Page 1 User Manual PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A, Series B PowerFlex 525 Catalog Number 25B Original Instructions...
Page 2: Important User Information
Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.
Page 3: Table Of Contents
Using the USB Port ..........67 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 4 Additional Information......... . 208 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 5 Establishing A Connection With EtherNet/IP ....247 Ground Connections for EtherNet/IP Networks ....248 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 6 Additional PM Motor Configuration ......262 Optional Parameter Adjustments for Optimum Performance ..266 Index Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 7: New And Updated Information
Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution” to Appendix E. Updated information to verify operation of the safety inputs in Appendix G. General maintenance updates. Throughout manual Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 8 Summary of Changes Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 9: Preface
The following publications provide specific PowerFlex 520-Series information on drive installation, features, specifications, and service: Title Publication PowerFlex 520-Series AC Drive Specifications 520-TD001 PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001 PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 10: Manual Conventions
Words Meaning Possible, able to do something Cannot Not possible, not able to do something Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not Recommended Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 11: 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 12: 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-UM001I-EN-E - July 2016...
Page 13: Catalog Number Explanation
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-UM001I-EN-E - July 2016...
Page 14 Preface Overview Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 15: Mounting Considerations
ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
Page 16 (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-UM001I-EN-E - July 2016...
Page 17 IP 20/Open Type IP 20/Open Type 30 35 40 45 50 55 60 65 70 75 80 70 75 80 30 35 40 45 50 55 60 65 Ambient Temperature (°C) Ambient Temperature (°C) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 18 • 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-UM001I-EN-E - July 2016...
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 IMPORTANT Tighten screw after jumper removal. Phase to Ground MOV Removal R/L1 Three-Phase S/L2 AC Input T/L3 Jumper Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 20: General Grounding Requirements
Requirements safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. Typical Grounding R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 SHLD Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 21 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-UM001I-EN-E - July 2016...
Page 22 Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 23: Fuses And Circuit Breakers
• Bulletin 140M can be used up stream from the drive without the need for fuses. (1) 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-UM001I-EN-E - July 2016...
Page 24 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 25 Installation/Wiring Chapter 1 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 26 Chapter 1 Installation/Wiring Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 27 Installation/Wiring Chapter 1 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
Page 30 3. Insert the catch at the top of the frame cover into the Power Module, then swing the frame cover to snap the side catches onto the Power Module (Frames B...E only). Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 31: Control Module Cover
To access the power terminals, the terminal guard must be removed. To remove: 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). Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 32: Power Wiring
Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable must be used. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 33 A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 34 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-UM001I-EN-E - July 2016...
Page 35: Power Terminal Block
5.3 mm (10 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) 26.7 mm (3 AWG) 8.4 mm (8 AWG) 3.09...3.77 Nm (27.3...33.4 lb-in.) (1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 36: Common Bus/Precharge Notes
Signal and Control Wire Types Recommendations are for 50 °C ambient temperature. 75 °C wire must be used for 60 °C ambient temperature. 90 °C wire must be used for 70 °C ambient temperature. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 37: Control I/O Terminal Block
Maximum Wire Size Minimum Wire Size Torque A...E 1.3 mm (16 AWG) 0.13 mm (26 AWG) 0.71...0.86 Nm (6.2...7.6 lb-in.) (1) Maximum/minimum sizes that the terminal block will accept – these are not recommendations. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 38 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-UM001I-EN-E - July 2016...
Page 39 Coast Per P045 [Stop Mode] 2 “DigIn TrmBlk” t062, t063 [DigIn TermBlk xx] below 3 “Serial/DSI” Coast 4 “Network Opt” Coast 5 “Ethernet/IP” Coast (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 40 Drive supplied power for digital inputs. Maximum output current is 100 mA. 12 +10V DC – Referenced to Analog Common. P047, P049 Drive supplied power for 0...10V external potentiometer. Maximum output current is 15 mA. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 41 (1) Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an undetermined frequency reference will result. (2) See Footnote (1) on page Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 42 P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop 1 “Keypad” Coast Per P045 [Stop Mode] 2 “DigIn TrmBlk” t062, t063 [DigIn TermBlk xx] below 3 “Serial/DSI” Coast 4 “Network Opt” Coast 5 “EtherNet/IP” Coast Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 43 +24V supply for safety circuit. Internally tied to the +24V DC – source (Pin 11). 11 +24V DC – Referenced to Digital Common. – Drive supplied power for digital inputs. Maximum output current is 100 mA. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 44 19 Opto Common – The emitters of the Optocoupler Outputs (1 and 2) are tied – together at Optocoupler Common. Electrically isolated from the rest of the drive. (1) See Footnote (1) on page Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 45 [Relay Out 2 Sel] = 10 “Above Anlg V” t082 [Relay Out 2 Level] = % Voltage Trip R PTC (hot) %V Trip = X 100 R PTC (hot) + R e R PTC Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 46 If both Run Forward and Run Reverse inputs are closed at the same time, an undetermined state could occur. 2 Wire SNK Control - Internal Supply (SNK) Run FWD/Run REV Stop-Run Forward Stop-Run Reverse Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 47 +24V Common such as a relay, install a Each Opto-Output is rated 30V DC 50 mA (Non-inductive). recovery diode parallel to the relay as shown, to prevent damage to the output. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 48 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-UM001I-EN-E - July 2016...
Page 49: 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 50 for information on selecting the correct digital input. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 50 Start and Direction [DigIn TermBlk [Start Source x] 02/03] = 48/49/50/51 command from = 2 (DigIn TrmBlk) (2-Wire or Terminal Block. 3-Wire) Drive will not start. Start and Direction command from [Start Source x]. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 51 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-UM001I-EN-E - July 2016...
Page 52: Ce Conformity
Refer to Appendix G for installation consideration related to Machinery Directive. ATEX Directive (94/9/EC and 2014/34/EU) • EN 50495 – Safety devices required for the safe functioning of equipment with respect to explosion risks. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 53 Consultation with the network operator and Rockwell Automation may be necessary. • If the optional NEMA 1 kit is not installed, the drive must be installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and top...
Page 54 When the cable shield is terminated at the drive end, it may be terminated either by using a shielded connector in conjunction with a conduit plate or conduit box, or the shield may be clamped to an “EMC plate.” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 55 • drives that have an internal EMC filter (25x-xxxxN114) • external EMC filter accessory kit (25-RFxxx) An enclosure, shielded input cable, and EMC cores are not required to meet IMPORTANT category C3 requirements. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 56 Input/Output Input/Output Input/Output Input/Output Input/Output 525...600V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...575V 3-Phase Output Input/Output Input/Output Input/Output Input/Output (1) An (*) indicates that EMC requirements are not met. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 57 • 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-UM001I-EN-E - July 2016...
Page 58 Chapter 1 Installation/Wiring Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 59: Prepare For Drive Start-Up
3. If replacing a drive, verify the current drive’s catalog number. Verify all options installed on the drive. 4. Verify that any digital control power is 24 volts. 5. Inspect grounding, wiring, connections, and environmental compatibility. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 60 Record these settings for your reference. • 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-UM001I-EN-E - July 2016...
Page 61 Variable Torque Fan/Pump Applications For improved motor and drive performance, tune the motor in SVC mode using parameter P040 [Autotune]. If V/Hz mode is selected, use parameter A530 [Boost Select] to adjust the boost. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 62: Display And Control Keys
Cancel a change to a parameter value and exit Program Mode. Select Advance one step in programming menu. Select a digit when viewing parameter value. Enter Advance one step in programming menu. Save a change to a parameter value. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 63: Viewing And Editing Parameters
The right digit will flash and the word Program on the LCD display will light up. PROGRAM 9. Press the Up Arrow or Down Arrow to change VOLTS the parameter value. PROGRAM Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 64: Drive Programming Tools
(2) Does not support the new dynamic parameter groups (AppView, CustomView), and CopyCat functionality is limited to the linear parameter list. Language Support Language Keypad/LCD Display RSLogix 5000/ Connected Components Logix Designer Workbench English French Spanish Italian German Japanese – – Portuguese – Chinese Simplified – Korean – – Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 65: Smart Start-Up With Basic Program Group Parameters
Drive Rated Power PF 525 Sets the motor nameplate power. Used in PM regulator. P038 [Voltage Class] 2 = “480V” 3 = “600V” Sets the voltage class of 600V drives. Only applicable to 600V drives. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 66 (1) When active, the Reverse key is also active unless disabled by A544 [Reverse Disable]. (2) If “DigIn TrmBlk” is selected, ensure that the digital inputs are properly configured. (3) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 67: Lcd Display With Quickview Technology
Simply connect the control module to your PC with a USB Type B cable and you can download a parameter configuration to your drive. You can also easily upgrade your drive with the latest firmware. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 68 Make sure your PC is powered by an AC power outlet or has a fully charged IMPORTANT battery before starting any operation. This prevents the operation from terminating before completion due to insufficient power. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 69 This means you cannot apply a multi-drive configuration using the USB utility application to a drive in single mode (parameter C169 [MultiDrv Sel] set to 0 “Disabled”), or apply a single mode configuration to a drive in multi-drive mode. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 70 Chapter 2 Start Up Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 71: About Parameters
Three types of parameters exist: • ENUM ENUM parameters allow a selection from 2 or more items. Each item is represented by a number. • Numeric Parameters These parameters have a single numerical value (0.1V). Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 72 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-UM001I-EN-E - July 2016...
Page 73: Parameter Groups
Units Traveled L d389 Analog In 4-20mA d361 Motor OL Level d369 PID1 Fdbk Displ d383 Fiber Status d390 Elapsed Time-hr d362 Slip Hz Meter d375 PID1 Setpnt Disp d384 Stp Logic Status d391 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 74 When a parameter has its default value changed, it is automatically added to this group. When a parameter has its value changed back to the factory default, it is automatically removed from this group. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 75 (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-UM001I-EN-E - July 2016...
Page 76 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-UM001I-EN-E - July 2016...
Page 77 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-UM001I-EN-E - July 2016...
Page 78: 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. Values Default: Read Only Min/Max: 00000/11111 Display: 00000 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 79 (1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the Start source and/or Frequency source. (2) Setting is specific to PowerFlex 525 drives only. Values Default: Read Only Min/Max: 0000/2165 Display: 0000 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 80 Display: 0.1% b017 [Output Power] Related Parameter(s): b018 Output power present at T1, T2 & T3 (U, V & W). Values Default: Read Only Min/Max: 0.00/(Drive Rated Power x 2) Display: 0.01 kW Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 81 [Accum kWh Sav] Related Parameter(s): b025 Total approximate accumulated energy savings of the drive compared to using an across the line starter. Values Default: Read Only Min/Max: 0.0/6553.5 kWh Display: 0.1 = 10 kWh Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 82 Present operating temperature of the drive control. Values Default: Read Only 0/120 °C Min/Max: 1 °C Display: b029 [Control SW Ver] Current drive firmware version. Values Default: Read Only Min/Max: 0.000/65.535 Display: 0.001 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 83: Basic Program Group
The drive will fault on an F007 “Motor Overload” if the value of this parameter is exceeded based on class 10 motor overload protection according to NEC article IMPORTANT 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572 Values Default: Drive Rated Amps Min/Max: 0.0/(Drive Rated Amps x 2) Display: 0.1 A Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 84 [Motor Fdbk Type] is set to 4 or 5, the drive is in closed loop PM motor control mode. (1) Setting is specific to PowerFlex 525 drives only. (2) Setting is available in PowerFlex 525 FRN 5.xxx and later. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 85 [Maximum Freq] to 0 Hz. Decel Rate = [Maximum Freq] / Decel Time x] [Maximum Freq] Speed [Accel Time x] Time [Decel Time x] Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 86 It is recommended to use braking resistors or set A550 [Bus Reg Enable] to 0 “Disabled” for better performance. Stop [Maximum Freq] Speed Calculated Stop Time Time [Decel Time x] Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 87 (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. Values Default: 0.00 Min/Max: 0.00/655.35 Display: 0.01 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 88 4 “Module Reset” Power cycle of the drive, NO parameters are reset. (1) Setting is available in PowerFlex 525 FRN 5.xxx and later. (2) Setting is available in PowerFlex 523 FRN 3.xxx and later. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 89: Terminal Block Group
Logic function input number 2. May be used to control the relay or opto outputs (t076, t081 [Relay Outx Sel] and t069, t072 [Opto Outx Sel], options 11...14). May be used in conjunction with StepLogic parameters L180...L187 [Stp Logic x]. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 90 Disables shear pin 1 but leaves shear pin 2 active. If A488 [Shear Pin 2 Level] is greater than 0.0 A, shear pin 2 is enabled. 44 Reserved 45 Reserved 46 Reserved 47 Reserved Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 91 • 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-UM001I-EN-E - July 2016...
Page 92 – 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – Values Default: Opto Out1 Sel: Opto Out2 Sel: Min/Max: 0/31 Display: (1) Setting is available in FRN 5.xxx and later. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 93 [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 Values Default: Min/Max: Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 94 30 “SafeTqPermit” Both safe-off inputs are inactive (closed). – (1)(2) 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – Values Default: Relay Out1 Sel: Relay Out2 Sel: Min/Max: 0/31 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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) Values Default: 2.00 s Min/Max: 0.00/10.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 96 (1) Filter A is a single pole digital filter with a 162 ms time constant. Given a 0...100% step input from a steady state, the output of Filter A takes 500 ms to get to 95% of maximum, 810 ms to get to 99%, and 910 ms to get to 100%. Values Default: Min/Max: 0/23 Display: (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 97 Enables/disables bi-polar control. In bi-polar mode direction is commanded by the polarity of the voltage. If bi-polar control is enabled, P043 [Minimum Freq] and t091 [Anlg In 0-10V Lo] are ignored. Options 0 “Uni-Polar In” (Default) 0-10V only 1 “Bi-Polar In” ±10V Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 98 If enabled, this function affects any input that is being used as a speed reference or PID reference or PID setpoint in the drive. Options 0 “Disabled” (Default) 1 “Fault (F29)” 2 “Stop” 3 “Zero Ref” 4 “Min Freq Ref” 5 “Max Freq Ref” 6 “Key Freq Ref” 7 “MOP Freq Ref” 8 “Continu Last” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 99 Default: 0.0 s Min/Max: 0.0/600.0 s Display: 0.1 s t103 [Wake Level] Sets the analog input level the drive must reach to wake from sleep mode. Values Default: 15.0% Min/Max: 0.0/100.0% Display: 0.1% Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 100 Sets the method of resetting fault F111 “Safety Hardware” either by means of a power cycle or fault clear operation. Options 0 “PwrCycleRset” (Default) Reset fault F111 using power cycle. 1 “FltClr Reset” Reset fault F111 using fault clear mechanism without power cycle. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 101: Communications Group
Appendix C for more information. IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the RS485 port. Values Default: 5.0 s Min/Max: 0.1/60.0 s Display: 0.1 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 102 [EN IP Addr Cfg 1] [EN IP Addr Cfg 2] [EN IP Addr Cfg 3] [EN IP Addr Cfg 4] IMPORTANT C128 [EN Addr Sel] must be set to 1 “Parameters”. Values Default: Min/Max: 0/255 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 103 Sets the network data rate at which EtherNet/IP communicates. A reset or power cycle is required after selection is made. Options 0 “Auto detect” (Default) 1 “10Mbps Full” 2 “10Mbps Half” 3 “100Mbps Full” 4 “100Mbps Half” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 104 [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” and the scanner is put into Program or Test mode. Writing (06) Logic Command Data on page 203 for more information. Values Default: 0000 Min/Max: 0000/FFFF Display: 0000 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 105 Datalink parameter number whose value is read from the embedded EtherNet/IP data table. This parameter cannot be changed when an I/O connection is established through the drive’s embedded EtherNet/IP port. Values Default: Min/Max: 0/800 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 106 Sets the configuration of the Drives that are active in the multi-drive mode. Identifies the connections that would be attempted on a reset or power cycle. A reset or power cycle is required after selection is made. Options 0 “Drive 0” (Default) 1 “Drive 0-1” 2 “Drive 0-2” 3 “Drive 0-3” 4 “Drive 0-4” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 107: 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-UM001I-EN-E - July 2016...
Page 108 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 Accel/Decel 2 Absolute Accel/Decel 2 Incremental Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 109 L212 [Step Units 6] L214 [Step Units 7] 32 bit parameter. PF 525 PowerFlex 525 only. Sets the position in user-defined units the drive must reach at each step. Values Default: 0.00 Min/Max: 0.00/6400.00 Display: 0.01 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 110: Advanced Display Group
Default: Read Only Min/Max: 0.0/9999.0 s Display: 0.1 s d367 [Drive Type] Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non Rockwell Automation technical personnel). Values Default: Read Only Min/Max: 0/65535 Display:...
Page 111 0/410VDC for 230V AC drives; 820VDC for 460VAC drives; 1025VDC for 600VAC drives Display: 1V DC d381 [Output Powr Fctr] Displays the angle in electrical degrees between motor voltage and motor current. Values Default: Read Only Min/Max: 0.0/180.0 deg Display: 0.1 deg Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 112 32 bit parameter. PowerFlex 525 only. PF 525 Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel. Values Default: Read Only Min/Max: 0/64000 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 113 [RdyBit Mode Act] Related Parameter(s): A574 (With PowerFlex 525 FRN 3.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Displays the value of A574 [RdyBit Mode Cfg]. Values Default: Read Only Min/Max: Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 114 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. Values Default: Read Only Min/Max: 0/15 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 115: Advanced Program Group
10.00 HZ Preset Freq 3: 20.00 Hz Preset Freq 4: 30.00 Hz Preset Freq 5: 40.00 Hz Preset Freq 6: 50.00 Hz Preset Freq 7...15: 60.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 116 Default: 10.00 Hz Min/Max: 0.00/[Maximum Freq] Display: 0.01 Hz A432 [Jog Accel/Decel] Sets the acceleration and deceleration time used when in jog mode. Values Default: 10.00 s Min/Max: 0.01/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 117 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 Values Default: 0.0 s Min/Max: 0.0/99.9 s Display: 0.1 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 118 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 Values Default: Min/Max: 0/100% Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 119 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] Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.01 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 120 Determines the band around A448, A450, A452 A454 [Skip Frequency x]. Frequency Command Frequency Drive Output Frequency 2x Skip Skip Frequency Frequency Band Time Values Default: 0.0 Hz Min/Max: 0.0/30.0 Hz Display: 0.1 Hz Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 121 6 “TrimOn 4-20” 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-UM001I-EN-E - July 2016...
Page 122 Related Parameter(s): A459, A471 A473 [PID 2 Prop Gain] PF 525 PowerFlex 525 only. Sets the value for the PID proportional component when the PID mode is enabled. Values Default: 0.01 Min/Max: 0.00/99.99 Display: 0.01 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 123 0.0/500.0 Hz Display: 0.1 Hz A467 [PID 1 Invert Err] A479 [PID 2 Invert Err] PF 525 PowerFlex 525 only. Changes the sign of the PID error. Options 0 “Normal” (Default) 1 “Inverted” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 124 P044 [Maximum Freq]. Values Default: 0.00 Min/Max: 0.00/99.99 Display: 0.01 A483 [Testpoint Sel] Used by Rockwell Automation field service personnel. Values Default: Min/Max: 0/FFFF Display: A484 [Current Limit 1] Related Parameter(s): P033 Maximum output current allowed before current limiting occurs.
Page 125 0 “No Derate” (Default) 1 “Min. Derate” 2 “Max. Derate” A494 [Motor OL Ret] Selects whether the motor overload counter is saved on power-down or reset on power-up. Options 0 “Reset” (Default) 1 “Save” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 126 PF 525 (With FRN 5.xxx and later.) Voltage across the stator resistance of the PM motor at the rated motor current displayed in line-to-line rms value. Values Default: 11.50V Min/Max: 0.00/655.35V Display: 0.01V Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 127 A510 [Freq 1] A512 [Freq 2] A514 [Freq 3] PF 525 PowerFlex 525 only. Sets the “Vector” control mode frequency. Values Default: Freq 1: 8.33% Freq 2: 15.00% Freq 3: 20.00% Min/Max: 0.00/200.00% Display: 0.01% Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 128 High Frequency Injection (HFI) North South Current to detect N/S Magnet. Values Default: 100% Min/Max: 0/300% Display: A520 [PM Bus Reg Kd] PowerFlex 525 only. PF 525 (With FRN 5.xxx and later.) Derivative gain for bus regulator. Values Default: Min/Max: 0/500 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 129 Display: A528 [PM FWKn 2 Kp] PowerFlex 525 only. PF 525 (With FRN 5.xxx and later.) The gain to ensure robustness under step load in weakening region. Values Default: 100% Min/Max: 100/8000% Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 130 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-UM001I-EN-E - July 2016...
Page 131 10V AC (on 230V AC Drives); 20V AC (on 460V 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) Display: 1V AC Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 132 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. Values Default: Min/Max: 0.0/200.0 Display: (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 133 A545 [Flying Start En] Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM. Options 0 “Disabled” (Default) 1 “Enabled” Catch and ramp to commanded speed at every drive start. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 134 Resets the active fault and clears all fault buffers to “0”. A552 [Program Lock] Related Parameter(s): A553 Protects parameters against change by unauthorized personnel with a 4-digit password. Values Default: 0000 Min/Max: 0000/9999 Display: 1111 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 135 Use Step Logic Commands. Always start from Step 0. 3 “Preset StpL” Use Preset Inputs to determine starting step then Step Logic commands. 4 “StpLogic-Lst” Use Step Logic commands from last Step Logic step at last drive stop. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 136 A561 [Home Save] PF 525 PowerFlex 525 only. Determines whether the current position is saved on power down. Options 0 “Home Reset” (Default) Position resets to zero on power up. 1 “Home Saved” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 137 Sets the error signal filter in the position regulator. Values Default: Min/Max: 0/15 Display: A566 [Pos Reg Gain] PowerFlex 525 only. PF 525 Sets the gain adjustment for the position regulator. Values Default: Min/Max: 0.0/200.0 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 138 New Drive #2 Reference New Drive #1 Reference Speed Sync Bit [Fiber Status] Change Ref's Drive #1 and #2 Sync Enable Input Time Values Default: 0.0 s Min/Max: 0.0/3200.0 s Display: 0.1 s Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 139 0 “Standard” (Default) 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. Options 0 “Disable” (Default) 1 “Enable” Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 140 [PM Stable 2 Kp]. Values Default: 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. Values Default: 250% Min/Max: 0/2000% Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 141: Network Parameter Group
Enable an embedded algorithm to reduce oscillation in output waveform (use with sPM motor only, do not enable for iPM motor). Network Parameter Group This group contains parameters for the network option card that is installed. Refer to the network option card’s user manual for more information on the available parameters. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 142: Modified 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. Values Default: Read Only Min/Max: 0.0/320.0 min Display: 0.1 min Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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. Values Default: Read Only Min/Max: 0/1200VDC Display: 1VDC Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 144 “Not Active (no connection)” Digit 1 “Internal option connected/active” Digit 2 2...8 “Reserved” Status Digit 3 “Internal com option faulted” Error Digit 4 Not Used Values Default: Read Only Min/Max: 0000/1911 Display: 0000 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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 Value Default: Read Only Min/Max: 00000/11111 Display: 00000 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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] Values Default: Read Only Min/Max: 0/255 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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. Values Default: Read Only Min/Max: 0/FFFF Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 148 Min/Max: 0/65535 Display: F729 [EN Tx Errors] PF 525 PowerFlex 525 only. A count of the number of transmit errors reported by the embedded EtherNet/IP interface. Values Default: Read Only Min/Max: 0/65535 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 149 PF 525 PowerFlex 525 only. The number of I/O packets missed. Values Default: Read Only Min/Max: 0/65535 Display: F731 [DSI Errors] The number of total DSI errors. Values Default: Read Only Min/Max: 0/65535 Display: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 150: Appview Parameter Groups
3. Press the Up Arrow or Down Arrow to scroll to the command G1->GC. 4. 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-UM001I-EN-E - July 2016...
Page 151: Customview Parameter Group
6. 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-UM001I-EN-E - July 2016...
Page 152: Parameter Cross Reference By Name
Counts Per Unit Drv 4 Addr EN IP Addr Cfg 3 Current Limit 1 Drv 4 Feedback EN IP Addr Cfg 4 Current Limit 2 Drv 4 Logic Cmd EN Missed IO Pkt Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 153 Opt Data Out 2 Fault 5 Freq Freq 3 BW Opt Data Out 3 Fault 5 Time-hr Freq 3 Ki Opt Data Out 4 Fault 5 Time-min Freq 3 Kp Opto Out Logic Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 154 PM Bus Reg Kd Relay Out1 Level Status @ Fault 8 (1)(3) PM Control Cfg Relay Out1 Sel Status @ Fault 9 (1)(3) PM DC Inject Cur Relay 2 Off Time Status @ Fault10 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 155 (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-UM001I-EN-E - July 2016...
Page 156 Chapter 3 Programming and Parameters Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 157: Drive Status
Non-Resettable This type of fault may require drive or motor repair, or is caused by wiring or programming errors. The cause of the fault must be corrected before the fault can be cleared. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 158 ATTENTION: Equipment damage and/or personal injury may result if these parameters are used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 159: Fault Descriptions
A current path to earth ground has been Check the motor and external wiring to detected at one or more of the drive the drive output terminals for a output terminals. grounded condition. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 160 EtherNet/IP adapter has been • Check communications cabling. interrupted. • Check EtherNet/IP setting. • Check external network status. F080 Autotune Failure The autotune function was either Restart procedure. cancelled by the user or failed. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 161 • Check safety input signals. If not malfunction. One of the safety inputs is using safety, verify and tighten not enabled. jumper for I/O terminals S1, S2 and • Replace control module if fault cannot be cleared. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 162: Common Symptoms And Corrective Actions
5. Reset default parameter values by setting P053 [Reset Defalts] to 2 “Factory Rset”. 6. If safe to do so for your application, press Start on drive keypad. Drive will run according to the speed potentiometer. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 163 • 2 wire control requires Run Forward, Run Reverse or Jog input. • 3 wire control requires Start and Stop inputs • Stop input is always required. Incorrect Sink/Source jumper setting. None Set switch to match wiring scheme. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 164 89). Choose correct input and program for reversing mode. Digital input is incorrectly wired. None Check input wiring (See page 45). Motor wiring is improperly phased for reverse. None Switch two motor leads. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 165 Motor is rotating at zero Hz or slip frequency is not correct. Cause(s) Indication Corrective Action Incorrect speed calculation. Improper speed. • Verify P032 [Motor NP Hertz]. • Reduce boost with A530 [Boost Select]. • Set P036 [Motor NP RPM] to motor synchronous speed. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 166 Chapter 4 Troubleshooting Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 167: Certifications
TUV 12 ATEX 7199 X Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards: Article 58-2 of Radio Waves Act, Clause 3 Standards applied: Low Voltage TP TC 004/2011 EMC TP TC 020/2011 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 168: Environmental Specifications
DIN rail or screw 30 g/ 2.5 g Screw only 15 g / 2 g Screw only 30 g/ 2.5 g Screw only 15 g / 1.5 g Screw only 30 g/ 2.5 g Screw only Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 169: 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-UM001I-EN-E - July 2016...
Page 170 (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 217. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 171 10 mA per 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-UM001I-EN-E - July 2016...
Page 172: Power Specifications
13.0 170.0 17.0 221.0 24.0 303.0 30.0 387.0 380...480V, 27.0 50/60 Hz 3-Phase 37.0 w/ EMC Filter 63.0 88.0 10.5 133.0 13.0 175.0 17.0 230.0 24.0 313.0 30.0 402.0 37.0 602.0 43.0 697.0 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 173 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-UM001I-EN-E - July 2016...
Page 174 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-UM001I-EN-E - July 2016...
Page 175: Product Selection
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 323...528 25A-D6P0N104 25B-D6P0N104 10.5 323...528 25A-D010N104 25B-D010N104 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 176 Minimum Resistance Resistance Input Voltage Ω ±10% Ω ±5% (1)(2) Catalog No. 100...120V 0.25 AK-R2-091P500 50/60 Hz AK-R2-091P500 1-Phase 0.75 AK-R2-091P500 AK-R2-091P500 200...240V 0.25 AK-R2-091P500 50/60 Hz AK-R2-091P500 1-Phase 0.75 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 177 (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 178 (1) EMC Line Filter size is based on the input current of the drive. See the tables on page 26 page 27 for more information. (2) This 600V drive rating needs to be matched with a frame B EMC Line Filter. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 179 25-ENC-1 WARNING: 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-UM001I-EN-E - July 2016...
Page 180 24.0 170...264 25-PM1-B024 10.0 10.0 32.2 170...264 25-PM1-B032 15.0 11.0 10.0 48.3 170...264 25-PM1-B048 20.0 15.0 15.0 11.0 62.1 170...264 25-PM1-B062 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 323...528 25-PM1-D1P4 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 181 Frame Item Description Size Catalog No. PowerFlex 523 Control Replacement cover for the control module I/O terminals, A...E 25A-CTMFC1 Module Front Cover EtherNet/IP and DSI ports. PowerFlex 525 Control 25B-CTMFC1 Module Front Cover Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 182 2.0 m serial cable with a locking low profile connector to 1203-SFC connect to the serial converter and a 9-pin sub-miniature D female connector to connect to a computer. Splitter Cable RJ45 one to two port splitter cable (Modbus only) AK-U0-RJ45-SC1 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 183 1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R35-B (HD) 1321-3RA35-B (HD) 1321-3R35-B (HD) 1321-3RA35-B (HD) 525...600V 50/60 Hz 3-Phase 1321-3R1-C 1321-3RA1-C 1321-3R1-C 1321-3RA1-C 0.75 0.75 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 184 (3) Catalog numbers listed are for 3% impedance at 60 Hz. 5% impedance reactor types are also available. See publication 1321-TD001. (4) Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD rated output currents. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 185: Product Dimensions
1.1 / 2.4 1.6 / 3.5 2.3 / 5.0 3.9 / 8.6 12.9 / 28.4 IP 20/Open Type – Frame A Dimensions are in millimeters and (inches) 72.0 (2.83) 172.0 (6.77) 57.5 (2.26) 6.0 (0.24) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 186 Dimensions are in millimeters and (inches) 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 6.0 (0.24) IP 20/Open Type – Frame C Dimensions are in millimeters and (inches) 109.0 (4.29) 184.0 (7.24) 90.5 (3.56) 6.0 (0.24) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 187 Dimensions are in millimeters and (inches) 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 6.0 (0.24) IP 20/Open Type – Frame E Dimensions are in millimeters and (inches) 185.0 (7.28) 279.0 (10.98) 160.0 (6.30) 7.6 (0.30) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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 using IMPORTANT the Control Module Fan Kit with drive frames A, B, and C. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 189 196.0 (7.72) 185.0 (7.28) 130.0 (5.12) 160.0 (6.30) 116.0 (4.57) Remove the label to access the built-in 24V supply on drive frames D and E for use with the IMPORTANT Control Module Fan Kit. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
Page 197 EMC Line Filter – Frame E Dimensions are in millimeters and (inches) 80.0 (3.15) 155.0 (6.10) 33.0 (1.30) 28.0 (1.10) 110.0 (4.33) ø5.5 (ø0.22) 390.0 (15.35) 375.0 375.0 (14.76) (14.76) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22) 110.0 (4.33) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 198: 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-UM001I-EN-E - July 2016...
Page 199 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-UM001I-EN-E - July 2016...
Page 200 Appendix B Accessories and Dimensions Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 201: 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 202: Parameter Configuration
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 203: Supported Modbus Function Codes
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-UM001I-EN-E - July 2016...
Page 204 011 = Freq. Source = P051 [Speed Reference3] 100 = A410 [Preset Freq 0] 101 = A411 [Preset Freq 1] 110 = A412 [Preset Freq 2] 111 = A413 [Preset Freq 3] 1 = MOP Decrement, 0 = Not Decrement Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 205: Writing (06) Comm Frequency Command
Function Code 03 reads to register address 2100H (Logic Data Status). PowerFlex 523 drives support only Velocity bit definitions. PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either Velocity or Position bit definitions. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 206 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-UM001I-EN-E - July 2016...
Page 207: Reading (03) Drive Error Codes
Embedded EtherNet/IP Adapter Communication Loss Encoder Loss Function Loss Parameter Checksum Error External Storage 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 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 208: Reading (03) Drive Operational Values
For example, a decimal “1” is used to address Parameter b001 [Output (06) Drive Parameters Freq] and decimal “41” is used to address Parameter P041 [Accel Time 1]. Additional Information http://www.ab.com/drives/ for additional information. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 209 The counter can be reset with a digital input programmed as “Reset Counter”. Use the Wizard in Connected Components Workbench to simplify setup instead of manually configuring the parameters. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 210: Velocity Steplogic Using Timed Steps
• Transition to Step 1 when Logic In 1 is true. Logic senses the edge of Logic In 1 when it transitions from off to on. Logic In 1 is not required to remain “on”. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 211: Timer Function
Example • Drive starts up and accelerates to 30 Hz. • After 30 Hz has been maintained for 20 seconds, a 4-20 mA analog input becomes the reference signal for speed control. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 212: Counter Function
– t065 [DigIn TermBlk 05] = 20 “Counter In” – t066 [DigIn TermBlk 06] = 22 “Reset Countr” – t076 [Relay Out1 Sel] = 26 “Counter Out” – t077 [Relay Out1 Level] = 5.0 Counts Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 213: Velocity Steplogic Parameters
Jump to Step 3 Jump to Step 4 Jump to Step 5 Jump to Step 6 Jump to Step 7 End Program (Normal Stop) End Program (Coast to Stop) End Program and Fault (F002) Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 214 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-UM001I-EN-E - July 2016...
Page 215: Encoder And Pulse Train Usage
It does not provide speed bandwidth improvement. The encoder usage, and position StepLogic application covered in this chapter IMPORTANT is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 216: Wiring Notes
24V inputs. The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary. If a single-channel input is used, it must be wired between the A (signal) and A- (signal common) channels. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 217: Speed Resolution
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 Therefore, using a 1024 PPR quadrature encoder will give a speed resolution of 0.49 Hz. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 218: Positioning Overview
[Torque Perf Mode] default setting is 1 “SVC”. However, any mode can be used to improve the low speed torque for positioning applications. For best results, tune the application first. The autotune routine can be completed to further improve the drive-motor performance. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 219 This will determine how close the drive must be to the commanded position before the drive will indicate “At Home” or “At Position” in units of raw encoder pulses. This has no effect on the actual positioning control of the motor. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 220: Positioning Operation
This only affects the initial step. After start, the drive will move through the steps in the same manner as if setting 2 was selected. This allows a process to be stopped and then restarted at the position where it stopped. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 221 Step Logic. Each of the 4 digits controls one aspect of the each position step. The following is a listing of the available settings for each digit: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 222 Note: Incremental move commands will cause the drive to move the amount specified based on the current position. Absolute commands are always with reference to “Home”. A565 [Pos Reg Filter] provides a low pass filter at the input of the position regulator. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 223: Homing Routine
A563 [Find Home Dir] sets the direction the drive will use while it is moving to the home position during the automatic homing routine. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 224: Encoder And Position Feedback
Bit 2 “At Home” indicates whether the drive is at Home. If the drive is within A564 [Encoder Pos Tol] of “Home”, this bit will be active. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 225: Use Over Communications
When this bit is deactivated the drive will accelerate to the new commanded frequency based on A571 [Sync Time]. Bit 5 “Traverse Dis” disables the traverse function when this bit is active. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 226: Setup Notes
Setup Notes The RA computer tool (Connected Components Workbench) can make setup of the positioning functions much easier. Refer to the latest versions for additional tools or wizards which can aid in the setup. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 227: Pid Loop
Fluctuations in actual system pressure, due to changes in flow, result in a PID Error value. • The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 228 • In a winder application, the PID Reference equals the Equilibrium set point. • The Dancer Pot signal provides PID Feedback to the drive. Fluctuations in tension result in a PID Error value. • The Master Speed Reference sets the wind/unwind speed. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 229: Pid Reference And Feedback
Encoder will be used as an input for the PID Reference. 13 “Ethernet/IP” The reference word from the Ethernet/IP communication network becomes the PID Reference. (1) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 230: Analog Pid Reference Signals
For a 4-20 mA signal, the following parameter settings are used so that a 20 mA signal = 0% PID Reference and a 4 mA signal = 100% PID Reference. • t095 [Anlg In4-20mA Lo] = 100.0% • t096 [Anlg In4-20mA Hi] = 0.0% Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 231 PID output and are only used in trim mode. [PID x Trim Hi] sets the maximum frequency for the PID output in trim mode. [PID x Trim Lo] sets the reverse frequency limit for the PID output in trim mode. Note that when the Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 232 233), decrease A461 or A473 [PID x Prop Gain]. – Typically, A461 or A473 [PID x Prop Gain] is set to some value below the point where the PID begins to go unstable. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 233 PID Gains. Unstable Response PID Reference PID Feedback Time Slow Response – Over Damped PID Reference PID Feedback Time Oscillation – Under Damped PID Reference PID Feedback Time Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 234 Appendix F PID Set Up Good Response – Critically Damped PID Reference PID Feedback Time Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 235: Powerflex 525 Safe-Torque-Off Overview
EN 62061, IEC 61508, and EN 61800-5-2. The function is suitable for performing mechanical work on the drive system or IMPORTANT affected area of a machine only. It does not provide electrical safety. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 236: Ec Type Examination Certification
Before use, a risk assessment should be Torque-Off performed that compares the PowerFlex 525 Safe-Torque-Off function specifications and all foreseeable operational and environmental characteristics of the machine to which it is to be fitted. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 237: Safety Concept
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 238 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-UM001I-EN-E - July 2016...
Page 239: Enabling Powerflex 525 Safe-Torque-Off
When used in combination Off Operation with a safety input device, the system satisfies the requirements of EN ISO 13849 and EN62061 for safe-torque-off and helps protect against restart. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 240: Verify 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-UM001I-EN-E - July 2016...
Page 241: 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-UM001I-EN-E - July 2016...
Page 242 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-UM001I-EN-E - July 2016...
Page 243 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-UM001I-EN-E - July 2016...
Page 244 Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock-out of the system at the next operation and will not cause loss of the safety function. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 245: Powerflex 525 Certification For Safe-Torque-Off
Safe-Torque-Off Function Appendix G PowerFlex 525 Certification Certification information can be viewed at http://www.rockwellautomation.com/global/certification/ for Safe-Torque-Off Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 246 Appendix G Safe-Torque-Off Function Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 247: Establishing A Connection With Ethernet/Ip
If you are setting your network addresses manually using parameters, you IMPORTANT must set the appropriate drive or 25-COMM-E2P adapter parameter value to 1 “Parameters”. See the respective EtherNet/IP adapter user manual for more information. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 248: Ground Connections For Ethernet/Ip Networks
PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter Terminal Description CS1/CS2 Provides a clean ground for the communication bus cable shields. CS1 or CS2 should be connected to a clean ground or PE ground on the drive. Terminals CS1/CS2 Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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-UM001I-EN-E - July 2016...
Page 250: Adjusting Speed Control Parameters
Set Speed Controller Gain Set Speed Controller Gain automatically manually: A521 [Freq 1 Kp] A522 [Freq 1 Ki] A523 [Freq 2 Kp] A524 [Freq 2 Ki] A525 [Freq 3 Kp] A526 [Freq 3 Ki] Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
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: Download Files
Appendix J PowerFlex 525 PM Motor Configuration 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 http://www.rockwellautomation.com/rockwellautomation/support/ pcdc.page You must sign in to the Rockwell Automation website before IMPORTANT downloading a firmware revision.
Page 253 6. Go back to step 2 and enter “AB Drives” into the Product Search field. The results appear in the box below. 7. Select both entries, then click Downloads. 8. Click the Show Downloads icon, then click the links to download the database files to your computer. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 254: Automatic Configuration Using Drive Startup Wizard
Manual Configuration Using Drive Keypad on page 261. 1. From Connected Components Workbench software, click the Wizard Browser icon. 2. In the Available Wizards dialog box, click on PowerFlex 525 Startup Wizard, then click Select. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 255 Follow the Startup Wizard steps exactly. If not, unexpected results can IMPORTANT occur. 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”. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 256 • PowerFlex 525 drive only supports incremental AB encoder (25-ENC-1). • Motor Feedback Type can be “Quadrature” or “Quad Check”. • Only Interior Permanent magnet motor (iPM) is supported for closed loop control. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 257 PowerFlex 525 PM Motor Configuration Appendix J Stop Mode/Brake Type Key in the details of your configuration. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 258 If the drive was never operated before (new installation), verify that safeguards IMPORTANT are in place to remove power safely from the drive during an unstable situation where the drive can produce undesired motion. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 259 Conversely, an improperly performed Auto Tune can cause the motor to exhibit instability at low speeds, uneven performances when running through the motor speed range, and can generate unnecessary faults such as overcurrent and overvoltage faults. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 260 For a closed loop system (A535 [Motor Fdbk Type] = 4 “Quadrature” or 5 “Quad Check”, you must perform an angle alignment after the Auto Tune test before running the motor normally. Additional PM Motor Configuration on page 262 for instructions. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 261: Manual Configuration Using Drive Keypad
After completing the configuration and running the Auto Tune test, you may need to perform additional configuration depending on whether you have an open loop or closed loop system. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 262: 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-UM001I-EN-E - July 2016...
Page 263 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-UM001I-EN-E - July 2016...
Page 264 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-UM001I-EN-E - July 2016...
Page 265 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-UM001I-EN-E - July 2016...
Page 266: Optional Parameter Adjustments For Optimum Performance
Increase 50 of A580 [Current Loop BW] for each trial when PM speed response is slow after adding load. Decrease 50 of A580 [Current Loop BW] for each trial when speed instability is observed after adding load. Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 267 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-UM001I-EN-E - July 2016...
Page 268 Appendix J PowerFlex 525 PM Motor Configuration Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 269 2-wire derating 3-wire factor circuit breakers temperature power digital inputs selecting start source dimensions logic mounting basic disconnect timed steps Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 270 Ethernet stop homing motor parameters storage environment positioning pulse train Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 271 Index temperature voltage reflections derating wiring wiring testing safety timer wave protection programming reflected tools wiring programming encoder noise immunity recommended RS485 (DSI) safety unshielded shielded wiring temperature unshielded voltage reflections writing Modbus Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 272 Index Notes: Rockwell Automation Publication 520-UM001I-EN-E - July 2016...
Page 274 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...

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