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78

Rockwell Automation Publication 520-UM002B-EN-E - December 2017

Chapter 3

Configuring the PowerFlex 527 Drive with Integrated Motion

The Motor Device Specification dialog box appears.

7.

From the Data Source pull-down menu, choose Nameplate Datasheet.
This is the default setting.

8.

From the Motor Type pull-down menu, choose Rotary Induction.

9.

From the motor nameplate or datasheet, enter the phase-to-phase values.

10.

Click Apply.

Summary of Contents for PowerFlex 527

Page 1: ...PowerFlex 527 Adjustable Frequency AC Drive Catalog Number 25C User Manual Original Instructions...

Page 2: ...Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Allen Bradley Rockwell Software Rockwell Automation PowerFlex Compac...

Page 3: ...ay section 49 Updated Configure the PowerFlex 527 Drive section with additional controllers 59 Updated Test the Axes section 83 Updated Tune the Axes section 85 Updated PHF Data section 89 Updated Ope...

Page 4: ...4 Rockwell Automation Publication520 UM002B EN E December 2017 Summary of Changes Notes...

Page 5: ...Fuses and Circuit Breakers 20 Power and Control Module 25 Control Module Cover 28 Power Module Terminal Guard 28 Power Wiring 29 Power Terminal Block 32 I O Wiring 32 Control I O Terminal Block 34 CE...

Page 6: ...tanding Integrated Safety Drive Replacement 107 Replacing an Integrated Safety Drive in a GuardLogix System 107 Motion Direct Commands in Motion Control Systems 114 Functional Safety Considerations 12...

Page 7: ...Rockwell AutomationPublication 520 UM002B EN E December 2017 7 Table of Contents Removing the Encoder Option Card 168 Encoder Option Card Usage 168 Wiring Notes 170 Index...

Page 8: ...8 Rockwell Automation Publication 520 UM002B EN E December 2017 Table of Contents Notes...

Page 9: ...tomation com literature To order paper copies of For information on See page Who Should Use this Manual 9 Additional Resources 9 Manual Conventions 10 Drive Frame Sizes 10 General Precautions 11 Catal...

Page 10: ...motion based systems The Studio 5000 environment is the foundation for system engineering design tools and capabilities it is the one tool for engineers to design and develop all the elements of thei...

Page 11: ...with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed...

Page 12: ...15 0 11 0 Output Current 3 Phase 380 480V Input Code Amps Frame ND HD HP kW HP kW 1P4 1 1 4 A 0 5 0 4 0 5 0 4 2P3 1 2 3 A 1 0 0 75 1 0 0 75 4P0 1 4 0 A 2 0 1 5 2 0 1 5 6P0 1 6 0 A 3 0 2 2 3 0 2 2 010...

Page 13: ...ns 13 AC Supply Source Considerations 17 General Grounding Requirements 18 Fuses and Circuit Breakers 20 Power and Control Module 25 Control Module Cover 28 Power Module Terminal Guard 28 Power Wiring...

Page 14: ...Zero Stacking No clearancebetweendrives Horizontal Zero Stacking with Control Module Fan Kit No clearancebetweendrives Vertical Vertical Zero Stacking with Control Module Fan Kit Noclearancebetweendr...

Page 15: ...5 C 9 F for all mounting methods 3 For catalogs 25C D1P4N104 and 25C E0P9N104 the temperature listed under the Maximum withControl Module Fan Kit Derate column is reduced by 10 C 18 F for vertical an...

Page 16: ...e Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation Storage Store within an ambient temperature range of 40 85 C 1 Store with...

Page 17: ...he jumper shown in the diagrams below 1 Turn the screw counterclockwise to loosen 2 Pull the jumper completely out of the drive chassis 3 Tighten the screw to keep it in place Jumper Location Typical...

Page 18: ...nput Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance Install Line Reactor 2 or Isolation Transformer 2 See Appendix B for accessory ordering info...

Page 19: ...should also be connected to the motor frame motor end Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal The earthing plate or conduit box option may be used wit...

Page 20: ...istings in the tables Fuses and Circuit Breakers for PowerFlex 527 on page 21 include inverse time circuit breakers instantaneous trip circuit breakers motor circuit protectors and 140M self protected...

Page 21: ...C25 140M D8E C20 CLASS RK5 CC J or T DLS R 40 140U D6D2 C25 140M D8E C20 25C V6P0N104 1 1 5 1 1 1 5 1 1 6 0 3 2 24 0 B 100 C23 30 50 140U D6D2 C30 140M F8E C25 CLASS RK5 CC J or T DLS R 50 140U D6D2...

Page 22: ...ing Circuit Breakers HP kW HP kW Min Rating Max Rating 140U 140M Class Catalog No 140U 140M 4 5 6 25C B2P5N104 1 0 5 0 4 0 5 0 4 2 5 1 2 2 7 A 100 C07 6 6 140U D6D3 B40 140M C2E B40 CLASS RK5 CC J or...

Page 23: ...A 100 C09 10 15 140U D6D3 B60 140M C2E B63 CLASS RK5 CC J or T DLS R 15 140M C2E B63 25C D4P0N114 1 2 0 1 5 2 0 1 5 4 0 5 2 5 7 A 100 C09 10 15 140U D6D3 B60 140M C2E B63 CLASS RK5 CC J or T DLS R 15...

Page 24: ...ax Rating Circuit Breakers HP kW HP kW Min Rating Max Rating 140U 140M Class Catalog No 140U 140M 4 5 6 25C E0P9N104 1 0 5 0 4 0 5 0 4 0 9 1 4 1 2 A 100 C09 3 6 140U D6D3 B20 140M C2E B25 CLASS RK5 CC...

Page 25: ...control terminals It is assumed that your drive is new and has not been installed SeparatingthePowerandControlModule 1 Press and hold down the catch on both sides of the frame cover then pull out and...

Page 26: ...tallation Wiring 3 Hold the sides and top of the Control Module firmly then pull out to separate it from the Power Module ConnectingthePowerandControlModule 1 Align the connectors on the Power Module...

Page 27: ...tallation 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 co...

Page 28: ...s 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 Power Module Terminal Guard To acce...

Page 29: ...sensitive circuits As an approximate guide allow a spacing of 0 3 m 1 ft for every 10 m 32 8 ft of length In all cases long parallel runs must be avoided Do not use cable with an insulation thickness...

Page 30: ...ted by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good c...

Page 31: ...atings and lower reflected wave effects do not need to be considered Output Disconnect The drive is intended to be commanded by motion commands that will start and stop the motor A device that routine...

Page 32: ...shipment Ensure that all terminal screwsaretightenedtotherecommendedtorquebeforeapplyingpowertothe drive Power Terminal Block Wire Specifications Frame Maximum Wire Size 1 1 Maximum minimum sizes that...

Page 33: ...t signals ATTENTION Due to its control circuitry difference from the PowerFlex 523 and PowerFlex 525 drives connecting Terminals 01 and 11 on the PowerFlex 527 drive causes an internal short and resul...

Page 34: ...the terminal block will accept these are not recommendations Minimum Wire Size 1 Torque A E 1 3 mm2 16 AWG 0 13 mm2 26 AWG 0 71 0 86 Nm 6 2 7 6 lb in R1 11 2 12 13 14 15 16 17 R2 R5 R6 01 2 02 03 04 0...

Page 35: ...and do not have the same functionality as system outputs when compared to chassis or remote I O products Refer to the Logix5000 Controllers General Instructions Reference Manual publication 1756 RM00...

Page 36: ...en set the ACO AVO attribute See Setting the ACO AVO Attributeon page 166 for instructions 17 Opto Common The emitters of the Optocoupler Outputs 1 and 2 are tied together at Optocoupler Common They a...

Page 37: ...rical electronic programmable electronic safety related systems Parts 1 7 General Considerations For CE compliance drives must satisfy installation requirements related to both EN 61800 5 1 and EN 618...

Page 38: ...iance with the LV Directive The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents Use of line filters in ungrounded systems is n...

Page 39: ...ielded connector installed in an EMC plate conduit box or similar At the motor end the motor cable shield or conduit must terminate in a shielded connector which must be properly installed in an earth...

Page 40: ...ex 527 RF Emission Compliance and Installation Requirements Filter Type Standard Limits EN61800 3 Category C1 EN61000 6 3 CISPR11 Group 1 Class B EN61800 3 Category C2 EN61000 6 4 CISPR11 Group 1 Clas...

Page 41: ...ernal EMC Filter 0 230V 3 Phase Output A Yes Yes Output only No No Input Output B Yes Yes Output only No No Input Output C Yes Yes Output only No No Input Output D Yes Yes No No No Input only E Yes Ye...

Page 42: ...E 3 CORE E 4 Ground cable Showscontactto shielded layer Secure EMC core by using cable zip ties Input cable to drive Shielded or Unshielded Output cable from drive Shielded IMPORTANT The ground cable...

Page 43: ...ility 6 Verify that the Sink SNK Source SRC jumper is set to match your control wiring scheme See the PowerFlex 527 Control I O Wiring Block Diagram on page 34 for location For information on See page...

Page 44: ...using a Logix motion instruction for example MSO command and no START INHIBIT condition exists See Configuring the PowerFlex 527 Drive with Integrated Motion on page 51 for instructions Verify the dr...

Page 45: ...ion Up Arrow Down Arrow Pressing either arrow moves the selection to the next or previous item When changing values pressing the Up arrow increments the highlighted value Values rollover after reachin...

Page 46: ...om the controller SYNCING The drive is waiting for a successful Group Sync service CONN_TIMEOUT The drive is trying to establish communication with the EtherNet IP controller but the connection has ti...

Page 47: ...o Provides information on the drive type network configuration and IP address PowerFlex 527 Static IP 192 168 1 180 or PowerFlex 527 DHCP 192 168 1 180 2 2 If 0 0 0 0 is displayed and DHCP is enabled...

Page 48: ...3 PresstheUporDownarrowtoselecteitherDHCPorStatic IP then press Enter If you choose DHCP go to step 4 If you choose Static IP go tostep 5 4 PressEntertoconfirmDHCPasthenetworkconfiguration option Choo...

Page 49: ...Info screen option to signify that a change has been made but has not taken effect For example after changing the network configuration from Static IP to DHCP when viewing the Device Info screen opti...

Page 50: ...using the Studio 5000 Logix Designer application The EtherNet IP network offers a full suite of control configuration and data collection services by layering the Common Industrial Protocol CIP over t...

Page 51: ...on Set the Network Configuration You can set the network configuration by using the LCD display and drive keypad 1 When the LCD display is showing the Device Axis state use the keypad to navigate to S...

Page 52: ...address of 192 168 1 180 See Configuring Network Settings on page 48 for help on configuring the IP settings Configure the Logix Designer Application Project These procedures assume that you have wir...

Page 53: ...CompactLogix 5370 controller it has dual embedded EtherNet IP ports In this example the typical dialog boxes for 1756 L7xS GuardLogix 5570 safety controllers and CompactLogix 5370 controllers are sho...

Page 54: ...ith GuardLogix 1756 7xS controller Controller Organizer with CompactLogix 5370 controller 6 Right click I O Configuration in the Controller Organizer and choose New Module IMPORTANT Ifyourprojectinclu...

Page 55: ...and Allen Bradley and select 1756 EN2T 1756 EN2TR or 1756 EN3TR as appropriate for your actual hardware configuration In this example the 1756 EN2T module is selected 8 Click Create The New Module di...

Page 56: ...u choose Time Sync and Motion 10 Click OK to close the Module Definition dialog box 11 Click Yes when prompted to confirm your module definition changes 12 Click OK to close the New Module dialog box...

Page 57: ...ive Follow these instructions to add the PowerFlex 527 drive to your project 1 Right click the Ethernet network node and choose New Module 2 Clear the small select all check boxes Module Type Category...

Page 58: ...dors Filters window check Allen Bradley In the Module Type Category Filters window check Drive 4 Choose the PowerFlex 527 drive and click create The Module Properties dialog box appears 5 Configure th...

Page 59: ...o configure the PowerFlex 527 drives with hardwired safety 1 Ensure that you have done the steps in Add a PowerFlex 527 Drive on page 57 before proceeding 2 Under Module Definition click Change The Mo...

Page 60: ...s the same as the connected drive If the two do not match a connection error occurs which indicates a power mismatch Verify Power Rating on Connection is checked by default It is enabled in offline mo...

Page 61: ...menu choose an option b From the Connection pull down menu choose the Connection mode for your motion application In this example choose Motion and Safety The Safety Network Number SNN field populate...

Page 62: ...ower structure defined in the profile is the same as the connected drive If the two do not match a connection error occurs which indicates a power mismatch Verify Power Rating on Connection is checked...

Page 63: ...Analyze each safety channel to determine the appropriate settings The smallest Input RPI allowed is 6 ms Selecting small RPI values consumes network bandwidth and can cause nuisance trips because oth...

Page 64: ...nfiguration After you have established your PowerFlex 527 drive in the Logix Designer application the remaining configuration steps are the same regardless of the drive catalog number 1 Right click th...

Page 65: ...27 Drive with Integrated Motion Chapter 3 The New Tag dialog box appears 4 Type the axis Name AXIS_CIP_DRIVE is the default Data Type 5 Click Create The axis Axis_1 in this example appears in the Cont...

Page 66: ...ted to the drive or the internal IGBT will be controlling the power dissipation to the resistor the type of shunt resistor is selected below Adjustable Frequency Default Thisselectionallowsthedrivetoe...

Page 67: ...otion Group The New Tag dialog box appears 2 Type the new motion group name 3 Click Create Your new motion group appears in the Controller Organizer under the Motion Groups folder 4 Right click the ne...

Page 68: ...for configuring induction motors Configure Induction Motor Axis Properties Frequency Control on page 68 Configure Induction Motors Axis Properties Velocity Loop on page 73 Configure Induction Motors...

Page 69: ...he Axis Configuration pull down menu choose Frequency Control 4 From the Module pull down menu your PowerFlex 527 drive The Module Type and Power Structure fields populate with the chosen drive catalo...

Page 70: ...Frequency Control category The Frequency Control dialog box appears 12 From the Frequency Control Method pull down menu choose the method appropriate for your application 13 If you chose the Basic Vo...

Page 71: ...Static Motor Test tab 17 Click Start to run the test and measure Motor Stator Resistance If you chose the Basic Volts Hertz category you can skip this test 18 Select the Actions category The Actions t...

Page 72: ...dialog box appears From this dialog box you can program actions and change the action for exceptions faults See Logix5000 Controller and Drive Behavior on page 129 for more information To obtain the b...

Page 73: ...motor axis properties 1 In the Controller Organizer right click an axis and choose Properties 2 Select the General category The General and Associated Module dialog box appears 3 From the Axis Configu...

Page 74: ...on dialog box appears 7 From the Data Source pull down menu choose Nameplate Datasheet This is the default setting 8 From the Motor Type pull down menu choose Rotary Induction 9 From the motor namepla...

Page 75: ...e PowerFlex 527 Drive with Integrated Motion Chapter 3 13 Click Apply 14 Select the Scaling category and edit the values as appropriate for your application 15 Click Apply if you make changes 16 Selec...

Page 76: ...more information 17 Select the Parameter List category The Motion Axis Parameters dialog box appears From this dialog box you can program actions and change the action for exceptions faults See Logix...

Page 77: ...motor axis properties 1 In the Controller Organizer right click an axis and choose Properties 2 Select the General category The General and Associated Module dialog box appears 3 From the Axis Configu...

Page 78: ...th Integrated Motion The Motor Device Specification dialog box appears 7 From the Data Source pull down menu choose Nameplate Datasheet This is the default setting 8 From the Motor Type pull down menu...

Page 79: ...rFlex 527 Drive with Integrated Motion Chapter 3 11 Select the Motor Feedback category 12 Enter the specifications of your encoder into the fields 13 Click Apply 14 Select the Scaling category and edi...

Page 80: ...to Take Upon Conditions dialog box appears From this dialog box you can program actions and change the action for exceptions faults See Logix5000 Controller and Drive Behavior on page 129 for more in...

Page 81: ...age 129 for more information To obtain the best performance from the drive regardless of which control method you are using you should configure the recommended out of box settings as described in Rec...

Page 82: ...are steady green If the two status indicators are not solid green see PowerFlex 527 Drive Status Indicators on page 126 for more information 4 Monitor the DC Bus voltage on the LCD display See Real ti...

Page 83: ...Logix 5370 controllers see Additional Resources on page 9 Test the Axes Note In the following example the Axis Configuration is set to Position Loop Follow these steps to test the axes 1 Verify the lo...

Page 84: ...in Frequency Control mode 9 Click Start The Logix Designer Motor and Feedback Test dialog box appears The Test State is Executing TESTING appears on the drive LCD display When the test completes succe...

Page 85: ...Tuning the Axes is not applicable when using the Frequency Control method Follow these steps to tune the axes 1 Verify the load is still removed from the axis being tuned 2 Click the Autotune categor...

Page 86: ...he test completes the Test State changes from Executing to Success Tuned values populate the Loop and Load parameter tables Actual bandwidth values Hz depend on your application and can require adjust...

Page 87: ...EN 61800 5 2 and EN 62061 in which removing the motion producing power is considered to be the safe state See CE Conformity on page 36 for more information regarding certification Important Safety Co...

Page 88: ...must be included in both a risk assessment and the determination of the achieved levels Refer to the EN ISO 13849 EN 61508 and EN 62061 standards for complete information on requirements for PL and S...

Page 89: ...data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data Safe Torque Off STO Feature The safe torque off circuit when used with suitab...

Page 90: ...ipped Safety Configuration The PowerFlex 527 drive is shipped with Safety control in out of box state Safety Bypass Jumper installed In this configuration the PowerFlex 527 safe torque off function is...

Page 91: ...rol is in the out of box state Restoring the Drive to the Out of Box State After the integrated safety connection configuration is applied to the PowerFlex 527 drive at least once you can follow these...

Page 92: ...ppears 3 Check Inhibit Module 4 Click Apply then click the Safety tab The Safety tab appears 5 In the Configuration Ownership field click Reset Ownership The safety connection must be inhibited before...

Page 93: ...DINT GuardFaultStatus 5 BOOL STO Fault Hardwired SafetyFaultStatus 8 BOOL STO Fault Network GuardStatus 1 1 Bits not shown are always zero 980 DINT GuardOKStatus 0 BOOL Not STO Fault Hardwired GuardG...

Page 94: ...rqueDisabledStatus 4 BOOL Status of SI TorqueDisabled SafetyOutputConnectionClosed 30 BOOL 1 if all output connections are closed SafetyOutputConnectionIdleStatus 31 BOOL 1 if output controller is in...

Page 95: ...of the following tags SI SafetyFault Axis SafetyFaultStatus Axis SafetyTorqueOffFault Propose TUNID Blocked MSG Parameter Value Description Service Code 0x0E Get Attribute Single Class 0x5A Safety Sto...

Page 96: ...age Safe Torque Off Fault Type MSG Parameter Value Description Service Code 0x0E Get Attribute Single Class 0x5A Safety Stop Functions Instance 1 Axis number Attribute 0x108 STO Fault Type Data Type S...

Page 97: ...dwired Safe Torque Off To select hardwired control of safe torque off STO The safety control must be in the out of box state The Safety Bypass Jumper must be removed An appropriate safety device must...

Page 98: ...cy limit Start Inhibit Torque Disabled DisableTorque No Fault No Fault Torque Disabled Exception Code on Drive Display Fault Message Logix Designer Problem Possible Solutions SAFE FLT 09 SS IN GuardSt...

Page 99: ...detected upon demand of the safe torque off function After troubleshooting a safety function must be executed to verify correct operation IMPORTANT TheSafeTorque Offfaultcanberesetonlyifboth inputsare...

Page 100: ...st of the drive S1 Safety 1 Safety input 1 S2 Safety 2 Safety input 2 S Safety 24V 24V supply for safety circuit This is internally tied to the 24V DC source terminal 11 IMPORTANT Digital Common termi...

Page 101: ...withferrulestopreventshortcircuits pertable D 7 of EN ISO 13849 2 Safe Torque Off STO Terminal Wiring Maximum Wire Size 1 Minimum Wire Size 1 Torque 1 3 mm2 16 AWG 0 13 mm2 26 AWG 0 71 0 86 Nm 6 2 7 6...

Page 102: ...102 Rockwell Automation Publication520 UM002B EN E December 2017 Chapter 5 Hardwired Control of Safe Torque Off Notes...

Page 103: ...equired for network control of the PowerFlex 527 safe torque off function The PowerFlex 527 safety connection can originate from a safety controller that provides both safety and motion control The Po...

Page 104: ...SNN verifying the safety signature and functional verification tests refer to the GuardLogix 5570 Controller Systems Safety Reference Manual publication 1756 RM099 Network Safe Torque off Specificati...

Page 105: ...ys zero 2 ConnectionStatus is determined by the Safety Validator in the GuardLogix controller DINT SI RunMode 0 BOOL See Table 10 Safety Connection Status in GuardLogix Safety Reference Manual publica...

Page 106: ...eTorqueOffActiveStatus Axis SafeTorqueOffDisabledStatus Axis SafeTorqueOffFault PermitTorque DisableTorque Exception Code on Drive Display Fault Message Logix Designer Problem Possible Solutions SAFE...

Page 107: ...wnership When the opened project owns the configuration Local is displayed A communication error is displayed if the module read fails Refer to Replacing an Integrated Safety Drive in a GuardLogix Sys...

Page 108: ...No Safety Signature Exists follow the appropriate instructions in Replacing a PowerFlex 527 Drive on page 108 to replace a PowerFlex 527 drive based on your scenario Once you have completed the steps...

Page 109: ...tedSafetyDriveIsOut of BoxandSafetySignatureExists 1 Remove and replace the existing integrated safety drive 2 Right click the replacement drive and choose Properties The General tab appears in the Mo...

Page 110: ...the replacement drive 7 Power cycle the drive 8 Follow your company prescribed procedures to functionally test the replacement drive and system and to authorize the system for use Scenario2 Replacemen...

Page 111: ...rk Control of Safe Torque Off Chapter 6 6 Right click the replacement drive and chooses Properties The General tab appears in the Module Properties dialog box 7 Click to the right of the Safety Networ...

Page 112: ...t the replacement drive and system and to authorize the system for use Scenario3 ReplacementIntegratedSafetyDriveSNNisDifferentfromOriginalandnoSafety SignatureExists 1 Remove and replace the existing...

Page 113: ...se steps when the Configure Always feature is enabled 1 Remove and replace the existing integrated safety drive 2 Right click the replacement drive and choose Properties ATTENTION Enable the Configure...

Page 114: ...tion Controllers Instructions Reference Manual publication MOTION RM002 for more information A typical use might involve a machine integrator testing different parts of the motion system while the mac...

Page 115: ...ss feature for the STO function in single safety controller configurations You can use the MDC feature to allow motion while following all the necessary and prescribed steps per your machine s safety...

Page 116: ...Safety state Not Running and Axis state Start Inhibited as shown in Safety State Indications After Controller Transitions to Program Mode on page 116 Safety State Indications After Controller Transit...

Page 117: ...message by clicking Yes torque is permitted by the drive and a warning message is indicated in the software as shown in Safety State Indications After Controller Transitions to Program Mode MDC Execut...

Page 118: ...i workstation Environment Warning Icon and Text in Axis Properties In addition to the other warnings that require your acknowledgment the Logix Designer application also provides warning icons and per...

Page 119: ...blication520 UM002B EN E December 2017 119 Network Control of Safe Torque Off Chapter 6 Axis and Safe State Indications on Motion Direct Commands Dialog Box Axis and Safe State Indications on the Moti...

Page 120: ...g procedures ATTENTION Motion is allowed and the STO function is not available when motion direct commands are used in Program mode Motion direct commands issued when the controller is in Program mode...

Page 121: ...rFlex 527 Display and Indicators on page 44 for more information For information on See page Safety Precautions 121 Interpret Status Indicators 121 General Troubleshooting 128 Logix5000 Controller and...

Page 122: ...BIT Mxx NODE FLTxx Exceptions that prevent normal operation of the drive NODE ALARM xx Exceptions that prevent normal operation of the drive but do not result in any action other than reporting the al...

Page 123: ...he incoming AC Monitor AC power source for glitches or line droop Install UPS on AC input Decrease Bus Undervoltage UL attribute value FLT S35 BUS OVERVOLT FL Bus Overvoltage Factory Limit Fault DC Bu...

Page 124: ...profile Verify sizing of the drive and motor Decrease Undertorque Limit and or Undertorque Limit Time attribute values FLT S61 ENABLE INPUT DEACTIVATED Enable Input Deactivated EnableInputhasbeendeact...

Page 125: ...in the Studio 5000 Logix Designer application INHIBIT S05 SAFE TORQUE OFF 1 Start Inhibit Safe Torque Off The safety function has disabled the power structure Check that Ethernet components such as c...

Page 126: ...ext Problem Possible Solutions NODE ALARM Fault Codes Exception Code on Display Exception Text Problem Possible Solutions NODE ALARM 01 LATE CTRL UPDATE Control Connection Update Alarm Updates from th...

Page 127: ...rable Flashing Red Abort Any State 1 Safety Supervisor Major Recoverable Steady Red Critical Fault Any State 1 Safety Supervisor Major Unrecoverable 1 Any State means any state that has lower preceden...

Page 128: ...Run Motor Test in the Logix Designer application Mechanical resonance Notch filter or output filter can be required refer to Axis Properties dialog box Output tab in the Logix Designer application You...

Page 129: ...ew speeds resulting in velocity disturbance Decouple the motor for verification Check and improve mechanical performance for example the gearbox or ballscrew mechanism No rotation The motor connection...

Page 130: ...tion Fault Status word but does not otherwise affect axis behavior However unlike AlarmanexplicitFaultResetisrequiredtoclearthefaultoncetheexceptionalcondition has cleared LikeIgnore andAlarm if theex...

Page 131: ...C Single Phase Loss Fault X X X X X Disable and Coast FLT S25 PRECHARGE FAILURE Pre charge Failure Fault X X Disable and Coast FLT S29 BUS OVERLOAD FL Bus Regulator Thermal OverLoad Factory Limit Faul...

Page 132: ...AFETY COMM Safety Module Communication Error X X Disable and Coast Drive Behavior NODE FLT xx Fault Codes Exception Fault Code Exception Text Induction Motor Fault Action Best Available Stopping Actio...

Page 133: ...inland Standards applied EN ISO 13849 1 EN 61800 5 2 EN 62061 EN 60204 1 IEC 61508 Part 1 7 Certified to ISO 13849 1 SIL3 PLe with embedded Safe Torque Off function Certified to ISO 61800 5 2 and EN 6...

Page 134: ...tionalControlModuleFan kit Storage Temperature Frame A D Frame E 40 85 C 40 185 F 40 70 C 40 158 F Atmosphere Relative Humidity 0 95 noncondensing Shock Vibration Complies with IEC 60068 2 27 Complies...

Page 135: ...nd on drive output Short Circuit Trip Phase to phase on drive output Specifications PowerFlex 527 Voltage Tolerance 15 10 Frequency Tolerance 47 63 Hz Input Phases Three phase input provides full rati...

Page 136: ...ons For more information see the Logix5000 Motion Controllers Instructions Reference Manual publication MOTION RM002 Intermittent Overload Normal Duty Heavy Duty 110 Overload capability for up to 60 s...

Page 137: ...ntity 2 1 Programmable Form A and 1 Programmable Form B Specification Resistive Rating Inductive Rating 3 0 A 30V DC 3 0 A 125V 3 0 A 240V AC 0 5 A 30V DC 0 5 A 125V 0 5 A 240V AC Opto Quantity 2 Prog...

Page 138: ...Phase 2 5 29 0 4 8 50 0 8 0 81 0 11 0 111 0 200 240V 50 60 Hz 1 Phase w EMC Filter 2 5 29 0 4 8 53 0 8 0 84 0 11 0 116 0 200 240V 50 60 Hz 3 Phase 2 5 29 0 5 0 50 0 8 0 79 0 11 0 107 0 17 5 148 0 24 0...

Page 139: ...P8N114 4 8 3 8 3 1 2 4 10 7 8 6 7 0 5 4 25C A8P0N114 8 0 6 4 5 2 4 0 18 0 14 4 11 7 9 0 25C A011N114 11 0 8 8 7 2 5 5 22 9 18 3 14 9 11 5 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25C B2P5...

Page 140: ...1 1 17 2 3 2 25C D030N114 30 0 24 0 19 5 15 0 33 0 26 4 21 5 16 5 25C D037N114 37 0 29 6 24 1 18 5 33 7 27 0 21 9 16 9 25C D043N114 43 0 34 4 28 0 21 5 38 9 31 1 25 3 19 5 525 600V AC 15 10 3 Phase In...

Page 141: ...0 264 A 25C A2P5N114 1 0 0 75 1 0 0 75 4 8 170 264 A 25C A4P8N114 2 0 1 5 2 0 1 5 8 0 170 264 B 25C A8P0N114 3 0 2 2 3 0 2 2 11 0 170 264 B 25C A011N114 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase...

Page 142: ...5C E4P2N104 5 0 4 0 5 0 4 0 6 6 446 660 B 25C E6P6N104 7 5 5 5 7 5 5 5 9 9 446 660 C 25C E9P9N104 10 0 7 5 10 0 7 5 12 0 446 660 C 25C E012N104 15 0 11 0 15 0 11 0 19 0 446 660 D 25C E019N104 20 0 15...

Page 143: ...0 15 0 10 15 AK R2 030P1K2 3 380 480V 50 60 Hz 3 Phase 0 5 0 4 89 360 AK R2 360P500 1 0 0 75 89 360 AK R2 360P500 2 0 1 5 89 360 AK R2 360P500 3 0 2 2 89 120 AK R2 120P1K2 5 0 4 0 47 120 AK R2 120P1K2...

Page 144: ...8 CL 10 0 7 5 17 0 C 25 RF018 CL 15 0 11 0 24 0 D 25 RF033 DL 20 0 15 0 30 0 D 25 RF033 DL 25 0 18 5 37 0 E 25 RF039 EL 30 0 22 0 43 0 E 25 RF039 EL 1 525 600V 50 60 Hz 3 Phase 0 5 0 4 0 9 A 25 RF8P0...

Page 145: ...tem Description B160 Frame Size Catalog No Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in existing installations to a PowerFlex 520 Series drive Select the catalog num...

Page 146: ...D010 7 5 5 5 7 5 5 5 13 0 323 528 C 25 PM1 D013 10 0 7 5 10 0 7 5 17 0 323 528 C 25 PM1 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM1 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM1 D030 380 480V AC 1...

Page 147: ...PowerFlex 527 Removable Terminal Blocks Kit Replacement terminal blocks for control wiring A E 25C RCTB PowerFlex 527 Control Module Internal Fan Kit Replacement internal fan for the control module A...

Page 148: ...1321 3R35 B HD 1321 3RA45 B ND 1321 3RA35 B HD 525 600V 50 60 Hz 3 Phase 0 5 0 4 0 5 0 4 1321 3R1 C 1321 3RA1 C 1321 3R1 C 1321 3RA1 C 1 0 0 75 1 0 0 75 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 2...

Page 149: ...vailable in five frame sizes See the PowerFlex 527 Drive Ratings on page 141 for information on power ratings IP 20 Open Type Frame A PowerFlex 527 Drive Weight Frame Size Weight kg lb A 1 1 2 4 B 1 6...

Page 150: ...nd Dimensions IP 20 Open Type Frame B IP 20 Open Type Frame C 87 0 3 43 72 5 2 85 172 0 6 77 6 0 0 24 92 7 3 65 168 0 6 61 180 0 7 09 Dimensions are in millimeters and inches 109 0 4 29 90 5 3 56 207...

Page 151: ...imensions Appendix B IP 20 Open Type Frame D IP 20 Open Type Frame E 130 0 5 12 116 0 4 57 247 0 9 72 260 0 10 24 6 0 0 24 212 0 8 35 Dimensions are in millimeters and inches 185 0 7 28 160 0 6 30 279...

Page 152: ...74 m3 min Maximum Air Pressure At zero air flow 7 70 mmH2O 9 598 mmH2O Acoustical Noise 40 5 dB A 46 0 dB A Insulation Type UL Class A Frame Size Frame A D Frame E Wire Size 0 32 mm2 22 AWG Torque 0 2...

Page 153: ...l Module Fan Kit Frame D E 130 0 5 12 32 0 1 26 260 0 10 24 247 0 9 72 116 0 4 57 185 0 7 28 196 0 7 72 52 0 2 05 300 0 11 81 280 0 11 02 160 0 6 30 Dimensions are in millimeters and inches Frame D Fr...

Page 154: ...P 30 NEMA 1 UL Type 1 Frame A 72 0 2 83 172 0 6 77 6 0 0 24 51 1 2 01 21 0 0 82 57 5 2 26 15 0 0 59 219 0 8 62 92 7 3 65 140 0 5 51 135 4 5 33 111 9 4 41 88 2 3 47 64 7 2 55 152 0 5 98 21 5 0 85 Dimen...

Page 155: ...Type 1 Frame B 87 0 3 43 172 0 6 77 6 1 0 24 72 5 2 85 66 1 2 60 63 1 2 48 33 5 1 32 23 9 0 94 15 0 0 59 92 7 3 65 218 0 8 58 180 0 7 09 168 0 6 61 128 5 5 06 108 5 4 27 88 3 3 48 67 3 2 65 21 5 0 85...

Page 156: ...NEMA 1 UL Type 1 Frame C 109 0 4 29 184 0 7 24 15 0 0 59 207 0 8 15 123 3 4 85 82 2 3 24 222 0 8 66 92 7 3 65 255 0 10 04 90 5 3 56 80 5 3 17 66 5 2 62 34 5 1 36 26 5 1 04 6 0 0 24 21 5 0 85 27 5 1 08...

Page 157: ...30 NEMA 1 UL Type 1 Frame D 130 0 5 12 212 0 8 35 6 0 0 24 260 0 10 24 295 0 11 61 15 0 0 59 247 0 9 72 109 8 4 32 153 3 6 04 116 0 4 57 96 0 3 78 44 0 1 73 30 0 1 18 70 0 2 76 21 5 0 85 33 5 1 32 Dim...

Page 158: ...1 UL Type 1 Frame E 185 0 7 28 160 0 6 30 127 5 5 02 82 5 3 25 62 5 2 46 42 5 1 67 279 0 10 98 15 0 0 59 350 0 13 78 300 0 11 81 280 0 11 02 212 0 8 35 181 0 7 13 164 0 6 46 7 6 0 30 21 5 0 85 43 7 1...

Page 159: ...2 54 0 2 13 23 0 0 91 20 0 0 79 30 0 1 18 55 0 2 17 234 0 9 21 223 0 8 78 223 0 8 78 Dimensions are in millimeters and inches Filtercan be mounted onto the back of the drive 5 5 0 22 87 0 3 43 58 0 2...

Page 160: ...28 0 1 10 76 0 2 99 5 5 0 22 275 0 10 83 109 0 4 29 70 0 2 76 76 0 2 99 37 0 1 46 Dimensions are in millimeters and inches Filtercan be mounted onto the back of the drive 5 5 0 22 80 0 3 15 130 0 5 12...

Page 161: ...ernal Fan Kit Installation Instructions publication 520 IN014 for detailed instructions ATTENTION Temperature inside the control module may exceed 80 C 176 F when the internal fan is not working Wait...

Page 162: ...162 Rockwell Automation Publication520 UM002B EN E December 2017 Appendix B Accessories and Dimensions Notes...

Page 163: ...our PowerFlex 527 drive to obtain the best performance from the drive You should apply these out of box settings first before configuring for your application Recommended Out of Box Settings Setting i...

Page 164: ...ion520 UM002B EN E December 2017 Appendix C Out of Box Configuration Torque Limits 200 of Motor Rated Torque Velocity Error Tolerance Change action to alarm Feedback Tap 16 Setting in Logix Designer E...

Page 165: ...ation520 UM002B EN E December 2017 165 Out of Box Configuration Appendix C Application Type setting in Velocity Loop Constant Speed Motion Group Base Update Rate 4 ms Setting in Logix Designer Example...

Page 166: ...output of the PowerFlex 527 drive to either current mA or voltage V Ensure that the Analog Out jumper J2 is also set to the same value See Analog Output on page 36 for instructions ACO AVO MSG Paramet...

Page 167: ...parate the power module and control module See Separating the Power and Control Module on page 25 for instructions 2 Place the encoder option card on the back of the control module Ensure that the tab...

Page 168: ...o remove Encoder Option Card Usage PowerFlex 527 drives support an optional encoder card The encoder supports up to 250 kHz dual channel at 5 12 or 24V and requires the optional encoder board to be in...

Page 169: ...n If the drive is reading encoder speed but the position regulator or other encoder function is not working properly remove power to thedriveandswaptheAandA NOT encoderchannelsorswapanytwomotor leads...

Page 170: ...Drive Power Internal drive 12V DC 250mA Encoder Power External Power Source Encoder Signal Single Ended Dual Channel Encoder Signal Differential Dual Channel Common 12V DC 250 mA A A B B Z Z Cm V to S...

Page 171: ...7 E encoder wiring 170 environment storage 16 F fault monitoring ground 19 fuses rating 20 G ground fault monitoring 19 motor 19 RFI filter 19 safety 19 shielding 19 I inputs circuit breakers 20 power...

Page 172: ...t motor 31 stop motor 31 storage environment 16 T temperature derating 15 wiring 30 tools programming 50 U unshielded wiring 30 V voltage reflections wiring 31 W wave protection reflected 31 wiring en...

Page 173: ...Rockwell Automation Publication520 UM002B EN E December 2017 173 Notes...

Page 174: ...174 Rockwell Automation Publication 520 UM002B EN E December 2017 Notes...

Page 175: ......

Page 176: ...needs to be returned follow these procedures Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complet...

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