Home

"user manual"

1. 87 0 3 43 172 0 6 77 72 5 2 85 se A Ma LLE I Aloo Bradley T7 WS I c o fl FALTO a d m c c S _ m mm gt c I 19 c 2 j UUUUU c gt A PowerFlex 8 ie g HN Eg s A N ARA l N Alen Bradiey t Tn 6 0 0 24 IN IP 20 0pen Type Frame C Dimensions are in millimeters and inches 109 0 4 29 184 0 7 24 90 5 3 56 E E 68 Allen Bradiey e g E M CC FAUTO Ne SOE S pu ES CL Booo N CL A m SS v n 3 E ers y C C o CLE a C C UUUUUVUUUU e C5 23 PORT O N Cc PowerFlex 93 a g Ec a CCo E m to am C3 Vo 35 ee N lt D g i Allen Bradley 1 Eo I 1 14 f _ 6 0 0 24 ik Rockwell Autom
2. a 720 283 S IP 30 NEMA 1 UL Type 1 top panel o m 57 5 2 26 2 172 0 6 77 50000000 l ff O c 2 Q C 2 S me 5 u M o m C 2 b ey C 2 D N C ti f 1 8 x 2 3 1 2 c eo s 2 3 Y e c c iN eI ao 2 i CL e e 3DJI ARR S a S PowerFlex E x penne C r RI 6 0 0 24 n i 9 ad x 51 1 Q 01 IP 30 NEMA 1 UL Type 1 conduit box 21 0 0 82 921 5 20 85 FT E B m 25 at D EE 1 aD One t nim U Hj N EO it A CD UA 1 T Ke i 178 Rockwell Automation Publication 520 UM001G EN E September 2014 IP 30 NEMA 1 UL Type 1 Frame B Dimensions are in millimeters and inches Accessories and Dimensions
3. m IP 30 NEMA 1 UL Type 1 top panel 130 0 5 12 212 0 8 35 116 0 4 57 EE arv00000000 7 asn yi d c N e s p CX Lo z EL pu o e SSS SS S a E Ss Powwertlex E N SS S11 angannanana S C N CL a Eg Sal i 10 n D Allen Bradley a A m r c 6 0 0 24 IL 96 0 3 78 IP 30 NEMA 1 UL Type 1 conduit box 70 0 2 76 4 44 0 1 73 30 0 1 18 TH titi JU pee 00 85 amp ed 033 5 91 32 c S m M m ji B T AONE Li TAR z E asc Rockwell Automation Publication 520 UM001G EN E September 2014 181 Appendix B 182 Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame E Dimensions are in millimeters and inches 185 0 7 28 160 0 6 30 IP 30 NEMA 1 UL Type 1 top panel 279 0 10 98 i sal Cro a GO TIT nannanna
4. Rockwell Automation Publication 520 UM001G EN E September 2014 d TET IP 30 NEMA 1 UL Type 1 top panel i 90 5 3 56 0 184 0 7 24 if A F Q T CMM e Bs YS ECN iN E iN E N 3 mE o gt v ceo 2 N e 3 e 3 3 e 23 C 2 n 3 PORTO T gey CL mE PowrerHlex NETAO 2 C CL EE 5 CS nannann nn rl C9 C H E S gt C Co 3 n 3 o c jas m E S D AllenBrediey V p 1 xi 6 0 0 24 l Pe 80 5 3 17 IP 30 NEMA 1 UL Type 1 conduit box 66 5 2 62 34 5 1 36 26 5 1 04 m UUU U 921 5 20 85 T x 927 5 21 08 c Bi 8 o e CRUE C4 a SPAM a o o e xm p T H B Accessories and Dimensions Appendix B IP 30 NEMA 1 UL Type 1 Frame D Dimensions are in millimeters and inches
5. IMPORTANT Specifications 25 FAN1 70C 25 FAN2 70C Rated Voltage 24V DC Operation Voltage 14 27 6V DC Input Current 0 1A 0 15A Speed Reference 7000 rpm 4500 10 rpm Maximum Air Flow At zero static pressure 0 575 m3 min 1 574 m min Maximum Air Pressure At zero air flow 7 70 mmH 0 9 598 mmH 0 Acoustical Noise 40 5 dB A 46 0 dB A Insulation Type UL Class A Frame Size Frame A D Frame E Wire Size 0 32 mm 22 AWG Torque 0 29 0 39 Nm 2 6 3 47 Ib in IP 20 0pen Type with Control Module Fan Kit Frame A C Frame B Frame C c 8 g gt 87 03 43 g 109 0 4 29 Ex c i 72 5 2 85 q 90 5 3 56 q E i QON e FALTO 3 gS n c m o 2 eo 3 pal N A 7 B Y a n RS c o o 2 8 S ES U 2 Q PowerFlex E Powerflex 3 NANA AAA annannanannannan Allen Bradley 4 An external 24V DC power source is required when using Allen Bradley the Control Module Fan Kit with drive frames A B and C Rockwell Automation Publication 520 UM001G EN E
6. 72 0 2 83 54 0 2 13 ys 20 22 Li L2 L3 66 6 234 0 9 21 223 0 8 78 Li L2 L3 n fark mt aci at ack e K 55027 54 0 2 13 Filter can be mounted onto the back of the drive 87 0 3 43 58 0 2 28 055 20 22 e L3 Lt max ace 55 0 22 58 0 2 28 Rockwell Automation Publication 520 UM001G EN E September 2014 183 Appendix B Accessories and Dimensions 184 EMC Line Filter Frame C Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive 70 0 2 76 109 0 4 29 37 0 1 46 76 0 2 99 tsi 1 955 0022 QUEE 0 6 0660 275 0 10 83 o 263 0 263 0 10 35 10 35 9 Lu L2 L3 LO No AV fee 25 0 0 98 28 0 1 10 5 5 0 22 76 0 2 99
7. Drive Error Codes Logic Status Address Decimal Value Decimal Description 2101H 8449 0 No Fault 2 Auxiliary Input 3 Power Loss 4 Undervoltage 5 Overvoltage 6 Motor Stalled 7 Motor Overload 8 Heatsink Overtemperature 9 Control Module Overtemperature 12 HW Overcurrent 300 13 Ground Fault 15 Load Loss 21 Output Phase Loss 29 Analog Input Loss 33 Auto Restart Tries 38 Phase U to Ground Short 39 Phase V to Ground Short 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short 48 Parameters Defaulted 59 Safety Open 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 7 DSI Network Loss 72 Option Card Network Loss 73 Embedded EtherNet IP Adapter Network Loss 80 AutoTune Fail 81 DSI Communication Loss 82 Option Card Communication Loss 83 Embedded EtherNet IP Adapter Communication Loss 91 Encoder Loss 94 Function Loss 100 Parameter Checksum Error 101 External Storage 105 Control Module Connect Error 106 Incompatible Control Power Module 107 Unrecognized Control Power Module 109 Mismatched Control Power Module 110 Keypad Membrane 111 Safety Hardware 114 Microprocessor Failure 122 1 0 Board Fail Rockwell Automation Publication 520 UM001G EN E September 2014 195 AppendixC RS485 DSI Protocol Reading 03 Drive Operational Values Reading 03 and W
8. Appendix B m 66 1 2 60 4 I 63 1 2 48 4 33 5 1 32 23 9 0 94 L UUUUUU 921 5 20 85 an l 927 5 21 08 S 18 cp T ar 28 RE uu 28 Rockwell Automation Publication 520 UM001G EN E September 2014 IP 30 NEMA 1 UL Type 1 conduit box S 870 3 43 S IP 30 NEMA 1 UL Type 1 top panel eo p 72 5 2 85 z 172 0 6 77 59000000 Lad zi te ee e z CMM L p lt gt S n Ss SS 5 E SS S55 e Cu A E 3 E 3 UUUUUUUUUUU s RE a Powerflex S SS SSS E n Uus 5 n LCE SS g h a amp 8 Allen Bradley 4 O L61024 179 Appendix B 180 Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame Dimensions are in millimeters and inches C
9. Values Default Read Only Min Max 0000 1111 Display 0000 b014 Dig In Status Related Parameter s t065 t068 State of the programmable digital inputs Lid Bd 1 Closed State 0 Open State Digln TBIk 5 Digit 1 Digln TBIk 6 Digit 2 Digin TBIK 77 Digit3 Digin TBIK 8 Digit 4 Not Used 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0000 1111 Display 0000 b015 Output RPM Related Parameter s P035 Current output frequency in rpm Scale is based on P035 Motor NP Poles Values Default Read Only Min Max 0 24000 rpm Display 1rpm b016 Output Speed Related Parameter s P044 Current output frequency in 96 Scale is 0 at 0 00 Hz to 10096 at P044 Maximum Freq Values Default Read Only Min Max 0 0 100 096 Display 0 196 b017 Output Power Related Parameter s b018 Output power present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW Rockwell Automation Publication 520 UM001G EN E September 2014 73 Chapter3 Programming and Parameters Basic Display Group continued b018 Power Saved Related Parameter s b017 Instantaneous power savings of using this drive compared to an across the line starter Values Default Read Only Min Max 0 00 655 35 kW Display 0 01 kW b019 Elapsed Run time
10. PowerFlex 523 PowerFlex 525 Output Input Catalog Number Catalog Number 1 2 3 4 5 6 7 8 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 25A D1P4N104 25B D1P4N104 14 1 1 0 9 0 7 1 9 1 5 1 2 1 0 25A D2P3N104 25B D2P3N104 23 1 8 1 5 12 32 2 6 2 1 1 6 25A DAPON104 25B D4PON104 4 0 32 2 6 20 57 46 37 29 25A D6PON104 25B D6PON104 6 0 4 8 3 9 30 75 6 0 49 3 8 25A D010N104 25B D010N104 105 8 4 6 8 53 138 11 0 9 0 6 9 25A D013N104 25B D013N104 130 104 85 6 5 15 4 123 100 177 25A D017N104 25B D017N104 17 0 13 6 11 1 8 5 18 4 14 7 12 0 9 2 25A D024N104 25B D024N104 240 192 15 6 120 2264 21 1 172 132 25A D030N104 25B D030N104 300 240 1195 150 0330 1264 0215 16 5 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 25A D1P4N114 25B D1P4N114 1 4 1 1 0 9 0 7 1 9 1 5 12 1 0 25A D2P3N114 25B D2P3N114 23 1 8 1 5 12 32 2 6 21 1 6 25A DAPON114 25B D4PON114 4 0 3 2 2 6 2 0 57 46 3 7 2 9 25A D6P0N114 25B D6P0N114 6 0 4 8 3 9 3 0 7 5 6 0 4 9 3 8 25A D010N114 25B D010N114 105 18 4 6 8 5 3 138 110 90 6 9 25A D013N114 25B D013N114 130 104 85 6 5 15 4 123 100 177 25A D017N114 25B D017N114 17 0 13 6 11 1 8 5 18 4 14 7 12 0 9 2 25A D024N114 25B D024N114 240 192 15 6 12 0 2264 1211 1172 32 25A D030N114 25B D030N114 30 0 240 1195 150 0330 1264 1215 165 25A D037N114 25B D037N114 37 0 2296 241 185 0337 1270 0219 169 25A D0
11. EMC Line Filter Frame D Dimensions are in millimeters and inches Filter can be mounted onto the back of the drive 80 0 3 15 130 0 5 12 33 0 1 30 28 0 1 10 90 0 3 54 05 5 00 22 5 S Q G upper a 60 00 E 310 0 12 20 298 0 298 0 11 73 11 73 o o uleg f cx ax aues e 33 0 1 30 28 0 1 10 diiL55 0 22 90 0 3 54 Rockwell Automation Publication 520 UM001G EN E September 2014 EMC Line Filter Frame E Dimensions are in millimeters and inches 80 0 3 15 33 0 1 30 28 0 1 10 l e 6 o 375 0 14 76 o o 33 0 1 30 280 110 Accessories and Dimensions Appendix B 155 0 6 10 110 0 4 33 65 5 00 22 390 0 15 35 375 0 14 76 5 5 0 22 110 0 4 33 Rockwell Automation Publication 520 UM001G EN E September 2014 185 AppendixB 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 2 Align the connectors on the
12. C 484 W0rL 05 140 SSVD 7 384 WOFL SE 999 50p1 0S c 001 8 6c 09 OLL TT OE CC OE vLILNLLOV dSC VLLNLLOV VSC 0 J84 WorL 05 140 T SSVD CO 384 WOtL SE 999 90b1 0S TE LED 00L 8 6c 09 OLL TT OE TT OE vOLNLLOV gSZ VOLNLLOV VSC SCYX38 WOVL SC cq90 00v1 0r 110 SSVD 384 WOzL 7 2090 NOFL Ov SC 7 00L 9 OBL Sv 08 SL OT SL OZ vLLNOdBV gG VL LNOdSV VSC J84 WOPL SC cq90 00v1 0p 110 SSVD 384 WOzL 7 2090 NOFL Ov SC 7 00L 9 08 Sv 08 SL OT SL 07 vOLNOdBV gG VOLNOdSV VSC 91530 WOrL S15 Ca90 f0vL SZ Y S10 L40 oH SSVD 912 30 WOPL SL9 709d NOrL SC OL ZLD OOL Y LOL 8 8v SLO OL SLO OL vLLNSdvV aSC vLLNBdvV VSC 9L JZ WOPL SLI 2090 NOvL SZ Y S10 L401 SMUSSWID 912 30 WOtL SL3 7090 NOvL SC 9L 712 00L V LOL 8c Sv SLO OLI SLO OL voLNSdvV dsc VOLNSdvV VSC 01230 WOPL 01 cd9Q fOvL SL 4 S10 L10 1 S4 SSVD 012 30 WOtL 0L9 7a90 NOvL 9L 01 605 00L V SO LL SC vo SO vo SO viLNSdCV 8SC vL LNSdCV VSC 0123O0 WOvL 0L ZA9A NOYL SL Y S10 L40 1 OR4 SSVD 012 3O WOFL 012 CQ90 00vL 9l OL 605 001 V 9 LL ST v0 S0 vO SO vOLNSdCV BSC VOLNSdCV VSC 9830 WOrL 015 cd90 f0vL SL 0 S10 L40 12 SAY SSVD 98 3O WOFL OL3 2090 NOrL 0L 9 600 001 V ESI VL OL 70 S20 70 STO VvLIN9dLV VSC 9830 WOrL 015 cd9
13. Re attach the front cover when wiring is complete Power Module Terminal To access the power terminals the terminal guard must be removed To remove Guard 1 Press and hold down the catch on both sides of the frame cover then pull out and swing upwards to remove Frames B E only 30 Rockwell Automation Publication 520 UM001G EN E September 2014 Power Wiring 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 outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION To avoid a possible shock hazard caused by induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit should be disabled This will help minimize the possible shock
14. PF 525 PowerFlex 525 only Sets the lower limit of the PID output Values Default 0 096 Min Max 0 0 10 0 Display 0 1 A466 PID 1 Preload A478 PID 2 Preload PowerFlex 525 only Sets the value used to preload the integral component on start or enable Values Default 0 0 Hz Min Max 0 0 500 0 Hz Display 0 1 Hz A467 PID 1 Invert Err A479 PID 2 Invert Err PF 525 PowerFlex 525 only Changes the sign of the PID error Options 0 Normal Default 1 Inverted Rockwell Automation Publication 520 UM001G EN E September 2014 115 Chapter3 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 01 A483 Testpoint Sel Used by Rockwell Automation field service personnel Values Default 400 Min Max 0 FFFF Display 1 A484 Current Limit 1 Related Parameter s P033 Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 Norm
15. g V sau saa Uol Ia Olg Ndu asbuq A0z 1 001 S NA SA119S 07ZS Xa JI9MOd 10 S49 ealg JN pue sasnj 23 Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 jeWayy 2ypads uone rddy uuinoo siy ur pay Dads auinjoA WNWIUI au YUM simsopue pare HnusA uou JO paje Huan e ui paj ejsur aq ISNW AHP ay UNLA JaMod SALI stu YUM 4a 04 UO 1030 uoneurquuo 3 ad pa a olg sjas jenue e bulsn uayM swuaysAs punoif exueisisai Uiu 10 punoJb 13u10 23 20 2420 A009 40 ADB UO asn 10 PASI IN ON Mdu JY A009 pue 2 A0gt 10 Parsi IN a ouo 1030 uoneurquuo 3 ad j papeioig Jjogjenuew din JOU JM 2249 ayy PPY uea uinuumumu ay o3 385 di JUaLIND ay aeu Pinoys ue juam ajgeysn pe YM Woy unang Shuey uoneddy siayearg INDI UOIa Olg 100 WOPL UNal ng sas fea Kew siayeadg 12r 01223014 1030 WOP L UN JINg ayy jo sbune1j v ay Bune1 zuan yndul Aup 40 ayejdaweu IAP ay 01 13J21 shuryes dwe samo YIM S1070W ur jonuoo si AAUP ay uauM aunsopua 13612 e auinbai Aew SUI eJapIsuod eNup S14 10 ajqejrene ase sunei GH fang AAeay pue GN fang jeuuoN lL m z SCL 120 SSY 06 999 90rL SCL 0L C 001 3 09s occ 1 29 OL OSL OSL 0 07 vOLNCO908 dSC VOLNC908 VGC CILL Sv2 393 WOvL E 06 1101 SSVD V 384 WOv L 029 999 90bL 06 9 099 00L 3 Orr l OC 87
16. 01 02 oo 24V Common 000000 oooooo Each digital input draws 6 mA Rockwell Automation Publication 520 UM001G EN E September 2014 43 Chapter Installation Wiring 1 0 Connection Example 3 Wire SNK Control Internal Supply SNK Non Reversing s amp 01 9 04 4 3 Wire SRC Control Internal Supply SRC External Supply SRC Reversing i P046 Start Source 1 2 1062 Digln TermBlk 02 o 49 and t063 Digln n TermBIk 03 51 E e 9 e A momentary input will om start the drive A stop Direction input to 1 0 Terminal 01 Direction l l e will stop the drive as V Common specified by P045 Stop PES Mode 1 0 Terminal 03 Each digital input draws 6 mA determines direction 3 Wire SNK Control Internal Supply SNK Reversing SJ 01 9 02 S 03 04 Direction Opto Output 1 amp 2 Opto Output 1 t069 Opto Out Sel determines Opto Output 1 1 0 Terminal 17 operation t072 Opto Out2 Sel determines Opto Output 2 1 0 Terminal 18 operation 19 When using Opto Output with an inductive load 43A Common such as a relay installa Each Opto Output is rated 30V DC 50 mA Non inductive recover
17. 2 Reset Time Resets min hr and x10 hr A556 Text Scroll Sets the scrolling speed of the text in the LCD display Options 0 Off No scroll 1 Low Speed 2 Mid Speed Default 3 High Speed A557 Out Phas Loss En Enable disable output phase loss detection ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Options 0 Disable Default 1 Enable A558 Positioning Mode O Kay drive before changing this parameter PowerFlex 525 only Defines the positioning transition mode used for the position steps Options 0 Time Steps Default Steps based on time 1 Preset Input Preset inputs directly commands a given step 2 Step Logic Use Step Logic Commands Always start from Step 0 3 Preset StpL Use Preset Inputs to determine starting step then Step Logic commands 4 StpLogic Lst Use Step Logic commands from last Step Logic step at last drive stop Rockwell Automation Publication 520 UM001G EN E September 2014 125 Chapter3 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 D
18. No Parameter Min Max Display Options Default P030 Language 1 15 1 English 1 Selects the language displayed x E Important The setting takes effect after the drive IET is power cyded 5 Deutsch 6 Reserved 7 Portugu s 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Polish 13 Reserved 14 Turkish 15 Czech P031 Motor NP Volts 10V for 200V Drives 20V 1V Based on Drive Rating for 400V Drives 25V for 600V Drives Drive Rated Volts Sets the motor nameplate rated volts P032 Motor NP Hertz 15 500 Hz 1Hz 60 Hz Sets the motor nameplate rated frequency P033 Motor OL Current 0 0 Drive Rated Amps x2 0 1A Based on Drive Rating Sets the motor nameplate overload current P034 Motor NP FLA 0 0 Drive Rated Amps x2 0 1A Drive Rated Amps Sets the motor nameplate FLA P035 Motor NP Poles 2 40 1 4 Sets the number of poles in the motor P036 Motor NP RPM 0 24000 rpm 1rpm 1750 rpm Sets the rated nameplate rpm of motor P037 Motor NP Power 0 00 Drive Rated Power 0 01 kW Drive Rated Power 5255 Sets the motor nameplate power Used in PM regulator P038 Voltage Class 2 3 2 480V 3 Sets the voltage class of 600V drives Only applicable 3 600V to 600V drives P039 Torque Perf Mode 0 3 0 V Hz 1 Selects the motor control mode la AC 2 Economize 1 Setting is specific to PowerFlex 525 drives only 3 Vector
19. A548 Power Loss Mode Sets the reaction to a loss of input power Options 0 Coast Default 1 Decel Drive faults and motor coasts to a stop Drive decelerates and attempts to keep the DC bus voltage above the undervoltage level A549 Half Bus Enable Enables disables the power ride through function which allows the drive to maintain power to the motor at 5096 drive input voltage during short term power sag conditions ATTENTION To guard against drive damage a minimum line impedance must be provided to limit inrush current when the power line recovers The input impedance should be equal or greater than the equivalent of a 596 transformer with a VA rating 6 times the drive s input VA rating if Half Bus is enabled Options 0 Disabled Default 1 Enabled A550 Bus Reg Enable Enables disables the bus regulator Options 0 Disabled 1 Enabled Default A551 Fault Clear so drive before changing this parameter Resets a fault and clears the fault queue Options 0 Ready Idle Default 1 Reset Fault 2 Clear Buffer Resets the active fault but does not clear any fault buffer Resets the active fault and clears all fault buffers to 0 A552 Program Lock Related Parameter s A553 Protects parameters against change by unauthorized personnel with a 4 digit password Values Default 0000 Min Max 0000 9999 Display 1111 124
20. Rockwell Automation Publication 520 UM001G EN E September 2014 61 Chapter2 Start Up Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only No Parameter Min Max Display Options Default P040 Autotune 0 2 0 Ready Idle 0 m 1 Static Tune Enables a static not spinning or dynamic motor a Spinning autotune 2 Rotate Tune P041 Accel Time 1 0 00 600 00 s 0 015 10 00 s Sets the time for the drive to accel from 0 Hz to Maximum Freg P042 Decel Time 1 0 00 600 00 s 0 015 10 00 s Sets the time for the drive to decel from Maximum Freq to 0 Hz P043 Minimum Freq 0 00 500 00 Hz 0 01 Hz 0 00 Hz Sets the lowest frequency the drive outputs P044 Maximum Freq 0 00 500 00 Hz 0 01 Hz 60 00 Hz Sets the highest frequency the drive outputs P045 Stop Mode 0 11 0 Ramp cem 0 1 z Coast cp Stop command for normal stop 2 DC Brake cp Important 1 0 Terminal 01 is always a stopinput 3 DCBrkAuto CF The stopping mode is determined by the drive 4 Ramp setting 5 Coast Important The drive is shipped with a jumper 6 DCBrake installed between 1 0 Terminals 01 and 11 Remove 7 DC BrakeAuto this jumper when using 1 0 Terminal 01 as a stop or 8 Ramp EM B cr enable input 9 Ramp EM Bk 10 PointStp CF 1 Stop input also clears act
21. ojojo S9 o 1 1 Active 0 Inactive Options 0 Standard Default 1 Enhanced Rockwell Automation Publication 520 UM001G EN E September 2014 129 Chapter3 Programming and Parameters Network Parameter Group This group contains parameters for the network option card that is installed Refer to the network option cards user manual for more information on the available parameters Modified Parameter Group This group contains parameters that have their values changed from the factory default When a parameter has its default value changed it is automatically added to this group When a parameter has its value changed back to the factory default it is automatically removed from this group Fault and Diagnostic Group F604 Fault 4 Code Related Parameter s b007 b009 F605 Fault 5 Code F606 Fault 6 Code F607 Fault 7 Code F608 Fault 8 Code F609 Fault 9 Code F610 Fault10 Code A code that represents a drive fault The codes appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults are only recorded once Values Default Read Only Min Max F0 F127 Display FO F611 Fault 1 Time hr F612 Fault 2 Time hr Related Parameter s d362 F613 Fault 3 Time hr F614 Fault 4 Time hr F615 Fault 5 Time hr F616 Fault 6 Time hr F617 Fault 7 Time hr F618 Fault 8 Time hr F619 Fault 9 Time hr F620 Fault10 Time hr
22. Control Module Cover Power Module Terminal Guard Power Wiring Power Terminal Block Common Bus Precharge Notes 1 0 Wiring Control 1 0 Terminal Block Start and Speed Reference Control CE Conformity KO PION ION 17 Oo le I I I IN INS IO RS ES E ES RIS IS sy RIS Most start up difficulties are the result of incorrect wiring Every precaution must be taken to assure that the wiring is done as instructed All items must be read and understood before the actual installation begins A ATTENTION The following information is merely a guide for proper installation Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation e Mount the drive upright on a flat vertical and level surface Frame A Screw Size M5 10 24 Screw Torque 1 56 1 96 Nm 14 17 Ib in 10 24 1 56 1 96 Nm 14 17 Ib in 10 24 1 56 1 96 Nm 14 17 Ib in J J J J m ojl aj M5 M5 M5 10 24 2 45 2 94 Nm 22 26 Ib in M8 5 16 in 6 0 7 4 Nm 53 65 Ib in e Protect the cooling fan by avoiding dust or metallic particles Rockwell Automation Publication 520 UM001G EN E Septem
23. Related Parameter s C128 Values Default 0 Min Max 0 255 Display 1 C137 EN Gateway Cfg 1 C138 EN Gateway Cfg 2 C139 EN Gateway Cfg 3 C140 EN Gateway Cfg 4 PowerFlex 525 only Sets the bytes of the gateway address A reset or power cycle is required after selection is made 192 168 1 1 EN Gateway Cfg 1 EN Gateway Cfg 2 EN Gateway Cfg 3 EN Gateway Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters Related Parameter s C128 Values Default 0 Min Max 0 255 Display 1 C141 EN Rate Cfg PF 525 PowerFlex 525 only Sets the network data rate at which EtherNet IP communicates A reset or power cycle is required after selection is made Options 0 Auto detect Default 1 10Mbps Full 10Mbps Half 100Mbps Full lw N 100Mbps Half 96 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Communications Group continued C143 EN Comm Fit Actn Related Parameter s P045 C145 C146 C147 C150 PF 525 PowerFlex 525 only Sets the action that the EtherNet IP interface and drive takes if the EtherNet IP interface detects that Ethernet communications have been disrupted IMPORTANT This setting is effective only if 1 0 that controls the drive is transmitted through the EtherNet IP interface ATTENTION Risk of injury or equipment damage exists Parameter C143 EN Comm
24. Related Parameter s b024 P052 A555 Total approximate accumulated cost savings of the drive compared to using an across the line starter Accum Cost Sav Average kWh cost x Accum kWh Sav Values Default Read Only Min Max 0 0 6553 5 Display 0 1 b026 Accum C02 Sav Related Parameter s A555 Total approximate accumulated C02 savings of the drive compared to using an across the line starter Values Default Read Only Min Max 0 0 6553 5 kg Display 0 1 kg b027 Drive Temp Present operating temperature of the drive heatsink inside module Values Default Read Only Min Max 0 120 C Display 1 C b028 Control Temp Present operating temperature of the drive control Values Default Read Only Min Max 0 120 C Display 1 C b029 Control SW Ver Current drive firmware version Values Default Read Only Min Max 0 000 65 535 Display 0 001 Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter3 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 Keypad RSLogix 5000 Connected LCD Display Logix Designer Components Workbench Options 1 English Default Y Y Y 2 Francais Y Y Y 3 Espafiol Y Y Y 4 Italiano Y Y Y 5 Deutsch Y
25. To begin the automatic homing routine activate the Find Home input and then initiate a valid start command The drive will then ramp to the speed set in A562 Find Home Freq and in the direction set in A563 Find Home Dir until the digital input defined as Home Limit is activated If the drive passes this Rockwell Automation Publication 520 UM001G EN E September 2014 Encoder Pulse Train Usage and Position StepLogic Application Appendix E Encoder and Position Feedback 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 che Find Home Freq and or Home Limit bits in A560 Enh Control Word can be activated instead of utilizing a digital input The inputs or bits should be returned to inactive after the routine is complete IMPORTANT After the position is reached the drive will stop If the Find Home is removed before the homing is complete the drive will begin running the position routine without the proper home In this case Home will not be reset and the position will be in relation to the power up position d376 Speed Feedback indicates the measured speed feedback or the calculated speed feedback when no feedback device is selected Parameter d376 Speed Feedback is the number value to the left of the decimal whole number and d377 Speed Fee
26. y 381 WOrL 08 1101 SSVD Sv 384 WOrL 099 999 90bL 08 05 099 00L 3 G68 9SE OEP 8L OST O 7Z 00 vLLNEVOQ gSC vLLNEVOQ VSC S 484 WOrL zi 0 110 SSVD v 384 WOv L 05 99 90b1 04 Sy tv2 00L d Lt SOE OLE OSL 0107 S BL O Sc vLENZEOQ gSC VLLNZEOQ VSC L 9S9 Sy 383 WOvL m 0 110 SSVD v 384 WOv L 059 999 90bL 0L Sy tv2 00L Q OEE COE ODE OL OSL OSL 0 07 VLLNOEOQ 8SC VLLNOEOQ VSC L 9S9 Sv 383 WOvL s 0 110 SSVD Sv 384 WOv L 059 999 90bL 0 Sy tv2 00L Q OEE COE ODE OL OSL OSL 0 07 vVOLNOEOQ 8SC VOLNOEOQ VSC g 999 C 0 381 WOvL 09 110 SSVD Z D A84 WOVL 05 295 50vL 9 SEJ 00L d YIT LZ OYT OLLI OSL OLL OSL vLLNECOQ 8SC VLLNPCOQ VSC L989 C 0 383 WOvL 09 110 SSVD C 0 383 WOtL 0 9 999 D0rL t9 001 d V9c LZ Ove OLL OSL OLLI OSL vVOLNVCOQ gSC vVOLNVCOQ VSC 00 380 WOvL n 0v 140 SSVD 00 380 WOPL 7 090 NOvL Ov S O 001 2 VBL SOL OLL SZ 001 SZ 00L VLINZLOQ GSC VLLNZLOQ VSC 00 380 WOvL E 0v 140 1 SSVD 07 38Q WOPL 7 090 NOvL Ov SC O 001 D VBL SOL OLL GZ OOL SZ 00L vVOLNZLOQ GSC VOLNZLOQ VSC 00 380 WOtvL in 140 SSVD 020 380 WOrL 7 090 NOrL H3 0c C00L 2 VSL LVL OEL SS SL SS SZ PLLNELOG 852 PLLNELOQ VSC 00 380 WOtvl 140 SSVD 020 380 WOL 7 090 NOrL H3 0c 29 00L 2 VSL LVL OEL SS SL SS GZ VOLNE
27. Digln TermBlk 02 03 48 49 50 51 2 Wire or 3 Wire Start Source x 2 Digln TrmBIk Start and Direction Drive will not start command from Start Source x Rockwell Automation Publication 520 UM001G EN E September 2014 47 Chapter Installation Wiring 48 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 Active Dighn TermBIk xx 32 Sync Enable Traverse active if Max Traverse gt 0 Hz Terminal Block Jog Input Enabled AND Accel Decel always Accel Decel 1 Sync Time is used for Accel Decel rate Traverse Inc Dec is used for Accel Decel rate Accel Decel from Jog Acc Dec Drive stopped Yes NOT running Input s is programmed as Acc Dec 2 3 4 No ls speed controlled by Preset Freq x Active Speed Referencex omms No Active Speed Referencex 13 Ste Logig No v Drive uses Accel 1 and Decel 1 1 Setting is specific to PowerFlex 525 drives only Accel Decel 2 is active when input is selected by Accel and Decel input Accel Decel 1 2 3 4 is selected by the d
28. Rockwell Automation Publication 520 UM001G EN E September 2014 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 2 Custom Only All parameters are locked and hidden except custom group and Program Lock 3 KeyPd Custom All parameters are locked and hidden except custom group and Program Lock from keypad access but can still be accessed over communications A554 Drv Ambient Sel Sets the maximum expected ambient of the drive when used above 50 C When ambient temperature is above 50 C the drive will apply necessary current derating Options 0 Normal Default 1 55C 60C 65C Fan Kit Fan kit required 70C Fan Kit Bl wj N A555 Reset Meters Related Parameter s b019 b021 b022 b023 b024 b025 b026 d362 d363 Resets the values stored in the parameters that track fault times and energy usage Options 0 Ready ldle Default 1 Reset Meters Resets kWh MWh Accum kWh Cost and C02 Sav parameter values
29. 300 0 11 81 280 0 11 02 Y X Allen Bradley 4 1378 1 15 0 0 59 N 350 0 r 127 5 5 02 4 p 825 3 25 62 5 2 46 42 5 1 67 UUCUUUUUUUU a IP 30 NEMA 1 UL Type 1 conduit box 921 5 20 85 943 7 91 72 e OCF e yea N Y AN Wj ES as e OM fs W SE iS Y L Z m 181 0 7 13 164 0 6 46 8 35 212 0 Rockwell Automation Publication 520 UM001G EN E September 2014 EMC Line Filter Frame A Dimensions are in millimeters and inches 20 0 0 79 55 0 2 17 30 0 1 18 o 223 0 8 78 o o 23 0 0 91 EMC Line Filter Frame B Dimensions are in millimeters and inches 25 0 0 98 70 0 2 76 35 0 1 38 258 0 10 16 oC RS 24 0 0 94 Accessories and Dimensions Appendix B Filter can be mounted onto the back of the drive
30. A Encoder A o TN r5 V Output DIP switch selects 12 or 5 volt power supplied at terminals V and Cm for the encoder 1 When using 12V Encoder power 24V 1 0 power maximum output current at 1 0 Terminal 11 is 50 mA 2 If Encoder requires 24V power it must be supplied by an external power source Encoder Wiring Examples 1 0 Encoder Power Internal Drive Power Internal drive Connection Example 1 0 Connection Example HIN DC Encoder Power a Fej oma External XZ cm d Common Power Source E y 4 S sito gt gt o to SHLD External Power ooooQQ 12V DC 250mA 9 Encoder Signal Encoder Signal Single Ended 75 Differential JS sup Dual Channel cm Dual Channel milo sur I B Hon x M ANOT e a He The encoder option card can supply 5V or 12V power 250 mA maximum for an encoder Be sure the DIP switch is set properly for the encoder In general 12V will provide higher noise immunity The encoder can handle 5V 12V or 24V inputs but the pulse train can handle only 24V inputs The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary If a single channel input is used it must be wired between the A signal and A signal common channels IMPORTANT A qu
31. 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 It should be mounted closest to the branch and sized to handle the total current of the branch circuit Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 196 line reactance Install Line Reactor Greater than 120 kVA supply transformer orlsolation Transformer Line has power factor correction capacitors Install Line Reactor or Isolation Transformer Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of normal line to line voltage Remove MOV jumper to ground e or Install Isolation Transformer with grounded secondary if necessary 240V open delta configuration stinger leg e Install Line Reactor Ungrounded distribution system 1 For drives applied on an open delta with a middle phase grounded neutral system the phase opposite the phase that is tapped in the middle to the neutral or e
32. 10Mbps Half 100Mbps Full 100Mbps Half Dup IP Addr Disabled Di wm m wl N F686 DSI 1 0 Act Displays the Drives that are active in Multi Drive mode rinininin LII LI LII 1 Drive Active 0 Drive Inactive Drive 0 Actv Digit 1 Drive 1 Actv Digit 2 Drive 2 Actv Digit 3 Drive 3 Actv Digit 4 Drive 4 Actv Digit 5 Value Default Read Only Min Max 00000 11111 Display 00000 Rockwell Automation Publication 520 UM001G EN E September 2014 133 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F687 HW Addr 1 F688 HW Addr 2 F689 HW Addr 3 F690 HW Addr 4 F691 HW Addr 5 F692 HW Addr 6 PowerFlex 525 only Shows the MAC address for the embedded EtherNet IP interface Values Default Read Only Min Max 0 255 Display 1 F693 EN IP Addr Act 1 F694 EN IP Addr Act 2 F695 EN IP Addr Act 3 F696 EN IP Addr Act 4 PowerFlex 525 only Shows the actual IP address used by the embedded EtherNet IP interface at the time This indicates 0 if no address is set 255 255 255 255 EN IP Addr Act 1 EN IP Addr Act 2 EN IP Addr Act 3 EN IP Addr Act 4 Values Default Read Only Min Max 0 255 Display 1 F697 EN Subnet Act 1 F698 EN Subnet Act 2 F699 EN Subnet Act 3 F700 EN Subnet Act 4 PowerFlex 525 only Shows the actual subnet mask used
33. A443 PID 2 Integ Time A444 PID 2 Diff Rate A445 PID 2 Setpoint A446 PID 2 Deadband A447 PID 2 reload A448 PID 2 Invert Err A449 Process Disp Lo A450 Process Disp Hi A451 Testpoint Sel A452 Current Limit 1 M53 Current Limit 2 A454 Shear Pin Level A455 ShearPin 1 Time A456 Shear Pin2 Level A457 Shear Pin 2 Time A458 Load Loss Level A459 Load Loss Time A460 Stall Fault Time A461 Motor OL Select A462 Motor OL Ret A463 Drive OL Mode A464 IR Voltage Drop A465 Flux Current Ref A466 Motor Rr M67 Motor Lm A468 Motor Lx A469 Speed Reg Sel A470 Freq1 A471 Freq 1 BW A472 Freq2 A473 Freq2 BW A474 Freq3 A475 Freq 3 BW A476 Freq 1Kp A477 Freq 1Ki A478 Freq 2 Kp A479 Freq 2 Ki M81 Freq 3 Kp A482 Freq 3 Ki A483 Boost Select A484 Start Boost A485 Break Voltage A486 Break Frequency A487 Maximum Voltage A488 Motor Fdbk Type A489 Encoder PPR A490 Pulse In Scale A491 KiSpeed Loop A492 Kp Speed Loop M93 Var PWM Disable A494 Auto Rstrt Tries A495 Auto Rstrt Delay A496 Start At PowerUp M97 Reverse Disable A498 Flying Start En A499 FlyStrt CurLimit This group contains parameters for the network option card that is installed Seethe 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 When a parameter has its default value changed it is automatically added to this group When
34. DriveTools SP When using these methods the parameter list can only be displayed linearly and there is no access to communications option card programming For information on See page About Parameters 65 Parameter Groups 66 Basic Display Group n Basic Program Group 76 Terminal Block Group 82 Communications Group 94 Logic Group 100 Advanced Display Group 103 Advanced Program Group 107 Network Parameter Group 130 Modified Parameter Group 130 Fault and Diagnostic Group 130 AppView Parameter Groups 138 CustomView Parameter Group 139 Parameter Cross Reference by Name 140 About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of parameters exist e ENUM ENUM parameters allow a selection from 2 or more items Each item is represented by a number e Numeric Parameters These parameters have a single numerical value 0 1V Rockwell Automation Publication 520 UM001G EN E September 2014 65 Chapter3 Programming and Parameters Bit Parameters Bit parameters have five individual digits associated with features or conditions If the digit is 0 the feature is off or the condition is false If the digit is 1 the feature is on or the condition is true Some parameters are marked as follows O Stop drive before changing this parameter IA 32 bit parameter Parameters marked 32 bit will have two parameter
35. Fluctuations in actual system pressure due to changes in flow result in a PID Error value e The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value Rockwell Automation Publication 520 UM001G EN E September 2014 215 AppendixF X PID Set Up e The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow e When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference eu Es Mm PID Feedback Pressure Transducer Signal E Pump PID Reference Desired System Pressure Trim Control In Trim Control the PID Output is added to the Speed Reference In Trim mode the output of the PID loop bypasses the accel decel ramp as shown Trim Control is used when A458 or A470 PID x Trim Sel is set to any option other than 0 Speed Referencex c EEE S i PID Loop Accel Decel PID Ref PID Prop Gain L Ramp po i ME rror utput PIDFdbk PID Integ Time H r XS gt p f l f l PID Diff Rate PID Selected Example e Ina winder application the PID Reference equals the Equilibrium set point e The Dancer Pot signal provides PID Feedback to the drive Fluctuations in tension res
36. Freq and Position Step 5 110 Freq and Position Step 6 111 Freq and Position Step 7 11 1 Find Home 12 1 Hold Step 13 1 Pos Redefine 14 1 Sync Enable 15 1 Traverse Disable The PowerFlex 520 series drive Comm Frequency Command can be controlled through the network by sending Function Code 06 writes to register address 2001H Comm Frequency Command Comm Frequency Command Reference Address Decimal Description 2001H 8193 Used by internal comm modules to control the reference of the drive In units of 0 01 Hz The PowerFlex 520 series drive Logic Status data can be read through the network by sending Function Code 03 reads to register address 2100H Logic Status PowerFlex 523 drives support only Velocity bit definitions PowerFlex 525 drives can use Parameter C122 Cmd Stat Select to select either Velocity or Position bit definitions Rockwell Automation Publication 520 UM001G EN E September 2014 193 AppendixC R 485 DSI Protocol Velocity Bit Definitions Comm Logic Status C122 0 Velocity Address Decimal Bit s 2100H 8448 Description 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 Referen
37. Key Name Description Up Arrow Scroll through user selectable display parameters or groups Down Arrow Increment values CS Escape Back one step in programming menu Cancel a change to a parameter value and exit Program Mode Select Advance one step in programming menu Sel Select a digit when viewing parameter value Enter Advance one step in programming menu Save a change to a parameter value Medic O 58 Rockwell Automation Publication 520 UM001G EN E September 2014 Viewing and Editing Parameters Key Name Reverse StartUp Chapter 2 Description Used to reverse direction of the drive Default is active Controlled by parameters P046 P048 and P050 Start Source x and A544 Reverse Disable 0 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 Default is active Controlled by parameters P047 P049 and P051 Speed Referencex The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program a parameter Step 1 When power is applied the last user selected Basic Display Group parameter number is briefly displayed with flashing character
38. L206 Step Units 3 A414 Preset Freq 4 L184 Stp Logic 4 L208 Step Units 4 Rockwell Automation Publication 520 UM001G EN E September 2014 207 Appendix E 208 Encoder Pulse Train Usage and Position StepLogic Application Frequency Source Step Source Position Source A415 Preset Freq 5 L185 Stp Logic 5 L210 Step Units 5 A416 Preset Freq 6 L186 Stp Logic 6 L212 Step Units 6 A417 Preset Freq 7 L187 Stp Logic 7 L214 Step Units 7 IMPORTANT The default value for A410 Preset Freq 0 is 0 00 Hz This value needs to be changed or the drive will not be able to move during Step 0 L190 L197 Stp Logic Time x are the parameters that define the time the drive will remain in each corresponding step if that step is time based For example if L192 Stp Logic Time 2 is set to 5 0 seconds and that step is time based the drive will remain in Step 2 for 5 0 seconds Note that this is the total time in that step not the time at that position Therefore it will include the time needed to accelerate run and decelerate to that position L180 L187 Stp Logic x are the parameters that allow additional flexibility and control various aspects of each step when a positioning mode is selected that utilizes the Step Logic functions Note that in Positioning mode these parameters have a different function than when used for normal velocity Step Logic Each of the 4 digits controls one aspect of the each position step T
39. PF 525 PowerFlex 525 only Displays the value of d362 Elapsed Time hr when the fault occurs Values Default Read Only Min Max 0 32767 hr Display Thr F621 Fault1Time min F622 Fault 2 Time min Related Parameter s d363 F623 Fault3 Time min F624 Fault 4 Time min F625 Fault 5 Time min F626 Fault6Time min F627 Fault 7 Time min F628 Fault8Time min F629 Fault 9 Time min F630 Fault10 Time min PowerFlex 525 only Displays the value of d363 Elapsed Time min when the fault occurs Values Default Read Only Min Max 0 0 320 0 min Display 0 1 min 130 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F631 Fault 1 Freq F632 Fault 2 Freq Related Parameter s b001 F633 Fault 3 Freq F634 Fault 4 Freq F635 Fault 5 Freq F636 Fault 6 Freq F637 Fault 7 Freq F638 Fault 8 Freq F639 Fault 9 Freq F640 Fault10 Freq PowerFlex 525 only Displays and stores the value of b001 Output Freq with the most recent 10 faults occurred Fault 1 Freq stores the most recent fault Fault 2 Freq stores the second most recent fault and Fault 3 Freq stores the third most recent fault Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz F641 Fault 1 Current F642 Fault 2 Current Related Parameter s b003 F643 Fault 3 C
40. PID reference or PID setpoint in the drive Options 0 Disabled Default 1 Fault F29 Stop Zero Ref Min Freq Ref Max Freq Ref Key Freq Ref MOP Freq Ref Continu Last co N DH Om A Ww N t095 Anlg In4 20mA Lo Related Parameter s P043 t096 so drive before changing this parameter Sets the percentage based on 4 20 mA of input current applied to the 4 20 mA analog input used to represent P043 Minimum Freq Analog inversion can be accomplished by setting this value larger than t096 Anlg In4 20mA Hi Values Default 0 0 Min Max 0 0 100 0 Display 0 1 t096 Anlg In4 20mA Hi Related Parameter s P044 t095 S drive before changing this parameter Sets the percentage based on 4 20 mA of input current applied to the 4 20 mA analog input used to represent P044 Maximum Freq Analog inversion can be accomplished by setting this value smaller than t095 Anlg In4 20mA Lo Values Default 100 096 Min Max 0 0 200 0 Display 0 1 t097 Anlg In mA Loss Related Parameter s P043 P044 A426 A427 Sets the response to a loss of input When the 4 20mA input is used for any reference any input less than 2 mA is reported as a signal loss Input must exceed 3 mA for the signal loss condition to end If enabled this function affects any input that is being used as a speed reference or PID reference or PID setpoint
41. PowerFlex 520 series drives are not intended to be used on public low voltage networks which supply domestic premises Without additional mitigation radio frequency interference is expected if used on such a network The installer is responsible for taking measures such as a supplementary line filter and enclosure see Connections and Grounding on page 52 to prevent interference in addition to the installation requirements of this document supplementary enclosure or equipped with a NEMA Type 1 Kit to be ATTENTION NEMA UL Open Type drives must either be installed in a CE compliant with respect to protection against electrical shock PowerFlex 520 series drives generate harmonic current emissions on the AC supply system When operated on a public low voltage network it is the responsibility of the installer or user to ensure that applicable requirements of the distribution network operator have been met Consultation with the network operator and Rockwell Automation may be necessary Ifthe optional NEMA 1 kit is not installed the drive must be installed in an enclosure with side openings less than 12 5 mm 0 5 in and top openings less than 1 0 mm 0 04 in to maintain compliance with the LV Directive The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents Use of line filters in ungrounded systems is not recommended In CE installations input power must
42. Program one of the digital inputs to 37 Pos Redefine Then move the system into the home position with a run command a jog command or by manually moving the system into the home position Then toggle the Pos Redefine input This will set the drive to Home at its current position and d388 Units Traveled H and d389 Units Traveled L are set to zero Alternately the Pos Redefine bit in A560 Enh Control Word can be toggled instead of utilizing a digital input IMPORTANT The Pos Redefine input or bit must be returned to inactive before starting the position routine Otherwise the drive will continuously read a position of 0 home and the position routine will not function correctly 2 Automatic Homing to Limit Switch Program the following drive parameters t062 t063 t065 068 DigIn TermBlk xx 35 Find Home Program one of the digital inputs to 35 Find Home t062 t063 t065 068 DigIn TermBlk xx 34 Home Limit Program one of the digital inputs to 34 Home Limit Normally the Home Limit input would be wired to a proximity switch or photo eye and will indicate the system is in the home position A562 Find Home Freq sets the frequency the drive will use while it is moving to the home position during the automatic homing routine A563 Find Home Dir sets the direction the drive will use while it is moving to the home position during the automatic homing routine
43. Remote Handheld LCD Display 22 HIM A3 1 Available as a free download at http ab rockwellautomation com programmable controllers connected components workbench software 2 Does not support the new dynamic parameter groups AppView CustomView and CopyCat functionality is limited to the linear parameter list Language Keypad LCD Display RSLogix 5000 Connected Components Logix Designer Workbench English Y Y Y French Y Y Y Spanish Y Y Y Italian Y Y Y German Y Y Y Japanese Y Portuguese Y Y Chinese Simplified Y Y Korean Y Rockwell Automation Publication 520 UM001G EN E September 2014 Smart Start Up with Basic Program Group Parameters StartUp Chapter 2 Language Keypad LCD Display RSLogix 5000 Connected Components Logix Designer Workbench Polish Y Turkish Y Czech Y 1 Due toa limitation of the LCD Display some ofthe characters for Polish Turkish and Czech will be modified The PowerFlex 520 series drive is designed so that start up is simple and efficient The Basic Program Group contains the most commonly used parameters See Programming and Parameters on page 65 for detailed descriptions of the parameters listed here as well as the full list of available parameters Stop drive before changing this parameter Parameter is specific to PowerFlex 525 drives only
44. Sle a gt 50mm j 2 0 in L E I EN Horizontal with Control Module Fan Kit Horizontal Zero Stacking with Control Module Fan Kit No clearance between drives 1 For Frame E with Control Module Fan Kit only clearance of 95 mm 3 7 in is required 2 For Frame E with Control Module Fan Kit only clearance of 12 mm 0 5 in is required 16 Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 Ambient Operating Temperatures See Appendix B for option kits Mounting Enclosure Rating 7 Ambient Temperature Minimum Maximum No Derate Maximum Derate 2 Maximum with Control Module Fan Kit Derate 3 5 Vertical IP 20 Open Type 50 C 122 F 60 C 140 F 70 C 158 F IP 30 NEMA 1 UL Type 1 45 C 113 F 55 C 131 F Vertical Zero Stacking IP 20 0pen Type 45 C 113 F 55 C 131 F 65 C 149 F IP 30 NEMA 1 UL Type1 5gec 4 F 40 C 104 F 50 C 122 F Horizontal with IP 20 0pen Type 50 C 122 F 70 C 158 F Control Module Fan Kit 9 Horizontal Zero Stacking IP 20 0pen Type o A 65 C 149 F with Control Module Fan Kit 45 C 113 F 1 IP 30 NEMA 1 UL Type 1 rating requires installation of the PowerFlex 520 Series IP 30 NEMA 1 UL Type 1 option kit catalog number 25 JBAx 2 For catalogs 25x D1P4N104 and 25x EOP9N104 the temperature listed under the Maximum Derate colu
45. Values Default Read Only Min Max 0 1 Display 1 106 Rockwell Automation Publication 520 UM001G EN E September 2014 Advanced Program Group A410 Preset Freq 0 M12 Preset Freq 2 A414 Preset Freq 4 M16 Preset Freq 6 A411 A413 A415 A417 Preset Freq 1 Preset Freq 3 Preset Freq 5 Preset Freq 7 A418 Preset Freq 8 A420 Preset Freq 10 A422 Preset Freq 12 A424 Preset Freq 14 PowerFlex 525 only A419 A421 A423 A425 Preset Freq 9 Preset Freq 11 Preset Freq 13 Preset Freq 15 Sets the frequency of the drive outputs to the programmed value when selected For PowerFlex 525 Programming and Parameters Chapter 3 Default Accel Decel Used Preset Input 1 DigIn TermBlk 05 Preset Input 2 Digln TermBlk 06 Preset Input 3 DigIn TermBlk 07 Preset Input 4 DigIn TermBlk 08 Preset Setting o 0 0 0 0 Preset Setting 1 Preset Setting 2 Preset Setting 3 Preset Setting 4 Preset Setting 5 Preset Setting 6 Preset Setting 7 Preset Setting 8 Preset Setting 9 Preset Setting 10 Preset Setting 11 Preset Setting 12 Preset Setting 13 Preset Setting 14 Preset Setting 15 n n nj n n n n n o of o o of o o o o o o o of 2 f of of of of of o o 0 0 0 0
46. l I l I Li I l I l I i f l 24V DC Gate control common T circuit Si 2 I UE mc E SEE E A EEEN E ele ne pomum ce NUT Mine input power PF 525 G GuardMaster 24V DC ate Trojan Stop Start 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I I 1 1 1 I Gate control latching i power supply button 1 l Gate control circuit a l Li i S1 Li i 2 i Ob e E cnc do onu ee RPE SSS E EE EO 1 Enclosure Recommended Note External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used 2 In some situations a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure Rockwell Automation Publication 520 UM001G EN E September 2014 229 Appendix G Safe Torque Off Function 230 24V DC Supply 24V DC COM Stop Category 0 Coast with Two PowerFlex 525 Drives pczosneceenctconpesectnMecSnEI a ca del 1 Reset ACline input power PF525 24V DC bem to p A Start Start Dig comm Gate control power supply Gate control circuit Gate contr
47. overhauling loads and eccentric loads However it can also cause either of the following two conditions to occur 1 Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes 2 Actual deceleration times can be longer than commanded deceleration times However a Stall Fault is generated if the drive remains in this state for 1 minute If this condition is unacceptable the bus regulator must be disabled see parameter A550 Bus Reg Enable In addition installing a properly sized dynamic brake resistor will provide equal or better performance in most cases ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis Rockwell Automation Publication 520 UM001G EN E September 2014 Overview Preface Catalog Number Explanation 1 3 4 5 6 8 9 10 11 12 13 14 25B B 2P3 N 1 1 4 oe Vag aig Dash Dash 4 Standard 25A PowerFlex 523 0 No Filter 25B PowerFlex 525 1 Filter V 120VAC 1 1 Standard A 240VAC 1 B 240VAC 3 7 D BNA l3 N IP20 NEMA Open E 600VAC 3 1P6 1 6 A 0 25 10 2 1025 02 1P4 14 A 05 04 10 5 104 2P5 25 A 05 04 10 5 10 4 2P3 23 A 10 10 75 10 10 75 4P8 48 B
48. page 221 or the PID Feedback does not become equal to the PID Reference decrease A462 or A474 PID x Integ Time Ifthere is alot 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 Atthis point the differential gain may not be needed However if after determining the values for A461 or A473 PID x Prop Gain and A462 or A474 PID x Integ Time Response is still slow after a step change increase A463 or A475 PID x Diff Rate Response is still unstable decrease A463 or A475 PID x Diff Rate The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains Unstable Response PID Reference PID Feedback Time Slow Response Over Damped PID Reference l PID Feedback Time Oscillation Under Damped PID Reference PID Feedback Time Rockwell Automation Publication 520 UM001G EN E September 2014 221 AppendixF X PID Set Up Good Response Critically Damped PID Reference PID Feedback Time 222 Rockwell Automation Publication 520 UM001G EN E September 2014 PowerFlex 525 Safe Torque Off Overview Appendix G Safe Torque Off Function The PowerFlex 525 Safe Iorque Off function when used with other safety components helps provide protection according to E
49. see parameter P053 Reset to Defalts To reset the communication adapters see the user manual of the adapter for more information Configure the basic program parameters related to the motor See Smart Start Up with Basic Program Group Parameters on page 61 Complete the autotune procedure for the drive See parameter P040 Autotune for more information If you are replacing a drive and have a backup of the parameter settings obtained using the USB utility application use the USB utility application to apply the backup to the new drive See Using the USB Port on page 63 for more information Otherwise set the necessary parameters for your application using the LCD keypad interface Connected Components Workbench or RSLogix or Logix Designer if using an Add on Profile through EtherNet IP e Configure the communication parameters needed for the application node number IP address Datalinks in and out communication rate speed reference start source and so on Record these settings for your reference e Configure the other drive parameters needed for the drive analog and digital I O to work correctly Verify the operation Record these settings for your reference 56 Rockwell Automation Publication 520 UM001G EN E September 2014 StartUp Chapter2 16 Verify the drive and motor perform as specified e Verify that the Stop input is present or the drive will not start IMPORTANT If1 0 Terminal 01 is used as
50. stop SRCwiring SNK wiring 01 iginte T H L Start Run FWD o o M a 2 Digin TermBlk 037 i 0 Direction Run REV oo cR SNK 5 hc SRC Digital Common Ww E Digln TermBlk 05 Pulse o Sa 06 Digln TermBlk 06 Go dom uw 3 24V DC Relay N 0 RE 10V 10V DC Relay Common Ro T L A 0 10V Input Relay N C l a zl 13 rpU Analog Common 14 Pot must be 15 4 20mA Input 1 10 k ohm 2W min a RJ45 Shield Q Comm Common V NV J8 J7 A SNK S Pulse In R 485 l 2 s V sm amp D E SRC E Digital v amp Input WV n m 01 02 03 04 05 06 8 X Oo Do Ga X R3 171 31 4 15 aA Q Control 1 0 Wiring Block Diagram Notes 1 See Digital Input Selection for Start Source on page 47 for more information on configuring the digital inputs IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting See the tables below for more information Start Method Stop Method P046 P048 P050 Start Source x 1 0 Terminal 01 Stop Normal Stop 1 Keypad Coast Per P045 2 Digln TrmBIK See t062 1063 Digln TermBlk xx below Stop Mode 3 Serial DSI Coast 4 Network Opt Coast 5 Ethernet IP Coast 1 Setting is specific to PowerFlex 5
51. to a 2 wire run reverse mode Also see t064 2 Wire Mode for level trigger settings For PowerFlex 523 drives this setting will be disabled If Digln TermBlk 03 is set to 7 Preset Freq 5 3 Wire Dir only for DigIn TermBlk 03 Select 3 Wire Dir for this input Select this option and set P046 P048 or P050 Start Source x to 2 DigIn TrmBlk to change the direction of Start Source x For PowerFlex 523 drives this setting will be disabled If Digln TermBlk 03 is set to 7 Preset Freq 52 Pulse Train PF523 only for DigIn TermBlk 05 PF525 only for DigIn TermBlk 07 Select pulse train for this input Use P047 P049 and P051 Speed Referencex to select pulse input Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In 1 This function may be tied to one input only 2 Setting is specific to PowerFlex 525 drives only t064 2 Wire Mode S drive before changing this parameter Related Parameter s P045 P046 P048 P050 t062 t063 Programs the mode of trigger only for t062 DigIn TermBlk 02 and t063 Digln TermBlk 03 when 2 wire option is being selected as P046 P048 or P050 Start Source x Options 0 Edge Trigger Default Standard 2 Wire operation 1 Level Sense OTerminal 01 Stop Coast to stop Drive will restart after a Stop command when Stop is removed and Start is held active e 1 0 Terminal 03 Run REV
52. 0 380 480V 1 4 27 0 50 60 Hz 3 Phase 23 370 4 0 62 0 6 0 86 0 10 5 129 0 13 0 170 0 17 0 221 0 24 0 303 0 30 0 387 0 380 480V 14 27 0 T a T 4 0 63 0 6 0 88 0 10 5 133 0 13 0 175 0 17 0 230 0 24 0 313 0 30 0 402 0 37 0 602 0 43 0 697 0 160 Rockwell Automation Publication 520 UM001G EN E September 2014 Supplemental Drive Information Appendix A PowerFlex 520 Series Estimated Watts Loss Rated Load Speed amp PWM Voltage Output Current A Total Watts Loss 525 600V 0 9 22 0 50 60 Hz 3 Phase 17 320 3 0 50 0 42 65 0 6 6 95 0 9 9 138 0 12 0 164 0 19 0 290 0 22 0 336 0 27 0 466 0 32 0 562 0 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 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 7 8 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A V1P6N104 1 6 13 1 0 0 8 6 4 52 4 0 32 25A V2P5N104 25B V2P5N104 25 2 0 1 6 13 9 6 77 6 2 48 25A V4P8N104 25B V4P8N104 48 3 8 3 1 2 4 19 2 154 125 9 6 25A V6P0N104 25B V6P0N104 6 0 4 8 3 9 3 0 240 1192 15 6 120 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25A A1P6N104 1 6 13 1 0 0 8 53 43 3 4 2 7 25A A2P5N104 25B A2P5N104 25 2 0 1 6 13 6 5 52 4 2 3 3 25A A4P8N104 25B A4P8N
53. 0 75 322 170 264 D 25A B032N104 25B B032N104 1 0 110 0100 75 483 170 264 E 25A B048N104 25B B048N104 20 0 15 0 150 110 62 1 170 264 E 25A B062N104 25B B062N104 380 480V AC 1596 10 3 Phase Input 0 460V 3 Phase Output D 05 o4 jos o4 14 323 528 A 25A D1P4N104 25B D1P4N104 1 0 075 10 075 23 323 528 A 25A D2P3N104 25B D2P3N104 2 0 1 5 2 0 1 5 4 0 323 528 A 25A DAPON104 25B D4P0N104 3 0 22 3 0 22 6 0 323 528 A 25A D6PON104 25B D6P0N104 5 0 4 0 5 0 4 0 10 5 323 528 B 25A D010N104 25B D010N104 Rockwell Automation Publication 520 UM001G EN E September 2014 163 Appendix B 164 Accessories and Dimensions PowerFlex 520 Series Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame PowerFlex 523 PowerFlex 525 HP kw HP kW Current A Voltage Range Size Catalog No Catalog No 75 5 5 7 5 5 5 13 0 323 528 C 25A D013N104 25B D013N104 100 175 100 175 17 0 323 528 C 25A D017N104 25B D017N104 15 0 110 1150 110 1240 323 528 D 25A D024N104 25B D024N104 20 0 15 0 115 0 110 30 0 323 528 D 25A D030N104 25B 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 14 323 528 A 25A D1P4N114 25B D1P4N114 1 0 075 10 075 23 323 528 A 25A D2P3N114 25B D2P3N114 2 0 1 5 2 0 1
54. 1 30 0 Hz e Thecontrol terminal block is wired such that a start command will also trigger the timer start e The relay output is wired to I O Terminal 02 DigIn TermBlk 02 so that it forces the input on when the timer starts r oo 3 e After the timer is complete the output is turned off releasing the preset speed command The drive defaults to following the analog input reference as programmed Note that a Reset Timer input is not required for this example since the Timer Start input both clears and starts the timer Counter Function Digital inputs and outputs control the counter function and are configured with parameters t062 t063 t065 t068 DigIn TermBlk xx set to 20 Counter In and 22 Reset Countr Digital outputs relay and opto type define a preset level and indicate when the level is reached Level parameters t077 Relay Out Level t082 Relay Out2 Level t070 Opto Outl Level and t073 Opto Out2 Level are used to set the desired count value Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out Sel and t072 Opto Out2 Sel are set to 26 Counter Out which causes the output to change state when the level is reached Example e A photo eye is used to count packages on a conveyor line e An accumulator holds the packages until 5 are collected e A diverter arm redirects the group of 5 packages to a bundling area e The diverter arm returns to its original positi
55. 150 for up to 3 s Applies for power rating above 15 kW 20 HP only Based on 480V drive rating Heavy Duty 150 Overload capability for up to 60 s 180 for up to 3 s Control Inputs Specifications PowerFlex 523 PowerFlex 525 Digital Bandwidth 10 Rad s for open and closed loop Quantity 1 Dedicated for stop 1 Dedicated for stop 4 Programmable 6 Programmable Current 6mA Type Source Mode SRC 18 24V ON 0 6V OFF Sink Mode SNK 0 6V ON 18 24V OFF Pulse Train Quantity 1 Shared with one of the programmable digital input terminals Input Signal Transistor contact open collector Input Frequency 0 100 kHz Current Consumption 7 mA 24V DC maximum Analog Quantity 2 Isolated 0 10V and 4 20mA 2 Isolated 10 10V and 4 20mA Specification Resolution 10 bit 0 10V DC Analog 100k ohm input impedance 4 20mA Analog 250 ohm input impedance External Pot 1 10k ohm 2 W minimum Control Outputs Specifications PowerFlex 523 PowerFlex 525 Relay Quantity 1 Programmable Form C 2 1 Programmable Form A and 1 Programmable Form B Specification Resistive Rating 3 0 A 30V DC 3 0 A 125V 3 0 A 240V AC Inductive Rating 0 5 A 30V DC 0 5 A 125V 0 5 A 240V AC Rockwell Automation Publication 520 UM001G EN E September 2014 Supplemental Drive Information Appendix A PowerFlex 523 PowerFlex 525 2 Programmable 30V DC 50 mA Non inductive Specifica
56. 2 circuit The PowerFlex 525 Safe Torque Off function disables the drive s output IGBT s by breaking the link with the drive microcontroller When used in combination with a safety input device the system satisfies the requirements of EN ISO 13849 and EN62061 for safe torque off and helps protect against restart Rockwell Automation Publication 520 UM001G EN E September 2014 227 Appendix G Safe Torque Off Function Verify Operation 228 Under normal drive operation both safety inputs Safety 1 and Safety 2 are energized and the drive is able to run If either input is de energized the gate control circuit becomes disabled To meet EN ISO 13849 operation both safety channels must be de energized Refer to the following examples for more information IMPORTANT Byitself the Safe Torque Off function initiates a coast to stop action Additional protective measures will need to be applied when an application requires a change to the stop action Test the safety function for proper operation after the initial setup of the PowerFlex 525 Safe Torque Off function Retest the safety function at the intervals determined by the safety analysis described on page 224 Verify that both safety channels are functioning according to the table below Channel Operation and Verification Safety Function Drive In Drive In Drive In Drive Status Safe State Safe State Safe State Able To Run Drive Status Configured byt105 Fault F111
57. 3 Kpl H d A526 Freq 3 Ki Ss me g 5 29 A523 Freq 2 Kpl F gt 5 amp e A524 Freq 2 Ki e AsnFeq1Kp A522 Freq 1 Ki A510 y Freq 1 A512 Freq 2 Freq Hz TII Rockwell Automation Publication 520 UM001G EN E September 2014 Ex a 2 i e ee 237 Appendix Control Diagrams Adjusting Speed Control These settings show how to adjust the speed control for motor tuning Parameters Speed Loop Bandwidth A511 Freq 1 BW 10 Hz A513 Freq 2 BW 10 Hz occurs decrease the bandwidth A515 Freq 3 BW 10 Hz i _ Increase the bandwidth to obtain faster speed response If oscillation L For Freq x Kp gradually increase by 1 For Freq x Ki gradually increase by 0 1 s Set A509 Speed Reg Sel For general use set A509 Speed Reg Sel to 0 Automatic A509 1 Manual A509 0 Automatic Set Speed Controller Gain Set Speed Controller Gain automatically manually A521 Freq 1 Kp A522 Freq 1 Ki A523 Freq 2 Kp A524 Freq 2 Ki A525 Freq 3 Kp A526 Freq 3 Ki 238 Rockwell Automation Publication 520 UM001G EN E September 2014 Numerics 2 wire inputs 47 3 wire inputs 47 A accel override priority 48 selecting 48 accessing control terminals 30 power terminals 30 applications safety 225 auxiliary contact drive 3
58. 5 4 0 323 528 A 25A DAPON114 25B D4P0N114 3 0 2 2 3 0 2 2 6 0 323 528 A 25A D6PON114 25B D6P0N114 5 0 4 0 5 0 4 0 10 5 323 528 B 25A D010N114 25B D010N114 7 5 5 5 7 5 5 5 13 0 323 528 C 25A D013N114 25B D013N114 100 175 10 0 175 17 0 323 528 C 25A D017N114 25B D017N114 15 0 111 0 1150 110 1240 323 528 D 25A D024N114 25B D024N114 20 0 15 0 1150 110 30 0 323 528 D 25A D030N114 25B D030N114 25 0 185 200 15 0 37 0 323 528 E 25A D037N114 25B D037N114 300 220 250 185 43 0 323 528 E 25A D043N114 25B D043N114 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 05 Jos os o4 o9 446 660 A 25A E0P9N104 25B E0P9N104 1 0 075 10 075 17 446 660 A 25A E1P7N104 25B ETP7N104 2 0 1 5 2 0 15 3 0 446 660 A 25A E3PON104 25B E3P0N104 3 0 22 3 0 22 4 2 446 660 A 25A E4P2N104 25B E4P2N104 5 0 4 0 5 0 4 0 6 6 446 660 B 25A EGPGN104 25B E6P6N104 75 5 5 7 5 5 5 9 9 446 660 C 25A E9P9N104 25B E9P9N104 100 175 10 0 175 12 0 446 660 C 25A E012N104 25B E012N104 15 0 111 0 1150 110 119 0 446 660 D 25A E019N104 25B E019N104 20 0 15 0 1150 11 0 220 446 660 D 25A E022N104 25B E022N104 25 0 185 200 15 0 270 446 660 E 25A E027N104 25B E027N104 300 22 0 250 185 320 446 660 E 25A E032N104 25B E032N104 1 Anon filtered drive is not available for 380 480V AC 25 HP 18 5 kW and 30 HP 22 0 kW ratings Filte
59. 5 HP and above 8 5 0 CT Default for drives below 5 HP Boost Voltage of Base Constant Torque 9 7 5 0 10 10 0 CT 11 12 5 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT 120 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A531 Start Boost Related Parameter s P031 P032 P039 A530 Sets the boost voltage 96 of P031 Motor NP Volts and redefines the V Hz curve when A530 Boost Select 0 Custom V Hz and P039 Torque Perf Mode 0 V Hz Maximum Voltage Motor NP Volts Voltage Break Voltage Start Boost di a Frequency de de 1 Break Frequency Motor NP Hertz T F Minimum Freq Maximum Freq Values Default 2 596 Min Max 0 0 25 0 Display 0 1 A532 Break Voltage Related Parameter s P031 P032 P039 A530 A533 Sets the voltage in percent of Base Frequency at the A533 Break Frequency if A530 Boost Select is set to 0 Custom V Hz Values Default 25 096 Min Max 0 0 100 096 Display 0 196 A533 Break Frequency Related Parameter s P031 P032 P039 A530 A532 Sets the frequency where A532 Break Voltage is applied if A530 Boost Select is set to 0 Custom V Hz Values Default 15 0 Hz Min Max 0 0 500 0 Hz Displ
60. 61 LL vi vo SO vo SO POLNDdLO 852 vOLNVdLO VSC Sie Worl 5ovL nori oN Boeye sser won 5or non xew uw ES S e S E wl an m an ainsopuq s p EE xew g uiw s4 ye ag JINDAL Bugey xew sasny s4 ye ag 4M1 Burey sasny FI PA qH qN SZS dd EZS dd e sBuney suonerjddy 10 10 uoN suonexijddy 531 yndu suey yndyno 1 ON fojee JV SUDI sa naq uoioajoJg 1ndu asbuq NOS 09 panunuo sanaq S M S QZS X2 449MOg 10 SJayealg PNN pue sasnj 25 Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 jeuuau gpeds uone rddy uunjoo siu ui pay Dads auinjoA LUNWIUIW au YUM aJnsopue paje InuaA uou 10 PILLUA e ui paj essur aq ISN ALP ay GULI JaMOd BALI stu YUM a 0u0 1030 uoneurquio 3 sd paya og JJas enue e Buisn uauM ULZ9 OL X gL x QL WW 8 697 X C LSY X C Sy JO azis WNWIUIW au YUM ansopua paje RnuaA uou 10 paje HUaA e ui pa ejsur aq INU OL 6d6I WSZ aU 1942319 UNU WOY L I4 YUM pasn UYM suigjs s punoif axuejsisa1 UD1U 10 punosb 1auJo2 2430 2420 A009 40 AOS Uo SN 10 PASIL IN JON Mdu JY p A009 pue Z AOBP 40 Parsi TIN 7a o 3u0 4030 uoneutquio 3 ad paa1oig j os enuew di JOU JIM adIAap ay Jey ebue1 NWI IY 0 Jas dij juam au aAeY Pinoys abue usum ajqeysn pe uy WOPL unsjng Shuey uorejddy siayealg MM UONIa Olg 1019 WOPL UNING eas eA Aew Siayearg UNY JOPa Olg JOOW WOPL UN JNg au Jo sues Di
61. A 50 140 150 4 0 1321 3R18 A 1321 3RA18 A 1321 3R18 A 1321 3RA18 A 75 55 75 55 1321 3R25 A 1321 3RA25 A 1321 3R25 A 1321 3RA25 A 100 7 5 100 7 5 1321 3R35 A 1321 3RA35 A 1321 3R35 A 1321 3RA35 A 1 0 111 0 110 0 75 1321 3R45 A 1321 3RM5 A 1321 3R45 A 1321 3RM5 A 20 0 15 0 15 0 11 0 1321 3R55 A ND 1321 3RA55 A ND 1321 3R55 A ND 1321 3RA55 A ND 1321 3R45 A HD 1321 3RA45 A HD 1321 3R45 A HD 1321 3RA45 A HD 380 480V 50 60 Hz 3 Phase 05 04 05 04 13213R2 B 13213RA2 B 1321 3R2 B 1321 3RA2 B 10 1075 11 0 10 75 1321 3R4 C 13213RM C 1321 3R4 C 1321 3RA4 C 20 15 20 415 1321 3R4 B 1321 3RA4 B 1321 3R4 B 1321 3RA4 B 30 422 3 0 422 13213R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 5 0 40 5 0 4 0 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 75 55 75 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 7 5 100 7 5 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 1 0 110 150 11 0 13213R25 B 1321 3RA25 B 1321 3R25 B 1321 3RA25 B 20 0 15 0 15 0 11 0 1321 3R35 B ND 1321 3RA35 B ND 1321 3R35 B ND 1321 3RA35 B ND 1321 3R25 B HD 1321 3RA25 B HD 1321 3R25 B HD 1321 3RA25 B HD 25 0 185 20 0 15 0 1321 3835 B 1321 3RA35 B 1321 3R35 B 1321 3RA35 B 300 220 250 18 5 1321 3R45 B ND 1321 3RA45 B ND 1321 3R45 B ND 1321 3RA45 B ND 1321 3R35 B HD 1321 3RA35 B HD 1321 3R35 B HD 1321 3RA35 B HD 525 600V 50 60 Hz 3 Phase 05 04 10
62. All of the position steps can be written to while the drive is running The changes will take place at the next move For example if step 0 is over written while the drive is moving to step 0 the drive will move to the previous commanded position at step 0 The next time the drive is commanded to return to step 0 it will proceed to the new position One possible use of this capability is when an application requires full control of the movement by a controller external to the drive The Step Logic program might be written to jump from step 0 back to step 0 when Input 1 is active The controller could write any desired position to step 0 and then toggle the input 1 bit of A560 Enh Control Word to cause the drive to move to the new position This allows almost unlimited flexibility and can be used with absolute or incremental moves The RA computer tool Connected Components Workbench can make setup of the positioning functions much easier Refer to the latest versions for additional tools or wizards which can aid in the setup Rockwell Automation Publication 520 UM001G EN E September 2014 213 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Notes 214 Rockwell Automation Publication 520 UM001G EN E September 2014 PID Loop Appendix F PID Set Up The PowerFlex 520 series drive features built in PID proportional integral derivative control loops The PID loop is used to maintain a process feedback su
63. B E only 2 Press down and slide out the top cover of the Control Module to unlock it from the Power Module Rockwell Automation Publication 520 UM001G EN E September 2014 27 Chapter1 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 28 Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter 1 Installation Wiring 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 Ae b uw 29 Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter 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 N
64. Cmd 713 EN Gateway Cfg 3 139 Comm Sts Opt 682 Drv 2 Logic Sts 715 EN Gateway Cfg al 140 Comm Write Mode 121 Drv 2 Reference 714 EN Idle Fit Actn 144 Commanded Freq 002 Drv 3 Addr 173 EN IP Addr Act 1 693 Compensation 547 Drv 3 Feedback 720 EN IP Addr Act 2 694 Contrl In Status 013 Drv 3 Logic Cmd 717 EN IP Addr Act 3 695 Control Source 012 Drv 3 Logic Sts 719 EN IP Addr Act 4 696 Control SW Ver 029 Drv 3 Reference 718 EN IP Addr Cfg 1 1 129 Control Temp 028 Drv 4 Addr 174 EN IP Addr Cfg 2 130 Counter Status 364 Drv 4 Feedback 724 EN IP Addr Cfg 3 l 131 Counts Per Unit 559 Drv 4 Logic Cmd 71 EN IP Addr Cfg 4 132 Current Limit 1 484 Drv 4 Logic Sts 723 EN Missed 10 Pkt 730 1 Parameter is specific to PowerFlex 525 drives only 140 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Parameter Name No Parameter Name No Parameter Name No EN Rate Act 685 Fault 5 Time hr 615 Freq 3 Bw 515 EN Rate Cfg 141 Fault 5 Time min 625 Freq 3 Ki 526 EN Rx Errors 727 Fault 6 BusVolts 656 Freq 3 Kp 525 EN Rx Overruns 725 Fault 6 Code 606 Half Bus Enable 549 EN Rx Packets 726 Fault 6 Current 646 Home Save 561 EN Subnet Act 1 697 Fault 6 Freq 636 HW Addr 1 687 EN Subnet Act 2 698 Fault 6 Time hr 616 HW Addr 2 688 EN Subn
65. Decel 2 Off REV Tagamental d Step after Stp Logic Time x and Logic In 1 is Not Active C Accel Decel 2 On FWD Absolute E Step after Stp Logic Tie x and Logic In 2 is Not Active d Accel Decel 2 On FWD Incremental j Do Not Step lgnore Digit 2 Settings E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incremental Rockwell Automation Publication 520 UM001G EN E September 2014 101 Chapter3 Programming and Parameters 1190 Stp Logic Time 0 1192 Stp Logic Time 2 1194 Stp Logic Time 4 1196 Stp Logic Time 6 PowerFlex 525 only L191 L193 L195 L197 Logic Group continued Stp Logic Time 1 Stp Logic Time 3 Stp Logic Time 5 Stp Logic Time 7 Sets the time to remain in each step ifthe corresponding command word is set to Step based on time Values Default 30 05 Min Max 0 0 999 9 s Display 0 15 L200 Step Units 0 L202 Step Units 1 1204 Step Units 2 L206 Step Units 3 L208 Step Units 4 L210 Step Units 5 1212 Step Units 6 1214 Step Units 7 TT 32 bit parameter PowerFlex 525 only Sets the position in user defined units the drive must reach at each step Values Default 0 Min Max 0 6400 Display 1 102 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Display Group d360 Analog In 0 10V Related Parameter s t091 t092 Displays the 0 1
66. Digital inputs and outputs control the timer function and are configured with parameters t062 t063 t065 t068 DigIn TermBlk xx set to 19 Timer Start and 21 Reset Timer Digital outputs relay and opto type define a preset level and indicate when the level is reached Level parameters t077 Relay Out Level t082 Relay Out2 Level t070 Opto Out1 Level and t073 Opto Out2 Level are used to set the desired time in seconds Parameters t076 Relay Out1 Sel t081 Relay Out2 Sel t069 Opto Out Sel and t072 Opto Out2 Sel are set to 25 Timer Out and causes the output to change state when the preset level is reached Example e Drive starts up and accelerates to 30 Hz e After 30 Hz has been maintained for 20 seconds a 4 20 mA analog input becomes the reference signal for speed control Rockwell Automation Publication 520 UM001G EN E September 2014 199 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions e The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active e Parameters are set to the following options P047 Speed Referencel 6 4 20mA Input P049 Speed Reference2 7 Preset Freq t062 DigIn TermBlk 02 1 Speed Ref 2 t063 DigIn TermBlk 03 19 Timer Start t076 Relay Outl Sel 25 Timer Out t077 Relay Out1 Level 20 0 Secs A411 Preset Freq
67. EN Addr Sel C147 EN Fit Cfg DL 1 C167 Opt Data Out 3 A486 Shear Pin1 Level C129 EN IP Addr Cfg 1 C148 EN Fit Cfg DL 2 C168 Opt Data Out 4 A488 Shear Pin2 Level C130 EN IP Addr Cfg 2 C149 EN Fit Cfg DL 3 C169 MultiDrv Sel A490 Load Loss Level C131 EN IP Addr Cfg 3 C150 EN Fit Cfg DL 4 C171 Drv 1 Addr A496 IR Voltage Drop C132 EN IP Addr Cfg 4 C153 EN Data In 1 C172 Drv 2 Addr A497 Flux Current Ref C133 EN Subnet Cfg 1 C154 EN Data In 2 C173 Drv 3 Addr A530 Boost Select C134 EN Subnet Cfg 2 155 EN Data In 3 C174 Drv 4 Addr A531 Start Boost C135 EN Subnet Cfg 3 C156 EN Data In 4 C175 DSI 1 0 Cfg A532 Break Voltage C136 EN Subnet Cfg 4 C157 EN Data Out 1 C137 EN Gateway Cfg 1 C158 EN Data Out 2 GC Parameters in Custom Group A533 Break Frequency A534 Maximum Voltage Options 0 Ready ldle Default 1 Param Reset Does not reset custom groups parameter P030 Language and communication parameters 2 Factory Rset Restore drive to factory condition 3 Power Reset Resets only power parameters Can be used when swapping power modules Rockwell Automation Publication 520 UM001G EN E September 2014 81 Chapter3 Programming and Parameters Terminal Block Group t062 Digln TermBlk 02 t065 Digln TermBlk 05 t063 Digin TermBlk 03 t066 Digln TermBlk 06 Related Parameter s b012 b013 b
68. FFFF None 22 Setpnt 4 20 4 20 mA 4mA 0 100 0 Setpoint setting None 1090 23 DCVolt 4 20 4 20 mA 4mA 0V 100 0 of trip value None b005 1 Filter A is a single pole digital filter with a 162 ms time constant Given a 0 100 step input from a steady state the output of Filter A takes 500 ms to get to 9596 of maximum 810 ms to get to 99 and 910 ms to get to 100 Values Default Min Max 0 23 Display Rockwell Automation Publication 520 UM001G EN E September 2014 89 Chapter3 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 10096 Min Max 0 800 Display 1 t090 Anlg Out Setpt Related Parameter s t088 PF 525 PowerFlex 525 only Sets the percentage of output desired when t088 Analog Out Sel is set to 6 14 or 22 Analog Setpoint Values Default 0 096 Min Max 0 0 100 096 Display 0 196 t091 Anlg In 0 10V Lo Related Parameter s P043 t092 t093 so drive before changing this parameter Sets the percentage based on 10V of input voltage applied to the 0 10V analog input used to represent P043 Minimum Freq Analog inversion can be accomplished by setting this value larger than t092 Anlg In 0 10V Hi If t093 10V Bipolar Enbl is set to 1 Bi Polar In this parameter is i
69. Fit Actn lets you determine the action of the EtherNet IP interface and connected drive if communications are disrupted By default this parameter faults the drive You can set this parameter so that the drive continues to run Precautions should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage When commissioning the drive verify that your system responds correctly to various situations for example a disconnected drive Options 0 Fault Default 1 Stop Drive stops per P045 Stop Mode setting 2 Zero Data Note The Reference and Datalink values transmitted to the drive will be set to 0 3 Hold Last Note The Logic Command Reference and Datalink values transmitted to the drive will be held at their last value 4 Send Flt Cfg E ora Command Reference and Datalink values will be transmitted to the drive as configured in C145 C146 and C144 EN Idle Fit Actn Related Parameter s P045 C145 C146 C147 C150 PowerFlex 525 only Sets the action that the EtherNet IP interface and drive takes if the EtherNet IP interface detects that the scanner is idle because the controller was switched to program mode ATTENTION Risk of injury or equipment damage exists Parameter C144 EN Idle Flt Actn lets you determine the action of the EtherNet IP interface and connected drive if the scanner is idle By default this parameter faults the dri
70. Force Keypad Control 0 Not Force Keypad Control 7 1 MOP Increment 0 Not Increment 9 8 00 No Command 01 Accel Rate 1 Enable 10 Accel Rate 2 Enable 11 Hold Accel Rate Selected 11 10 00 No Command 01 Decel Rate 1 Enable 10 Decel Rate 2 Enable 11 Hold Decel Rate Selected 14 13 12 000 No Command 001 Freq Source P047 Speed Reference1 010 Freq Source P049 Speed Reference2 011 Freq Source P051 Speed Reference3 100 A410 Preset Freq 0 101 A411 Preset Freq 1 110 A412 Preset Freq 2 111 M13 Preset Freq 3 15 1 MOP Decrement 0 Not Decrement 192 Rockwell Automation Publication 520 UM001G EN E September 2014 Writing 06 Comm Frequency Command Reading 03 Logic Status Data RS485 DSI Protocol Appendix C Position Bit Definitions Comm Logic Command C122 1 Position Address Decimal Bit s Description 2000H 8192 0 1 Stop 0 Not Stop 1 1 Start 0 Not Start 2 1 Jog 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 5 4 00 No Command 01 Forward Command 10 Reverse Command 11 No Command 6 1 LogicIn 1 7 1 LogicIn 2 10 9 8 000 Freq and Position Step 0 001 Freq and Position Step 1 010 Freq and Position Step 2 011 Freq and Position Step 3 100 Freq and Position Step 4 101
71. GC a gt d y I r id AEN 4 Press Enter or Sel to view the parameters that nn are stored in the CustomView group Rose em LILIC 5 Press the Up Arrow or Down Arrow to scroll J through the list of parameters a gt S p 11 ry j LILIE FRORA 6 Press Enter to delete the parameter from the CustomView group The LCD display will show a y 4 Ww E Y confirmation lt TIP The Connected Components Workbench software can be used to speed up this process with drag and drop functionality Rockwell Automation Publication 520 UM001G EN E September 2014 139 Chapter3 Programming and Parameters Parameter Cross Reference by Name Parameter Name No Parameter Name No Parameter Name No 10V Bipolar Enb 093 Current Limit 27 485 Drv 4 Reference 722 2 Wire Mode 064 DB Resistor Sel 437 Drv Ambient Sel 554 Accel Time 1 041 DB Threshold 438 DSI Errors 731 Accel Time 2 442 DC Brake Level 435 DSI 1 0 Act 686 Accel Time 3 444 DC Brake Time 434 DSI 1 0 Cfg 175 Accel Time 4 446 DC Brk Time Strt 436 Elapsed kWh 021 Accum C02 Sav 026 DC Bus Ripple 380 Elapsed MWh 022 Accum Cost Sav 025 DC Bus Voltage 005 Elapsed Run Time 019 Accum kWh Sav 024 Decel Time 1 042 Elapsed Time hr 362 Analog In 0 10V 360 Decel Time 2 443 Elapsed Time min 363 Analog In 4 20mA 36
72. Not Step Ignore Digit 2 Settings Use the Wizard in Connected Components Workbench to simplify setup instead of manually configuring the parameters Note Incremental move commands will cause the drive to move the amount specified based on the current position Absolute commands are always with reference to Home A565 Pos Reg Filter provides a low pass filter at the input of the position regulator A566 Pos Reg Gain is a single adjustment for increasing or decreasing the responsiveness of the position regulator For faster response the filter should be reduced and or the gain should be increased For smoother response with less 209 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Homing Routine 210 overshoot the filter should be increased and or the gain should be reduced In general the gain will have a larger effect on most systems than the filter This drive supports incremental encoders only Therefore when the drive powers up it will reset the current position to zero If this is known to be correct the position routine can be started without further adjustment However in most applications the drive will need to be homed after each power up and prior to starting the position routine This can be accomplished in one of the following two ways 1 Manual Homing Program the following drive parameters t062 t063 t065 068 DigIn TermBlk xx 37 Pos Redefine
73. Power and Control Modules 25 osec ito oeuvre RU UU DERIT 27 Control Module OVer ac coss ue 2525 vee s Rada ehe Ses bien 30 Power Module Terminal Guard Ee ede LER 30 Power Wiring Soonsein ied eeu a eec td koe ete tur dee 31 Power Terminal Blocked S Re Eni n 34 Common Bus Precharge Notes eee Eher ay ache eer te rt ats 35 LO NBI A eheu tok ctl ad ed tailed tUe d zd dale 35 Control I O Terminal BIoCE oec ro vuoto nt 36 Start and Speed Reference Control coto t idv esta 46 CE Conformity 11 ere ee oe qe Ro ge 49 Chapter 2 Prepare for Drive Starts W Du cues toS eset Rare aegstss os pee eae 55 Display and Control Keysciccie 229i Hecho serie a 58 Viewing and Editing Parainctersa xviii ie ceci ere ehe Vere t RE P en 59 Drive Programming Tools isset SHE e Qe CERRO ad 60 Language Support 24 4 cnnusivn rehenes e vea ne a epa 60 Smart Start Up with Basic Program Group Parameters 61 LCD Display with QuickView 225 12220 9456 soot uod esee ute od 63 Usingethe CLS DPOF Csiro tig qatexsteatu uci esa a dito p abus ovale 63 Chapter 3 About Parameters EM PPP EE 65 Parameter FOU Pseriz oser dt tenta uinte an E s ustuc us ii sche ipta 66 Basic Display Group ccedeeecd tere REN oap vended chee 71 Basic Pro ram Group eus cup esee vi ease elt pe nece gn 76 Terminal Block Group 5 5 22b dai ioo Ree one ded etu Ren 82 Communications Group cvcevexenscc m bees Fr E eer eres easet 94 Logie Groups ales Ch etse bb al alo De UE ace olet 100 Advance
74. Protection Provides class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL 508C File 29572 Overcurrent 200 hardware limit 300 instantaneous fault Ground Fault Trip Phase to ground on drive output Short Circuit Trip Phase to phase on drive output Flectrical Specifications PowerFlex 523 PowerFlex 525 Voltage Tolerance 15 10 Frequency Tolerance 47 63 Hz Input Phases Three phase input provides full rating Single phase input provides 35 rating on three phase drives Displacement Power Factor 0 98 across entire speed range Maximum Short Circuit Rating 100 000 Amps Symmetrical Actual Short Circuit Rating Determined by AIC Rating of installed fuse circuit breaker Transistor Type Isolated Gate Bipolar Transistor IGBT Internal DC Bus Choke 200 240V AC Input 380 480V AC Input 525 600V AC Input Only for Frame E drive ratings 11 kW 15 HP 15 18 5 kW 20 25 HP Heavy Duty 15 18 5 kW 20 25 HP Heavy Duty Control Specifications PowerFlex 523 PowerFlex 525 Method Sinusoidal PWM Volts Hertz Sensorless Vector Control Economizer SVC motor control and Closed Loop Velocity Vector Control Closed Loop Velocity Vector Control is not applicable to PowerFlex 523 drives Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequ
75. Reference 2 Serial DSI The reference word from the Serial DS communication network becomes the PID Reference 4 5 Network Opt The reference word from a communication network option becomes the PID Reference 0 10V Input Selects the 0 10V Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 6 4 20mA Input Selects the 4 20 mA Input 7 Preset Freq A410 A425 Preset Freq x will be used as an input for the PID Reference 8 Anlgin Multi The product of the 0 10V and 4 20mA Inputs will be used as an input for the PID Reference 9 MOP Freq A427 MOP Freq will be used as an input for the PID Reference 10 Pulse Input Pulse train will be used as an input for the PID Reference 11 Step Logic Step Logic will be used as an input for the PID Reference 12 Encoder Encoder will be used as an input for the PID Reference 13 Ethernet IP The reference word from the Ethernet IP communication network becomes the PID Reference 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 217 Appendix F Analog PID Reference Signals 218 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 Desc
76. Related Parameter s A555 Accumulated time drive is outputting power Time is displayed in 10 hour increments Values Default Read Only Min Max 0 65535 x 10 hr Display 1 10hr b020 Average Power Related Parameter s A555 Average power used by the motor since the last reset of the meters Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW b021 Elapsed kWh Related Parameter s b022 Accumulated output energy of the drive When the maximum value of this parameter is reached it resets to zero and b022 Elapsed MWh is incremented Values Default Read Only Min Max 0 0 100 0 kWh Display 0 1 kWh b022 Elapsed MWh Related Parameter s b021 Accumulated output energy ofthe drive Values Default Read Only Min Max 0 0 6553 5 MWh Display 0 1 MWh b023 Energy Saved Related Parameter s A555 Total energy savings of using this drive compared to an across the line starter since the last reset of the meters Values Default Read Only Min Max 0 0 6553 5 kWh Display 0 1 kWh b024 Accum kWh Sav Related Parameter s b025 Total approximate accumulated energy savings of the drive compared to using an across the line starter Values Default Read Only Min Max 0 0 6553 5 kWh Display 0 1 10 kWh Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Basic Display Group continued b025 Accum Cost Sav
77. Time min 630 Motor NP Hertz 032 Fault 3 Code 009 Fiber Status 390 Motor NP Poles 035 Fault 3 Current 643 Find Home Dir 563 Motor NP Power 037 Fault 3 Freq 633 Find Home Freq 562 Motor NP RPM 036 Fault 3 Time hr 613 Flux Current Ref 497 Motor NP Volts 031 Fault 3 Time min 623 Flying Start En 545 Motor OL Current 033 Fault 4 BusVolts 654 FlyStrt CurLimit 546 Motor OL Level 369 Fault 4 Code 604 Freq 10 510 Motor OL Ret 494 Fault 4 Current 644 Freq 1 gw 511 Motor OL Select 493 Fault 4 Freq 634 Freq 1 Ki 522 Motor Re 498 Fault 4 Time hr 614 Freq 1 kp 521 Mtr Options Cfg 573 Fault 4 Time min 624 Freq 20 512 MultiDrv Sel 169 Fault 5 BusVolts 655 Freq 2 aw 513 Opt Data In 1 161 Fault 5 Code 605 Freq 2 Kit 524 Opt Data In 2 162 Fault 5 Current 645 Freq 2 Kp 523 Opt Data In 3 163 Fault 5 Freq 635 Freq 30 514 Opt Data In 4 164 1 Parameter is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 141 Chapter3 Programming and Parameters Parameter Name No Parameter Name No Parameter Name No Opt Data Out 1 165 Position Status 387 Shear Pin 2 Time 489 Opt Data Out 2 166 Positioning Model 558 Shear Pin2 Level 488 Opt Data Out 3 167 Power Loss Mode 548 Skip Freq Band 1 449 Opt Data Out 4 168 Power Saved 018 Skip Freq Band 2 4
78. a stop input the jumper between 1 0 Terminals 01 and 11 must be removed e Verify the drive is receiving the speed reference from the correct place and that the reference is scaled correctly e Verify the drive is receiving start and stop commands correctly e Verify input currents are balanced e Verify motor currents are balanced 17 Save a backup of the drive settings using the USB utility application See Using the USB Port on page 63 for more information Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from the keypad No programming is required to start stop change direction and control speed directly from the keypad IMPORTANT To disable reverse operation see A544 Reverse Disable If a fault appears on power up see Fault Descriptions on page 147 for an explanation of the fault code Variable Torque Fan Pump Applications For improved motor tuning performance when using a premium efficient motor on a variable torque loading SVC mode set A530 Boost Select to 2 35 0 VT Rockwell Automation Publication 520 UM001G EN E September 2014 57 Chapter2 Start Up Display and Control Keys PowerFlex 523 Menu Parameter Group and Description Basic Display l Commonly viewed drive operating conditions Allen Bradley An H f EX p Basic Program De Commonly used programmable functions Termina
79. after completing the homing routine Bit 2 Hold Step overrides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released Bit 3 Pos Redefine resets the home position to the current position of the machine Deactivate this bit after completing the homing routine Bit 4 Sync Enable holds the existing frequency when A571 Sync Time is set to enable speed synchronization When this bit is deactivated the drive will accelerate to the new commanded frequency based on A571 Sync Time Bit 5 Traverse Dis disables the traverse function when this bit is active Bit 6 Logic In 1 provides an identical function and is logically ORed with setting 24 Logic In 1 for t062 t063 t065 t068 DigIn TermBlk xx It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions Bit 7 Logic In 2 provides an identical function and is logically ORed with setting 25 Logic In 2 for t062 t063 t065 t068 DigIn TermBlk xx It can be used to move through the Step Logic functions speed or Rockwell Automation Publication 520 UM001G EN E September 2014 Setup Notes 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
80. by the embedded EtherNet IP interface at the time This will indicate 0 if no address is set 255 255 255 255 EN Subnet Act 1 EN Subnet Act 2 EN Subnet Act 3 EN Subnet Act 4 Values Default Read Only Min Max 0 255 Display 1 134 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F701 EN Gateway Act 1 F702 EN Gateway Act 2 F703 EN Gateway Act 3 F704 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 255 255 255 255 EN Gateway Act 1 EN Gateway Act 2 EN Gateway Act 3 EN Gateway Act 4 Values Default Read Only Min Max 0 255 Display 1 F705 DrvO Logic Cmd F709 Drv 1 Logic Cmd F713 Drv 2 Logic Cmd F717 Drv3 Logic Cmd F721 Drv 4 Logic Cmd In multi drive mode this is the logic command being transmitted to drive 0 1 2 3 4 In single drive mode this is the logic command being used by the drive whether HS DSI EtherNet IP or DSI at the time If comms control is NOT being used and the drive is in single drive mode then this parameter will show 0 Values Default Read Only Min Max 0 FFFF Display 1 F706 Drv 0 Reference F710 Drv 1 Reference F714 Drv 2 Reference F718 Drv 3 Reference F722 Drv 4 Reference In multi drive mode t
81. digital control power is 24 volts 5 Inspect grounding wiring connections and environmental compatibility Rockwell Automation Publication 520 UM001G EN E September 2014 55 Chapter2 Start Up 6 Verify that the Sink SNK Source SRC jumper is set to match your control wiring scheme See the PowerFlex 523 Control I O Wiring Block Diagram on page 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 If the control scheme is changed to Sink SNK the jumper must be removed from 1 0 Terminals 01 and 11 and installed between 1 0 Terminals 01 and 04 Wire I O as required for the application 8 Wire the power input and output terminals 10 11 12 13 14 15 Confirm that all inputs are connected to the correct terminals and are secure Collect and record motor nameplate and encoder or feedback device information Verify motor connections e Is the motor uncoupled e What direction will the motor need to turn for the application Verify the input voltage to the drive Verify if the drive is on a grounded system Ensure the MOV jumpers are in the correct position See AC Supply Source Considerations on page 19 for more information Apply power and reset the drive and communication adapters to factory default settings To reset the drive
82. fault is a condition that stops the drive There are two fault types Fault Types Type Fault Description 1 Auto Reset Run When this type of fault occurs and A541 Auto Rstrt Tries is set to a value greater than 0 a user configurable timer A542 Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted 2 Non Resettable This type of fault may require drive or motor repair or is caused by wiring or programming errors The cause of the fault must be corrected before the fault can be cleared Rockwell Automation Publication 520 UM001G EN E September 2014 145 Chapter4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault SESLI IY The integral LCD display provides visual notification of a fault condition by displaying the i i following 4024 LISTS e Flashing fault number NH e Flashing fault indicator LED FAULT GP Press the Esc key to regain control of the display Cy Manually Clearing Faults Step Key s 1 Press Escto acknowledge the fault The fault information will be removed so that you can use the integral keypad Access b007 Fault 1 Code to view the most recent fault information Esc 2 Address the condition that caused the fault The cause must be corrected before the fault can be cle
83. given to all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment A good example of recommended cable is Belden 295xx xx determines gauge This cable has four 4 XLPE insulated conductors with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Rockwell Automation Publication 520 UM001G EN E September 2014 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 Unless specified in the individual distance tables as tested with the drive these cables are not recommended and their performance against the lead length limits supplied is not known Recommended Shielded Wire Location Rating Type Description Standard Option 1 600V 90 C 194 F XHHW2 RHW 2 e Four tinned copper conductors with XLPE insulation Anixter B209500 B209507 Belden Copper braid aluminu
84. homed either manually or automatically It will remain active until the next power down Rockwell Automation Publication 520 UM001G EN E September 2014 211 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Use Over Communications 212 If 8 steps are not adequate for the application or if dynamic program changes are required many of the positioning functions can be controlled through an active communication network The following parameters will allow this control C121 Comm Write Mode Repeated writes to parameters over a communication network can cause damage to the drive EEPROM This parameter allows the drive to accept parameter changes without writing to the EEPROM IMPORTANT Parameter values set prior to setting 1 RAM only are saved in RAM C122 Cmd Stat Select Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network A560 Enh Control Word This parameter allows many of the positioning functions to be completed through parameter control using an explicit message This allows the operation over communications instead of with hardware inputs The bits have the same functions as the digital input options of the same name Options relating to positioning are Bit 0 Home Limit indicates the drive is at the home position Bit 1 Find Home causes the drive to find home at the next start command Deactivate this bit
85. line is removed there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop An auxiliary braking method may be required Alternatively use the drive s safety input function i ATTENTION A contactor or other device that routinely disconnects and Important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0 3 m 1 ft IMPORTANT 1 0 terminals labeled Common are not referenced to the safety ground PE terminal and are designed to greatly reduce common mode interference cause component damage Verify proper configuration prior to applying input f ATTENTION Driving the 4 20 mA analog input from a voltage source could signals Signal and Control Wire Types Recommendations are for 50 C ambient temperature 75 C wire must be used for 60 C ambient temperature 90 C wire must be used for 70 C ambient temperature Rockwell Automation Publication 520 UM001G EN E September 2014 35 Chapter1 Installation Wiring Control 1 0 Terminal Block 36 Recommended Signal Wire Signal Type Belden Wire Type s 7 Description Min Insulation Where Used or equivalent Rating M m Analog 1 0 amp PTC 8760 9460 0 750 mm 18 AWG 300V twisted pair 100 shield with drain Remote Pot 87
86. matched with a frame B EMC Line Filter EMC Plates Item EMC Plate Description Optional grounding plate for shielded cables Rockwell Automation Publication 520 UM001G EN E September 2014 Frame Size Catalog No A 25 EMC1 FA B 25 EMCT FB C 25 EMCT FC D 25 EMCT FD E 25 EMC1 FE Accessories and Dimensions Appendix B Human Interface Module HIM Option Kits and Accessories Item Description Catalog No LCD Display Remote Panel Digital speed control 22 HIM C2S Mount CopyCat capable IP66 NEMA Type 4X 12 indoor use only Includes 2 9 meter cable LCD Display Remote Digital speed control 22 HIM A3 Handheld Full numeric keyboard CopyCat capable IP 30 NEMA Type 1 Includes 1 0 meter cable Panel mount with optional Bezel Kit Bezel Kit Panel mount for LCD Display Remote Handheld unit IP 30 NEMA Type 1 22 HIM B1 Includes 2 0 m DSI cable DSI HIM Cable 1 0 m 3 3 ft 22 HIM H10 IP 30 NEMA 1 UL Type 1 Kit Frame Item Description Size Catalog No IP 30 NEMA 1 UL Type 1 Kit Field installed kit Converts drive to IP 30 NEMA 1 ULType1 A 25 JBAA enclosure Includes conduit box with mounting screws and B 25 JBAB plastic top panel C 25 JBAC D 25 JBAD E 25 JBAE Control Module Fan Kit Frame Item Description Size Catalog No Control Module Fan Kit For use with drive in environments with ambient A D 25 FAN1 70C temperatures up to 70 C
87. motor nameplate FLA Used to assist the Autotune routine and motor control Values Default Based on Drive Rating Min Max 0 1 Drive Rated Amps x 2 Display 0 1A P035 Motor NP Poles Related Parameter s b015 Sets the number of poles in the motor Values Default 4 Min Max 2 40 Display 1 P036 Motor NP RPM O Ray drive before changing this parameter Sets the rated nameplate rpm of the motor Used to calculate the rated slip of the motor To reduce the slip frequency set this parameter closer to the motor synchronous speed Values Default 1750 rpm Min Max 0 24000 rpm Display 1rpm P037 Motor NP Power PowerFlex 525 only Sets the motor nameplate power Used in PM regulator Values Default Drive Rated Power Min Max 0 00 Drive Rated Power Display 0 01 kW P038 Voltage Class O Bay drive before changing this parameter Sets the voltage class of 600V drives Only applicable to 600V drives Options 2 480V 3 600V Default P039 Torque Perf Mode O Kay drive before changing this parameter Selects the motor control mode Options 0 V Hz 1 SVC Default 2 Economize 3 Vector Related Parameter s P040 A530 A531 A532 A533 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 77 Chapter3 Programming and Parameters Basic Program Group contin
88. need to be met from digital inputs programmed as Logic In 1 and Logic In 2 before stepping from one preset speed to the next A timer is available for each of the eight steps and is used to program a time delay before stepping from one preset speed to the next The status of a digital output can also be controlled based on the step being executed e Basic Logic Function specific to PowerFlex 525 drives only Up to two digital inputs can be programmed as Logic In 1 and or Logic In 2 A digital output can be programmed to change state based on the condition of one or both inputs based on basic logic functions such as AND OR NOR The basic logic functions can be used with or without StepLogic e Timer Function A digital input can be programmed for Timer Start A digital output can be programmed as a Timer Out with an output level programmed to the desired time When the timer reaches the time programmed into the output level the output will change state The timer can be reset with a digital input programmed as Reset Timer e Counter Function A digital input can be programmed for Counter In A digital output can be programmed as Counter Out with an output level programmed to the desired number of counts When the counter reaches the count programmed into the output level the output will change state The counter can be reset with a digital input programmed as Reset Counter TIP Use the Wizard in Co
89. numbers Step Units x and Step Units F x when using RS485 communications and programming software The second parameter number is shown only in the Parameter Groups and Parameter Cross Reference by Name tables for reference PF525 Parameter is specific to PowerFlex 525 drives only Parameter Groups For an alphabetical listing of parameters see Parameter Cross Reference by Name on page 140 Basic Display Output Voltage b004 Control Source b012 Elapsed Run Time b019 Accum C02 Sav b026 DC Bus Voltage b005 Contrl In Status b013 Average Power b020 Drive Temp b027 US Drive Status b006 Dig In Status b014 Elapsed kWh b021 Control Temp b028 Fault 1 Code b007 Output RPM b015 Elapsed MWh b022 Control SW Ver b029 Output Freq b001 Fault 2 Code b008 Output Speed b016 Energy Saved b023 Commanded Freq b002 Fault 3 Code b009 Output Power b017 Accum kWh Sav b024 Output Current b003 Process Display b010 Power Saved b018 Accum Cost Sav b025 Basic Program Motor NP Hertz P032 Voltage Class P038 Maximum Freq P044 Start Source 3 P050 Motor OL Current P033 Torque Perf Mode P039 Stop Mode P045 Speed Reference3 P051 US Motor NP FLA P034 Autotune P040 Start Source 1 P046 Average kWh Cost P052 Motor NP Poles P035 Accel Time 1 P041 Speed Reference1 P047 Reset To Defalts P053 Language P030 Motor NP RPM P036 Decel Time 1 P042 Start Source 2 P048 Motor NP Volts P031 Motor NP Power P037 Minimum Freq P043 Speed Reference2 P049 Terminal Blocks Digln TermBlk 07 1067 Rela
90. successful application and understanding of the product Allen Bradley Rockwell Automation Rockwell Software PowerFlex Connected Components Workbench Studio 5000 Studio 5000 Logix Designer DriveTools SP AppView CustomView QuickView MainsFree Programming PointStop and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Topic Page Added Warning table for Motor Cable Length Restrictions 32 Updated Maximum Control Wire Recommendations information on noise immunity 36 Updated Start Method and Stop Method tables for PowerFlex 523 drives 37 Updated Start Method and Stop Method tables for PowerFlex 525 drives 40 Added Important table for EMC category C3 installation information 52 Updated Additional Installation Requirements table for meeting EMC 53 Updated Recommended Placement of EMC Cores table 54 Added software version requirement for Automatic Device Configuration ADC support 60 Added new parameter d392 RdyBit Mode Act 67 106 142 Added new parameter A574 RdyBit Mode Cfg 67 129 142 Updated descriptions of options for parameter P040 Autotune 78 Updated description of PointStop for option 10 and 11 of parameter P045 St
91. the frequency Hz value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 7 Above Cur Drive exceeds the current Amps value set in t077 or t082 Relay Outx Level 100 ms time delay on or off IMPORTANT Value for t077 or t082 Relay Outx Level must be entered in percent of drive rated output current 8 Above DCVolt Drive exceeds the DC bus voltage value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 9 Retries Exst Value set in A541 Auto Rstrt Tries is exceeded None 10 Above Anlg V Analog input voltage 0 10V input exceeds the value set in t077 or t082 Relay Outx Level 100 ms time delay on or off IMPORTANT Donotuseift093 10V Bipolar Enbl is set to 1 Bi Polar In 11 Above PF Ang Power Factor angle exceeds the value set in t077 or t082 Relay Outx Level 100 ms time delay on or off 12 Anlg In Loss Analog input loss has occurred Program t094 Anlg In V Loss or t097 Anlg In mA Loss for desired action when On 2 mA 1V input loss occurs Off 3 mA 1 5V 13 ParamControl Output will be directly controlled by the state of the t077 or t082 Relay Outx Level A value of 0 causes the output to turn off A value of 1 or greater in this parameter causes the output to turn on None 14 NonRec Fault e Value set in A541 Auto Rstrt Tries is exceeded or None A541 Auto Rstrt Tries is not enabled or e Anon resettable fault has occur
92. you can change 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 If pressing Esc does not change the display then b001 Output Freq is displayed Press Enter or Sel to enter the group list again zn 7 7 r1 VOLTS ee e j LJ e Jg Key s Example Display p JE PA L L NI T Esc ZIS Some features in the PowerFlex 520 series drive are not supported by older configuration software tools It is strongly recommended that customers using such tools migrate to RSLogix 5000 version 17 0 or greater or Logix Designer version 21 0 or greater with Add On Profile AOP or Connected Components Workbench version 5 0 or greater to enjoy a richer full featured configuration experience For Automatic Device Configuration ADC support RSLogix 5000 version 20 0 or greater is required Description Catalog Number Release Version Connected Components Workbench Version 5 0 or greater Logix Designer Version 21 0 or greater RSLogix 5000 Version 17 0 or greater Built in USB software tool Serial Converter Module 22 SCM 232 USB Converter Module 1203 USB Remote Panel Mount LCD Display 22 HIM C2S
93. 0 0 0 1 1 1 1 1 1 1 1 For PowerFlex 523 Default Accel Decel Used Preset Input 1 DigIn TermBlk 05 Preset Input 2 Digln TermBIk 06 Preset Input 3 DigIn TermBIk 03 Preset Setting 0 0 0 0 Preset Setting 1 Preset Setting 2 Preset Setting 3 Preset Setting 4 Preset Setting 5 Preset Setting 6 Preset Setting 7 1 Preset Setting 0 is only available if P047 P049 or P051 Speed Referencex is set to 7 Preset Freq 1 1 2 2 1 1 2 2 o of of 0 1 1 0 0 1 1 af Tofl ol o Values Defaults Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 15 0 00 Hz 5 00 Hz 10 00 HZ 20 00 Hz 30 00 Hz 40 00 Hz 50 00 Hz 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz Rockwell Automation Publication 520 UM001G EN E September 2014 107 Chapter3 Programming and Parameters Advanced Program Group continued M26 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
94. 0 Skip Frequency 2 A452 Skip Frequency 3 A454 Skip Frequency 4 PF 525 PowerFlex 525 only Works in conjunction with A449 A451 A453 and A455 Skip Freq Band x creating a range of frequencies at which the drive does not operate continuously Values Default 0 0 Hz Disabled Min Max 0 0 500 0 Hz Display 0 1 Hz A449 Skip Freq Band 1 Related Parameter s A448 A450 A452 M54 A451 Skip Freq Band 2 A453 Skip Freq Band 3 A455 Skip Freq Band 4 PowerFlex 525 only Determines the band around A448 A450 A452 and A454 Skip Frequency x Frequency Command frequency Drive Output pFrequency Skip Frequency RM Band besuisamszececemcck N k E LIcoocoW Time Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz 112 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A456 PID 1 Trim Hi A468 PID 2 Trim Hi PowerFlex 525 only Scales the upper value of the trim frequency when trim is active Values Default Min Max 0 0 500 0 Hz Display M57 PID 1 Trim Lo A469 PID 2 Trim Lo PF 525 PowerFlex 525 only Scales the lower value ofthe trim frequency when trim is active Values Default Min Max 0 0 500 0 Hz Display A458 PID 1 Trim Sel M
95. 0 UM001G EN E September 2014 LCD Display with QuickView Using the USB Port StartUp Chapter 2 QuickView enables text to scroll across the LCD display of the PowerFlex 520 series 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 The PowerFlex 520 series drive has a USB port that connects to a PC for the purpose of upgrading drive firmware or uploading downloading a parameter configuration IMPORTANT Tousethe USB feature of the PowerFlex 520 series drive Microsoft Net Framework 2 0 and Windows XP or later is required MainsFree Programming The MainsFree programming feature allows you to quickly configure your PowerFlex 520 series drive without having to power up the control module or install additional software Simply connect the control module to your PC with a USB Type B cable and you can download a parameter configuration to your drive You can also easily upgrade your drive with the latest firmware Connecting a PowerFlex 520 series drive to a PC Control Module USB port USB Type B cable Connect to PC Connect to Control Module When connected the drive appears on the PC and contai
96. 0 f0vL SL 0 S10 140 2 OH SSVD 99 4Z WOPL OL9 7090 NOrL 0L 9 609 001 V eS VL 91 TOSTO TOJ STO VOLN9dLV Vsc gud TA WorL 50pL DOvL ON Bojeye sep wort sorunon xew uw EE S UNIS 3 y qui wil gu ainsopuq vXeXe Rx 3 xew 3 UIW 19y291g INDI1 Bugey xew sasn sa ye ag mar Buey sasny a g e aH aN SZS dd EZS dd S g sBuney suone iddy 10 10 uoN suone iiddy 53 yndu sburjyey 1nding oN Hojeye gt JY SAWDIy SIAI U0 IA 01d jndu aSDud AOFC OOZ 0 384WOvL 0 Cd90 n0rL OS 4 S10 L40 12 4 SSVD O 393 WO L 0 2 Cd90 00vL 0S 7E 2 00L 8 Ove TE 09 LL SL VL SL POLNOd9A 8S2 POLNOdSA SZ 00 380 WOrL SC cq90 f0vL Ov Y STd L40 2 SHH SSVID 07 380 WOrL 2 7090 NOrL 0r SZ EZD 00L 8 C6l ST 8v SLO OL SLO OL volN8dvA aSc vVOLNSdVA VSC 01230 WOrL c2 O90 f0vL OZ Y S10 L40 2 OH SSVD 012330 WOPL 7ZL9 7090 NOrL 0c 9L ZLD 00L V 96 EL SZ vo SOL v0 CO vOLNSdCA 8SC VOLNSdCA VSC 983O WOrL 089 2090 NOvL SL Y S10 L40 2 SAY SSVD 98 3O WOPL 089 709d NOrL 9L OL 609 00L V v9 80 91 cO SCO CO STO vOLN9dL VSC qu wA WorL 50pL DOvl ON Boeye ssep wort sorunon xew uw EE S UIS 3 y an wil gu ainsopuq vXeXc mM Be S xew ad UIW S19y201g 3ImJr Bugey xew sasn4 sa ye ag 4M1 Buey sasn4 a g e dH aN SZS dd EZS dd 5 sBuney suoljerijddy 10 10 uoN suone iiddy 53 yndu sBuney yndyng ON 5ojeje
97. 00 30 122 89 120 AK R2 120P1K2 50 40 4 120 AK R2 120P1K2 75 55 147 120 AK R2 120P1K2 10 0 17 5 47 120 AK R2 120P1K2 15 0 111 0 43 60 AK R2 120P1K2 200 150 143 60 AK R2 120P1K2 250 185 27 40 AK R2 120P1K2 30 0 20 40 AK R2 120P 11009 525 600V 0 5 04 112 360 AK R2 360P500 50 60 Hz 10 1075 112 360 AK R2 360P500 3 Phase 2 0 1 5 112 360 AK R2 360P500 30 42 2 112 120 AK R2 120P1K2 50 40 86 120 AK R2 120P1K2 7 5 55 59 120 AK R2 120P1K2 10 0 17 5 59 120 AK R2 120P1K2 150 11 0 59 60 AK R2 120P1K2 200 115 0 159 60 AK R2 120P 1100 25 0 185 53 60 AK R2 120P1K2 300 220 134 40 AK R2 120P 11009 1 The resistors listed in this tables are rated for 5 duty cycle 2 Use of Rockwell Automation resistors is always recommended The resistors listed have been carefully selected for optimizing performance in a variety of applications Alternative resistors may be used however care must be taken when making a selection See the PowerFlex Dynamic Braking Resistor Calculator publication PFLEX ATO01 3 Requires two resistors wired in parallel 4 Requires three resistors wired in parallel EMCLine Filters Drive Ratings Input Voltage HP kW Current A Frame Size Catalog No 100 120V 025 0 2 1 6 A 25 RF011 AL 50 60 Hz 05 lo4 25 A 25 REOTI AL 1 Phase 10 1075 14 8 B 25 RF023 BL 1 5 11 6 0 B 25 RF023 BL Rockwell Automation Publication 520 UM001G EN E September 2014 165 Appendix B 1
98. 00 0 e 1096 Anlg In4 20mA Hi 0 0 Rockwell Automation Publication 520 UM001G EN E September 2014 PIDSetUp Appendix F e A459 PID 1 Ref Sel 6 4 20mA Input 24 20 216 bd 12 a ES be Mm 4 0 10 20 30 40 50 60 70 80 90 100 PID Reference PID Deadband Parameters A465 and A477 PID x Deadband are used to set a range in percent of the PID Reference that the drive will ignore Example e A465 PID 1 Deadband 5 0 e The PID Reference is 25 0 e The PID Regulator will not act on a PID Error that falls between 20 0 and 30 0 PID Preload The value set in A466 or A478 PID x Preload in Hz will be pre loaded into the integral component of the PID at any start or enable This will cause the drive s frequency command to initially jump to that preload frequency and the PID loop starts regulating from there Pid Enabled Loy ii td a a aa PID Pre load Value J Le Hi L 2 PID Output Freq Cmd PID Pre load Value gt 0 PID Limits A456 and A468 PID x Trim Hi and A457 and A469 PID x Trim Lo are used to limit the PID output and are only used in trim mode PID x Trim Hi sets the maximum frequency for the PID output in trim mode PID x Trim Lo sets the reverse frequency limit for the PID output in trim mode Note that when the Rockwell Automation Publication 520 UM001G EN E September 2014 219 Appendix F 220 PID S
99. 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 DEBBIE Options Description 1 Enabled 0 Disabled Jerk Select Limits the rate of change to the velocity reference for improved current limiting Set to Jerk Select Digit 1 0 Disabled for positioning type applications with fast Accel or Decel times ZeroSpd Slip Digit 2 ZeroSpdSlip Sets slip compensation to 0 0 Hz when the following conditions are met Not Used Commanded speed 0 00 Hz Not Used Status of drive At speed Not Used ZeroSpd Slip 1 Enabled Values Default 11 Min Max 00 11 Display 00 A574 RdyBit Mode Cfg Related Parameter s d392 S drive before changing this parameter PF 525 PowerFlex 525 only With FRN 3 xxx and later Determines which Stop conditions causes the drive s Ready bit Network Logic Status bit 1 to go low 0 A reset or power cycle is required after selection is made Ready Bit Status Stop Conditions Standard Enhanced Drive fault 0 Stop digital input terminal 01 11 open 1 Holding down the drive s keypad or the Remote DSI HIM Stop button 1 1 1 0 Stop commanded through Comms Stop bit 1 Software SW Enable digital input terminal open Safe Torque Off STO condition with value of t105 Safety Open En set to 1 FaultDisabled
100. 014 P045 P046 P048 P049 P050 P051 t064 t086 A410 A425 A427 A431 A432 A433 A434 A435 t067 Digin TermBlk 07 PF 525 PowerFlex 525 only t068 Digln TermBlk 08 M42 M43 A488 A535 A560 A562 A563 A567 A571 so drive before changing this parameter Programmable digital input Changes to these inputs takes effect as soon as they are entered If a digital input is set for a selection that is only usable on one input no other input can be set for the same selection Options 0 Not Used Terminal has no function but can be read over network communications with b013 Contrl In Status and b014 Dig In Status 1 Speed Ref 2 Selects P049 Speed Reference2 as drive s speed command 2 Speed Ref 3 Selects P051 Speed Reference3 as drive s speed command 3 Start Src 2 Selects P048 Start Source 2 as control source to start the drive 4 Start Src 3 Selects P050 Start Source 3 as control source to start the drive 5 Spd rStrt 2 DigIn TermBlk 07 default Selects combination of P049 Speed Reference2 and P048 Start Source 2 as speed command with control source to start the drive 6 Spd Strt 3 Selects combination of P051 Speed Reference3 and P050 Start Source 3 as speed command with control source to start the drive 7 Preset Freq PF523 only for DigIn TermBlk 03 05 Digln TermBlk 05 and DigIn TermBlk 06 default Se
101. 02 b003 P031 P032 P033 P034 P032 P033 P034 P035 P040 P041 P042 P043 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 Digln TermBlk 02 Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 Relay Outi Sel Analog Out Sel Analog Out High Anlg Out Setpt P042 P043 P044 P045 P046 P047 t062 P035 P040 P041 P042 P043 P044 P044 P045 P046 P047 t076 t088 t089 t090 Digln TermBlk 03 Opto Out Sel Relay Out Sel Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 20mA Hi Stop Mode Start Source 1 Speed Reference1 Relay Out Sel Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 20mA Hi Anlg In mA Loss Preset Freq 0 Auto Rstrt Tries Auto Rstrt Delay Rockwell Automation Publication 520 UM001G EN E September 2014 t063 t069 t076 t091 t092 t095 t096 P045 P046 P047 t076 t091 t092 t091 t092 t095 t096 t097 A410 A541 A542 Anlg In mA Loss Slip Hz Meter Preset Freq 0 Jog Frequency Jog Accel Decel S Curve 96 Reverse Disable Anlg In4 20mA Lo Anlg In4 20mA Hi Anlg In mA Loss Preset Freq 0 Stall Fault Time Start At PowerUp Reverse Disable Power Loss Mode Half Bus Enable t097 d375 A410 A431 A432 A439 A544 t095 t096 t097 A410 A492 A543 A544 A548 A549 Programming and Param
102. 024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM1 D030 Rockwell Automation Publication 520 UM001G EN E September 2014 Accessories and Dimensions Appendix B Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current A Voltage Range Size Catalog No 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 14 323 528 A 25 PM2 D1P4 1 0 0 75 1 0 0 75 23 323 528 A 25 PM2 D2P3 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM2 D4P0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM2 D6P0 5 0 4 0 5 0 4 0 10 5 323 528 B 25 PM2 D010 7 5 5 5 7 5 5 5 13 0 323 528 C 25 PM2 D013 10 0 75 10 0 75 17 0 323 528 C 25 PM2 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM2 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM2 D030 25 0 18 5 20 0 15 0 37 0 323 528 E 25 PM2 D037 30 0 22 0 25 0 18 5 43 0 323 528 E 25 PM2 D043 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 0 5 0 4 0 5 0 4 0 9 446 660 A 25 PM1 E0P9 1 0 0 75 1 0 0 75 17 446 660 A 25 PM1 E1P7 2 0 1 5 2 0 1 5 3 0 446 660 A 25 PM1 E3P0 3 0 2 2 3 0 22 42 446 660 A 25 PM1 E4P2 5 0 4 0 5 0 4 0 6 6 446 660 B 25 PM1 E6P6 7 5 5 5 7 5 5 5 9 9 446 660 C 25 PM1 E9P9 10 0 75 10 0 75 12 0 446 660 C 25 PM1 E012 15 0 11 0 15 0 11 0 19 0 446 660 D 25 PM1 E019 20 0 15 0 15 0 11 0
103. 0V analog input as a percent of full scale Values Default Read Only Min Max 0 0 100 096 Display 0 196 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 0 100 096 Display 0 196 d362 Elapsed Time hr Related Parameter s A555 Displays the total elapsed powered up time in hours since timer reset The timer stops when it reaches the maximum value Values Default Read Only Min Max 0 32767 hr Display 1hr d363 Elapsed Time min Related Parameter s d362 A555 Displays the total elapsed powered up time in minutes since timer reset Resets to zero when maximum value is reached and increments d362 Elapsed Time hr by one Values Default Read Only Min Max 0 0 60 0 min Display 0 1 min d364 Counter Status Displays the current value of the counter if enabled Values Default Read Only Min Max 0 65535 Display 1 d365 Timer Status 7 32 bit parameter Displays the current value of the timer if enabled Values Default Read Only Min Max 0 9999 s Display 1s d367 Drive Type Used by Rockwell Automation field service personnel Default Read Only Min Max 0 65535 Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 103 Chapter3 Programming and Parameters Advanced Display Group continued d368 Testpoint Data Displays the present value of t
104. 1 6 170 264 A 25 PM1 A1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 A2P5 1 0 0 75 1 0 0 75 4 8 170 264 A 25 PM1 A4P8 2 0 1 5 2 0 1 5 8 0 170 264 B 25 PM1 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM1 A011 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM2 A1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM2 A2P5 1 0 0 75 1 0 0 75 4 8 170 264 A 25 PM2 A4P8 2 0 1 5 2 0 1 5 8 0 170 264 B 25 PM2 A8P0 3 0 2 2 3 0 2 2 11 0 170 264 B 25 PM2 A011 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 170 264 A 25 PM1 B1P6 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 B2P5 1 0 0 75 1 0 0 75 5 0 170 264 A 25 PM1 B5P0 2 0 1 5 2 0 1 5 8 0 170 264 A 25 PM1 B8P0 3 0 2 2 3 0 2 2 11 0 170 264 A 25 PM1 B011 5 0 4 0 5 0 40 17 5 170 264 B 25 PM1 B017 75 5 5 75 5 5 24 0 170 264 C 25 PM1 B024 10 0 75 10 0 75 32 2 170 264 D 25 PM1 B032 15 0 11 0 10 0 75 48 3 170 264 E 25 PM1 B048 20 0 15 0 15 0 11 0 62 1 170 264 E 25 PM1 B062 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output 0 5 0 4 0 5 0 4 14 323 528 A 25 PM1 D1P4 1 0 0 75 1 0 0 75 23 323 528 A 25 PM1 D2P3 2 0 1 5 2 0 1 5 4 0 323 528 A 25 PM1 D4P0 3 0 2 2 3 0 2 2 6 0 323 528 A 25 PM1 D6P0 5 0 4 0 5 0 4 0 10 5 323 528 B 25 PM1 D010 7 5 5 5 7 5 5 5 13 0 323 528 C 25 PM1 D013 10 0 75 10 0 75 17 0 323 528 C 25 PM1 D017 15 0 11 0 15 0 11 0 24 0 323 528 D 25 PM1 D
105. 1 Decel Time 3 445 EM Brk Off Delay 086 Analog In Filter 099 Decel Time 4 447 EM Brk On Delay 087 Analog Out High 089 Dig In Status 014 EN Addr Sel 128 Analog Out Sel 088 Digln TermBlk 02 062 EN Addr Srl 684 Anlg In 0 10V Hi 092 Digln TermBlk 03 063 EN Comm Fit Actn 143 Anlg In 0 10V Lo 091 Digin TermBlk 05 065 EN Data In 1 153 Anlg In mA Loss 097 Digln TermBlk 06 066 EN Data In 2 154 Anlg In V Loss 094 Digln TermBlk 070 067 EN Data In 3 155 Anlg In4 20mA Hi 096 Digln TermBlk 08 068 EN Data In 4 156 Anlg In4 20mA Lo 095 Drive OL Mode 495 EN Data Out 1 157 Anlg Loss Delay 098 Drive Status 006 EN Data Out 2 158 Anlg Out Setpt 090 Drive Temp 027 EN Data Out 3 159 Auto Rstrt Delay 542 Drive Type 367 EN Data Out 4 160 Auto Rstrt Tries 541 Droop Hertz FLA 44 EN Fit Cfg DL 1 147 Autotune 040 Drv 0 Feedback 708 EN Fit Cfg DL 2 148 Average kWh Cost 052 Drv 0 Logic Cmd 705 EN Fit Cfg DL 30 149 Average Power 020 Drv 0 Logic Sts 707 EN Fit Cfg DL 40 150 Boost Select 530 Drv 0 Reference 706 EN Fit Cfg Logic 145 Break Frequency 533 Drv 1 Addr 171 EN Flt Cfg Ref 146 Break Voltage 532 Drv 1 Feedback 712 EN Gateway Act 1 701 Bus Reg Enable 550 Drv 1 Logic Cmd 709 EN Gateway Act X 702 Cmd Stat Select 12 Drv 1 Logic Sts 711 EN Gateway Act 3l 703 Com Sts Emb Enet 683 Drv 1 Reference 710 EN Gateway Act 4 704 Comm Loss Action 125 Drv 2 Addr 172 EN Gateway Cfg 1 137 Comm Loss Time 126 Drv 2 Feedback 716 EN Gateway Cfg 2 138 Comm Sts DSI 681 Drv 2 Logic
106. 10 10 75 10 0 75 4P0 4 0 A 20 415 20 415 6P0 6 0 B 15 11 15 11 6P0 6 0 A 30 22 13 0 422 010 10 5 B 50 40 150 140 013 13 0 C 75 55 75 45 5 017 17 0 C 10 0 75 10 0 7 5 wr qe Ao psp qus o uuo D 5o mno 50 n9 SLE OBI ML INL 037 370 E 50 185 200 150 4P8 4 8 A 10 10 75 10 0 75 EB EN zm F Ti TE 8P0 8 0 B 20 15 320 415 011 11 0 B 30 22 30 12 2 A 05 04 10 5 10 4 1P6 1 6 A 0 25 02 1025 02 n 2P5 25 A 05 04 10 5 10 4 i 30 35 30 3j 5P0 5 0 A 10 10 75 10 0 75 7 T m T m 8P0 8 0 A 20 15 320 415 i T ms T zE 011 11 0 A 30 22 30 12 2 a 7 35 m T 017 17 5 B 50 40 15 0 140 5 eA F TT a j 024 24 0 C 75 55 75 45 5 SETS 7 3m m m TM 032 322 D 10 0 17 5 10 0 7 5 30 E 350 5 zm 50 EE pas HUM S 0322 320 E 300 23 50 185 0627 1621 E 20 0 15 0 15 0 11 0 1 This rating is only available for PowerFlex 523 drives 2 Normal and Heavy Duty ratings are available for this drive Rockwell Automation Publication 520 UM001G EN E September 2014 13 Preface Overview Notes 14 Rockwell Automation Publication 520 UM001G EN E September 2014 Mounting Considerations Installation Wiring Chapter 1 This chapter provides information on mounting and wiring the PowerFlex 520 series drives For information on See page Mounting Considerations 15 AC Supply Source Considerations 19 General Grounding Requirements Fuses and Circuit Breakers Power and Control Module
107. 104 4 8 3 8 3 1 2 4 107 8 6 7 0 54 25A A8PON104 25B A8PON104 8 0 6 4 52 4 0 18 0 144 117 19 0 25A A011N104 25B A011N104 1 0 88 72 5 5 229 183 149 115 200 240V AC 15 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25A A1P6N114 1 6 13 1 0 0 8 53 43 3 4 2 7 25A A2P5N114 25B A2P5N114 25 2 0 1 6 13 6 5 52 4 2 3 3 25A A4P8N114 25B A4P8N114 4 8 3 8 3 1 2 4 107 8 6 7 0 54 25A A8PON114 25B A8PON114 8 0 6 4 5 2 4 0 18 0 144 117 19 0 25A A011N114 25B A011N114 11 0 8 8 72 5 5 22 9 18 3 14 9 11 5 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25A B1P6N104 1 6 13 1 0 0 8 1 9 15 12 10 25A B2P5N104 25B B2P5N104 2 5 2 0 1 6 13 27 2 2 1 8 14 25A B5PON104 25B B5PON104 5 0 4 0 32 2 5 5 8 4 6 3 8 2 9 25A B8P0N104 25B B8P0N104 8 0 6 4 5 2 4 0 9 5 7 6 6 2 4 8 25A B011N104 25B B011N104 11 0 18 8 7 2 5 5 13 8 110 9 0 6 9 25A B017N104 25B B017N104 17 5 14 0 114 8 8 21 1 16 9 137 10 6 25A B024N104 25B B024N104 240 192 15 6 120 266 1213 173 1133 25A B032N104 25B B032N104 322 1258 1209 161 0348 1278 0226 174 25A B048N104 25B B048N104 483 38 6 314 242 44 0 31352 286 22 0 25A B062N104 25B B062N104 62 1 497 404 31 1 560 1448 36 4 280 Rockwell Automation Publication 520 UM001G EN E September 2014 161 Appendix A 162 Supplemental Drive Information PowerFlex 520 Series Input Current Scaled By Motor Current
108. 1187 Stp Logic 7 so drive before changing this parameter PowerFlex 525 only Values Default 00F1 Min Max 0000 FAFF Display 0001 See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic Parameters L180 L187 are only active if P047 P049 or P051 Speed Referencex is set to 13 Step Logic or 16 Positioning These parameters can be used to create a custom profile of frequency commands Each step can be based on time status of a Logic input or a combination of time and the status of a Logic input Digits 1 4 for each Stp Logic x parameter must be programmed according to the desired profile A Logic input is established by setting a digital input parameters t062 t063 1065 1068 DigIn TermBlk xx to 24 Logic In 1 and or 25 Logic In 2 or by using Bits 6 and 7 of A560 Enh Control Word A time interval between steps can be programmed using parameters L190 L197 Stp Logic Time x See the table below for related parameters The speed for any step is programmed using parameters A410 A417 Preset Freq x Step StepLogic Parameter Related Preset Frequency Parameter Related StepLogic Time Parameter Can be activated independent of StepLogic Parameters Active when L180 L187 Digit 1 or 2 are set to 1 b C d or E 0 L180 Stp Logic 0 A410 Preset Freq 0 L190 Stp Logic Time 0 1 L181 Stp Logic 1 A411 Preset Freq 1
109. 146 EN Fit Cfg Ref Related Parameter s C143 C144 wy 32 bit parameter PF 525 PowerFlex 525 only Sets the Reference data that is sent to the drive if any of the following is true C143 EN Comm Fit Actn is set to 4 Send Fit Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Flt Cfg and the scanner is put into Program or Test mode Values Default 0 Min Max 0 50000 Display 1 C147 EN Fit Cfg DL 1 C148 EN Fit Cfg DL 2 C149 EN Fit Cfg DL 3 C150 EN Fit Cfg DL 4 PF 525 PowerFlex 525 only Sets the Ethernet Datalink Input data that is sent to the drive if any of the following is true C143 EN Comm Fit Actn is set to 4 Send Fit Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Fit Cfg and the scanner is put into Program or Test mode Values Default 0 Min Max 0 65535 Display 1 C153 EN Data In 1 C154 EN Data In 2 C155 EN Data In 3 C156 EN Data In 4 PowerFlex 525 only Datalink parameter number whose value is written from the embedded EtherNet IP data table This parameter cannot be changed when an 1 0 connection is established through the drive s embedded EtherNet IP port Values Default 0 Min Max 0 800 Display 1 C157 EN Data Out 1 C158 EN Data Out 2 C159 EN Data Out 3 C160 EN Data Out 4 PowerFlex 525 only Datalink parameter number whose value is read from the
110. 2 A 25A V1P6N1042 0 5 0 4 0 5 0 4 2 5 85 132 A 25A V2P5N104 25B V2P5N104 1 0 075 10 075 48 85 132 B 25A VAP8N104 25B V4P8N104 1 5 1 1 1 5 1 1 6 0 85 132 B 25A V6PON104 25B V6PON104 200 240V AC 1596 10 1 Phase Input 0 230V 3 Phase Output 025 02 025 02 1 6 170 264 A 25A A1P6N1042 0 5 0 4 0 5 0 4 2 5 170 264 A 25A A2P5N104 125B A2P5N104 1 0 075 10 075 48 170 264 A 25A A4P8N104 25B A4P8N104 2 0 1 5 2 0 15 8 0 170 264 B 25A A8PON104 25B A8PON104 3 0 2 2 3 0 2 2 11 0 170 264 B 25A A011N104 25B A011N104 200 240V AC 1596 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 025 02 025 02 1 6 170 264 A 25A A1P6N114 0 5 0 4 0 5 0 4 2 5 170 264 A 25A A2P5N114 125B A2P5N114 1 0 075 10 075 48 170 264 A 25A A4P8N114 25B A4P8N114 2 0 1 5 2 0 15 8 0 170 264 B 25A A8PON114 25B A8PON114 3 0 2 2 3 0 22 11 0 170 264 B 25A A011N114 25B A011N114 200 240V AC 1596 10 3 Phase Input 0 230V 3 Phase Output 025 02 025 02 16 170 264 A 25A B1P6N1042 0 5 0 4 0 5 0 4 2 5 170 264 A 25A B2P5N104 25B B2P5N104 1 0 075 10 075 50 170 264 A 25A B5PON104 25B B5PON104 2 0 1 5 2 0 1 5 8 0 170 264 A 25A B8PON104 25B B8P0N104 3 0 2 2 3 0 2 2 11 0 170 264 A 25A B011N104 25B B011N104 5 0 4 0 5 0 4 0 17 5 170 264 B 25A B017N104 25B B017N104 75 5 5 7 5 5 5 24 0 170 264 C 25A B024N104 25B B024N104 100 175 10
111. 21 3 3 to level 3C2 chemical and gases only Surrounding Environment See Pollution Degree Ratings According to EN 61800 5 1 on page 49 Pollution Degree for descriptions Pollution Degree 1 amp 2 All enclosures acceptable Sound Pressure Level Measurements are taken 1 m from the drive A weighted Frame A amp B Maximum 53 dBA Frame C Maximum 57 dBA Frame D Maximum 64 dBA Frame E Maximum 68 dBA 156 Rockwell Automation Publication 520 UM001G EN E September 2014 Technical Specifications Protection Specifications Bus Overvoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input Supplemental Drive Information Appendix A PowerFlex 523 PowerFlex 525 405V DC bus equivalent to 150V AC incoming line 405V DC bus equivalent to 290V AC incoming line 810V DC bus equivalent to 575V AC incoming line 1005V DC bus equivalent to 711V AC incoming line Bus Undervoltage Trip 100 120V AC Input 200 240V AC Input 380 480V AC Input 525 600V AC Input P038 3 600V P038 2 480V 190V DC bus equivalent to 75V AC incoming line 190V DC bus equivalent to 150V AC incoming line 390V DC bus equivalent to 275V AC incoming line 487V DC bus equivalent to 344V AC incoming line 390V DC bus equivalent to 275V AC incoming line Power Ride Thru 100 ms Logic Control Ride Thru 0 5 s minimum 2 s typical Electronic Motor Overload
112. 22 0 446 660 D 25 PM1 E022 25 0 18 5 20 0 15 0 27 0 446 660 E 25 PM1 E027 30 0 22 0 25 0 18 5 32 0 446 660 E 25 PM1 E032 PowerFlex 520 Series Control Module PowerFlex 523 Control Replacement control module for use with 25A CTM1 Module PowerFlex 520 Series drives Includes PowerFlex 525 Control Control Module 25B CTM1 Module e Control Module Front Cover Other Parts Frame Item Description Size Catalog No PowerFlex 523 Control Replacement cover for the control module 1 0 terminals A E 25A CTMFC1 Module Front Cover EtherNet IP and DSI ports PowerFlex 525 Control 25B CTMFC1 Module Front Cover PowerFlex 520 Series Replacement cover for the PowerFlex 520 Series power B 25 PMFC FB Power Module Front Cover module C J5 PMFC FC D 25 PMFC FD E 25 PMFC FE PowerFlex 520 Series Replacement finger guard for power terminals A 25 PTG1 FA Power Terminal Guard B 25 PTGT FB C 25 PTG1 FC D 25 PTG1 FD E 25 PTG1 FE Rockwell Automation Publication 520 UM001G EN E September 2014 169 Appendix B 170 Accessories and Dimensions Other Parts Frame Item Description Size Catalog No PowerFlex 520 Series Replacement fan for drive power module A 25 FAN1 FA Heatsink Fan Kit B 25 FAN1 FB C 25 FANT FC D 25 FANT FD E 25 FANT FE PowerFlex 520 Series EMC Replacement EMC cores A 25 CORE A Cores 25 CORE RF A B 25 CORE B 25 CORE RF B C 25 CORE C 25 CORE RF C D 25 CORE D 25 CORE RF D E 25 CORE E 25 COR
113. 25 COMM P adapters as the speed reference 2 Setting is specific to PowerFlex 525 drives only P052 Average kWh Cost Related Parameter s b025 Sets the average cost per kWh Values Default 0 00 Min Max 0 00 655 35 Display 0 01 80 Rockwell Automation Publication 520 UM001G EN E September 2014 Basic Program Group continued P053 Reset To Defalts S drive before changing this parameter Programming and Parameters Chapter 3 Resets all parameters to their factory default values After a Reset command the value of this parameter returns to zero Parameters that are NOT Reset when P053 1 Parameters that are Reset when P053 3 Parameter Parameter Parameter Parameter Name P030 Language C138 EN Gateway Cfg 2 C159 EN Data Out 3 P031 Motor NP Volts C121 Comm Write Mode C139 EN Gateway Cfg 3 C160 EN Data Out 4 P033 Motor OL Current C122 Cmd Stat Select C140 EN Gateway Cfg 4 C161 Opt Data In 1 P034 Motor NP FLA C123 RS485 Data Rate C141 EN Rate Cfg C162 Opt Data In 2 P035 Motor NP Poles C124 RS485 Node Addr C143 EN Comm Flt Actn C163 Opt Data In 3 P038 Voltage Class C124 Comm Loss Action C144 EN Idle Fit Actn C164 Opt Data In 4 A435 DC Brake Level C126 Comm Loss Time C145 EN Flt Cfg Logic C165 Opt Data Out 1 A484 Current Limit 1 C127 RS485 Format C146 EN Fit Cfg Ref C166 Opt Data Out 2 A485 Current Limit 2 C128
114. 25 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 37 Chapter 1 38 Installation Wiring Start Method Stop Method t062 t063 Digln TermBlk xx 1 0 Terminal 01 Stop Normal Stop 48 2 Wire FWD t064 2 Wire Mode is set to Per P045 0 1 0r2 Coast Stop Mode e 3 per P045 Stop Mode 49 3 Wire Start Per P045 Stop Mode 50 2 Wire REV t064 2 Wire Mode is set to 0 1 0r2 Coast 3 per P045 Stop Mode 51 3 Wire Dir Per P045 Stop Mode IMPORTANT The drive is shipped with a jumper installed between 1 0 Terminals 01 and 11 Remove this jumper when using 1 0 Terminal 01 as a stop or enable input 2 Two wire control shown For three wire control use a momentary input To on 1 0 Terminal 02 to command a start Use a maintained input oo for 1 0 Terminal 03 to change direction Control 1 0 Terminal Designations No Signal Default Description Parameter R1 Relay N 0 Fault Normally open contact for output relay 7 R2 RelayCommon Fault Common for output relay ise R3 Relay N C Motor Running Normally closed contact for output relay t081 01 Stop Coast Three wire stop However it functions as a stop under all input p045 modes and cannot be disabled 02 Digin TermBIk 02 Run FWD Used to initiate motion and also can be used as a programmable P045 P046 Start Run FWD digital input It can be programmed with t062 DigIn TermBIk P048
115. 3 35 basic operation 61 drive 56 61 150 programming 61 safety 228 C circuit breakers inputs 22 ratings 22 common bus drive 35 communications positioning 212 configuring RS485 DSI 190 control terminals accessing 30 counter programming 197 200 D decel override priority 48 selecting 48 derating factor 117 temperature 17 digital inputs selecting 47 Start source 47 dimensions mounting 16 173 disconnect output 33 drive auxiliary contact 33 35 basic operation 56 61 150 common bus 35 mount 15 programming 57 60 safety 227 drive damage preventing 19 ungrounded distribution systems 19 encoder programming 203 wiring 204 environment storage 18 Ethernet programming 235 F fault monitoring ground 21 fuses rating 22 G ground fault monitoring 21 motor 21 RFI filter 21 safety 21 shielding 21 homing automatic 210 manual 210 programming 210 inputs 2 wire 47 3 wire 47 circuit breakers 22 power 20 L logic basic 197 198 timed steps 197 198 M Modbus reading 193 195 196 Rockwell Automation Publication 520 UM001G EN E September 2014 239 writing 191 193 196 motor ground 21 start 33 stop 33 mount drive 15 mounting dimensions 16 173 N noise immunity wiring 36 190 0 output disconnect 33 override priority accel 48 decel 48 speed reference 46 start source 46 P paramete
116. 4 A485 Current Limit x for too long e Check for overhauling load F007 Motor Overload 1 Internal electronic overload trip Anexcessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current Verify A530 Boost Select setting F008 Heatsink Ovrimp 1 Heatsink Power Module temperature e Check for blocked or dirty heat sink exceeds a predefined value fins Verify that ambient temperature has not exceeded the rated ambient temperature e Check fan F009 CCOvrTmp 1 Control module temperature exceedsa e Check product ambient predefined value temperature e Check for airflow obstruction e Check for dirt or debris e Check fan F012 HW OverCurrent 2 The drive output current has exceeded Check programming Check for excess the hardware current limit load improper A530 Boost Select setting DC brake volts set too high or other causes of excess current F013 Ground Fault 18 A current path to earth ground has been Check the motor and external wiring to detected at one or more of the drive output terminals Rockwell Automation Publication 520 UM001G EN E September 2014 the drive output terminals for a grounded condition 147 Chapter 4 148 Troubleshooting Fault Types Descriptions and Actions No Fault Type Description Action F015 Load Loss 2 The output torque
117. 4 Maximum Freq Related Parameter s b001 b002 b013 b016 P043 A530 A531 Ts drive before changing this parameter Sets the highest frequency the drive outputs IMPORTANT This value must be greater than the value set in P043 Minimum Freq Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz P045 Stop Mode Related Parameter s t086 t087 A434 A435 A550 Determines the stopping mode used by the drive when a stop is initiated Options 0 Ramp CF Default Ramp to Stop Stop command clears active fault 1 Coast CF Coast to Stop Stop command clears active fault 2 DCBrake CF DC Injection Braking Stop Stop command clears active fault 3 DC BrkAuto CF DC Injection Braking Stop with Auto Shutoff aum DC Injection Braking for value set in A434 DC Brake Time Drive shuts off if the drive detects that the motor is stopped Stop command clears active fault 4 Ramp Ramp to Stop 5 Coast Coast to Stop 6 DCBrake DC Injection Braking Stop 7 DC BrakeAuto DC Injection Braking Stop with Auto Shutoff Standard DC Injection Braking for value set in A434 DC Brake Time OR Drive shuts off if the drive detects that the motor is stopped 8 Ramp EM B CF Ramp to Stop with EM Brake Control Stop command clears active fault 9 Ramp EM Brk Ramp to Stop with EM Brake Control 10 PointStp CF PointStop Stop comm
118. 4 Status Fault 9 F669 EN Gateway Act 4 F704 EN Tx Errors F729 Fault10 Time hr F620 Fault 5 Current F645 Status Fault10 F670 Drv 0 Logic Cmd F705 EN Missed 10 Pkt F730 Fault 1 Time min F621 Fault 6 Current F646 Comm Sts DSI F681 Drv 0 Reference F706 DSI Errors F731 Fault 2 Time min F622 Fault 7 Current F647 Comm Sts Opt F682 Drv 0 Logic Sts F707 Fault 3 Time min F623 Fault 8 Current F648 Com Sts Emb Enet F683 Drv 0 Feedback F708 Fault 4 Time min F624 Fault 9 Current F649 EN Addr Src F684 Drv 1 Logic Cmd F709 1 Parameter is specific to PowerFlex 525 drives only Conveyor E Language Output Freq Commanded Freq Mixer B Language Output Freq Compressor E Language Output Freq Commanded Freq Motor NP Volts 68 P030 b001 b002 P030 b001 P030 b001 b002 P031 Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Commanded Freq Output Current Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq AppView Parameter Groups PowerFlex 520 series drives include various AppView parameter groups that groups certain parameters together for quick and easy access based on different types of applications See AppView Parameter Groups on page 138 for more information P031 P032 P033 P034 P035 P040 P041 b0
119. 4 pole motor Velocity Vector Control VVC 500 x number of poles 2 Speed range 1000 1 1000 PPR 4 pole motor The maximum encoder pulse is 250 kHz Values Default 1024 PPR Min Max 1 20000 PPR Display 1 PPR A537 Pulse In Scale Related Parameter s t065 t067 A535 Sets the scale factor gain for the Pulse Input when t065 or t067 Digln TermBlk xx is set to 52 Pulse Train or A535 Motor Fdbk Type is set to 1 Pulse Train Input frequency Hz Pulse in Scale Output frequency Hz Values Default 64 Min Max 0 20000 Display 1 A538 KiSpeed Loop PowerFlex 525 only Sets the I gain used in the PI calculation of the speed loop when feedback is used Values Default 2 0 Min Max 0 0 400 0 Display 0 1 A539 Kp Speed Loop PF 525 PowerFlex 525 only Sets the P gain used in the PI calculation ofthe speed loop when feedback is used Values Default 5 0 Min Max 0 0 200 0 Display 0 1 122 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A540 Var PWM Disable Related Parameter s A440 S 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
120. 43N114 25B D043N114 43 0 34 4 280 215 1389 311 125 3 119 5 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25A EOP9N104 25B E0P9N104 0 9 0 7 0 6 0 5 12 1 0 0 8 0 6 25A E1P7N104 25B E1P7N104 17 14 1 1 0 9 23 18 15 12 25A E3PON104 25B E3PON104 3 0 24 2 0 1 5 3 8 3 0 2 5 1 9 25A E4P2N104 25B E4P2N104 4 2 3 4 2 7 2 1 5 3 4 2 3 4 2 7 25A E6P6N104 25B E6P6N104 6 6 5 3 43 33 8 0 6 4 5 2 4 0 25A E9P9N104 25B E9P9N104 9 9 79 6 4 5 0 11 2 90 73 5 6 25A E012N104 25B E012N104 120 96 7 8 6 0 135 108 88 6 8 25A E019N104 25B E019N104 19 0 152 124 95 240 192 15 6 120 25A E022N104 25B E022N104 220 176 1143 411 0 20273 1218 1777 1137 25A E027N104 25B E027N104 270 216 17 6 1135 247 1198 116 1 12 4 25A E032N104 25B E032N104 32 0 2256 1208 160 292 1234 190 14 6 Rockwell Automation Publication 520 UM001G EN E September 2014 Appendix B Accessories and Dimensions Product Selection Catalog Number Description 25B V N 1 90 4 Drive VoltageRating Rating Enclosure HIM Emission Class Version PowerFlex 520 Series Drive Ratings Output Ratings Normal Duty Heavy Duty Output Input Frame PowerFlex 523 PowerFlex 525 HP kw HP kW Current A Voltage Range Size Catalog No Catalog No 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 025 02 025 02 1 6 85 13
121. 5 Motor Fdbk Type must be set to the match the feedback device Positioning mode must use A535 Motor Fdbk Type option 4 A535 Motor Fdbk Type Options 0 None indicates no encoder is used This can not be used for positioning 1 Pulse Train is a single channel input no direction speed feedback only This should not be used for positioning The Single Channel selection is similar to a Pulse Train but uses the standard encoder scaling parameters 2 Single Chan is a single channel input no direction speed feedback only This should not be used for positioning Single channel uses the standard encoder scaling parameters 3 Single Check is a single channel input with encoder signal loss detection The drive will fault if it detects that the input pulses do not match the expected motor speed This should not be used for positioning 4 Quadrature is a dual channel encoder input with direction and speed from the encoder This may be used for positioning control 5 Quad Check is a dual channel encoder with encoder signal loss detection The drive will fault if it detects that the encoder speed does not match the expected motor speed A544 Reverse Disable should be set to 0 Rev Enabled to allow bidirectional movement necessary for position control P039 Torque Perf Mode default setting is 1 SVC However any mode can be used to improve the low speed torque for positioning applications For best r
122. 5 0 4 13213RI C 1321 3RA1 C 1321 3R1 C 1321 3RA1 C 10 1075 11 0 075 13213R2 B 13213RA2 B 1321 3R2 B 1321 3RA2 B 20 415 20 415 1321 3R4 C 1321 3RA4 C 1321 3R4 C 1321 3RA4 C 30 22 3 0 422 1321 3R4 B 1321 3RA4 B 1321 3R4 B 1321 3RA4 B 50 40 5 0 4 0 13213R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 75 55 75 55 13213R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 10 0 7 5 100 7 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 15 0 110 150 11 0 13213R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 20 0 150 150 11 0 1321 3R25 B ND 1321 3RA25 B ND 1321 3R25 B ND 1321 3RA25 B ND 1321 3R18 B HD 1321 3RA18 B HD 1321 3R18 B HD 1321 3RA18 B HD 25 0 185 20 0 15 0 1321 3R35 C ND 1321 3RA35 C ND 1321 3R35 C ND 1321 3RA35 C ND 1321 3R25 C HD 1321 3RA25 C HD 1321 3R25 C HD 1321 3RA25 C HD 30 0 220 250 18 5 1321 3R35 C ND 1321 3RA35 C ND 1321 3R35 C ND 1321 3RA35 C ND 1321 3R25 B HD 1321 3RA25 B HD 1321 3R25 B HD 1321 3RA25 B HD Rockwell Automation Publication 520 UM001G EN E September 2014 171 AppendixB 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 Ca
123. 508 Parts 1 7 2010 Intended application The integrated safety function Safe Torque Off of the Frequency AC Drive PowerFlex 525 complies with the requirements of the relevant standards Cat 3 PL d acc to EN ISO 13849 1 SILCL 2 acc to EN 62061 EN 61800 5 2 IEC 61508 and can be used in applications up to Cat 3 PL d acc to EN ISO 13849 1 SIL 2 acc to EN 62061 IEC 61508 Specific requirements The instructions of the associated Installation and Operating Manual shall be considered It is confirmed that the product under test complies with the requirements for machines defined in Annex of the EC Directive 2006 42 EC This certificate is valid until 2017 09 24 Type Approved certificate D Functional Safety The test report no 968 M 365 00 12 dated 2012 09 24 is an integral part of this FS The holder ofa valid Conca certificate for the product tested is AURIS to TOVRheiniend E Berlin 2012 09 24 Tel 49 30 7562 1557 Fax 49 30 7562 1370 E Mat uvat de tuv com TOV Rheinland Industrie Service GmbH Alboinst 56 12103 Berlin Germany Certification Body for Machinery NB 0035 Dipl Ing Eberhard Frejno Rockwell Automation Publication 520 UM001G EN E September 2014 233 AppendixG Safe Torque Off Function Notes 234 Rockwell Automation Publication 520 UM001G EN E September 2014 Establishing A Connection With EtherNet IP Appendix H EtherNet IP This section contains only basic infor
124. 51 Opto Out Logi 075 Preset Freq 0 410 Skip Freq Band 30 453 Opto Out1 Level 070 Preset Freq 1 411 Skip Freq Band 40 455 Opto Out1 Sel 069 Preset Freq 2 412 Skip Frequency 1 448 Opto Out2 Level 073 Preset Freq 3 413 Skip Frequency 2 450 Opto Out2 Sel 072 Preset Freq 4 414 Skip Frequency 30 452 Out Phas Loss En 557 Preset Freq 5 415 Skip Frequency 40 454 Output Current 003 Preset Freq 6 416 Sleep Level 101 Output Freq 001 Preset Freq 7 417 Sleep Time 102 Output Power 017 Preset Freq gU 418 Sleep Wake Sel 100 Output Powr Fctr 381 Preset Freq 90 419 Slip Hz Meter 375 Output RPM 015 Preset Freq 100 420 Speed Feedback 376 Output Speed 016 Preset Freq 110 421 Speed Ratio 572 Output Voltage 004 Preset Freq 12 422 Speed Reference1 047 P Jump 570 Preset Freq BO 423 Speed Reference2 049 PID 1 Deadband 465 Preset Freq 140 424 Speed Reference3 051 PID 1 Diff Rate 463 Preset Freq 150 425 Speed Reg Sell 509 PID 1 Fdback Sel 460 Process Disp Hi 482 Stall Fault Time 492 PID 1 Integ Time 462 Process Disp Lo 481 Start At PowerUp 543 PID 1 Invert Err 467 Process Display 010 Start Boost 531 PID 1 Preload 466 Program Lock 552 Start Source 1 046 PID 1 Prop Gain 461 Program Lock Mod 553 Start Source 2 048 PID 1 Ref Sel 459 Pulse In Scale 537 Start Source 3 050 PID 1 Setpoint 464 Purge Frequency 433 Status Fault 1 661 PID 1 Trim Hi 456 PWM Frequency 440 Status Fault 2 662 PID 1 Trim Lo 457 RdyBit Mode Act 392 Status Fault 3 663 PID 1 Trim Sel 458 RdyBit Mode
125. 66 Accessories and Dimensions EMC Line Filters Drive Ratings Input Voltage HP kW Current A Frame Size Catalog No 200 240V 0 25 02 116 A 25 RFO11 AL uu 05 04 25 A 25 RFOTI AL 10 075 14 8 A 25 RFOT1 AL 20 15 80 B 25 RFO23 BL 30 22 111 0 B 25 RFO23 BL 200 240V 0 25 02 116 A 25 RFO14 AL dude 05 o4 25 A 25 RFOT4 AL 10 075 5 0 A 25 RFO14 AL 20 15 80 A 25 RFO14 AL 30 22 110 A 25 RFO14 AL 50 40 175 B 25 RFO21 BL 75 155 240 C 25 RF027 CL 100 17 5 322 D 25 RFO35 DL 150 11 0 483 E 25 RFO56 EL 200 150 162 1 E 25 RFO56 EL 380 480V 05 Jog 114 A 25 RF7P5 AL Ain 10 jo 3 A 25 RF7P5 AL 20 fis 40 A 25 RF7P5 AL 30 22 160 A 25 RF7P5 AL 50 40 105 B 25 RFO14 BL 75 155 130 C 25 RFO18 CL 100 175 0 C 25 RFO18 CL 150 11 0 124 0 D 25 RF033 DL 200 15 0 130 0 D 25 RF033 DL 250 185 137 0 E 25 RFO39 EL 30 0 220 143 0 E 25 RFO39 ELU 525 600V 05 o4 09 A 25 RF8PO BL ee 10 075 17 A 25 RFSPO BL 20 15 30 A 25 RF8PO BL 30 22 42 A 25 RF8P0 BL2 50 40 66 B 25 RF8PO BL 75 55 99 C 25 RFO14 CL 100 175 120 C 25 RFO14 CL 150 11 0 19 0 D 25 RFO27 DL 200 150 122 0 D 25 RFO27 DL 25 0 185 127 0 E 25 RFO29 EL 300 220 320 E 25 RFO29 ELU 1 EMC Line Filter size is based on the input current of the drive See the tables on page 25 and page 26 for more information 2 This 600V drive rating needs to be
126. 70 0 750 mm 18 AWG 3 conductor shielded Encoder Pulse 1 0 9728 9730 60 C 140 F 0 196 mm 24 AWG individually shielded pairs 1 Stranded or solid wire 2 Ifthe wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Recommended Control Wire for Digital 1 0 Type Wire Type s Description Min Insulation Rating Unshielded Per US NEC or applicable 300V national or local code 60 C 140 F Shielded Multi conductor shielded 0 750 mm 18 AWG 3 conductor shielded cable such as Belden 8770 or equivalent Maximum Control Wire Recommendations Do not exceed control wiring length of 30 m 100 ft Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the I O terminal block Common may be connected to ground terminal protective earth Control 1 0 Terminal Block Wire Specifications A E 1 3 mm 16 AWG 0 13 mm 26 AWG 0 71 0 86 Nm 6 2 7 6 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 PowerFlex 523 Control 1 0 Terminal Block PowerFlex 523 Control 1 0 Wiring Block Diagram Typical Typical
127. 70 PID 2 Trim Sel PF 525 PowerFlex 525 only S drive before changing this parameter Sets the PID output as trim to the source reference Options 0 Disabled Default PID Trim is disabled 1 TrimOn Pot 2 TrimOn Keypd 3 TrimOn DSI 4 TrimOn NetOp 5 Trim0n 0 10V 6 TrimOn 4 20 7 TrimOn Prset 8 TrimOn AnMit 9 Trim0n MOP 10 TrimOn Pulse 11 TrimOn Slgic 12 TrimOn Encdr 13 TrimOn ENet 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 113 Chapter3 Programming and Parameters Advanced Program Group continued M59 PID 1 Ref Sel A471 PID 2 Ref Sel PowerFlex 525 only O Bay drive before changing this parameter Selects the source of the PID reference Options 0 PID Setpoint Default Drive Pot Keypad Freq Serial DSI Network Opt 0 10V Input 4 20mA Input Preset Freq Anlgin Multi MOP Freq Pulse Input 11 Step Logic 12 Encoder 13 EtherNet I wo CO NI AJl BS N ce 1 Setting is specific to PowerFlex 525 drives only A460 PID 1 Fdback Sel A472 PID 2 Fdback Sel PowerFlex 525 only Selects the source of the PID feedback Options 0 0 10V Input Default Note PID does not function with bipolar input Negative voltages are ignored and tre
128. ATTENTION Hazard of injury exists due to unintended operation When t064 2 Wire Mode is set to option 1 and the Run input is maintained the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop function is provided only when the Stop input is active open 2 Hi Spd Edge IMPORTANT There is greater potential voltage on the output terminals when using this option Outputs are kept in a ready to run state The drive will respond to a Start command within 10 ms 1 0 Terminal 01 Stop Coast to stop 1 0 Terminal 03 Run REV 3 Momentary Drive will start after a momentary input from either the Run FWD input 1 0 Terminal 02 or the Run REV input 1 0 Terminal 03 1 0 Terminal 01 Stop Stop according to the value set in P045 Stop Mode 84 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Terminal Block Group continued t069 Opto Out1 Sel t072 Opto Out2 Sel PowerFlex 525 only Determines the operation of the programmable digital outputs Related Parameter s P046 P048 P050 t070 t073 t077 t082 t086 t087 t093 t094 t097 A541 A564 Options 0 Ready Fault Setting Output Changes State When Opto outputs are active when power is applied Indicates that the drive is ready for operation Opto outputs are inactive when power is removed or a fault occurs Hysteresis N
129. Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION In safe off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor ATTENTION In the event of the failure of two output IGBTs in the drive when the PowerFlex 525 Safe Torque Off has controlled the drive outputs to the off state the drive may provide energy for up to 180 of rotation in a 2 pole motor before torque production in the motor ceases ATTENTION The following information is merely a guide for proper The PowerFlex 525 Safe Torque Off function is suitable for use in safety applications up to and including Category 3 PL d according to EN ISO 13849 1 and SIL 2 according to EN 62061 EN 61800 5 2 IEC 61508 In addition the PowerFlex 525 STO may be used together with other components in a safety application to achieve an overall Category 3 PL e according to EN ISO 13849 1 and SIL 3 according to EN 62061 and IEC 61508 This is illustrated in Example 3 in this appendix Safety requirements are based on the standards current at the time of certification The PowerFlex 525 Safe Torque Off function is inte
130. C e EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements e EN 61800 5 2 2007 Adjustable speed electrical power drive systems Part 5 2 Safety requirement Functional Refer to Appendix G for installation consideration related to Machinery Directive General Considerations e For CE compliance drives must satisfy installation requirements related to both EN 61800 5 1 and EN 61800 3 provided in this document e PowerFlex 520 series drives must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive See Pollution Degree Ratings According to EN 61800 5 1 on page 49 for descriptions of each pollution degree rating Rockwell Automation Publication 520 UM001G EN E September 2014 49 Chapter 1 50 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
131. C installations e UL Only inverse time circuit breakers and the specified 140M self protected combination motor controllers are acceptable for UL installations Bulletin 140M Self Protected Combination Controller UL489 Circuit Breakers When using Bulletin 140M or UL489 rated circuit breakers the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection e Bulletin 140M can be used in single motor applications e Bulletin 140M can be used up stream from the drive without the need for fuses 1 Typical designations include but may not be limited to the following Parts 1 amp 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG GH Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter 1 Installation Wiring swuaysAs punoib arueysisas YBiy 10 punosb 13u10 eje q e1jeq A009 10 AOS UO asn 104 pais IN JON Mdu JY A009 PUL Z A08t 10 Parsi IN a 03u0 1030 uoreurquuo 3 ad pa ajolg sjas enuey di JOU adiAap au PPY abued uinum ay o3 Jas dr jus um Y ALY pjnous abued juam ajqexsnfpe YM Wop Unaling sbureg uoreddy siayearg M UOII Olg JOOW WOPL UMa sas fea Aew siayeadg 3210 401223014 1030 WOP L UBaling ay jo sbune1j jv au Bunes zuan 3ndui Alp 104 ayejdaweu aAup ay 01 Jajad sburje dwe samo 31 03001 Burjouoo S BAUP ay Udy
132. Cfg 574 Status Fault 4 664 PID1 Fdbk Displ 383 Relay 1 Off Time 080 Status Fault 5 665 PID1 Setpnt Disp 384 Relay 1 0n Time 079 Status Fault 6 666 PID 2 Deadband 477 Relay Out Level 077 Status Fault 7 667 PID 2 Diff Rate 475 Relay Out Sel 076 Status Fault 8 668 PID 2 Fdback Sel 472 Relay 2 Off Time 085 Status Fault 9 669 PID 2 Integ Time 474 Relay 2 On Time 084 Status Fault10 670 PID 2 Invert Err 479 Relay Out2 Level 082 Step Units 0 200 PID 2 Preload 478 Relay Out2 Sel 081 Step Units 1 202 PID 2 Prop Gain 473 Reset Meters 555 Step Units 20 204 PID 2 Ref Sel 471 Reset to Defalts 053 Step Units 3 206 PID 2 Setpoint 7 476 Reverse Disable 544 Step Units 40 208 PID 2 Trim Hi 468 RS485 Data Rate 123 Step Units 5 210 PID 2 Trim Lo 469 RS485 Format 127 Step Units 6 212 PID 2 Trim Sel 470 RS485 Node Addr 124 Step Units 7 214 PID2 Fdbk Displ 385 S Curve 96 439 Stop Mode 045 PID2 Setpnt Disp 386 Safety Open En 105 Stp Logico 180 Pos Reg Filter 565 Shear Pin 1 Time 487 Stp Logic 10 181 Pos Reg Gain 566 Shear Pin1 Level 486 Stp Logic 2 182 1 Parameter is specific to PowerFlex 525 drives only 12 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Parameter Name No Parameter Name No Parameter Name No Stp Logic 37 183 Stp Logic Time 4m 194 Torque Perf Mode 039 Stp Logic 40 184 Stp Logic Time 50 195 Trav
133. DRIVES IN001 Unshielded THHN THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity N ATTENTION Do not use THHN or similarly coated wire in wet areas Shielded Armored Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit ofa copper braided shield that can contain much of the noise generated by a typical AC Drive Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications In addition the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES INO01 Consideration should be
134. Digital input and digital output parameters can be configured to use logic to transition to the next step Logic In 1 and Logic In 2 are defined by programming parameters t062 t063 t065 t068 DigIn TermBlk xx to 24 Logic In 1 or 25 Logic In 2 Example e Runat Step 0 e Transition to Step 1 when Logic In 1 is true Logic senses the edge of Logic In 1 when it transitions from off to on Logic In 1 is not required to remain on 198 Rockwell Automation Publication 520 UM001G EN E September 2014 Velocity StepLogic Basic Logic and Timer Counter Functions Appendix D e Transition to Step 2 when both Logic In 1 and Logic In 2 are true The drive senses the level of both Logic In 1 and Logic In 2 and transitions to Step 2 when both are on e Transition to Step 3 when Logic In 2 returns to a false or off state Inputs are not required to remain in the on condition except under the logic conditions used for the transition from Step 2 to Step 3 Start Step 0 Stpl Stp2 Step 3 Frequency LogicIn 1 gt LogicIn 2 gt Time The step time value and the basic logic may be used together to satisfy machine conditions For instance the step may need to run for a minimum time period and then use the basic logic to trigger a transition to the next step Start Step 0 Step 1 V Frequency LogicIn 1 gt LogicIn 2 gt Time Timer Function
135. E 1 2 RTU 8 0 1 3 RTU 8 N 2 4 RTU 8 E 2 5 RTU 8 0 2 C128 EN Addr Sel Related Parameter s C129 C132 C133 C136 C137 C140 PF 525 PowerFlex 525 only Enables the IP address subnet mask and gateway address to be set with a BOOTP server Identifies the connections that would be attempted on a reset or power cycle A reset or power cycle is required after selection is made Options 1 Parameters 2 BOOTP Default C129 EN IP Addr Cfg 1 Related Parameter s C128 C130 EN IP Addr Cfg 2 C131 EN IP Addr Cfg 3 C132 EN IP Addr Cfg 4 PF 525 PowerFlex 525 only Sets the bytes in the IP address A reset or power cycle is required after selection is made 192 168 1 62 EN IP Addr Cfg 1 EN IP Addr Cfg 2 EN IP Addr Cfg 3 EN IP Addr Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters Values Default 0 Min Max 0 255 Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 95 Chapter3 Programming and Parameters Communications Group continued C133 EN Subnet Cfg 1 C134 EN Subnet Cfg 2 C135 EN Subnet Cfg 3 C136 EN Subnet Cfg 4 PowerFlex 525 only Sets the bytes of the subnet mask A reset or power cycle is required after selection is made 255 255 255 0 EN Subnet Cfg 1 EN Subnet Cfg 2 EN Subnet Cfg 3 EN Subnet Cfg 4 IMPORTANT C128 EN Addr Sel must be set to 1 Parameters
136. E RF E Communication Option Kits and Accessories Item Description Catalog No Communication Adapters Embedded communication options for use with the PowerFlex 520 Series drives e DeviceNet 25 COMM D e Dual Port EtherNet IP 25 COMM E2P PROFIBUS DP V1 25 COMM P Compact 1 0 Module Three channel 1769 SM2 Universal Serial Bus USB Provides serial communication with DF1 protocol for use with 1203 USB Converter Module Connected Components Workbench software Includes 2m USB cable 1 e 20 HIM H10 cable 1 e 22 HIM H10 cable 1 Serial Converter Module Provides serial communication with DF1 protocol for use with 22 SCM 232 RS485 to RS232 Connected Components Workbench software Includes DSI to RS232 serial converter 1 e 1203 SFC serial cable 1 e 22 RJ45CBL C20 cable 1 DSI Cable 2 0 m RJ45 to RJ45 cable male to male connectors 22 RJ45CBL C20 Serial Cable 2 0 m serial cable with a locking low profile connector to connect to the serial converter and a 9 pin sub miniature D female connector to connect to a computer 1203 SFC Splitter Cable RJ45 one to two port splitter cable Modbus only AK U0 RJ45 SC1 Terminating Resistors RJ45 120 Ohm resistors 2 pieces AK U0 RJ45 TR1 Terminal Block RJ45 Two position terminal block 5 pieces AK U0 RJ45 TB2P Connected Components Workbench Software Download or DVD ROM Windows based software packages for pro
137. Fault F111 Ready Run Safety Open En Safety Hardware Safety Hardware Safety Channel Operation Safety Input S1 No Power Applied Power Applied Power Applied No Power Applied Safety Input 52 No Power Applied No Power Applied Power Applied Power Applied IMPORTANT Ifan external fault is present on the wiring or circuitry controlling the Safety 1 or Safety 2 inputs for a period of time the Safe Torque Off function may not detect this condition When the external fault condition is removed the Safe Torque Off function will allow an enable condition Fault in the external wiring shall either be detected by external logic or excluded wiring must be protected by cable ducting or armoring according to EN ISO 13849 2 Rockwell Automation Publication 520 UM001G EN E September 2014 Safe Torque OffFunction Appendix G Connection Examples Example 1 Safe Torque Off Connection with Coast to Stop Action SIL 2 PL d Stop Category 0 Coast input power E Stop latching button MSR ise A2 22 S14 S34 42 14 24 34 iub i eta rni Cii ii o Fd y i rm a E id PF 525 24V DC Stop Stop L O Start 9 At 52118111552 41 13 23 33 Start I I I L i L I i L I I L Gate control 1 power supply I Li L
138. G Example 2 Safe Torque Off Connection with Controlled Stop Action SIL 2 PL d Stop Category 1 Controlled MTT Kline input power l I i I I LI GuardMaster PF 525 Trojan Gate 24V DC Al 921511 552512 522 Gate control Minotaur power supply MSR138DP A2 X1 X2 X3 X4 Y39Y40 T LI LI LJ 24V DC Common CAS Gate contro circuit 4 CB S1 9 1 Enclosure Recommended External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits 11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 will issue a Stop command to the drive and cause a controlled deceleration After the programmed delay the timed output circuits 47 48 amp 57 58 will cause the Safe Torque Off Enable circuit to trip If the motor is rotating when the trip occurs it will coast to stop To restart the drive the Minot
139. G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued M33 Purge Frequency Related Parameter s t062 t063 t065 t068 Provides a fixed frequency command value when 1062 t063 t065 t068 Digln 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 0s Min Max 0 0 99 9 s Display 0 15 A435 DC Brake Level Related Parameter s P045 Defines the maximum DC brake current in amps applied to the motor when P045 Stop Mode is set to either 4 Ramp or 6 DC Brake Ramp to Stop Mode DC Injection Stop Mode DC Brake Time Voltage REPRE i E 2 DC Brake Time 2 E Magnitude s Magnitude N depends on depends on Time DC Brake Level ime DC Brake Level Stop Command T Stop Command ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used This feature should not be used with synchronous motors Motors may be demagnetized during braking Values Default Drive Rated Amps x 0 05 Min Max 0 00 Drive Rated Amps x 1 80 Display 0 01A M36 DC Brk Time Strt Related Parameter s P045 A435 Sets the length of time that DC brake current is injected into the motor aft
140. Homing Routier sss Mace ssec alt aang nte 210 Encoder and Position Feedback Lulusuesusss 211 Use Over Communications eeeeeeee ee han 212 Settip NGS TU 213 Appendix F PID BOO cR UT TEE 215 PID Reference and Feedback 0 cece eee eee eee een eee 217 Analog PID Reference Signals i see ere xn Per ES 218 Appendix G PowerFlex 525 Safe Torque Off Overview 00 seen ee eee 223 EC Type Examination Certification s44 c c0e0264cedeessaS ho reccka 224 EMC Instructions 0 ccc cece eee e eee 224 Using PowerFlex 525 Safe Torque Off is cocduids sesh ore ete ma 224 Safety Concept sse eee EI SRI E YR e uet EA IST 225 Enabling PowerFlex 525 Safe Torque OfE oisi eeee vete reke rre 227 NOME oS Ree Dee Eos dada da gd nt tosta eee ad 227 PowerFlex 525 Safe Torque Off Operation seeusese 227 VenbvOpermtiol sesso Dott s fotu cand Luis de Potete 228 Connection Examples coco EI a Rei uL iad 229 PowerFlex 525 Certification for Safe Torque Off Lsu 233 Appendix H Establishing A Connection With EtherNet IP ssuuu 235 Appendix I Induction Motor Tuning Diagrams 0 00 00 cece eee eee ees 237 Adjusting Speed Control Patametets e Lester oer dhe 238 Rockwell Automation Publication 520 UM001G EN E September 2014 7 Table of Contents Notes 8 Rockwell Automation Publication 520 UM001G EN E September 2014 Who Should Use this Manual Recommende
141. Hz Display 0 1Hz A563 Find Home Dir S drive before changing this parameter PF 525 PowerFlex 525 only Sets the direction the drive commands when Find Home is issued Options 0 Forward Default 1 Reverse A564 Encoder Pos Tol PowerFlex 525 only Sets the At Position and the At Home tolerance around the encoder count The value is added to and subtracted from the target encoder unit value to create the tolerance range Values Default 100 Min Max 1 50000 Display 1 A565 Pos Reg Filter PowerFlex 525 only Sets the error signal filter in the position regulator Values Default 8 Min Max 0 15 Display 1 A566 Pos Reg Gain PowerFlex 525 only Sets the gain adjustment for the position regulator Values Default 3 0 Min Max 0 0 200 0 Display 0 1 Rockwell Automation Publication 520 UM001G EN E September 2014 127 Chapter3 Programming and Parameters Advanced Program Group continued A567 MaxTraverse Sets the amplitude of triangle wave speed modulation ieee ark P Jump Max Traverse Output Freq E _ Traverse Bit L Fiber status L 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 freque
142. L191 Stp Logic Time 1 2 L182 Stp Logic 2 A412 Preset Freq 2 L192 Stp Logic Time 2 3 L183 Stp Logic 3 A413 Preset Freq 3 L193 Stp Logic Time 3 4 L184 Stp Logic 4 A414 Preset Freq 4 L194 Stp Logic Time 4 5 L185 Stp Logic 5 A415 Preset Freq 5 L195 Stp Logic Time 5 6 L186 Stp Logic 6 A416 Preset Freq 6 L196 Stp Logic Time 6 7 L187 Stp Logic 7 A417 Preset Freq 7 L197 Stp Logic Time 7 The position for any step is programmed using parameters L200 L214 Step Units x Step StepLogic Position Parameter 0 1200 Step Units 0 amp L201 Step Units F 0 1 L202 Step Units 1 amp L203 Step Units F 1 2 L204 Step Units 2 amp L205 Step Units F 2 3 L206 Step Units 3 amp L207 Step Units F 3 4 L208 Step Units 4 amp L209 Step Units F 4 5 6 7 L210 Step Units 5 amp L211 Step Units F 5 L212 Step Units 6 amp L213 Step Units F 6 L214 Step Units 7 amp L215 Step Units F 7 How StepLogic Works The StepLogic sequence begins with a valid start command A normal sequence always begins with L180 Stp Logic 0 Digit 1 Logic for next step This digit defines the logic for the next step When the condition is met the program advances to the next step Step 0 follows Step 7 Example Digit 1 is set to 3 When Logic In 2 becomes active the program advances to the next step Digit 2 Logic to jump to a different step For all settings other than F when
143. LOQ GSC POLNELOQ VSC 9100 WOtlL 0E 4 S10 140 ojg SS 91 30 WOvL SLJ Q90 NOYL ce 0c 2 00L 8 SEL NCL SOL Ov O S Ov O S PLLNOLOG S2 VLLNOLOQ VSC 9L 9 32 WO0rL 0E S10 140 ojg SSvD 91 30 WOvL SLD 090 NOFL tE 0c 001 8 SEL OTL SOL Ov OS Ov OS vOLNOLOQ dSC VOLNOLOQ VSC 0150 WOvL SL 4 S10 140 Ojg SSVD 01 30 WOvL OLD 09A NOFL 9L 0L 600 001 V GL 69 09 CC OE CC OE PLLNOd9G 8S2 vLLNOd9Q VSC 0L 32 W0rL SL U S10 1409 SMUSSWID 01 30 WOPL OLD a9d NOrL 9 OL 60 00L V GL 69 09 TCT OE CC OE VOLNOd9G 852 vVOLNOd9Q VSC 98 0 WOtl SL u S10 140 fD SAASSYID 99 30 WOvL 098 Ed90 norL 9L OL 60 00L V LS CS Ov SL OZ SL OC viLNOdvQ 8SC vLLNOdvQ VSC 98 0 WOtl SsL u S10 140 SH SSVD 99 30 WOvL 098 Ed90 norL 9L OL 60 00L V LS CS OV GL OC SL OC VOLNOdvd 8S7 VOLNOdv VSC 0v8 32 W0rL 0L 4 S10 140 SMH SSVT OP9 JZ WOrL 099 090 NOFL OL 9 60 00L V TE ET EC SLO OL SLO OL PLLNEdZ0 8S2 vLLNEdCO VSC 0va 32 WOrL OL Y S1d 140 FD SMU SSVT OP9 JZ WOrL 099 090 NOFL 0L 9 609 001 V TE ET ET SLO OL SLO OL POLNEdZO 852 VOLNEdC I VSC SC O WOvL 94FS10 110 O4 SSVD SC8 30 WOvL 0 8 EQ90 nObL 9 60 00L V 61 LL vi vo SO vo SO vLLNVdLO GSC vLLNVdLO VSC SCdO WOtl 9 4 S10 L10 fD SHY SSVD SC8 300 WOvL 0 8 EQ90 nObL 9 609 00L V
144. Logic 4 Stp Logic 5 Stp Logic 0 L180 Stp Logic 6 Stp Logic 1 L181 Stp Logic 7 Advanced Display Elapsed Time hr Elapsed Time min s Counter Status Timer Status Analog In 0 10V d360 Drive Type Analog In 4 20mA d361 Testpoint Data Advanced Program DB Resistor Sel DB Threshold a S Curve 96 PWM Frequency Preset Freq 0 A410 Droop Hertz FLAO Preset Freq 1 A411 Accel Time 2 Preset Freq 2 A412 Decel Time 2 Preset Freq 3 A413 Accel Time 3 Preset Freq 4 A414 Decel Time 3 Preset Freq 5 A415 Accel Time 4 Preset Freq 6 A416 Decel Time 4 Preset Freq 7 A417 Skip Frequency 1 Preset Freq gt A418 Skip Freq Band 1 Preset Freq 9 A419 Skip Frequency 2 Preset Freq 10 A420 Skip Freq Band 2 Preset Freq 110 M21 Skip Frequency 30 Preset Freq 120 A422 Skip Freq Band 30 Preset Freq 130 M23 Skip Frequency 4O Preset Freq 140 A424 Skip Freq Band 40 Preset Freq 15 7 M25 PID 1 Trim Hi Keypad Freq A426 PID 1 Trim Lo MOP Freq A427 PID 1 Trim Sel MOP Reset Sel A428 PID 1 Ref Sel MOP Preload A429 PID 1 Fdback Sel MOP Time M30 PID 1 Prop Gain Jog Frequency M31 PID 1 Integ Time Jog Accel Decel M32 PID 1 Diff Rate Purge Frequency M33 PID 1 Setpoint DC Brake Time A434 PID 1 Deadband DC Brake Level A435 PID 1 Preload DC Brk Time Strt A436 PID 1 Invert Err Network 1 Parameter is specific to PowerFlex 525 drives only Modified M37 PID 2 Trim Hit M38 PID 2 Trim Lo M39 PID 2 Trim Sel A440 PID 2 Ref Sel A441 PID 2 Fdback Sel A442 PID 2 Prop Gain
145. Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544 Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 PID 1 Integ Time M62 Flying Start En A545 Extruder Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 Encoder PPR A536 Motor OL Current P033 Start Source 1 P046 Anlg In4 20mA Hi t096 Pulse In Scale A537 a Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 Ki Speed Loop A538 Motor NP Poles P035 Relay Out1 Sel t076 Slip Hz Meter d375 Kp Speed Loop A539 Language P030 Autotune P040 Analog Out Sel 1088 Speed Feedback d376 Power Loss Mode A548 Output Freq b001 Accel Time 1 P041 Analog Out High 1089 Encoder Speed d378 Half Bus Enable A549 Commanded Freq b002 Decel Time 1 P042 Anlg Out Setpt t090 Preset Freq 0 A410 Output Current b003 Minimum Freq P043 Anlg In 0 10V Lo t091 Stall Fault Time A492 Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 Motor Fdbk Type A535 Positioning Stop Mode P045 Stp Logic 5 L185 Step Units 6 L212 Jog Accel Decel A432 Start Source 1 P046 Stp Logic 6 L186 Step Units 7 L214 DB Threshold A438 en Speed Reference1 P047 StpLogic7 L187 Slip Hz Meter d375 SCurve96 A439 Digln TermBlk 02 1062 Stp Logic Time 0 L190 Speed Feedback d376 Motor Fdbk Type A535 Language P030 Digln TermBlk 03 1063 Stp Logic Time 1 L191 Encoder Speed d378 Encoder PPR A536 Output Freq b001 Digin TermBlk 05 t065 Stp Logic Time 2 L192 Units Traveled H d388 Pulse In Scale A537 Command
146. N ISO 13849 and EN62061 for safe off and protection against restart The PowerFlex 525 Safe Torque Off function is just one component in a safety control system Components in the system must be chosen and applied appropriately to achieve the desired level of operator safeguarding For information on See page PowerFlex 525 Safe Torque Off Overview 223 EC Type Examination Certification 224 EMC Instructions 224 Using PowerFlex 525 Safe Torque Off 224 Enabling PowerFlex 525 Safe Torque Off 227 Wiring 27 Verify Operation 228 PowerFlex 525 Safe Torque Off Operation 227 Connection Examples 229 PowerFlex 525 Certification for Safe Torque Off 233 IMPORTANT The Safe Torque Off function covered in this chapter is specific to PowerFlex 525 drives only The PowerFlex 525 Safe Iorque Off function e Provides the Safe Torque Off STO function defined in EN IEC 61800 5 2 e Blocks gate firing signals from reaching the Insulated Gate Bipolar Transistor IGBT output devices of the drive This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor e Can be used in combination with other safety devices to fulfill the requirements of a system safe torque off function which satisfies Category 3 PL d according to EN ISO 13849 1 and SIL CL2 according to EN IEC 62061 IEC 61508 and EN IEC 61800 5 2 IMPORTANT Thefunction is suitable for performing me
147. P050 02 as three wire Start Dir with Stop or two wire Run FWD A544 t062 Run REV control Current consumption is 6 mA 03 Digln TermBlk 03 Run REV Used to initiate motion and also can be used as a programmable t063 Dir Run REV digital input It can be programmed with t063 DigIn TermBlk 03 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 Digital Common Return for digital 1 0 Electrically isolated along with the digital 1 0 from the rest of the drive 05 Digln TermBlk 05 Preset Freq Program with t065 DigIn TermBlk 05 Also functions as a Pulse t065 Pulse In Train input for reference or speed feedback The maximum frequency is 100 kHz Current consumption is 6 mA 06 Digin TermBlk 06 Preset Freq Program with t066 DigIn TermBlk 06 t066 Current consumption is 6 mA 11 24V DC Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100 mA 12 10V DC Referenced to Analog Common P047 P049 Drive supplied power for 0 10V external potentiometer Maximum output current is 15 mA 13 10 10V In Not Active For external 0 10V unipolar input supply or potentiometer P047 P049 wiper 1062 t063 Input impedance 1065 t066 Voltage source 100 kQ ey M59 Allowable potentiometer resistance range 1 10 KQ 14 AnalogCommon Return for the analog 1 0 Electrically isol
148. Parameter 0 OutFreq 0 10 0 10V 0v 0Hz Maximum Freq None b001 1 OutCurr 0 10 0 10V OV 0A 200 Drive Rated Current Filter A b003 2 OutVolt 0 10 0 10V OV 0V 120 Drive Rated Output Volts None b004 3 OutPowr 0 10 0 10V 0V 0kW 200 Drive Rated Power Filter A b017 4 OutTorq 0 10 0 10V OV 0A 200 Drive Rated Current Filter A 382 5 TstData 0 10 0 10V OV 0000 65535 Hex FFFF None 6 Setpnt 0 10 0 10V 0V 096 100 096 Setpoint setting None 1090 7 DCVolt 0 10 0 10V 0v 0v 100 096 of trip value None b005 8 OutFreq 0 20 0 20 mA 0mA 0Hz Maximum Freq None b001 9 OutCurr 0 20 0 20 mA OmA 0A 200 Drive Rated Current Filter A b003 10 OutVolt 0 20 0 20 mA OmA 0V 120 Drive Rated Output Volts None b004 11 OutPowr 0 20 0 20 mA OmA 0kW 200 Drive Rated Power Filter A b017 12 OutTorq 0 20 0 20 mA OmA 0A 200 Drive Rated Current Filter A 382 13 TstData 0 20 0 20 mA 0 mA 0000 65535 Hex FFFF None 14 Setpnt 0 20 0 20 mA 0 mA 096 100 096 Setpoint setting None 1090 15 DCVolt 0 20 0 20 mA 0 mA 0V 100 0 of trip value None b005 16 OutFreq 4 20 4 20 m 4mA 0hz Maximum Freq None b001 17 OutCurr 4 20 4 20 mA 4mA 0A 200 Drive Rated Current Filter A b003 18 OutVolt 4 20 4 20 mA 4mA 0V 120 Drive Rated Output Volts None b004 19 OutPowr 4 20 4 20 mA 4mA 0kW 200 Drive Rated Power Filter A b017 20 OutTorq 4 20 4 20 m 4mA 0A 200 Drive Rated Current Filter A d382 21 TstData 4 20 4 20 mA 4 mA 0000 65535 Hex
149. Run FWD Used to initiate motion and also can be used as a programmable P045 P046 Start Run FWD digital input It can be programmed with t062 DigIn TermBIk P048 P050 02 as three wire Start Dir with Stop or two wire Run FWD A544 t062 Run REV control Current consumption is 6 mA 03 Digin TermBlk 03 Run REV Used to initiate motion and also can be used as a programmable t063 Dir Run REV digital input It can be programmed with t063 DigIn TermBlk 03 as three wire Start Dir with Stop or two wire Run FWD Run REV control Current consumption is 6 mA 04 Digital Common Return for digital 1 0 Electrically isolated along with the digital 1 0 from the rest of the drive 05 Digin TermBlk 05 Preset Freq Program with t065 DigIn TermBlk 05 t065 Current consumption is 6 mA Rockwell Automation Publication 520 UM001G EN E September 2014 Control 1 0 Terminal Designations Installation Wiring Chapter 1 No Signal Default Description Parameter 06 Digin TermBIk 06 Preset Freq Program with t066 DigIn TermBlk 06 t066 Current consumption is 6 mA 07 Digln TermBlk 07 Start Source 2 Program with t067 DigIn TermBlk 07 Also functions as a Pulse t067 Pulse In Speed Train input for reference or speed feedback The maximum Reference2 frequency is 100 kHz Current consumption is 6 mA 08 Digin Ter
150. S10 L10 f D SAY SSVD 98 30 WOvL 089 090 NOrL OL OL 609 001 V eS 9 Ty CC OE CC OE volNcdv3 SC vOLNCdv3 Vsc 0v8 3O0 WOvL OL Y S1d 140 6D SW SSY 0rg 30 WOvL OSg Eqoq norL OL 9 60 00L V 8t Ev OE SL OC SL OC vOLNOdET 8SC VOLNOdET VSC StC8 3O WOvlL 94FS10 110 O4 SSVD SC8 30 WOvL 0 8 EQ90 nObL 9 609 001 V ET 97 LL SLO OL SLO OL vOLNZdL3 BSC VOLNZdL3 VSC St8 3O0 WOVL 9 4 S10 L10 fD SAY SSVD SC8 30 WOvL 078 EQ90 f0vL 9 60 00L V TL VL 60 vo 0 v0 0 VOLN6d03 4SZ VOLN6dOT VSC gu 10A iub uw ES god F ainsopug sXexg WOvL 50t L n0OvL ON boje3e ssel WOvL DOvL NOvL ew UW S 2 S xew gt S Mj dH MA dH uw SJoyealg 1mJr Bugey xew sasny siayeag mar Bugey sasny 2g e gH aN SZS dd EZS dd i sBuney suone iiddy 10 10 uoN suonexijddy 531 yndu suey yndyno 1 ON fojee JV SUDI sa naq uoioajoJg 1ndu asbuq A009 62 panunuo saMaq seueS ozs Xo jJ8Mog 10 SJayealg PNN pue sasny Rockwell Automation Publication 520 UM001G EN E September 2014 26 Installation Wiring Chapter 1 Power and Control Module PowerFlex 520 series drives consist of a Power Module and Control Module Separating the Power and Control Module N 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
151. SZ OOL OLLI O SL vOLNSPOS BSC VOLNSTOS VSC v 3841WOFvL 0 3 S10 110 2 OR SSVD S 2 393 WO L 099 999 90r1 0 Sv tv 001 d SVE OSL TCE S 001 SZ OOL VOLNZEOS dS7 VOLNCEOR VSC 0 0 38 HWOFvL 09 140 T SSVD C 383 WOvL SE 999 90b1 9 SE 001 99c TCL OVC SS SL SS SZ VOLNVCOS dSC VOLNVCOG VSC SC J84 WOPL S7 090 NOGL p 140 SSVD S7 384 WOPL 7 090 NOvL Sy C O 00L 8 Lic 96 ZL Ov O S Ov OS vOLNZLOS GGC VOLNZLOG VSC 91023O WOrL S15 Ed90 n0rL OE Y S10 L40 5 SR SSVD 912 3O WOtL SLI 090 NOrL ce 0Z 29 00L V SEL 9 01L C7 CEJ CC OE vOLNLLOS GGC POLNLLOG VS7 01230 WOvL OLD 090 NOPL OZ Y S10 L40 f D SAASSYTID OL IZI WOYL O1D 09C NOrL 0c 9L CD0 00L V G6 E 08 SL OZ SL O POLNOd88 8S7 VOLNOdSS VSC t98 1O WOvL 089 090 NOPL SL U S10 140 T I SWUSSYTD 99 37 WOPL 084 090 NOrL 9L OL 609 001 V 8S LT OS SLO OL SLO OL POLNOdS8 dS7 VOLNOdSQ VSC Or8 1O WOrL Obg Ed9Q nOvL 9 4 S10 L40 f D SAASSYD 0v8 3O WOrL 0vg EQ90 NOYL 9 9 609 001 V LC CTL ST v0 SO vO 0 vOLNSdCE WSC VOLNSdCQ VSC SC8O WOvL O 4 Q9G NOPL SL Y S10 L10 1 o4 SSVD SC8 30 WOPL 0 8 EQ90 00vL 9 600 001 V 61 60 91 TOSTO CO SCO VOLNOdLG Vsc gt 10A ON Bojeje sse xe ul BS F dw s 3 ainsopuy Spe WOP L 50t L n0OvL N boje3e sser WObL DOvL NOvL W IW ae 3 xw S M1 dH MM
152. Safety FS when used with embedded Safe Torque Off function ATEX Not applicable Certified to ATEX directive 94 9 EC 9 Group II Category 2 GD Applications with ATEX li 2 GD Approved Motors KCC Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards Article 58 2 of Radio Waves Act Clause 3 GOST R Russian GOST R Certificate no POCC US ME92 H00040 AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification Testing of Nonstructural Components and 2003 International Building Code for worst case seismic level for USA excluding site class F Rockwell Automation Publication 520 UM001G EN E September 2014 155 AppendixA X Supplemental Drive Information Certifications PowerFlex 523 PowerFlex 525 EPRI Electric Power Research Institute PR amp Certified compliant with the following standards T IEC 61000 434 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 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems Environmental Specifications Specifications Altitude Without derating Wi
153. Sel 3 If not enabled by the Speed Reference or PID function parameters the encoder or pulse train can be used with A535 Motor Fdbk Type for direct feedback and trim of the speed command The normal slip compensation is not used in this case Instead the drive will use the encoder or pulse train to determine actual output frequency and adjust the output frequency to match the command Parameters A538 Ki Speed Loop and A539 Kp Speed Loop are used in this control loop The primary benefit of this mode is increased speed accuracy when compared to open loop slip compensation It does not provide speed bandwidth improvement IMPORTANT Theencoder usage and position StepLogic application covered in this chapter is specific to PowerFlex 525 drives only Encoder Interface The incremental encoder option card can source 5 or 12 volt power and accept 5 12 or 24 volt single ended or differential inputs See Appendix B for ordering information Rockwell Automation Publication 520 UM001G EN E September 2014 203 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Wiring Notes 204 No Signal Description V 4X 5 12 Power 77 ea m nternal power source 250 mA isolated Cm Cm Power Return P B B Encoder B NOT d tature B innit uadrature B input b B Encoder B A A Encoder A NOT i A Single channel pulse train or quadrature A input
154. September 2014 Accessories and Dimensions IP 20 0pen Type with Control Module Fan Kit Frame D E Dimensions are in millimeters and inches Frame D Frame E 130 0 5 12 116 0 4 57 32 0 1 26 196 0 7 72 185 0 7 28 160 0 6 30 Appendix B N 52 0 2 05 S R A 8853 260 0 10 24 247 0 9 72 D 6500 C iu 3 ay D IMPORTANT 280 0 11 02 Allen Bradley 4 300 0 11 81 Control Module Fan Kit Rockwell Automation Publication 520 UM001G EN E September 2014 Remove the label to access the built in 24V supply on drive frames D and E for use with the 177 AppendixB Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame A Dimensions are in millimeters and inches
155. Stp Logic Time x and Logic In 1 is not active logically false TIMED OR E Step after Stp Logic Time x and Logic In 2 is not active logically false TIMED OR F Do not step OR no jump to so use Digit 0 logic IGNORE Digit 1 Defines what logic must be met to jump to the very next step Setting Description Logic 0 Skip Step jump immediately SKIP 1 Step based on the time programmed in the respective Stp Logic Time x parameter TIMED 2 Step if Logic In 1 is active logically true TRUE 3 Step if Logic In 2 is active logically true TRUE 4 Step if Logic In 1 is not active logically false FALSE 5 Step if Logic In 2 is not active logically false FALSE 6 Step if either Logic In 1 or Logic In 2 is active logically true OR 7 Step if both Logic In 1 and Logic In 2 is active logically true AND 8 Step if neither Logic In 1 or Logic In 2 is active logically true NOR 9 Step if Logic In 1 is active logically true and Logic In 2 is not active logically false XOR A Step if Logic In 2 is active logically true and Logic In 1 is not active logically false XOR b Step after Stp Logic Time x and Logic In 1 is active logically true TIMED AND C Step after Stp Logic Time x and Logic In 2 is active logically true TIMED AND d Step after Stp Logic Time x and Logic In 1 is not active logically false TIMED OR E Step after Stp Logic
156. TermBlk xx below Stop Mode 3 Serial DSI Coast 4 Network Opt Coast 5 EtherNet IP Coast Start Method Stop Method t062 t063 Digln TermBlk xx 1 0 Terminal 01 Stop Normal Stop 48 2 Wire FWD t064 2 Wire Mode is set to Per P045 0 1 0r2 Coast Stop Mode 3 per P045 Stop Mode 49 3 Wire Start Per P045 Stop Mode 50 2 Wire REV t064 2 Wire Mode is set to 0 1 0r2 Coast 3 per P045 Stop Mode 51 3 Wire Dir Per P045 Stop Mode IMPORTANT The drive is shipped with a jumper installed between 1 0 Terminals 01 and 11 Remove this jumper when using 1 0 Terminal 01 as a stop or enable input 2 Two wire control shown For three wire control use a momentary input so on 1 0 Terminal 02 to command a start Use a maintained input oo for 1 0 Terminal 03 to change direction 3 When using an opto output with an inductive load such as a relay install a recovery diode parallel to the relay as shown to prevent damage to the output Control 1 0 Terminal Designations No Signal Default Description Parameter R1 Relay 1 N 0 Fault Normally open contact for output relay i R2 Relay 1 Common Fault Common for output relay ix R5 Relay2 Common Motor Running Common for output relay i R6 Relay 2 N C Motor Running Normally closed contact for output relay Ta 01 Stop Coast Three wire stop However it functions as a stop under all input p045 modes and cannot be disabled 02 Digin TermBlk 02
157. Time min F630 Fault 5 BusVolts F655 HW Addr 4 F690 Drv 2 Logic Sts F715 Fault 6 Code F606 Fault 1 Freq F631 Fault 6 BusVolts F656 HW Addr 5 F691 Drv 2 Feedback F716 Fault 7 Code F607 Fault 2 Freq F632 Fault 7 BusVolts F657 HW Addr 6 F692 Drv 3 Logic Cmd F717 Fault 8 Code F608 Fault 3 Freq F633 Fault 8 BusVolts F658 EN IP Addr Act 1 F693 Drv3 Reference F718 Fault 9 Code F609 Fault 4 Freq F634 Fault 9 BusVolts F659 EN IP Addr Act 2 F694 Drv3 Logic Sts F719 Fault10 Code F610 Fault 5 Freq F635 Fault10 BusVolts F660 EN IP Addr Act 3 F695 Drv3 Feedback F720 Fault 1 Time hr F611 Fault 6 Freg F636 Status Fault 1 F661 EN IP Addr Act 4 F696 Drv 4 Logic Cmd F721 Fault 2 Time hr F612 Fault 7 Freq F637 Status Fault 2 F662 EN Subnet Act 1 F697 Drv 4 Reference F722 Fault 3 Time hr F613 Fault 8 Freg F638 Status Fault 3 F663 EN Subnet Act 2 F698 Drv 4 Logic Sts F723 Fault 4 Time hr F614 Fault 9 Freq F639 Status Fault 4 F664 EN Subnet Act 3 F699 Drv 4 Feedback F724 Fault 5 Time hr F615 Fault10 Freg F640 Status Fault 5 F665 EN Subnet Act 4 F700 EN Rx Overruns F725 Fault 6 Time hr F616 Fault 1 Current F641 Status Fault 6 F666 EN Gateway Act 1 F701 EN Rx Packets F726 Fault 7 Time hr F617 Fault 2 Current F642 Status Fault 7 F667 EN Gateway Act 2 F702 ENRx Errors F727 Fault 8 Time hr F618 Fault3 Current F643 Status Fault 8 F668 EN Gateway Act 3 F703 EN Tx Packets F728 Fault 9 Time hr F619 Fault 4 Current F64
158. Time x and Logic In 2 is not active logically false TIMED OR F Use logic programmed in Digit 1 IGNORE 202 Rockwell Automation Publication 520 UM001G EN E September 2014 Encoder and Pulse Train Usage Appendix E Encoder Pulse Train Usage and Position StepLogic Application The PowerFlex 520 series drives include a pulse train input built into the terminal block PowerFlex 525 drives also support an optional encoder card The pulse train and encoder can be used for many of the same functions but the pulse train supports up to 100 kHz at 24V and uses the drive built in terminal block The encoder supports up to 250 kHz dual channel at 5 12 or 24V and requires the optional encoder board to be installed When A535 Motor Fdbk Type is set to a value other than zero the drive is set to use an encoder or pulse train The drive will use the encoder or pulse train in several ways depending on the settings of other parameters The drive will use the encoder or pulse train as shown below listed in order of priority 1 Ifenabled by P047 P049 or P051 Speed Referencex the encoder or pulse train will be used directly as a commanded speed normally used with a pulse train or as a position reference normally used with a quadrature encoder 2 If not enabled by the Speed Reference parameters the encoder or pulse train can be used with the PID function if enabled by A459 or A471 PID x Ref Sel or A460 or A472 PID x Fdback
159. User Manual Allen Bradley PowerFlex 520 Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A PowerFlex 525 Catalog Number 25B Original Instructions Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with re
160. Y Y 6 Japanese Y 7 Portugu s Y Y 8 Chinese Chinese Simplified Y Y 9 Reserved 10 Reserved 11 Korean Y 12 Polish Y 13 Reserved 14 Turkish Y 15 Czech Y 1 Due to a limitation of the LCD Display some of the characters for Polish Turkish and Czech will be modified P031 Motor NP Volts Related Parameter s b004 A530 A531 A532 A533 O Ray drive before changing this parameter Sets the motor nameplate rated volts Values Default Drive Rated Volts Min Max 10V for 230V Drives 20V for 460V Drives 25V for 600V Drives Drive Rated Volts Display 1V P032 Motor NP Hertz Related Parameter s A493 A530 A531 A532 A533 O Bay drive before changing this parameter Sets the motor nameplate rated frequency Values Default 60 Hz Min Max 15 500 Hz Display 1Hz P033 Motor OL Current Related Parameter s t069 t072 t076 t081 A484 A485 A493 Sets the motor nameplate overload current Used to determine motor overload conditions and can be set from 0 1 A to 200 of drive rated current IMPORTANT The drive will fault on an F007 Motor Overload if the value of this parameter is exceeded by 150 for 60 s Values Default Drive Rated Amps Min Max 0 0 Drive Rated Amps x 2 Display 0 1A 76 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Basic Program Group continued P034 Motor NP FLA Related Parameter s P040 Sets the
161. a parameter has its value changed back to the factory default it is automatically removed from this group Rockwell Automation Publication 520 UM001G EN E September 2014 A500 Compensation A509 Power Loss Mode A510 Half Bus Enable A511 Bus Reg Enable A512 Fault Clear A513 Program Lock A514 Program Lock Mod A515 Drv Ambient Sel A521 Reset Meters A522 Text Scroll A523 Out Phas Loss En A524 Positioning Model A525 Counts Per Unit A526 Enh Control Word A530 Home Save A531 FindHome Freq A532 Find Home Dir A533 Encoder Pos Tol A534 Pos Reg Filter A535 Pos Reg Gain A536 Max Traverse A537 Traverse Inc A538 Traverse Dec A539 P Jump A540 Sync Time A541 Speed Ratio A542 Mtr Options Cfg A543 RdyBit Mode Cfg A544 A545 A546 A547 A548 A549 A550 A551 A552 A553 A554 A555 A556 A557 A558 A559 A560 A561 A562 A563 A564 A565 A566 A567 A568 A569 A570 A571 A572 A573 A574 67 Chapter 3 Programming and Parameters Fault and Diagnostic Fault 5 Time min F625 Fault10 Current F650 EN Rate Act F685 Drv 1 Reference F710 Fault 6 Time min F626 Fault 1 BusVolts F651 DSI 1 0 Act F686 Drv 1 Logic Sts F711 a Fault 7 Time min F627 Fault 2 BusVolts F652 HW Addr 1 F687 Drv 1 Feedback F712 Fault 8 Time min F628 Fault 3 BusVolts F653 HW Addr 2 F688 Drv 2 Logic Cmd F713 Fault 4 Code F604 Fault 9 Time min F629 Fault 4 BusVolts F654 HW Addr 3 F689 Drv 2 Reference F714 Fault 5 Code F605 Fault10
162. adrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forward direction matches the motor forward direction If the drive is reading encoder speed but the position regulator or other encoder function is not working properly remove power to the drive then do one of the following Swap the A and A NOT encoder channels e Swap the B and B NOT encoder channels e Swap any two motor leads Drives will fault when an encoder is incorrectly wired and A535 Motor Fdbk Type is set to 5 Quad Check Rockwell Automation Publication 520 UM001G EN E September 2014 Positioning Overview Common Guidelines for All Applications Encoder Pulse Train Usage and Position StepLogic Application 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 Please note that this is not intended to replace high end servo controllers or any application that needs high bandwidth or very high torque at low speeds The position regulator can be configured for operation appropriate for a variety of applications Certain parameters will need to be adjusted in all cases P047 Speed Reference1 must be set to 16 Positioning A53
163. al Duty Drive Rated Amps x 1 5 Heavy Duty Min Max 0 0 Drive Rated Amps x 1 5 Normal Duty Drive Rated Amps x 1 8 Heavy Duty Display 0 1A A485 Current Limit 2 Related Parameter s P033 PowerFlex 525 only Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 1 Min Max 0 0 Drive Rated Amps x 1 5 Normal Duty Drive Rated Amps x 1 8 Heavy Duty Display 0 1A A486 Shear Pin1 Level A488 Shear Pin2 Level PowerFlex 525 only Related Parameter s A487 A48 Mo Sets the value of current at which the shear pin fault occurs after the time set in A487 A489 Shear Pin x Time Setting the value at 0 0 A disables this function Values Default 0 0 A Disabled Min Max 0 0 Drive Rated Amps x 2 Display 0 1A A487 Shear Pin 1 Time A489 Shear Pin 2 Time PowerFlex 525 only Related Parameter s A486 A488 Sets the continuous time the drive must be at or above the value set in A486 A488 Shear Pinx Level before a shear pin fault occurs Values Default 0 00 s Min Max 0 00 30 00 s Display 0 015 116 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued M90 Load Loss Level Related Parameter s A491 PF 525 PowerFlex 525 only Provides a software trip Load Loss fault when the c
164. alues Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg 104 Rockwell Automation Publication 520 UM001G EN E September 2014 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 01A d383 PID1 Fdbk Displ 4385 PID2 Fdbk Displ PowerFlex 525 only Displays the active PID Feedback value Values Default Read Only Min Max 0 0 100 096 Display 0 196 d384 PID1Setpnt Disp d386 PID2 Setpnt Disp PowerFlex 525 only Displays the active PID Setpoint value Values Default Read Only Min Max 0 0 100 096 Display 0 196 d387 Position Status PF 525 PowerFlex 525 only Displays the present operating condition of the drive When in Positioning mode Bit 1 indicates positive or negative position in relation to Home Firm Laf LALA LA LLA 1 Condition True 0 Condition False Dir Positive Digit 1 At Position Digit 2 At Home Digit 3 Drive Homed Digit 4 Not Used Values Default Read Only Min Max 0000 1111 Display 0000 d388 Units Traveled H Related Parameter s d387 so drive before changing this parameter N 32 bit parameter PowerFlex 525 only Displays the number of user defined unit
165. am Normal Stop End Program Coast to Stop zsSlwololwnl alulalwl rn alo End Program and Fault F002 Rockwell Automation Publication 520 UM001G EN E September 2014 201 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Digit 2 Defines what logic must be met to jump to a step other than the very next step Setting Description Logic 0 Skip Step jump immediately SKIP 1 Step based on the time programmed in the respective Stp Logic Time x parameter TIMED 2 Step if Logic In 1 is active logically true TRUE 3 Step if Logic In 2 is active logically true TRUE 4 Step if Logic In 1 is not active logically false FALSE 5 Step if Logic In 2 is not active logically false FALSE 6 Step if either Logic In 1 or Logic In 2 is active logically true OR 7 Step if both Logic In 1 and Logic In 2 is active logically true AND 8 Step if neither Logic In 1 or Logic In 2 is active logically true NOR 9 Step if Logic In 1 is active logically true and Logic In 2 is not active logically false XOR A Step if Logic In2 is active logically true and Logic In 1 is not active logically false XOR b Step after Stp Logic Time x and Logic In 1 is active logically true TIMED AND C Step after Stp Logic Time x and Logic In 2 is active logically true TIMED AND d Step after
166. and clears Provides a method to stop at a constant distance instead of a fixed rate active fault When a Stop command is given the distance required for the machine to travel to 11 PointStop PointStop standstill based on the programmed maximum speed and deceleration time is calculated Ifthe drive is running slower than the maximum speed the function will apply a calculated deceleration time that allows the machine to travel to standstill in the same distance based on the current speed It is recommended to use braking resistors or set A550 Bus Reg Enable to 0 Disabled for better performance Stop Maximum Freq Speed Calculated Stop Time NE DecelTimex P Time Rockwell Automation Publication 520 UM001G EN E September 2014 79 Chapter3 Programming and Parameters Basic Program Group continued P046 Start Source 1 Related Parameter s b012 t064 C125 P048 Start Source 2 P050 Start Source 3 O Ray 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 IMPORTANT orallsettings except when t064 2 Wire Mode is set to 1 Level Sense the drive must receive a leading edge from the start input for the drive to start after a stop input loss of power
167. ared See Fault Types Descriptions and Actions on page 147 3 After corrective action has been taken clear the fault by one of these methods e Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 DigIn TermBlk xx is set to 13 Clear Fault Automatically Clearing Faults Option Step Clear a Type 1 fault and restart the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to 0 parameters are used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines ATTENTION Equipment damage and or personal injury may result if these 146 Rockwell Automation Publication 520 UM001G EN E September 2014 Fault Descriptions Auto Restart Reset Run Troubleshooting Chapter 4 The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention This allows remote or unattended operation Only certain f
168. arrow keys Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz A427 MOP Freq Provides the drive frequency command using the built in Motor Operated Potentiometer MOP IMPORTANT Frequency is not written to non volatile storage until drive is powered down If both MOP Up and MOP Down are applied at the same time the inputs are ignored and the frequency is unchanged Values Default 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz A428 MOP Reset Sel Determines if the current MOP reference command is saved on power down Options 0 Zero MOP Ref Resets the MOP frequency to zero on power down and stop 1 Save MOP Ref Default A429 MOP Preload Determines the operation of the MOP function Options 0 No preload Default 1 Preload Bumpless Transfer whenever MOP mode is selected the current output value of the speed is loaded M30 MOP Time Sets the rate of change of the MOP reference Values Default 10 05 Min Max 0 1 600 0 s Display 0 15 M31 Jog Frequency Sets the output frequency when a jog command is issued Related Parameter s P044 Values Default 10 00 Hz Min Max 0 00 Maximum Freq Display 0 01 Hz M32 Jog Accel Decel Sets the acceleration and deceleration time used when in jog mode Values Default 10 00 s Min Max 0 01 600 00 s Display 0 015 Rockwell Automation Publication 520 UM001
169. arth is referred to as the stinger leg high leg red leg etc This leg should be identified throughout the system with red or orange tape on the wire at each connection point The stinger leg should be connected to the center Phase B on the reactor See Bulletin 1321 3R Series Line Reactors on page 171 for specific line reactor part numbers 2 See Appendix B for accessory ordering information The drive Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity ofall ground connections should be periodically checked Typical Grounding Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 Ground Fault Monitoring If a system ground fault monitor RCD is to be used only Type B adjustable devices should be used to avoid nuisance tripping Safety Ground PE This is the safety ground for the drive that is required by code One of these points must be connected to adjacent building steel girder joist a floor ground rod or bus bar Grounding points must comply with national and local industrial safety regulations and or electrical codes Motor Ground The motor ground must be c
170. ated along withthe analog 1 0 from the rest of the drive Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 Control 1 0 Terminal Designations No Signal Default Description Parameter 15 4 20mA In Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 Q 1062 t063 1065 1066 A459 A471 a ja This terminal is tied to the RJ 45 port shield Tie this terminal to a clean ground in order to improve noise immunity when using external communication peripherals Q Q This is the signal common for the communication signals 1 Only one analog frequency source may be connected at a time If more than one reference is connected at the same time an undetermined frequency reference will result 2 See Footnote 1 on page 37 PowerFlex 525 Control 1 0 Terminal Block PowerFlex 525 Control 1 0 Wiring Block Diagram Typical Typical stop SRCwiring SNK wiring Safety 1 81 ol ig r tern k 02 2 ole 2 Start Run FWD Safe Torque O
171. ated as zero 1 4 20mA Input Serial DSI Network Opt Pulse Input Encoder EtherNet Ip 9 HDi wm lw N 1 Setting is specific to PowerFlex 525 drives only A461 PID 1 Prop Gain Related Parameter s A459 A471 M73 PID 2 Prop Gain PF 525 PowerFlex 525 only Sets the value for the PID proportional component when the PID mode is enabled Values Default 0 01 Min Max 0 00 99 99 Display 0 01 114 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued M62 PID 1 Integ Time Related Parameter s A459 M71 M74 PID 2 Integ Time PowerFlex 525 only Sets the value for the PID integral component when PID mode is enabled Values Default 2 05 Min Max 0 0 999 9 s Display 0 15 M63 PID 1 Diff Rate Related Parameter s A459 M71 M75 PID 2 Diff Rate PF 525 PowerFlex 525 only Sets the value in 1 second for the PID differential component when PID mode is enabled Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A464 PID 1 Setpoint Related Parameter s A459 M71 A476 PID 2 Setpoint PF 525 PowerFlex 525 only Provides an internal fixed value for process setpoint when PID mode is enabled Values Default 0 096 Min Max 0 0 100 096 Display 0 196 A465 PID 1 Deadband M77 PID 2 Deadband
172. ation Publication 520 UM001G EN E September 2014 IP 20 0pen Type Frame D Dimensions are in millimeters and inches I 130 0 5 12 116 0 MN Accessories and Dimensions 212 0 8 35 Appendix B S C le e o x us e O lt E eo AAR Ko F N N ard a Powerflex wo es a RAR RA AAA a T T Allen Bradley s NA IP 20 0pen Type Frame E Dimensions are in millimeters and inches 185 0 7 28 279 0 10 98 160 0 6 30 I eT a 1 SSS S 9 eo Ss a gt o Ee e Ss _ gt a SSS o e e U o e 2 e oo C p N SS SS gt z E Allen Bradley 4 U AREE Rockwell Automation Publication 520 UM001G EN E September 2014 175 Appendix B 176 Accessories and Dimensions Control Module Fan Kit Dimensions are in millimeters and inches Frame A m 72 0 2 83 4 r 57 5 2 26
173. aults 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 See Fault Descriptions on page 147 for more information Use caution when enabling this feature since the drive will attempt to issue its own start command based on user selected programming Fault Types Descriptions and Actions No Fault Type Description Action F000 No Fault No fault present F002 Auxiliary Input 1 External trip Auxiliary input e Check remote wiring e Verify communications programming for intentional fault F003 Power Loss 2 Single phase operation detected with e Monitor the incoming AC line for low excessive load voltage or line power interruption e Check input fuses Reduce load F004 UnderVoltage 1 DC bus voltage fell below the minimum Monitor the incoming AC line for low value voltage or line power interruption F005 OverVoltage 1 DC bus voltage exceeded maximum Monitor the AC line for high line voltage value or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option F006 Motor Stalled 1 Drive is unable to accelerate or Increase P041 M42 M44 A446 decelerate motor Accel Time x or reduce load so drive output current does not exceed the current set by parameter A48
174. aur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function A single fault detected on the PowerFlex 525 safety enable redundant inputs will result in the lock out of the drive and will not cause the loss of the safety function Rockwell Automation Publication 520 UM001G EN E September 2014 231 Appendix G 232 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 External 24V DC I I I I I I I L I I 21 922 Closed ACline input power PF 525 24V DC Stop Start COM Gate control power supply Gate control druit 4 X1 AUX c x2 13 23 33 A1 Coil 142434 A2 External 100 C 1 contactor 100S C J 1 Enclosure Recommended External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating P
175. ay 0 1Hz A534 Maximum Voltage Related Parameter s b004 Sets the highest voltage the drive outputs Values Default Drive Rated Volts Min 10V AC on 230V AC Drives 20V AC on 460V AC Drives 25V AC on 600V AC Drives Max 255V AC on 230V AC Drives 510V AC on 460V AC Drives 637 5V AC on 600V AC Drives Display WAC Rockwell Automation Publication 520 UM001G EN E September 2014 121 Chapter3 Programming and Parameters Advanced Program Group continued A535 Motor Fdbk Type Related Parameter s A537 Ts 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 Allowable Control Modes Hardware Inputs Options 0 None Default For all motor types 1 Pulse Train All except Vector DigIn TermBlk 07 2 Single Chan All except Vector 3 Single Check All except Vector Optional incremental encoder card 4 Quadrature For all motor types catalog number 25 ENC 1 5 Quad Check For all motor types A536 Encoder PPR PowerFlex 525 only Specifies the encoder Pulses Per Revolution PPR when an encoder is used Motor Control Mode Recommended Minimum Encoder PPR Sensorless Vector Control SVC 42 x number of poles 2 Speed range 100 1 84 PPR
176. b in C 8 4 mm 8 AWG 2 1 mm 14 AWG 16 2 16 Nm 15 6 19 1 Ib in D 13 3 mm 6 AWG 5 3 mm 10 AWG 1 76 2 16 Nm 15 6 19 1 Ib in E 26 7 mm 3 AWG 8 4 mm 8 AWG 3 09 3 77 Nm 27 3 33 A Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 Common Bus Prech arge If drives are used with a disconnect switch to the common DC bus then an Notes auxiliary contact on the disconnect must be connected to a digital input of the drive The corresponding input parameter t062 t063 t065 068 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 1 0 Wiring Motor Start Stop Precautions reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage The drive is designed to use control input signals that will start and stop the motor If used the input device must not exceed one operation per minute or drive damage can occur ATTENTION The drive start stop control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC line to the drive When the AC
177. b002 Commanded Freq to verify correct command Incorrect reference source is being selected by remote device or digital inputs None Check b012 Control Source for correct source Check b014 Dig In Status to see if inputs are selecting an alternate source Verify settings for t062 t063 t065 t068 DigIn TermBlk xx Check P047 P049 P051 Speed Referencex for the source of the speed reference Reprogram as necessary Review the Speed Reference Control chart on page 46 Verify communications if used Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive None Reprogram P041 A442 A444 A446 Accel Time x Excess load or short acceleration times force the drive into None Compare b003 Output Current with A484 A485 Current Limit x current limit slowing or stopping acceleration Remove excess load or reprogram P041 A442 A444 A446 Accel Time x Check for improper A530 Boost Select setting Speed command source or value is not as expected None e Verify b002 Commanded Freq e Check b012 Control Source for the proper Speed Command Programming is preventing the drive output from exceeding None Check P044 Maximum Freq to ensure that speed is not limited by programming limiting values e Verify programming of A572 Speed Ratio Torque performance does not match motor characterist
178. be a Balanced Wye with Center Ground configuration for EMC compliance Installation Requirements Related to EN 61800 5 1 and the Low Voltage Directive e 600V PowerFlex 520 series drives can only be used on a center grounded supply system for altitudes up to and including 2000 m 6562 ft When used at altitudes above 2000 m 6562 ft up to a maximum of 4800 m 15 748 ft PowerFlex 520 series drives of voltage classes up to 480V may not be powered from a corner earthed supply system in order to maintain compliance with the CE LV Directive See Derating Guidelines for High Altitude on page 18 Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 e PowerFlex 520 series drives produce leakage current in the protective earthing conductor which exceeds 3 5 mA AC and or 10 mA DC The minimum size of the protective earthing grounding conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment protective earthing conductor which may reduce the ability of RCD s residual current operated protective devices or RCM s residual current operated monitoring devices of type A or AC to provide protection for other equipment in the installation Where an RCD or RCM is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product ATTENTION PowerF
179. be used If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive Aux Fault or Coast to Stop Rockwell Automation Publication 520 UM001G EN E September 2014 33 Chapter1 Installation Wiring Power Terminal Block Power Terminal Block Frame A B C amp D Frame E R L1 S2 T3 Uf Vv WB R1 S L2 TA3 UMI V T2 WIT EE oe Terminal Description R L1 S L2 1 Phase Input Line Voltage Connection R L1 S L2 T L3 3 Phase Input Line Voltage Connection U T1 V T2 W T3 Motor Phase Connection Switch any two motor leads to change G XG forward direction LJ DC DC DC Bus Connection except for 110V 1 Phase BR BR Dynamic Brake Resistor Connection Q Safety Ground PE IMPORTANT Terminal screws may become loose during shipment Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive Power Terminal Block Wire Specifications Frame Maximum Wire Size Minimum Wire Size Torque A 5 3 mm 10 AWG 0 8 mm 18 AWG 1 76 2 16 Nm 15 6 19 1 Ib in B 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 2 16 Nm 15 6 19 1 I
180. ber 2014 15 Chapter Installation Wiring e Donot expose to a corrosive atmosphere e Protect from moisture and direct sunlight Minimum Mounting Clearances See Appendix B for mounting dimensions Vertical Vertical Zero Stacking Vertical with Control Module Fan Kit Vertical Zero Stacking with No clearance between drives Control Module Fan Kit No clearance between drives L i 50mm 50mm 2 0 in 2 0 in v Il Oooo oii COCO oooh re Oe 50mm 50mm 50mm ve 2 0 in 2 0 in 2 0 in 50 E in mm we 50mm AE le MULA Mon V He GE Ow FE o eu B PE el 25mm E D 1 0 in E Em EE l
181. bient Temperature C 17 Chapter Installation Wiring Derating Guidelines for High Altitude The drive can be used without derating at a maximum altitude of 1000 m 3300 ft If the drive is used above 1000 m 3300 ft e Derate the maximum ambient temperature by 5 C 9 F for every additional 1000 m 3300 ft subject to limits listed in the Altitude Limit Based on Voltage table below Or e Derate the output current by 1096 for every additional 1000 m 3300 ft up to 3000 m 9900 ft subject to limits listed in the Altitude Limit Based on Voltage table below Altitude Limit Based on Voltage Drive Rating Center Ground Wye Neutral Corner Ground Impedance Ground or Ungrounded 100 120V 1 Phase 6000 m 6000 m 200 240V 1 Phase 2000 m 2000 m 200 240V 3 Phase 6000 m 2000 m 380 480V 3 Phase 4000 m 2000 m 525 600V 3 Phase 2000 m 2000 m High Altitude _ 120 60 mo 100 g 5 2 9 s z Fi g g 0 5 70 e S 60 30 amp 50 E amp 4 20 0 1000 2000 3000 4000 0 1000 2000 3000 4000 Altitude m Altitude m Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation Storage e Store within an ambient temperature range of 40 85 C e Store within a relative humidity range of 0 95 noncondensing e Do not expose to a corrosive atmosphere 1 The maximum ambient temperature for storing a Frame E d
182. cable is used the cable shield should be terminated with a low impedance connection to earth at only one end of the cable preferably the end where the receiver is located When the cable shield is terminated at the drive end it may be terminated either by using a shielded connector in conjunction with a conduit plate or conduit box or the shield may be clamped to an EMC plate e Motor cabling must be separated from control and signal wiring wherever possible Rockwell Automation Publication 520 UM001G EN E September 2014 51 Chapter1 Installation Wiring e Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520 Series RF Emission Compliance and Installation Requirements on page 2 for compliance with radio frequency emission limits for the specific standard and installation environment Connections and Grounding iD Shielded enclosure e aes IP 30 NEMA 1 UL Type 1 wW option kit or EMC kit BI J PswwHex E j FEE eo i EMI fittings and metal conduit HWE EMI filter as r al L um i D D S L2 Bo BB H o Building structure steel 1 Some installations require a shielded enclosur
183. cancelled by the user or failed Rockwell Automation Publication 520 UM001G EN E September 2014 Troubleshooting Chapter 4 Fault Types Descriptions and Actions No Fault Type Description Action F081 DSICommLoss 2 Communications between the driveand e Cycle power the Modbus or DSI master device have e Check communications cabling been interrupted e Check Modbus or DSI setting e Check Modbus or DSI status Modify using C125 Comm Loss Action e Connecting 1 0 terminals C1 and C2 to ground may improve noise immunity Replace wiring Modbus master device or control module F082 OptCommLoss 2 Communications between the drive and e Cycle power the network option card have been e Reinstall option card in drive interrupted e Modify using C125 Comm Loss Action Replace wiring port expander option card or control module F083 EN Comm Loss 2 Internal communications between the e Cycle power drive and the embedded EtherNet IP e Check EtherNet IP setting adapter have been interrupted Check drives Ethernet settings and diagnostic parameters e Modify using C125 Comm Loss Action Replace wiring Ethernet switch or control module F091 Encoder Loss 2 Requires differential encoder e Check Wiring One of the 2 encoder channel signals is IfP047 PO49 POST Speed missing Referencex 16 Positioning and A535 Motor Fdbk Type 5 Q
184. ce Ol olny DAD Mm SB wl rm gt 1 Main Freq Controlled by Active Comm 1 Operation Cmd Controlled by Active Comm 1 Parameters have been locked Digital Input 1 Status Digital Input 2 Status Digital Input 3 Status Position Bit Definitions Comm Logic Status C122 1 Position Digital Input 4 Status Address Decimal Bit s 2100H 8448 Description 1 Ready 0 Not Ready 1 Active Running 0 Not Active 1 Cmd Forward 0 Cmd Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating 1 Forward Travel Position 0 Reverse Travel Position 1 Faulted 0 Not Faulted 1 At Reference 0 Not At Reference Ol ol ms DA nm BS wl rm co 1 At Position 0 Not At Position ce 1 At Home 0 Not At Home 1 Drive Homed 0 Not Drive Homed 1 Sync Hold 0 Not Sync Hold 1 Sync Ramp 0 Not Sync Ramp 1 Traverse On 0 Traverse Off 1 Traverse Decel 0 Not Traverse Decel 194 Rockwell Automation Publication 520 UM001G EN E September 2014 Reading 03 Drive Error Codes RS485 DSI Protocol Appendix C The PowerFlex 520 series Error Code data can be read through the network by sending Function Code 03 reads to register address 2101H Drive Error Codes
185. ch as pressure flow or tension at a desired set point The PID loop works by subtracting the PID feedback from a reference and generating an error value The PID loop reacts to the error based on the PID Gains and outputs a frequency to try to reduce the error value to 0 To enable the PID loop P047 P049 or P051 Speed Referencex must be set to 11 PID1 Output or 12 PID2 Output and the corresponding speed reference activated IMPORTANT PowerFlex 523 has one PID control loop PowerFlex 525 has two PID control loops of which only one can be in use at any time Exclusive Control and Trim Control are two basic configurations where the PID loop may be used Exclusive Control In Exclusive Control the Speed Reference becomes 0 and the PID Output becomes the entire Freq Command Exclusive Control is used when A458 or A470 PID x Trim Sel is set to option 0 This configuration does not require a master reference only a desired set point such as a flow rate for a pump i PID Loop l PID Ref gt gt PID Prop Gain i PID i PID L Error Output alee P Accel Decel Freq PID Fdbk PID Integ Time Gu Ramp Command gt PID Diff Rate PID Selected Example e Ina pumping application the PID Reference equals the Desired System Pressure set point e The Pressure Transducer signal provides PID Feedback to the drive
186. chanical work on the drive system or affected area of a machine only It does not provide electrical safety Rockwell Automation Publication 520 UM001G EN E September 2014 223 AppendixG Safe Torque Off Function ECType Examination Certification EMC Instructions Using PowerFlex 525 Safe Torque Off 224 are de energized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part 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 ATTENTION Electric Shock Hazard Verify that all sources of AC and DC power In safe off mode hazardous voltages may still be present at the motor To avoid an electric shock hazard disconnect power to the motor and verify that the voltage is zero before performing any work on the motor TUV Rheinland has certified the PowerFlex 525 Safe Torque Off function compliant with the requirements for machines defined in Annex I ofthe EC Directive 2006 42 EC and that it complies with the requirements of the relevant standards listed below e EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design PowerFlex 525 STO achieves Category 3 PL d e EN 61800 5 2 2007 Adjustabl
187. command Speed Referencex 11 or 12 PIDx Output AND PID x Ref Sel 7 Preset Freq Preset Inputs Active R Run as specified by Run as specified by 0 Preset Freq x PIDx Output Start and Direction Start and Direction commands come from commands come from Start Source x Start Source x Start and Direction command from Start Source 3 2 Run as specified by Ye Start Source 3 Speed Reference3 select Speed Reference3 select 1 Start and Direction command from Start Source 2 2 Run as specified by _ Start S 2 Speed Reference2 Start Source 2 select 1 Speed Reference2 select 1 Start and Direction command from Start Source 1 Run as specified by Speed Reference1 1 Start Source 2 3 and Speed Reference2 3 can be selected by the control terminal block or communication commands 2 See Digital Input Selection for Start Source on page 47 for information on selecting the correct digital input Rockwell Automation Publication 520 UM001G EN E September 2014 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 and Direction command from Terminal Block
188. communication adapter to the communication adapter interface connector then push the back cover down 186 Rockwell Automation Publication 520 UM001G EN E September 2014 Accessories and Dimensions Appendix B 3 Press along the edges of the back cover until it snaps firmly into place Communication adapter interface 4 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 C Acum AL SSIS ES Rockwell Automation Publication 520 UM001G EN E September 2014 187 AppendixB Accessories and Dimensions Notes 188 Rockwell Automation Publication 520 UM001G EN E September 2014 Network Wiring Appendix C RS485 DSI Protocol PowerFlex 520 series drives support the RS485 DSI protocol to allow efficient operation with Rockwell Automation peripherals In addition some Modbus functions are supported to allow simple networking PowerFlex 520 series drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode PowerFlex 520 Series Drive Network Controller For information regarding EtherNet IP or other communication protocols refer to the approp
189. ctive but not both Verify that 1 0 Terminal 01 is active Verify that P046 P048 P050 Start Source x matches your configuration Verify that A544 Reverse Disable is not prohibiting movement Verify that safety inputs Safety 1 and Safety 2 are active Improper boost setting at initial start up None Set A530 Boost Select to 2 35 0 VT Drive is Faulted Flashing red status light Clear fault Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 Digln TermBlk xx is set to 13 Clear Fault Incorrect programming None Check setting for b012 Control Source P046 P048 P050 Start Source x is set incorrectly Incorrect input wiring None Wire inputs correctly and or install jumper See page 42 for wiring examples Ifthe PowerFlex 525 Safe Torque Off function is used verify that inputs are active 2 wire control requires Run Forward Run Reverse or Jog If2 wire or 3 wire mode is used verify that t062 DigIn TermBIk 02 and t063 DigIn input TermBlk 03 are set properly e 3 wire control requires Start and Stop inputs Stop input is always required Incorrect Sink Source jumper setting None Set switch to match wiring scheme Cause s Drive is Faulted Indication Flashing red status light Drive does
190. current is below the e Verify connections between motor value programmed in A490 Load Loss and load Level for a time period greater than the e Verify level and time requirements time programmed in A491 Load Loss Time F021 OutputPhLoss 1 Output Phase Loss if enabled Verify motor wiring Configure with A557 Out Phas Loss En Verify motor F029 Analog In Loss 1 An analog input is configured to fault on e Check for broken loose connections signal loss A signal loss has occurred at inputs Configure with t094 Anlg In V Loss or Check parameters t097 Anlg In mA Loss F033 AutoRstrt Tries 2 Drive unsuccessfully attempted to reset Correct the cause of the fault and a fault and resume running for the manually clear programmed number of A541 Auto Rstrt Tries F038 PhaseUtoGnd 2 A phase to ground fault has been e Check the wiring between the drive detected between the drive and motor and motor F032 Phase V to Gnd in this phase e Check motor for grounded phase F040 Phase W to Gnd Replace drive if fault cannot be cleared F041 PhaseUVShort 2 Excessive current has been detected e Check the motor and drive output F042 Phase UW Short between these two output terminals a for a shorted F043 Phase VW Short Replace drive if fault cannot be cleared F048 Params Defaulted 1 The drive was commanded to write e Clear the fault or cycle power to the default values to EEPROM drive Program the drive parameters a
191. d Documentation Overview Preface The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex 520 Series Adjustable Frequency AC Drive For information on See page Who Should Use this Manual 9 Recommended Documentation 9 Manual Conventions 10 Drive Frame Sizes 11 General Precautions 12 Catalog Number Explanation 13 This manual is intended for qualified personnel You must be able to program and operate Adjustable Frequency AC Drive devices In addition you must have an understanding of the parameter settings and functions All the recommended documentation listed in this section is available online at http www rockwellautomation com literature The following publications provide general drive information Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES IN001 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 The following publications provide specific PowerFlex 520 Series information on drive installation features specifications and service Title Publication PowerFlex 520 Series AC Dri
192. d Display Group 22 3312 CHR gt eds 103 Advanced Program Group s sctenvaweuies Pad Fa patet tup VE uaates 107 Network Parameter Group 4 see roe E 130 Rockwell Automation Publication 520 UM001G EN E September 2014 5 Table of Contents Troubleshooting Supplemental Drive Information Accessories and Dimensions RS485 DSI Protocol Velocity StepLogic Basic Logic and Timer Counter Functions Modified Parameter Group s cv ease Ge i e 130 Fault and Diagnostic Groups wet qua cicer Na de eeeh wwaupunyarannns 130 AppView Parameter Groips asasdu sea k rote tial d e edid 138 CustomView Parameter Gtolp 4 ise e ee er ehh eres per 139 Parameter Cross Reference by Name ice eae een 140 Chapter 4 Drive Status dea oo see vovv Ex auod Rees Gate eta ET e 145 Faults usd ii xe eerte pd ERE ERROR eS qi 145 Fault Descriptio NSi icerum ete ed auch area coda dre getan 147 Common Symptoms and Corrective Actions esses 150 Appendix A CErDBEALIOIBS tesa oper hio es dant ems Sa uu PU AE faxit 155 Environmental Specifications ico oceces i pere ER Re Ep ord 156 Technical Specifications s i2 operit rero erue Herbst IS TS 157 Power SPCC UIA LONG o eee Linen tut ou Ch buts Ses heri dat vts 160 Appendix B Product Selection 2i deco EO E HER as 163 Product DimensiobSos siete uic Ruan acaae helen debuit S le 173 Optional Accessories and Kites osea i ep seed aie ES oes etd 186 Appendix C Network Wiring deua Cpaitetacatex orb Due Feat qui
193. d the home position Tolerance is adjusted with A564 Encoder Pos Tol 29 Safe Off Both safe off inputs are active Values Default Relay Out Sel 0 Relay Out2 Sel 2 Min Max 0 29 Display 1 1 Setting is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter3 Programming and Parameters Terminal Block Group continued t077 Relay Out1 Level Related Parameter s t076 t081 t082 Relay Out2 Level PowerFlex 525 only KA 32 bit parameter Determines the on off point for the output relay when t076 or t081 Relay Outx Sel is set to the values shown below Min Max Value Range Based On Relay Outx Sel Setting 6 0 500Hz 10 0 10096 16 T0 1 9999s 20 071 7 10 18096 11 10 1 17 1 9999 counts 26 0 150 8 10 815V 13 0 800 18 0 180 Values Default 0 Min Max 0 9999 Display 1 t079 Relay 1 On Time t084 Relay 2 On Time PowerFlex 525 only Sets the delay time before Relay energizes after required condition is met Values Default 0 05 Min Max 0 0 600 0 s Display 0 15 t080 Relay 1 Off Time t085 Relay 2 Off Time PowerFlex 525 only Sets the delay time before Relay de energizes after required condition ceases Values Default 0 05 Min Max 0 0 600 0 s Display 0 15 t086 EM Brk Off Dela
194. dH uw S1ayeaJg HINDI Bugey xew sasn4 sjexea1g umor Buey s snd a amp a aH QN SZS dd EZS dd eS B sbuney suoerijddy 10 1N WON suonerijddy 53 yndu suey yndyno 1 ON fojee JV sau sa naq uoioajoJg 1ndu asbuq AOFZ 00 panunuo sanaq seueS ozs X2 449MOg 10 sJayealg INDI pue sasnj Rockwell Automation Publication 520 UM001G EN E September 2014 24 Chapter 1 Installation Wiring Jeuueu ypeds uone ijddy uuunjo siu ur pay Dads aunjo LiNLUJUIW au YUM sunso pue pare nuaA uou JO pate Inuea e ui pa feysU aq JSNW aALIP au une JaMod BAP stu YIM 49 03300 10704 uoneuiquio 3 d L payarorg sjas Jenuey e Husn uauM suleis s punoib axuejsisai uD1u Jo punoi 1102 e3jeq eyeq A009 40 A0gr uo asn 10 PASIL IN JON Mdu JY A009 pue z A0gy 40 PASIL 11 alonuo 4030 uoneutquuo 3 ad pa atoig jas enuey dia JOU JIM adIAap ay eun aBuer uinum au 0 Jas dia uam Y e eu pjnoys abues yuauind ajqeisnfpe uir wor unajng SHUEY uoreddy si9yeaig WNIT uom31oig 30108 Worl Ug a35 Kuen Aew siayearg UNUN 403221014 1030 WOY L UN JIN ay Jo Suea y IYL Bunea zuan ndur eAup 104 a3ejdauieu aAup au 03 1321 surea due samo ui sjo3oui Burjionuo S AAUP ayJUayM c ejnsopua 13612 e ambas kew SUOI eJapisuo AUP S14 10 ajqejree ase sunei GH fang Anka pue GN fang jeuuoN L
195. dback F is the value to the right of the decimal the portion less than 1 joo d378 Encoder Speed indicates the measured speed of the feedback device This is useful if the encoder is not used for motor speed control However the encoder must be used for some purpose in order for d378 Encoder Speed to indicate a value Parameter d378 Encoder Speed is the number value to the left of the decimal whole number and d379 Encoder Speed F is the number to the right of the decimal the portion less than 1 d388 d389 Units Traveled x indicate the current position ofthe system in terms of units away from Home Parameter d388 Units Traveled H is the number value to the left of the decimal whole number and d389 Units Traveled L is the number to the right of the decimal the portion less than 1 d387 Position Status indicates the status of the positioning functions The indication bits are Bit 0 Dir Positive indicates the current direction the drive has moved from Home Bit 1 At Position indicates whether the drive is at its commanded position If the drive is within A564 Encoder Pos Tol of the commanded position this bit will be active Bit 2 At Home indicates whether the drive is at Home If the drive is within A564 Encoder Pos Tol of Home this bit will be active Bit 3 Drive Homed indicates whether the drive has been homed since power up This bit will be active once the drive has been
196. drive will move directly to whatever step is currently commanded by A410 A425 Preset Freq x and L200 L214 Step Units x This is useful when an application Rockwell Automation Publication 520 UM001G EN E September 2014 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 This can be used to move through the steps Step 0 to Step 7 and back to Step 0 or can jump to a different step at any time based on time or the status of digital inputs or communication commands In this mode the drive always starts at Step 0 of the Step Logic profile 3 Preset StpL is identical to 2 Step Logic except the drive will use the current status of the Preset Inputs to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if setting 2 was selected 4 StpLogic Lst is identical to 2 Step Logic except the drive will use the step prior to its last stop command to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if setting 2 was selec
197. e Keep wire length as short as possible between the enclosure entry point and the EMI filter PowerFlex 520 Series RF Emission Compliance and Installation Requirements Filter Type Standard Limits EN61800 3 Category C1 EN61800 3 Category C2 EN61800 3 Category C3 EN61000 6 3 EN61000 6 4 I lt 1004 CISPR11 Group 1 Class B CISPR11 Group 1 Class A CISPR11 Group 1 Class A Input power lt 20 kVA Input power gt 20 kVA Internal 10 m 33 ft 20 m 66 ft External 30m 16 ft 100 m 328 ft 100 m 328 ft 1 See Appendix B for more information on optional external filters Additional Installation Requirements This section provides information on additional requirements for Class C1 and C2 installation such as enclosures and EMC cores IMPORTANT IMPORTANT 52 EMC cores are included with e drives that have an internal EMC filter 25x xxxxN114 e external EMC filter accessory kit 25 RFxxx An enclosure shielded input cable and EMC cores are not required to meet class C3 requirements Rockwell Automation Publication 520 UM001G EN E September 2014 Additional Installation Requirements Installation Wiring Chapter 1 Frame Class C1 Class C2 Size Endosure Conduit or Shielded EMC Cores Required Enclosure Conduit or Shielded EMC Cores Required Cable Input Included with
198. e automatic setting of A497 Flux Current Ref A start command is required following initiation of this setting The parameter returns to 0 Ready Idle following the test at which time another start transition is required to operate the drive in normal mode Important Used when motor is uncoupled from the load Results may not be valid if a load is coupled to the motor during this procedure P041 Accel Time 1 Related Parameter s P044 A439 Sets the time for the drive to accelerate from 0 Hz to P044 Maximum Freq Accel Rate Maximum Freq Accel Time x Maximum Freq 0 B Accel Timex amp Time Decel Timex 0 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 P042 Decel Time 1 Related Parameter s P044 A439 Sets the time for the drive to decelerate from P044 Maximum Freq to 0 Hz Decel Rate Maximum Freq Decel Time x Maximum Freq 0 9 Accel Time x la Time mI Decel Time x la 0 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 78 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Basic Program Group continued P043 Minimum Freq Related Parameter s b001 b002 b013 P044 A530 A531 S 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 P04
199. e speed electrical power drive systems Part 5 2 Safety requirements Functional PowerFlex 525 STO achieves SIL CL 2 e EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e IEC 61508 Part 1 7 2010 Functional safety of electrical electronic programmable electronic safety related systems Parts 1 7 TUV also certifies that the PowerFlex 525 STO may be used in applications up to Category 3 PL d according to EN ISO 13849 1 and SIL 2 according to EN 62061 EN 61800 5 2 IEC 61508 The TUV Rheinland certificate may be found at www rockwellautomation com products certification PowerFlex 525 Safe Torque Off function requires CE Conformity as described on page 49 The PowerFlex 525 Safe Iorque Off function is intended to be part of the safety related control system of a machine Before use a risk assessment should be performed that compares the PowerFlex 525 Safe Iorque Off function specifications and all foreseeable operational and environmental characteristics of the machine to which it is to be fitted Rockwell Automation Publication 520 UM001G EN E September 2014 Safety Concept Safe Torque OffFunction Appendix G A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine installation Rockwell
200. e the PTC and External Resistor typically matched to the PTC Hot Resistance to 1 0 For Drive Fault Terminals 12 13 14 Wire R2 R3 Relay Output SRC to 1 0 Terminals 5 amp 11 1065 DigIn TermBlk 05 12 Aux Fault t081 Relay Out 2 Sel 10 Above Anlg V t082 Relay Out 2 Level Voltage Trip i _ Perc hot WV ip eX 100 5 Tib Rec hot Re Pulse Train Input PowerFlex 523 PowerFlex 525 PowerFlex 523 t065 Digln TermBIk 05 n 52 amp Pulse In amp Pulse In PowerFlex 525 PA 2 EUNT Tene Common 12 le 04 E Common 9 04 E i m Pulse n _ Oo 6 sS N ee T S Digital Pulsen amp 5 Digital Use P047 P049 and P051 hi Lis je g input Speed Referencex to select pulse input Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 1 0 Connection Example 2 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing P046 Start Source 1 2 2 and t062 DigIn TermBlk 02 48 Input must be active for the drive to run When input is opened the drive will stop as specified by P045 Stop Mode If desired a User Supplied 24V DC power source can be used Refer to the Ext
201. ed Freq b002 Digln TermBlk 06 t066 Stp Logic Time 3 L193 Units Traveled L d389 Ki Speed Loop A538 Motor NP Volts P031 Opto Outi Sel 1069 Stp Logic Time 4 L194 Preset Freq 0 A410 Kp Speed Loop A539 Motor NP Hertz P032 Opto Out Sel 1072 Stp Logic Time 5 L195 Preset Freq 1 A411 Bus Reg Enable A550 Motor OL Current P033 Relay Out1 Sel t076 Stp Logic Time 6 L196 Preset Freq 2 A412 Positioning Mode A558 Motor NP FLA P034 EM Brk Off Delay 1086 Stp Logic Time 7 L197 Preset Freq 3 A413 Counts Per Unit A559 Motor NP Poles P035 EM Brk On Delay 1087 Step Units 0 L200 Preset Freq 4 A414 Enh Control Word A560 Autotune P040 Stp Logic 0 L180 Step Units 1 1202 Preset Freq 5 M15 Find Home Freq A562 Accel Time 1 P041 Stp Logic 1 L181 Step Units 2 L204 Preset Freq 6 A416 Find Home Dir A563 Decel Time 1 P042 Stp Logic 2 L182 Step Units 3 L206 Preset Freq 7 A417 Encoder Pos Tol A564 Minimum Freq P043 StpLogic3 L183 Step Units 4 L208 Preset Freq 8 A418 Pos Reg Filter A565 Maximum Freq P044 StpLogic4 L184 Step Units 5 L210 Jog Frequency M31 Pos Reg Gain A566 Textile Fiber Motor NP FLA P034 Digln TermBlk 02 t062 Slip Hz Meter d375 Max Traverse A567 Motor NP Poles P035 Digln TermBlk 03 t063 Fiber Status d390 Traverse Inc A568 VR Autotune P040 Opto Out Sel 1069 Preset Freq 0 A410 Traverse Dec A569 Accel Time 1 P041 Opto Out Sel t072 Jog Frequency A431 P Jump A570 Language P030 Decel Time 1 P042 Relay Out Sel t076 Jog Accel Decel M32 Sync Time A571 Output Freq b001 Minimu
202. ed in the table below are contingent upon the Proof Test Interval PTI Before the end of the PTI specified in the table below a proof test of the STO safety function must be performed in order for the specified PFD and PFH values to remain valid PFD and PFH Data PFD and PFH calculations are based on the equations from Part 6 of EN 61508 This table provides data for a 20 year proof test interval and demonstrates the worst case effect of various configuration changes on the data PFD and PFH for 20 year Proof Test Interval Attribute Value PFD 6 62E 05 MTTF 3593 years PFHp 8 13E 10 SFF 83 DC 62 5 CAT 3 HFT 1 1002 PTI 20 YEARS Hardware Type Type A Safety Reaction Time The safety reaction time is the amount of time from a safety related event as input to the system until the system is in the Safe State The safety reaction time from an input signal condition that triggers a safe stop to the initiation of safe torque off is 100 ms maximum Rockwell Automation Publication 520 UM001G EN E September 2014 Enabling PowerFlex 525 Safe Torque Off Wiring PowerFlex 525 Safe Torque Off Operation Safe Torque OffFunction Appendix G 1 Remove all power to the drive on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals or test points refer to your drive s user manual for the location of the term
203. efault Preset Freq x setting Accel Decel 1 or 2 is selected according to Comms Accel Decel 1 2 3 4 is Selected according to Step Logic Rockwell Automation Publication 520 UM001G EN E September 2014 CE Conformity Installation Wiring 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 com products certification Low Voltage Directive 2006 95 EC e EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy Pollution Degree Ratings According to EN 61800 5 1 Pollution Description Degree 1 No pollution or only dry non conductive pollution occurs The pollution has no influence 2 Normally only non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation is to be expected when the drive is out of operation EMC Directive 2004 108 EC e EN 61800 3 2004 A1 2012 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods Machinery Directive 2006 42 E
204. efault 4096 Min Max 1 32000 Display 1 A560 Enh Control Word Related Parameter s t062 t063 t065 t068 A571 PF 525 PowerFlex 525 only Allows control of positioning and other functions through parameter control for use over comms The functions replicate the digital input options and function in the same way FIIIT LJ LJ LIJLILILILILILI LI LI LI 1 Input Present 0 Input Not Present Home Limit Digit 1 Find Home Digit 2 Hold Step Digit 3 Pos Redefine Digit 4 Sync Enable Digit 5 Traverse Dis Digit 6 Logic In 1 Digit 7 Logic In 2 Digit 8 Not Used Values Default 0000 0000 Min Max 0000 0000 1111 1111 Display 0000 0000 Digits 0 Home Limit In Positioning mode this indicates the drive is at the home position 1 Find Home When set the next start command causes the drive to find home Set this bit to 0 after completing the homing routine 2 Hold Step In Positioning mode this input over rides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released 3 Pos Redefine In Positioning mode this input resets the home position to the current position of the machine Set this bit to 0 after completing the homing routine 4 Sync Enable Must be used in order to hold the existing frequency when Sync Time is se
205. embedded EtherNet IP data table This parameter cannot be changed when an 1 0 connection is established through the drive s embedded EtherNet IP port Values Default 0 Min Max 0 800 Display 1 98 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Communications Group continued C161 Opt Data In 1 C162 Opt Data In 2 C163 Opt Data In 3 C164 Opt Data In 4 Datalink parameter number whose value is written from the High Speed Drive Serial Interface HSDSI data table This parameter cannot be changed when an 1 0 connection is established through the communication adapter Values Default 0 Min Max 0 800 Display 1 C165 Opt Data Out 1 C166 Opt Data Out 2 C167 Opt Data Out 3 C168 Opt Data Out 4 Datalink parameter number whose value is read from the HSDSI data table This parameter cannot be changed when an 1 0 connection is established through the communication adapter Values Default 0 Min Max 0 800 Display 1 C169 MultiDrv Sel Sets the configuration of the drive that is in multi drive mode A reset or power cycle is required after selection is made Options 0 Disabled Default No multi drive master from the internal network option module or embedded Ethernet port The drive can still function as a multi drive slave or as a single drive no multi drive used 1 Network Opt Multi drive is enabled wi
206. emental C Accel Decel 2 On FWD Absolute d Accel Decel 2 On FWD Incremental E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incremental TIP Rockwell Automation Publication 520 UM001G EN E September 2014 Settings Digit 3 Setting Description 0 Jump to Step 0 1 Jump to Step 1 2 Jump to Step 2 3 Jump to Step 3 4 Jump to Step 4 5 Jump to Step 5 6 Jump to Step 6 7 Jump to Step 7 8 End Program Normal Stop 9 End Program Coast to Stop A End Program and Fault F2 Settings Digit 2 and 1 Setting Description Skip Step Jump Immediately Step Based on Stp Logic Time x Step if Logic In 1 is Active Step if Logic In 2 is Active Step if Logic In 1 is Not Active Step if Logic In 2 is Not Active Step if either Logic In 1 or Logic In 2 is Active Step if both Logic In 1 and Logic In 2 are Active Step if neither Logic In 1 nor Logic In 2 is Active Step if Logic In 1 is Active and Logic In 2 is Not Active Step if Logic In 2 is Active and Logic In 1 is Not Active Step after Stp Logic Time x and Logic In 1 is Active Step after Stp Logic Time x and Logic In 2 is Active Step after Stp Logic Time x and Logic In 1 is Not Active Step after Stp Logic Time x and Logic In 2 is Not Active maj m a alo eS s co SY HD UO BB WwW Nr A Oo Do
207. ency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 596 of maximum output frequency 10 Bit resolution Analog Output 2 of full scale 10 Bit resolution Performance V Hz Volts per Hertz 1 of base speed across a 60 1 speed range SVC Sensorless Vector 0 5 of base speed across a 100 1 speed range SVC Economizer WC Velocity Vector Control 0 5 of base speed across a 100 1 speed range 0 5 of base speed across a 60 1 speed range Not applicable to PowerFlex 523 drives Rockwell Automation Publication 520 UM001G EN E September 2014 157 Appendix A 158 Supplemental Drive Information Specifications PowerFlex 523 PowerFlex 525 Performance with Encoder SVC Sensorless Vector 0 1 of base speed across a 100 1 speed range SVC Economizer 0 1 of base speed across a 100 1 speed range WC Velocity Vector Control 0 1 of base speed across a 1000 1 speed range Output Voltage Range OV to rated motor voltage Output Frequency Range 0 500 Hz programmable Efficiency 97 596 typical Stop Modes Multiple programmable stop modes including Ramp Coast DC Brake and Ramp to Stop Accel Decel Four independently programmable accel and decel times Each time may be programmed from 0 600 s in 0 01 s increments Intermittent Overload Normal Duty 110 Overload capability for up to 60 s
208. er 16 10 Hexadecimal Preset Write Multiple Registers IMPORTANT Modbus devices can be 0 based registers are numbered starting at 0 or 1 based registers are numbered starting at 1 Depending on the Modbus Master used the register addresses listed on the following pages may need to be offset by 1 For example Logic Command may be register address 8192 for some master devices e g ProSoft 3150 MCM SLC Modbus scanner and 8193 for others e g PanelViews The PowerFlex 520 series drive can be controlled through the network by sending Function Code 06 writes to register address 2000H Logic Command P046 Start Source 1 must be set to 3 Serial DSI in order to accept the commands PowerFlex 523 drives support only Velocity bit definitions PowerFlex 525 drives can use Parameter C122 Cmd Stat Select to select either Velocity or Position bit definitions TIP Powerup Reset the drive after selecting an option for C122 Cmd Stat Select for the change to take effect Rockwell Automation Publication 520 UM001G EN E September 2014 191 AppendixC RS485 DSI Protocol Velocity Bit Definitions Comm Logic Command C122 0 Velocity Address Decimal Bit s Description 2000H 8192 0 1 Stop 0 Not Stop 1 1 Start 0 Not Start 2 1 Jog 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 5 4 00 No Command 01 Forward Command 10 Reverse Command 11 No Command 6 1
209. er a valid start command is received DC Brk Time Strt Volts Speed DC Brake Level Start eau Time Values Default 0 05 Min Max 0 0 99 9 s Display 0 15 Rockwell Automation Publication 520 UM001G EN E September 2014 109 Chapter3 Programming and Parameters Advanced Program Group continued M37 DB Resistor Sel Ts 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 DutyCyde M38 DB Threshold Related Parameter s A437 Sets the DC bus voltage threshold for Dynamic Brake operation If DC bus voltage rises above this level Dynamic Brake turns on Lower values makes the dynamic braking function more responsive but may result in nuisance Dynamic Brake activation ATTENTION Equipment damage may result if this parameter is set to a value that causes the dynamic braking resistor to dissipate excessive power Parameter settings less than 10096 should be carefully evaluated to ensure that the Dynamic Brake resistor s wattage rating is not exceeded In general values less than 90 are not needed This parameter s setting is especially important if parameter A437 DB Resistor Sel is set to 2 NoProtection Values Default 100 096 Min Max 10 0 110 096 Display 0 196 M39 S Curve Enables a fi
210. eries drive To simplify drive setup the most commonly programmed parameters are organized in a single Basic Program Group For information on See page Prepare for Drive Start Up 55 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 ISS ISS S 18 les w l i IS 19 l IMPORTANT Read the General Precautions section before proceeding start up procedures Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove All Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing ATTENTION Power must be applied to the drive to perform the following Prepare for Drive Start Up Drive Startup Task List 1 Disconnect and lock out power to the machine 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 If replacing a drive verify the current drive s catalog number Verify all options installed on the drive 4 Verify that any
211. ernal Supply SRC example 2 Wire SNK Control Internal Supply SNK Non Reversing Q 01 S 02 oO O O Stop Run Stop Run 24V Common ooo00 oooooQ Each digital input draws 6 mA oo c OS OOOO 2 Wire SRC Control Run FWD Run REV P046 Start Source 1 2 t062 DigIn TermBlk 02 48 and t063 DigIn TermBlk 03 50 Input must be active for the drive to run When input is opened the drive Stop Run will stop as specified by Reverse P045 Stop Mode If both Run Forward and Run Reverse inputs are closed at the same time an undetermined state could occur 2 Wire SNK Control Internal Supply SNK Run FWD Run REV External Supply SRC 1 CO O top Run CY Forward top Run Forward o O O Oo O O O O t O Stop Run Reverse 2 20006 O 24V oo Each digital input draws 6 mA M Run Forward 03 O O Stop Run Reverse AAAA 3 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing 5 P046 Start Source 1 2 t062 DigIn TermBIk 02 49 and t063 DigIn TermBlk 03 51 A momentary input will start the drive A stop input to 1 0 Terminal 01 will stop the drive as specified by P045 Stop Mode
212. erse Dec 569 Stp Logic 50 185 Stp Logic Time 60 196 Traverse Inc 568 Stp Logic 6 186 Stp Logic Time 7 197 Units Traveled HU 388 Stp Logic 7 187 Sync Time 571 Units Traveled L 389 Stp Logic Status 391 Testpoint Data 368 Var PWM Disable 540 Stp Logic Time o 190 Testpoint Sel 483 Voltage Class 038 Stp Logic Time 19 191 Text Scroll 556 Wake Level 103 Stp Logic Time 2 192 Timer Status 365 Wake Time 104 Stp Logic Time 30 193 Torque Current 382 1 Parameter is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 143 Chapter3 Programming and Parameters Notes 144 Rockwell Automation Publication 520 UM001G EN E September 2014 Drive Status Faults Chapter 4 Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex 520 series drive Included is a listing and description of drive faults with possible solutions when applicable For information on See page Drive Status 145 Faults 145 Fault Descriptions 147 Common Symptoms and Corrective Actions 150 ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis The condition or state of your drive is constantly monitored Any changes will be indicated through the integral LCD display See Display and Control Keys on page 58 for information on drive status indicators and controls A
213. es No No No Input Output D Yes Yes No No No Input Output E Yes Yes No Yes No No 1 An indicates that EMC requirements are not met Rockwell Automation Publication 520 UM001G EN E September 2014 53 Chapter 1 Installation Wiring Recommended Placement of EMC Cores Frame A With optional EMC plate 25 EMC Fx Frame B Frame C Frame D Frame E CORE xx A 1 CORE xx B 1 CORE xx C 1 CORE xx D 1 CORE xx A 2 CORE xx B 2 CORE xx C 2 CORE xx D 2 Without EMC plate Ground cable CORE xx x 1 CORE xx x 2 4 Input cable to drive Shielded or Unshielded Output cable from drive Shielded aS Shows contact to v Secure EMC core by pL shielded layer using cable zip ties IMPORTANT The ground cable shield for both input and output must pass through the EMC core s except for the following e Frame E drives with internal filters where the grounded input cable must not pass through EMC CORE E 1 e 600V drives with external filters where the grounded output cable must not pass through the EMC core s Recommended Placement of EMC Cores Relative to External Filter All Frame sizes 54 Incoming power EMC Filter Drive Motor Input core Output core Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter 2 Start Up This chapter describes how to start up the PowerFlex 520 s
214. es cat pleb apap 189 Parameter Configuration ced beu ae eu cubed ide a tud a heh ok 190 Supported Modbus Function Codes euueeuuuee 191 Writing 06 Logic Command Data 1 eie en rre 191 Writing 06 Comm Frequency Command 00 006 193 Reading 03 Logic Status Data oos eee ete tee reet etu hne 193 Reading 03 Drive Error Codes 2 t D eU 195 Reading 03 Drive Operational Values 22sec eee 196 Reading 03 and Writing 06 Drive Parameters 196 Additional Information ccd ceder cud rosa d Rer or Uxot RO I Res 196 Appendix D Velocity StepLogic Using Timed Steps eee ere eee 198 Velocity StepLogic Using Basic Logic Functions sss 198 Timer Functions s neqoe ss ouo RD ERE A is due pM 199 Counter Functio dioe ere ce en Eee Gud id bi peii Aaa 200 Velocity StepLogic Parameters solve eie ed ew Er Re eret EPA pres 201 Rockwell Automation Publication 520 UM001G EN E September 2014 Encoder Pulse Train Usage and Position StepLogic Application PID Set Up Safe Torque Off Function EtherNet IP Control Diagrams Table of Contents Appendix E Encoder and Pulse Train Usage id aee e Pr E S 203 Wiring NOLES exito d bs og Mirae eons epee APESQE NUDO au aS 204 Positioning Overview sama sa ni 33 PIERDE ER PIG OAM C RSETRE S 205 Common Guidelines for All Applications 0 0 00 e eee eee 205 Positioning Operaons sec Fane Meanie ees ap eo ie 206
215. esults tune the application first The autotune routine can be completed to further improve the drive motor performance Rockwell Automation Publication 520 UM001G EN E September 2014 205 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Positioning Operation 206 A550 Bus Reg Enable default setting is 1 Enabled If the deceleration time is too short the drive may overshoot the desired position For best results a longer deceleration time may be necessary A550 Bus Reg Enable can be disabled to provide precise stopping movements but the deceleration time will need to be manually tuned so that it is long enough to avoid F005 OverVoltage faults A437 DB Resistor Sel default setting is 0 Disabled If improved deceleration performance is required a Dynamic Brake resistor can be used If used this parameter should be set to the appropriate setting for the resistor selected P035 Motor NP Poles must be set to match the number of motor poles on the motor driven by the PowerFlex 520 series drive A536 Encoder PPR must be set to match the number of pulses per revolution of the encoder used i e 1024 PPR Encoder 4559 Counts Per Unit sets the number of encoder counts that will be used to define one position unit This allows the encoder positions to be defined in terms of units important to the application For example if 1cm of travel on a conveyor belt requires 0 75 turns of the mo
216. et Act 3 699 Fault 6 Time min 626 HW Addr 3v 689 EN Subnet Act 4 700 Fault 7 BusVolts 657 HW Addr 47 690 EN Subnet Cfg 1 133 Fault 7 Code 607 HW Addr 5 691 EN Subnet Cfg 2 134 Fault 7 Current 647 HW Addr 6 692 EN Subnet Cfg 3 1 135 Fault 7 Freq 637 IR Voltage Drop 496 EN Subnet Cfg 4 l 136 Fault 7 Time hr 617 Jog Accel Decel 432 EN Tx Errors 729 Fault 7 Time min 627 Jog Frequency 431 EN Tx Packets 728 Fault 8 BusVolts 658 Keypad Freq 426 Encoder Pos Tol 564 Fault 8 Code 608 Ki Speed Loop 538 Encoder PPR 536 Fault 8 Current 648 Kp Speed Loop 539 Encoder Speed 378 Fault 8 Freq 638 Language 30 Energy Saved 023 Fault 8 Time hr 618 Load Loss Level 490 Enh Control Word 560 Fault 8 Time min 628 Load Loss Time 491 Fault 1 BusVolts 651 Fault 9 BusVolts 659 Max Traverse 567 Fault 1 Code 007 Fault 9 Code 609 Maximum Freq 044 Fault 1 Current 64 Fault 9 Current 649 Maximum Voltage 534 Fault 1 Freq 631 Fault 9 Freq 639 Minimum Freq 043 Fault 1 Time hr 611 Fault 9 Time hrl 619 MOP Freq 427 Fault 1 Time min 621 Fault 9 Time min 629 MOP Preload 429 Fault 2 BusVolts 652 Fault Clear 551 MOP Reset Sel 428 Fault 2 Code 008 Fault10 BusVolts 660 MOP Time 430 Fault 2 Current 642 Fault10 Code 610 Motor Fdbk Type 535 Fault 2 Freq 632 Fault10 Current 650 Motor Lm 499 Fault 2 Time hr 612 Fault10 Freq 640 Motor Lx 500 Fault 2 Time min 622 Fault10 Time hr 620 Motor NP FLA 034 Fault 3 BusVolts 653 Fault10
217. et Up PID reaches the Hi or Lo limit the PID regulator stops integrating so that windup does not occur PID Gains The proportional integral and differential gains make up the PID regulator e A461 and A473 PID x Prop Gain The proportional gain unitless affects how the regulator reacts to the magnitude ofthe error The proportional component ofthe PID regulator outputs a speed command proportional to the PID error For example a proportional gain of 1 would output 10096 of max frequency when the PID error is 10096 of the analog input range A larger value for PID x Prop Gain makes the proportional component more responsive and a smaller value makes it less responsive Setting PID x Prop Gain to 0 00 disables the proportional component of the PID loop A462 and A474 PID x Integ Time The integral gain units of seconds affects how the regulator reacts to error over time and is used to get rid of steady state error For example with an integral gain of 2 seconds the output of the integral gain component would integrate up to 10096 of max frequency when the PID error is 10096 for 2 seconds A larger value for PID x Integ Time makes the integral component less responsive and a smaller value makes it more responsive Setting PID x Integ Time to 0 0 disables the integral component of the PID loop A463 and A475 PID x Diff Rate The Differential gain units of 1 seconds affects the rate of change of the PID output The di
218. eters Chapter 3 Centrifugal Pump Motor OL Current P033 Start Source 1 P046 Anlg In4 20m4A Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464 n Motor NP Poles P035 Relay Out Sel t076 Preset Freq 0 M10 PID 1 Deadband A465 Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466 Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541 Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542 Commanded Freq b002 Minimum Freq P043 Anlg In 0 10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543 Motor NP Volts P031 Maximum Freq P044 Anlg In 0 10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544 Motor NP Hertz P032 Stop Mode P045 Anlg In4 20mA Lo t095 PID 1 Integ Time A462 Blower Fan Motor OL Current P033 Start Source 1 P046 Anlg In4 20mA Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464 VY Motor NP Poles P035 Relay Out Sel t076 Preset Freq 0 M10 PID 1 Deadband A465 Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466 Language P030 Accel Time 1 P041 Analog Out High 1089 PID 1 Trim Lo A457 Auto Rstrt Tries A541 Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542 Commanded Freq b002 Minimum Freq P043 Anlg In 0 10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543
219. fault 19 200 38 400 nl wj N C124 RS485 Node Addr Sets the Modbus drive node number address for the RS485 port if using a network connection A reset or power cycle is required after selection is made Values Default 100 Min Max 1 247 Display 1 C125 Comm Loss Action Related Parameter s P045 Sets the drive s response to a loss of connection or excessive communication errors on the RS485 port Options 0 Fault Default 1 Coast Stop Stops drive using Coast to stop 2 Stop Stops drive using P045 Stop Mode setting 3 Continu Last Drive continues operating at communication commanded speed saved in RAM C126 Comm Loss Time Related Parameter s C125 Sets the time that the drive remains in communication loss with the RS485 port before taking the action specified in C125 Comm Loss Action See Appendix C for more information IMPORTANT This setting is effective only if 1 0 that controls the drive is transmitted through the RS485 port Values Default 5 05 Min Max 0 1 60 0 s Display 0 15 94 Rockwell Automation Publication 520 UM001G EN E September 2014 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 RTU8 N 1 Default 1 RTU 8
220. ff Safety2 s 3 S X 02 Digin TermBlk 03 Safety 24V em 03 irection Run REV ec oul SNK Bc SRC igital Common VY igin TermBlk 05 eed e m igIn TermBlk 06 Ge 07 igIn TermBlk 07 Pulse or gets m igin TermBlk 08 are ers N 24V DC Relay 1 N 0 1 R poe iW 10V DC Relay 1 Common R2 LT i au 8 0 10V or 10V Input Relay 2 Common R5 7 Analog Common x RSy2NC Rg ag 1420m input Tero kahm i 0 10V 2W min Qo tee Analog Output 0 4 20mA 16 aE EE Opto Output 1 E B orem d WE 8 Opto Output 2 n sy 50 mA Non inductive 9 Opto Common a RJ45 Shield V y V Q Comm Common Jo J9 J5 mm 0 4 20mA amp Pulse In SNK qa m E a 2 eK EL 8M 0 10V amp Digital SRC Vy amp Input wA ww m R R5 R6 01 02 03 04 05 06 07 08 a o CS CIC SISAS AAA AlS SA GIAO iw O CN Siete O SC O Sle S S 8 S 9 S 1 1 B 4 15 6 7 18 19 Rockwell Automation Publication 520 UM001G EN E September 2014 39 Chapter 1 40 Installation Wiring Control 1 0 Wiring Block Diagram Notes 1 See Digital Input Selection for Start Source on page 47 for more information on configuring the digital inputs IMPORTANT 1 0 Terminal 01 is always a stop input The stopping mode is determined by the drive setting See the tables below for more information Start Method Stop Method P046 P048 P050 Start Source x 1 0 Terminal 01 Stop Normal Stop 1 Keypad Coast Per P045 2 DigIn TrmBlk See t062 t063 Digln
221. fferential gain is multiplied by the difference between the previous error and current error Thus with a large error the D hasa large effect and with a small error the D has less of an effect This parameter is scaled so that when it is set to 1 00 the process response is 0 196 of P044 Maximum Freq when the process error is changing at 196 second A larger value for PID x Diff Rate makes the differential term have more of an effect and a small value makes it have less of an effect In many applications the D gain is not needed Setting PID x Diff Rate to 0 00 factory default disables the differential component of the PID loop Guidelines for Adjusting the PID Gains 1 Adjust the proportional gain During this step it may be desirable to disable the integral gain and differential gain by setting them to 0 After a step change in the PID Feedback Ifthe response is too slow increase A461 or A473 PID x Prop Gain Ifthe response is too quick and or unstable see Unstable Response on page 221 decrease A461 or A473 PID x Prop Gain Typically A461 or A473 PID x Prop Gain is set to some value below the point where the PID begins to go unstable Rockwell Automation Publication 520 UM001G EN E September 2014 PIDSetUp Appendix F 2 Adjust the integral gain leave the proportional gain set as in Step 1 After a step change in the PID Feedback Ifthe response is too slow see Slow Response Over Damped on
222. g Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not Recommended Rockwell Automation Publication 520 UM001G EN E September 2014 Overview Preface e The Studio 5000 Engineering and Design Environment combines engineering and design elements into a common environment The first element in the Studio 5000 environment is 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 The Studio 5000 environment is the foundation for the future of Rockwell Automation engineering design tools and capabilities It is the one place for design engineers to develop all the elements of their control system Drive Frame Sizes Similar PowerFlex 520 series drive sizes are grouped into frame sizes to simplify spare parts ordering dimensioning etc A cross reference of drive catalog numbers and their respective frame sizes is provided in Appendix B Rockwell Automation Publication 520 UM001G EN E September 2014 11 Preface Overview General Precautions 12 A ATTENTION The drive contains high voltage capacitors which take time to discharge after removal of mains supply Before working
223. gnored Values Default 0 096 Min Max 0 0 200 0 Display 0 1 t092 Anlg In 0 10V Hi Related Parameter s P044 t091 t093 so drive before changing this parameter Sets the percentage based on 10V of input voltage applied to the 0 10V analog input used to represent P044 Maximum Freq Analog inversion can be accomplished by setting this value smaller than t091 Anlg In 0 10V Lo If t093 10V Bipolar Enbl is set to 1 Bi Polar In the same value applies to positive and negative voltage Values Default 100 0 Min Max 0 0 200 0 Display 0 1 t093 10V Bipolar Enbl Related Parameter s t091 t092 PowerFlex 525 only Enables disables bi polar control In bi polar mode direction is commanded by the polarity of the voltage If bi polar control is enabled P043 Minimum Freq and t091 Anlg In 0 10V Lo are ignored Options 0 Uni Polar In Default 0 10V only 1 Bi Polar In 10V Rockwell Automation Publication 520 UM001G EN E September 2014 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
224. gramming and configuring Allen Bradley drives and other Rockwell Automation products Compatibility Windows XP Windows Vista and Windows 7 Rockwell Automation Publication 520 UM001G EN E September 2014 http ab rockwellautomation co m programmable controllers connected components workbench software Accessories and Dimensions Appendix B Bulletin 1321 3R Series Line Reactors Output Ratings n Input Line Reactor Output Line Reactor IP00 IP11 IP00 IP11 Normal Duty Heavy Duty Open Style NEMA UL Type 1 Open Style NEMA UL Type 1 HP kW HP kW Catalog No Catalog No Catalog No Catalog No 200 240V 50 60 Hz 1 Phase 025 02 025 0 2 1321 3R4 A 1321 3RA4 A 1321 3R2 D 1321 3RA2 D 05 04 0 5 04 1321 3R8 A 1321 3RA8 A 1321 3R2 D 1321 3RA2 D 10 1075 11 0 0 75 13213R8 A 1321 3RA8 A 1321 3R4 A 1321 3RA4 A 20 15 20 415 1321 3R18 A 1321 3RA18 A 1321 3R8 A 1321 3RA8 A 30 22 030 422 1321 3R18 A 1321 3RA18 A 1321 3R12 A 1321 3RA12 A 200 240V 50 60 Hz 3 Phase 025 02 0 25 02 13213R2 D 13213RA2 D 1321 3R2 D 1321 3RA2 D 05 04 10 5 04 1321 3R2 D 1321 3RA2 D 1321 3R2 D 13213RA2 D 10 1075 10 075 13213R4 A 1321 3RM A 1321 3R4 A 1321 3RA4 A 20 15 20 415 1321 3R8 A 1321 3RA8 A 1321 3R8 A 1321 3RA8 A 30 22 30 422 1321 3R12 A 1321 3RA12 A 1321 3R12 A 1321 3RA12
225. hazard from cross coupled power leads ATTENTION National Codes and standards NEC VDE BSI etc and local codes Motor Cable Types Acceptable for 100 600 Volt Installations A variety of cable types are acceptable for drive installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide allow a spacing of 0 3 m 1 ft for every 10 m 32 8 ft of length In all cases long parallel runs must be avoided Do not use cable with an insulation thickness less than 15 mils 0 4 mm 0 015 in Do not route more than three sets of motor leads in a single conduit to minimize cross talk If more than three drive motor connections per conduit are required shielded cable must be used Rockwell Automation Publication 520 UM001G EN E September 2014 31 Chapter 1 32 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 maximum cable length stated in the Motor Cable Length Restrictions Tables in WARNING The distance between the drive and motor must not exceed the Wiring and Grounding Guide PWM AC Drives publication
226. he following is a listing of the available settings for each digit Rockwell Automation Publication 520 UM001G EN E September 2014 Encoder Pulse Train Usage and Position StepLogic Application Appendix E HHH Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Velocity Control Settings Digit 4 Required Accel Decel StepLogic Commanded Setting Param Used Output State Direction 0 Accel Decel 1 Off FWD 1 Accel Decel 1 Off REV 2 Accel Decel 1 Off No Output 3 Accel Decel 1 On FWD 4 Accel Decel 1 On REV 5 Accel Decel 1 On No Output 6 Accel Decel 2 Off FWD 7 Accel Decel 2 Off REV 8 Accel Decel 2 Off No Output 9 Accel Decel 2 On FWD A Accel Decel 2 On REV b Accel Decel 2 On No Output Positioning Settings Digit 4 Required Accel Decel StepLogic Direction Type of Setting Param Used Output State From Home Command 0 Accel Decel 1 Off FWD Absolute 1 Accel Decel 1 Off FWD Incremental 2 Accel Dece off REV Absolute 3 Accel Dece off REV Incremental 4 Accel Decel 1 On FWD Absolute 5 Accel Decel On FWD Incremental 6 Accel Decel 1 On REV Absolute 7 Accel Dece On REV Incremental 8 Accel Decel 2 Off FWD Absolute 9 Accel Decel 2 Off FWD Incremental A Accel Decel 2 Off REV Absolute b Accel Decel 2 Off REV Incr
227. he function selected in A483 Testpoint Sel Related Parameter s A483 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 1 d375 Slip Hz Meter Related Parameter s P032 Displays the current amount of slip or droop absolute value being applied to the motor frequency Drives applies slip based on the setting for P032 Motor NP Hertz Values Default Read Only Min Max 0 0 25 0 Hz Display 0 1 Hz d376 Speed Feedback bd 32 bit parameter Displays the value of the actual motor speed whether measured by encoder pulse train feedback or estimated Values Default Read Only Min Max 0 64000 rpm Display 1rpm 4378 Encoder Speed Y 32 bit parameter PowerFlex 525 only Provides a monitoring point that reflects the speed measured from the feedback device This shows the encoder or pulse train speed even if not used directly to control motor speed Values Default Read Only Min Max 0 64000 rpm Display 1rpm d380 DC Bus Ripple Displays the real time value of the DC bus ripple voltage Values Default Read Only Min Max 0 410VDC for 230V AC drives 820VDC for 460VAC drives 1025VDC for 600VAC drives Display 1V DC d381 Output Powr Fctr Displays the angle in electrical degrees between motor voltage and motor current V
228. his is the reference being transmitted to drive 0 1 2 3 4 In single drive mode this is the reference being used by the drive whether HS DSI EtherNet IP or DSI at the time If comms control is NOT being used and the drive is in single drive mode then this parameter will show 0 Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz F707 Drv 0 Logic Sts F711 Drv 1 Logic Sts F715 Drv 2 Logic Sts F719 Drv 3 Logic Sts F723 Drv 4 Logic Sts In multi drive mode this is the logic status being received from drive 0 1 2 3 4 In single drive mode this is the logic status of the drive at the time Values Default Read Only Min Max 0 FFFF Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 135 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F708 Drv 0 Feedback F712 Drv 1 Feedback F716 Drv 2 Feedback F720 Drv 3 Feedback F724 Drv 4 Feedback In multi drive mode this is the feedback being received from drive 0 1 2 3 4 In single drive mode this is the feedback of the drive at the time Values Default Read Only Min Max 0 00 500 00 Hz Display 0 01 Hz F725 EN Rx Overruns PowerFlex 525 only A count ofthe number of receive overrun errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F726 EN Rx Packets PowerFlex 525 only A co
229. icas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 520 UM001G EN E September 2014 Supersedes P
230. ics None Set motor nameplate full load amps in parameter P034 Motor NP FLA e Perform P040 Autotune Static Tune or Rotate Tune procedure Set P039 Torque Perf Mode to 0 V Hz Motor operation is unstable Cause s Motor data was incorrectly entered Indication Drive will not reverse motor direction Corrective Action 1 Correctly enter motor nameplate data into P031 P032 and P033 2 Enable A547 Compensation 3 Use A530 Boost Select to reduce boost level Cause s Indication Corrective Action Reverse is disabled None Check A544 Reverse Disable Digital input is not selected for reversing control None Check DigIn TermBlk xx See page 82 Choose correct input and program for reversing mode Digital input is incorrectly wired None Check input wiring See page 42 None Switch two motor leads Motor wiring is improperly phased for reverse 152 Rockwell Automation Publication 520 UM001G EN E September 2014 Cause s No input power to drive Troubleshooting Chapter 4 Drive does not power up Indication Corrective Action None e Check the power circuit e Check the supply voltage e Check all fuses and disconnects Control module is not connected properly to power module Cause s Incorrect speed calculation None 1 Remove power 2 Verify that the control module is properly and fully installed on the power module 3 Reapply power Motor i
231. in the drive Options 0 Disabled Default 1 Fault F29 Stop Zero Ref Min Freq Ref Max Freq Ref Key Freq Ref MOP Freq Ref Continu Last col NI AJA A Ww N Rockwell Automation Publication 520 UM001G EN E September 2014 91 Chapter3 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 05 Min Max 0 0 20 0 s Display 0 15 t099 Analog In Filter Sets the level of additional filtering of the analog input signals A higher number increases filtering and decreases bandwidth Each setting doubles the applied filtering 1 2x filter 2 4y filter and so on Values Default 0 Min Max 0 14 Display 1 t100 Sleep Wake Sel Related Parameter s t101 t102 t103 RIVE SNe Drive sleeps if the appropriate analog input drops below the set t101 Sleep Level for the time set in t102 Sleep Time and the drive is running When entering sleep mode the drive ramps to zero and the run indicator on the keypad display flashes to indicate the drive is in sleep mode When the appropriate analog input rises above the set Wake Level the drive wakes and ramps to the co
232. inals The voltage must be zero ATTENTION To avoid an electric shock hazard verify that the voltage 2 Loosen the screw of terminals Safety 1 Safety 2 and Safety 24V S1 S2 S on the control I O terminal block 3 Remove the protective jumper R1 R2 R5 R6 01 02 03 04 05 06 07 08 S1919 9989189888 eleieiegiee es ee 1 s2 St ASR B WM 15 16 17 18 19 V oon Safe Torque Off function is now enabled and the terminals are ready to function as safety inputs Important points to remember about wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control wires should be separated from power wires by at least 0 3 m 1 ft Recommended Wire Type Wire Type Description Min Insulation Rating Shielded Multi conductor shielded cable such as Belden 8770 or equiv 0 750 mm 18 AWG 300V 60 C 140 F 3 conductor shielded 1 Recommendations are for 50 C ambient temperature 75 C wire must be used for 60 C ambient temperature 90 C wire must be used for 70 C ambient temperature See I O Wiring on page 35 for wiring recommendations and Control I O Terminal Designations on page 40 for terminal descriptions If Safety Inputs S1 and S2 are powered by an external 24V source apply it only in SELV system PELV system or low voltage Class
233. input loss has occurred Program t094 Anlg In V Loss or t097 Anlg In mA Loss for desired action when On 2 mA X 1V input loss occurs Off 3 mA 1 5V 13 ParamControl Output is directly controlled by the state of the t070 or t073 Opto Outx Level A value of 0 causes the output to None turn off A value of 1 or greater in this parameter causes the output to turn on 14 NonRecFault Value set in A541 Auto Rstrt Tries is exceeded or None A541 Auto Rstrt Tries is not enabled or e Anon resettable fault has occurred 15 EM Brk Cntrl EM Brake is energized Program t087 EM Brk On Delay and t086 EM Brk Off Delay for desired action None 16 Thermal OL Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 Relay Outx Level It None also energizes if the drive is within 5 C of the drive overheat trip point 17 Amb OverTemp Relay energizes when control module over temperature occurs None 18 Local Active Active when drive P046 P048 or P050 Start Source x is in local keypad control None 19 Comm Loss Active when communication is lost from any comm source with reference or control None 20 Logic In 1 An input is programmed as Logic Input 1 and is active None 21 Logic In 2 An input is programmed as Logic Input 2 and is active None 22 Logic 1 amp 2 Both Logic inputs are programmed and active None 23 Logic 1 or 2 One or both Logic inputs are programmed and o
234. ive fault 11 PointStop P046 Start Source 1 1 5 1 z Keypad D 0 P046 1 P048 2 Digln TrmBIk P048 2 Sets the default control scheme used to start the Pre i P050 drive unless overriden by P048 Start Source 2 or Fels P050 din s owerFlex P050 Start Source 3 5 Ethernet IP 9 1 When active the Reverse key is also active unless disabled by A544 Reverse Disable Q If Digln TrmBIk is selected ensure that the digital inputs are properly configured 3 Setting is specific to PowerFlex 525 drives only P047 Speed Reference 1 16 1 Drive Pot P047 1 P049 2 Keypad Freq P049 5 Sets the default speed command of the drive unless m p P051 overridden by P049 Speed Reference2 or P051 7 Pied m yat nani 2 owerFlex Speed Reference3 5 0 10V Input 1 Setting is specific to PowerFlex 525 drives only 6 4 20mA Input 7 Preset Freq 8 Anlg In Mult 9 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Outpur 13 Step Logic 14 Encoder 15 Ethernet IP 16 Positioning P052 Average kWh Cost 0 00 655 35 0 01 0 00 Sets the average cost per kWh P053 ResetToDefalts 0 3 0 Ready ldle 0 Resets parameters to their factory defaults values After a Reset command the value of this parameter returns to zero 1 Param Reset 2 Factory Rset 3 Power Reset 62 Rockwell Automation Publication 52
235. jumper to 0 20 mA Program with t088 Analog Out Sel Maximum analog value can be scaled with t089 Analog Out High Maximum Load 4 20 mA 525 Q 10 5V 0 10V 1 kQ 10 mA 17 Opto Output 1 Motor Running Program with t069 Opto Out Sel t069 t070 Each Opto Output is rated 30V DC 50 mA Non inductive 1075 18 Opto Output 2 At Frequency Program with t072 Opto Out1 Sel t072 t073 Each Opto Output is rated 30V DC 50 mA Non inductive 1075 19 OptoCommon The emitters of the Optocoupler Outputs 1 and 2 are tied together at Optocoupler Common Electrically isolated from the rest ofthe drive 1 See Footnote 1 on page 37 Rockwell Automation Publication 520 UM001G EN E September 2014 41 Chapter 1 42 Installation Wiring 1 0 Wiring Examples 1 0 Connection Example Potentiometer P047 Speed Reference1 5 0 10V Input 1 10k Q Pot Recommended p 2 W minimum MEE LL 14 lo Analog Input Bipolar Unipolar Voltage Unipolar Current 0 10V 100k Q impedance P047 Speed Reference1 P047 Speed Reference1 P047 Speed Reference1 4 20 mA 250 Q 5 0 10V Input and 5 0 10V Input 6 4 20mA Input impedance t093 10V Bipolar Enbl 1 Bi Polar In x1 2B Ie S Common tte Common Common ol Ile N 15 I Is j x Analog Input PTC Wir
236. l Blocks FAULT i Programmable terminal functions v CD Communications A L Programmable communication functions a Logic PowerFlex 525 only CaS L Programmable logic functions Advanced Display Advanced drive operating conditions Advanced Program em H Remaining programmable functions Allen Bradley J N m etwork functions that are shown only when a comm riri FX l FID E h LILI Pe a m Lee Ns M odifie FAULTCO l Functions from the other groups with values changed from default Fault and Diagnostic Consists of list of codes for specific fault conditions Oo m O r AppView and CustomView LN Ld Functions from the other groups organized for specific Ss SSS applications Control and Navigation Keys Display Display State Description ENET PowerFlex 525 only Off Adapter is not connected to the network Steady Adapter is connected to the network and drive is controlled through Ethernet Flashing Adapter is connected to the network but drive is not controlled through Ethernet LINK PowerFlex 525 only Off Adapter is not connected to the network Steady Adapter is connected to the network but not transmitting data Flashing Adapter is connected to the network and transmitting data LED LED State Description FAULT Flashing Red Indicates drive is faulted
237. lects a preset frequency in Velocity mode P047 P049 P051 Speed Referencex 1 15 See A410 A425 Preset Freq x Selects a preset frequency and position in Positioning mode P047 P049 P051 Speed Referencex 16 See L200 L214 and 06 Step Units x only for PowerFlex 525 drives PF525 only for Digln TermBlk 05 08 IMPORTANT Digital Inputs have priority for frequency control when programmed as Preset Speed and are active See Start Source and Speed Reference Selection on page 46 for more information 8 Jog e When input is present drive accelerates according to the value set in A432 Jog Accel Decel and ramps to the value set in A431 Jog Frequency e When input is removed drive ramps to a stop according to the value set in A432 Jog Accel Decel e Avalid Start command will override this input 9 Jog Forward DigIn TermBlk 08 default Drive accelerates to A431 Jog Frequency according to A432 Jog Accel Decel and ramps to a stop when input becomes inactive A valid Start command will override this input 10 Jog Reverse Drive accelerates to A431 Jog Frequency according to A432 Jog Accel Decel and ramps to a stop when input becomes inactive A valid Start command will override this input 11 Acc Dec Sel2 If active determines which Accel Decel time will be used for all ramp rates except jog Can be used with option 29 Acc Dec Sel3 for additional Accel Decel
238. lex 520 series drives produce DC current in the Installation Requirements Related to EN 6 1800 3 and the EMC Directive e The drive must be earthed grounded as described in Connections and Grounding on page 52 See General Grounding Requirements on page 20 for additional grounding recommendations e Output power wiring to the motor must employ cables with a braided shield providing 7596 or greater coverage or the cables must be housed in metal conduit or equivalent shield must be provided Continuous shielding must be provided from the drive enclosure to the motor enclosure Both ends of the motor cable shield or conduit must terminate with a low impedance connection to earth Drive Frames A E At the drive end of the motor either a The cable shield must be clamped to a properly installed EMC Plate for the drive Kit number 25 EMCI Fx Or b The cable shield or conduit must terminate in a shielded connector installed in an EMC plate conduit box or similar e At the motor end the motor cable shield or conduit must terminate in a shielded connector which must be properly installed in an earthed motor wiring box attached to the motor The motor wiring box cover must be installed and earthed e All control I O and signal wiring to the drive must use cable with a braided shield providing 7596 or greater coverage or the cables must be housed in metal conduit or equivalent shielding must be provided When shielded
239. lity and ease of use compared to BOOTP in configuring the IP address subnet mask and gateway address for the adapter usinga DHCP server IMPORTANT Ifyou are setting your network addresses manually using parameters you must set the appropriate drive or 25 COMM E2P adapter parameter value to 1 Parameters See the respective EtherNet IP adapter user manual for more information Rockwell Automation Publication 520 UM001G EN E September 2014 235 AppendixH EtherNet IP IMPORTANT Regardless of the method used to set the adapter IP address each node on the EtherNet IP network must have a unique IP address To change an IP address you must set the new value and then remove and reapply power to or reset the adapter 236 Rockwell Automation Publication 520 UM001G EN E September 2014 Appendix Induction Motor Tuning Diagrams Control Diagrams This chapter contains various diagrams on the PowerFlex 520 series drive functions and behaviors Speed Reg Sel Diagrams For Motor Tuning Low Speed Mid Speed Control Mode Control Mode High Speed Control Mode Speed Controller Gain Sm AS1S Freq3 BW 7 ss s oE ee Bs AS13 Freq2BWI gt a5 nun ae EO ASI Freq 1 BW A510 I e A512 Freq Hz i Freq 2 4514 Freq 3 Low Speed Mid Speed High Speed Control Mode Control Mode Control Mode Speed Controller Gain A525 Freq
240. lt Cfg Ref C146 EN Data Out 3 C159 Drv 1 Addr 171 RS485 Node Addr C124 EN Subnet Cfg 3 C135 EN Flt Cfg DL1 C147 EN Data Out 4 C160 Drv2 Addr 172 Comm Loss Action C125 EN Subnet Cfg 4 C136 EN Flt Cfg DL 2 C148 Opt Data In 1 C161 Drv3 Addr 173 Comm Loss Time 126 EN Gateway Cfg 1 C137 EN Flt Cfg DL 3 C149 Opt Data In 2 C162 Drv4 Addr 174 RS485 Format C127 EN Gateway Cfg 2 C138 EN Flt Cfg DL 4 C150 Opt Data In 3 C163 DSII 0 Cfg C175 1 Parameter is specific to PowerFlex 525 drives only 66 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 L182 Stp Logic Time 0 L183 Stp Logic Time 1 L184 Stp Logic Time 2 L185 Stp Logic Time 3 L186 Stp Logic Time 4 L187 Stp Logic Time 5 L190 Stp Logic Time 6 L191 Stp Logic Time 7 L192 Step Units 0 L193 Step Units 1 L194 Step Units 2 L195 Step Units 3 L196 Step Units 4 L197 Step Units 5 L200 Step Units 6 L202 Step Units 7 L204 L206 L208 L210 L212 L214 d362 Motor OL Level d363 Slip Hz Meter d364 Speed Feedback d365 Encoder Speed 1 d367 DC Bus Ripple d368 Output Powr Fctr d369 Torque Current d375 PID1 Fdbk Displ d376 PID1Setpnt Disp d378 PID2 Fdbk Displ d380 PID2 Setpnt Disp d381 Position Status d382 Units Traveled H d383 Units Traveled L d384 Fiber Status d385 Stp Logic Status d386 RdyBit Mode Act d387 d388 d389 d390 d391 d392 Logic Stp Logic 2 Stp Logic 3 Ww Stp
241. m Freq P043 Anlg In 0 10V Lo t091 S Curve A439 Speed Ratio A572 Commanded Freq b002 Maximum Freq P044 Anlg In 0 10V Hi t092 Reverse Disable A544 Motor NP Volts P031 Stop Mode P045 Anlg In4 20mA Lo 1095 Power Loss Mode A548 Motor NP Hertz P032 Start Source 1 P046 Anlg In4 20m4A Hi t096 Half Bus Enable A549 Motor OL Current P033 Speed Reference1 P047 Anlg In mA Loss t097 Bus Reg Enable A550 1 This AppView parameter group is specific to PowerFlex 525 drives only Rockwell Automation Publication 520 UM001G EN E September 2014 69 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 70 This group can store up to 100 parameters Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Basic Display Group b001 Output Freq Related Parameter s b002 b010 P043 P044 P048 P050 P052 Output frequency present at T1 T2 amp T3 U V amp W Does not include slip frequency Values Default Read Only Min Max 0 00 Maximum Freq Display 0 01 Hz b002 Commanded Freq Related Parameter s b001 b013 P043 P044 P048 P050 P052 Value of the active frequency command even if the drive is not running IMPORTANT The frequency c
242. m foil combination shield and 29501 29507 or equivalent tinned copper drain wire e PVC jacket Standard Option 2 Tray rated 600V 90 C 194 F Three tinned copper conductors with XLPE insulation RHH RHW 2 Anixter OLF 7xxxxx or 5 mil single helical copper tape 25 overlap min equivalent with three bare copper grounds in contact with shield e PVC jacket Class amp Il Tray rated 600V 90 C 194 F Three bare copper conductors with XLPE insulation Division amp II RHH RHW 2 Anixter 7V 7xxxx 3G or and impervious corrugated continuously welded equivalent aluminum armor Black sunlight resistant PVC jacket overall Three copper grounds on 10 AWG and smaller Reflected Wave Protection The drive should be installed as close to the motor as possible Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor reflected wave phenomena Refer to Reflected Wave in Wiring and Grounding Guide PWM AC Drives publication DRIVES INOO1 The reflected wave data applies to all carrier frequencies 2 16 kHz For 240V ratings and lower reflected wave effects do not need to be considered Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not
243. mBlk 08 Jog Forward Program with t068 DigIn TermBlk 08 t068 Current consumption is 6 mA a ja This terminal is tied to the RJ 45 port shield Tie this terminal to a clean ground in order to improve noise immunity when using external communication peripherals Q Q This is the signal common for the communication signals S1 Safety 1 Safety input 1 Current consumption is 6 mA S2 Safety2 Safety input 2 Current consumption is 6 mA S Safety 24V 24V supply for safety circuit Internally tied to the 24V DC source Pin 11 11 24V DC Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100 mA 12 10V DC Referenced to Analog Common P047 P049 Drive supplied power for 0 10V external potentiometer Maximum output current is 15 mA 13 x10VIn Not Active For external 0 10V unipolar or 10V bipolar input supply or P047 P049 potentiometer wiper 1062 t063 Input impedance 1065 t066 Voltage source 100 kQ E M3 Allowable potentiometer resistance range 1 10 KQ 14 Analog Common Return for the analog 1 0 Electrically isolated along withthe analog 1 0 from the rest of the drive 15 4 20mA In Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 Q 1062 1063 1065 1066 A459 A471 16 Analog Output OutFreq 0 10 The default analog output is 0 10V To convert a current value t088 t089 change the Analog Output
244. mation 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 e PowerFlex 525 Embedded EtherNet IP Adapter User Manual publication 520COM UMO01 e PowerFlex 25 COMM E2P Dual Port EtherNet IP Adapter User Manual publication 5S20COM UM0023 EtherNet IP adapter PowerFlex 525 drives support both the embedded ATTENTION PowerFlex 523 drives support only the 25 COMM E2P dual port EtherNet IP adapter and the 25 COMM E2P dual port EtherNet IP adapter It is recommended to use Allen Bradley Ethernet RJ45 cables shielded or unshielded catalog number 1585J M8xBJM x for connecting your PowerFlex 520 series drive to an EtherNet IP network There are three methods for configuring the Ethernet IP address e BootP Server Use BootP if you prefer to control the IP addresses of devices using a server The IP address subnet mask and gateway addresses will then be provided by the BootP server e Adapter Parameters Use adapter parameters when you want more flexibility in setting up the IP address or need to communicate outside the control network using a gateway The IP address subnet mask and gateway addresses will then come from the adapter parameters you set e DHCP Dynamic Host Configuration Protocol only with PowerFlex 25 COMM E2P adapter Use DHCP when you want additional flexibi
245. mmanded frequency Inversion can be accomplished by setting Sleep Level to a higher setting than t103 Wake Level ATTENTION Enabling the Sleep Wake function can cause unexpected machine operation during the Wake mode Equipment damage and or personal injury can result if this parameter is used in an inappropriate application In addition all applicable local national and international codes standards regulations or industry guidelines must be considered Options 0 Disabled Default 1 0 10V Input 2 4 20mA Input 3 Command Freq Sleep enabled from 0 10V Analog Input 1 Sleep enabled from 4 20 mA Analog Input 2 Sleep enabled based on drive commanded frequency t101 Sleep Level Sets the analog input level the drive must reach to enter sleep mode Values Default 10 0 Min Max 0 0 100 0 Display 0 1 t102 Sleep Time Sets the analog input time the drive must stay below to enter sleep mode Values Default 0 05 Min Max 0 0 600 0 s Display 0 15 t103 Wake Level Sets the analog input level the drive must reach to wake from sleep mode Values Default 15 0 Min Max 0 0 100 0 Display 0 1 92 Rockwell Automation Publication 520 UM001G EN E September 2014 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 Val
246. mn is reduced by 5 C 9 F for all mounting methods 3 For catalogs 25x D1P4N104 and 25x EOP9N104 the temperature listed under the Maximum with Control Module Fan Kit Derate column is reduced by 10 C 18 F for vertical and vertical with zero stacking mounting methods only 4 Catalogs 25x D1P4N104 and 25x EOP9N104 cannot be mounted using either of the horizontal mounting methods Requires installation of the PowerFlex 520 Series Control Module Fan Kit catalog number 25 FANx 70C i Current Derating Curves Rockwell Automation Publication 520 UM001G EN E September 2014 Vertical Mounting Single Drive Zero Stacking 120 IP30 NEMATT T with Control 120 IP30 NEMAT 7 7 With Control 110 Module Fan Kit 110 Module Fan Ki 100 100 90 IP 20 0pen Type 90 IP 20 0pen Type 80 80 Percentage of Rated Current 96 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Horizontal Floor Mounting Percentage of Rated Current Single Drive 120 with Control 110 Module Fan Kit 100 90 80 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Percentage of Rated Current 96 Percentage of Rated Current 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Zero Stacking 120 With Control 110 Module Fan Kit 100 90 80 IP 20 0pen Type 70 60 50 40 30 35 40 45 50 55 60 65 70 75 80 Am
247. n auxiliary mechanical braking device must be used 4 Freeze Fire When inactive will cause an immediate F094 Function Loss fault Use to safely bypass the drive with an external switching device 4 N SW Enable Works like an interlock that has to be active for the drive to run 43 SherPin1 Dis Disables shear pin 1 but leaves shear pin 2 active If A488 Shear Pin 2 Level is greater than 0 0 A shear pin 2 is enabled 44 Reserved 4 o Reserved 46 Reserved 47 Reserved Rockwell Automation Publication 520 UM001G EN E September 2014 83 Chapter3 Programming and Parameters Options 48 2 Wire FWD only for DigIn TermBlk 02 Digln TermBlk 02 default Select 2 Wire FWD for this input Select this option and set P046 P048 or P050 Start Source x to 2 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 Select this option and set P046 P048 or P050 Start Source x to 2 DigIn TrmBlk to configure Start Source x to a 3 wire start mode 50 2 Wire REV only for DigIn TermBlk 03 Digln TermBlk 03 default Select 2 Wire REV for this input Select this option and set P046 P048 or P050 Start Source x to 2 DigIn TrmBlk to configure Start Source x
248. ncy See the diagram at A567 Max Traverse Values Default 0 005 Min Max 0 00 300 00 s Display 0 015 A569 Traverse Dec Related Parameter s A567 Sets the time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency See the diagram at A567 Max Traverse Values Default 0 005 Min Max 0 00 300 00 s Display 0 015 A570 P Jump Related Parameter s A567 Sets the frequency amplitude that is added to or subtracted from the commanded frequency See the diagram at A567 Max Traverse Values Default 0 00 Hz Min Max 0 00 300 00 Hz Display 0 01 Hz A571 Sync Time Related Parameter s t062 t063 t065 t068 A560 Enables the function that holds the drive at the current frequency even if the commanded frequency changes Used with t062 t063 t065 t068 Digln TermBlk xx 32 Sync Enable r Sync Time y I New Drive 2 Reference E New Drive 1 Reference Speed Sync Bit L Fiber Status Change Ref s Drive 1 and 2 Sync Enable Input Time Values Default 0 0 s Min Max 0 0 3200 0 s Display 0 15 128 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A572 Speed Ratio S drive before changing this parameter Scales the drive speed command Values Default 1 00 Min Max 0
249. nd Circuit Breakers 22 The PowerFlex 520 series drive does not provide branch short circuit protection This product should be installed with either input fuses or an input circuit breaker National and local industrial safety regulations and or electrical codes may determine additional requirements for these installations The tables found on pages 23 26 provide recommended AC line input fuse and circuit breaker information See Fusing and Circuit Breakers below for UL and IEC requirements Sizes listed are the recommended sizes based on 40 C 104 F and the US N E C Other country state or local codes may require different ratings Fusing The recommended fuse types are listed in the tables found on pages 23 26 If available current ratings do not match those listed in the tables provided choose the next higher fuse rating IEC BS88 British Standard Parts 1 amp 2 7 EN60269 1 Parts 1 amp 2 type GG or equivalent should be used e UL UL Class CC T RK1 or J should be used Circuit Breakers The non fuse listings in the tables found on pages 23 26 include inverse time circuit breakers instantaneous trip circuit breakers motor circuit protectors and 140M self protected combination motor controllers If one of these is chosen as the desired protection method the following requirements apply e IEC Both types of circuit breakers and 140M self protected combination motor controllers are acceptable for IE
250. nded for use in safety related applications where the de energized state is considered to be the safe state All of the examples in this manual are based on achieving de energization as the safe state for typical Machine Safety and Emergency Shutdown ESD systems Important Safety Considerations The system user is responsible for e the set up safety rating and validation of any sensors or actuators connected to the system e completing a system level risk assessment and reassessing the system any time a change is made e certification of the system to the desired safety performance level e project management and proof testing e programming the application software and the safety option configurations in accordance with the information in this manual Rockwell Automation Publication 520 UM001G EN E September 2014 225 Appendix G 226 Safe Torque Off Function e access control to the system including password handling e analyzing all configuration settings and choosing the proper setting to achieve the required safety rating IMPORTANT When applying Functional Safety restrict access to qualified authorized personnel who are trained and experienced the machine ifthe door locks while they are in the machine Additional ATTENTION When designing your system consider how personnel will exit safeguarding devices may be required for your specific application Functional Proof Test The PFD and PFH values provid
251. ne or both is active None 24 StpLogic Out Drive enters StepLogic step with Command Word set to enable Logic output None 25 Timer Out Timer has reached the value set in t070 or t073 Opto Outx Level or not timing None 26 Counter Out Counter has reached the value set in t070 or t073 Opto Outx Level or not counting None 27 At Position Drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with A564 Encoder Pos Tol 28 At Home Drive is in Positioning mode and has reached the home position Tolerance is adjusted with A564 Encoder Pos Tol 29 Safe Off Both safe off inputs are active Values Default Opto Out1 Sel 2 Opto Out Sel 1 Min Max 0 29 Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 85 Chapter3 Programming and Parameters Terminal Block Group continued t070 Opto Out1 Level Related Parameter s t069 t072 t073 Opto Out2 Level ird 32 bit parameter PowerFlex 525 only Determines the on off point for the digital outputs when t069 or t072 Opto Outx Sel is set to the values shown below Min Max Value Range Based On Opto Outx Sel Setting 6 0 500Hz 10 0 10096 16 0 1 9999s 20 T0 1 7 10 18096 11 0 1 17 1 9999 counts 26 0 150 8 10 815V 13 0 800 18 0 180 Values Default 0 Min Max 0 9999 Display 1 t075 Op
252. nerally Slip and Droop would not both be used but if both are enabled they simply subtract from each other Typically used in load sharing schemes Values Default 0 0 Hz Min Max 0 0 10 0 Hz Display 0 1Hz M42 Accel Time 2 Time for the drive to ramp from 0 0 Hz to P044 Maximum Freq if Accel Time 2 is selected Accel Rate Maximum Freq Accel Time Related Parameter s P044 Maximum Freq 0 9 Accel Time x la Time mI Decel Time x la 0 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A443 Decel Time 2 Time for the drive to ramp from P044 Maximum Freq to 0 0 Hz if Decel Time 2 is selected Decel Rate Maximum Freq Decel Time Related Parameter s P044 Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 Rockwell Automation Publication 520 UM001G EN E September 2014 111 Chapter3 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 0 015 A445 Decel Time 3 A447 Decel Time 4 Sets the rate of deceleration for all speed decreases when selected by digital inputs Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A448 Skip Frequency 1 Related Parameter s A449 A451 A453 A455 A45
253. nergized the pre charge relay opens and the drive coasts to a stop 31 Inertia Dcel Forces drive into Inertia Ride Through state The drive attempts to regulate the DC bus at the current level 32 Sync Enable Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization When this input is released the drive accelerates to the commanded frequency in A571 Sync Time 33 Traverse Dis When an input is programmed the traverse function is disabled while this input is active See A567 Max Traverse 34 Home Limit In Positioning mode indicates the drive is at the home position See Appendix E for more information on Positioning 35 Find Home In Positioning mode causes the drive to return to the Home position when a Start command is issued Uses A562 Find Home Freq and A563 Find Home Dir until the Home Limit input is activated If it passes this point it then runs inthe reverse direction at 1 10th the frequency of Find Home Freq until the Home Limit is activated again As long as this input is active any start command causes the drive to enter the homing routine Only functions if in Positioning mode Once the Find Home routine has finished the drive stops See Appendix E for more information on Positioning w an Hold Step In Positioning mode overrides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its p
254. nnected Components Workbench to simplify setup instead of manually configuring the parameters Rockwell Automation Publication 520 UM001G EN E September 2014 197 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Velocity StepLogic Using IMPORTANT This function is specific to PowerFlex 525 drives only Timed Steps To activate this function set one of the three speed reference sources parameter P047 P049 or POS1 Speed Referencex to 13 Step Logic and activate that speed reference source Three parameters are used to configure the logic speed reference and time for each step e Logic is defined using parameters L180 L187 Stp Logic x e Preset Speeds are set with parameters A410 A417 Preset Freq 0 7 e Time of operation for each step is set with parameters L190 L197 Stp Logic Time x The direction of motor rotation can be forward or reverse Using Timed Steps StepO Step1 Step2 Step3 Step4 Step5 Step6 Step7 a Forward 0p Reverse w Time Velocity StepLogic Sequence e Sequence begins with a valid start command e A normal sequence begins with Step 0 and transition to the next step when the corresponding StepLogic time has expired e Step 7 is followed by Step 0 e Sequence repeats until a stop is issued or a fault condition occurs Velocity StepLogic Using A IMPORTANT This function is specific to PowerFlex 525 drives only Basic Logic Functions
255. not Start from Start or Run Inputs wired to the terminal block Corrective Action Clear fault Press Stop if P045 Stop Mode is set to a value between 0 and 3 Cycle drive power Set A551 Fault Clear to 1 Reset Fault or 2 Clear Buffer Cycle digital input if t062 t063 t065 t068 Digln TermBlk xx is set to 13 Clear Fault Incorrect programming P046 P048 P050 Start Source x is set incorrectly 1062 t063 DigIn TermBlk 02 03 is set incorrectly None Check parameter settings Incorrect input wiring See page 42 for wiring examples e 2 wire control requires Run Forward Run Reverse or Jog input e 3 wire control requires Start and Stop inputs Stop input is always required None e Wire inputs correctly and or install jumper Ifthe PowerFlex 525 Safe Torque Off function is used verify that inputs are active Incorrect Sink Source jumper setting None Set switch to match wiring scheme Rockwell Automation Publication 520 UM001G EN E September 2014 151 Chapter4 Troubleshooting Drive does not respond to changes in speed command Cause s Indication The drive Run indicator is Corrective Action No value is coming from the source of the command lit and output is 0 Hz e Check b012 Control Source for correct source Ifthe source is an analog input check wiring and use a meter to check for presence of signal Check
256. ns two files e GUIDE PDF This file contains links to relevant product documentation and software downloads BB PF52XUSB EXE This file is an application to flash upgrade firmware or upload download a parameter configuration It is not possible to delete these files or add more to the drive Rockwell Automation Publication 520 UM001G EN E September 2014 63 Chapter2 Start Up Double click on the PF52XUSB EXE file to launch the USB utility application The main menu is displayed Follow the program instructions to upgrade the firmware or upload download configuration data B PowerFlex 520 Series USB Application Drive Peripheral PowerFlex 525 1P240V 50HP 1 3 Only one control module can be connected via USB at any time Upload a configuration from the drive or peripheral Download a configuration to the drive or peripheral Flash the drive or peripheral To obtain the latest version of Connected Components Workbench go to http ab rockwellautomation com Programmable Controllers Connected Components Workbench Software For the latest drive or peripheral firmware updates go to http www ab com support abdrives webupdate index html Forthe latest product manuals go to http Aliterature rockwellautomation com idc aroups public documents webassets browse category hcst IMPORTANT Make sure your PC is powered by an AC power outlet or has a fully charged battery before starting any operation This prevents
257. occur b007 Fault 1 Code the most recent fault Repetitive faults are only recorded once See Fault and Diagnostic Group for more information Values Default Read Only Min Max F0 F127 Display FO b010 Process Display Related Parameter s b001 A481 A482 WT 32 bit parameter Output frequency scaled by Process Disp Hi and Process Disp Lo Values Default Read Only Min Max 0 9999 Display 1 b012 Control Source Related Parameter s P046 P047 P048 P049 P050 P051 1062 t063 t065 t068 L180 L187 M10 A425 Active source of the Start Command and Frequency Command Normally defined by the settings of P046 P048 P050 Start Source x and P047 P049 P051 Speed Referencex See Start and Speed Reference Control on page 46 for more information FIFTH LaL LALALA Example Start Command Source Digit1 Display reads Description 1 Keypad 2 Digln TrmBlk Parameters t062 t063 t065 t068 2004 Start source comes from Network Opt and Frequency source is Purge rae m 113 Start source comes from Serial DSI and Frequency source comes from PID1 Output 5 EtherNet D2 155 Start source and Frequency source comes from EtherNet IP Frequency Command Source Digit2 amp 3 092 Start source comes from Digln TrmBIk and Frequency source from 0 10V Input oiher i 011 Start source comes from Keypad and Frequency source comes from Drive Pot 02 Keypad 03 Se
258. of times the drive attempts to reset a fault and restart See Chapter 4 for more information on faults and fault codes Clear a Type 1 fault and restart the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A541 Auto Rstrt Tries to a value other than 0 2 Set A542 Auto Rstrt Delay to 0 ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Values Default 0 Min Max 0 9 Display 1 A542 Auto Rstrt Delay Related Parameter s A541 Sets the time between restart attempts if A541 Auto Rstrt Tries is not zero Values Default 1 05 Min Max 0 0 120 0 s Display 0 15 A543 Start At PowerUp O Kay drive before changing this parameter Enables disables drive start on power up without a Start command being cycled Requires a digital input configured for Run or Start and a valid start contact ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or indust
259. ol Power supply ACline input power PF 525 H 24V DC Stop Stop L O Start Start Dig comm Gate control circuit 1 Enclosure Recommended Note External wiring failure modes must be considered as described in EN ISO 13849 2 Enclosure or other measure to exclude these failure modes should be used 2 Each safety input draws 6 mA from the supply Circuit Status Circuit shown with guard door closed and system ready for normal drive operation Operating Principle This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits 13 S14 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 will cause the Safe Torque Off Enable circuit to trip and the motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function A single fault detected on the PowerFlex 525 safety enable redundant inputs will result in the lock out of the drive and will not cause loss of the safety function Rockwell Automation Publication 520 UM001G EN E September 2014 Safe Torque OffFunction Appendix
260. ommand can come from a number of sources See Start and Speed Reference Control on page 46 for more information Values Default Read Only Min Max 0 00 Maximum Freq Display 0 01 Hz b003 Output Current Output current present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01 A b004 Output Voltage Related Parameter s P031 A530 A534 Output voltage present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 0 Drive Rated Volts Display 0 1V b005 DCBus Voltage Filtered DC bus voltage level of the drive Values Default Read Only Min Max 0 1200VDC Display 1VDC b006 Drive Status Related Parameter s A544 Present operating condition of the drive HHHH 1 True Active 0 False Inactive Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive Digit 5 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 00000 11111 Display 00000 Rockwell Automation Publication 520 UM001G EN E September 2014 71 Chapter3 Programming and Parameters Basic Display Group continued b007 Fault 1 Code Related Parameter s F604 F610 b008 Fault 2 Code b009 Fault 3 Code A code that represents a drive fault Codes appear in these parameters in the order they
261. on and triggers a limit switch that resets the counter e Parameters are set to the following options t065 DigIn TermBlk 05 20 Counter In t066 DigIn TermBlk 06 22 Reset Countr t076 Relay Out Sel 26 Counter Out t077 Relay Out1 Level 5 0 Counts 200 Rockwell Automation Publication 520 UM001G EN E September 2014 Velocity StepLogic Parameters Output Frequency Start Relay Out Photo Eye Digin TermBlk 05 Counter In Digin TermBlk 06 Reset Counter Limit Switch Velocity StepLogic Basic Logic and Timer Counter Functions Appendix D gt gt gt gt gt gt gt Code Descriptions for Parameters L180 L187 Digit 4 0 Digit 4 Defines the action during the step currently executing Setting Mes Parameter StepLogic Output State Commanded Direction se 0 1 Off FWD 1 1 Off REV 2 1 Off No Output 3 1 On FWD 4 1 On REV 5 1 On No Output 6 2 Off FWD 7 2 Off REV 8 2 Off No Output 9 2 On FWD A 2 On REV b 2 On No Output Digit 3 Defines what step to jump to or how to end program when the logic conditions specified in Digit 2 are met Setting Logic Jump to Step 0 Jump to Step 1 Jump to Step 2 Jump to Step 3 Jump to Step 4 Jump to Step 5 Jump to Step 6 Jump to Step 7 End Progr
262. on drive ensure isolation of mains supply from line inputs R S T L1 L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations
263. on of other drives that share the same 0 Common connection may occur Multiple Analo es LER Cuna cooooooo ooooooo loooooooo 12 13 14 13 14 1314 9900000 b09900000 009900000 Remote Potentiometer 7 77 Optional Ground Connection When connecting a single potentiometer to multiple drives it is important to connect 1 0 Terminal 14 common together for all drives 1 0 Terminal 14 common and 1 0 Terminal 13 potentiometer wiper should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly Rockwell Automation Publication 520 UM001G EN E September 2014 45 Chapter1 Installation Wiring Start and Speed Reference Control 46 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 Referencel However various inputs can override this selection See below for the override priority Drive will start and run at Purge Speed Purge Input Enabled AND Active Direction is always FORWARD Drive will start and run at Jog Speed Direction is from Terminal Jog Input Enabled Drive stopped Block REV terminal 03 AND Active NOT running Comms OR FWD REV determined by Jog FWD Jog REV
264. one 1 At Frequency Drive reaches commanded frequency 0 5 Hz above 1 0 Hz below 2 MotorRunning Motor is receiving power from the drive None 3 Reverse Drive is commanded to run in reverse direction None 4 Motor Overld Motor overload condition exists 100 ms time delay on or off 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from 100 ms time delay on or off occurring 6 Above Freq Drive exceeds the frequency Hz value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 7 Above Cur Drive exceeds the current 96 Amps value set in t070 or t073 Opto Outx Level 100 ms time delay on or off IMPORTANT Value for t070 or t073 Opto Outx Level must be entered in percent of drive rated output current 8 Above DCVolt Drive exceeds the DC bus voltage value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 9 Retries Exst Value set in A541 Auto Rstrt Tries is exceeded None 10 Above Anlg V Analog input voltage 0 10V input exceeds the value set in t070 or t073 Opto Outx Level 100 ms time delay on or off IMPORTANT Do not use if t093 10V Bipolar EnbI is set to 1 Bi Polar In 11 Above PF Ang Power Factor angle exceeds the value set in t070 or t073 Opto Outx Level 100 ms time delay on or off 12 Anlg In Loss Analog
265. onnected to one of the ground terminals on the drive Shield Termination SHLD Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield The motor cable shield connected to one of these terminals drive end should also be connected to the motor frame motor end Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal The earthing plate or conduit box option may be used with a cable clamp for a grounding point for the cable shield When shielded cable is used for control and signal wiring the shield should be grounded at the source end only not at the drive end RFI Filter Grounding Using a drive with filter may result in relatively high ground leakage currents Therefore the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded bonded to the building power distribution ground Ensure that the incoming supply neutral is solidly connected bonded to the same building power distribution ground Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection Some local codes may require redundant ground connections The integrity of all connections should be periodically checked Rockwell Automation Publication 520 UM001G EN E September 2014 21 Chapter Installation Wiring Fuses a
266. op Mode 79 Added Important table to parameter P046 P048 P050 Start Source x 80 Updated entries for Maximum Output column of parameter t088 Analog Out Sel from 89 200 Drive Rated FLA to 200 Drive Rated Current Added table of recommended minimum Encoder PPR to parameter A536 Encoder PPR 122 Updated Intermittent Overload specification for PowerFlex 523 158 Added catalog numbers for replacement EMC cores 170 Updated 1 0 Terminals C1 and C2 wiring information on noise immunity 190 Added recommended Ethernet cables to description of Appendix H 235 General maintenance updates Throughout manual Rockwell Automation Publication 520 UM001G EN E September 2014 3 Summary of Changes Notes 4 Rockwell Automation Publication 520 UM001G EN E September 2014 Overview Installation Wiring Start Up Programming and Parameters Table of Contents Preface Who Should Use this Manual 5 IR Ree EE MEER 9 Recommended Docunentationc vx oder RU Ere UU dees PLA 9 Manual Conventions 225554 23A TERT TREE AE RA TERE 10 Drive Frame SIZES a ccc ie ece re temere eene b ea ee dede 11 General Precautions evee a oon eod ace ede notet dated 12 Catalog Number Explanation i eee ERE 13 Chapter 1 Mounting Considerations see tovek waa ack oie ede a n RW eh 15 AG Supply Source Considerations c eet Een 19 General Grounding Requirements ac eesconv enna eene e ab eic 20 Fuses and Circuit Breakers iiid tel cU Rh PELA LAUS Rie 22
267. or fault condition Options 1 Keypad Start Source 1 default 2 Digin TrmBIk Start Source 2 default 3 Serial DSI Start Source 3 default for PowerFlex 523 4 Network Opt 5 EtherNet Ip Start Source 3 default for PowerFlex 525 1 Select this setting if using the optional PowerFlex 25 COMM E2P 25 COMM D or 25 COMM P adapters as the start source 2 Setting is specific to PowerFlex 525 drives only P047 Speed Reference1 Related Parameter s C125 P049 Speed Reference2 P051 Speed Reference3 Selects the source of speed command for the drive Changes to these inputs take effect as soon as they are entered P047 Speed Reference1 is the factory default speed reference unless overridden See Start and Speed Reference Control on page 46 for more information Options 1 Drive Pot Speed Reference1 default Keypad Freq Serial DSI Speed Reference3 default for PowerFlex 523 Network Opt 0 10V Input Speed Reference2 default 4 20mA Input Preset Freq Anlg In Mult MOP Pulse Input PID1 Output 12 PID2 Output 13 Step Logic 14 Encoder 15 EtherNet Ip 2 Speed Reference3 default for PowerFlex 525 16 Positioning Referencing from A558 Positioning Mode wo CO N AJ A A wl N 1 Select this setting if using the optional PowerFlex 25 COMM E2P 25 COMM D or
268. or horizontal mounting E 25 FAN2 70C Incremental Encoder Input Option Item Description Catalog No Incremental Encoder Incremental encoder input option board 25 ENC 1 Bulletin 160 to PowerFlex 520 Series Mounting Adapter Plate B160 Frame Item Description Size Catalog No Mounting Adapter Plate For use with drive when replacing Bulletin 160 drives in 25 MAP FA existing installations to a PowerFlex 520 Series drive Select 25 MAP FB the catalog number based on the frame size of your Bulletin 160 drive Rockwell Automation Publication 520 UM001G EN E September 2014 167 Appendix B 168 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 e Power Module e Power Module Front Cover Power Terminal Guard e Heatsink Fan Output Ratings Normal Duty Heavy Duty Output Input Frame HP kW HP kW Current A Voltage Range Size Catalog No 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2 1 6 85 132 A 25 PM1 V1P6 0 5 0 4 0 5 0 4 2 5 85 132 A 25 PM1 V2P5 1 0 0 75 1 0 0 75 48 85 132 B 25 PM1 V4P8 1 5 1 1 1 5 1 1 6 0 85 132 B 25 PM1 V6P0 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 0 25 0 2 0 25 0 2
269. osition until released While in Hold the drive ignores any input command which would normally result in a move to a new step Timers continue to run Therefore when the Hold is removed the drive must see any required digital inputs transition even if they already transitioned during the hold but it does not reset any timer See Appendix E for more information on Positioning v2 7 Pos Redefine In Positioning mode resets the home position to the current position of the machine See Appendix E for more information on Positioning 38 Force DC If the drive is not running causes the drive to apply a DC Holding current A435 DC Brake Level ignoring A434 DC Brake Time while the input is applied w Mo Damper Input When active drive is allowed to run normally When inactive drive is forced into sleep mode and is prevented from accelerating to command speed purge Starts the drive at A433 Purge Frequency regardless of the selected control source Supersedes the keypad Control function as well as any other control command to take control of the drive Purge can occur and is operational at any time whether the drive is running or stopped regardless of the selected logic source selection If a valid stop other than from comms or SW enable is present the drive will not start on the purge input transition ATTENTION If a hazard of injury due to movement of equipment or material exists a
270. ource 1 Set to 3 Serial DSI if Start is controlled from the network page 80 P047 Speed Reference Set to 3 Serial DSI if the Speed Reference is controlled from the network page 80 C123 RS485 Data Rate Setsthe data rate for the RS485 DSI Port All nodes on the network must be page 94 setto the same data rate C124 RS485 Node Addr Sets the node address for the drive on the network Each device on the page 94 network requires a unique node address C125 Comm Loss Action Selects the drive s response to communication problems page 94 C126 Comm Loss Time Sets the time that the drive will remain in communication loss before the page 94 drive implements C125 Comm Loss Action C127 Comm Format Sets the transmission mode data bits parity and stop bits for the RS485 DSI page 95 Port All nodes on the network must be set to the same setting C121 Comm Write Mode Set to 0 Save when programming drive page 94 Set to 1 RAM only to only write to volatile memory Rockwell Automation Publication 520 UM001G EN E September 2014 Supported Modbus Function Codes Writing 06 Logic Command Data RS485 DSI Protocol Appendix C The peripheral interface DSI used on PowerFlex 520 series drives supports some of the Modbus function codes Supported Modbus Function Codes Modbus Function Code Decimal Command 03 Read Holding Registers 06 Preset Write Single Regist
271. peed Reg Sel is set to 1 Manual these parameters can be changed Values Default 0 100 s Min Max 0 000 10 000 s Display 0 001 s Rockwell Automation Publication 520 UM001G EN E September 2014 119 Chapter3 Programming and Parameters A530 Boost Select Advanced Program Group continued Sets the boost voltage 96 of P031 Motor NP Volts and redefines the V Hz curve Only used for V Hz and SVC control modes Maximum Voltage can be set anywhere If itis gt Motor NP Volts then it defines a point on the V Hz curve 100 Maximum Voltage can be set anywhere If itis lt Motor NP Volts then it functions as a limit only does not change the V Hz curve 96 Motor NP Volts v Settings 5 14 EU If itis lt Motor NP Hertz then it functions as a limit only 50 f nwa 1 2 Motor NP Hertz l Motor NP Hertz 50 i Maximum Freq can be set anywhere 4 Maximum Freq can be set anywhere If itis gt Motor NP Hertz then it defines a does not change the V Hz curve point on the V Hz curve Related Parameter s b004 P031 P032 P039 Options 0 Custom V Hz 1 30 0 VT 35 0 VT 40 0 VT Fan Pump Curves Variable Torque 45 0 VT 0 0 no IR Ni wm e wl N 0 0 Default for 400V and 600V drives 5 HP and above 7 25 0 Default for 200V drives
272. product 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 No No B No No 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 No Input Output B Yes Yes Output only No No Input Output 200 240V AC 15 10 1 Phase Input with Internal EMC Filter 0 230V 3 Phase Output A ui P al Yes No No B Yes No No 200 240V AC 15 10 3 Phase Input with External EMC Filter 0 230V 3 Phase Output A Yes Yes Output only No No Input Output B Yes Yes Output only No No Input Output C Yes Yes Output only No No Input Output D Yes Yes No No No Input only E Yes Yes Output only No No Input only 380 480V AC 15 10 3 Phase Input with External EMC Filter 0 460V 3 Phase Output A Yes Yes No No No Input Output B Yes Yes No No No Input Output C Yes Yes No No No Input only D Yes Yes Output only No No Input Output E Yes Yes No Yes No Input Output 380 480V AC 15 10 3 Phase Input with Internal EMC Filter 0 460V 3 Phase Output A is r No No Input Output B s s No No Input Output C No No Input Output D No No Input Output E No No Input Output 525 600V AC 15 10 3 Phase Input with External EMC Filter 0 575V 3 Phase Output A Yes Yes No No No Input Output B Yes Yes No No No Input Output C Yes Y
273. r control mode speed regulator is set automatically or manually Parameters A521 4526 are set automatically by this parameter Options 0 Automatic Default 1 Manual 118 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A510 Freq 1 A512 Freq2 A514 Freq3 PF 525 PowerFlex 525 only Sets the Vector control mode frequency Values Default Freq 1 8 3396 Freq 2 15 0096 Freq 3 20 0096 Min Max 0 00 200 00 Display 0 01 A511 Freq 1 BW A513 Freq 2 BW A515 Freq 3 BW PF 525 PowerFlex 525 only Speed control loop bandwidth for Vector control mode Values Default 10 Hz Min Max 0 40 Hz Display 1Hz A521 Freq 1 Kp Related Parameter s A509 A510 A523 Freq2 Kp A525 Freq3 Kp PowerFlex 525 only Sets P gain of Vector control mode when in frequency region 1 2 or 3 for faster speed response during dynamic state where motor is still accelerating If A509 Speed Reg Sel is set to 1 Manual these parameters can be changed Values Default 100 096 Min Max 0 0 500 0 Display 0 1 A522 Freq 1 Ki Related Parameter s A509 A510 A524 Freq 2 Ki A526 Freq 3 Ki PF 525 PowerFlex 525 only Sets l gain of Vector control mode when in frequency region 1 2 or 3 for faster speed response during steady state where motor is at its rated speed If A509 S
274. rameters Advanced Program Group continued M95 Drive OL Mode Determines how the drive handles overload conditions that would otherwise cause the drive to fault Options 0 Disabled 1 Reduce CLim 2 Reduce PWM 3 Both PWM 1st Default A496 IR Voltage Drop Related Parameter s P040 Value of volts dropped across the resistance of the motor stator autotune for induction motor Values Default Based on Drive Rating Min Max 0 0 600 0VAC Display 0 1VAC A497 Flux Current Ref Related Parameter s P040 This is the current necessary for full motor flux The value should be set to the full speed no load current of the motor Values Default Based on Drive Rating Min Max 0 00 Drive Rated Amps x 1 4 Display 0 01A A498 Motor Rr PF 525 PowerFlex 525 only Rotor resistance of induction motor Values Default Based on Drive Rating Min Max 0 00 655 35 ohm Display 0 01 ohm A499 Motor Lm PF 525 PowerFlex 525 only Mutual Inductance of induction motor Values Default Based on Drive Rating Min Max 0 0 6553 5 mH Display 0 1 mH A500 Motor Lx PowerFlex 525 only Leakage Inductance of induction motor Values Default Based on Drive Rating Min Max 0 0 6553 5 mH Display 0 1 mH A509 Speed Reg Sel Related Parameter s A521 A522 A523 A524 A525 A526 PowerFlex 525 only Determines if PI gain of the Vecto
275. red 15 EM Brk Cntrl EM Brake is energized Program t087 EM Brk On Delay and t086 EM Brk Off Delay for desired action None 16 Thermal OL Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 Relay Outx Level It None also energizes if the drive is within 5 C of the drive overheat trip point 17 Amb OverTemp Relay energizes when control module over temperature occurs None 18 Local Active Active when drive P046 P048 or P050 Start Source x is in local keypad control None 19 Comm Loss Active when communication is lost from any comm source with reference or control None 20 Logic In TU An input is programmed as Logic Input 1 and is active None 21 Logic In 240 An input is programmed as Logic Input 2 and is active None 22 Logic 1 amp rau Both Logic inputs are programmed and active None 23 Logic 1 or 27 One or both Logic inputs are programmed and one or both is active None 24 StpLogic Out 7 Drive enters StepLogic step with Command Word set to enable Logic output None 25 Timer Out Timer has reached the value set in t077 or t082 Relay Outx Level or not timing None 26 Counter Out Counter has reached the value set in t077 or t082 Relay Outx Level or not counting None 27 At Position 7 Drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with A564 Encoder Pos Tol 28 At Home Drive is in Positioning mode and has reache
276. red drives are available however you must verify that the application will support a filtered drive 2 These drive ratings do not come with a heatsink cooling fan and are in accordance with design specifications Dynamic Brake Resistors Drive Ratings Input Voltage 100 120V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase Rockwell Automation Publication 520 UM001G EN E September 2014 MM esistance esistance E KW Q 10 Q 5 Catalog No 0 025 10 2 56 91 AK R2 091P500 05 04 56 91 AK R2 091P500 10 1075 56 91 AK R2 091P500 15 11 41 91 AK R2 091P500 025 10 2 56 91 AK R2 091P500 05 04 56 91 AK R2 091P500 10 1075 56 91 AK R2 091P500 20 0115 M 91 AK R2 091P500 30 22 2 47 AK R2 047P500 Accessories and Dimensions Appendix B Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Input Volt HP kW dd Q 10 Q 5 Catalog No 0 200 240V 025 0 2 56 91 AK R2 091P500 50 60 Hz 05 04 56 91 AK R2 091P500 3 Phase 10 1075 56 91 AK R2 091P500 2 0 15 41 91 AK R2 091P500 30 122 32 47 AK R2 047P500 50 40 18 47 AK R2 047P500 75 55 16 30 AK R2 030P1K2 100 17 5 14 30 AK R2 030P1K2 15 0 11 0 n 15 AK R2 030P 1120 20 0 150 10 15 AK R2 030P1K2 380 480V 0 5 04 89 360 AK R2 360P500 50 60 Hz 10 1075 89 360 AK R2 360P500 3 Phase 2 0 1 5 89 360 AK R2 360P5
277. rform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware 3 This fault may be cleared by the auto restart routine and will be attempted only once It ignores the value set in parameter A541 Auto Rstrt Tries The drive is designed to start from the keypad when shipped For a basic test of drive operation Remove all user I O wire Verify safety terminals S1 S2 and S jumper is in place and tightened 1 2 3 Verify wire jumper is in place between I O terminals 01 and 11 4 Verify that the three jumpers are in their proper default positions on the control board See PowerFlex 525 Control I O Wiring Block Diagram on page 39 for more information 5 Reset default parameter values by setting P053 Reset Defalts to 2 Factory Rset 6 Ifsafe to do so for your application press Start on drive keypad Drive will run according to the speed potentiometer Rockwell Automation Publication 520 UM001G EN E September 2014 Cause s No output voltage to the motor Troubleshooting Chapter 4 Motor does not Start Indication Corrective Action None Check the power circuit Check the supply voltage e Check all fuses and disconnects Check the motor Verify that the motor is connected properly Check the control input signals e Verify that a Start signal is present If 2 Wire control is used verify that either the Run Forward or Run Reverse signal is a
278. rial DSI 04 Network Opt 05 0 10V Input 06 4 20mA Input 07 Preset Freq Parameters A410 A425 08 Anlg In Mult 09 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 13 Step Logic Parameters L180 L187 14 Encoder 15 EtherNet IP2 16 Positioning Frequency Command Source Digit 4 0 Other Digit 2 amp 3 are used Digit 4 is not shown 1 Jog 2 Purge Not Used 1 Select this setting if using the optional PowerFlex 25 COMM E2P 25 COMM D or 25 COMM P adapters as the Start source and or Frequency source 2 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0000 2165 Display 0000 72 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Basic Display Group continued b013 Contri In Status Related Parameter s b002 P044 P045 State of the digital terminal blocks 1 3 and DB transistor IMPORTANT Actual control commands may come from a source other than the control terminal block ninininin LILA LALALA 1 Closed State 0 Open State Digln TBIk 1 Digit 1 Digln TBIk 2 Digit 2 Digln TBIk 3 Digit 3 DB Trans On Digit 4 Not Used 1 The DB Transistor on indication must have a 0 5 s hysteresis It will turn on and stay on for at least 0 5 s every time the DB transistor is turned on
279. riate user manual Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node ATTENTION Never attempt to connect a Power over Ethernet PoE cable to the RS485 port Doing so may damage the circuitry Network Wiring Diagram Example PowerFlex525 PowerFlex523 PowerFlex 525 ode n Master Node 1 Node 2 TxRxD DRD 4 DRD 4 120 ohm resistor FRONT 120 ohm resistor m s M DAD s Shield y Shield y Shield aul ONS aa aa RS485 RS485 DSI DSI AK UO RJ45 182P__ L LU TxRxD TxRxD TRD O S TRD SI R LT S L2 NS WT 7L s2 WLIW w m DC DC BR DC DC BR BR BR IMPORTANT The shield is connected at ONLY ONE end of each cable segment Rockwell Automation Publication 520 UM001G EN E September 2014 189 AppendixC R5485 DSI Protocol Parameter Configuration 190 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
280. rinciple This is a dual channel system with monitoring of the Safe Torque Off circuit and drive Opening the guard door will switch the input circuits S11 S12 amp S21 S22 to the Minotaur monitoring safety relay unit The output circuits 13 14 amp 23 24 amp 33 34 will cause the output contact and Safe Torque Off Enable circuit to trip and the motor will coast to stop To restart the drive the Minotaur safety relay must first be reset followed by a valid start command to the drive Fault Detection A single fault detected on the Minotaur safety input circuits will result in the lock out of the system at the next operation and will not cause loss of the safety function Rockwell Automation Publication 520 UM001G EN E September 2014 Safe Torque OffFunction Appendix G PowerFlex 525 Certification for Safe Torque Off A TUVRheinland ZERTIFIKAT EC Type Examination Certificate CERTIFICATE Reg No 04 205 5249 12 Product tested Safety Function Safe Torque Certificate Rockwell Automation Off STO within the adjustable holder 6400 West Enterprise Drive Frequency AC Drive PowerFlex Mequon WI 53092 525 USA Type designation PowerFlex 525 25B 120V Manufacturer see certificate holder 240V 400 480V and 600V Codes and standards EN 61800 5 2 2007 EN ISO 13849 1 2008 AC 2009 forming the basis of EN 61800 5 1 2007 in extracts EN 60204 1 2006 A1 2009 in testing EN 61800 3 2004 extracts EN 62061 2005 IEC 61
281. ription 0 0 10V Input Selects the 0 10V Input default setting Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 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 3 Network Opt The reference word from a communication network option becomes the PID Reference 4 PulseInput Pulse train will be used as an input for the PID Feedback 5 Encoder Encoder will be used as an input for the PID Feedback 6 Ethernet IP Ethernet IP will be used as an input for the PID Feedback 1 Setting is specific to PowerFlex 525 drives only scale or invert Parameters t091 Anlg In 0 10V Lo and 1092 Anlg In 0 10V Hi are used to an analog PID Reference or PID Feedback Scale Function For a 0 5V signal the following parameter settings are used so that a OV signal 0 PID Reference and a 5V signal 100 PID Reference e t091 Anlg In 0 10V Lo 0 096 t092 Anlg In 0 10V Hi 50 0 A459 PID 1 Ref Sel 5 0 10V Input 12 10 28 6 ga EET a m 0 10 20 30 40 50 60 70 80 90 100 PID Reference 96 Invert Function For a 4 20 mA signal the following parameter settings are used so that a 20 mA signal 0 PID Reference and a 4 mA signal 100 PID Reference e 1092 Anlg In4 20mA Lo 1
282. riting 06 Drive Parameters Additional Information 196 Drive Error Codes Logic Status Address Decimal Value Decimal Description 2101H 8449 125 Flash Update Required 126 Non Recoverable Error 127 DSI Flash Update Required The PowerFlex 520 series Drive Operational Values can be read through the network by sending Function Code 03 reads to register addresses 2102H 210AH Drive Operational Values Reference Address Decimal Description 2102H 8450 Frequency Command xxx xx Hz 2103H 8451 Output Frequency xxx xx Hz 2104H 8452 Output Current xxx xx A 2105H 8453 DC BUS Voltage xxxV 2106H 8454 Output Voltage xxx xV To access drive parameters the Modbus register address equals the parameter number For example a decimal 1 is used to address Parameter b001 Output Freq and decimal 41 is used to address Parameter P041 Accel Time 1 See http www ab com drives for additional information Rockwell Automation Publication 520 UM001G EN E September 2014 Appendix D Velocity StepLogic Basic Logic and Timer Counter Functions Four PowerFlex 520 series logic functions provide the capability to program simple logic functions without a separate controller e Velocity StepLogic Function specific to PowerFlex 525 drives only Steps through up to eight preset speeds based on programmed logic Programmed logic can include conditions that
283. rive is 70 C 18 Rockwell Automation Publication 520 UM001G EN E September 2014 AC Supply Source Considerations Installation Wiring Chapter 1 Ungrounded Distribution Systems referenced to ground These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system ATTENTION Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground ATTENTION PowerFlex 520 series drives contain protective MOVs that are Disconnecting MOVs To prevent drive damage the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system IT mains where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect these devices remove the jumper shown in the diagrams below 1 Turn the screw counterclockwise to loosen 2 Pull the jumper completely out of the drive chassis 3 Tighten the screw to keep it in place Jumper Location Typical Power Module IMPORTANT Tighten screw after jumper removal Phase to Ground MOV Removal dies S ACInput p T L3 O Jumper 1 1 1 1 N w 4 Rockwell Automation Publication 520 UM001G EN E September 2014 19 Chapter1 Installation Wiring General Grounding Requirements 20
284. rs 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 basic logic 197 198 counter 197 200 drive 57 60 encoder 203 Ethernet 235 homing 210 parameters 59 63 PID 217 positioning 205 206 pulse train 203 timed steps 197 198 timer 197 199 tools 60 pulse train programming 203 rating fuses 22 ratings circuit breakers 22 reading Modbus 193 195 196 recommended wiring 35 227 reflected wave protection 33 RFI filter ground 21 RS485 DSI configuring 190 S safety applications 225 basic operation 228 drive 227 ground 21 testing 226 wiring 227 selecting accel 48 decel 48 digital inputs 47 speed reference 46 start source 46 separating power and control module 27 Shielded wiring 32 shielding ground 21 speed reference override priority 46 selecting 46 start motor 33 start source digital inputs 47 override priority 46 selecting 46 stop motor 33 Storage environment 18 T temperature derating 17 wiring 32 testing safety 226 timer Rockwell Automation Publication 520 UM001G EN E September 2014 programming 197 199 tools programming 60 U unshielded wiring 32 V voltage reflections wiring 33 Ww wave pro
285. rtain 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 AppView parameter groups are available for the following applications e Conveyor e Mixer e Compressor e Centrifugal Pump e Blower Fan e Extruder e Positioning PowerFlex 525 only e Textile Fiber You cannot add or remove parameters to or from the AppView parameter groups If you require quick access to additional parameters to what is already included in the different AppView parameter groups use the CustomView parameter group instead The parameters in the AppView parameter groups can be quickly added to the CustomView parameter group by doing the following Step Key s Example Displays 1 Pressthe Up Arrow or Down Arrow to scroll to M T in F an AppView group G1 G8 a gt V h LI ALIIT d ZELISN 2 Press Enter or Sel to enter a group The right LZ most digit of the last viewed parameter in that ab HI group will flash lt or LJ LLII J A 3 Pressthe Up Arrow or Down Arrow to scroll to lt a gt TNT Fr the command G1 gt GC Vv I L3 UF LIL 18 4 Press Enter or Sel to add all the parameters in this AppView group to the CustomView group Y y y 1 y The LCD display will show a confirmation lt or Rockwell Automation Publication 520 UM001G EN E September 2014 CustomView Parameter Gro
286. ry guidelines Options 0 Disabled Default 1 Enabled A544 Reverse Disable Related Parameter s b006 S drive before changing this parameter Enables disables the function that allows the direction of motor rotation to be changed Options 0 Rev Enabled Default 1 Rev Disabled A545 Flying Start En Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM Options 0 Disabled Default 1 Enabled Catch and ramp to commanded speed at every drive start Rockwell Automation Publication 520 UM001G EN E September 2014 123 Chapter3 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 15096 Min Max 30 200 Display 1 A547 Compensation Enables disables correction options that may improve problems with motor instability Options 0 Disabled No compensation 1 Electrical Default Some drive motor combinations have inherent instabilities which are exhibited as non sinusodial motor currents This setting attempts to correct this condition 2 Mechanical Some motor load combinations have mechanical resonances which can be excited by the drive current regulator This setting slows down the current regulator response and attempts to correct this condition 3 Both
287. s The display then defaults to that parameter s current value Example shows the value of b001 Output Freq with the drive stopped Press Escto display the Basic Display Group parameter number shown on power up The parameter number will flash Press Escto enter the parameter group list The parameter group letter will flash Press the Up Arrow or Down Arrow to scroll through the group list b P t C L d A f and Gy Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameter list Press Enter to view the value of the parameter Or Press Esc to return to the parameter list Press Enter or Sel to enter Program Mode and edit the value The right digit will flash and the word Program on the LCD display will light up Press the Up Arrow or Down Arrow to change the parameter value Key s Example Display m ririri LILI Lier NIZ 2 L rne s ILILI I AU A L nnm E uu or Dni Coa POT ue PH C2 7C v PII 18 e qq NI Q5 2 T J Ju PROER DN Rockwell Automation Publication 520 UM001G EN E September 2014 59 Chapter2 Start Up Drive Programming Tools Language Support 60 Step 10 If desired press Sel to move from digit to digit or bit to bit The digit or bit that
288. s needed F059 Safety Open 1 Both of the safety inputs Safety 1 e Check safety input signals If not Safety 2 are not enabled using safety verify and tighten Configure with t105 Safety Open En npe 1 0 terminals 1 52 and 4 F063 SWOverCurrent 1 Programmed A486 A488 Shear Pinx e Verify connections between motor Level has been exceeded for a time and load period greater than the time e Verify level and time requirements programmed in A487 A489 Shear Pin x Time F064 Drive Overload 2 Drive overload rating has been Reduce load or extend Accel Time exceeded F070 Power Unit 2 Failure has been detected in the drive e Check maximum ambient power section temperature has not been exceeded e Cycle power Replace drive if fault cannot be deared F071 DSI Net Loss 2 Control over the Modbus or DSI Cycle power communication link has been e Check communications cabling interrupted e Check Modbus or DSI setting e Check Modbus or DSI status F072 Opt Net Loss 2 Control over the network option card s e Cycle power remote network has been interrupted e Check communications cabling e Check network adapter setting e Check external network status F0737 EN Net Loss 2 Control through the embedded Cycle power EtherNet IP adapter has been e Check communications cabling interrupted Check EtherNet IP setting e Check external network status F080 Autotune Failure 2 The autotune function was either Restart procedure
289. s rotating at zero Hz or slip frequency is not correct Indication Corrective Action Improper speed e Verify P032 Motor NP Hertz Reduce boost with A530 Boost Select Set P036 Motor NP RPM to motor synchronous speed Rockwell Automation Publication 520 UM001G EN E September 2014 153 Chapter4 Troubleshooting Notes 154 Rockwell Automation Publication 520 UM001G EN E September 2014 Certifications Appendix A Supplemental Drive Information For information on See page Certifications 155 Environmental Specifications 156 Technical Specifications 157 Power Specifications 160 Certifications PowerFlex 523 PowerFlex 525 c UL us Listed to UL508C and CAN CSA C22 2 No 14 05 ipu CTick Australian Communications and Media Authority In conformity with the following Radiocommunications Act 1992 N223 Radiocommunications Standard 2008 Radiocommunications Labelling Notice 2008 Standards applied EN 61800 3 2004 A1 2012 CE In conformity with the following European Directives Ce EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Standards applied EN 61800 3 2004 A1 2012 EN 61800 5 1 2007 TUV T V 5 Rheinland Not applicable T V Rheinland Standards applied EN ISO 13849 1 2008 EN 61800 5 2 2007 EN 61508 PARTS 1 7 2010 EN 62061 2005 EN 60204 1 2009 Certified to ISO 13849 1 SIL2 PLd with embedded Safe Torque Off function Meets Functional
290. s traveled from the home position See d387 Position Status for direction of travel Values Default Read Only Min Max 0 64000 Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 105 Chapter3 Programming and Parameters Advanced Display Group continued d389 Units Traveled L Related Parameter s d387 Ts 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 Ooa l 1 Condition True 0 Condition False Sync Hold Digit 1 Sync Ramp Digit 2 Traverse On Digit 3 Traverse Dec Digit 4 Not Used Values Default Read Only Min Max 0000 1111 Display 0000 d391 Stp Logic Status Related Parameter s P047 L180 L187 Ny 32 bit parameter PF 525 PowerFlex 525 only Displays the current step of the Step Logic profile as defined by parameters L180 L187 Step Logic x when P047 Speed Reference is set to 13 Step Logic or 16 Positioning Values Default Read Only Min Max 0 8 Display 1 d392 RdyBit Mode Act Related Parameter s A574 PF 525 PowerFlex 525 only With FRN 3 xxx and later Displays the value of A574 RdyBit Mode Cfg
291. spect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE p gt PP gt IMPORTANT Identifies information that is critical for
292. t malfunction One of the safety inputsis using safety verify and tighten not enabled jumper for 1 0 terminals 1 2 and S4 e Replace control module if fault cannot be cleared F114 uC Failure 2 Microprocessor failure Cycle power e Replace control module if fault cannot be cleared Rockwell Automation Publication 520 UM001G EN E September 2014 149 Chapter4 Troubleshooting Common Symptoms and Corrective Actions 150 Fault Types Descriptions and Actions No Fault Type Description Action F122 1 0 Board Fail 2 Failure has been detected in the drive control and 1 0 section Cycle power Replace drive or control module if fault cannot be cleared F125 Flash Update Req N The firmware in the drive is corrupt mismatched or incompatible with the hardware Perform a firmware flash update operation to attempt to load a valid set of firmware F126 NonRecoverablErr 2 A non recoverable firmware or hardware error was detected The drive was automatically stopped and reset e Clear fault or cycle power to the drive Replace drive or control module if fault cannot be cleared N F127 DSIFlashUpdatReq A critical problem with the firmware was detected and the drive is running using backup firmware that only supports DSI communications 1 This fault is not applicable to PowerFlex 523 drives 2 See Fault Types for more information Pe
293. t to enable speed synchronization When this bit is reset to zero the drive accelerates to the new commanded frequency based on A571 Sync Time setting 5 Traverse Dis When set the traverse function is disabled 6 Logic In 1 This provides an identical function as the Logic In1 Digital Input option This bit is logically ORed with a digital input t062 t063 065 068 DigIn TermBlk xx set to 24 Logic In1 It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions 7 Logic n 2 This provides and identical function as the Logic In2 Digital Input option This bit is logically ORed with a digital input t062 t063 065 068 DigIn TermBlk xx set to 25 Logic In2 It can be used to move through the Step Logic functions speed or position using comms control without requiring actual digital input transitions A561 Home Save PF 525 PowerFlex 525 only Determines whether the current position is saved on power down Options 0 Home Reset Default Position resets to zero on power up 1 Home Saved 126 Rockwell Automation Publication 520 UM001G EN E September 2014 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
294. talog numbers listed are for 396 impedance at 60 Hz 596 impedance reactor types are also available See publication 1321 TD001 4 Input line reactors were sized based on the NEC fundamental motor amps Output line reactors were sized based on the VFD rated output currents 172 Rockwell Automation Publication 520 UM001G EN E September 2014 Accessories and Dimensions Appendix B Product 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 Weight kg Ib A 1 1 2 4 B 1 6 3 5 C 2 3 5 0 D 3 9 8 6 E 12 9 28 4 IP 20 0pen Type Frame A Dimensions are in millimeters and inches H 72 0 2 83 4 m 172 0 6 77 57 5 2 26 Rockwell Automation Publication 520 UM001G EN E September 2014 173 Appendix B 174 Accessories and Dimensions IP 20 0pen Type Frame B Dimensions are in millimeters and inches
295. tection 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 Notes 242 Rockwell Automation Publication 520 UM001G EN E September 2014 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At hetp www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support amer
296. ted This allows a process to be stopped and then restarted at the position where it stopped In all position modes the following parameters will control the characteristics at each step L200 L202 L204 L206 L208 L210 L212 and L214 Step Units x are the number value to the left ofthe decimal whole number of the 8 positions desired for an application beginning with Step 0 L200 and continuing with each step until Step 7 L214 For example enter 2 into this parameter if you would like a commanded position of 2 77 L201 L203 L205 L207 L209 L211 L213 and L215 Step Units F x are the number value to the right of the decimal the portion less than 1 of the 8 positions desired for an application beginning with Step 0 L201 and continuing with each step until Step 7 L215 For example enter 0 77 into this parameter if you would like a commanded position of 2 77 A410 A417 Preset Freq x are the parameters that define the maximum frequency the drive will run at during the corresponding step For example if Preset Freq 2 is set to 40 Hz the drive will accelerate to 40 Hz maximum when moving to Position 2 Frequency Source A410 Preset Freq 0 Step Source L180 Stp Logic 0 Position Source L200 Step Units 0 A411 Preset Freq 1 L181 Stp Logic 1 L202 Step Units 1 L204 Step Units 2 A412 Preset Freq 2 L182 Stp Logic 2 A413 Preset Freq 3 L183 Stp Logic 3
297. th derating PowerFlex 523 PowerFlex 525 See Current Derating Curves on page 17 for derating guidelines 1000 m 3300 ft max Up to 4000 m 13 200 ft max with the exception of 600V drives at 2000 m 6600 ft max Max Surrounding Air See Current Derating Curves on page 17 for derating guidelines Temperature 20 50 C 4 122 F Without derating 20 60 C 4 140 F or 20 70 C 4 158 F with optional Control Module Fan With derating kit Storage Temperature Frame A D 40 85 C 40 185 F Frame E 40 70 C 40 158 F Atmosphere IMPORTANT Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity 0 95 noncondensing Shock Complies with IEC 60068 2 27 Vibration Complies with IEC 60068 2 6 1995 Operating and Nonoperating Nonoperating Transportation Frame Force Force Size Shock Vibration Mounting Type Shock Vibration Mounting Type A 15g 2g DIN rail or screw 30g 2 59 Screw only B 15g 2g DIN rail or screw 30g 2 59 Screw only C 15g 2g DIN rail or screw 309 2 5g Screw only D 15g 2g Screw only 309 2 5g Screw only E 15g 1 5g Screw only 309 2 5g Screw only Conformal Coating Complies with IEC 607
298. th the internal network option as a multi drive master The host drive is Drive 0 and up to four slave drives can be daisy chained from its RS485 port 2 EtherNet Ip Multi drive is enabled with the embedded Ethernet port as the multi drive master The host drive is Drive 0 and up to four slave drives can be daisy chained from its RS485 port 1 Setting is specific to PowerFlex 525 drives only C171 Drv 1 Addr Related Parameter s C169 C172 Drv 2 Addr C173 Drv3 Addr C174 Drv 4 Addr Sets the corresponding node addresses of the daisy chained drives when C169 MultiDrv Sel is set to 1 Network Opt or 2 EtherNet IP A reset or power cycle is required after selection is made Values Default Drv 1 Addr 2 Drv 2 Addr 3 Drv 3 Addr 4 Drv 4 Addr 5 Min Max 1 247 Display 1 C175 DSII 0 Cfg Sets the configuration of the Drives that are active in the multi drive mode Identifies the connections that would be attempted on a reset or power cycle A reset or power cycle is required after selection is made Options 0 Drive 0 Default 1 Drive 0 1 Drive 0 2 Drive 0 3 Drive 0 4 Bl wl rn Rockwell Automation Publication 520 UM001G EN E September 2014 99 Chapter3 Programming and Parameters Logic Group 1180 Stp Logic 0 1181 Stp Logic 1 Related Parameter s 1182 Stp Logic 2 1183 Stp Logic 3 1184 Stp Logic 4 1185 Stp Logic 5 1186 Stp Logic 6
299. the condition is met the program overrides Digit 0 and jumps to the step defined by Digit 3 Digit 3 Different step to jump When the condition for Digit 2 is met this digit setting determines the next step or to end the program Digit 4 Step settings This digit defines additional characteristics of each step Any StepLogic parameter can be programmed to control a relay or opto output but you can not control different outputs based on the condition of different StepLogic commands 100 Rockwell Automation Publication 520 UM001G EN E September 2014 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 Bu Bu Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Velocity Control Settings Digit 4 Settings Digit 3 Required Acel Decel StepLogic Commanded Setting Description Setting Param Used Output State Direction 0 Jump to Step 0 0 Accel Decel 1 Off FWD 1 Jump to Step 1 1 Accel Decel 1 Off REV 2 Jump to Step 2 2 Accel Decel 1 Off No Output 3 J
300. the drive nan Digit 3 Internal Com option 1 Condition True 0 Condition False Not Active no connection Rx Digit 1 Internal option connected active Ix Digit2 2 8 Reserved Status Digit3 9 Internal com option faulted Error Digit 4 Not Used Values Default Read Only Min Max 0000 1911 Display 0000 132 Rockwell Automation Publication 520 UM001G EN E September 2014 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 Mgogo Digit 3 Embedded EtherNet IP 1 Condition True 0 Condition False 0 Not Active no connection Rx Digit 1 Embedded EtherNet IP active Ix Digit2 2 8 Reserved Status Digit3 9 Embedded EtherNet IP faulted Error Digit 4 Not Used Values Default Read Only Min Max 0000 1911 Display 0000 F684 EN Addr Src PowerFlex 525 only Displays the actual source of the Ethernet configuration IP address subnet mask and gateway address Options 1 Parameters Read Only 2 BOOTP F685 EN Rate Act PF 525 PowerFlex 525 only Displays the network data rate currently used by the embedded EtherNet IP interface Options 0 NoLink Read Only 1 10Mbps Full
301. the operation from terminating before completion due to insufficient power Limitation in Downloading pf5 Configuration Files with the USB Utility Application Before downloading a pf5 configuration file using the USB utility application parameter C169 MultiDrv Sel in the destination drive must match the incoming configuration file If it does not set the parameter manually to match and then cycle drive power This means you cannot apply a multi drive configuration using the USB utility application to a drive in single mode parameter C169 MultiDrv Sel set to 0 Disabled or apply a single mode configuration to a drive in multi drive mode 64 Rockwell Automation Publication 520 UM001G EN E September 2014 Chapter 3 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 520 series drive parameters Parameters are programmed viewed edited using either the drive s built in keypad RSLogix 5000 version 17 0 or greater Logix Designer version 21 0 or greater or Connected Components Workbench version 5 0 or greater software The Connected Components Workbench software can be used offline through USB to upload parameter configurations to the drive or online through Ethernet connection Limited functionality is also available when using the Connected Components Workbench software online through DSI and serial converter module a legacy external HIM or legacy software online
302. times See A442 Accel Time 2 for more information 12 Aux Fault When enabled an F002 Auxiliary Input fault will occur when the input is removed 13 Clear Fault When active clears an active fault 14 RampStop CF Causes drive to immediately ramp to a stop regardless of how P045 Stop Mode is set 15 CoastStop CF Causes drive to immediately coast to a stop regardless of how P045 Stop Mode is set 16 DCInjStop CF Causes drive to immediately begin a DC Injection stop regardless of how P045 Stop Mode is set 17 MOP Up Increases the value of A427 MOP Freq at the rate set in A430 MOP Time 18 MOP Down Decreases the value of A427 MOP Freq at the rate set in A430 MOP Time 19 Timer Start Clears and starts the timer function May be used to control the relay or opto outputs 20 Counter In Starts the counter function May be used to control the relay or opto outputs 21 Reset Timer Clears the active timer 22 Reset Countr Clears the active counter 23 Rset Tim amp Cnt Clear the active timer and counter 24 LogicIn 100 Logic function input number 1 May be used to control the relay or opto outputs t076 t081 Relay Outx Sel and t069 t072 Opto Outx Sel options 11 14 May be used in conjunction with StepLogic parameters L180 L187 Stp Logic x 25 Logic In 22 82 Logic function input number 2 May be
303. tions Opto Quantity Specification Analog Quantity Specification Resolution 0 10V DC Analog 4 20 mA Analog Encoder Specifications PowerFlex 523 Type Supply Quadrature Duty Cyde Requirements 1 Non Isolated 0 10V or 4 20 mA 10 bit 1kohm minimum 525 ohm maximum PowerFlex 525 Incremental dual channel 12V 250 mA 90 27 25 C 50 10 Encoders must be line driver type quadrature dual channel or pulse single channel 3 5 26V DC output single ended or differential and capable of supplying a minimum of 10 mA per channel Allowable input is DC up to a maximum frequency of 250 kHz The encoder I 0 automatically scales to allow 5V 12V and 24V DC nominal voltages Rockwell Automation Publication 520 UM001G EN E September 2014 159 AppendixA X Supplemental Drive Information Power Specifications Watts Loss PowerFlex 520 Series Estimated Watts Loss Rated Load Speed amp PWM Voltage Output Current A Total Watts Loss 100 120V 1 6 20 0 50 60 Hz 1 Phase 25 370 48 53 0 6 0 67 0 200 240V 1 6 20 0 50 60 Hz 1 Phase 25 290 48 50 0 8 0 81 0 11 0 111 0 200 240V 1 6 20 0 soe qm T 48 53 0 8 0 84 0 11 0 116 0 200 240V 1 6 20 0 50 60 Hz 3 Phase 25 290 5 0 50 0 8 0 79 0 11 0 107 0 17 5 148 0 24 0 259 0 322 323 0 48 3 584 0 62 1 708
304. to Out Logic PowerFlex 525 only Determines the logic Normally Open NO or Normally Closed NC of the digital outputs only Setting Digital Out 1 Logic Digital Out 2 Logic 0 NO NO 1 NC NO 2 NO NC 3 NC NC Values Default 0 Min Max 0 3 Display 1 86 Rockwell Automation Publication 520 UM001G EN E September 2014 t076 Relay Out1 Sel t081 Relay Out2 Sel PowerFlex 525 only Programming and Parameters Terminal Block Group continued Chapter 3 Related Parameter s P046 P048 P050 t070 t073 t077 1082 t086 t087 t093 t094 t097 A541 A564 Determines the operation of the programmable output relay Options 0 Ready Fault Output Relay Changes State When Relay changes state when power is applied Indicates that the drive is ready for operation Relay returns drive to Shelf state when power is removed or a fault occurs Hysteresis None 1 At Frequency Drive reaches commanded frequency 0 5 Hz above 1 0 Hz below 2 MotorRunning Motor is receiving power from the drive None 3 Reverse Drive is commanded to run in reverse direction None 4 Motor Overld Motor overload condition exists 100 ms time delay on or off 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from 100 ms time delay on or off occurring 6 Above Freq Drive exceeds
305. tor the motor encoder is 1024 PPR and the Motor Feedback type is set to Quadrature then this parameter would need to be set to 4x 1024 x 0 75 3072 counts for one cm of travel Then all other positions could be setup in units of cm A564 Encoder Pos Tol indicates the desired position tolerance for the system This will determine how close the drive must be to the commanded position before the drive will indicate At Home or At Position in units of raw encoder pulses This has no effect on the actual positioning control of the motor Parameter A558 Positioning Mode must be set to properly match the desired operation of the positioning function A558 Positioning Mode Options 0 Time Steps uses Step Logic times This mode ignores the Step Logic settings and moves through the steps Step 0 to Step 7 and back to Step 0 based on the times programmed into L190 L197 Stp Logic Time x This can be used when the desired position is based only on time In addition this mode only accepts absolute positions in a positive direction from home This option provides an easy way to implement a simple positioning program or to test the basic positioning setup For additional flexibility one ofthe other settings should be used 1 Preset Input directly commands movement to any step based on the status of the digital inputs programmed for Preset Freq This setting ignores the Step Logic Commands settings and instead the
306. tus Fault 5 F666 Status Fault 6 F667 Status Fault 7 F668 Status Fault 8 F669 Status Fault 9 F670 Status Fault10 PowerFlex 525 only Displays the value of b006 Drive Status with the most recent 10 faults occurred Status Fault 1 stores the most recent fault Status Fault 2 stores the second most recent fault and Status Fault 3 stores the third most recent fault Bau uu 1 Condition True 0 Condition False Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive Digit 5 1 Setting is specific to PowerFlex 525 drives only Values Default Read Only Min Max 0 0x1F Display 1 F681 Comm Sts DSI Displays the status of the RS485 serial DSI port to the drive Higa oe Digit 3 Connection Status 1 Condition True 0 Condition False 0 Not Active Rx Digit 1 1 Modbus slave network external Modbus master Ix Digit2 2 Modbus multi drive w internal com option master Status Digit3 3 Modbus multi drive w embedded com master 7 Error Digit4 4 DSI peripheral connected Not Used 5 8 Reserved 9 RS 485 network faulted 1 Setting is specificto PowerFlex 525 drives only Values Default Read Only Min Max 0000 1911 Display 0000 F682 Comm Sts Opt Displays the status of the internal communication to
307. uad Check swap the Encoder channel inputs or swap any two motor leads Replace encoder F094 Function Loss 2 Freeze Fire Function Loss inputis Close input to the terminal and cycle inactive input to the programmed power terminal is open F100 Parameter Chksum 2 Drive parameter non volatile storage is Set P053 Reset To Defalts to 2 Factory corrupted Rset F101 External Storage 2 External non volatile storage has failed Set P053 Reset To Defalts to 2 Factory Rset F105 C Connect Err 2 Control module was disconnected while Clear fault and verify all parameter drive was powered settings Do not remove or install the control module while power is applied F106 Incompat C P 2 The PowerFlex 525 control module does e Change to a different power module not support power modules with 0 25 e Change to a PowerFlex 523 control HP power rating module F107 Replaced CP 2 The control module could not recognize e Change to a different power module the power module Hardware failure e Replace control module if changing power module does not work F109 Mismatch C P 2 The control module was mounted toa Set P053 Reset To Defalts to 3 Power different drive type power module Reset F110 Keypad Membrane 2 Keypad membrane failure e Cycle power disconnected Replace control module if fault cannot be cleared ri Safety Hardware 2 Safety input enable hardware e Check safety input signals If no
308. ublication 520 UM001F EN E March 2014 Copyright 2014 Rockwell Automation Inc All rights reserved
309. ued P040 Autotune Related Parameter s P034 P039 A496 M97 Ts drive before changing this parameter Enables a static not spinning or dynamic motor spinning autotune to automatically set the motor parameters Start must be pressed to begin the routine After the routine is complete the parameter resets to a zero A failure such as if a motor is not connected results in an Autotune Fault IMPORTANT All motor parameters in the Basic Program group must be set before running the routine If a start command is not given or a stop command is given within 305 the parameter automatically returns to a zero and an Autotune Fault occurs ATTENTION Rotation of the motor in an undesired direction can occur during this procedure To guard against possible injury and or equipment damage it is recommended that the motor be disconnected from the load before proceeding Options 0 Ready ldle Default 1 Static Tune Atemporary command that initiates a non rotational motor stator resistance test for the best possible automatic setting of A496 IR Voltage Drop A start command is required following initiation of this setting The parameter returns to 0 Ready ldle following the test at which time another start transition is required operate the drive in normal mode Used when motor cannot be uncoupled from the load 2 Rotate Tune Atemporary command that initiates a Static Tune followed by a rotational test for the best possibl
310. ues Default 0 05 Min Max 0 0 600 0 s Display 0 15 t105 Safety Open En PF 525 PowerFlex 525 only Sets the action when both safety inputs Safety 1 and Safety 2 are disabled de energized no power is applied Options 0 FaultEnable Default 1 FaultDisable Rockwell Automation Publication 520 UM001G EN E September 2014 93 Chapter3 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 Parameter values set prior to setting 1 RAM only are saved in RAM Options 0 Save Default 1 RAM only C122 Cmd Stat Select PowerFlex 525 only Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network See Writing 06 Logic Command Data on page 191 for more information This parameter cannot be changed when an 1 0 connection is established through the communication adapter or the drive s embedded EtherNet IP port Options 0 Velocity Default 1 Position C123 RS485 Data Rate Sets the communications baud rate bits second for the RS485 port A reset or power cycle is required after selection is made Options 0 1200 1 2400 4800 9600 De
311. ult in a PID Error value e The Master Speed Reference sets the wind unwind speed 216 Rockwell Automation Publication 520 UM001G EN E September 2014 PID Reference and Feedback PIDSetUp Appendix F e As tension increases or decreases during winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point lt 0V wom PID Reference TN gt f PID Feedback Equilibrium Set Point J Dancer Pot Signal QI aw A Feman Ei A Speed Referencex PID mode is enabled by setting P047 P049 or P051 Speed Referencex to 11 PID1 Output or 12 PID2 Output and activating the corresponding speed r efer ence IMPORTANT PowerFlex 523 has one PID control loop PowerFlex 525 has two PID control loops of which only one can be in use at any time If A459 or A471 PID x Ref Sel is not set to 0 PID Setpoint PID can still be disabled by select programmable digital input options parameters t062 t063 t065 t0068 DigIn TermBlk xx such as Purge A459 A471 PID x Ref Sel Options Options Description 0 PID Setpoint A464 or A476 PID x Setpoint will be used to set the value of the PID Reference 1 Drive Pot The drive potentiometer will be used to set the value of the PID Reference 2 Keypad Freq The drive keypad will be used to set the value of the PID
312. ump to Step 3 3 Accel Decel 1 On FWD 4 Jump to Step 4 4 Accel Decel 1 On REV 5 Jump to Step 5 5 Accel Decel 1 On No Output 6 Jump to Step 6 6 Accel Decel 2 Off FWD 7 Jump to Step 7 7 Accel Decel 2 off REV 8 End Program Normal Stop 8 Accel Decel 2 off No Output 9 End Program Coast to Stop 9 Accel Decel 2 On FWD A End Program and Fault F2 A Accel Decel 2 On REV b Accel Decel 2 On No Output Settings Digit 2 and 1 Positioning Settings Digit 4 Setting Description 0 Skip Step Jump Immediately E a iue Dome Dela T Senin paced o heel Deel 0f D sot 2 Step if Logic In 1 n iiis 1 Accel Decel 1 Off FWD ncremental 3 step if Logic Inz b HANE 2 Accel Decel 1 Off REV Absolute d step if Logicin i b Not nae 3 Accel Decel 1 Off REV ncremental 5 Step if Logic In 2 is Not Active 1 Accel Decel 1 On FWD Absolute 6 Step if either Logic In 1 or Logic In 2 is Active Accel Decel 1 On FWD nemenil 7 Step if both Logic In 1 and Logic In 2 are Active 5 Accel Decel 1 On REV Absolute 8 Step neither Logic In E nor Logic In 2 EAS 7 Accel Decel 1 On REV Feremnenial 9 Step if Logic In 1 is Active and Logic In 2 is Not Active 3 Accel Decel 2 Off FWD Absolute A Step if Logic In 2 is Active and Logic In 1 is Not Active 9 Accel Decel 2 Off FWD rementa b Step after Stp Logic Time x and Logic In 1 is Active A Accel Decel2 Off REV Absolute C Step after Stp Logic Time x and Logic In 2 is Active b Accel
313. unt ofthe number of receive packets reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F727 EN Rx Errors PowerFlex 525 only A count ofthe number of receive errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F728 EN Tx Packets PF 525 PowerFlex 525 only A count ofthe number of transmitted packets reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F729 EN Tx Errors PowerFlex 525 only A count of the number of transmit errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 136 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F730 EN Missed IO Pkt PF 525 PowerFlex 525 only The number of 1 0 packets missed Values Default Read Only Min Max 0 65535 Display 1 F731 DSI Errors The number of total DSI errors Values Default Read Only Min Max 0 65535 Display 1 Rockwell Automation Publication 520 UM001G EN E September 2014 137 Chapter3 Programming and Parameters AppView Parameter Groups 138 AppView parameter groups provide a simple starting point for using the PowerFlex 520 series drives by grouping ce
314. up Programming and Parameters 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 You can copy one entire AppView parameter group to the CustomView parameter group as shown on page 138 or add individual parameters as show below Step Key s Example Displays 1 Pressthe Up Arrow or Down Arrow to scroll to Tr the CustomView group GC group 60 a gt Las JE LIIIN 2 Press Enter to view the parameters that can be added to the CustomView group FD 4 lt 3 Press the Up Arrow or Down Arrow to scroll or rn n through the list of parameters Noe a T TULC PROBA 4 Press Enter to add the parameter to the CustomView group The LCD display will show a y Ww Ww y y confirmation To delete parameters from the CustomView parameter group Step Key s e Displays 1 Press the Up Arrow or Down Arrow to scroll to M d r nn the CustomView group GC a gt V h LLC 2 Press Enter to view the parameters that are in 7 2 the CustomView group aol E APT lt L1L LILI ic 3 Press the Up Arrow or Down Arrow to scroll to Nie the command
315. urrent F644 Fault 4 Current F645 Fault 5 Current F646 Fault 6 Current F647 Fault 7 Current F648 Fault 8 Current F649 Fault 9 Current F650 Fault10 Current PowerFlex 525 only Displays and stores the value of b003 Output Current with the most recent 10 faults occurred Fault 1 Current stores the most recent fault Fault 2 Current stores the second most recent fault and Fault 3 Current stores the third most recent fault Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01A F651 Fault 1 BusVolts F652 Fault 2 BusVolts Related Parameter s b005 F653 Fault 3 BusVolts F654 Fault 4 BusVolts F655 Fault 5 BusVolts F656 Fault6BusVolts F657 Fault 7 BusVolts F658 Fault8 BusVolts F659 Fault 9 BusVolts F660 Fault10 BusVolts PowerFlex 525 only Displays and stores the value of b005 DC Bus Voltage with the most recent 10 faults occurred Fault 1 BusVolts stores the most recent fault Fault2 BusVolts stores the second most recent fault and Fault 3 BusVolts stores the third most recent fault Values Default Read Only Min Max 0 1200VDC Display 1VDC Rockwell Automation Publication 520 UM001G EN E September 2014 131 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F661 Status Fault 1 F662 Status Fault 2 Related Parameter s b006 F663 Status Fault3 F664 Status Fault 4 F665 Sta
316. urrent drops below this level for the time specified in A491 Load Loss Time Values Default 0 0A Min Max 0 0 Drive Rated Amps Display 0 1A A491 Load Loss Time Related Parameter s A490 PF 525 PowerFlex 525 only Sets the required time for the current to be below A490 Load Loss Level before a Load Loss fault occurs Values Default 0s Min Max 0 9999 s Display 1s M92 Stall Fault Time Sets the time that the drive remains in stall mode before a fault is issued Options 0 60 Seconds Default 1 120 Seconds 2 240 Seconds 3 360 Seconds 4 480 Seconds 5 Fit Disabled M93 Motor OL Select Related Parameter s P032 P033 Drive provides Class 10 overload protection Settings 0 2 select the derating factor for the It overload function No Derate Min Derate Max Derate 100 ES 100 100 n E m 5 om Z 3 Z 8 60 60 g 6 S 40 4 5 20 s 20 S 20 E EI 0 0 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 of Motor NP Hertz of Motor NP Hertz of Motor NP Hertz Options 0 No Derate Default 1 Min Derate 2 Max Derate M94 Motor OL Ret Selects whether the motor overload counter is saved on power down or reset on power up Options 0 Reset Default 1 Save Rockwell Automation Publication 520 UM001G EN E September 2014 117 Chapter3 Programming and Pa
317. used to control the relay or opto outputs t076 t081 Relay Outx Sel and t069 t072 Opto Outx Sel options 11 14 May be used in conjunction with StepLogic parameters L180 L187 Stp Logic x Rockwell Automation Publication 520 UM001G EN E September 2014 Options 26 Current Lmt2 2 Programming and Parameters Chapter 3 When active A485 Current Limit 2 determines the drive current limit level 27 Anlg Invert Inverts the scaling of the analog input levels set in 1091 Anlg In 0 10V Lo and t092 Anlg In 0 10V Hi or 1095 Anlg In4 20mA Lo and t096 Anlg In4 20mA Hi 28 EM Brk Rise If EM brake function is enabled this input releases the brake See t086 EM Brk Off Delay for more information ATTENTION If a hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used 29 Acc Dec Sela If active determines which Accel Decel time is used for all ramp rates except jog Used with option 11 Acc Dec Sel2 for the Accel Decel times listed in this table Option Description 29 11 0 0 Ac Dec1 0 Ac Dec2 1 0 Ac Dec3 1 1 J AcDec4 30 Precharge En Forces drive into precharge state Typically controlled by auxiliary contact on the disconnect at the DC input to the drive If this input is assigned it must be energized for the pre charge relay to close and for the drive to run If it is de e
318. user manual for network terminations Note that there is no standard for the and wires and consequently Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wires at the master controller Standard RS485 wiring practices apply e Termination resistors need to be applied at each end of the network cable e RS485 repeaters may need to be used for long cable runs or if greater than 32 nodes are needed on the network e Network wiring should be separated from power wires by at least 0 3 meters 1 foot e Network wiring should only cross power wires at a right angle I O Terminal C1 RJ45 Shield for the Ethernet and DSI network cables on the PowerFlex 520 series drive must also be connected to PE ground there are two PE terminals on the drive The shield for the network cables should be connected to PE ground at one end only I O Terminal C2 Comm Common is internally tied to Network Common for the network signals and NOT to RJ45 Shield Tying I O Terminal C2 to PE ground may improve noise immunity in some applications See I O Control Terminal Designations on page 38 and page 40 for more information The following PowerFlex 520 series drive parameters are used to configure the drive to operate on a DSI network Configuring Parameters for DSI Network Parameter Details Reference P046 Start S
319. ve you can set this parameter so that the drive continues to run Precautions should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage When commissioning the drive verify that your system responds correctly to various situations for example a disconnected drive Options 0 Fault Default 1 Stop Drive stops per P045 Stop Mode setting 2 Zero Data Note The Reference and Datalink values transmitted to the drive will be set to 0 3 Hold Last Note The Logic Command Reference and Datalink values transmitted to the drive will be held at their last value 4 Send Flt Cfg ipn n Command Reference and Datalink values will be transmitted to the drive as configured in C145 C146 and C145 EN Fit Cfg Logic KA 32 bit parameter PowerFlex 525 only Sets the Logic Command data that is sent to the drive if any ofthe following is true C143 EN Comm Flt Actn is set to 4 Send Fit Cfg and communications are disrupted C144 EN Idle Fit Actn is set to 4 Send Flt Cfg and the scanner is put into Program or Test mode See Writing 06 Logic Command Data on page 191 for more information Related Parameter s C143 C144 Values Default 0000 Min Max 0000 FFFF Display 0000 Rockwell Automation Publication 520 UM001G EN E September 2014 97 Chapter3 Programming and Parameters Communications Group continued C
320. ve Specifications 520 TD001 PowerFlex Dynamic Braking Resistor Calculator PFLEX ATOO1 PowerFlex AC Drives in Common Bus Configurations DRIVES ATO02 Rockwell Automation Publication 520 UM001G EN E September 2014 Preface Overview Manual Conventions 10 The following publications provide specific Network Communications information Title PowerFlex 525 Embedded EtherNet IP Adapter Publication 520COM UM001 PowerFlex 25 COMM D DeviceNet Adapter 520COM UM002 PowerFlex 25 COMM E2P Dual Port EtherNet IP Adapter 520COM UM003 PowerFlex 25 COMM P PROFIBUS DPV1 Adapter 520COM UM004 e In this manual we refer to PowerFlex 520 Series Adjustable Frequency AC Drive as drive PowerFlex 520 series PowerFlex 520 series drive or PowerFlex 520 series AC drive e Specific drives within the PowerFlex 520 series may be referred to as PowerFlex 523 PowerFlex 523 drive or PowerFlex 523 AC drive PowerFlex 525 PowerFlex 525 drive or PowerFlex 525 AC drive e Parameter numbers and names are shown in this format P 031 Motor NP Volts Name Number Group b Basic Display P Basic Program t Terminal Blocks C Communications L Logic d Advanced Display A Advanced Program N Network M Modified f Fault and Diagnostic G AppView and CustomView e The following words are used throughout the manual to describe an action Words Meanin
321. xed shape S Curve that is applied to the acceleration and deceleration ramps including jog S Curve Time Accel or Decel Time x S Curve Setting in percentage 10096 S Curve 5096 S Curve Example Target ae Target Accel Time 10 s S Curve Setting 30 S Curve Time 10x 0 3 2 35s 4 S Curve Time Accel Time gt 4 S CurveTime Total Time to Accelerate Accel Time S Curve Time gt Total Time to Accelerate Accel Time S Curve Time gt Values Default 096 Min Max 0 10096 Display 196 110 Rockwell Automation Publication 520 UM001G EN E September 2014 Programming and Parameters Chapter 3 Advanced Program Group continued A440 PWM Frequency Related Parameter s A540 Sets the carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM frequency setting 100 96 92 88 84 80 76 72 68 64 60 56 50 Output Curent A 123 45 67 8 9 0 11 12 1 1 15 16 Carrier Frequency kHz IMPORTANT lonoring derating guidelines can cause reduced drive performance The drive may automatically reduce the PWM carrier frequency at low output speeds unless prevented from doing so by A540 Var PWM Disable Values Default 4 0 kHz Min Max 2 0 16 0 kHz Display 0 1 kHz A441 Droop Hertz FLA PF 525 PowerFlex 525 only Reduces the frequency based on current This frequency is subtracted from the commanded output frequency Ge
322. y Related Parameter s P045 Sets the time the drive remains at minimum frequency before ramping up to the commanded frequency and engaging the brake coil relay if Electromechanical EM Brake Control Mode is enabled with P045 Stop Mode EM Brk On Delay ty A Minimum Freq gt a PN Start EM Brk Stop EMBrk Drive stops commanded energized Off commanded de energized On Values Default 2 005 Min Max 0 00 10 00 s Display 0 015 88 Rockwell Automation Publication 520 UM001G EN E September 2014 t087 EM Brk On Delay Minimum Freq gt EM Brk Off Delay Q m Terminal Block Group continued Programming and Parameters Chapter 3 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 RES M ad Off aminan i TOUR Drive tops Values Default 2 005 Min Max 0 00 10 00 s Display 0 015 t088 Analog Out Sel PowerFlex 525 only Related Parameter s t090 The 0 10V 0 20 mA or 4 2 0 mA analog output can be used to provide a signal proportional to several drive conditions This parameter also selects which analog calibration parameters to use Options Output Range Minimum Output Value Maximum Output Value Filter Related t089 Analog Out High
323. y 1 On Time t079 Analog Out High t089 Anlg Loss Delay t098 Digln TermBIk 08 t068 Relay 1 Off Time t080 Anlg Out Setpt t090 Analog In Filter 099 un Opto Out1 Sel t069 Relay Out2 Sel t081 AnlgIn 0 10V Lo 1091 Sleep Wake Sel t100 Opto Out1 Level t070 Relay Out2 Level 1082 Anlg In 0 10V Hi t092 Sleep Level t101 Digln TermBIk 02 t062 Opto Out2 Sel t072 Relay 2 On Time 1084 10V Bipolar EnbI 1093 Sleep Time t102 Digln TermBlk 03 1063 Opto Out2 Level t073 Relay 2 Off Time t085 Anlg In V Loss t094 Wake Level t103 2 Wire Mode t064 Opto Out Logic 1075 EM Brk Off Delay t086 Anlg In4 20mA Lo 1095 Wake Time t104 Digln TermBlk 05 t065 Relay Out1 Sel 1076 EM Brk On Delay 1087 Anlg In4 20mA Hi t096 Safety Open En t105 Digln TermBlk 06 t066 Relay Out Level 1077 Analog Out Sel t088 AnlgIn mA Loss t097 Communications EN Addr Sel C128 EN Gateway Cfg 3 C139 EN Data In 1 C153 Opt Data In 4 C164 EN IP Addr Cfg 1 129 EN Gateway Cfg 4 C140 EN Data In 2 C154 Opt Data Out 1 C165 Y EN IP Addr Cfg 2 C130 EN Rate Cfg C141 EN Data In 37 C155 Opt Data Out 2 C166 EN IP Addr Cfg 3 C131 EN Comm Fit Actn C143 EN Data In 4 C156 Opt Data Qut 3 167 Comm Write Mode C121 ENIP Addr Cfg 4 C132 EN Idle Fit Actn C144 EN Data Out 1 C157 Opt Data Out 4 168 Cmd Stat Select C122 EN Subnet Cfg 1 C133 EN Fit Cfg Logic C145 EN Data Out 2 C158 MultiDrv Sel C169 RS485 Data Rate C123 EN Subnet Cfg 2 C134 EN F
324. y ay E Bunea yuan 3ndui Ap 10 ayejdaweu aup ay 01 Jajad suea dwe samo YIM S10JOW Bur joruo S Aup ay UaYy Ayng Aaea pue qn Ang jeuJoN ainsopua sabe e auinbad Aew suoerapisuo SAU SIY 404 a qejreae ae sfunei QH 1 QOOLbL C 184 WOvL 09 1105 SSVD CE 384 WOvL 05 999 90bL t9 Ot 001 3 767 VEE OE 8L OSTI OTZ 00 vOLNCEO3 BSC VOLNCEOT VSC QO 9LvL cE2 383 WOFL 0s 140 SSVD Z 384 WOPL SED 999 D0rL 0s SE 0ED 00L 3 Zvc C8C OLT OSL OOT amp 8L OSZ POLNZZ03 8S7 VOLNZCO3 VSC g 999 c 0 384 WOvL x 09 1101 SSVD C 384 WOvL SED 999 90bL t9 SE 0 00L Q ELTI TLE 0 cC 0 LL O SL O SL OOT VOLNCCO3 8SC VOLNCCOT VSC q L999 80 383 WOrL 05 1401 SSVD C0 383 WOtL 0 9 999 50rL 0S 7E 0 9 001 Q OHTI VLC 06L OLLI OSL OLLI OSL vOLNGLO3 dSC VOLNGLOT VSC 912 380 WOvL 0E 4 S10 L10 f D SAY SSVD 912 30 WOtL 07 Q90 00vL 43 OZ 001 2 SEL vSL OCL SZ O OL SZ O OL vOLNCLO3 BSC VOLNCLOT VSC 7 1 912 380 WOrL S2 H S10 140 FD SHH SSY 915 30 WOvL SLD 09G NOrL SC OL OLD OOL 2 CIL SCL 66 SS SZ SS SZ vOLN6d63 gSC vVOLN6d61 VSC 015380 WOvL 02 H S10 14069 Sa SSVI 015 30 WOvL 01D 09G NOrL 0c OL 609 00L 8 08 VL6 99 Qv OS Ov O S vOLNOg93 HGC VOLNOdO3 VSC 98 380 WOvL SL 4
325. y diode parallel to the relay as shown to prevent damage to the output Analog Output 1088 Analog Out Sel 0 through 23 1088 Analog Out Sel The Analog Output Select jumper must be set to match the analog output signal mode set in determines analog output t088 Analog Out Sel type and drive conditions 0 10V 9 1k Q minimum 0 20 mA 4 20 mA Common 2 1 e 525 Q maximum tte be 1 Feature is specific to PowerFlex 525 drives only 44 Rockwell Automation Publication 520 UM001G EN E September 2014 Installation Wiring Chapter 1 Typical Multiple Drive Connection Examples Input Output Connection Example Multiple Digital Input o2 o4 Connections OAA AANA ooQ 200000 Customer Inputs can be wired per External Supply eocleclooec ooocoooooo ooocoooooo SRO O Customer Inputs TI 7 Optional Ground Connection When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives it is important to connect 1 0 Terminal 04 common together for all drives If they are to be tied into another common such as earth ground or separate apparatus ground only one point of the daisy chain of 1 0 Terminal 04 should be connected ATTENTION 1 0 Common terminals should not be tied together when using SNK Internal Supply mode In SNK mode if power is removed from one drive inadvertent operati

"user manual"

Contents

Download Pdf Manuals

Related Search

Related Contents

&quot;user manual&quot;

Contents

Download Pdf Manuals

Related Search

Related Contents

"user manual"