Home

PowerFlex 520-Series Adjustable Frequency AC Drive

1. 8 i Sa P Sx les T u 1 Controle JC OLE For information regarding EtherNet IP or other communication protocols refer to the appropriate user manual Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node ATTENTION Never attempt to connect a Power over Ethernet PoE cable to the RS485 port Doing so may damage the circuitry Network Wiring Diagram Example PowerFlex525 PowerFlex523 PowerFlex 525 Master Node 1 Node 2 Node n TxRxD DRD 4 DI 4 120 ohm resistor FRONT 120 ohm resistor iti ae e D I e D I Shield Y me y mi y BNT ONS aa aa RS485 RS485 DSI DSI AK U0 RJ45 182P__ L LU TxRxD TxRxD TRD O S TRD OS Wu 11 S 2 WLIW WIT DC DC BR DC DC e BR BR IMPORTANT The shield is connected at ONLY ONE end of each cable segment Rockwell Automation Publication 520 UM001D EN E September 2013 189 AppendixC RS485 DSI Protocol Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 520 series drive s RJ45 socket must not be connected because they contain power etc for other Rockwell Automation peripheral devices Wir
2. Output Current A Total Watts Loss 1 6 20 0 2 5 27 0 4 8 53 0 6 0 67 0 1 6 20 0 2 5 29 0 4 8 50 0 8 0 81 0 11 0 111 0 1 6 20 0 2 5 29 0 4 8 53 0 8 0 84 0 11 0 116 0 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 1 4 27 0 23 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 Rockwell Automation Publication 520 UM001D EN E September 2013 161 AppendixA Supplemental Drive Information PowerFlex 520 Series Estimated Watts Loss Rated Load Speed amp PWM Voltage Output Current A Total Watts Loss 380 480V 14 27 0 e 0 4 0 63 0 6 0 88 0 10 5 133 0 13 0 175 0 17 0 230 0 24 0 313 0 30 0 402 0 37 0 602 0 43 0 697 0 525 600V 0 9 22 0 50 60 Hz 3 Phase 17 320 3 0 50 0 42 65 0 6 6 95 0 9 9 138 0 12 0 164 0 19 0 290 0 22 0 336 0 27 0 466 0 32 0 562 0 162 Rockwell Automation Publication 520 UM001D EN E September 2013 Product Selection Accessories and Dimensions Catalog Number Description 25B v 5 N j 0o 4 De Wee Ex Erdos W PowerFlex 523 Drive Ratings Emission Class Output Ratings Heavy Duty Output Input Frame Catalog No HP kW Current A Voltage Range Size 100
3. fe X 50 mm 50 mm 2 0 in 25 mm 2 0 in w PT 1 0 in a r le C e r le CA e l Ee ee BBDDBBBBBDBH MOO 50mm 2 0in Vol Vol TITI v op E gt pa E gt 25mm E D Ge Wl Dm I SCH E 50mm 2 0 in e s _ SS Horizontal with Control Module Fan Kit Horizontal Zero Stacking with Control Module Fan Kit No clearance between drives 1 For Frame E with Control Module Fan Kit only clearance of 95 mm 3 7 in is required 2 For Frame E with Control Module Fan Kit only clearance of 12 mm 0 5 in is required 16 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 Ambient Operating Temperatures See Appendix B for option kits Mounting Enclosure Rating y Ambient Temperature Mini
4. Basic Program Group P030 Language Language Support Selects the language displayed A reset or power cycle is required after selection is made Keypad RSLogix 5000 Connected LCD Display Logix Designer Components Workbench Options 1 English Default Y Y Y 2 Francais Y Y Y 3 Espa ol Y Y Y 4 ltaliano Y Y Y 5 Deutsch Y Y Y 6 Japanese _ Y _ 7 Portugu s Y Y 8 Chinese Chinese Simplified Y Y 9 Reserved 10 Reserved 11 Korean _ Y _ 12 Polish D 13 Reserved 14 Turkish Y 15 Czech Y 1 Due to a limitation of the LCD Display some of the characters for Polish Turkish and Czech will be modified P031 Motor NP Volts Related Parameter s b004 A530 A531 A532 A533 O Ray 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 so drive before changing this parameter Sets the motor nameplate rated frequency Values Default 60 Hz Min Max 15 500 Hz Display 1Hz P033 Motor OL Current Related Parameter s t069 t072 t076 t081 A484 A485 A493 Sets the motor nameplate overload current Used to determine motor overload conditions and can be set from 0 1 A to 200 of drive rated current IMPORTANT The drive will fault on an F007
5. nilaitaltefltel LILA LALALA 1 Closed State 0 Open State Digln TBIk 1 Digit 1 Digln TBIk 2 Digit 2 Digln TBIk 3 Digit 3 DB Trans On Digit 4 Not Used 1 The DB Transistor on indication must have a 0 5 s hysteresis It will turn on and stay on for at least 0 5 s every time the DB transistor is turned on Values Default Read Only Min Max 0000 1111 Display 0000 b014 Dig In Status Related Parameter s t065 t068 State of the programmable digital inputs Ca 1 Closed State 0 Open State DigIn TBIk 5 Digit 1 Digin TBIk 6 Digit 2 Digin TBIk 7 Digit 3 Digin TBIk 8 Digit4 Not Used 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0000 1111 Display 0000 b015 Output RPM Related Parameter s P035 Current output frequency in rpm Scale is based on P035 Motor NP Poles Values Default Read Only Min Max 0 24000 rpm Display 1rpm 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 amp T3 U V amp W Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW Rockwell Aut
6. Step Key s Example Displays 1 Press the Up Arrow or Down Arrow to scroll to a Lei e the CustomView group GC af CED Ee gg ZILIN 2 Press Enter to view the parameters that can be added to the CustomView group FD r i l lt 3 Press the Up Arrow or Down Arrow to scroll A rT Ar through the list of parameters S v DI tT LUC 4 Press Enter to add the parameter to the CustomView group The LCD display will show a d W y confirmation To delete parameters from the CustomView parameter group Step Key s Example Displays 1 Press the Up Arrow or Down Arrow to scroll to Se ren aba the CustomView group GC S y A ULC Dages 2 Press Enter to view the parameters that are in N L the ustomView group aol TIT lt LL UL 3 Press the Up Arrow or Down Arrow to scroll to _ Ne 2 the command GC C4 gt Z v Pe ie Serie gt LIL vas 4 Press Enter or Sel to view the parameters that mma are stored in the CustomView group Mise as LILIC 5 Press the Up Arrow or Down Arrow to scroll N14 through the list of parameters S gt w ee PITTI LILIL PROGRAMA 6 Press Enter to delete the parameter from the CustomView group The LCD display will show a tt W W confirmation lt H TIP The Connected Components Workbench software can be used to speed up this process with drag and drop functionality Rockwell Automation Publication 520 UM001D EN E September 2013 141
7. 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 Rockwell Automation Publication 520 UM001D EN E September 2013 177 AppendixB Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame A Dimensions are in millimeters and inches a 72 0 2 83 S IP 30 NEMA 1 UL Type 1 top panel m 57 5 2 26 2 172 0 6 77 50000000 a fi O C gt Q C C gt S MI 5 0 IT c D D o C C 2 Ger N C P gt f 3 E 3 c 5 2 c Q d 7 N C C LO Ze Lee a in ei SI Eet a PowerFlex CG o nnnnnnnnn s i gt ai 6 0 0 24 li wd a di 51 1 2 01 IP 30 NEMA 1 UL Type 1 conduit box 21 0 0 82 21 5 60 85 FT Z Wi E at m 20 O aD s I m s TI T N ES UN d SD 4 4 Ke i 178 Rockwell Automation Pu
8. Rockwell Automation Publication 520 UM001D EN E September 2013 175 Appendix B 176 Accessories and Dimensions Control Module Fan Kit Dimensions are in millimeters and inches Frame A m 72 0 2 83 m 57 5 2 26 IMPORTANT Specifications 25 FAN1 70C 25 FAN2 70C Rated Voltage 24V DC Operation Voltage 14 27 6V DC Input Current 0 1A 0 15A Speed Reference 7000 rpm 4500 10 rpm Maximum Air Flow At zero static pressure 0 575 m3 min 1 574 m min Maximum Air Pressure At zero air flow 7 70 mmH 0 9 598 mmH 0 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 mm 22 AWG Torque 0 29 0 39 Nm 2 6 3 47 lb in IP 20 0pen Type with Control Module Fan Kit Frame A C Frame B Frame C s 8 g gt 87 0 3 43 g 109 0 4 29 o m 72 5 2 85 A 90 5 3 56 q E D QON e FALTO 3 2 m Sa
9. Gate control I circuit i 1 Enclosure Recommended Note External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used 2 Each safety input draws 6 mA from the supply Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S13 S14 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 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 function A single fault detected on the PowerFlex 525 safety enable redundant inputs will result in the lock out of the drive and will not cause loss of the safety function 230 Rockwell Automation Publication 520 UM001D EN E September 2013 Safe Torque Off Function Appendix G Example 2 Safe Torque 0ff Connection with Controlled Stop Action SIL 2
10. dek Example a a Source Digit Display reads Description 2 Digln TrmBlk Parameters t062 1063 t065 t068 2004 Start source comes from Network Opt and Frequency source is Purge Fs UPSI 113 Start source comes from Serial DSI and Frequency source comes from PID1 Output 5 GH 155 Start source and Frequency source comes from EtherNet IP Frequency Command Source Digit2 amp 3 ei Start source comes from Digln TrmBlk and Frequency source from 0 10V Input 01 ety 011 Start source comes from Keypad and Frequency source comes from Drive Pot 03 Serial DS 04 Network Opt 05 0 10V Hee 06 4 20mA Input 07 Preset Freq Parameters A410 A425 08 Anlg In Mult 09 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 13 Step Logi Parameters 1180 1187 14 Encoder 15 Deep 16 Positioning Frequency ommand Source Digit 4 S Other Digit 2 amp 3 are used Digit 4 is not shown 2 Purge Not Used 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0000 2165 Display 0000 76 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Basic Display Group continued b013 Contri In Status Related Parameter s b002 P044 P045 State of the digital terminal blocks 1 3 and DB transistor IMPORTANT Actual control commands may come from a source other than the control terminal block
11. A545 Flying Start En Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM Options 0 Disabled Default 1 Enabled Catch and ramp to commanded speed at every drive start 126 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A546 FlyStrt CurLimit Used to determine when the drive has matched the motor frequency if flying start is enabled Values Default 150 Min Max 30 200 Display 1 A547 Compensation Enables disables correction options that may improve problems with motor instability Options 0 Disabled No compensation 1 Electrical Default Some drive motor combinations have inherent instabilities which are exhibited as non sinusodial motor currents This setting attempts to correct this condition 2 Mechanical Some motor load combinations have mechanical resonances which can be excited by the drive current regulator This setting slows down the current regulator response and attempts to correct this condition 3 Both A548 Power Loss Mode Sets the reaction to a loss of input power Options 0 Coast Default 1 Decel Drive faults and motor coasts to a stop Drive decelerates and attempts to keep the DC bus voltage above the undervoltage level A549 Half Bus Enable Enables disabl
12. t077 Relay Out Level 20 0 Secs A411 Preset Freq 1 30 0 Hz e The control terminal block is wired such that a start command will also trigger the timer start e The relay output is wired to I O Terminal 02 DigIn TermBlk 02 so that it forces the input on when the timer starts sa aT oO FH e After the timer is complete the output is turned off releasing the preset speed command The drive defaults to following the analog input reference as programmed Note that a Reset Timer input is not required for this example since the Timer Start input both clears and starts the timer Counter Function Digital inputs and outputs control the counter function and are configured with parameters t062 t063 t065 t068 DigIn TermBlk 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 Our Level t082 Relay Out2 Level t070 Opto Our Level and t073 Opto Our Level are used to set the desired count value Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out Sel and t072 Opto Out2 Sel are set to 26 Counter Out which causes the output to change state when the level is reached Example e A photo eye is used to count packages on a conveyor line e An accumulator holds the packages until 5 are collected e A diverter arm redirects the group of 5 packages
13. IMPORTANT Value for t077 or t082 Relay Outx Level must be entered in percent of drive rated output current 8 Above DCVolt Drive exceeds the DC bus voltage value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 9 Retries Exst Value set in A541 Auto Rstrt Tries is exceeded None 10 Above Anlg V Analog input voltage 0 10V input exceeds the value set in t077 or t082 Relay Outx Level IMPORTANT De not use if t093 10V Bipolar Enbl is set to 1 Bi Polar In 100 ms time delay on or off 11 Above PF Ang Power Factor angle exceeds the value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 12 Anlg In Loss Analog input loss has occurred Program t094 Anlg In V Loss or t097 Anlg In mA Loss for desired action when On 2mA 1V input loss occurs Off 3 mA 1 5V 13 ParamControl Output will be directly controlled by the state of the t077 or t082 Relay 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 e Value set in A541 Auto Rstrt Tries is exceeded or None e A541 Auto Rstrt Tries is not enabled or Anon resettable fault has occurred 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 Relay energizes w
14. Pulse Input Encoder EtherNet 1P O Ei Q N 1 Setting is specific to PowerFlex 525 drives only A461 PID 1 Prop Gain Related Parameter s A459 A471 A473 PID 2 Prop Gain PF 525 PowerFlex 525 only Sets the value for the PID proportional component when the PID mode is enabled Values Default 0 01 Min Max 0 00 99 99 Display 0 01 Rockwell Automation Publication 520 UM001D EN E September 2013 117 Chapter3 Programming and Parameters Advanced Program Group continued A462 PID 1 Integ Time Related Parameter s A459 A471 A474 PID 2 Integ Time PowerFlex 525 only Sets the value for the PID integral component when PID mode is enabled Values Default 2 05 Min Max 0 0 999 9 s Display 0 15 A463 PID 1 Diff Rate Related Parameter s A459 A471 A475 PID 2 Diff Rate PF 525 PowerFlex 525 only Sets the value in 1 second for the PID differential component when PID mode is enabled Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A464 PID 1 Setpoint Related Parameter s A459 A471 A476 PID 2 Setpoint PF 525 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 A465 PID 1 Deadband A477 PID 2 Deadband PF 525 PowerFlex 525 only Sets the lower
15. SHHSSWID 912 40O WOPL SL9 2090 NObL 713 001 V LOL g sv SCH OL PLLN8drV VSO 9L F2I WOVL SL TA9A NOY L SZ 4 S10 140 T yu SSD 9L IO WOPL s1D 90 n0t1 719 001 Y LOL g sv SCH DL POLN8drV VSO OL 32 WOVL OLD 7090 NOL SL 4 S10 L10 T oU SSY OLD 3ZI WOrL 0L Z090 NOY L 609 001 V SO Ll GC v0 0 YLLNSdZV YSZ 0L9 JZ WOvL OL9 7090 NOVL SL 4 S10 L10 TDD SAY SSY OLD IZ WOPL OLD 7d9C NOvL 609 001 V G9 Ll SC v0 SO vOLNSd7V VSZ 99 JZ WOvL 0S9 2090 NOFL SL Y S10 L10 T SAY SSY 9gq 3 O WOPLI 0S8 2090 NOrL 409 001 V ES rl 9l TOJ SCO YLLN9dLY YSZ E99 IO W0YL 0S9 Z090 NOYL SL Y S10 110 T J yu SSY E99 IO W0YL 0S9 7090 N0Y L 09 001 V kl OL 70 SCH POLIN9dlIV VSZ tex W0FL Nov ON Bojeyey sser NOvL une xew Guney um on 5olele suy ul sdwy Wi dH oN boeze siayearg HUM Buney xew sasn4 s1ayeaig UN sasny 202340 xew Ayng Aneay suonerjddy 19 suone3iddvy 1N U0N J31 suey ynduy sbuneu yndyno JY SAWDIy SIAI U01 22101J jnduj asDUd 1 40577 OOZ S7 J84 WOrL 0 2090 NOFL 0S U S10 L10 SHUSSYTD S7 3B4 WOPL 0 7090 NOrL 7 00L DH TE 09 NI SL POLNOd9A WSZ 07 J8d WOrL Z 2090 NOFL Op u S1Q L10 TJ SAY ee D 073 380 W0vL 7 2090 NOrL 7 00L C GC 8 SCH OL POLNSdrA WSZ 0L JZ WOrL Z19 2990 NOvL 0Z 4 S10 L10 f D SAY SSY OLD 4IZI WOPL 1 D 090 n0tl 7L 001 96 el ST v0 SO POLNSdZA VSZ 99 37 WOrL 089 2090 NO
16. 01 Forward Command 10 Reverse Command 11 No Command 6 1 Force Keypad Control 0 Not Force Keypad Control d 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 Source P051 Speed Reference3 100 A410 Preset Freq 0 101 A411 Preset Freq 1 110 A412 Preset Freq 2 111 A413 Preset Freq 3 15 1 MOP Decrement 0 Not Decrement 192 Rockwell Automation Publication 520 UM001D EN E September 2013 Writing 06 Comm Frequency Command Reading 03 Logic Status Data RS485 DSI Protocol Appendix C Position Bit Definitions Comm Logic Command 122 1 Position Address Decimal Bit s Description 2000H 8192 0 1 Stop 0 Not Stop 1 1 Start 0 Not 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 LogicIn 1 7 1 Logic In 2 10 9 8 000 Freq and Position Step 0 001 Freq and Position Step 1 010 Freq and Po
17. EEN e ele e O O 275 0 10 83 263 0 263 0 10 35 10 35 Q Li L2 L3 J 7 aa ae fuo 25 0 0 98 28 0 1 10 5 5 0 22 76 0 2 99 EMC Line Filter Frame D Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive 80 0 3 15 130 0 5 12 33 0 1 30 28 0 1 10 90 0 3 54 05 5 00 22 Q i ers ep T n ea 310 0 12 20 298 0 298 0 11 73 11 73 Li 2151 A PT T 33 0 130 28 0 1 10 IER 0 22 90 0 3 54 Rockwell Automation Publication 520 UM001D EN E September 2013 EMC Line Filter Frame E Dimensions are in millimeters and inches 80 0 3 15 33 0 1 30 28 0 1 10 l 375 0 14 76 33 0 1 30 58 0 1 10 Accessories and Dimensions Appendix B 155 0 6 10 110 0 4 33 5 5 00 22 390 0 15 35 375 0 14 76 5 5 0 22 110 0 4 33 Rockwell Automation Publication 520 UM001D EN E September 2013 185 AppendixB Accessories and Dimensions Optional Accessories and Kits Installing a Communication Adapter 1 Insert the communication
18. 1 2400 4800 0600 Default 19 200 38 400 nl wl FA 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 Action Related Parameter s P045 Sets the drive s response to a loss of connection or excessive communication errors on the RS485 port Options 0 Fault Default 1 Coast Stop Stops drive using Coast to stop 2 Stop Stops drive using P045 Stop Mode setting 3 Continu Last Drive continues operating at communication commanded speed saved in RAM C126 Comm Loss Time Related Parameter s 125 Sets the time that the drive remains in communication loss with the RS485 port before taking the action specified in C125 Comm Loss Action See Appendix C for more information IMPORTANT This setting is effective only if 1 0 that controls the drive is transmitted through the RS485 port Values Default 5 05 Min Max 0 1 60 0s Display 0 15 Rockwell Automation Publication 520 UM001D EN E September 2013 97 Chapter3 Programming and Parameters Communications Group continued C127 RS485 Format Determines the details related to the specific Modbus protocol used by the drive A reset or power cycle is required after selec
19. F S2 S 11 12 13 14 15 16 7 18 19 Control 1 0 Wiring Block Diagram Notes 1 See Digital Input Selection for Start Source on page 50 for more information on configuring the digital inputs IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting See the tables below for more information P046 P048 P050 Start Source x Normal Stop 1 U0 Terminal 01 Stop 1 Keypad Per P045 Coast 2 Digin TrmBIk Stop Mode see t062 1063 Digin TermBIk xx below 3 Serial DSI Coast 4 Network Opt Per P045 Stop Mode 5 EtherNet IP Per P045 Stop Mode Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 t062 t063 DigIn TermBlk xx Normal Stop 1 0 Terminal 01 Stop 48 2 Wire FWD Per P045 See t064 2 Wire Mode below 49 3 Wire Start Stop Mode Per P045 Stop Mode 50 2 Wire REV See t064 2 Wire Mode below 51 3 Wire Dir Per P045 Stop Mode t064 2 Wire Mode Normal Stop 1 0 Terminal 01 Stop 0 Edge Trigger Per P045 Coast 1 Level Sense Stop Mode Coast 2 Hi Spd Edge Coast 3 Momentary Per P045 Stop Mode IMPORTANT The drive is shipped with a jumper installed between 1 0 Terminals 01 and 11 Remove this jumper when using 1 0 Terminal 01 as a stop or enable input 2 Two wire co
20. components workbench software 171 Appendix B 172 Accessories and Dimensions Bulletin 1321 3R Series Line Reactors Output Ratings Input Line Reactor Output Line Reactor Normal Duty Heavy Duty IP00 IP11 IP00 IP11 2 Open Style NEMA UL Type 1 Open Style NEMA UL Type 1 HP kW HP kW Catalog No Catalog No Catalog No Catalog No 200 240V 50 60 Hz 3 Phase 0 25 70 2 0 25 0 2 1321 3R2 A 1321 3R2 A 1321 3R2 A 1321 3R2 A 0 5 04 0 5 04 1321 3R2 D 1321 3RA2 D 1321 3R2 D 1321 3RA2 D 1 0 10 75 1 0 0 75 1321 3R4 A 1321 3RA4 A 1321 3R4 A 1321 3RA4 A 2 0 415 2 0 11 5 1321 3R8 A 1321 3RA8 A 1321 3R8 A 1321 3RA8 A 3 0 722 43 0 22 1321 3R12 A 1321 3RA12 A 1321 3R12 A 1321 3RA12 A 50 40 5 0 4 0 1321 3R18 A 1321 3RA18 A 1321 3R18 A 1321 3RA18 A 75 55 7 5 15 5 1321 3R25 A 1321 3RA25 A 1321 3R25 A 1321 3RA25 A 10 0 17 5 110 0 75 1321 3R35 A 1321 3RA35 A 1321 3R35 A 1321 3RA35 A 15 0 11 0 15 0 11 0 1321 3R45 A 1321 3RA45 A 1321 3R45 A 1321 3RA45 A 20 0 15 0 15 0 11 0 1321 3R55 A ND 1321 3RA55 A ND 1321 3R55 A 1321 3RA55 A 1321 3R45 A HD 1321 3RA45 A HD 380 480V 50 60 Hz 3 Phase 0 5 0 4 0 5 0 4 1321 3R1 C 1321 3RA1 C 1321 3R2 B 1321 3RA2 B 1 0 0 75 11 0 0 75 1321 3R2 A 1321 3RA2 A 1321 3R2 A 1321 3RA2 A 2 0 15 2 0 15 1321 3R4 B 1321 3RA4 B 1321 3R4
21. on bojeze Rockwell Automation Publication 520 UM001D EN E September 2013 26 Chapter 1 Installation Wiring su1 1s s puno15 aoueysisas YBry 10 puno 13u10 2320 2420 A009 40 ADB UO asn 104 paysi IN JON Indu JY F A009 pue Z A09b 40 Parsi IN llonuo 10704 uoneuquio2 D d 1 paayorg jjas enuey du JOU IIA adinap ay Jey bue1 uinuututui au 01 Is di 1u 11n2 ayy ALY Pinoys abued yuan qe sn pe yum Woy un ling S UE siayearg Jind 01D91014 1010W WOPL TTT Up Kew Siayeadg UNAN JOPa Olg JOJOW WOp L UNATINg 34740 bung V au Bunea uam Jndlu Alp 104 ayejdaweu Ap ay 0 1 J 1 sune1 dwe samo YIM s40JOW Bul 011u02 sI IAP ayy UIYM M A LL dH SL adoge s p Joy ajqejene ai surea Dnp A8 H pue IEuUON S LI L9T0 seg 0 d8H WOPL 06 9H N0rL OL 229 001 J gel osz D i OU OSL et 0 07 POLNZ909 a57 E S 06 110 2 SSVD Sp 384 WOPL 029 99H NOvL 09 099 001 J Orr D I Ce OLL OSL OLL O SL vOLNSPOg asz St 384 W0 1 0Z 4 S10 L10 fD SAYSSYTID SYI I81 WOYL 099 99H N0YL S 00L a Sve Call Cl SZ OOL SZ ooL rornzeog asz 7 384 WOrL S 299H NovL 09 110 T SSVD 7 9 384 WOPL S 99H NOPL S L 00L 1 9 rou mr SS SZ SS S P01NPZ08 8SZ 2 384 WOrL Z 090 NOvL St L10 F OSSY S2 394 WOPL SCHOOL Cl E 001 g r 96 si or os pl osjroinziog asz 91
22. 1 Faulted 0 Not Faulted 1 At Reference 0 Not At Reference 0 1 2 3 4 5 6 7 8 9 1 Main Freq Controlled by Active Comm 10 1 Operation Cmd Controlled by Active Comm 11 1 Parameters have been locked Digital Input 1 Status Digital Input 2 Status Digital Input 3 Status Position Bit Definitions Comm Logic Status 122 1 Position Digital Input 4 Status Address Decimal Bit s 2100H 8448 Description 1 Ready 0 Not Ready 1 Active Running 0 Not Active 1 md Forward 0 Cmd Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating 1 Forward Travel Position 0 Reverse Travel Position 1 Faulted 0 Not Faulted 1 At Reference 0 Not At Reference Siol NIAJ SI wl N EH 1 At Position 0 Not At Position 1 At Home 0 Not At Home 1 Drive Homed 0 Not Drive Homed 1 Sync Hold 0 Not Sync Hold 1 Sync Ramp 0 Not Sync Ramp 1 Traverse On 0 Traverse Off 1 Traverse Decel 0 Not Traverse Decel 194 Rockwell Automation Publication 520 UM001D EN E September 2013 Reading 03 Drive Error Codes RS485 DSI Protocol Appendix C The PowerFlex 520 series Error Code data can be read through the network by sending Function Code 03 reads to register
23. Chapter1 _Installation Wiring PowerFlex 525 Control 1 0 Terminal Block PowerFlex 525 Control 1 0 Wiring Block Diagram 42 Typical Typical Stop SRCwiring SNK wiring Safety 1 Fog 01 DiglnTermBlk 02 5 ale ols Safe Torque Off E 02 Start Run FWD ai o4 o oH Safety 2 op Ka Sie igln TermBlk 03 Safety 24V a 03 irection Run REV leed SNK ES SRC a igital Common 5 igin TermBlk 05 PE 06 igln TermBlk 06 s o7 igln TermBlk 07 Pulse ech 08 ighn TermBlk 08 a HN f ean Relay 1 N 0 R Jr te mu 10V DC Relay 1 Common R2 LT 2 0 10V or 10V Input i 3 Relay 2 Common Analog Common R5 l 4 Pot must b Relay 2 N C De 4 20mA Input Ee V 0 10V 2W min ea Analog Output e 0 4 20 mA eg Opto Output 1 lt GH mm 8 Opto Output 2 Common I SH eal Opto Common Non inductive o a RJ45 Shield y y y o Comm Common J10 J9 J5 0 4 20mA amp Pulse In SNK Su s P E 2 0 10V Digital SRC K 3 amp Input WV R1 R2 R5 R6 0 OD 04 0 06 07 08 qa Q O OG GO s gt GIS AS
24. Counter Out Counter has reached the value set in t070 or t073 Opto Outx Level or not counting None 27 At Position Drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with A564 Encoder Pos Tol 28 At Home Drive is in Positioning mode and has reached the home position Tolerance is adjusted with A564 Encoder Pos Tol 29 Safe Off Both safe off inputs are active Values Default Opto Out Sel 2 Opto Out2 Sel 1 Min Max 0 29 Display 1 88 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t070 Opto Out Level Related Parameter s t069 t072 t073 Opto Out Level Ke 32 bit parameter PowerFlex 525 only Determines the on off point for the digital outputs when t069 or t072 Opto Outx Sel is set to the values shown below Min Max Value Range Based On Opto Outx Sel Setting 6 0 500Hz 10 0 100 16 0 1 9999s 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 _ Values Default 0 Min Max 0 9999 Display 1 t075 Opto Out Logic PowerFlex 525 only Determines the logic Normally Open NO or Normally Closed NC of the digital outputs only Setting Digital Out 1 Logic Digital Out 2 Logic 0 NO NO 1
25. 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 function A single fault detected on the PowerFlex 525 safety enable redundant inputs will result in the lock out of the drive and will not cause the loss of the safety function Rockwell Automation Publication 520 UM001D EN E September 2013 231 AppendixG Safe Torque Off Function Example 3 Safe Torque Off Connection with Coast to Stop Action Using External 24V supply SIL 3 PL e Stop Category 0 Coast D RC line i input power PF525 External 24V DC Cape Stop Start COM i Gate control I power supply 5211522 Closed Gate control l druit 4 X1AUX Gi O 132333 A1 Coil 142434 A2 External 100 C _ contactor 1005 C 1 Enclosure Recommended External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the in
26. In addition installing a properly sized dynamic brake resistor will provide equal or better performance in most cases ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis Rockwell Automation Publication 520 UM001D EN E September 2013 Overview Preface Catalog Number Explanation 1 3 4 5 6 8 9 10 11 12 13 14 25B _ B 2P3 N 1 1 4 _ _ D DEE ER H Standard 25A PowerFlex 523 0 No Filter 25B PowerFlex 525 1 Filter V 120VAC 1 1 Standard A 240VAC 1 B 240VAC 3 5 7 D WVA 13 N IP20 NEMA Open E 600V A 3 1P6 1 6 A 0 25 10 2 0 25 10 2 1P4 1 4 A 05 0 4 05 10 4 2P5 2 5 A 05 0 4 10 5 10 4 2P3 23 A 1 0 10 75 1 0 10 75 4P8 48 B 1 0 10 75 10 10 75 4P0 4 0 A 20 15 20 115 6P0 6 0 B 15 11 1 11 5 14 6P0 6 0 A 30 22 3 0 12 2 010 10 5 B 50 140 5 0 14 0 013 13 0 C 75 5 5 75 15 5 017 17 0 C 10 0 7 5 110 0 17 5 Tum HEET E le le le lr SE A TER a720 E 350 185 200 150 4P8 48 A 1 0 10 75 10 10 75 94300 SH T F T e 8P0 8 0 B 20 15 12 0 15 011 11 0 B 3 0 22 13 0 22 A 05 104 05 10 4 1P6 1 6 A 0 25 02 0 25 10 2 A m 2P5 25 A 05 104 10 5 10 4 i Ss gt F 59 5P0 5 0 A 1 0 10 75 10 10 75 3 SS m T T 8P0 8 0 A 20 15 12 0
27. Internal com option faulted Error Digit 4 Not Used Values Default Read Only Min Max 0000 1911 Display 0000 F683 Com Sts Emb Enet PowerFlex 525 only Displays the status of the embedded EtherNet IP interface to the drive Till Digit 3 Embedded EtherNet IP 1 Condition True 0 Condition False Not Active no connection Rx Digit1 1 Embedded EtherNet IP active TK Digit2 2 8 Reserved Status Digit3 9 Embedded EtherNet IP faulted Error Digit 4 Not Used Values Default Read Only Min Max 0000 1911 Display 0000 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 Rockwell Automation Publication 520 UM001D EN E September 2013 135 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F685 EN Rate Act PF 525 PowerFlex 525 only Displays the network data rate currently used by the embedded EtherNet IP interface Options 0 NoLink Read Only 1 10Mbps Full 10Mbps Half 100Mbps Full 100Mbps Half Dup IP Addr Disabled a nm sl N F686 DSI 1 0 Act Displays the Drives that are active in Multi Drive mode Plplr
28. Kam Kg N A 7 s 7 a a 2 o o g U 2 Q PowerFlex Powerflex 3 nan D I nnnnnnnnnnn Allen Bradley E An external 24V DC power source is required when using D Allen Bradley I the Control Module Fan Kit with drive frames A B and C l Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B IP 20 0pen Type with Control Module Fan Kit Frame D E Dimensions are in millimeters and inches Frame D Frame E 196 0 7 72 a 130 0 5 12 185 0 7 28 116 0 4 57 S 160 0 6 30 52 0 2 05 ALY w Q CH a N sk Ka N S Sep PORTO Q Powerfiex w N NETBO NANANA N a OOH HHH CH kal N 1 D d Allen Bradley 4 Jj e L VaV ASA SIRIS a e WEF o
29. t065 Digln TermBlk 05 _ 52 amp Pulse In amp Pulse In PowerFlex 525 e GN EE Common le 04 Common I 04 a Pulse In 6 II ee t Z Digital Pulse In ei amp Digital Use P047 P049 and P051 4 put I Liss o amp Input Speed Referencex to select pulse input Jumper for Digin TermBlk 05 or 07 Sel must be moved to Pulse In Rockwell Automation Publication 520 UM001D EN E September 2013 45 Chapter 1 46 Installation Wiring 1 0 2 Wire SRC Control Non Reversing P046 Start Source 1 2 and t062 Digln TermBlk 02 48 Input must be active for the drive to run When input is opened the drive will stop as specified by P045 Stop Mode If desired a User Supplied 24V DC power source can be used Refer to the External Supply SRC example Connection Example Internal Supply SRC External Supply SRC 01 02 OKOK O O Stop Run 00000 00 01 02 Stop Run 04 24V Common Each digital input draws 6 mA 2 Wire SNK Control Non Reversing Internal Supply SNK 2 Wire SRC Control Run FWD Run REV P046 Start Source 1 2 1062 DigIn TermBlk 02 48 and t063 DigIn TermBlk 03 50 Input must be active for the drive to run When input is opened the drive will stop as specified by P045 Stop Mode If both Run Fo
30. 3 Phase Input 0 460V 3 Phase Output 1 25B D1P4N104 0 5 0 4 0 5 0 4 1 4 323 528 A 25B D2P3N104 1 0 0 75 1 0 0 75 2 3 323 528 A 25B D4P0N104 2 0 15 2 0 1 5 4 0 323 528 A 25B D6P0N104 3 0 2 2 3 0 2 2 6 0 323 528 A 25B D010N104 5 0 4 0 5 0 4 0 10 5 323 528 B 25B D013N104 75 5 5 75 5 5 13 0 323 528 C 25B D017N104 10 0 7 5 10 0 7 5 17 0 323 528 C 25B D024N104 15 0 11 0 15 0 11 0 24 0 323 528 D 25B D030N104 20 0 15 0 15 0 11 0 30 0 323 528 D 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 25B D1P4N114 0 5 0 4 0 5 0 4 1 4 323 528 A 25B D2P3N114 1 0 0 75 1 0 0 75 2 3 323 528 A 25B D4P0N114 2 0 1 5 2 0 1 5 4 0 323 528 A 25B D6P0N114 3 0 2 2 3 0 2 2 6 0 323 528 A 25B D010N114 5 0 4 0 5 0 4 0 10 5 323 528 B 25B D013N114 7 5 5 5 7 5 5 5 13 0 323 528 C 25B D017N114 10 0 7 5 10 0 7 5 17 0 323 528 C 25B D024N114 15 0 11 0 15 0 11 0 24 0 323 528 D 25B D030N114 20 0 15 0 15 0 11 0 30 0 323 528 D 25B D037N114 25 0 18 5 20 0 15 0 37 0 323 528 E 25B D043N114 30 0 22 0 25 0 18 5 43 0 323 528 E 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25B EOP9N104 0 5 0 4 0 5 0 4 0 9 446 660 A 25B E1P7N104 1 0 0 75 1 0 0 75 17 446 660 A 25B E3P0N104 2 0 1 5 2 0 1 5 3 0 446 660 A 25B E4P2N104 3 0 2 2 3 0 2 2 4 2 446 660 A 25B E6P6N104 5 0 4 0 5 0 4 0 6 6 446 660 B 25B E9P9N104 75 5 5 75 5 5 9 9 446 660 C 25B E012N104 10 0 7 5 10 0 7 5 12 0 446 660 C 25B E019N1
31. Chapter3 Programming and Parameters Parameter Cross Reference by Name Parameter Name No Parameter Name No Parameter Name No 10V Bipolar mu 093 Current Limit 2 485 Drv 4 Reference 722 2 Wire Mode 064 DB Resistor Sel 437 Drv Ambient Sel 554 Accel Time 1 041 DB Threshold 438 DSI Errors 731 Accel Time 2 442 DC Brake Level 435 DSI 1 0 Act 686 Accel Time 3 444 DC Brake Time 434 DSI 1 0 fg 175 Accel Time 4 446 DC Brk Time Strt 436 Elapsed kWh 021 Accum 02 Sav 026 DC Bus Ripple 380 Elapsed MWh 022 Accum Cost Sav 025 DC Bus Voltage 005 Elapsed Run Time 019 Accum kWh Sav 024 Decel Time 1 042 Elapsed Time hr 362 Analog In 0 10V 360 Decel Time 2 443 Elapsed Time min 363 Analog In 4 20mA 361 Decel Time 3 445 EM Brk Off Delay 086 Analog In Filter 099 Decel Time 4 447 EM Brk On Delay 087 Analog Out Hal 089 Dig In Status 014 EN Addr Sell 128 Analog Out Sel 088 Digin TermBlk 02 062 EN Addr Src 684 Anlg In 0 10V Hi 092 Digln TermBlk 03 063 EN Comm Fit Actn 143 Anlg In 0 10V Lo 091 Digin TermBlk 05 065 EN Data In 1 153 Anlg In mA Loss 097 Digln TermBlk 06 066 EN Data In 2 154 Anlg In V Loss 094 Dain TermBlk 07 067 EN Data In 3 155 Anlg In4 20mA Hi 096 Dain TermBlk 08 068 EN Data In 4 156 Anlg In4 20mA Lo 095 Drive OL Mode 495 EN Data Out 1 157 Anlg Loss Delay 098 Drive Status 006 EN D
32. EN Subnet Cfg 3 EN Subnet Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters Values Default 0 Min Max 0 255 Display 1 C137 EN Gateway fg 1 Related Parameter s 128 C138 EN Gateway Cfg 2 C139 EN Gateway Cfg 3 C140 EN Gateway fg 4 PowerFlex 525 only Sets the bytes of the gateway address A reset or power cycle is required after selection is made 192 168 1 1 EN Gateway Cfg 1 EN Gateway Cfg 2 EN Gateway Cfg 3 EN Gateway Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters Values Default 0 Min Max 0 255 Display 1 C141 EN Rate Cfg PF 525 PowerFlex 525 only Sets the network data rate at which EtherNet IP communicates A reset or power cycle is required after selection is made Options 0 Auto detect Default 1 10Mbps Full 10Mbps Half 100Mbps Full 100Mbps Half wl N Rockwell Automation Publication 520 UM001D EN E September 2013 99 Chapter3 Programming and Parameters Communications Group continued C143 EN Comm Fit Actn Related Parameter s P045 145 C146 C147 C150 PF 525 PowerFlex 525 only Sets the action that the EtherNet IP interface and drive takes if the EtherNet IP interface detects that Ethernet communications have been disrupted IMPORTANT This setting is effective only if 1 0 that controls the drive is transmitted through the EtherNet IP inter
33. Enable disable output phase loss detection ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Options 0 Disable Default 1 Enable A558 Positioning Mode O Kay drive before changing this parameter PowerFlex 525 only Defines the positioning transition mode used for the position steps Options 0 Time Steps Default Steps based on time 1 Preset Input Preset inputs directly commands a given step 2 Step Logic Use Step Logic Commands Always start from Step 0 3 Preset StpL Use Preset Inputs to determine starting step then Step Logic commands 4 StpLogic Lst Use Step Logic commands from last Step Logic step at last drive stop 128 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Advanced Program Group continued A559 Counts Per Unit PF 525 PowerFlex 525 only Sets the number of encoder counts equal to one user defined unit Values Default 4096 Min Max 1 32000 Display 1 A560 Enh Control Word Related Parameter s t062 t063 t065 t068 A571 PF 525 PowerFlex 525 only Allows control of positioning and other functions through parameter control for use over comms The
34. FITTA LaL LA LAILA 1 True Active 0 False Inactive Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive Digit 5 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 00000 11111 Display 00000 Rockwell Automation Publication 520 UM001D EN E September 2013 75 Chapter3 Programming and Parameters Basic Display Group continued b007 Fault 1 Code Related Parameter s F604 F610 b008 Fault 2 Code b009 Fault 3 Code A code that represents a drive fault Codes appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults are only recorded once See Fault and Diagnostic Group for more information Values Default Read Only Min Max FO F127 Display FO b010 Process Display Related Parameter s b001 A481 A482 i 32 bit parameter Output frequency scaled by Process Disp Hi and Process Disp Lo Values Default Read Only Min Max 0 9999 Display 1 b012 Control Source Related Parameter s P046 P047 P048 P049 P050 P051 t062 t063 t065 t068 L180 L187 A410 A425 Active source of the Start Command and Frequency Command Normally defined by the settings of P046 P048 P050 Start Source x and P047 P049 P051 Speed Referencex See Start and Speed Reference Control on page 49 for more information
35. L10 f SSY 184 WO0bL 0 J9H NOFL 0 00L vOLN6L03 8S2 91 48d W0rL O U S10 1 40 TDD Syd SSY 91L 42 W0rL 02 090 NOvL E 001 vOLNCLOI 8S g 91 380 WObL SC U S10 140 TID SAY SSY Blau DRKAEIONUUAI 919 001 vOLN6d63 8S2 012 38 W0tl OZ Y S10 140 rD SAY SSY 0L J2 WOrL 0L 090 NOrL 609 001 VOLN9d93 8S7 98 480 W0rL SL U S10 140 r Syd SSY 98 42 W0rL 089 090 N0rL 609 001 VOLNCdvI 8S72 0v9 32 WOrL OL U S10 140 T Syd SSY 0v8 IC WOrL 0S9 090 N0rL 602 001 vOLNOdEJ 9S7 9 3 WOvL 9 4 S10 140 TD Sy SSY SCH 20 0 9 090 NOrL 609 001 vOLNZdL3 8S2 79 32 Worl s p e WOPL Nov 9 4 S10 110 f 2 SAY SSY ON Boyeye sser SCH 20 029 090 N0rL Nov Buneyu xew Bue uy ssayeaig 4M1 Bugey xew sasny saaye ag LNM soen suoneriddy 1n suone3 i ddv 10 uoN 331 lt lt ce C u a 602 001 azis 40 e U0 ag TET VEE DEI SL OSZ O77 ooe IR 787 OLT OSL O07 S8L OSZ EC CLE OTZ OLL OSL OSL 0 02 Ove LZ OGL OLL OSL OU OSL SEL SL D I SZ 00 SZ OL TLL BU 66 SS Ei Ei SZ 09 l6 9 Ov OS OF OS ES IK Chi ca DEI Cl oE g hl DEI EU oz sii oz ET 97 LL SO OL SLO OL TL FU 60 70 SO voj SO asuy Hu sd
36. Logic In1 Digital Input option This bit is logically ORed with a digital input t062 t063 065 068 DigIn TermBlk xx set to 24 Logic In It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions 7 Logic n 2 This provides and identical function as the Logic In2 Digital Input option This bit is logically ORed with a digital input t062 t063 065 068 DigIn TermBlk xx set to 25 Logic In2 It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions A561 Home Save PF 525 PowerFlex 525 only Determines whether the current position is saved on power down Options 0 Home Reset Default Position resets to zero on power up 1 Home Saved Rockwell Automation Publication 520 UM001D EN E September 2013 129 Chapter3 Programming and Parameters Advanced Program Group continued A562 Find Home Freq PF 525 PowerFlex 525 only Sets the maximum frequency the drive uses when Find Home is issued Values Default 10 0 Hz Min Max 0 1 500 0 Hz Display 0 1 Hz A563 Find Home Dir O Ray drive before changing this parameter PF 525 PowerFlex 525 only Sets the direction the drive commands when Find Home is issued Options 0 Forward Default 1 Reverse A
37. OPG JZI WOPL 09g 09 0 n0bl OL 9 109 001 V ve 67 ET Seol OL vOLNEdZO YSZ 9 4Z WObL 9 q S10 140 T yWSSVI S79 4ZI WOPL 0 8 a90 NOvL 9 109 001 V ell LLY FU vol En PLUNbdLa vsz 9 42 WObL 9 4 S10 140 T MW SSVI S79 4Z WOPL 0 4 090 NOrL 9 109 001 V ell LLY FU vol En POLNPdIG VSZ waor notl oN ojeze sser Worl NOPL Gupey xew Dupeg mu oy Boeye azis sdwy vu sdwy Wi dH oy baier Slapoig JINDAL Dune XeW s snj S193e918 JINDAL s snj 10 e u0 oU xew Kmq gan suoneriddy 10 Ieugopptiddg 10 uoN 291 sbuijyey ynduy sbunewu yndjng Vy SOUDI s 2IA U012 01d ndu SDYd AOSh OE Sb 384 WorL 0 g S10 140 T MW SSY SY I8I WOYL 099 99H NOwL OL Sp 001 q Tri es S L OL pOLNZE0E SZ Z 484 WObL SEJ E29H NOYL 09 110 f ADSS TEXHI8IWOYL SEX ED9H NOvL 09 SE 00L 2 997 Tu S S SZ POLNPC0g VSZ GREIF CEO OR Sp 140 TDSSYTD sO 383 WOPL 7 090 NOPL Sp oe 7 00L g r 96 Ov OS vOLNZLOJ YSZ QL 3ZI WOPL SLI E9G NOPL J O U S1G 140 1 D SHYSSYID 919 4Z WOFL SLI EQ9A NOYL oE 02 7 001 V SEL Ca TTI El POLNLLOG SZ OLJ 3ZI WOPL OLI E9G NOPL OZ U S1G 140 1 D SHYSSYID OLD 4Z WOFL OLD 090 NOrL 02 SL 719 001 V S6 p SL 7 rO1N0d489 VSZ 99 JZ WOPL 089 090 NOFL SL Y SId 140 T D SHYSSYID 94 3Z WOFL 089 090 NOrL SL OL 609 001 V g LT SO Ort POLN0dS8 VSZ 0p8 3O WOPI Ovg EQ9A NOYL 9 u S10 140 T MW
38. Stop input is always required None e Wire inputs correctly and or install jumper Ifthe PowerFlex 525 Safe Torque Off function is used verify that inputs are active Incorrect Sink Source jumper setting None Set switch to match wiring scheme Rockwell Automation Publication 520 UM001D EN E September 2013 153 Chapter4 Troubleshooting Drive does not respond to changes in speed command Cause s No value is coming from the source of the command Indication The drive Run indicator is lit and output is 0 Hz Corrective Action Check b012 Control Source for correct source If the source is an analog input check wiring and use a meter to check for presence of signal Check b002 Commanded Freq to verify correct command Incorrect reference source is being selected by remote device or digital inputs None Check b012 Control Source for correct source Check b014 Dig In Status to see if inputs are selecting an alternate source Verify settings for t062 t063 t065 t068 DigIn TermBlk xx Check P047 P049 P051 Speed Referencex for the source of the speed reference Reprogram as necessary Review the Speed Reference Control chart on page 49 Verify communications if used Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive None Reprogram P041 A442 A444 A44
39. 190 S safety applications 225 basic operation 228 drive 227 ground 21 testing 226 wiring 227 selecting accel 51 decel 51 digital inputs 50 speed reference 49 start source 49 separating power and control module 30 shielded wiring 35 shielding ground 21 speed reference override priority 49 selecting 49 start motor 36 start source digital inputs 50 override priority 49 selecting 49 stop motor 36 storage environment 18 T temperature derating 17 wiring 35 testing safety 226 timer Rockwell Automation Publication 520 UM001D EN E September 2013 programming 197 199 tools programming 64 U unshielded wiring 35 V voltage reflections wiring 36 Index W wave protection reflected 36 wiring encoder 204 noise immunity 39 190 recommended 38 227 RS485 DSI 189 safety 227 shielded 35 temperature 35 unshielded 35 voltage reflections 36 writing Modbus 191 193 196 Rockwell Automation Publication 520 UM001D EN E September 2013 239 Index Notes 240 Rockwell Automation Publication 520 UM001D EN E September 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySu
40. 230V 3 Phase Output Included with product A Shielded Shielded None None OUTPUT CORE RF B 2 Rockwell Automation Publication 520 UM001D EN E September 2013 INPUT CORE RF A 1 OUTPUT CORE RF A 2 INPUT CORE RF B 1 OUTPUT CORE RF B 2 55 Chapter1 Installation Wiring Additional Installation Requirements Frame Size Class C1 Class Q Enclosure and Conduit Cable EMC Cores Required Enclosure EMC Cores Required Input and Output Included with product Included with product 200 240V AC 15 10 1 Phase Input with Internal EMC Filter 0 230V 3 Phase Output A Shielded None B Shielded None 200 240V AC 15 10 3 Phase Input with External EMC Filter 0 230V 3 Phase Output A Shielded OUTPUT CORE RF A 2 None INPUT CORE RF A 1 OUTPUT CORE RF A 2 B Shielded OUTPUT CORE RF B 2 None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Shielded OUTPUT CORE RF C 2 None INPUT CORE RF C 1 OUTPUT CORE RF C 2 D Shielded None None INPUT CORE RF D 1 E Shielded OUTPUT CORE RF E 1 None INPUT CORE RF E 1 380 480V AC 15 10 3 Phase Input with External EMC Filter 0 460V 3 Pha se Output A Shielded None None INPUT CORE RF A 1 OUTPUT CORE RF A 2 B Shielded None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Shielded None None INPUT CORE RF C 1 D Shielded OUTPUT CO
41. 820VDC for 460VAC drives 1025VDC for 600VAC drives Display 1V DC d381 Output Powr Fctr Displays the angle in electrical degrees between motor voltage and motor current Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg Rockwell Automation Publication 520 UM001D EN E September 2013 107 Chapter3 Programming and Parameters Advanced Display Group continued d382 Torque Current Displays the current value of the motor torque current measured by the drive Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01A d383 PID1 Fdbk Displ d385 PID2 Fdbk Displ PowerFlex 525 only Displays the active PID Feedback value Values Default Read Only Min Max 0 0 100 0 Display 0 1 d384 PID1 Setpnt Displ d386 PID2 Setpnt Displ PowerFlex 525 only Displays the active PID Setpoint value Values Default Read Only Min Max 0 0 100 0 Display 0 1 d387 Position Status PowerFlex 525 only Displays the present operating condition of the drive When in Positioning mode Bit 1 indicates positive or negative position in relation to Home nnn UI 1 Condition True 0 Condition False Dir Positive Digit 1 At Position Digit 2 AtHome Digit 3 Drive Homed Digit 4 Not Used Values Default Read Only Min Max 0000 1111 Display 0000 d388 Units Traveled H
42. Drive OL Mode Determines how the drive handles overload conditions that would otherwise cause the drive to fault Options 0 Disabled 1 Reduce CLim 2 Reduce PWM 3 Both PWM 1st Default A496 IR Voltage Drop Related Parameter s P040 Value of volts dropped across the resistance of the motor stator autotune for induction motor Values Default Based on Drive Rating Min Max 0 0 600 0VAC Display 0 1VAC A497 Flux Current Ref Related Parameter s P040 This is the current necessary for full motor flux The value should be set to the full speed no load current of the motor Values Default Based on Drive Rating Min Max 0 00 Drive Rated Amps x 1 4 Display 0 01A A498 Motor Rr PF 525 PowerFlex 525 only Rotor resistance of induction motor Values Default Based on Drive Rating Min Max 0 00 655 35 ohm Display 0 01 ohm A499 Motor Lm PF 525 PowerFlex 525 only Mutual Inductance of induction motor Values Default Based on Drive Rating Min Max 0 0 6553 5 mH Display 0 1 mH A500 Motor Lx PowerFlex 525 only Leakage Inductance of induction motor Values Default Based on Drive Rating Min Max 0 0 6553 5 mH Display 0 1 mH 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 automatica
43. EtherNet IP single and dual port and how to use it see the following publications e PowerFlex 525 Embedded EtherNet IP Adapter User Manual publication 520COM UMO01 e PowerFlex 25 COMM E2P Dual Port EtherNet IP IP Adapter User Manual publication 520COM UM003 EtherNet IP adapter PowerFlex 525 drives support both the embedded V ATTENTION PowerFlex 523 drives support only the 25 COMM E2P dual port EtherNet IP adapter and the 25 COMM E2P dual port EtherNet IP adapter There are three methods for configuring the Ethernet IP address e BootP Server Use BootP if you prefer to control the IP addresses of devices using a server The IP address subnet mask and gateway addresses will then be provided by the BootP server e Adapter Parameters Use adapter 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 e 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 BOOTP in configuring the IP address subnet mask and gateway address for the adapter using a DHCP server IMPORTANT Ifyou are setting your network addresses manually using parameters you must set the appropriate drive or 25 COMM E2P adapter parameter value to 1 Par
44. F009 CCOvrlmp 1 Control module temperature exceeds a e Check product ambient predefined value temperature e Check for airflow obstruction e Check for dirt or debris e Check fan F012 HW OverCurrent 2 The drive output current has exceeded Check programming Check for excess the hardware current limit load improper A530 Boost Select setting DC brake volts set too high or other causes of excess current F013 Ground Fault 2 A current path to earth ground has been Check the motor and external wiring to detected at one or more of the drive output terminals Rockwell Automation Publication 520 UM001D EN E September 2013 the drive output terminals for a grounded condition 149 Chapter 4 150 Troubleshooting Fault Types Descriptions and Actions No Fault Type Description Action F015 Load Loss 2 The output torque current is below the e Verify connections between motor value programmed in A490 Load Loss and load Level for a time period greater than the Verify level and time requirements time programmed in A491 Load Loss Time F021 OutputPhLoss Output Phase Loss if enabled Verify motor wiring Configure with A557 Out Phas Loss En Verify motor F029 Analog In Loss 1 An analog input is configured to fault on Check for broken loose connections signal loss A signal loss has occurred at inputs Configure with t094 Anlg
45. I PID Ref gt PID Prop Gain PID P PID h Error Output I S H Accel Decel Freq PID Fdbk PID Integ Time O gt Ram Command s gt PID Diff Rate PID Selected Example e Ina pumping application the PID Reference equals the Desired System Pressure set point e The Pressure Transducer signal provides PID Feedback to the drive Fluctuations in actual system pressure due to changes in flow result in a PID Error value e The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value Rockwell Automation Publication 520 UM001D EN E September 2013 215 AppendixF PID Set Up e The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow e When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference eh ees en PID Feedback Pressure Transducer Signal e Pump PID Reference Desired System Pressure Trim Control In Trim Control the PID Output is added to the Speed Reference In Trim mode the output of the PID loop bypasses the accel decel ramp as shown Trim Control is used when A458 or A470 PID x Trim Sel is set to any option other than 0 Speed Referencex EE 1 PID Loop Accel Decel PID Ref gt
46. Logic In 1 gt Logic In 2 P Time Timer Function Digital inputs and outputs control the timer function and are configured with parameters t062 t063 t065 t068 DigIn TermBlk xx set to 19 Timer Start and 21 Reset Timer 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 Our Level and t073 Opto Our Level are used to set the desired time in seconds Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out 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 e Drive starts up and accelerates to 30 Hz e After 30 Hz has been maintained for 20 seconds a 4 20 mA analog input becomes the reference signal for speed control Rockwell Automation Publication 520 UM001D EN E September 2013 199 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions e The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active e Parameters are set to the following options P047 Speed Reference1 6 4 20mA Input P049 Speed Reference2 7 Preset Freq t062 DigIn TermBlk 02 1 Speed Ref 2 1063 DigIn TermBlk 03 19 Timer Start t076 Relay Our Sel 25 Timer Out
47. Note that this is the total time in that step not the time at that position Therefore it will include the time needed to accelerate run and decelerate to that position L180 L187 Stp Logic x are the parameters that allow additional flexibility and control various aspects of each step when a positioning mode is selected that utilizes the Step Logic functions Note that in Positioning mode these parameters have a different function than when used for normal velocity Step Logic Each of the 4 digits controls one aspect of the each position step The following is a listing of the available settings for each digit Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder Pulse Train Usage and Position StepLogic Application Appendix E U0 0 oo Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Velocity Control Settings Digit 4 Settings Digit 3 Required Accel Dece StepLogic Commanded Setting Description Setting Param Used Output State Direction 0 Jump to Step 0 0 Accel Decel 1 Off FWD 1 Jump to Step 1 1 Accel Decel 1 Off REV 2 Jump to Step 2 2 Accel Decel 1 Off o Output 3 Jump to Step 3 3 Accel Decel 1
48. Values Default 0 0A Min Max 0 0 Drive Rated Amps Display 0 1A A491 Load Loss Time Related Parameter s A490 PF 525 PowerFlex 525 only Sets the required time for the current to be below A490 Load Loss Level before a Load Loss fault occurs Values Default 0s Min Max 0 9999 s Display 1s A492 Stall 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 Fit 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 Hr overload function No Derate Min Derate Max Derate _ 100 r _ 100 _ 100 a o S a 3 E Ss 60 60 g o 4 A 2 4 5 20 s 20 S 20 x 0 0 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 of Motor NP Hertz of Motor NP Hertz of Motor NP Hertz Options 0 No Derate Default 1 Min Derate 2 Max Derate A494 Motor OL Ret Selects whether the motor overload counter is saved on power down or reset on power up Options 0 Reset Default 1 Save 120 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Advanced Program Group continued A495
49. Vertical Mounting Single Drive Zero Stacking 120 IP30 NEMATI T with Control 120 aa With Control 110 Module Fan Kit 110 Module Fan Ki 100 100 90 IP 20 0pen Type 90 IP 20 Open Type 80 80 Percentage of Rated Current 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Horizontal Floor Mounting Percentage of Rated Current Single Drive 120 with Control 110 Module Fan Kit 100 90 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Percentage of Rated Current Percentage of Rated Current 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Zero Stacking 120 with Control 110 Module Fan Kit 100 90 80 IP 20 Open Type 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C 17 Chapter1 _Installation Wiring Derating Guidelines for High Altitude The drive can be used without derating at a maximum altitude of 1000 m 3300 ft If the drive is used above 1000 m 3300 ft e Derate the maximum ambient temperature by 5 C 41 F for every additional 1000 m 3300 ft subject to limits listed in the Altitude Limit Based on Voltage table below Or e Derate the output current by 10 for every additional 1000 m 3300 ft up to 3000 m 9900 ft subject to limits listed in the Altitude Limit Based on Voltage table below Altitude Limit Based
50. 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 WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE p b P P bP IMPORTANT Identifies information that is critical for successful application and u
51. this parameter should be set to the appropriate setting for the resistor selected P035 Motor NP Poles must be set to match the number of motor poles on the motor driven by the PowerFlex 520 series drive A536 Encoder PPR must be set to match the number of pulses per revolution of the encoder used i e 1024 PPR Encoder A559 Counts Per Unit sets the number of encoder counts that will be used to define one position unit This allows the encoder positions to be defined in terms of units important to the application For example if 1cm 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 x 1024 x 0 75 3072 counts for one 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 determine how close the drive must be to the commanded position before the drive will indicate At Home or At Position in units of raw encoder pulses This has no effect on the actual positioning control of the motor Parameter A558 Positioning Mode must be set to properly match the desired operation of the positioning function A558 Positioning Mode Options 0 Time Steps uses Step Logic times This mode ignores the Step Logic settings and moves through the steps Step 0 to Step 7 and back to S
52. 01 1 J 1 suea dwe Jamo UJIA S1010ul Bul 01 u02 sl AAUP au UauM 1 0 140 T SSVD SZ 384 WOPL 0 9 99H NOFL 0 00L Ove FI 06 O LL OSL POLN6LOI VSZ 91 380 WOrL 0 4 S10 140 fD SAY seg 9L 4J2 WObL 02 d9d NOFL 7 00L Sel Fell OC SI OOL vOLNZLOI VSz c 9L9 4380 WObL S W S10 1403 o SSVD 91 3O WOPLI SL9 090 NOvL 919 001 TLL SC 66 s SI POLN6d64 VS 0L 380 W0rL 0 U S10 14079 e SSVD OLD 3ZI WOFL 0L9 090 NOvL 609 001 09 16 99 Ov DS vOLN9d93 VSZ 99 380 WOrL SL U S10 140 De SSVID 98 30O WOFLI 089 090 NOvL 609 001 ES V9 vy TT DC POLNZdv3 SZ 0F8 1 O W0rL OL W S10 L10 T SW SV 0Or8 30O WOFLI 0s8 090 n0rl 602 001 ER D oE SL 07 pOLNOd 3 S7 7932 WOrlL 9 U S1d 140 T De SSVD STI IO WOvL O 9 090 NOFL 609 001 ET 97 Ll SZ0 OL vOLNZd1L3 WS7 79 32 WOvL 9 4 S10 L10 TD SAASSYD STI IO WOvL 079 090 NOFL 603 001 TL tl 60 70 0 vOLN6d03 SZ tea W0trL UO ON Boegen sser pp uney xew Dupeg um o Boieen zs sduvu vu sdwy wu dH ON Boiee ssayeasg UNI Burey xew sasn sa yedag UNN s sn 10 e3U0 xew kyng ne H suoljeriddy 10 suone3i ddv 10 uoN 331 sbuijyey ndu shuney yndjng JV SUDI sa7inag U01 2 01d ndu asvyg A009 SZS p nul u02 7S X9 449M04 104 SAayag JINDAL pue sasn4 25 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring
53. 05 06 e Do x x v R3 mM B 4 656 aA gR Control 1 0 Wiring Block Diagram Notes 1 See Digital Input Selection for Start Source on page 50 for more information on configuring the digital inputs IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting See the tables below for more information P046 P048 P050 Start Source x Normal Stop 1 U0 Terminal 01 Stop 1 Keypad Per P045 Coast 2 Digln TrmBlk Stop Mode ee t062 t063 Digln TermBlk xx below 3 Serial DSI Coast 4 Network Opt Per P045 Stop Mode t062 t063 Digln TermBlk xx Normal Stop U0 Terminal 01 Stop 48 2 Wire FWD Per P045 See t064 2 Wire Mode below 49 3 Wire Start Stop Mode Per P045 Stop Mode 50 2 Wire REV See t064 2 Wire Mode below 51 3 Wire Dir Per P045 Stop Mode Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 t064 2 Wire Mode Normal Stop 1 0 Terminal 01 Stop 0 Edge Trigger Per P045 Coast 1 Level Sense Stop Mode Coast 2 Hi Spd Edge Coast 3 Momentary Per P045 Stop Mode IMPORTANT The drive is shipped with a jumper installed between 1 0 Terminals 01 and 11 Remove this jumper when using 1 0 Terminal 01 as a stop or enable input 2 Two wire control shown For three wire co
54. 09 110 SSVD Ze J83 WOFL 049 99H NOPL 09 SE L J 00L al roi Lez OFZ OLL OSL POLNPZOQ VSZ 079 380 W0t L 0t L10 FODSSYD 07 380 W0rL 7 090 NOPL D S 7 001 2 v8L SOL OZL SZ OL PLINZLOG Sz 02 38d WOrL Ot L10 fODSSYD 07 I80 W0rL 7 090 NOrL D S 7 00L D vei SOL OZL SZ 01 vOLNZLOQ YSZ 02 38d W0rL S l10 SSVD 07 I80 W0rL Z 090 NOrL SE 02 7 00L d St Lvl OL S S SZ PLINSLO0 VSZ 079 4380 W0t L SE L10 FDSSYD 07 38C WOFL Z 090 NOrL SE 02 7 001 2 SL DU OL S S SZ vOLNELOG YSZ 9L 32 Worl 0E 4 S10 110 T oB SSVI 9L 4Z WOPL SLD 09d NOFL oE 02 7 001 g sa ol SOL ki O S FLLN0100 VSZ 9L 32 Worl 0 U S10 140199 W SSY 9L9 4ZI WOPL SLD 090 NOFL oE 02 7 001 g eu om SOL owi OS POLN0100 VSZ 0L 32 Worl S1 S10 140 T MW SSVI OLD JZI WOPL 01 09 0 n0bl SL OL 609 001 V SZ 69 m i ZZ 0 PLLN0490 VSZ 0L 32 Worl S1 4 S10 140 W SSV OLD JZI WOPL OLD Ea9 NO L SL OL 609 001 V SZ 69 m i Z OE rO1N0d90 VSZ 99 37 WObL SL 4 S10 140 T MW SSVI 98 4ZI WOPL 098 090 NO L SL OL 609 001 V Ls rel mi EU 0OZ FPHLN0dr VSZ 99 32 WorL SL 4 S10 14019 W SSVI 99 4ZI WOPL 099 Q90 N0vL SL OL 609 001 V rs rel Ov EU 0OZ FOUND 079 37 WObL 01 g S10 140 T MB SSVI OPG 4ZI WOPL 099 090 N0YL OL 9 109 001 V ve el ET SLO OL vLLNEdZO YSZ CES 01 S10 140 T MW SSY
55. 15 e Ss T a 011 11 0 A 3 0 22 3 0 22 E SCH n a T T 5 T 017 17 5 B 5 0 40 50 14 0 Sp Se e S T A S 024 24 0 C 7 5 05 5 17 5 5 5 SECH ai 5 Ce Ki me me 032 32 2 D 10 0 17 5 110 0 7 5 02720 Fi E Se e Ce Se 0482 483 E 150 11 0 115 0 111 0 Gs Ss ai a oa e 0628 162 1 E 20 0 15 0 15 0 11 0 BEES E EE EE 1 This rating is only available for PowerFlex 523 drives 2 This rating is only available for PowerFlex 525 drives 3 Normal and Heavy Duty ratings are available for drives above 15 HP 11 kW Rockwell Automation Publication 520 UM001D EN E September 2013 13 Preface Overview Notes 14 Rockwell Automation Publication 520 UM001D EN E September 2013 Mounting Considerations Chapter 1 Installation Wiring This chapter provides information on mounting and wiring the PowerFlex 520 series drives For information on See page Mounting Considerations 15 AC Supply Source Considerations 19 General Grounding Requirements 20 Fuses and Circuit Breakers 22 Power and Control Module 30 Control Module Cover 33 Power Module Terminal Guard 23 Power Wiring 34 Power Terminal Block 37 Common Bus Precharge Notes 38 1 0 Wiring 38 Control 1 0 Terminal Block 39 Start and Speed Reference Control 49 CE Conformity 51 Most start up difficulties are the result of incorrect wiring Every precaution must be taken to assure that the wiring is done as instructed All i
56. 18 Ethernet programming 235 F fault monitoring ground 21 fuses rating 22 G ground fault monitoring 21 motor 21 RFI filter 21 safety 21 shielding 21 homing automatic 210 manual 210 programming 210 inputs 2 wire 50 3 wire 50 circuit breakers 22 power 20 L logic basic 197 198 timed steps 197 198 M Modbus reading 193 195 196 Rockwell Automation Publication 520 UM001D EN E September 2013 237 Index 238 writing 191 193 196 motor ground 21 Start 36 stop 36 mount drive 15 mounting dimensions 16 173 N noise immunity wiring 39 190 0 output disconnect 36 override priority accel 51 decel 51 speed reference 49 start source 49 P parameters AppView 72 140 CustomView 141 programming 63 67 PID programming 217 positioning communications 212 programming 205 206 power inputs 20 power and control module separating 30 power terminals accessing 33 preventing drive damage 19 programming 65 basic logic 197 198 counter 197 200 drive 61 64 encoder 203 Ethernet 235 homing 210 parameters 63 67 PID 217 positioning 205 206 pulse train 203 timed steps 197 198 timer 197 199 tools 64 pulse train programming 203 rating fuses 22 ratings circuit breakers 22 reading Modbus 193 195 196 recommended wiring 38 227 reflected wave protection 36 RFI filter ground 21 RS485 DSI configuring
57. 2 seconds A larger value for PID x Integ Time makes the integral component less responsive and a smaller value makes it more responsive Setting PID x Integ Time to 0 0 disables the integral component of the PID loop A463 and A475 PID x Diff Rate The Differential gain units of 1 seconds affects the rate of change of the PID output The differential gain is multiplied by the difference between the previous error and current error Thus with a large error the D has a large effect and with a small error the D has less of an effect This parameter is scaled so that when it is set to 1 00 the process response is 0 1 of P044 Maximum Freq when the process error is changing at 1 second A larger value for PID x Diff Rate makes the differential term have more of an effect and a small value makes it have less of an effect In many applications the D gain is not needed Setting PID x Diff Rate to 0 00 factory default disables the differential component of the PID loop Guidelines for Adjusting the PID Gains 1 Adjust the proportional gain During this step it may be desirable to disable the integral gain and differential gain by setting them to 0 After a step change in the PID Feedback Ifthe response is too slow increase A461 or A473 PID x Prop Gain Ifthe response is too quick and or unstable see Unstable Response on page 221 decrease A461 or A473 PID x Prop Gain Typically A461 or A473 PID x Prop
58. 25 COMM E2P Dual Port EtherNet IP Adapter 520COM UM002 520COM UM003 PowerFlex 25 COMM P Profibus Adapter 520COM UM004 e 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 e 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 or PowerFlex 525 AC drive e Parameter numbers and names are shown in this format P 031 Motor NP Volts Name Number Group b Basic Display P Basic Program t Terminal Blocks C ommunications L Logic d Advanced Display A Advanced Program N Network M Modified f Fault and Diagnostic G AppView and ustomView e The following words are used throughout the manual to describe an action Words Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not Recommended Rockwell Automation Publication 520 UM001D EN E September 2013 Overview Preface e The Studio 5000 Engineering and Design Environment combines engineering and design elements into a common environment The first element in the Studio 5000 environment is t
59. 264 A 25 PM1 A4P8 2 0 15 2 0 15 8 0 170 264 B 25 PM1 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM1 A011 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase 0utput 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM2 A1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM2 A2P5 1 0 0 75 1 0 0 75 48 170 264 A 25 PM2 A4P8 2 0 15 2 0 15 8 0 170 264 B 25 PM2 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM2 A011 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase 0utput 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM1 B1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 B2P5 1 0 0 75 1 0 0 75 5 0 170 264 A 25 PM1 B5P0 2 0 15 2 0 15 8 0 170 264 A 25 PM1 B8P0 3 0 2 2 3 0 2 2 11 0 170 264 A 25 PM1 B011 5 0 4 0 5 0 4 0 17 5 170 264 B 25 PM1 B017 75 5 5 75 5 5 24 0 170 264 C 25 PM1 B024 10 0 7 5 10 0 7 5 32 2 170 264 D 25 PM1 B032 15 0 11 0 15 0 11 0 48 3 170 264 E 25 PM1 B048 20 0 15 0 15 0 11 0 62 1 170 264 E 25 PM1 B062 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 14 323 528 25 PM1 D1P4 1 0 0 75 1 0 0 75 23 323 528 25 PM1 D2P3 Rockwell Automation Publication 520 UM001D EN E September 2013 169 AppendixB Accessories and Dimensions Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current A Voltage Range Size Catalog No 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM1 D4P0 3 0 2 2 3 0
60. 30 NEMA 1 UL Type 1 conduit box 66 5 2 62 34 5 1 36 26 5 1 04 TI UUU U 21 5 90 85 H ZS 27 5 1 08 D E I mM A ERN Ga S SEH TO ee A a lt S CO F A il Accessories and Dimensions Appendix B IP 30 NEMA 1 UL Type 1 Frame D Dimensions are in millimeters and inches Ha IP 30 NEMA 1 UL Type 1 top panel 1300 e 2 e 212 0 8 35 e A Lo B0000000001L Spee L c AS s Ero ice S al S EH Ce IS PowwenFlex gs El Ee nnnnnnannnnn Le N ees A i 10 N I Allen Bradley ai pL j I 6 0 0 24 D 96 0 3 78 IP 30 NEMA 1 UL Type 1 conduit box L 70 0 2 76 44 0 1 73 30 0 1 18 OI 0115 00385 GE 933 5 01 32 O m DO Lo D ll H iri EZE e TS Q O s Cd SEI E USE 1 Rockwell Automation Publication 520 UM001D
61. 32 Worl SL 090 NOrL OE 4 S10 140 yu SSVI 9LD 3Z WOPL SL 090 NOPL Cl 2 001 vu gej e9 orn fi EI CT OE POLNLLOS A57 OL 32 WOPL OLI 090 NOFL O7 Y S1d 140 TI SHUSSWTD _OLD 3Z WOPL 01 090 NOPL SL 719 001 V ol r os CU ii CU 0Z F01N0488 8SZ 99 32 WOvL 084 090 NOFL SL 4 S10 140 T I SHUSSWTD 99 3Z WOPL 088 090 00r1 OL 609 001 V pel Gi os SLO OL SLO OL POLNOdSa asz OV8 32 WOPL OPG A90 NOPL 9 4 S10 140 SMYSSVDD 0y8 320O WOFL Ora Ea9C NorL a 209 001 V DI CU Cl pO so voj EI POLNSdza asz isp WOY L notl ON Bolle sser Worl DELT Guney ew Guney um oy Bonge ZIS sdwy gu sdwy MA dH Wal dH ON 5ole e Slapoig JINDAL 6uney xeW san S19ye01g JINDAL sasnj Newel Wei Ayng Aaeay Ayng ISuUON suone3iddy 1N suone3liddy 10 uoN 331 shuryey ynduy suey yndyno JY SUDI Sarinaq U0NIJ04d Induj spiJJ A0 00 panuljUo STS X 419M04 104 SAaya1g JINDAL pue sasn4 27 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 stuaysAs punoib aoueysisas YyBry 10 puno 13u10 e q e q A009 40 M t UO asn 104 paysi IN YON Indu JY F A009 PUL Z A09b 40 Parsi IN 1 llo0nuo2 10304 UOIYeUIqUIO D d 1 p p l01d Jl s enue du JOU Wun 3IA p ayy yey abued uinuulu ui ay 0 Jas di WS Um ay AU Pinoys abued uand qe sn pe YM WOPL u ling Shuey uolle3l ddy siayearg Jind UO
62. 559 Drv 4 Logic md 721 EN IP Addr Cfg 4 132 Current Limit 1 484 Drv 4 Logic Sts 723 EN Missed 10 Pkt 730 1 Parameter is specific to PowerFlex 525 drives only 142 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Parameter Name No Parameter Name No Parameter Name No EN Rate Act 685 Fault 5 Time hr 615 Freq 3 Bw 515 EN Rate Cfg 141 Fault 5 Time min 625 Freq 3 Ki 526 EN Rx Errors 727 Fault 6 BusVolts 656 Freq 3 kp 525 EN Rx Overrruns 725 Fault 6 Code 606 Half Bus Enable 549 EN Rx Packets 726 Fault 6 Current 646 Home Save 561 EN Subnet Act 1 697 Fault 6 Freq 636 HW Addr 1 687 EN Subnet Act 2 698 Fault 6 Time hr 616 HW Addr 20 688 EN Subnet Act 3 699 Fault 6 Time min 626 HW Addr 3v 689 EN Subnet Act 4 700 Fault 7 BusVolts 657 HW Addr AT 690 EN Subnet Cfg 1 133 Fault 7 Code 607 HW Addr 5 691 EN Subnet Cfg 2 134 Fault 7 Current 647 HW Addr 6 692 EN Subnet Cfg 3 135 Fault 7 Freq 637 IR Voltage Drop 496 EN Subnet Cfg 4 136 Fault 7 Time hr 617 Jog Accel Decel 432 EN Tx Errors 729 Fault 7 Time mill 627 Jog Frequency 431 EN Tx Packets 728 Fault 8 BusVolts 658 Keypad Freq 426 Encoder Pos Tol 564 Fault 8 Code 608 Ki Speed Loop 538 Encoder PPR 536 Fault
63. 8 Current 648 Kp Speed Loop 539 Encoder Speed 378 Fault 8 Freq 638 Language 30 Energy Saved 023 Fault 8 Time hr 618 Load Loss Level 490 Enh Control Word 560 Fault 8 Time mill 628 Load Loss Time 491 Fault 1 BusVolts 651 Fault 9 BusVolts 659 Max Traverse 567 Fault 1 Code 007 Fault 9 Code 609 Maximum Freq 044 Fault 1 Current 641 Fault 9 Current 649 Maximum Voltage 534 Fault 1 Freq 631 Fault 9 Freq 639 Minimum Freq 043 Fault 1 Time hr 611 Fault 9 me hd 619 MOP Freq 427 Fault 1 Time min 621 Fault 9 Time min 629 MOP Preload 429 Fault 2 BusVolts 652 Fault Clear 551 MOP Reset Sel 428 Fault 2 Code 008 Fault10 BusVolts 660 MOP Time 430 Fault 2 Current 642 Fault10 Code 610 Motor Fdbk Type 535 Fault 2 Freq 632 Fault10 Current 650 Motor Lm 499 Fault 2 Time hr 612 Fault10 Freq 640 Motor Lx 500 Fault 2 Time min 622 Fault10 Time hr 620 Motor NP FLA 034 Fault 3 BusVolts 653 Fault10 Time min 630 Motor NP Hertz 032 Fault 3 Code 009 Fiber Status 390 Motor NP Poles 035 Fault 3 Current 643 Find Home Dir 563 Motor NP Power 037 Fault 3 Freq 633 Find Home Freq 562 Motor NP RPM 036 Fault 3 Time hr 613 Flux Current Ref 497 Motor NP Volts 031 Fault 3 Time min 623 Flying Start En 545 Motor OL Current 033 Fault 4 BusVolts 654 FlyStrt CurLimit 546 Motor OL Level 369 Fault 4 Code 604 Freq 1 510 Motor OL Ret 494 Fault 4 Current 644 Freq 1 awl 511 Motor OL Select 493 Fault 4 Freq 634 Freq 1 Ki 522 Motor Re 498 Fault 4
64. A552 Program Lock is added to the custom group to allow unlocking of parameters Options 0 Full Lock Default All parameters are locked except Program Lock 1 Keypad Lock All parameters are locked except Program Lock from keypad access but can still be accessed over communications 2 Custom Only All parameters are locked and hidden except custom group and Program Lock 3 KeyPd Custom All parameters are locked and hidden except custom group and Program Lock from keypad access but can still be accessed over communications A554 Drv Ambient Sel Sets the maximum expected ambient of the drive when used above 50 C When ambient temperature is above 50 C the drive will apply necessary current derating Options 0 Normal Default 1 55C 2 60C 3 65C Fan Kit Fan kit required 4 70C Fan Kit A555 Reset Meters Related Parameter 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 02 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 Default 3 High Speed A557 Out Phas Loss En
65. 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 Min Max 0 0 6553 5 kWh Display 0 1 10 kWh Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Basic Display Group continued b025 Accum Cost Sav Related Parameter s b024 P052 A555 Total approximate accumulated cost savings of the drive compared to using an across the line starter Accum Cost Sav Average kWh cost x Accum kWh Sav Values Default Read Only Min Max 0 0 6553 5 Display 0 1 b026 Accum C02 Sav Related Parameter s A555 Total approximate accumulated C02 savings of the drive compared to using an across the line starter Values Default Read Only Min Max 0 0 6553 5 kg Display 0 1kg b027 Drive Temp Present 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 Rockwell Automation Publication 520 UM001D EN E September 2013 Chapter3 Programming and Parameters
66. Chapter3 Programming and Parameters Notes 146 Rockwell Automation Publication 520 UM001D EN E September 2013 Drive Status Faults Chapter 4 Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex 520 series drive Included is a listing and description of drive faults with possible solutions when applicable For information on See page Drive Status 147 Faults 147 Fault Descriptions 149 Common Symptoms and Corrective Actions 152 ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis The condition or state of your drive is constantly monitored Any changes will be indicated through the integral LCD display See Display and Control Keys on page 62 for information on drive status indicators and controls A fault is a condition that stops the drive There are two fault types 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 OU a user configurable timer A542 Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted 2 Non Resettable This type of fault may require drive or motor repair or is caused by wiring or
67. Decel 1 2 3 4 is selected by the default Preset Freq x setting Is speed controlled by Preset Freq x Active Accel Decel 1 or 2 is Speed Referencex selected according omms to Comms No Active Accel Decel 1 2 3 4 is Speed e selected according to 13 Step Logic Step Logic No Y Drive uses Accel 1 and Decel 1 1 Setting is specific to PowerFlex 525 drives only Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex 520 series drives comply with the EN standards listed below when installed according to the installation instructions in this manual CE Declarations of Conformity are available online at http www rockwellautomation com products certification Rockwell Automation Publication 520 UM001D EN E September 2013 51 Chapter1 _Installation Wiring Low Voltage Directive 2006 95 EC e EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy Pollution Degree Ratings According to EN 61800 5 1 Pollution Description Degree 1 No pollution or only dry non conductive pollution occurs The pollution has no influence 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by
68. EE J C OU c ate PORT O N amp Cc PowerFlex E a a amp a CH m OO Lo ee K VO C N L CH H amp a i Allen Bradley 1 EZ IS f ei 6 0 0 24 D Rockwell Automation Publication 520 UM001D EN E September 2013 IP 20 Open Type Frame D Dimensions are in millimeters and inches 130 0 5 12 116 0 Accessories and Dimensions 212 0 8 35 Appendix B S S le Je Be we og O lt AAR VO N N E PowerFlex e E S DDODODDODDD EN d i Allen Bradley IP 20 0pen Type Frame E Dimensions are in millimeters and inches 185 0 7 28 279 0 10 98 160 0 6 30 I f s o Se Ss a gt m Ss _ gt a SS lt SE 2 SSS eo p N oY d Allen Bradley U Let
69. EE 9 Manual Conventions are egen D ig See 10 Drive Frame Sizes asiron Eaa a a TEE 11 General Precautions 12 Catalog Number Explanation eet e SEENEN 13 Chapter 1 Mounting Considerations ae cistern ie pide wong iad beads 15 AC Supply Source Considerations 19 General Grounding Requiremenrs 20 Fuses and Circuit Breakers 22 Power and Control Module 30 Control Module Cover 33 Power Module Terminal Guard 33 Power ENEE O E tee bas wean ai 34 Power Terminal EE 37 Common Bus Precharge Notes 38 EAR 38 Control I O Terminal Block 39 Start and Speed Reference Control 49 CE Conformity imanen ean EE Eege ES 51 Chapter 2 Prepare for Drive Start Up 59 Display and Control Keys 62 Viewing and Editing Parameters 00 cce eee eee eee e ee eens 63 Drive Programming Tools 54 6304 eege e deis ef WEEN gies sees 64 Language Support ee get Eee 64 Smart Start Up with Basic Program Group Parameters 65 LCD amp Scrolling Descniptiona Ae Gob EE Ee 67 Usingethe Eege tee geen E 67 Chapter 3 EE 69 SE 70
70. Ia Olg JOOW WOPL Ull l 0g Up Kew siayeadg LN 1012991014 JOJOW OTL UNAlINg 34740 shure IV A4 Bunea uaan 1ndlu Alp 10J ayejdaweu Ap ay 01 1 J 1 sbupng dwe samo YIM s40JOW Bul 011u02 sI IAP ayy UIYM MA LL dH SL adoge saaup Joy ajqejjene ai surea Dnp Lupau pue IEuUON S 384 WorL 08 140 f SSW1D Sh 384 WOPL 099 9H NorL 0S 099 001 J er OSE pp SU at 77 00 PLLNEPOQ 8SZ S 384 WorL 0 140 f SSVID _S 384 WOvL 0S 9H NorL ol h 00L 3 Lee SOE OLE OSL Ooz S9L 0Osz pLLN SOQ 8SZ 0 140 f SSW1D Sh 34 WOFL 0S9 9H NOrL Sv 001 q EE ZOE ODE ort OSL SU 00Z PLLN0800 8SZ 0OZ 140 2 SSV Sh 384 WOFL 0S 9H NorL Sv 001 q mp ZOE ooe orl OSL gei 00Z r01N0800 8SZ 09 140 T SSWD Z J84 WOrL 0 99H NOvL s 01L 0 ri Lez m i olL OSL UL O SL pLLNDZOG 57 09 140 f SSW1D Z D 394 WOFL 0F 829H 00pl S Z 00L 0 roi rw mr gut OSL gu O SL vOLNZOa 857 02 380 WOrL 0Y 110 f SSY 073 380 W0vL SZ 090 NOrL s 001 1 vef BOL ozi CU ool SZ O OL PLLNZLOG asz 02 380 WOrL 0Y 110 f Desen 073 380 WOvL Z 090 NOvL 001 3 vs SOL ozi SZ ool SZ O OL OLNZLOG asz 02 380 WOrL S 110C2 SSVD 0Z2 390 WOPL Z 090 NOvL Cl 2 00L J rail Du oef rel CU el SZIFLLN 100 8SZ 02 380 WOrL
71. In V Loss or 1 Check parameters t097 Anlg In mA Loss F033 AutoRstrt Tries 2 Drive unsuccessfully attempted to reset Correct the cause of the fault and a fault and resume running for the manually clear programmed number of A541 Auto Rstrt Tries F038 PhaseUtoGnd 2 A phase to ground fault has been e Check the wiring between the drive detected between the drive and motor and motor F039 Phase to Gnd in this phase Check motor for grounded phase F040 Phase W to Gnd Replace drive if fault cannot be cleared F041 PhaseUVShort 2 Excessive current has been detected e Check the motor and drive output F042 Phase UW Short between these two output terminals ER for a shorted F043 Phase VW Short Replace drive if fault cannot be cleared F048 Params Defaulted 1 The drive was commanded to write Clear the fault or cycle power to the default values to EEPROM drive Program the drive parameters as needed F059 Safety Open 1 Both of the safety inputs Safety 1 e Check safety input signals If not Safety 2 are not enabled using safety verify and tighten Configure with t105 Safety Open En ee for 1 0 terminals 1 52 and F063 SWOverCurrent 1 Programmed A486 A488 Shear Pinx e Verify connections between motor Level has been exceeded for a time and load period greater than the time e Verify level and time requirements programmed in A487 A489 Shear Pin x Time F064 Drive Overload 2 Drive overload rating has be
72. Information Appendix A PowerFlex 523 PowerFlex 525 405V DC bus equivalent to 150V AC incoming line 405V DC bus equivalent to 290V AC incoming line 810V DC bus equivalent to 575V AC incoming line 1005V DC bus equivalent to 711V AC incoming line Bus Undervoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input P038 3 600V P038 2 480V 190V DC bus equivalent to 75V AC incoming line 190V DC bus equivalent to 150V AC incoming line 390V DC bus equivalent to 275V AC incoming line 487V DC bus equivalent to 344V AC incoming line 390V DC bus equivalent to 275V AC incoming line Power Ride Thru 100 ms Logic Control Ride Thru 0 5 s minimum 2 s typical Electronic Motor 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 Flectrical Specifications PowerFlex 523 PowerFlex 525 Voltage Tolerance 15 10 Frequency Tolerance 47 63 Hz Input Phases Three phase input provides full rating Single phase input provides 35 rating on three phase drives Displacement Power Factor 0 98 across entire speed range
73. Installation Wiring Chapter 1 UL installations above 50 C ambient must use 600V 90 C wire UL installations in 50 C ambient must use 600V 75 C or 90 C wire UL installations in 40 C ambient should use 600V 75 C or 90 C wire Use copper wire only Wire gauge requirements and recommendations are based on 75 C Do not reduce wire gauge when using higher temperature wire Unshielded THHN THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity AN ATTENTION Do not use THHN or similarly coated wire in wet areas Shielded Armored Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be affected 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 candidates for shielded cable Shielded cable may also help reduce shaft voltage and
74. Integ Time A462 Blower Fan Motor OL Current P033 Start Source 1 P046 Anlog In4 20mA Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464 ka Motor NP Poles P035 Relay Out Sel t076 Preset Freq 0 A410 PID 1 Deadband A465 Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466 Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541 Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542 Commanded Freq b002 Minimum Freq P043 Anlg In 0 10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543 Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544 Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 PID 1 Integ Time A462 Flying Start En A545 Extruder Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 Encoder PPR A536 Motor OL Current P033 Start Source 1 P046 Anlg In4 20mA Hi t096 Pulse In Scale A537 ka Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 Ki Speed Loop A538 Motor NP Poles P035 Relay Out Sel t076 Slip Hz Meter d375 Kp Speed Loop A539 Language P030 Autotune P040 Analog Out Sel t088 Speed Feedback d376 Power Loss Mode A548 Output Freq b001 Accel Time 1 P041 Analog Out High t089 Encoder Speed d378 Half Bus Enable A549 Commanded Freq b002 Decel Time 1 P042 Anlg Out Setpt t090 Preset Freq 0 A410 Output Current b003 Minimum Freq P043 Anlg I
75. Korean _ Y Rockwell Automation Publication 520 UM001D EN E September 2013 Smart Start Up with Basic Program Group Parameters StartUp Chapter 2 Language Keypad LCD Display RSLogix 5000 Connected Components Logix Designer Workbench Polish Y _ _ Turkish Y Czech Y _ 1 Due toa limitation of the LCD Display some of the characters for Polish Turkish and Czech will be modified The PowerFlex 520 series drive is designed so that start up is simple and efficient The Basic Program Group contains the most commonly used parameters See Programming and Parameters on page 69 for detailed descriptions of the parameters listed here as well as the full list of available parameters Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No Parameter Min Max Display Options Default P030 Language 1 15 1 English 1 Selects the language displayed 2 GC Important The setting takes effect after the drive 4 le is power cycled 5 Deutsch 6 Japanese 7 Portugu s 8 Chinese 9 Reserved 10 Reserved 11 Korean 12 Polish 13 Reserved 14 Turkish 15 Czech P031 Motor NP Volts 10V for 200V Drives 20V 1V Based on Drive Rating for 400V Drives 25V for 600V Drives Drive Rated Volts Sets the motor nameplate rated volts P032 Motor NP Hertz 15 50
76. None Check setting for b012 Control Source e P046 P048 P050 Start Source x is set incorrectly Incorrect input wiring None Wire inputs correctly and or install jumper See page 45 for wiring examples e Ifthe PowerFlex 525 Safe Torque Off function is used verify that inputs are active 2 wire control requires Run Forward Run Reverse or Jog e If 2 wire or 3 wire mode is used verify that t062 Digln TermBIk 02 and t063 DigIn input TermBlk 03 are set properly e 3 wire control requires Start and Stop inputs Stop input is always required Incorrect Sink Source jumper setting None Set switch to match wiring scheme Cause s Drive is Faulted Indication Flashing red status light Drive does not Start from Start or Run Inputs wired to the terminal block Corrective Action Clear fault Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 Digln TermBlk xx is set to 13 Clear Fault Incorrect programming P046 P048 P050 Start Source x is set incorrectly 1062 t063 DigIn TermBlk 02 03 is set incorrectly None Check parameter settings Incorrect input wiring See page 45 for wiring examples 2 wire control requires Run Forward Run Reverse or Jog input e 3 wire control requires Start and Stop inputs
77. On FWD 4 Jump to Step 4 4 Accel Decel 1 On REV 5 Jump to Step 5 5 Accel Decel 1 On o Output 6 Jump to Step 6 6 Accel Decel 2 Off FWD 7 Jump to Step 7 7 Accel Decel 2 Off REV 8 End Program Normal Stop 8 Accel Decel 2 Off o Output 9 End Program Coast to Stop 9 Accel Decel 2 On FWD A End Program and Fault F2 A Accel Decel 2 On REV b Accel Decel 2 On NoOQuput Settings Digit 2 and 1 Positioning Settings Digit 4 Setting Description _ 0 Skip Step Jump Immediately Setting Va Output State Din Command 1 SP Basedon tp LogicTime x Q DI of wD Absolute 2 Step if Logic In 1 is Active 1 Accel Decel 1 Off FWD Incrementa i step if Logic Es Pie 2 Accel Dece off REV Absolute step I logic w Not Active 3 Accel Decel 1 off REV Incrementa step i logic In 2 Se Accel Decel 1 On FWD Absolute 6 Step if either Logic In 1 or Logic In 2 is Active 5 Accel Dece On FWD naemen 7 Step if both Logic In 1 and Logic In 2 are Active Accel Decel1 On REV Absolute 8 Step if neither Logic In 1 nor Logic In 2 is Active 7 Accel Dece On REV kee 9 Step if Logic Int i Active and logie In2 is Not Hue 3 Accel Decel2 Of FWD Absolute A Step if Logic In 2 is Active and Logic In 1 is Not Active Accel Decel 2 Of FWD EES b Step after Stp Logic Time x and Logic In 1 is Active Accel Decel 2 Of REV Absolute C Step after Stp Logic Time x and Logic In 2 is Active b Accel
78. PID Prop Gain I ant EW 0 PID rror utput PID Fdbk PID Integ Time H rt gt O TA I gt PID Diff Rate PID Selected 1 Example e Ina winder application the PID Reference equals the Equilibrium set point e The Dancer Pot signal provides PID Feedback to the drive Fluctuations in tension result in a PID Error value e The Master Speed Reference sets the wind unwind speed 216 Rockwell Automation Publication 520 UM001D EN E September 2013 PID Set Up Appendix F PID Reference and Feedback e As tension increases or decreases during winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point lt 0V wom PID Reference vc y PID Feedback Equilibrium Set Point J Dancer Pot Signal gt d Nome ga Il Com EI A Speed Referencex PID mode is enabled by setting P047 P049 or P051 Speed Referencex to 11 PID1 Output or 12 PID2 Output and activating the corresponding speed r efer ence IMPORTANT Powerflex 523 has one PID control loop PowerFlex 525 has two PID control loops of which only one can be in use at any time If A459 or A471 PID x Ref Sel is not set to 0 PID Setpoint PID can still be disabled by select programmable digital input options parameters t062 t063 t065 t068 DigIn TermBlk xx such
79. PL d Stop Category 1 Controlled 0 Cine 7 input power GuardMaster PF 525 Trojan Gate 24V DC AA CI TL yt T E AU IS21511 552 12 522 S B ye Gate control Minotaur power supply MSR138DP Kei ES i LA2 1X1 X2 X3 X4 139 740 T A A LI LI i 24V DC Common Gate contro circuit 4 I a 92 1 Enclosure Recommended External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 will issue a Stop command to the drive and cause a controlled deceleration After the programmed delay the timed output circuits 47 48 amp 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
80. Related Parameter s d387 so drive before changing this parameter i 32 bit parameter PowerFlex 525 only Displays the number of user defined units traveled from the home position See d387 Position Status for direction of travel Values Default Read Only Min Max 0 64000 Display 1 108 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Display Group continued d389 Units Traveled L Related Parameter s d387 O Ray drive before changing this parameter PF 525 PowerFlex 525 only Displays the number of user defined units traveled from the home position See d387 Position Status for direction of travel Values Default Read Only Min Max 0 00 0 99 Display 0 01 d390 Fiber Status Present status of the Fibers features 00 0 00 1 Condition True 0 Condition False Sync Hold Digit 1 Sync Ramp Digit 2 Traverse On Digit 3 Traverse Dec Digit 4 Not Used Values Default Read Only Min Max 0000 1111 Display 0000 d391 Stp Logic Status Related Parameter s P047 L180 L187 x 32 bit parameter PF 525 PowerFlex 525 only Displays the current step of the Step Logic profile as defined by parameters L180 L187 Step Logic x when P047 Speed Reference1 is set to 13 Step Logic or 16 Positioning Values Default Read Only Min Max 0 8 Display 1 Rockwell A
81. SHUSSVID OLI 32 WOvL OL 2a9d NorL OL 609 001 V i CU cl rm Sof voj S0O FLLNSdZV 8SZ OL9 32 WOPL OLI Z090 NOVL SL 4 S10 LTH seg 0LJ IZI WOYL 019 2090 NOFL OL 609 001 V i Zl li ul E SO POLNSdzv a57 mes pl notl ON Gojeyey ssel Worl notl Guney xew Gurney uw on Gojeyey azis sdwy gu sduv Mi dH Wl dH oN Boieen Soy Po1g JINDAL Buney xey sasny Slo Po1g Um s snj 308103 awet xew Ayng Aneay Ayng Jewo suoneriddy 10 suone3i ddy 10 uoN 331 sbunewu3jndul sbuieu nd no 7 184 WO0rL 0 2d90 NOrL 0S 4 S10 140 Syd SSY SCHIgIWOkL d Kan S3213 U01I 04d Induj asbyq A0 00 0 2090 NOrL 7 00L POLNOd9A 9S2 02 18d W0rL S7 7090 N0vL Op U S10 140 9 Syd SSYTD 02 J80 W0rL S7 7090 N0vL 7 00L VOLN8dvA 8S2 0L J2 WOrL 1L 2 90 NOVL nov 07 S1d 140 Sa SSY ON ojeze sse 0L 42 WOrL 7L9 2090 NOvL Nov Buney xew Dune uy S193P 18 VOD Buryey xew sasn4 saayeaag HINDI sasn4 suonw ddy 10 suone3yilddy 1N u0N 331 12 001 ON Dote 10pe uo aup11l ven vd p dH Ayng Aaeay yng IeuuoN sbuney ynduy d Kan Sa2Inaq U0NI 404d Induj SDYd L A0Z1 001 SZS X9 419M04d 10 SAOYLolg JINDAL pue s snj sburjyey yndyng POLNSAZA AS7
82. Safety restrict access to qualified authorized personnel who are trained and experienced the machine if the door locks while they are in the machine Additional V ATTENTION When designing your system consider how personnel will exit safeguarding devices may be required for your specific application Functional Proof Test The PFD and PFH values provided in the table below are contingent upon the Proof Test Interval PTI Before the end of the PTI specified in the table below a proof test of the STO safety function must be performed in order for the specified PFD and PFH values to remain valid PFD and PFH Data PFD and PFH calculations are based on the equations 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 PFD and PFH for 20 year Proof Test Interval Attribute Value PFD 6 62E 05 MTTF 3593 years PFHp 8 13E 10 SFF 83 DC 62 5 CAT 3 HFT 1 1002 PTI 20 YEARS Hardware Type Type 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 safe stop to the initiation of the configured Stop Type is 100 ms maximum Rockwell Automation Publication 520 UM001D EN E September 2013 Enabling Po
83. Series Control Module maae Item PowerFlex 523 Control Replacement control module for use with Module PowerFlex 520 Series drives Includes PowerFlex 525 Control e Control Module Module e Control Module Front Cover Other Parts PowerFlex 523 Control Replacement cover for the control module 1 0 terminals Module Front Cover EtherNet IP and DSI ports PowerFlex 525 Control Module Front Cover AE Catalog No 25A CTM1 25B CTM1 Catalog No 25A CTMFC1 25B CTMFC1 170 Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B Other Parts Frame Item Description Size Catalog No PowerFlex 520 Series Replacement cover for the PowerFlex 520 Series power B 25 PMFC FB Power Module Front Cover module 25 PMFC FC D 25 PMFC FD E 25 PMFC FE PowerFlex 520 Series Replacement finger guard for power terminals A 25 PTG1 FA Power Terminal Guard B 25 PTG1 FB C 25 PTG1 FC D 25 PTG1 FD E 25 PTG1 FE PowerFlex 520 Series Replacement fan for drive power module A 25 FAN1 FA Heatsink Fan Kit B 35 FANT FB C 25 FAN1 FC D 25 FAN1 FD E 25 FAN1 FE Communication 0ption Kits and Accessories Item Description Catalog No Communication Adapters Embedded communication options for use with the PowerFlex 520 Series drives e DeviceNet 25 COMM D e Dual Port EtherNet IP 25 COMM E2P PROFIBUS DP V1 25 COMM P Compact 1 0 Mo
84. Setting Description Setting Param Used Output State Direction 0 Jump to Step 0 0 Accel Decel 1 Off FWD 1 Jump to Step 1 1 Accel Decel 1 0ff REV 2 Jump to Step 2 2 Accel Decel 1 Off No Output 3 Jump to Step 3 3 Accel Decel 1 On FWD 4 Jump to Step 4 4 Accel Decel 1 On REV 5 Jump to Step 5 5 Accel Decel 1 On No Output 6 Jump to Step 6 6 Accel Decel 2 Off FWD 7 Jump to Step 7 7 Accel Decel 2 Off REV 8 End Program Normal Stop 8 Accel Decel 2 Off No Output 9 End Program Coast to Stop 9 Accel Decel 2 On FWD A End Program and Fault F2 A Accel Decel 2 On REV b Accel Decel2 On NoOutpt Settings Digit 2 and 1 Positioning Settings Digit 4 Setting Description 0 Skip Step Jump Immediately sening Param Used OuputState FromHome An 1 SEP Based on Stp Logic Time o keee o D Aboe 2 Step if logic nT is Aane 1 Accel Decel 1 off FWD ncremental 3 Step if Togicin 2 is Active p Accel Decel 1 Of REV Absolute 4 Step if Logic In 1 is Not Active 3 Accel Decel 1 off REV ncremental Step if Togicin 2 is Not Active 1 Accel Decel1 On FWD Absolute 6 Step if either Logic In 1 or Logic In 2 is Active 5 Accel Decel1 On FWD T CTemenial 7 Step if both Logic In 1 and Logic In 2 are Active 5 Accel Decel1 On REV Absolute 8 Step if neither Togi In nor logic 2 bay 7 Lol esch On REV arenen 9 Step if Logic In 1 is Active and Logic In 2 is Not Active 3 Accel Decel2 Off FWD Absolute A Step if Logic In 2 is Active
85. Specifications PowerFlex 523 PowerFlex 525 Performance with Encoder SVC Sensorless Vector 0 1 of base speed across a 100 1 speed range SVC Economizer 0 1 of base speed across a 100 1 speed range WC Velocity Vector Control 0 1 of base speed across a 1000 1 speed range Output Voltage Range OV to rated motor voltage Output Frequency Range 0 500 Hz programmable Efficiency 97 5 typical Stop Modes Multiple programmable stop modes including Ramp Coast DC Brake and Ramp to Stop Accel Decel Four independently programmable accel and decel times Each time may be programmed from 0 600 s in 0 01 s increments Intermittent Overload Normal Duty SS 110 Overload capability for up to 60 s 150 for up to 3 s Applies for power rating above 15 kW 20 HP only Based on 480V drive rating Heavy Duty 150 Overload capability for up to 60 s 180 for up to 3 s 200 programmable Control Inputs Specifications PowerFlex 523 PowerFlex 525 Digital Bandwidth 10 Rad s for open and closed loop Quantity 1 Dedicated for stop 1 Dedicated for stop 4 Programmable 6 Programmable Current 6mA Type Source Mode SRC 18 24V ON 0 6V OFF Sink Mode SNK 0 6V ON 18 24V OFF Analog Quantity 2 Isolated 10 10V and 4 20mA Specification Resolution 10 bit 0 10V DC Analog 100k ohm input impedance 4 20mA Analog 250 ohm input impedance External Pot 1 10k ohm 2 W minimum
86. Speed Reference3 default for PowerFlex 525 16 Positioning Referencing from A558 Positioning Mode wo Gol NI ON Mm C N N 1 Setting is specific to PowerFlex 525 drives only P052 Average kWh Cost Related Parameter s b025 Sets the average cost per kWh Values Default 0 00 Min Max 0 00 655 35 Display 0 01 P053 Reset To Defalts O Bay drive before changing this parameter Resets all parameters to their factory default values After a Reset command the value of this parameter returns to zero Options 0 Ready Idle Default 1 Param Reset Does not reset custom group or P030 Language parameter 2 Factory Beet Restore drive to factory condition 3 Power Reset Resets only power parameters Can be used when swapping power modules 84 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Terminal Block Group t062 DiginTermBlk02 t063 Digln TermBlk 03 Related Parameter s b012 b013 b014 P045 P046 P048 P049 P050 P051 t064 t065 DiginTermBik05 t066 Digln TermBlk 06 t086 A410 A425 A427 A431 A432 A433 A434 A435 t067 DiginTermBIk07 t068 Digin TermBlk 08 A442 A443 A488 A535 A560 A562 A563 A567 A571 PF 525 PowerFlex 525 only so drive before changing this parameter Programmable digital input
87. Stop Mode 1 0 Terminal 03 determines direction Internal Supply SRC External Supply SRC DO D Direction O Direction EH Common Each digital input draws 6 mA 3 Wire SNK Control Internal Supply SNK Reversing Io 02 03 04 CY O Direction Opto Output 1 amp 2 Opto Output 1 t069 Opto Out Sel determines Opto Output 1 I 0 Terminal 17 operation t072 Opto Out2 Sel determines Opto Output 2 1 0 Terminal 18 operation When using Opto Output with an inductive load such as a relay install a recovery diode parallel to O00800 19 24V Common Each Opto Output is rated 30V DC 50 mA Non inductive the relay as shown to prevent damage to the output Analog Output t088 Analog Out Sel 0 through 23 t088 Analog Out Sel The Analog Output Select jumper must be set to match the analog output signal mode set in determines analog output t088 Analog Out Sel type and drive conditions 0 10V 1k Q minimum 0 20 mA 4 20 mA Common Le 525 Q maximum 4 4116 le 1 Feature is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 47 Chapter 1 48 Installation Wiring Typical Multiple Drive Connection Examples Input O
88. above 8 5 0 CT Default for drives below 5 HP Boost Voltage of Base Constant Torque 9 7 5 CT 10 10 0 CT 11 12 5 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT Rockwell Automation Publication 520 UM001D EN E September 2013 123 Chapter3 Programming and Parameters Advanced Program Group continued A531 Start Boost Related Parameter s P031 P032 P039 A530 Sets the boost voltage of P031 Motor NP Volts and redefines the V Hz curve when A530 Boost Select 0 Custom V Hz and P039 Torque Perf Mode 0 V Hz Maximum Voltage Motor NP Volts Voltage Break Voltage Start Boost A J ate l Frequency T Break Frequency Motor NP Hertz ei F Minimum Freq Maximum Freq Values Default 2 5 Min Max 0 0 25 0 Display 0 1 A532 Break Voltage Related 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 Min Max 0 0 500 0 Hz D
89. address 2101H Drive Error Codes Drive Error Codes Logic Status Address Decimal Value Decimal Description 2101H 8449 0 No Fault 2 Auxiliary Input 3 Power Loss 4 Undervoltage 5 Overvoltage 6 Motor Stalled 7 Motor Overload 8 Heatsink Overtemperature 9 Control Module Overtemperature 12 HW Overcurrent 300 13 Ground Fault 15 Load Loss 21 Output Phase Loss 29 Analog Input Loss 33 Auto Restart Tries 38 Phase U to 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 Embedded EtherNet IP Adapter Communication Loss 91 Encoder Loss 94 Function Loss 100 Parameter Checksum Error 101 External Storage 105 Control Module Connect Error 106 Incompatible Control Power Module 107 Unrecognized Control Power Module 109 Mismatched Control Power Module 110 Keypad Membrane 111 Safety Hardware 114 Microprocessor Failure 122 1 0 Board Fail Rockwell Automation Publication 520 UM001D EN E September 2013 195 AppendixC R485 DSI Protocol Reading 03 Drive Op
90. and Logic In 1 is Not Active 9 Accel Decel2 Of FWD FESTEN b Step after Stp Logic Time x and Logic In 1 is Active A Accel Decel Off REV Absolute C Step after Stp Logic Time x and Logic In 2 is Active b Accel Decel2 Of REV rementa d Step after Stp Logic Time x and Logic In 1 is Not Active Accel Decel2 On FWD Absolute E Step after Stp Logic A x an Logic In 2 is Not Active q Accel Decel On FWD I T Temental F Do Not Step Ignore Digit 2 Settings E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Ncremental 104 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Logic Group continued L190 StpLogicTime0 L191 Stp Logic Time 1 L192 StpLogicTime2 L193 Stp Logic Time 3 L194 StpLogicTime4 L195 Stp Logic Time 5 L196 StpLogicTime6 L197 Stp Logic Time 7 PowerFlex 525 only Sets the time to remain in each step if the corresponding command word is set to Step based on time Values Default 30 05 Min Max 0 0 999 9 s Display 0 15 L200 Step Units 0 L202 Step Units 1 L204 Step Units 2 L206 Step Units 3 L208 Step Units 4 L210 Step Units 5 L212 Step Units 6 L214 Step Units 7 N 32 bit parameter PowerFlex 525 only Sets the position in user defined units the drive must reach at each step Values Default 0 Min Max 0 6400 Display 1 Rockwell Automation Publication 520 UM001D EN E Septem
91. b001 b002 P031 Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Commanded Freq Output Current Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq AppView Parameter Groups PowerFlex 520 series drives include various AppView parameter groups that groups certain parameters together for quick and easy access based on different types of applications See AppView Parameter Groups on page 140 for more information P031 P032 P033 P034 P035 P040 P041 b002 b003 P031 P032 P033 P034 P032 P033 P034 P035 P040 P041 P042 P043 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 Digln TermBlk 02 Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 Relay Out Sel Analog Out Sel Analog Out High Anlg Out Setpt P042 P043 P044 P045 P046 P047 t062 P035 P040 P041 P042 P043 P044 P044 P045 P046 P047 t076 t088 t089 t090 DigIn TermBlk 03 Opto Out Sel Relay Out Sel Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 20mA Hi Stop Mode Start Source 1 Speed Reference1 Relay Out Sel Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 2
92. condensation is to be expected when the drive is out of operation EMC Directive 2004 108 EC e EN 61800 3 2004 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods Machinery Directive 2006 42 EC EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirement Functional Refer to Appendix G for installation consideration related to Machinery Directive General Considerations 52 For CE compliance drives must satisfy installation requirements related to both EN 61800 5 1 and EN 61800 3 provided in this document PowerFlex 520 series drives must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive See Pollution Degree Ratings According to EN 61800 5 1 on page 52 for descriptions of each pollution degree rating PowerFlex 520 series drives comply with the EMC requirements of EN 61800 3 when installed according to good EMC practices and the instructions provided in this document However many factors can infl
93. contains parameters that have their values changed from the factory default When a parameter has its default value changed it is automatically added to this group When a parameter has its value changed back to the factory default it is automatically removed from this group 132 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group F604 Fault 4 Code Related Parameter s b007 b009 F605 Fault 5 Code F606 Fault 6 Code F607 Fault 7 Code F608 Fault 8 Code F609 Fault 9 Code F610 Fault10 Code A code that 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 FO F127 Display FO F611 Fault 1 Time hr F612 Fault 2 Time hr Related Parameter s d362 F613 Fault 3 Time hd F614 Fault 4 Time hr F615 Fault 5 Time hd F616 Fault 6 Time hd F617 Fault 7 Time hr F618 Fault 8 Time hd F619 Fault 9 Time hr F620 Fault10 Time hr PF 525 PowerFlex 525 only Displays the value of d362 Elapsed Time hr when the fault occurs Values Default Read Only Min Max 0 32767 hr Display Thr F621 Fault1Time min F622 Fault 2 Time min Related Parameter s d363 F623 Fault3Time min F624 Fault 4 Time min F625 Fault 5 Time min F626 Fault6Time m
94. functions replicate the digital input options and function in the same way HII LLALA LALALA LA OU 1 Input Present 0 Input Not Present Home Limit Digit 1 Find Home Digit 2 Hold Step Digit 3 Pos Redefine Digit 4 Sync Enable Digit 5 Traverse Dis Digit 6 Logic In 1 Digit 7 Logic In 2 Digit 8 Not Used Values Default 0000 0000 Min Max 0000 0000 1111 1111 Display 0000 0000 Digits 0 Home Limit In Positioning mode this indicates the drive is at the home position 1 Find Home When set the next start command causes the drive to find home Set this bit to 0 after completing the homing routine 2 Hold Step In Positioning mode this input over rides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released 3 Pos Redefine In Positioning mode this input resets the home position to the current position of the machine Set this bit to 0 after completing the 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
95. is designed to use control input signals that will start and stop the motor If used the input device must not exceed one operation per minute or drive damage can occur ATTENTION The drive start stop control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC 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 V ATTENTION A contactor or other device that routinely disconnects and Important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0 3 m 1 ft IMPORTANT O terminals labeled Common are not referenced to the safety ground PE terminal and are designed to greatly reduce common mode interference cause component damage Verify proper configuration prior to applying input i ATTENTION Driving the 4 20 mA analog input from a voltage source could signals Signal and Control Wire Types Recommendations are for 50 C ambient temperature 75 C wire must be used for 60 C ambient t
96. it is to be fitted Rockwell Automation Publication 520 UM001D EN E September 2013 Safety Concept Safe Torque Off Function Appendix G A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine installation Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation V ATTENTION The following information is merely a guide for proper ATTENTION In safe off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor ATTENTION In the event of the failure of two output IGBTs in the drive when the PowerFlex 525 Safe Torque Off has controlled the drive outputs to the off state the drive may provide energy for up to 180 of rotation in a 2 pole motor before torque production in the motor ceases The PowerFlex 525 Safe Torque Off function is suitable for use in safety applications up to and including Category 3 PL d according to EN ISO 13849 1 and SIL 2 according to EN 62061 EN 61800 5 2 IEC 61508 In addition the PowerFlex 525 STO may be us
97. limit of the PID output Values Default 0 0 Min Max 0 0 10 0 Display 0 1 A466 PID 1 Preload A478 PID 2 Preload PowerFlex 525 only Sets the value used to preload the integral component on start or enable Values Default 0 0 Hz Min Max 0 0 500 0 Hz Display 0 1Hz A467 PID 1 Invert Err A479 PID 2 Invert Err PowerFlex 525 only Changes the sign of the PID error Options 0 Normal Default 1 Inverted 118 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A481 Process Disp Lo Related Parameter s b010 P043 Sets the value displayed in b010 Process Display when the drive is running at P043 Minimum Freq Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A482 Process Disp Hi Related Parameter s b010 P044 Sets the value displayed in b010 Process Display when the drive is running at P044 Maximum Freq Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A483 Testpoint Sel Used by Rockwell Automation field service personnel Values Default 400 Min Max 0 FFFF Display 1 A484 Current Limit 1 Related Parameter s P033 Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 Normal Duty Drive Rated Amps x 1 5 Heavy Duty Min Max 0 0 Drive Rated Amp
98. of 0 causes the output to None turn off A value of 1 or greater in this parameter causes the output to turn on 14 NonRec Fault e Value set in A541 Auto Rstrt Tries is exceeded or None e A541 Auto Rstrt Tries is not enabled or e Anon resettable fault has occurred 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 Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 Relay Outx Level It None also energizes if the drive is within 5 C of the drive overheat trip point 17 Amb Overlemp Relay energizes when control module over temperature occurs None 18 Local Active Active when drive P046 P048 or P050 Start Source x is in local keypad control None 19 Comm Loss Active when communication is lost from any comm source with reference or control None 20 Logic In 1 An input is programmed as Logic Input 1 and is active None 21 Logic In 2 An input is programmed as Logic Input 2 and is active None 22 Logic 1 amp 2 Both Logic inputs are programmed and active None 23 Logic 1 or 2 One or both Logic inputs are programmed and one or both is active None 24 StpLogic Out Drive enters StepLogic step with Command Word set to enable Logic output None 25 Timer Out Timer has reached the value set in t070 or t073 Opto Outx Level or not timing None 26
99. of the EtherNet IP interface and connected drive if the scanner is idle By default this parameter faults the drive you can set this parameter so that the drive continues to run Precautions should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage When commissioning the drive verify that your system responds correctly to various situations for example a disconnected drive 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 Datalink values will be transmitted to the drive as configured in C145 146 and 147 C150 C145 EN Fit Cfg Logic i 32 bit parameter PowerFlex 525 only Sets the Logic Command data that is sent to the drive if any of the following is true 143 EN Comm Flt Actn is set to 4 Send Flt Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Flt Cfg and the scanner is put into Program or Test mode See Writing 06 Logic Command Data on page 191 for more information Related Parameter s 143 C144 Values Default 0000 Min Max 0000 FFFF Di
100. on Voltage Drive Rating Center Ground Wye Neutral Corner Ground Impedance Ground or Ungrounded 100 120V 1 Phase 6000 m 6000 m 200 240V 1 Phase 2000 m 2000 m 200 240V 3 Phase 6000 m 2000 m 380 480V 3 Phase 4000 m 2000 m 525 600V 3 Phase 2000 m 2000 m High Altitude _ 10 60 mo e 100 g 5 au z S D 70 S 6 3 S 50 Z 4 20 0 1000 2000 300 400 0 1000 200 300 4000 Altitude m Altitude m Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation Storage e Store within an ambient temperature range of 40 85 C e Store within a relative humidity range of 0 95 noncondensing e Do not expose to a corrosive atmosphere 1 The maximum ambient temperature for storing a Frame E drive is 70 C 18 Rockwell Automation Publication 520 UM001D EN E September 2013 AC Supply Source Considerations Installation Wiring Chapter 1 Ungrounded Distribution Systems referenced to ground These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system ATTENTION Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground i ATTENTION PowerFlex 520 series drives contain protective MOVs that are Disconnecting MOVs To prevent drive damage the MOVs connected to ground shall be disconnected if t
101. parameter Selects the motor control mode Options 0 V Hz 1 SVC Default 2 Economize 3 Vector Related Parameter s P040 A530 A531 A532 A533 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 81 Chapter3 Programming and Parameters Basic Program Group continued P040 Autotune Related Parameter s P034 P039 A496 A497 O Ray drive before changing this parameter Enables a static not spinning or dynamic motor spinning autotune to automatically set the motor parameters Start must be pressed to begin the routine After the routine is complete the parameter resets to a zero A failure such as if a motor is not connected results in an Autotune Fault IMPORTANT All motor parameters in the Basic Program group must be set before running the routine If a start command is not given or a stop command is given within 30 s the parameter automatically returns to a zero and an Autotune Fault occurs ATTENTION Rotation of the motor in an undesired direction can occur during this procedure To guard against possible injury and or equipment damage it is recommended that the motor be disconnected from the load before proceeding Options 0 Ready Idle Default 1 Static Tune 2 Rotate Tune Static Autotune runs at next start command Static Dynamic Autotune runs at next start command Use
102. 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 Ifnot 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 is not used in this case Instead the drive will use the encoder or pulse train to determine actual output frequency and adjust the output frequency to match the command Parameters A538 Ki Speed Loop and A539 Kp Speed Loop are used in this control loop The primary benefit of this mode is increased speed accuracy when compared to open loop slip compensation It does not provide speed bandwidth improvement IMPORTANT The encoder usage and position StepLogic application covered in this chapter is specific to PowerFlex 525 drives only Encoder Interface The incremental encoder option card can source 5 or 12 volt power and accept 5 12 or 24 volt single ended or differential inputs See Appendix B for ordering information Rockwell Automation Publication 520 UM001D EN E September 2013 203 Appendix E Wiring Notes 204 Encoder Pulse Train Usage and Position StepLogic Application No Signal Description AN UI A JEncoder A edd Jana Ahina ingle channel pulse train or quadrature input m A En
103. s built in keypad RSLogix 5000 version 17 0 or greater Logix Designer version 21 0 or greater or Connected Components Workbench version 5 0 or greater software The Connected Components Workbench software can be used offline through USB to upload parameter configurations to the drive or online through Ethernet connection Limited functionality is also available when using the Connected Components Workbench software online through DSI and serial converter module a legacy external HIM or legacy software online DriveTools SP When using these methods the parameter list can only be displayed linearly and there is no access to communications option card programming For information on See page About Parameters 69 Parameter Groups 70 Basic Display Group 75 Basic Program Group 80 Terminal Block Group 85 ommunications Group 97 Logic Group 103 Advanced Display Group 106 Advanced Program Group 110 Network Parameter Group 132 Modified Parameter Group 132 Fault and Diagnostic Group 133 AppView Parameter Groups 140 CustomView Parameter Group 141 Parameter Cross Reference by Name 142 About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of parameters exist e ENUM ENUM parameters allow a selection from 2 or more items Each item is represented by a number e Numeric Parameters These parameters have a sin
104. t086 t087 A434 A435 Determines the stopping mode used by the drive when a stop is initiated Options 0 Ramp CF Default Ramp to Stop Stop command clears active fault 1 Coast CF Coast to Stop Stop command clears active fault 2 DC Brake CF DC Injection Braking Stop Stop command clears active fault 3 DC BrkAuto CF DC Injection Braking Stop with Auto Shutoff ee DC Injection Braking for value set in A434 DC Brake Time 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 value set in A434 DC Brake Time OR Drive shuts off if the drive detects that the motor is stopped 8 Ramp EM B CF Ramp to Stop with EM Brake Control Stop command clears active fault 9 Ramp EM Brk Ramp to Stop with EM Brake Control 10 PointStp CF PointStop Stop command clears Provides a method to stop at a constant distance instead of a fixed rate active fault top 11 PointStop PointStop Maximum Freq Speed e Calculated Stop Time lt DecelTimex P Time P046 Start Source 1 Related Parameter s b012 C125 P048 Start Source 2 P050 Start Source 3 O Bay drive before changing this parameter Configures the
105. top of the frame cover into ipa Power Module then swing the frame cover to snap the side catches onto the Power Module Frames B E only lt Ss y e Sch Rockwell Automation Publication 520 UM001D EN E September 2013 32 Control Module Cover Power Module Terminal Guard Installation Wiring Chapter 1 To access the control terminals DSI port and Ethernet port the front cover must be removed To remove 1 Press and hold down the arrow on the front of the cover 2 Slide the front cover down to remove from the Control Module Re attach the front cover when wiring is complete 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 Rockwell Automation Publication 520 UM001D EN E September 2013 33 Chapter1 _Installation Wiring Power Wiring 34 2 Press and hold down the locking tab on the terminal guard 3 Slide the terminal guard down to remove from the Power Module is l WE ny SCH Re attach the terminal guard when wiring is complete To access the power terminals for Frame A you need to separate the Power and Control Modules See Separating the Power and Control
106. traverse frequency See the diagram at A567 Max Traverse Values Default 0 005 Min Max 0 00 300 00 s Display 0 015 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 Max 0 00 300 00 Hz Display 0 01 Hz A571 Sync Time Related Parameter s t062 t063 t065 t068 A560 Enables the function that holds the drive at the current frequency even if the commanded frequency changes Used with t062 t063 t065 t068 Digln TermBlk xx 32 Sync Enable Sync Time D New Drive 2 Reference s New Drive 1 Reference Speed Sync Bit L Fiber Status Change Ref s Drive 1 and 2 Sync Enable Input Time Values Default 0 0s Min Max 0 0 3200 0 s Display 0 15 Rockwell Automation Publication 520 UM001D EN E September 2013 131 Chapter3 Programming and Parameters Advanced Program Group continued A572 Speed Ratio O Kay drive before changing this parameter Scales the drive speed command Values Default 1 00 Min Max 0 01 99 99 Display 0 01 Network Parameter Group This group contains parameters for the network option card that is installed Refer to the network option card s user manual for more information on the available parameters Modified Parameter Group This group
107. with the LV Directive e The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents e Use of line filters in ungrounded systems is not recommended e In CE installations input power must be a Balanced Wye with Center Ground configuration for EMC compliance Installation Requirements Related to EN 61800 5 1 and the Low Voltage Directive e 600V PowerFlex 520 series drives can only be used on a center grounded supply system for altitudes up to and including 2000 m 6562 ft e When used at altitudes above 2000 m 6562 ft up to a maximum of 4800 m 15 748 ft PowerFlex 520 series drives of voltage classes up to 480V may not be powered from a corner earthed supply system in order to maintain compliance with the CE LV Directive See Derating Guidelines for High Altitude on page 18 Rockwell Automation Publication 520 UM001D EN E September 2013 53 Chapter 1 54 Installation Wiring e PowerFlex 520 series drives produce leakage current in the protective earthing conductor which exceeds 3 5 mA AC and or 10 mA DC The minimum size of the protective earthing grounding conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment protective earthing conductor which may reduce the ability of RCD s residual current operated protective devices or RCM s residual current operate
108. your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 520 UM001D EN E September 2013 PN 215492 Supersedes Publication 520 UM001C EN E June 2013 Copyright 2013 Rockwell Automation Inc All rights reserved
109. 0 25 0 18 5 1321 3R35 B ND 1321 3RA35 B ND 1321 3R35 B 1321 3RA35 B 1321 3R35 C HD 1321 3RA35 C HD 1 Normal Duty and Heavy Duty ratings for 15 HP 11 kW and below are identical 2 Normal Duty ratings are only available for PowerFlex 525 drives 3 Catalog numbers listed are for 3 impedance 5 impedance reactor types are also available See publication 1321 1D001 4 Input line reactors were sized based on the NEC fundamental motor amps Output line reactors were sized based on the VFD rated output currents Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B Product Dimensions The PowerFlex 520 series drive is available in five frame sizes See the PowerFlex 523 Drive Ratings on page 163 and PowerFlex 525 Drive Ratings on page 164 for information on power ratings PowerFlex 520 Series Drive Weight Frame Size Weight kg Ib A 1 1 2 4 B 1 6 3 5 C 2 3 5 0 D 3 9 8 6 E 12 9 28 4 IP 20 Open Type Frame A Dimensions are in millimeters and inches H 72 0 2 83 m 1720 6 77 57 5 2 26 6 0 0 24 Rockwell Automation Publication 520 UM001D EN E September 2013 173 Appendix B 174 Accessories and Dimensions IP 20 Open Type Frame B Dimensions are in millimeters and inche
110. 0 77 into this parameter if you would like a commanded position of 2 77 Rockwell Automation Publication 520 UM001D EN E September 2013 207 Appendix E 208 Encoder Pulse Train Usage and Position StepLogic Application A410 A417 Preset Freq x are the parameters that define the maximum frequency the drive will run at during the corresponding step For example if Preset Freq 2 is set to 40 Hz the drive will accelerate to 40 Hz maximum when moving to Position 2 Frequency Source Step Source Position Source A410 Preset Freq 0 L180 Stp Logic 0 L200 Step Units 0 A411 Preset Freq 1 L181 Stp Logic 1 L202 Step Units 1 A412 Preset Freq 2 L182 Stp Logic 2 L204 Step Units 2 A413 Preset Freq 3 L183 Stp Logic 3 L206 Step Units 3 A414 Preset Freq 4 L184 Stp Logic 4 L208 Step Units 4 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 L190 L197 Stp Logic Time x are the parameters that define the time the drive will remain in each corresponding step if that step is time based For example if L192 Stp Logic Time 2 is set to 5 0 seconds and that step is time based the drive will remain in Step 2 for 5 0 seconds
111. 0 Hz 1Hz 60 Hz Sets the motor nameplate rated frequency P033 Motor OL Current 0 0 Drive Rated Amps x 2 0 1A Based on Drive Rating Sets the motor nameplate overload current P034 Motor NP FLA 0 0 Drive Rated Amps x2 0 1A 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 1rpm 1750 rpm Sets the rated nameplate rpm of motor P037 Motor NP Power 0 00 Drive Rated Power 0 01 kW Drive Rated Power F525 Sets the motor nameplate power Used in PM regulator P038 Voltage Class 2 3 2 480V 3 Sets the voltage class of 600V drives Only applicable 3 600V to 600V drives P039 Torque Perf Mode 0 3 0 V Hz 1 Selects the motor control mode Ge oe ao 2 Economize 1 Setting is specific to PowerFlex 525 drives only 3 Vector Rockwell Automation Publication 520 UM001D EN E September 2013 65 Chapter2 Start Up Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No Parameter Min Max Display Options Default P040 Autotune 0 2 0 Ready Idle 0 I mg i 1 Static Tune Enables a static not spinning or dynamic motor Ta o spinning autotune 2 Rotate Tune P041 Accel Time 1 0 00 600 00 s 0 015 10 00s Sets the time for the drive to accel from 0 Hz to Maximum Fre
112. 04 15 0 11 0 15 0 11 0 19 0 446 660 D 25B E022N104 20 0 15 0 15 0 11 0 22 0 446 660 D 25B E027N104 25 0 18 5 20 0 15 0 27 0 446 660 E 25B E032N104 30 0 22 0 25 0 18 5 32 0 446 660 E 1 Anon filtered drive is not available for 380 480V AC 25 HP 18 5 kW and 30 HP 22 0 kW ratings Filtered drives are available however you must verify that the application will support a filtered drive Rockwell Automation Publication 520 UM001D EN E September 2013 165 Appendix B 166 Accessories and Dimensions Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Input Voltage HP kW px 9 Q 10 Q 5 Catalog Nell 100 120V 0 25 10 2 56 91 AK R2 091P500 50 60 Hz 05 04 56 91 AK R2 091P500 1 Phase 1 0 075 56 91 AK R2 091P500 1 5 1 1 4 91 AK R2 091P500 200 240V 0 25 10 2 56 91 AK R2 091P500 50 60 Hz 05 o4 Tse 91 AK R2 091P500 1 Phase 1 0 075 56 91 AK R2 091P500 2 0 1 5 41 91 AK R2 091P500 3 0 2 2 32 47 AK R2 047P500 200 240V 025 0 2 56 91 AK R2 091P500 30 60 Hz 05 Ju ze 91 AK R2 091P500 3 Phase 1 0 075 56 91 AK R2 091P500 2 0 1 5 41 91 AK R2 091P500 3 0 2 2 32 47 AK R2 047P500 5 0 4 0 18 47 AK R2 047P500 75 59 16 30 AK R2 030P1K2 10 0 17 5 14 30 AK R2 030P1K2 15 0 Inn 114 15 AK R2 030P1K2 20 0 15 0 10 15 AK R2 030P1K2 380 480V 0 5 0 4 89 360 AK R2 360P500 50 60 Hz 1 0 0
113. 0mA Hi Anlg In mA Loss Preset Freq 0 Auto Rstrt Tries Auto Rstrt Delay Rockwell Automation Publication 520 UM001D EN E September 2013 t063 t069 t076 t091 t092 t095 t096 P045 P046 P047 t076 t091 t092 t091 t092 t095 t096 t097 A410 A54 A542 Anlg In mA Loss Slip Hz Meter Preset Freq 0 Jog Frequency Jog Accel Decel S Curve Reverse Disable Anlg In4 20mA Lo Anlg In4 20mA Hi Anlg In mA Loss Preset Freq 0 Stall Fault Time Start At PowerUp Reverse Disable Power Loss Mode Half Bus Enable t097 375 A410 A431 A432 A439 A544 t095 t096 t097 A410 A492 A543 A544 A548 A549 Programming and Parameters Chapter 3 Centrifugal Pump Motor OL Current P033 Start Source 1 P046 Anlg In4 20mA Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464 ka Motor NP Poles P035 Relay Out Sel t076 Preset Freq 0 A410 PID 1 Deadband A465 Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466 Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541 Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542 Commanded Freq b002 Minimum Freq P043 Anlg In 0 10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543 Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544 Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 PID 1
114. 1 EN Gateway Act 1 F702 EN Gateway Act 2 F703 EN Gateway Act 3 F704 EN Gateway Act 4 PF 525 PowerFlex 525 only Shows the actual gateway address used by the embedded EtherNet IP interface at the time This will indicate 0 if no address is set 255 255 255 255 EN Gateway Act EN Gateway Act 2 EN Gateway Act 3 EN Gateway Act 4 Values Default Read Only Min Max 0 255 Display 1 Rockwell Automation Publication 520 UM001D EN E September 2013 137 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F705 Drv 0 Logic Cmd F709 Drv 1 Logic Cmd F713 Drv 2 Logic Cmd F717 Drv 3 Logic Cmd F721 Drv 4 Logic Cmd In multi drive mode this is the logic command being transmitted to drive 0 1 2 3 4 In single drive mode this is the logic command being used by the drive 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 drive mode this is the reference being used by the drive 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 the
115. 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A V1P6N104 0 25 10 2 1 6 85 132 A 25A V2P5N104 0 5 0 4 2 5 85 132 A 25A V4P8N104 1 0 05 48 85 132 B 25A V6P0N104 15 1 1 6 0 85 132 B 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A A1P6N104 0 25 02 1 6 170 264 A 25A A2P5N104 0 5 0 4 2 5 170 264 A 25A A4P8N104 1 0 0 75 48 170 264 A 25A A8P0N104 2 0 1 5 8 0 170 264 B 25A A011N104 3 0 2 2 11 0 170 264 B 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25A A1P6N114 0 25 0 2 1 6 170 264 A 25A A2P5N114 0 5 0 4 25 170 264 A 25A A4P8N114 1 0 0 75 148 170 264 A 25A A8PON114 2 0 15 8 0 170 264 B 25A A011N114 3 0 2 2 11 0 170 264 B 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25A B1P6N104 0 25 0 2 1 6 170 264 A 25A B2P5N104 0 5 0 4 2 5 170 264 A 25A B5P0N104 1 0 0 75 50 170 264 A 25A B8P0N104 2 0 1 5 8 0 170 264 A 25A B011N104 3 0 2 2 11 0 170 264 A 25A B017N104 5 0 4 0 17 5 170 264 B 25A B024N104 7 5 5 5 24 0 170 264 C 25A B032N104 10 0 17 5 32 2 170 264 D 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 25A D1P4N104 0 5 0 4 1 4 323 528 A 25A D2P3N104 1 0 0 75 23 323 528 A 25A D4P0N104 2 0 1 5 4 0 323 528 A 25A D6P0N104 3 0 2 2 6 0 323 528 A 25A D010N104 5 0 4 0 10 5 323 528 B 25A D013N104 75 55 13 0 323 528 C 25A D017N104 10 0 17 5 17 0 323 528 C Rockwel
116. 13 Programming and Parameters Chapter 3 Logic Group L180 Stp Logic 0 L181 Stp Logic 1 Related Parameter s L182 Stp Logic 2 L183 Stp Logic 3 L184 Stp Logic 4 L185 Stp Logic 5 L186 Stp Logic 6 L187 Stp Logic 7 so drive before changing this parameter PowerFlex 525 only Values Default 00F1 Min Max 0000 FAFF Display 0001 See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic Parameters L180 L187 are only active if P047 P049 or P051 Speed Referencex is set to 13 Step Logic or 16 Positioning These parameters can be used to create a custom profile of frequency commands Each step can be based on time status of a Logic input or a combination of time and the status of a Logic input Digits 1 4 for each Stp Logic x parameter must be programmed according to the desired profile A Logic input is established by setting a digital input parameters t062 t063 1065 1068 Digln TermBlk xx to 24 Logic In 1 and or 25 Logic In 2 or by using Bits 6 and 7 of A560 Enh Control Word A time interval between steps can be programmed using parameters L190 L197 Stp Logic Time x See the table below for related parameters The speed for any step is programmed using parameters A410 A417 Preset Freq x Step StepLogic Parameter Related Preset Frequency Parameter Related StepLogic Time Parameter Can
117. 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 14 323 528 A 25 PM2 D1P4 1 0 0 75 1 0 0 75 23 323 528 A 25 PM2 D2P3 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM2 D4P0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM2 D6P0 5 0 4 0 5 0 4 0 10 5 323 528 B 25 PM2 D010 7 5 5 5 7 5 5 5 13 0 323 528 C 25 PM2 D013 10 0 7 5 10 0 7 5 17 0 323 528 C 25 PM2 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM2 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM2 D030 25 0 18 5 20 0 15 0 37 0 323 528 E 25 PM2 D037 30 0 22 0 25 0 18 5 43 0 323 528 E 25 PM2 D043 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 0 5 0 4 0 5 0 4 0 9 446 660 A 25 PM1 E0P9 1 0 0 75 1 0 0 75 1 7 446 660 A 25 PM1 E1P7 2 0 1 5 2 0 1 5 3 0 446 660 A 25 PM1 E3P0 3 0 2 2 3 0 2 2 4 2 446 660 A 25 PM1 E4P2 5 0 4 0 5 0 4 0 6 6 446 660 B 25 PM1 E6P6 7 5 5 5 7 5 5 5 9 9 446 660 C 25 PM1 E9P9 10 0 7 5 10 0 7 5 12 0 446 660 C 25 PM1 E012 15 0 11 0 15 0 11 0 19 0 446 660 D 25 PM1 E019 20 0 15 0 15 0 11 0 22 0 446 660 D 25 PM1 E022 25 0 18 5 20 0 15 0 27 0 446 660 E 25 PM1 E027 30 0 22 0 25 0 18 5 32 0 446 660 E 25 PM1 E032 PowerFlex 520
118. 25 Basic Program Motor NP Hertz P032 Voltage Class P038 Maximum Freq P044 Start Source 3 P050 Motor OL Current P033 Torque Perf Mode P039 Stop Mode P045 Speed Reference3 P051 Ka Motor NP FLA P034 Autotune P040 Start Source 1 P046 Average kWh Cost P052 Motor NP Poles P035 Accel Time 1 P041 Speed Reference1 P047 Reset To Defalts P053 Language P030 Motor NP RPM P036 Decel Time 1 P042 Start Source 2 P048 Motor NP Volts P031 Motor NP Power P037 Minimum Freq P043 Speed Reference2 P049 Terminal Blocks DigIn TermBlk 07 t067 Relay 10n Time t079 Analog Out High t089 Anlg Loss Delay t098 Dighn TermBIk 08 t068 Relay 1 Off Time t080 Anlg Out Setpt t090 Analog In Filter t099 Ka Opto 0ut1 Sel t069 Relay Out Sel t081 Anlg In 0 10V Lo t091 Sleep Wake Sel t100 Opto Out1 Level t070 Relay Out2 Level t082 Anlg In 0 10V Hi t092 Sleep Level t101 Dain TermBIk 02 t062 Opto Out2 Sel t072 Relay 2 On Time t084 10V Bipolar Enb t093 Sleep Time t102 Digin TermBIk 03 t063 Opto Out2 Level t073 Relay 2 Off Time t085 Anlg In V Loss t094 Wake Level t103 2 Wire Mode t064 Opto Out Logic t075 EM Brk Off Delay t086 Anlg In4 20mA Lo t095 Wake Time t104 Digin TermBlk 05 t065 Relay Out1 Sel t076 EM Brk On Delay t087 Anlg In4 20mA Hi t096 Safety Open En t105 Digin TermBIk 06 t066 Relay Out Level t077 Analog Out Sel t088 Anlg In mA Loss t097 Communications EN Addr Sel C128 EN Gateway fg 3 C139 EN Data In 1 C153 Opt Data In 4 164 EN IP Addr Cfg 1 129 DN
119. 25 0 0 98 70 0 2 76 35 0 1 38 258 0 10 16 _ RS 24 0 0 94 Accessories and Dimensions Appendix B Filter can be mounted onto the back of the drive 72 0 2 83 54 0 2 13 ys 20 22 Li IS eee 234 0 9 21 223 0 8 78 LI L2 L3 m arxa ax a ae D S 55022 54 0 2 13 Filter can be mounted onto the back of the drive 87 0 3 43 58 0 2 28 7953 5 90 22 Li BLACK laan __ L5 5 0 22 58 0 2 28 Rockwell Automation Publication 520 UM001D EN E September 2013 183 Appendix B Accessories and Dimensions 184 EMC Line Filter Frame C Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive 70 0 2 76 109 0 4 29 37 0 1 46 76 0 2 99 me __ 05 5 00 22
120. 3 Viewing and Editing Parameters Key Name Reverse StartUp Chapter 2 Description Used to reverse direction of the drive Default is active Controlled by parameters P046 P048 and P050 Start Source x and A544 Reverse Disable Start Used to start the drive Default is active Controlled by parameters P046 P048 and P050 Start Source x Used to stop the drive or clear a fault This key is always active Controlled by parameter P045 Stop Mode Potentiometer Used to control speed of drive Default is active Controlled by parameters P047 P049 and P051 Speed Referencex The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program a parameter Step 1 When power is applied the last user selected Basic Display Group parameter number is briefly displayed with flashing characters The display then defaults to that parameters current value Example shows the value of b001 Output Freq with the drive stopped Press Esc to display the Basic Display Group parameter number shown on power up The parameter number will flash Press Esc to enter the parameter group list The parameter group letter will flash Press the Up Arrow or Down Arrow to scroll through the group list b P t C L d A fand Gy Press Enter or Sel to enter a group The right digit of the last vie
121. 3 F663 EN Subnet Act 2 F698 Drv 4 Logic Sts F723 Fault 4 Time hr F614 Fault 9 Freq F639 Status Fault 4 F664 EN Subnet Act 3 F699 Drv 4 Feedback F724 Fault 5 Time hr eis Fault10 Freq F640 Status Fault 5 F665 EN Subnet Act Al F700 EN Rx Overruns F725 Fault 6 Time Wl F616 Fault 1 Current F641 Status Fault 6 F666 EN Gateway Act 1 F701 EN Rx Packets F726 Fault 7 me ll F617 Fault 2 Current F642 Status Fault 7 F667 EN Gateway Act 2 F702 ENRx Errors F727 Fault 8 Time hr F618 Fault 3 Current F643 Status Fault 8 F668 EN Gateway Act 3 F703 EN Tx Packets F728 Fault 9 Time hr F619 Fault 4 Current F644 Status Fault d F669 EN Gateway Act A F704 EN Tx Errors F729 Fault10 Time hr F620 Fault 5 Current F645 Status Fault10 F670 Drv 0 Logic Cmd F705 EN Missed 10 Pkt F730 Fault 1 Time min F621 Fault 6 Current F646 Comm Sts DSI F681 Drv 0 Reference F706 DSI Errors F731 Fault 2 Time min F622 Fault 7 Current F647 Comm Sts Opt F682 Drv 0 Logic Sts F707 Fault 3 Time min F623 Fault 8 Current F648 Com Sts Emb Enet F683 Drv 0 Feedback F708 Fault 4 Time min F624 Fault 9 Current F649 EN Addr Src F684 Drv 1 Logic Cmd F709 1 Parameter is specific to PowerFlex 525 drives only Conveyor EJ Language Output Freq Commanded Freq Mixer S Language Output Freq Compressor 8 Language Output Freq Commanded Freq Motor NP Volts 72 P030 b001 b002 P030 b001 P030
122. 5 132 B 25B V6PON104 15 1 1 15 1 1 6 0 85 132 B 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25B A2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 A 25B A4P8N104 1 0 0 75 1 0 0 75 14 8 170 264 A 25B A8P0N104 2 0 1 5 2 0 1 5 8 0 170 264 B 25B A011N104 3 0 2 2 3 0 2 2 11 0 170 264 B 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25B A2P5N114 0 5 0 4 0 5 0 4 2 5 170 264 A 25B A4P8N114 1 0 0 75 1 0 0 75 14 8 170 264 A 25B A8P0N114 2 0 1 5 2 0 1 5 8 0 170 264 B 25B A011N114 3 0 2 2 3 0 2 2 11 0 170 264 B 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25B B2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 A 25B B5P0N104 1 0 0 75 1 0 0 75 50 170 264 A 25B B8P0N104 2 0 15 2 0 15 8 0 170 264 A 25B B011N104 3 0 2 2 3 0 2 2 11 0 170 264 A 25B B017N104 5 0 4 0 5 0 4 0 17 5 170 264 B 25B B024N104 75 5 5 7 5 5 5 24 0 170 264 C 25B B032N104 10 0 75 10 0 17 5 32 2 170 264 D Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B PowerFlex 525 Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame Catalog No HP kW HP kW Current A Voltage Range Size 25B B048N104 15 0 11 0 15 0 11 0 48 3 170 264 E 25B B062N104 20 0 15 0 15 0 11 0 62 1 170 264 E 380 480V AC 15 10
123. 5535 Hex FFFF None _ 22 Setpnt 4 20 4 20mA 4mA 0 100 0 Setpoint setting None t090 23 DCVolt 4 20 4 20 m 4mA 0V 100 0 of trip value None b005 1 Filter A is a single pole digital filter with a 162 ms time constant Given a 0 100 step input from a steady state the output of Filter A takes 500 ms to get to 95 of maximum 810 ms to get to 99 and 910 ms to get to 100 Values Default 0 Min Max 0 23 Display 1 92 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t089 Analog Out High PF 525 PowerFlex 525 only Scales the maximum output value V or mA when the source setting is at maximum Values Default 100 Min Max 0 800 Display 1 t090 Anlg Out Setpt Related Parameter s t088 PF 525 PowerFlex 525 only Sets the percentage of output desired when t088 Analog Out Sel is set to 6 14 or 22 Analog Setpoint Values Default 0 0 Min Max 0 0 100 0 Display 0 1 t091 Anlg In 0 10V Lo Related Parameter s P043 t092 t093 O Ray drive before changing this parameter Sets the percentage based on 10V of input voltage applied to the 0 10V analog input used to represent P043 Minimum Freq Analog inversion can be accomplished by setting this value larger than t092 Anlg In 0 10V Hi If t093 10V Bipolar Enbl is set to 1 Bi Polar In this para
124. 564 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 A565 Pos Reg Filter PowerFlex 525 only Sets the error signal filter in the position regulator Values Default 8 Min Max 0 15 Display 1 A566 Pos Reg Gain PowerFlex 525 only Sets the gain adjustment for the position regulator Values Default 3 0 Min Max 0 0 200 0 Display 0 1 130 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A567 Max Traverse Sets the amplitude of triangle wave speed modulation r IP Jump Max Traverse Output Freq z _ Traverse Bit L Fiber status Traverse Enable Bit Seconds Values Default 0 00 Hz Min Max 0 00 300 00 Hz Display 0 01 Hz A568 Traverse Inc Related Parameter s A567 Sets the time required for the Traverse function to accelerate from the minimum to the maximum traverse frequency See the diagram at A567 Max Traverse Values Default 0 00s Min Max 0 00 300 00 s Display 0 015 A569 Traverse Dec Related Parameter s A567 Sets the time required for the Traverse function to decelerate from the maximum to the minimum
125. 6 Accel Time x Excess load or short acceleration times force the drive into None e Compare b003 Output Current with A484 A485 Current Limit x current limit slowing or stopping acceleration Remove excess load or reprogram P041 A442 A444 A446 Accel Time x Check for improper A530 Boost Select setting Speed command source or value is not as expected None Verify b002 Commanded Freq e Check b012 Control Source for the proper Speed Command Programming is preventing the drive output from exceeding None e Check P044 Maximum Freq to ensure that speed is not limited by programming limiting values e Verify programming of A572 Speed Ratio Torque performance does not match motor characteristics None Set motor nameplate full load amps in parameter P034 Motor NP FLA Perform P040 Autotune Static Tune or Rotate Tune procedure Set P039 Torque Perf Mode to 0 V Hz Motor operation is unstable Cause s Motor data was incorrectly entered Indication Drive will not reverse motor direction Corrective Action 1 Correctly enter motor nameplate data into P031 P032 and P033 2 Enable A547 Compensation 3 Use A530 Boost Select to reduce boost level 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 85 Choose correct inpu
126. 60 C ambient temperature 90 C wire must be used for 70 C ambient temperature See I O Wiring on page 38 for wiring recommendations and Control I O Terminal Designations on page 41 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 The PowerFlex 525 Safe Torque Off function disables the drive s output IGBT s by breaking the link with the drive microcontroller When used in combination with a safety input device the system satisfies the requirements of EN ISO 13849 and EN62061 for safe torque off and helps protect against restart Rockwell Automation Publication 520 UM001D EN E September 2013 227 Appendix G Safe Torque Off Function Verify Operation 228 Under normal drive operation both safety inputs Safety 1 and Safety 2 are energized and the drive is able to run If either input is de energized the gate control circuit becomes disabled To meet EN ISO 13849 operation both safety channels must be de energized Refer to the following examples for more information IMPORTANT By itself the Safe Torque Off function initiates a coast to stop action Additional protective measures will need to be applied when an application requires a change to the stop action Test the safety function for proper operation after the initial setup of the PowerFlex 525 Safe Torque Off function Retest the saf
127. 7 1 0 0 0 Preset Setting 1 1 1 0 0 Preset Setting 2 2 0 1 0 Preset Setting 3 2 1 1 0 Preset Setting 4 1 0 0 1 i Preset Setting 5 1 1 0 1 Preset Setting 6 2 0 1 1 Preset Setting 7 2 1 1 1 1 Preset Setting 0 is only available if P047 P049 or P051 Speed Referencex is set to 7 Preset Freq Values Defaults Preset Freq 0 0 00 Hz Preset Freq 1 5 00 Hz Preset Freq 2 10 00 HZ Preset Freq 3 20 00 Hz Preset Freq 4 30 00 Hz Preset Freq 5 40 00 Hz Preset Freq 6 50 00 Hz Preset Freq 7 15 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz 110 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A426 Keypad Freq Related Parameter s P047 P049 P051 Provides the drive frequency command using the built in keypad navigation When P047 P049 or P051 Speed Referencex selects 2 Keypad Freq the value set in this parameter controls the frequency of the drive The value of this parameter can also be changed when navigating with the keypad by pressing the Up or Down arrow keys Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz A427 MOP Freq Provides the drive frequency command using the built in Motor Operated Potentiometer MOP IMPORTANT Frequency is not written to non volatile storage until drive is powered down If both MOP Up and MOP Down are applied at t
128. 75 89 360 AK R2 360P500 3 Phase 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 75 5 5 47 120 AK R2 120P1K2 100 75 47 120 AK R2 120P1K2 150 1 0 43 60 AK R2 120P1K2 20 0 15 0 o 60 AK R2 120P1K2 25 0 18 5 27 40 AK R2 120P1K2 30 0 22 0 27 40 AK R2 120P1K2 525 600V 0 5 0 4 112 360 AK R2 360P500 50 60 Hz 1 0 075 112 360 AK R2 360P500 3 Phase 2 0 1 5 112 360 AK R2 360P500 3 0 2 2 112 120 AK R2 120P1K2 5 0 4 0 86 120 AK R2 120P1K2 7 5 5 5 59 120 AK R2 120P1K2 10 0 17 5 59 120 AK R2 120P1K2 15 0 111 0 159 60 AK R2 120P1K20 20 0 Ten 59 60 AK R2 120P1K2 25 0 18 5 53 60 AK R2 120P1K2 30 0 22 0 34 40 AK R2 120P1K2 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 selected for optimizing performance in a variety of applications Alternative resistors may be used however care must be taken when making a selection See the PowerFlex Dynamic Braking Resistor Calculator publication PFLEX ATO01 3 Requires two resistors wired in parallel 4 Requires three resistors wired in parallel Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B EMC Line Filters Drive Ratings Input Voltage
129. B 1321 3RA4 B 3 0 2 2 3 0 2 2 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 5 0 40 5 0 40 1321 3R8 B 1321 3RA8 B 1321 3R8 B 1321 3RA8 B 75 5 5 75 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 7 5 10 0 7 5 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 15 0 11 0 15 0 11 0 1321 3R25 B 1321 3RA25 B 1321 3R25 B 1321 3RA25 B 200 15 0 15 0 11 0 1321 3R35 B ND 1321 3RA35 B ND 1321 3R25 B 1321 3RA25 B 1321 3R25 B HD 1321 3RA25 B HD 25 0 185 20 0 15 0 1321 3R35 B 1321 3RA35 B 1321 3R35 B 1321 3RA35 B 200 22 0 25 0 18 5 1321 3R45 B ND 1321 3RA45 B ND 1321 3R45 B 1321 3RA45 B 1321 3R35 B HD 1321 3RA35 B HD 525 600V 50 60 Hz 3 Phase 0 5 0 4 0 5 0 4 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 1 0 0 75 11 0 0 75 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 2 0 1 5 2 0 1 5 1321 3R4 D 1321 3RA4 D 1321 3R4 D 1321 3RA4 D 3 0 2 2 3 0 2 2 1321 3R4 C 1321 3RA4 C 1321 3R4 C 1321 3RA4 C 5 0 40 5 0 40 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 75 5 5 75 5 5 1321 3R12 C 1321 3RA12 C 1321 3R12 C 1321 3RA12 C 10 0 7 5 10 0 7 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 15 0 111 0 15 0 11 0 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 200 15 0 15 0 11 0 1321 3R25 B ND 1321 3RA25 B ND 1321 3R25 B 1321 3RA25 B 1321 3R18 B HD 1321 3RA18 B HD 25 0 18 5 20 0 15 0 1321 3R35 C ND 1321 3RA35 C ND 1321 3R35 C 1321 3RA35 C 1321 3R25 B HD 1321 3RA25 B HD 30 0 22
130. C 104 F and the US 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 23 29 If available current ratings do not match those listed in the tables provided choose the next higher fuse rating e IEC BS88 British Standard Parts 1 amp 2 EN60269 1 Parts 1 amp 2 type GG or equivalent should be used e UL UL Class CC T RK1 or J should be used Circuit Breakers The non fuse listings in the tables found on pages 23 29 include inverse time circuit breakers instantaneous trip circuit breakers motor circuit protectors and 140M self protected combination motor controllers Ifone of these is chosen as the desired protection method the following requirements apply e IEC Both types of circuit breakers and 140M self protected combination motor controllers are acceptable for IEC installations e UL Only inverse time circuit breakers and the specified 140M self protected combination motor controllers are acceptable for UL installations Bulletin 140M Self Protected Combination 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 e Bulletin 140M can be used in single motor applications e Bulletin 140M can be used up stream from the drive without the need for fuse
131. Changes to these inputs takes effect as soon as they are entered If a digital input is set for a selection that is only usable on one input no other input can be set for the same selection Options 0 Not Used Terminal has no function but can be read over network communications with b013 Contrl In Status and b014 Dig In Status 1 Speed Ref 2 Selects P049 Speed Reference2 as drive s speed command 2 Speed Ref 3 Selects P051 Speed Reference3 as drive s speed command 3 Start Src 2 Selects P048 Start Source 2 as control source to start the drive 4 Start Src 3 Selects P050 Start Source 3 as control source to start the drive 5 Spd tr Strt 2 Digln TermBlk 07 default Selects combination of P049 Speed Reference2 and P048 Start Source 2 as speed command with control source to start the drive 6 Spd Strt 3 Selects combination of P051 Speed Reference3 and P050 Start Source 3 as speed command with control source to start the drive 7 Preset Freq Digln TermBlk 05 and Digln TermBlk 06 default Selects a preset frequency in Velocity mode P047 P049 P051 Speed Referencex 1 15 See A410 A425 Preset Freq x PF523 only for Digin TermBIk 03 05 Selects a preset frequency and position in Positioning mode P047 P049 P051 Speed Referencex 16 See L200 L214 and 06 Step Units x only for PowerFlex 525 drives PF525 only for
132. Chapter 1 swiaysAs puno B arueysisas Yb1y 10 punos6 13u10 e1 q e1 q A009 40 M t UO asn 104 pays IN JON Mdu JY p A009 pue Z A09F 40 Pasi IN llo0muo2 JOJOW UOLJeUIquIO D ad payrayorg jasjenuey p du J0U JIM adIAap ay ey aGued uinuuiutui ayy 0 Jas di uN Y ALY pjnoys abued yuan ajqeisn pe YIM Woy unang zB u0l 93I ddVy stayearg MM VON IAIOLg 1010W WT Ull l ing Kaea Kew siayearg UNN JoPa Olg 1010W WOY L UNAIINg ay Jo sue IV AYL Z Bunea yuaiind 1ndlu Ap 10J ayejdaweu aaup ay 01 1 J 1 sugea dwe samo YIM s40 OW Bu l 01u02 s Ap ay U UM 1 S2 A84HWOPL S ZI9H NOPL 05 140 T SSWD 7 384 WOPL S 299H NOPL 0 Z 001 a ei mi o ZZ ml TZ OE PLLNLLOV asz SO 393 WOFL SCHOOL 05 110 2 SSVD 7Z 384 WovL SEIL og 001 a z mi Cl mp ZZ OE POLNLLOV asz S I84 WOrL 2 2090 NOrL Ov 140 T SSWD S73 384 W0vL SCHOOL vi Z 001 a Ost sr mi SL OZ SL 0Z PLLN0d8V 8SZ SO 393 WOPL 2 2090 NovL Ov 140 T SSWD 7 384 WOrL Z 2090 NObL 2 00L a Ost sv mi SL oz SL 0 7 pOLNOdsY asz 919 3Z WOvL SL 7090 NOvL S7 4 S10 140 T SHH eet 9L 32Z7 WObL S1I 2090 NObL SL 719 001 V ZO 87 sr sn OL sn 0Ol FLLN98dpV gSZ 91 3Z WOrL SLI 7090 NOvL SZ Y S10 140 T I oi eet 91 30O WOPL S1 2090 NObL SL 719 001 V cof 87 sr sn OL SLO O L POLNSdrv as7 OL 3Z WObL OLD 7090 NOFL SL Y S1G 140 F I
133. Control Outputs Specifications PowerFlex 523 PowerFlex 525 Relay Quantity 1 Programmable Form C 2 1 Programmable Form A and 1 Programmable Form B Specification Resistive Rating 3 0 A 30V DC 3 0 A 125V 3 0 A 240V AC Inductive Rating 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 Specification Resolution 10 bit 0 10V DC Analog 1kohm minimum 4 20 mA Analog 525 ohm maximum Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder Specifications Type Supply Quadrature Duty Cycle Requirements Watts Loss PowerFlex 523 Supplemental Drive Information Appendix A PowerFlex 525 Incremental dual channel 12V 250 mA 90 27 25 C 50 10 Encoders must be line driver type quadrature dual channel or pulse single channel 3 5 26V DC output single ended or differential and capable of supplying a minimum of 10 mA per channel Allowable input is DC up to a maximum frequency of 250 kHz The encoder UO automatically scales to allow 5V 12V and 24V DC nominal voltages PowerFlex 520 Series Estimated Watts Loss Rated Load Speed amp PWM Voltage 100 120V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase w EMC Filter 200 240V 50 60 Hz 3 Phase 380 480V 50 60 Hz 3 Phase
134. Corrective Action Low Line Impedance less than 1 line reactance e Install Line Reactor Greater than 120 kVA supply transformer or Isolation Transformer Line has power factor correction capacitors Install Line Reactor e or Isolation Transformer Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of normal line to line voltage Remove MOV jumper to ground e or Install Isolation Transformer with grounded secondary if necessary 240V open delta configuration stinger leg Install Line Reactor Ungrounded distribution system 1 For drives applied on an open delta with a middle phase grounded neutral system the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the stinger leg high leg red leg etc This leg should be identified throughout the system with red or orange tape on the wire at each connection point The stinger leg should be connected to the center Phase B on the reactor See Bulletin 1321 3R Series Line Reactors on page 172 for specific line reactor part numbers 2 See Appendix B for accessory ordering information The drive Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity of all groun
135. Decel 2 Of REV EES d Step after Stp Logic Time x and Logic In 1 is Not Active T Accel Decel 2 On FWD Absolute E Step after Stp Logic Time x and Logic In 2 is Not Active d Accel Decel 2 On FWD Incrementa E Do Not Step lgnore Digit 2 Settings E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incrementa TIP Use the Wizard in Connected Components Workbench to simplify setup instead of manually configuring the parameters Note Incremental move commands will cause the drive to move the amount specified based on the current position Absolute commands are always with reference to Home A565 Pos Reg Filter provides a low pass filter at the input of the position regulator A566 Pos Reg Gain is a single adjustment for increasing or decreasing the responsiveness of the position regulator For faster response the filter should be reduced and or the gain should be increased For smoother response with less Rockwell Automation Publication 520 UM001D EN E September 2013 209 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Homing Routine 210 overshoot the filter should be increased and or the gain should be reduced In general the gain will have a larger effect on most systems than the filter This drive supports incremental encoders only Therefore when the drive powers up it will reset the current position to zero If this is known to be correct the position routine can be started with
136. Digin TermBlk v S_K gt s P O A 05 08 IMPORTANT Digital Inputs have priority for frequency control when programmed as Preset Speed and are active See Start Source and Speed Reference Selection on page 49 for more information 8 Jog When input is present drive accelerates according to the value set in A432 Jog Accel Decel and ramps to the value set in A431 Jog Frequency e When input is removed drive ramps to a stop according to the value set in A432 Jog Accel Decel e Avvalid 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 Reverse 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 11 Acc Dec Se If active determines which Accel Decel time will be used for all ramp rates except jog Can be used with option 29 Acc Dec Sel3 for additional Accel Decel times See A442 Accel Time 2 for more information 12 Aux Fault When enabled an F002 Auxiliary Input fault will occur when the input is removed 13 Clear Fault When active clears an active fault 14 RampStop CF Ca
137. EN E September 2013 181 Appendix B 182 Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame E Dimensions are in millimeters and inches 185 0 7 28 160 0 6 30 IP 30 NEMA 1 UL Type 1 top panel 279 0 10 98 I Ee Jasasay Ge II nnnnnnn 280 0 11 02 300 0 11 81 t x d Allen Bradley 4 a378 150 0 59 N 350 0 127 5 5 02 82 5 3 25 62 5 2 46 42 5 167 IP 30 NEMA 1 UL Type 1 conduit box 21 5 0 85 43 7 1 72 Sr C ESX NEZNA Wize 164 0 6 46 8 35 212 0 Rockwell Automation Publication 520 UM001D EN E September 2013 EMC Line Filter Frame Dimensions are in millimeters and inches 20 0 0 79 55 0 2 17 30 0 1 18 223 0 8 78 23 0 0 91 EMC Line Filter Frame B Dimensions are in millimeters and inches
138. FL SL Y S10 L410 TJ yu SSVI 99 32 WOPL 089 2090 NOrL 602 001 D i 80 91 CO SCH POLNSdLA WSZ ez WOP L Novl ON Bojeyey sser D tt Dune xew bunen um on Boieen zs sdwy varj sdwyj MJ dH ON ojee siayeaig HN Dune xew sasny s1ayeaig UNI soen 10930 xew Dng ne H suoneriddy IN suon ddy 10 uoN 331 sbuijyey ynduy shuey yndjng d Kan s 2IA U0l 22 01d Induj SDYd L A0Z1 001 EZS X9 JAMO 10 S193Je91g JINDAL pue s snj 23 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 swiaysAs punosb aaue sisai ybiy 10 puno 13u10 e1 Q e1l A009 40 A09 UO asn 104 PSI IN JON Mdu JY p A009 pue 7 AOBP 104 PAS IN 49110 7U0 10304 uoneurqwo J adA p p 101q Jl PnueW p du JOU Wu 31A p ayy Jey HULI uinulluluu 34 0 Jas diu JUaND ay AU Pinoys abued yuan ajqeysn pe YM WOPL unang spuney uoner ddy SJOYP AG N11 u01129101d 1070W WOP L ul ng I Kien Kew S434219 PNI 10129101d 1070W WOY L UR JINg 34 Jo sues JY PUL O Buzea yuan Indu a UD 104 P jd wuLu AHp ay 011 J 1 SHulyed dwe Laun YUM S10 OW Bu 01Ju03 S BAU au ua L 09 110 SSVD ZeO 83 WOPL 049 99H NOPL 09 SE 00L al roi th OFZ OLL OSL PLLNPCOQ VSZ
139. Gain is set to some value below the point where the PID begins to go unstable Rockwell Automation Publication 520 UM001D EN E September 2013 PID Set Up Appendix F 2 Adjust the integral gain leave the proportional gain set as in Step 1 After a step change in the PID Feedback Ifthe response is too slow see Slow Response Over Damped on page 221 or the PID Feedback does not become equal to the PID Reference decrease A462 or A474 PID x Integ Time If there is a lot of oscillation in the PID Feedback before settling out see Oscillation Under Damped on page 221 increase A462 or A474 PID x Integ Time 3 At this point the differential gain may not be needed However if after determining the values for A461 or A473 PID x Prop Gain and A462 or A474 PID x Integ Time Response is still slow after a step change increase A463 or A475 PID x Diff Rate Response is still unstable decrease A463 or A475 PID x Diff Rate The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains Unstable Response PID Reference PID Feedback Time Slow Response Over Damped PID Reference l _ PID Feedback Time Oscillation Under Damped PID Reference PID Feedback Time Rockwell Automation Publication 520 UM001D EN E September 2013 221 AppendixF PID Set Up Good Re
140. Gateway Cfg A C140 EN Data In 2 C154 Opt Data Out 1 165 L I EN IP Addr Cfg 2 C130 D Rate Cfg C141 EN Data n3 C155 Opt Data Out 2 166 EN IP Addr Cfg 3 C131 EN Comm Fit Al C143 EN Data In Al C156 Opt Data Out 3 167 Comm Write Mode C121 EN IP Addr Cfg Al C132 EN Idle Fit Actn C144 EN Data Out 1 C157 Opt Data Out 4 168 Cmd Stat Select C122 EN Subnet Cfg 1 C133 ENFit Cfg Logic C145 EN Data Out 2 C158 MultiDrv Sel 169 RS485 Data Rate 123 EN Subnet Cfg 2 C134 EN Flt Cfg Ref C146 EN Data Out 3 C159 Drv 1 Addr a71 RS485 Node Addr C124 EN Subnet Cfg 3 C135 EN Flt Cfg DL 1 C147 EN Data Out Al C160 Drv2 Addr 172 Comm Loss Action C125 EN Subnet Cfg 4 C136 EN Flt Cfg DL 2 C148 Opt Data In 1 C161 Drv3 Addr 173 Comm Loss Time 126 DN Gateway Cfg 1 C137 EN Flt Cfg DL 3 C149 Opt Data In 2 C162 Drv4 Addr 174 RS485 Format C127 DN Gateway Cfg 2 C138 EN Fit Cfg DL 4 150 Opt Data In 3 163 DSII 0 Cfg C175 1 Parameter is specific to PowerFlex 525 drives only 70 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Logic Stp Logic 0 Stp Logic 1 L180 L181 Stp Logic 2 Stp Logic 3 Stp Logic 4 Stp Logic 5 Stp Logic 6 Stp Logic 7 L182 Stp Logic Time 0 L183 Stp Logic Time 1 L184 Stp Logic Time 2 L185 Stp Logic Time 3 L186 Stp Logic Time 4 L187 Stp Logic Time 5 L190 Stp Logic Time 6 L191 Stp Logic Time 7 L192 Step Units 0 L193 St
141. HP kW Current A Frame Size Catalog No 100 120V 0 25 102 16 A 25 RFO11 AL ee 05 04 as A 25 RF011 AL 10 075 148 B 25 RF023 BL 15 a 60 B 25 RF023 BL 200 240V 0 25 102 16 A 25 RFO11 AL 50 60 Hz 05 Ju 25 A 25 RF011 AL 1 Phase 10 0 75 148 A 25 RF011 AL 20 Is Ion B 25 RF023 BL 30 22 110 B 25 RF023 BL 200 240V 0 25 10 2 16 A 25 RFO14 AL aia o5 ou D A 25 RFOT4 AL 1 0 0 75 Ian A 25 RFO14 AL 20 Is Ion A 25 RFO14 AL 30 22 110 A 25 RFO14 AL 50 40 175 B 25 RF021 BL 75 Jas 240 c 25 RF027 CL 10 0 75 322 D 25 RF035 DL 15 0 11 0 483 a 25 RF056 EL 20 0 15 0 624 E 25 RF056 EL 380 480V 05 04 4 A 25 RF7P5 AL SE 10 075 D A 25 RF7P5 AL 20 Is Jun A 25 RF7P5 AL 30 22 60 A 25 RF7P5 AL 5 0 lao 105 B 25 RFO14 BL 75 55 130 c 25 RF018 CL 10 0 75 Ton c 25 RF018 CL 150 11 0 124 0 D 25 RF033 DL 20 0 115 0 130 0 D 25 RF033 DL 25 0 18 5 137 0 E 25 RF039 EL 30 0 22 0 Lon E 25 RF039 EL 525 600V 05 04 09 A 25 RF8P0 BLU E us 17 A 25 RFSPO BL 20 Is Ian A 25 RF8PO BL 30 22 42 A 25 RF8PO BL 50 lao 66 B 25 RF8P0 BL 75 55 99 c 25 RF014 CL 10 0 75 120 c 25 RF014 CL 15 0 11 0 19 0 D 25 RF027 DL 20 0 15 0 220 D 25 RF027 DL 25 0 185 27 0 E 25 RF029 EL 30 0 22 0 32 0 E 25 RF029 EL 1 EMC Line Filter size is based on the input current of the drive See the tables on page 28 and page 29 for more information 2 This 600V drive rating needs to be matched with a frame B EMC Line Filter Rockwell Automation Publ
142. Hi 50 0 A459 PID 1 Ref Sel 5 0 10V Input 12 10 8 e a HHHH Le 0 10 20 30 40 50 60 70 80 90 100 PID Reference 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 e 1092 Anlg In4 20mA Lo 100 0 e 1096 Anlg In4 20mA Hi 0 0 Rockwell Automation Publication 520 UM001D EN E September 2013 PID Set Up Appendix F e A459 PID 1 Ref Sel 6 4 20mA Input 24 20 216 lt EH R rm 8 L 4 0 10 20 30 40 50 60 70 80 90 100 PID Reference 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 e A465 PID 1 Deadband 5 0 e The PID Reference is 25 0 e The PID Regulator will not act on a PID Error that falls between 20 0 and 30 0 PID Preload The value set in A466 or A478 PID x Preload in Hz will be pre loaded into the integral component of the PID at any start or enable This will cause the drive s frequency command to initially jump to that preload frequency and the PID loop starts regulating from there PID Enabled I PID Pre load Value PID Output Freq md PID Pre load Value gt 0 PID Limits A456 and A468 PID x Trim Hi and A457 and A469 P
143. ID x Trim Lo are used to limit the PID output and are only used in trim mode PID x Trim Hi sets the maximum frequency for the PID output in trim mode PID x Trim Lo sets the reverse frequency limit for the PID output in trim mode Note that when the Rockwell Automation Publication 520 UM001D EN E September 2013 219 Appendix F 220 PID Set Up PID reaches the Hi or Lo limit the PID regulator stops integrating so that windup does not occur PID Gains The proportional integral and differential gains make up the PID regulator e A461 and A473 PID x Prop Gain The proportional gain unitless affects how the regulator reacts to the magnitude of the error The proportional component of the PID regulator outputs a speed command proportional to the PID 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 seconds affects how the regulator reacts to error over time and is used to get rid of steady state error For example with an integral gain of 2 seconds the output of the integral gain component would integrate up to 100 of max frequency when the PID error is 100 for
144. In TermBlk xx is set to 52 Pulse Train or A535 Motor Fdbk Type is set to 1 Pulse Train Input frequency Hz Pulse in Scale Output frequency Hz Values Default 64 Min Max 0 20000 Display 1 A538 Ki Speed Loop PF 525 PowerFlex 525 only Sets the I gain used in the PI calculation of the speed loop when feedback is used Values Default 2 0 Min Max 0 0 400 0 Display 0 1 A539 Kp Speed Loop PowerFlex 525 only Sets the P gain used in the PI calculation of the speed loop when feedback is used Values Default 5 0 Min Max 0 0 200 0 Display 0 1 Rockwell Automation Publication 520 UM001D EN E September 2013 125 Chapter3 Programming and Parameters Advanced Program Group continued A540 Var PWM Disable Related Parameter s A440 O Ray drive before changing this parameter Enables disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 PWM Frequency Options 0 Enabled Default 1 Disabled A541 Auto Rstrt Tries Related Parameter s A542 Sets the maximum number of times the drive attempts to reset a fault and restart See Chapter 4 for more information on faults and fault codes Clear a Type 1 fault and restart the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsi
145. Jump to Step 5 Jump to Step 6 Jump to Step 7 End Program Normal Stop End Program Coast to Stop sSlwololwnl alul alwl rn alo End Program and Fault F002 Rockwell Automation Publication 520 UM001D EN E September 2013 201 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Digit 2 Defines what logic must be met to jump to a step other than the very next step Setting Description Logic 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 is not active logically false FALSE 5 Step 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 In2 is active logically true and Logic In 1 is not active logically false XOR b Step after Stp Logic Time x and Logic In 1 is active logically true TIMED AND C Step after Stp Logic Tim
146. Max 0 00 500 00 Hz Display 0 01 Hz A434 DC Brake Time Related Parameter s P045 A435 Sets the length of time that DC brake current is injected into the motor Values Default 0 0s Min Max 0 0 99 9 s Display 0 15 A435 DC Brake Level Related Parameter s P045 Defines the maximum DC brake current in amps applied to the motor when P045 Stop Mode is set to either 4 Ramp or 6 DC Brake Ramp to Stop Mode DC Injection Stop Mode DC Brake Time Voltage D a speed 3 DC Brake Time pee Magnitude s Magnitude depends on depends on Time DC Brake Level Time DC Brake Level Stop Command Stop Command ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used This feature should not be used with synchronous motors Motors may be demagnetized during braking Values Default Drive Rated Amps x 0 5 Min Max 0 0 Drive Rated Amps x 1 8 Display 0 1A A436 DC Brk Time Strt Related Parameter s P045 A435 Sets the length of time that DC brake current is injected into the motor after a valid start command is received DC Brk Time Strt Volts Speed DC Brake Level Start GE im Values Default 0 0s Min Max 0 0 99 9 s Display 0 15 112 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 A
147. Maximum Short Circuit Rating 100 000 Amps Symmetrical Actual Short Circuit Rating Determined by AIC Rating of installed fuse circuit breaker Transistor Type Isolated Gate Bipolar Transistor IGBT Internal DC Bus Choke 200 240V AC Input 380 480V AC Input 525 600V AC Input Only for Frame E drive ratings 11 kW 15 HP 15 18 5 kW 20 25 HP 15 18 5 kW 20 25 HP Control Specifications PowerFlex 523 PowerFlex 525 Method Sinusoidal PWM Volts Hertz Sensorless Vector Control Economizer SVC motor control and Closed Loop Velocity Vector Control Closed Loop Velocity Vector Control is not applicable to PowerFlex 523 drives Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency 10 Bit resolution Analog Output 2 of full scale 10 Bit resolution Performance V Hz Volts per Hertz 1 of base speed across a 60 1 speed range SVC Sensorless Vector 0 5 of base speed across a 100 1 speed range SVC Economizer WC Velocity Vector Control 0 5 of base speed across a 100 1 speed range 0 5 of base speed across a 60 1 speed range Not applicable to PowerFlex 523 drives Rockwell Automation Publication 520 UM001D EN E September 2013 159 Appendix A 160 Supplemental Drive Information
148. Maximum output current is 100 mA 12 10V DC Referenced to Analog Common P047 P049 Drive supplied power for 0 10V external potentiometer Maximum output current is 15 mA 13 10V In Not Active For external 0 10V unipolar or 10V bipolar input supply or P047 P049 potentiometer wiper t062 t063 Input impedance t065 t066 Voltage source 100 kQ ea A459 Allowable potentiometer resistance range 1 10 KQ 14 Analog Common Return for the analog 1 0 Electrically isolated along withthe analog 1 0 from the rest of the drive 15 4 20mA In Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 Q 1062 t063 1065 t066 A459 A471 16 Analog Output OutFreq 0 10 The default analog output is 0 10V To convert a current value t088 t089 change the Analog Output jumper to 0 20 mA Program with t088 Analog Out Sel Maximum analog value can be scaled with t089 Analog Out High Maximum Load 4 20 mA 525 Q 10 5V 0 10V 1 KQ 10 mA 17 Opto Output 1 Motor Running Program with t069 Opto Out Sell t069 t070 Each Opto Output is rated 30V DC 50 mA Non inductive t075 18 OptoOutput2 AtFrequency Program with t072 Opto Out Sel t072 t073 Each Opto Output is rated 30V DC 50 mA Non inductive t075 19 Opto Common The emitters of the Optocoupler Outputs 1 and 2 are tied together at Optocoupler Common Electrically isolated fro
149. Module on page 30 for instructions outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION To avoid a possible shock hazard caused by induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled This will help minimize the possible shock hazard from cross coupled power leads i ATTENTION National Codes and standards NEC VDE BSI etc and local codes Motor Cable Types Acceptable for 100 600 Volt Installations A variety of cable types are acceptable for drive installations For many installations unshielded cable is adequate provided it can be separated from 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 less than 15 mils 0 4 mm 0 015 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 Rockwell Automation Publication 520 UM001D EN E September 2013
150. Motor Overload if the value of this parameter is exceeded by 150 for 60 s Values Default Drive Rated Amps Min Max 0 0 Drive Rated Amps x 2 Display 0 1A 80 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Basic Program Group continued P034 Motor NP FLA Related Parameter s P040 Sets the motor nameplate FLA Used to assist the Autotune routine and motor control Values Default Based on Drive Rating Min Max 0 1 Drive Rated Amps x 2 Display 0 1A P035 Motor NP Poles Related Parameter s b015 Sets the number of poles in the motor Values Default 4 Min Max 2 40 Display 1 P036 Motor NP RPM O Ray drive before changing this parameter Sets the rated nameplate rpm of the motor Used to calculate the rated slip of the motor To reduce the slip frequency set this parameter closer to the motor synchronous speed Values Default 1750 rpm Min Max 0 24000 rpm Display 1rpm P037 Motor NP Power PowerFlex 525 only Sets the motor nameplate power Used in PM regulator Values Default Drive Rated Power Min Max 0 00 Drive Rated Power Display 0 01 kW P038 Voltage Class so drive before changing this parameter Sets the voltage class of 600V drives Only applicable to 600V drives Options 2 480V 3 600V Default P039 Torque Perf Mode o drive before changing this
151. NC NO 2 NO NC 3 NC NC Values Default 0 Min Max 0 3 Display 1 Rockwell Automation Publication 520 UM001D EN E September 2013 89 Chapter 3 t076 Relay Out Sel t081 Relay Out Sel PowerFlex 525 only Programming and Parameters Terminal Block Group continued Related Parameter s P046 P048 P050 t070 t073 t077 t082 t086 t087 t093 t094 t097 A541 A564 Determines the operation of the programmable output relay Options 0 Ready Fault Output Relay Changes State When Relay changes state when power is applied Indicates that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs Hysteresis None 1 At Frequency Drive reaches commanded frequency 0 5 Hz above 1 0 Hz below 2 MotorRunning Motor is receiving power from the drive None 3 Reverse Drive is commanded to run in reverse direction None 4 Motor Overld Motor overload condition exists 100 ms time delay on or off 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from 100 ms time delay on or off occurring 6 Above Freq Drive exceeds the frequency Hz value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 7 Above Cur Drive exceeds the current Amps value set in t077 or t082 Relay Outx Level 100 ms time delay on or off
152. RE RF D 2 None INPUT CORE RF D 1 OUTPUT CORE RF D 2 E Shielded None Shielded INPUT 1 CORE E 1 and INPUT 2 CORE E 2 OUTPUT 1 CORE E 3 and OUTPUT 2 CORE E 4 380 480V AC 15 10 3 Phase Input with Internal EMC Filter 0 460V 3 Phase Output A None INPUT CORE A 1 OUTPUT CORE A 2 B None INPUT CORE B 1 OUTPUT CORE B 2 C _ None INPUT CORE C 1 OUTPUT CORE C 2 D _ None INPUT CORE D 1 OUTPUT CORE D 2 E None INPUT 1 CORE E 1 and INPUT 2 CORE E 2 OUTPUT 1 CORE E 3 and OUTPUT 2 CORE E 4 525 600V AC 15 10 3 Phase Input with External EMC Filter 0 575V 3 Phase Output A Metal Enclosure None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 B Metal Enclosure None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Metal Enclosure None None INPUT CORE RF C 1 OUTPUT CORE RF C 2 D Metal Enclosure None None INPUT CORE RF D 1 OUTPUT CORE RF D 2 E Metal Enclosure None Metal Enclosure None Recommended Placement of EMC Cores with Optional EMC Plate Frame A Frame B Frame C Frame D A Input cable to drive Shielded or Unshielded Frame E CORE INPUT CORE INPUT CORE OUTPUT CORE OUTPUT CORE INPUT CORE OUTPUT CORE INPUT CORE OUTPUT CORE OUTPUT 2 56 A Output cable from drive Shielded a Shows contactto Le WI shielded laye
153. Rotate Tune for best performance P041 Accel Time 1 Related Parameter s P044 A439 Sets the time for the drive to accelerate from 0 Hz to P044 Maximum Freq Accel Rate Maximum Freq Accel Time x Maximum Freq 0 Accel Timex Time Decel Time x Values Default 10 00s Min Max 0 00 600 00 s Display 0 015 P042 Decel Time 1 Related Parameter s P044 A439 Sets the time for the drive to decelerate from P044 Maximum Freq to 0 Hz Decel Rate Maximum Freq Decel Time x Maximum Freq 0 Accel Timex Time Decel Timex 0 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 P043 Minimum Freq Related Parameter s b001 b002 b013 P044 A530 A531 O Ray drive before changing this parameter Sets the lowest frequency the drive outputs Values Default 0 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz 82 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Basic Program Group continued P044 Maximum Freq Related Parameter s b001 b002 b013 b016 P043 A530 A531 O Kay drive before changing this parameter Sets the highest frequency the drive outputs IMPORTANT This value must be greater than the value set in P043 Minimum Freq Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz P045 Stop Mode Related Parameter s
154. S 110 C2 SSVD 02 390 WOPL Z 090 NOvL Cl 2 00L J rail Du oef ss CU Cl S WOLN8100 8SZ 91 32 WOrl 0E 4 S10 14019 SHHSSYTD 9L9 32 WObL SLI 090 NObL z 2 00L a Sel oi SOL ml os OF O S PLLNOLOG aSz 91 32 WOrl 0E 4 S10 110 f D AYSSYD 9LI 3Z WOPL S1 090 NOPL o 001 a sej gel SOL ml os pl 0s POLN0100 8SZ 0L 32 WOrl SL Y S10 L10 fD SHU seg 01D 3O WOPL 013 090 N0YL OL 609 001 v SZ 69 09 fi EI CT O PLLN0490 8SZ 01 32 WOrl SL 4 S10 110 fD SHU seg 01D 30O WOPL 01 09d NOrL OL 609 001 v SZ 69 09 fi og CT O PO0LN0d90 8 SZ 99 32 WOrL SL 4 S10 110 8 SSVI 98 3Z WOPL 099 090 NObL OL 60001 v foi Cl ml zi oz CU 0OZ FLLN0drGQ 8SZ Glace SL 4 S10 110 2 8 ef 98 320O WOPL 099 090 NOPL OL 609 001 vu LS Cl ml si oz CU 07 POLNOdva A57 0v8 32 WOPL OL Y S1 1409 SHU ef 0r8 320O WOPL 099 090 NOFL a 000 v Ei el El sco OL SO OL vLiNedza asz 0v8 32 WOPL 01 8 S10 L10 T 0 SSVD Ov8 3Z WorL 099 090 NorL 9 209 001 V Cl eil Cl sn OL sr OL pOLNEdZa 887 79 42 WOrL 9 4 5710 140 T Dat seg SZ9 3Z7 WOL 0 8 090 NOFL 209 001 v 61 LL FU voj sof voj SO PLLNPdIG 8SZ 79 42 WOrL 9 4 51 L10 T SHU SSV1 sz8 3O WOP1 0 9 EQ90 N0YL 200 001 V EU DU EU vof Sof voj SO POLNrdLO a57 gi W0PL notl ON ojee sser Worl notl Guney xew Buneu unw oN Gojeyey azis sduy gu sdwy Mi dH MA
155. SI Network Parameter Details Reference P046 Start Source 1 Set to 3 Serial DSI if Start is controlled from the network page 83 P047 Speed Reference1 Set to 3 Serial DSI if the Speed Reference is controlled from the network page 8 F C123 RS485 Data Rate Sets the data rate for the RS485 DSI Port All nodes on the network must be set to the same data rate D oO Ka K C124 RS485 Node Addr Sets the node address for the drive on the network Each device on the age 9 network requires a unique node address C125 Comm Loss Action Selects the drive s response to communication problems 126 Comm Loss Time Sets the time that the drive will remain in communication loss before the drive implements C125 Comm Loss Action oo C127 Comm Format Sets the transmission mode data bits parity and stop bits for the RS485 DSI page 9 Port All nodes on the network must be set to the same setting EI C121 Comm Write Mode Set to 0 Save when programming drive Set to 1 RAM only to only write to volatile memory 190 Rockwell Automation Publication 520 UM001D EN E September 2013 Supported Modbus Function Codes Writing 06 Logic Command Data RS485 DSI Protocol Appendix C The peripheral interface DSI used on PowerFlex 520 series drives supports some of the Modbus function codes Supported Modbus Function Codes Modbus F
156. SSVI Obg 32O WOPL 0vg Q90 N0YL 9 9 109 001 V c C v0 S0O POLNSd28 VSZ SZ8 3O WOPI 0O g Q9q nOpl s1 u S10 140 T oyWSSV s g 32O WOPL 0 4 090 NObL 9 109 001 V ell 60 TO SCO vOLN9dLE S7 waa Norl Novi ON Bojeyey sseD Wor NOvL Buueg ven Guney uiw on Dog azis sdwy Ou MA dH ON Boiee Sloyeo1g Um 6uney xXeW s snj S19JJe91g Um s snj JOE oU HEN kng Kaeay suoneriddy 1 suoiye gt 1 ddy 1 UON 931 shuryey ynduy sbuney dung OR SUDI sariaag U0I 2 01d ndu SDYd E AOPZ 007 p nullu02 7S X 449M04 10J S1 e 1g JINDAL pue sasn4 Rockwell Automation Publication 520 UM001D EN E September 2013 24 Chapter 1 Installation Wiring UL Z9 OL X 81 XBL WU g 692 X 7 IER X C SP Jo zIs uuntulului a UI ANSOPU paye QUAA UOU 10 pal Du A e u p lle sui aq INU 016463 8SZ a4 LA MOD WOY L au YLM pasn aM suiayscs puno DU eysisaJ Ybiy 10 punou 19W10 2430 240 A009 10 A08r UO SN 104 Doll IN JON ndui W LvE A009 pue 2 A09r 40 PRSI IN 18 0J U0 1030W UO JeUIqWO D adi D9 D29101d J 9 enuey S du JOU JIM adIAap ay PPY bue1 wuntu IY 0 Jas di Wa um ay JAVY Pinoys uea Wa um qe snfpe yum Woy ugang shuney UO ddy S193991g WN u01 29101d 1070W WOP L UNIMA Kaen Kew S492319 JINDAL 10199 01d 1070W WOY ul ng I4 Jo sbure DIV PUL 2 Bunea waum mu aAU p 104 a e daweu AUP ay
157. The Stop terminal is jumpered to allow starting from the keypad or comms If the control scheme is changed to Sink SNK the jumper must be removed from 1 0 Terminals 01 and 11 and installed between 1 0 Terminals 01 and 04 Wire I O as required for the application 8 Wire the power input and output terminals 10 11 12 13 14 15 Confirm that all inputs are connected to the correct terminals and are secure Collect and record motor nameplate and encoder or feedback device information Verify motor connections e Is the motor uncoupled e What direction will the motor need to turn for the application Verify the input voltage to the drive Verify if the drive is on a grounded system Ensure the MOV jumpers are in the correct position See AC Supply Source Considerations on page 19 for more information Apply power and reset the drive and communication adapters to factory default settings To reset the drive see parameter P053 Reset to Defalts To reset the communication adapters see the user manual of the adapter for more information Configure the basic program parameters related to the motor See Smart Start Up with Basic Program Group Parameters on page 65 Complete the autotune procedure for the drive See parameter P040 Autotune for more information If you are replacing a drive and have a backup of the parameter settings obtained using the USB utility application use the USB utility ap
158. Time 10x0 3 35s I Target Gr i I I i l 3 S Curve Time Accel Time gt l 3 S Curve Time l 4 Total Time to Accelerate Accel Time S Curve Time gt Total Time to Accelerate Accel Time S Curve Time gt Values Default 0 Min Max 0 100 Display 1 Rockwell Automation Publication 520 UM001D EN E September 2013 113 Chapter3 Programming and Parameters Advanced Program Group continued A440 PWM Frequency Related Parameter s A540 Sets the carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM frequency setting 100 96 92 88 84 80 76 72 68 64 60 56 50 Output Curent A 123 45 67 8 9 0 11 12 1 14 15 16 Carrier Frequency kHz IMPORTANT noring derating guidelines can cause reduced drive performance The drive may automatically reduce the PWM carrier frequency at low output speeds unless prevented from doing so by A540 Var PWM Disable Values Default 4 0 kHz Min Max 2 0 16 0 kHz Display 0 1 kHz A441 Droop Hertz FLA PF 525 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 Display 0 1 Hz A442 Accel Ti
159. Time hr 614 Freq 1 kp 521 MultiDrv Sel 169 Fault 4 Time min 624 Freq 20 512 Opt Data In 1 161 Fault 5 BusVolts 655 Freq 2 BWO 513 Opt Data In 2 162 Fault 5 Code 605 Freq 2 Kit 524 Opt Data In 3 163 Fault 5 Current 645 Freq 2 Kp 523 Opt Data In 4 164 Fault 5 Freq 635 Freq 30 514 Opt Data Out 1 165 1 Parameter is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 143 Chapter3 Programming and Parameters Parameter Name No Parameter Name No Parameter Name No Opt Data Out 2 166 Positioning Mode 558 Skip Freq Band 2 451 Opt Data Out 3 167 Power Loss Mode 548 Skip Freq Band 30 453 Opt Data Out 4 168 Power Saved 018 Skip Freq Band Al 455 Opto Out Logic 075 Preset Freq 0 410 Skip Frequency 1 448 Opto 0ut1 Levelt 070 Preset Freq 1 411 Skip Frequency 2 450 Opto 0ut1 Sel 069 Preset Freq 2 412 Skip Frequency 30 452 Opto Out2 Level 073 Preset Freq 3 413 Skip Frequency Al 454 Opto Out2 Sel 072 Preset Freq 4 414 Sleep Level 101 Out Phas Loss En 557 Preset Freq 5 415 Sleep Time 102 Output Current 003 Preset Freq 6 416 Sleep Wake Sel 100 Output Freq 001 Preset Freq 7 417 Slip Hz Meter 375 Output Power 017 Preset Freq DR 418 Speed Feedback 376 Output Powr Fctr 381 Preset Freq di 419 Speed Ratio 572 Output RPM 015 Preset Freq 100 420 Speed Reference1 047 O
160. Time is set to enable speed synchronization When this input is released the drive accelerates to the commanded frequency in A571 Sync Time 33 Traverse Dis When an input is programmed the traverse function is disabled while this input is active See A567 Max Traverse 34 Home Limit 2 In Positioning mode indicates the drive is at the home position See Appendix E for more information on Positioning 35 Find Home In Positioning mode causes the drive to return to the Home position when a Start command is issued Uses A562 Find Home Freq and A563 Find Home Dir until the Home Limit input 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 Positioning 36 Hold Step In Positioning mode overrides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released While in Hold the drive ignores any input command which would normally result in a move to a new step Timers continue to run Therefore when the Hold is removed the drive must see any required d
161. User Manual Allen Bradley PowerFlex 520 Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information
162. a speed reference PID reference or PID setpoint in the drive Options 0 Disabled Default 1 Fault F29 Stop Zero Ref Min Freq Ref Max Freq Ref Key Freq Ref MOP Freq Ref Continu Last co N ON Cn A C N t095 Anlg In4 20mA Lo Related Parameter s P043 t096 so drive before changing this parameter Sets the percentage based on 4 20 mA of input current applied to the 4 20 mA analog input used to represent P043 Minimum Freq Analog inversion can be accomplished by setting this value larger than t096 Anlg In4 20mA Hi Values Default 0 0 Min Max 0 0 100 0 Display 0 1 t096 Anlg In4 20mA Hi Related Parameter s P044 t095 o drive before changing this parameter Sets the percentage based on 4 20 mA of input current applied to the 4 20 mA analog input used to represent P044 Maximum Freq Analog inversion can be accomplished by setting this value smaller than t095 Anlg In4 20mA Lo Values Default 100 0 Min Max 0 0 200 0 Display 0 1 t097 Anlgin mA Loss Related Parameter s P043 P044 A426 A427 Sets the response to a loss of input When the 4 20mA input is used for any reference any input less than 2 mA is reported as a signal loss Input must exceed 3 mA for the signal loss condition to end If enabled this function affects any input that is being used as a speed reference or PID referenc
163. adapter interface connector into the Control Module Make sure the indicator line on the connector is aligned with the surface of the Control Module For PowerFlex 523 Communication adapter interface connector For PowerFlex 525 Communication 2 Align the connectors on the communication adapter to the communication adapter interface connector then push the back cover down 186 Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B 3 Press along the edges of the back cover until it snaps firmly into place Communication adapter interface f connector A 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 Kp Rockwell Automation Publication 520 UM001D EN E September 2013 187 AppendixB Accessories and Dimensions Notes 188 Rockwell Automation Publication 520 UM001D EN E September 2013 Network Wiring Appendix C RS485 DSI Protocol PowerFlex 520 series drives support the RS485 DSI protocol to allow efficient operation with Rockwell Automation peripherals In addition some Modbus functions are supported to allow simple networking PowerFlex 520 series drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode PowerFlex 520 Series Drive Network
164. al Common Return for digital I 0 Electrically isolated along with the digital 1 0 from the rest of the drive 05 Digin TermBlk 05 Preset Freq Program with t065 DigIn TermBlk 05 t065 Current consumption is 6 mA 06 Digin TermBlk 06 Preset Freq Program with t066 Digln TermBlk 06 t066 Current consumption is 6 mA 07 Digin TermBlk 07 Start Source 2 Program with t067 Digln TermBlk 07 Also functions as a Pulse t067 Pulse In Speed Train input for reference or speed feedback The maximum Reference2 _ frequency is 100 kHz Current consumption is 6 mA 08 Digin TermBlk 08 Jog Forward Program with t068 DigIn TermBlk 08 1068 Current consumption is 6 mA q ja 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 Q Q _ This is the signal common for the communication signals _ S1 Safety 1 Safety input 1 Current consumption is 6 mA S2 Safety 2 Safety input 2 Current consumption is 6 mA S Safety 24V 24V supply for safety circuit Internally tied to the 24V DC source Pin 11 Rockwell Automation Publication 520 UM001D EN E September 2013 43 Chapter1 _Installation Wiring Control 1 0 Terminal Designations No Signal Default Description Parameter 11 24V DC Referenced to Digital Common Drive supplied power for digital inputs
165. ameter 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 Up Arrow or Down Arrow to scroll to e be S an AppView group G1 G8 S e gt UW LIIIN 2 Press Enter or Sel to enter a group The right L most digit of the last viewed parameter in that aol HI group will flash o LJ UI J A 3 Press the Up Arrow or Down Arrow to scroll to _ Le the command G1 gt GC a gt gt wl d TT UI U AL ZIN 4 Press Enter or Sel to add all the parameters in this AppView group to the CustomView group d d y 4 The LCD display will show a confirmation or 140 Rockwell Automation Publication 520 UM001D EN E September 2013 CustomView Parameter Group Programming and Parameters Chapter 3 Use the CustomView parameter group to e store frequently used parameters for your application for quicker access e select only those parameters needed for your application and if required hide all other parameters with A552 Program Lock Up to 100 parameters can be stored in the CustomView parameter group You can copy one entire AppView parameter group to the CustomView parameter group as shown above or add individual parameters as show below
166. ameters See the respective EtherNet IP adapter user manual for more information IMPORTANT Regardless of the method used to set the adapter IP address each node on the EtherNet IP network must have a unique IP address To change an IP address you must set the new value and then remove and reapply power to or reset the adapter Rockwell Automation Publication 520 UM001D EN E September 2013 235 AppendixH EtherNet IP Notes 236 Rockwell Automation Publication 520 UM001D EN E September 2013 Numerics 2 wire inputs 50 3 wire inputs 50 A accel override priority 51 selecting 51 accessing control terminals 33 power terminals 33 applications safety 225 auxiliary contact drive 36 38 basic operation 65 drive 60 65 152 programming 65 safety 228 C circuit breakers inputs 22 ratings 22 common bus drive 38 communications positioning 212 configuring RS485 DSI 190 control terminals accessing 33 counter programming 197 200 D decel override priority 51 selecting 51 derating factor 120 temperature 17 digital inputs selecting 50 start source 50 dimensions mounting 16 173 disconnect output 36 drive auxiliary contact 36 38 Index basic operation 60 65 152 common bus 38 mount 15 programming 61 64 safety 227 drive damage preventing 19 ungrounded distribution systems 19 encoder programming 203 wiring 204 environment storage
167. amming and Parameters Options 26 Current Lmt2 2 When active A485 Current Limit 2 determines the drive current limit level 27 Anlg Invert Inverts the scaling of the analog input levels set in 1091 Anlg In 0 10V Lo and t092 Anlg In 0 10V Hi or t095 Anlg In4 20mA Lo and t096 Anlg In4 20mA Hil 28 EM Brk Rise If EM brake function is enabled this input releases the brake See t086 EM Brk Off Delay for more information ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used 29 Acc Dec Sel3 If active determines which Accel Decel time is used for all ramp rates except jog Used with option 11 Acc Dec Sel2 for the Accel Decel times listed in this table Option Description 29 11 0 O Acc Dec1 0 1 jAcc Dec2 1 10 Acc Dec3 1 1 Ac Dec4 30 Precharge En Forces drive into precharge state Typically controlled by auxiliary contact on the disconnect at the DC input to the drive If this input is assigned it must be energized for the pre charge relay to close and for the drive to run If it is de energized the pre charge relay opens and the drive coasts to a stop 31 Inertia Deel Forces drive into Inertia Ride Through state The drive attempts to regulate the DC bus at the current level 32 Sync Enable Must be used in order to hold the existing frequency when Sync
168. arameter 0 OutFreg 0 10 0 10V 0V 0Hz Maximum Freq None b001 1 OutCurr 0 10 0 10V OV 0A 200 Drive Rated FLA Filter A b003 2 OutVolt 0 10 0 10V OV 0V 120 Drive Rated Output Volts None b004 3 OutPowr 0 10 0 10V 0V 0kW 200 Drive Rated Power Filter A b017 4 OutTorg 0 10 0 10V OV 0A 200 Drive Rated FLA Filter A 382 5 TstData 0 10 0 10V 0V 0000 65535 Hex FFFF None 6 Setpnt 0 10 0 10V DN 0 100 0 Setpoint setting None t090 7 DCVolt 0 10 0 10V DN ON 100 0 of trip value None b005 8 OutFreg 0 20 0 20 mA OmA 0Hz Maximum Freq None b001 9 OutCurr 0 20 0 20 mA OmA 0A 200 Drive Rated FLA Filter A b003 10 OutVolt 0 20 0 20 mA OmA 0V 120 Drive Rated Output Volts None b004 11 OutPowr 0 20 0 20 mA OmA 0kW 200 Drive Rated Power Filter A b017 12 OutTorg 0 20 0 20 mA OmA 0A 200 Drive Rated FLA Filter A 382 13 TstData 0 20 0 20 mA 0 mA 0000 65535 Hex FFFF None 14 Setpnt 0 20 0 20mA 0 mA 0 100 0 Setpoint setting None t090 15 DCVolt 0 20 0 20 mA 0 mA 0V 100 0 of trip value None b005 16 OutFreq 4 20 4 20 mA 4mA 0hz Maximum Freq None b001 17 OutCurr 4 20 4 20 mA 4mA 0A 200 Drive Rated FLA Filter A b003 18 OutVolt 4 20 4 20 mA 4mA 0V 120 Drive Rated Output Volts None b004 19 OutPowr 4 20 4 20 mA 4mA 0kW 200 Drive Rated Power Filter A b017 20 OutTorg 4 20 4 20mA 4mA 0A 200 Drive Rated FLA Filter A 382 21 TstData 4 20 4 20 mA 4 mA 0000 6
169. art IA S21 511 552 41 13 23 33 Start 7 ahs asa S 1 MSR Gate control oc i ANY power supply button PAD S22 S14 S34 42 14 24 34 I 24V DC 3 Gate control common circuit 91 i ER E GE geed i Mine I input power PF 525 G GuardMaster TND ate Trojan Stop Stop _L o Start Start ow Gate control circuit 3 WS S1 i s2 1 Enclosure Recommended Note External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude 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 Rockwell Automation Publication 520 UM001D EN E September 2013 229 AppendixG Safe Torque Off Function 24V DC Supply 1 24V DC COM Stop Category 0 Coast with Two PowerFlex 525 Drives Wie input power PF 525 ACline EE input power Lo Stop PF 525 Stop Start Start H 24V DC Dig comm Stop I Stol l Gate control p Li Start I power supply Start I Dig comm Gate control I L Reset Gate control ower suppl circuit P SC
170. arts at Step 0 of the Step Logic profile 3 Preset StpL is identical to 2 Step Logic except the drive will use the current status of the Preset Inputs to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if setting 2 was selected 4 StpLogic Lst is identical to 2 Step Logic except the drive will use the step prior to its last stop command to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if setting 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 continuing with each step until Step 7 L214 For example enter 2 into this parameter if you would like a commanded position of 2 77 L201 L203 L205 L207 L209 L211 L213 and L215 Step Units F x are the number value to the right of the decimal the portion less than 1 of the 8 positions desired for an application beginning with Step 0 L201 and continuing with each step until Step 7 L215 For example enter
171. as Purge A459 A471 PID x Ref Sel Options Options Description 0 PID Setpoint A464 or A476 PID x Setpoint will be used to set the value of the PID Reference 1 Drive Pot The drive potentiometer will be used to set the value of the PID Reference 2 Keypad Freq The drive keypad will be used to set the value of the PID Reference 2 Serial DSI The reference word from the Serial DS communication network becomes the PID Reference 4 5 Network Opt The reference word from a communication network option becomes the PID Reference 0 10V Input Selects the 0 10V Input Note that the PID will not function with 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 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 will be used as an input for the PID Reference 10 Pulse Input Pulse train will be used as an input for the PID Reference 11 Step Logi Step Logic will be used as an input for the PID Reference 12 Encoder Encoder will be used as an input for the PID Reference 13 Ethernet IP The reference word from the Ethernet IP communication network beco
172. ata Out 2 158 Anlg Out zetet 090 Drive Temp 027 EN Data Out 3 159 Auto Rstrt Delay 542 Drive Type 367 EN Data Out 4 160 Auto Rstrt Tries 541 Droop Hertz FLA 44 EN Fit Cfg DL 1 147 Autotune 040 Drv 0 Feedback 708 EN Fit Cfg DL 2 148 Average kWh Cost 052 Drv 0 Logic Cmd 705 EN Fit Cfg DL 30 149 Average Power 020 Drv 0 Logic Sts 707 EN Fit Cfg DL 40 150 Boost Select 530 Drv 0 Reference 706 EN Flt Cfg Logic 145 Break Frequency 533 Drv 1 Addr 171 EN Flt Cfg Refl 146 Break Voltage 532 Drv 1 Feedback 712 EN Gateway Act 1 701 Bus Reg Enable 550 Drv 1 Logic Cmd 709 EN Gateway Act H 702 Cmd Stat Select 122 Drv 1 Logic Sts 711 EN Gateway Act H 703 Com Sts Emb Enet 683 Drv 1 Reference 710 EN Gateway Act A 704 Comm Loss Action 125 Drv 2 Addr 172 EN Gateway Cfg 1 137 Comm Loss Time 126 Drv 2 Feedback 716 EN Gateway Cfg 2 138 Comm Sts DSI 681 Drv 2 Logic Cmd 713 EN Gateway Cfg 3l 139 Comm Sts Opt 682 Drv 2 Logic Sts 715 EN Gateway Cfg A 140 Comm Write Mode 121 Drv 2 Reference 714 EN Idle Fit Actn 144 Commanded Freq 002 Drv 3 Addr 173 EN IP Addr Act 1 693 Compensation 547 Drv 3 Feedback 720 EN IP Addr Act 2 694 Contrl In Status 013 Drv 3 Logic md 717 EN IP Addr Act 3 695 Control Source 012 Drv 3 Logic Sts 719 EN IP Addr Act 4 696 Control SW Ver 029 Drv 3 Reference 718 EN IP Addr Cfg 1 1 129 Control Temp 028 Drv 4 Addr 174 EN IP Addr Cfg 2 130 Counter Status 364 Drv 4 Feedback 724 EN IP Addr Cfg 3 131 Counts Per Unit
173. ata Rate 123 Step Units 5 210 PID 2 Setpoint 476 RS485 Format 127 Step Units 6 212 PID 2 Trim Hi 468 RS485 Node Addr 124 Step Units 7 214 PID 2 Trim Lo 469 S Curve 439 Stop Mode 045 PID 2 Trim Sell 470 Safety Open En 105 Stp Logic 0 180 PID2 Fdbk Dispi 385 Shear Pin 1 Time 487 Stp Logic 1 181 PID2 Setpnt Dispi 386 Shear Pin1 Level 486 Stp Logic 2 182 Pos Reg Filter 565 Shear Pin 2 Time 489 Stp Logic 3 183 Pos Reg Gain 566 Shear Pin2 Level 488 Stp Logic 4 184 Position Status 387 Skip Freq Band 1 449 Stp Logic 50 185 1 Parameter is specific to PowerFlex 525 drives only 144 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Parameter Name No Parameter Name No Parameter Name No Stp Logic dl 186 Stp Logic Time dl 196 Traverse Dec 569 Stp Logic 7 187 Stp Logic Time 7 197 Traverse Inc 568 Stp Logic Status 391 Sync Time 571 Units Traveled H 388 Stp Logic Time 0 190 Testpoint Data 368 Units Traveled UI 389 Stp Logic Time 1 191 Testpoint Sel 483 Var PWM Disable 540 Stp Logic Time 20 192 Text Scroll 556 Voltage Class 038 Stp Logic Time 30 193 Timer Status 365 Wake Level 103 Stp Logic Time 40 194 Torque Current 382 Wake Time 104 Stp Logic Time 50 195 Torque Perf Mode 039 1 Parameter is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 145
174. ay This group contains parameters for the network option card that is installed See the network option card s user manual for more information on the available parameters This group contains parameters that have their values changed from the factory default d382 Units Traveled H 383 Units Traveled UI d384 Fiber Status d385 Stp Logic Status d386 d387 A497 Start At PowerUp A498 Reverse Disable A499 Flying Start En A500 FlyStrt CurLimit A509 Compensation A510 Power Loss Mode A511 Half Bus Enable A512 Bus Reg Enable A513 Fault Clear A514 Program Lock A515 Program Lock Mod A521 Drv Ambient Sel A522 Reset Meters A523 Text Scroll A524 Out Phas Loss En A525 Positioning Mode A526 Counts Per Unit A530 Enh Control Word A531 Home Savel A532 Find Home Freg A533 Find Home Dir A534 Encoder Pos Tol A535 Pos Reg Filter A536 Pos Reg Gain A537 Max Traverse A538 Traverse Inc A539 Traverse Dec A540 P Jump A541 Sync Time A542 Speed Ratio d388 d389 d390 d391 A543 A544 A545 A546 A547 A548 A549 A550 A551 A552 A553 A554 A555 A556 A557 A558 A559 A560 A561 A562 A563 A564 A565 A566 A567 A568 A569 A570 A571 A572 When a parameter has its default value changed it is automatically added to this group When a parameter has its value changed back to the 1 Parameter is specific to PowerFlex 525 drives only factory default it is automatically removed from this group R
175. back 217 Analog PID Reference Signals 218 Appendix G PowerFlex 525 Safe Torque Off Overview 223 EC Type Examination Certification 224 EMC Instructions 224 Using Power Flex 525 Safe Torque Off 224 KEE 225 Enabling PowerFlex 525 Safe Torque Off 227 WIE de Batt Nish ee M S eh 227 PowerFlex 525 Safe Torque Off Operation 227 KE 228 Connection Kamera d ve Ae endo erie tae 229 PowerFlex 525 Certification for Safe Torque Off 233 Appendix H Establishing A Connection With EtherNet IP 235 Rockwell Automation Publication 520 UM001D EN E September 2013 7 Table of Contents Notes 8 Rockwell Automation Publication 520 UM001D EN E September 2013 Who Should Use this Manual Recommended Documentation Overview Preface The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex 520 Series Adjustable Frequency AC Drive For information on See page Who Should Use this Manual 9 Recommended Documentation 9 Manual Conventions 10 Drive Frame Sizes 11 General Precautions 12 Catalog Number Explanation B This manual is intended for qualified pe
176. be activated independent of StepLogic Parameters Active when L180 L187 Digit 1 or 2 are set to 1 b C d or E 0 L180 Stp Logic 0 A410 Preset Freq 0 L190 Stp Logic Time 0 1 L181 Stp Logic 1 A411 Preset Freq 1 L191 Stp Logic Time 1 2 L182 Stp Logic 2 A412 Preset Freq 2 L192 Stp Logic Time 2 3 L183 Stp Logic 3 A413 Preset Freq 3 L193 Stp Logic Time 3 4 L184 Stp Logic 4 A414 Preset Freq 4 L194 Stp Logic Time 4 5 L185 Stp Logic 5 A415 Preset Freq 5 L195 Stp Logic Time 5 6 L186 Stp Logic 6 A416 Preset Freq 6 L196 Stp Logic Time 6 7 L187 Stp Logic 7 A417 Preset Freq 7 L197 Stp Logic Time 7 The position for any step is programmed using parameters L200 L214 Step Units x Step StepLogic Position Parameter O 1200 Step Units 0 amp L201 Step Units F 0 1 L202 Step Units 1 amp L203 Step Units F 1 2 L204 Step Units 2 amp L205 Step Units F 2 3 L206 Step Units 3 amp L207 Step Units F 3 4 L208 Step Units 4 amp L209 Step Units EA 5 6 7 L210 Step Units 5 amp L211 Step Units F 5 L212 Step Units 6 amp L213 Step Units F 6 L214 Step Units 7 amp L215 Step Units F 7 How StepLogic Works The StepLogic sequence begins with a valid start command A normal sequence always begins with L180 Stp Logic 0 Digit 1 Logic for next step This digit defines the logic for the next step When the condition is met the program advances to t
177. ber 2013 105 Chapter3 Programming and Parameters Advanced Display Group d360 Analog In 0 10V Related Parameter s t091 t09 Displays the 0 10V analog input as a percent of full scale t092 Values Default Read Only Min Max 0 0 100 0 Display 0 1 d361 Analog In 4 20mA Displays the 4 20 mA analog input as a percent of full scale Related Parameter s t095 t096 Values Default Read Only Min Max 0 0 100 0 Display 0 1 d362 Elapsed Time hr Related Parameter s A555 Displays the total elapsed powered up time in hours since timer reset The timer stops when it reaches the maximum value Values Default Read Only Min Max 0 32767 hr Display 1hr 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 the current value of the counter if enabled Values Default Read Only Min Max 0 65535 Display 1 d365 Timer Status W 32 bit parameter Displays the current value of the timer if enabled Values Default Read Only Min Max 0 9999 s Display 1s d367 Drive Type Used by Rockwell Automation field service personnel Values Default Read Only Min Max 0 65535 Display 1 Ro
178. blication 520 UM001D EN E September 2013 IP 30 NEMA 1 UL Type 1 Frame B Dimensions are in millimeters and inches Accessories and Dimensions Appendix B 66 1 2 60 63 1 2 48 33 5 1 32 23 9 0 94 UUUUUUUUUU 221 5 20 85 Z 927 5 91 08 NL A 5 J gy J 128 5 5 06 108 5 4 27 88 3 3 48 aa fi sh I 67 3 2 65 Rockwell Automation Publication 520 UM001D EN E September 2013 IP 30 NEMA 1 UL Type 1 conduit box Ea C 8700343 S IP 30 NEMA 1 UL Type 1 top panel 72 5 2 85 172 0 6 77 deeg St A w Ge es X a gt SS SS Fa EH eg gt es Ki gt Cc gt z SR I Ye E KS a gt G PowerFlex
179. can store up to 100 parameters Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Basic Display Group b001 Output Freq Related Parameter s b002 b010 P043 P044 P048 P050 P052 Output frequency present at T1 T2 amp T3 U V amp W Does not include slip frequency Values Default Read Only Min Max 0 00 Maximum Freq Display 0 01 Hz b002 Commanded Freq Related Parameter s b001 b013 P043 P044 P048 P050 P052 Value of the active frequency command even if the drive is not running IMPORTANT The frequency command can come from a number of sources See Start and Speed Reference Control on page 49 for more information Values Default Read Only Min Max 0 00 Maximum Freq Display 0 01 Hz b003 Output Current Output current present at T1 T2 amp T3 U V amp 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 amp T3 U V amp W Values Default Read Only Min Max 0 0 Drive Rated Volts Display 0 1V b005 DC Bus Voltage Filtered DC bus voltage level of the drive Values Default Read Only Min Max 0 1200VDC Display 1vDC b006 Drive Status Related Parameter s A544 Present operating condition of the drive
180. ckwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Display Group continued d368 Testpoint Data Displays the present value of the function selected in A483 Testpoint Sel Related Parameter s A483 Values Default Read Only Min Max 0 FFFF Display 1 d369 Motor 0L Level Displays the motor overload counter Values Default Read Only Min Max 0 0 150 0 Display 0 1 d375 Slip Hz Meter Related Parameter s P032 Displays the current amount of slip or droop absolute value 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 ZS 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 64000 rpm Display 1rpm d378 Encoder Speed i 32 bit parameter PowerFlex 525 only Provides a monitoring point that reflects the speed measured from the feedback device This shows the encoder or pulse train speed even if not used directly to control motor speed Values Default Read Only Min Max 0 64000 rpm Display 1 rpm d380 DC Bus Ripple Displays the real time value of the DC bus ripple voltage Values Default Read Only Min Max 0 410VDC for 230V AC drives
181. coderA NOT j i p B B Encoder B WEE uadrature B input A B Encoder B NOT P I m PowerReturn s A T Internal power source 250 mA isolated V 5 12V Power o UN ra a Output DIP switch selects 12 or 5 volt power supplied at terminals V and Cm for the encoder 1 When using 12V Encoder power 24V 1 0 power maximum output current at 1 0 Terminal 11 is 50 mA 2 If Encoder requires 24V power it must be supplied by an external power source IMPORTANT A quadrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forward direction matches the motor forward direction If the drive is reading encoder speed but the position regulator or other encoder function is not working properly remove power to the drive and swap the A and A NOT encoder channels or swap any two motor leads Drive will fault when an encoder is incorrectly wired and A535 Motor Fdbk Type is set to 5 Quad Check Encoder Wiring Examples 1 0 Connection Example 1 0 Connection Example Encoder Power 12VDC Encoder Power Internal Drive v Jopa External S Power 2 Sir Power Source LE A B HOJ wm LD z A e External Internal drive He Power 12V DC 250mA I Encoder Signal to Power Supply Encoder Signal Single Ended wie Differentia
182. cting 1 0 terminals C1 and 2 to ground may improve noise immunity e Replace wiring Modbus master device or control module F082 OptCommLoss 2 Communications between the driveand Cycle power the network option card have been e Reinstall option card in drive interrupted e Modify using 125 Comm Loss Action e Replace wiring port expander option card or control module F083 EN Comm Loss 2 Internal communications between the Cycle power drive and the embedded EtherNet IP e Check EtherNet IP setting adapter have been interrupted e Check drive s Ethernet settings and diagnostic parameters e Modify using C125 Comm Loss Action e Replace wiring Ethernet switch or control module F091 Encoder Loss 2 Requires differential encoder e Check Wiring One of the 2 encoder channel signals is fP047 P049 P051 Speed missing Referencex 16 Positioning and A535 Motor Fdbk Type 5 Quad Check swap the Encoder channel inputs or swap any two motor leads e Replace encoder F094 Function Loss 2 Freeze Fire Function Loss inputis Close input to the terminal and cycle inactive input to the programmed power terminal is open F100 Parameter Chksum 2 Drive parameter non volatile storage is Set P053 Reset To Defalts to 2 Factory corrupted Beet F101 External Storage 2 External non volatile storage has failed Set P053 Reset To Defalts to 2 Factory Beet F105 C C
183. d Edge IMPORTANT There e greater potential voltage on the output terminals when using this option e Outputs are kept in a ready to run state The drive will respond to a Start command within 10 ms 1 0 Terminal 01 Stop Coast to stop 1 0 Terminal 03 Run REV 3 Momentary Drive will start after a momentary input from either the Run FWD input 1 0 Terminal 02 or the Run REV input 1 0 Terminal 03 1 0 Terminal 01 Stop Stop according to the value set in P045 Stop Mode Rockwell Automation Publication 520 UM001D EN E September 2013 87 Chapter 3 t069 Opto Out Sel t072 Opto Out Sel PowerFlex 525 only Programming and Parameters Terminal Block Group continued Related Parameter s P046 P048 P050 t070 t073 t077 t082 t086 t087 t093 t094 t097 A541 A564 Determines the operation of the programmable digital outputs Options 0 Ready Fault Setting Output Changes State When Opto outputs are active when power is applied Indicates that the drive is ready for operation Opto outputs are inactive when power is removed or a fault occurs Hysteresis None occurring 1 At Frequency Drive reaches commanded frequency 0 5 Hz above 1 0 Hz below 2 MotorRunning Motor is receiving power from the drive None 3 Reverse Drive is commanded to run in reverse direction None 4 Motor Overld Motor overload conditio
184. d connections should be periodically checked Typical Grounding Ss o le Onde nannanana SHLD Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 Ground Fault Monitoring If a system ground fault monitor RCD is to be used only Type B adjustable devices should be used to avoid nuisance tripping Safety Ground PE This is the safety ground for the drive that is required by code One of these points must be connected to adjacent building steel girder joist a floor ground rod or bus bar Grounding points must comply with national and local industrial safety regulations and or electrical codes 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 block provides a grounding point for the motor cable shield The motor cable shield connected to one of these terminals drive end 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 with a cable clamp for a grounding point for the cable shield When
185. d monitoring devices of type A or AC to provide protection for other equipment in the installation Where an RCD or RCM is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product V ATTENTION PowerFlex 520 series drives produce DC current in the Installation Requirements Related to EN 6 1800 3 and the EMC Directive e The drive must be earthed grounded as described in Connections and Grounding on page 55 See General Grounding Requirements on page 20 for additional grounding recommendations Output power wiring to the motor must employ cables with a braided shield providing 75 or greater coverage or the cables must be housed in metal conduit or equivalent shield must be provided Continuous shielding must be provided from the drive enclosure to the motor enclosure Both ends of the motor cable shield or conduit must terminate with a low impedance connection to earth Drive Frames A E At the drive end of the motor either a The cable shield must be clamped to a properly installed EMC Plate for the drive Kit number 25 EMC1 Fx or b The cable shield or conduit must terminate in a shielded 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 earthed motor wiring box attached to the motor The motor wir
186. dH yON boeze Sloyeo1g Um Dune xelW sasn Slay e01g UO s snj Newel Wei Kmq gan Ayng jewoN suone3iddy 1N suone gt iddy 10 uoN 331 shuryey ynduy suey yndyng J SUDI S 2A UOIDa10 Indu SDYd E NOS OSE p nul u02 SZ X9 449M04 104 SAaya1g N11 pue sasn4 Rockwell Automation Publication 520 UM001D EN E September 2013 28 Chapter 1 Installation Wiring UL Z9 OLX BL XL WW 8 697 x Z Sh X C LSY JO zIs Wu IY YIM ainsopus p lellu A uou 10 PLUJA e U p l 1su aq INU FOL 6d6I ASZ a AL UNA WOY L ayy YAM pasn au swuaysAs Dun arueysisas YBIy 10 punos6 au 103 e1 q e1l q A009 40 A08F UO sn 104 paysi IN JON INdUI JY P A009 pue Z A09F 104 Parsi IN 49 04 U0 1010W uoneurqwo D ad payra olg sJas IenueW du JOU Wun 3IA p ay yey Bue1 UnL ay 0 3s di WS Um ay ALY Pinoys au uan ajqeysn pe YM WOY L un ling Huey VOTE stayearg Wn U01D31014 1010W WOPL ull l ng Aaea Kew siayeadg UNAN JOPa Old JOOW WOPL UN JING ay jo sbuned 2 ayy Bunea quand yndyul aAup 10J aye daweu IAP ay 01 19J 1 suea dwe Jamo YIM S1010uu Bul 011u02 SI AAUP ay U UM M A LL dH SL anoge s p 10J age Eug aue surea Dnp Aneay pue jeWUON 09 110 SSY 384 WOrL 05 9H NOvL Z 001 POLNZE0I S2 0S 140 C SSY e 394 W0rL SEIEOIIORL 0 00L VOLNZ 03 S2 09 140 SSY 484 WObL SEXEDIH N0YL 0 001 VOLNCC03 8S 0S
187. dule Three channel 1769 SM2 Universal Serial Bus USB Provides serial communication with DF1 protocol for use with 1203 USB Converter Module Connected Components Workbench software Includes e 2m USB cable 1 20 HIM H10 cable 1 e 22 HIM H10 cable 1 Serial Converter Module Provides serial communication with DF1 protocol for use with 22 SCM 232 RS485 to RS232 Connected Components Workbench software Includes e DSI to RS232 serial converter 1 e 1203 SFC serial cable 1 e 22 RJ45CBL C20 cable 1 DSI Cable 2 0 m RJ45 to RJ45 cable male to male connectors 22 RJ45CBL C20 Serial Cable 2 0 m serial cable with a locking low profile connector to connect to the serial converter and a 9 pin sub miniature D female connector to connect to a computer 1203 SFC Splitter Cable RJ45 one to two port splitter cable Modbus only AK U0 RJ45 SC1 Terminating Resistors RJ45 120 Ohm resistors 2 pieces AK U0 RJ45 TR1 Terminal Block RJ45 Two position terminal block 5 pieces AK U0 RJ45 TB2P Connected Components Workbench Software Download or DVD ROM Windows based software packages for programming and configuring Allen Bradley drives and other Rockwell Automation products Compatibility Windows XP Windows Vista and Windows 7 Rockwell Automation Publication 520 UM001D EN E September 2013 http ab rockwellautomation co m programmable controllers connected
188. dvanced Program Group continued A437 DB Resistor Sel O Ray drive before changing this parameter Enables disables external dynamic braking and selects the level of resistor protection Options 0 Disabled Default 1 Norml RA Res 5 2 NoProtection 100 3 99 3 99 DutyCycle A438 DB Threshold Related Parameter s A437 Sets the DC bus voltage threshold for Dynamic Brake operation If DC bus voltage rises above this level Dynamic Brake turns on Lower values makes the dynamic braking function more responsive but may result in nuisance Dynamic Brake activation 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 than 90 are not needed This parameter s setting is especially important if parameter A437 DB Resistor Sel is set to 2 NoProtection Values Default 100 0 Min Max 10 0 110 0 Display 0 1 A439 S Curve Enables a fixed shape S Curve that is applied to the acceleration and deceleration ramps including jog S Curve Time Accel or Decel Time x S Curve Setting in percentage 100 S Curve 50 S Curve Example Target Se Target Accel Time 10s wa l a S Curve Setting 30 S urve
189. e or PID setpoint in the drive Options 0 Disabled Default 1 Fault F29 Stop Zero Ref Min Freq Ref Max Freq Ref Key Freq Ref MOP Freq Ref Continu Last col N ON Cn Ww N 94 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t098 Anlg Loss Delay Related Parameter s t094 t097 Sets the length of time after power up during which the drive detects no analog signal loss Response to an analog signal loss is set in t094 or t097 Analog In x Loss Values Default 0 0s Min Max 0 0 20 0s Display 0 15 t099 Analog In Filter Sets the level of additional filtering of the analog input signals A higher number increases filtering and decreases bandwidth Each setting doubles the applied filtering 1 2x filter 2 4y filter and so on Values Default 0 Min Max 0 14 Display 1 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 on the keypad display flashes to indicate the drive is in sleep mode When the appropriate analog input rises above the set Sleep Level the drive wakes and
190. e proceeding start up procedures Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove All Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing V ATTENTION Power must be applied to the drive to perform the following Prepare for Drive Start Up Drive Startup Task List 1 Disconnect and lock out power to the machine 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Ifreplacing a drive verify the current drive s catalog number Verify all options installed on the drive 4 Verify that any digital control power is 24 volts 5 Inspect grounding wiring connections and environmental compatibility Rockwell Automation Publication 520 UM001D EN E September 2013 59 Chapter2 Start Up 6 Verify that the Sink SNK Source SRC jumper is set to match your control wiring scheme See the PowerFlex 523 Control I O Wiring Block Diagram on page 40 and PowerFlex 525 Control I O Wiring Block Diagram on page 42 for location IMPORTANT The default control scheme is Source SRC
191. e x and Logic In 2 is active logically true TIMED AND d Step after Stp Logic Time x and Logic In 1 is not active logically false TIMED OR E Step after Stp Logic Time x and Logic In 2 is not active logically false TIMED OR F Do not step OR no jump to so use Digit 0 logic IGNORE Digit 1 Defines what logic must be met to jump to 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 is not active logically false FALSE 5 Step 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 logically true and Logic In 1 is not active logically false XOR b Step after Stp Logic Time x and Logic In 1 is active logically true TIMED AND C Step after Stp Logic Time x and Logic In 2 is active l
192. ed together with other components in a safety application to achieve an overall Category 3 PL e according to EN ISO 13849 1 and SIL 3 according to EN 62061 and IEC 61508 This is illustrated in Example 3 in this appendix Safety requirements are based on the standards current at the time of certification The PowerFlex 525 Safe Torque Off function 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 e the set up safety rating and validation of any sensors or actuators connected to the system e completing a system level risk assessment and reassessing the system any time a change is made certification of the system to the desired safety performance level e project management and proof testing e programming the application software and the safety option configurations in accordance with the information in this manual Rockwell Automation Publication 520 UM001D EN E September 2013 225 Appendix G 226 Safe Torque Off Function e access control to the system including password handling e analyzing all configuration settings and choosing the proper setting to achieve the required safety rating IMPORTANT When applying Functional
193. ee SS E SE SS SSC x Cc N A D AAARAARA i d Allen Bradley q An d 6 1 0 24 179 Appendix B 180 Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame Dimensions are in millimeters and inches C Rockwell Automation Publication 520 UM001D EN E September 2013 Sg 109 0 4 29 e IP 30 NEMA 1 UL Type 1 top panel 90 5 3 56 5 184 0 7 24 off S A arn D CH Lo E L N A SSS OAN Ei L J N l N C N E C a SSS SS PORTO Ke gey Cl Powerlex won O Ed Cl Cc Se SS nnnnnn an P GH 5 SS nr SS 3 bai S gt G apen iser M 100 P S Fa N E 6 0 0 24 GE 80 5 3 17 IP
194. eed Referencel 1 16 1 Drive Pot P047 1 P049 8 2 Keypad Freq P049 5 Sets the default speed command of the drive unless Degen e PO51 overridden by P049 Speed Reference2 or P051 x ee ig p051 Se Se owerFlex Speed Reference3 5 0 10V Input 1 Setting is specific to PowerFlex 525 drives only 6 4 20mA Input 7 Preset Freq 8 Anlg In Mult 9 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 13 Step Logic 14 Encoder 15 Ethernet Ip 16 Positioning P052 Average kWh Cost 0 00 655 35 0 01 0 00 Sets the average cost per kWh P053 ResetToDefalts 0 3 0 Ready Idle 0 Resets parameters to their factory defaults values After a Reset command the value of this parameter returns to zero 1 Param Reset 2 Factory Beet 3 Power Reset 66 Rockwell Automation Publication 520 UM001D EN E September 2013 LCD amp Scrolling Description Using the USB Port StartUp Chapter 2 Use parameter A556 Text Scroll to set the speed at which the text scrolls across the display Select 0 Off to turn off text scrolling See Language Support on page 64 for the languages supported by the PowerFlex 520 series drive The PowerFlex 520 series drive has a USB port that connects to a PC for the purpose of upgrading drive firmware or uploading downloading a parameter configuration You do not
195. emental Encoder In Item Incremental Encoder put Option Tee t Incremental encoder input option board 25 ENC 1 Rockwell Automation Publication 520 UM001D EN E September 2013 Accessories and Dimensions Appendix B Bulletin 160 to PowerFlex 520 Series Mounting Adapter Plate Frame Item Description Size Catalog No Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in 25 MAP FA existing installations to a PowerFlex 520 Series drive Select 75 MAP FB the catalog number based on the frame size of your Bulletin 160 drive Replacement Parts PowerFlex 520 Series Power Module Item Description PowerFlex 520 Series Replacement power module for use with PowerFlex 520 Series drives Includes Power Module Power Module e Power Module Front Cover e Power Terminal Guard Heatsink Fan Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current A Voltage Range Size Catalog No 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 85 132 A 25 PM1 V1P6 0 5 0 4 0 5 0 4 2 5 85 132 A 25 PM1 V2P5 1 0 0 75 1 0 0 75 48 85 132 B 25 PM1 V4P8 15 1 1 15 1 1 6 0 85 132 B 25 PM1 V6P0 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM1 A1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 A2P5 1 0 0 75 1 0 0 75 48 170
196. ements for machines defined in Annex I of the EC Directive 2006 42 EC and that it complies with the requirements of the relevant standards listed below e EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design PowerFlex 525 STO achieves Category 3 PL d e EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional PowerFlex 525 STO achieves SIL CL 2 e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e IEC 61508 Part 1 7 2010 Functional safety of electrical electronic programmable electronic safety related systems Parts 1 7 TUV 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 TUV Rheinland certificate may be found at www rockwellautomation com products certification PowerFlex 525 Safe Torque Off function requires CE Conformity as described on page 51 The PowerFlex 525 Safe Torque Off function is intended to be part of the safety related control system of a machine Before use a risk assessment should be performed that compares the PowerFlex 525 Safe Torque Off function specifications and all foreseeable operational and environmental characteristics of the machine to which
197. emperature 90 C wire must be used for 70 C ambient temperature Rockwell Automation Publication 520 UM001D EN E September 2013 Control 1 0 Terminal Block Installation Wiring Chapter 1 Recommended Signal Wire Signal Type Belden Wire Type s Description Min Insulation Where Used or equivalent Rating TEEN ee oe ee o SO Analog UD amp PTC 8760 9460 0 750 mm 18 AWG twisted pair 300V 100 shield with drain 60 C 140 F Remote Pot 8770 0 750 mm 18 AWG 3 conductor shielded Encoder Pulse 1 0 9728 9730 0 196 mm 24 AWG individually shielded pairs 1 Stranded or solid wire 2 If the wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Recommended Control Wire for Digital 1 0 Type Wire Type s Description Min Insulation Rating Unshielded Per US NEC or applicable 300V national or local code 60 C 140 F Shielded Multi conductor shielded 10 750 mm 18 AWG 3 conductor shielded cable such as Belden 8770 or equivalent Maximum Control Wire Recommendations Do not exceed control wiring length of 30 m 100 ft Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the I O terminal block Common may be connected to ground terminal protective earth If using the RS485 DSI port I O Termina
198. en Reduce load or extend Accel Time exceeded F070 Power Unit 2 Failure has been detected in the drive Check maximum ambient power section temperature has not been exceeded e Cycle power e Replace drive if fault cannot be cleared F071 DSI Net Loss 2 Control over the Modbus or DSI Cycle power communication link has been e Check communications cabling interrupted e Check Modbus or DSI setting Check Modbus or DSI status F072 Opt Net Loss 2 Control over the network option cards e Cycle power remote network has been interrupted e Check communications cabling Check network adapter setting e Check external network status F073 EN Net Loss 2 Control through the embedded Cycle power EtherNet IP adapter has been e Check communications cabling interrupted e Check EtherNet IP setting e Check external network status F080 Autotune Failure 2 The autotune function was either Restart procedure cancelled by the user or failed Rockwell Automation Publication 520 UM001D EN E September 2013 Troubleshooting Chapter 4 Fault Types Descriptions and Actions No Fault Type Description Action F081 DSICommLoss 2 Communications between the driveand Cycle power the Modbus or DSI master device have e Check communications cabling been interrupted e Check Modbus or DSI setting e Check Modbus or DSI status e Modify using C125 Comm Loss Action e Conne
199. ent F002 Auxiliary Input 1 External trip Auxiliary input e Check remote wiring e Verify communications programming for intentional fault F003 Power Loss 2 Single phase operation detected with e Monitor the incoming AC line for low excessive load voltage or line power interruption e Check input fuses Reduce load F004 UnderVoltage 1 DC bus voltage fell below the minimum Monitor the incoming AC line for low value voltage or line power interruption F005 OverVoltage 1 DC bus voltage exceeded maximum Monitor the AC line for high line voltage value or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F006 Motor Stalled 1 Drive is unable to accelerate or Increase P041 A442 A444 A446 decelerate motor Accel Time x or reduce load so drive output current does not exceed the current set by parameter A484 A485 Current Limit x for too long e Check for overhauling load F007 Motor Overload 1 Internal electronic overload trip Anexcessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current e Verify A530 Boost Select setting F008 Heatsink OvrImp 1 Heatsink Power Module temperature Check for blocked or dirty heat sink exceeds a predefined value fins Verify that ambient temperature has not exceeded the rated ambient temperature e Check fan
200. ep Units 1 L194 Step Units 2 L195 Step Units 3 L196 Step Units 4 L197 Step Units 5 L200 Step Units 6 L202 Step Units 7 L204 L206 L208 L210 L212 L214 Advanced Display a Analog In 0 10V Analog In 4 20mA Advanced Program E Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Preset Freq 80 Preset Freq al Preset Freq 10 Preset Freq WW Preset Freq mw Preset Freq 13 1 Preset Freq 14 1 Preset Freq 15 1 Keypad Freq MOP Freq MOP Reset Sel MOP Preload MOP Time Jog Frequency Jog Accel Decel Purge Frequency DC Brake Time DC Brake Level Modified d360 d361 A410 A411 A412 A413 A414 A415 A416 A417 A418 A419 A420 A421 A422 A423 A424 A425 A426 A427 A428 A429 A430 A431 A432 A433 A434 A435 Elapsed Time hr Elapsed Time min Counter Status Timer Status Drive Type Testpoint Data DC Brk Time Strt DB Resistor Sel DB Threshold S Curve PWM Frequency Droop Hertz FLA Accel Time 2 Decel Time 2 Accel Time 3 Decel Time 3 Accel Time 4 Decel Time 4 Skip Frequency 1 Skip Freq Band 1 Skip Frequency 2 Skip Freq Band 2 Skip Frequency 30 Skip Freq Band A Skip Frequency Al Skip Freq Band A PID 1 Trim Hi PID 1 Trim Lo PID 1 Trim Sel PID 1 Ref Sel PID 1 Fdback Sel PID 1 Prop Gain PID 1 Integ Time PID 1 Diff Rate PID 1 Setpoint PID 1 Deadband d362 Motor OL Level d363 Slip H
201. ep mode Values Default 0 0s Min Max 0 0 600 0s Display 0 15 t105 Safety Open En PF 525 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 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Communications Group C121 Comm Write Mode Saves parameter values in active drive memory RAM or in drive non volatile memory EEPROM ATTENTION If Automatic Drive Configuration ADC is used this parameter must remain at its default value of 0 Save IMPORTANT Parameter values set prior to setting 1 RAM only are saved in RAM Options 0 Save Default 1 RAM only C122 Cmd Stat Select PowerFlex 525 only Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network See Writing 06 Logic Command Data on page 191 for more information This parameter cannot be changed when an 1 0 connection is established through the communication adapter or the drive s embedded EtherNet IP port Options 0 Velocity Default 1 Position C123 RS485 Data Rate Sets the communications baud rate bits second for the RS485 port A reset or power cycle is required after selection is made Options 0 1200
202. eq 7 A417 Encoder Pos Tol A564 Minimum Freq P043 Stp Logic 3 L183 Step Units 4 L208 Preset Freq 8 A418 Pos Reg Filter A565 Maximum Freq P044 Stp Logic 4 L184 Step Units 5 L210 Jog Frequency A431 Pos Reg Gain A566 Textile Fiber Motor NP FLA P034 Digin TermBlk 02 t062 Slip Hz Meter d375 Max Traverse A567 Motor NP Poles P035 Digln TermBlk 03 t063 Fiber Status d390 Traverse Inc A568 ei Autotune P040 Opto Out Sel t069 Preset Freq 0 A410 Traverse Dec A569 Accel Time 1 P041 Opto Out Sel t072 Jog Frequency A431 P Jump A570 Language P030 Decel Time 1 P042 Relay Out Sel t076 Jog Accel Decel A432 Sync Time A571 Output Freq b001 Minimum Freq P043 Anlg In 0 10V Lo t091 S Curve A439 Speed Ratio A572 Commanded Freq b002 Maximum Freq P044 Anlg In 0 10V Hi t092 Reverse Disable A544 Motor NP Volts P031 Stop Mode P045 Anlg In4 20mA Lo t095 Power Loss Mode A548 Motor NP Hertz P032 Start Source 1 P046 Anlg In4 20mA Hi t096 Half Bus Enable A549 Motor OL Current P033 Speed Reference1 P047 Anlg In mA Loss t097 Bus Reg Enable A550 1 This AppView parameter group is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 73 Chapter 3 Programming and Parameters CustomView Parameter Group PowerFlex 520 series drives include a CustomView parameter group for you to store frequently used parameters for your application See CustomView Parameter Group on page 141 for more information Custom Group 74 This group
203. er than 0 2 Set A542 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to 0 parameters are used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines V ATTENTION Equipment damage and or personal injury may result if these 148 Rockwell Automation Publication 520 UM001D EN E September 2013 Fault Descriptions Auto Restart Reset Run Troubleshooting Chapter 4 The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention This allows remote or unattended operation Only certain faults are allowed to be reset Certain faults Type 2 that indicate possible drive component malfunction are not resettable Fault types are listed in the table Fault Types on page 147 See Fault Descriptions on page 149 for more information Use caution when enabling this feature since the drive will attempt to issue its own start command based on user selected programming Fault Types Descriptions and Actions No Fault Type Description Action F000 No Fault No fault pres
204. erational Values Reading 03 and Writing 06 Drive Parameters Additional Information 196 Drive Error Codes Logic Status Address Decimal Value Decimal Description 2101H 8449 125 Flash Update Required 126 Non Recoverable Error 127 DSI Flash Update Required The PowerFlex 520 series Drive Operational Values can be read through the network by sending Function Code 03 reads to register addresses 2102H 210AH Drive Operational Values Reference Address Decimal Description 2102H 8450 Frequency Command xxx xx Hz 2103H 8451 Output Frequency xxx xx Hz 2104H 8452 Output Current xxx xx A 2105H 8453 DC BUS Voltage xxxV 2106H 8454 Output Voltage xxx xV To 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 See http www ab com drives for additional information Rockwell Automation Publication 520 UM001D EN E September 2013 Appendix D Velocity StepLogic Basic Logic and Timer Counter Functions Four PowerFlex 520 series logic functions provide the capability to program simple logic functions without a separate controller e Velocity StepLogic Function specific to PowerFlex 525 drives only Steps through up to eight preset speeds based on programmed logic Prog
205. ers by Cross Reference tables Throughout Chapter 3 Updated parameters Updated Fault Types Descriptions and Actions table 149 Updated Certifications table with PowerFlex 523 information Throughout Appendix A Updated Environmental Specifications table with PowerFlex 523 information Updated Technical Specifications table with PowerFlex 523 information Updated Watts Loss table 161 Added PowerFlex 523 Drive Ratings table 163 Updated PowerFlex 525 Drive Ratings table 164 Updated Dynamic Brake Resistors and EMC Line Filters tables 166 167 Updated PowerFlex 520 Series Control Module and Power Module Replacement Parts tables 169 170 Updated Bulletin 1321 3R Series Line Reactors table 172 Added Control Module Fan Kit diagrams and tables 176 Updated Installing a Communication Adapter diagram 186 Updated Network Wiring Diagram Example 189 Updated Writing 06 Logic Command Data topic 191 Updated Reading 03 Logic Status Data topic 193 Updated Encoder and Pulse Train Usage topic 203 Updated Safe Torque Off Connection Examples diagrams 229 232 Updated EtherNet IP topic Throughout Appendix H Rockwell Automation Publication 520 UM001D EN E September 2013 3 Summary of Changes Notes 4 Rockwell Automation Publication 520 UM001D EN E September 2013 Overview Installation Wiring Start Up Programming and Parameters Table of Contents Preface Who Should Use this Manual 9 Recommended Documentation
206. es 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 ATTENTION To guard against drive damage a minimum line impedance must be provided to limit inrush current when the power line recovers The input impedance should be equal or greater than the equivalent of a 5 transformer with a VA rating 6 times the drive s input VA rating if Half Bus is enabled Options 0 Disabled Default 1 Enabled A550 Bus Reg Enable Enables disables the bus regulator Options 0 Disabled 1 Enabled Default A551 Fault Clear O Ray drive before changing this parameter Resets a fault and clears the fault queue Options 0 Ready Idle Default 1 Reset Fault 2 Clear Buffer Resets the active fault but does not clear any fault buffer Resets the active fault and clears all fault buffers to 0 A552 Program Lock Related Parameter s A553 Protects parameters against change by unauthorized personnel with a 4 digit password Values Default 0000 Min Max 0000 9999 Display 1111 Rockwell Automation Publication 520 UM001D EN E September 2013 127 Chapter3 Programming and Parameters Advanced Program Group continued A553 Program Lock Mod Related Parameter s A552 Determines the lock mode used in parameter A552 Program Lock When set to 2 or 3
207. essary to generate torque in the motor e Can be used in combination with other safety devices to fulfill the requirements of a system safe torque off function which satisfies Category 3 PL d according to EN ISO 13849 1 and SIL CL2 according to EN IEC 62061 IEC 61508 and EN IEC 61800 5 2 IMPORTANT The functionis suitable for performing mechanical work on the drive system or affected area of a machine only It does not provide electrical safety Rockwell Automation Publication 520 UM001D EN E September 2013 223 AppendixG Safe Torque Off Function EC Type Examination Certification EMC Instructions Using PowerFlex 525 Safe Torque Off 224 are de energized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part Il To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points refer to your drive s User Manual for locations The voltage must be zero i ATTENTION Electric Shock Hazard Verify that all sources of AC and DC power In safe off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor T V Rheinland has certified the PowerFlex 525 Safe Torque Off function compliant with the requir
208. ety function at the intervals determined by the safety analysis described on page 224 Verify that both safety channels are functioning according to the table below Channel Operation and Verification Safety Function Drive In Drive In Drive In Drive Status Safe State Safe State Safe State Able To Run Drive Status Configured byt105 Fault F111 Fault F111 Ready Run Safety Open En Safety Hardware Safety Hardware Safety Channel Operation Safety Input S1 No Power Applied Power Applied Power Applied No Power Applied Safety Input S2 No Power Applied No Power Applied Power Applied Power Applied IMPORTANT fan external fault is present on the wiring or circuitry controlling the Safety 1 or Safety 2 inputs for a period of time the Safe Torque Off function may not detect this condition When the external fault condition is removed the Safe Torque Off function will allow an enable condition Fault in the external wiring shall either be detected by external logic or excluded wiring must be protected by cable ducting or armoring according to EN ISO 13849 2 Rockwell Automation Publication 520 UM001D EN E September 2013 Safe Torque Off Function Appendix G Connection Examples Example 1 Safe Torque Off Connection with Coast to Stop Action SIL 2 PL d Stop Category 0 Coast ACline input power PF 525 24V DC Stop Stop L o St
209. face ATTENTION Risk of injury or equipment damage exists Parameter 143 EN Comm Fit Actn lets you determine the action of the EtherNet IP interface and connected drive if communications are disrupted By default this parameter faults the drive You can set this parameter so that the drive continues to run Precautions should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage When commissioning the drive verify that your system responds correctly to various situations for example a disconnected drive 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 Datalink values will be transmitted to the drive as configured in C145 146 and 147 C150 C144 EN Idle Fit Actn Related Parameter s P045 C145 C146 C147 C150 PowerFlex 525 only Sets the action that the EtherNet IP interface and drive takes if the EtherNet IP interface detects that the scanner is idle because the controller was switched to program mode ATTENTION Risk of injury or equipment damage exists Parameter C144 EN Idle Flt Actn lets you determine the action
210. g kesi a MI odifie FAULT A JI Functions from the other groups with values changed from default W Fault and Diagnostic Consists of list of codes for specific fault conditions O 6 Sg O E AppView and CustomView Sa S LJ Functions from the other groups organized for specific a applications Control and Navigation Keys Display Display State Description ENET PowerFlex 525 only Off Adapter is not connected to the network Steady Adapter is connected to the network and drive is controlled through Ethernet Flashing Adapter is connected to the network but drive is not controlled through Ethernet LINK PowerFlex 525 only Off Adapter is not connected to the network Steady Adapter is connected to the network but not transmitting data Flashing Adapter is connected to the network and transmitting data LED LED State Description FAULT Flashing Red Indicates drive is faulted Key Name Description Up Arrow Scroll through user selectable display parameters or groups Down Arrow 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 Sel Select a digit when viewing parameter value Enter Advance one step in programming menu Save a change to a parameter value opel 62 Rockwell Automation Publication 520 UM001D EN E September 201
211. gle numerical value 0 1V Rockwell Automation Publication 520 UM001D EN E September 2013 69 Chapter3 Programming and Parameters Bit Parameters Bit parameters have five individual digits associated with features or conditions If the digit is 0 the feature is off or the condition is false If the digit is 1 the feature is on or the condition is true Some parameters are marked as follows O Stop drive before changing this parameter E 32 bit parameter Parameters marked 32 bit will have two parameter numbers Step Units x and Step Units F x when using RS485 communications and programming software The second parameter number is shown only in the Parameter Groups and Parameter Cross Reference by Name tables for reference PF 525 Parameter is specific to PowerFlex 525 drives only Parameter Groups For an alphabetical listing of parameters see Parameter Cross Reference by Name on page 142 Basic Display Output Voltage b004 Control Source b012 Elapsed Run Time b019 Accum C02 Sav b026 DC Bus Voltage b005 Contrl In Status b013 Average Power b020 Drive Temp b027 Ka Drive Status b006 Dig In Status b014 Elapsed kWh b021 Control Temp b028 Fault 1 Code b007 Output RPM b015 Elapsed MWh b022 Control SW Ver b029 Output Freq b001 Fault 2 Code b008 Output Speed b016 Energy Saved b023 Commanded Freq b002 Fault 3 Code b009 Output Power b017 Accum kWh Sav b024 Output Current b003 Process Display b010 Power Saved b018 Accum Cost Sav b0
212. has to be active for the drive to run 43 SherPin1 Dis Disables shear pin 1 but leaves shear pin 2 active If A488 Shear Pin 2 Level is greater than 0 0 A shear pin 2 is enabled 44 Reserved 45 Reserved 46 Reserved 47 Reserved 86 Rockwell Automation Publication 520 UM001D EN E September 2013 Options 48 2 Wire FWD only for Digln TermBlk 02 Programming and Parameters Chapter 3 Digln TermBlk 02 default Select 2 Wire FWD for this input Select this option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to configure Start Source x to a 2 wire run forward mode Also see t064 2 Wire Mode for level trigger settings 49 3 Wire Start only for Digln TermBlk 02 Select 3 Wire Start for this input Select this option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to configure Start Source x to a 3 wire start mode 50 2 Wire REV only for Digln TermBlk 03 Digln TermBlk 03 default Select 2 Wire REV for this input Select this option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to configure Start Source x to a 2 wire run reverse mode Also see t064 2 Wire Mode for level trigger settings For PowerFlex 523 drives this setting will be disabled If Digln TermBlk 03 is set to 7 Preset Freq 51 3 Wire Dir only for Digln TermBlk 03 Select 3 Wire Dir for this input Select t
213. he Logix Designer application The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix 5000 controllers for discrete process batch motion safety and drive based solutions The Studio 5000 environment is the foundation 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 etc A cross reference of drive catalog numbers and their respective frame sizes is provided in Appendix B Rockwell Automation Publication 520 UM001D EN E September 2013 11 Preface Overview General Precautions 12 A ATTENTION The drive contains high voltage capacitors which take time to discharge after removal of mains supply Before working on drive ensure isolation of mains supply from line inputs R S T L1 L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the sy
214. he drive is installed on an ungrounded distribution system IT mains where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect these devices remove the 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 Power Module IMPORTANT Tighten screw after jumper removal Phase to Ground MOV Removal ege Ce i AC Input i T L3 O Jumper I 1 L 1 1 L 1 N w gt Rockwell Automation Publication 520 UM001D EN E September 2013 19 Chapter1 _Installation Wiring General Grounding Requirements 20 Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see page 159 Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life Ifany of these conditions exist install one of the devices listed under the heading Corrective Action on the line side of the drive IMPORTANT Only one device per branch circuit is required It should be mounted closest to the branch and sized to handle the total current of the branch circuit Input Power Conditions Input Power Condition
215. he 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 the condition for Digit 2 is met this digit setting determines the next step or to end the program Digit 4 Step settings This digit defines additional characteristics of each step Any StepLogic parameter can be programmed to control a relay or opto output but you can not control different outputs based on the condition of different StepLogic commands Rockwell Automation Publication 520 UM001D EN E September 2013 103 Chapter3 Programming and Parameters StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter The following is a listing of the available settings for each digit See Appendix D for more information UD Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Velocity Control Settings Digit 4 Settings Digit 3 Required Accel Decel StepLogic Commanded
216. he same time the inputs are ignored and the frequency is unchanged Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz A428 MOP Reset Sel Determines if the current MOP reference command is saved on power down Options 0 Zero MOP Ref 1 Save MOP Ref Default Resets the MOP frequency to zero on power down and stop A429 MOP Preload Determines the operation of the MOP function Options 0 No preload Default 1 Preload Bumpless Transfer whenever MOP mode is selected the current output value of the speed is loaded A430 MOP Time Sets the rate of change of the MOP reference Values Default 10 05 Min Max 0 1 600 0 s Display 0 15 A431 Jog Frequency Sets the output frequency when a jog command is issued Related Parameter s P044 Values Default 10 00 Hz Min Max 0 00 Maximum Freq Display 0 01 Hz A432 Jog Accel Decel Sets the acceleration and deceleration time used when in jog mode Values Default 10 00 s Min Max 0 01 600 00 s Display 0 015 Rockwell Automation Publication 520 UM001D EN E September 2013 111 Chapter3 Programming and Parameters Advanced Program Group continued A433 Purge Frequency Related Parameter s t062 t063 t065 t068 Provides a fixed frequency command value when t062 t063 t065 t068 Digln TermBlk xx is set to 40 Purge Values Default 5 00 Hz Min
217. he second most recent fault and Fault 3 Current stores the third most recent fault Related Parameter s b003 Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01A F651 Fault 1 BusVolts F653 Fault 3 BusVolts F655 Fault 5 BusVolts F652 Fault 2 BusVolts F654 Fault 4 BusVolts F656 Fault 6 BusVolts F658 Fault 8 BusVolts F657 Fault 7 BusVolts F659 Fault 9 BusVolts Related Parameter s b005 F660 Fault10 BusVolts PowerFlex 525 only Displays and stores the value of b005 DC Bus Voltage with the most recent 10 faults occurred Fault 1 BusVolts stores the most recent fault Fault2 BusVolts stores the second most recent fault and Fault 3 BusVolts stores the third most recent fault Values Default Read Only Min Max 0 1200VDC Display 1VDC F661 Status Fault 1 F662 Status Fault 2 Related Parameter s b006 F663 Status e Fault 3 F664 Status Fault 4 F665 Status e Fault 5 F666 Status e Fault 6 F667 Status Fault 7 F668 Status Fault 8 F669 Status Fault 9 F670 Status e Fault10 PF 525 PowerFlex 525 only Displays the value of b006 Drive Status with the most recent 10 faults occurred Status Fault 1 stores the most recent fault Status Fault 2 stores the second most recent fault and Status Fault 3 stores the third most recent faul
218. hen b001 Output Freq is displayed Press Enter or Sel to enter the group list again Drive Programming Tools Language Support 64 Some features in the PowerFlex 520 series drive are not supported by older configuration software tools It is strongly recommended that customers using such tools migrate to RSLogix 5000 version 17 0 or greater or Logix Designer version 21 0 or greater with Add On Profile AOP or Connected Components Workbench version 5 0 or greater to enjoy a richer full featured configuration experience Description Catalog Number Release Version Connected Components Workbench Version 5 0 or greater Logix Designer Version 21 0 or greater RSLogix 5000 Version 17 0 or greater Built in USB software tool Serial Converter Module 22 SCM 232 USB Converter Module 1203 USB Remote Panel Mount LCD Display 22 HIM C2S Remote Handheld LCD Display 22 HIM A3 1 Available as a free download at http ab rockwellautomation com programmable controllers connected components workbench software 2 Does not support the new dynamic parameter groups AppView CustomView and CopyCat functionality is limited to the linear parameter list Language Keypad LCD Display RSLogix 5000 Connected Components Logix Designer Workbench English Y Y Y French Y Y Y Spanish Y Y Y Italian Y Y Y German Y Y Y Japanese _ Y _ Portuguese Y Y _ hinese Simplified Y Y
219. hen thermal Motor overload counter is above the value set in t077 or t082 Relay Outx Level It None also energizes if the drive is within 5 C of the drive overheat trip point 17 Amb OverTemp Relay energizes when control module over temperature occurs None 18 Local Active Active when drive P046 P048 or P050 Start Source x is in local keypad control None 19 Comm Loss Active when communication is lost from any comm source with reference or control None 20 Logic In IW An input is programmed as Logic Input 1 and is active None 21 Logic In yU An input is programmed as Logic Input 2 and is active None 22 Logic 1 amp rau Both Logic inputs are programmed and active None 23 Logic 1 or 2 One or both Logic inputs are programmed and one or both is active None 24 StpLogic out Drive enters StepLogic step with Command Word set to enable Logic output None 25 Timer Out Timer has reached the value set in t077 or t082 Relay Outx Level or not timing None 26 Counter Out Counter has reached the value set in t077 or t082 Relay Outx Level or not counting None 27 At Position Drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with A564 Encoder Pos Tol 28 At Home Drive is in Positioning mode and has reached the home position Tolerance is adjusted with A564 Encoder Pos Tol 29 Safe off Both safe off inputs are acti
220. his option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to change the direction of Start Source x For PowerFlex 523 drives this setting will be disabled If Digln TermBlk 03 is set to 7 Preset Freq 52 Pulse Train PF523 only for Digln TermBlk 05 PF525 only for Digln TermBlk 07 Select pulse train for this input Use P047 P049 and P051 Speed Reference to select pulse input Jumper for Digln TermBIk 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 t064 2 Wire Mode O Bay drive before changing this parameter Related Parameter s P045 P046 P048 P050 t062 t063 Programs the mode of trigger only for t062 Digln TermBlk 02 and t063 Digln TermBlk 03 when 2 wire option is being selected as P046 P048 or P050 Start Source x Options 0 Edge Trigger Default Standard 2 Wire operation 1 Level Sense UO Terminal 01 Stop Coast to stop Drive will restart after a Stop command when Stop is removed and Start is held active e 1 0 Terminal 03 Run REV ATTENTION Hazard of injury exists due to unintended operation When set to option 3 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop function is provided only when the Stop input is active open 2 Hi Sp
221. ication 520 UM001D EN E September 2013 167 Appendix B 168 Accessories and Dimensions EMC Plates Frame Item Description Size Catalog No EMC Plate Optional grounding plate for shielded cables A 25 EM C1 FA B 25 EMC1 FB C 25 EMC1 FC D 25 EMC1 FD E 25 EMC1 FE Human Interface Module HIM Option Kits and Accessories Item Description Catalog No LCD Display Remote Panel Digital speed control 22 HIM C2S Mount CopyCat capable IP66 NEMA Type 4X 12 indoor use only Includes 2 9 meter cable LCD Display Remote Digital speed control 22 HIM A3 Handheld Full numeric keyboard CopyCat capable IP 30 NEMA Type 1 Includes 1 0 meter cable Panel mount with optional Bezel Kit Bezel Kit Panel mount for LCD Display Remote Handheld unit IP 30 NEMA Type 1 22 HIM B1 Includes 2 0 m DSI cable DSI HIM Cable 1 0 m 3 3 ft 22 HIM H10 DSI HIM to RJ45 cable 2 9m 9 51 ft 22 HIM H30 IP 30 NEMA 1 UL Type 1 Kit Frame Item Description Size Catalog No IP 30 NEMA 1 UL Type 1 Kit Field installed kit Converts drive to IP 30 NEMA 1 UL Type1 A 25 JBAA enclosure Includes conduit box with mounting screws and plastic top panel b E C 25 JBAC D 25 JBAD E 25 JBAE Control Module Fan Kit Frame Item Description Size Catalog No ontrol Module Fan Kit For use with drive in environments with ambient A D 25 FAN1 70C temperatures up to 70 C or horizontal mounting E 75 FAN2 70C Incr
222. ific to PowerFlex 525 drives only 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 t063 t065 t068 DigIn TermBlk xx to 24 Logic In 1 or 25 Logic In 2 Example e Runat Step 0 e Transition to Step 1 when Logic In 1 is true Logic senses the edge of Logic In 1 when it transitions from off to on Logic In 1 is not required to remain on 198 Rockwell Automation Publication 520 UM001D EN E September 2013 Velocity StepLogic Basic Logic and Timer Counter Functions Appendix D e Transition to Step 2 when both Logic In 1 and Logic In 2 are true The drive senses the level of both Logic In 1 and Logic In 2 and transitions to Step 2 when both are on e Transition to Step 3 when Logic In 2 returns to a false or off state Inputs are not required to remain in the on condition except under the logic conditions used for the transition from Step 2 to Step 3 Start Step 0 pl Step2 Step 3 Frequency Logic In 1 P Logic In2 gt Time The step time value and the basic logic may be used together to satisfy machine conditions For instance the step may need to run for a minimum time period and then use the basic logic to trigger a transition to the next step Start Step 0 Step 1 Frequency
223. igital inputs transition even if they already transitioned during the hold but it does not reset any timer See Appendix E for more information on Positioning 37 Pos Redefine In Positioning mode resets the home position to the current position of the machine See Appendix E for more information on Positioning 38 Force DC If the drive is not running causes the drive to apply a DC Holding current A435 DC Brake Level ignoring A434 DC Brake Time while the input is applied 39 Damper Input When active drive is allowed to run normally When inactive drive is forced into sleep mode and is prevented from accelerating to command speed 40 Purge Starts the drive at A433 Purge Frequency regardless of the selected control source Supersedes the keypad Control function as well as any other control command to take control of the drive Purge can occur and is operational at any time whether the drive is running or stopped regardless of the selected logic source selection If a valid stop other than from comms or SW enable is present the drive will not start on the purge input transition ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used 41 Freeze Fire When inactive will cause an immediate F094 Function Loss fault Use to safely bypass the drive with an external switching device 42 SW Enable Works like an interlock that
224. imOn Keypd TrimOn DSI TrimOn NetOp TrimOn 0 10V TrimOn 4 20 TrimOn Prset TrimOn AMi Y col NI aJ WM Bw N TrimOn MOP TrimOn Pulse TrimOn Sigi TrimOn Encdr N 13 TrimOn Eer 1 Setting is specific to PowerFlex 525 drives only 116 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A459 PID 1 Ref Sel A471 PID 2 Ref Sel PowerFlex 525 only O Ray drive before changing this parameter Selects the source of the PID reference Options 0 PID Setpoint Default Drive Pot Keypad Freq Serial DSI Network Opt 0 10V Input 4 20mA Input Preset Freq Anigin Multi MOP Freq Pulse Input 11 Step Logic 12 Encoder 13 EtherNet IP wo CO NI DD Cn A wl N 1 Setting is specific to PowerFlex 525 drives only 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 Serial DSI Network Opt
225. in F627 Fault 7 Time min F628 Fault8Time min F629 Fault 9 Time min F630 Fault10 Time min PowerFlex 525 only Displays the value of d363 Elapsed Time min when the fault occurs Values Default Read Only Min Max 0 0 320 0 min Display 0 1 min F631 Fault 1 Freq F632 Fault 2 Freq Related Parameter s b001 F633 Fault 3 Freq F634 Fault 4 Freq F635 Fault 5 Freq F636 Fault 6 Freq F637 Fault 7 Freq F638 Fault 8 Freq F639 Fault 9 Freq F640 Fault10 Freq PF 525 PowerFlex 525 only Displays and stores the value of b001 Output Freq with the most recent 10 faults occurred Fault 1 Freq stores the most recent fault Fault 2 Freq stores the second most recent fault and Fault 3 Freq stores the third most recent fault Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz Rockwell Automation Publication 520 UM001D EN E September 2013 133 Chapter3 Programming and Parameters F641 Fault 1 Current F643 Fault 3 Current F645 Fault 5 Current Fault and Diagnostic Group continued F642 Fault 2 Current F644 Fault 4 Current F646 Fault 6 Current 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 t
226. induced bearing currents for some applications In addition the increased impedance of shielded 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 Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES INOO1 Consideration should be given to all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment A good example of recommended cable is Belden 295xx xx determines gauge This cable has four 4 XLPE insulated conductors with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Other types of shielded cable are available but the selection of these types may limit the allowable cable length Particularly some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield This construction can greatly increase the cable charging current required and reduce Rockwell Automation Publication 520 UM001D EN E September 2013 35 Chapter 1 36 Installation Wiring the overall drive performance Unless specified i
227. ing 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 cable is used the cable shield should be terminated with a low impedance connection to earth at only one end of the cable preferably the end where the receiver is located When the cable shield is terminated at the drive end it may be terminated either by using a shielded connector in conjunction with a conduit plate or conduit box or the shield may be clamped to an EMC plate Motor cabling must be separated from control and signal wiring wherever possible Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 e Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520 Series RF Emission Compliance and Installation Requirements on page for compliance with radio frequency emission limits for the specific standard and installation environment Connections and Grounding Shielded enclosure SL Sap ef IP 30 NEMA 1 UL Type 1 Size EA option kit or EMC kit el Tel el SS EMI fitting
228. ing terminations on the master controller will vary depending on the master controller used and TxRxD and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations Note that there is no standard for the and wires and consequently Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wires at the master controller Standard RS485 wiring practices apply e Termination resistors need to be applied at each end of the network cable e RS485 repeaters may need to be used for long cable runs or if greater than 32 nodes are needed on the network e Network wiring should be separated from power wires by at least 0 3 meters 1 foot e Network wiring should only cross power wires at a right angle I O Terminal C1 RJ45 Shield on the PowerFlex 520 series drive must also be connected to PE ground there are two PE terminals on the drive See I O Control Terminal Designations on page 41 and page 43 for more information I O Terminal C2 Comm Common is internally tied to Network Common and NOT to RJ45 Shield Tying I O Terminal C2 to PE ground may improve noise immunity in some applications Parameter Configuration The following PowerFlex 520 series drive parameters are used to configure the drive to operate on a DSI network Configuring Parameters for D
229. ins volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity 0 95 noncondensing Shock Complies with IEC 60068 2 27 Vibration Complies with IEC 60068 2 6 1995 Operating and Nonoperating Nonoperating Transportation Frame Force Force Size Shock Vibration Mounting Type Shock Vibration Mounting Type A 15g 2g DIN rail or screw 30g 2 59 Screw only B 15g 2g DIN rail or screw 30g 2 59 Screw only C 15g 2g DIN rail or screw 309 2 5g Screw only D 15g 2g Screw only 309 2 5g Screw only E 15g 1 5g Screw only 30g 2 59 Screw only Conformal Coating Complies with IEC 60721 3 3 to level 3C2 chemical and gases only Surrounding Environment See Pollution Degree Ratings According to EN 61800 5 1 on page 52 Pollution Degree for descriptions Pollution Degree 1 amp 2 All enclosures acceptable Sound Pressure Level Measurements are taken 1 m from the drive A weighted Frame A amp B Maximum 53 dBA Frame C Maximum 57 dBA Frame D Maximum 64 dBA Frame E Maximum 68 dBA Not applicable to PowerFlex 523 drives 158 Rockwell Automation Publication 520 UM001D EN E September 2013 Technical Specifications Protection Specifications Bus Overvoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input Supplemental Drive
230. ioning 4 Quadrature is a dual channel encoder input with direction and speed from the encoder This may be used for positioning control Rockwell Automation Publication 520 UM001D EN E September 2013 205 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Positioning Operation 206 5 Quad Check is a dual channel encoder with encoder signal loss detection The drive will fault if it detects that the encoder speed does not match the expected motor speed A544 Reverse Disable should be set to 0 Rev Enabled to allow bidirectional movement necessary for position control P039 Torque Perf Mode default setting is 1 SVC However any mode can be used to improve the low speed torque for positioning applications For best results tune the application first The autotune routine can be completed to further improve the drive motor performance A550 Bus Reg Enable default setting is 1 Enabled If the deceleration time is too short the drive may overshoot the desired position For best results a longer deceleration time may be necessary A550 Bus Reg Enable can be disabled to provide precise stopping movements but the deceleration time will need to be manually tuned so that it is long enough to avoid F005 OverVoltage faults A437 DB Resistor Sel default setting is 0 Disabled If improved deceleration performance is required a Dynamic Brake resistor can be used If used
231. ions EPRI SEMI Q Lloyds Register PowerFlex 523 PowerFlex 525 Electric Power Research Institute Certified compliant with the following standards SEMI F47 IEC 61000 4 34 Not applicable Lloyd s Register Type Approval Certificate 12 10068 E1 RoHS Compliant with the European Restriction of Hazardous Substances Directive The drive is also designed to meet the appropriate portions of the following specifications NFPA 70 US National Electrical Code NEMA ICS 7 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems Environmental Specifications Specifications Altitude Without derating With derating PowerFlex 523 PowerFlex 525 See Current Derating Curves on page 17 for derating guidelines 1000 m 3300 ft max Up to 4000 m 13 200 ft max with the exception of 600V drives at 2000 m 6600 ft max Max Surrounding Air See Current Derating Curves on page 17 for derating guidelines Temperature 20 50 C 4 122 F Without derating 20 60 C 4 140 F or 20 70 C 4 158 F with optional Control Module Fan With derating kit Storage Temperature Frame A D 40 85 C 40 185 F Frame E 40 70 C 40 158 F Not applicable to PowerFlex 523 drives Atmosphere IMPORTANT Drive must not be installed in an area where the ambient atmosphere conta
232. ipin LLL LI Li 1 Drive Inactive 0 Drive Active Drive 0 Actv Digit 1 Drive 1 Actv Digit 2 Drive 2 Actv Digit 3 Drive 3 Actv Digit 4 Drive 4 Actv Digit 5 Value Default Read 0nly Min Max 00000 11111 Display 00000 F687 HW Addr 1 F688 HW Addr 2 F689 HW Addr 3 F690 HW Addr 4 F691 HW Addr 5 F692 HW Addr 6 PF 525 PowerFlex 525 only Shows the MAC address for the embedded EtherNet IP interface Values Default Read Only Min Max 0 255 Display 1 136 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F693 EN IP Addr Act 1 F694 EN IP Addr Act 2 F695 EN IP Addr Act 3 F696 EN IP Addr Act 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 255 255 255 255 EN IP Addr Act 1 EN IP Addr Act 2 EN IP Addr Act 3 EN IP Addr Act 4 Values Default Read Only Min Max 0 255 Display 1 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 actual subnet mask used by the embedded EtherNet IP interface at the time This will indicate 0 if no address is set 255 255 255 255 EN Subnet Act 1 EN Subnet Act 2 EN Subnet Act 3 EN Subnet Act 4 Values Default Read Only Min Max 0 255 Display 1 F70
233. isplay 0 1 Hz A534 Maximum Voltage Related Parameter s b004 Sets the highest voltage the drive outputs Values Default Drive Rated Volts Min 10VAC on 230VAC Drives 20VAC on 460VAC Drives 25VAC on 600VAC Drives Max 255VAC on 230VAC Drives 510VAC on 460VAC Drives 637 5VAC on 600VAC Drives Display 1VAC 124 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A535 Motor Fdbk Type O Ray drive before changing this parameter PF 525 PowerFlex 525 only Selects the encoder type Related Parameter s A537 ATTENTION The loss of analog input encoder or other feedback may cause unintended speed or motion Take appropriate precautions to guard against possible unintended speed or motion Allowable Control Modes Hardware Inputs Options 0 None Default For all motor types _ 1 Pulse Train All except Vector 2 Single Chan All except Vector 3 Single Check All except Vector Gi ere S 4 Quadrature For all motor types 5 Quad Check For all motor types A536 Encoder PPR PowerFlex 525 only Specifies the encoder Pulses Per Revolution PPR when an encoder is used Values Default 1024 PPR Min Max 0 20000 PPR Display 1PPR A537 Pulse In Scale Related Parameter s t065 t067 A535 Sets the scale factor gain for the Pulse Input when t065 or t067 Dig
234. isplay 1 C157 EN Data Out 1 C158 EN Data Out 2 C159 EN Data Out 3 C160 EN Data Out 4 PowerFlex 525 only Datalink parameter number whose value is read from the embedded EtherNet IP data table This parameter cannot be changed when an 1 0 connection is established through the drive s embedded EtherNet IP port Values Default 0 Min Max 0 800 Display 1 Rockwell Automation Publication 520 UM001D EN E September 2013 101 Chapter3 Programming and Parameters Communications Group continued C161 Opt Data In 1 C162 Opt Data In 2 C163 Opt Data In 3 C164 Opt Data In 4 Datalink parameter number whose value is written from the High Speed Drive Serial Interface HSDSI data table This parameter cannot be changed when an 1 0 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 1 0 connection is established through the communication adapter Values Default 0 Min Max 0 800 Display 1 C169 MultiDrv Sel Sets the configuration of the drive that is in multi drive mode A reset or power cycle is required after selection is made Options 0 Disabled Default No multi drive master from the internal network optio
235. ive e Cycle power control and 1 0 section Replace drive or control module if fault cannot be cleared F125 Flash Update Req 2 The firmware in the drive is corrupt Perform a firmware flash update mismatched or incompatible with the operation to attempt to load a valid set hardware of firmware F126 NonRecoverablErr 2 A non recoverable firmware or e Clear fault or cycle power to the hardware error was detected The drive drive was automatically stopped and reset e Replace drive or control module if fault cannot be cleared F127 DSIHashUpdatReq 2 A critical problem with the firmware Perform a firmware flash update was detected and the drive is running operation using DSI communications to using backup firmware that only attempt to load a valid set of firmware supports DSI communications 1 This fault is not applicable to PowerFlex 523 drives 2 See Fault Types for more information Common Sym ptoms and The drive is designed to start from the keypad when shipped For a basic test of e drive operation Corrective Actions p 152 1 2 3 4 Remove all user I O wire Verify safety terminals S1 S2 and S jumper is in place and tightened Verify wire jumper is in place between I O terminals 01 and 11 Verify that the three jumpers are in their proper default positions on the control board See PowerFlex 525 Control I O Wiring Block Diagram on page 42 for more information Reset default paramete
236. ive is within A564 Encoder Pos Tol of the commanded position this bit will be active Bit 2 At Home indicates whether the drive is at Home If the drive is within A564 Encoder Pos Tol of Home this bit will be active Bit 3 Drive Homed indicates whether the 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 Rockwell Automation Publication 520 UM001D EN E September 2013 211 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Use Over Communications 212 If 8 steps are not adequate for the application or if dynamic program changes are required many of the positioning functions can be controlled through an active communication network The following parameters will allow this control C121 Comm Write Mode Repeated writes to parameters over a communication network can cause damage to the drive EEPROM This parameter allows the drive to accept parameter changes without writing to the EEPROM IMPORTANT Parameter values set prior to setting 1 RAM only are saved in RAM C122 Cmd Stat Select Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network A560 Enh Control Word This parameter allows many of the positioning functions to be completed through parameter control using an explicit me
237. l Dual Channel nile Dual Channel miO B NOT e Or B B e n B r fom i ae a Joji a fe to SHLD The encoder option card can supply 5V or 12V power 250 mA maximum for an encoder Be sure the DIP switch is set properly for the encoder In general 12V will provide higher noise immunity The encoder can handle 5V 12V or 24V inputs but the pulse train can handle only 24V inputs The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary If a single channel input is used it must be wired between the A signal and A signal common channels Rockwell Automation Publication 520 UM001D EN E September 2013 Positioning Overview Common Guidelines for All Applications Encoder Pulse Train Usage and Position StepLogic Application Appendix E IMPORTANT A quadrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forward direction matches the motor forward direction If the drive is reading encoder speed but the position regulator or other encoder function is not working properly remove power to the drive and swap the A and A NOT encoder channels or swap any two motor leads Drives will fault when an encoder is incorrectly wired and A535 Motor Fdbk Type is set to 5 Quad Check The PowerFlex 525 drive includes a simple position regulator which can be used in a variety of position app
238. l C1 should also be connected to ground terminal protective earth Additionally communication noise immunity can also be improved by connecting I O Terminal C2 to ground terminal protective earth Control 1 0 Terminal Block Wire Specifications DEENEN 1 3 mm 16 AWG 0 13 mm 26 AWG 0 71 0 86 Nm 6 2 7 6 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Rockwell Automation Publication 520 UM001D EN E September 2013 39 Chapter 1 40 Installation Wiring PowerFlex 523 Control 1 0 Terminal Block PowerFlex 523 Control 1 0 Wiring Block Diagram Typical Typical Stop SRCwiring SNK wiring D iginte 25 H m Start Run FWD ot oo a 02 DiglnTermBlk 037 Sei Direction Run REV el E SNK 5 5 SRC D Digital Common E Digin TermBlk 05 Pulse 6h 06 DigIn TermBlk 06 ergs 22 V SE Relay N 0 Rt wal 10V 10V DC Relay Common Ro T eB A 0 10V Input Relay N C Te ch 1 ape Analog Common 14 Pot must be 5 4 20mA Input 1 10 kohm 2W min a RJ45 Shield Q Comm Common V V J8 D I SNK Pulse In RS485 d S 2 os ail ke SRC Digital amp Input 3 HI R2 0 02 03 04
239. l Automation Publication 520 UM001D EN E September 2013 Appendix B Version 163 Appendix B 164 Accessories and Dimensions PowerFlex 523 Drive Ratings Output Ratings Heavy Duty Output Input Frame Catalog No HP kW Current A Voltage Range Size 25A D024N104 15 0 11 0 240 323 528 D 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 25A D1P4N114 0 5 0 4 14 323 528 A 25A D2P3N114 1 0 0 75 23 323 528 A 25A D4P0N114 2 0 15 40 323 528 A 25A D6P0N114 3 0 2 2 6 0 323 528 A 25A D010N114 5 0 4 0 10 5 323 528 B 25A D013N114 7 5 5 5 13 0 323 528 C 25A D017N114 10 0 17 5 17 0 323 528 C 25A D024N114 15 0 111 0 240 323 528 D 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25A EOP9N104 0 5 0 4 0 9 446 660 A 25A E1P7N104 1 0 05 11 7 446 660 A 25A E3P0N104 2 0 15 3 0 446 660 A 25A F4P2N104 3 0 2 2 42 446 660 A 25A E6P6N104 5 0 4 0 6 6 446 660 B 25A E9P9N104 7 5 5 5 9 9 446 660 C 25A E012N104 10 0 17 5 12 0 446 660 C 25A E019N104 15 0 111 0 190 446 660 D PowerFlex 525 Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame Catalog No HP kw HP kw Current A Voltage Range Size 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25B V2P5N104 0 5 0 4 0 5 0 4 2 5 85 132 A 25B V4P8N104 1 0 0 75 1 0 0 75 A8 8
240. lications without the need for multiple limit switches or photo eyes This can be used as a stand alone controller for simple applications up to 8 positions or in conjunction with a controller for more flexibility Please note that this is not intended to replace high end servo controllers or any application that needs high bandwidth or very high torque at low speeds The position regulator can be configured for operation appropriate for a variety of applications Certain parameters will need to be adjusted in all cases P047 Speed Reference1 must be set to 16 Positioning A535 Motor Fdbk Type must be set to the match the feedback device Positioning mode must use A535 Motor Fdbk Type 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 only This should not be used for positioning Single channel uses the standard encoder scaling parameters 3 Single Check is a single channel input with encoder signal loss detection The drive will fault if it detects that the input pulses do not match the expected motor speed This should not be used for posit
241. lies with the requirements of the relevant standards Cat 3 PL d acc to EN ISO 13849 1 SILCL 2 acc to EN 62061 EN 61800 5 2 IEC 61508 and can be used in applications up to Cat 3 PL d acc to EN ISO 13849 1 SIL 2 acc to EN 62061 IEC 61508 Specific requirements The instructions of the associated Installation and Operating Manual shall be considered It is confirmed that the product under test complies with the requirements for machines defined in Annex of the EC Directive 2006 42 EC This certificate is valid until 2017 09 24 Type Approved certificate A Functional Safety ne test report no 968 M 365 00 12 dated 2012 09 24 is an integral part of this FS The holder of a valid licence certificate for the product tested is authorized to T VRheiniand Berlin 2012 09 24 Tel 49 30 7562 1557 F ax 49 30 7562 1370 E Mail tivat de tuv com TOV Rheiniand Industrie Service GmbH Alboinst 56 12103 Berlin Germany Certification Body for Machinery NB 0035 Dipl Ing Eberhard Frejno Rockwell Automation Publication 520 UM001D EN E September 2013 233 AppendixG Safe Torque Off Function Notes 234 Rockwell Automation Publication 520 UM001D EN E September 2013 Establishing A Connection With EtherNet IP Appendix H EtherNet IP This section contains only basic information to setup an EtherNet IP connection with your PowerFlex 520 series drive For comprehensive information about
242. llation Wiring Chapter 1 Start and Speed Reference Start Source and Speed Reference Selection Control The start and drive speed command can be obtained from a number of different sources By default start source is determined by P046 Start Source 1 and drive speed source is determined by P047 Speed Reference1 However various inputs can override this selection See below for the override priority Drive will start and run at Purge Speed Purge Input Enabled AND Active Direction is always FORWARD Drive will start and run at Jog Speed Direction is from Terminal Jog Input Enabled Drive stopped S Yes Block REV terminal 03 AND Active NOT running Comms OR FWD REV determined by Jog FWD Jog REV command Run as specified by Preset Freq x Preset Inputs Active ADIE CHUN commands come from Start Source x Start and Direction command from Start Source 31 2 Run as specified by _ Ye Start Source 3 Speed Reference3 select Speed Reference3 select Start and Direction command from Start Source 2 2 Run as specified by _ Start S 2 Speed Reference2 Start Source 2 select Speed Reference2 select 1 Run as specified by Start and Direction command from Speed Reference1 Start Source 1 1 Start Source 2 3 and Speed Reference2 3 can be selected by the control terminal block or communication commands 2 See Digi
243. lly or manually Parameters A521 4526 are set automatically by this parameter Options 0 Automatic Default 1 Manual Rockwell Automation Publication 520 UM001D EN E September 2013 121 Chapter3 Programming and Parameters Advanced Program Group continued A510 Freq 1 A512 Freq 2 A514 Freq 3 PF 525 PowerFlex 525 only Sets the Vector control mode frequency Values Default Freq 1 8 33 Freq 2 15 00 Freq 3 20 00 Min Max 0 00 200 00 Display 0 01 A511 Freq 1 BW A513 Freq 2 BW A515 Freq 3 BW PF 525 PowerFlex 525 only Speed control loop bandwidth for Vector control mode Values Default 10 Hz Min Max 0 40 Hz Display 1Hz A521 Freq 1 Kp Related Parameter s A509 A510 A523 Freq 2 Kp A525 Freq 3 Kp PowerFlex 525 only Sets P gain of Vector control mode when in frequency region 1 2 or 3 for faster speed response during dynamic state where motor is still accelerating If A509 Speed Reg Sel is set to 1 Manual these parameters can be changed Values Default 100 0 Min Max 0 0 500 0 Display 0 1 A522 Freq 1 Ki Related Parameter s A509 A510 A524 Freq 2 Ki A526 Freq 3 Ki PF 525 PowerFlex 525 only Sets Loan of Vector control mode when in frequency region 1 2 or 3 for faster speed response during steady state where motor is at its rated speed If A509 Speed Reg Sel is set
244. m the rest of the drive 1 See Footnote 1 on page 40 44 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 1 0 Wiring Examples 1 0 Connection Example Potentiometer P047 Speed Reference1 5 0 10V Input 1 10k Q Pot Recommended _ n 2 W minimum ES Li 14 ei Analog Input Bipolar Unipolar Voltage Unipolar Current 0 10V 100k Q impedance P047 Speed Reference1 P047 Speed Reference1 P047 Speed Reference1 4 20 mA 250 Q 5 0 10V Input and 5 0 10V Input 6 4 20mA Input impedance t093 10V Bipolar Enbl 1 Bi Polar In 10 2B Le Common tte Common Common ol Ie 115 I S 2 Analog Input PTC Wire the PTC and External Resistor typically matched to the PTC Hot Resistance to 1 0 For Drive Fault Terminals 12 13 14 Wire R2 R3 Relay Output SRC to 1 0 Terminals 5 amp 11 t065 DigIn TermBIk 05 12 Aux Fault t081 Relay Out 2 Sel 10 Above Anlg V t082 Relay Out 2 Level Voltage Trip e wien TUN x 100 TI Ber hot Re Pulse Train Input PowerFlex 523 PowerFlex 525 PowerFlex 523
245. mber 2013 213 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Notes 214 Rockwell Automation Publication 520 UM001D EN E September 2013 PID Loop Appendix F PID Set Up The PowerFlex 520 series drive features built in PID proportional integral derivative control loops The PID loop is used to maintain a process feedback such as pressure flow or tension at a desired set point The PID loop works by subtracting the PID feedback from a reference and generating an error value The PID loop reacts to the error based on the PID Gains and outputs a frequency to try to reduce the error value to 0 To enable the PID loop P047 P049 or P051 Speed Referencex must be set to 11 PID1 Output or 12 PID2 Output and the corresponding speed reference activated IMPORTANT PowerFlex 523 has one PID control loop PowerFlex 525 has two PID control loops of which only one can be in use at any time Exclusive Control and Trim Control are two basic configurations where the PID loop may be used Exclusive Control In Exclusive Control the Speed 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 I PID Loop
246. me 2 Time for the drive to ramp from 0 0 Hz to P044 Maximum Freq if Accel Time 2 is selected Accel Rate Maximum Freq Accel Time Related Parameter s P044 Maximum Freq 0 Wl Accel Time x Time mI Decel Time x l 0 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A443 Decel Time 2 Time for the drive to ramp from P044 Maximum Freq to 0 0 Hz if Decel Time 2 is selected Decel Rate Maximum Freq Decel Time Related Parameter s P044 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 114 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter3 Advanced Program Group continued A444 Accel Time 3 A446 Accel Time 4 Sets the rate of acceleration for all speed increases when selected by digital inputs Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A445 Decel Time 3 A447 Decel Time 4 Sets the rate of deceleration for all speed decreases when selected by digital inputs Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A448 Skip Frequency 1 Related Parameter s A449 A451 A453 A455 A450 Skip Frequency 2 A452 Skip Frequency 3 A454 Skip Frequency 4 PF 525 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 co
247. mes the PID Reference 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 217 Appendix F PID Set Up A460 and A472 PID x Fdback Sel are used to select the source of the PID feedback A460 A472 PID x Fdback Sel Options Options Description 0 0 10V Input Selects the 0 10V Input default setting Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 4 20mA Input Selects the 4 20 mA Input Serial DSI Serial DSI will be used as an input for the PID Feedback Network Opt The reference word from a communication network option becomes the PID Reference Pulse Input Pulse train will be used as an input for the PID Feedback Encoder Encoder will be used as an input for the PID Feedback olal bel wl rn Ethernet IP Ethernet IP will be used as an input for the PID Feedback 1 Setting is specific to PowerFlex 525 drives only Analog PID Reference Signals Parameters t091 Anlg In 0 10V Lo and 1092 Anlg In 0 10V Hi are used to 218 scale or invert an analog PID Reference or PID Feedback Scale Function For a 0 5V signal the following parameter settings are used so that a OV signal 0 PID Reference and a 5V signal 100 PID Reference e t091 Anlg In 0 10V Lo 0 0 t092 Anlg In 0 10V
248. meter is ignored Values Default 0 0 Min Max 0 0 200 0 Display 0 1 t092 Anlg In 0 10V Hi Related Parameter s P044 t091 t093 so drive before changing this parameter Sets the percentage based on 10V of input voltage applied to the 0 10V analog input used to represent P044 Maximum Freq Analog inversion can be accomplished by setting this value smaller than t091 Anlg In 0 10V Lo If t093 10V Bipolar Enbl is set to 1 Bi Polar In the same value applies to positive and negative voltage Values Default 100 0 Min Max 0 0 200 0 Display 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 Rockwell Automation Publication 520 UM001D EN E September 2013 93 Chapter3 Programming and Parameters Terminal Block Group continued t094 Anlg In V Loss Related Parameter s P043 P044 A426 A427 Sets the response to a loss of input When the 0 10V input or 10 to 10V is used for any reference any input less than 1V is reported as a signal loss Input must exceed 1 5V for the signal loss condition to end If enabled this function affects any input that is being used as
249. mum Maximum No Derate Maximum Derate 2 Maximum with Control Module Fan Kit Derate 3 5 Vertical IP 20 Open Type 50 C 122 F 60 C 140 F 70 C 158 F IP 30 NEMA 1 UL Type 1 45 C 113 F 55 C 131 F Vertical Zero Stacking IP 20 Open Type 45 C 113 F 55 C 131 F 65 C 149 F IP 30 NEMA 1 UL Type1 _29 c 4 F 40 C 104 F 50 C 122 F _ Horizontal with IP 20 0pen Type 50 C 122 F 70 C 158 F Control Module Fan Kit Horizontal Zero Stacking IP 20 Open Type S 65 C 149 F with Control Module Fan Kit 45 C 113 F 1 IP 30 NEMA 1 UL Type 1 rating requires installation of the PowerFlex 520 Series IP 30 NEMA 1 UL Type 1 option kit catalog number 25 JBAX 2 For catalogs 25x D1P4N104 and 25x EOP9N104 the temperature listed under the Maximum Derate column is reduced by 5 C 9 F for all mounting methods 3 For catalogs 25x D1P4N104 and 25x EOP9N104 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 EOP9N104 cannot be mounted using either of the horizontal mounting methods Requires installation of the PowerFlex 520 Series Control Module Fan Kit catalog number 25 FANx 70C Current Derating Curves Rockwell Automation Publication 520 UM001D EN E September 2013
250. n 0 10V Lo t091 Stall Fault Time A492 Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 Motor Fdbk Type A535 Positioning Stop Mode P045 Stp Logic 5 L185 Step Units 6 L212 Jog Accel Decel A432 Start Source 1 P046 Stp Logic 6 L186 Step Units 7 L214 DB Threshold A438 ke Speed Reference1 P047 Stp Logic 7 L187 Slip Hz Meter d375 S Curve A439 Digln TermBlk 02 t062 Stp Logic Time 0 L190 Speed Feedback d376 Motor Fdbk Type A535 Language P030 Digln TermBlk 03 t063 Stp Logic Time 1 L191 Encoder Speed d378 Encoder PPR A536 Output Freq b001 Digln TermBlk 05 t065 Stp Logic Time 2 L192 Units Traveled H d388 Pulse In Scale A537 Commanded Freq b002 Digln TermBlk 06 t066 Stp Logic Time 3 L193 Units Traveled L d389 Ki Speed Loop A538 Motor NP Volts P031 Opto Outi Sel t069 Stp Logic Time 4 L194 Preset Freq 0 A410 Kp Speed Loop A539 Motor NP Hertz P032 Opto Out2 Sel t072 Stp Logic Time 5 L195 Preset Freq 1 A411 Bus Reg Enable A550 Motor OL Current P033 Relay Out Sel t076 Stp Logic Time 6 L196 Preset Freq 2 A412 Positioning Mode A558 Motor NP FLA P034 EM Brk Off Delay t086 Stp Logic Time 7 L197 Preset Freq 3 A413 Counts Per Unit A559 Motor NP Poles P035 EM Brk On Delay t087 Step Units 0 L200 Preset Freq 4 A414 Enh Control Word A560 Autotune P040 Stp Logic 0 L180 Step Units 1 L202 Preset Freq 5 A415 Find Home Freq A562 Accel Time 1 P041 Stp Logic 1 L181 Step Units 2 L204 Preset Freq 6 A416 Find Home Dir A563 Decel Time 1 P042 Stp Logic 2 L182 Step Units 3 L206 Preset Fr
251. n exists 100 ms time delay on or off 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from 100 ms time delay on or off 6 Above Freq Drive exceeds the frequency Hz value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 7 Above Cur Drive exceeds the current Amps value set in t070 or t073 Opto Outx Level 100 ms time delay on or off IMPORTANT Value for t070 or t073 Opto Outx Level must be entered in percent of drive rated output current 8 Above DCVolt Drive exceeds the DC bus voltage value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 9 Retries Exst Value set in A541 Auto Rstrt Tries is exceeded None 10 Above Anlg V Analog input voltage 0 10V input exceeds the value set in t070 or t073 Opto Outx Level 100 ms time delay on or off IMPORTANT Do not use if t093 10V Bipolar Enbl is set to 1 Bi Polar In 11 Above PF Ang Power Factor angle exceeds the value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 12 Anlg In Loss Analog input loss has occurred Program t094 Anlg In V Loss or t097 Anlg In mA Loss for desired action when On 2mA 1V input loss occurs Off 3 mA 1 5V 13 Param ontrol Output is directly controlled by the state of the t070 or t073 Opto Outx Level A value
252. n module or embedded Ethernet port The drive can still function as a multi drive slave or as a single drive no multi drive used 1 Network Opt Multi drive is enabled with the internal network option as a multi drive master The host drive is Drive 0 and up to four slave drives can be daisy chained from its RS485 port 2 EtherNet IP Multi drive is enabled with the embedded Ethernet port as the multi drive master The host drive is Drive 0 and up to four slave drives can be daisy chained from its RS485 port 1 Setting is specific to PowerFlex 525 drives only C171 Drv 1 Addr Related Parameter s 169 C172 Drv 2 Addr C173 Drv 3 Addr C174 Drv 4 Addr Sets the corresponding node addresses of the daisy chained drives when C169 MultiDrv 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 2 Drv 2 Addr 3 Drv 3 Addr 4 Drv 4 Addr 5 Min Max 1 247 Display 1 C175 DSI ugoe 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 required after selection is made Options 0 Drive 0 Default 1 Drive 0 1 Drive 0 2 Drive 0 3 Drive 0 4 Bl wl rn 102 Rockwell Automation Publication 520 UM001D EN E September 20
253. n the individual distance tables as tested with the drive these cables are not recommended and their performance against the lead length limits supplied is not known Recommended Shielded Wire Location Rating Type Description Standard Option 1 600V 90 C 194 F XHHW2 RHW 2 e Four tinned copper conductors with XLPE insulation Anixter B209500 B209507 Belden Copper braid aluminum foil combination shield and 29501 29507 or equivalent tinned copper drain wire PVCjacket Standard Option 2 Tray rated 600V 90 C 194 F Three tinned copper conductors with XLPE insulation RHH RHW 2 Anixter OLF 7xxxxx or 5 mil single helical copper tape 25 overlap min equivalent with three bare copper grounds in contact with shield e PVC jacket Class amp Il Tray rated 600V 90 C 194 F Three bare copper conductors with XLPE insulation Division amp Il RHH RHW 2 Anixter 7V 7xxxx 3G or and impervious corrugated continuously welded equivalent aluminum armor Black sunlight resistant PVC jacket overall Three copper grounds on 10 AWG and smaller Reflected Wave Protection The drive should be installed as close to the motor as possible Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor reflected wave phenomena Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES INOO1 The reflec
254. n this parameter will show 0 Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz F707 Drv 0 Logic Sts F711 Drv 1 Logic Sts F715 Drv 2 Logic Sts F719 Drv 3 Logic Sts F723 Drv 4 Logic Sts In multi drive mode this is the logic status being received from drive 0 1 2 3 4 In single drive mode this is the logic status of the drive at the time Values Default Read Only Min Max 0 FFFF Display 1 F708 Drv 0 Feedback F712 Drv 1 Feedback F716 Drv 2 Feedback F720 Drv 3 Feedback F724 Drv 4 Feedback In multi drive mode this is the feedback being received from drive 0 1 2 3 4 In single drive mode this is the feedback of the drive at the time Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz F725 EN Rx Overruns PF 525 PowerFlex 525 only A count of the number of receive overrun errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 138 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F726 EN Rx Packets PF 525 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 F727 EN Rx Errors PF 525 PowerFlex 525 only A count of the number of recei
255. nch go to http ab rockwellautomation com Programmable Controllers Connected Components Workbench Software For the latest drive or peripheral firmware updates go to http www ab com support abdrives webupdate index html For the latest product manuals go to http Aliterature rockwellautomation com idc groups public documents webassets browse category hcst IMPORTANT Make sure your PC is powered by an AC power outlet or has a fully charged battery before starting any operation This prevents the operation from terminating before completion due to insufficient power Limitation in Downloading pf5 Configuration Files with the USB Utility Application Before downloading a pf5 configuration file using the USB utility application parameter C169 MultiDrv Sel in the destination drive must match the incoming configuration file If it does not set the parameter manually to match and then cycle drive power This means you cannot apply a multi drive configuration using the USB utility application to a drive in single mode parameter C169 MultiDrv Sel set to 0 Disabled or apply a single mode configuration to a drive in multi drive mode 68 Rockwell Automation Publication 520 UM001D EN E September 2013 Chapter 3 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 520 series drive parameters Parameters are programmed viewed edited using either the drive
256. ncy is 100 kHz Current consumption is 6 mA 06 Digin TermBlk 06 Preset Freq Program with t066 DigIn TermBlk 06 t066 Current consumption is 6 mA 11 24V DC Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100 mA 12 10V DC Referenced to Analog Common P047 P049 Drive supplied power for 0 10V external potentiometer Maximum output current is 15 mA 13 0 10V In Not Active For external 0 10V unipolar input supply or potentiometer P047 P049 wiper t062 t063 Input impedance t065 t066 Voltage source 100 kQ a A459 Allowable potentiometer resistance range 1 10 KQ 14 AnalogCommon Return for the analog 1 0 Electrically isolated along with the analog 1 0 from the rest of the drive 15 4 20mA wll Not Active For external 4 20 m input supply P047 P049 Input impedance 250 Q 1062 t063 1065 1066 A459 A471 q q _ 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 Q Q _ This is the signal common for the communication signals 1 Only one analog frequency source may be connected at a time If more than one reference is connected at the same time an undetermined frequency reference will result 2 See Footnote 1 on page 40 Rockwell Automation Publication 520 UM001D EN E September 2013 41
257. nded frequency and engaging the brake coil relay if Electromechanical EM Brake Control Mode is enabled with P045 Stop Mode EM Brk On Delay ty A Minimum Freq P E a Time a a a Start EM Brk Stop _ EMBrk Drive stops commanded energized Off commanded de energized On Values Default 2 00 s Min Max 0 00 10 00 s Display 0 015 Rockwell Automation Publication 520 UM001D EN E September 2013 91 Chapter3 Programming and Parameters Terminal Block Group continued t087 EM Brk On Delay Related Parameter s P045 Sets the time the drive remains at minimum frequency after releasing the brake coil relay before stopping if EM Brake Control Mode is enabled with P045 Stop Mode EM Brk On Delay EM Brk Off Delay i 2 I vy M h amp Minimum Freq P eene eer PN a Time a a a Start EM Brk Stop _ EMBrk Drive stops commanded energized Off commanded de energized On Values Default 2 00 s Min Max 0 00 10 00 s Display 0 015 t088 Analog Out Sel Related Parameter s t090 PowerFlex 525 only The 0 10V 0 20 mA or 4 2 0 mA analog output can be used to provide a signal proportional to several drive conditions This parameter also selects which analog calibration parameters to use Options Output Range Minimum Output Value Maximum Output Value Filter Related t089 Analog Out High P
258. nderstanding of the product Allen Bradley Rockwell Automation Rockwell Software PowerFlex Connected Components Workbench Studio 5000 DriveTools SP AppView CustomView MainsFree Programming and PointStop are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Topic Page Added PowerFlex 523 information Throughout manual Updated Connected Components Workbench version number Throughout manual Updated Catalog Number Explantion tables B Updated Fuses and Circuit Breaker information 22 Added PowerFlex 523 Fuses and Circuit Breaker tables 23 25 Updated PowerFlex 525 Fuses and Circuit Breaker tables 26 29 Added PowerFlex 523 Control 1 0 Terminal Block diagram and Designations table 40 41 Updated PowerFlex 525 Control UO Terminal Block diagram and Designations table 42 43 Updated 1 0 Wiring Examples 45 Updated Additional Installation Requirements topic and table 55 Updated Prepare for Drive Start Up topic 59 Updated Display and Control Keys diagram and table 62 Updated Smart Start Up with Basic Program Group Parameters table 65 Updated Using the USB Port topic 67 Updated Parameter Groups and Paramet
259. need to power up the control module Simply connect the PowerFlex 520 series drive to your PC with a USB Type B cable and you will benefit from MainsFree programming IMPORTANT To use the USB feature of the PowerFlex 520 series drive Microsoft Met Framework 2 0 and Windows XP or later is required Connecting a PowerFlex 520 series drive to a PC Control Module USB port USB Type B cable SX Connect to PC Connect to Control Module When connected the drive appears on the PC and contains two files e GUIDE PDF This file contains links to relevant product documentation and software downloads PF52XUSB EXE This file is an application to flash upgrade firmware or upload download a parameter configuration It is not possible to delete these files or add more to the drive Rockwell Automation Publication 520 UM001D EN E September 2013 67 Chapter2 Start Up Double click on the PF52XUSB EXE file to launch the USB utility application The main menu is displayed Follow the program instructions to upgrade the firmware or upload download configuration data B PowerFlex 520 Series USB Application Drive Peripheral PowerFlex 525 1P240V SOHP 1 3 Only one control module can be connected via USB at any time Upload a configuration from the drive or peripheral Download a configuration to the drive or peripheral Flash the drive or peripheral To obtain the latest version of Connected Components Workbe
260. nk OvrTmp fault without restarting the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to 0 ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Values Default 0 Min Max 0 9 Display 1 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 05 Min Max 0 0 120 0 s Display 0 15 A543 Start At PowerUp Ti drive before changing this parameter Enables disables drive start on power up without a Start command being cycled Requires a digital input configured for Run or Start and a valid start contact ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Options 0 Disabled Default 1 Enabled A544 Reverse Disable Related Parameter s b006 O Ray drive before changing this parameter Enables disables the function that allows the direction of motor rotation to be changed Options 0 Rev Enabled Default 1 Rev Disabled
261. ntinuously Values Default 0 0 Hz Disabled Min Max 0 0 500 0 Hz Display 0 1Hz A449 Skip Freq Band 1 Related Parameter s A448 A450 A452 A454 A451 Skip Freq Band 2 A453 Skip Freq Band 3 A455 Skip Freq Band 4 PowerFlex 525 only Determines the band around A448 A450 A452 and A454 Skip Frequency x Frequency Command frequency EE Drive Output frequen 2x Skip Frequency Band Skip Frequency gt Time Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz Rockwell Automation Publication 520 UM001D EN E September 2013 115 Chapter3 Programming and Parameters A456 PID 1 Trim Hi A468 PID 2 Trim Hi PowerFlex 525 only Advanced Program Group continued Scales the upper value of the trim frequency when trim is active Values Default 60 0 Hz Min Max 0 0 500 0 Hz Display 0 1Hz A457 PID 1 Trim Lo A469 PID 2 Trim Lo PF 525 PowerFlex 525 only Scales 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 1Hz A458 PID 1 Trim Sel A470 PID 2 Trim Sel PF 525 PowerFlex 525 only O Ray drive before changing this parameter Sets the PID output as trim to the source reference Options 0 Disabled Default PID Trim is disabled TrimOn Pot Tr
262. ntrol shown For three wire control use a momentary input Ta on UO Terminal 02 to command a start Use a maintained input o for 1 0 Terminal 03 to change direction 3 When using an opto output with an inductive load such as a relay install a recovery diode parallel to the relay as shown to prevent damage to the output Control 1 0 Terminal Designations No Signal Default Description Parameter R1 Relay 1 N 0 Fault Normally open contact for output relay we R2 Relay 1 Common Fault Common for output relay Ta R5 Relay 2 Common Motor Running Common for output relay 08 R6 Relay 2 N C Motor Running Normally closed contact for output relay 01 Stop Coast Three wire stop However it functions as a stop under all input Pool modes and cannot be disabled ber A Is 02 Digln TermBlk 02 Run FWD Used to initiate motion and also can be used as a programmable P045 Start Run FWD digital input It can be programmed with t062 DigIn TermBlk P048 02 as three wire Start Dir with Stop or two wire Run FWD A544 t062 Co al oe Run REV control Current consumption is 6 mA Sg 03 Digln TermBlk 03 Run REV Used to initiate motion and also can be used as a programmable t063 Dir Run REV digital input It can be programmed with t063 DigIn TermBlk 03 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 Digit
263. ntrol use a momentary input aa on 1 0 Terminal 02 to command a start Use a maintained input o for 1 0 Terminal 03 to change direction Control 1 0 Terminal Designations No Signal Default Description Parameter R1 Relay N O Fault Normally open contact for output relay ee R2 RelayCommon Fault Common for output relay pies R3 Relay N C Motor Running Normally closed contact for output relay t081 01 Stop Coast Three wire stop However it functions as a stop under all input Poos modes and cannot be disabled 02 Digin TermBlk 02 Run FWD Used to initiate motion and also can be used as a programmable P045 P046 Start Run FWD digital input It can be programmed with t062 DigIn TermBlk P048 P050 02 as three wire Start Dir with Stop or two wire Run FWD A544 t062 Run REV control Current consumption is 6 mA 03 Digin TermBlk 03 Run REV Used to initiate motion and also can be used as a programmable t063 Dir Run REV digital input It can be programmed with t063 DigIn TermBlk 03 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 Digital Common Return for digital 1 0 Electrically isolated along with the digital 1 0 from the rest of the drive 05 Digln TermBlk 05 Preset Freq Program with t065 DigIn TermBlk 05 Also functions as a Pulse t065 Pulse In Train input for reference or speed feedback The maximum freque
264. ockwell Automation Publication 520 UM001D EN E September 2013 71 Chapter 3 Programming and Parameters Fault and Diagnostic Fault 5 Time min F625 Fault10 Current F650 EN Rate Act F685 Drv 1 Reference F710 Fault 6 Time min F626 Fault 1 BusVolts F651 DSI 1 0 Act F686 Drv 1 Logic Sts F711 Da Fault 7 Time min F627 Fault 2 BusVolts F652 HW Addr 1 F687 Drv 1 Feedback F712 Fault 8 Time min F628 Fault 3 BusVolts F653 HW Addr 2 F688 Drv 2 Logic Cmd F713 Fault 4 Code F604 Fault 9 Time min F629 Fault 4 BusVolts F654 HW Addr 3 F689 Drv 2 Reference F714 Fault 5 Code et Fault10 Time min F630 Fault 5 BusVolts F655 HW Addr Al F690 Drv 2 Logic Sts F715 Fault 6 Code F606 Fault 1 Freq F631 Fault 6 BusVolts F656 HW Addr 5 F691 Drv 2 Feedback F716 Fault 7 Code F607 Fault 2 Freq F632 Fault 7 BusVolts F657 HW Addr 6 F692 Drv3 Logic Cmd F717 Fault 8 Code F608 Fault 3 Freq F633 Fault 8 BusVolts F658 EN IP Addr Act 1 F693 Drv3 Reference F718 Fault 9 Code F609 Fault 4 Freq F634 Fault 9 BusVolts F659 EN IP Addr Act 2 F694 Drv 3 Logic Sts F719 Fault10 Code F610 Fault 5 Freq F635 Fault10 BusVolts F660 EN IP Addr Act 3 F695 Drv3 Feedback F720 Fault 1 Time hr F611 Fault 6 Freg F636 Status Fault 1 F661 EN IP Addr Act 4 F696 Drv 4 Logic Cmd F721 Fault 2 Time hr F612 Fault 7 Freq F637 Status Fault 2 F662 EN Subnet Act 1 F697 Drv 4 Reference F722 Fault 3 Time hr F613 Fault 8 Freg F638 Status Fault
265. ogically true TIMED AND d Step after Stp Logic Time x and Logic In 1 is not active logically false TIMED OR E Step after Stp Logic Time x and Logic In 2 is not active logically false TIMED OR F Use logic programmed in Digit 1 IGNORE 202 Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder and Pulse Train Usage Appendix E Encoder Pulse Train Usage and Position StepLogic Application The PowerFlex 520 series drives include a pulse train input built into the terminal block PowerFlex 525 drives also support an optional encoder card The pulse train and encoder can be used for many of the same functions but the pulse train supports up to 100 kHz at 24V and uses the drive built in terminal block The encoder supports up to 250 kHz dual channel at 5 12 or 24V and requires the optional encoder board to be installed When A535 Motor Fdbk Type is set to a value other than zero the drive is set to use an encoder or pulse train The drive will use the encoder or pulse train in several ways depending on the settings of other parameters The drive will use the encoder or pulse train as shown below listed in order of priority 1 Ifenabled by P047 P049 or P051 Speed Referencex the encoder or pulse train will be used directly as a commanded speed normally used with a pulse train or as a position reference normally used with a quadrature encoder 2 Ifnot enabled by the Speed Reference
266. ogrammed as Reset Counter TIP Use the Wizard in Connected Components Workbench to simplify setup instead of manually configuring the parameters Rockwell Automation Publication 520 UM001D EN E September 2013 197 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Velocity StepLogic Using IMPORTANT This function is specific to PowerFlex 525 drives only Timed Steps To activate this function set one of the three speed reference sources parameter P047 P049 or POS1 Speed Referencex to 13 Step Logic and activate that speed reference source Three parameters are used to configure the logic speed reference and time for each step e Logic is defined using parameters L180 L187 Stp Logic x e Preset Speeds are set with parameters A410 A417 Preset Freq 0 7 e Time of operation for each step is set with parameters L190 L197 Stp Logic Time x The direction of motor rotation can be forward or reverse Using Timed Steps Step0 Step1 Step2 Step3 Step4 Step5 Menn Step7 a Forward Ob Reverse Time Velocity StepLogic Sequence e Sequence begins with a valid start command e A normal sequence begins with Step 0 and transition to the next step when the corresponding StepLogic time has expired e Step 7 is followed by Step 0 e Sequence repeats until a stop is issued or a fault condition occurs Velocity StepLogic Using S fi IMPORTANT This function is spec
267. omation Publication 520 UM001D EN E September 2013 77 Chapter3 Programming and Parameters Basic Display Group continued b018 Power Saved Related Parameter s b017 Instantaneous power savings of using this drive compared to an across the line starter Values Default Read Only Min Max 0 00 655 35 kW Display 0 01 kW b019 Elapsed Run time Related Parameter s A555 Accumulated time drive is outputting power Time is displayed in 10 hour increments Values Default Read Only Min Max 0 65535 x 10 hr Display 1 10hr b020 Average Power Related Parameter s A555 Average power used by the motor since the last reset of the meters Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW b021 Elapsed kWh Related Parameter s b022 Accumulated output energy of the drive When the maximum value of this parameter is reached it resets to zero and b022 Elapsed MWh is incremented Values Default Read Only Min Max 0 0 100 0 kWh Display 0 1 kWh b022 Elapsed MWh Related Parameter s b021 Accumulated output energy of the drive Values Default Read Only Min Max 0 0 6553 5 MWh Display 0 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
268. onnect Err 2 Control module was disconnected while Clear fault and verify all parameter drive was powered settings Do not remove or install the control module while power is applied F106 Incompat CH 2 The control module could not recognize gt Cycle power the power module Flash with newer firmware version e Replace drive if fault cannot be cleared F107 Replaced C P 2 The control module was mounted toa Set P053 Reset To Defalts to any of the power module with a different power reset options rating F109 Mismatch C P 2 The control module was mounted toa Set P053 Reset To Defalts to any of the different drive type power module reset options F110 Keypad Membrane 2 Keypad membrane failure Cycle power disconnected e Replace control module if fault cannot be cleared BU Safety Hardware 2 Safety input enable hardware e Check safety input signals If not malfunction One of the safety inputsis using safety verify and tighten not enabled jumper for UO terminals 1 2 and S e Replace control module if fault cannot be cleared F114 uC Failure 2 Microprocessor failure e Cycle power e Replace control module if fault cannot be cleared Rockwell Automation Publication 520 UM001D EN E September 2013 151 Chapter4 Troubleshooting Fault Types Descriptions and Actions No Fault Type Description Action F122 1 0 Board Fail 2 Failure has been detected inthe dr
269. out further adjustment However in most applications the drive will need to be homed after each power up and prior to starting the position routine This can be accomplished in one of the following two ways 1 Manual Homing Program the following drive parameters t062 t063 t065 t068 DigIn TermBlk xx 37 Pos Redefine Program one of the digital inputs to 37 Pos Redefine Then move the system into the home position with a run command a jog command or by manually moving the system into the home position Then toggle the Pos Redefine input This will set the drive to Home at its current position and d388 Units Traveled H and d389 Units Traveled L are set to zero Alternately the Pos Redefine bit in A560 Enh Control Word can be toggled instead of utilizing a digital input IMPORTANT The Pos Redefine input or bit must be returned to inactive before starting the position routine Otherwise the drive will continuously read a position of 0 home and the position routine will not function correctly 2 Automatic Homing to Limit Switch Program the following drive parameters t062 t063 t065 t068 DigIn TermBlk xx 35 Find Home Program one of the digital inputs to 35 Find Home t062 t063 t065 1068 DigIn TermBlk xx 34 Home Limit Program one of the digital inputs to 34 Home Limit Normally the Home Limit input would be wired to a pr
270. oximity switch or photo eye and will indicate the system is in the home position A562 Find Home Freq sets the frequency the drive will use while it is moving to the home position during the automatic homing routine A563 Find Home Dir sets the direction the drive will use while it is moving to the home position during the automatic homing routine To begin the automatic homing routine activate the Find Home input and then initiate a valid start command The drive will then ramp to the speed set in A562 Find Home Freq and in the direction set in A563 Find Home Dir until the digital input defined as Home Limit is activated If the drive passes this Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder and Position Feedback Encoder Pulse Train Usage and Position StepLogic Application Appendix E point too quickly it will then reverse direction at 1 10th A562 Find Home Freq to the point where the Home Limit switch reactivates Approximately one second after the routine finds home the drive will stop Alternately the Find Home Freq and or Home Limit bits in A560 Enh Control Word can be activated instead of utilizing a digital input The inputs or bits should be returned to inactive after the routine is complete IMPORTANT After the position is reached the drive will stop If the Find Home is removed before the homing is complete the drive will begin running the position routine without
271. plication to apply the backup to the new drive See Using the USB Port on page 67 for more information Otherwise set the necessary parameters for your application using the LCD keypad interface Connected Components Workbench or RSLogix or Logix Designer if using an Add on Profile through EtherNet IP e Configure the communication parameters needed for the application node number IP address datalinks in and out communication rate speed reference start source and so on Record these settings for your reference e Configure the other drive parameters needed for the drive analog and digital I O to work correctly Verify the operation Record these settings for your reference 60 Rockwell Automation Publication 520 UM001D EN E September 2013 StartUp Chapter 3 16 Verify the drive and motor perform as specified e Verify that the Stop input is present or the drive will not start IMPORTANT UO Terminal 01 is used as a stop input the jumper between 1 0 Terminals 01 and 11 must be removed e Verify the drive is receiving the speed reference from the correct place and that the reference is scaled correctly e Verify the drive is receiving start and stop commands correctly e Verify input currents are balanced e Verify motor currents are balanced 17 Save a backup of the drive settings using the USB utility application See Using the USB Port on page 67 for more information Start Stop Direction and Speed Cont
272. pport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve
273. programming errors The cause of the fault must be corrected before the fault can be cleared Rockwell Automation Publication 520 UM001D EN E September 2013 147 Chapter4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault SISIA IY The integral LCD display provides visual notification of a fault condition by displaying the e 4 d d b following PAPAE LISTS e Flashing fault number W Flashing fault indicator LED FAULT Press the Esc key to regain control of the display lt gt Manually Clearing Faults Step Key s 1 Press Escto acknowledge the fault The fault information will be removed so that you can use the integral keypad Access b007 Fault 1 Code to view the most recent fault information Ese 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 149 3 After corrective action has been taken clear the fault by one of these methods e Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power e Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 DigIn TermBIk xx is set to 13 Clear Fault Automatically Clearing Faults Option Step Clear a Type 1 fault and restart the drive 1 Set A541 Auto Rstrt Tries to a value oth
274. put circuits S11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 amp 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 of the system at the next operation and will not cause loss of the safety function 232 Rockwell Automation Publication 520 UM001D EN E September 2013 Safe Torque Off Function Appendix G PowerFlex 525 Certification for Safe Torque 0ff A TUVRheinland ZERTIFIKAT EC Type Examination Certificate CERTIFICATE Reg No 04 205 5249 12 Product tested Safety Function Safe Torque Certificate Rockwell Automation Off STO within the adjustable holder 6400 West Enterprise Drive Frequency AC Drive PowerFlex Mequon WI 53092 525 USA Type designation PowerFlex 525 25B 120V Manufacturer see certificate holder 240V 400 480V and 600V Codes and standards EN 61800 5 2 2007 EN ISO 13849 1 2008 AC 2009 forming the basis of EN 61800 5 1 2007 in extracts EN 60204 1 2006 A1 2009 in testing EN 61800 3 2004 extracts EN 62061 2005 IEC 61508 Parts 1 7 2010 Intended application The integrated safety function Safe Torque Off of the Frequency AC Drive PowerFlex 525 comp
275. q P042 Decel Time 1 0 00 600 00 s 0 015 10 00s Sets the time for the drive to decel from Maximum Freq to 0 Hz P043 Minimum Freq 0 00 500 00 Hz 0 01 Hz 0 00 Hz Sets the lowest frequency the drive outputs P044 Maximum Freq 0 00 500 00 Hz 0 01 Hz 60 00 Hz Sets the highest frequency the drive outputs P045 Stop Mode 0 11 0 Ramp Rail 0 1 Coast cr Stop command for normal stop 2 DC Brake ce Important 1 0 Terminal O1is always a stopinput 3 DCBrkAuto CF The stopping mode is determined by the drive 4 Ramp setting 5 Coast Important The drive is shipped with a jumper 6 DCBrake installed between 1 0 Terminals 01 and 11 Remove 7 DC BrakeAuto this jumper when using 1 0 Terminal 01 as a stopor 8 Ramp EM pc enable input 9 Ramp EM d 2 10 PointStp CF 1 Stop input also clears active fault 11 PointStop P046 Start Source 1 1 5 1 Keypad o P046 1 P048 2 Digln TrmBlk P048 2 Sets the default control scheme used to start the Wess e 7 POSO drive unless overriden by P048 Start Source 2 or x ie dier P050 i a Se owerFlex P050 Start Source 3 5 Ethernet IP 1 When active the Reverse key is also active unless disabled by A544 Reverse Disable 2 If Digln TrmBlk is selected ensure that the digital inputs are properly configured 3 Setting is specific to PowerFlex 525 drives only P047 Sp
276. r KR Rockwell Automation Publication 520 UM001D EN E September 2013 Shows cable zip tie for securing EMC Core Recommended Placement of EMC Cores Relative to External Filter All Frame sizes IMPORTANT Incoming power The ground cable shield for both input and output must pass through the EMC 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 EMC Filter Drive CORE INPUT 1 2 Motor CORE OUTPUT 1 2 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 57 Chapter1 Installation Wiring Notes 58 Rockwell Automation Publication 520 UM001D EN E September 2013 Chapter 2 Start Up This chapter describes how to start up the PowerFlex 520 series drive To simplify drive setup the most commonly programmed parameters are organized in a single Basic Program Group For information on See page Prepare for Drive Start Up 59 Display and Control Keys Viewing and Editing Parameters Drive Programming Tools Smart Start Up with Basic Program Group Parameters LCD amp Scrolling Description Using the USB Port s s s e IS I NINI M i io INO IMPORTANT Readthe General Precautions section befor
277. r values by setting P053 Reset Defalts to 2 Factory Rset If safe to do so for your application press Start on drive keypad Drive will run according to the speed potentiometer Rockwell Automation Publication 520 UM001D EN E September 2013 Cause s No output voltage to the motor Troubleshooting Chapter 4 Motor does not Start Indication Corrective Action None Check the power circuit Check the supply voltage e Check all fuses and disconnects Check the motor Verify that the motor is connected properly Check the control input signals e Verify that a Start signal is present If 2 Wire control is used verify that either the Run Forward or Run Reverse signal is active but not both Verify that 1 0 Terminal 01 is active Verify that P046 P048 P050 Start Source x matches your configuration Verify that A544 Reverse Disable is not prohibiting movement Verify that safety inputs Safety 1 and Safety 2 are active Improper boost setting at initial start up None Set A530 Boost Select to 2 35 0 VT Drive is Faulted Flashing red status light Clear fault Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power e Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 Digln TermBlk xx is set to 13 Clear Fault Incorrect programming
278. rammed logic can include conditions that need to be met from digital inputs programmed as Logic In 1 and Logic In 2 before stepping from one preset speed to the next A timer is available for each of the eight steps and is used to program a time delay before stepping from one preset speed to the next The status of a digital output can also be controlled based on the step being executed e Basic Logic Function specific to PowerFlex 525 drives only Up to two digital 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 e Timer Function A digital input can be programmed for Timer Start A digital output can be programmed as a Timer Out with an output level programmed to the desired time When the timer reaches the time programmed into the output level the output will change state The timer can be reset with a digital input programmed as Reset Timer e Counter Function A digital input can be programmed for Counter In A digital output can be programmed as Counter Out with an output level programmed to the desired number of counts When the counter reaches the count programmed into the output level the output will change state The counter can be reset with a digital input pr
279. ramps to the commanded frequency Inversion can be accomplished by setting Sleep Level to a higher setting than t103 Wake Level ATTENTION Enabling the Sleep Wake function can cause unexpected machine operation during the Wake mode Equipment damage and or personal injury can result if this parameter is used in an inappropriate application In addition all applicable local national and international codes standards regulations or industry guidelines must be considered Options 0 Disabled Default 1 0 10V Input 2 4 20mA Input 3 Command Freq Sleep enabled from 0 10V Analog Input 1 Sleep enabled from 4 20 mA Analog Input 2 Sleep enabled based on drive commanded frequency t101 Sleep Level Sets the analog input level the drive must reach to enter sleep mode Values Default 10 0 Min Max 0 0 100 0 Display 0 1 t102 Sleep Time Sets the analog input time the drive must stay below to enter sleep mode Values Default 0 0s Min Max 0 0 600 0s Display 0 15 t103 Wake Level Sets the analog input level the drive must reach to wake from sleep mode Values Default 15 0 Min Max 0 0 100 0 Display 0 1 Rockwell Automation Publication 520 UM001D EN E September 2013 95 96 Chapter3 Programming and Parameters Terminal Block Group continued t104 Wake Time Sets the analog input time the drive must stay above to wake from sle
280. reegt Aste yukuta uk at eebe E A a 75 Basic Program Groupe sss ose ies ee ete eee ees 80 Terminal Block E 85 Communications Group ed e geg Dee ce EEN ase SE 97 Logic GIOUD See e odie EE wits 103 Advanced Display Group 106 Advanced Program Group wws6i65 ESA Ee 110 Rockwell Automation Publication 520 UM001D EN E September 2013 5 Table of Contents Troubleshooting Supplemental Drive Information Accessories and Dimensions RS485 DSI Protocol Velocity StepLogic Basic Logic and Timer Counter Functions Network Parameter Group 132 Modified Parameter Group sce o07 ct acta behest ede SE 132 Fault and Diagnostic Group os aeue eh ed seal ie 133 App View Parameter Groups gn de ed eg 140 Custom View Parameter Lampe sus sass da SE eh 141 Parameter Cross Reference by Name 142 Chapter 4 Dive Stats sau ah sy ayy upas aaa y Dua EANG 147 Faults eebe ger eieiei gel gen 147 Fault Descriptions saa ayasa ana aqyay ke aus qaa 149 Common Symptoms and Corrective Actions 152 Appendix A EE 157 Environmental Specifications 158 Technical Specifications 159 Appendix B Product Selection lt 5 4 Sage 163 eege Neste tie leer ance hee ee atest amelie 173 Optional Accessories and Kits 186 Appendix Net
281. rol Factory default parameter values allow the drive to be controlled from the keypad No programming is required to start stop change direction and control speed directly from the keypad IMPORTANT To disable reverse operation see A544 Reverse Disable If a fault appears on power up see Fault Descriptions on page 149 for an explanation of the fault code Variable Torque Fan Pump Applications For improved motor tuning performance when using a premium efficient motor on a variable torque loading SVC mode set A530 Boost Select to 2 35 0 VT Rockwell Automation Publication 520 UM001D EN E September 2013 61 Chapter2 StartUp Display and Control Keys PowerFlex 523 Menu Parameter Group and Description Basic Display h ommonly viewed drive operating conditions Allen Bradley he b FR D Basic Program De Commonly used programmable functions d i Terminal Blocks FAULT Programmable terminal functions Cy Cu r7 Communications A L Programmable communication functions Se l Logic PowerFlex 525 only CaS L Programmable logic functions Advanced Display d Advanced drive operating conditions Advanced Program aaa aa H Remaining programmable functions Allen Bradley d wiere Ge e etwork functions that are shown only when a comm rir st EF X j d D D LILI Ca S
282. rsonnel You must be able to program and operate Adjustable Frequency AC Drive devices In addition you must have an understanding of the parameter settings and functions All the recommended documentation listed in this section is available online at http www rockwellautomation com literature The following publications provide general drive information 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 Maintenance of Solid State ontrol SGI 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following publications provide specific PowerFlex 520 Series information on drive installation features specifications and service Title Publication PowerFlex 520 Series AC Drive Specifications 520 TD001 PowerFlex Dynamic Braking Resistor Calculator PFLEX ATO01 PowerFlex AC Drives in Common Bus Configurations DRIVES AT002 Rockwell Automation Publication 520 UM001D EN E September 2013 Preface Overview Manual Conventions 10 The following publications provide specific Network Communications information Title PowerFlex 525 Embedded EtherNet IP Adapter Publication 520COM UM001 PowerFlex 25 COMM D DeviceNet Adapter PowerFlex
283. rward and Run Reverse inputs are closed at the same time an undetermined state could occur External Supply SRC 1 O top Run Forward O SG O O Stop Run Reverse Ge top Run Foward 0 Stop Run Reverse Soo 74V Common Each digital input draws 6 mA 2 Wire SNK Control Run FWD Run REV Internal Supply SNK 4 Run e Forward 03 O oO Stop Run Reverse 3 Wire SRC Control Non Reversing P046 Start Source 1 2 and t062 DigIn TermBlk 02 49 A momentary input will start the drive A stop input to 1 0 Terminal 01 will stop the drive as specified by P045 Stop Mode External Supply SRC 01 02 ooo Q AAAA Rockwell Automation Publication 520 UM001D EN E September 2013 O O 24V Common Each digital input draws 6 mA 1 0 3 Wire SNK Control Non Reversing Connection Example Internal Supply SNK Installation Wiring Chapter 1 01 e 1 e e 3 Wire SRC Control Reversing P046 Start Source 1 2 t062 Digln TermBlk 02 49 and t063 DiglIn TermBlk 03 51 A momentary input will start the drive A stop input to 1 0 Terminal 01 will stop the drive as specified by P045
284. s 87 0 3 43 172 0 6 77 m 72 5 2 85 r LI Ji zeen j Tei ae c o fl FALTO a 5 c c 9 C A An nnn w gt I I Ko c 5 gt c VC UVVU Ki S x gt a m Z Foy mo c gt c n OWORIEX Eg S A N ARA Sien Sage R ug lt h 6 0 0 24 IP 20 0pen Type Frame C Dimensions are in millimeters and inches 109 0 4 29 184 0 7 24 O 5 3 56 I N Allen Bradiay a g _ H C FAUTO O s gt O S Eh ou s N 7 A lt SSS T n a E
285. s 1 Typical designations include but may not be limited to the following Parts 1 amp 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG GH Rockwell Automation Publication 520 UM001D EN E September 2013 Chapter 1 Installation Wiring swiaysfs punoib yue1sis 1 uBiu 10 punosb 13u10 2430 242 A009 10 A08 UO asn 104 PSI IN ON INdU JY p A009 PUL Z A09F 40 Parsi TIN lo1uo2 10304 uo euiquio2 D d payajog sJas enuey f du JOU Wu 3IA p ay PY abued uinullutui u 0 Jas dil JUAN Y IALY Pinoys abued yuaund qe sn pe yum WOPL unang spuney Tone ddy SJOYCOG N1 U01129101d 10 0W WO ull ng I Kaen kew SJOYCA PNI 10 01d 1070W WOY L Ue Ng 94 Jo sues RIED O Bunea waum mu AUp 104 1e d tueu AUP I4 01 19J 1 bung dwe Jamo UA S10 0ui Bul 01 u03 S AAUP ay UaUM L S7 384 W0YL SE Z 9H NOPL 0S 140 T SSVD SZ 384 WOPL s D O9H nOrlI Hari g GC 09 OLL CC Dr YLLNLLOV YSZ S7 484 WOPL S D O9H n00rl 05 140 fD SSY S7 384 W0tL SED O9H N0t L Z 001 H 677 09 OU CC DE POLNLLOV VSZz SCHISIWORLT S2 7090 NOPL Or L10 f SSY S70 384 W0tL 2 7090 N0rL 7 00L q 081 8t 09 cL 07 PLLNOd8V VSZ S7 384 W0PL 2 2090 NOrL Ot L10 SSVD S2O J84 WOhLI 7 7090 NOFL 7 00L g osl gy 09 SL 07 POLNOd8V VSZ 9L F2I WOVL SL TA9A NOY L SZ 4 S10 140
286. s and metal conduit III EMI filter r Ao d L um fm H SS B 3 JD E Enclosure ground connection Shie Ided motor cable Building structure steel 1 Some installations require a shielded enclosure Keep wire length as short as possible between the enclosure entry point and the EMI filter PowerFlex 520 Series RF Emission Compliance and Installation Requirements Filter Type Standard Limits EN61800 3 Category C1 EN61800 3 Category 2 EN61800 3 Category G EN61000 6 3 EN61000 6 4 I lt 100A CISPR11 Group 1 Class B CISPR11 Group 1 Class A CISPR11 Group 1 Class A Input power lt 20 kVA Input power gt 20 kVA Internal 10 m 33 ft 20 m 66 ft External 30 m 16 ft 100 m 328 ft 100 m 328 ft 1 See Appendix B for more information on optional external filters Additional Installation Requirements This section provides information on additional requirements for Class C1 and C2 installation such as enclosures and EMC cores EMC cores are included with IMPORTANT e drives that have an internal EMC filter 25x xxxxN114 e external EMC filter accessory kit 25 RFxxx Additional Installation Requirements Frame Size Class C1 Class C2 Enclosure and Conduit Cable EMC Cores Required Enclosure EMC Cores Required Input and Output Included with product 200 240V AC 15 10 1 Phase Input with External EMC Filter 0
287. s x 1 5 Normal Duty Drive Rated Amps x 1 8 Heavy Duty Display 0 1A 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 1A A486 Shear Pin Level A488 Shear Pin2 Level PowerFlex 525 only Related Parameter s A487 A489 Sets the value of current at which the shear pin fault occurs after the time set in A487 A489 Shear Pin x Time Setting the value at 0 0 A disables this function Values Default 0 0 A Disabled Min Max 0 0 Drive Rated Amps x 2 Display 0 1A A487 Shear Pin 1 Time A489 Shear Pin 2 Time PowerFlex 525 only Related Parameter s A486 A488 Sets the continuous time the drive must be at or above the value set in A486 A488 Shear Pinx Level before a shear pin fault occurs Values Default 0 00 s Min Max 0 00 30 00 s Display 0 015 Rockwell Automation Publication 520 UM001D EN E September 2013 119 Chapter3 Programming and Parameters Advanced Program Group continued A490 Load Loss Level Related Parameter s A491 PF 525 PowerFlex 525 only Provides a software trip Load Loss fault when the current drops below this level for the time specified in A491 Load Loss Time
288. shielded cable is used for control and signal wiring the shield should be grounded at the source end only not at the drive end RFI Filter Grounding Using a drive with filter may result in relatively high ground leakage currents Therefore the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded bonded to the building power distribution ground Ensure that the incoming supply neutral is solidly connected bonded to the same building power distribution ground Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection Some local codes may require redundant ground connections The integrity of all connections should be periodically checked Rockwell Automation Publication 520 UM001D EN E September 2013 21 Chapter1 _Installation Wiring Fuses and Circuit Breakers 22 The PowerFlex 520 series drive does not provide branch short circuit protection This product should be installed with either input fuses or an input circuit breaker National and local industrial safety regulations and or electrical codes may determine additional requirements for these installations The tables found on pages 23 29 provide 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
289. sition 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 11 1 Find Home 12 1 Hold Step 13 1 Pos Redefine 14 1 Sync Enable 15 1 Traverse Disable The PowerFlex 520 series drive Comm Frequency Command can be controlled through the network by sending Function Code 06 writes to register address 2001H Comm Frequency Command Comm Frequency Command Reference Address Decimal Description 2001H 8193 Used by internal comm modules to control the reference of the drive In units of 0 01 Hz The PowerFlex 520 series drive Logic Status data can be read through the network by sending Function Code 03 reads to register address 2100H Logic Status PowerFlex 523 drives support only Velocity bit definitions PowerFlex 525 drives can use Parameter C122 Cmd Stat Select to select either Velocity or Position bit definitions Rockwell Automation Publication 520 UM001D EN E September 2013 193 AppendixC gt RS485 DSI Protocol Velocity Bit Definitions Comm Logic Status 122 0 Velocity Address Decimal Bit s 2100H 8448 Description 1 Ready 0 Not Ready 1 Active Running 0 Not Active 1 md Forward 0 md Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating Not Used
290. splay 0000 100 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Communications Group continued C146 EN Fit Cfg Ref Related Parameter s 143 C144 i 32 bit parameter PF 525 PowerFlex 525 only Sets the Reference data that is sent to the drive if any of the following is true 143 EN Comm Fit Actn is set to 4 Send Fit Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Fit Cfg and the scanner is put into Program or Test mode Values Default 0 Min Max 0 50000 Display 1 C147 EN Fit Cfg DL 1 C148 EN Fit Cfg DL 2 C149 EN Fit Cfg DL 3 C150 EN Fit Cfg DL 4 PF 525 PowerFlex 525 only Sets the Ethernet Datalink Input data that is sent to the drive if any of the following is true 143 EN Comm Fit Actn is set to 4 Send Fit Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Flt Cfg and the scanner is put into Program or Test mode Values Default 0 Min Max 0 65535 Display 1 C153 EN Data In 1 C154 EN Data In 2 C155 EN Data In 3 C156 EN Data In 4 PowerFlex 525 only Datalink parameter number whose value is written from the embedded EtherNet IP data table This parameter cannot be changed when an 1 0 connection is established through the drive s embedded EtherNet IP port Values Default 0 Min Max 0 800 D
291. sponse Critically Damped PID Reference PID Feedback Time 222 Rockwell Automation Publication 520 UM001D EN E September 2013 PowerFlex 525 Safe Torque Off Overview Appendix G Safe Torque Off Function The PowerFlex 525 Safe Torque Off function when used with other safety components helps provide protection according to EN ISO 13849 and EN62061 for safe off and protection against restart The PowerFlex 525 Safe Torque Off function is just one component in a safety control system Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding For information on See page PowerFlex 525 Safe Torque Off Overview 223 EC Type Examination Certification 224 EMC Instructions 224 Using PowerFlex 525 Safe Torque Off 224 Enabling PowerFlex 525 Safe Torque Off 227 Wiring 227 Verify Operation 228 PowerFlex 525 Safe Torque 0ff Operation Zar Connection Examples 229 PowerFlex 525 Certification for Safe Torque Off 233 IMPORTANT The Safe Torque Off function covered in this chapter is specific to PowerFlex 525 drives only The PowerFlex 525 Safe Torque Off function e Provides the Safe Torque Off STO function defined in EN IEC 61800 5 2 e 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 nec
292. ssage This allows the operation over communications instead of with hardware inputs The bits have the same functions as the digital input options of the same name Options relating to positioning are Bit 0 Home Limit indicates the drive is at the home position Bit 1 Find Home causes the drive to find home at the next start command Deactivate this bit after completing the homing routine Bit 2 Hold Step overrides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released Bit 3 Pos Redefine resets the home position to the current position of the machine Deactivate this bit after completing the homing routine Bit 4 Sync Enable holds the existing frequency when A571 Sync Time is set to enable speed synchronization When this bit is deactivated the drive will accelerate to the new commanded frequency based on A571 Sync Time Bit 5 Traverse Dis disables the traverse function when this bit is active Bit 6 Logic In 1 provides an identical function and is logically ORed with setting 24 Logic In 1 for t062 t063 t065 t068 DigIn TermBlk xx It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions Bit 7 Logic In 2 provides an identical function and is logically ORed with setting 25 Logic In 2 for t062 t063
293. start source of the drive Changes to these inputs take effect as soon as they are entered P046 Start Source 1 is the factory default start source unless overridden See Start and Speed Reference Control on page 49 for more information Options 1 Keypad Start Source 1 default 2 Digln TrmBlk Start Source 2 default 3 Serial DSI Start Source 3 default for PowerFlex 523 4 Network Opt 5 EtherNet Ip Start Source 3 default for PowerFlex 525 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001D EN E September 2013 83 Chapter3 Programming and Parameters Basic Program Group continued P047 Speed Reference1 Related Parameter s 125 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 overridden See Start and Speed Reference Control on page 49 for more information Options 1 Drive Pot Speed Reference1 default Keypad Freq Serial DSI Speed Reference3 default for PowerFlex 523 Network Opt 0 10V Input Speed Reference2 default 4 20mA Input Preset Freq Anlg In Mult MOP Pulse Input PID1 Output PID2 Output 13 Step Logi 14 Encoder 15 EtherNet IP
294. stem Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar 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 drive can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations overhauling loads and eccentric loads However it can also cause either of the following two conditions to occur 1 Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes 2 Actual deceleration times can be longer than commanded deceleration times However a Stall Fault is generated if the drive remains in this state for 1 minute If this condition is unacceptable the bus regulator must be disabled see parameter A550 Bus Reg Enable
295. t ODDUD 1 Condition True 0 Condition False Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive 1 Digit 5 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0 0x1F Display 1 134 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F681 Comm Sts DSI Displays the status of the RS485 serial DSI port to the drive GGG Digit 3 Connection Status 1 Condition True 0 Condition False 0 Not Active Rx Digit 1 1 Modbus slave network external Modbus master Ix Digit2 2 Modbus multi drive w internal com option master Status Digit3 3 Modbus multi drive w embedded com master Error Digit4 4 DSI peripheral connected Not Used 5 8 Reserved 9 RS 485 network faulted 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0000 1911 Display 0000 F682 Comm Sts Opt Displays the status of the internal communication to the drive Mgogo Digit 3 Internal Com option 1 Condition True 0 Condition False 0 Not Active no connection Rx Digit 1 Internal option connected active Tx Digit2 2 8 Reserved Status Digit3 9
296. t and program for reversing mode Digital input is incorrectly wired None Check input wiring See page 45 Motor wiring is improperly phased for reverse None Switch two motor leads 154 Rockwell Automation Publication 520 UM001D EN E September 2013 Cause s No input power to drive Troubleshooting Chapter 4 Drive does not power up Indication Corrective Action None Check the power circuit Check the supply voltage e Check all fuses and disconnects Control module is not connected properly to power module Cause s Incorrect speed calculation 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 Indication Corrective Action Improper speed Verify P032 Motor NP Hertz Reduce boost with A530 Boost Select Set P036 Motor NP RPM to motor synchronous speed Rockwell Automation Publication 520 UM001D EN E September 2013 155 Chapter4 Troubleshooting Notes 156 Rockwell Automation Publication 520 UM001D EN E September 2013 Certifications Appendix A Supplemental Drive Information For information on See page Certifications 157 Environmental Specifications 158 Technical Specifications 159 Certifications PowerFlex 523 PowerFlex 525 c UL us Listed to UL508C and CAN CSA 22 2 No 14 05 Ous CTick Aus
297. t065 1068 DigIn TermBlk xx It can be used to move through the Step Logic functions speed or Rockwell Automation Publication 520 UM001D EN E September 2013 Setup Note Encoder Pulse Train Usage and Position StepLogic Application Appendix E position using comms control without requiring actual digital input transitions L200 L214 Step Units x All of the position steps can be written to while the drive is running The changes will take place at the next move For example if step 0 is over written while the drive is moving to step 0 the drive will move to the previous commanded position at step 0 The next time the drive is commanded to return to step 0 it will proceed to the new position One possible use of this capability is when an application requires full control of the movement by a controller external to the drive The Step Logic program might be written to jump from step 0 back to step 0 when Input 1 is active The controller could write any desired position to step 0 and then toggle the input 1 bit of A560 Enh Control Word to cause the drive to move to the new position This allows almost unlimited flexibility and can be used with absolute or incremental moves The RA computer tool Connected Components Workbench can make setup of the positioning functions much easier Refer to the latest versions for additional tools or wizards which can aid in the setup Rockwell Automation Publication 520 UM001D EN E Septe
298. tal Input Selection for Start Source on page 50 for information on selecting the correct digital input Rockwell Automation Publication 520 UM001D EN E September 2013 49 Chapter 1 50 Installation Wiring Digital Input Selection for Start Source If P046 P048 or P050 Start Source x has been set to 2 DigIn TermBlk then t062 and t063 DigIn TermBlk xx must be configured for 2 Wire or 3 Wire control for the drive to function properly Start Source x Digln TermBlk 02 03 48 49 50 51 2 Wire or 3 Wire Start Source x 2 Digln TrmBlk Start and Direction Drive will not start command from Start Source x Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 CE Conformity Accel Decel Selection The Accel Decel rate can be obtained by a variety of methods The default rate is determined by P041 Accel Time 1 and P042 Decel Time 1 Alternative Accel Decel rates can be made through digital inputs communications and or parameters See below for the override priority Accel Decel always Purge Input Enabled Tae Accel Decel 1 AND Active Accel Decel from Jog Acc Dec Terminal Block Jog Yes Drive stopped Input Enabled AND NOT running No Input s is programmed as Acc Dec 2 3 4 Accel Decel 2 is active when input is selected by Accel and Decel input No Accel
299. ted wave data applies to all carrier frequencies 2 16 kHz For 240V ratings and lower reflected wave effects do not need to be considered Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies output power 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 Rockwell Automation Publication 520 UM001D EN E September 2013 Power Terminal Block Installation Wiring Chapter 1 Power Terminal Block Frame A B C amp D Frame E R L1 S L2 T3 Um VI WB HUT S L2 T L3 UI WII WI EEN ANAN ANAN AN 2 0 26 aD H DCH Py DC DC BR D p BR BR BR Terminal Description R L1 S L2 1 Phase Input Line Voltage Connection R L1 S L2 T L3 3 Phase Input Line Voltage Connection U T1 V T2 W T3 Motor Phase Connection Switch any two motor leads to change G 8 forward direction DC DC DC Bus Connection BR BR Dynamic Brake Resistor Connec
300. tems must be read and understood before the actual installation begins A ATTENTION The following information is merely a guide for proper installation Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation e Mount the drive upright on a flat vertical and level surface Frame Screw Size Screw Torque A M5 10 24 1 56 1 96 Nm 14 17 Ib in B M5 10 24 1 56 1 96 Nm 14 17 Ib in C M5 10 24 1 56 1 96 Nm 14 17 Ib in D M5 10 24 2 45 2 94 Nm 22 26 Ib in E M8 5 16 in 6 0 7 4 Nm 53 65 Ib in e Protect the cooling fan by avoiding dust or metallic particles Rockwell Automation Publication 520 UM001D EN E September 2013 15 Chapter1 _Installation Wiring e Do not expose to a corrosive atmosphere e Protect from moisture and direct sunlight Minimum Mounting Clearances See Appendix B for mounting dimensions Vertical Vertical Zero Stacking Vertical with Control Module Fan Kit Vertical Zero Stacking with No clearance between drives Control Module Fan Kit No clearance between drives
301. tep 0 based on the times programmed into L190 L197 Stp Logic Time x Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder Pulse Train Usage and Position StepLogic Application Appendix E This can be used when the desired position is based only on time In addition this mode only accepts absolute positions in a positive direction from home This option provides an easy way to implement a simple positioning program or to test the basic positioning setup For additional flexibility one of the other settings should be used 1 Preset Input directly commands movement to any step based on the status of the digital inputs programmed for Preset Freq This setting ignores the Step Logic Commands settings and instead the drive will move directly to whatever step is currently commanded by A410 A425 Preset Freq x and L200 L214 Step Units x This is useful when an application needs direct access to any position step based on discrete inputs This mode moves in the forward direction from Home and is an absolute move IMPORTANT Advanced Step Logic options such as incremental move are not available in this mode 2 Step Logic provides a highly flexible mode of operation This can be used to move through the steps Step 0 to Step 7 and back to Step 0 or can jump to a different step at any time based on time or the status of digital inputs or communication commands In this mode the drive always st
302. the proper home In this case Home will not be reset and the position will be in relation to the power up position d376 Speed Feedback indicates the measured speed feedback or the calculated speed feedback when no feedback device is selected Parameter d376 Speed Feedback is the number value to the left of the decimal whole number and d377 Speed Feedback F is the value to the right of the decimal the portion less than 1 Ka d378 Encoder Speed indicates the measured speed of the feedback device This is useful if the encoder is not used for motor speed control However the encoder must be used for some purpose in order for d378 Encoder Speed to indicate a value Parameter d378 Encoder Speed is the number value to the left of the decimal whole number and d379 Encoder Speed F is the number to the right of the decimal the portion less than 1 d388 d389 Units Traveled x indicate the current position of the system in terms of units away from Home Parameter d388 Units Traveled H is the number value to the left of the decimal whole number and d389 Units Traveled L is the number to the right of the decimal the portion less than 1 d387 Position Status indicates the status of the positioning functions The indication bits are Bit 0 Dir Positive indicates the current direction the drive has moved from Home Bit 1 At Position indicates whether the drive is at its commanded position If the dr
303. tion Safety Ground PE IMPORTANT Terminal screws may become loose during shipment Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive Power Terminal Block Wire Specifications Frame Maximum Wire Size Minimum Wire Size Torque A 5 3 mm 10 AWG 0 8 mm 18 AWG 1 76 2 16 Nm 15 6 19 1 Ib in B 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 2 16 Nm 15 6 19 1 Ib in C 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 2 16 Nm 15 6 19 1 Ib in D 13 3 mm 6 AWG 5 3 mm 10 AWG 1 76 2 16 Nm 15 6 19 1 Ib in E 26 7 mm 3 AWG 8 4 mm 8 AWG 3 09 3 77 Nm 27 3 33 4 b in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Rockwell Automation Publication 520 UM001D EN E September 2013 37 Chapter1 _Installation Wiring Common Bus Precharge Notes 1 0 Wiring 38 If drives are used with a disconnect switch to the common DC bus then an auxiliary contact on the disconnect must be connected to a digital input of the drive The corresponding input parameter t062 t063 t065 t068 DigIn TermBlk xx must be set to 30 Precharge En This provides the proper precharge interlock guarding against possible damage to the drive when connected to a common DC bus Motor Start Stop Precautions reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage The drive
304. tion is made Options 0 RTU8 N 1 Default 1 RTU 8 E 1 2 RTU 8 0 1 3 RTU 8 N 2 4 RTU 8 E 2 5 RTU 8 0 2 C128 EN Addr Sel Related Parameter s C129 C132 133 C136 C137 C140 PF 525 PowerFlex 525 only Enables the IP address subnet mask and gateway address to be set with a BOOTP server Identifies the connections that would be attempted on a reset or power cycle A reset or power cycle is required after selection is made Options 1 Parameters 2 BOOTP Default C129 EN IP Addr Cfg 1 Related Parameter s 128 C130 EN IP Addr Cfg 2 C131 EN IP Addr Cfg 3 C132 EN IP Addr Cfg 4 PF 525 PowerFlex 525 only Sets the bytes in the IP address A reset or power cycle is required after selection is made 192 168 1 62 EN IP Addr Cfg 1 EN IP Addr Cfg 2 EN IP Addr Cfg 3 EN IP Addr Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters Values Default 0 Min Max 0 255 Display 1 98 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Communications Group continued C133 EN Subnet Cfg 1 Related Parameter s 128 C134 EN Subnet Cfg 2 C135 EN Subnet Cfg 3 C136 EN Subnet Cfg 4 PowerFlex 525 only Sets the bytes of the subnet mask A reset or power cycle is required after selection is made 255 255 255 0 EN Subnet Cfg 1 EN Subnet Cfg 2
305. to 1 Manual these parameters can be changed Values Default 0 100s Min Max 0 000 10 000 s Display 0 001 s 122 Rockwell Automation Publication 520 UM001D EN E September 2013 A530 Boost Select Advanced Program Group continued Sets the boost voltage of P031 Motor NP Volts and redefines the V Hz curve Only used for V Hz and SVC control modes Maximum Voltage can be set anywhere If itis gt Motor NP Volts then it defines a point on the V Hz curve 100 Maximum Voltage can be set anywhere If it is lt Motor NP Volts then it functions as a limit only does not change the V Hz curve Motor NP Volts v Settings 5 14 If it is lt Motor NP Hertz then it functions as a limit only 50 f nwa 1 2 Motor NP Hertz l Motor NP Hertz l 50 I i Maximum Freq can be set anywhere 4 Maximum Freq can be set anywhere If it is gt Motor NP Hertz then it defines a does not change the V Hz curve point on the V Hz curve Programming and Parameters Chapter 3 Related Parameter s b004 P031 P032 P039 Options 0 Custom V Hz 1 30 0 VT 35 0 VT 40 0 VT Fan Pump Curves Variable Torque 45 0 VT 0 0 no IR Cl wm w N 0 0 Default for 400V and 600V drives 5 HP and above 7 2 5 T Default for 200V drives 5 HP and
306. to a bundling area e The diverter arm returns to its original position and triggers a limit switch that resets the counter e Parameters are set to the following options t065 DigIn TermBlk 05 20 Counter In t066 DigIn TermBlk 06 22 Reset Countr t076 Relay Our Sel 26 Counter Out t077 Relay Our Level 5 0 Counts 200 Rockwell Automation Publication 520 UM001D EN E September 2013 Velocity StepLogic Parameters Output Frequency Start Relay Out Photo Eye Digin TermBlk 05 Counter In Digin TermBlk 06 Reset Counter Limit Switch Velocity StepLogic Basic Logic and Timer Counter Functions Appendix D gt gt gt gt gt gt gt Code Descriptions for Parameters L180 L187 bata DEE i C h Digit 4 Defines the action during the step currently executing Setting Ve Parameter StepLogic Output State Commanded Direction se 0 1 Off FWD 1 1 Off REV 2 1 Off No Output 3 1 On FWD 4 1 On REV 5 1 On No Output 6 2 Off FWD 7 2 Off REV 8 2 Off No Output 9 2 On FWD A 2 On REV b 2 On No Output Digit 3 Defines what step to jump to or how to end program when the logic conditions specified in Digit 2 are met Setting Logic Jump to Step 0 Jump to Step 1 Jump to Step 2 Jump to Step 3 Jump to Step 4
307. tralian Communications and Media Authority In conformity with the following Radiocommunications Act 1992 N223 Radiocommunications Standard 2008 Radiocommunications Labelling Notice 2008 Standards applied EN 61800 3 2004 CE In conformity with the following European Directives d TUV T V Rheinland EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Standards applied EN 61800 3 2004 EN 61800 5 1 2007 Not applicable T V Rheinland Standards applied EN ISO 13849 1 2008 EN 61800 5 2 2007 EN 61508 PARTS 1 7 2010 EN 62061 2005 EN 60204 1 2009 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 Not applicable Certified to ATEX directive 94 9 EC es Group II Category 2 GD Applications with ATEX II 2 GD Approved Motors KCC Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards Article 58 2 of Radio Waves Act Clause 3 GOST R Russian GOST R Certificate no POCC US ME92 H00040 AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003 International Building Code for worst case seismic level for USA excluding site class F Rockwell Automation Publication 520 UM001D EN E September 2013 157 AppendixA Supplemental Drive Information Certificat
308. uence the EMC compliance of an entire machine or installation and compliance of the drive itself does not ensure compliance of all applications Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 e PowerFlex 520 series drives are not intended to be used on public low voltage networks which supply domestic premises Without additional mitigation radio frequency interference is expected if used on such a network The installer is responsible for taking measures such as a supplementary line filter and enclosure see Connections and Grounding on page 55 to prevent interference in addition to the installation requirements of this document supplementary enclosure or equipped with a NEMA Type 1 Kit to be V ATTENTION NEMA UL Open Type drives must either be installed in a CE compliant with respect to protection against electrical shock e PowerFlex 520 series drives generate harmonic current 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 e Ifthe optional NEMA 1 kit is not installed the drive must be installed in an enclosure with side openings less than 12 5 mm 0 5 in and top openings less than 1 0 mm 0 04 in to maintain compliance
309. unction Code Decimal Command 03 Read Holding Registers 06 Preset Write Single Register 16 10 Hexadecimal Preset Write Multiple Registers IMPORTANT Modbus devices can be 0 based registers are numbered starting at 0 or 1 based registers are numbered starting at 1 Depending on the Modbus Master used the register addresses listed on the following pages may need to be offset by 1 For example Logic Command may be register address 8192 for some master devices e g ProSoft 3150 MCM SLC Modbus scanner and 8193 for others e g PanelViews The PowerFlex 520 series drive can be controlled through the network by sending Function Code 06 writes to register address 2000H Logic Command P046 Start Source 1 must be set to 3 Serial DSI in order to accept the commands PowerFlex 523 drives support only Velocity bit definitions PowerFlex 525 drives can use Parameter C122 Cmd Stat Select to select either Velocity or Position bit definitions TIP Powerup Reset the drive after selecting an option for 122 Cmd Stat Select for the change to take effect Rockwell Automation Publication 520 UM001D EN E September 2013 191 AppendixC RS485 DSI Protocol Velocity Bit Definitions Comm Logic Command 122 0 Velocity Address Decimal Bit s Description 2000H 8192 0 1 Stop 0 Not Stop 1 1 Start 0 Not Start 2 1 Jog 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 5 4 00 No Command
310. uses drive to immediately ramp to a stop regardless of how P045 Stop Mode is set 15 CoastStop CF Causes drive to immediately coast to a stop regardless of how P045 Stop Mode is set 16 DCnjStop CF Causes drive to immediately begin a DC Injection stop regardless of how P045 Stop Mode is set 17 MOP Up Increases the value of A427 MOP Freq at the rate set in A430 MOP Time 18 MOP Down Decreases the value of A427 MOP Freq at the rate set in A430 MOP Time 19 Timer Start Clears and starts the timer function May be used to control the relay or opto outputs 20 Counter In Starts the counter function May be used to control the relay or opto outputs 21 Reset Timer Clears the active timer 22 Reset Countr Clears the active counter 23 Rset Tim amp Cnt Clear the active timer and counter 24 Logic In rog Logic function input number 1 May be used to control the relay or opto outputs t076 t081 Relay Outx Sel and t069 t072 Opto Outx Sel options 11 14 May be used in conjunction with StepLogic parameters L180 L187 Stp Logic x 25 Logic In xow Logic function input number 2 May be used to control the relay or opto outputs t076 t081 Relay Outx Sel and t069 t072 Opto Outx Sel options 11 14 May be used in conjunction with StepLogic parameters L180 L187 Stp Logic x Rockwell Automation Publication 520 UM001D EN E September 2013 85 Chapter3 Progr
311. utomation Publication 520 UM001D EN E September 2013 109 Chapter 3 Programming and Parameters Advanced Program Group A410 Preset Freq 0 A412 Preset Freq 2 A414 Preset Freq 4 A416 Preset Freq 6 A411 Preset Freq 1 A413 Preset Freq 3 A415 Preset Freq 5 A417 Preset Freq 7 A418 Preset Freq 8 A420 Preset Freq 10 A422 Preset Freq 12 A424 Preset Freq 14 PowerFlex 525 only A419 Preset Freq 9 A421 Preset Freq 11 A423 Preset Freq 13 A425 Preset Freq 15 Sets the frequency of the drive outputs to the programmed value when selected For PowerFlex 525 Default Accel Decel Used Preset Input 1 Preset Input 2 Preset Input 3 Preset Input 4 DigIn TermBIk 05 DigIn TermBlk 06 DigIn TermBIk 07 DigIn TermBIk 08 Preset Setting om 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 Preset Setting 6 2 0 1 1 0 Preset Setting 7 2 1 1 1 0 Preset Setting 8 1 0 0 0 1 Preset Setting 9 1 1 0 0 1 Preset Setting 10 2 0 1 0 1 Preset Setting 11 2 1 1 0 1 Preset Setting 12 1 0 0 1 1 Preset Setting 13 1 1 0 1 1 Preset Setting 14 2 0 1 1 1 Preset Setting 15 2 1 1 1 1 For PowerFlex 523 Default Accel Decel Used Preset Input 1 Preset Input 2 Preset Input 3 Digin TermBlk 05 Digin TermBIk 06 DigIn TermBlk 03 Preset Setting 0
312. utput Multiple Digital Input Connections Customer Inputs can be wired per External Supply SRC Connection Example eege dead 8 Q8 AAA 8 Q Q Q 77 7 Optional Ground Connection O O Customer Inputs When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives it is important to connect 1 0 Terminal 04 common together for all drives If they are to be tied into another common such as earth ground or separate apparatus ground only one point of the daisy chain of 1 0 Terminal 04 should be connected ATTENTION 1 0 Common terminals should not be tied together when using SNK Internal Supply mode In SNK mode if power is removed from one drive inadvertent operation of other drives that share the same 0 Common connection may occur Multiple Analog Connections Gel eeeeeeoo Jee 12 13 14 13 14 13 14 2920080 000900000 000000000 Remote Potentiometer 7 77 Optional Ground Connection When connecting a single potentiometer to multiple drives it is important to connect 1 0 Terminal 14 common together for all drives 1 0 Terminal 14 common and 1 0 Terminal 13 potentiometer wiper should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly Rockwell Automation Publication 520 UM001D EN E September 2013 Insta
313. utput Speed 016 Preset Freq 110 421 Speed Reference2 049 Output Voltage 004 Preset Freq 12 422 Speed Reference3 051 P Jump 570 Preset Freq BO 423 Speed Reg Sell 509 PID 1 Deadband 465 Preset Freq 140 424 Stall Fault Time 492 PID 1 Diff Rate 463 Preset Freq 15 425 Start At PowerUp 543 PID 1 Fdback Sel 460 Process Disp Hi 482 Start Boost 531 PID 1 Integ Time 462 Process Disp Lo 481 Start Source 1 046 PID 1 Invert Err 467 Process Display 010 Start Source 2 048 PID 1 Preload 466 Program Lock 552 Start Source 3 050 PID 1 Prop Gain 461 Program Lock Mod 553 Status Fault 1 661 PID 1 Ref Sel 459 Pulse In Scale 537 Status Fault 2 662 PID 1 Setpoint 464 Purge Frequency 433 Status Fault 3 663 PID 1 Trim Hi 456 PWM Frequency 440 Status Fault 4 664 PID 1 Trim Lo 457 Relay 1 Off Time 080 Status Fault 5 665 PID 1 Trim Sel 458 Relay 1 On Time 079 Status Fault 6 666 PID1 Fdbk Displ 383 Relay Out Level 077 Status Fault 7 667 PID1 Setpnt Displ 384 Relay Out1 Sel 076 Status Fault 8 668 PID 2 Deadband 477 Relay 2 Off Time 085 Status Fault 9 669 PID 2 Diff Rate 475 Relay 2 On Time 084 Status Fault10 670 PID 2 Fdback Sel 472 Relay Out Level 082 Step Units 0 200 PID 2 Integ Time 474 Relay Out2 Sel 081 Step Units 1 202 PID 2 Invert Err 479 Reset Meters 555 Step Units 20 204 PID 2 Preload 478 Reset to Defalts 053 Step Units 3 206 PID 2 Prop Gain 473 Reverse Disable 544 Step Units 40 208 PID 2 Ref Self 471 RS485 D
314. ve Values Default Relay Out1 Sel 0 Relay Out2 Sel 2 Min Max 0 29 Display 1 1 Setting is specific to PowerFlex 525 drives only 90 Rockwell Automation Publication 520 UM001D EN E September 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t077 Relay Out Level Related Parameter s t076 t081 t082 Relay Out2 Level PowerFlex 525 only KA 32 bit parameter Determines the on off point for the output relay when t076 or t081 Relay Outx Sel is set to the values shown below Min Max Value Range Based On Relay Outx Sel Setting 6 0 500Hz 10 0 100 16 10 1 9999s 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 Values Default 0 Min Max 0 9999 Display 1 t079 Relay 1 On Time t084 Relay 2 On Time PowerFlex 525 only Sets the delay time before Relay energizes after required condition is met Values Default 0 0s Min Max 0 0 600 0s Display 0 15 t080 Relay 1 Off Time t085 Relay 2 Off Time PowerFlex 525 only Sets the delay time before Relay de energizes after required condition ceases Values Default 0 0s Min Max 0 0 600 0s Display 0 15 t086 EM Brk Off Delay Related Parameter s P045 Sets the time the drive remains at minimum frequency before ramping up to the comma
315. ve errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F728 EN Tx Packets PowerFlex 525 only A count of the number of transmitted packets reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F729 EN Tx Errors PowerFlex 525 only A count of the number of transmit errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F730 EN Missed 10 Pkt PowerFlex 525 only The number of 1 0 packets missed Values Default Read Only Min Max 0 65535 Display 1 F731 DSI Errors The number of total DSI errors Values Default Read Only Min Max 0 65535 Display 1 Rockwell Automation Publication 520 UM001D EN E September 2013 139 Chapter3 Programming and Parameters AppView Parameter Groups PowerFlex 520 series drives include various AppView parameter groups that groups certain parameters together for quick and easy access based on different types of applications These applications include e Conveyor e Mixer e Compressor e Centrifugal Pump e Blower Fan e Extruder e Positioning PowerFlex 525 only e Textile Fiber You cannot 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 par
316. wed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameter list Press Enter to view the value of the parameter Or Press Esc to return to the parameter list 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 Press the Up Arrow or Down Arrow to change the parameter value Key s Example Display opt ririri LILI Lle L ep L rir JUL Le a L riri DUU or Dn Coa gt e PITI T Pogi CS PnJ LIN SE NI a mes lt or E JU Siz or igi e VOLTS Le d Gei Rockwell Automation Publication 520 UM001D EN E September 2013 63 Chapter2 Start Up Step Key s Example Display 10 If desired press Sel to move from digit to digit orbit to bit The digit or bit that you can change m JJ will flash L DPA 11 Press Esc to cancel a change and exit Program bla Mode FWD C J LJ Or Esc or or Press Enter to save a change and exit Program SC Can Mode mp d d u The digit will stop flashing and the word eg Program on the LCD display will turn off 12 Press Esc to return to the parameter list BECH E Continue to press Esc to back out of the A H 1 programming menu Ese LJ J A If pressing Esc does not change the display t
317. werFlex 525 Safe Torque Off Wiring PowerFlex 525 Safe Torque Off Operation Safe Torque OffFunction Appendix G 1 Remove all power to the drive on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points refer to your drive s user manual for the location of the terminals The voltage must be zero V ATTENTION To avoid an electric shock hazard verify that the voltage 2 Loosen the screw of terminals Safety 1 Safety 2 and Safety 24V S1 S2 S on the control I O terminal block 3 Remove the protective jumper R1 R2 R5 R6 01 02 03 04 05 06 07 08 SSS 9989189188 SEI S1 s2 St TO 133 14 15 16 17 18 19 V 4 Safe Torque Off function is now enabled and the terminals are ready to function as safety inputs Important points to remember about wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control wires should be separated from power wires by at least 0 3 m 1 ft Recommended Wire Type Wire Type Description Min Insulation Rating Shielded Multi conductor shielded cable such as Belden 8770 or equiv 0 750 mm 18 AWG 300V 60 C 140 F 3 conductor shielded 1 Recommendations are for 50 C ambient temperature 75 C wire must be used for
318. work Wiring 22 ge dt enee ee 189 Parameter Configuration sersrsrsassassaassas 190 Supported Modbus Function Codes 191 Writing 06 Logic Command Data 191 Writing 06 Comm Frequency Command 193 Reading 03 Logic Status RE 193 Reading 03 Drive Error Codes 195 Reading 03 Drive Operational Values 196 Reading 03 and Writing 06 Drive Parameters 196 Additional Information d Seed Ee Gelee eg Bee 196 Appendix D Velocity StepLogic Using Timed Steps 198 Velocity StepLogic Using Basic Logic Functions 198 Timer EE 199 Coulter Functio e geet 200 Velocity StepLogic Parameters sarsrsssa 201 Rockwell Automation Publication 520 UM001D EN E September 2013 Encoder Pulse Train Usage and Position StepLogic Application PID Set Up Safe Torque Off Function EtherNet IP Index Table of Contents Appendix E Encoder and Pulse Train enee geit Ee 203 KT 204 Positioning Ovyervie Wa AE 948 E EE 205 Common Guidelines for All Applications 205 ergeet ee ee 206 Homing Routiies 5 EE 210 Encoder and Position Feedback 211 Use Over Communications 0 C KUSI cece eee u aN 212 KEE 213 Appendix F ENEE 215 PID Reference and Feed
319. wy Wl dH WI dH xew Ayng Aaeay yng jewion suey ynduy suey dung J SUDI SadInaq UOIDa10 Indu SDYd E A009 GZS p nul u02 SZ X9 449M04 104 SAayag JINDAL pue sasn4 VOLN6d03 8S7 ON Bop 29 Rockwell Automation Publication 520 UM001D EN E September 2013 Chapter1 _Installation Wiring Power and Control Module PowerFlex 520 series drives consist of 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 30 Rockwell Automation Publication 520 UM001D EN E September 2013 Installation Wiring Chapter 1 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 Rockwell Automation Publication 520 UM001D EN E September 2013 31 Installation Wiring Chapter 1 2 Push the top cover of the Control Module towards the Power Module to lock it 3 Insert the catch at the
320. z Meter d364 Speed Feedback d365 Encoder Speed d367 DC Bus Ripple d368 Output Powr Fctr A436 PID 1 Preload A437 PID 1 Invert Err A438 PID 2 Trim Hi A439 PID 2 Trim Lo A440 PID 2 Trim Sel A441 PID 2 Ref Sel MA PID 2 Fdback Sel A443 PID 2 Prop Gain A444 PID 2 Integ Time A445 PID 2 Diff Rate A446 PID 2 Setpoint A447 PID 2 Deadband A448 PID 2 Preload A449 PID 2 Invert Err A450 Process Disp Lo A451 Process Disp Hi A452 Testpoint Sel A453 Current Limit 1 A454 Current Limit 2 A455 Shear Pin1 Level A456 Shear Pin 1 Time A457 Shear Pin2 Level A458 Shear Pin 2 Time A459 Load Loss Level A460 Load Loss Time A461 Stall Fault Time A462 Motor OL Select A463 Motor OL Ret A464 Drive OL Mode A465 IR Voltage Drop d369 Torque Current d375 PID1 Fdbk Displ d376 PID1 Setpnt Disp d378 PI Fdbk Displ d380 PID2 Setpnt Disp d381 Position Status A466 Flux Current Ref Mei Motor Rr Map Motor Lm A469 Motor Lx A470 Speed Reg Sel A471 Freq A472 Freq 1 BW A473 Freq 2 A474 Freq2 BW A475 Pen A476 Freq 3 BW A477 Freq 1Kp A478 Freq 1Ki A479 Freq 2 Kp A481 Freq 2 Ki A482 Freq 3 Kp A483 Freq 3 Ki A484 Boost Select A485 Start Boost A486 Break Voltage A487 Break Frequency A488 Maximum Voltage A489 Motor Fdbk Type A490 Encoder PPR A491 Pulse In Scale A492 KiSpeed Loop A493 Kp Speed Loop A494 Var PWM Disable A495 Auto Rstrt Tries A496 Auto Rstrt Del

PowerFlex 520-Series Adjustable Frequency AC Drive

Contents

Download Pdf Manuals

Related Search

Related Contents