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520-QS001 - Rockwell Automation

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1. A C D IL we D Ateaaaioy XS I SGH o SSS 1 oe p a So i 5 Se Powerflex z A SS aN Allen Bradley 1 00 0 bel Frame Size A B C D E Weight A 72 0 2 83 152 0 5 98 172 0 6 77 57 5 2 26 140 0 5 51 1 1 2 4 B 87 0 3 43 180 0 7 09 172 0 6 77 72 5 2 85 168 0 6 61 1 6 3 5 C 109 0 4 29 220 0 8 66 184 0 7 24 90 5 3 56 207 0 8 15 2 3 5 0 D 130 0 5 12 260 0 10 24 212 0 8 35 116 0 4 57 247 0 9 72 3 9 8 6 E 185 0 7 28 300 0 11 81 279 0 10 98 160 0 6 30 280 0 11 02 12 9 28 4 EMC Line Filter Dimensions are in mm and in Frame A D Frame E A B _ 05 5 A H B 05 5 t D F l 00 22 a E A F 00 22 Osses olbleleiso g o E C E E C E oC No G N A o ER HAR G H E Real F Frame Size A B c D E F G H l A 55 0
2. Typical Typical Stop SRCwiring SNK wiring Safety 1 01 Digin em 02 gt at gt o Safe Torque Off tart Run on on Safety 2 i ine ee 0 DigIn TermBIk 03 Safety 24V 03 Direction Run REV ee gor SNK o aS SRC T Digital Common m DigIn TermBIk 05 a oe 06 Digin TermBlk 06 a ae y DigIn TermBIk 07 Pulse ae ber 08 DigIn TermBlk 08 ses we 24V 24V DC Relay 1 N 0 1 1 E 10V 10V DC Relay 1 Common ar g 12 i 0 10V or 10V Input i 13 Relay 2 Common Analog Common Relay 2 N C A by Pot must be elay 2 N C 7 y 7 4 20mA Input 1 10 kohm i 0 10V 2W min Analog Output P m 6 moo T Opto Output 1 lan 17 4 0 W a 3 Opto Output 2 Common ah me m Non inductive 19 Opto Common a RJ45 Shield y h Yy Q Comm Common J10 J9 J5 0 4 20mA amp Pulse In SNK 5 5 zm m 2h gt 2 a 0 10V Digital SRC amp Input 4 wy R1 R2 R5 R 01 02 03 04 05 06 07 08 a Q S191919 9199 88 ee wy S ISIS SlSlSlS lS SS S S S1 99 S 11 12 B 144 15 16 17 18 19 1 IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting The dri
3. PowerFlex 523 Menu Parameter Group and Description PowerFlex 525 Embedded EtherNet IP Indicators l Basic Display Allen Bradley 1 Commonly viewed drive operating conditions Display iri l ER J Basic Program No Display State Description FWD De ILILI Cae p Commonly used programmable functions ENET Off Adapter is not connected to Y i the network LTO O t telen i PERI e networ C49 2 rogrammaoe terminaituncuons Steady Adapter is connected to the r7 Communications network and drive is E N L Programmable communication functions controlled through Ethernet ar isr pe only Flashing Adapter is connected to the a rogrammab e logic functions network but drive is not B m 4 Advanced Display controlled through Ethernet L Advanced drive operating conditions LINK Off Adapter is not connected to PowerFlex 525 a Advanced Program the network Remaining programmable functions Allen Bradley MI Network Steady Adapter is connected to the ein L rir ER IN Network functions that are shown only when a comm network but not transmitting HOLL ie card is used data O ner V 1 Wa Modified Flashing Adapter is connected to the FUTO Il Functions from the other groups with values changed network and transmitting lt gt a from default data i eN f Fault and Diagnostic SC ap ag
4. Item Name State Description 1 ENET Off Adapter is not connected to the network ENET LINK i Steady Adapter is connected to the network and drive is controlled through Ethernet EtherNet IP Flashing Adapter is connected to the network but drive is not controlled through Ethernet S 2 LINK Off Adapter is not connected to the network jlonBradioy Steady Adapter is connected to the network but not transmittingdata Flashing Adapter is connected to the network and transmitted data FAULT Flashing Red Indicates drive is faulted Setting the IP Address Subnet Mask and Gateway Address Setting an IP Addresss Using Parameters 3 Verify that parameter C128 EN Addr Sel is set to 1 Parameters This parameter must be set to Parameters to configure the IP address using parameters Set the value of parameters C129 EN IP Addr Cfg 1 through C132 EN IP Addr Cfg 4 to a unique IP address Reset the adapter by power cycling the drive Setting a Subnet Mask Using Parameters 3 Verify that parameter C128 EN Addr Sel is set to 1 Parameters This parameter must be set to Parameters to configure the subnet mask using parameters Set the value of parameters C133 EN Subnet Cfg 1 through C136 EN Subnet Cfg 4 to the desired value for the subnet mask Reset the adapter by po
5. b003 Output Current 0 00 Drive Rated Amps x 2 0 01 A Output current present at T1 T2 amp T3 U V amp W b004 Output Voltage 0 0 Drive Rated Volts 0 1V Output voltage present at T1 T2 amp T3 U V amp W b005 DC Bus Voltage 0 1200VDC 1VDC Filtered DC bus voltage level of the drive b006 Drive Status 00000 11111 Digit 5 Digit 4 Digit 3 Digit2 Digit 1 Present operating condition of the drive SafetyActivel Decelerating Accelerating Forward Running 1 Setting is specific to PowerFlex 525 drives only b007 Fault x Code FO F127 FO b008 A code that represents a drive fault Codes appear in these parameters in the order they occur b007 b009 Fault 1 Code the most recent fault Repetitive faults are only recorded once See Fault and Diagnostic Group for more information b010 Process Display 0 9999 1 Output frequency scaled by Process Disp Hi and Process Disp Lo b0012 Control Source 0000 2165 Digit 4 3 amp 2 Digit 1 Active source of the Start Command and Frequency Command Normally defined by the settings of Freq Command Source Start Command Source P046 P048 P050 Start Source x and P047 P049 P051 Speed Referencex b013 Contrl In Status 0000 1111 Digit 4 Digit 3 Digit 2 Digit 1 State of the digital terminal blocks 1 3 and DB transistor DB Trans On Digin TBIk3 Digin TBIk2 Digin TBIk 1 Important Actual control comman
6. Resets parameters to their factory defaults values After a Reset command the value of this parameter returns to zero 1 Param Reset 2 Factory Rset 3 Power Reset Rockwell Automation Publication 520 QS001A EN E March 2014 21 PowerFlex 520 Series Adjustable Frequency AC Drive Advanced Program Group Parameters See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UMO001 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 Default Typo A410 Preset Freq x 0 00 500 00 Hz 0 01 Hz Preset Freq 0 0 00 Hz A417 Sets the frequency of the drive outputs to the programmed value when selected Preset Freq 1 5 00 Hz Preset Freq 2 10 00 Hz A418 Preset Freq 3 20 00 Hz A425 Preset Freq 4 30 00 Hz F535 Preset Freq 5 40 00 Hz Preset Freq 6 50 00 Hz Preset Freq 7 15 60 00 Hz A426 Keypad Freq 0 00 500 00 Hz 0 01 Hz 60 00 Hz 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 ke
7. 1 Stop input also clears active fault 6 DC Brake 7 DC BrakeAuto 8 Ramp EM B CF 9 Ramp EM Brk 10 PointStp CF 11 PointStop P046 Start Source x 1 5 1 Keypad a P046 1 P048 Sets the default control scheme used to start the drive unless overriden by P048 Start Source 2 or P050 2 Digin TrmBIk P048 2 P050 Start Source 3 3 Serial DSI P050 3 PowerFlex 523 1 When active the Reverse key is also active unless disabled by A544 Reverse Disable 7 Pcie 5 PowerFlex 525 2 If Dighn TrmBIk is selected ensure that the digital inputs are properly configured ue 3 Setting is specific to PowerFlex 525 drives only P047 Speed Referencex 1 16 1 Drive Pot P047 1 P049 Sets the default speed command of the drive unless overridden by P049 Speed Reference2 or P051 2 Keypad Freq P049 5 P051 Speed Reference3 3 Serial DSI P051 3 PowerFlex 523 oo i 4 Network Opt 15 PowerFlex 525 1 Setting is specific to PowerFlex 525 drives only 5 0 10V Input 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 Reset To Defalts 0 3 0 Ready Idle 0
8. 4 50mm 2 0in qo T 2 E t 50mm 2 0 in Horizontal Zero Stacking with Control Module Fan Kit No clearance between drives Horizontal with Control Module Fan Kit 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 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Ambient Operating Temperatures See Appendix B of the PowerFlex 520 Series User Manual publication 520 UM001 for option kits Ambient Temperature Maximum with Control Module Mounting Enclosure Rating Minimum Maximum No Derate Maximum Derate Fan Kit Derate 2 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 oC 4 F 45 C 113 F 55 C 131 F 65 C 149 F 20 C 4 F IP 30 NEMA 1 UL Type 1 40 C 104 F 50 C 122 F Horizontal IP 20 Open Type 50 C 122 F 70 C 158 F with Control Module Fan Kit Horizontal Zero Stacking IP 20 Open Type 45 C 113 F 65
9. 24VDC Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100 mA 12 10VDC Referenced to Analog Common Drive supplied power for 0 10V external potentiometer P047 P049 Maximum output current is 15 mA 13 0 10V n Not Active For external 0 10V unipolar input supply or potentiometer wiper P047 P049 Input impedance Voltage source 100 kW t062 t063 t065 t066 Allowable potentiomet t 1 10 kW DREA owable potentiometer resistance range 1093 A459 A471 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 n Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 W t062 t063 t065 t066 A459 A471 a a 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 12 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 525 Control 1 0 Wiring Block Diagram PowerFlex 520 Series Adjustable Frequency AC Drive
10. TrimOn Encdr 13 TrimOn ENet A459 PID x Ref Sel 0 13 0 PID Setpoint 0 PID Setpoint Selects the source of the PID reference a es Boy es Keypad Freq 1 Setting is specific to PowerFlex 525 drives only 3 Serial DSI A471 4 Network Opt 5 0 10V Input 6 4 20mA Input 7 Preset Freq 8 Anigin Multi 9 MOP Freq 10 Pulse Input 11 Step Logi 12 Encoder 13 EtherNet IP A460 PID x Fdback Sel 0 6 0 0 10V Input 0 0 10V Input Selects the source of the PID feedback 1 4 20m4 Input Daa 2 Serial DSI A472 1 Setting is specific to PowerFlex 525 drives only r 3 Network Opt 4 Pulse Input 5 Encoder 6 EtherNet IP A461 PID x Prop Gain 0 00 99 99 0 01 0 01 Sets the value for the PID proportional component when the PID mode is enabled A473 A462 PID x Integ Time 0 0 999 9 s 0 15 2 05 Sets the value for the PID integral component when PID mode is enabled A474 A463 PID x Diff Rate 0 00 99 99 0 01 0 00 Sets the value in 1 second for the PID differential component when PID mode is enabled A475 A464 PID x Setpoint 0 0 100 0 0 1 0 0 Provides an internal fixed value for process setpoint when PID mode is enabled A476 A465 PID x Deadband 0 0 10 0 0 1 0 0 Sets the lower limit of the PID output A477 24 Rockwell Automation Publication 520 QS001A EN
11. 24 1 26 4 35 63 100 037 140M F8E 32 656 7 313 0 25A D030N114 25B DO30N114 20 0 15 0 15 0 11 0 30 0 323 528 30 2 33 0 45 70 100 43 140M F8E C45 656 7 402 0 25A D037N114 25B D037N114 25 0 18 5 20 0 15 0 37 0 323 528 30 8 33 7 45 70 100 C43 140M F8E C45 602 0 25A D043N114 25B D043N114 30 0 22 0 25 0 18 5 43 0 323 528 35 6 38 9 50 80 100 C60 140M F8E C45 697 0 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25A EOP9N104 25B EOP9N104 0 5 04 05 10 4 0 9 446 660 14 1 2 3 6 100 C09 140M C2E B25 22 0 25A E1P7N104 25B E1P7N104 1 0 0 75 10 0 75 1 7 446 660 26 23 3 6 100 C09 140M C2E B25 32 0 25A E3PON104 25B E3PON104 2 0 15 2 0 1 5 3 0 446 660 4 3 3 8 6 10 100 C09 140M C2E B40 50 0 25A E4P2N104 25B E4P2N104 3 0 2 2 3 0 2 2 42 446 660 6 1 5 3 10 16 100 C09 140M D8E B63 65 0 25A E6P6N104 25B E6P6N104 5 0 4 0 50 4 0 66 446 660 9 1 8 0 10 20 100 C09 140M D8E C10 95 0 25A E9P9N104 25B E9P9N104 7 5 5 5 7 5 55 99 446 660 12 8 11 2 16 25 100 C16 140M D8E C16 138 0 25A E012N104 25B E012N104 10 0 7 5 10 0 7 5 12 0 446 660 15 4 13 5 20 32 100 23 140M D8E C16 164 0 25A E019N104 25B E019N104 15 0 11 0 15 0 11 0 19 0 446 660 27 4 24 0 32 50 100 C30 140M F8E 25 656 7 290 0 25A E022N104 25B E022N
12. C 149 F with Control Module Fan Kit General Grounding Requirements 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 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 For catalogs 25x D1P4N104 and 25x E0P9N104 the temperature listed under the Max Derate column is reduced by 5 C 9 F for all mounting methods For catalogs 25x D1P4N104 and 25x E0P9N104 the temperature listed under the Max with Control Module Fan Kit Derate column is reduced by 10 C 18 F for vertical and vertical with zero stacking mounting methods only 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 ground connections should be periodically checked Typical Grounding le gi z il Aa ua Tum vm nl G maa SHLD Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Serie
13. Ramp or 6 DC Brake 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 A436 DC Brk Time Strt 0 0 99 9 s 0 15 0 0s Sets the length of time that DC brake current is injected into the motor after a valid start command is received A437 DB Resistor Sel 0 99 0 Disabled 0 Disabled 22 Enables disables external dynamic braking and selects the level of resistor protection 1 Norml RA Res 2 NoProtection 3 99 3 99 DutyCycle Rockwell Automation Publication 520 QS001A EN E March 2014 Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only PowerFlex 520 Series Adjustable Frequency AC Drive No DisplayOptions Default A438 DB Threshold 10 0 110 0 0 1 100 0 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 10
14. V Hz A532 Break Voltage 0 0 100 0 0 1 25 0 Sets the voltage in percent of Base Frequency at the A533 Break Frequency if A530 Boost Select is set to 0 Custom V Hz A533 Break Frequency 0 0 500 0 Hz 0 1 Hz 15 0 Hz Sets the frequency where A532 Break Voltage is applied if A530 Boost Select is set to 0 Custom V Hz A534 Maximum Voltage Min 10V AC on 230V AC Drives 20V AC on 460V 1V AC Drive Rated Volts AC Drives 25V AC on 600V AC Drives Max 255V AC on 230V AC Drives 510V AC on 460V AC Drives 637 5V AC on 600V AC Drives Sets the highest voltage the drive outputs 26 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only Typo Default A535 Motor Fdbk Type 0 None 0 None Selects the encoder type T Pulse Train 7 ATTENTION The loss of analog input encoder or other feedback may cause unintended speed or motion ee he Take appropriate precautions to guard against possible unintended speed or motion 4 Quadrature 5 Quad Check A536 Encoder PPR 1 20000 PPR 1 PPR 1024 PPR PF 525 Specifies the encoder Pulses Per Revolution PPR when an encoder is used A537 Pulse In Scale 0 20000 1 64 Sets the scal
15. srt wiring SNK wiring v Daga T an ORo aE m ee tart Run m oo ia A we Digin TermBIk 03 03 Direction Run REV ee ee SNK y SRC 04 Digital Common WY 7 DigIn TermBIk 05 Pulse Pos p 06 Digin TermBlk 06 a ae 24V 24V DC Relay N O 1 R1 10v 10VDC Relay Common Re O TE 12 0 10V Input Relay N C R3 rat 13 npu Analog Common e 14 a Pot must be _ 4 20mA Input 1 10 kohm _ 15 l 2W min a RJ45 Shield Comm Common C V V J8 7 SNK amp Pulse In RS485 2 os U e a 81 D AS 2 NN SRC Digital kA amp Input Ww R1 R2 01 02 03 04 05 06 ele lelelelelele el lefelelelelejle 14 R3 W 2 B 5 0 Q IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting 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 control use a momentary input E on 0 Terminal 02 to command a start Use a maintained input oo for 1 0 Terminal 03 to change direction 3 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 Rockwell Automation Publication 520 QS001A EN E March 2014 11 PowerFlex 520 Series Adjustable Frequency AC Drive PowerFlex 523 Control 1 0 Ter
16. 3 600V P039 Torque Perf Mode 0 3 0 V Hz 1 Selects the motor control mode is ae Soe tote Economize 1 Setting is specific to PowerFlex 525 drives only 3 Vector P040 Autotune 0 2 0 Ready Idle 0 Enables a static not spinning or dynamic motor spinning autotune 1 Static Tune 2 Rotate Tune P041 Accel Time 1 0 00 600 00 s 0 015 10 00 s Sets the time for the drive to accel from 0 Hz to Maximum Freq P042 Decel Time 1 0 00 600 00 s 0 015 10 005 Sets the time for the drive to decel from Maximum Freq to 0 Hz 20 Rockwell Automation Publication 520 QS001A EN E March 2014 Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only PowerFlex 520 Series Adjustable Frequency AC Drive No DsplayOptons Defaut 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 ah 0 u 1 Stop command for normal stop A cet Important 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting 3 Neha cpr t Important The drive is shipped with a jumper installed between 1 0 Terminals 01 and 11 Remove this 4 Ramp jumper when using 1 0 Terminal 01 as a stop or enable input 5 Coast
17. Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then b001 Output Freq is displayed Press Enter or Sel to enter the group list again Fa ey o or L Sg or lt a gt g ae or GD GD Rockwell Automation Publication 520 QS001A EN E March 2014 So A o So 2 Example Display mmn LLLI Lier EnA I EILILI U LIITT BL LJ lt DMJ Pu 4 Ora an J 1 F i 7 AN 1 po 1 t an 717 mes gag an I fi ry L TU 7 J FE ans L Ca E IIE VOLTS L TA RRM 4 CU or pp lt Oma i PUA 21N 17 PowerFlex 520 Series Adjustable Frequency AC Drive Basic Display Group Parameters See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UMO001 for detailed descriptions of the parameters listed here as well as the full list of available parameters No Parameter Min Max Display Options b001 Output Freq 0 00 Maximum Freq 0 01 Hz Output frequency present at T1 T2 amp T3 U V amp W Does not include slip frequency b002 Commanded Freq 0 00 Maximum Freq 0 01 Hz Value of the active frequency command even if the drive is not running Important The frequency command can come from a number of sources
18. Frequency AC Drive Fuses and Circuit Breakers Catalog No 1 Output Ratings Input Ratings Branch Circuit Protection z v Normal Duty Heavy Duty aa Z 5 Fuse 140M Motor Zs as PowerFlex PowerFlex 2 Voltage Max Ratings Protectors 5 z 523 525 HP kW HP kW Range kVA Amps Min Max Contactors 9 4 5 ZSS 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A V1P6N104 0 25 0 2 0 25 0 2 1 6 85 132 08 6 4 10 16 100 C09 140M C2E B63 20 0 25A V2P5N104 25B V2P5N104 0 5 04 05 04 25 85 132 13 9 6 16 20 100 C12 140M C2E C10 27 0 25A V4P8N104 25B V4P8N104 1 0 0 75 1 0 0 75 48 85 132 2 5 19 2 25 40 100 23 140M D8E C20 53 0 25A V6PON104 25B V6PON104 1 5 1 1 15 11 160 85 132 3 2 24 0 32 50 100 C23 140M F8E 25 67 0 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A A1P6N104 0 25 0 2 0 25 0 2 1 6 170 264 14 53 6 10 100 C09 140M C2E B63 20 0 25A A2P5N104 25B A2P5N104 0 5 04 05 04 25 170 264 1 7 65 10 16 100 C09 140M C2E C10 29 0 25A A4P8N104 25B A4P8N104 1 0 0 75 1 0 075 4 8 170 264 2 8 10 7 16 25 100 C12 140M C2E C16 50 0 25A A8PON104 25B A8PON104 2 0 15 2 0 1 5 80 170 264 4 8 18 0 25 40 100 C23 140M F8E 25 81 0 25A A011N104 25B AO11N104 3 0 2 2 3 0 2 2
19. Phase U to Gnd e Check the wiring between the drive and motor F039 Phase V to Gnd se a she F040 Phase Wto Gnd Replace drive if fault cannot be cleared F041 Phase UV Short e Check the motor and drive output terminal wiring for a shorted condition F042 Phase UW Short e Replace drive if fault cannot be cleared F043 Phase VW Short F048 Params Defaulted e Clear the fault or cycle power to the drive e Program the drive parameters as needed F059 Safety Open Check safety input signals If not using safety verify and tighten jumper for 1 0 terminals 1 S2 and S F063 SW OverCurrent e Verify connections between motor and load e Verify level and time requirements F064 Drive Overload Reduce load or extend Accel Time F070 Power Unit e Check maximum ambient temperature has not been exceeded Cycle power e Replace drive if fault cannot be cleared F071 DSI Net Loss e Cycle power e Check communications cabling e Check Modbus or DSI setting e Check Modbus or DSI status F072 Opt Net Loss e Cycle power e Check communications cabling e Check network adapter setting e Check external network status F073 EN Net Loss Cycle power e Check communications cabling e Check EtherNet IP setting e Check external network status F080 Autotune Failure Restart procedure F081 DSI Comm Loss Cycle power e Check communications cabling e Check Modbus or DSI setting e Check Modbus or DSI status e Modify using C125 Comm Loss Action e Conn
20. RTU mode PowerFlex 520 Series Drive Network Controller oor ee PowerFlex 520 Series Drives e 50 MEG Fo BEET ete Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node AN 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 o iln Master Node 1 Node n TxRxD _ RD 4 RD 4 120 ohm resistor FRONT Ti mm ohm resistor 5 TxRxD 5 TxRxD 5 Shield X Shield X Shield X PINI PINS RS485 ag RS485 _ DSI DSI AK U0 RJ45 TB2P L TxRxD TxRxD TxRXD JOS TxRxD 6 O R L1 S L2 T L R W T3 L1 S L2 T L W T3 DC DG BR DC DG BR BR BR IMPORTANT The shield is connected at ONLY ONE end of each cable segment Rockwell Automation Publication 520 QS001A EN E March 2014 33 PowerFlex 520 Series Adjustable Frequency AC Drive The
21. Voltage 100 120V AC Input Trip occurs 405V DC bus voltage equivalent to 150V AC incoming line 200 240V AC Input Trip occurs 405V DC bus voltage equivalent to 290V AC incoming line 380 480V AC Input Trip occurs 810V DC bus voltage equivalent to 575V AC incoming line 525 600V AC Input Trip occurs 1005V DC bus voltage equivalent to 711V AC incoming line Under Voltage 100 120V AC Input Trip occurs 190V DC bus voltage equivalent to 75V AC incoming line 200 240V AC Input Trip occurs 190V DC bus voltage equivalent to 150V AC incoming line 380 480V AC Input Trip occurs 390V DC bus voltage equivalent to 275V AC incoming line 525 600V AC Input If P038 3 600V trip occurs 487V DC bus voltage 344V AC incoming line If P038 2 480V trip occurs 390V DC bus voltage 275V AC incoming line Control Ride Through Minimum ride through is 0 5 s typical value 2 s Faultless Power Ride Through 100 ms PowerFlex 525 Specifications Input Output Ratings Approvals UL508C csa 22 2 N223 Ae me Rhei LV Directive 2006 95 EC EN 61800 5 1 3 2004 POk GR SEMI FAT Es EMC Directive 2004 108 EC EN 61800 E 1 2 GD Output Frequency 0 500 Hz Programmable Efficiency 97 5 Typical AC156 KCC Article 58 2 of Radio Waves Act Clause 3 GOST R POCC US ME92 H00040 Digital Control Inputs Input Current 6 mA Analog Control Inputs F
22. and Wiring Specifications Terminal Description Frame A D R L1 S L2 1 Phase Input Line Voltage Connection Os e eee JIESHE ESE Se V T2 a y two motor leads to change aie K ek Connection IN 16 forward direction o va t DC DC DC Bus Connection except for 110V 1 Phase BR BR Dynamic Brake Resistor Connection Frame E Safety Ground PE R L1 S L2 T 3 UM ee Fes S K aby ECE Frame Maximum Wire Size Minimum Wire Size Torque c 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 2 16 Nm 15 6 19 1 Ib in M D R D 133mm2 6AWG 53mm 10AWG 1 76 2 16Nm 156 19 1 b n 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance e Install Line Reactor Greater than 120 kVA supply transformer e or Isolation Transformer Line has power factor correction capacitors Install Line Reactor 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 li
23. fault occurs after the time set in A487 A489 Shear Pin x A488 Time Setting the value at 0 0 A disables this function A487 Shear Pin x Time 0 00 30 00 s 0 015 0 00 s Sets the continuous time the drive must be at or above the value set in A486 A488 Shear Pinx Level A489 before a shear pin fault occurs A490 Load Loss Level 0 0 Drive Rated Amps 0 1A 0 0A E525 Provides a software trip Load Loss fault when the current drops below this level for the time specified in A491 Load Loss Time A491 Load Loss Time 0 9999 s 1s 0s PF 525 Sets the required time for the current to be below A490 Load Loss Level before a Load Loss fault occurs A492 Stall Fault Time 0 5 0 60 Seconds 0 60 Seconds Sets the time that the drive remains in stall mode before a fault is issued 1 120 Seconds 2 240 Seconds 3 360 Seconds 4 480 Seconds 5 Fit Disabled A493 Motor OL Select 0 2 0 No Derate 0 No Derate Drive provides Class 10 overload protection Settings 0 2 select the derating factor for the It overload 1 Min Derate function 2 Max Derate A494 Motor OL Ret 0 1 0 Reset 0 Reset Selects whether the motor overload counter is saved on power down or reset on power up 1 Save A495 Drive OL Mode 0 3 0 Disabled 3 Both PWM 1st Determines how the drive handles overload conditions that would otherwise cause the drive to fault 1 Reduce CLim 2
24. the rest of the drive 14 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Prepare For Drive Start Up 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 A ATTENTION Power must be applied to the drive to perform the following start up procedures Some of the voltages present are at Before Applying Power to the Drive Av eR WY N Disconnect and lock out power to the machine Verify that AC line power at the disconnect device is within the rated value of the drive If replacing a drive verify the current drive s catalog number Verify all options installed on the drive Verify that any digital control power is 24 volts Inspect grounding wiring connections and environmental compatibility 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 11 and PowerFlex 525 Control I O Wiring Block Diagram on page 13 for location IMPORTANT Th
25. 0 4 0 5 0 C 5 5 7 5 5 5 7 5 7 5 10 0 5 5 7 5 7 5 10 0 5 5 7 5 7 5 10 0 D 7 5 10 0 11 0 15 0 15 0 20 0 11 0 15 0 15 0 20 0 11 0 15 0 15 0 20 0 E 11 0 15 0 15 0 20 0 18 5 22 0 25 0 30 0 18 5 22 0 25 0 30 0 PowerFlex 525 Frames Ratings are in kW and HP 1 Phase 3 Phase 1 Phase 1 Phase 200 240V 3 Phase 3 Phase 380 480V 3 Phase 100 120V 200 240V w Filter 200 240V 380 480V w Filter 525 600V A 0 4 0 5 0 4 0 75 0 5 1 0 0 4 0 75 0 5 1 0 0 4 2 2 0 5 3 0 0 4 2 2 0 5 3 0 0 4 2 2 0 5 3 0 0 4 2 2 0 5 3 0 B 0 75 1 1 1 0 1 5 1 5 2 2 2 0 3 0 1 5 2 2 2 0 3 0 4 0 5 0 4 0 5 0 4 0 5 0 4 0 5 0 C 5 5 7 5 5 5 7 5 7 5 10 0 5 5 7 5 7 5 10 0 5 5 7 5 7 5 10 0 D 7 5 10 0 11 0 15 0 15 0 20 0 11 0 15 0 15 0 20 0 11 0 15 0 15 0 20 0 E 11 0 15 0 15 0 20 0 18 5 22 0 25 0 30 0 18 5 22 0 25 0 30 0 Rockwell Automation Publication 520 QS001A EN E March 2014 31 PowerFlex 520 Series Adjustable Frequency AC Drive Dimensions and Weight IP 20 0pen Type Dimensions are in mm and in Weights are in kg and Ib
26. 0 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 A439 S Curve 0 100 1 0 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 A440 PWM Frequency 2 0 16 0 kHz 0 1 kHz 4 0 kHz Sets the carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM frequency setting Important Ignoring 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 A441 Droop Hertz FLA 0 0 10 0 Hz 0 1 Hz 0 0 Hz PFS25 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 A442 Accel Time x 0 015 0 00 600 00 s 10 00 5 Time for the drive to ramp from 0 0 Hz to P044 Maximum Freq if Accel Time x is selected Accel Rate Maximum Freq Accel Time A443 Decel Time x 0 00 600 00 s 0 015 10 00 5 A445 Time for the drive to ramp from P
27. 0 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 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 QS001A EN E March 2014 Mounting Considerations e Mount the drive upright on a flat vertical and level surface PowerFl
28. 044 Maximum Freq to 0 0 Hz if Decel Time x is selected REN Decel Rate Maximum Freq Decel Time A448 Skip Frequency x 0 0 500 0 Hz 0 1 Hz 0 0 Hz Disabled A450 Works in conjunction with A449 A451 A453 and A455 Skip Freq Band x creating a range of frequencies at which the drive does not operate continuously A452 A454 A449 Skip Freq Band x 0 0 30 0 Hz 0 1 Hz 0 0 Hz A451 Determines the band around A448 A450 A452 and A454 Skip Frequency x A453 A455 A456 PID x Trim Hi 0 0 500 0 Hz 0 1 Hz 60 0 Hz Scales the upper value of the trim frequency when trim is active A468 A457 PID x Trim Lo 0 0 500 0 Hz 0 1 Hz 0 0 Hz Scales the lower value of the trim frequency when trim is active A469 Rockwell Automation Publication 520 QS001A EN E March 2014 23 PowerFlex 520 Series Adjustable Frequency AC Drive Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only Typo Default A458 PID x Trim Sel 0 13 0 Disabled 0 Disabled Sets the PID output as trim to the source reference ee ad d DRA TrimOn Keyp 1 Setting is specific to PowerFlex 525 drives only 3 TrimOn DSI A470 4 TrimOn NetOp 5 TrimOn 0 10V 6 TrimOn 4 20 7 TrimOn Prset 8 TrimOn AnMit 9 TrimOn MOP 10 TrimOn Pulse 11 TrimOn Sigi 12
29. 104 20 0 15 0 15 0 11 0 22 0 446 660 31 2 27 3 35 63 100 C30 140M F8E 32 656 7 336 0 25A E027N104 25B E027N104 25 0 18 5 20 0 15 0 27 0 446 660 28 2 24 7 35 50 100 C30 140M F8E C32 1416 0 466 0 25A E032N104 25B E032N104 30 0 22 0 25 0 18 5 32 0 446 660 33 4 29 2 40 63 100 37 140M F8E 32 1416 07 562 0 Normal Duty ND and Heavy Duty HD ratings are available for this drive When the drive is controlling motors with lower amp ratings refer to the drive nameplate for drive input current rating The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary See Bulletin 140M Motor Protection Circuit Breakers Application Ratings N EU Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip Manual Self Protected Type E Combination Motor Controller UL listed for 480Y 277 and 600Y 347 AC input Not UL listed for use on 480V or 600V Delta Delta corner ground or high resistance ground systems 6 When used with the 140M circuit breaker the 25A E9P9104 must be installed in a ventilated or non ventilated enclosure with the minimum size of 457 2 x 457 2 x 269 8 mm 18 x 18 x 10 62 in 7 When using a Manual Self Protected Type E Combination Motor Controller with this drive power rating the drive must be installed in a venti
30. 11 0 170 264 6 0 22 9 32 50 100 37 140M F8E C25 111 0 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25A A1P6N114 0 25 0 2 0 25 0 2 1 6 170 264 14 53 6 10 100 C09 140M C2E B63 20 0 25A A2P5N114 25B A2P5N114 0 5 04 05 04 25 170 264 1 7 65 10 16 100 C09 140M C2E C10 29 0 25A A4P8N114 25B A4P8N114 1 0 0 75 1 0 0 75 4 8 170 264 2 8 10 7 16 25 100 C12 140M C2E C16 53 0 25A A8PON114 25B A8PON114 2 0 15 2 0 1 5 80 170 264 4 8 18 0 25 40 100 23 140M F8E C25 84 0 25A AO11N114 25B AO11N114 3 0 2 2 3 0 2 2 11 0 170 264 6 0 22 9 32 50 100 37 140M F8E C25 116 0 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25A B1P6N104 0 25 0 2 0 25 0 2 1 6 170 264 0 9 1 9 3 6 100 C09 140M C2E B25 20 0 25A B2P5N104 25B B2P5N104 0 5 04 05 04 25 170 264 1 2 2 7 6 6 100 C09 140M C2E B40 29 0 25A B5PON104 25B BSPON104 1 0 0 75 1 0 0 75 5 0 170 264 2 7 5 8 10 16 100 C09 140M C2E B63 50 0 25A B8PON104 25B B8PON104 2 0 1 5 2 0 15 80 170 264 4 3 9 5 16 20 100 C12 140M C2E C10 79 0 25A B011N104 25B BO11N104 3 0 2 2 3 0 2 2 11 0 170 264 6 3 13 8 20 32 100 C23 140M C2E C16 107 0 25A B017N104 25B BO17N104 5 0 4 0 5 0 40 17 5 170 264 9 6 21 1 32 45 100 C23 140M F8E C25 148 0 25A B024N104 25B B024N104 7 5 5 5 7 5
31. 15 5 24 0 170 264 12 2 26 6 35 63 100 37 140M F8E C32 259 0 25A B032N104 25B B032N104 10 0 7 5 10 0 7 5 32 2 170 264 15 9 34 8 45 70 100 C43 140M F8E C45 323 0 25A B048N104 25B B048N104 15 0 11 0 10 0 7 5 48 3 170 264 20 1 44 0 63 90 100 60 140M F8E C45 1416 07 584 0 25A B062N104 25B B062N104 20 0 15 0 15 0 11 0 62 1 170 264 25 6 56 0 70 125 100 72 708 0 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 25A D1P4N104 25B D1P4N104 0 5 04 10 5 04 14 323 528 1 7 1 9 3 6 100 C09 140M C2E B25 27 0 25A D2P3N104 25B D2P3N104 1 0 0 75 1 0 0 75 2 3 323 528 2 9 3 2 6 10 100 C09 140M C2E B40 37 0 25A D4PON104 25B D4PON104 2 0 15 2 0 15 4 0 323 528 5 2 5 7 10 16 100 C09 140M C2E B63 80 0 25A D6PON104 25B D6PON104 3 0 2 2 3 0 2 2 6 0 323 528 6 9 7 5 10 16 100 C09 140M C2E C10 86 0 25A D010N104 25B D010N104 5 0 40 50 40 10 5 323 528 12 6 13 8 20 32 100 C23 140M C2E C16 129 0 25A D013N104 25B DO10N104 7 5 55 7 5 15 5 13 0 323 528 14 1 15 4 20 35 100 23 140M D8E C20 170 0 25A D017N104 25B D017N104 10 0 7 5 10 0 7 5 17 0 323 528 16 8 18 4 25 40 100 23 140M D8E C20 221 0 25A D024N104 25B D024N104 10 0 7 5 10 0 7 5 17 0 323 528 24 1 26 4 35 63 100 37 140M F8E 32 656 7 221 0 25A D030N104 25B D030N104 20 0 15 0 15 0 11 0 30 0
32. 2 17 72 0 2 83 234 0 9 21 30 0 1 18 223 0 8 78 54 0 2 13 20 0 0 79 23 0 0 91 5 5 0 22 B 70 0 2 76 87 0 3 43 270 0 10 63 35 0 1 38 258 0 10 16 58 0 2 28 25 0 0 98 24 0 0 94 5 5 0 22 C 70 0 2 76 109 0 4 29 275 0 10 83 37 0 1 46 263 0 10 35 76 0 2 99 25 0 0 98 28 0 1 10 5 5 0 22 D 80 0 3 15 130 0 5 12 310 0 12 20 33 0 1 30 298 0 11 73 90 0 3 54 33 0 1 30 28 0 1 10 5 5 0 22 E 80 0 3 15 155 0 6 10 390 0 15 35 33 0 1 30 375 0 14 76 110 0 4 33 33 0 1 30 28 0 1 10 5 5 0 22 1 See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for instructions on complying with the EMC Directive 32 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Network Communication PowerFlex 520 Series RS784 DSI Protocol This section contains only basic information to setup the PowerFlex 520 series RS485 DSI protocol connection with your PowerFlex 520 series drive See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UMO001 for more information 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
33. 22 Elapsed MWh 0 0 6553 5 MWh 0 1 MWh Accumulated output energy of the drive b023 Energy Saved 0 0 6553 5 kWh 0 1 kWh Total energy savings of using this drive compared to an across the line starter since the last reset of the meters b024 Accum kWh Sav 0 0 6553 5 kWh 0 1 10kWh Total approximate accumulated energy savings of the drive compared to using an across the line starter b025 Accum Cost Sav 0 0 6553 5 0 1 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 b026 Accum C02 Sav 0 0 6553 5 kg 0 1kg Total approximate accumulated C02 savings of the drive compared to using an across the line starter b027 Drive Temp 0 120 C 1 C Present operating temperature of the drive heatsink inside module b028 Control Temp 0 120 C 1 C Present operating temperature of the drive control b029 Control SW Ver 0 000 65 535 0 001 Current drive firmware version Rockwell Automation Publication 520 QS001A EN E March 2014 19 PowerFlex 520 Series Adjustable Frequency AC Drive Smart Start Up with Basic Program Group Parameters 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 the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for detailed descriptions of the parameters listed
34. 323 528 30 2 33 0 45 70 100 43 140M F8E C45 656 7 387 0 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 25A D1P4N114 25B D1P4N114 0 5 04 10 5 0 4 14 323 528 1 7 1 9 3 6 100 C09 140M C2E B25 27 0 25A D2P3N114 25B D2P3N114 1 0 0 75 1 0 0 75 2 3 323 528 2 9 3 2 6 10 100 C09 140M C2E B40 37 0 25A D4PON114 25B D4PON114 2 0 15 2 0 1 5 4 0 323 528 5 2 5 7 10 16 100 C09 140M C2E B63 81 0 25A D6PON114 25B D6PON114 3 0 2 2 3 0 2 2 6 0 323 528 6 9 7 5 10 16 100 C09 140M C2E C10 88 0 25A D010N114 25B DO10N114 5 0 4 0 50 40 10 5 323 528 12 6 13 8 20 32 100 23 140M C2E C16 133 0 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Catalog No Output Ratings Input Ratings Branch Circuit Protection o a Normal Duty Heavy Duty Belts a Fuse 140M Motor 77 8 PowerFlex PowerFlex a Voltage Max Ratings Protectors 22 8 E 523 525 HP kW HP kW lt Range kVA Amps Min Max Contactors S 25 25A D013N114 25B DO13N114 7 5 5 5 7 5 5 5 13 0 323 528 14 1 15 4 20 35 100 23 140M D8E 20 175 0 25A DO17N114 25B DO17N114 10 0 7 5 10 0 7 5 17 0 323 528 16 8 18 4 25 40 100 23 140M D8E 20 230 0 25A D024N114 25B DO24N114 15 0 11 0 15 0 11 0 24 0 323 528
35. 4 t062 03 Digin TermBIk 03 Run REV Used to initiate motion and also can be used as a programmable digital input It can be programmed with t062 Digln t063 Dir Run REV TermBIk 02 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 DigitalCommon Return for digital 1 0 Electrically isolated along with the digital 1 0 from the rest of the drive 05 DiginTermBlk05 PresetFreq Program with t065 DigIn TermBlk 05 Current consumption is 6 mA t065 06 DiginTermBlk06 Preset Freq Program with t066 DigIn TermBIk 06 Current consumption is 6 mA t066 07 Digln TermBIk07 Start Source2 Program with t067 Digln TermBIk 07 Also functions as a Pulse Train input for reference or speed feedback The t067 Pulse In Speed maximum frequency is 100 kHz Current consumption is 6 mA Reference2 08 Digin TermBIk08 Jog Forward Program with t068 DigIn TermBIk 08 Current consumption is 6 mA t068 a a 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 IQ 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 11 24V DC Reference
36. A446 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 An excessive 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 Ovrlmp e Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded the rated ambient temperature e Check fan F009 CC Ovrlmp e Check product ambient temperature e Check for airflow obstruction e Check for dirt or debris e Check fan F012 HW OverCurrent Check programming Check for excess load improper A530 Boost Select setting DC brake volts set too high or other causes of excess current F013 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition F015 Load Loss e Verify connections between motor and load e Verify level and time requirements F021 Output Ph Loss e Verify motor wiring e Verify motor F029 Analog In Loss Check for broken loose connections at inputs e Check parameters Rockwell Automation Publication 520 QS001A EN E March 2014 29 PowerFlex 520 Series Adjustable Frequency AC Drive No Fault Action F033 Auto Rstrt Tries Correct the cause of the fault and manually clear F038
37. E March 2014 Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only PowerFlex 520 Series Adjustable Frequency AC Drive Ne DsplayOptions Defaut A466 PID x Preload 0 0 500 0 Hz 0 1 Hz 0 0 Hz Sets the value used to preload the integral component on start or enable A478 A467 PID x Invert Err 0 1 0 Normal 0 Normal Changes the sign of the PID error 1 Inverted A479 A481 Process Disp Lo 0 00 99 99 0 01 0 00 Sets the value displayed in b010 Process Display when the drive is running at P043 Minimum Freq A482 Process Disp Hi 0 00 99 99 0 01 0 00 Sets the value displayed in b010 Process Display when the drive is running at P044 Maximum Freq A483 Testpoint Sel 0 FFFF 1 400 Used by Rockwell Automation field service personnel A484 Current Limit 1 0 0 Drive Rated Amps x 1 5 Normal Duty Drive 0 1A Drive Rated Amps x 1 1 Rated Amps x 1 8 Heavy Duty Normal Duty Drive Rated Maximum output current allowed before current limiting occurs Amps x 1 5 Heavy Duty A485 Current Limit 2 0 0 Drive Rated Amps x 1 5 Normal Duty Drive 0 1A Drive Rated Amps x 1 1 Rated Amps x 1 8 Heavy Duty Maximum output current allowed before current limiting occurs A486 Shear Pinx Level 0 0 Drive Rated Amps x 2 0 1A 0 0 A Disabled Sets the value of current at which the shear pin
38. Flex 25 COMM P PROFIBUS DP Adapter User Manual 520COM UM004 Dynamic Braking Resistor Calculator PFLEX AT001 Wiring and Grounding Guidelines for PWM AC Drives DRIVES INO01 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Allen Bradley Rockwell Software Automation PowerFlex 520 Series Adjustable Frequency AC Drive A ATTENTION e Before installing configuring operating or maintaining this product read this document and the documents listed in the Additional Resources section for installing configuring or operating equipment Users should familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards e Installation adjustments putting into service use assembly disassembly and maintenance shall be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired Solid state equipment has operational characteristics differing f
39. Quick Start Allen Bradley wy PowerFlex 520 Series Adjustable Frequency AC Drive Quick Start Quick Start Guide for PowerFlex 523 and PowerFlex 525 AC Drives PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B This Quick Start guide summarizes the basic steps needed to install start up and program the PowerFlex 520 Series Adjustable Frequency AC Drive The information provided DOES NOT replace the User Manual and is intended for qualified drive service personnel only For detailed PowerFlex 520 Series information including EMC instructions application considerations and related precautions see the PowerFlex 520 Series User Manual publication 520 UMO001 Topic Page General Precautions 2 Mounting Considerations 3 Fuses and Circuit Breakers 6 Technical Specifications 8 Power Wiring 9 1 0 Wiring 10 Control Terminal Block ii Prepare For Drive Start Up 15 Network Communication 33 Additional Resources These documents contain additional information concerning related products from Rockwell Automation Title Publication PowerFlex 520 Series Adjustable Frequency AC Drive User Manual 520 UM001 PowerFlex 4 Class Human Interface Module HIM DSI Quick Reference 22HIM QRO01 PowerFlex 525 Embedded EtherNet IP Adapter User Manual 520COM UM001 PowerFlex 25 COMM D DeviceNet Adapter User Manual 520COM UM002 PowerFlex 25 COMM E2P EtherNet IP Adapter User Manual 520COM UM003 Power
40. Reduce PWM 3 Both PWM 1st A496 IR Voltage Drop 0 0 600 0VAC 0 1VAC Based on Drive Rating Value of volts dropped across the resistance of the motor stator autotune for induction motor A497 Flux Current Ref 0 00 Drive Rated Amps x 1 4 0 01 A Based on Drive Rating This is the current necessary for full motor flux The value should be set to the full speed no load current of the motor Rockwell Automation Publication 520 QS001A EN E March 2014 25 PowerFlex 520 Series Adjustable Frequency AC Drive Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No DsplayOptions Defaut A498 Motor Rr 0 00 655 35 ohm 0 01 ohm Based on Drive Rating PF525 Rotor resistance of induction motor A499 Motor Lm 0 0 6553 5 mH 0 1mH Based on Drive Rating P55 Mutual Inductance of induction motor A500 Motor Lx 0 0 6553 5 mH 0 1mH Based on Drive Rating PF 5 Leakage Inductance of induction motor A509 Speed Reg Sel 0 1 0 Automatic 0 Automatic F525 Determines if PI gain of the Vector control mode speed regulator is set automatically or manually 1 Manual Parameters A521 A526 are set automatically by this parameter A510 Freq x 0 00 200 00 0 01 Freq 1 8 33 A512 Sets the Vector control mode frequency Freq 2 15 00 A514 Fr
41. ch 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 publication 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 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 Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at hettp www rockwellautomation com literature Allen Bradley Rockwell Software Rockwell Automation PowerFlex Connected Components Workbench Studio 5000 DriveTools SP AppView CustomView MainsFree Programming and P ointStop are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Soluti
42. d to Digital Common Drive supplied power for digital inputs Maximum output current is 100 mA 12 10VDC Referenced to Analog Common Drive supplied power for 0 10V external potentiometer P047 P049 Maximum output current is 15 mA 13 10VIn Not Active For external 0 10V unipolar or 10V bipolar input supply or potentiometer wiper P047 P049 Input impedance Voltage source 100 kW HE e Allowable potentiometer resistance range 1 10 kW 1093 M459 A471 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 In Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 W 1062 t063 t065 t066 A459 A471 16 Analog Output OutFreq 0 10 The default analog output is 0 10V To convert a current value change the Analog Output jumper to 0 20 mA Program t088 t089 with t088 Analog Out Sel Maximum analog value can be scaled with t089 Analog Out High Maximum Load 4 20 mA 525 W 10 5V 0 10V 1 kW 10 mA 17 Opto Output 1 Motor Running Program with t069 Opto Out1 Sel t069 t070 Each Opto Output is rated 30V DC 50 mA Non inductive t075 18 Opto Output 2 At Frequency 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 from
43. ds may come from a source other than the control terminal block 1 Setting is specific to PowerFlex 525 drives only b014 Dig In Status 0000 1111 Digit 4 Digit 3 Digit 2 Digit 1 State of the programmable digital inputs Digln TBlk gt DigIn TBlk 7 Digin TBIk6 Digin TBIk 5 1 Setting is specific to PowerFlex 525 drives only b015 Output RPM 0 24000 rpm 1rpm Current output frequency in rpm Scale is based on P035 Motor NP Poles b016 Output Speed 0 0 100 0 0 1 Current output frequency in Scale is 0 at 0 00 Hz to 100 at P044 Maximum Freq b017 Output Power 0 00 Drive Rated Power x 2 0 01 kW Output power present at T1 T2 amp T3 U V amp W b018 Power Saved 0 00 655 35 kW 0 01 kW Instantaneous power savings of using this drive compared to an across the line starter b019 Elapsed Run time 0 65535 x 10 hr 1 10hr Accumulated time drive is outputting power Time is displayed in 10 hour increments b020 Average Power 0 00 Drive Rated Power x 2 0 01 kW Average power used by the motor since the last reset of the meters b021 Elapsed kWh 0 0 100 0 kWh 0 1 kWh 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 18 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive No Parameter Min Max Display Options b0
44. e Consists of list of codes for specific fault conditions 7 m No LED LEDState Description r AppView and CustomView SS t lt CS LJ Functions from the other groups organized for specific FAULT Flashing Red Indicates drive is faulted applications Key Name Description Key Name Description Up Arrow Scroll through user selectable display parameters Reverse Used to reverse direction of the drive Default is a gt Down Arrow OF groups active Increment values Controlled by parameters P046 P048 and P050 z gt Start Source x and A544 Reverse Disable Escape Back one step in programming menu CD Start Used to start the drive Default is active Cancel a change to a parameter value and exit Controlled by parameters P046 P048 and P050 Esc Program Mode Start Source x Select Advance one step in programming menu Stop Used to stop the drive or clear a fault Select a digit when viewing parameter value This key is always active Controlled by parameter P045 Stop Mode Enter Advance one step in programming menu Potentiometer Used to control speed of drive Default is active Save a change to a parameter value Controlled by parameters P047 P049 and P051 Speed Referencex 16 Rockwell Automation Publication 520 QS001A EN E March 2014 Viewing and Editing Parameters PowerFlex 520 Series Adjustable Frequency AC Drive The following is an example of basic integral keypad and display functions This example provides bas
45. e default control scheme is Source SRC 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 7 Wire I O as required for the application 11 12 13 14 15 Wire the power input and output terminals Confirm that all inputs are connected to the correct terminals and are secure 10 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 Ungrounded Distribution Systems on page 5 for more information on MOVs 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 20 for more information 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
46. e factor gain for the Pulse Input when t065 or t067 DigIn TermBIk 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 A538 Ki Speed Loop 0 0 400 0 0 1 2 0 PES Sets the I gain used in the PI calculation of the speed loop when feedback is used A539 Kp Speed Loop 0 0 200 0 0 1 5 0 F525 Sets the P gain used in the PI calculation of the speed loop when feedback is used A540 Var PWM Disable 0 1 0 Enabled 0 Enabled Enables disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 1 Disabled PWM Frequency A541 Auto Rstrt Tries 0 9 1 0 Sets the maximum number of times the drive attempts to reset a fault and restart 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 A542 Auto Rstrt Delay 0 0 120 0s 0 15 1 05 Sets the time between restart attempts if A541 Auto Rstrt Tries is not zero A543 Start At PowerUp 0 1 0 Enabled 0 Disabled 1 Disabled 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 p
47. ecting 1 0 terminals C1 and C2 to ground may improve noise immunity e Replace wiring Modbus master device or control module F082 Opt Comm Loss e Cycle power e Reinstall option card in drive e Modify using C125 Comm Loss Action e Replace wiring port expander option card or control module F083 EN Comm Loss e Cycle power e Check EtherNet IP setting 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 e Check Wiring If P047 P049 P051 Speed 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 Close input to the terminal and cycle power F100 Parameter Chksum Set P053 Reset To Defalts to 2 Factory Rset F101 External Storage Set P053 Reset To Defalts to 2 Factory Rset F105 C Connect Err Clear fault and verify all parameter settings Do not remove or install the control module while power is applied F106 Incompat C P e Change to a different power module e Change to a PowerFlex 523 control module F107 Replaced C P e Change to a different power module Replace control module if changing power module does not work 30 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive No Fau
48. eq 3 20 00 PF 525 A511 Freqx BW 0 40 Hz 1Hz 10 Hz yee Speed control loop bandwidth for Vector control mode PF 525 A521 Freqx Kp 0 0 500 0 0 1 100 0 A523 Sets P gain of Vector control mode when in frequency region 1 2 or 3 for faster speed response during A525 dynamic state where motor is still accelerating If A509 Speed Reg Sel is set to 1 Manual these a parameters can be changed A522 Freq x Kil 0 000 10 000 s 0 0015 0 100 s A524 Sets l gain of Vector control mode when in frequency region 1 2 or 3 for faster speed response during A526 steady state where motor is at its rated speed If A509 Speed Reg Sel is set to 1 Manual these parameters can be changed A530 Boost Select 0 14 0 Custom V Hz 6 0 0 For 400V and Sets the boost voltage of P031 Motor NP Volts and redefines the V Hz curve Only used for V Hz and 1 30 0 VT 600V drives 5 HP and above SVC control modes 2 35 0 VT 7 2 5 CT For 200V 3 40 0 VT drives 5 HP and above 4 45 0 VT 8 5 0 CT For drives 5 0 0 no IR below 5 HP 6 0 0 7 2 5 C1 8 5 0 CT 9 7 5 C1 10 10 0 CT 11 12 5 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT A531 Start Boost 0 0 25 0 0 1 2 5 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
49. ers 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 A550 Bus Reg Enable 0 1 0 Disabled 1 Enabled 1 Enabled Enables disables the bus regulator Rockwell Automation Publication 520 QS001A EN E March 2014 27 PowerFlex 520 Series Adjustable Frequency AC Drive Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No DisplayOptions Defaut A551 Fault Clear 0 2 0 Ready Idle 0 Ready Idle Resets a fault and clears the fault queue i Reset Fault 2 Clear Buffer A552 Program Lock 0000 9999 1111 0000 Protects parameters against change by unauthorized personnel with a 4 digit password A553 Program Lock Mod 0 3 0 Full Lock 0 Full Lock Determines the lock mode used in parameter A552 Program Lock When set to 2 or 3 A552 Program 1 Keypad Lock Lock is added to the custom group to allow unlocking of parameters 2 Custom Only 3 KeyPd Custom A554 Drv Ambient Sel 0 4 0 Normal 0 Normal Sets the maximum expected ambient of the drive when used above 50 C When ambient temperature is T 55C above 50 C the drive will apply necessary current derati
50. ersonal inj inappropriate application Do not use this function wi ury may result if this parameter is used in an ithout considering applicable local national and international codes standards regulations or industry guidelines A544 Reverse Disable 0 1 0 Rev Enabled 0 Rev Enabled Enables disables the function that allows the direction of motor rotation to be changed 1 Rev Disabled A545 Flying Start En 0 1 0 Enabled 0 Disabled Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM 1 Disabled A546 FlyStrt CurLimit 30 200 1 150 Used to determine when the drive has matched the motor frequency if flying start is enabled A547 Compensation 0 3 0 Disabled 1 Electrical Enables disables correction options that may improve problems with motor instability 1 Electrical 2 Mechanical 3 Both A548 Power Loss Mode 0 1 0 Coast 0 Coast Sets the reaction to a loss of input power 1 Decel A549 Half Bus Enable 0 1 0 Disabled 0 Disabled Enables disables the power ride through function which allows the drive to maintain power to the motor 1 Enabled 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 recov
51. ex 520 Series Adjustable Frequency AC Drive Frame Screw Size Screw Torque A M5 10 24 1 56 1 96 Nm 14 17 Ib in 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 e Do not expose to a corrosive atmosphere e Protect from moisture and direct sunlight Minimum Mounting Clearances See Dimensions and Weight on page 32 for mounting dimensions Vertical with Control Module Fan Kit Vertical Zero Stacking with Control Module Fan Kit No clearance between drives Vertical Zero Stacking No clearance between drives Vertical D gt gt 50mm 50mm 50mm 2 0 in 25mm 2 0 in E in D Ain od mois pate uy fi 50 mm 50 mm 2 0 in 2 0 in v v gt RS 3 BS v Toy
52. following PowerFlex 520 series drive parameters are used to configure the drive to operate on a DSI network Configuring Parameters for DSI Network Parameter Description P046 Start Source 1 Set to 3 Serial DSI if Start is controlled from the network P047 Speed Reference Set to 3 Serial DSI if Speed Reference is controlled from the network 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 124 RS485 Node Addr Sets the node address for the drive on the network Each device on the network requires a unique node address 125 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 C127 Comm Format Sets the transmission mode data bits parity and stop bits for the RS485 DSI port All nodes on the network must be set to the same setting C128 Comm Write Mode Set to 0 Save when programming drive Set to 1 RAM only to only write to volatile memory PowerFlex 525 Embedded EtherNet IP This section contains only basic information to setup an EtherNet IP connection with your PowerFlex 525 drive For comprehensive information about EtherNet IP single and dual port and how to use it see the following publications e PowerFlex 525 Embedded EtherNet IP Adapter User Manual p
53. git 1 FindHome Home Limit A561 Home Save 0 1 0 Home Reset 0 Home Reset PF 25 Determines whether the current position is saved on power down 1 Home Saved A562 Find Home Freq 0 1 500 0 Hz 0 1 Hz 10 0 Hz PF 525 Sets the maximum frequency the drive uses when Find Home is issued A563 Find Home Dir 0 1 0 Forward 0 Forward Sets the direction the drive commands when Find Home is issued 1 Reverse PF 525 A564 Encoder Pos Tol 1 50000 1 100 me 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 A565 Pos Reg Filter 0 15 1 8 ere Sets the error signal filter in the position regulator 28 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No DisplayOptions Default A566 Pos Reg Gain 0 0 200 0 0 1 3 0 cs Sets the gain adjustment for the position regulator A567 Max Traverse 0 00 300 00 Hz 0 01 Hz 0 00 Hz Sets the amplitude of triangle wave speed modulation A568 Traverse Inc 0 00 300 00 s 0 01s 0 00s Sets the time required for the Traverse function to accelerate from the minimum to the ma
54. 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 DisplayOptons Defaut P030 Language 1 15 1 English 1 Selects the language displayed de j 8 Espafio Important The setting takes effect after the drive is power cycled 4 Italiano 5 Deutsch 6 Reserved 7 Portugu s 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Polish 13 Reserved 14 Turkish 15 Czech P031 Motor NP Volts 10V for 200V Drives 20V for 400V Drives 1V Based on Drive Rating 25V for 600V Drives Drive Rated Volts Sets the motor nameplate rated volts P032 Motor NP Hertz 15 500 Hz 0 1A 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 x 2 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 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 to 600V drives
55. ic navigation instructions and illustrates how to program a parameter Step 1 11 12 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 parameter s 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 f and Gx Press Enter or Sel to enter a group The right digit of the last viewed 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 If desired press Sel to move from digit to digit or bit to bit The digit or bit that you can change will flash Press Esc to cancel a change and exit Program Mode Or Press Enter to save a change and exit Program Mode The digit will stop flashing and the word Program on the LCD display will turn off Press
56. id wire 2 Ifthe 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 Wire Type s Per US NEC or applicable national or local code Minimum Insulation Rating 300V 60 C 140 F Unshielded Unshielded Multi conductor shielded cable such as Belden 8770 or equivalent 0 750 mm 18 AWG 3 conductor shielded Control 1 0 Terminal Block Wire Specifications Frame Maximum Wire Size Minimum Wire Size Torque A E 1 3 mm 16 AWG 1 3 mm 16 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 See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UMO001 for recommendations on maximum power and control cable length 10 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Control Terminal Block PowerFlex 523 Control 1 0 Wiring Block Diagram Typical Typical Stop
57. lated or non ventilated enclosure with the minimum volume specified in this column Application specific thermal considerations may require a larger enclosure C Rockwell Automation Publication 520 QS001A EN E March 2014 7 PowerFlex 520 Series Adjustable Frequency AC Drive Technical Specifications PowerFlex 523 Specifications Input Output Ratings Digital Control Inputs Input Current 6 mA Ww Output Frequency 0 500 Hz Programmable Efficiency 97 5 Typical SRC Source Mode SNK Sink Mode 18 24V ON 0 6V ON 0 6V OFF 18 24V OFF Approvals Guso Goss 22 2 Pk LV Directive 2006 95 EC EN 61800 5 1 EMC Directive 2004 108 EC EN 61800 3 2004 AC156 KCC Article 58 2 of Radio Waves Act Clause 3 GOST R POCC US ME92 H00040 Control Output Analog Control Inputs Fuses and Circuit Breakers Programmable Output Form C Resistive Rating 3 0 A 30V DC 125V AC and 240V AC Inductive Rating 0 5 A 30V DC 125V AC and 240V AC 4 20 mA Analog 250 Q input impedance 0 10V DC Analog 100 KQ input impedance External Pot 1 10 kQ 2 W min Recommended Fuse Type UL Class CC J T or Type BS88 600V 550V or equivalent Recommended Circuit Breakers HMCP or equivalent Protective Features Motor Protection I2t overload protection 150 for 60 s 200 for 3 s Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fault Over
58. lt Action F109 Mismatch C P Set P053 Reset To Defalts to 3 Power Reset F110 Keypad Membrane Cycle power e Replace control module if fault cannot be cleared p110 Safety Hardware e Check safety input signals If not using safety verify and tighten jumper for 1 0 terminals 1 2 and S e Replace control module if fault cannot be cleared F114 uC Failure Cycle power e Replace control module if fault cannot be cleared F122 1 0 Board Fail e Cycle power e Replace drive or control module if fault cannot be cleared F125 Flash Update Req Perform a firmware flash update operation to attempt to load a valid set of firmware F126 NonRecoverablErr e Clear fault or cycle power to the drive e Replace drive or control module if fault cannot be cleared F127 DSIFlashUpdatReq Perform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware 1 This fault is not applicable to PowerFlex 523 drives Drive Ratings PowerFlex 523 Frames Ratings are in kW and HP 1 Phase 3 Phase 1 Phase 1 Phase 200 240V 3 Phase 3 Phase 380 480V 3 Phase 100 120V 200 240V w Filter 200 240V 380 480V w Filter 525 600V A 0 2 0 4 0 25 0 5 0 2 0 75 0 25 1 0 0 2 0 75 0 25 1 0 0 2 2 2 0 25 3 0 0 4 2 2 0 5 3 0 0 4 2 2 0 5 3 0 0 4 2 2 0 5 3 0 B 0 75 1 1 1 0 1 5 1 5 2 2 2 0 3 0 1 5 2 2 2 0 3 0 4 0 5 0 4 0 5 0 4 0 5
59. minal Designations No Signal Default Description Parameter R1 Relay N O Fault Normally open contact for output relay t076 R2 Relay Common Fault Common for output relay t081 R3 Relay N C Motor Running Normally closed contact for output relay P045 01 Stop Coast Three wire stop However it functions as a stop under all input modes and cannot be disabled P045 P046 P048 P050 A544 t062 02 Digin TermBlk 02 Run FWD Used to initiate motion and also can be used as a programmable digital input It can be programmed with t062 Digin t063 Start Run FWD TermBIk 02 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 03 Digln TermBlk 03 Run REV Used to initiate motion and also can be used as a programmable digital input It can be programmed with t063 Digln t063 Dir Run REV TermBlk 03 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 DigitalCommon Return for digital 1 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 Also functions as a Pulse Train input for reference or speed feedback The t065 Pulse In maximum frequency is 100 kHz Current consumption is 6 mA 06 Digin TermBIk06 Preset Freq Program with t066 DigIn TermBIk 06 Current consumption is 6 mA t066 11
60. ne to line voltage Remove MOV jumper to ground Ungrounded distribution system or Install Isolation Transformer with grounded secondary if necessary 240V open delta configuration stinger leg Install Line Reactor 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 Appendix B of the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for specific line reactor part numbers 2 See Appendix B of the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for accessory ordering information Rockwell Automation Publication 520 QS001A EN E March 2014 9 PowerFlex 520 Series Adjustable Frequency AC Drive 1 0 Wiring Recommended Signal Wire Signal Type Where Used Belden Wire Type or equivalent Minimum Insulation Rating Analog 1 0 amp PTC 8760 9460 0 750 mm 18 AWG twisted pair 100 shield with drain 300V Remote Pot 8770 0 750 mm 18 AWG 3 conductor shielded 60 C 140 F Encoder Pulse 1 0 9728 9730 0 196 mm 24 AWG individually shielded pairs 1 Stranded or sol
61. ng 2 60C 3 65C Fan Kit 4 70C Fan Kit A555 Reset Meters 0 2 0 Ready Idle 0 Ready Idle Resets the values stored in the parameters that track fault times and energy usage 1 Reset Meters 2 Reset Time A556 Text Scroll 0 3 0 Off 2 Mid Speed Sets the scrolling speed of the text in the LCD display 1 Low Speed 2 Mid Speed 3 High Speed A557 Out Phas Loss En 0 1 0 Disabled 0 Disabled Enable disable output phase loss detection 1 Enabled 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 A558 Positioning Mode 0 4 0 Time Steps 0 Time Steps Defines the positioning transition mode used for the position steps e 3 Preset Stpl 4 StpLogic Lst A559 Counts Per Unit 1 32000 1 4096 Sets the number of encoder counts equal to one user defined unit A560 Enh Control Word 0000 0000 1111 1111 Digit 8 Digit 7 0000 0000 P6525 Allows control of positioning and other functions through parameter control for use over comms The Logic In 2 Logic In 1 functions replicate the digital input options and function in the same way Digit 6 Digit 5 Traverse Dis Sync Enable Digit 4 Digit 3 Pos Redefine Hold Step Digit 2 Di
62. ons 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 QS001A EN E March 2014 Copyright 2014 Rockwell Automation Inc All rights reserved
63. rom 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 General Precautions 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 system 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 800
64. s Adjustable Frequency AC Drive Ungrounded Distribution Systems ATTENTION PowerFlex 520 Series drives contain protective MOVs that are referenced to ground These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system ATTENTION Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground Disconnecting MOVs To prevent drive damage the MOVs connected to ground shall be disconnected if the 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 Three Phase Bie AC Input S l2 o T L3 T ime 1 2 13 4 Ae i CE Conformity See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for details on how to comply with the Low Voltage LV and Electromagnetic Compatibility EMC Directives Rockwell Automation Publication 520 QS001A EN E March 2014 5 PowerFlex 520 Series Adjustable
65. ublication 520COM UM001 e PowerFlex 25 COMM E2P Dual Port EtherNet IP Adapter User Manual publication 520COM UMO003 Connecting the Adapter to the Network power from the drive and then verify power has been discharged before connecting the embedded EtherNet IP adapter to the ATTENTION Risk of injury or death exists The PowerFlex drive may contain high voltages that can cause injury or death Remove 34 me oN E network Remove power from the drive Remove the drive control module cover Use static control precautions Connect one end of an Ethernet cable to the EtherNet IP network 1769 L36ERM CompactLogix controller with embedded EtherNet IP bridge Powerflex 525 witli embedded I EtherNet IP adapter Frame A shown ITO Tol e JEE i d D i Ethernet switch zE Pu R Route the other end of the Ethernet cable through the bottom of the PowerFlex 525 drive and insert the cable s plug into the embedded EtherNet IP adapter s mating socket Rockwell Automation Publication 520 QS001A EN E March 2014 Drive and Adapter Status Indicators PowerFlex 520 Series Adjustable Frequency AC Drive
66. urs 390V DC bus voltage equivalent to 275V AC incoming line 525 600V AC Input If P038 3 600V trip occurs 487V DC bus voltage 344V AC incoming line If P038 2 480V trip occurs 390V DC bus voltage 275V AC incoming line Control Ride Through Minimum ride through is 0 5 s typical value 2 s Faultless Power Ride Through 100 ms 8 Rockwell Automation Publication 520 QS001A EN E March 2014 PowerFlex 520 Series Adjustable Frequency AC Drive Power Wiring 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 29501 29507 or equivalent Copper braid aluminum foil combination shield and tinned copper drain wire e PVCjacket Standard Option 2 Tray rated 600V 90 C 194 F e Three tinned copper conductors with XLPE insulation RHH RHW 2 Anixter OLF 7xxxxx or equivalent 5milsingle helical copper tape 25 overlap min with three bare copper grounds in contact with shield e PVCjacket Class amp Il Division amp II Tray rated 600V 90 C 194 F Three bare copper conductors with XLPE insulation and impervious corrugated RHH RHW 2 Anixter 7V 7xxxx 3G or equivalent continuously welded aluminum armor Black sunlight resistant PVC jacket overall Three copper grounds on 10 AWG and smaller Power Terminal Block Diagrams
67. uses and Circuit Breakers SRC Source Mode SNK Sink Mode 4 20 mA Analog 250 Q input impedance Recommended Fuse Type 18 24V 0N 0 6V ON 0 10V DC Analog 100 KQ input impedance UL Class J T or Type BS88 600V 550V or equivalent 0 6V OFF 18 24V OFF External Pot 1 10 kQ 2 W min Recommended Circuit Breakers HMCP or equivalent Control Output Programmable Output Form A and Form B Opto Outputs Analog Outputs 10 bit Resistive Rating 3 0 A 30V DC 125V AC and 240V AC 30V DC 50 mA 0 10V 1 kQ min Inductive Rating 0 5 A 30V DC 125V ACand 240V AC Non inductive 4 20 mA 525 Q max Protective Features Motor Protection I2t overload protection 150 for 60 s 200 for 3 s Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fault Over Voltage 100 120V AC Input Trip occurs 405V DC bus voltage equivalent to 150V AC incoming line 200 240V AC Input Trip occurs 405V DC bus voltage equivalent to 290V AC incoming line 380 480V AC Input Trip occurs 810V DC bus voltage equivalent to 575V AC incoming line 525 600V AC Input Trip occurs 1005V DC bus voltage equivalent to 711V AC incoming line Under Voltage 100 120V AC Input Trip occurs 190V DC bus voltage equivalent to 75V AC incoming line 200 240V AC Input Trip occurs 190V DC bus voltage equivalent to 150V AC incoming line 380 480V AC Input Trip occ
68. using the USB utility application use the USB utility application to apply the backup to the new drive See the PowerFlex 520 Series Adjustable Frequency AC Drive User Manual publication 520 UM001 for more information on using the USB utility application 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 Rockwell Automation Publication 520 QS001A EN E March 2014 15 PowerFlex 520 Series Adjustable Frequency AC Drive Start Stop Direction and Speed Control 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 See Fault Codes on page 29 for an explanation of the fault codes Display Control and Navigation Keys
69. ve 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 control use a momentary input 5o on 0 Terminal 02 to command a start Use a maintained input o0 for 1 0 Terminal 03 to change direction 3 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 Rockwell Automation Publication 520 QS001A EN E March 2014 13 PowerFlex 520 Series Adjustable Frequency AC Drive PowerFlex 525 Control 1 0 Terminal Designations No Signal Default Description Parameter R1 Relay 1N 0 Fault Normally open contact for output relay t076 R2 Relay1Common Fault Common for output relay R5 Relay2Common Motor Running Common for output relay t081 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 modes and cannot be disabled P045 02 Digin TermBlk 02 Run FWD Used to initiate motion and also can be used as a programmable digital input It can be programmed with t062 Digin P045 P046 Start Run FWD TermBIk 02 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA P048 P050 A54
70. wer cycling the drive Setting a Gateway Addresss Using Parameters Verify that parameter C128 EN Addr Sel is set to 1 Parameters This parameter must be set to Parameters to configure the gateway address using parameters Set the value of parameters C137 EN Gateway Cfg 1 through C140 EN Gateway Cfg 4 to desired value for the gateway address Reset the adapter by power cycling the drive Rockwell Automation Publication 520 QS001A EN E March 2014 Default 0 0 0 0 192 168 1 62 EN IP Addr Cfg 1 EN IP Addr Cfg 2 EN IP Addr Cfg 3 EN IP Addr Cfg 4 Detauit ie 255 255 255 0 EN Subnet Cfg 1 EN Subnet Cfg 2 EN Subnet Cfg 3 EN Subnet Cfg 4 Default 0 0 0 0 192 168 1 1 EN Gateway Cfg 1 EN Gateway Cfg 2 EN Gateway Cfg 3 EN Gateway Cfg 4 35 Important 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 ea
71. ximum traverse frequency See the diagram at A567 Max Traverse A569 Traverse Dec 0 00 300 00 s 0 015 0 005 Sets the time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency See the diagram at A567 Max Traverse A570 P Jump 0 00 300 00 Hz 0 01 Hz 0 00 Hz Sets the frequency amplitude that is added to or subtracted from the commanded frequency See the diagram at A567 Max Traverse A571 Sync Time 0 0 3200 0 s 0 15 0 0s Enables the function that holds the drive at the current frequency even if the commanded frequency changes Used with t062 t063 t065 t068 DigIn TermBlk xx 32 Sync Enable A572 Speed Ratio 0 01 99 99 0 01 1 00 Scales the drive speed command A573 Mtr Options Cfg 00 11 Digit 2 Digit 1 11 Sets the configuration of the motor option ZeroSpd Slip Jerk Select Fault Codes No Fault Action F000 No Fault F002 Auxiliary Input e Check remote wiring e Verify communications programming for intentional fault F003 Power Loss e Monitor the incoming AC line for low voltage or line power interruption e Check input fuses e Reduce load F004 UnderVoltage Monitor the incoming AC line for low voltage or line power interruption F005 OverVoltage Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F006 Motor Stalled e Increase P041 A442 A444
72. ypad by pressing the Up or Down arrow keys A427 MOP Freq 0 00 500 00 Hz 0 01 Hz 60 00 Hz 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 the same time the inputs are ignored and the frequency is unchanged A428 MOP Reset Sel 0 1 0 Zero MOP Ref 1 Save MOP Ref Determines if the current MOP reference command is saved on power down 1 Save MOP Ref A429 MOP Preload 0 1 0 No preload 0 No preload Determines the operation of the MOP function 1 Preload A430 MOP Time 0 1 600 0s 0 15 10 05 Sets the rate of change of the MOP reference A431 Jog Frequency 0 00 Maximum Freq 0 01 Hz 10 00 Hz Sets the output frequency when a jog command is issued A432 Jog Accel Decel 0 01 600 00 s 0 015 10 005 Sets the acceleration and deceleration time used when in jog mode A433 Purge Frequency 0 00 500 00 Hz 0 01 Hz 5 00 Hz Provides a fixed frequency command value when t062 t063 t065 t068 DigIn TermBIk xx is set to 40 Purge A434 DC Brake Time 0 0 99 9 s 0 15 0 0s Sets the length of time that DC brake current is injected into the motor A435 DC Brake Level 0 00 Drive Rated Amps x 1 80 0 01A Drive Rated Amps x 0 05 Defines the maximum DC brake current in amps applied to the motor when P045 Stop Mode is set to either 4

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