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

121

Chapter

7

Troubleshooting

This chapter provides troubleshooting tables and related information for your
PowerFlex® 527 drive.

Safety Precautions

Observe the following safety precautions when troubleshooting your
PowerFlex 527 drive.

Interpret Status Indicators

Refer to these troubleshooting tables to identify faults, potential causes, and the
appropriate actions to resolve the fault. If the fault persists after attempting to
troubleshoot the system, please contact your Rockwell Automation sales
representative for further assistance.

Display Interface

The LCD display provides fault messages and troubleshooting information by
using the soft menu items and navigation buttons. See

Understanding the

PowerFlex 527 Display and Indicators on page 44

for more information.

For information on...

See page...

Safety Precautions

Interpret Status Indicators

General Troubleshooting

Logix5000 Controller and Drive Behavior

ATTENTION:

Capacitors on the DC bus can retain hazardous voltages after input

power has been removed. Before working on the drive, measure the DC bus
voltage to verify it has reached less than 50V DC, or wait three minutes. Failure
to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:

Do not attempt to defeat or override the drive fault circuits. You

must determine the cause of a fault and correct it before you attempt to operate
the system. Failure to correct the fault could result in personal injury and/or
damage to equipment as a result of uncontrolled machine operation.

ATTENTION:

Provide an earth ground for test equipment (oscilloscope) used in

troubleshooting. Failure to ground the test equipment could result in personal
injury.

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Содержание PowerFlex 527

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 27: ...tallation Wiring Chapter 1 2 Push the top cover of the Control Module towards the Power Module to lock it 3 Insert the catch at the top of the frame cover into the Power Module then swing the frame co...

Страница 28: ...s and hold down the arrow on the front of the cover 2 Slide the front cover down to remove from the Control Module Re attach the front cover when wiring is complete Power Module Terminal Guard To acce...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 175: ......

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

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