Rockwell Automation Allen-Bradley PowerFlex 520 Series User Manual
  1. Manuals
  2. Brands
  3. Rockwell Automation Manuals
  4. DC Drives
  5. Allen-Bradley PowerFlex 520 Series
  6. User manual

Rockwell Automation Allen-Bradley PowerFlex 520 Series User Manual

Adjustable frequency ac drive
Hide thumbs Also See for Allen-Bradley PowerFlex 520 Series:
Table of Contents

Advertisement

Quick Links

Download this manual
PowerFlex 520-series
Adjustable Frequency AC Drive
Bulletin Numbers 25A series B, 25B
User Manual
Original Instructions

Advertisement

Table of Contents
loading

Related Manuals for Rockwell Automation Allen-Bradley PowerFlex 520 Series

Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 520 Series

  • Page 1 PowerFlex 520-series Adjustable Frequency AC Drive Bulletin Numbers 25A series B, 25B User Manual Original Instructions...
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 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.

  • Page 3: Table Of Contents

    Signal and Control Wire Types....... . 36 Maximum Control Wire Recommendations....37 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 4 Parameter Cross Reference by Name......152 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 5 Encoder Interface ......... . 217 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 6 Using External +24V supply, SIL 3/PL e ..... . . 246 PowerFlex 525 Certification for Safe-Torque-Off ....246 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 7 ............. . . 267 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 8 Table of Contents Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 9: Preface

    Corrected PCR with ID 1541 on parameter reference t105 [Safety Open En] for Fault F059 Added Efficiency Class certification based on Ecodesign Regulation (EU) 2019/1781 Updated Input Current Scaling section and table to improve clarity Added column “For 150 m” to EMC Line Filters table Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 10: Who Should Use This Manual

    PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004 Download Files Follow these steps to download the files for your PowerFlex 525 drive. 1. Go to the Rockwell Automation Product Compatibility and Download Center at rok.auto/pcdc. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 11: Manual Conventions

    Preface IMPORTANT You must sign in to the Rockwell Automation website before downloading a firmware revision. 2. Click the Find Downloads link. 3. Enter “PowerFlex 525” into the Product Search field. The results appears in the box below. 4. Select the entry and the firmware revision, then click Downloads.

  • Page 12: Drive Frame Sizes

    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.

  • Page 13: General Precautions

    (see parameter A550 [Bus Reg Enable]). In addition, installing a properly sized dynamic brake resistor will provide proper stopping requirements based on braking resistor sizing. ATTENTION: Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 14: Catalog Number Explanation

    48.3 15.0 11.0 10.0 32.0 30.0 22.0 25.0 18.5 62.1 20.0 15.0 15.0 11.0 (1) This rating is only available for PowerFlex 523 drives. Normal and Heavy-Duty ratings are available for this drive. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 15: Installation/Wiring

    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.

  • Page 16: Minimum Mounting Clearances

    (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-UM001K-EN-E - August 2021...

  • Page 17: Ambient Operating Temperatures

    IP 20/Open Type IP 20/Open Type 30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature (°C) Ambient Temperature (°C) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 18: Debris Protection

    Store within an ambient temperature range of -40...85 °C • Store within a relative humidity range of 0...95%, noncondensing. • Do not expose to a corrosive atmosphere. (1) The maximum ambient temperature for storing a Frame E drive is 70 °C. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 19: Ac Supply Source Considerations

    2. Pull the jumper completely out of the drive chassis. 3. Tighten the screw to keep it in place. Jumper Location (Typical) Power Module Tighten screw after jumper removal. IMPORTANT Phase to Ground MOV Removal R/L1 Three-Phase S/L2 AC Input T/L3 Jumper Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 20: Input Power Conditioning

    R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 SHLD 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 21: Safety Ground - (Pe)

    When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 22: Rfi Filter Grounding

    UL installations. (a) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 23 NEC requirements for branch circuit protection. • Bulletin 140M can be used in single motor applications. • Bulletin 140M can be used up stream from the drive without the need for fuses. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 24: Fuses And Circuit Breakers For Powerflex 520-Series Drives

    Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 25 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 26 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 27 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 28: 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 29 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-UM001K-EN-E - August 2021...

  • Page 30: Control Module Cover

    Control Module Cover To access the control terminals, DSI port, and Ethernet port, the front cover must be removed. To remove: 1. Press and hold down the arrow on the front of the cover. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 31: Power Module Terminal Guard

    1. Press and hold down the catch on both sides of the frame cover, then pull out and swing upwards to remove (Frames B...E only). 2. Press and hold down the locking tab on the terminal guard. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 32: Power Wiring

    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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 33 THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 34: Reflected Wave Protection

    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-UM001K-EN-E - August 2021...

  • Page 35: Power Terminal Block

    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. For more information, see Drives in Common Bus Configurations, publication DRIVES-AT002. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 36: I/O Wiring

    Per US NEC or applicable Unshielded – national or local code 300V, Multi-conductor shielded 60 °C (140 °F) Shielded cable such as Belden 8770 0.750 mm (18 AWG), 3 conductor, shielded. (or equivalent) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 37: Maximum Control Wire Recommendations

    Relay N.O. +10V DC +10V Relay Common 0-10V Input Relay N.C. Analog Common Pot must be 4-20mA Input 1...10 k ohm 2 W min. RJ45 Shield Comm Common RS485 Pulse In (DSI) Digital Input Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 38 Coast 2 “DigIn TrmBlk” t062, t063 [DigIn TermBlk xx] below Per P045 3 “Serial/DSI” Coast [Stop Mode] 4 “Network Opt” Coast Coast 5 “EtherNet/IP” (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 39 Drive supplied power for digital inputs. – Maximum output current is 100 mA. Referenced to Analog Common. 12 +10V DC – Drive supplied power for 0...10V external potentiometer. P047, P049 Maximum output current is 15 mA. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 40 (1) Setting is specific to PowerFlex 525 drives only. (2) 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-UM001K-EN-E - August 2021...

  • Page 41: Powerflex 525 Control I/O Terminal Block

    P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop 1 “Keypad” Coast 2 “DigIn TrmBlk” t062, t063 [DigIn TermBlk xx] below Per P045 3 “Serial/DSI” Coast [Stop Mode] 4 “Network Opt” Coast 5 “EtherNet/IP” Coast Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 42 +24V supply for safety circuit. Internally tied to the +24V DC S+ Safety +24V – – source (Pin 11). Referenced to Digital Common. +24V DC – Drive supplied power for digital inputs. – Maximum output current is 100 mA. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 43: I/O Wiring Examples

    (1) Setting is specific to PowerFlex 525 drives only. I/O Wiring Examples Connection Example P047 [Speed Reference1] = 5 “0-10V Input” Potentiometer 1...10 kΩ Pot. Recommended (2 W minimum) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 44 The device connected to terminal 5 (for PowerFlex 523) or terminal 7 (for PowerFlex 525) TermBlk 05 or 07 Sel needs to be NPN or push-pull output driver. must be moved to Pulse Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 45 TermBlk 03] = 51 A momentary input will start the drive. A stop +24V Common input to I/O Terminal 01 will stop the drive as specified by P045 [Stop Each digital input draws 6 mA. Mode]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 46 Common 0…20 mA/4…20 mA, 525 Ω 0…20 mA/ 4…20 mA, 525 Ω max (1) Feature is specific to PowerFlex 525 drives only. (2) Feature is not applicable to PowerFlex 523 series A drives. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 47 Terminal 14 common together for all drives. I/O Terminal 14 common and I/O 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-UM001K-EN-E - August 2021...

  • Page 48: Start And Speed Reference Control

    (1) [Start Source 2/3] and [Speed Reference2/3] can be selected by the control terminal block or communication commands. (2) See Digital Input Selection for Start Source on page 49 for information on selecting the correct digital input. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 49: Accel/Decel Selection

    [Start Source x]. 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]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 50 5 “EtherNet/IP” Active Accel/Decel 1/2/3/4 is [Speed Referencex] selected according to = 13 (Step Logic) Step Logic Drive uses Accel 1 and Decel 1. (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 51: Ce Conformity

    Safety requirement – Functional Appendix G for installation consideration related to Machinery Directive. ATEX Directive (2014/34/EU) • EN 50495 – Safety devices required for the safe functioning of equipment with respect to explosion risks. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 52: General Considerations

    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. •...
  • Page 53 Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520-Series RF Emission Compliance and Installation Requirements on page 54 for compliance with radio frequency emission limits for the specific standard and installation environment. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 54 100...120V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...120V 1-Phase Output 200...240V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...230V 3-Phase Output Input/Output Output only Input/Output 200...240V AC (-15%, +10%) – 1-Phase Input with Internal EMC Filter, 0...230V 3-Phase Output Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 55 Without EMC plate Ground cable CORE-E-3 CORE-E-1 CORE-E-4 CORE-E-2 CORE-xx-x-1 CORE-xx-x-2 Input cable to drive (Shielded or Unshielded) Output cable from drive (Shielded) Secure EMC core by Shows contact to using cable/zip ties shielded layer Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 56 • 600V drives with external filters where the grounded output cable must not pass through the EMC core(s). Recommended Placement of EMC Cores Relative to External Filter All Frame sizes Incoming power EMC Filter Drive Motor Input core Output core Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 57: Start Up

    Sink (SNK), the jumper must be removed from I/O Terminals 01 and 11 and installed between I/O Terminals 01 and 04. 7. Wire I/O as required for the application. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 58 • Verify input currents are balanced. • 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 65 for more information. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 59: Start, Stop, Direction, And Speed Control

    Functions from the other groups with values EtherNet/IP changed from default. Fault and Diagnostic Consists of list of codes for specific fault conditions. AppView and CustomView Functions from the other groups organized for specific applications. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 60: Control And Navigation Keys

    Used to stop the drive or clear a fault. Stop This key is always active. Controlled by parameter P045 [Stop Mode]. Used to control speed of drive. Default is active. Potentiometer Controlled by parameters P047, P049, and P051 [Speed Referencex]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 61: Viewing And Editing Parameters

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

  • Page 62: Drive Programming Tools

    Korean – – – – Polish – – Turkish – – Czech (1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 63: Smart Startup With Basic Program Group Parameters

    Enables a static (not spinning) or dynamic 2 = “Rotate Tune” (motor spinning) autotune. [Accel Time 1] 0.00/600.00 s P041 0.01 s 10.00 s Sets the time for the drive to accel from 0 Hz to [Maximum Freq]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 64 (1) Power cycle of the drive, NO parameters are 3 = “Power Reset” reset. (1)(2)(3) (2) Setting is available in PowerFlex 525 FRN 5.xxx 4 = “Module Reset” and later. (3) Setting is available in PowerFlex 523 FRN 3.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 65: Lcd Display With Quickview Technology

    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-UM001K-EN-E - August 2021...

  • Page 66: Using Drive Startup In Ccw Or Logix Designer Application

    Using Drive Startup in CCW or Logix Designer application on page Alternatively, you can manually configure the parameters by using the drive keypad. For instructions, see Manual Configuration Using Drive Keypad on page 256. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 67 Select the option shown below. 4. Complete each step in the Startup Wizard to configure the drive. IMPORTANT Follow the Startup Wizard steps exactly. If not, unexpected results can occur. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 68 Chapter 2 Start Up Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 69: Programming And 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 70 10 Hz, the Process Value will be 1.66. On the drive LCD display, only parameter b010 [Process Display] is shown. In Connected Components Workbench software, parameter b010 [Process Display] and b011 [Process Fract] are shown separately. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 71: Parameter Groups

    RdyBit Mode Act d392 (2)(3) Elapsed Time-hr d362 Slip Hz Meter d375 PID1 Fdbk Displ d383 Drive Status 2 d393 (2)(3) Elapsed Time-min d363 Speed Feedback d376 PID1 Setpnt Disp d384 Dig Out Status d394 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 72 Droop Hertz@ FLA A441 PID 2 Preload A478 PM Bus Reg Kd A520 Out Phas Loss En A557 Accel Time 2 A442 PID 2 Invert Err A479 Freq 1 Kp A521 Positioning Mode A558 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 73 (3) Parameter is available in PowerFlex 525 FRN 5.xxx and later. (4) Parameter is available in PowerFlex 525 FRN 3.xxx and later. (5) Parameter is available in PowerFlex 525 FRN 2.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 74: Appview Parameter Groups

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

  • Page 75: 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 151 for more information. Custom Group This group can store up to 100 parameters. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 76: Basic Display Group

    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. Default: Read Only Values Min/Max: 00000/11111 Display: 00000 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 77 [Process Disp Hi]. Scaled Process Value (PV) = (([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [Minimum Freq]) Default: Read Only Values Min/Max: 0.00/0.99 Display: 0.01 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 78 (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. Default: Read Only Values Min/Max: 0000/1111 Display: 0000 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 79 [Elapsed Run time] Related Parameter(s): A555 Accumulated time drive is outputting power. Time is displayed in 10 hour increments. Default: Read Only Values Min/Max: 0/65535 x 10 hr Display: 1 = 10 hr Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 80 [Accum CO2 Sav] Related Parameter(s): A555 Total approximate accumulated CO2 savings of the drive compared to using an across the line starter. Default: Read Only Values Min/Max: 0.0/6553.5 kg Display: 0.1 kg Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 81 Present operating temperature of the drive control. Default: Read Only Values Min/Max: 0/120 °C Display: 1 °C b029 [Control SW Ver] Current drive firmware version. Default: Read Only Values Min/Max: 0.000/65.535 Display: 0.001 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 82: Basic Program Group

    NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572 Default: Drive Rated Amps Values Min/Max: 0.0/(Drive Rated Amps x 2) Display: 0.1 A Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 83 Set P039 [Torque Perf Mode] to 5 to enable the use of Synchronous Reluctance Motor control. (1) Setting is specific to PowerFlex 525 drives only. (2) Setting is available in PowerFlex 525 FRN 5.xxx and later. (3) Setting is available in PowerFlex 525 FRN 7.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 84 [Maximum Freq] to 0 Hz. Decel Rate = [Maximum Freq] / Decel Time x] [Maximum Freq] Speed [Accel Time x] Time [Decel Time x] Default: 10.00 s Values Min/Max: 0.00/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 85 It is recommended to use braking resistors or set A550 [Bus Reg Enable] to 0 “Disabled” for better performance. Stop PointStop. [Maximum Freq] Speed Calculated Stop Time Time [Decel Time x] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 86 (1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the speed reference. (2) Setting is specific to PowerFlex 525 drives only. P052 [Average kWh Cost] Related Parameter(s): b025 Sets the average cost per kWh. Default: 0.00 Values Min/Max: 0.00/655.35 Display: 0.01 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 87 Sets the parameter to display on the drive LCD display when the drive powers up. 0 “Keypad Disp” (Default) Without ADC = shows last selected display parameter With ADC = shows parameter b001 [Output Freq] Options 1 “Output Freq” Basic Display group parameters Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 88: Terminal Block Group

    Resets the count in the accumulated internal active counter, d364 [Counter Status]. For more information, Counter Function on page 214. 23 “Rset Tim&Cnt” Resets both the internal active timer and accumulated internal active counter. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 89 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 has to be active for the drive to run. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 90 • Drive will start after a momentary input from either the Run FWD input (I/O Terminal 02) or the Run REV input (I/O Terminal 03). • I/O Terminal 01 “Stop” = Stop according to the value set in P045 [Stop Mode]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 91 Both safe-off inputs are active. – 30 “SafeTqPermit” Both safe-off inputs are inactive (closed). – 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – (1) Setting is available in FRN 5.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 92 [Opto Out Logic] PowerFlex 525 only. PF 525 Determines the logic (Normally Open/NO or Normally Closed/NC) of the digital outputs only. Setting Digital Out 1 Logic Digital Out 2 Logic Default: Values Min/Max: Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 93 Both safe-off inputs are inactive (closed). – (1)(2) 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – (1) Setting is specific to PowerFlex 525 drives only. (2) Setting is available in FRN 5.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 94 [Relay 1 Off Time] t085 [Relay 2 Off Time] PowerFlex 525 only. PF 525 Sets the delay time before Relay de-energizes after required condition ceases. Default: 0.0 s Values Min/Max: 0.0/600.0 s Display: 0.1 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 95 [EM Brk Off Delay] [EM Brk On Delay] [Minimum Freq] Time Start EM Brk Stop EM Brk Drive stops commanded energized (Off) commanded de-energized (On) Default: 2.00 s Values Min/Max: 0.00/10.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 96 [Analog Out Sel] is set to 6, 14 or 22 “Analog Setpoint”. Default: 0.0% Values Min/Max: 0.0/100.0% Display: 0.1% (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 97 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]. Default: 0.0% Values Min/Max: 0.0/200.0% Display: 0.1% Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 98 3 “Command Freq” Sleep enabled based on drive commanded frequency t101 [Sleep Level] Sets the analog input level the drive must reach to enter sleep mode. Default: 10.0% Values Min/Max: 0.0/100.0% Display: 0.1% Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 99 Sets the method of resetting fault F111 “Safety Hardware” either by means of a power cycle or fault clear operation. 0 “PwrCycleRset” (Default) Reset fault F111 using power cycle. Options 1 “FltClr Reset” Reset fault F111 using fault clear mechanism without power cycle. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 100: Communications Group

    Appendix C for more information. This setting is effective only if I/O that controls the drive is transmitted through the RS485 port. IMPORTANT Default: 5.0 s Values Min/Max: 0.1/60.0 s Display: 0.1 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 101 255.255.255.0 [EN Subnet Cfg 1] [EN Subnet Cfg 2] [EN Subnet Cfg 3] [EN Subnet Cfg 4] IMPORTANT C128 [EN Addr Sel] must be set to 1 “Parameters”. Default: Values Min/Max: 0/255 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 102 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, C146, and C147...C150. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 103 [EN Comm Flt Actn] is set to 4 “Send Flt Cfg” and communications are disrupted. – C144 [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” and the scanner is put into Program or Test mode. Default: Values Min/Max: 0/65535 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 104 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 105 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. 0 “Drive 0” (Default) 1 “Drive 0-1” Options 2 “Drive 0-2” 3 “Drive 0-3” 4 “Drive 0-4” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 106: Logic Group

    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-UM001K-EN-E - August 2021...
  • Page 107 Step after [Stp Logic Time x] and “Logic In 1” is Not Active Accel/Decel 2 Incremental Step after [Stp Logic Time x] and “Logic In 2” is Not Active Accel/Decel 2 Absolute Do Not Step/Ignore Digit 2 Settings Accel/Decel 2 Incremental Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 108 L215 [Step Units F 7] PowerFlex 525 only . PF 525 Sets the position in user-defined units (fractional portion) the drive must reach at each step. Default: Read Only Values Min/Max: 0.00/0.99 Display: 0.01 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 109: Advanced Display Group

    Read Only Values Min/Max: 0.0/9999.0 s Display: 0.1 s d366 [Timer StatusF] Displays the current value of the timer (fractional portion) if enabled. Default: Read Only Values Min/Max: 0.0/0.9 s Display: 0.1 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 110 Chapter 3 Programming and Parameters Advanced Display Group (continued) d367 [Drive Type] Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non Rockwell Automation technical personnel). Default: Read Only Values Min/Max: 0/65535 Display:...
  • Page 111 Read Only Values Min/Max: 0.0/100.0% Display: 0.1% d384 [PID1 Setpnt Disp] d386 [PID2 Setpnt Disp] PowerFlex 525 only. PF 525 Displays the active PID Setpoint value. Default: Read Only Values Min/Max: 0.0/100.0% Display: 0.1% Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 112 Displays the current step of the StepLogic profile as defined by parameters L180...L187 [Step Logic x] when P047 [Speed Reference1] is set to 13 “Step Logic” or 16 “Positioning”. Default: Read Only Values Min/Max: Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 113 Opto 1 status Not activated Activated Opto2 Status Digit 4 Opto 2 status Not activated Activated Not Used (1) Setting is specific to PowerFlex 525 drives only. Default: Read Only Values Min/Max: 0/15 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 114: Advanced Program Group

    10.00 HZ Preset Freq 3: 20.00 Hz Preset Freq 4: 30.00 Hz Values 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 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 115 10.00 Hz Values 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. Default: 10.00 s Values Min/Max: 0.01/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 116 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] [DC Brake Level] Time Start Command Default: 0.0 s Values Min/Max: 0.0/99.9 s Display: 0.1 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 117 S-Curve Time = Accel Time S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time Default: Values Min/Max: 0/100% Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 118 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] Default: 10.00 s Values Min/Max: 0.00/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 119 Determines the band around A448, A450, A452 A454 [Skip Frequency x]. Command Frequency Frequency Drive Output Frequency 2x Skip Skip Frequency Frequency Band Time Default: 0.0 Hz Values Min/Max: 0.0/30.0 Hz Display: 0.1 Hz Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 120 6 “TrimOn 4-20” Options 7 “TrimOn Prset” 8 “TrimOn AnMlt” 9 “TrimOn MOP” 10 “TrimOn Pulse” 11 “TrimOn Slgic” 12 “TrimOn Encdr” 13 “TrimOn ENet” (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 121 Related Parameter(s): A459, A471 A473 [PID 2 Prop Gain] PowerFlex 525 only. PF 525 Sets the value for the PID proportional component when the PID mode is enabled. Default: 0.01 Values Min/Max: 0.00/99.99 Display: 0.01 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 122 0.0/500.0 Hz Display: 0.1 Hz A467 [PID 1 Invert Err] A479 [PID 2 Invert Err] PowerFlex 525 only. PF 525 Changes the sign of the PID error. 0 “Normal” (Default) Options 1 “Inverted” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 123 P044 [Maximum Freq]. Default: 0.00 Values Min/Max: 0.00/99.99 Display: 0.01 A483 [Testpoint Sel] Used by Rockwell Automation field service personnel. Default: Values Min/Max: 0/FFFF Display: A484 [Current Limit 1] Related Parameter(s): P033 Maximum output current allowed before current limiting occurs.
  • Page 124 0 “No Derate” (Default) Options 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. 0 “Reset” (Default) Options 1 “Save” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 125 (With FRN 5.xxx and later.) Voltage across the stator resistance of the PM or SynRM motor at the rated motor current displayed in line-to-line rms value. Default: 11.50V Values Min/Max: 0.00/655.35V Display: 0.01V Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 126 A511 [Freq 1 BW] A513 [Freq 2 BW] A515 [Freq 3 BW] PowerFlex 525 only. PF 525 Speed control loop bandwidth for “Vector” control mode. Default: 10 Hz Values Min/Max: 0/40 Hz Display: 1 Hz Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 127 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. Default: 100.0% Values Min/Max: 0.0/500.0% Display: 0.1% Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 128 1 = Condition True, 0 = Condition False FFD (Feed Forward Decouple) Digit 1 MTPA (Maximum Torque Per Amp) Digit 2 LDOB (Load Disturbance Observer) Digit 3 Not Used Not Used Default: 00111 Values Min/Max: 00000/00111 Display: 00000 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 129 8 “5.0, CT” Boost Voltage (% of Base) (Constant Torque) (Default for drives below 5 HP) 9 “7.5, CT” 10 “10.0, CT” 11 “12.5, CT” 12 “15.0, CT” 13 “17.5, CT” 14 “20.0, CT” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 130 10V AC (on 230V AC Drives); 20V AC (on 460V AC Drives); 25V AC (on 600V AC Drives) Values Max: 255V AC (on 230V AC Drives); 510V AC (on 460V AC Drives); 637.5V AC (on 600V AC Drives) Display: 1V AC Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 131 Sets the P-gain used in the PI calculation of the speed loop when feedback is used. Applicable to V/Hz and SVC modes in closed loop control only. Default: Values Min/Max: 0.0/200.0 Display: (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 132 A545 [Flying Start En] Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM. 0 “Disabled” (Default) Options 1 “Enabled” Catch and ramp to commanded speed at every drive start. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 133 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 access code. Default: 0000 Values Min/Max: 0000/9999 Display: 1111 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 134 Use StepLogic Commands. Always start from Step 0. 3 “Preset StpL” Use Preset Inputs to determine starting step then StepLogic commands. 4 “StpLogic-Lst” Use StepLogic commands from last Step Logic step at last drive stop. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 135 A561 [Home Save] PowerFlex 525 only. PF 525 Determines whether the current position is saved on power down. 0 “Home Reset” (Default) Position resets to zero on power up. Options 1 “Home Saved” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 136 Sets the error signal filter in the position regulator. Default: Values Min/Max: 0/15 Display: A566 [Pos Reg Gain] PowerFlex 525 only. PF 525 Sets the gain adjustment for the position regulator. Default: Values Min/Max: 0.0/200.0 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 137 New Drive #2 Reference New Drive #1 Reference Speed Sync Bit [Fiber Status] Change Ref's Drive #1 and #2 Sync Enable Input Time Default: 0.0 s Values Min/Max: 0.0/3200.0 s Display: 0.1 s Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 138 Options 1 “Enhanced” A575 [Flux Braking En] Related Parameter(s): A550 (With PowerFlex 525 FRN 5.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Enables/disables flux braking. 0 “Disable” (Default) Options 1 “Enable” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 139 [PM Stable 2 Kp]. Default: Values Min/Max: 0/100% Display: A584 [PM Stable 2 Kp] PowerFlex 525 only. PF 525 (With FRN 5.xxx and later.) The gain for stabilization loop. Default: 250% Values Min/Max: 0/2000% Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 140 A590 [SYNRM SW Freq] Related Parameter(s): PowerFlex 525 only. PF 525 (With FRN 7.xxx and later.) Switching Frequency point from Low-Speed Observer (Freq1) to High-Speed Observer (Freq2). Default: 10 Hz Values Min/Max: 0/600 Hz Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 141 Decreasing the setting causes the motor to stall during startup and high-speed (Freq2) operations. When the motor running speed is higher than the switching frequency A590, adjust the setting. Default: 1.00 Values Min/Max: 0.1/10.00 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 142: Network Parameter Group

    F629 [Fault 9 Time-min] F630 [Fault10 Time-min] PowerFlex 525 only. PF 525 Displays the value of d363 [Elapsed Time-min] when the fault occurs. Default: Read Only Values Min/Max: 0.0/320.0 min Display: 0.1 min Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 143 [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. Default: Read Only Values Min/Max: 0/1200V DC Display: 1V DC Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 144 0 “Not Active (no connection)” Digit 1 1 “Internal option connected/active” Digit 2 2...8“Reserved” Status Digit 3 9 “Internal com option faulted” Error Digit 4 Not Used Default: Read Only Values Min/Max: 0000/1911 Display: 0000 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 145 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 Default: Read Only Value Min/Max: 00000/11111 Display: 00000 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 146 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] Default: Read Only Values Min/Max: 0/255 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 147 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. Default: Read Only Values Min/Max: 0/FFFF Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 148 Min/Max: 0/65535 Display: F729 [EN Tx Errors] PowerFlex 525 only. PF 525 A count of the number of transmit errors reported by the embedded EtherNet/IP interface. Default: Read Only Values Min/Max: 0/65535 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 149 PowerFlex 525 only. PF 525 The number of I/O packets missed. Default: Read Only Values Min/Max: 0/65535 Display: F731 [DSI Errors] The number of total DSI errors. Default: Read Only Values Min/Max: 0/65535 Display: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 150: Appview Parameter Groups

    Press the Up Arrow or Down Arrow to scroll to the command G1->GC. Press Enter or Sel to add all the parameters in this AppView group to the CustomView group. The LCD display will show a confirmation. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 151: Customview Parameter Group

    Press Enter to delete the parameter from the CustomView group. The LCD display will show a confirmation. The Connected Components Workbench software can be used to speed up this process with drag and drop functionality. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 152: Parameter Cross Reference By Name

    Contrl In Status Drv 3 Addr EN IP Addr Act 2 Control Source Drv 3 Feedback EN IP Addr Act 3 Control SW Ver Drv 3 Logic Cmd EN IP Addr Act 4 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 153 Fault 3 Freq Flux Current Ref Motor OL Level Fault 3 Time-hr Flying Start En Motor OL Ret Fault 3 Time-min FlyStrt CurLimit Motor OL Select Fault 4 BusVolts Freq 1 Motor Rr Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 154 PID 2 Diff Rate Preset Freq 10 Speed Reference1 PID 2 Fdback Sel Preset Freq 11 Speed Reference2 PID 2 Integ Time Preset Freq 12 Speed Reference3 PID 2 Invert Err Preset Freq 13 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 155 (3) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. (4) Parameter is available in PowerFlex 525 FRN 2.xxx and later. (5) Parameter is available in PowerFlex 525 FRN 3.xxx and later. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 156 Chapter 3 Programming and Parameters Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 157: Drive Status

    This type of fault may require drive or motor repair, or is caused by wiring or Non-Resettable programming errors. The cause of the fault must be corrected before the fault can be cleared. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 158: Fault Indication

    Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Fault types are listed in the table Fault Types on page 157. See Fault Descriptions on page 159 for more information. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 159: Fault Descriptions

    A491 • Verify level and time requirements [Load Loss Time]. Output Phase Loss (if enabled). • Verify motor wiring. F021 Output Ph Loss Configure with A557 [Out Phas Loss • Verify motor. En]. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 160 Modbus or DSI master device Action]. have been interrupted. • Connecting I/O terminals C1 and C2 to ground may improve noise immunity. • Replace wiring, Modbus master device, or control module. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 161 • Replace control module if fault cannot be cleared. • Cycle power. Failure has been detected in the drive F122 I/O Board Fail • Replace drive or control module if control and I/O section. fault cannot be cleared. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 162: Common Symptoms And Corrective Actions

    Flashing red status light • Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”. • Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to 13 “Clear Fault”. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 163 • Set motor nameplate full load amps in parameter P034 [Motor NP FLA]. Torque performance does not match motor characteristics. None • Perform P040 [Autotune] “Static Tune” or “Rotate Tune” procedure. • Set P039 [Torque Perf Mode] to 0 “V/Hz”. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 164 Motor is rotating at zero Hz or slip frequency is not correct Cause(s) Indication Corrective Action • Verify P032 [Motor NP Hertz]. Incorrect speed calculation. Improper speed. • Reduce boost with A530 [Boost Select]. • Set P036 [Motor NP RPM] to motor synchronous speed. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 165: Certifications

    Low Voltage TP TC 004/2011 EMC TP TC 020/2011 Ecodesign regulation (EU) 2019/1781, IE2 efficiency class, refer to PowerFlex AC Drive Efficiency Class Performance Specifications per Ecodesign Regulation (EU) 2019/1781, publication PFLEX- TD003 for additional information. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 166: Environmental Specifications

    Sound Pressure Level Measurements are taken 1 m from the drive. (A-weighted) Frame A & B: Maximum 53 dBA Frame C: Maximum 57 dBA Frame D: Maximum 64 dBA Frame E: Maximum 68 dBA Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 167: Technical Specifications

    Only for Frame E drive ratings 200...240V AC Input: 11 kW (15 HP) 380...480V AC Input: 15...18.5 kW (20...25 HP) – Heavy Duty 525...600V AC Input: 15...18.5 kW (20...25 HP) – Heavy Duty Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 168 (1) For details on specific motor performance, see Knowledge Base article “PowerFlex 525 PM Motor Performance Testing Summary”. (2) For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on page 219. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 169 10 mA per Requirements: channel. Allowable input is DC up to a maximum frequency of 250 kHz. The encoder I/O automatically scales to allow 5V, 12V and 24V DC nominal voltages. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 170: Power Specifications

    13.0 170.0 17.0 221.0 24.0 303.0 30.0 387.0 27.0 37.0 63.0 88.0 10.5 133.0 380...480V, 50/60 Hz 3-Phase 13.0 175.0 w/ EMC Filter 17.0 230.0 24.0 313.0 30.0 402.0 37.0 602.0 43.0 697.0 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 171 11.5 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output 25A-B1P6N104 – 25A-B2P5N104 25B-B2P5N104 25A-B5P0N104 25B-B5P0N104 25A-B8P0N104 25B-B8P0N104 25A-B011N104 25B-B011N104 11.0 13.8 11.0 25A-B017N104 25B-B017N104 17.5 14.0 11.4 21.1 16.9 13.7 10.6 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 172 19.2 15.6 12.0 25A-E022N104 25B-E022N104 22.0 17.6 14.3 11.0 27.3 21.8 17.7 13.7 25A-E027N104 25B-E027N104 27.0 21.6 17.6 13.5 24.7 19.8 16.1 12.4 25A-E032N104 25B-E032N104 32.0 25.6 20.8 16.0 29.2 23.4 19.0 14.6 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 173: Product Selection

    48.3 170...264 25A-B048N104 25B-B048N104 20.0 15.0 15.0 11.0 62.1 170...264 25A-B062N104 25B-B062N104 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 323...528 25A-D1P4N104 25B-D1P4N104 0.75 0.75 323...528 25A-D2P3N104 25B-D2P3N104 323...528 25A-D4P0N104 25B-D4P0N104 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 174 Minimum Resistance (1)(2) Resistance Catalog No. Ω ±5% Input Voltage Ω ±10% 0.25 AK-R2-091P500 100...120V AK-R2-091P500 50/60 Hz 0.75 AK-R2-091P500 1-Phase AK-R2-091P500 0.25 AK-R2-091P500 AK-R2-091P500 200...240V 50/60 Hz 0.75 AK-R2-091P500 1-Phase AK-R2-091P500 AK-R2-047P500 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 175 (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.
  • Page 176 — 25-RF029-EL (1) Requires series B filters to achieve 150 m rating. EMC Plates Frame Item Description Catalog No. Size 25-EMC1-FA 25-EMC1-FB EMC Plate Optional grounding plate for shielded cables. 25-EMC1-FC 25-EMC1-FD 25-EMC1-FE Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 177 • Analog/Signal Configuration Jumper PowerFlex 520 Series Communication Adapter Spare Kit Item Description Catalog No. • PowerFlex 525 Encoder card removable Terminal Block Communication adapter spare kits 25-ACCS-COMM • PowerFlex 523/525 Communication Adapter interface connector Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 178 22A-D6P0N104 25-AP0-FB 25-AP1-FB 22A-D8P7N104 (1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC filter to PowerFlex 520-series drives with external EMC filter only. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 179 (2) Mounting Adapter Plate is not required for the following ratings, as it comes with matching footprint and mounting holes. • Three-Phase 200…240V: 7.5 kW/10 HP • Three-Phase 380…480V: 11 kW/15 HP • Three-Phase 500…600V: 11 kW/15 HP Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 180 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.25 85...132 25-PM1-V1P6 85...132 25-PM1-V2P5 0.75 0.75 85...132 25-PM1-V4P8 85...132 25-PM1-V6P0 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.25 170...264 25-PM1-A1P6 170...264 25-PM1-A2P5 0.75 0.75 170...264 25-PM1-A4P8 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 181 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 446...660 25-PM1-E0P9 0.75 0.75 446...660 25-PM1-E1P7 446...660 25-PM1-E3P0 446...660 25-PM1-E4P2 446...660 25-PM1-E6P6 446...660 25-PM1-E9P9 10.0 10.0 12.0 446...660 25-PM1-E012 15.0 11.0 15.0 11.0 19.0 446...660 25-PM1-E019 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 182 25-FAN1-FA 25-FAN1-FB PowerFlex 520-Series Replacement fan for drive power module. 25-FAN1-FC Heatsink Fan Kit 25-FAN1-FD 25-FAN1-FE 25-CORE-A 25-CORE-RF-A 25-CORE-B 25-CORE-RF-B 25-CORE-C PowerFlex 520-Series EMC Replacement EMC cores Cores 25-CORE-RF-C 25-CORE-D 25-CORE-RF-D 25-CORE-E 25-CORE-RF-E Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 183 1321-3R35-A 1321-3RA35-A 15.0 11.0 10.0 1321-3R45-A 1321-3RA45-A 1321-3R45-A 1321-3RA45-A 1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R55-A (ND) 1321-3RA55-A (ND) 20.0 15.0 15.0 11.0 1321-3R45-A (HD) 1321-3RA45-A (HD) 1321-3R45-A (HD) 1321-3RA45-A (HD) 380...480V 50/60 Hz 3-Phase Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 184: Product Dimensions

    PowerFlex 520-Series Drive Ratings on page 173 for information on power ratings. PowerFlex 520-Series Drive Weight Frame Size Weight (kg/lb) 1.1 / 2.4 1.6 / 3.5 2.3 / 5.0 3.9 / 8.6 12.9 / 28.4 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 185 Dimensions are in millimeters and (inches) 72.0 (2.83) 172.0 (6.77) 57.5 (2.26) 6.0 (0.24) IP 20/Open Type – Frame B Dimensions are in millimeters and (inches) 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 6.0 (0.24) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 186 Dimensions are in millimeters and (inches) 109.0 (4.29) 184.0 (7.24) 90.5 (3.56) 6.0 (0.24) IP 20/Open Type – Frame D Dimensions are in millimeters and (inches) 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 6.0 (0.24) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 187 Air Pressure (At zero air flow) min 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 N•m (2.6...3.47 lb•in) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 188 87.0 (3.43) 109.0 (4.29) 57.5 (2.26) 72.5 (2.85) 90.5 (3.56) An external 24V DC power source is required when IMPORTANT using the Control Module Fan Kit with drive frames A, B, and C. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 189 196.0 (7.72) 185.0 (7.28) 130.0 (5.12) 160.0 (6.30) 116.0 (4.57) 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-UM001K-EN-E - August 2021...
  • Page 190 Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 72.0 (2.83) 57.5 (2.26) 172.0 (6.77) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 191 IP 30/NEMA 1/ UL Type 1 top panel 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 6.1 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 66.1 (2.60) 63.1 (2.48) 33.5 (1.32) 23.9 (0.94) ø21.5 (ø0.85) ø27.5 (ø1.08) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 192 IP 30/NEMA 1/ UL Type 1 top panel 109.0 (4.29) 90.5 (3.56) 184.0 (7.24) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 80.5 (3.17) 66.5 (2.62) 34.5 (1.36) 26.5 (1.04) ø21.5 (ø0.85) ø27.5 (ø1.08) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 193 IP 30/NEMA 1/ UL Type 1 top panel 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 96.0 (3.78) 70.0 (2.76) 44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) ø33.5 (ø1.32) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 194 IP 30/NEMA 1/ UL Type 1 top panel 185.0 (7.28) 160.0 (6.30) 279.0 (10.98) 7.6 (0.30) IP 30/NEMA 1/ UL Type 1 conduit box 127.5 (5.02) 82.5 (3.25) 62.5 (2.46) 42.5 (1.67) ø21.5 (ø0.85) ø43.7 (ø1.72) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 195 Filter can be mounted onto the back of the drive. 70.0 (2.76) 87.0 (3.43) 35.0 (1.38) 58.0 (2.28) ø5.5 (ø0.22) 270.0 (10.63) 258.0 258.0 (10.16) (10.16) 25.0 (0.98) 24.0 (0.94) 5.5 (0.22) 58.0 (2.28) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 196 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) ø5.5 (ø0.22) 310.0 (12.20) 298.0 298.0 (11.73) (11.73) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22) 90.0 (3.54) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 197: Adapter Plate Dimensions

    Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate Dimensions Dimensions are in millimeters and (inches) Frame A Frame B 25-MAP-FA 25-MAP-FB 39.2 (1.54) 92.0 (3.62) 39.2 (1.54) 80.0 (3.15) 20.2 (0.80) 20.2 (0.80) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 198 60.0 (2.36) 67.0 (2.64) Adapter Plate - Frame B Dimensions are in millimeters and (inches) Frame B Frame B 25-AP1-FB 25-AP0-FB 100.0 (3.94) 78.0 (3.07) 10.6 (0.42) 100.0 (3.94) 87.0 (3.43) 12.0 (0.47) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 199 25-AP0-FC 130.0 (5.12) 90.0 (3.54) 10.6 (0.42) 130.0 (5.12) 9.4 (0.37) 116.0 (4.57) Adapter Plate - Frame D Dimensions are in millimeters and (inches) Frame D 25-AP0-FD 130.0 (5.12) 11.0 (0.43) 116.0 (4.57) Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 200: Optional Accessories And Kits

    For PowerFlex 523 Communication adapter interface connector For PowerFlex 525 Communication adapter interface connector 2. Align the connectors on the communication adapter to the communication adapter interface connector, then push the back cover down. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 201: Removing A Communication Adapter

    3. Press along the edges of the back cover until it snaps firmly into place. Communication adapter interface connector 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 202 Appendix B Accessories and Dimensions Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 203: Network Wiring

    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.
  • Page 204 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. Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+”...

  • Page 205: Parameter Configuration

    PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either Velocity or Position bit definitions. Powerup/Reset the drive after selecting an option for C122 [Cmd Stat Select] for the change to take effect. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 206 14, 13, 12 100 = A410 [Preset Freq 0] 101 = A411 [Preset Freq 1] 110 = A412 [Preset Freq 2] 111 = A413 [Preset Freq 3] 1 = MOP Decrement, 0 = Not Decrement Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 207: Writing (06) Comm Frequency Command

    Function Code 06 writes to register address 2001H (Comm Frequency Command). Comm Frequency Command Reference Address (Decimal) Description Used by internal comm modules to control the reference of the drive. In units of 2001H (8193) 0.01 Hz. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 208: Reading (03) Logic Status Data

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

  • Page 209: Reading (03) Drive Error Codes

    Control Module Connect Error Incompatible Control-Power Module Unrecognized Control-Power Module Mismatched Control-Power Module Keypad Membrane Safety Hardware Microprocessor Failure I/O Board Fail Flash Update Required 2101H (8449) Non Recoverable Error DSI Flash Update Required Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 210: Reading (03) Drive Operational Values

    (06) Drive Parameters number. For example, a decimal “1” is used to address Parameter b001 [Output Freq] and decimal “41” is used to address Parameter P041 [Accel Time 1]. Additional Information https://www.ab.com/drives for additional information. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 211 The counter can be reset with a digital input programmed as “Reset Counter”. Use the Wizard in Connected Components Workbench software to simplify setup instead of manually configuring the parameters. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 212: Velocity Steplogic Using Timed Steps

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

  • Page 213: Timer Function

    - P047 [Speed Reference1] = 6 “4-20mA Input” - P049 [Speed Reference2] = 7 “Preset Freq” - t062 [DigIn TermBlk 02] = 1 “Speed Ref 2” - t063 [DigIn TermBlk 03] = 19 “Timer Start” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 214: Counter Function

    - t076 [Relay Out1 Sel] = 26 “Counter Out” - t077 [Relay Out1 Level] = 5.0 Counts Output Frequency Start Relay Out Photo Eye DigIn TermBlk 05 Counter In DigIn TermBlk 06 Reset Counter Limit Switch Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 215: Velocity Steplogic Parameters

    Step if “Logic In2” is active (logically true) and “Logic In 1” is not active (logically false) XOR Step after [Stp Logic Time x] and “Logic In 1” is active (logically true) TIMED AND Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) TIMED AND Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 216 Step after [Stp Logic Time x] and “Logic In 1” is not active (logically false) TIMED OR Step after [Stp Logic Time x] and “Logic In 2” is not active (logically false) TIMED OR Use logic programmed in Digit 1 IGNORE Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 217: Encoder And Pulse Train Usage

    Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. IMPORTANT Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 218: Htl/Ttl Dip Switches

    I M PORT ANT Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 219: Wiring Notes

    0.06 Hz. Example 2 To determine the speed resolution, using a 1024 PPR quadrature incremental encoder on a 4-pole (2-pole pair) motor: Speed resolution (Hz) = 1024 x 4 = 0.49 Hz Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 220: Positioning Overview

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

  • Page 221: Positioning Operation

    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 StepLogic Commands settings and instead the Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 222 [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] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 223 Accel/Decel 2 Jump to Step 7 Accel/Decel 2 End Program (Normal Stop) Accel/Decel 2 No Output End Program (Coast to Stop) Accel/Decel 2 End Program and Fault (F2) Accel/Decel 2 Accel/Decel 2 No Output Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 224: Homing Routine

    [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, Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 225: Encoder And Position Feedback

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

  • Page 226: Use Over Communications

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

  • Page 227: Setup Notes

    Setup Notes The RA computer tool (Connected Components Workbench software) can make setup of the positioning functions much easier. See the latest versions for additional tools or wizards, which can aid in the setup. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 228 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 229: Pid Set Up

    The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value. • The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 230: Trim Control

    As tension increases or decreases during winding, the Speed Reference is trimmed to compensate. Tension is maintained near the Equilibrium set point. PID Reference = PID Feedback = Equilibrium Set Point Dancer Pot Signal [Speed Referencex] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 231: Pid Reference And Feedback

    Encoder will be used as an input for the PID Feedback. 5“Encoder” EtherNet/IP will be used as an input for the PID Feedback. 6“EtherNet/IP” (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 232: Analog Pid Reference Signals

    PID Reference that the drive will ignore. Example • A465 [PID 1 Deadband] = 5.0% • The PID Reference is 25.0% • The PID Regulator will not act on a PID Error that falls between 20.0 and 30.0% Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 233: Pid Preload

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

  • Page 234: Guidelines For Adjusting The Pid Gains

    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 PID Feedback Time Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 235 Appendix F PID Set Up Oscillation – Under Damped PID Reference PID Feedback Time Good Response – Critically Damped PID Reference PID Feedback Time Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 236 Appendix F PID Set Up Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 237: Safe Torque Off Function

    • Can be used in combination with other safety devices to fulfill the requirements of a system “safe torque off” function which satisfies Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 238: Ec Type Examination Certification

    Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508. The TÜV Rheinland certificate may be found at: rok.auto/certifications. EMC Instructions PowerFlex 525 Safe-Torque-Off function requires CE Conformity as described page Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 239: Using Powerflex 525 Safe-Torque-Off

    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 equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

  • Page 240: Functional Proof Test

    Safe State. The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of safe-torque-off, is 100 ms (maximum). Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 241: Enabling Powerflex 525 Safe-Torque-Off

    Terminal Designations on page 42 for terminal descriptions. If Safety Inputs S1 and S2 are powered by an external +24V source, apply it only in SELV system, PELV system or low voltage Class 2 circuit. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 242: Powerflex 525 Safe-Torque-Off Operation

    F059 “Safety Open” will occur. The discrepancy time is one second for PowerFlex 525 FRN 5.xxx and later. The discrepancy time is 10 milliseconds for PowerFlex 525 FRN 4.xxx and earlier. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 243: Connection Examples

    (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-UM001K-EN-E - August 2021...
  • Page 244 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. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 245: Example 2 - Safe-Torque-Off Connection With Controlled Stop

    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-UM001K-EN-E - August 2021...

  • Page 246: Example 3 - Safe-Torque-Off Connection With Coast-To-Stop Action Using External +24V Supply, Sil 3/Pl E

    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. PowerFlex 525 Certification Certification information can be viewed at for Safe-Torque-Off rok.auto/certifications. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 247: Establishing A Connection With Ethernet/Ip

    IMPORTANT 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-UM001K-EN-E - August 2021...

  • Page 248: Ground Connections For Ethernet/Ip Networks

    PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter Terminal Description Provides a clean ground for the communication bus cable shields. CS1/CS2 CS1 or CS2 should be connected to a clean ground or PE ground on the drive. Terminals CS1/CS2 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 249: Induction Motor Tuning Diagrams

    A525 [Freq 3 Kp] A526 [Freq 3 Ki] A523 [Freq 2 Kp] A524 [Freq 2 Ki] A521 [Freq 1 Kp] A522 [Freq 1 Ki] A510 Freq (Hz) [Freq 1] A512 [Freq 2] A514 [Freq 3] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 250: Adjusting Speed Control Parameters

    Set Speed Controller Gain Set Speed Controller Gain manually: automatically A521 [Freq 1 Kp] A522 [Freq 1 Ki] A523 [Freq 2 Kp] A524 [Freq 2 Ki] A525 [Freq 3 Kp] A526 [Freq 3 Ki] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 251 ATTENTION: It is the responsibility of the startup engineer / end user to use proper safety precautions with any equipment used during this startup. 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.

  • Page 252: Motor Control

    From the Torq Perf Mode drop-down list, select “PM Motor”. This configuration can also be done by setting parameter P039 [Torq Perf Mode] to 4 “PM Motor”. Motor Data Key in the details of your Motor Nameplate. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 253: Feedback

    • Motor Feedback Type can be “Quadrature” or “Quad Check”. • Only Interior Permanent magnet motor (iPM) is supported for closed loop control. Stop Mode/Brake Type Key in the details of your configuration. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 254: Direction Test

    The Auto Tune is used to identify the correct motor flux and stator electrical properties, including the following: • IR volt drop, which is voltage drop over resistance. • IXd volt drop, which is voltage drop over inductance. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 255 Rotate tune is generally used to better identify motor flux and stator electrical properties, which are used to automatically tune the torque current loop. The Rotate Tune test causes motor rotation at different speeds while it is executing. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 256: Manual Configuration Using Drive Keypad

    6. Enter Stop mode and dynamic brake data, if any. • P045 [Stop Mode] • A437 [DB Resistor Sel] 7. Ensure the load is uncoupled and perform a Rotate Tune test Set P040 [Autotune] = 2 “Rotate Tune” Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 257: Additional Pm Motor Configuration

    7. If the motor reverses, repeat steps 2 and 3. 8. If A519 [PM HFI NS Cur] has reached its maximum value again and a reverse motor startup still occurs, the motor setup has failed. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 258 Perform a test run at Check command frequency Repeat steps 2 and 3 of Additional Setup for Open Loop PM Motor Do you see reverse startup? Drive is aligned and ready to run Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 259: Additional Setup For Closed Loop Pm Motor

    4 “Quadrature” or 5 “Quad Check”. 2. Increase A517 [PM DC Inject Cur] by 50%. 3. Increase A518 [PM Align Time] by 0.2 s. 4. Repeat the Align the PM Angle instructions again, beginning from step 3. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 260 See Align the PM Angle See Adjustments if PM Angle Alignment has Failed Does drive align successfully? No (Fault F012 or F013 is observed during acceleration and deceleration.) Drive is aligned and ready to run Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 261: Optional Parameter Adjustments For Optimum Performance

    Increase 100 of A584 [PM Stable 2 Kp] for each trial if fault F064 (Drive overload) is experienced at high load. Applicable to open loop tuning especially for sPM motor. In most cases, the default value will work. Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 262 Appendix J PowerFlex 525 PM Motor Configuration Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 263: Synrm Structure

    Adjusting Speed Control Parameters on page 250 for more information on speed loop bandwidth A591 [SYNRM Flux Cur] A592 [SYNRM Freq1 Volt] adjustment. A593 [SYNRM Freq1 Kp] A594 [SYNRM Freq1 Comp] A595 [SYNRM Freq2 BW] A596 [SYNRM Freq2 Kp] Rockwell Automation Publication 520-UM001K-EN-E - August 2021...

  • Page 264: Synrm Control Configuration

    Press Run Check the following motor parameters: A501 [PM IR Voltage] Is the motor No SynRM parameters A502 [PM IXd Voltage] auto-tuning A503 [PM IXq Voltage] successful? A504 [PM BEMF Voltage] No-Load Run Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 265 2. Adjust A595 [SYNRM Freq2 BW] 3. Adjust A596 [SYNRM Freq2 Kp] When the frequency operation exceeds A590 [SYNRM SW Freq], is the speed stable and Frequency speed vibration does not oscillate? Load operation test Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 266 1. Adjust A595 [SYNRM Freq2 BW] 2. Adjust A596 [SYNRM Freq2 Kp] 3. Adjust ASR Bandwidth Induction Motor Tuning Diagrams on Did the high-frequency loading performance meet the request? Insufficient high-frequency loading performance Finish Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 267 49 3-wire 49 derating circuit breakers 22 factor 124 power 20 temperature 17 digital inputs selecting 49 start source 49 logic dimensions basic 211 mounting 16 timed steps 211 disconnect output 34 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 268 61 derating 17 PID 231 wiring 32 positioning 220 testing pulse train 217 safety 240 timed steps 211 timer timer 211 programming 211 tools 62 tools pulse train programming 62 programming 217 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 269 34 wave protection reflected 34 wiring encoder 219 noise immunity 37 recommended 36 RS485 (DSI) 203 safety 241 shielded 33 temperature 32 unshielded 33 voltage reflections 34 writing Modbus 205 Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 270 Index Notes: Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 271 PowerFlex 520-Series Adjustable Frequency AC Drive User Manual Rockwell Automation Publication 520-UM001K-EN-E - August 2021...
  • Page 272 Allen-Bradley, AppView, Compact I/O, Connected Components Workbench, CustomView, DriveTools, expanding human possibility, FactoryTalk, Logix 5000, MainsFree, Minotaur, PanelView, PowerFlex, QuickView, Rockwell Automation, RSLogix, RSLogix 5000, SLC, StepLogic, Studio 5000, Studio 5000 Logix Designer, and TechConnect are trademarks of Rockwell Automation, Inc.

Table of Contents