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Rockwell Automation Allen-Bradley PowerFlex 520 Series User Manual Download Page 164

164

Rockwell Automation Publication 520-UM001K-EN-E - August 2021

Chapter 4          Troubleshooting

Motor operation is unstable

Cause(s)

Indication

Corrective Action

Motor data was incorrectly entered.

None

1. Correctly enter motor nameplate data into 

P031

, 

P032

 and 

P033

.

2. Enable 

A547

 [Compensation].

3. Use 

A530

 [Boost Select] to reduce boost level.

Drive will not reverse motor direction

Cause(s)

Indication

Corrective Action

Reverse is disabled.

None

Check 

A544

 [Reverse Disable].

Digital input is not selected for reversing control.

None

Check [DigIn TermBlk xx] (See 

page 88

). Choose correct input and program for 

reversing mode.

Digital input is incorrectly wired.

None

Check input wiring (See 

page 43

).

Motor wiring is improperly phased for reverse.

None

Switch two motor leads.

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. Remove power.

2. Verify that the control module is properly and fully installed on the power module.

3. Reapply power.

Motor is rotating at zero Hz or slip frequency is not correct

Cause(s)

Indication

Corrective Action

Incorrect speed calculation.

Improper speed.

• Verify 

P032

 [Motor NP Hertz].

• Reduce boost with 

A530

 [Boost Select].

• Set 

P036

 [Motor NP RPM] to motor synchronous speed.

Summary of Contents for Allen-Bradley PowerFlex 520 Series

Page 1: ...PowerFlex 520 series Adjustable Frequency AC Drive Bulletin Numbers 25A series B 25B User Manual Original Instructions ...

Page 2: ...ty is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipm...

Page 3: ...iderations 19 Ungrounded Distribution Systems 19 Input Power Conditioning 20 General Grounding Requirements 20 Ground Fault Monitoring 20 Safety Ground PE 21 Network Ground 21 Motor Ground 21 Shield Termination SHLD 21 RFI Filter Grounding 22 Fuses and Circuit Breakers 22 Fusing 22 Circuit Breakers 22 Fuses and Circuit Breakers for PowerFlex 520 Series Drives 24 Power and Control Module 28 Control...

Page 4: ...Applications 59 Display and Control Keys 59 Control and Navigation Keys 60 Viewing and Editing Parameters 61 Drive Programming Tools 62 Language Support 62 Smart Startup with Basic Program Group Parameters 63 LCD Display with QuickView Technology 65 Using the USB Port 65 MainsFree Programming 65 Using Drive Startup in CCW or Logix Designer application 66 Chapter 3 Programming and Parameters About ...

Page 5: ...mmunication Adapter 200 Removing a Communication Adapter 201 Appendix C RS485 DSI Protocol Network Wiring 203 Parameter Configuration 205 Supported Modbus Function Codes 205 Writing 06 Logic Command Data 205 Writing 06 Comm Frequency Command 207 Reading 03 Logic Status Data 208 Reading 03 Drive Error Codes 209 Reading 03 Drive Operational Values 210 Reading 03 and Writing 06 Drive Parameters 210 A...

Page 6: ...delines for Adjusting the PID Gains 234 Appendix G Safe Torque Off Function PowerFlex 525 Safe Torque Off Overview 237 EC Type Examination Certification 238 EMC Instructions 238 Using PowerFlex 525 Safe Torque Off 239 Safety Concept 239 Important Safety Considerations 239 Functional Proof Test 240 PFD and PFH Data 240 Safety Reaction Time 240 Enabling PowerFlex 525 Safe Torque Off 241 Wiring 241 P...

Page 7: ...rFlex 525 PM Motor Configuration Motor Control 252 Motor Data 252 Feedback 253 Stop Mode Brake Type 253 Direction Test 254 Auto Tune 254 Manual Configuration Using Drive Keypad 256 Additional PM Motor Configuration 257 Additional Setup for Open Loop PM Motor 257 Additional Setup for Closed Loop PM Motor 259 Optional Parameter Adjustments for Optimum Performance 261 Appendix K PowerFlex 525 Synchro...

Page 8: ...8 Rockwell Automation Publication 520 UM001K EN E August 2021 Table of Contents Notes ...

Page 9: ...ved column Min Enclosure Vol from Fuses and Circuit Breaker tables 24 27 Updated C2 and C3 categories external requirements in PowerFlex 520 Series RF Emission Compliance and Installation Requirements table 54 Added footnote on EMC enclosure dimension 55 Corrected PCR with ID 1018 on description of P043 Minimum Freq 85 Corrected PCR with ID 1539 on fractional parameters Added t071 Opto Out1 LevelF...

Page 10: ...w these steps to download the files for your PowerFlex 525 drive 1 Go to the Rockwell Automation Product Compatibility and Download Center at rok auto pcdc Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES IN001 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and M...

Page 11: ... firmware revision and AOP files to your computer Manual Conventions In this manual we refer to PowerFlex 520 Series Adjustable Frequency AC Drive as drive PowerFlex 520 series PowerFlex 520 series drive or PowerFlex 520 series AC drive Specific drives within the PowerFlex 520 series may be referred to as PowerFlex 523 PowerFlex 523 drive or PowerFlex 523 AC drive PowerFlex 525 PowerFlex 525 drive...

Page 12: ...on for the future of Rockwell Automation engineering design tools and capabilities It is the one place for design engineers to develop all the elements of their control system Drive Frame Sizes Similar PowerFlex 520 series drive sizes are grouped into frame sizes to simplify spare parts ordering dimensioning and so on A cross reference of drive catalog numbers and their respective frame sizes is p...

Page 13: ...ng or repairing this assembly Component damage may result if ESD controlproceduresarenotfollowed Ifyouarenotfamiliarwithstaticcontrol procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION Anincorrectlyappliedorinstalleddrivecanresultincomponent damage or a reduction in product life Wiring or application error...

Page 14: ... 2 48 3 E 15 0 11 0 10 0 7 5 062 2 62 1 E 20 0 15 0 15 0 11 0 Output Current 3 Phase 380 480V Input Code Amps Frame ND HD HP kW HP kW 1P4 1 4 A 0 5 0 4 0 5 0 4 2P3 2 3 A 1 0 0 75 1 0 0 75 4P0 4 0 A 2 0 1 5 2 0 1 5 6P0 6 0 A 3 0 2 2 3 0 2 2 010 10 5 B 5 0 4 0 5 0 4 0 013 13 0 C 7 5 5 5 7 5 5 5 017 17 0 C 10 0 7 5 10 0 7 5 024 24 0 D 15 0 11 0 15 0 11 0 030 2 30 0 D 20 0 15 0 15 0 11 0 037 2 37 0 E ...

Page 15: ...s 19 General Grounding Requirements 20 Fuses and Circuit Breakers 22 Power and Control Module 28 Control Module Cover 30 Power Module Terminal Guard 31 Power Wiring 32 Power Terminal Block 35 Common Bus Precharge Notes 35 I O Wiring 36 Control I O Terminal Block 37 Start and Speed Reference Control 48 CE Conformity 51 ATTENTION Thefollowinginformationismerelyaguideforproperinstallation Rockwell Au...

Page 16: ...2 0 in 50 mm 2 0 in 1 50 mm 2 0 in 1 50 mm 2 0 in 1 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in Esc Sel Esc Sel Esc Sel Esc Sel 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in Esc Sel Esc Sel 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in 50 mm 2 0 in 1 Esc Sel Esc Sel Esc Sel Esc Sel Esc Sel Esc Sel Vertical Zero Stacking No clearance between drives Horizontal Zero Stacking with Control Modul...

Page 17: ...sted under the Maximum Derate column is reduced by 5 C 9 F for all mounting methods 3 For catalogs 25x D1P4N104 and 25x E0P9N104 the temperature listed under the Maximum with Control Module Fan Kit Derate column is reduced by 10 C 18 F for vertical and vertical with zero stacking mounting methods only 4 Catalogs 25x D1P4N104 and 25x E0P9N104 cannot be mounted using either of the horizontal mountin...

Page 18: ...ude 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 within a relative humidity range of 0 95 noncondensing Do not expose to a corrosive atmosphere 1 The maximum ambient temperature for storing a Frame E drive is 70 C Altitude Limit Based on Voltage Drive...

Page 19: ...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 Phase to Ground MOV Removal 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 re...

Page 20: ...branch circuit Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance Install Line Reactor 1 or Isolation Transformer 1 See Appendix B for accessory ordering information Greater than 120 kVA supply transformer Line has power factor correction capacitors Install Line Reactor 1 or Isolation Transformer Line has frequent power interruptions Line h...

Page 21: ...ork with a ring topology EtherNet IP For more information on EtherNet IP networks see Ground Connections for EtherNet IP Networks on page 248 For more information on RS485 networks see Network Wiring on page 203 Motor Ground The motor ground must be connected to one of the ground terminals on the drive Shield Termination SHLD Either of the safety ground terminals located on the power terminal bloc...

Page 22: ...rovide recommended AC line input fuse and circuit breaker information See Fusing and Circuit Breakers below for UL and IEC requirements Sizes listed are the recommended sizes based on 40 C 104 F and the U S N E C Other country state or local codes may require different ratings Fusing The recommended fuse types are listed in the tables found on pages 24 27 If available current ratings do not match ...

Page 23: ...Controller UL489 Circuit Breakers When using Bulletin 140M or UL489 rated circuit breakers the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection Bulletin 140M can be used in single motor applications Bulletin 140M can be used up stream from the drive without the need for fuses ...

Page 24: ... 1 1 6 0 3 2 24 0 B 100 C23 32 50 140U D6D2 C30 140M F8E C25 CLASS RK5 CC J or T DLS R 50 140U D6D2 C30 140M F8E C25 200 240V 1 Phase Input Protection Devices Frames A B Catalog No Output Ratings Input Ratings Frame Size Contactor Catalog No IEC Applications Non UL UL Applications PF 523 PF 525 ND HD Amps kVA Max Amps 1 Fuses Rating Circuit Breakers Fuses Max Rating Circuit Breakers HP kW HP kW Mi...

Page 25: ... kVA Max Amps 2 Fuses Rating Circuit Breakers Fuses Max Rating Circuit Breakers HP kW HP kW Min Max 140U 140G 140M Class Catalog No 140U 140G 140M 3 4 5 25A B1P6N104 0 25 0 2 0 25 0 2 1 6 0 9 1 9 A 100 C09 3 6 140U D6D3 B30 140M C2E B25 CLASS RK5 CC J or T DLS R 15 140U D6D3 B30 140M C2E B25 25A B2P5N104 25B B2P5N104 0 5 0 4 0 5 0 4 2 5 1 2 2 7 A 100 C09 6 6 140U D6D3 B40 140M C2E B40 CLASS RK5 CC...

Page 26: ...D6D3 B60 140M C2E B40 CLASS RK5 CC J or T DLS R 10 7 140M C2E B40 25A D4P0N104 25B D4P0N104 2 0 1 5 2 0 1 5 4 0 5 2 5 7 A 100 C09 10 16 140U D6D3 B60 140M C2E B63 CLASS RK5 CC J or T DLS R 15 7 140M C2E B63 25A D4P0N114 25B D4P0N114 2 0 1 5 2 0 1 5 4 0 5 2 5 7 A 100 C09 10 16 140U D6D3 B60 140M C2E B63 CLASS RK5 CC J or T DLS R 15 7 140M C2E B63 25A D6P0N104 25B D6P0N104 3 0 2 2 3 0 2 2 6 0 6 9 7 ...

Page 27: ... UL Applications PF 523 PF 525 ND HD Amps kVA Max Amps 2 Fuses Rating Circuit Breakers Fuses Max Rating Circuit Breakers HP kW HP kW Min Max 140U 140G 140M Class Catalog No 140U 140G 140M 3 4 5 25A E0P9N104 25B E0P9N104 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 J or T DLS R 6 8 140M C2E B25 25A E1P7N104 25B E1P7N104 1 0 0 75 1 0 0 75 1 7 2 6 2 3 A 100 C09 3 ...

Page 28: ...a Power Module and Control Module Separating the Power and Control Module 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 2 Press down and slide out the top cover of the Control Module to unlock it from the Power Module ATTENTION Perform this action only when drive is NOT powered 1 2 ...

Page 29: ...llation 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 30: ...odule 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 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 ...

Page 31: ...l Module Re attach the front cover when wiring is complete Power Module Terminal Guard To access the power terminals the terminal guard must be removed To remove 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 2 Press and hold down the locking tab on the terminal guard 1 2 ...

Page 32: ... 015 in Do not route more than three sets of motor leads in a single conduit to minimize cross talk If more than three drive motor connections per conduit are required shielded cable must be used 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 ATTENTION Na...

Page 33: ...elded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks See Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES IN001 Consideration should be given to all of the general specifications dictated by the environment of the installation including temperature flexibility ...

Page 34: ... to the motor for the purpose of starting and stopping the motor should not be used If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive Aux Fault or Coast to Stop Recommended Shielded Wire Location Rating Type Description Standard Option 1 600V 90 C 194 F XHHW2 RHW 2 Anixter B209500 B209507 Belden 2...

Page 35: ...on U T1 V T2 W T3 Motor Phase Connection Switch any two motor leads to change forward direction DC DC DC Bus Connection except for 110V 1 Phase BR BR Dynamic Brake Resistor Connection Safety Ground PE IMPORTANT Terminal screws may become loose during shipment Ensure that all terminalscrewsaretightenedtotherecommendedtorquebeforeapplying power to the drive Power Terminal Block Wire Specifications F...

Page 36: ...line to the drive When the AC line is removed there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop An auxiliary braking method may be required Alternatively use the drive s safety input function IMPORTANT I Oterminalslabeled Common arenotreferencedtothesafetyground PE terminal and are designed to greatly reduce common mode interferen...

Page 37: ...Block Wire Specifications Frame Maximum Wire Size 1 1 Maximum minimum sizes that 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 N m 6 2 7 6 lb in 04 05 06 01 02 03 11 12 13 14 15 C1 C2 Digital Common DigInTermBlk 05 Pulse DigInTermBlk 06 Stop 1 DigInTermBlk 02 Start Run FWD 2 DigInTermBlk 03 Direction Run REV R1 ...

Page 38: ... See t062 t063 DigIn TermBlk xx below 3 Serial DSI Coast 4 Network Opt Coast 5 EtherNet IP 1 1 Setting is specific to PowerFlex 525 drives only Coast 04 05 06 01 02 03 11 12 13 14 15 C1 C2 Digital Common DigInTermBlk 05 Pulse DigInTermBlk 06 Stop 1 DigInTermBlk 02 Start Run FWD 2 DigInTermBlk 03 Direction Run REV R1 R2 Relay N O Relay Common 24V DC 10V DC Analog Input Analog Common Analog Output 3...

Page 39: ...ly open contact for output relay t076 R2 Relay Common Fault Common for output relay R3 Relay N C Fault Normally closed contact for output relay 01 Stop Coast Three wire stop However it functions as a stop under all input modes and cannot be disabled P045 1 02 DigIn TermBlk 02 Start Run FWD Run FWD Used to initiate motion and also can be used as a programmabledigitalinput Itcanbeprogrammedwitht062 ...

Page 40: ... from the rest of the drive 15 For Series A 4 20 mA In 2 Not Active For external 4 20 mA input supply Input impedance 250 Ω P047 P049 t062 t063 t065 t066 A459 A471 For Series B Analog Output OutFreq 0 10 The default analog output is 0 10V To convert a current value change the Analog Output jumper to 0 20 mA Programwitht088 AnalogOutSel Maximumanalogvalue can be scaled with t089 Analog Out High Max...

Page 41: ...erial DSI Coast 4 Network Opt Coast 5 EtherNet IP Coast 04 05 06 07 01 02 03 08 11 12 13 14 15 16 17 18 19 Digital Common DigInTermBlk 05 DigInTermBlk 06 DigInTermBlk 07 Pulse Stop 1 DigInTermBlk 02 Start Run FWD 2 DigInTermBlk 03 Direction Run REV DigInTermBlk 08 R1 R2 S1 S2 S Relay 1 N O Relay 1 Common 24V DC 10V DC 0 10V or 10V Input Analog Common 4 20mA Input Analog Output Opto Output 1 Opto O...

Page 42: ...ammabledigitalinput Itcanbeprogrammedwitht062 DigInTermBlk02 asthreewire Start DirwithStop ortwo wire Run FWD Run REV control Current consumption is 6 mA P045 P046 P048 P050 A544 t062 03 DigIn TermBlk 03 Dir Run REV Run REV Used to initiate motion and also can be used as a programmabledigitalinput Itcanbeprogrammedwitht063 DigInTermBlk03 asthreewire Start DirwithStop ortwo wire Run FWD Run REV con...

Page 43: ...ault analog output is 0 10V To convert a current value change the Analog Output jumper to 0 20 mA Programwitht088 AnalogOutSel Maximumanalogvalue can be scaled with t089 Analog Out High Maximum Load 4 20 mA 525 Ω 10 5V 0 10V 1 kΩ 10 mA t088 t089 17 Opto Output 1 MotorRunning Program with t069 Opto Out1 Sel Each Opto Output is rated 30V DC 50 mA Non inductive t069 t070 t075 18 Opto Output 2 At Freq...

Page 44: ...082 Relay Out 2 Level Voltage Trip Pulse Train Input PowerFlex 523 t065 DigIn TermBlk 05 52 PowerFlex 525 t067 DigIn TermBlk 07 52 UseP047 P049andP051 Speed Referencex to select pulse input Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In I O Wiring Examples Continued I O Continued Connection Example 13 14 10V Common 13 14 Common 14 15 Common 13 14 Common PowerFlex 523 Series B Powe...

Page 45: ... as specified by P045 Stop Mode If both Run Forward and Run Reverse inputs are closedatthesametime an undetermined state could occur Internal Supply SRC External Supply SRC Each digital input draws 6 mA 2 Wire SNK Control Run FWD Run REV Internal Supply SNK 3 Wire SRC Control Non Reversing P046 Start Source 1 2 t062 DigIn TermBlk 02 49 and t063 DigIn TermBlk 03 51 A momentary input will start the ...

Page 46: ...on WhenusingOpto Output with an inductive load such as a relay install a recovery diode parallel totherelayasshown to prevent damage to the output Opto Output 1 Each Opto Output is rated 30V DC 50 mA Non inductive Analog Output 2 t088 Analog Out Sel determines analog output type and drive conditions 0 10V 1k Ω min 0 20 mA 4 20 mA 525 Ω 0 20 mA 4 20 mA 525 Ω max t088 Analog Out Sel 0 23 The Analog ...

Page 47: ...of I O Terminal 04 should be connected Multiple Analog Connections When connecting a single potentiometer to multiple drives it is important to connect I O Terminal 14 common together for all drives I O Terminal 14 common and I O Terminal 13 potentiometerwiper should be daisychained to each drive Alldrives must be poweredup for the analog signal to be read correctly Customer Inputs Optional Ground...

Page 48: ...bled AND Active Preset Inputs Active Speed Referencex 11 or 12 PIDx Output AND PID x Ref Sel 7 Preset Freq Speed Reference3 select 1 Start Source 3 select 1 Start Source 2 select 1 Speed Reference2 select 1 Drive stopped NOT running Drive will start and run at Purge Speed Direction is always FORWARD Drive will start and run at Jog Speed Direction is fromTerminal Block REV terminal 03 Comms OR FWD ...

Page 49: ...figured for 2 Wire or 3 Wire control for the drive to function properly 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 Start Source x 2 DigInTrmBlk DigInTermBlk 02 03 48 49 50 51 2 Wire or 3 Wire Drive will not start Start and Direction command from Terminal Block Start Source x Start and ...

Page 50: ...Comms and StartSourcex 3 Serial DSI or 4 NetworkOpt or 5 EtherNet IP Active SpeedReferencex 13 StepLogic 1 Drivestopped NOTrunning Accel Decelalways Accel Decel1 Accel Decelfrom JogAcc Dec Accel Decel2isactive wheninputisselected byAccelandDecelinput DriveusesAccel1 andDecel1 No No No No No No No Yes Yes Yes Yes Yes Yes Yes Accel Decel1 2 3 4is selectedbythedefault PresetFreqx setting Accel Decel1...

Page 51: ...t methods Machinery Directive 2006 42 EC EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61800 5 2 Adjustable ...

Page 52: ...rent emissions on the AC supply system When operated on a public low voltage network it is the responsibility of the installer or user to ensure that applicable requirements of the distribution network operator have been met Consultation with the network operator and Rockwell Automation may be necessary If the optional NEMA 1 kit is not installed the drive must be installed in an enclosure with si...

Page 53: ...must terminate in a shielded connector which must be properly installed in an earthed motor wiring box attached to the motor The motor wiring box cover must be installed and earthed All control I O and signal wiring to the drive must use cable with a braided shield providing 75 or greater coverage or the cables must be housed in metal conduit or equivalent shielding must be provided When shielded ...

Page 54: ...0 m 492 ft 150 m 492 ft IMPORTANT EMC cores are included with drives that have an internal EMC filter 25x xxxxN114 external EMC filter accessory kit 25 RFxxx IMPORTANT Anenclosure shieldedinputcable andEMCcoresarenotrequiredtomeet category C3 requirements R L1 S L2 T L3 U T1 V T2 W T3 EMIfittingsandmetalconduit IP30 NEMA1 ULType1 optionkitorEMCkit Shieldedenclosure 1 Buildingstructuresteel Enclosu...

Page 55: ...5V 3 Phase Output A Yes Yes No No No Input Output B Yes Yes No No No Input Output C Yes Yes No No No Input Output D Yes Yes No No No Input Output E Yes Yes No Yes No No 1 Minimum EMC enclosure dimension 60 x 55 x 80 cm with a shielding attenuation of at least 92 dB 2 An indicates that EMC requirements are not met Additional Installation Requirements Continued Frame Size Category C1 Category C2 Enc...

Page 56: ...C core s except for the following Frame E drives with internal filters where the grounded input cable must not pass through EMC CORE E 1 600V drives with external filters where the grounded output cable must not pass through the EMC core s Recommended Placement of EMC Cores Relative to External Filter Input core Output core Incoming power EMC Filter Drive Motor All Frame sizes ...

Page 57: ...Drive Startup 57 Display and Control Keys 59 Viewing and Editing Parameters 61 Drive Programming Tools 62 Smart Startup with Basic Program Group Parameters 63 LCD Display with QuickView Technology 65 Using the USB Port 65 IMPORTANT Read the General Precautions on page 13 section before proceeding ATTENTION Power must be applied to the drive to perform the following start up procedures Some of the ...

Page 58: ...he USB utility application use the USB utility application to apply the backup to the new drive See Using the USB Port on page 65 for more information Otherwise set the necessary parameters for your application using the LCD keypad interface Connected Components Workbench software or RSLogix or Studio 5000 Logix Designer application if using an Add on Profile through EtherNet IP Configure the comm...

Page 59: ...ORTANT To disable reverse operation see A544 Reverse Disable Esc Sel FWD Esc Sel FWD ENET LINK EtherNet IP 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 func...

Page 60: ...Description Up Arrow Down Arrow Scroll through user selectable display parameters or groups Increment values Escape Back one step in programming menu Cancel a change to a parameter value and exit Program Mode Select Advance one step in programming menu Select a digit when viewing parameter value Enter Advance one step in programming menu Save a change to a parameter value Reverse Used to reverse d...

Page 61: ...t viewed parameter in that group will flash 6 Press the Up Arrow or Down Arrow to scroll through the parameter list 7 Press Enter to view the value of the parameter Or Press Esc to return to the parameter list 8 Press Enter or Sel to enter Program Mode and edit the value The right digit will flash and the word Program on the LCD display will light up 9 Press the Up Arrow or Down Arrow to change th...

Page 62: ...Version Connected Components Workbench 1 software 1 Available to download at rok auto ccw Version 5 0 or later Logix Designer application Version 21 0 or later RSLogix 5000 software Version 17 0 or later Built in USB software tool Serial Converter Module 2 2 Does not support the new dynamic parameter groups AppView CustomView and CopyCat functionality is limited to the linear parameter list 22 SCM...

Page 63: ...z Sets the motor nameplate rated frequency P033 Motor OL Current 0 0 Drive Rated Amps x 2 0 1 A Based on Drive Rating Sets the motor nameplate overload current P034 Motor NP FLA 0 0 Drive Rated Amps x 2 0 1 A Drive Rated Amps Sets the motor nameplate FLA P035 Motor NP Poles 2 40 1 4 Sets the number of poles in the motor P036 Motor NP RPM 0 24000 rpm 1 rpm 1750 rpm Sets the rated nameplate rpm of m...

Page 64: ...rce 3 1 When active the Reverse key is also active unless disabled by A544 Reverse Disable 2 If DigIn TrmBlk is selected ensure that the digital inputs are properly configured 3 Setting is specific to PowerFlex 525 drives only P047 P049 P051 Speed Reference1 1 16 1 Drive Pot 2 Keypad Freq 3 Serial DSI 4 Network Opt 5 0 10V Input 6 4 20mA Input 7 Preset Freq 8 Anlg In Mult 1 9 MOP 10 Pulse Input 11...

Page 65: ...ree Programming The MainsFree programming feature allows you to quickly configure your PowerFlex 520 series drive without having to power up the control module or install additional software Simply connect the control module to your PC with a USB Type B cable and you can download a parameter configuration to your drive You can also easily upgrade your drive with the latest firmware Connecting a Po...

Page 66: ...single mode parameter C169 MultiDrv Sel set to 0 Disabled or apply a single mode configuration to a drive in multi drive mode Using Drive Startup in CCW or Logix Designer application To use the PowerFlex 525 Startup Wizard in Connected Components Workbench software to automatically configure the parameters make sure you have installed the following PowerFlex 525 drive firmware revision 5 001 or la...

Page 67: ... In the Available Wizards dialog box click PowerFlex 525 Startup Wizard then click Select 3 Before tuning the drive it is recommended to reset all parameters to their default values Select the option shown below 4 Complete each step in the Startup Wizard to configure the drive IMPORTANT Follow the Startup Wizard steps exactly Ifnot unexpected results can occur ...

Page 68: ...68 Rockwell Automation Publication 520 UM001K EN E August 2021 Chapter 2 Start Up Notes ...

Page 69: ...ds the parameter list can only be displayed linearly and there is no access to communications option card programming About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of parameters exist ENUM ENUM parameters allow a selection from two or more items Each item is represented by a number Numeric Parameters These parameters have a singl...

Page 70: ...Freq 0 Hz P044 Maximum Freq 60 Hz A481 Process Display Lo 0 A482 Process Display Hi 10 Using the formula when the drive is running at 10 Hz the Process Value will be 1 66 On the drive LCD display only parameter b010 Process Display is shown In Connected Components Workbench software parameter b010 Process Display and b011 Process Fract are shown separately Stop drive before changing this parameter...

Page 71: ...Flt RstCfg 1 3 t106 Communications Comm Write Mode C121 Cmd Stat Select 1 C122 RS485 Data Rate C123 RS485 Node Addr C124 Comm Loss Action C125 Comm Loss Time C126 RS485 Format C127 EN Addr Sel 1 C128 EN IP Addr Cfg 1 1 C129 EN IP Addr Cfg 2 1 C130 EN IP Addr Cfg 3 1 C131 EN IP Addr Cfg 4 1 C132 EN Subnet Cfg 1 1 C133 EN Subnet Cfg 2 1 C134 EN Subnet Cfg 3 1 C135 EN Subnet Cfg 4 1 C136 EN Gateway C...

Page 72: ... Select A493 Motor OL Ret A494 Drive OL Mode A495 IR Voltage Drop A496 Flux Current Ref A497 Motor Rr 1 A498 Motor Lm 1 A499 Motor Lx 1 A500 PM IR Voltage 1 3 A501 PM IXd Voltage 1 3 A502 PM IXq Voltage 1 3 A503 PM BEMF Voltage 1 3 A504 Speed Reg Sel 1 A509 Freq 1 1 A510 Freq 1 BW 1 A511 Freq 2 1 A512 Freq 2 BW 1 A513 Freq 3 1 A514 Freq 3 BW 1 A515 PM Initial Sel 1 3 A516 PM DC Inject Cur 1 3 A517...

Page 73: ...t 2 BusVolts F652 Fault 3 BusVolts F653 Fault 4 BusVolts F654 Fault 5 BusVolts F655 Fault 6 BusVolts 1 F656 Fault 7 BusVolts 1 F657 Fault 8 BusVolts 1 F658 Fault 9 BusVolts 1 F659 Fault10 BusVolts 1 F660 Status Fault 1 F661 Status Fault 2 F662 Status Fault 3 F663 Status Fault 4 F664 Status Fault 5 F665 Status Fault 6 1 F666 Status Fault 7 1 F667 Status Fault 8 1 F668 Status Fault 9 1 F669 Status F...

Page 74: ...1 P047 Relay Out1 Sel t076 Analog Out Sel t088 Analog Out High t089 Anlg Out Setpt t090 Anlg In 0 10V Lo t091 Anlg In 0 10V Hi t092 Anlg In4 20mA Lo t095 Anlg In4 20mA Hi t096 Anlg In mA Loss t097 Preset Freq 0 A410 Auto Rstrt Tries A541 Auto Rstrt Delay A542 Start At PowerUp A543 Reverse Disable A544 Power Loss Mode A548 Half Bus Enable A549 Centrifugal Pump Language P030 Output Freq b001 Command...

Page 75: ...gic 7 L187 Stp Logic Time 0 L190 Stp Logic Time 1 L191 Stp Logic Time 2 L192 Stp Logic Time 3 L193 Stp Logic Time 4 L194 Stp Logic Time 5 L195 Stp Logic Time 6 L196 Stp Logic Time 7 L197 Step Units 0 L200 Step Units 1 L202 Step Units 2 L204 Step Units 3 L206 Step Units 4 L208 Step Units 5 L210 Step Units 6 L212 Step Units 7 L214 Slip Hz Meter d375 Speed Feedback d376 Encoder Speed d378 Units Trave...

Page 76: ...ces See Start and Speed Reference Control on page 48 for more information b003 Output Current Output current present at T1 T2 T3 U V W Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01 A b004 Output Voltage Related Parameter s P031 A530 A534 Output voltage present at T1 T2 T3 U V W Values Default Read Only Min Max 0 0 Drive Rated Volts Display 0 1V b005 DC Bus Voltage Filtere...

Page 77: ...ad Only Min Max F0 F127 Display F0 b010 Process Display Related Parameter s b001 A481 A482 32 bit parameter Output frequency scaled by A481 Process Disp Lo and A482 Process Disp Hi Scaled Process Value PV Process Disp Hi Process Disp Lo x Output Freq Minimum Freq Maximum Freq Minimum Freq Values Default Read Only Min Max 0 9999 00 Display 0 01 32 b011 Process Fract Related Parameter s b001 A481 A4...

Page 78: ...425 08 Anlg In Mult 2 09 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 2 13 Step Logic Parameters L180 L187 1 14 Encoder 2 15 EtherNet IP 2 16 Positioning 2 Frequency Command Source Digit 4 0 Other Digit 2 3 are used Digit 4 is not shown 1 Jog 2 Purge Not Used Example Display reads Description 2004 Start source comes from Network Opt and Frequency source is Purge 113 Start source comes from Ser...

Page 79: ...efault Read Only Min Max 0 24000 rpm Display 1 rpm b016 Output Speed Related Parameter s P044 Current output frequency in Scale is 0 at 0 00 Hz to 100 at P044 Maximum Freq Values Default Read Only Min Max 0 0 100 0 Display 0 1 b017 Output Power Related Parameter s b018 Output power present at T1 T2 T3 U V W Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW b018 Power Save...

Page 80: ...1 MWh b023 Energy Saved Related Parameter s A555 Total energy savings of using this drive compared to an across the line starter since the last reset of the meters Values Default Read Only Min Max 0 0 6553 5 kWh Display 0 1 kWh b024 Accum kWh Sav Related Parameter s b025 Total approximate accumulated energy savings of the drive compared to using an across the line starter Values Default Read Only ...

Page 81: ...esent operating temperature of the drive heatsink inside module Values Default Read Only Min Max 0 120 C Display 1 C b028 Control Temp Present operating temperature of the drive control Values Default Read Only Min Max 0 120 C Display 1 C b029 Control SW Ver Current drive firmware version Values Default Read Only Min Max 0 000 65 535 Display 0 001 ...

Page 82: ... drive before changing this parameter Sets the motor nameplate rated volts Values Default Drive Rated Volts Min Max 10V for 230V Drives 20V for 460V Drives 25V for 600V Drives Drive Rated Volts Display 1V P032 Motor NP Hertz Related Parameter s A493 A530 A531 A532 A533 Stop drive before changing this parameter Sets the motor nameplate rated frequency Values Default 60 Hz Min Max 15 500 Hz Display ...

Page 83: ... Values Default Drive Rated Power Min Max 0 00 Drive Rated Power Display 0 01 kW PF 525 P039 Torque Perf Mode Related Parameter s P040 A530 A531 A532 A533 A535 Stop drive before changing this parameter Selects the motor control mode The PowerFlex 523 and PowerFlex 525 drives are capable of performing with the following motor control modes Options 0 V Hz 1 SVC Default 2 Economize 3 Vector 1 Voltage...

Page 84: ...llowing initiation of this setting The parameter returns to 0 Ready Idle following the test at which time another start transition is required to operate the drive in normal mode Important Used when motor is uncoupled from the load Results may not be valid if a load is coupled to the motor during this procedure If P039 5 it is the same with Static Tune IMPORTANT All motor parameters in the Basic P...

Page 85: ...t 3 DC BrkAuto CF DC Injection Braking Stop with Auto Shutoff Standard DC Injection Braking for value set in A434 DC Brake Time OR Drive shuts off if the drive detects that the motor is stopped Stop command clears active fault 4 Ramp Ramp to Stop 5 Coast Coast to Stop 6 DC Brake DC Injection Braking Stop 7 DC BrakeAuto DC Injection Braking Stop with Auto Shutoff Standard DC Injection Braking for v...

Page 86: ...eceive a leading edge from the start input for the drive to start after a stop input loss of power or fault condition P047 Speed Reference1 Related Parameter s C125 P049 Speed Reference2 P051 Speed Reference3 Selects the source of speed command for the drive Changes to these inputs take effect as soon as they are entered P047 Speed Reference1 is the factory default speed reference unless overridde...

Page 87: ...at are NOT Reset when P053 1 Parameter Parameter Parameter P030 Language C138 EN Gateway Cfg 2 C159 EN Data Out 3 C121 Comm Write Mode C139 EN Gateway Cfg 3 C160 EN Data Out 4 C122 Cmd Stat Select C140 EN Gateway Cfg 4 C161 Opt Data In 1 C123 RS485 Data Rate C141 EN Rate Cfg C162 Opt Data In 2 C124 RS485 Node Addr C143 EN Comm Flt Actn C163 Opt Data In 3 C124 Comm Loss Action C144 EN Idle Flt Actn...

Page 88: ... to the value set in A431 Jog Frequency When input is removed drive ramps to a stop according to the value set in A432 Jog Accel Decel A valid Start command will override this input 9 Jog Forward DigIn TermBlk 08 default Drive accelerates to A431 Jog Frequency according to A432 Jog Accel Decel and ramps to a stop when input becomes inactive A valid Start command will override this input 10 Jog Rev...

Page 89: ...nput is activated If it passes this point it then runs in the reverse direction at 1 10th the frequency of Find Home Freq until the Home Limit is activated again As long as this input is active any start command causes the drive to enter the homing routine Only functions if in Positioning mode Once the Find Home routine has finished the drive stops See Appendix E for more information on Positionin...

Page 90: ...put Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In 1 This function may be tied to one input only 2 Setting is specific to PowerFlex 525 drives only Programmable Digital Inputs Continued Drive Start Condition Matrix for t062 and t063 t062 Setting t063 Setting 3 Wire Start 2 Wire FWD 2 Wire REV Drive will not start OK 3 Wire Dir OK Drive will not start t064 2 Wire Mode Related Param...

Page 91: ... Opto Outx Level A value of 0 causes the output to turn off A value of 1 or greater in this parameter causes the output to turn on None 14 NonRec Fault Value set in A541 Auto Rstrt Tries is exceeded or A541 Auto Rstrt Tries is not enabled or A non resettable fault has occurred None 15 EM Brk Cntrl EM Brake is energized Program t087 EM Brk On Delay and t086 EM Brk Off Delay for desired action None ...

Page 92: ...0 Min Max 0 0 9999 0 Display 0 1 32 PF 525 Min Max Value Range Based On Opto Outx Sel Setting 6 0 500 Hz 10 0 100 16 0 1 9999 s 20 0 1 7 0 180 11 0 1 17 1 9999 counts 26 0 150 8 0 815V 13 0 800 18 0 180 t071 Opto Out1 LevelF t074 Opto Out2 LevelF PowerFlex 525 only Determines the on off point fractional portion for the digital outputs Values Default Read Only Min Max 0 0 0 9 s Display 0 1 s PF 525...

Page 93: ... A value of 0 causes the output to turn off A value of 1 or greater in this parameter causes the output to turn on None 14 NonRec Fault Value set in A541 Auto Rstrt Tries is exceeded or A541 Auto Rstrt Tries is not enabled or A non resettable fault has occurred None 15 EM Brk Cntrl EM Brake is energized Program t087 EM Brk On Delay and t086 EM Brk Off Delay for desired action None 16 Thermal OL Re...

Page 94: ...lay Outx Sel Setting 6 0 500 Hz 10 0 100 16 0 1 9999 s 20 0 1 7 0 180 11 0 1 17 1 9999 counts 26 0 150 8 0 815V 13 0 800 18 0 180 C t078 RelayOut1 LevelF t083 RelayOut2 LevelF PowerFlex 525 only Determines the on off point fractional portion for the output relay Values Default Read Only Min Max 0 0 0 9 s Display 0 1 s PF 525 t079 Relay 1 On Time t084 Relay 2 On Time PowerFlex 525 only Sets the del...

Page 95: ...splay 0 01 s Frequency Time Minimum Freq EM Brk Off Delay EM Brk On Delay Stop commanded Start commanded EM Brk de energized On Drive stops EM Brk energized Off R a m p a c c e l Rampdecel 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 Val...

Page 96: ...Maximum Freq None b001 9 OutCurr 0 20 0 20 mA 0 mA 0 A 200 Drive Rated Current Filter A b003 10 OutVolt 0 20 0 20 mA 0 mA 0V 120 Drive Rated Output Volts None b004 11 OutPowr 0 20 0 20 mA 0 mA 0 kW 200 Drive Rated Power Filter A b017 12 OutTorq 0 20 0 20 mA 0 mA 0 A 200 Drive Rated Current Filter A d382 13 TstData 0 20 0 20 mA 0 mA 0000 65535 Hex FFFF None 14 Setpnt 0 20 0 20 mA 0 mA 0 100 0 Setpo...

Page 97: ...splay 0 1 t093 10V Bipolar Enbl Related Parameter s t091 t092 PowerFlex 525 only Enables disables bi polar control In bi polar mode direction is commanded by the polarity of the voltage If bi polar control is enabled P043 Minimum Freq and t091 Anlg In 0 10V Lo are ignored Options 0 Uni Polar In Default 0 10V only 1 Bi Polar In 10V PF 525 t094 Anlg In V Loss Related Parameter s P043 P044 A426 A427 ...

Page 98: ...ss Response to an analog signal loss is set in t094 or t097 Analog In x Loss Values Default 0 0 s Min Max 0 0 20 0 s Display 0 1 s t100 Sleep Wake Sel Related Parameter s t101 t102 t103 Drive sleeps if the appropriate analog input drops below the set t101 Sleep Level for the time set in t102 Sleep Time and the drive is running When entering sleep mode the drive ramps to zero and the run indicator ...

Page 99: ...input time the drive must stay above to wake from sleep mode Values Default 0 0 s 0 0 600 0 s 1 FaultDisable 0 1 s t105 Safety Open En PowerFlex 525 only Sets the action when both safety inputs Safety 1 and Safety 2 are disabled de energized no power is applied Options 0 FaultEnable Default 1 FaultDisable PF 525 t106 SafetyFlt RstCfg PowerFlex 525 only With FRN 5 xxx and later Sets the method of r...

Page 100: ...ications baud rate bits second for the RS485 port A reset or power cycle is required after selection is made Options 0 1200 1 2400 2 4800 3 9600 Default 4 19 200 5 38 400 C124 RS485 Node Addr Sets the Modbus drive node number address for the RS485 port if using a network connection A reset or power cycle is required after selection is made Values Default 100 Min Max 1 247 Display 1 C125 Comm Loss ...

Page 101: ...election is made Options 1 Parameters 2 BOOTP Default PF 525 C129 EN IP Addr Cfg 1 Related Parameter s C128 C130 EN IP Addr Cfg 2 C131 EN IP Addr Cfg 3 C132 EN IP Addr Cfg 4 PowerFlex 525 only Sets the bytes in the IP address A reset or power cycle is required after selection is made Values Default 0 Min Max 0 255 Display 1 PF 525 192 168 1 62 EN IP Addr Cfg 1 EN IP Addr Cfg 2 EN IP Addr Cfg 3 EN ...

Page 102: ...face detects that Ethernet communications have been disrupted Options 0 Fault Default 1 Stop Drive stops per P045 Stop Mode setting 2 Zero Data Note The Reference and Datalink values transmitted to the drive will be set to 0 3 Hold Last Note The Logic Command Reference and Datalink values transmitted to the drive will be held at their last value 4 Send Flt Cfg Note The Logic Command Reference and ...

Page 103: ...ent damage When commissioning the drive verify that your system responds correctly to various situations for example a disconnected drive C145 EN Flt Cfg Logic Related Parameter s C143 C144 32 bit parameter PowerFlex 525 only Sets the Logic Command data that is sent to the drive if any of the following is true C143 EN Comm Flt Actn is set to 4 Send Flt Cfg and communications are disrupted C144 EN ...

Page 104: ...arameter cannot be changed when an I O connection is established through the communication adapter Values Default 0 Min Max 0 800 Display 1 C165 Opt Data Out 1 C166 Opt Data Out 2 C167 Opt Data Out 3 C168 Opt Data Out 4 Datalink parameter number whose value is read from the HSDSI data table This parameter cannot be changed when an I O connection is established through the communication adapter Val...

Page 105: ...iDrv Sel is set to 1 Network Opt or 2 EtherNet IP A reset or power cycle is required after selection is made Values Default Drv 1 Addr Drv 2 Addr Drv 3 Addr Drv 4 Addr 2 3 4 5 Min Max 1 247 Display 1 C175 DSI I O Cfg Sets the configuration of the Drives that are active in the multi drive mode Identifies the connections that would be attempted on a reset or power cycle A reset or power cycle is req...

Page 106: ... next step When the condition is met the program advances to the next step Step 0 follows Step 7 Example Digit 1 is set to 3 When Logic In 2 becomes active the program advances to the next step Digit 2 Logic to jump to a different step For all settings other than F when the condition is met the program overrides Digit 0 and jumps to the step defined by Digit 3 Digit 3 Different step to jump When t...

Page 107: ...l Decel 1 On FWD Incremental 6 Accel Decel 1 On REV Absolute 7 Accel Decel 1 On REV Incremental 8 Accel Decel 2 Off FWD Absolute 9 Accel Decel 2 Off FWD Incremental A Accel Decel 2 Off REV Absolute b Accel Decel 2 Off REV Incremental C Accel Decel 2 On FWD Absolute d Accel Decel 2 On FWD Incremental E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incremental Settings Digit 3 Setting Descrip...

Page 108: ...y 0 1 s PF 525 L200 Step Units 0 L204 Step Units 2 L208 Step Units 4 L212 Step Units 6 L202 Step Units 1 L206 Step Units 3 L210 Step Units 5 L214 Step Units 7 32 bit parameter PowerFlex 525 only Sets the position in user defined units the drive must reach at each step Values Default 0 00 Min Max 0 00 6400 00 Display 0 01 32 PF 525 L201 Step Units F 0 L205 Step Units F 2 L209 Step Units F 4 L213 St...

Page 109: ...ops when it reaches the maximum value Values Default Read Only Min Max 0 32767 hr Display 1 hr d363 Elapsed Time min Related Parameter s d362 A555 Displays the total elapsed powered up time in minutes since timer reset Resets to zero when maximum value is reached and increments d362 Elapsed Time hr by one Values Default Read Only Min Max 0 0 60 0 min Display 0 1 min d364 Counter Status Displays th...

Page 110: ...e being applied to the motor frequency Drives applies slip based on the setting for P032 Motor NP Hertz Values Default Read Only Min Max 0 0 25 0 Hz Display 0 1 Hz d376 Speed Feedback 32 bit parameter Displays the value of the actual motor speed whether measured by encoder pulse train feedback or estimated Values Default Read Only Min Max 0 0 64000 0 rpm Display 0 1 rpm 32 d377 Speed Feedback F Di...

Page 111: ...30V AC drives 820V DC for 460V AC drives 1025V DC for 600V AC drives Display 1V DC d381 Output Powr Fctr Displays the angle in electrical degrees between motor voltage and motor current Values Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg 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...

Page 112: ...for direction of travel Values Default Read Only Min Max 0 64000 Display 1 32 PF 525 d389 Units Traveled L Related Parameter s d387 Stop drive before changing this parameter PowerFlex 525 only Displays the number of user defined units fractional portion traveled from the home position See d387 Position Status for direction of travel Values Default Read Only Min Max 0 00 0 99 Display 0 01 PF 525 d3...

Page 113: ... J o g g i n g F l u x B r a k i n g M o t o r O v e r l d A u t o R s t C t d n D C B r a k i n g A t F r e q A u t o T u n i n g E M B r a k i n g C u r r L i m i t S a f e t y S 1 1 S a f e t y S 2 1 F 1 1 1 S t a t u s 1 S a f e T q P e r m i t 1 Nibble 1 Nibble 2 Nibble 3 Nibble 4 Enhanced Control Option Only d394 Dig Out Status With PowerFlex 525 FRN 5 xxx and later With PowerFlex 523 FRN 3 ...

Page 114: ...el Used Preset Input 1 DigIn TermBlk 05 Preset Input 2 DigIn TermBlk 06 Preset Input 3 DigIn TermBlk 07 Preset Input 4 DigIn TermBlk 08 Preset Setting 0 1 1 Preset Setting 0 is only available if P047 P049 or P051 Speed Referencex is set to 7 Preset Freq 1 0 0 0 0 Preset Setting 1 1 1 0 0 0 Preset Setting 2 2 0 1 0 0 Preset Setting 3 2 1 1 0 0 Preset Setting 4 1 0 0 1 0 Preset Setting 5 1 1 0 1 0 P...

Page 115: ... non volatile storage until drive is powered down If both MOP Up and MOP Down are applied at the same time the inputs are ignored and the frequency is unchanged A428 MOP Reset Sel Determines if the current MOP reference command is saved on power down Options 0 Zero MOP Ref Resets the MOP frequency to zero on power down and stop 1 Save MOP Ref Default A429 MOP Preload Determines the operation of th...

Page 116: ...Stop Mode is set to either 0 Ramp CF 2 DC Brake CF 4 Ramp 6 DC Brake 10 PointStp CF or 11 PointStop Values Default Drive Rated Amps x 0 05 Min Max 0 00 Drive Rated Amps x 1 80 Display 0 01 A DC Injection Stop Mode Volts Speed Voltage Time Stop Command Speed DCBrakeTime Volts Speed Ramp to Stop Mode Time Stop Command Magnitude depends on DC Brake Level Magnitude depends on DC Brake Level DC Brake T...

Page 117: ...tivation IGBT can modulate continuously Values Default 100 0 Min Max 10 0 110 0 Display 0 1 ATTENTION Equipment damage may result if this parameter is set to a value that causes the dynamic braking resistor to dissipate excessive power Parameter settings less than 100 should be carefully evaluated to ensure that the Dynamic Brake resistor s wattage rating is not exceeded In general values less tha...

Page 118: ...he drive will forcibly reduce the carrier frequency to 8 kHz A441 Droop Hertz FLA PowerFlex 525 only Reduces the frequency based on current This frequency is subtracted from the commanded output frequency Generally Slip and Droop would not both be used but if both are enabled they simply subtract from each other Typically used in load sharing schemes Values Default 0 0 Hz Min Max 0 0 10 0 Hz Displ...

Page 119: ... Related Parameter s A449 A451 A453 A455 A450 Skip Frequency 2 A452 Skip Frequency 3 A454 Skip Frequency 4 PowerFlex 525 only Works in conjunction with A449 A451 A453 and A455 Skip Freq Band x creating a range of frequencies at which the drive does not operate continuously Values Default 0 0 Hz Disabled Min Max 0 0 500 0 Hz Display 0 1 Hz PF 525 A449 Skip Freq Band 1 Related Parameter s A448 A450 ...

Page 120: ...les the lower value of the trim frequency when trim is active Values Default 0 0 Hz Min Max 0 0 500 0 Hz Display 0 1 Hz PF 525 A458 PID 1 Trim Sel A470 PID 2 Trim Sel PowerFlex 525 only Stop drive before changing this parameter Sets the PID output as trim to the source reference Options 0 Disabled Default PID Trim is disabled 1 TrimOn Pot 2 TrimOn Keypd 3 TrimOn DSI 4 TrimOn NetOp 5 TrimOn 0 10V 6...

Page 121: ...13 EtherNet IP 1 1 Setting is specific to PowerFlex 525 drives only PF 525 A460 PID 1 Fdback Sel A472 PID 2 Fdback Sel PowerFlex 525 only Selects the source of the PID feedback Options 0 0 10V Input Default Note PID does not function with bipolar input Negative voltages are ignored and treated as zero 1 4 20mA Input 2 Serial DSI 3 Network Opt 4 Pulse Input 5 Encoder 1 6 EtherNet IP 1 1 Setting is ...

Page 122: ...splay 0 01 PF 525 A464 PID 1 Setpoint Related Parameter s A459 A471 A476 PID 2 Setpoint PowerFlex 525 only Provides an internal fixed value for process setpoint when PID mode is enabled Values Default 0 0 Min Max 0 0 100 0 Display 0 1 PF 525 A465 PID 1 Deadband A477 PID 2 Deadband PowerFlex 525 only Sets a range in percent above and below the PID Reference that the PID output will ignore Values De...

Page 123: ...ted Amps x 1 5 Heavy Duty Min Max 0 0 Drive Rated Amps x 1 5 Normal Duty Drive Rated Amps x 1 8 Heavy Duty Display 0 1 A A485 Current Limit 2 Related Parameter s P033 PowerFlex 525 only Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 Min Max 0 0 Drive Rated Amps x 1 5 Normal Duty Drive Rated Amps x 1 8 Heavy Duty Display 0 1 A PF 525 A486 Shear P...

Page 124: ... Fault Time Sets the time that the drive remains in stall mode before a fault is issued Options 0 60 Seconds Default 1 120 Seconds 2 240 Seconds 3 360 Seconds 4 480 Seconds 5 Flt Disabled A493 Motor OL Select Related Parameter s P032 P033 Drive provides Class 10 overload protection Settings 0 2 select the derating factor for the I2t overload function Options 0 No Derate Default 1 Min Derate 2 Max ...

Page 125: ...s x 1 4 Display 0 01 A A498 Motor Rr PowerFlex 525 only Rotor resistance of induction motor The value of this parameter will populate when a full rotate tune is performed Values Default Based on Drive Rating Min Max 0 00 655 35 ohm Display 0 01 ohm PF 525 A499 Motor Lm PowerFlex 525 only Mutual Inductance of induction motor The value of this parameter will populate when a full rotate tune is perfo...

Page 126: ...55 35V Display 0 01V PF 525 A504 PM BEMF Voltage PowerFlex 525 only With FRN 5 xxx and later Back electromotive force EMF voltage of the PM or SynRM motor Values Default 328 0 V PM 164 0 V SynRM Min Max 0 0 1200 0 V Display 0 1V PF 525 A509 Speed Reg Sel Related Parameter s A521 A522 A523 A524 A525 A526 PowerFlex 525 only Determines if PI gain of the Vector control mode speed regulator is set auto...

Page 127: ... Magnetic pole reorientation time Values Default 0 7 s Min Max 0 0 60 0 s Display 0 1 s PF 525 A519 PM HFI NS Cur PowerFlex 525 only With FRN 5 xxx and later High Frequency Injection HFI North South Current to detect N S Magnet Values Default 100 Min Max 0 300 Display 1 PF 525 A520 PM Bus Reg Kd PowerFlex 525 only With FRN 5 xxx and later Derivative gain for bus regulator Values Default 2 Min Max ...

Page 128: ...owerFlex 525 only With FRN 5 xxx and later The gain to ensure good performance in field weakening region Values Default 350 Min Max 0 2000 Display 1 PF 525 A528 PM FWKn 2 Kp PowerFlex 525 only With FRN 5 xxx and later The gain to ensure robustness under step load in weakening region Values Default 300 Min Max 100 8000 Display 1 PF 525 A529 PM Control Cfg PowerFlex 525 only With FRN 5 xxx and later...

Page 129: ... 2 5 CT Default for 200V drives 5 HP and above 8 5 0 CT Default for drives below 5 HP 9 7 5 CT 10 10 0 CT 11 12 5 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT Motor NP Hertz Motor NP Volts 100 50 1 2 Motor NP Volts Maximum Voltage can be set anywhere If it is Motor NP Volts then it defines a point on the V Hz curve Maximum Freq can be set anywhere If it is Motor NP Hertz then it defines a point on the V Hz...

Page 130: ...lated Parameter s P031 P032 P039 A530 A533 Sets the voltage in percent of Base Frequency at the A533 Break Frequency if A530 Boost Select is set to 0 Custom V Hz Values Default 25 0 Min Max 0 0 100 0 Display 0 1 A533 Break Frequency Related Parameter s P031 P032 P039 A530 A532 Sets the frequency where A532 Break Voltage is applied if A530 Boost Select is set to 0 Custom V Hz Values Default 15 0 Hz...

Page 131: ...ifies the encoder Pulses Per Revolution PPR when an encoder is used To achieve speed range accuracy for SVC and VVC closed loop control a minimum of 1024 PPR encoder is recommended The maximum encoder pulse is 250 kHz For more information see Determine Encoder Pulse Per Revolution PPR Specification Based on Speed Resolution on page 219 Values Default 1024 PPR Min Max 1 20000 PPR Display 1 PPR PF 5...

Page 132: ...n Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines A542 Auto Rstrt Delay Related Parameter s A541 Sets the time between restart attempts if A541 Auto Rstrt Tries is not zero Values Default 1 0 s Min Max 0 0 120 0 s Display 0 1 s A543 Start At PowerUp Stop drive before changing this parameter Enables disables...

Page 133: ...celerates and attempts to keep the DC bus voltage above the undervoltage level A549 Half Bus Enable Enables disables the power ride through function which allows the drive to maintain power to the motor at 50 drive input voltage during short term power sag conditions Options 0 Disabled Default 1 Enabled ATTENTION To guard against drive damage a minimum line impedance must be provided to limit inru...

Page 134: ...meter s b019 b021 b022 b023 b024 b025 b026 d362 d363 Resets the values stored in the parameters that track fault times and energy usage Options 0 Ready Idle Default 1 Reset Meters Resets kWh MWh Accum kWh Cost and CO2 Sav parameter values 2 Reset Time Resets min hr and x10 hr A556 Text Scroll Sets the scrolling speed of the text in the LCD display Options 0 Off No scroll 1 Low Speed 2 Mid Speed De...

Page 135: ... homing routine 4 Sync Enable Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization When this bit is reset to zero the drive accelerates to the new commanded frequency based on A571 Sync Time setting 5 Traverse Dis When set the traverse function is disabled 6 Logic In 1 This provides an identical function as the Logic In1 Digital Input option Th...

Page 136: ...ds when Find Home is issued Options 0 Forward Default 1 Reverse PF 525 A564 Encoder Pos Tol PowerFlex 525 only Sets the At Position and the At Home tolerance around the encoder count The value is added to and subtracted from the target encoder unit value to create the tolerance range Values Default 100 Min Max 1 50000 Display 1 PF 525 A565 Pos Reg Filter PowerFlex 525 only Sets the error signal fi...

Page 137: ...ets the time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency See the diagram at A567 Max Traverse Values Default 0 00 s Min Max 0 00 300 00 s Display 0 01 s A570 P Jump Related Parameter s A567 Sets the frequency amplitude that is added to or subtracted from the commanded frequency See the diagram at A567 Max Traverse Values Default 0 00 Hz Min M...

Page 138: ...00 Hz Status of drive At speed ZeroSpd Slip 1 Enabled A574 RdyBit Mode Cfg Related Parameter s d392 Stop drive before changing this parameter With PowerFlex 525 FRN 3 xxx and later With PowerFlex 523 FRN 3 xxx and later Determines which Stop conditions causes the drive s Ready bit Network Logic Status bit 1 to go low 0 A reset or power cycle is required after selection is made Options 0 Standard D...

Page 139: ... of current loop Values Default 0 Hz Min Max 0 65535 Hz Display 1 Hz PF 525 A581 PM Stable 1 Freq PowerFlex 525 only With FRN 5 xxx and later The start frequency for stabilization loop P032 Motor NP Hertz x A581 PM Stable 1 Freq Values Default 0 Min Max 0 100 Display 1 PF 525 A582 PM Stable 2 Freq PowerFlex 525 only With FRN 5 xxx and later Stabilization function will return to normal output after...

Page 140: ...in Max 0 2000 Display 1 PF 525 A588 PM 2 Efficiency PowerFlex 525 only With FRN 5 xxx and later Reduce no load current Values Default 500 Min Max 0 2000 Display 1 PF 525 A589 PM Algor Sel Related Parameter s A550 Stop drive before changing this parameter PowerFlex 525 only With FRN 5 xxx and later Selects the algorithm to use with your motor Check with the manufacturer of your motor to determine w...

Page 141: ... 525 A594 SYNRM Freq1 Comp RelatedParameter s PowerFlex 525 only With FRN 7 xxx and later The Scaling of Mutual Inductance Compensation At Low Speed Observer Freq1 Increasing or decreasing the setting enhances the loading performance during Freq1 operation depending on the motor Values Default 1 00 Min Max 0 10 00 PF 525 A595 SYNRM Freq2 BW RelatedParameter s PowerFlex 525 only With FRN 7 xxx and ...

Page 142: ...t represents a drive fault The codes appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults are only recorded once Values Default Read Only Min Max F0 F127 Display F0 F611 Fault 1 Time hr F613 Fault 3 Time hr F615 Fault 5 Time hr F612 Fault 2 Time hr Related Parameter s d362 F614 Fault 4 Time hr F616 Fault 6 Time hr F618 Fault 8 Time hr F620 Fa...

Page 143: ...urrent F648 Fault 8 Current F650 Fault10 Current PowerFlex 525 only F647 Fault 7 Current F649 Fault 9 Current Displays and stores the value of b003 Output Current with the most recent 10 faults occurred Fault 1 Current stores the most recent fault Fault 2 Current stores the second most recent fault and Fault 3 Current stores the third most recent fault Values Default Read Only Min Max 0 00 Drive R...

Page 144: ...igit 4 SafetyActive 1 Digit 5 1 Setting is specific to PowerFlex 525 drives only F681 Comm Sts DSI Displays the status of the RS485 serial DSI port to the drive Values Default Read Only Min Max 0000 1911 Display 0000 1 Condition True 0 Condition False Rx Digit 1 Tx Digit 2 Status Digit 3 Error Digit 4 Not Used Digit 3 Connection Status 0 Not Active 1 Modbus slave network external Modbus master 2 M...

Page 145: ...edded EtherNet IP faulted F684 EN Addr Src PowerFlex 525 only Displays the actual source of the Ethernet configuration IP address subnet mask and gateway address Options 1 Parameters Read Only 2 BOOTP PF 525 F685 EN Rate Act PowerFlex 525 only Displays the network data rate currently used by the embedded EtherNet IP interface Options 0 No Link Read Only 1 10Mbps Full 2 10Mbps Half 3 100Mbps Full 4...

Page 146: ...ct 4 PowerFlex 525 only Shows the actual IP address used by the embedded EtherNet IP interface at the time This indicates 0 if no address is set Values Default Read Only Min Max 0 255 Display 1 PF 525 255 255 255 255 EN IP Addr Act 1 EN IP Addr Act 2 EN IP Addr Act 3 EN IP Addr Act 4 F697 EN Subnet Act 1 F698 EN Subnet Act 2 F699 EN Subnet Act 3 F700 EN Subnet Act 4 PowerFlex 525 only Shows the ac...

Page 147: ... whether HS DSI EtherNet IP or DSI at the time If comms control is NOT being used and the drive is in single drive mode then this parameter will show 0 Values Default Read Only Min Max 0 FFFF Display 1 F706 Drv 0 Reference F710 Drv 1 Reference F714 Drv 2 Reference F718 Drv 3 Reference F722 Drv 4 Reference In multi drive mode this is the reference being transmitted to drive 0 1 2 3 4 In single driv...

Page 148: ... Default Read Only Min Max 0 65535 Display 1 PF 525 F726 EN Rx Packets PowerFlex 525 only A count of the number of receive packets reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 PF 525 F727 EN Rx Errors PowerFlex 525 only A count of the number of receive errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535...

Page 149: ...ng and Parameters Fault and Diagnostic Group continued F730 EN Missed IO Pkt PowerFlex 525 only The number of I O packets missed Values Default Read Only Min Max 0 65535 Display 1 PF 525 F731 DSI Errors The number of total DSI errors Values Default Read Only Min Max 0 65535 Display 1 ...

Page 150: ...nnot add or remove parameters to or from the AppView parameter groups If you require quick access to additional parameters to what is already included in the different AppView parameter groups use the CustomView parameter group instead The parameters in the AppView parameter groups can be quickly added to the CustomView parameter group by doing the following Step Key s Example Displays 1 Press the...

Page 151: ...he CustomView group GC 2 Press Enter to view the parameters that can be added to the CustomView group 3 Press the Up Arrow or Down Arrow to scroll through the list of parameters 4 Press Enter to add the parameter to the CustomView group The LCD display will show a confirmation Step Key s Example Displays 1 Press the Up Arrow or Down Arrow to scroll to the CustomView group GC 2 Press Enter to view ...

Page 152: ...7 1 067 EN Data In 3 1 155 Anlg In4 20mA Lo 095 DigIn TermBlk 08 1 068 EN Data In 4 1 156 Anlg Loss Delay 098 Drive OL Mode 495 EN Data Out 1 1 157 Anlg Out Setpt 2 090 Drive Status 006 EN Data Out 2 1 158 Auto Rstrt Delay 542 Drive Status 2 2 3 393 EN Data Out 3 1 159 Auto Rstrt Tries 541 Drive Temp 027 EN Data Out 4 1 160 Autotune 040 Drive Type 367 EN Flt Cfg DL 1 1 147 Average kWh Cost 052 Dro...

Page 153: ... 648 Language 30 Encoder Pos Tol 1 564 Fault 8 Freq 1 638 Load Loss Level 1 490 Encoder PPR 1 536 Fault 8 Time hr 1 618 Load Loss Time 1 491 Encoder Speed 2 378 Fault 8 Time min 1 628 Max Traverse 567 Energy Saved 023 Fault 9 BusVolts 1 659 Maximum Freq 044 Enh Control Word 1 560 Fault 9 Code 1 609 Maximum Voltage 534 Fault 1 BusVolts 651 Fault 9 Current 1 649 Minimum Freq 043 Fault 1 Code 007 Fau...

Page 154: ... 1 3 582 S Curve 439 Output Speed 016 PM Stable 2 Kp 1 3 584 Safety Open En 1 105 Output Voltage 004 PM Stable Brk Pt 1 3 585 SafetyFlt RstCfg 1 3 106 P Jump 570 PM Stepload Kp 1 3 586 Shear Pin 1 Time 487 Phase Loss Level 2 3 576 Pos Reg Filter 1 565 Shear Pin1 Level 486 PID 1 Deadband 465 Pos Reg Gain 1 566 Shear Pin 2 Time 1 489 PID 1 Diff Rate 463 Position Status 1 387 Shear Pin2 Level 1 488 P...

Page 155: ...atus Fault10 1 670 Step Units 0 1 200 Stp Logic Status 1 391 Testpoint Sel 483 Step Units 1 1 202 Stp Logic Time 0 1 190 Text Scroll 556 Step Units 2 1 204 Stp Logic Time 1 1 191 Testpoint Data 368 Step Units 3 1 206 Stp Logic Time 2 1 192 Timer Status 365 Step Units 4 1 208 Stp Logic Time 3 1 193 Timer StatusF 366 Step Units 5 1 210 Stp Logic Time 4 1 194 Torque Current 382 Step Units 6 1 212 Stp...

Page 156: ...156 Rockwell Automation Publication 520 UM001K EN E August 2021 Chapter 3 Programming and Parameters Notes ...

Page 157: ...ve Status 157 Faults 157 Fault Descriptions 159 Common Symptoms and Corrective Actions 162 ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis Fault Types Type Fault Description 1 Auto Reset Run When this type of fault occurs and A541 Auto Rstrt Tries is set to a value greater than 0 a user configurable timer A542 ...

Page 158: ... so that you can use the integral keypad Access b007 Fault 1 Code to view the most recent fault information 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared See Fault Types Descriptions and Actions on page 159 3 After corrective action has been taken clear the fault by one of these methods Press Stop if P045 Stop Mode is set to a value betwe...

Page 159: ...long Check for overhauling load F007 Motor Overload 1 Internal electronic overload trip An excessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current Verify A530 Boost Select setting F008 Heatsink OvrTmp 1 Heatsink Power Module temperature exceeds a predefined value Check for blocked or dirty heat sink fins Verify that ambient...

Page 160: ...nt 1 Programmed A486 A488 Shear Pinx Level has been exceeded for a time period greater than the time programmed in A487 A489 Shear Pin x Time Verify connections between motor and load Verify level and time requirements F064 Drive Overload 2 Drive overload rating has been exceeded Reduce load or extend Accel Time F070 Power Unit 2 Failure has been detected in the drive power section Check max ambie...

Page 161: ... Err 2 Control module was disconnected while drive was powered Clear fault and verify all parameter settings Do not remove or install the control module while power is applied F106 Incompat C P 2 The PowerFlex 525 control module does not support power modules with 0 25 HP power rating Change to a different power module Change to a PowerFlex 523 control module F107 Replaced C P 2 The control module...

Page 162: ...ackup firmware that only supports DSI communications Perform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware 1 See Fault Types for more information 2 This fault may be cleared by the auto restart routine and will be attempted only once It ignores the value set in parameter A541 Auto Rstrt Tries 3 This fault is not applicable to PowerFlex 523 dr...

Page 163: ...mper setting None Set switch to match wiring scheme 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 lit and output is 0 Hz Check b012 Control Source for correct source Ifthesourceisananaloginput checkwiringanduseametertocheckforpresence of signal Check b002 Commanded Freq to verify ...

Page 164: ...d program for reversing mode Digital input is incorrectly wired None Check input wiring See page 43 Motor wiring is improperly phased for reverse None Switch two motor leads 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 modul...

Page 165: ...ds applied EN 61800 3 EN 61800 5 1 Functional Safety Applicable to PowerFlex 525 drives only TÜV Rheinland Standards applied EN ISO 13849 1 EN 61800 5 2 EN 61508 PARTS 1 7 EN 62061 EN 60204 1 Certified to ISO 13849 1 SIL2 PLd with embedded Safe Torque Off function Meets Functional Safety FS when used with embedded Safe Torque Off function ATEX TUV 12 ATEX 7199 X Applicable to PowerFlex 525 drives ...

Page 166: ...hout derating With derating See Current Derating Curves on page 17 for derating guidelines 20 50 C 4 122 F 20 60 C 4 140 F or 20 70 C 4 158 F withoptionalControlModule Fan 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 with IEC 60068 2 6 1995 Conformal Coating Complies...

Page 167: ...otor Overload Protection Provides class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL 508C File 29572 Overcurrent 200 hardware limit 300 instantaneous fault Ground Fault Trip Phase to ground on drive output Short Circuit Trip Phase to phase on drive output Specifications PowerFlex 523 PowerFlex 525 Voltage To...

Page 168: ...range 0 5 of base speed across a 100 1 speed range Applicable to PowerFlex 525 drives only 0 5 of base speed across a 60 1 speed range 0 5 of base speed up to a 20 1 speed range Performance with Encoder SVC Sensorless Vector SVC Economizer VVC Velocity Vector Control PM Motor iPM motor 10 HP rating and below 1 Applicable to PowerFlex 525 drives only 0 1 of base speed across a 100 1 speed range 2 0...

Page 169: ... 2 W minimum Specifications PowerFlex 523 PowerFlex 525 Relay Quantity 1 Programmable Form C 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 Programmable Specification 30V DC 50 mA Non inductive Analog Quantity 1 Non Isolated 0 10V or 4 20 mA 1 1 Feature is ...

Page 170: ... 81 0 11 0 111 0 200 240V 50 60 Hz 1 Phase w EMC Filter 1 6 20 0 2 5 29 0 4 8 53 0 8 0 84 0 11 0 116 0 200 240V 50 60 Hz 3 Phase 1 6 20 0 2 5 29 0 5 0 50 0 8 0 79 0 11 0 107 0 17 5 148 0 24 0 259 0 32 2 323 0 48 3 584 0 62 1 708 0 380 480V 50 60 Hz 3 Phase 1 4 27 0 2 3 37 0 4 0 62 0 6 0 86 0 10 5 129 0 13 0 170 0 17 0 221 0 24 0 303 0 30 0 387 0 380 480V 50 60 Hz 3 Phase w EMC Filter 1 4 27 0 2 3 ...

Page 171: ... 2 0 1 6 1 3 9 6 7 7 6 2 4 8 25A V4P8N104 25B V4P8N104 4 8 3 8 3 1 2 4 19 2 15 4 12 5 9 6 25A V6P0N104 25B V6P0N104 6 0 4 8 3 9 3 0 24 0 19 2 15 6 12 0 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A A1P6N104 1 6 1 3 1 0 0 8 5 3 4 3 3 4 2 7 25A A2P5N104 25B A2P5N104 2 5 2 0 1 6 1 3 6 5 5 2 4 2 3 3 25A A4P8N104 25B A4P8N104 4 8 3 8 3 1 2 4 10 7 8 6 7 0 5 4 25A A8P0N104 25B A8P0N104 8 0 6 ...

Page 172: ...N114 25B D6P0N114 6 0 4 8 3 9 3 0 7 5 6 0 4 9 3 8 25A D010N114 25B D010N114 10 5 8 4 6 8 5 3 13 8 11 0 9 0 6 9 25A D013N114 25B D013N114 13 0 10 4 8 5 6 5 15 4 12 3 10 0 7 7 25A D017N114 25B D017N114 17 0 13 6 11 1 8 5 18 4 14 7 12 0 9 2 25A D024N114 25B D024N114 24 0 19 2 15 6 12 0 26 4 21 1 17 2 3 2 25A D030N114 25B D030N114 30 0 24 0 19 5 15 0 33 0 26 4 21 5 16 5 25A D037N114 25B D037N114 37 0 ...

Page 173: ...011N104 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25A A1P6N114 0 5 0 4 0 5 0 4 2 5 170 264 A 25A A2P5N114 25B A2P5N114 1 0 0 75 1 0 0 75 4 8 170 264 A 25A A4P8N114 25B A4P8N114 2 0 1 5 2 0 1 5 8 0 170 264 B 25A A8P0N114 25B A8P0N114 3 0 2 2 3 0 2 2 11 0 170 264 B 25A A011N114 25B A011N114 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Out...

Page 174: ... 75 1 7 446 660 A 25A E1P7N104 25B E1P7N104 2 0 1 5 2 0 1 5 3 0 446 660 A 25A E3P0N104 25B E3P0N104 3 0 2 2 3 0 2 2 4 2 446 660 A 25A E4P2N104 25B E4P2N104 5 0 4 0 5 0 4 0 6 6 446 660 B 25A E6P6N104 25B E6P6N104 7 5 5 5 7 5 5 5 9 9 446 660 C 25A E9P9N104 25B E9P9N104 10 0 7 5 10 0 7 5 12 0 446 660 C 25A E012N104 25B E012N104 15 0 11 0 15 0 11 0 19 0 446 660 D 25A E019N104 25B E019N104 20 0 15 0 15...

Page 175: ...R2 120P1K2 5 0 4 0 86 120 AK R2 120P1K2 7 5 5 5 59 120 AK R2 120P1K2 10 0 7 5 59 120 AK R2 120P1K2 15 0 11 0 59 60 AK R2 120P1K2 3 20 0 15 0 59 60 AK R2 120P1K2 3 25 0 18 5 53 60 AK R2 120P1K2 3 30 0 22 0 34 40 AK R2 120P1K2 4 1 The resistors listed in this tables are rated for 5 duty cycle 2 Use of Rockwell Automation resistors is always recommended The resistors listed have been carefully select...

Page 176: ...L 3 0 2 2 6 0 A 25 RF7P5 AL 25 RF014 BL 5 0 4 0 10 5 B 25 RF014 BL 7 5 5 5 13 0 C 25 RF018 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 BL 2 1 0 0 75 1 7 A 25 RF8P0 BL 2 2 0 1 5 3 0 A 25 RF8P0 BL 2 3 0 2 2 4 2 A 25 RF8P0 BL 2 5 0 4 0 6 6 B 25 RF8P...

Page 177: ... JBAA B 25 JBAB C 25 JBAC D 25 JBAD E 25 JBAE Control Module Fan Kit Item Description Frame Size Catalog No Control Module Fan Kit For use with drive in environments with ambient temperatures up to 70 C or horizontal mounting A D 25 FAN1 70C E 25 FAN2 70C Incremental Encoder Input Option Item Description Catalog No Incremental Encoder Incremental encoder input option board 25 ENC 1 WARNING Only th...

Page 178: ... 0 8 22A V4P5N104 B 25 AP0 FB 25 AP1 FB 1 5 1 1 22A V6P0N104 B 200 240V Single Phase 50 60 Hz 0 3 0 2 22A A1P5N104 A 25 AP0 FA 25 AP1 FA 0 5 0 4 22A A2P3N104 A 1 0 0 8 22A A4P5N104 A 2 0 1 5 22A A8P0N104 B 25 AP0 FB 25 AP1 FB No Brake IGBT 0 3 0 2 22A A1P4N103 A 25 AP0 FA 25 AP1 FA 0 5 0 4 22A A2P1N103 A 1 0 0 8 22A A3P6N103 A 2 0 1 5 22A A6P8N103 B 25 AP0 FB 25 AP1 FB 3 0 2 2 22A A9P6N103 B 200 2...

Page 179: ...25 AP1 FB 1 0 0 8 22B A5P0N114 B 2 0 1 5 22B A8P0N114 B 3 0 2 2 22B A012N114 C 25 AP0 FC 25 AP1 FC 200 240V Three Phase 50 60 Hz 0 5 0 4 22B B2P3N104 B 25 AP0 FB 25 AP1 FB 1 0 0 8 22B B5P0N104 B 2 0 1 5 22B B8P0N104 B 3 0 2 2 22B B012N104 B 5 0 3 7 22B B017104 B 7 5 5 5 22B B024N104 C 25 AP0 FC 25 AP1 FC 10 0 7 5 22B B033N104 C 25 AP0 FD 2 2 Mounting Adapter Plate is not required for the following...

Page 180: ... 4 22D D1P4N104 B 25 AP0 FB 25 AP1 FB 1 0 0 8 22D D2P3N104 B 2 0 1 5 22D D4P0N104 B 3 0 2 2 22D D6P0N104 B 5 0 3 7 22D D010N104 B 7 5 5 5 22D D012N104 C 25 AP0 FC 25 AP1 FC 10 0 7 5 22D D017N104 C 15 0 11 0 22D D024N104 C 25 AP0 FD 2 525 600V Three Phase50 60 Hz 1 0 0 8 22D E1P7N104 B 25 AP0 FB 25 AP1 FB 2 0 1 5 22D E3P0N104 B 3 0 2 2 22D E4P2N104 B 5 0 3 7 22D E6P6N104 B 7 5 5 5 22D E9P9N104 C 25...

Page 181: ...0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM1 D6P0 5 0 4 0 5 0 4 0 10 5 323 528 B 25 PM1 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 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 1 4 323 528 A 25 PM2 D1P4 1 0 0 75 1 0 0 75 2...

Page 182: ... O terminals EtherNet IP and DSI ports A E 25A CTMFC1 PowerFlex 525 Control Module Front Cover 25B CTMFC1 PowerFlex 520 Series Power Module Front Cover Replacement cover for the PowerFlex 520 Series power module B 25 PMFC FB C 25 PMFC FC D 25 PMFC FD E 25 PMFC FE PowerFlex 520 Series Power Terminal Guard Replacement finger guard for power terminals A 25 PTG1 FA B 25 PTG1 FB C 25 PTG1 FC D 25 PTG1 ...

Page 183: ...iptionPortalorDVD ROM rok auto ccw Windows based software packages for programming and configuring Allen Bradley drives and other Rockwell Automation products Compatibility Windows XP Windows Vista and Windows 7 rok auto ccw Bulletin 1321 3R Series Line Reactors Output Ratings 1 Input Line Reactor 2 4 Output Line Reactor 2 3 Normal Duty Heavy Duty IP00 Open Style IP11 NEMA UL Type 1 IP00 Open Styl...

Page 184: ...B 5 0 4 0 5 0 4 0 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 7 5 5 5 7 5 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 7 5 10 0 7 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 15 0 11 0 15 0 11 0 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 20 0 15 0 15 0 11 0 1321 3R25 B ND 1321 3R18 B HD 1321 3RA25 B ND 1321 3RA18 B HD 1321 3R25 B ND 1321 3R18 B HD 1321 3RA25 B ND 1321...

Page 185: ...nsions IP 20 Open Type Frame A IP 20 Open Type Frame B 72 0 2 83 172 0 6 77 6 0 0 24 57 5 2 26 140 0 5 51 152 0 5 98 92 7 3 65 Esc Sel Dimensions are in millimeters and inches Esc Sel 87 0 3 43 172 0 6 77 72 5 2 85 6 0 0 24 180 0 7 09 92 7 3 65 168 0 6 61 Dimensions are in millimeters and inches ...

Page 186: ...imensions IP 20 Open Type Frame C IP 20 Open Type Frame D Esc Sel 109 0 4 29 90 5 3 56 220 0 8 66 207 0 8 15 184 0 7 24 6 0 0 24 92 7 3 65 Dimensions are in millimeters and inches 130 0 5 12 260 0 10 24 247 0 9 72 116 0 4 57 212 0 8 35 6 0 0 24 Esc Sel Dimensions are in millimeters and inches ...

Page 187: ...0 15 A Speed Reference 7000 rpm 4500 10 rpm Air Flow At zero static pressure max 0 575 m3 min 1 574 m3 min Air Pressure At zero air flow min 7 70 mm H2O 9 598 mm H2O 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 29 0 39 N m 2 6 3 47 lb in Esc Sel 185 0 7 28 160 0 6 30 300 0 11 81 280 0 11 02 279 0 10 98 7 6 0 30 Dime...

Page 188: ...Sel 72 0 2 83 32 0 1 26 140 0 5 51 152 0 5 98 57 5 2 26 Esc Sel 87 0 3 43 32 0 1 26 180 0 7 09 168 0 6 61 72 5 2 85 Esc Sel 109 0 4 29 32 0 1 26 220 0 8 66 207 0 8 15 90 5 3 56 Frame A Frame B Dimensions are in millimeters and inches Frame C IMPORTANT An external 24V DC power source is required when using the Control Module Fan Kit with drive frames A B and C ...

Page 189: ... Fan Kit Frame D E Esc Sel 130 0 5 12 32 0 1 26 260 0 10 24 247 0 9 72 116 0 4 57 Esc Sel 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 Frame E IMPORTANT Remove the label to access the built in 24V supply on drive frames D and E for use with the Control Module Fan Kit ...

Page 190: ... NEMA 1 UL Type 1 Frame A Esc Sel 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 ø21 5 ø0 85 Dimensions are in millimeters and inches IP 30 NEMA 1 UL Type 1 conduit box IP 30 NEMA 1 UL Type 1 top panel ...

Page 191: ...1 Frame B Esc Sel 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 ø21 5 ø0 85 ø27 5 ø1 08 Dimensions are in millimeters and inches IP 30 NEMA 1 UL Type 1 conduit box IP 30 NEMA 1 UL Type 1 top panel ...

Page 192: ... UL Type 1 Frame C Esc Sel 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 ø21 5 ø0 85 ø27 5 ø1 08 Dimensions are in millimeters and inches IP 30 NEMA 1 UL Type 1 conduit box IP 30 NEMA 1 UL Type 1 top panel ...

Page 193: ...MA 1 UL Type 1 Frame D Esc Sel 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 ø21 5 ø0 85 ø33 5 ø1 32 Dimensions are in millimeters and inches IP 30 NEMA 1 UL Type 1 conduit box IP 30 NEMA 1 UL Type 1 top panel ...

Page 194: ... Type 1 Frame E Esc Sel 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 ø21 5 ø0 85 ø43 7 ø1 72 Dimensions are in millimeters and inches IP 30 NEMA 1 UL Type 1 conduit box IP 30 NEMA 1 UL Type 1 top panel ...

Page 195: ...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 Filter can be mounted onto the back of the drive ø5 5 ø0 22 87 0 3 43 58 0 2 28 270 0 10 63 58 0 2 28 5 5 0 22 258 0 10 16 258 0 10 16 24 0 0 94 25 0 0 98 35 0 1 38 70 0 2 76 Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive ...

Page 196: ...8 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 Filter can be mounted onto the back of the drive ø5 5 ø0 22 80 0 3 15 130 0 5 12 90 0 3 54 33 0 1 30 33 0 1 30 28 0 1 10 28 0 1 10 298 0 11 73 298 0 11 73 310 0 12 20 90 0 3 54 5 5 0 22 Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive ...

Page 197: ...0 Series Mounting Adapter Plate Dimensions 80 0 3 15 28 0 1 10 155 0 6 10 110 0 4 33 110 0 4 33 33 0 1 30 28 0 1 10 33 0 1 30 375 0 14 76 375 0 14 76 390 0 15 35 ø5 5 ø0 22 5 5 0 22 Dimensions are in millimeters and inches Dimensions are in millimeters and inches Frame A 25 MAP FA Frame B 25 MAP FB 80 0 3 15 39 2 1 54 20 2 0 80 198 0 7 80 92 0 3 62 39 2 1 54 20 2 0 80 240 0 9 45 ...

Page 198: ...Frame A Adapter Plate Frame B Dimensions are in millimeters and inches 80 0 3 15 164 0 6 46 139 5 5 49 67 0 2 64 12 0 0 47 80 0 3 15 60 0 2 36 248 0 9 76 207 5 8 17 10 6 0 42 Frame A 25 AP0 FA Frame A 25 AP1 FA Dimensions are in millimeters and inches 100 0 3 94 87 0 3 43 192 0 7 56 167 5 6 59 12 0 0 47 100 0 3 94 78 0 3 07 270 0 10 63 216 0 8 50 10 6 0 42 Frame B 25 AP0 FB Frame B 25 AP1 FB ...

Page 199: ...C Adapter Plate Frame D Dimensions are in millimeters and inches Frame C 25 AP0 FC Frame C 25 AP1 FC 130 0 5 12 116 0 4 57 260 0 10 24 245 5 9 67 9 4 0 37 130 0 5 12 90 0 3 54 296 5 11 67 309 0 12 17 10 6 0 42 Dimensions are in millimeters and inches Frame D 25 AP0 FD 130 0 5 12 116 0 4 57 272 0 10 71 245 5 9 67 11 0 0 43 ...

Page 200: ...dapter interface connector into the Control Module Make sure the indicator line on the connector is aligned with the surface of the Control Module 2 Align the connectors on the communication adapter to the communication adapter interface connector then push the back cover down Communication adapter interface connector For PowerFlex 523 For PowerFlex 525 Communication adapter interface connector ...

Page 201: ...ies and Dimensions 3 Press along the edges of the back cover until it snaps firmly into place 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 Communication adapter interface connector ...

Page 202: ...202 Rockwell Automation Publication 520 UM001K EN E August 2021 Appendix B Accessories and Dimensions Notes ...

Page 203: ...20 series drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode PowerFlex 520 Series Drive Network For information regarding EtherNet IP or other communication protocols refer to the appropriate user manual Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node Controller Esc Sel Esc Sel Esc Sel Esc Sel ATTENTION N...

Page 204: ...cable runs or if greater than 32 nodes are needed on the network Network wiring should be separated from power wires by at least 0 3 meters 1 foot Network wiring should only cross power wires at a right angle I O Terminal C1 RJ45 Shield for the Ethernet and DSI network cables on the PowerFlex 520 series drive must also be connected to PE ground there are two PE terminals on the drive The shield fo...

Page 205: ... same data rate page 100 C124 RS485 Node Addr Sets the node address for the drive on the network Each device on the network requires a unique node address page 100 C125 Comm Loss Action Selects the drive s response to communication problems page 100 C126 Comm Loss Time Sets the time that the drive will remain in communication loss before the drive implements C125 Comm Loss Action page 100 C127 Com...

Page 206: ... 11 No Command 6 1 Force Keypad Control 0 Not Force Keypad Control 7 1 MOP Increment 0 Not Increment 9 8 00 No Command 01 Accel Rate 1 Enable 10 Accel Rate 2 Enable 11 Hold Accel Rate Selected 11 10 00 No Command 01 Decel Rate 1 Enable 10 Decel Rate 2 Enable 11 Hold Decel Rate Selected 14 13 12 000 No Command 001 Freq Source P047 Speed Reference1 010 Freq Source P049 Speed Reference2 011 Freq Sour...

Page 207: ... Start 2 1 Jog 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 5 4 00 No Command 01 Forward Command 10 Reverse Command 11 No Command 6 1 Logic In 1 7 1 Logic In 2 10 9 8 000 Freq and Position Step 0 001 Freq and Position Step 1 010 Freq and Position Step 2 011 Freq and Position Step 3 100 Freq and Position Step 4 101 Freq and Position Step 5 110 Freq and Position Step 6 111 Freq and Position Step 7 1...

Page 208: ...Faulted 8 1 At Reference 0 Not At Reference 9 1 Main Freq Controlled by Active Comm 10 1 Operation Cmd Controlled by Active Comm 11 1 Parameters have been locked 12 Digital Input 1 Status DigIn TermBlk 05 13 Digital Input 2 Status DigIn TermBlk 06 14 Digital Input 3 Status DigIn TermBlk 07 15 Digital Input 4 Status DigIn TermBlk 08 Position Bit Definitions Comm Logic Status C122 1 Position Address...

Page 209: ...o Ground Short 39 Phase V to Ground Short 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short 48 Parameters Defaulted 59 Safety Open 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 71 DSI Network Loss 72 Option Card Network Loss 73 Embedded EtherNet IP Adapter Network Loss 80 AutoTune Fail 81 DSI Communication Loss 82 Option Card Communication Loss 83 Embe...

Page 210: ...access drive parameters the Modbus register address equals the parameter number For example a decimal 1 is used to address Parameter b001 Output Freq and decimal 41 is used to address Parameter P041 Accel Time 1 Additional Information See https www ab com drives for additional information Drive Operational Values Reference Address Decimal Description 2102H 8450 Frequency Command xxx xx Hz 2103H 84...

Page 211: ...l inputs can be programmed as Logic In 1 and or Logic In 2 A digital output can be programmed to change state based on the condition of one or both inputs based on basic logic functions such as AND OR NOR The basic logic functions can be used with or without StepLogic Timer Function A digital input can be programmed for Timer Start A digital output can be programmed as a Timer Out with an output l...

Page 212: ...nd transition to the next step when the corresponding StepLogic time has expired Step 7 is followed by Step 0 Sequence repeats until a stop is issued or a fault condition occurs Velocity StepLogic Using Basic Logic Functions Digital input and digital output parameters can be configured to use logic to transition to the next step Logic In 1 and Logic In 2 are defined by programming parameters t062 ...

Page 213: ...d indicate when the level is reached Level parameters t077 Relay Out1 Level t082 Relay Out2 Level t070 Opto Out1 Level and t073 Opto Out2 Level are used to set the desired time in seconds Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out1 Sel and t072 Opto Out2 Sel are set to 25 Timer Out and causes the output to change state when the preset level is reached Example Drive starts up ...

Page 214: ... xx set to 20 Counter In and 22 Reset Countr Digital outputs relay and opto type define a preset level and indicate when the level is reached Level parameters t077 Relay Out1 Level t082 Relay Out2 Level t070 Opto Out1 Level and t073 Opto Out2 Level are used to set the desired count value Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out1 Sel and t072 Opto Out2 Sel are set to 26 Coun...

Page 215: ... Coast to Stop A End Program and Fault F002 Digit 2 Defines what logic must be met to jump to a step other than the very next step Setting Description Logic 0 Skip Step jump immediately SKIP 1 Step based on the time programmed in the respective Stp Logic Time x parameter TIMED 2 Step if Logic In 1 is active logically true TRUE 3 Step if Logic In 2 is active logically true TRUE 4 Step if Logic In 1...

Page 216: ...tep if Logic In 2 is not active logically false FALSE 6 Step if either Logic In 1 or Logic In 2 is active logically true OR 7 Step if both Logic In 1 and Logic In 2 is active logically true AND 8 Step if neither Logic In 1 or Logic In 2 is active logically true NOR 9 Step if Logic In 1 is active logically true and Logic In 2 is not active logically false XOR A Step if Logic In 2 is active logicall...

Page 217: ...er 2 If not enabled by the Speed Reference parameters the encoder or pulse train can be used with the PID function if enabled by A459 or A471 PID x Ref Sel or A460 or A472 PID x Fdback Sel 3 If not enabled by the Speed Reference or PID function parameters the encoder or pulse train can be used with A535 Motor Fdbk Type for direct feedback and trim of the speed command The normal slip compensation ...

Page 218: ...nput A Encoder A Output DIP switch selects 12 or 5 volt power supplied at terminals V and Cm for the encoder HTL TTL DIP switches Set the position of the DIP switches based on the type of encoder signal used You must set all switches to the same position Encoder Wiring Examples I O Connection Example I O Connection Example Encoder Power Internal Drive Power Internal drive 12V DC 250 mA Encoder Pow...

Page 219: ...or 2 pole pair with a base speed of 60 Hz Therefore select 8333 PPR or higher for the quadrature encoder to achieve the desired speed resolution of 0 06 Hz Example 2 To determine the speed resolution using a 1024 PPR quadrature incremental encoder on a 4 pole 2 pole pair motor IMPORTANT A quadrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forwar...

Page 220: ... option 4 A535 Motor Fdbk Type Options 0 None indicates no encoder is used This can not be used for positioning 1 Pulse Train is a single channel input no direction speed feedback only This should not be used for positioning The Single Channel selection is similar to a Pulse Train but uses the standard encoder scaling parameters 2 Single Chan is a single channel input no direction speed feedback o...

Page 221: ...or example if 1 cm of travel on a conveyor belt requires 0 75 turns of the motor the motor encoder is 1024 PPR and the Motor Feedback type is set to Quadrature then this parameter would need to be set to 4 x 1024 x 0 75 3072 counts for 1 cm of travel Then all other positions could be setup in units of cm A564 Encoder Pos Tol indicates the desired position tolerance for the system This will determi...

Page 222: ...2 was selected This allows a process to be stopped and then restarted at the position where it stopped In all position modes the following parameters will control the characteristics at each step L200 L202 L204 L206 L208 L210 L212 and L214 Step Units x are the number value to the left of the decimal whole number of the 8 positions desired for an application beginning with Step 0 L200 and continuin...

Page 223: ...available settings for each digit 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 L214 Step Units 7 IMPORTANT The default value for A410 Preset Freq 0 is 0 00 Hz This value needs to be changed or the drive will not be able to move during Step 0 Frequency Source Step Source Position Source Logic for next...

Page 224: ...un command a jog command Positioning Settings Digit 4 Required Setting Accel Decel Param Used StepLogic Output State Direction From Home Type of Command 0 Accel Decel 1 Off FWD Absolute 1 Accel Decel 1 Off FWD Incremental 2 Accel Decel 1 Off REV Absolute 3 Accel Decel 1 Off REV Incremental 4 Accel Decel 1 On FWD Absolute 5 Accel Decel 1 On FWD Incremental 6 Accel Decel 1 On REV Absolute 7 Accel De...

Page 225: ... is activated If the drive passes this 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 and or Home Limit bits in A560 Enh Control Word can be activated instead of utilizing a digital input The inputs or bits sho...

Page 226: ...drive has been homed since power up This bit will be active once the drive has been homed either manually or automatically It will remain active until the next power down 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 paramete...

Page 227: ...c In 2 provides an identical function and is logically ORed with setting 25 Logic In 2 for t062 t063 t065 t068 DigIn TermBlk xx It can be used to move through the StepLogic functions speed or 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...

Page 228: ...228 Rockwell Automation Publication 520 UM001K EN E August 2021 Appendix E Encoder Pulse Train Usage and Position StepLogic Application Notes ...

Page 229: ...eed Reference becomes 0 and the PID Output becomes the entire Freq Command Exclusive Control is used when A458 or A470 PID x Trim Sel is set to option 0 This configuration does not require a master reference only a desired set point such as a flow rate for a pump Example In a pumping application the PID Reference equals the Desired System Pressure set point The Pressure Transducer signal provides ...

Page 230: ... the Equilibrium set point The Dancer Pot signal provides PID Feedback to the drive Fluctuations in tension result in a PID Error value The Master Speed Reference sets the wind unwind speed As tension increases or decreases during winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point Pump PID Feedback Pressure Transducer Signal PID Reference Desi...

Page 231: ...h a bipolar analog input It will ignore any negative voltages and treat them like a zero 6 4 20mA Input Selects the 4 20 mA Input 7 Preset Freq A410 A425 Preset Freq x will be used as an input for the PID Reference 8 AnlgIn Multi 1 1 Setting is specific to PowerFlex 525 drives only The product of the 0 10V and 4 20mA Inputs will be used as an input for the PID Reference 9 MOP Freq A427 MOP Freq wi...

Page 232: ...nput Invert Function For a 4 20 mA signal the following parameter settings are used so that a 20 mA signal 0 PID Reference and a 4 mA signal 100 PID Reference t095 Anlg In4 20mA Lo 100 0 t096 Anlg In4 20mA Hi 0 0 A459 PID 1 Ref Sel 6 4 20mA Input PID Deadband Parameters A465 and A477 PID x Deadband are used to set a range in percent of the PID Reference that the drive will ignore Example A465 PID ...

Page 233: ... error For example a proportional gain of 1 would output 100 of max frequency when the PID error is 100 of the analog input range A larger value for PID x Prop Gain makes the proportional component more responsive and a smaller value makes it less responsive Setting PID x Prop Gain to 0 00 disables the proportional component of the PID loop A462 and A474 PID x Integ Time The integral gain units of...

Page 234: ...PID x Prop Gain Typically A461 or A473 PID x Prop Gain is set to some value below the point where the PID begins to go unstable 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 234 or the PID Feedback does not become equal to the PID Reference decrease A462 or A474 PID x...

Page 235: ...ckwell Automation Publication 520 UM001K EN E August 2021 235 Appendix F PID Set Up Oscillation Under Damped Good Response Critically Damped PID Feedback PID Reference Time PID Feedback PID Reference Time ...

Page 236: ...236 Rockwell Automation Publication 520 UM001K EN E August 2021 Appendix F PID Set Up Notes ...

Page 237: ...ion defined in EN 61800 5 2 Blocks gate firing signals from reaching the Insulated Gate Bipolar Transistor IGBT output devices of the drive This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor Can be used in combination with other safety devices to fulfill the requirements of a system safe torque off function which satisfies Topic Page PowerFlex 525 Safe...

Page 238: ...fety related systems Parts 1 7 TÜV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3 PL d according to EN ISO 13849 1 and SIL 2 according to EN 62061 EN 61800 5 2 IEC 61508 The TÜV Rheinland certificate may be found at rok auto certifications EMC Instructions PowerFlex 525 Safe Torque Off function requires CE Conformity as described on page 51 IMPORTANT The fun...

Page 239: ...n is intended for use in safety related applications where the de energized state is considered to be the safe state All of the examples in this manual are based on achieving de energization as the safe state for typical Machine Safety and Emergency Shutdown ESD systems Important Safety Considerations The system user is responsible for the set up safety rating and validation of any sensors or actu...

Page 240: ...s from Part 6 of EN 61508 This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data Safety Reaction Time The safety reaction time is the amount of time from a safety related event as input to the system until the system is in the Safe State The safety reaction time from an input signal condition that triggers a sa...

Page 241: ...signations on page 42 for terminal descriptions If Safety Inputs S1 and S2 are powered by an external 24V source apply it only in SELV system PELV system or low voltage Class 2 circuit 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 r...

Page 242: ... fault F111 Safety Hardware will occur However if S1 is disable and S2 follows before the discrepancy time fault F059 Safety Open will occur The discrepancy time is one second for PowerFlex 525 FRN 5 xxx and later The discrepancy time is 10 milliseconds for PowerFlex 525 FRN 4 xxx and earlier IMPORTANT By itself the Safe Torque Off function initiates a coast to stop action Additional protective me...

Page 243: ...de these failure modes should be used 2 In some situations a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure Stop Start A1 S21 S11 S52 41 13 23 33 A2 24V DC common 24V DC S22 S14 S34 42 14 24 34 MSR GuardMaster Trojan Gate E Stop latching button 24V DC PF 525 Stop Start Gate control power supply Gate control circuit AC line input power S1 S2 M ...

Page 244: ...s 13 14 23 24 will cause the Safe Torque Off Enable circuit to trip and the motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety funct...

Page 245: ...ve and cause a controlled deceleration After the programmed delay the timed output circuits 47 48 57 58 will cause the Safe Torque Off Enable circuit to trip If the motor is rotating when the trip occurs it will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safe...

Page 246: ...notaur monitoring safety relay unit The output circuits 13 14 23 24 33 34 will cause the output contact and Safe Torque Off Enable circuit to trip and the motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out ...

Page 247: ...pter parameters when you want more flexibility in setting up the IP address or need to communicate outside the control network using a gateway The IP address subnet mask and gateway addresses will then come from the adapter parameters you set DHCP Dynamic Host Configuration Protocol only with PowerFlex 25 COMM E2P adapter Use DHCP when you want additional flexibility and ease of use compared to BO...

Page 248: ...a network with a ring topology PowerFlex 25 COMM E2P Dual Port EtherNet IP Adapter FWD ENET LINK EtherNet IP Esc Sel Terminal Description C1 This terminal is tied to the RJ 45 port shield Tie this terminal to a clean ground in order to improve noise immunity when using external communication peripherals C2 This is the signal common for the communication signals Terminals C1 C2 Terminal Description...

Page 249: ...ler Gain Freq Hz A515 Freq 3 BW A513 Freq 2 BW A511 Freq 1 BW Low Speed Control Mode Mid Speed Control Mode High Speed Control Mode A509 Speed Reg Sel 0 Gain set automatically A512 Freq 2 A514 Freq 3 A510 Freq 1 Speed Controller Gain A509 Speed Reg Sel 1 Gain set manually Freq Hz A525 Freq 3 Kp A526 Freq 3 Ki A523 Freq 2 Kp A524 Freq 2 Ki A521 Freq 1 Kp A522 Freq 1 Ki A510 Freq 1 A512 Freq 2 A514 ...

Page 250: ...5 Freq 3 BW 10 Hz Set Speed Controller Gain automatically A509 0 Automatic A509 1 Manual Set Speed Controller Gain manually A521 Freq 1 Kp A522 Freq 1 Ki A523 Freq 2 Kp A524 Freq 2 Ki A525 Freq 3 Kp A526 Freq 3 Ki Increase the bandwidth to obtain faster speed response If oscillation occurs decrease the bandwidth For general use set A509 Speed Reg Sel to 0 Automatic SetA509 SpeedRegSel For Freq x K...

Page 251: ... equipment used during this startup InnoeventwillRockwellAutomation Inc beresponsibleorliableforindirector consequentialdamagesresultingfromtheuseorapplicationofthisequipment Theexamplesanddiagramsinthisdocumentareincludedsolelyforillustrative purposes Because of the many variables and requirements associated with anyparticularinstallation RockwellAutomationcannotassumeresponsibility or liability ...

Page 252: ...1 Appendix J PowerFlex 525 PM Motor Configuration Motor Control From the Torq Perf Mode drop down list select PM Motor This configuration can also be done by setting parameter P039 Torq Perf Mode to 4 PM Motor Motor Data Key in the details of your Motor Nameplate ...

Page 253: ...loop PM motor control key in the details of your incremental encoder Stop Mode Brake Type Key in the details of your configuration IMPORTANT Note the following PowerFlex 525 drive only supports incremental AB encoder 25 ENC 1 Motor Feedback Type can be Quadrature or Quad Check Only Interior Permanent magnet motor iPM is supported for closed loop control ...

Page 254: ...Tune test Run the drive with P040 Autotune 2 Rotate Tune configured to complete the autotune process This process measures and configures the following A501 PM IR Voltage A502 PM IXd Voltage A503 PM IXq Voltage A504 PM BEMF Voltage The Auto Tune is used to identify the correct motor flux and stator electrical properties including the following IR volt drop which is voltage drop over resistance IXd...

Page 255: ... and can generate unnecessary faults such as overcurrent and overvoltage faults Static Tune This test is used when the motor is connected to a high friction load and cannot easily be uncoupled from the motor or when the load cannot be rotated due to mechanical constraints or a limited range of movement The Static Tune test does not generate any motor movement The Static tune test results may not b...

Page 256: ...drive keypad Make sure you have installed the PowerFlex 525 drive firmware revision 5 001 or later To configure the parameters do the following 1 Reset all parameters to their default values Set P053 Reset to Defalts 2 Factory Rset 2 Select the Control Mode Set P039 Torque Perf Mode 4 PM Control 3 Enter Motor nameplate data Set P031 Motor NP Volts Set P032 Motor NP Hertz Set P033 Motor OL Current ...

Page 257: ...en loop PM motor iPM and sPM control some parameters need to be adjusted to prevent reverse startup For a closed loop PM motor iPM an angle alignment procedure needs to be performed before the motor is run normally Additional Setup for Open Loop PM Motor After performing an autotune on an open loop PM motor a momentary reverse startup may occur To prevent this from occurring perform the following ...

Page 258: ...ltage A502 PM IXdVoltage A503 PM IXqVoltage A504 PM BEMFVoltage P031 Motor NPVolts P032 Motor NP Hertz P033 Motor OL Current P034 Motor NP FLA P035 Motor NP Poles P036 Motor NP RPM P037 Motor NP Power P043 Minimum Freq P044 Maximum Freq Set Autotune Reverse Startup Check Control Mode Selection Load Default Basic setting Set Motor Parameters Repeat steps 2 and 3 of AdditionalSetupfor OpenLoopPMMoto...

Page 259: ...Set the Start Source Check the setting for P046 Start Source 1 Start source can be from POT control panel of Connected Components Workbench software and so on 5 Start the drive to run at the desired speed 6 Drive will begin to align itself move forward and reverse and run to the desired speed 7 Stop the drive The drive is now aligned Adjustments if PM Angle Alignment has Failed If the PM angle ali...

Page 260: ...e A501 PM IRVoltage A502 PM IXdVoltage A503 PM IXqVoltage A504 PM BEMFVoltage P031 Motor NPVolts P032 Motor NP Hertz P033 Motor OL Current P034 Motor NP FLA P035 Motor NP Poles P036 Motor NP RPM P037 Motor NP Power P043 Minimum Freq P044 Maximum Freq Set Autotune Set Alignment Control Mode Selection Load Default Basic setting Set Motor Parameters See AdjustmentsifPMAngle AlignmenthasFailed Yes No ...

Page 261: ... F012 HW Overcurrent or F013 Ground Fault is observed during acceleration and deceleration Default 0 7 s Increase A518 PM Align Time to 4 7 s 3 A527 PM FWKn 1 Kp The gain to ensure good performance in field weakening region Default 450 Increase 100 of A527 PM FWKn 1Kp for each trial when PM speed response is slow after adding load Decrease 100 of A527 PM FWKn 1Kp for each trial when speed vibratio...

Page 262: ...262 Rockwell Automation Publication 520 UM001K EN E August 2021 Appendix J PowerFlex 525 PM Motor Configuration Notes ...

Page 263: ...firmware revision 7 001 SynRM control can only be configured manually using the keypad Topic Page SynRM Structure 263 SynRM Control Configuration 264 Speed Theta estimated Speed Reference Keyboard 2 wire digital P1 Regulator Speedcmd Currentcmd P1 Regulator Speed Loop Current Loop Voltageout abc dq Currentfeedback dq abc Motor A510 Freq 1 A511 Freq 1 BW A512 Freq 2 A513 Freq 2 BW A514 Freq 3 A515 ...

Page 264: ...motor auto tuning successful Check the following motor parameters A501 PM IR Voltage A502 PM IXd Voltage A503 PM IXq Voltage A504 PM BEMF Voltage Start Set the motor parameters setting Rated Voltage P031 Motor NP Volts Rated Frequency P032 Motor NP Hertz OL Current P033 Motor OL Current Rated Current P034 Motor NP FLA Pole Numbers P034 Motor NP Poles Rated RPM P036 Motor NP RMP Rated Power P037 Mo...

Page 265: ... A595 SYNRM Freq2 BW 3 Adjust A596 SYNRM Freq2 Kp Is the speed stable and does not oscillate before A590 SYNRM SW Freq No Load Test Motor starts running Load operation test Yes No 1 The start up direction is wrong and causes F013 fault 2 Motor stalls 3 Motor speed vibrates extremely Increase A591 SYNRM Flux Cur Adjust A593 SYNRM Freq1 Kp When the frequency operation exceeds A590 SYNRM SW Freq is t...

Page 266: ... Bandwidth 2 Adjust the A593 SYNRM Freq1 Kp Transient load If the speed drops drastically increase the setting to improve the response Steady state load If there is extreme frequency vibration decrease the setting Did the high frequency loading performance meet the request No Insufficient high frequency loading performance 1 When the motor increases the load at low frequency the speed drop is too ...

Page 267: ...14 D decel override priority 50 selecting 49 derating factor 124 temperature 17 digital inputs selecting 49 start source 49 dimensions mounting 16 184 disconnect output 34 drive auxiliary contact 34 35 basic operation 58 63 162 common bus 35 mount 15 programming 59 62 safety 242 drive damage preventing 19 ungrounded distribution systems 19 E encoder programming 217 wiring 219 environment storage 1...

Page 268: ...rnet 247 homing 224 parameters 61 65 PID 231 positioning 220 221 pulse train 217 timed steps 211 212 timer 211 213 tools 62 pulse train programming 217 R rating fuses 22 ratings circuit breakers 23 reading Modbus 208 209 210 recommended wiring 36 241 reflected wave protection 34 RFI filter ground 22 RS485 DSI configuring 205 S safety applications 239 basic operation 242 drive 242 ground 21 testing...

Page 269: ...ndex U unshielded wiring 33 V voltage reflections wiring 34 W wave protection reflected 34 wiring encoder 219 noise immunity 37 204 recommended 36 241 RS485 DSI 203 safety 241 shielded 33 temperature 32 unshielded 33 voltage reflections 34 writing Modbus 205 207 210 ...

Page 270: ...270 Rockwell Automation Publication 520 UM001K EN E August 2021 Index Notes ...

Page 271: ...Rockwell Automation Publication 520 UM001K EN E August 2021 271 PowerFlex 520 Series Adjustable Frequency AC Drive User Manual ...

Page 272: ...onesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and access product release notes rok auto pcdc At the end of life this equipment should be collected separately from any unsorted municipal waste Rockwell Otomasyo...

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