal - 1ø 230V only,

External - 3ø

Yes, All Frames

Internal DB

Transistor

Internal DB Resistor

Option

Encoder Input

Standard

Yes, all Frames C frame only (7.5 HP and higher)

0.5…5 Hp 0.5-15 HP

No N/A N/A N/A

N/A N/A N/A N/A

Additional Feedback

Options

Number of Comms.

Supported

Simultaneously in

Drive

Removable MOV to

Ground

N/A N/A N/A No

1 0 0 1

No Yes Yes Yes

Max. Short Circuit

Rating

Standard Discrete

Inputs

Analog Inputs

Discrete Outputs

Analog Outputs

100,000A 100,000A 100,000A 100,000A

12V Internal Supply only. (Start/Stop function set by Input

Mode)

1 - (Bipolar 0-10 V or

Unipolar 4-20 mA)

1 - Form C Relay

5…24V Sink/Source

(3 - Start/Stop/Reverse,

2 - Fully Prog.)

5…24V Sink/Source

(3 - Start/Stop/Reverse,

2 - Fully Prog.)

7…24V Sink/Source

(3 - Start/Stop/Reverse,

4 - Fully Prog.)

1 Unipolar (0-10 V or

4-20 mA)

1 - Form C Relay

1 Unipolar (0-10V or

4-20 mA)

1 - Form C Relay

1 Bipolar, ±10V or

4-20 mA, 1 Unipolar

4-20mA

1 - Form C Relay,

2-optos

1 - (0-10V or 4-20 mA)

Optional I/O Voltage 115V N/A N/A N/A

Input Timer / Counter

Functions

No No No Yes

Output Timer /

Counter Functions

No No No No

Specifications and Features

(continued)

Drive Model

Catalog Number

Digital Input Scan

Time (Not Through

Put Time)

Analog Input

Resolution

160 SSC

160-AAxxxx

10 ms

10 Bit

PowerFlex 4M

22F-xxxxxxxx

2 ms

10 Bit

12 ms Analog Input Scan

Time (Not Through

Put Time)

Analog Output

Resolution

Analog Output Scan

Time (Not Through

Put Time)

8 ms

HIM - Local LCD No

HIM - Remote LCD Yes

HIM - Hand-held

HIM - CopyCat function

HIM - Languages

HIM - Local LED

Yes

(1) Remote HIM

Yes, including pot and control keys

HIM - Auto/ Manual function

PowerFlex 4

22A-xxxxxxxx

2 ms

10 Bit

12 ms

PowerFlex 40

22B-xxxxxxx

1 ms

10 Bit

10 ms

(7) Remote HIM

Yes, including pot and control keys

(7) Remote HIM

Yes, including pot and control keys

(7) Remote HIM

Yes, including pot and control keys

No (Yes - Remote HIM) No (Yes - Remote HIM) No (Yes - Remote HIM)

Specifications and Features

(continued)

Drive Model

Catalog Number

160 SSC

160-AAxxxx

PowerFlex 4M

22F-xxxxxxxx

Motor Control Type V/Hz V/Hz

PowerFlex 4

22A-xxxxxxxx

V/Hz

PowerFlex 40

22B-xxxxxxx

V/Hz and Sensorless

Vector

Drive Overload

Protection

Advanced

Diagnostics

Input Phase Loss

User Sets

Yes Yes Yes Yes

Process Control

Loop

Fast Flux Up

Feedback Loss

Switchover

Battery Back-up

Yes No No PID

Fast Brake to Stop No

Flux Braking No

Multi-Motor

Parameters

Drive Model

Catalog Number

160 SSC

160-AAxxxx

SynchLink No

Motion Controller No

Inertia Adaptation No

Power Up Time 0.8 Sec.

PowerFlex 4M

22F-xxxxxxxx

1.5…2.5 Sec.

PowerFlex 4

22A-xxxxxxxx

1.5…2.5 Sec.

PowerFlex 40

22B-xxxxxxx

1.5…2.5 Sec.

P-jump (traverse function)

Lifting Application No

Winder Application No

Electronic

Gearing/Line Shaft

Dimensions

160 SSC PowerFlex 4M

Frame/Hp

Height

Width

Depth

Frame/Hp

Height

Width

Depth

A/0.5…3 152 80 165.4 A/0.5…2 174 72 136

B/5 192.5 92 193.3 B/3…5 174 100 136

C/7.5…10 130

PowerFlex 4

Frame/HP

Height

Width

Depth

PowerFlex 40

Frame/HP

Height

Width

Depth

Terminal Comparison

Terminal Designation

Description

Input AC Line – R/L1

Input AC Line – S/L2

Input AC Line – T/L3

Motor – U/T1

Motor – V/T2

Motor – W/T3

Brake Resistor

160 SSC

R/L1

S/L2

T/L3

U/T1

V/T2

W/T3

BR+

BR–

DC Bus –

DC Bus +

DC Bus Inductor Connection

DC–

DC+

PowerFlex 4M

R/L1

S/L2

T/L3

U/T1

PowerFlex 4

R/L1

S/L2

T/L3

U/T1

V/T2

W/T3

V/T2

W/T3

BR+ (C Frame only) BR+

BR– (C Frame Only) BR–

DC–

DC+

P2 (C Frame Only

P1 (C Frame Only

PowerFlex 40

R/L1

S/L2

T/L3

U/T1

V/T2

W/T3

BR+

BR–

DC–

DC+

P2 (C Frame Only)

P1 (C Frame Only)

Analog Input 1 Comm.

Analog Input 1 (+/–)

2 - (0…10V)

Shield 19

Analog Input 2 Comm. 3

Analog Input 2 (+/-)

Analog Input 3 (NTC-) Com.

4 - (4…20 mA)

Analog Input 3 (NTC+)

Shield

Analog Output 1 (–)

Analog Output 1 (+)

Analog Output 2 (–)

Analog Output 2 (+)

Encoder A (Not)

Encoder B (Not)

Encoder Z (Not)

Terminal Comparison

(continued)

Terminal Designation

Description

160 SSC PowerFlex 4M PowerFlex 4 PowerFlex 40

24V DC Common (–)

24V DC Source (+)

Digital/Relay Output 1(N.O) 11

Digital/Relay Output 1Com. 10

Digital/Relay Output 1(N.C) 9

Digital/Relay Output 2 (N.O)

Digital/Relay Output 2 Com.

Digital/Relay Output 2 (N.C)

Digital/Relay Output 3 (NC)

Digital/Relay Output 3 Com.

Digital/Relay Output 3 (NO)

Digital/Relay Output 4 (NC)

Digital/Relay Output 4 Com.

Digital/Relay Output 4 (NO)

Digital Input 4-6 Comm.

Digital Input 4

Digital Input 5

48V Control Power Supply

Drive Enable (Secure

Disable Function)

Enabled could be terminal #8 terminal #1

Communications

Product Model Number

DF1

AS-i

160 SSC

Yes

PowerFlex 4M

Yes (with SCM adapter)

PowerFlex 4

Yes (with SCM adapter)

PowerFlex 40

Yes (with SCM adapter)

No No No No

BACnet No Yes (with X-Comm) Yes

CANopen No No No No

CC-Link No No No No

ControlNet No Yes (with X-Comm) Yes (with X-Comm) Yes

DeviceNet Yes Yes (with X-Comm) Yes (with X-Comm) Yes

Ethernet No No No No

EtherNet/IP No Yes (with X-Comm) Yes (with X-Comm) Yes

FIP No No No No

Interbus Yes No No No

LonWorks No Yes (with X-Comm) Yes (with X-Comm) Yes

Modbus RTU No Yes (Standard) Yes (Standard) Yes (Standard)

PROFIBUS DP Yes Yes (with X-Comm) Yes (with X-Comm) Yes

PROFINET No No No No

SERCOS No No No No

Uni-Telway No No No No converter)

Yes (with USB converter)

Software

Software Versions

Connectivity

Select Features

Used With …

Full version

'Lite' version

Pocket PC version

Palm version

Serial Point-to-Point

Serial Multi-drop

Ethernet Direct

ControlNet

DeviceNet

Profibus DP

Bluetooth

WiFi

Other / Proprietary

Offline capability

Setup Wizards

Diagram Views

User-created Views

I/O Terminal Configuration

Control

Oscilloscope / Graph

Project Management

Flash

File Conversion Tool

On-line Help

Multi-language

Yes

Yes (freeware)

Yes

English only

PowerFlex 7-Class, PowerFlex 4-

Class, 160(with DF1 160-RS1 adapter)

Drive Catalog Numbers

Following are part number explanations for the 160 SSC, PowerFlex 4M, PowerFlex 4, and

PowerFlex 40.

160 SSC Catalog Number

More information on the 160 SSC in the following publication at:

http://literature.rockwellautomation.com

160-UM009 160-SSC Variable Speed Drive User Manual

PowerFlex 4 Catalog Number

More information on the PowerFlex 4 in the following publication at:

http://literature.rockwellautomation.com

22A-UM001 PowerFlex 4 User Manual

PowerFlex 4M Catalog Number

More information on the PowerFlex 4M in the following publication at:

http://literature.rockwellautomation.com

22F-UM001 PowerFlex 4M User Manual

PowerFlex 40 Catalog Number

More information on the PowerFlex 40 in the following publication at:

http://literature.rockwellautomation.com

22B-UM001 PowerFlex 40 User Manual

Drive Configuration

The 160 SSC drive will be an Analog Speed Follower or a Preset Speed module and possibly have a DN2 DeviceNet option module. Because of this, the following examples put the 160 SSC to PowerFlex conversions into three broad categories:

Analog Speed Follower

Preset Speed

DeviceNet

The remainder of this document is broken into these three sections.

General Notes

The points apply to the PowerFlex drive whether it’s being used as an Analog Speed Follower,

Preset Speed, or DeviceNet

SNK/SRC DIP Switch

The PowerFlex digital inputs can operate in Sink or Source. To replicate 160 SSC functionality, the SNK/SRC DIP Switch is set to SRC so digital devices are applying a

+24VDC to inputs.

PowerFlex +24VDC power

The PowerFlex drive digital I/O has the ability to use internal or external +24VDC supply.

To replicate the wiring of the 160 SSC, the wiring diagrams will show the PowerFlex drive using internal +24VDC supply.

Motor Rotation

The output phasing of a 160 SSC series A and B drive is different than the output phasing of a 160 SSC series C and PowerFlex. Replacing a 160 SSC series A or B with a PowerFlex using the same U, V, and W (T1, T2, and T3) connections will reverse the motor rotation. To keep the same direction of rotation, switch any 2 of the output wires connected to U, V, or W (T1, T2, or T3) to the motor.

Analog Speed Follower

The 160 SSC Analog Speed Follower model accepts a speed reference from a potentiometer, +/-

10VDC source, 0-10VDC source, or 4-20 mA source. The 160 SSC can be configured to accept various methods of Start/Stop/Direction control.

Three examples show the 160 SSC configured to use different speed reference inputs and

Start/Stop/Direction control and equivalent PowerFlex configurations.

3 Wire Control, Pot Speed Reference

The control method is 3 Wire Start/Stop/Direction (Factory Default). The speed reference for the

160 SSC Analog Speed Follower comes from a 10K Ohm 2W potentiometer wired to the drive’s

10VDC power supply.

Wiring Examples

Parameter Comparison

The following parameters are the minimum required to configure the PowerFlex for the motor attributes and to control it with a 3 Wire Start/Stop/Direction method. The table shows a cross reference to the 160 SSC parameters.

NOTE: This example uses a 5HP, 460VAC, 6.0FLA, 60Hz motor. PowerFlex Parameters 31, 32,

33, 34, and 35, are dependant on your motor and application. PowerFlex Parameters 37, 39, and

40 are dependant on your applications stop mode and Accel/decel rates.

No.

160 SSC analog

Parameter Value

PowerFlex 40

No. Parameter Value

Base Voltage

Base Frequency

Motor OL Current

Minimum Frequency

Maximum Frequency

Input Mode

Stop Mode Select

Frequency Select

Analog Select

460 V

60 Hz

6.0 A

0 Hz

60 Hz

0 – 3 Wire Control

0 - Ramp to Stop

0 – TB3 Freq Input

0 - Unipolar

Motor NP Volts

Motor NP Hertz

Motor OL Current

Minimum Frequency

Maximum Frequency

Start Source

Stop Mode

Speed Reference

123 Analog Select

460 V

60 Hz

6.0 A

0 Hz

60 Hz

1 – 3 Wire

0 – Ramp CF

2 – 0-10V Input

0 - Unipolar

30 Accel Time 1 10.0 Sec 39 Accel Time 1 10.0 Sec

31 Decel Time 1 10.0 Sec 40 Decel Time 1 10.0 Sec

160 SSC Notes:

- Changing the Input Mode requires a power cycle or an entry of “2” Reset Input Mode on

Parameter 56.

PowerFlex Notes:

- By default the PowerFlex 40 is in Sensorless Vector control mode. It can be changed to

Volts/Hertz with Parameter 125.

- The ENBL jumper on the PowerFlex 40 determines the Stop Mode. If the jumper is installed the Stop Mode is as programmed in Parameter 37. If the jumper is removed the stop is always a Coast Stop.

- Parameter 123 Analog Select is available on the PowerFlex 40 only. PowerFlex 4M and 4 are Unipolar only.

2 Wire Control, Analog Input Speed Reference

The control method is 2 Wire Run Fwd/Run Rev. The speed reference for the 160 SSC Analog

Speed Follower comes from a 4-20mA, 0-10VDC or +/-10VDC(PowerFlex 40 only) input. The

Stop Pushbutton shown in the examples is not required. The drives run while a Run Fwd or Run

Rev input is on. To eliminate the Stop Pushbutton connect terminal 7 and 8 on the 160 SSC and terminal 1 and 11 on the PowerFlex.

Wiring Examples

Parameter Comparison

The following parameters are the minimum required to configure the PowerFlex for the motor attributes and to control it with a 2 Wire Run Fwd/Run Rev method. The table shows a cross reference to the 160 SSC parameters.

NOTE: This example uses a 5HP, 460VAC, 6.0FLA, 60Hz motor. PowerFlex Parameters 31, 32,

33, 34, and 35, are dependant on your motor and application. PowerFlex Parameters 37, 39, and

40 are dependant on your applications stop mode and Accel/decel rates.

160 SSC analog PowerFlex 40

No. Parameter Value No. Parameter Value

36 Base Voltage 460 V 31 Motor NP Volts 460 V

35 Base Frequency 60 Hz 32 Motor NP Hertz 60 Hz

42 Motor OL Current 6.0 A 33 Motor OL Current 6.0 A

32 Minimum Frequency 0 Hz 34 Minimum Frequency 0 Hz

33 Maximum Frequency 60 Hz 35 Maximum Frequency 60 Hz

46 Input Mode 1 – 2 Wire Control 36 Start Source 2 – 2 Wire

34 Stop Mode Select 0 - Ramp to Stop 37 Stop Mode 0 – Ramp CF

59 Frequency Select 0 – TB3 Freq Input 38 Speed Reference 2 – 0-10V Input

74 Analog Select 0 - Unipolar 123 Analog Select 0 - Unipolar

30 Accel Time 1 10.0 Sec 39 Accel Time 1 10.0 Sec

31 Decel Time 1 10.0 Sec 40 Decel Time 1 10.0 Sec

160 SSC Notes:

- Changing the Input Mode requires a power cycle or an entry of “2” Reset Input Mode on

Parameter 56

- If Parameter 46 set to “1” 2 Wire Control the drive will ramp to stop if terminal 8 is open. If

Parameter 46 set to “5” 2 Wire Control With Enable the drive will coast stop if terminal 8 is open

PowerFlex Notes:

- By default the PowerFlex 40 is in Sensorless Vector control mode. It can be changed to

Volts/Hertz with Parameter 125.

- The ENBL jumper on the PowerFlex 40 determines the Stop Mode. If the jumper is installed the Stop Mode is as programmed in Parameter 37. If the jumper is removed the stop is always a Coast Stop if terminal 8 is open.

- Parameter 123 Analog Select is available on the PowerFlex 40 only. PowerFlex 4M and 4 are Unipolar only.

- In this mode of operation, Parameter 37 controls the stop mode when the Run Fwd or

Run Rev switch is opened

- Parameter 38 should be set to “3” 4-20 mA Input if using 4-20mA speed reference.

Preset Speed

The control method is 2 Wire Run Fwd/Run Rev. The speed reference for the 160 SSC Preset

Speed model is selected with 3 digital inputs. The 160 SSC and PowerFlex 40 are capable of eight preset speeds and the PowerFlex 4M and 4 are capable of four preset speeds.

Wiring Examples

Parameter Comparison

NOTE: This example uses a 5HP, 460VAC, 6.0FLA, 60Hz motor. PowerFlex Parameters 31, 32,

33, 34, and 35, are dependant on your motor and application. PowerFlex Parameters 37, 39, and

40 are dependant on your applications stop mode and Accel/decel rates.

160 SSC preset PowerFlex 40

No. Parameter

36 Base Voltage

Base Frequency

Motor OL Current

Minimum Frequency

Maximum Frequency

Input Mode

Stop Mode Select

Frequency Select

Accel Time 1

Value

460 V

60 Hz

6.0 A

0 Hz

60 Hz

1 – 2 Wire Control

0 - Ramp to Stop

1 – Internal

10.0 Sec

Decel Time 1

Preset Freq 0

Preset Freq 1

Preset Freq 2

Preset Freq 3

Preset Freq 4

Preset Freq 5

10.0 Sec

3.0 Hz

5.0 Hz

10.0 Hz

20.0 Hz

30.0 Hz

40.0 Hz

No. Parameter

31 Motor NP Volts

Motor NP Hertz

Motor OL Current

Minimum Frequency

Maximum Frequency

Start Source

Stop Mode

Speed Reference

Accel Time 1

Value

460 V

60 Hz

6.0 A

0 Hz

60 Hz

2 – 2 Wire

0 – Ramp CF

4 – Preset Freq

10.0 Sec

Decel Time 1

Preset Freq 0

Preset Freq 1

Preset Freq 2

Preset Freq 3

Preset Freq 4

Preset Freq 5

10.0 Sec

0.0 Hz

5.0 Hz

10.0 Hz

20.0 Hz

30.0 Hz

40.0 Hz

Preset Freq 6

Preset Freq 7

50.0 Hz

60.0 Hz

Preset Freq 6

Preset Freq 7

Digital In 1 Sel

Digital In 2 Sel

50.0 Hz

60.0 Hz

4 – 2 Preset Freq

53 Digital In 3 Sel 4 – 2 Preset Freq

160 SSC Notes:

- Changing the Input Mode requires a power cycle or an entry of “2” Reset Input Mode on

Parameter 56

- If Parameter 46 set to “1” 2 Wire Control the drive will ramp to stop if terminal 8 is open. If

Parameter 46 set to “5” 2 Wire Control With Enable the drive will coast stop if terminal 8 is open

PowerFlex Notes:

- By default the PowerFlex 40 is in Sensorless Vector control mode. It can be changed to

Volts/Hertz with Parameter 125.

- In this mode of operation, Parameter 37 controls the stop mode when the Run Fwd or

Run Rev switch is opened.

- The PowerFlex 40 has eight speed presets and the PowerFlex 4M and 4 have four speed presets. Parameters 74-77 and 53 are not on PowerFlex 4M or 4.

DeviceNet

General

A 160 SSC with a DN2 DeviceNet option can be replaced with a PowerFlex 4/4M or PowerFlex

40 Drive. The PowerFlex 4/4M drive requires a 22-XCOMM base and a 22-COMM-D communication adapter to connect the DSI port to DeviceNet. The PowerFlex 40 drive requires a

22-COMM-D communication adapter and adapter cover (22B-CCB or 22B-CCC) to communicate on DeviceNet.

The intent of the following procedure is to “Replace” the 160 SSC with a new PowerFlex drive.

The new PowerFlex drive will occupy the 160 SSC’s address on DeviceNet, Input/Output space in the DeviceNet scanner, and use the control logic in the PLC.

The following are the steps to replace a 160 SSC with a PowerFlex.

• Save existing network configuration. Save the network prior to replacing the 160 SSC.

Print a report for reference. The network configuration containing the 160 SSC needs to be referenced for PowerFlex drive and Scanner configuration.

• Install and configure new PowerFlex drive. Edit the PowerFlex drive parameters for motor size and control over DeviceNet.

• Configure DeviceNet Scanner. Use existing 160 SSC Input/Output mapping in Scanner for PowerFlex Input/Output.

• Edit PLC logic. Control logic for the 160 SSC needs to be edited because the Command and Status for the PowerFlex may be different. Examples for ControlLogix, and SLC are given.

Software Versions

RSNetworx for DeviceNet is used to configure the DeviceNet and the PowerFlex drive.

RSNetworx v7.00 or higher is recommended. RSNetworx v 9.00 was used for this document.

Hardwired Drive Enable

When the 160 SSC is being controlled over DeviceNet, hardwired devices wired to the Start,

Direction, or Stop are not required. However, when Parameter 46 (Input Mode) is set to 2

(Network Control), Terminal TB3-8 is configured as an Enable. Terminal TB3-8 has to be high to start or run. Terminal TB3-8 may be jumped to TB3-7 Common or connected through a hardware enable circuit such as a guard or safety circuit.

This function can be replicated with the PowerFlex 4/4M and the PowerFlex 40. By default,

Terminal 1 is configured as Coast to Stop and shipped with a jumper between Terminal 1 and

Terminal 11 (+24VDC). If the 160 SSC has a hardware enable circuit wired between TB3-7 and

TB3-8, the same circuit can be wired between Terminal 1 and Terminal 11 on the PowerFlex 4M,

4, and 40

The type of stop the 160 SSC performs when terminal 7 and 8 are opened up is determined by

Parameter 34. The type of stop the PowerFlex performs when terminal 1 and 11 when configured for network control is always a Coast Stop.

ENBL Jumper

NOTE: The PowerFlex 40 has an enable (ENBL) jumper. If the enable jumper is removed

Terminal 1 will always act as a hardware enable regardless of software configuration.

Save Existing Network

The existing network and drive configuration containing the 160 SSC needs to be referenced for

PowerFlex drive and Scanner configuration. Save the Network prior to replacing the 160 SSC.

NOTE: Be sure to have the EDS file for the 160 SSC installed on PC. EDS file for 160 SSC can be downloaded at:

http://www.rockwellautomation.com/resources/eds/

An EDS file can be created for the 160 SSC or PowerFlex. See the procedures in the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

22COMM-UM003

22-COMM-D DeviceNet Adapter User Manual

Go online with DeviceNet.

Start RSNetworx for DeviceNet

Set Online Path to Network.

Select

Set Online Path

Browse the RSLinx path to the DeviceNet Network

Select the DeviceNet Network

Go online with DeviceNet Network.

Select Network>Online

When online, RSNetworx will browse and display the devices on the network.

Upload entire Network.

Select Network>Upload from Network

Click Ok

The scanner and device parameters will be uploaded.

Save the DeviceNet project.

Select File>Save As

Enter a unique project name.

Click Save.

This saves the existing DeviceNet project and allows us to generate a report.

Go offline.

RSNetworx will go offline

Generate Network Report.

Select File>Generate Report

Select Generate report for entire network

Click Ok

RSNetworx will generate a report in html format for the entire network. It will contain the configuration for the Scanner and the 160 SSC drive. The file has an .html extension and is saved in the same folder as the DeviceNet project (.dnt) file. It can be viewed and printed.

The current Scanner and the 160 SSC configuration will be needed in later steps. The DeviceNet project file (.dnt) saved in this step can be opened up offline or the .html report generated in this step can be viewed offline.

Following is a sample of the information contained in the report:

Scanlist Summary

Node Active Key Input Size Input Mapped Output Size Output Mapped

01, 'Slave Mode' No

22, 160 SSC Analog 3....

Input Memory

Assembly Data

Memory Offset

Yes

Bit Length

1:I.Data[10].0 32

Output Memory

Assembly Data

Memory Offset Bit Length

No 0

Yes 4

Node

22, 160 SSC Analog 3....

Node

Yes

Message Type

Polled

Message Type

Yes

1:O.Data[10].0 32 22, 160 SSC Analog 3.... Polled

The Scanner configuration in the report shows that the 160 SSC drive is address 22. Four bytes are mapped to input word 10 and four bytes are mapped to output word 10.

The report for the 160 SSC (address 22) configuration shows all the parameters of the drive. The parameters needed to configure the new PowerFlex are highlighted.

Parameters

ID Name Value

Output Frequency

Output Voltage

0.0 Hz

0 Volt

Output Power

Bus Voltage

Cmd Frequency

Present Fault

Heatsink Temp

Drive Status

Input Status

Power Factor Ang

Preset Status

17 Fault Buffer 0

Fault Buffer 1

Fault Buffer 2

20 Reserved

21 Reserved

22 Reserved

23 Reserved

24 Reserved

25 Reserved

26 Reserved

27 Reserved

28 Reserved

0.00 kW

669 Volt

0.0 Hz

No Fault

69 Deg

XXXXXXXX 10000010

7.06

XXXXXXXX XXXX0010

0.0 Deg

40960

XXXXXXXX XXXXXX00

0.0

Under Volt Fault

Motor OL Fault

Under Volt Fault

29 Reserved

30 Accel Time 1

31 Decel Time 1

Minimum Freq

Maximum Freq

Stop Mode Select

Base Frequency

Base Voltage

Maximum Voltage

Skip Frequency

Skip Freq Band

Overload Select

Motor Overload

Current Limit

DC Hold Time

DC Hold Voltage

Input Mode

49 PWM Frequency

51 Restart Time

53 S-Curve

56 Reset Functions

Freq Select

Zero Offset

Preset Freq 0

Preset Freq 1

63 Reserved

64 Reserved

65 Preset Freq 4

66 Preset Freq 5

67 Reserved

68 Reserved

69 Accel Time 2

70 Decel Time 2

IR Compensation

Slip Comp

Reverse Disable

75 Analog Minimum

76 Analog Maximum

77 Reserved

78 Compensation

79 Current Trip

24574

No Action

Unlocked

Internal Freq

0.0 %

3.0 Hz

20.0 Hz

45.0 Hz

50.0 Hz

20.0 Sec

50 %

2.0 Hz

Not Disabled

Unipolar

0.0 %

100.0 %

10.0 Sec

0 Hz

60 Hz

Ramp to Stop

60 Hz

460 Volt

5.0%

240 Hz

0 Hz

No Derating

6.00 Amps

150 %

0.0 Sec

0 Volt

Network Control

Ready/Faulted

4.0 kHz

10.0 Sec

0 %

Proc Kp Gain

Proc Ki Gain

Proc Reference

Proc Invert

85 Reserved

86 Reserved

87 Reserved

88 Reserved

89 Reserved

90 Reserved

91 Reserved

92 Reserved

93 Reserved

94 Reserved

95 Reserved

96 Reserved

102

103

104

105

106

97 Reserved

98 Reserved

99 Reserved

100 Reserved

101 Switches MAC ID

Switches Baud

NV MAC ID

NV Baud Rate

Bus Off Error

Bus Off Count

107

108

113

114

Output Assembly

Input Assembly

DN Fault Mode

Motor Base RPM

0.01

0.0 %

125K Baud

Hold Error State

103

104

Fault and Stop

1778 RPM

115

116

117

DN Idle Mode

DN SW Version

COS Mask

Stop Drive

3.002

11111111 11111111

118 Local Return Md 3 Wire Control

DeviceNet Parameters on Report.

Parameter 101 MAC ID is the DeviceNet address and Parameter 102 is the DeviceNet baud.

These values will be use later in the PowerFlex DeviceNet configuration.

Parameter 107 Output Assembly and 108 Input Assembly are the I/O Assemblies used to control the drive over DeviceNet. They are needed later to configure the data size in the DeviceNet

Scanner and the method of control for the ladder logic.

Configure PowerFlex Drive

Determine Address and Baud from 160 SSC

The new PowerFlex will replace the 160 SSC at the same address on the DeviceNet.

The address and baud rate can be determined by viewing the 160 SSC parameters. These can be viewed by opening up the saved DeviceNet project with the 160 SSC or the report generated from this project.

Parameter 101 – Switches MAC ID

Parameter 102 – Switches Baud

The address and the baud rate of the 160 SSC can also be determined from the DIP switches on the back of the 160-DN2 DeviceNet Communication module.

DIP switches 6 through 1 set the module’s address. Factory default setting is 63. Note that when switches 7 and 8 are ON, the address is set to the value in Parameter 103 – NV MAC ID.

DIP switches 7 and 8 set the module’s baud rate. Factory default setting is 125 kbps. Note that when switches 7 and 8 are ON, the baud rate is set to the value in Parameter 104 – NV Baud

Rate.

For more on address and baud rate DIP settings reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

Install DeviceNet Comms Adapter in PowerFlex Drive

Install 22-COMM-D adapter in PowerFlex 40 or 22-XCOMM for PowerFlex 4/4M per the following publications at:

http://literature.rockwellautomation.com

22COMM-UM003

22COMM-IN001

22-COMM-D DeviceNet Adapter User Manual

22-XCOMM External Comms Installation Manual

Set DIP switches on Communication Adapter

Set address and baud rate on the PowerFlex communication adapter the same as the

160 SSC.

Set Single/Multi Drive Operation jumper (J2) to Single Drive Operation.

DIP switches 1 through 6 set the address and switches 7 and 8 set the baud rate. Note that when all switches are CLOSED (0), the address is set to the value in Parameter 2 – DN Addr Cfg and the Baud is set to the value in Parameter 4 – DN Rate Cfg

Install and Configure PowerFlex drive.

NOTE: It’s recommended that the PLC be in program mode for this step. The new PowerFlex drive is taking the place of the 160 SSC on the DeviceNet network. The existing PLC logic for the

160 SSC could inadvertently start the PowerFlex drive. It is also recommended that the hardware enable to the PowerFlex drive (terminals 1 and 11) be open.

Install the PowerFlex 4/4M/40 per the recommendations in the following publications at:

http://literature.rockwellautomation.com

22A-UM001

22B-UM001

22F-UM001

PowerFlex 4 User Manual

PowerFlex 40 User Manual

PowerFlex 4M User Manual

Configure PowerFlex Drive.

It is possible to configure the PowerFlex many ways.

Explorer

Drive

HIM

DeviceNet

The following description uses RSNetworx to set parameters in the PowerFlex drive and configure the scanner online.

NOTE: Be sure to have the EDS file for the PowerFlex drive installed on PC. EDS file for

PowerFlex can be downloaded at:

http://www.rockwellautomation.com/resources/eds/

An EDS file can be created for the PowerFlex. See the procedures in the following publications at:

http://literature.rockwellautomation.com

22COMM-UM003

22-COMM-D DeviceNet Adapter User Manual

The PowerFlex drive and DeviceNet need to be powered up.

Go online with DeviceNet.

Start RSNetworx for DeviceNet

Set Online Path to Network.

Network>Properties

Set Online Path

Browse the RSLinx path to the DeviceNet Network

Select the DeviceNet Network

Click

Go online with DeviceNet Network.

Select Network>Online

RSNetworx will do a single pass browse and the new PowerFlex drive should show up on the network at the address of the 160 SSC.

Set PowerFlex drive parameters.

Double click on PowerFlex Drive.

The PowerFlex Properties is displayed.

Select the Parameters tab

Click on Upload parameters.

PowerFlex parameters are displayed.

Edit Parameters

The following parameters are the minimum required to configure the PowerFlex for the motor attributes and to accept commands over DeviceNet. The table shows a cross reference to the

160 SSC parameters that can be seen in the Offline DeviceNet file or the report generated in the previous step.

NOTE: This example uses a 5HP, 460VAC, 6.0FLA, 60Hz motor. PowerFlex Parameters 31, 32,

33, 34, and 35, are dependant on your motor and application. PowerFlex Parameters 37, 39, and

40 are dependant on your applications stop mode and Accel/Decel rates.

160 SSC analog PowerFlex 40

No. Parameter Value No. Parameter Value

Base Voltage 460 V

Base Frequency 60 Hz

Motor OL Current 6.0 A

Minimum Frequency 0 Hz

Maximum Frequency 60 Hz

Input Mode 2 - Network Control

Stop Mode Select 0 - Ramp to Stop

Frequency Select 1 – Internal

Accel Time 1 10.0 Sec

Motor NP Volts

Motor NP Hertz

Motor OL Current

Minimum Frequency

460 V

60 Hz

6.0 A

0 Hz

Maximum Frequency 60 Hz

Start Source

Stop Mode

Speed Reference

Accel Time 1

5 – Comm Port

0 – Ramp CF

5 – Comm Port

10.0 Sec

31 Decel Time 1 10.0 Sec 40 Decel Time 1 10.0 Sec

NOTE: PowerFlex 40 on DeviceNet. Parameter 164 may need to be edited if doing explicit messaging over DeviceNet. See the information on this parameter in the sections for

ControlLogix Explicit Messaging and SLC Explicit Messaging.

Click Apply.

Click Ok to close the properties.

Configure DeviceNet Scanner

Before configuring the DeviceNet scanner for the new PowerFlex drive, we need to know how the

160 SSC is mapped into the Input/Output of the scanner. The 160 SSC is mapped in the Scanlist with Output Assemblies of one to four bytes, and Input Assemblies from one to eight bytes.

The size in bytes of the data mapped to the 160 SSC is dependant on the configurable

Input/Output Assemblies used for DeviceNet. The size in bytes of the data mapped to the

PowerFlex is dependant on the fixed Input/Output Assemblies used for DeviceNet.

The Input/Output Assemblies used by the 160 SSC are determined by values in Parameter 107

Output Assembly and 108 Input Assembly. These can be viewed by opening up the saved

DeviceNet project with the 160 SSC or the report generated from this project. A typical example of Output Assembly 20 and Input Assembly 70 would be mapped in the scanner as four bytes out and four bytes in.

160 SSC Output Assembly 20 and Input Assembly 70 example.

For an explanation of the Input/Output Assemblies for 160 SSC, reference the following manual at:

http://literature.rockwellautomation.com

160-UM002

160-DN2 Device Net Communication Module User Manual

The PowerFlex drive Input and Output Assemblies are fixed at four bytes in and four bytes out.

For an explanation of the Input/Output Assemblies for PowerFlex 4, reference the following manual at:

http://literature.rockwellautomation.com

22COMM-UM003

22-COMM-D DeviceNet Adapter User Manual

If the 160 SSC used one byte Output Assemblies 1…5 or Input Assemblies 50…54 then we need to verify that the space in the scanner that the 160 SSC occupied is large enough for the four bytes of the PowerFlex.

Go online with DeviceNet.

Start RSNetworx for DeviceNet

Set Online Path to Network.

Network>Properties

Click

Browse the RSLinx path to the DeviceNet Network

Select the DeviceNet Network

Click

Go online with DeviceNet Network.

Select Network>Online

When online, RSNetworx will browse and display the devices on the network.

Edit Scanlist.

In the following example, the 1756-DNB scanner is shown. Editing other scanners is similar.

Double-Click on DeviceNet Scanner.

Select Scanlist tab and Upload.

The Scanlist will upload.

Scanlist will show an error because of the key mismatch between the 160 SSC drive in the configuration and the new PowerFlex Drive connected to the network at the same address.

Click Update Key.

This will replace the 160 SSC with the PowerFlex in the Scanlist. It is possible the I/O sizes are different. We need to verify the mapping and sizes.

The Scanlist will be displayed including the new PowerFlex.

Select the PowerFlex drive in the Scanlist

Click Edit I/O Parameters

This will allow us to change the Input and Output size to 4 bytes.

The I/O Parameters will be displayed.

Check the Polled check box.

Set Input size to 4 bytes.

Set Output size to 4 bytes.

Select Poll rate as Every Scan

Click OK and (Yes to Unmap and Yes to Automap if the size changed)

View Input/Output Mapping.

This procedure replaced the 160 SSC Input/Output mapping with the PowerFlex map. As stated earlier the PowerFlex Input/Output Assemblies are fixed at 4 bytes in and 4 bytes out. The 160

SSC Input/Output Assemblies are configurable depending on the values in drive parameters 107 and 108. If Input or Output Assemblies for the 160 SSC were less than 4 bytes, the new

PowerFlex mapping may overlap and existing device. Follow the next steps to verify the mapping and possibly move the PowerFlex.

Click on Input tab

Select the PowerFlex

The display will show the location in the Scanner’s Input table that the 4 bytes from the PowerFlex are mapped to. In this example, word 10. Also, this example uses a 1756-DNB. If a 1747-SDN or a 1771-1771-SDN is used the mapping will display in 16 bit words. Notice in this example another device has 1 byte located at word 11.

If it needs to be moved or is overlapping with another device complete the

following steps. Click on Advanced…

If the mapping is correct and does not overlap another device then click on Output tab

The Advanced Input mapping will be displayed

NOTE: Complete this step if it needs to be moved or is overlapping with another device.

Select Memory:

Select memory location from the pull down depending on the type of DeviceNet scanner being used.

Type of Scanner Memory Locations

1747-SDN Discrete of M-File

1771-SDN Block Xfer 62-57

Enter Word or DWord to map Input assembly to.

In this example, a 1756-DNB is used so 32 bits (4 bytes) are mapped to Dword

10. If you are using a 17xx-SDN, it will show 32 bits (4 bytes) mapped to Word

10, and 11

Click Apply Mapping

Close

The inputs should be mapped to the proper location on the Input tab.

Click on Output tab.

Select the PowerFlex

The display will show the location in the Scanner’s Output table that the four bytes to the PowerFlex are mapped to. In this example, word 10. Also, this example uses a 1756-DNB. If a 1747-SDN or a 1771-1771-SDN is used the mapping will display in 16 bit words. Notice in this example another device has one byte located at word 11.

NOTE: If it needs to be moved or is overlapping with another device go to the

Advanced mapping as described for inputs in the previous step. Otherwise go on to next step.

If it needs to be moved or is overlapping with another device complete the

following steps. Click on Advanced…

If the mapping is correct and does not overlap another device then go on to the next step to download to the scanner.

Download to Scanner.

NOTE: The PLC needs to be in program mode for this step. The new PowerFlex drive is taking the place of the 160 SSC on the DeviceNet network. It is also recommended that the hardware enable to the PowerFlex drive (terminals 1 and 11) be open.

Select the Scanlist Tab

Select the PowerFlex drive in the Scanlist

Click Download to Sanner

Select the Selected Scanlist Records radio button.

Click Download

This will download the changes for the PowerFlex replacement of the 160 SSC to the

Scanner.

When the download is complete, click OK to close the Scanner dialog.

Save the DeviceNet project.

Select File>Save As

Enter a unique project name.

Click Save.

This saves the new DeviceNet project which includes the PowerFlex drive.

Example Ladder Logic

The DeviceNet configuration has been aimed at placing the new PowerFlex in the same

Input/Output space as the 160 SSC. The logic examples provided are to replace the 160 SSC with a new PowerFlex with minimal changes to the control logic.

The ladder logic of the 160 SSC is dependant on the data mapping of the configurable

Input/Output Assemblies used for DeviceNet. The ladder logic for the PowerFlex is dependant on the fixed Input/Output Assemblies used for DeviceNet.

The Input/Output Assemblies used 160 SSC are determined by values in Parameter 107 Output

Assembly and 108 Input Assembly. These can be viewed by opening up the saved DeviceNet project of the 160 SSC or the report generated from this project.

The following tables show the data mapping for two of the most common 160 SSC Input/Output

Assemblies and the PowerFlex Input/Output Assemblies.

160 SSC Output Assembly 20 and Input Assembly 70

160 SSC Output Assembly 103 and Input Assembly 104

PowerFlex Output Assembly and Input Assembly

Logic examples for ControlLogix, and SLC500 are shown for the two common 160 SSC assemblies and equivalent logic to control a PowerFlex in the same manner. The 160 SSC logic can vary depending on Input/Output Assemblies. The logic for the PowerFlex attempts to use the same bits and method of control by minor edits to the commands to the drive and status from the drive while keeping the original command and status logic intact.

If the 160 SSC used Customizable Input Assemblies 102 or 105, the configurable parameters being read from the drive will have to be cross-referenced to the PowerFlex and possibly be transferred using an explicit message.

NOTE: Preset Speed Model.

The example logic sends a speed reference to the drives and assumes it is configured as a speed follower. The 160 SSC could be a Preset model and use Output Assembly 103 to select

Preset speed. This can also be accomplished with the PowerFlex fixed output assembly.

160 SSC Output Assembly 20 and Input Assembly 70

Default and common configuration.

160 SSC Output Assembly 103 and Input Assembly 104

PowerFlex 40 Output and Input Assembly

For Input/Output Assemblies not shown in these examples or for a more in-depth discussion reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

22COMM-UM003 22-COMM-D DeviceNet Adapter User Manual

ControlLogix I/O Messaging Examples

In this example, DeviceNet is configured for the drive Outputs to start at Slot 1 Output Word 10

(Local:1:O.Data[10]) and drive Inputs to start at Slot 1 Input Word 10 (Local:1:I.Data[10]) in the

1756-DNB Scanner.

Tags for Example Program

Description Tag Name

Local:1:I.Data[10]

Type

Dint[]

Local:1:O.Data[10] Dint[]

DriveInputImage Int[2]

Local I/O Slot 1 Input

Local I/O Slot 1 Output

Drive Input Dint to Int conversion

Drive Output Int to Dint conversion DriveOutputImage

DriveSpdFbk

DriveSpdRef

DriveStaReady

Int[2]

Int

Bool

Speed Feedback from drive +/- 0-32767

Speed Reference to drive 0-32767

Drive Status to user logic – Ready

Drive Status to user logic – Running DriveStaRunning

DriveStaFwd

DriveStaFault

DriveStaAtRef

DriveCmdStop

DriveCmdStart

Bool

Drive Status to user logic – Forward Direction

Drive Status to user logic – Faulted

Drive Status to user logic – Running at speed reference

Drive Command from user logic – Stop

Drive Command from user logic – Start

DriveCmdJog

DriveCmdClrFault

DriveCmdFwd

Bool

Drive Command from user logic – Jog

Drive Command from user logic – Clear Fault (reset)

Drive Command from user logic – Fwd/Rev Direction

ControlLogix

160 SSC Control with Output Assembly 103 and Input Assembly 104

Using the Output Assembly 103, the 160 SSC is started with a momentary DriveCmdStart bit and stopped with a momentary DriveCmdStop bit.

Speed Reference is 0-32767 (32767 = Maximum frequency).

ControlLogix

Equivalent PowerFlex Control for Output Assembly 103 and Input Assembly 104

The PowerFlex is started with a momentary DriveCmdStart bit and stopped with a momentary

DriveCmdStop bit.

The 160 SSC Speed Reference was 0-32767 (32767 = Maximum frequency). The PowerFlex

Speed Reference is 0-600 (0.0Hz *10). The speed reference from the user logic has to be scaled for the PowerFlex 0-600.

ControlLogix

160 SSC Control with Output Assembly 20 and Input Assembly 70

Using the Output Assembly 70, the 160 SSC is started with DriveCmdRunFwd bit being held high and stopped when DriveCmdRunFwd goes low.

Speed Reference is 0-1750 RPM.

ControlLogix

Equivalent PowerFlex Control for Output Assembly 20 and Input Assembly 70

The 160 SSC is started with DriveCmdRunFwd bit being held high and stopped when

DriveCmdRunFwd goes low. The PowerFlex is started with a momentary start bit and stopped with a momentary stop bit. Logic has to be added to start the Powerflex when the

DriveCmdRunFwd bit goes high and stop the PowerFlex when the DriveCmdRunFwd bit goes low.

The 160 SSC Speed Reference was 0-1750RPM. The PowerFlex Speed Reference is 0-600

(0.0Hz *10). The speed reference from the user logic has to be scaled for the PowerFlex 0-600.

ControlLogix Explicit Messaging Examples

Explicit Messaging is used to transfer data that does not require continuous updates. It can also be configured to read or write parameters not included in the fixed Input and Output Assemblies.

Two examples are shown for 160 SSC and equivalent for PowerFlex. One example reads the

Output current from the drive and the other writes Accel Rate to the drive.

NOTE: PowerFlex 40 Explicit Messaging. Writing parameter data to the PowerFlex 40 over the communications port can be stored to RAM only or Non-Volatile Storage (NVS) depending on

Parameter A164 (Comm Write Mode). If stored in RAM, the values will be lost at power down.

However, if they are stored in NVS, and the controller is programmed to write parameter data frequently, the NVS will quickly exceed its life cycle and cause the drive to malfunction.

Parameter A164 (Comm Write Mode)

0 – Save (default)

1 – RAM Only

Read Output Current, ParamReadMsg Rungs.

The following rung triggers the message to read the Output Current from the drive when bit

ParamRead goes from OFF to ON. Bit ParamRead is the result of user’s logic.

Read Output Current, ParamReadMsg Configuration.

The message control rungs for reading a value from the 160 SSC and the PowerFlex could be same, but the message configuration is different. The DeviceNet objects differ between the 160

SSC and Powerflex. Following shows the message configuration differences to read the Output

Current from a PowerFlex compared to a 160 SSC.

For a complete list of DeviceNet objects reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

22COMM-UM003 22-COMM-D DeviceNet Adapter User Manual

For a cross reference of 160 SSC parameters to PowerFlex parameters see the Parameter Cross

Reference section at the end.

Message Configuration

The message type must be CIP Generic.

160 SSC – CIP Generic

PowerFlex – CIP Generic

Service Type

The service type is the requested DeviceNet service. Available services depend on the class and instance that you are using.

160 SSC – Get Attribute Single (Service Code – e)

PowerFlex – Get Attribute Single (Service Code – e)

Class

The object type is a DeviceNet class.

160 SSC – b3 (Parameter Table Object)

PowerFlex – f (Parameter Object)

Instance

The object ID is an instance of a DeviceNet class.

160 SSC – 1 (Parameter Value)

PowerFlex – 3 (Parameter #)

Attribute

The attribute is a class or instance attribute.

160 SSC – 3 (Parameter #3 Output Current)

PowerFlex – 1 (Parameter Value)

Source Element

The Source Element is the name of the tag for any data to be sent from the scanner to the drive. A tag must be specified even if it is not used.

160 SSC – blank

PowerFlex – blank

Source Length

The number of bytes of service data to be sent of received in the message.

160 SSC – 0

PowerFlex – 0

Destination

The Destination is the name of the tag that will receive service response data from the drive. A tag must be specified even if it is not used.

160 SSC – DriveOutCurr (Int Tag)

PowerFlex – DriveOutCurr (Int Tag)

Path

The path includes the following:

Name of DeviceNet scanner - DNET01

Communication port on the front of the 1756-DNB scanner. - Always 2.

Node address of the DeviceNet adapter on drive – 22

Write Accel Rate, ParamWriteMsg1 Rungs.

The following rung triggers the message to write the Accel Rate to the drive when bit ParamWrite goes from OFF to ON. Bit ParamWrite is the result of user’s logic.

Write Accel Rate, ParamWriteMsg1 Configuration.

The message control rungs for writing a value to the 160 SSC and the PowerFlex could be same, but the message configuration is different. The DeviceNet objects differ between the 160 SSC and Powerflex. Following shows the message configuration differences to write an Accel Rate to a PowerFlex compared to a 160 SSC.

For a complete list of DeviceNet objects reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

22COMM-UM003 22-COMM-D DeviceNet Adapter User Manual

For a cross reference of 160 SSC parameters to PowerFlex parameters see the Parameter Cross

Reference section at the end.

Message Configuration

The message type must be CIP Generic.

160 SSC – CIP Generic

PowerFlex – CIP Generic

Service Type

The service type is the requested DeviceNet service. Available services depend on the class and instance that you are using.

160 SSC – Set Single Attribute (Service Code – 10)

PowerFlex – Set Single Attribute (Service Code – 10)

Class

The object type is a DeviceNet class.

160 SSC – b3 (Parameter Table Object)

PowerFlex – f (Parameter Object)

Instance

The object ID is an instance of a DeviceNet class.

160 SSC – 1 (Parameter Value)

PowerFlex – 39 (Parameter #)

Attribute

The attribute is a class or instance attribute.

160 SSC – 1e (30 decimal) (Parameter #30 Accel Rate)

PowerFlex – 1 (Parameter Value)

Source Element

The Source Element is the name of the tag for any data to be sent from the scanner to the drive. A tag must be specified even if it is not used.

160 SSC – DriveAccelRate (Int Tag)

PowerFlex – DriveAccelRate (Int Tag)

Source Length

The number of bytes of service data to be sent of received in the message.

160 SSC – 2

PowerFlex – 2

Destination

The Destination is the name of the tag that will receive service response data from the drive. A tag must be specified even if it is not used.

160 SSC – blank

PowerFlex – blank

Path

The path includes the following:

Name of DeviceNet scanner - DNET01

Communication port on the front of the 1756-DNB scanner. - Always 2.

Node address of the DeviceNet adapter on drive – 22

SLC 500 I/O Messaging Examples

I:2.10/3

I:2.10/7

I:2.10/8

B21:10/0

B21:10/1

B21:10/2

B21:10/3

B21:10/4

B21:10/5

O:2.10/0

O:2.10/1

O:2.10/2

O:2.10/3

O:2.10/4

O:2.10/5

In this example, the DeviceNet is configured for the drive Outputs to start at Slot 2 Output Word

10 (O:2.10) and drive Inputs to start at Slot 2 Input Word 10 (I:2.10) in the 1747-SDN Scanner.

Data Table Elements for Example Program

Address

N23:10

N22:10

I:2.11

Description

Speed Feedback from drive +/- 0-32767

Speed Reference to drive 0-32767

160 SSC Speed Feedback from DeviceNet

O:2.11

B20:10/0

B20:10/1

B20:10/3

B20:10/7

B20:10/8

I:2.10/0

I:2.10/1

160 SSC Speed Reference to DeviceNet

Drive Status to user logic – Ready

Drive Status to user logic – Running

Drive Status to user logic – Forward Direction

Drive Status to user logic – Faulted

Drive Status to user logic – Running at speed reference

160 SSC Status from DeviceNet – Ready

160 SSC Status from DeviceNet – Running

160 SSC Status from DeviceNet – Forward Direction

160 SSC Status from DeviceNet – Faulted

160 SSC Status from DeviceNet – Running at speed reference

Drive Command from user logic – Stop

Drive Command from user logic – Start

Drive Command from user logic – Jog

Drive Command from user logic – Clear Fault (reset)

Drive Command from user logic – Run Forward

Drive Command from user logic – Fwd/Rev Direction

160 SSC Command to DeviceNet – Stop

160 SSC Command to DeviceNet – Start

160 SSC Command to DeviceNet – Jog

160 SSC Command to DeviceNet – Clear Fault (reset)

160 SSC Command to DeviceNet – Run Forward

160 SSC Command to DeviceNet – Fwd/Rev Direction

SLC500

160 SSC Control with Output Assembly 103 and Input Assembly 104

Using the Output Assembly 103, the 160 SSC is started with a momentary Start (O:2.10/1) bit and stopped with a momentary Stop (O:2.10/0) bit.

Speed Reference is 0-32767 (32767 = Maximum frequency).

SLC500

Equivalent PowerFlex Control for Output Assembly 103 and Input Assembly 104

The PowerFlex is started with a momentary Start (O:2.10/1) bit and stopped with a momentary

Stop (O:2.10/0) bit.

The 160 SSC Speed Reference was 0-32767 (32767 = Maximum frequency). The PowerFlex

Speed Reference is 0-600 (0.0Hz *10). The speed reference from the user logic has to be scaled for the PowerFlex 0-600.

SLC500

160 SSC Control with Output Assembly 20 and Input Assembly 70

Using the Output Assembly 70, the 160 SSC is started with RunFwd (O:2.10/0) bit being held high and stopped when RunFwd (O:2.10/0) bit goes low.

Speed Reference is 0-1750 RPM.

SLC500

Equivalent Control for Output Assembly 20 and Input Assembly 70

Using the Output Assembly 70, the 160 SSC is started with RunFwd (O:2.10/0) bit being held high and stopped when RunFwd (O:2.10/0) bit goes low. The PowerFlex is started with a momentary start bit and stopped with a momentary stop bit. Logic has to be added to start the

Powerflex when the RunFwd (O:2.10/0) bit goes high and stop the PowerFlex when the RunFwd

(O:2.10/0) bit goes low.

The 160 SSC Speed Reference was 0-1750RPM. The PowerFlex Speed Reference is 0-600

(0.0Hz *10). The speed reference from the user logic has to be scaled for the PowerFlex 0-600.

SLC 500 Explicit Messaging Examples

Explicit Messaging is used to transfer data that does not require continuous updates. It can also be configured to read or write parameters not included in the fixed Input and Output Assemblies.

There are two methods of explicit messaging in the SLC 500. One method uses the DEM instruction and the other uses the Module files (M0 and M1) of the DeviceNet scanner. The DEM instruction simplifies programming and configuration. However it requires RSLogix 500 ver 7.10 or later, and a SLC 503,504, or 505 firmware level Series C, FRN 10 or later. The examples are given with the Module file method because it is more difficult but also more common.

Two examples are shown for 160 SSC and equivalent for PowerFlex. One example reads the

Output current from the drive and the other writes Accel Rate to the drive.

NOTE: PowerFlex 40 Explicit Messaging. Writing parameter data to the PowerFlex 40 over the communications port can be stored to RAM only or Non-Volatile Storage (NVS) depending on

Parameter A164 (Comm Write Mode). If they are stored in RAM, the values will be lost at power down. However, if they are stored in NVS, and the controller is programmed to write parameter data frequently, the NVS will quickly exceed its life cycle and cause the drive to malfunction.

Parameter A164 (Comm Write Mode)

0 – Save (default)

1 – RAM Only

SLC Message Format

The example uses N10:0 as the message request file and N11:0 as the message response file.

The request file and the response file need to be formatted as shown:

The N10 and N11 files are sent to and received from the M0 and M1 files of the 1747-SDN

DeviceNet scanner to control the explicit messaging. The M0 and M1 files are data files that reside in the module. M0 file is a module output file and the M1 is a module input file.

The addressing format for the M0 and M1 files

Mf : S . w / b

M = module

f = file (0 or 1)

S = slot (1 - 30)

w = word (0 – Max of the module)

b = bit (0 - 15)

In this example the 1747-SDN DeviceNet scanner resides in slot 2 so S = 2.

Read Output Current, Message Rungs.

The following rung triggers the message to read the Output Current from the drive when bit

B3:0/0 goes from OFF to ON. The message request configuration in N10:0 is copied to M0:2.224 to start the message. The scanner notifies the processor that it has a response from the drive by setting I:2.0/15 ON and the ladder the copies the response data from M1:2.224 to N11:0. The

Output Current is in word 3 of the response data and is divided by 100.

Read Output Current, Message Configuration.

The message control rungs for reading a value from the 160 SSC and the PowerFlex could be same, but the message configuration is different. The DeviceNet objects differ between the 160

SSC and PowerFlex. Following shows the message configuration differences to read the Output

Current from a PowerFlex compared to a 160 SSC.

For a complete list of DeviceNet objects reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comm Module User Manual

22COMM-UM003 22-COMM-D DeviceNet Adapter User Manual

For a cross reference of 160 SSC parameters to PowerFlex parameters see the Parameter Cross

Reference section at the end.

N10:0 (Least Significant Byte) Command

160 SSC – 01h (Execute)

PowerFlex – 01h (Execute)

N10:0 (Most Significant Byte) TXID

160 SSC – 01h (ID = 1)

PowerFlex – 01h (ID = 1)

N10:1 (Least Significant Byte) Size

160 SSC – 06h (6 bytes)

PowerFlex – 06h (6 bytes)

N10:1 (Most Significant Byte) Port

160 SSC – 00h (Scanner port 0)

PowerFlex – 00h (Scanner port 0)

N10:2 (Least Significant Byte) Address

160 SSC – 16h (DeviceNet address 22d)

PowerFlex – 16h (DeviceNet address 22d)

N10:2 (Most Significant Byte) Service

The service type is the requested DeviceNet service. Available services depend on the class and instance that you are using

160 SSC – 0Eh (Get Single Attribute)

PowerFlex – 0Eh (Get Single Attribute)

N10:3 Class

The object type is a DeviceNet class.

160 SSC – B3h (Parameter Table Object)

PowerFlex – 0Fh (Parameter Object)

N10:4 Instance

The object ID is an instance of a DeviceNet class.

160 SSC – 01h (Parameter Value)

PowerFlex – 03h (Parameter #3 Output Current)

N10:5 Attribute

The attribute is a class or instance attribute.

160 SSC – 03h (30 decimal) (Parameter #3 Output Current)

PowerFlex – 01h (Parameter Value)

Write Accel Rate, Message Rungs.

The following rung triggers the message to write Accel Rate to the drive when bit B3:1/0 goes from OFF to ON. The Accel Rate is in Floating Point F8:1. It is multiplied by 10 and put in word 6

(N10:56) of the request configuration. The message request configuration in N10:50 is copied to

M0:2.224 to start the message. The scanner notifies the processor that it has a response from the drive by setting I:2.0/15 ON and the ladder the copies the response data from M1:2.224 to

N11:50.

Write Accel Rate, Message Configuration.

The message control rungs for writing a value to the 160 SSC and the PowerFlex could be same, but the message configuration is different. The DeviceNet objects differ between the 160 SSC and PowerFlex. Following shows the message configuration differences to write the Accel Rate to a PowerFlex compared to a 160 SSC.

For a complete list of DeviceNet objects reference the following publications at:

http://literature.rockwellautomation.com

160-UM002 160-DN2 Device Net Comms Module User Manual

22COMM-UM003 22-COMM-D DeviceNet Adapter User Manual

For a cross reference of 160 SSC parameters to PowerFlex parameters see the Parameter Cross

Reference section at the end.

N10:50 (Least Significant Byte) Command

160 SSC – 01h (Execute)

PowerFlex – 01h (Execute)

N10:50 (Most Significant Byte) TXID

160 SSC – 02h (ID = 1)

PowerFlex – 02h (ID = 1)

N10:51 (Least Significant Byte) Size

160 SSC – 08h (6 bytes)

PowerFlex – 08h (6 bytes)

N10:51 (Most Significant Byte) Port

160 SSC – 00h (Scanner port 0)

PowerFlex – 00h (Scanner port 0)

N10:52 (Least Significant Byte) Address

160 SSC – 16h (DeviceNet address 22d)

PowerFlex – 16h (DeviceNet address 22d)

N10:52 (Most Significant Byte) Service

The service type is the requested DeviceNet service. Available services depend on the class and instance that you are using

160 SSC – 10h (Get Single Attribute)

PowerFlex – 10h (Get Single Attribute)

N10:53 Class

The object type is a DeviceNet class.

160 SSC – B3h (Parameter Table Object)

PowerFlex – 0Fh (Parameter Object)

N10:54 Instance

The object ID is an instance of a DeviceNet class.

160 SSC – 01h (Parameter Value)

PowerFlex – 27h (Parameter #39 Accel Rate)

N10:55 Attribute

The attribute is a class or instance attribute.

160 SSC – 1Eh (30 decimal) (Parameter #30 Accel Rate)

PowerFlex – 01h (Parameter Value)

N10:56 Value

Value to be written to drive.

160 SSC – 60h (96 decimal) (Value)

PowerFlex – 5Bh (91 decimal) (Value)

Parameter Cross Reference

The following table cross references 160 SSC parameters to equivalent PowerFlex 40 parameters.

160 SSC PowerFlex 40

Firmware 7.03 and higher Firmware 5.x and higher Comments

No. Parameter

Output Frequency

Output Voltage

Output Current

Output Power

Bus Voltage

Frequency Command

Active Fault

Heatsink Temperature

Drive Status

Drive Type

Firmware Version

Input Status

Power Factor Angle

Memory Probe Display

Preset Status

16 Analog Input

Fault Buffer 0

Fault Buffer 1

Fault Buffer 2

Accel Time 1

Decel Time 1

Minimum Frequency

Maximum Frequency

Stop Mode Select

Base Frequency

Base Voltage

Maximum Voltage

Boost Select

Skip Frequency

Skip Frequency Band

Motor Overload Select

Motor Overload Current

Current Limit

DC Hold Time

DC Hold Voltage

Input Mode

Output Configure

No. Parameter

Output Frequency

Output Voltage

Output Current

Output Power

DC Bus Voltage

Commanded Freq

Fault Code 1

Drive Temp

Drive Status

Drive Type

Control SW Ver

Contrl In Status

Output Pwr Fctr

Testpoint Sata

Dig In Status

Analog In 0-10V

Analog In 4-20mA

Fault Code 1

Fault Code 2

Fault Code 3

Accel Time 1

Decel Time 1

Minimum Frequency

Maximum Frequency

Stop Mode

Motor NP Hertz

Motor NP Volts

Maximum Voltage

Boost Select

119 Skip Frequency

120 Skip Freq Band

Motor OL Select

Motor OL Current

Current Limit 1

DC Brake Time

DC Brake Level

Start Source

Relay Out sel

Depending on input used

Additional OPTO Out 1/2 available

Output Threshold

PWM Frequency

Restart Tries

Restart Time

DB Enable

S-Curve

Clear Fault

Memory Probe Address

Reset Functions

Program Lock

Internal Frequency

Frequency Select

Zero Offset

Preset Frequency 0

Preset Frequency 1

Preset Frequency 2

Preset Frequency 3

Preset Frequency 4

Preset Frequency 5

Preset Frequency 6

Preset Frequency 7

Accel Time 2

Decel Time 2

IR Compensation

Slip Compensation

Reverse Disable

Analog Select

75 Analog Input Minimum

76 Analog Input Maximum

Compensation

Software Current Trip

Stall Fault Time

PI Proportional Gain

PI Integral Gain

PI Process Reference

PI Deadband

Relay Our level

PWM Frequency

Auto Rstrt Tries

Auto Rstrt Delay

DB Resistor Sel

S Curve %

100 Fault Clear

19 Testpoint Data

41 Reset to Defaults

101 Program Lock

69 Internal Freq

Speed Reference

Preset Frequency 0

Preset Frequency 1

Preset Frequency 2

Preset Frequency 3

Preset Frequency 4

Preset Frequency 5

Preset Frequency 6

Preset Frequency 7

Accel Time 2

Decel Time 2

128 IR Voltage Drop

114 Slip Hertz @ FLA

95 Reverse Disable

132 10V Bipolar Enbl

110 Analog In 0-10V Lo

112 Analog In 4-20mA Lo

111 Analog In 0-10V Hi

113 Analog In 4-20mA Hi

Compensation

SW Current Trip

121 Stall Fault Time

134 PID Prop Gain

135 PID Integ Time

137 PID Setpoint

138 PID Deadband

Not applicable

Depending on input used

Notes:

Drive Explorer, DriveExecutive, SSC, PowerFlex and Rockwell Automation are trademarks of Rockwell Automation, Inc Trademarks not belonging to Rockwell

Automation are property of their respective companies.

Publication DRIVES-AP005A-EN-E – April 2009

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