Allen-Bradley PowerFlex 520 Series Original Instructions Manual
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Allen-Bradley PowerFlex 520 Series Original Instructions Manual

Adjustable frequency ac drive
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PowerFlex 520-Series Adjustable Frequency AC Drive
PowerFlex 523 Catalog Number 25A
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Summary of Contents for Allen-Bradley PowerFlex 520 Series

  • Page 1 User Manual PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B Original Instructions...
  • Page 2 Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.
  • Page 3 Summary of Changes This manual contains new and updated information. New and Updated This table contains the changes made to this revision. Information Topic Page Added Warning table for Motor Cable Length Restrictions Updated Maximum Control Wire Recommendations information on noise immunity Updated Start Method and Stop Method tables for PowerFlex 523 drives Updated Start Method and Stop Method tables for PowerFlex 525 drives Added Important table for EMC category C3 installation information...
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 5: Table Of Contents

    Table of Contents Preface Overview Who Should Use this Manual ........9 Recommended Documentation .
  • Page 6 Table of Contents Modified Parameter Group ........130 Fault and Diagnostic Group.
  • Page 7 Table of Contents Appendix E Encoder/Pulse Train Usage and Encoder and Pulse Train Usage........203 Wiring Notes .
  • Page 8 Table of Contents Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 9: Preface

    Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex® 520-Series Adjustable Frequency AC Drive. For information on… See page… Who Should Use this Manual Recommended Documentation Manual Conventions Drive Frame Sizes General Precautions...

  • Page 10: Manual Conventions

    Preface Overview The following publications provide specific Network Communications information: Title Publication PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001 PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002 PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM003 PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004 • In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC Manual Conventions Drive as;...

  • Page 11: Drive Frame Sizes

    Overview Preface • The Studio 5000® Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Studio 5000 Logix Designer™ application is the rebranding of RSLogix™...

  • Page 12: General Precautions

    Preface Overview General Precautions ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels.

  • Page 13: Catalog Number Explanation

    Overview Preface Catalog Number Explanation – – – Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash Code Braking Standard Code Type Code EMC Filter PowerFlex 523 No Filter PowerFlex 525 Filter Code Interface Module Code Voltage Phase Standard 120V AC...
  • Page 14 Preface Overview Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 15: Installation/Wiring

    Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 520- series drives. For information on... See page... Mounting Considerations AC Supply Source Considerations General Grounding Requirements Fuses and Circuit Breakers Power and Control Module Control Module Cover Power Module Terminal Guard Power Wiring Power Terminal Block...
  • Page 16 Chapter 1 Installation/Wiring • Do not expose to a corrosive atmosphere. • Protect from moisture and direct sunlight. Minimum Mounting Clearances Appendix B for mounting dimensions. Vertical Vertical, Zero Stacking Vertical with Control Module Fan Kit Vertical, Zero Stacking with No clearance between drives.
  • Page 17 Installation/Wiring Chapter 1 Ambient Operating Temperatures Appendix B for option kits. Mounting Enclosure Rating Ambient Temperature Minimum Maximum (No Derate) Maximum (Derate) Maximum with (3)(5) Control Module Fan Kit (Derate) 50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F) Vertical IP 20/Open Type 45 °C (113 °F)
  • Page 18 Chapter 1 Installation/Wiring Derating Guidelines for High Altitude The drive can be used without derating at a maximum altitude of 1000 m (3300 ft). If the drive is used above 1000 m (3300 ft): • Derate the maximum ambient temperature by 5 °C (9 °F) for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage)

  • Page 19: Ac Supply Source Considerations

    Installation/Wiring Chapter 1 AC Supply Source Ungrounded Distribution Systems Considerations ATTENTION: PowerFlex 520-series drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.

  • Page 20: General Grounding Requirements

    Chapter 1 Installation/Wiring Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see page 157). Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life.
  • Page 21 Installation/Wiring Chapter 1 Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Safety Ground - (PE) This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar.

  • Page 22: Fuses And Circuit Breakers

    Chapter 1 Installation/Wiring Fuses and Circuit Breakers The PowerFlex 520-series drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.
  • Page 23 Installation/Wiring Chapter 1 Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 24 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 25 Installation/Wiring Chapter 1 Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 26 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 27: Power And Control Module

    Installation/Wiring Chapter 1 Power and Control Module PowerFlex 520-series drives consist of a Power Module and Control Module. Separating the Power and Control Module ATTENTION: Perform this action only when drive is NOT powered. 1. Press and hold down the catch on both sides of the frame cover, then pull out and swing upwards to remove (Frames B...E only).
  • Page 28 Chapter 1 Installation/Wiring 3. Hold the sides and top of the Control Module firmly, then pull out to separate it from the Power Module. Connecting the Power and Control Module 1. Align the connectors on the Power Module and Control Module, then push the Control Module firmly onto the Power Module.
  • Page 29 Installation/Wiring Chapter 1 2. Push the top cover of the Control Module towards the Power Module to lock it. 3. Insert the catch at the top of the frame cover into the Power Module, then swing the frame cover to snap the side catches onto the Power Module (Frames B...E only).

  • Page 30: Control Module Cover

    Chapter 1 Installation/Wiring Control Module Cover To access the control terminals, DSI port, and Ethernet port, the front cover must be removed. To remove: 1. Press and hold down the arrow on the front of the cover. 2. Slide the front cover down to remove from the Control Module. Re-attach the front cover when wiring is complete.

  • Page 31: Power Wiring

    Installation/Wiring Chapter 1 2. Press and hold down the locking tab on the terminal guard. 3. Slide the terminal guard down to remove from the Power Module. Re-attach the terminal guard when wiring is complete. To access the power terminals for Frame A, you need to separate the Power and Control Modules.
  • Page 32 Chapter 1 Installation/Wiring UL installations above 50 °C ambient must use 600V, 90 °C wire. UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire. UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire. Use copper wire only.
  • Page 33 Installation/Wiring Chapter 1 Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance.

  • Page 34: Power Terminal Block

    Chapter 1 Installation/Wiring Power Terminal Block Power Terminal Block Frame A, B, C & D Frame E R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 DC- DC+ Terminal Description R/L1, S/L2 1-Phase Input Line Voltage Connection R/L1, S/L2, T/L3 3-Phase Input Line Voltage Connection U/T1, V/T2, W/T3 Motor Phase Connection =...

  • Page 35: Common Bus/Precharge Notes

    Installation/Wiring Chapter 1 Common Bus/Precharge If drives are used with a disconnect switch to the common DC bus, then an auxiliary contact on the disconnect must be connected to a digital input of the Notes drive. The corresponding input (parameter t062, t063, t065...t068 [DigIn TermBlk xx]) must be set to 30, “Precharge En”...

  • Page 36: Control I/O Terminal Block

    Chapter 1 Installation/Wiring Recommended Signal Wire Signal Type/ Belden Wire Type(s) Description Min. Insulation Where Used (or equivalent) Rating Analog I/O & PTC 8760/9460 0.750 mm (18 AWG), twisted pair, 300V, 60 °C (140 °F) 100% shield with drain Remote Pot 8770 0.750 mm (18 AWG), 3 conductor, shielded...
  • Page 37 Installation/Wiring Chapter 1 PowerFlex 523 Control I/O Terminal Block PowerFlex 523 Control I/O Wiring Block Diagram Typical Typical SRC wiring SNK wiring Stop DigIn TermBlk 02/ Start/Run FWD DigIn TermBlk 03/ Direction/Run REV Digital Common DigIn TermBlk 05/Pulse DigIn TermBlk 06 +24V +24V DC Relay N.O.
  • Page 38 Chapter 1 Installation/Wiring Start Method Stop Method t062, t063 [DigIn TermBlk xx] I/O Terminal 01 Stop Normal Stop 48 “2-Wire FWD” t064 [2-Wire Mode] is set to: Per P045 • 0, 1, or 2 = Coast [Stop Mode] • 3 = per P045 [Stop Mode] 49 “3-Wire Start”...
  • Page 39 Installation/Wiring Chapter 1 Control I/O Terminal Designations No. Signal Default Description Parameter 15 4-20mA In Not Active For external 4-20 mA input supply. P047, P049, Input impedance = 250 Ω t062, t063, t065, t066, A459, A471 C1 C1 – This terminal is tied to the RJ-45 port shield. Tie this terminal to –...
  • Page 40 Chapter 1 Installation/Wiring Control I/O Wiring Block Diagram Notes (1) See Digital Input Selection for Start Source on page 47 for more information on configuring the digital inputs. I/O Terminal 01 is always a stop input. The stopping mode is determined by the IMPORTANT drive setting.
  • Page 41 Installation/Wiring Chapter 1 Control I/O Terminal Designations No. Signal Default Description Parameter 06 DigIn TermBlk 06 Preset Freq Program with t066 [DigIn TermBlk 06]. t066 Current consumption is 6 mA. 07 DigIn TermBlk 07/ Start Source 2 Program with t067 [DigIn TermBlk 07]. Also functions as a Pulse t067 Pulse In + Speed...
  • Page 42 Chapter 1 Installation/Wiring I/O Wiring Examples Connection Example Potentiometer P047 [Speed Reference1] = 5 “0-10V Input” 1...10k Ω Pot. Recommended (2 W minimum) Analog Input Bipolar Unipolar (Voltage) Unipolar (Current) 0-10V, 100k Ω impedance P047 [Speed Reference1] P047 [Speed Reference1] P047 [Speed Reference1] 4-20 mA, 250 Ω...
  • Page 43 Installation/Wiring Chapter 1 Connection Example 2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Non-Reversing P046 [Start Source 1] = 2 and t062 [DigIn TermBlk 02] = 48 Stop-Run Stop-Run Input must be active for the drive to run. When input is opened, the drive +24V Common will stop as specified by...
  • Page 44 Chapter 1 Installation/Wiring Connection Example 3 Wire SNK Control - Internal Supply (SNK) Non-Reversing Stop Start 3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Reversing P046 [Start Source 1] = 2, Stop t062 [DigIn TermBlk 02] Stop = 49 and t063 [DigIn TermBlk 03] = 51 Start...
  • Page 45 Installation/Wiring Chapter 1 Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input Connections Customer Inputs can be wired per External Supply (SRC). Customer Inputs Optional Ground Connection When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives.

  • Page 46: Start And Speed Reference Control

    Chapter 1 Installation/Wiring Start and Speed Reference Start Source and Speed Reference Selection Control The start and drive speed command can be obtained from a number of different sources. By default, start source is determined by P046 [Start Source 1] and drive speed source is determined by P047 [Speed Reference1].
  • Page 47 Installation/Wiring Chapter 1 Digital Input Selection for Start Source If P046, P048 P050 [Start Source x] has been set to 2, “DigIn TermBlk”, then t062 t063 [DigIn TermBlk xx] must be configured for 2-Wire or 3-Wire control for the drive to function properly. [Start Source x] Start and Direction [DigIn TermBlk...
  • Page 48 Chapter 1 Installation/Wiring Accel/Decel Selection The Accel/Decel rate can be obtained by a variety of methods. The default rate is determined by P041 [Accel Time 1] and P042 [Decel Time 1]. Alternative Accel/Decel rates can be made through digital inputs, communications and/or parameters.

  • Page 49: Ce Conformity

    Installation/Wiring Chapter 1 CE Conformity Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex 520-series drives comply with the EN standards listed below when installed according to the installation instructions in this manual.
  • Page 50 Chapter 1 Installation/Wiring • PowerFlex 520-series drives comply with the EMC requirements of EN 61800-3 when installed according to good EMC practices and the instructions provided in this document. However, many factors can influence the EMC compliance of an entire machine or installation, and compliance of the drive itself does not ensure compliance of all applications.
  • Page 51 Installation/Wiring Chapter 1 • PowerFlex 520-series drives produce leakage current in the protective earthing conductor which exceeds 3.5 mA AC and/or 10 mA DC. The minimum size of the protective earthing (grounding) conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment.
  • Page 52 Chapter 1 Installation/Wiring • Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520-Series RF Emission Compliance and Installation Requirements on page 52 for compliance with radio frequency emission limits for the specific standard and installation environment. Connections and Grounding Shielded enclosure (1) IP 30/NEMA 1/UL Type 1...
  • Page 53 Installation/Wiring Chapter 1 Additional Installation Requirements Frame Class C1 Class C2 Size Enclosure Conduit or Shielded EMC Cores Required Enclosure Conduit or Shielded EMC Cores Required Cable @ Input (Included with product) Cable @ Input (Included with product) 100...120V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...120V 1-Phase Output 200...240V AC (-15%, +10%) –...
  • Page 54 Chapter 1 Installation/Wiring Recommended Placement of EMC Cores Frame A Frame B Frame C Frame D Frame E With optional EMC plate (25-EMC-Fx) Ground cable CORE-E-1 CORE-E-3 CORE-xx-B-1 CORE-xx-D-1 CORE-xx-A-1 CORE-xx-C-1 CORE-E-2 CORE-xx-B-2 CORE-xx-D-2 CORE-E-4 CORE-xx-A-2 CORE-xx-C-2 Without EMC plate Ground cable CORE-E-3...

  • Page 55: Start Up

    Chapter Start Up This chapter describes how to start up the PowerFlex 520-series drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group. For information on... See page... Prepare for Drive Start-Up Display and Control Keys Viewing and Editing Parameters Drive Programming Tools...
  • Page 56 Chapter 2 Start Up 6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your control wiring scheme. See the PowerFlex 523 Control I/O Wiring Block Diagram on page 37 PowerFlex 525 Control I/O Wiring Block Diagram on page 39 for location.
  • Page 57 Start Up Chapter 2 16. Verify the drive and motor perform as specified. • Verify that the Stop input is present or the drive will not start. If I/O Terminal 01 is used as a stop input, the jumper between I/O IMPORTANT Terminals 01 and 11 must be removed.

  • Page 58: Display And Control Keys

    Chapter 2 Start Up Display and Control Keys PowerFlex 523 Menu Parameter Group and Description Basic Display Commonly viewed drive operating conditions. Basic Program Commonly used programmable functions. Terminal Blocks Programmable terminal functions. Communications Programmable communication functions. Logic (PowerFlex 525 only) Programmable logic functions.

  • Page 59: Viewing And Editing Parameters

    Start Up Chapter 2 Name Description Reverse Used to reverse direction of the drive. Default is active. Controlled by parameters P046, P048 and P050 [Start Source x] and A544 [Reverse Disable]. Start Used to start the drive. Default is active. Controlled by parameters P046, P048 and P050 [Start Source x].

  • Page 60: Drive Programming Tools

    Chapter 2 Start Up Step Key(s) Example Display 10. If desired, press Sel to move from digit to digit VOLTS or bit to bit. The digit or bit that you can change will flash. PROGRAM 11. Press Esc to cancel a change and exit Program VOLTS Mode.

  • Page 61: Smart Start-Up With Basic Program Group Parameters

    Start Up Chapter 2 Language Keypad/LCD Display RSLogix 5000/ Connected Components Logix Designer Workbench Polish – – Turkish – – Czech – – (1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified. Smart Start-Up with Basic The PowerFlex 520-series drive is designed so that start up is simple and efficient.
  • Page 62 Chapter 2 Start Up = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. PF 525 Parameter Min/Max Display/Options Default P040 [Autotune] 0 = “Ready/Idle” 1 = “Static Tune” Enables a static (not spinning) or dynamic (motor 2 = “Rotate Tune”...

  • Page 63: Lcd Display With Quickview

    Start Up Chapter 2 LCD Display with QuickView QuickView™ enables text to scroll across the LCD display of the PowerFlex 520- series drive. This allows you to easily configure parameters, troubleshoot faults and view diagnostic items without using a separate device. Use parameter A556 [Text Scroll] to set the speed at which the text scrolls across...
  • Page 64 Chapter 2 Start Up Double-click on the PF52XUSB.EXE file to launch the USB utility application. The main menu is displayed. Follow the program instructions to upgrade the firmware or upload/download configuration data. Make sure your PC is powered by an AC power outlet or has a fully charged IMPORTANT battery before starting any operation.

  • Page 65: Programming And Parameters

    Chapter Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 520- series drive parameters. Parameters are programmed (viewed/edited) using either the drive’s built-in keypad, RSLogix 5000 version 17.0 or greater, Logix Designer version 21.0 or greater, or Connected Components Workbench version 5.0 or greater software.

  • Page 66: Parameter Groups

    Chapter 3 Programming and Parameters • Bit Parameters Bit parameters have five individual digits associated with features or conditions. If the digit is 0, the feature is off or the condition is false. If the digit is 1, the feature is on or the condition is true. Some parameters are marked as follows.
  • Page 67 Programming and Parameters Chapter 3 Logic Stp Logic 2 L182 Stp Logic Time 0 L190 Stp Logic Time 6 L196 Step Units 4 L208 Stp Logic 3 L183 Stp Logic Time 1 L191 Stp Logic Time 7 L197 Step Units 5 L210 Stp Logic 4 L184...
  • Page 68 Chapter 3 Programming and Parameters Fault and Diagnostic Fault 5 Time-min F625 Fault10 Current F650 EN Rate Act F685 Drv 1 Reference F710 Fault 6 Time-min F626 Fault 1 BusVolts F651 DSI I/O Act F686 Drv 1 Logic Sts F711 Fault 7 Time-min F627 Fault 2 BusVolts...
  • Page 69 Programming and Parameters Chapter 3 Centrifugal Pump Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464 Motor NP Poles P035 Relay Out1 Sel...
  • Page 70 Chapter 3 Programming and Parameters CustomView Parameter Group PowerFlex 520-series drives include a CustomView™ parameter group for you to store frequently used parameters for your application. See CustomView Parameter Group on page 139 for more information. Custom Group This group can store up to 100 parameters. Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 71: Basic Display Group

    Programming and Parameters Chapter 3 Basic Display Group b001 [Output Freq] Related Parameter(s): b002, b010, P043, P044, P048, P050, P052 Output frequency present at T1, T2 & T3 (U, V & W). Does not include slip frequency. Values Default: Read Only Min/Max: 0.00/[Maximum Freq] Display:...
  • Page 72 Chapter 3 Programming and Parameters Basic Display Group (continued) b007 [Fault 1 Code] Related Parameter(s): F604-F610 b008 [Fault 2 Code] b009 [Fault 3 Code] A code that represents a drive fault. Codes appear in these parameters in the order they occur (b007 [Fault 1 Code] = the most recent fault).
  • Page 73 Programming and Parameters Chapter 3 Basic Display Group (continued) b013 [Contrl In Status] Related Parameter(s): b002, P044, P045 State of the digital terminal blocks 1...3 and DB transistor. IMPORTANT Actual control commands may come from a source other than the control terminal block. 1 = Closed State, 0 = Open State DigIn TBlk 1 Digit 1...
  • Page 74 Chapter 3 Programming and Parameters Basic Display Group (continued) b018 [Power Saved] Related Parameter(s): b017 Instantaneous power savings of using this drive compared to an across the line starter. Values Default: Read Only Min/Max: 0.00/655.35 kW Display: 0.01 kW b019 [Elapsed Run time] Related Parameter(s): A555 Accumulated time drive is outputting power.
  • Page 75 Programming and Parameters Chapter 3 Basic Display Group (continued) b025 [Accum Cost Sav] Related Parameter(s): b024, P052, A555 Total approximate accumulated cost savings of the drive compared to using an across the line starter. [Accum Cost Sav] = [Average kWh cost] x [Accum kWh Sav] Values Default: Read Only...

  • Page 76: Basic Program Group

    Chapter 3 Programming and Parameters Basic Program Group P030 [Language] Language Support Selects the language displayed. A reset or power cycle is required after selection is made. Keypad/ RSLogix 5000/ Connected LCD Display Logix Designer Components Workbench Options 1 English (Default) 2 Français 3 Español 4 Italiano...
  • Page 77 Programming and Parameters Chapter 3 Basic Program Group (continued) P034 [Motor NP FLA] Related Parameter(s): P040 Sets the motor nameplate FLA. Used to assist the Autotune routine and motor control. Values Default: Based on Drive Rating Min/Max: 0.1/(Drive Rated Amps x 2) Display: 0.1 A P035 [Motor NP Poles]...
  • Page 78 Chapter 3 Programming and Parameters Basic Program Group (continued) P040 [Autotune] Related Parameter(s): P034, P039, A496, A497 Stop drive before changing this parameter. Enables a static (not spinning) or dynamic (motor spinning) autotune to automatically set the motor parameters. Start must be pressed to begin the routine. After the routine is complete the parameter resets to a zero.
  • Page 79 Programming and Parameters Chapter 3 Basic Program Group (continued) P043 [Minimum Freq] Related Parameter(s): b001, b002, b013, P044, A530, A531 Stop drive before changing this parameter. Sets the lowest frequency the drive outputs. Values Default: 0.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz P044 [Maximum Freq]...
  • Page 80 Chapter 3 Programming and Parameters Basic Program Group (continued) P046 [Start Source 1] Related Parameter(s): b012, t064, C125 P048 [Start Source 2] P050 [Start Source 3] Stop drive before changing this parameter. Configures the start source of the drive. Changes to these inputs take effect as soon as they are entered. P046 [Start Source 1] is the factory default start source unless overridden. Start and Speed Reference Control on page 46 for more information.
  • Page 81 Programming and Parameters Chapter 3 Basic Program Group (continued) P053 [Reset To Defalts] Stop drive before changing this parameter. Resets all parameters to their factory default values. After a Reset command, the value of this parameter returns to zero. Parameters that are NOT Reset when P053 = 1 Parameters that are Reset when P053 = 3 Parameter Parameter...

  • Page 82: Terminal Block Group

    Chapter 3 Programming and Parameters Terminal Block Group t062 [DigIn TermBlk 02] t063 [DigIn TermBlk 03] Related Parameter(s): b012, b013, b014, P045, P046, P048, P049, P050, P051, t064, t065 [DigIn TermBlk 05] t066 [DigIn TermBlk 06] t086, A410-A425, A427, A431, A432, A433, A434, A435, A442, A443, A488, A535, A560, A562, A563, A567, A571 t067 [DigIn TermBlk 07]...
  • Page 83 Programming and Parameters Chapter 3 Options 26 “Current Lmt2” When active, A485 [Current Limit 2] determines the drive current limit level. 27 “Anlg Invert” Inverts the scaling of the analog input levels set in t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] or t095...
  • Page 84 Chapter 3 Programming and Parameters Options 48 “2-Wire FWD” [DigIn TermBlk 02] default. Select 2-Wire FWD for this input. (only for DigIn TermBlk 02) Select this option and set P046, P048 P050 [Start Source x] to 2 “DigIn TrmBlk” to configure [Start Source x] to a 2-wire run forward mode.
  • Page 85 Programming and Parameters Chapter 3 Terminal Block Group (continued) t069 [Opto Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t072 [Opto Out2 Sel] t086, t087, t093, t094, t097, A541, A564 PF 525 PowerFlex 525 only. Determines the operation of the programmable digital outputs. Options Setting Output Changes State When...
  • Page 86 Chapter 3 Programming and Parameters Terminal Block Group (continued) t070 [Opto Out1 Level] Related Parameter(s): t069, t072 t073 [Opto Out2 Level] 32 bit parameter. PF 525 PowerFlex 525 only. Determines the on/off point for the digital outputs when t069 t072 [Opto Outx Sel] is set to the values shown below.
  • Page 87 Programming and Parameters Chapter 3 Terminal Block Group (continued) t076 [Relay Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564 t081 [Relay Out2 Sel] PowerFlex 525 only. PF 525 Determines the operation of the programmable output relay. Options Output Relay Changes State When...
  • Page 88 Chapter 3 Programming and Parameters Terminal Block Group (continued) t077 [Relay Out1 Level] Related Parameter(s): t076, t081 t082 [Relay Out2 Level] PowerFlex 525 only. PF 525 32 bit parameter. Determines the on/off point for the output relay when t076 t081 [Relay Outx Sel] is set to the values shown below.
  • Page 89 Programming and Parameters Chapter 3 Terminal Block Group (continued) t087 [EM Brk On Delay] Related Parameter(s): P045 Sets the time the drive remains at minimum frequency (after releasing the brake coil relay) before stopping if EM Brake Control Mode is enabled with P045 [Stop Mode].
  • Page 90 Chapter 3 Programming and Parameters Terminal Block Group (continued) t089 [Analog Out High] PF 525 PowerFlex 525 only. Scales the maximum output value (V or mA) when the source setting is at maximum. Values Default: 100% Min/Max: 0/800% Display: t090 [Anlg Out Setpt] Related Parameter(s): t088 PowerFlex 525 only.
  • Page 91 Programming and Parameters Chapter 3 Terminal Block Group (continued) t094 [Anlg In V Loss] Related Parameter(s): P043, P044, A426, A427 Sets the response to a loss of input. When the 0-10V input (or –10 to +10V) is used for any reference, any input less than 1V is reported as a signal loss. Input must exceed 1.5V for the signal loss condition to end.
  • Page 92 Chapter 3 Programming and Parameters Terminal Block Group (continued) t098 [Anlg Loss Delay] Related Parameter(s): t094, t097 Sets the length of time after power-up during which the drive detects no analog signal loss. Response to an analog signal loss is set in t094 t097 [Analog In x Loss].
  • Page 93 Programming and Parameters Chapter 3 Terminal Block Group (continued) t104 [Wake Time] Sets the analog input time the drive must stay above to wake from sleep mode. Values Default: 0.0 s Min/Max: 0.0/600.0 s Display: 0.1 s t105 [Safety Open En] PF 525 PowerFlex 525 only.

  • Page 94: Communications Group

    Chapter 3 Programming and Parameters Communications Group C121 [Comm Write Mode] Saves parameter values in active drive memory (RAM) or in drive non-volatile memory (EEPROM). ATTENTION: If Automatic Drive Configuration (ADC) is used, this parameter must remain at its default value of 0 “Save”. IMPORTANT Parameter values set prior to setting 1 “RAM only”...
  • Page 95 Programming and Parameters Chapter 3 Communications Group (continued) C127 [RS485 Format] Determines the details related to the specific Modbus protocol used by the drive. A reset or power cycle is required after selection is made. Options 0 “RTU 8-N-1” (Default) 1 “RTU 8-E-1”...
  • Page 96 Chapter 3 Programming and Parameters Communications Group (continued) C133 [EN Subnet Cfg 1] Related Parameter(s): C128 C134 [EN Subnet Cfg 2] C135 [EN Subnet Cfg 3] C136 [EN Subnet Cfg 4] PowerFlex 525 only. PF 525 Sets the bytes of the subnet mask. A reset or power cycle is required after selection is made. 255.255.255.0 [EN Subnet Cfg 1] [EN Subnet Cfg 2]...
  • Page 97 Programming and Parameters Chapter 3 Communications Group (continued) C143 [EN Comm Flt Actn] Related Parameter(s): P045, C145, C146, C147-C150 PF 525 PowerFlex 525 only. Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that Ethernet communications have been disrupted. IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the EtherNet/IP interface.
  • Page 98 Chapter 3 Programming and Parameters Communications Group (continued) C146 [EN Flt Cfg Ref] Related Parameter(s): C143, C144 32 bit parameter. PF 525 PowerFlex 525 only. Sets the Reference data that is sent to the drive if any of the following is true: –...
  • Page 99 Programming and Parameters Chapter 3 Communications Group (continued) C161 [Opt Data In 1] C162 [Opt Data In 2] C163 [Opt Data In 3] C164 [Opt Data In 4] Datalink parameter number whose value is written from the High Speed Drive Serial Interface (HSDSI) data table. This parameter cannot be changed when an I/O connection is established through the communication adapter.

  • Page 100: Logic Group

    Chapter 3 Programming and Parameters Logic Group L180 [Stp Logic 0] L181 [Stp Logic 1] Related Parameter(s): L182 [Stp Logic 2] L183 [Stp Logic 3] L184 [Stp Logic 4] L185 [Stp Logic 5] L186 [Stp Logic 6] L187 [Stp Logic 7] Stop drive before changing this parameter.
  • Page 101 Programming and Parameters Chapter 3 StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. See Appendix D for more information. Logic for next step Digit 1 Logic to jump to a different step...
  • Page 102 Chapter 3 Programming and Parameters Logic Group (continued) L190 [Stp Logic Time 0] L191 [Stp Logic Time 1] L192 [Stp Logic Time 2] L193 [Stp Logic Time 3] L194 [Stp Logic Time 4] L195 [Stp Logic Time 5] L196 [Stp Logic Time 6] L197 [Stp Logic Time 7] PowerFlex 525 only.

  • Page 103: Advanced Display Group

    Programming and Parameters Chapter 3 Advanced Display Group d360 [Analog In 0-10V] Related Parameter(s): t091, t092 Displays the 0-10V analog input as a percent of full scale. Values Default: Read Only Min/Max: 0.0/100.0% Display: 0.1% d361 [Analog In 4-20mA] Related Parameter(s): t095, t096 Displays the 4-20 mA analog input as a percent of full scale.
  • Page 104 Chapter 3 Programming and Parameters Advanced Display Group (continued) d368 [Testpoint Data] Related Parameter(s): A483 Displays the present value of the function selected in A483 [Testpoint Sel]. Values Default: Read Only Min/Max: 0/FFFF Display: d369 [Motor OL Level] Displays the motor overload counter. Values Default: Read Only...
  • Page 105 Programming and Parameters Chapter 3 Advanced Display Group (continued) d382 [Torque Current] Displays the current value of the motor torque current measured by the drive. Values Default: Read Only Min/Max: 0.00/(Drive Rated Amps x 2) Display: 0.01 A d383 [PID1 Fdbk Displ] d385 [PID2 Fdbk Displ] PowerFlex 525 only.
  • Page 106 Chapter 3 Programming and Parameters Advanced Display Group (continued) d389 [Units Traveled L] Related Parameter(s): d387 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.

  • Page 107: Advanced Program Group

    Programming and Parameters Chapter 3 Advanced Program Group A410 [Preset Freq 0] A411 [Preset Freq 1] A412 [Preset Freq 2] A413 [Preset Freq 3] A414 [Preset Freq 4] A415 [Preset Freq 5] A416 [Preset Freq 6] A417 [Preset Freq 7] A418 [Preset Freq 8] A419 [Preset Freq 9] A420 [Preset Freq 10]...
  • Page 108 Chapter 3 Programming and Parameters Advanced Program Group (continued) A426 [Keypad Freq] Related Parameter(s): P047, P049, P051 Provides the drive frequency command using the built-in keypad navigation. When P047, P049 P051 [Speed Referencex] selects 2 “Keypad Freq”, the value set in this parameter controls the frequency of the drive.
  • Page 109 Programming and Parameters Chapter 3 Advanced Program Group (continued) A433 [Purge Frequency] Related Parameter(s): t062, t063, t065-t068 Provides a fixed frequency command value when t062, t063, t065-t068 [DigIn TermBlk xx] is set to 40 “Purge”. Values Default: 5.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz...
  • Page 110 Chapter 3 Programming and Parameters Advanced Program Group (continued) A437 [DB Resistor Sel] Stop drive before changing this parameter. Enables/disables external dynamic braking and selects the level of resistor protection. Options “Disabled” (Default) “Norml RA Res” “NoProtection” 100% 3...99 “3...99% DutyCycle” A438 [DB Threshold] Related Parameter(s): A437...
  • Page 111 Programming and Parameters Chapter 3 Advanced Program Group (continued) A440 [PWM Frequency] Related Parameter(s): A540 Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting. Carrier Frequency (kHz) Ignoring derating guidelines can cause reduced drive performance. The drive may automatically reduce the PWM carrier frequency at low output speeds, IMPORTANT unless prevented from doing so by A540 [Var PWM Disable].
  • Page 112 Chapter 3 Programming and Parameters Advanced Program Group (continued) A444 [Accel Time 3] A446 [Accel Time 4] Sets the rate of acceleration for all speed increases when selected by digital inputs. Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.01 s A445 [Decel Time 3] A447 [Decel Time 4] Sets the rate of deceleration for all speed decreases when selected by digital inputs.
  • Page 113 Programming and Parameters Chapter 3 Advanced Program Group (continued) A456 [PID 1 Trim Hi] A468 [PID 2 Trim Hi] PowerFlex 525 only. PF 525 Scales the upper value of the trim frequency when trim is active. Values Default: 60.0 Hz Min/Max: 0.0/500.0 Hz Display:...
  • Page 114 Chapter 3 Programming and Parameters Advanced Program Group (continued) A459 [PID 1 Ref Sel] A471 [PID 2 Ref Sel] PowerFlex 525 only. PF 525 Stop drive before changing this parameter. Selects the source of the PID reference. Options 0 “PID Setpoint” (Default) 1 “Drive Pot”...
  • Page 115 Programming and Parameters Chapter 3 Advanced Program Group (continued) A462 [PID 1 Integ Time] Related Parameter(s): A459, A471 A474 [PID 2 Integ Time] PowerFlex 525 only. PF 525 Sets the value for the PID integral component when PID mode is enabled. Values Default: 2.0 s...
  • Page 116 Chapter 3 Programming and Parameters Advanced Program Group (continued) A481 [Process Disp Lo] Related Parameter(s): b010, P043 Sets the value displayed in b010 [Process Display] when the drive is running at P043 [Minimum Freq]. Values Default: 0.00 Min/Max: 0.00/99.99 Display: 0.01 A482 [Process Disp Hi] Related Parameter(s): b010,...
  • Page 117 Programming and Parameters Chapter 3 Advanced Program Group (continued) A490 [Load Loss Level] Related Parameter(s): A491 PF 525 PowerFlex 525 only. Provides a software trip (Load Loss fault) when the current drops below this level for the time specified in A491 [Load Loss Time].
  • Page 118 Chapter 3 Programming and Parameters Advanced Program Group (continued) A495 [Drive OL Mode] Determines how the drive handles overload conditions that would otherwise cause the drive to fault. Options 0 “Disabled” 1 “Reduce CLim” 2 “Reduce PWM” 3 “Both-PWM 1st” (Default) A496 [IR Voltage Drop] Related Parameter(s): P040...
  • Page 119 Programming and Parameters Chapter 3 Advanced Program Group (continued) A510 [Freq 1] A512 [Freq 2] A514 [Freq 3] PowerFlex 525 only. PF 525 Sets the “Vector” control mode frequency. Values Default: Freq 1: 8.33% Freq 2: 15.00% Freq 3: 20.00% Min/Max: 0.00/200.00% Display:...
  • Page 120 Chapter 3 Programming and Parameters Advanced Program Group (continued) A530 [Boost Select] Related Parameter(s): b004, P031, P032, P039 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve. Only used for V/Hz and SVC control modes. [Maximum Voltage] can be set anywhere.
  • Page 121 Programming and Parameters Chapter 3 Advanced Program Group (continued) A531 [Start Boost] Related Parameter(s): P031, P032, P039, A530 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve when A530 [Boost Select] = 0 “Custom V/Hz” and P039 [Torque Perf Mode] = 0 “V/Hz”.
  • Page 122 Chapter 3 Programming and Parameters Advanced Program Group (continued) A535 [Motor Fdbk Type] Related Parameter(s): A537 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Selects the encoder type. ATTENTION: The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against possible unintended speed or motion.
  • Page 123 Programming and Parameters Chapter 3 Advanced Program Group (continued) A540 [Var PWM Disable] Related Parameter(s): A440 Stop drive before changing this parameter. Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 [PWM Frequency]. Options 0 “Enabled”...
  • Page 124 Chapter 3 Programming and Parameters Advanced Program Group (continued) A546 [FlyStrt CurLimit] Used to determine when the drive has matched the motor frequency if flying start is enabled. Values Default: 150% Min/Max: 30/200% Display: A547 [Compensation] Enables/disables correction options that may improve problems with motor instability. Options 0 “Disabled”...
  • Page 125 Programming and Parameters Chapter 3 Advanced Program Group (continued) A553 [Program Lock Mod] Related Parameter(s): A552 Determines the lock mode used in parameter A552 [Program Lock]. When set to 2 or 3, A552 [Program Lock] is added to the custom group to allow unlocking of parameters. Options 0 “Full Lock”...
  • Page 126 Chapter 3 Programming and Parameters Advanced Program Group (continued) A559 [Counts Per Unit] PF 525 PowerFlex 525 only. Sets the number of encoder counts equal to one user-defined unit. Values Default: 4096 Min/Max: 1/32000 Display: A560 [Enh Control Word] Related Parameter(s): t062, t063, t065 - t068, A571...
  • Page 127 Programming and Parameters Chapter 3 Advanced Program Group (continued) A562 [Find Home Freq] PF 525 PowerFlex 525 only. Sets the maximum frequency the drive uses when “Find Home” is issued. Values Default: 10.0 Hz Min/Max: 0.1/500.0 Hz Display: 0.1 Hz A563 [Find Home Dir] Stop drive before changing this parameter.
  • Page 128 Chapter 3 Programming and Parameters Advanced Program Group (continued) A567 [Max Traverse] Sets the amplitude of triangle wave speed modulation. [P Jump] [Max Traverse] [Output Freq] Traverse Bit [Fiber Status] Traverse Enable Bit Seconds Values Default: 0.00 Hz Min/Max: 0.00/300.00 Hz Display: 0.01 Hz A568 [Traverse Inc]...
  • Page 129 Programming and Parameters Chapter 3 Advanced Program Group (continued) A572 [Speed Ratio] Stop drive before changing this parameter. Scales the drive speed command. Values Default: 1.00 Min/Max: 0.01/99.99 Display: 0.01 A573 [Mtr Options Cfg] PowerFlex 525 only. PF 525 (With FRN 2.xx and later.) Sets the configuration of the motor option.

  • Page 130: Network Parameter Group

    Chapter 3 Programming and Parameters Network Parameter Group This group contains parameters for the network option card that is installed. Refer to the network option card’s user manual for more information on the available parameters. Modified Parameter Group This group contains parameters that have their values changed from the factory default.

  • Page 131: Default

    Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F631 [Fault 1 Freq] F632 [Fault 2 Freq] Related Parameter(s): b001 F633 [Fault 3 Freq] F634 [Fault 4 Freq] F635 [Fault 5 Freq] F636 [Fault 6 Freq] F637 [Fault 7 Freq] F638 [Fault 8 Freq] F639 [Fault 9 Freq] F640 [Fault10 Freq]...
  • Page 132 Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F661 [Status @ Fault 1] F662 [Status @ Fault 2] Related Parameter(s): b006 F663 [Status @ Fault 3] F664 [Status @ Fault 4] F665 [Status @ Fault 5] F666 [Status @ Fault 6] F667 [Status @ Fault 7] F668 [Status @ Fault 8] F669 [Status @ Fault 9]...

  • Page 133: Values Default

    Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F683 [Com Sts-Emb Enet] PF 525 PowerFlex 525 only. Displays the status of the embedded EtherNet/IP interface to the drive. Digit 3 = “Embedded EtherNet/IP” 1 = Condition True, 0 = Condition False 0 “Not Active (no connection)”...

  • Page 134: Display

    Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F687 [HW Addr 1] F688 [HW Addr 2] F689 [HW Addr 3] F690 [HW Addr 4] F691 [HW Addr 5] F692 [HW Addr 6] PowerFlex 525 only. PF 525 Shows the MAC address for the embedded EtherNet/IP interface. Values Default: Read Only...

  • Page 135: Min/Max

    Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F701 [EN Gateway Act 1] F702 [EN Gateway Act 2] F703 [EN Gateway Act 3] F704 [EN Gateway Act 4] PowerFlex 525 only. PF 525 Shows the actual gateway address used by the embedded EtherNet/IP interface at the time. This will indicate 0 if no address is set. 255.255.255.255 [EN Gateway Act 1] [EN Gateway Act 2]...
  • Page 136 Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F708 [Drv 0 Feedback] F712 [Drv 1 Feedback] F716 [Drv 2 Feedback] F720 [Drv 3 Feedback] F724 [Drv 4 Feedback] In multi-drive mode, this is the feedback being received from drive 0/1/2/3/4. In single-drive mode, this is the feedback of the drive at the time.
  • Page 137 Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F730 [EN Missed IO Pkt] PF 525 PowerFlex 525 only. The number of I/O packets missed. Values Default: Read Only Min/Max: 0/65535 Display: F731 [DSI Errors] The number of total DSI errors. Values Default: Read Only...

  • Page 138: Appview Parameter Groups

    Chapter 3 Programming and Parameters AppView Parameter Groups AppView parameter groups provide a simple starting point for using the PowerFlex 520-series drives by grouping certain commonly used parameters based on different types of applications. Use these parameter groups to quickly and easily setup the PowerFlex 520-series drive for your application.

  • Page 139: Customview Parameter Group

    Programming and Parameters Chapter 3 CustomView Parameter CustomView allows you to quickly access only the parameters needed for your application by storing them in a custom parameter group. Add your frequently Group used parameters to this group, then hide all other parameters with A552 [Program Lock] to simplify your drive configuration process.

  • Page 140: Parameter Cross Reference By Name

    Chapter 3 Programming and Parameters Parameter Cross Reference by Name Parameter Name Parameter Name Parameter Name 10V Bipolar Enbl Current Limit 2 Drv 4 Reference 2-Wire Mode DB Resistor Sel Drv Ambient Sel Accel Time 1 DB Threshold DSI Errors Accel Time 2 DC Brake Level DSI I/O Act...
  • Page 141 Programming and Parameters Chapter 3 Parameter Name Parameter Name Parameter Name EN Rate Act Fault 5 Time-hr Freq 3 BW EN Rate Cfg Fault 5 Time-min Freq 3 Ki EN Rx Errors Fault 6 BusVolts Freq 3 Kp EN Rx Overruns Fault 6 Code Half Bus Enable EN Rx Packets...
  • Page 142 Chapter 3 Programming and Parameters Parameter Name Parameter Name Parameter Name Opt Data Out 1 Position Status Shear Pin 2 Time Opt Data Out 2 Positioning Mode Shear Pin2 Level Opt Data Out 3 Power Loss Mode Skip Freq Band 1 Opt Data Out 4 Power Saved Skip Freq Band 2...
  • Page 143 Programming and Parameters Chapter 3 Parameter Name Parameter Name Parameter Name Stp Logic 3 Stp Logic Time 4 Torque Perf Mode Stp Logic 4 Stp Logic Time 5 Traverse Dec Stp Logic 5 Stp Logic Time 6 Traverse Inc Stp Logic 6 Stp Logic Time 7 Units Traveled H Stp Logic 7...
  • Page 144 Chapter 3 Programming and Parameters Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 145: Drive Status

    Chapter Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex 520-series drive. Included is a listing and description of drive faults with possible solutions, when applicable. For information on... See page... Drive Status Faults Fault Descriptions Common Symptoms and Corrective Actions ATTENTION: Risk of injury or equipment damage exists.
  • Page 146 Chapter 4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. The integral LCD display provides visual notification of a fault condition by displaying the following. • Flashing fault number FAULT • Flashing fault indicator (LED) Press the Esc key to regain control of the display. Manually Clearing Faults Step Key(s)

  • Page 147: Fault Descriptions

    Troubleshooting Chapter 4 Auto Restart (Reset/Run) The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset.
  • Page 148 Chapter 4 Troubleshooting Fault Types, Descriptions and Actions Fault Type Description Action F015 Load Loss The output torque current is below the • Verify connections between motor value programmed in A490 [Load Loss and load. Level] for a time period greater than the •...
  • Page 149 Troubleshooting Chapter 4 Fault Types, Descriptions and Actions Fault Type Description Action F081 DSI Comm Loss Communications between the drive and • Cycle power. the Modbus or DSI master device have • Check communications cabling. been interrupted. • Check Modbus or DSI setting. •...

  • Page 150: Common Symptoms And Corrective Actions

    Chapter 4 Troubleshooting Fault Types, Descriptions and Actions Fault Type Description Action F122 I/O Board Fail Failure has been detected in the drive • Cycle power. control and I/O section. • Replace drive or control module if fault cannot be cleared. F125 Flash Update Req 2 The firmware in the drive is corrupt,...
  • Page 151 Troubleshooting Chapter 4 Motor does not Start. Cause(s) Indication Corrective Action None No output voltage to the motor. Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Check the motor. • Verify that the motor is connected properly. Check the control input signals.
  • Page 152 Chapter 4 Troubleshooting Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action No value is coming from the source of the command. The drive “Run” indicator is • Check b012 [Control Source] for correct source. lit and output is 0 Hz. •...
  • Page 153 Troubleshooting Chapter 4 Drive does not power up. Cause(s) Indication Corrective Action No input power to drive. None • Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Control module is not connected properly to power module. None 1.
  • Page 154 Chapter 4 Troubleshooting Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 155: Certifications

    Appendix Supplemental Drive Information For information on... See page... Certifications Environmental Specifications Technical Specifications Power Specifications Certifications Certifications PowerFlex 523 PowerFlex 525 c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05. C-Tick Australian Communications and Media Authority In conformity with the following: Radiocommunications Act: 1992 Radiocommunications Standard: 2008 Radiocommunications Labelling Notice: 2008...

  • Page 156: Environmental Specifications

    Appendix A Supplemental Drive Information Certifications PowerFlex 523 PowerFlex 525 EPRI Electric Power Research Institute Certified compliant with the following standards: SEMI F47 IEC 61000-4-34 Lloyds Register Not applicable Lloyd’s Register Type Approval Certificate 12/10068(E1) RoHS Compliant with the European “Restriction of Hazardous Substances” Directive The drive is also designed to meet the appropriate portions of the following specifications: NFPA 70 - US National Electrical Code NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable...

  • Page 157: Technical Specifications

    Supplemental Drive Information Appendix A Technical Specifications Protection Specifications PowerFlex 523 PowerFlex 525 Bus Overvoltage Trip 100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line) 200...240V AC Input: 405V DC bus (equivalent to 290V AC incoming line) 380...480V AC Input: 810V DC bus (equivalent to 575V AC incoming line) 525...600V AC Input:...
  • Page 158 Appendix A Supplemental Drive Information Specifications PowerFlex 523 PowerFlex 525 Performance with Encoder – SVC (Sensorless Vector): ±0.1% of base speed across a 100:1 speed range ±0.1% of base speed across a 100:1 speed SVC Economizer: range ±0.1% of base speed across a 1000:1 VVC (Velocity Vector Control): speed range Output Voltage Range:...
  • Page 159 Supplemental Drive Information Appendix A Specifications PowerFlex 523 PowerFlex 525 Opto: Quantity: – (2) Programmable Specification: 30V DC, 50 mA Non-inductive Analog Quantity: – (1) Non-Isolated 0-10V or 4-20 mA Specification Resolution: 10-bit 0-10V DC Analog: 1 k ohm minimum 4-20 mA Analog: 525 ohm maximum Encoder...

  • Page 160: Power Specifications

    Appendix A Supplemental Drive Information Power Specifications Watts Loss PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Voltage Output Current (A) Total Watts Loss 100...120V, 20.0 50/60 Hz 1-Phase 27.0 53.0 67.0 200...240V, 20.0 50/60 Hz 1-Phase 29.0 50.0 81.0 11.0...
  • Page 161 Supplemental Drive Information Appendix A PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Voltage Output Current (A) Total Watts Loss 525...600V, 22.0 50/60 Hz 3-Phase 32.0 50.0 65.0 95.0 138.0 12.0 164.0 19.0 290.0 22.0 336.0 27.0 466.0 32.0 562.0 Input Current Scaling (Optional)
  • Page 162 Appendix A Supplemental Drive Information PowerFlex 520-Series Input Current Scaled By Motor Current PowerFlex 523 PowerFlex 525 Output Input Catalog Number Catalog Number 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 25A-D1P4N104 25B-D1P4N104 25A-D2P3N104 25B-D2P3N104 25A-D4P0N104 25B-D4P0N104 25A-D6P0N104 25B-D6P0N104 25A-D010N104 25B-D010N104...

  • Page 163: Product Selection

    Appendix Accessories and Dimensions Product Selection Catalog Number Description Drive Voltage Rating Rating Enclosure Emission Class Version PowerFlex 520-Series Drive Ratings Output Ratings Normal Duty Heavy Duty PowerFlex 523 PowerFlex 525 Output Input Frame Current (A) Voltage Range Size Catalog No. Catalog No.
  • Page 164 Appendix B Accessories and Dimensions PowerFlex 520-Series Drive Ratings Output Ratings Normal Duty Heavy Duty PowerFlex 523 PowerFlex 525 Output Input Frame Current (A) Voltage Range Size Catalog No. Catalog No. 13.0 323...528 25A-D013N104 25B-D013N104 10.0 10.0 17.0 323...528 25A-D017N104 25B-D017N104 15.0 11.0...
  • Page 165 Accessories and Dimensions Appendix B Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Input Voltage Ω ±10% Ω ±5% (1)(2) Catalog No. 200...240V 0.25 AK-R2-091P500 50/60 Hz AK-R2-091P500 3-Phase 0.75 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-047P500 AK-R2-030P1K2 10.0 AK-R2-030P1K2 15.0 11.0 AK-R2-030P1K2 20.0 15.0 AK-R2-030P1K2...
  • Page 166 Appendix B Accessories and Dimensions EMC Line Filters Drive Ratings Input Voltage Current (A) Frame Size Catalog No. 200...240V 0.25 25-RF011-AL 50/60 Hz 25-RF011-AL 1-Phase 0.75 25-RF011-AL 25-RF023-BL 11.0 25-RF023-BL 200...240V 0.25 25-RF014-AL 50/60 Hz 25-RF014-AL 3-Phase 0.75 25-RF014-AL 25-RF014-AL 11.0 25-RF014-AL 17.5...
  • Page 167 Accessories and Dimensions Appendix B Human Interface Module (HIM) Option Kits and Accessories Item Description Catalog No. LCD Display, Remote Panel Digital speed control 22-HIM-C2S Mount CopyCat capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.9 meter cable LCD Display, Remote Digital speed control 22-HIM-A3 Handheld...
  • Page 168 Appendix B Accessories and Dimensions Replacement Parts PowerFlex 520-Series Power Module Item Description PowerFlex 520-Series Replacement power module for use with PowerFlex 520-Series drives. Includes: Power Module • Power Module • Power Module Front Cover • Power Terminal Guard • Heatsink Fan Output Ratings Normal Duty Heavy Duty...
  • Page 169 Accessories and Dimensions Appendix B Output Ratings Normal Duty Heavy Duty Output Input Frame Current (A) Voltage Range Size Catalog No. 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 323...528 25-PM2-D1P4 0.75 0.75 323...528 25-PM2-D2P3 323...528 25-PM2-D4P0 323...528...
  • Page 170 AK-U0-RJ45-TR1 Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P Connected Components Windows-based software packages for programming and http:// Workbench Software configuring Allen-Bradley drives and other Rockwell ab.rockwellautomation.co (Download or DVD-ROM) Automation products. m/programmable- controllers/connected- Compatibility: components-workbench- Windows XP, Windows Vista and Windows 7...
  • Page 171 Accessories and Dimensions Appendix B Bulletin 1321-3R Series Line Reactors (3)(4) (3)(4) Output Ratings Input Line Reactor Output Line Reactor IP00 IP11 IP00 IP11 Normal Duty Heavy Duty (Open Style) (NEMA/UL Type 1) (Open Style) (NEMA/UL Type 1) Catalog No. Catalog No.
  • Page 172 Appendix B Accessories and Dimensions (1) Normal Duty and Heavy Duty ratings for 15 HP (11 kW) and below are identical except for 200...240V 3-Phase 15 HP (11 kW) drive. (2) Standard 3-phase reactors can be used for 1-phase applications by routing each of the two supply conductors through an outside coil and leaving the center open.

  • Page 173: Product Dimensions

    Accessories and Dimensions Appendix B Product Dimensions The PowerFlex 520-series drive is available in five frame sizes. See the PowerFlex 520-Series Drive Ratings on page 163 for information on power ratings. PowerFlex 520-Series Drive Weight Frame Size Weight (kg/lb) 1.1 / 2.4 1.6 / 3.5 2.3 / 5.0 3.9 / 8.6...
  • Page 174 Appendix B Accessories and Dimensions IP 20/Open Type – Frame B Dimensions are in millimeters and (inches) 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 6.0 (0.24) IP 20/Open Type – Frame C Dimensions are in millimeters and (inches) 109.0 (4.29) 184.0 (7.24) 90.5 (3.56) 6.0 (0.24) Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 175 Accessories and Dimensions Appendix B IP 20/Open Type – Frame D Dimensions are in millimeters and (inches) 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 6.0 (0.24) IP 20/Open Type – Frame E Dimensions are in millimeters and (inches) 185.0 (7.28) 279.0 (10.98) 160.0 (6.30) 7.6 (0.30) Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 176 Appendix B Accessories and Dimensions Control Module Fan Kit 25-FAN1-70C 25-FAN2-70C Specifications 25-FAN1-70C 25-FAN2-70C Rated Voltage 24V DC Operation Voltage 14...27.6V DC Input Current 0.1 A 0.15 A Speed (Reference) 7000 rpm 4500 ± 10% rpm Maximum Air Flow (At zero static pressure) 0.575 m /min 1.574 m...
  • Page 177 Accessories and Dimensions Appendix B IP 20/Open Type with Control Module Fan Kit – Frame D...E Dimensions are in millimeters and (inches) Frame D Frame E 196.0 (7.72) 185.0 (7.28) 130.0 (5.12) 160.0 (6.30) 116.0 (4.57) Remove the label to access the built-in 24V supply on drive frames D and E for use with the IMPORTANT Control Module Fan Kit.
  • Page 178 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame A Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 72.0 (2.83) 57.5 (2.26) 172.0 (6.77) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85)
  • Page 179 Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame B Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 6.1 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 66.1 (2.60) 63.1 (2.48) 33.5 (1.32)
  • Page 180 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame C Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 109.0 (4.29) 90.5 (3.56) 184.0 (7.24) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 80.5 (3.17) 66.5 (2.62) 34.5 (1.36)
  • Page 181 Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame D Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 96.0 (3.78) 70.0 (2.76) 44.0 (1.73)
  • Page 182 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame E Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 185.0 (7.28) 160.0 (6.30) 279.0 (10.98) 7.6 (0.30) IP 30/NEMA 1/ UL Type 1 conduit box 127.5 (5.02) 82.5 (3.25) 62.5 (2.46)
  • Page 183 Accessories and Dimensions Appendix B EMC Line Filter – Frame A Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 55.0 (2.17) 72.0 (2.83) 30.0 (1.18) 54.0 (2.13) ø5.5 (ø0.22) 234.0 223.0 (9.21) 223.0 (8.78) (8.78) 20.0 (0.79)
  • Page 184 Appendix B Accessories and Dimensions EMC Line Filter – Frame C Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 70.0 (2.76) 109.0 (4.29) 37.0 (1.46) 76.0 (2.99) ø5.5 (ø0.22) 275.0 (10.83) 263.0 263.0 (10.35) (10.35)
  • Page 185 Accessories and Dimensions Appendix B EMC Line Filter – Frame E Dimensions are in millimeters and (inches) 80.0 (3.15) 155.0 (6.10) 33.0 (1.30) 28.0 (1.10) 110.0 (4.33) ø5.5 (ø0.22) 390.0 (15.35) 375.0 375.0 (14.76) (14.76) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22) 110.0 (4.33) Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 186: Optional Accessories And Kits

    Appendix B Accessories and Dimensions Optional Accessories and Kits Installing a Communication Adapter 1. Insert the communication adapter interface connector into the Control Module. Make sure the indicator line on the connector is aligned with the surface of the Control Module. For PowerFlex 523 Communication adapter interface...
  • Page 187 Accessories and Dimensions Appendix B 3. Press along the edges of the back cover until it snaps firmly into place. Communication adapter interface connector Removing a Communication Adapter 1. Insert a finger into the slot at the top of the back cover. Lift to separate the back cover from the Control Module.
  • Page 188 Appendix B Accessories and Dimensions Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 189: Network Wiring

    Appendix RS485 (DSI) Protocol PowerFlex 520-series drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some Modbus functions are supported to allow simple networking. PowerFlex 520-series drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.

  • Page 190: Parameter Configuration

    Appendix C RS485 (DSI) Protocol Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 520-series drive’s RJ45 socket must not be connected because they contain power, etc. for other Rockwell Automation peripheral devices. Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+”...

  • Page 191: Supported Modbus Function Codes

    RS485 (DSI) Protocol Appendix C Supported Modbus Function The peripheral interface (DSI) used on PowerFlex 520-series drives supports some of the Modbus function codes. Codes Supported Modbus Function Codes Modbus Function Code (Decimal) Command Read Holding Registers Preset (Write) Single Register 16 (10 Hexadecimal) Preset (Write) Multiple Registers Modbus devices can be 0-based (registers are numbered starting at 0) or 1-...
  • Page 192 Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Command – C122 = 0 “Velocity” Address (Decimal) Bit(s) Description 2000H (8192) 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 5, 4 00 = No Command...

  • Page 193: Writing (06) Comm Frequency Command

    RS485 (DSI) Protocol Appendix C Position Bit Definitions Comm Logic Command – C122 = 1 “Position” Address (Decimal) Bit(s) Description 2000H (8192) 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 5, 4 00 = No Command...
  • Page 194 Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Status – C122 = 0 “Velocity” Address (Decimal) Bit(s) Description 2100H (8448) 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse 1 = Accelerating, 0 = Not Accelerating 1 = Decelerating, 0 = Not Decelerating...

  • Page 195: Reading (03) Drive Error Codes

    RS485 (DSI) Protocol Appendix C Reading (03) Drive Error The PowerFlex 520-series Error Code data can be read through the network by sending Function Code 03 reads to register address 2101H (Drive Error Codes). Codes Drive Error Codes Logic Status Address (Decimal) Value (Decimal) Description 2101H (8449) No Fault...

  • Page 196: Reading (03) Drive Operational Values

    Appendix C RS485 (DSI) Protocol Drive Error Codes Logic Status Address (Decimal) Value (Decimal) Description 2101H (8449) Flash Update Required Non Recoverable Error DSI Flash Update Required Reading (03) Drive The PowerFlex 520-series Drive Operational Values can be read through the network by sending Function Code 03 reads to register addresses Operational Values 2102H...210AH.
  • Page 197 Appendix Velocity StepLogic, Basic Logic and Timer/ Counter Functions Four PowerFlex 520-series logic functions provide the capability to program simple logic functions without a separate controller. • Velocity StepLogic™ Function (specific to PowerFlex 525 drives only) Steps through up to eight preset speeds based on programmed logic. Programmed logic can include conditions that need to be met from digital inputs programmed as “Logic In 1”...

  • Page 198: Velocity Steplogic Using Timed Steps

    Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions Velocity StepLogic Using This function is specific to PowerFlex 525 drives only. IMPORTANT Timed Steps To activate this function, set one of the three speed reference sources, parameter P047, P049 or P051[Speed Referencex] to 13 “Step Logic” and activate that speed reference source.

  • Page 199: Timer Function

    Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D • Transition to Step 2 when both Logic In 1 and Logic In 2 are true. The drive senses the level of both Logic In 1 and Logic In 2 and transitions to Step 2 when both are on.

  • Page 200: Counter Function

    Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions • The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active. • Parameters are set to the following options: –...

  • Page 201: Velocity Steplogic Parameters

    Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D Output Frequency Start Relay Out Photo Eye DigIn TermBlk 05 Counter In DigIn TermBlk 06 Reset Counter Limit Switch Velocity StepLogic Code Descriptions for Parameters L180...L187 Parameters Digit 4 Digit 3 Digit 2 Digit 1 Digit 4 –...
  • Page 202 Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions Digit 2 – Defines what logic must be met to jump to a step other than the very next step. Setting Description Logic Skip Step (jump immediately) SKIP Step based on the time programmed in the respective [Stp Logic Time x] parameter. TIMED Step if “Logic In 1”...

  • Page 203: Encoder And Pulse Train Usage

    Appendix Encoder/Pulse Train Usage and Position StepLogic Application Encoder and Pulse Train The PowerFlex 520-series drives include a pulse train input built into the terminal block. PowerFlex 525 drives also support an optional encoder card. The Usage pulse train and encoder can be used for many of the same functions, but the pulse train supports up to 100 kHz at 24V, and uses the drive built-in terminal block.

  • Page 204: Wiring Notes

    Appendix E Encoder/Pulse Train Usage and Position StepLogic Application No. Signal Description (1)(2) 5...12V Power Internal power source 250 mA (isolated). Power Return Encoder B (NOT) Quadrature B input. Encoder B Encoder A (NOT) Single channel, pulse train or quadrature A input. Encoder A ...

  • Page 205: Positioning Overview

    Encoder/Pulse Train Usage and Position StepLogic Application Appendix E Positioning Overview The PowerFlex 525 drive includes a simple position regulator which can be used in a variety of position applications without the need for multiple limit switches or photo-eyes. This can be used as a stand-alone controller for simple applications (up to 8 positions) or in conjunction with a controller for more flexibility.

  • Page 206: Positioning Operation

    Appendix E Encoder/Pulse Train Usage and Position StepLogic Application A550 [Bus Reg Enable] default setting is 1 “Enabled”. If the deceleration time is too short, the drive may overshoot the desired position. For best results, a longer deceleration time may be necessary. A550 [Bus Reg Enable] can be disabled to provide precise stopping movements, but the deceleration time will need to be...
  • Page 207 Encoder/Pulse Train Usage and Position StepLogic Application Appendix E needs direct access to any position step based on discrete inputs. This mode moves in the forward direction from Home and is an absolute move. Advanced Step Logic options such as incremental move are not IMPORTANT available in this mode.
  • Page 208 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Frequency Source Step Source Position Source A415 [Preset Freq 5] L185 [Stp Logic 5] L210 [Step Units 5] A416 [Preset Freq 6] L186 [Stp Logic 6] L212 [Step Units 6] A417 [Preset Freq 7] L187 [Stp Logic 7]...
  • Page 209 Encoder/Pulse Train Usage and Position StepLogic Application Appendix E Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Velocity Control Settings (Digit 4) Settings (Digit 3) Required Accel/Decel...

  • Page 210: Homing Routine

    Appendix E Encoder/Pulse Train Usage and Position StepLogic Application overshoot, the filter should be increased and/or the gain should be reduced. In general, the gain will have a larger effect on most systems than the filter. Homing Routine This drive supports incremental encoders only. Therefore, when the drive powers up it will reset the current position to zero.

  • Page 211: Encoder And Position Feedback

    Encoder/Pulse Train Usage and Position StepLogic Application Appendix E point too quickly it will then reverse direction at 1/10th A562 [Find Home Freq] to the point where the Home Limit switch reactivates. Approximately one second after the routine finds home the drive will stop. Alternately, the “Find Home Freq”...

  • Page 212: Use Over Communications

    Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Use Over Communications If 8 steps are not adequate for the application or if dynamic program changes are required, many of the positioning functions can be controlled through an active communication network. The following parameters will allow this control. C121 [Comm Write Mode] Repeated writes to parameters over a communication network can cause damage...

  • Page 213: Setup Notes

    Encoder/Pulse Train Usage and Position StepLogic Application Appendix E position) using comms control without requiring actual digital input transitions. L200...L214 [Step Units x] All of the position steps can be written to while the drive is running. The changes will take place at the next move. For example, if step 0 is over-written while the drive is moving to step 0, the drive will move to the previous commanded position at step 0.
  • Page 214 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 215: Pid Loop

    Appendix PID Set Up PID Loop The PowerFlex 520-series drive features built-in PID (proportional, integral, derivative) control loops. The PID loop is used to maintain a process feedback (such as pressure, flow or tension) at a desired set point. The PID loop works by subtracting the PID feedback from a reference and generating an error value.
  • Page 216 Appendix F PID Set Up • The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow. • When the PID Control Loop is disabled, the Commanded Speed is the Ramped Speed Reference.

  • Page 217: Pid Reference And Feedback

    PID Set Up Appendix F • As tension increases or decreases during winding, the Speed Reference is trimmed to compensate. Tension is maintained near the Equilibrium set point. PID Reference = PID Feedback = Equilibrium Set Point Dancer Pot Signal [Speed Referencex] PID mode is enabled by setting P047, P049...

  • Page 218: Analog Pid Reference Signals

    Appendix F PID Set Up A460 A472 [PID x Fdback Sel] are used to select the source of the PID feedback. A460, A472 [PID x Fdback Sel] Options Options Description 0 “0-10V Input” Selects the 0-10V Input (default setting). Note that the PID will not function with a bipolar analog input.
  • Page 219 PID Set Up Appendix F • A459 [PID 1 Ref Sel] = 6 “4-20mA Input” 0 10 20 30 40 50 60 70 80 90 100 PID Reference (%) PID Deadband Parameters A465 A477 [PID x Deadband] are used to set a range, in percent, of the PID Reference that the drive will ignore.
  • Page 220 Appendix F PID Set Up PID reaches the Hi or Lo limit, the PID regulator stops integrating so that windup does not occur. PID Gains The proportional, integral, and differential gains make up the PID regulator. • A461 A473 [PID x Prop Gain] The proportional gain (unitless) affects how the regulator reacts to the magnitude of the error.
  • Page 221 PID Set Up Appendix F 2. Adjust the integral gain (leave the proportional gain set as in Step 1). After a step change in the PID Feedback: – If the response is too slow (see Slow Response – Over Damped on page 221), or the PID Feedback does not become equal to the PID Reference, decrease A462 or A474 [PID x Integ Time].
  • Page 222 Appendix F PID Set Up Good Response – Critically Damped PID Reference PID Feedback Time Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 223: Powerflex 525 Safe-Torque-Off Overview

    Appendix Safe-Torque-Off Function The PowerFlex 525 Safe-Torque-Off function, when used with other safety components, helps provide protection according to EN ISO 13849 and EN62061 for safe-off and protection against restart. The PowerFlex 525 Safe- Torque-Off function is just one component in a safety control system. Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding.

  • Page 224: Ec Type Examination Certification

    Appendix G Safe-Torque-Off Function ATTENTION: Electric Shock Hazard. Verify that all sources of AC and DC power are de-energized and locked out or tagged out in accordance with the requirements of ANSI/NFPA 70E, Part II. To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.

  • Page 225: Safety Concept

    Safe-Torque-Off Function Appendix G A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine. ATTENTION: The following information is merely a guide for proper installation.
  • Page 226 Appendix G Safe-Torque-Off Function • access control to the system, including password handling. • analyzing all configuration settings and choosing the proper setting to achieve the required safety rating. When applying Functional Safety, restrict access to qualified, authorized IMPORTANT personnel who are trained and experienced. ATTENTION: When designing your system, consider how personnel will exit the machine if the door locks while they are in the machine.

  • Page 227: Enabling Powerflex 525 Safe-Torque-Off

    Safe-Torque-Off Function Appendix G Enabling PowerFlex 525 1. Remove all power to the drive. Safe-Torque-Off ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the +DC and -DC terminals or test points (refer to your drive’s user manual for the location of the terminals).

  • Page 228: Verify Operation

    Appendix G Safe-Torque-Off Function Under normal drive operation, both safety inputs (Safety 1 and Safety 2) are energized, and the drive is able to run. If either input is de-energized, the gate control circuit becomes disabled. To meet EN ISO 13849 operation, both safety channels must be de-energized.

  • Page 229: Connection Examples

    Safe-Torque-Off Function Appendix G Connection Examples Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d Stop Category 0 – Coast AC line input power PF 525 +24V DC +24V DC GuardMaster Gate Trojan Stop Stop Start Start A1 S21 S11 S52 41 13 23 33 Gate control E-Stop power supply...
  • Page 230 Appendix G Safe-Torque-Off Function Stop Category 0 – Coast with Two PowerFlex 525 Drives 24V DC Supply AC line Reset input power PF 525 AC line input power E-Stop +24V DC Stop PF 525 Stop Start Start +24V DC Dig. comm Stop Stop Gate control...
  • Page 231 Safe-Torque-Off Function Appendix G Example 2 – Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d Stop Category 1 – Controlled AC line input power PF 525 GuardMaster Trojan +24V DC Gate Stop Stop +24V DC Start Start S21 S11 S52 S12 37 47 57 13 23 Gate control...
  • Page 232 Appendix G Safe-Torque-Off Function Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e Stop Category 0 – Coast AC line input power PF 525 External +24V DC +24V DC Stop Reset Start Open A1 S11 S52 S12 13 23 33 41 Gate control power supply MSR127TP...

  • Page 233: Powerflex 525 Certification For Safe-Torque-Off

    Safe-Torque-Off Function Appendix G PowerFlex 525 Certification for Safe-Torque-Off Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 234 Appendix G Safe-Torque-Off Function Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...

  • Page 235: Establishing A Connection With Ethernet/Ip

    EtherNet/IP adapter. PowerFlex 525 drives support both the embedded EtherNet/IP adapter and the 25-COMM-E2P dual-port EtherNet/IP adapter. It is recommended to use Allen-Bradley Ethernet RJ45 cables, shielded or unshielded (catalog number 1585J-M8xBJM-x), for connecting your PowerFlex 520-series drive to an EtherNet/IP network.
  • Page 236 Appendix H EtherNet/IP Regardless of the method used to set the adapter IP address, each node on the IMPORTANT EtherNet/IP network must have a unique IP address. To change an IP address, you must set the new value and then remove and reapply power to (or reset) the adapter.

  • Page 237: Induction Motor Tuning Diagrams

    Appendix Control Diagrams This chapter contains various diagrams on the PowerFlex 520-series drive functions and behaviors. Induction Motor Tuning [Speed Reg Sel] Diagrams For Motor Tuning Diagrams Low Speed Mid Speed High Speed Control Mode Control Mode Control Mode Speed Controller Gain A515 [Freq 3 BW] A513 [Freq 2 BW]...

  • Page 238: Adjusting Speed Control Parameters

    Appendix I Control Diagrams Adjusting Speed Control These settings show how to adjust the speed control for motor tuning. Parameters Speed Loop Bandwidth: Increase the bandwidth to obtain A511 [Freq 1 BW] = 10 Hz faster speed response. If oscillation A513 [Freq 2 BW] = 10 Hz occurs, decrease the bandwidth.
  • Page 239 Numerics basic operation common bus 2-wire mount inputs programming 3-wire safety drive damage inputs preventing ungrounded distribution systems accel override priority encoder selecting accessing programming wiring control terminals environment power terminals applications storage Ethernet safety auxiliary contact programming drive fault monitoring basic operation ground fuses...
  • Page 240 writing motor rating ground fuses start ratings stop circuit breakers mount reading drive Modbus mounting recommended dimensions wiring reflected wave protection RFI filter noise immunity ground wiring RS485(DSI) configuring output disconnect safety override priority applications accel basic operation decel drive speed reference ground start source...
  • Page 241 programming tools wave protection programming reflected wiring encoder noise immunity unshielded recommended wiring RS485 (DSI) safety shielded temperature voltage reflections unshielded voltage reflections wiring writing Modbus Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 242 Notes: Rockwell Automation Publication 520-UM001G-EN-E - September 2014...
  • Page 244 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. , you can find technical manuals, a knowledge base of FAQs, technical and http://www.rockwellautomation.com/support/ application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

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