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PowerFlex 520-Series Adjustable Frequency AC Drive

PowerFlex 523 Catalog Number 25A

PowerFlex 525 Catalog Number 25B

User Manual

Original Instructions

Summary of content (244 pages)

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User Manual PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B Original Instructions
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Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
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Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision.
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Summary of Changes Notes: 4 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Table of Contents Preface Overview Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Precautions . . . . . . . . . . .
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Table of Contents Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameter Cross Reference by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . .
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Table of Contents Notes: 8 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex® 520-Series Adjustable Frequency AC Drive. For information on… Who Should Use this Manual Recommended Documentation Manual Conventions Drive Frame Sizes General Precautions Catalog Number Explanation See page… 9 9 10 11 12 13 Who Should Use this Manual This manual is intended for qualified personnel.
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Preface Overview The following publications provide specific Network Communications information: Title PowerFlex 525 Embedded EtherNet/IP Adapter PowerFlex 25-COMM-D DeviceNet Adapter PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter Manual Conventions Publication 520COM-UM001 520COM-UM002 520COM-UM003 520COM-UM004 • In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC Drive as; drive, PowerFlex 520-series, PowerFlex 520-series drive or Pow
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Overview Preface • The Studio 5000® Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Studio 5000 Logix Designer™ application is the rebranding of RSLogix™ 5000 software and will continue to be the product to program Logix 5000 controllers for discrete, process, batch, motion, safety, and drive-based solutions.
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Preface Overview General Precautions ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels.
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Overview Preface Catalog Number Explanation 1-3 4 5 6-8 9 10 11 12 13 14 25B – B 2P3 N 1 1 4 – – Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash Code 25A 25B Type PowerFlex 523 PowerFlex 525 Code V A B D E Code 0 1 Voltage 120V AC 240V AC 240V AC 480V AC 600V AC Phase 1 1 3 3 3 Code 1 Code N EMC Filter No Filter Filter Code 4 Braking Standard Interface Module Standard Enclosure IP20 NEMA / Open Output Current @ 1 Phase, 100...
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Preface Overview Notes: 14 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Chapter 1 Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 520series drives. For information on... Mounting Considerations AC Supply Source Considerations General Grounding Requirements Fuses and Circuit Breakers Power and Control Module Control Module Cover Power Module Terminal Guard Power Wiring Power Terminal Block Common Bus/Precharge Notes I/O Wiring Control I/O Terminal Block Start and Speed Reference Control CE Conformity See page...
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Chapter 1 Installation/Wiring • Do not expose to a corrosive atmosphere. • Protect from moisture and direct sunlight. Minimum Mounting Clearances See Appendix B for mounting dimensions. Vertical Vertical, Zero Stacking No clearance between drives. 50 mm (2.0 in.) Esc Sel 50 mm (2.0 in.) 25 mm (1.0 in.) Esc Vertical with Control Module Fan Kit Esc Sel 50 mm (2.0 in.) 50 mm (2.0 in.)(1) Esc Sel Esc Sel Esc 25 mm (1.0 in.) 50 mm (2.0 in.)(1) Sel (2) Esc Sel Esc Sel 25 mm (1.0 in.
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Installation/Wiring Chapter 1 Ambient Operating Temperatures See Appendix B for option kits.
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Chapter 1 Installation/Wiring Derating Guidelines for High Altitude The drive can be used without derating at a maximum altitude of 1000 m (3300 ft). If the drive is used above 1000 m (3300 ft): • Derate the maximum ambient temperature by 5 °C (9 °F) for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage) table below.
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Installation/Wiring AC Supply Source Considerations Chapter 1 Ungrounded Distribution Systems ATTENTION: PowerFlex 520-series drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.
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Chapter 1 Installation/Wiring Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see page 157). Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life. If any of these conditions exist, install one of the devices listed under the heading Corrective Action on the line side of the drive. IMPORTANT Only one device per branch circuit is required.
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Installation/Wiring Chapter 1 Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Safety Ground - (PE) This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.
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Chapter 1 Installation/Wiring Fuses and Circuit Breakers The PowerFlex 520-series drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. The tables found on pages 23...26 provide recommended AC line input fuse and circuit breaker information.
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Rockwell Automation Publication 520-UM001G-EN-E - September 2014 (1) (2) (3) (4) 0.2 0.2 0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2 0.25 0.25 0.5 0.5 1.0 1.0 2.0 2.0 3.0 3.0 0.2 0.2 0.4 0.4 0.75 0.75 1.5 1.5 2.2 2.2 kW 0.2 0.4 0.75 1.1 kW 0.8 1.3 2.5 3.2 A A B B 100-C09 100-C12 100-C23 100-C23 10 16 25 32 16 20 40 50 140U-D6D2-B80 140U-D6D2-C12 140U-D6D2-C25 140U-D6D2-C30 140M-C2E-B63 140M-C2E-C10 140M-D8E-C20 140M-F8E-C25 Fuses (Rating) Circuit Breakers Min. Max. 140U/140G 140M 1.6 1.6 2.5 2.5 4.8 4.
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(1) (2) (3) (4) (5) (6) – 25B-B2P5N104 25B-B5P0N104 25B-B8P0N104 25B-B011N104 25B-B017N104 25B-B024N104 25B-B032N104 25B-B048N104 25B-B062N104 25A-B1P6N104 25A-B2P5N104 25A-B5P0N104 25A-B8P0N104 25A-B011N104 25A-B017N104 25A-B024N104 25A-B032N104 25A-B048N104 25A-B062N104 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 10.0 15.0 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 7.5 11.0 kW 1.6 2.5 5.0 8.0 11.0 17.5 24.0 32.2 48.3 62.1 0.9 1.2 2.7 4.3 6.3 9.6 12.2 15.9 20.1 25.
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Rockwell Automation Publication 520-UM001G-EN-E - September 2014 (1) (2) (3) (4) (5) (6) 25B-D1P4N104 25B-D1P4N114 25B-D2P3N104 25B-D2P3N114 25B-D4P0N104 25B-D4P0N114 25B-D6P0N104 25B-D6P0N114 25B-D010N104 25B-D010N114 25B-D013N104 25B-D013N114 25B-D017N104 25B-D017N114 25B-D024N104 25B-D024N114 25B-D030N104 25B-D030N114 25B-D037N114 25B-D043N114 25A-D1P4N104 25A-D1P4N114 25A-D2P3N104 25A-D2P3N114 25A-D4P0N104 25A-D4P0N114 25A-D6P0N104 25A-D6P0N114 25A-D010N104 25A-D010N114 25A-D013N104 25A-D013N114 25A-
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(1) (2) (3) (4) (5) (6) (7) 25B-E0P9N104 25B-E1P7N104 25B-E3P0N104 25B-E4P2N104 25B-E6P6N104 25B-E9P9N104 25B-E012N104 25B-E019N104 25B-E022N104 25B-E027N104 25B-E032N104 25A-E0P9N104 25A-E1P7N104 25A-E3P0N104 25A-E4P2N104 25A-E6P6N104 25A-E9P9N104 25A-E012N104 25A-E019N104 25A-E022N104 25A-E027N104 25A-E032N104 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 15.0 20.0 25.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 11.0 15.0 18.5 kW 0.9 1.7 3.0 4.2 6.6 9.9 12.0 19.0 22.0 27.
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Installation/Wiring Power and Control Module Chapter 1 PowerFlex 520-series drives consist of a Power Module and Control Module. Separating the Power and Control Module ATTENTION: Perform this action only when drive is NOT powered. 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.
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Chapter 1 Installation/Wiring 3. Hold the sides and top of the Control Module firmly, then pull out to separate it from the Power Module. Connecting the Power and Control Module 1. Align the connectors on the Power Module and Control Module, then push the Control Module firmly onto the Power Module.
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Installation/Wiring Chapter 1 2. Push the top cover of the Control Module towards the Power Module to lock it. 3. Insert the catch at the 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).
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Chapter 1 Installation/Wiring 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. 2. Slide the front cover down to remove from the Control Module. 1 2 Re-attach the front cover when wiring is complete. Power Module Terminal Guard 30 To access the power terminals, the terminal guard must be removed. To remove: 1.
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Installation/Wiring Chapter 1 2. Press and hold down the locking tab on the terminal guard. 3. Slide the terminal guard down to remove from the Power Module. Re-attach the terminal guard when wiring is complete. To access the power terminals for Frame A, you need to separate the Power and Control Modules. See Separating the Power and Control Module on page 27 for instructions. Power Wiring ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.
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Chapter 1 Installation/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. Use copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge when using higher temperature wire.
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Installation/Wiring Chapter 1 Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance.
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Chapter 1 Installation/Wiring Power Terminal Block Power Terminal Block Frame A, B, C & D Frame E R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 DC- DC- DC+ BRBR+ Terminal R/L1, S/L2 R/L1, S/L2, T/L3 U/T1, V/T2, W/T3 Description 1-Phase Input Line Voltage Connection 3-Phase Input Line Voltage Connection Motor Phase Connection = DC+, DCBR+, BR- DC Bus Connection (except for 110V 1-Phase) Dynamic Brake Resistor Connection Safety Ground - PE IMPORTANT DC+ BR+ BR- Switch any two
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Installation/Wiring Chapter 1 Common Bus/Precharge Notes If drives are used with a disconnect switch to the common DC bus, then an auxiliary contact on the disconnect must be connected to a digital input of the drive. The corresponding input (parameter t062, t063, t065...t068 [DigIn TermBlk xx]) must be set to 30, “Precharge En” This provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus.
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Chapter 1 Installation/Wiring Recommended Signal Wire Belden Wire Type(s)(1) Description (or equivalent) 8760/9460 0.750 mm2 (18 AWG), twisted pair, 100% shield with drain(2) Remote Pot 8770 0.750 mm2 (18 AWG), 3 conductor, shielded Encoder/Pulse I/O 9728/9730 0.196 mm2 (24 AWG), individually shielded pairs Signal Type/ Where Used Analog I/O & PTC Min. Insulation Rating 300V, 60 °C (140 °F) (1) Stranded or solid wire.
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Installation/Wiring Chapter 1 PowerFlex 523 Control I/O Terminal Block PowerFlex 523 Control I/O Wiring Block Diagram 01 02 03 SNK SRC 04 05 06 +24V Relay N.O. Relay Common Relay N.C. 11 R1 +10V R2 12 13 R3 14 15 C1 C2 Digital In DigIn TermBlk 05 Sel J8 SNK SRC R2 R1 R3 01 11 02 12 J7 Pulse In Typical SRC wiring Typical SNK wiring Digital Common DigIn TermBlk 05/Pulse DigIn TermBlk 06 +24V DC +10V DC 0-10V Input Analog Common Pot must be 1...10 k ohm 2 W min.
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Chapter 1 Installation/Wiring Start Method t062, t063 [DigIn TermBlk xx] 48 “2-Wire FWD” 49 “3-Wire Start” 50 “2-Wire REV” 51 “3-Wire Dir” IMPORTANT Stop Method I/O Terminal 01 Stop t064 [2-Wire Mode] is set to: • 0, 1, or 2 = Coast • 3 = per P045 [Stop Mode] Per P045 [Stop Mode] t064 [2-Wire Mode] is set to: • 0, 1, or 2 = Coast • 3 = per P045 [Stop Mode] Per P045 [Stop Mode] Normal Stop Per P045 [Stop Mode] The drive is shipped with a jumper installed between I/O Terminals 01 and 11.
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Installation/Wiring Chapter 1 Control I/O Terminal Designations No. Signal 15 4-20mA In(1) Default Not Active C1 C1 – C2 C2 – Description For external 4-20 mA input supply. Input impedance = 250 Ω Parameter P047, P049, t062, t063, t065, t066, A459, A471 This terminal is tied to the RJ-45 port shield. Tie this terminal to – a clean ground in order to improve noise immunity when using external communication peripherals. This is the signal common for the communication signals.
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Chapter 1 Installation/Wiring Control I/O Wiring Block Diagram Notes (1) See Digital Input Selection for Start Source on page 47 for more information on configuring the digital inputs. IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is determined by the drive setting. See the tables below for more information.
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Installation/Wiring Chapter 1 Control I/O Terminal Designations No. Signal Default 06 DigIn TermBlk 06 Preset Freq Description Program with t066 [DigIn TermBlk 06]. Current consumption is 6 mA. 07 DigIn TermBlk 07/ Start Source 2 Program with t067 [DigIn TermBlk 07]. Also functions as a Pulse Pulse In + Speed Train input for reference or speed feedback. The maximum Reference2 frequency is 100 kHz. Current consumption is 6 mA. 08 DigIn TermBlk 08 Jog Forward Program with t068 [DigIn TermBlk 08].
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Chapter 1 Installation/Wiring I/O Wiring Examples I/O Potentiometer 1...10k Ω Pot.
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Installation/Wiring I/O Connection Example 2 Wire SRC Control Internal Supply (SRC) Non-Reversing 11 P046 [Start Source 1] = 2 and t062 [DigIn TermBlk 02] = 48 Stop-Run Input must be active for the drive to run. When input is opened, the drive will stop as specified by P045 [Stop Mode]. If desired, a User Supplied 24V DC power source can be used. Refer to the “External Supply (SRC)” example.
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Chapter 1 Installation/Wiring I/O 3 Wire SNK Control Non-Reversing Connection Example Internal Supply (SNK) Stop 01 02 Start 04 Internal Supply (SRC) 3 Wire SRC Control Reversing 11 P046 [Start Source 1] = 2, t062 [DigIn TermBlk 02] Stop = 49 and t063 [DigIn TermBlk 03] = 51 Start A momentary input will start the drive. A stop Direction input to I/O Terminal 01 will stop the drive as specified by P045 [Stop Mode]. I/O Terminal 03 determines direction.
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Installation/Wiring Chapter 1 Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input 02 04 Connections Customer Inputs can be wired per External Supply (SRC). Customer Inputs 02 04 02 04 Optional Ground Connection When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives.
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Chapter 1 Installation/Wiring Start and Speed Reference Control Start Source and Speed Reference Selection The start and drive speed command can be obtained from a number of different sources. By default, start source is determined by P046 [Start Source 1] and drive speed source is determined by P047 [Speed Reference1]. However, various inputs can override this selection, See below for the override priority. Purge Input Enabled Yes AND Active Drive will start and run at Purge Speed.
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Installation/Wiring Chapter 1 Digital Input Selection for Start Source If P046, P048 or P050 [Start Source x] has been set to 2, “DigIn TermBlk”, then t062 and t063 [DigIn TermBlk xx] must be configured for 2-Wire or 3-Wire control for the drive to function properly. [Start Source x] [Start Source x] = 2 (DigIn TrmBlk) No Start and Direction command from [Start Source x]. Yes [DigIn TermBlk 02/03] = 48/49/50/51 (2-Wire or 3-Wire) Yes Start and Direction command from Terminal Block.
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Chapter 1 Installation/Wiring Accel/Decel Selection The Accel/Decel rate can be obtained by a variety of methods. The default rate is determined by P041 [Accel Time 1] and P042 [Decel Time 1]. Alternative Accel/Decel rates can be made through digital inputs, communications and/or parameters. See below for the override priority. Purge Input Enabled AND Active Yes Accel/Decel always Accel/Decel 1.
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Installation/Wiring CE Conformity Chapter 1 Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex 520-series drives comply with the EN standards listed below when installed according to the installation instructions in this manual. CE Declarations of Conformity are available online at: http://www.rockwellautomation.
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Chapter 1 Installation/Wiring • PowerFlex 520-series drives comply with the EMC requirements of EN 61800-3 when installed according to good EMC practices and the instructions provided in this document. However, many factors can influence the EMC compliance of an entire machine or installation, and compliance of the drive itself does not ensure compliance of all applications. • PowerFlex 520-series drives are not intended to be used on public lowvoltage networks which supply domestic premises.
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Installation/Wiring Chapter 1 • PowerFlex 520-series drives produce leakage current in the protective earthing conductor which exceeds 3.5 mA AC and/or 10 mA DC. The minimum size of the protective earthing (grounding) conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment.
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Chapter 1 Installation/Wiring • Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520-Series RF Emission Compliance and Installation Requirements on page 52 for compliance with radio frequency emission limits for the specific standard and installation environment.
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Installation/Wiring Chapter 1 Additional Installation Requirements Frame Size Class C1 Enclosure Class C2 Conduit or Shielded EMC Cores Required Enclosure Cable @ Input (Included with product) 100...120V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...120V 1-Phase Output A No No No No B No No No No 200...240V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...230V 3-Phase Output A Yes Yes No No B Yes Yes Output only No 200...
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Chapter 1 Installation/Wiring Recommended Placement of EMC Cores Frame A Frame B With optional EMC plate (25-EMC-Fx) Frame C Frame D Frame E Ground cable CORE-E-1 CORE-xx-B-1 CORE-xx-A-1 CORE-xx-A-2 CORE-xx-B-2 CORE-E-3 CORE-xx-D-1 CORE-xx-C-1 CORE-E-2 CORE-xx-D-2 CORE-xx-C-2 CORE-E-4 Without EMC plate Ground cable CORE-E-1 CORE-E-3 CORE-E-4 CORE-xx-x-1 CORE-E-2 CORE-xx-x-2 Input cable to drive (Shielded or Unshielded) Output cable from drive (Shielded) Secure EMC core by using cable/z
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Chapter 2 Start Up This chapter describes how to start up the PowerFlex 520-series drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group. For information on... Prepare for Drive Start-Up Display and Control Keys Viewing and Editing Parameters Drive Programming Tools Smart Start-Up with Basic Program Group Parameters LCD Display with QuickView Using the USB Port IMPORTANT See page...
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Chapter 2 Start Up 6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your control wiring scheme. See the PowerFlex 523 Control I/O Wiring Block Diagram on page 37 and PowerFlex 525 Control I/O Wiring Block Diagram on page 39 for location. IMPORTANT The default control scheme is Source (SRC). The Stop terminal is jumpered to allow starting from the keypad or comms.
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Start Up Chapter 2 16. Verify the drive and motor perform as specified. • Verify that the Stop input is present or the drive will not start. IMPORTANT If I/O Terminal 01 is used as a stop input, the jumper between I/O Terminals 01 and 11 must be removed. • Verify the drive is receiving the speed reference from the correct place and that the reference is scaled correctly. • Verify the drive is receiving start and stop commands correctly. • Verify input currents are balanced.
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Chapter 2 Start Up Display and Control Keys PowerFlex 523 Menu FWD Esc Sel PowerFlex 525 FWD ENET LINK EtherNet/IP Esc Sel Parameter Group and Description Basic Display Commonly viewed drive operating conditions. Basic Program Commonly used programmable functions. Terminal Blocks Programmable terminal functions. Communications Programmable communication functions. Logic (PowerFlex 525 only) Programmable logic functions. Advanced Display Advanced drive operating conditions.
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Start Up Key Viewing and Editing Parameters Chapter 2 Name Reverse Description Used to reverse direction of the drive. Default is active. Controlled by parameters P046, P048 and P050 [Start Source x] and A544 [Reverse Disable]. Start Used to start the drive. Default is active. Controlled by parameters P046, P048 and P050 [Start Source x]. Stop Used to stop the drive or clear a fault. This key is always active. Controlled by parameter P045 [Stop Mode]. Potentiometer Used to control speed of drive.
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Chapter 2 Start Up Step Key(s) 10. If desired, press Sel to move from digit to digit or bit to bit. The digit or bit that you can change Sel will flash. 11. Press Esc to cancel a change and exit Program Mode. Or Press Enter to save a change and exit Program Mode. The digit will stop flashing and the word Program on the LCD display will turn off. 12. Press Esc to return to the parameter list. Continue to press Esc to back out of the programming menu.
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Start Up Language Keypad/LCD Display Polish(1) Turkish(1) Czech(1) Y Y Y RSLogix 5000/ Logix Designer – – – Chapter 2 Connected Components Workbench – – – (1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified. Smart Start-Up with Basic Program Group Parameters The PowerFlex 520-series drive is designed so that start up is simple and efficient. The Basic Program Group contains the most commonly used parameters.
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Chapter 2 Start Up PF 525 No. P040 P041 P042 P043 = Stop drive before changing this parameter. = Parameter is specific to PowerFlex 525 drives only. Parameter Min/Max [Autotune] 0/2 Enables a static (not spinning) or dynamic (motor spinning) autotune. [Accel Time 1] 0.00/600.00 s Sets the time for the drive to accel from 0 Hz to [Maximum Freq]. [Decel Time 1] 0.00/600.00 s Sets the time for the drive to decel from [Maximum Freq] to 0 Hz. [Minimum Freq] 0.00/500.
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Start Up LCD Display with QuickView Chapter 2 QuickView™ enables text to scroll across the LCD display of the PowerFlex 520series drive. This allows you to easily configure parameters, troubleshoot faults and view diagnostic items without using a separate device. Use parameter A556 [Text Scroll] to set the speed at which the text scrolls across the display. Select 0 “Off ” to turn off text scrolling. See Language Support on page 60 for the languages supported by the PowerFlex 520-series drive.
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Chapter 2 Start Up Double-click on the PF52XUSB.EXE file to launch the USB utility application. The main menu is displayed. Follow the program instructions to upgrade the firmware or upload/download configuration data. IMPORTANT Make sure your PC is powered by an AC power outlet or has a fully charged battery before starting any operation. This prevents the operation from terminating before completion due to insufficient power. Limitation in Downloading .
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Chapter 3 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 520series drive parameters. Parameters are programmed (viewed/edited) using either the drive’s built-in keypad, RSLogix 5000 version 17.0 or greater, Logix Designer version 21.0 or greater, or Connected Components Workbench version 5.0 or greater software.
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Chapter 3 Programming and Parameters • Bit Parameters Bit parameters have five individual digits associated with features or conditions. If the digit is 0, the feature is off or the condition is false. If the digit is 1, the feature is on or the condition is true. Some parameters are marked as follows. = Stop drive before changing this parameter. = 32 bit parameter.
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Programming and Parameters Logic(1) Stp Logic 0 Stp Logic 1 Advanced Display L180 L181 Analog In 0-10V Analog In 4-20mA Advanced Program d360 d361 Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Preset Freq 8(1) Preset Freq 9(1) Preset Freq 10(1) Preset Freq 11(1) Preset Freq 12(1) Preset Freq 13(1) Preset Freq 14(1) Preset Freq 15(1) Keypad Freq MOP Freq MOP Reset Sel MOP Preload MOP Time Jog Frequency Jog Accel/Decel Purge Frequency DC
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Chapter 3 Programming and Parameters Fault and Diagnostic Fault 4 Code Fault 5 Code Fault 6 Code Fault 7 Code Fault 8 Code Fault 9 Code Fault10 Code Fault 1 Time-hr Fault 2 Time-hr Fault 3 Time-hr Fault 4 Time-hr Fault 5 Time-hr Fault 6 Time-hr(1) Fault 7 Time-hr(1) Fault 8 Time-hr(1) Fault 9 Time-hr(1) Fault10 Time-hr(1) Fault 1 Time-min Fault 2 Time-min Fault 3 Time-min Fault 4 Time-min F604 F605 F606 F607 F608 F609 F610 F611 F612 F613 F614 F615 F616 F617 F618 F619 F620 F621 F622 F623 F624 Fault 5 Ti
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Programming and Parameters Centrifugal Pump Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Blower/Fan P030 b001 b002 P031 P032 Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Extruder P030 b001 b002 P031 P032 Language Output Freq Commanded Freq Output Current Motor NP Volts Positioning(1) P030 b001 b002 b003 P031 Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimu
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Chapter 3 Programming and Parameters CustomView Parameter Group PowerFlex 520-series drives include a CustomView™ parameter group for you to store frequently used parameters for your application. See CustomView Parameter Group on page 139 for more information. Custom Group This group can store up to 100 parameters.
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Programming and Parameters Chapter 3 Basic Display Group b001 [Output Freq] Related Parameter(s): b002, b010, P043, P044, P048, P050, P052 Output frequency present at T1, T2 & T3 (U, V & W). Does not include slip frequency. Values Default: Read Only Min/Max: 0.00/[Maximum Freq] Display: 0.01 Hz b002 [Commanded Freq] Related Parameter(s): b001, b013, P043, P044, P048, P050, P052 Value of the active frequency command even if the drive is not running.
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Chapter 3 Programming and Parameters Basic Display Group (continued) b007 [Fault 1 Code] b008 [Fault 2 Code] b009 [Fault 3 Code] Related Parameter(s): F604-F610 A code that represents a drive fault. Codes appear in these parameters in the order they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults are only recorded once. See Fault and Diagnostic Group for more information.
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Programming and Parameters Chapter 3 Basic Display Group (continued) b013 [Contrl In Status] Related Parameter(s): b002, P044, P045 State of the digital terminal blocks 1...3 and DB transistor. IMPORTANT Actual control commands may come from a source other than the control terminal block. DigIn TBlk 1 DigIn TBlk 2 DigIn TBlk 3 DB Trans On(1) Not Used (1) 1 = Closed State, 0 = Open State Digit 1 Digit 2 Digit 3 Digit 4 The DB Transistor “on” indication must have a 0.5 s hysteresis.
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Chapter 3 Programming and Parameters Basic Display Group (continued) b018 [Power Saved] Related Parameter(s): b017 Instantaneous power savings of using this drive compared to an across the line starter. Values Default: Read Only Min/Max: 0.00/655.35 kW Display: 0.01 kW b019 [Elapsed Run time] Related Parameter(s): A555 Accumulated time drive is outputting power. Time is displayed in 10 hour increments.
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Programming and Parameters Chapter 3 Basic Display Group (continued) b025 [Accum Cost Sav] Related Parameter(s): b024, P052, A555 Total approximate accumulated cost savings of the drive compared to using an across the line starter. [Accum Cost Sav] = [Average kWh cost] x [Accum kWh Sav] Values Default: Read Only Min/Max: 0.0/6553.5 Display: 0.1 b026 [Accum CO2 Sav] Related Parameter(s): A555 Total approximate accumulated CO2 savings of the drive compared to using an across the line starter.
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Chapter 3 Programming and Parameters Basic Program Group P030 [Language] Language Support Selects the language displayed. A reset or power cycle is required after selection is made.
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Programming and Parameters Chapter 3 Basic Program Group (continued) P034 [Motor NP FLA] Related Parameter(s): P040 Sets the motor nameplate FLA. Used to assist the Autotune routine and motor control. Values Default: Based on Drive Rating Min/Max: 0.1/(Drive Rated Amps x 2) Display: 0.1 A P035 [Motor NP Poles] Related Parameter(s): b015 Sets the number of poles in the motor. Values Default: 4 Min/Max: 2/40 Display: 1 P036 [Motor NP RPM] Stop drive before changing this parameter.
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Chapter 3 Programming and Parameters Basic Program Group (continued) P040 [Autotune] Related Parameter(s): P034, P039, A496, A497 Stop drive before changing this parameter. Enables a static (not spinning) or dynamic (motor spinning) autotune to automatically set the motor parameters. Start must be pressed to begin the routine. After the routine is complete the parameter resets to a zero. A failure (such as if a motor is not connected) results in an Autotune Fault.
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Programming and Parameters Chapter 3 Basic Program Group (continued) P043 [Minimum Freq] Related Parameter(s): b001, b002, b013, P044, A530, A531 Stop drive before changing this parameter. Sets the lowest frequency the drive outputs. Values Default: 0.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz P044 [Maximum Freq] Related Parameter(s): b001, b002, b013, b016, P043, A530, A531 Stop drive before changing this parameter. Sets the highest frequency the drive outputs.
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Chapter 3 Programming and Parameters Basic Program Group (continued) P046 [Start Source 1] P048 [Start Source 2] P050 [Start Source 3] Related Parameter(s): b012, t064, C125 Stop drive before changing this parameter. Configures the start source of the drive. Changes to these inputs take effect as soon as they are entered. P046 [Start Source 1] is the factory default start source unless overridden. See Start and Speed Reference Control on page 46 for more information.
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Programming and Parameters Chapter 3 Basic Program Group (continued) P053 [Reset To Defalts] Stop drive before changing this parameter. Resets all parameters to their factory default values. After a Reset command, the value of this parameter returns to zero.
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Chapter 3 Programming and Parameters Terminal Block Group t062 [DigIn TermBlk 02] t065 [DigIn TermBlk 05] t063 [DigIn TermBlk 03] t066 [DigIn TermBlk 06] t067 [DigIn TermBlk 07] t068 [DigIn TermBlk 08] PF 525 Related Parameter(s): b012, b013, b014, P045, P046, P048, P049, P050, P051, t064, t086, A410-A425, A427, A431, A432, A433, A434, A435, A442, A443, A488, A535, A560, A562, A563, A567, A571 PowerFlex 525 only. Stop drive before changing this parameter. Programmable digital input.
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Programming and Parameters Options 26 “Current Lmt2”(2) When active, A485 [Current Limit 2] determines the drive current limit level. 27 “Anlg Invert” Inverts the scaling of the analog input levels set in t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] or t095 [Anlg In4-20mA Lo] and t096 [Anlg In4-20mA Hi]. 28 “EM Brk Rlse” If EM brake function is enabled, this input releases the brake. See t086 [EM Brk Off Delay] for more information.
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Chapter 3 Options Programming and Parameters 48 “2-Wire FWD” (only for DigIn TermBlk 02) [DigIn TermBlk 02] default. Select 2-Wire FWD for this input. Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to configure [Start Source x] to a 2-wire run forward mode. Also see t064 [2-Wire Mode] for level trigger settings. 49 “3-Wire Start” (only for DigIn TermBlk 02) Select 3-Wire Start for this input.
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Programming and Parameters Chapter 3 Terminal Block Group (continued) t069 [Opto Out1 Sel] t072 [Opto Out2 Sel] PF 525 Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564 PowerFlex 525 only. Determines the operation of the programmable digital outputs. Options 0 “Ready/Fault” 1 2 3 4 5 “At Frequency” “MotorRunning” “Reverse” “Motor Overld” “Ramp Reg” 6 “Above Freq” 7 “Above Cur” Setting Output Changes State When...
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Chapter 3 Programming and Parameters Terminal Block Group (continued) t070 [Opto Out1 Level] t073 [Opto Out2 Level] 32 PF 525 Related Parameter(s): t069, t072 32 bit parameter. PowerFlex 525 only. Determines the on/off point for the digital outputs when t069 or t072 [Opto Outx Sel] is set to the values shown below. Min/Max Value Range Based On [Opto Outx Sel] Setting 6: 0...500 Hz 10: 0...100% 16: 0.1...9999 s 20: 0/1 7: 0...180% 11 0/1 17: 1...9999 counts 26: 0...150% 8: 0...815V 13 0...800 18: 0...
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Programming and Parameters Chapter 3 Terminal Block Group (continued) t076 [Relay Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564 t081 [Relay Out2 Sel] PF 525 PowerFlex 525 only. Determines the operation of the programmable output relay. Options 0 “Ready/Fault” 1 2 3 4 5 “At Frequency” “MotorRunning” “Reverse” “Motor Overld” “Ramp Reg” 6 “Above Freq” 7 “Above Cur” Output Relay Changes State When...
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Chapter 3 Programming and Parameters Terminal Block Group (continued) t077 [Relay Out1 Level] Related Parameter(s): t076, t081 t082 [Relay Out2 Level] PF 525 32 PowerFlex 525 only. 32 bit parameter. Determines the on/off point for the output relay when t076 or t081 [Relay Outx Sel] is set to the values shown below. Min/Max Value Range Based On [Relay Outx Sel] Setting 6: 0...500 Hz 10: 0...100% 16: 0.1...9999 s 20: 0/1 7: 0...180% 11: 0/1 17: 1...9999 counts 26: 0...150% 8: 0...815V 13: 0...
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Programming and Parameters Chapter 3 Terminal Block Group (continued) t087 [EM Brk On Delay] Related Parameter(s): P045 Sets the time the drive remains at minimum frequency (after releasing the brake coil relay) before stopping if EM Brake Control Mode is enabled with P045 [Stop Mode]. Frequency Ram cce l [EM Brk Off Delay] [EM Brk On Delay] pd Ram pa ece l [Minimum Freq] Start commanded Values Time EM Brk Stop energized (Off) commanded Default: 2.00 s Min/Max: 0.00/10.00 s Display: 0.
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Chapter 3 Programming and Parameters Terminal Block Group (continued) t089 [Analog Out High] PF 525 PowerFlex 525 only. Scales the maximum output value (V or mA) when the source setting is at maximum. Values Default: 100% Min/Max: 0/800% Display: 1% t090 [Anlg Out Setpt] PF 525 Related Parameter(s): t088 PowerFlex 525 only. Sets the percentage of output desired when t088 [Analog Out Sel] is set to 6, 14 or 22 “Analog Setpoint”. Values Default: 0.0% Min/Max: 0.0/100.0% Display: 0.
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Programming and Parameters Chapter 3 Terminal Block Group (continued) t094 [Anlg In V Loss] Related Parameter(s): P043, P044, A426, A427 Sets the response to a loss of input. When the 0-10V input (or –10 to +10V) is used for any reference, any input less than 1V is reported as a signal loss. Input must exceed 1.5V for the signal loss condition to end. If enabled, this function affects any input that is being used as a speed reference, PID reference or PID setpoint in the drive.
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Chapter 3 Programming and Parameters Terminal Block Group (continued) t098 [Anlg Loss Delay] Related Parameter(s): t094, t097 Sets the length of time after power-up during which the drive detects no analog signal loss. Response to an analog signal loss is set in t094 or t097 [Analog In x Loss]. Values Default: 0.0 s Min/Max: 0.0 /20.0 s Display: 0.1 s t099 [Analog In Filter] Sets the level of additional filtering of the analog input signals.
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Programming and Parameters Chapter 3 Terminal Block Group (continued) t104 [Wake Time] Sets the analog input time the drive must stay above to wake from sleep mode. Values Default: 0.0 s Min/Max: 0.0/600.0 s Display: 0.1 s t105 [Safety Open En] PF 525 PowerFlex 525 only. Sets the action when both safety inputs (Safety 1 and Safety 2) are disabled (de-energized – no power is applied).
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Chapter 3 Programming and Parameters Communications Group C121 [Comm Write Mode] Saves parameter values in active drive memory (RAM) or in drive non-volatile memory (EEPROM). ATTENTION: If Automatic Drive Configuration (ADC) is used, this parameter must remain at its default value of 0 “Save”. IMPORTANT Options Parameter values set prior to setting 1 “RAM only” are saved in RAM. 0 “Save” (Default) 1 “RAM only” C122 [Cmd Stat Select] PF 525 PowerFlex 525 only.
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Programming and Parameters Chapter 3 Communications Group (continued) C127 [RS485 Format] Determines the details related to the specific Modbus protocol used by the drive. A reset or power cycle is required after selection is made. Options 0 “RTU 8-N-1” (Default) 1 “RTU 8-E-1” 2 “RTU 8-O-1” 3 “RTU 8-N-2” 4 “RTU 8-E-2” 5 “RTU 8-O-2” C128 [EN Addr Sel] PF 525 Related Parameter(s): C129-C132, C133-C136, C137-C140 PowerFlex 525 only.
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Chapter 3 Programming and Parameters Communications Group (continued) C133 C134 C135 C136 PF 525 [EN Subnet Cfg 1] [EN Subnet Cfg 2] [EN Subnet Cfg 3] [EN Subnet Cfg 4] Related Parameter(s): C128 PowerFlex 525 only. Sets the bytes of the subnet mask. A reset or power cycle is required after selection is made. 255.255.255.0 [EN Subnet Cfg 1] [EN Subnet Cfg 2] [EN Subnet Cfg 3] [EN Subnet Cfg 4] IMPORTANT Values C137 C138 C139 C140 PF 525 C128 [EN Addr Sel] must be set to 1 “Parameters”.
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Programming and Parameters Chapter 3 Communications Group (continued) C143 [EN Comm Flt Actn] PF 525 Related Parameter(s): P045, C145, C146, C147-C150 PowerFlex 525 only. Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that Ethernet communications have been disrupted. IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the EtherNet/IP interface. ATTENTION: Risk of injury or equipment damage exists.
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Chapter 3 Programming and Parameters Communications Group (continued) C146 [EN Flt Cfg Ref] 32 PF 525 Related Parameter(s): C143, C144 32 bit parameter. PowerFlex 525 only. Sets the Reference data that is sent to the drive if any of the following is true: – C143 [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.
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Programming and Parameters Chapter 3 Communications Group (continued) C161 C162 C163 C164 [Opt Data In 1] [Opt Data In 2] [Opt Data In 3] [Opt Data In 4] Datalink parameter number whose value is written from the High Speed Drive Serial Interface (HSDSI) data table. This parameter cannot be changed when an I/O connection is established through the communication adapter.
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Chapter 3 Programming and Parameters Logic Group L180 L182 L184 L186 [Stp Logic 0] [Stp Logic 2] [Stp Logic 4] [Stp Logic 6] L181 L183 L185 L187 [Stp Logic 1] [Stp Logic 3] [Stp Logic 5] [Stp Logic 7] Related Parameter(s): Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Values Default: 00F1 Min/Max: 0000/FAFF Display 0001 See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic. Parameters L180...
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Programming and Parameters Chapter 3 StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. See Appendix D for more information. Logic for next step Logic to jump to a different step Different step to jump Step settings Not Used Digit 1 Digit 2 Digit 3 Digit 4 Velocity Control Settings (Digit 4) Required Setting 0 1 2 3 4 5 6 7 8 9 A b Accel/Decel Param.
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Chapter 3 Programming and Parameters Logic Group (continued) L190 L192 L194 L196 PF 525 [Stp Logic Time 0] [Stp Logic Time 2] [Stp Logic Time 4] [Stp Logic Time 6] L191 L193 L195 L197 [Stp Logic Time 1] [Stp Logic Time 3] [Stp Logic Time 5] [Stp Logic Time 7] PowerFlex 525 only. Sets the time to remain in each step if the corresponding command word is set to “Step based on time”. Values L200 L204 L208 L212 32 PF 525 Default: 30.0 s Min/Max: 0.0/999.9 s Display: 0.
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Programming and Parameters Chapter 3 Advanced Display Group d360 [Analog In 0-10V] Related Parameter(s): t091, t092 Displays the 0-10V analog input as a percent of full scale. Values Default: Read Only Min/Max: 0.0/100.0% Display: 0.1% d361 [Analog In 4-20mA] Related Parameter(s): t095, t096 Displays the 4-20 mA analog input as a percent of full scale. Values Default: Read Only Min/Max: 0.0/100.0% Display: 0.
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Chapter 3 Programming and Parameters Advanced Display Group (continued) d368 [Testpoint Data] Related Parameter(s): A483 Displays the present value of the function selected in A483 [Testpoint Sel]. Values Default: Read Only Min/Max: 0/FFFF Display: 1 d369 [Motor OL Level] Displays the motor overload counter. Values Default: Read Only Min/Max: 0.0/150.0% Display: 0.
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Programming and Parameters Chapter 3 Advanced Display Group (continued) d382 [Torque Current] Displays the current value of the motor torque current measured by the drive. Values Default: Read Only Min/Max: 0.00/(Drive Rated Amps x 2) Display: 0.01 A d383 [PID1 Fdbk Displ] d385 [PID2 Fdbk Displ] PF 525 PowerFlex 525 only. Displays the active PID Feedback value. Values Default: Read Only Min/Max: 0.0/100.0% Display: 0.
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Chapter 3 Programming and Parameters Advanced Display Group (continued) d389 [Units Traveled L] Related Parameter(s): d387 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel. Values Default: Read Only Min/Max: 0.00/0.99 Display: 0.01 d390 [Fiber Status] Present status of the Fibers features.
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Programming and Parameters Chapter 3 Advanced Program Group A410 A412 A414 A416 [Preset Freq 0] [Preset Freq 2] [Preset Freq 4] [Preset Freq 6] A411 A413 A415 A417 [Preset Freq 1] [Preset Freq 3] [Preset Freq 5] [Preset Freq 7] A418 A420 A422 A424 [Preset Freq 8] [Preset Freq 10] [Preset Freq 12] [Preset Freq 14] A419 A421 A423 A425 [Preset Freq 9] [Preset Freq 11] [Preset Freq 13] [Preset Freq 15] PF 525 PowerFlex 525 only.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A426 [Keypad Freq] Related Parameter(s): P047, P049, P051 Provides the drive frequency command using the built-in keypad navigation. When P047, P049 or P051 [Speed Referencex] selects 2 “Keypad Freq”, the value set in this parameter controls the frequency of the drive. The value of this parameter can also be changed when navigating with the keypad by pressing the Up or Down arrow keys. Values Default: 60.00 Hz Min/Max: 0.00/500.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A433 [Purge Frequency] Related Parameter(s): t062, t063, t065-t068 Provides a fixed frequency command value when t062, t063, t065-t068 [DigIn TermBlk xx] is set to 40 “Purge”. Values Default: 5.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz A434 [DC Brake Time] Related Parameter(s): P045, A435 Sets the length of time that DC brake current is “injected” into the motor. Values Default: 0.0 s Min/Max: 0.0/99.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A437 [DB Resistor Sel] Stop drive before changing this parameter. Enables/disables external dynamic braking and selects the level of resistor protection. Options 0 “Disabled” (Default) 1 “Norml RA Res” 5% 2 “NoProtection” 100% 3...99 “3...99% DutyCycle” A438 [DB Threshold] Related Parameter(s): A437 Sets the DC bus voltage threshold for Dynamic Brake operation.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A440 [PWM Frequency] Related Parameter(s): A540 % Output Curent (A) Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting. 100 96 92 88 84 80 76 72 68 64 60 56 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Carrier Frequency (kHz) Ignoring derating guidelines can cause reduced drive performance.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A444 [Accel Time 3] A446 [Accel Time 4] Sets the rate of acceleration for all speed increases when selected by digital inputs. Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.01 s A445 [Decel Time 3] A447 [Decel Time 4] Sets the rate of deceleration for all speed decreases when selected by digital inputs. Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A456 [PID 1 Trim Hi] A468 [PID 2 Trim Hi] PF 525 PowerFlex 525 only. Scales the upper value of the trim frequency when trim is active. Values Default: 60.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.1 Hz A457 [PID 1 Trim Lo] A469 [PID 2 Trim Lo] PF 525 PowerFlex 525 only. Scales the lower value of the trim frequency when trim is active. Values Default: 0.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A459 [PID 1 Ref Sel] A471 [PID 2 Ref Sel] PF 525 PowerFlex 525 only. Stop drive before changing this parameter. Selects the source of the PID reference.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A462 [PID 1 Integ Time] Related Parameter(s): A459, A471 A474 [PID 2 Integ Time] PF 525 PowerFlex 525 only. Sets the value for the PID integral component when PID mode is enabled. Values Default: 2.0 s Min/Max: 0.0/999.9 s Display: 0.1 s A463 [PID 1 Diff Rate] Related Parameter(s): A459, A471 A475 [PID 2 Diff Rate] PF 525 PowerFlex 525 only.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A481 [Process Disp Lo] Related Parameter(s): b010, P043 Sets the value displayed in b010 [Process Display] when the drive is running at P043 [Minimum Freq]. Values Default: 0.00 Min/Max: 0.00/99.99 Display: 0.01 A482 [Process Disp Hi] Related Parameter(s): b010, P044 Sets the value displayed in b010 [Process Display] when the drive is running at P044 [Maximum Freq]. Values Default: 0.00 Min/Max: 0.00/99.99 Display: 0.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A490 [Load Loss Level] PF 525 Related Parameter(s): A491 PowerFlex 525 only. Provides a software trip (Load Loss fault) when the current drops below this level for the time specified in A491 [Load Loss Time]. Values Default: 0.0 A Min/Max: 0.0/Drive Rated Amps Display: 0.1 A A491 [Load Loss Time] PF 525 Related Parameter(s): A490 PowerFlex 525 only.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A495 [Drive OL Mode] Determines how the drive handles overload conditions that would otherwise cause the drive to fault. Options 0 “Disabled” 1 “Reduce CLim” 2 “Reduce PWM” 3 “Both-PWM 1st” (Default) A496 [IR Voltage Drop] Related Parameter(s): P040 Value of volts dropped across the resistance of the motor stator (autotune) for induction motor. Values Default: Based on Drive Rating Min/Max: 0.0/600.0VAC Display: 0.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A510 [Freq 1] A512 [Freq 2] A514 [Freq 3] PF 525 PowerFlex 525 only. Sets the “Vector” control mode frequency. Values Default: Freq 1: Freq 2: Freq 3: 8.33% 15.00% 20.00% Min/Max: 0.00/200.00% Display: 0.01% A511 [Freq 1 BW] A513 [Freq 2 BW] A515 [Freq 3 BW] PF 525 PowerFlex 525 only. Speed control loop bandwidth for “Vector” control mode.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A530 [Boost Select] Related Parameter(s): b004, P031, P032, P039 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve. Only used for V/Hz and SVC control modes. [Maximum Voltage] can be set anywhere. If it is > [Motor NP Volts] then it defines a point on the V/Hz curve 100 1/2 [Motor NP Volts] 50 1/2 [Motor NP Hertz] % [Motor NP Volts] [Maximum Voltage] can be set anywhere.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A531 [Start Boost] Related Parameter(s): P031, P032, P039, A530 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve when A530 [Boost Select] = 0 “Custom V/Hz” and P039 [Torque Perf Mode] = 0 “V/Hz”. [Maximum Voltage] [Break Voltage] [Start Boost] Voltage [Motor NP Volts] [Break Frequency] [Minimum Freq] Values Frequency [Motor NP Hertz] [Maximum Freq] Default: 2.5% Min/Max: 0.0/25.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A535 [Motor Fdbk Type] Related Parameter(s): A537 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Selects the encoder type. ATTENTION: The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against possible unintended speed or motion.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A540 [Var PWM Disable] Related Parameter(s): A440 Stop drive before changing this parameter. Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 [PWM Frequency]. Options 0 “Enabled” (Default) 1 “Disabled” A541 [Auto Rstrt Tries] Related Parameter(s): A542 Sets the maximum number of times the drive attempts to reset a fault and restart.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A546 [FlyStrt CurLimit] Used to determine when the drive has matched the motor frequency if flying start is enabled. Values Default: 150% Min/Max: 30/200% Display: 1% A547 [Compensation] Enables/disables correction options that may improve problems with motor instability. Options 0 “Disabled” No compensation.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A553 [Program Lock Mod] Related Parameter(s): A552 Determines the lock mode used in parameter A552 [Program Lock]. When set to 2 or 3, A552 [Program Lock] is added to the custom group to allow unlocking of parameters. Options 0 “Full Lock” (Default) All parameters are locked except [Program Lock]. 1 “Keypad Lock” All parameters are locked except [Program Lock] from keypad access but can still be accessed over communications.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A559 [Counts Per Unit] PF 525 PowerFlex 525 only. Sets the number of encoder counts equal to one user-defined unit. Values Default: 4096 Min/Max: 1/32000 Display: 1 A560 [Enh Control Word] PF 525 Related Parameter(s): t062, t063, t065 - t068, A571 PowerFlex 525 only. Allows control of positioning and other functions through parameter control for use over comms.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A562 [Find Home Freq] PF 525 PowerFlex 525 only. Sets the maximum frequency the drive uses when “Find Home” is issued. Values Default: 10.0 Hz Min/Max: 0.1/500.0 Hz Display: 0.1 Hz A563 [Find Home Dir] Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Sets the direction the drive commands when “Find Home” is issued.
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Chapter 3 Programming and Parameters Advanced Program Group (continued) A567 [Max Traverse] Sets the amplitude of triangle wave speed modulation. [P Jump] [Max Traverse] Hertz [Output Freq] Traverse Bit [Fiber Status] Traverse Enable Bit Seconds Values Default: 0.00 Hz Min/Max: 0.00/300.00 Hz Display: 0.01 Hz A568 [Traverse Inc] Related Parameter(s): A567 Sets the time required for the Traverse function to accelerate from the minimum to the maximum traverse frequency.
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Programming and Parameters Chapter 3 Advanced Program Group (continued) A572 [Speed Ratio] Stop drive before changing this parameter. Scales the drive speed command. Values Default: 1.00 Min/Max: 0.01/99.99 Display: 0.01 A573 [Mtr Options Cfg] PF 525 PowerFlex 525 only. (With FRN 2.xx and later.) Sets the configuration of the motor option.
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Chapter 3 Programming and Parameters This group contains parameters for the network option card that is installed. Network Parameter Group Refer to the network option card’s user manual for more information on the available parameters. This group contains parameters that have their values changed from the factory default. Modified Parameter Group When a parameter has its default value changed, it is automatically added to this group.
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Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F631 [Fault 1 Freq] F633 [Fault 3 Freq] F635 [Fault 5 Freq] F632 [Fault 2 Freq] F634 [Fault 4 Freq] F636 [Fault 6 Freq] F638 [Fault 8 Freq] F640 [Fault10 Freq] F637 [Fault 7 Freq] F639 [Fault 9 Freq] PF 525 Related Parameter(s): b001 PowerFlex 525 only. Displays and stores the value of b001 [Output Freq] with the most recent 10 faults occurred.
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Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F661 [Status @ Fault 1] F663 [Status @ Fault 3] F665 [Status @ Fault 5] F662 [Status @ Fault 2] F664 [Status @ Fault 4] F666 [Status @ Fault 6] F668 [Status @ Fault 8] F670 [Status @ Fault10] F667 [Status @ Fault 7] F669 [Status @ Fault 9] PF 525 Related Parameter(s): b006 PowerFlex 525 only. Displays the value of b006 [Drive Status] with the most recent 10 faults occurred.
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Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F683 [Com Sts-Emb Enet] PF 525 PowerFlex 525 only. Displays the status of the embedded EtherNet/IP interface to the drive.
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Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F687 F688 F689 F690 F691 F692 PF 525 [HW Addr 1] [HW Addr 2] [HW Addr 3] [HW Addr 4] [HW Addr 5] [HW Addr 6] PowerFlex 525 only. Shows the MAC address for the embedded EtherNet/IP interface. Values F693 F694 F695 F696 PF 525 Default: Read Only Min/Max: 0/255 Display: 1 [EN IP Addr Act 1] [EN IP Addr Act 2] [EN IP Addr Act 3] [EN IP Addr Act 4] PowerFlex 525 only.
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Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F701 F702 F703 F704 PF 525 [EN Gateway Act 1] [EN Gateway Act 2] [EN Gateway Act 3] [EN Gateway Act 4] PowerFlex 525 only. Shows the actual gateway address used by the embedded EtherNet/IP interface at the time. This will indicate 0 if no address is set. 255.255.255.
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Chapter 3 Programming and Parameters Fault and Diagnostic Group (continued) F708 F712 F716 F720 F724 [Drv 0 Feedback] [Drv 1 Feedback] [Drv 2 Feedback] [Drv 3 Feedback] [Drv 4 Feedback] In multi-drive mode, this is the feedback being received from drive 0/1/2/3/4. In single-drive mode, this is the feedback of the drive at the time. Values Default: Read Only Min/Max: 0.00/500.00 Hz Display: 0.01 Hz F725 [EN Rx Overruns] PF 525 PowerFlex 525 only.
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Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) F730 [EN Missed IO Pkt] PF 525 PowerFlex 525 only. The number of I/O packets missed. Values Default: Read Only Min/Max: 0/65535 Display: 1 F731 [DSI Errors] The number of total DSI errors.
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Chapter 3 Programming and Parameters AppView Parameter Groups AppView parameter groups provide a simple starting point for using the PowerFlex 520-series drives by grouping certain commonly used parameters based on different types of applications. Use these parameter groups to quickly and easily setup the PowerFlex 520-series drive for your application.
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Programming and Parameters CustomView Parameter Group Chapter 3 CustomView allows you to quickly access only the parameters needed for your application by storing them in a custom parameter group. Add your frequently used parameters to this group, then hide all other parameters with A552 [Program Lock] to simplify your drive configuration process. Up to 100 parameters can be stored in the CustomView parameter group.
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Chapter 3 Programming and Parameters Parameter Cross Reference by Name Parameter Name 10V Bipolar Enbl(1) 2-Wire Mode Accel Time 1 Accel Time 2 Accel Time 3 Accel Time 4 Accum CO2 Sav Accum Cost Sav Accum kWh Sav Analog In 0-10V Analog In 4-20mA Analog In Filter Analog Out High(1) Analog Out Sel(1) Anlg In 0-10V Hi Anlg In 0-10V Lo Anlg In mA Loss Anlg In V Loss Anlg In4-20mA Hi Anlg In4-20mA Lo Anlg Loss Delay Anlg Out Setpt(1) Auto Rstrt Delay Auto Rstrt Tries Autotune Average kWh Cost Average Power Boo
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Programming and Parameters Parameter Name EN Rate Act(1) EN Rate Cfg(1) EN Rx Errors(1) EN Rx Overruns(1) EN Rx Packets(1) EN Subnet Act 1(1) EN Subnet Act 2(1) EN Subnet Act 3(1) EN Subnet Act 4(1) EN Subnet Cfg 1(1) EN Subnet Cfg 2(1) EN Subnet Cfg 3(1) EN Subnet Cfg 4(1) EN Tx Errors(1) EN Tx Packets(1) Encoder Pos Tol(1) Encoder PPR(1) Encoder Speed(1) Energy Saved Enh Control Word(1) Fault 1 BusVolts Fault 1 Code Fault 1 Current Fault 1 Freq Fault 1 Time-hr Fault 1 Time-min Fault 2 BusVolts Fault 2 Co
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Chapter 3 Programming and Parameters Parameter Name Opt Data Out 1 Opt Data Out 2 Opt Data Out 3 Opt Data Out 4 Opto Out Logic(1) Opto Out1 Level(1) Opto Out1 Sel(1) Opto Out2 Level(1) Opto Out2 Sel(1) Out Phas Loss En Output Current Output Freq Output Power Output Powr Fctr Output RPM Output Speed Output Voltage P Jump PID 1 Deadband PID 1 Diff Rate PID 1 Fdback Sel PID 1 Integ Time PID 1 Invert Err PID 1 Preload PID 1 Prop Gain PID 1 Ref Sel PID 1 Setpoint PID 1 Trim Hi PID 1 Trim Lo PID 1 Trim Sel PID1
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Programming and Parameters Parameter Name Stp Logic 3(1) Stp Logic 4(1) Stp Logic 5(1) Stp Logic 6(1) Stp Logic 7(1) Stp Logic Status(1) Stp Logic Time 0(1) Stp Logic Time 1(1) Stp Logic Time 2(1) Stp Logic Time 3(1) No. 183 184 185 186 187 391 190 191 192 193 Parameter Name Stp Logic Time 4(1) Stp Logic Time 5(1) Stp Logic Time 6(1) Stp Logic Time 7(1) Sync Time Testpoint Data Testpoint Sel Text Scroll Timer Status Torque Current No.
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Chapter 3 Programming and Parameters Notes: 144 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Chapter 4 Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex 520-series drive. Included is a listing and description of drive faults with possible solutions, when applicable. For information on... Drive Status Faults Fault Descriptions Common Symptoms and Corrective Actions See page... 145 145 147 150 ATTENTION: Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis.
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Chapter 4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. The integral LCD display provides visual notification of a fault condition by displaying the FWD following. • Flashing fault number • Flashing fault indicator (LED) Press the Esc key to regain control of the display. Esc FAULT Sel Manually Clearing Faults Step Key(s) 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the integral keypad.
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Troubleshooting Chapter 4 Auto Restart (Reset/Run) The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Fault types are listed in the table Fault Types on page 145.
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Chapter 4 Troubleshooting Fault Types, Descriptions and Actions No. Fault F015(1) Load Loss 148 Type(2) Description 2 The output torque current is below the value programmed in A490 [Load Loss Level] for a time period greater than the time programmed in A491 [Load Loss Time]. 1 Output Phase Loss (if enabled). Configure with A557 [Out Phas Loss En]. 1 An analog input is configured to fault on signal loss. A signal loss has occurred. Configure with t094 [Anlg In V Loss] or t097 [Anlg In mA Loss].
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Troubleshooting Chapter 4 Fault Types, Descriptions and Actions No. F081 Fault DSI Comm Loss Type(2) Description 2 Communications between the drive and the Modbus or DSI master device have been interrupted.
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Chapter 4 Troubleshooting Fault Types, Descriptions and Actions Type(2) Description 2 Failure has been detected in the drive control and I/O section. No. F122 Fault I/O Board Fail F125 Flash Update Req 2 F126 NonRecoverablErr 2 F127 DSIFlashUpdatReq 2 Action • Cycle power. • Replace drive or control module if fault cannot be cleared. The firmware in the drive is corrupt, Perform a firmware flash update mismatched, or incompatible with the operation to attempt to load a valid set hardware.
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Troubleshooting Chapter 4 Motor does not Start. Cause(s) No output voltage to the motor. Indication None Improper boost setting at initial start-up. Drive is Faulted None Flashing red status light Incorrect programming. • P046, P048, P050 [Start Source x] is set incorrectly. Incorrect input wiring. See page 42 for wiring examples. • 2 wire control requires Run Forward, Run Reverse or Jog input. • 3 wire control requires Start and Stop inputs • Stop input is always required.
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Chapter 4 Troubleshooting Drive does not respond to changes in speed command. Cause(s) No value is coming from the source of the command. Indication Corrective Action The drive “Run” indicator is • Check b012 [Control Source] for correct source. • If the source is an analog input, check wiring and use a meter to check for presence of lit and output is 0 Hz. signal. • Check b002 [Commanded Freq] to verify correct command.
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Troubleshooting Chapter 4 Drive does not power up. Cause(s) No input power to drive. Indication None Control module is not connected properly to power module. None Corrective Action • Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. 1. Remove power. 2. Verify that the control module is properly and fully installed on the power module. 3. Reapply power. Motor is rotating at zero Hz or slip frequency is not correct. Cause(s) Incorrect speed calculation.
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Chapter 4 Troubleshooting Notes: 154 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Appendix A Supplemental Drive Information For information on... Certifications Environmental Specifications Technical Specifications Power Specifications Certifications See page... 155 156 157 160 Certifications c-UL-us PowerFlex 523 PowerFlex 525 Listed to UL508C and CAN/CSA-C22.2 No. 14-05.
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Appendix A Supplemental Drive Information Certifications EPRI PowerFlex 523 PowerFlex 525 Electric Power Research Institute Certified compliant with the following standards: SEMI F47 IEC 61000-4-34 Lloyds Register Not applicable Lloyd’s Register Type Approval Certificate 12/10068(E1) RoHS Compliant with the European “Restriction of Hazardous Substances” Directive The drive is also designed to meet the appropriate portions of the following specifications: NFPA 70 - US National Electrical Code NEMA ICS 7.
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Supplemental Drive Information Technical Specifications Appendix A Protection Specifications Bus Overvoltage Trip 100...120V AC Input: 200...240V AC Input: 380...480V AC Input: 525...600V AC Input: Bus Undervoltage Trip 100...120V AC Input: 200...240V AC Input: 380...480V AC Input: 525...
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Appendix A Supplemental Drive Information Specifications Performance with Encoder SVC (Sensorless Vector): PowerFlex 523 – ±0.1% of base speed across a 100:1 speed range ±0.1% of base speed across a 100:1 speed range ±0.1% of base speed across a 1000:1 speed range SVC Economizer: VVC (Velocity Vector Control): Output Voltage Range: Output Frequency Range: Efficiency: Stop Modes: Accel/Decel: Intermittent Overload Normal Duty: Heavy Duty: PowerFlex 525 0V to rated motor voltage 0...
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Supplemental Drive Information Specifications Opto: Quantity: Specification: Analog Quantity: Specification Resolution: 0-10V DC Analog: 4-20 mA Analog: PowerFlex 523 – – Appendix A PowerFlex 525 (2) Programmable 30V DC, 50 mA Non-inductive (1) Non-Isolated 0-10V or 4-20 mA 10-bit 1 k ohm minimum 525 ohm maximum Encoder Specifications Type: Supply: Quadrature: Duty Cycle: Requirements: PowerFlex 523 – PowerFlex 525 Incremental, dual channel 12V, 250 mA 90 °, ±27 ° @ 25 °C 50%, +10% Encoders must be l
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Appendix A Supplemental Drive Information Power Specifications Watts Loss PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Voltage 100...120V, 50/60 Hz 1-Phase 200...240V, 50/60 Hz 1-Phase 200...240V, 50/60 Hz 1-Phase w/ EMC Filter 200...240V, 50/60 Hz 3-Phase 380...480V, 50/60 Hz 3-Phase 380...480V, 50/60 Hz 3-Phase w/ EMC Filter 160 Output Current (A) 1.6 2.5 4.8 6.0 1.6 2.5 4.8 8.0 11.0 1.6 2.5 4.8 8.0 11.0 1.6 2.5 5.0 8.0 11.0 17.5 24.0 32.2 48.3 62.1 1.4 2.3 4.0 6.0 10.
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Supplemental Drive Information Appendix A PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Voltage 525...600V, 50/60 Hz 3-Phase Output Current (A) 0.9 1.7 3.0 4.2 6.6 9.9 12.0 19.0 22.0 27.0 32.0 Total Watts Loss 22.0 32.0 50.0 65.0 95.0 138.0 164.0 290.0 336.0 466.0 562.0 Input Current Scaling (Optional) You can use a higher drive rating by scaling the input current based on the output current required for your application.
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Appendix A Supplemental Drive Information PowerFlex 520-Series Input Current Scaled By Motor Current PowerFlex 523 PowerFlex 525 Output Input Catalog Number Catalog Number 1 2 3 4 5 6 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 25A-D1P4N104 25B-D1P4N104 1.4 1.1 0.9 0.7 1.9 1.5 25A-D2P3N104 25B-D2P3N104 2.3 1.8 1.5 1.2 3.2 2.6 25A-D4P0N104 25B-D4P0N104 4.0 3.2 2.6 2.0 5.7 4.6 25A-D6P0N104 25B-D6P0N104 6.0 4.8 3.9 3.0 7.5 6.0 25A-D010N104 25B-D010N104 10.5 8.4 6.8 5.3 13.8 11.
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Appendix B Accessories and Dimensions Product Selection Catalog Number Description 25B Drive - V 2P5 N 1 0 4 Voltage Rating Rating Enclosure HIM Emission Class Version PowerFlex 520-Series Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame PowerFlex 523 HP kW HP kW Current (A) Voltage Range Size Catalog No. 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 85...132 A 25A-V1P6N104(2) 0.5 0.4 0.5 0.4 2.5 85...132 A 25A-V2P5N104 1.
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Appendix B Accessories and Dimensions PowerFlex 520-Series Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame PowerFlex 523 HP kW HP kW Current (A) Voltage Range Size Catalog No. 7.5 5.5 7.5 5.5 13.0 323...528 C 25A-D013N104 10.0 7.5 10.0 7.5 17.0 323...528 C 25A-D017N104 15.0 11.0 15.0 11.0 24.0 323...528 D 25A-D024N104 20.0 15.0 15.0 11.0 30.0 323...528 D 25A-D030N104 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 0.5 0.4 0.5 0.4 1.4 323...
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Accessories and Dimensions Appendix B Dynamic Brake Resistors Drive Ratings Input Voltage 200...240V 50/60 Hz 3-Phase 380...480V 50/60 Hz 3-Phase 525...600V 50/60 Hz 3-Phase HP kW 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.
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Appendix B Accessories and Dimensions EMC Line Filters Drive Ratings Input Voltage 200...240V 50/60 Hz 1-Phase 200...240V 50/60 Hz 3-Phase 380...480V 50/60 Hz 3-Phase 525...600V 50/60 Hz 3-Phase HP 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 0.5 1.0 2.0 3.0 5.0 7.5 10.0 15.0 20.0 25.0 30.0 kW 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 0.4 0.75 1.5 2.2 4.0 5.5 7.5 11.0 15.0 18.5 22.0 0.4 0.75 1.5 2.2 4.0 5.5 7.
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Accessories and Dimensions Appendix B Human Interface Module (HIM) Option Kits and Accessories Item Description LCD Display, Remote Panel Digital speed control Mount CopyCat capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.9 meter cable LCD Display, Remote Digital speed control Handheld Full numeric keyboard CopyCat capable IP 30 (NEMA Type 1) Includes 1.0 meter cable Panel mount with optional Bezel Kit Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) Includes 2.
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Appendix B Accessories and Dimensions Replacement Parts PowerFlex 520-Series Power Module Item PowerFlex 520-Series Power Module Description Replacement power module for use with PowerFlex 520-Series drives. Includes: • Power Module • Power Module Front Cover • Power Terminal Guard • Heatsink Fan Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current (A) Voltage Range Size 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.2 0.25 0.2 1.6 85...132 A 0.5 0.
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Accessories and Dimensions Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current (A) Voltage Range Size 380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output 0.5 0.4 0.5 0.4 1.4 323...528 A 1.0 0.75 1.0 0.75 2.3 323...528 A 2.0 1.5 2.0 1.5 4.0 323...528 A 3.0 2.2 3.0 2.2 6.0 323...528 A 5.0 4.0 5.0 4.0 10.5 323...528 B 7.5 5.5 7.5 5.5 13.0 323...528 C 10.0 7.5 10.0 7.5 17.0 323...528 C 15.0 11.0 15.0 11.0 24.0 323...528 D 20.0 15.0 15.0 11.0 30.0 323...
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Appendix B Accessories and Dimensions Other Parts Item PowerFlex 520-Series Heatsink Fan Kit Description Replacement fan for drive power module. PowerFlex 520-Series EMC Replacement EMC cores Cores Frame Size A B C D E A B C D E Catalog No.
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Accessories and Dimensions Appendix B Bulletin 1321-3R Series Line Reactors Output Ratings(1) Normal Duty Heavy Duty HP kW HP kW 200...240V 50/60 Hz 1-Phase(2) 0.25 0.2 0.25 0.2 0.5 0.4 0.5 0.4 1.0 0.75 1.0 0.75 2.0 1.5 2.0 1.5 3.0 2.2 3.0 2.2 200...240V 50/60 Hz 3-Phase 0.25 0.2 0.25 0.2 0.5 0.4 0.5 0.4 1.0 0.75 1.0 0.75 2.0 1.5 2.0 1.5 3.0 2.2 3.0 2.2 5.0 4.0 5.0 4.0 7.5 5.5 7.5 5.5 10.0 7.5 10.0 7.5 15.0 11.0 10.0 7.5 20.0 15.0 15.0 11.0 380...480V 50/60 Hz 3-Phase 0.5 0.4 0.5 0.4 1.0 0.75 1.0 0.75 2.
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Appendix B Accessories and Dimensions (1) Normal Duty and Heavy Duty ratings for 15 HP (11 kW) and below are identical except for 200...240V 3-Phase 15 HP (11 kW) drive. (2) Standard 3-phase reactors can be used for 1-phase applications by routing each of the two supply conductors through an outside coil and leaving the center open. (3) Catalog numbers listed are for 3% impedance at 60 Hz. 5% impedance reactor types are also available. See publication 1321-TD001.
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Accessories and Dimensions The PowerFlex 520-series drive is available in five frame sizes. See the PowerFlex 520-Series Drive Ratings on page 163 for information on power ratings. PowerFlex 520-Series Drive Weight Frame Size A B C D E Weight (kg/lb) 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) 57.5 (2.26) 152.0 (5.98) Esc 172.0 (6.77) Sel 92.7 (3.65) 140.0 (5.51) Product Dimensions Appendix B 6.0 (0.
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Appendix B Accessories and Dimensions IP 20/Open Type – Frame B Dimensions are in millimeters and (inches) 87.0 (3.43) 72.5 (2.85) 180.0 (7.09) Sel 92.7 (3.65) 168.0 (6.61) Esc 172.0 (6.77) 6.0 (0.24) IP 20/Open Type – Frame C Dimensions are in millimeters and (inches) 184.0 (7.24) Sel 92.7 (3.65) 207.0 (8.15) Esc 220.0 (8.66) 109.0 (4.29) 90.5 (3.56) 6.0 (0.
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Accessories and Dimensions Appendix B IP 20/Open Type – Frame D Dimensions are in millimeters and (inches) 212.0 (8.35) 130.0 (5.12) Sel 247.0 (9.72) Esc 260.0 (10.24) 116.0 (4.57) 6.0 (0.24) IP 20/Open Type – Frame E Dimensions are in millimeters and (inches) 185.0 (7.28) 160.0 (6.30) 300.0 (11.81) Sel 280.0 (11.02) Esc 279.0 (10.98) 7.6 (0.
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Appendix B Accessories and Dimensions Control Module Fan Kit 25-FAN1-70C Specifications Rated Voltage Operation Voltage Input Current Speed (Reference) Maximum Air Flow (At zero static pressure) Maximum Air Pressure (At zero air flow) Acoustical Noise Insulation Type Frame Size Wire Size Torque 25-FAN2-70C 25-FAN1-70C 24V DC 14...27.6V DC 0.1 A 7000 rpm 0.575 m3/min 7.70 mmH2O 40.5 dB-A UL Class A Frame A...D 0.32 mm2 (22 AWG) 0.29...0.39 Nm (2.6...3.47 lb-in.) 25-FAN2-70C 0.15 A 4500 ± 10% rpm 1.
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Accessories and Dimensions Appendix B IP 20/Open Type with Control Module Fan Kit – Frame D...E Dimensions are in millimeters and (inches) Frame E 130.0 (5.12) Sel IMPORTANT 300.0 (11.81) Esc 280.0 (11.02) Sel 247.0 (9.72) Esc 260.0 (10.24) 52.0 (2.05) 116.0 (4.57) 196.0 (7.72) 185.0 (7.28) 160.0 (6.30) 32.0 (1.26) Frame D Remove the label to access the built-in 24V supply on drive frames D and E for use with the Control Module Fan Kit.
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Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame A 15.0 (0.59) Dimensions are in millimeters and (inches) 72.0 (2.83) Sel 92.7 (3.65) Esc 172.0 (6.77) 140.0 (5.51) 152.0 (5.98) 219.0 (8.62) 57.5 (2.26) IP 30/NEMA 1/ UL Type 1 top panel 6.0 (0.24) 51.1 (2.01) IP 30/NEMA 1/ UL Type 1 conduit box 21.0 (0.82) 64.7 (2.55) 88.2 (3.47) 111.9 (4.41) 135.4 (5.33) ø21.5 (ø0.
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Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame B 15.0 (0.59) Dimensions are in millimeters and (inches) 87.0 (3.43) Sel 92.7 (3.65) 168.0 (6.61) 180.0 (7.09) Esc 172.0 (6.77) 218.0 (8.58) 72.5 (2.85) IP 30/NEMA 1/ UL Type 1 top panel 6.1 (0.24) 66.1 (2.60) 63.1 (2.48) IP 30/NEMA 1/ UL Type 1 conduit box 33.5 (1.32) 23.9 (0.94) ø21.5 (ø0.85) 67.3 (2.65) 88.3 (3.48) 108.5 (4.27) 128.5 (5.06) ø27.5 (ø1.
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Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame C 15.0 (0.59) Dimensions are in millimeters and (inches) 184.0 (7.24) Sel 92.7 (3.65) 207.0 (8.15) 222.0 (8.66) Esc IP 30/NEMA 1/ UL Type 1 top panel 255.0 (10.04) 109.0 (4.29) 90.5 (3.56) 6.0 (0.24) 80.5 (3.17) 66.5 (2.62) IP 30/NEMA 1/ UL Type 1 conduit box 34.5 (1.36) 26.5 (1.04) ø21.5 (ø0.85) 82.2 (3.24) 123.3 (4.85) ø27.5 (ø1.
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Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame D 15.0 (0.59) Dimensions are in millimeters and (inches) Esc Sel IP 30/NEMA 1/ UL Type 1 top panel 212.0 (8.35) 247.0 (9.72) 260.0 (10.24) 295.0 (11.61) 130.0 (5.12) 116.0 (4.57) 6.0 (0.24) 96.0 (3.78) 70.0 (2.76) IP 30/NEMA 1/ UL Type 1 conduit box 44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) 109.8 (4.32) 153.3 (6.04) ø33.5 (ø1.
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Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame E 15.0 (0.59) Dimensions are in millimeters and (inches) Esc IP 30/NEMA 1/ UL Type 1 top panel 279.0 (10.98) 280.0 (11.02) 300.0 (11.81) 350.0 (13.78) 185.0 (7.28) 160.0 (6.30) Sel 7.6 (0.30) 127.5 (5.02) 82.5 (3.25) IP 30/NEMA 1/ UL Type 1 conduit box 62.5 (2.46) 42.5 (1.67) ø21.5 (ø0.85) 164.0 (6.46) 181.0 (7.13) 212.0 (8.35) ø43.7 (ø1.
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Accessories and Dimensions Appendix B EMC Line Filter – Frame A Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 55.0 (2.17) 72.0 (2.83) 30.0 (1.18) 54.0 (2.13) 223.0 (8.78) 20.0 (0.79) ø5.5 (ø0.22) 234.0 (9.21) 223.0 (8.78) 23.0 (0.91) 5.5 (0.22) 54.0 (2.13) EMC Line Filter – Frame B Dimensions are in millimeters and (inches) 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) 258.0 (10.16) 25.
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Appendix B Accessories and Dimensions EMC Line Filter – Frame C Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 70.0 (2.76) 37.0 (1.46) 109.0 (4.29) 76.0 (2.99) 275.0 (10.83) 263.0 (10.35) 263.0 (10.35) 25.0 (0.98) ø5.5 (ø0.22) 28.0 (1.10) 76.0 (2.99) 5.5 (0.22) EMC Line Filter – Frame D Dimensions are in millimeters and (inches) 80.0 (3.15) 33.0 (1.30) 184 130.0 (5.12) 90.0 (3.54) 28.0 (1.10) 298.0 (11.73) 33.0 (1.
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Accessories and Dimensions Appendix B EMC Line Filter – Frame E Dimensions are in millimeters and (inches) 33.0 (1.30) 80.0 (3.15) 375.0 (14.76) 33.0 (1.30) 155.0 (6.10) 110.0 (4.33) 28.0 (1.10) ø5.5 (ø0.22) 390.0 (15.35) 375.0 (14.76) 28.0 (1.10) Rockwell Automation Publication 520-UM001G-EN-E - September 2014 110.0 (4.33) 5.5 (0.
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Appendix B Accessories and Dimensions Optional Accessories and Kits Installing a Communication Adapter 1. Insert the communication adapter interface connector into the Control Module. Make sure the indicator line on the connector is aligned with the surface of the Control Module. For PowerFlex 523 Communication adapter interface connector For PowerFlex 525 Communication adapter interface connector 2.
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Accessories and Dimensions Appendix B 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.
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Appendix B Accessories and Dimensions Notes: 188 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Appendix C RS485 (DSI) Protocol PowerFlex 520-series drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some Modbus functions are supported to allow simple networking. PowerFlex 520-series drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.
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Appendix C RS485 (DSI) Protocol Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 520-series drive’s RJ45 socket must not be connected because they contain power, etc. for other Rockwell Automation peripheral devices. Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+” and “TxRxD-” are shown for illustration purposes only. Refer to the master controller’s user manual for network terminations.
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RS485 (DSI) Protocol Supported Modbus Function Codes The peripheral interface (DSI) used on PowerFlex 520-series drives supports some of the Modbus function codes.
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Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Command – C122 = 0 “Velocity” Address (Decimal) Bit(s) 2000H (8192) 0 1 2 3 5, 4 6 7 9, 8 11, 10 14, 13, 12 15 192 Description 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 01 = Forward Command 10 = Reverse Command 11 = No Command 1 = Force Keypad Control, 0 = Not Force Keypad Control 1 = MOP Increment, 0 = Not Increment 00 = No Command 01 = Accel Rate 1 En
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RS485 (DSI) Protocol Appendix C Position Bit Definitions Comm Logic Command – C122 = 1 “Position” Address (Decimal) Bit(s) 2000H (8192) 0 1 2 3 5, 4 6 7 10, 9, 8 11 12 13 14 15 Writing (06) Comm Frequency Command Description 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 01 = Forward Command 10 = Reverse Command 11 = No Command 1 = Logic In 1 1 = Logic In 2 000 = Freq. and Position Step 0 001 = Freq.
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Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Status – C122 = 0 “Velocity” Address (Decimal) Bit(s) 2100H (8448) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse 1 = Accelerating, 0 = Not Accelerating 1 = Decelerating, 0 = Not Decelerating Not Used 1 = Faulted, 0 = Not Faulted 1 = At Reference, 0 = Not At Reference 1 = Main Freq Controlled by Act
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RS485 (DSI) Protocol Reading (03) Drive Error Codes Appendix C The PowerFlex 520-series Error Code data can be read through the network by sending Function Code 03 reads to register address 2101H (Drive Error Codes).
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Appendix C RS485 (DSI) Protocol Drive Error Codes Logic Status Address (Decimal) Value (Decimal) 2101H (8449) 125 126 127 Reading (03) Drive Operational Values Description Flash Update Required Non Recoverable Error DSI Flash Update Required The PowerFlex 520-series Drive Operational Values can be read through the network by sending Function Code 03 reads to register addresses 2102H...210AH.
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Appendix D Velocity StepLogic, Basic Logic and Timer/ Counter Functions Four PowerFlex 520-series logic functions provide the capability to program simple logic functions without a separate controller. • Velocity StepLogic™ Function (specific to PowerFlex 525 drives only) Steps through up to eight preset speeds based on programmed logic.
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Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions Velocity StepLogic Using Timed Steps IMPORTANT This function is specific to PowerFlex 525 drives only. To activate this function, set one of the three speed reference sources, parameter P047, P049 or P051[Speed Referencex] to 13 “Step Logic” and activate that speed reference source. Three parameters are used to configure the logic, speed reference and time for each step. • Logic is defined using parameters L180...L187 [Stp Logic x].
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Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D • 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. • Transition to Step 3 when Logic In 2 returns to a false or off state. Inputs are not required to remain in the “on” condition except under the logic conditions used for the transition from Step 2 to Step 3.
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Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions • The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active.
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Velocity StepLogic, Basic Logic and Timer/Counter Functions Appendix D Output Frequency Start Relay Out Photo Eye DigIn TermBlk 05 Counter In DigIn TermBlk 06 Reset Counter Limit Switch Velocity StepLogic Parameters Code Descriptions for Parameters L180...
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Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions Digit 2 – Defines what logic must be met to jump to a step other than the very next step. Setting 0 1 2 3 4 5 6 7 8 9 A b C d E F Description Skip Step (jump immediately) Step based on the time programmed in the respective [Stp Logic Time x] parameter.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Encoder and Pulse Train Usage The PowerFlex 520-series drives include a pulse train input built into the terminal block. PowerFlex 525 drives also support an optional encoder card. The pulse train and encoder can be used for many of the same functions, but the pulse train supports up to 100 kHz at 24V, and uses the drive built-in terminal block.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application No. +V Cm BB AA +V Cm BB AA 12V 5V  Signal 5...12V Power(1)(2) Power Return Encoder B (NOT) Encoder B Encoder A (NOT) Encoder A Description Output DIP switch selects 12 or 5 volt power supplied at terminals “+V” and “Cm” for the encoder. Internal power source 250 mA (isolated). Quadrature B input. Single channel, pulse train or quadrature A input.
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Encoder/Pulse Train Usage and Position StepLogic Application Positioning Overview Appendix E The PowerFlex 525 drive includes a simple position regulator which can be used in a variety of position applications without the need for multiple limit switches or photo-eyes. This can be used as a stand-alone controller for simple applications (up to 8 positions) or in conjunction with a controller for more flexibility.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application A550 [Bus Reg Enable] default setting is 1 “Enabled”. If the deceleration time is too short, the drive may overshoot the desired position. For best results, a longer deceleration time may be necessary. A550 [Bus Reg Enable] can be disabled to provide precise stopping movements, but the deceleration time will need to be manually tuned so that it is long enough to avoid F005 “OverVoltage” faults.
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Encoder/Pulse Train Usage and Position StepLogic Application Appendix E needs direct access to any position step based on discrete inputs. This mode moves in the forward direction from Home and is an absolute move. IMPORTANT Advanced Step Logic options such as incremental move are not available in this mode. 2 “Step Logic” provides a highly flexible mode of operation.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Frequency Source A415 [Preset Freq 5] A416 [Preset Freq 6] A417 [Preset Freq 7] IMPORTANT Step Source L185 [Stp Logic 5] L186 [Stp Logic 6] L187 [Stp Logic 7] Position Source L210 [Step Units 5] L212 [Step Units 6] L214 [Step Units 7] The default value for A410 [Preset Freq 0] is 0.00 Hz. This value needs to be changed or the drive will not be able to move during Step 0. L190...
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Encoder/Pulse Train Usage and Position StepLogic Application Logic for next step Logic to jump to a different step Different step to jump Step settings Not Used Digit 1 Digit 2 Digit 3 Digit 4 Velocity Control Settings (Digit 4) Required Setting 0 1 2 3 4 5 6 7 8 9 A b Accel/Decel Param.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application overshoot, the filter should be increased and/or the gain should be reduced. In general, the gain will have a larger effect on most systems than the filter. Homing Routine This drive supports incremental encoders only. Therefore, when the drive powers up it will reset the current position to zero. If this is known to be correct the position routine can be started without further adjustment.
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Encoder/Pulse Train Usage and Position StepLogic Application Appendix E point too quickly it will then reverse direction at 1/10th A562 [Find Home Freq] to the point where the Home Limit switch reactivates. Approximately one second after the routine finds home the drive will stop. Alternately, the “Find Home Freq” and/or “Home Limit” bits in A560 [Enh Control Word] can be activated instead of utilizing a digital input. The inputs or bits should be returned to inactive after the routine is complete.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Use Over Communications If 8 steps are not adequate for the application or if dynamic program changes are required, many of the positioning functions can be controlled through an active communication network. The following parameters will allow this control. C121 [Comm Write Mode] Repeated writes to parameters over a communication network can cause damage to the drive EEPROM.
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Encoder/Pulse Train Usage and Position StepLogic Application Appendix E position) using comms control without requiring actual digital input transitions. L200...L214 [Step Units x] All of the position steps can be written to while the drive is running. The changes will take place at the next move. For example, if step 0 is over-written while the drive is moving to step 0, the drive will move to the previous commanded position at step 0.
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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Notes: 214 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Appendix F PID Set Up PID Loop The PowerFlex 520-series drive features built-in PID (proportional, integral, derivative) control loops. The PID loop is used to maintain a process feedback (such as pressure, flow or tension) at a desired set point. The PID loop works by subtracting the PID feedback from a reference and generating an error value. The PID loop reacts to the error, based on the PID Gains, and outputs a frequency to try to reduce the error value to 0.
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Appendix F PID Set Up • The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow. • When the PID Control Loop is disabled, the Commanded Speed is the Ramped Speed Reference. Esc Sel PID Feedback = Pressure Transducer Signal Pump PID Reference = Desired System Pressure Trim Control In Trim Control, the PID Output is added to the Speed Reference. In Trim mode, the output of the PID loop bypasses the accel/decel ramp as shown.
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PID Set Up Appendix F • As tension increases or decreases during winding, the Speed Reference is trimmed to compensate. Tension is maintained near the Equilibrium set point. 0V PID Reference = Equilibrium Set Point PID Feedback = Dancer Pot Signal Esc Sel 10V [Speed Referencex] PID Reference and Feedback PID mode is enabled by setting P047, P049 or P051 [Speed Referencex] to 11 “PID1 Output” or 12 “PID2 Output”, and activating the corresponding speed reference.
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Appendix F PID Set Up A460 and A472 [PID x Fdback Sel] are used to select the source of the PID feedback. A460, A472 [PID x Fdback Sel] Options Options 0 “0-10V Input” Description Selects the 0-10V Input (default setting). Note that the PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero. 1 “4-20mA Input“ Selects the 4-20 mA Input. 2 “Serial/DSI” Serial/DSI will be used as an input for the PID Feedback.
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PID Set Up Appendix F • A459 [PID 1 Ref Sel] = 6 “4-20mA Input” 4-20 mA Input 24 20 16 12 8 4 0 10 20 30 40 50 60 70 80 90 100 PID Reference (%) PID Deadband Parameters A465 and A477 [PID x Deadband] are used to set a range, in percent, of the PID Reference that the drive will ignore. Example • 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.
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Appendix F PID Set Up PID reaches the Hi or Lo limit, the PID regulator stops integrating so that windup does not occur. PID Gains The proportional, integral, and differential gains make up the PID regulator. • A461 and A473 [PID x Prop Gain] The proportional gain (unitless) affects how the regulator reacts to the magnitude of the error. The proportional component of the PID regulator outputs a speed command proportional to the PID error.
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PID Set Up Appendix F 2. Adjust the integral gain (leave the proportional gain set as in Step 1). After a step change in the PID Feedback: – If the response is too slow (see Slow Response – Over Damped on page 221), or the PID Feedback does not become equal to the PID Reference, decrease A462 or A474 [PID x Integ Time]. – If there is a lot of oscillation in the PID Feedback before settling out (see Oscillation – Under Damped on page 221), increase A462 or A474 [PID x Integ Time]. 3.
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Appendix F PID Set Up Good Response – Critically Damped PID Reference PID Feedback Time 222 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Appendix G Safe-Torque-Off Function The PowerFlex 525 Safe-Torque-Off function, when used with other safety components, helps provide protection according to EN ISO 13849 and EN62061 for safe-off and protection against restart. The PowerFlex 525 SafeTorque-Off function is just one component in a safety control system. Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding. For information on...
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Appendix G Safe-Torque-Off Function ATTENTION: Electric Shock Hazard. Verify that all sources of AC and DC power are de-energized and locked out or tagged out in accordance with the requirements of ANSI/NFPA 70E, Part II. To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the +DC and -DC terminals or test points (refer to your drive’s User Manual for locations). The voltage must be zero.
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Safe-Torque-Off Function Appendix G A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine. 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.
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Appendix G Safe-Torque-Off Function • access control to the system, including password handling. • analyzing all configuration settings and choosing the proper setting to achieve the required safety rating. IMPORTANT When applying Functional Safety, restrict access to qualified, authorized personnel who are trained and experienced. ATTENTION: When designing your system, consider how personnel will exit the machine if the door locks while they are in the machine.
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Safe-Torque-Off Function Enabling PowerFlex 525 Safe-Torque-Off Appendix G 1. Remove all power to the drive. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the +DC and -DC terminals or test points (refer to your drive’s user manual for the location of the terminals). The voltage must be zero. 2.
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Appendix G Safe-Torque-Off Function Under normal drive operation, both safety inputs (Safety 1 and Safety 2) are energized, and the drive is able to run. If either input is de-energized, the gate control circuit becomes disabled. To meet EN ISO 13849 operation, both safety channels must be de-energized. Refer to the following examples for more information. IMPORTANT Verify Operation By itself, the Safe-Torque-Off function initiates a coast to stop action.
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Safe-Torque-Off Function Connection Examples Appendix G Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d Stop Category 0 – Coast AC line input power PF 525 +24V DC +24V DC GuardMaster Trojan Gate Stop Stop Start Start A1 S21 S11 S52 41 13 23 33 Gate control power supply MSR E-Stop latching button A2 S22 S14 S34 42 14 24 34 24V DC common Gate control circuit S1 S2 (1) M AC line input power PF 525 +24V DC GuardMaster Trojan Gate Stop Stop Start E-Stop latchin
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Appendix G Safe-Torque-Off Function Stop Category 0 – Coast with Two PowerFlex 525 Drives (1) 24V DC Supply AC line input power Reset PF 525 E-Stop AC line input power +24V DC A1 S11 L12 SI S21 Start PF 525 Start +24V DC Dig. comm Y32 S12 S22 L11 Stop Stop Reset 0 Stop Stop Gate control power supply S34 Start Start Dig.
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Safe-Torque-Off Function Appendix G Example 2 – Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d Stop Category 1 – Controlled (1) AC line input power PF 525 GuardMaster Trojan +24V DC Gate +24V DC A1 Stop Stop Start S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34 Gate control power supply Minotaur MSR138DP A2 X1 X2 X3 X4 Y39 Y40 38 48 58 Start 14 24 Y2 Y1 24V DC Common Gate control circuit S1 S2 M (1) Enclosure Recommended.
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Appendix G Safe-Torque-Off Function Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e Stop Category 0 – Coast (1) AC line input power PF 525 External +24V DC +24V DC Stop Reset Open A1 S11 S52 S12 13 23 33 41 Start COM Gate control power supply MSR127TP S21 S22 S34 A2 14 24 34 42 Closed Gate control circuit S1 S2 X1 AUX X2 A1 Coil A2 24V DC COM 13 23 33 14 24 34 External 100-C contactor 100S-C M (1) Enclosure Recommended.
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Safe-Torque-Off Function Appendix G PowerFlex 525 Certification for Safe-Torque-Off Rockwell Automation Publication 520-UM001G-EN-E - September 2014 233
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Appendix G Safe-Torque-Off Function Notes: 234 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Appendix H EtherNet/IP This section contains only basic information to setup an EtherNet/IP connection with your PowerFlex 520-series drive. For comprehensive information about EtherNet/IP (single and dual-port) and how to use it, see the following publications: • PowerFlex 525 Embedded EtherNet/IP Adapter User Manual, publication 520COM-UM001. • PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter User Manual, publication 520COM-UM003.
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Appendix H EtherNet/IP IMPORTANT 236 Regardless of the method used to set the adapter IP address, each node on the EtherNet/IP network must have a unique IP address. To change an IP address, you must set the new value and then remove and reapply power to (or reset) the adapter.
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Appendix I Control Diagrams This chapter contains various diagrams on the PowerFlex 520-series drive functions and behaviors.
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Appendix I Control Diagrams Adjusting Speed Control Parameters These settings show how to adjust the speed control for motor tuning. Increase the bandwidth to obtain faster speed response. If oscillation occurs, decrease the bandwidth. Speed Loop Bandwidth: A511 [Freq 1 BW] = 10 Hz A513 [Freq 2 BW] = 10 Hz A515 [Freq 3 BW] = 10 Hz For [Freq x Kp], gradually increase by 1% For [Freq x Ki], gradually increase by 0.
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Numerics 2-wire inputs, 47 3-wire inputs, 47 A basic operation, 56, 61, 150 common bus, 35 mount, 15 programming, 57, 60 safety, 227 drive damage preventing, 19 ungrounded distribution systems, 19 accel override priority, 48 selecting, 48 accessing control terminals, 30 power terminals, 30 applications safety, 225 auxiliary contact drive, 33, 35 B basic operation, 61 drive, 56, 61, 150 programming, 61 safety, 228 C circuit breakers inputs, 22 ratings, 22 common bus drive, 35 communications positioning,
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writing, 191, 193, 196 motor ground, 21 start, 33 stop, 33 mount drive, 15 mounting dimensions, 16, 173 N noise immunity wiring, 36, 190 O output disconnect, 33 override priority accel, 48 decel, 48 speed reference, 46 start source, 46 P parameters AppView, 68, 138 CustomView, 139 programming, 59, 63 PID programming, 217 positioning communications, 212 programming, 205, 206 power inputs, 20 power and control module separating, 27 power terminals accessing, 30 preventing drive damage, 19 programming, 61 b
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programming, 197, 199 tools programming, 60 U unshielded wiring, 32 V voltage reflections wiring, 33 W wave protection reflected, 33 wiring encoder, 204 noise immunity, 36, 190 recommended, 35, 227 RS485 (DSI), 189 safety, 227 shielded, 32 temperature, 32 unshielded, 32 voltage reflections, 33 writing Modbus, 191, 193, 196 Rockwell Automation Publication 520-UM001G-EN-E - September 2014 241
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Notes: 242 Rockwell Automation Publication 520-UM001G-EN-E - September 2014
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Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support/, you can find technical manuals, a knowledge base of FAQs, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.