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520-UM001B-EN-E PowerFlex 525 Adjustable Frequency AC Drive

1. a 870 343 S IP 30 NEMA 1 UL Type 1 top panel 72 5 2 85 3 172 0 6 77 200000000 ey a T Alor T c E e m D FATO e D E 3 o m O O lt 1 Sa eae 5 Ss Y o 3 a E CL pem Cc C 9 be p ed 2 SS S55 ra owerFlex 2 a ae m NR Mop si C 25 Cc N E Aa m C 5 o 4 0 Allen Bradley q 00 Fs ell h i 61 0 24 66 1 2 60 IP 30 NEMA 1 UL Type 1 conduit box 63 1 2 48 33 5 1 32 23 9 0 94 UPUUUUUU 21 5 20 85 AN 027 5 01 08 MU EX iH L Ko DN X 5 C gt KS oun m 38 on EE Iya GOV in 2 KEY 3 CIS 0c 5 ji Rockwell Automation Publication 520 UM001B EN E February 2013 163 Appendix B 164 Accessories and Dimensions IP 30 NEMA 1
2. Liu B uu 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 Accel 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 o Output 3 Jump 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 o 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 o 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 NoOuput Settings Digit 2 and 1 Positioning Settings Digit 4 Setting Description 0 Skip Step Jump Immediately Setting Param sed ututitate FromHome Command 1 P Basedon tp LogicTime x 7x Accel Decell 0f wD About 2 Step if Logic In 1 is Active 1 Accel Decel 1 Off FWD Incrementa i step if Logic ues A Active 2 Accel Decel Off REV Absolute step T logic w i Not Active 3 Accel Decel 1 off REV Incrementa Step T
3. 168 0 6 61 E E gt RT 92 7 3 65 NANNNNANNAN 6 0 0 24 n 158 Rockwell Automation Publication 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B IP 20 Open Type Frame C Dimensions are in millimeters and inches 109 0 4 29 184 0 7 24 90 5 3 56 k x rye C g 2 C 95 FATO 6 Esc E C5 XI eel Ec ama N CL Co a CL S55 P A eS Te a a CL e C 3 C _ U U e C y E RAD N
4. T H e e ee fad i g4 gd g 3 P la i Controller TE cee For information regarding EtherNet IP or other communication protocols refer to the appropriate 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 PowerFlex525 PowerFlex525 PowerFlex 525 Master Node 1 Node 2 Node n TxRxD 5 ID 5 bm s 120 ohm resistor sp ee 4 RD p Rt 4 N png pint Shield y Shield y Shield y M 7 a 7 FRONT RS485 RS485 ae DPI DPI AK 00 RJ45 TB2P gt H U TxRxD TxRxD TxRxD S S TxRXD eS LUR 12 5 L NIKUV24 3 W IR L2 S BG NIU 2A T3 W BOS CEE amp DC DG BR amp DC DG BR BR BR IMPORTANT The shield is connected at ONLY ONE end of each cable segment Rockwell Automation Publication 520 UM001B EN E February 2013 173 AppendixC RS485 DSI Protocol Parameter Configuration 174 Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 525 RJ45 socket must not be connected because t
5. Connection Examples Example 1 Safe Torque Off Connection with Coast to Stop Action SIL 2 PL d Stop Category 0 Coast s NI Aline input power PF 525 24V DC Stop Stop O Start Start Gate control aa power supply button Gate control druit 4 81 i 82 Ea ee zs ee J ee ACline f input power I ld i PF525 i EE G i GuardMaster oe ate Trojan Stop Stop o Start Start E Stop latching 1 button U i l Gate control druit 4 Ce l S1 i 2 Bois ea da emer adres ere ES 1 Safety relay and PowerFlex 525 must be installed in the same enclosure 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 UM001B EN E February 2013 213 Appendix G 214 Safe Torque Off Function 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 v
6. PowerFlex 525 Drives Output Ratings Normal Duty Heavy Duty Output Input Frame Catalog No HP kW HP kW Current A Voltage Range Size 380 480V AC 15 10 3 Phase Input with EMC Filter 0 460V 3 Phase Output 25B D1P4N114 0 5 0 4 0 5 0 4 1 4 323 528 A 25B D2P3N114 1 0 0 75 1 0 0 75 23 323 528 A 25B D4P0N114 2 0 1 5 2 0 1 5 4 0 323 528 A 25B D6P0N114 3 0 2 2 3 0 2 2 6 0 323 528 A 25B D010N114 5 0 4 0 5 0 4 0 10 5 323 528 B 25B D013N114 7 5 5 5 7 5 5 5 13 0 323 528 C 25B D017N114 10 0 7 5 10 0 7 5 17 0 323 528 C 25B D024N114 15 0 11 0 15 0 11 0 24 0 323 528 D 25B D030N114 20 0 15 0 15 0 11 0 30 0 323 528 D 25B D037N114 25 0 18 5 20 0 15 0 37 0 323 528 E 25B D043N114 30 0 22 0 25 0 18 5 43 0 323 528 E 525 600V AC 15 10 3 Phase Input 0 575V 3 Phase Output 25B EOP9N104 0 5 0 4 0 5 0 4 0 9 446 660 A 25B E1P7N104 1 0 0 75 1 0 0 75 17 446 660 A 25B E3PON104 2 0 1 5 2 0 15 3 0 446 660 A 25B E4P2N104 3 0 2 2 3 0 2 2 42 446 660 A 25B E6P6N104 5 0 3 7 5 0 3 7 6 6 446 660 B 25B E9P9N104 7 5 5 5 7 5 5 5 9 9 446 660 C 25B E012N104 10 0 7 5 10 0 75 12 0 446 660 C 25B E019N104 15 0 11 0 15 0 11 0 19 0 446 660 D 25B E022N104 20 0 15 0 15 0 11 0 22 0 446 660 D 25B E027N104 25 0 18 5 20 0 15 0 27 0 446 660 E 25B E032N104 30 0 22 0 25 0 18 5 32 0 446 660 E 1 Anon filtered drive is not available for 380 480V AC 25 HP 18 5 kW
7. StartUp Chapter 2 Stop drive before changing this parameter No Parameter Min Max Display Options Default P041 Accel Time 1 0 00 600 00 s 0 015 10 00 s Sets the time for the drive to accel from 0 Hz to Maximum Freq P042 Decel Time 1 0 00 600 00 s 0 015 10 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 ce 0 1 Coast cp Stop command for normal stop 2 DC Brake CP Important 1 0 Terminal 01 is always a stop input 3 pCBrkAuto CR 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 stopor 8 Ramp EMB CcF enable input 9 Ramp EM zd 10 PointStp CF 1 Stop input also clears active fault 11 PointStop P046 Start Source 1 1 5 1 Keypad P046 1 ba Sets the default control scheme used to start the Fieber is drive unless overriden by P048 Start Source 2 or 4 u Pian Opt T P050 Start Source 3 5 Ethernet IP 1 When active the Reverse key is also active
8. Values Default Read Only Min Max 0 1200VDC Display 1VDC b006 Drive Status Related Parameter s A544 Present operating condition of the drive FITTA LaL LA LAILA 1 True Active 0 False Inactive Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive Digit 5 Values Default Read Only Min Max 00000 11111 Display 00000 Rockwell Automation Publication 520 UM001B EN E February 2013 63 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 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 yy 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 t062 t063 t065 t068 L180 L187 A410 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 R
9. swing the frame cover to snap the side catches onto the Power Module Frames B E only Rockwell Automation Publication 520 UM001B EN E February 2013 24 Control Module Cover Power Module Terminal Guard Installation Wiring Chapter 1 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 Re attach the front cover when wiring is complete To access the power terminals the terminal guard must be removed To remove 1 Press and hold down the catch on both sides of the frame cover then pull out and swing upwards to remove Frames B E only Rockwell Automation Publication 520 UM001B EN E February 2013 25 Chapter1 Installation Wiring Power Wiring 26 2 Pressand hold down the locking tab on the terminal guard 3 Slide the terminal guard down to remove from the Power Module S gt ie E 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 22 for instructions outline provisions for safely installing electr
10. 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 Digln TrmBIk to configure Start Source x to a 3 wire start mode 50 2 Wire REV only for DigIn TermBlk 03 Digln TermBlk 03 default Selects 2 Wire REV for this input Select this option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to configure Start Source x to a 2 wire run reverse mode Also see t064 2 Wire Mode for level trigger settings 5 3 Wire Dir Select 3 Wire Dir for this input only for Digln TermBlk 03 Select this option and set P046 P048 or P050 Start Source x to 2 DigIn TrmBlk to change the direction of Start Source x 52 Pulse Train Selects pulse train for this input only for Digin TermBlk 07 Use P047 P049 and P051 Speed Referencex to select pulse input Jumper for DigIn TermBlk 07 Sel must be moved to Pulse In 1 This function may be tied to one input only t064 2 Wire Mode O Ray 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 Coa
11. PID Feedback Pressure Transducer Signal PID Reference Desired System Pre Trim Control ssure 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 1 PID Loop Accel Decel PID Ref gt PID Prop Gain fam I pp i A ME Error utput PID Fdbk PID Integ Time H 2 f gt 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 result in a PID Error value e The Master Speed Reference sets the wind unwind speed e As tension increases or decreases during winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point PID Reference Equilibrium Set Point d lt 0V wom 7 PID Feedback J Dancer Pot Signal lt 10V Speed Referencex Rockwell Automation Publication 520 UM001B EN E February 2013 a I i Foam Fi A PID Reference and Feedback Analog PID Reference Signals
12. 380 480V AC 15 10 3 Phase Input with External EMC Filter 0 460V 3 Phase Output A Shielded None None INPUT CORE RF A 1 OUTPUT CORE RF A 2 B Shielded None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Shielded None None INPUT CORE RF C 1 D Shielded OUTPUT CORE RF D 2 None INPUT CORE RF D 1 OUTPUT CORE RF D 2 E Shielded None Shielded INPUT 1 CORE E 1 and INPUT 2 CORE E 2 Rockwell Automation Publication 520 UM001B EN E February 2013 OUTPUT 1 CORE E 3 and OUTPUT 2 CORE E 4 45 Chapter 1 Installation Wiring Additional Installation Requirements Frame Size 380 480V AC 15 10 3 Phase Input with Internal EMC Filter 0 460V 3 Phase Output Class C1 Class C2 Enclosure and Conduit Cable EMC Cores Required Endosure EMC Cores Required Input and Output A None INPUT CORE A 1 OUTPUT CORE A 2 B None INPUT CORE B 1 OUTPUT CORE B 2 C None INPUT CORE C 1 OUTPUT CORE C 2 D None INPUT CORE D 1 OUTPUT CORE D 2 E None INPUT 1 CORE E 1 and INPUT 2 CORE E 2 OUTPUT 1 CORE E 3 and OUTPUT 2 CORE E 4 525 600V AC 1596 10 3 Phase Input with External EMC Filter 0 575V 3 Phase Output A Shielded None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 B Shielded None None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Shielded None None INP
13. Other Parts Frame Item Description Size Catalog No PowerFlex 525 Control Replacement cover for the control module 1 0 terminals A E 25B CTMFC1 Module Front Cover EtherNet IP and DSI ports PowerFlex 520 Series Replacement cover for the PowerFlex 520 Series power B 25 PMFC FB Power Module Front Cover module C 25 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 PowerFlex 520 Series Replacement fan for drive power module A 25 FAN1 FA Heatsink Fan Kit B 75 FAN1 FB C 25 FANT FC D 25 FANT FD E 25 FANT FE Rockwell Automation Publication 520 UM001B EN E February 2013 155 Appendix B 156 Accessories and Dimensions 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 t
14. Values Default 0 Min Max 0 255 Display 1 C141 EN Rate Cfg 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 AJ w N 100Mbps Half C143 EN Comm Fit Actn Related Parameter s P045 C145 C146 C147 C150 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 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
15. Values Default Read Only Min Max 0 1200VDC Display 1VDC F661 Status Fault 1 F662 Status Fault 2 Related Parameter s b006 F663 Status Fault 3 F664 Status Fault 4 F665 Status Fault 5 F666 Status Fault 6 F667 Status Fault 7 F668 Status Fault 8 F669 Status Fault 9 F670 Status Fault10 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 rrr LI LE LI LII 1 Condition True 0 Condition False Running Digit 1 Forward Digit 2 Accelerating Digit 3 Decelerating Digit 4 SafetyActive Digit 5 Values Default Read Only Min Max 0 0x1F Display 1 F681 Comm Sts DSI Displays the status of the RS485 serial DS port to the drive HIHIHIHI Digit 3 Connection Status 1 Condition True 0 Condition False 0 Not Active Rx Digit 1 1 Modbus slave network external Modbus master Tx Digit2 2 Modbus multi drive w internal com option master Status Digit3 3 Modbusmulti drive w embedded com master Error Digit4 4 DSI peripheral connected Not Used 5 8 Reserved 9 RS 485 network faulted Values Default Read Only Min Max 0000 1911 Display 0000 120 R
16. 154 Rockwell Automation Publication 520 UM001B EN E February 2013 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 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 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 1 7 446 660 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 2 2 4 2 446 660 A 25 PM1 E4P2 5 0 37 5 0 3 7 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 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 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 Item Description PowerFlex 525 Control Replacement control module for use with Module PowerFlex 520 Series drives Includes e Control Module Control Module Front Cover
17. 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 UM001B EN E February 2013 153 AppendixB Accessories and Dimensions Replacement Parts PowerFlex 520 Series Power Module Item Description PowerFlex 525 Power Replacement power module for use with PowerFlex 520 Series drives Includes Module Power Module Power Module Front Cover e 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 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 5 0 4 0 5 0 4 2 5 170 264 A 25 PM1 A2P5 1 0 0 75 1 0 0 75 48 170 264 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
18. 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 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 _ O 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 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 UM001B EN E February 2013 Installation Wiring Chapter 1 Recom
19. 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 active 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 34 for wiring examples Ifthe PowerFlex 525 Safe Torque Off function is used verify that inputs are active 2wire contr
20. Values Default 1024 PPR Min Max 0 20000 PPR Display 1PPR A537 Pulse In Scale Related Parameter s A535 Sets the scale factor gain for the Pulse Input when A535 Motor Fdbk Type is set to 1 Pulse Train Values Default 64 Min Max 0 20000 Display 1 A538 Ki Speed Loop 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 Sets the P gain used in the PI calculation of the speed loop when feedback is used Values Default 5 0 Min Max 0 0 200 0 Display 0 1 A540 Var PWM Disable Related Parameter s A440 O Bay 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 112 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A541 Auto Rstrt Tries Related Parameter s A542 Sets the maximum number 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 with
21. 1 055 0022 ae 0 6 0666 275 0 10 83 o 263 0 263 0 10 35 10 35 9 Li L2 3 Sa AV jener 25 0 0 98 28 0 1 10 5 5 0 22 76 0 2 99 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 E Q d upupu es n ea E 310 0 12 20 298 0 298 0 11 73 11 73 o o ueg f cx aux aues 33 0 130 28 0 1 10 LSS 0 22 90 0 3 54 Rockwell Automation Publication 520 UM001B EN E February 2013 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 E 14 76 e 33 0 1 30 286 1 10 Accessories and Dimensions Appendix B 155 0 6 10 110 0 4 33 5 5 20 22 390 0 15 35 375 0 14 76 5 5 0 22 110 0 4 33 Rockwell Automation Publication 520 UM001B EN E February 2013 169 AppendixB Accessories and Dimensions Optional Accessories and Kits Installing a Communication Adapter 1 Insert the communica
22. 27 25 C Duty Cycle 50 10 Requirements 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 Control Relay Quantity 2 1 Programmable Form A and 1 Programmable Form B Outputs 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 Opto Quantity 2 Programmable Specification 30V DC 50 mA Non inductive Analog Quantity 1 Non Isolated 0 10V or 4 20 mA Specification Resolution 10 bit 0 10V DC Analog 1kohm minimum 4 20 mA Analog 525 ohm maximum PowerFlex 525 Estimated Watts Loss Rated Load Speed amp PWM Voltage 100 120V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase w EMC Filter 200 240V 50 60 Hz 3 Phase Rockwell Automation Publication 520 UM001B EN E February 2013 Output Current A Total Watts Loss 2 5 27 0 4 8 53 0 6 0 67 0 2 5 29 0 4 8 50 0 8 0 81 0 11 0 111 0 2 5 29 0 4 8 53 0 8 0 84 0 11 0 116 0 25 29 0 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 0 147 AppendixA X Supp
23. 40 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 ofthe 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 an auxiliary mechanical braking device must be used 41 Freeze Fire When inactive will cause an immediate F094 Function Loss fault Use to safely bypass the drive with an external switching device 42 SW Enable Works like an interlock that has to be active for the drive to run 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 45 Reserved 46 Reserved 74 Rockwell Automation Publication 520 UM001B EN E February 2013 Options 47 Reserved Programming and Parameters Chapter 3 48 2 Wire FWD only for DigIn TermBlk 02 Digln TermBlk 02 default Selects 2 Wire FWD for this input Select this option and set P046 P048 or P050 Start Source x to 2 Digln TrmBlk to configure Start Source x to a 2 wire run forward mode Also see t064 2 Wire Mode for level trigger settings
24. 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 americas 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 com
25. Conveyor Motor NP Volts P031 Decel Time 1 P042 Digln TermBlk 03 t063 Anlg In mA Loss Motor NP Hertz P032 Minimum Freq P043 Opto Outi Sel 1069 Slip Hz Meter ial Motor OL Current P033 Maximum Freq P044 Relay Out Sel t076 Preset Freq 0 Motor NP FLA P034 Stop Mode P045 Anlg In 0 10V Lo t091 Jog Frequency Language P030 Motor NP Poles P035 Start Source 1 P046 Anlg In 0 10V Hi t092 Jog Accel Decel Output Freq b001 Autotune P040 Speed Reference1 P047 Anlg In4 20mA Lo t095 S Curve Commanded Freq b002 Accel Time 1 P041 Digin TermBlk 02 t062 Anlg In4 20mA Hi t096 Reverse Disable Mixer Output Current b003 Autotune P040 Start Source 1 P046 Anlg In4 20m4A Hi Motor NP Volts P031 Accel Time 1 P041 Speed Reference1 P047 Anlg In mA Loss il Motor NP Hertz P032 Decel Time 1 P042 Relay Out Sel t076 Preset Freq 0 Motor OL Current P033 Minimum Freq P043 Anlg In 0 10V Lo t091 Stall Fault Time Language P030 Motor NP FLA P034 Maximum Freq P044 Anlg In 0 10V Hi t092 Output Freq b001 Motor NP Poles P035 Stop Mode P045 Anlg In4 20mA Lo t095 Compressor Motor NP Hertz P032 Maximum Freq P044 Anlg In 0 10V Lo t091 Start At PowerUp Motor OL Current P033 Stop Mode P045 Anlg In 0 10V Hi t092 Reverse Disable tn Motor NP FLA P034 Start Source 1 P046 Anlg In4 20mA Lo 1095 Power Loss Mode Motor NP Poles P035 Speed Reference1 P047 Anlg In4 20m4A Hi t096 Half Bus Enable Language P030 Autotune P040 Relay Out Sel 1076 AnlgIn mA Loss t097 Output Freq b001
26. Rockwell Automation Publication 520 UM001B EN E February 2013 65 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 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 of the 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 Di
27. 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 30 for wiring recommendations and Control I O Terminal Designations on page 33 for terminal descriptions If Safety Inputs S1 and S2 are powered by an external 24V source apply it only in SELV system PELV system or low voltage Class 2 circuit 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 UM001B EN E February 2013 211 Appendix G Safe Torque Off Function Verify Operation 212 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 By itself 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 a
28. 110 5 150 111 0 1321 3R25 B 1321 3RA25 B 1321 3R25 B 1321 3RA25 B 20 0 15 0 1150 110 1321 3R35 B ND 1321 3RA35 B ND 1321 3R25 B 1321 3RA25 B 1321 3R25 B HD 1321 3RA25 B HD 25 0 185 20 0 115 0 1321 3R35 B 1321 3RA35 B 1321 3R35 B 1321 3RA35 B 30 0 220 1250 185 1321 3R45 B ND 1321 3RA45 B ND 1321 3R45 B 1321 3RA45 B 1321 3R35 B HD 1321 3RA35 B HD 460 600V 50 60 Hz 3 Phase 0 5 04 05 0 4 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 1 0 075 10 0 75 1321 3R2 B 1321 3RA2 B 1321 3R2 B 1321 3RA2 B 2 0 1 5 2 0 1 5 1321 3R4 D 1321 3RA4 D 1321 3R4 D 1321 3RA4 D 3 0 2 2 3 0 2 2 1321 3R4 C 1321 3RA4 C 1321 3R4 C 1321 3RA4 C 5 0 37 5 0 37 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 75 5 5 75 5 5 1321 3R12 C 1321 3RA12 C 1321 3R12 C 1321 3RA12 C 10 0 75 10 0 17 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B 15 0 3110 1150 11 0 13213R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 20 0 150 150 110 1321 3R25 B ND 1321 3RA25 B ND 1321 3R25 B 1321 3RA25 B 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 1321 3RA35 C 1321 3R25 B HD 1321 3RA25 B HD 300 220 1250 185 1321 3R35 B ND 1321 3RA35 B ND 1321 3R35 B 1321 3RA35 B 1321 3R35 C HD 1321 3RA35 C HD 1 Normal Duty and Heavy Duty ratings for 15 HP 11 kW and below are identical 2 Catalog numbers lis
29. 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 Remote Handheld HIM Wireless Interface Module with Bluetooth technology IP 30 NEMA Type 22 WIM N1 1 Panel Mount with optional bezel kit Does not support the new dynamic parameter groups AppView CustomView Remote Panel Mount HIM Wireless Interface Module with Bluetooth technology IP66 NEMA Type 22 WIM N4S 4X 12 indoor use only Does not support the new dynamic parameter groups AppView CustomView 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 DSI HIM to RJ45 cable 2 9m 9 51 ft 22 HIM H30 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 Control Module Fan Kit For use with drive in environments with ambient M 25 FAN1 70C temperatures up to 70 C or horizontal mounting 25 FAN2 70C Incremental Encoder Input Option Item Description Catalog No
30. Oscillation Under Damped PID Reference PID Feedback Time Good Response Critically Damped PID Reference E PID Feedback Time Rockwell Automation Publication 520 UM001B EN E February 2013 205 AppendixF X PID Set Up Notes 206 Rockwell Automation Publication 520 UM001B EN E February 2013 PowerFlex 525 Safe Torque Off Overview Appendix G Safe Torque Off Function The PowerFlex 525 Safe Torque Off function when used with other safety components helps provide protection according to EN ISO 13849 and EN62061 for safe off and protection against restart The PowerFlex 525 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 207 EC Type Examination Certification 208 EMC Instructions 208 Using PowerFlex 525 Safe Torque Off 208 Enabling PowerFlex 525 Safe Torque Off 211 Wiring A Verify Operation 212 PowerFlex 525 Safe Torque Off Operation 211 Connection Examples 213 PowerFlex 525 Certification for Safe Torque Off 217 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 I
31. 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 Display 0 1Hz A534 Maximum Voltage Related Parameter s b004 Sets the highest voltage the drive outputs Values Default Drive Rated Volts Min 10VAC on 230VAC Drives 20VAC on 460VAC Drives 25VAC on 600VAC Drives Max 255VAC on 230VAC Drives 510VAC on 460VAC Drives 637 5VAC on 600VAC Drives Display 1VAC Rockwell Automation Publication 520 UM001B EN E February 2013 111 Chapter3 Programming and Parameters Advanced Program Group continued A535 Motor Fdbk Type Related Parameter s A537 O Kay drive before changing this parameter 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 Specifies the encoder Pulses Per Revolution PPR when an encoder is used
32. Programming and Parameters Chapter 3 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 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 175 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 Default 19 200 38 400 Un Bl UC NO 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 o
33. Rockwell Automation Publication 520 UM001B EN E February 2013 PID SetUp Appendix F PID mode is enabled by setting P047 P049 or P051 Speed Referencex to 11 PID1 Output or 12 PID2 Output and activating the corresponding speed reference 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 t068 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 Reference 2 Serial DSI The reference word from the Serial DS communication network becomes the PID Reference 4 Network Opt The reference word from a communication network option becomes the PID Reference 5 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
34. X1 AUX 3 v 132333 A1 Coil 142434 A2 External 100 C _ contactor 100S C 1 Safety relay and PowerFlex 525 must be installed in the same enclosure 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 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 216 Rockwell Automation Publication 520 UM001B EN E February 2013 Safe Torque Off Function 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 PowerF
35. logic h 2 s Not Active 1 Accel Decel 1 On FWD Absolute 6 Step if either Logic In 1 or Logic In 2 is Active Accel Dece On FWD Wgementa 7 Step if both Logic In 1 and Logic In 2 are Active 5 Accel Decel1 On REV Absolute 8 Step if neither Logic In 1 nor Logic In 2 is Active 7 Accel Dece On REV haremet 9 Step if Logic In 1 E Active and logie In 2 is Not Hue 8 Accel Decel2 Of FWD Absolute A Step if Logic In 2 is Active and Logic In 1 is Not Active 9 Accel Decel 2 Of FWD TReraimenta b Step after Stp Logic Time x and Logic In 1 is Active rn Accel Decel 2 Of REV Absolute C Step after Stp Logic Time x and Logic In 2 is Active b Accel Decel 2 Of REV Incainenta 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 Time x and Logic In 2 is Not Active d Accel Decel 2 On FWD Incrementa Do Not Step lgnore Digit 2 Settings E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incrementa TIP 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 responsiv
36. 01 02 03 04 O Direction Opto Output 1 amp 2 Opto Output 1 t069 Opto Out1 Sel determines Opto Output 1 I 0 Terminal 17 operation t072 Opto Out2 Sel determines Opto Output 2 1 0 Terminal 18 17 operation th 19 When using Opto Output with an inductive load 43V Common such as a relay installa Each Opto Output is rated 30V DC 50 mA Non inductive recovery diode parallel to the relay as shown to prevent damage to the output Analog Output t088 Analog Out Sel 0 through 23 t088 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 1k Q minimum 0 20 mA 4 20 mA 525 Q maximum a i 3 3 S 3 3 i e o o0 Rockwell Automation Publication 520 UM001B EN E February 2013 37 Chapter 1 38 Installation Wiring Typical Multiple Drive Connection Examples Input Output Multiple Digital Input Connections Customer Inputs can be wired per External Supply SRC Connection Example 2eeoqe0eo 8 Q8 AAA 8 8 0A TI 7 Optional Ground Connection O Customer Inputs When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives
37. 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 71 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 UM001B EN E February 2013 179 AppendixC RS485 DSI Protocol Reading 03 Drive Operational Values Reading 03 and Writing 06 Drive Parameters Additional Information 180 Drive Error Codes Logic Status Address Decimal Value Decimal Description 2101H 8449 125 Flash Update Required 126 Non Recoverabl
38. 912 3O WOL SL3 090 NOPL 0 001 g os 0t 0 S v0LNOLOQ gSC 012 3O WOvL SL YS10 L40 f SAY SSYTD 012 3O WOFL OLI 090 NOPL SL 602 001 V 0t e 0 PLLNOd90 852 015 3O WOvL SL S10 1J0 cyH SSVD 012 30 WOFL OLI 090 NOPL SL 602 001 V 0t TT 0 POLNOd9d 952 9g 3O WOv L SLu S10 1Jo eyH SSVD 98330 WOrL 099 09d NOvL SL 602 001 V 07 SL O Z vLLNOdYQ 8SC 9g 3O WOv L SL u S10 LJo cyH SSV 98 33O WOrL 099 090 NOvL SL 602 001 V 0c SL O Z POLNOdvd 852 079 32 WOrL OL AwS1Q0 L1Jo CyH SSVID 0v8 3O WOFL 099 090 NOrL OL 102 001 V OL S 0 OL vLLNEdCQ 8SC 0v8 3O WOr L OL U S1 L10 SY SSVD 078 30 WOtvL 099 090 NOrL OL 100 001 V OL S 0 OL vOLNEdCQ 8SC SC8 3O WOrL 9 4 S10 110 f SAY SSVD Sc8 3O WOFL 0EG EQ90 fOvL 9 102 001 V 0 70 0 vLLNFdLO SSC C8 3O WOvL 9 4 S10 110 f SAY SSVD S79 IO W0YL O 8 090 NOvL 9 102 001 V 50 70 0 VOLNVdLO 8SC WopL orL1n NOvL 68h 1n ON Gojeyey sser Worl NOvL Guney xew Buey uw on Bojeye sduy dH MA dH y 9N boeze S19 eaJg HINDI Gurney xew sesnj s1ayeag UNI sasn4 10p83u0 auiei kyng kaea Kang jeuuoN suoneiiddy 1 suone iddy 10 uoN 531 sbuney 3ndu sBuney 1nding JV SUDI sa aq uoiajoJg Indu asbuq NOS 09 Rockwell Automation Publication 520 UM001B EN E February 2013 20 Chapter 1 Installation Wiring NUL LL dH SL a oqe s p 104 a qejreAe aie sured Aynp KA
39. 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 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 M97 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 Rotor resistance of induction motor Values Default Based on Drive Rating Min Max 0 00 655 35 ohm Display 0 01 ohm 108 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A499 Motor Lm 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 Leakage Inductance of induction motor Values Default Based on Drive Rating Min Max 0 0 6553 5 mH Displa
40. 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 Rockwell Automation Publication 520 UM001B EN E February 2013 83 Chapter3 Programming and Parameters Terminal Block Group continued t104 Wake Time Sets the analog input time the drive must stay above to wake from sleep mode Values Default 0 05 Min Max 0 0 600 0 s Display 0 15 t105 Safety Open En 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 UM001B EN E February 2013
41. PID 1 Preload 466 Program Lock Mod 553 Start Source 3 050 PID 1 Prop Gain 461 Pulse In Scale 537 Status Fault 1 661 PID 1 Ref Sel 459 Purge Frequency 433 Status Fault 2 662 PID 1 Setpoint 464 PWM Frequency 440 Status Fault 3 663 PID 1 Trim Hi 456 Relay 1 Off Time 080 Status Fault 4 664 PID 1 Trim Lo 457 Relay 1 On Time 079 Status Fault 5 665 PID 1 Trim Sel 458 Relay 2 Off Time 085 Status Fault 6 666 PID 2 Deadband 47 Relay 2 On Time 084 Status Fault 7 667 PID 2 Diff Rate 475 Relay Out1 Level 077 Status Fault 8 668 PID 2 Fdback Sel 472 Relay Out1 Sel 076 Status Fault 9 669 PID 2 Integ Time 474 Relay Out2 Level 082 Status Fault10 670 PID 2 Invert Err 479 Relay Out2 Sel 081 Step Units 0 200 PID 2 Preload 478 Relay Out1 LevelF 078 Step Units 1 202 PID 2 Prop Gain 473 Relay Out2 LevelF 083 Step Units 2 204 PID 2 Ref Sel 471 Reset Meters 555 Step Units 3 206 PID 2 Setpoint 476 Reset to Defalts 053 Step Units 4 208 PID 2 Trim Hi 468 Reverse Disable 544 Step Units 5 210 PID 2 Trim Lo 469 RS485 Data Rate 123 Step Units 6 212 PID 2 Trim Sel 470 RS485 Format 127 Step Units 7 214 PID1 Fdbk Displ 383 RS485 Node Addr 124 Step Units F 0 201 PID1 Setpnt Displ 384 S Curve 439 Step Units F 1 203 PID2 Fdbk Displ 385 Safety Open En 105 Step Units F 2 205 PID2 Setpnt Displ 386 Shear Pin 1 Time 487 Step Units F 3 207 Pos Reg Filter 565 Shear Pin 2 Time 489 Step Units F 4 209 Pos Reg Gain 566 Shear Pin1 Level 486 Step Units F 5 211 Position Status 387
42. Selects P051 Speed Reference3 as drive s speed command 3 StartSrc2 Selects P048 Start Source 2 as control source to start the drive 4 StartSrc3 Selects P050 Start Source 3 as control source to start the drive 5 Spd Strt 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 Spd 4 Strt 3 Selects combination of P051 Speed Reference3 and P050 Start Source 3 as speed command with control source to start the drive Preset Freq only for DigIn TermBlk 05 08 Digln TermBlk 05 and DigIn TermBlk 06 default Selects 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 Step Units x 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 39 for more information 8 Jog 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 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 Digl
43. Ungrounded Distribution Systems 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 525 contains protective MOVs that are referenced to Disconnecting MOVs To prevent drive damage the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system IT mains where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect these devices remove the jumper shown in the diagrams below 1 Turn the screw counterclockwise to loosen 2 Pull the jumper completely out of the drive chassis 3 Tighten the screw to keep it in place Jumper Location Typical Power Module IMPORTANT Tighten screw after jumper removal Phase to Ground MOV Removal Three Phase NH Oo ACInput S L2 p T L3 Jumper 1 2 43 4 1 l 1 1 1 Rockwell Automation Publication 520 UM001B EN E February 2013 15 Chapter1 Installation Wiring General Grounding Requirements 16 Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see Appendix A Listed in the Input Power Cond
44. and 30 HP 22 0 kW ratings Filtered drives are available however you must verify that the application will support a filtered drive 150 Rockwell Automation Publication 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance Input Volt HP kW I I Q 10 Q 5 Catalog No 72 100 120V 0 5 0 4 60 91 AK R2 091P500 0 60 Hz 10 075 60 91 AK R2 091P500 1 Phase 1 5 1 1 48 91 AK R2 091P500 200 240V 0 5 0 4 60 91 AK R2 091P500 50 60 Hz 10 075 60 91 AK R2 091P500 1 Phase 2 0 1 5 48 91 AK R2 091P500 3 0 2 2 32 47 AK R2 047P500 200 240V 0 5 0 4 60 91 AK R2 091P500 0 60 Hz 10 075 60 91 AK R2 091P500 3 Phase 2 0 1 5 60 91 AK R2 091P500 3 0 2 2 32 47 AK R2 047P500 5 0 3 7 19 47 AK R2 047P500 75 5 5 19 30 AK R2 030P1K2 100 17 5 15 30 AK R2 030P1K2 150 11 0 15 15 AK R2 030P 1120 200 150 1 15 AK R2 030P 1120 380 480V 0 5 0 4 97 360 AK R2 360P500 50 60 Hz 10 075 97 360 AK R2 360P500 3 Phase 2 0 1 5 97 360 AK R2 360P500 3 0 2 2 97 120 AK R2 120P1K2 5 0 4 0 7 120 AK R2 120P1I2 7 5 55 55 120 AK R2 120P1I2 100 17 5 55 120 AK R2 120P1K2 15 0 110 050 60 AK R2 120P1K2 20 0 15 0 150 60 AK R2 120P1K2 250 185 30 40 AK R2 120P 11009 300 1220 30 40 AK R2 120P1K2 525 600V 0 5 0 4 120 360 AK R2 360P500 50 60 Hz 1 0 075 120 360 AK R2 3
45. es ccet se eu er pe etu IIS 128 Chapter 4 Drive Stats M kare ee teanen saa ve eh Oates ee ew esd 133 ij pe ME E 133 Fault Descriptions ids cis dVLese d UE HH eu at 135 Common Symptoms and Corrective Actions 00 0 eee ee 138 Appendix A Drives Fuse amp Circuit Breaker Ratings 02 cete 143 Specifications 6 tos nas caa dur euo Sese o eur dd rum Dess Saad ams 144 Appendix B Product Selection i te EG EUR 149 Product DimensiobSos siete teresa Ruan asaeae hol anten uae omer 157 Optional Accessories and Kites osea i epus TEE ES Re du ett 170 Appendix C Network Wiring q4epie Upxdtelouaexu oda patito quies cat ple tbi aE 173 Parameter Configuration cocos tens AN el cubist a dtu a aede 174 Supported Modbus Function Codes cece seen eee e eens 175 Writing 06 Logic Command Data eie en renes 175 Writing 06 Comm Frequency Command 000 06 177 Reading 03 Logic Status Data oos ne liad coer reete 177 Reading 03 Drive Error Codes 2 te DEDE 179 Reading 03 Drive Operational Values ete 180 Reading 03 and Writing 06 Drive Parameters 180 Additional Information sd oeeses cud repu d Rer ur uxo s RUP Ies 180 Appendix D Velocity StepLogic Using Timed Steps 0 c cece eee ees 182 Velocity StepLogic Using Basic Logic Functions 08 182 Timer Functions s eee Seb vaso dq SER MR aad duel he PRSE DEN 183 Counter PuticHoDe exieeee e eser terr penat
46. ratings circuit breakers 18 reading Modbus 177 179 180 recommended circuit breakers 143 fuses 143 wiring 30 211 reflected wave protection 28 RFI filter ground 17 RS485 DSI configuring 174 S safety applications 209 basic operation 212 drive 211 ground 17 testing 210 wiring 211 selecting accel 41 decel 41 digital inputs 40 speed reference 39 start source 39 separating power and control module 22 Shielded wiring 27 shielding ground 17 speed reference override priority 39 selecting 39 start motor 28 start source digital inputs 40 override priority 39 selecting 39 stop motor 28 storage environment 14 T temperature Rockwell Automation Publication 520 UM001B EN E February 2013 derating 13 wiring 27 testing safety 210 timer programming 181 183 tools programming 51 U unshielded wiring 27 V voltage reflections wiring 28 Ww wave protection reflected 28 wiring encoder 188 noise immunity 31 174 recommended 30 211 RS485 DSI 173 safety 211 shielded 27 temperature 27 unshielded 27 voltage reflections 28 writing Modbus 175 177 180 Rockwell Automation Publication 520 UM001B EN E February 2013 225 Notes 226 Rockwell Automation Publication 520 UM001B EN E February 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products
47. 0 3 Hold Last Note The Reference and Datalink values transmitted to the drive will be held at their last value 4 Send Flt Cfg Note The Logic Reference and Datalink values will be transmitted to the drive as configured in C145 C146 and C147 C150 Rockwell Automation Publication 520 UM001B EN E February 2013 87 Chapter3 Programming and Parameters Communications Group continued C144 EN Idle Fit Actn Related Parameter s P045 C145 C146 C147 C150 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 connected drive if the scanner is idle 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 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 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 Ref
48. 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B IP 30 NEMA 1 UL Type 1 Frame D Dimensions are in millimeters and inches x IP 30 NEMA 1 UL Type 1 top panel 1300 o 2 212 0 8 35 e w sE600000000 Ales amp radiey 1 E N s B C SO z l gm Ceo g DF TI E e C5 EI 2 _ eo CL eS IS gt SE PoworFlex S A SS nanaanaaaan 2 gt S55 o N Cc gt a a gt a SS SI iD 10 n D Allen Bradley fat E d P 6 0 0 24 LL 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 La 5 90 85 O ear 33 5 91 32 d B 2 ies d m mMm a agl B Lines i IRIA 2 BULO Me E eo pes E Rockwell Automation Publication 520 UM001B EN E February 2013 165 AppendixB Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame
49. 71 0 86 Nm 6 2 7 6 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations 1 0 Wiring Examples 1 0 Connection Example Potentiometer P047 Speed Reference1 5 0 10V Input 1 10k Q Pot Recommended TS 2 W minimum TB ooooQ 34 Rockwell Automation Publication 520 UM001B EN E February 2013 Installation Wiring Chapter 1 1 0 Connection Example 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 S 10 2B Ile Common Le Common Common ol Ie 115 I e Is ii e e e amp Analog Input PTC Wire 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 t065 DigIn TermBlk 05 12 Aux Fault t081 Relay Out 2 Sel 10 Above Anlg V 1082 Relay Out 2 Level Voltage Trip Re RP TC hot WV rip X 100 MP ReTc hot Re
50. A 25 RF014 AL 10 075 5 0 A 25 RF014 AL 2 0 1 5 8 0 A 25 RF014 AL 30 22 11 0 A 25 RF014 AL 50 37 17 5 B 25 RF021 BL 75 5 5 24 0 C 25 RF027 CL 100 17 5 322 D 25 RF035 DL 15 0 110 483 E 25 RF056 EL 200 150 62 1 E 25 RF056 EL 05 10 4 114 A 25 RF7P5 AL 10 1075 123 A 25 RF7P5 AL 2 0 15 40 A 25 RF7P5 AL 30 22 60 A 25 RF7P5 AL 50 40 10 5 B 25 RF014 BL 75 5 5 13 0 C 25 RF018 CL 100 17 5 17 0 C 25 RF018 CL 15 0 110 24 0 D 25 RF033 DL 20 0 15 0 300 D 25 RF033 DL 25 0 185 370 E 25 RF039 EL 300 220 430 E 25 RFO39 EL 05 10 4 09 A 25 RF8P0 BL 10 0 75 117 A 25 RF8PO BL 2 0 15 3 0 A 25 RF8PO BL 30 22 42 A 25 RF8PO BL 50 13 7 66 B 25 RF8PO BL 75 55 9 9 C 25 RF014 CL 10 0 17 5 12 0 C 25 RF014 CL 15 0 11 0 19 0 D 25 RF027 DL 20 0 15 0 22 0 D 25 RF027 DL 25 0 185 270 E 25 RF029 EL 300 220 320 E 25 RFO29 EL 1 EMCLine Filter size is based on the input current of the drive See the tables on page 20 and page 21 for more information EMC Plates Item EMC Plate Description Optional grounding plate for shielded cables Rockwell Automation Publication 520 UM001B EN E February 2013 Frame Size Catalog No A 25 EMC1 FA B 25 EMC1 FB C 25 EMC1 FC D 25 EMC1 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
51. A8PON104 2 0 1 5 2 0 1 5 8 0 170 264 B 25B A011N104 3 0 22 3 0 22 11 0 170 264 B 200 240V AC 1596 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 25B A2P5N114 0 5 0 4 0 5 0 4 2 5 170 264 A 25B MP8N114 1 0 0 75 1 0 075 148 170 264 A 25B A8PON114 2 0 1 5 2 0 1 5 8 0 170 264 B 25B A011N114 3 0 22 3 0 22 11 0 170 264 B 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 25B B2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 A 25B B5PON104 1 0 0 75 1 0 075 50 170 264 A 25B B8PON104 2 0 1 5 2 0 1 5 8 0 170 264 A 25B B011N104 3 0 22 30 22 11 0 170 264 A 25B B017N104 5 0 3 7 5 0 3 7 17 5 170 264 B 25B B024N104 7 5 5 5 75 5 5 24 0 170 264 C 25B B032N104 10 0 75 10 0 175 322 170 264 D 25B B048N104 15 0 11 0 15 0 110 3483 170 264 E 25B B062N104 20 0 15 0 15 0 111 0 621 170 264 E 380 480V AC 15 10 3 Phase Input 0 460V 3 Phase Output D 25B D1P4N104 0 5 0 4 0 5 04 14 323 528 A 25B D2P3N104 1 0 0 75 1 0 075 23 323 528 A 25B D4P0N104 2 0 1 5 2 0 1 5 4 0 323 528 A 25B D6P0N104 3 0 2 2 3 0 2 2 6 0 323 528 A 25B D010N104 5 0 4 0 5 0 4 0 10 5 323 528 B 25B D013N104 7 5 5 5 7 5 5 5 13 0 323 528 C 25B D017N104 10 0 7 5 100 175 17 0 323 528 C 25B D024N104 15 0 11 0 1 0 11 0 240 323 528 D 25B D030N104 20 0 15 0 15 0 110 130 0 323 528 D Rockwell Automation Publication 520 UM001B EN E February 2013 149 AppendixB Accessories and Dimensions
52. Accessories and Dimensions IP 30 NEMA 1 UL Type 1 Frame A Dimensions are in millimeters and inches a 720 2 83 S IP 30 NEMA 1 UL Type 1 top panel 2 57 5 2 26 2 172 0 6 77 50000000 X ff O 2 Q C 2 S me 5 u M o m C 2 b ey C 2 m N C ti f 1 ES 2 C 2 e c e N C C w z lm SSS a i CL m SI K E amp PowerFlex E x anagananaas i la 6 0 0 24 H ib ad x 51 1 Q 01 IP 30 NEMA 1 UL Type 1 conduit box 21 0 0 82 921 5 20 85 FT Z B m 25 at m Ec O 9 OL i e TT Hi N EO it A CD UA 1 Ke i 162 Rockwell Automation Publication 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B IP 30 NEMA 1 UL Type 1 Frame B Dimensions are in millimeters and inches
53. Both Logic inputs are programmed and active None 23 Logic 1 or 2 One or both Logic inputs are programmed and one 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 Out Sel 2 Opto Out Sel 1 Min Max 0 29 Display 1 76 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t070 Opto Out1 Level Related Parameter s t069 t072 t073 Opto Out2 Level TE 32 bit parameter Determines the on off point for the digital outputs when t069 or t072 Opto Outx Sel is set to the values shown below Min Max Value Range Based On Opto Outx Sel Setting 6 0 500 Hz 10 0 100 18 0 180 7 10 18096 16 0 1 9999 s 20 10 1 8 10 815V 17 1 9999 counts 26 0 150 Value
54. 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 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 shi
55. Cx S S S S e998 1 2 St 1 2 317 4 15 6 7 18 19 Control 1 0 Wiring Block Diagram Notes 1 See Digital Input Selection for Start Source on page 40 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 P046 P048 P050 Start Source x 1 Keypad 2 Digln TrmBlk 3 Serial DSI 4 Network Opt 5 EtherNet IP t062 t063 Digln TermBlk xx 48 2 Wire FWD 49 3 Wire Start 50 2 Wire REV 51 3 Wire Dir Rockwell Automation Publication 520 UM001B EN E February 2013 Normal Stop 1 0 Terminal 01 Stop Per P045 Coast Stop Mode See t062 t063 DigIn TermBlk xx below Coast Per P045 Stop Mode Per P045 Stop Mode Normal Stop _ 1 0 Terminal 01 Stop Per P045 See t064 2 Wire Mode below Stop Mode Per P045 Stop Mode See t064 2 Wire Mode below Per P045 Stop Mode Installation Wiring Chapter 1 t064 2 Wire Mode Normal Stop 1 0 Terminal 01 Stop 0 Edge Trigger Per P045 Coast 1 Level Sense Stop Mode Per P045 Stop Mode 2 Hi Spd Edge Coast 3 Momentary 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 wir
56. Dec Sela If active determines which Accel Decel time is used for all ramp rates except jog L Used with option 11 Acc Dec Sel2 for the Accel Decel times listed in this table Option Description 29 11 0 0 Acc Dec1 0 1 Ac Dec2 1 0 Ac Dec3 1 1 JAc Dec4 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 energized 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 i
57. Decel 1 Off REV ncremental 7 Step if LogicIn 2 is Not Active 1 Accel Decel1 On FWD Absolute 6 Step if either Logic In 1 or Logic In 2 is Active Accel Decel1 On FWD idemental 7 Step if both Logic In 1 and Logic In 2 are Active 5 Accel Decel1 On REV Absolute 8 Step if neither Togi In r nor egi 25 EAS 7 Accel Decel 1 On REV arenen 9 Step if Logic In 1 is Active and Logic In 2 is Not Active 3 Accel Decel2 Off FWD Absolute A Step if Logic In 2 is Active and Logic In 1 is Not Active 9 Accel Decal 2 Of FWD R remental b Step after Stp Logic Time x and Logic In 1 is Active A Accel Decel Off REV Absolute C Step after Stp Logic Time x and Logic In 2 is Active b Accel Decel 2 Of REV rementa 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 iL x AM Logic In 2 is Not Active d Acel Decel 2 On FWD nerememtal F Do Not Step Ignore Digit 2 Settings E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV ncremental 92 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Logic Group continued L190 StpLogicTime0 L191 Stp Logic Time 1 1192 StpLogicTime2 L193 Stp Logic Time 3 1194 StpLogicTime4 L195 Stp Logic Time 5 1196 StpLogicTime6 L197 Stp Logic Time 7 Sets the time to remain in each step if the corresponding command word is set to Step ba
58. Drv 1 Addr 2 Drv 2 Addr 3 Drv 3 Addr 4 Drv 4 Addr 5 Min Max 1 247 Display 1 C175 DSI 1 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 lw N 90 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Logic Group L180 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 1187 Stp Logic 7 so drive before changing this parameter 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
59. E Dimensions are in millimeters and inches 166 185 0 7 28 160 0 6 30 IP 30 NEMA 1 UL Type 1 top panel 279 0 10 98 i SS eee E e u i TIT PowerHex 3 nnnanna 300 0 11 81 280 0 11 02 4 Allen Bradley Ls 1378 1 15 0 0 59 d 350 0 F 127 5 5 02 4 82 5 3 25 62 5 2 46 42 5 1 67 OU UUUUUUUU IP 30 NEMA 1 UL Type 1 conduit box 921 5 20 85 943 7 91 72 e S e P S ES XA XJ fam T MSS SU BESS oO fe K Y 181 0 7 13 164 0 6 46 8 35 212 0 Rockwell Automation Publication 520 UM001B EN E February 2013 EMC Line Filter Frame A Dimensions are in millimeters and inches 20 0 0 79 55 0 2 17 30 0 1 18 o 2230 8 78 o o 23 0 0 91 EMC Line Filter Frame B Dimensions are in mill
60. EA C5 Powegy go e p 5 a AAA NAANA gt AANA 1 5 c SS SS a a m J Re n E Ei A D Allen Bradley i 1 Loy i 1 4 i 6 0 0 24 L IP 20 0pen Type Frame D Dimensions are in millimeters and inches 130 0 5 12 4 p 212 0 8 35 116 0 4 57 T e Hf e pru rs es eS e CLE o c S a CL N e l a gt SS R 3 eJ P gt SS iar D Ea a PowerFlex 25 o Si ijan N p a t bg g BE gt st C N a CL SS Ex gt gt SS a a ao d un Allen Bradley 6 0 0 24 Rockwell Automation Publication 520 UM001B EN E February 2013 159 Appendix B 160 Accessories and Dimensions IP 20 0pen Type Frame E Dimensions are in millimeters and inches Rockwell Automation Publication 520 UM001B EN E February 2013 185 0 7 28 279 0 10 98 160 0 6 30 HII CT C 5 E e 0ce s RCM S 2 F S e3 e e Ru PowerHex Ej b E Em eo Ss SS S E co C SSS N CL CL D Allen Bradley 4 L 7 6 0 30 Accessories and Dimensions Appendix B IP 20 0pen Type with Control Module Fan Kit Frame A E Dimensions are in millimeters and inch
61. 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 intended 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 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 UM001B EN E February 2013 209 Appendix G 210 Safe Torque Off Function e access control to the system including password handling e analyzing all configuration settings and choosing the proper setting to a
62. EN Rx Errors A count of the number of receive errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 124 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F728 EN Tx Packets A count of the 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 A count ofthe number of transmit errors reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F730 EN Missed 10 Pkt 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 UM001B EN E February 2013 125 Chapter3 Programming and Parameters AppView Parameter Groups PowerFlex 525 drives include various AppView parameter groups that groups certain parameters together for quick and easy access based on different types of applications These applications include e Conveyor e Mixer e Compressor e Centrifugal Pump e Blower Fan e Extruder e Positioning e Textile Fiber You cannot add or remove parameters to or from the AppView parameter groups I
63. GS GL vVOLNVCOG 8SC 7 384 W0vL SC EQ90 n0vL Sy lJ0 SSVD 7 384 WOPL 7 090 NOrL Sy 0 001 g os t O S VOLNZLOS 8SC 9 3 WOv L SL Ed90 f0vL 0t 4 910 110 S SSVD 910 30 WOvL SL 09G NOrL oE 0c 001 V Of ct 0 VOLNLLOS gSC 015 3O WOtL 01 Ed90 f0vL Oc H 910 110 Sg SSVD 010 3O WOtL OLD Ea9G NOrL 0c Sl 719 001 V 07 SL O Z vOLNOd89 852 9g 3 WOvL O88 E090 NOPL SL 4 S1d L10 f SAY SSY 99 4Z WOrL 089 EQ90 N0Y L Sl 0L 602 001 V OL S 0 O L VOLNOdS8 8S7 Ov8 3Z WOPL OVE EQ9 NOVL 9 4 S10 110 f SAY SSY 078 3 WOvL OFd 090 NOFL 9 9 0 001 Y 0 vo 0 vOLNSd79 852 Worl OPL IN NovL 68h 1n ON Boyeyey sser Worl fori buney xew Guney uw oN boeze dH MA dH oNboje s1ayeaig JINDAL Buney xew sasn4 s1ayearg HM sasny 2032340 owtedy kyng ne y Kyng jeuuoy suoljerijddy 1N suone iddy 10 uoN J331 sbuney 3nduj sBuney 1nding j y Sau SJAA uomoa oJd nduJ aSDud AOFC 00 7 384 W0vL SE O9H f0vL 0S 140 SSW1D 0 383 WOrL SE O9H OvL 0S oE 00L g oE 77 OE VLINLLOV gSC C 384 WOt L SE O9H f0vL 0S 110f SSY 0 383 WOrL SE O9H OvL 0S oE 00L g oE CC OE vOLNLLOV 8SC C 381 WOrL Z 7090 NOrL 0r lJ0fSSVD 0 383 WOrL 7 7090 NOrL Ov SC 7 00L g 07 3 O Z vLLNOd8V 8Sc C 383 WOrL SC cq907n0vL Or lJ0 SSVD 0384 WOvL 2 7090 NOFL Ov SC O 001 8 07 cL O ZI POLNOd8Y 8S7 9L 3Z WObL SLI 7090 NOVL SZ Y S10 110 f SAY SSYD 91
64. 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 set 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 LogicIn 1 This provides an identical function as the Logic In1 Digital Input option This bit is logically ORed with a digital input t062 1063 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 digit
65. Main Freq Controlled by Active Comm 10 1 Operation Cmd Controlled by Active Comm 11 1 Parameters have been locked 12 Digital Input 1 Status 13 Digital Input 2 Status 14 Digital Input 3 Status 15 Digital Input 4 Status Address Decimal 2100H 8448 Bit s Description 0 1 Ready 0 Not Ready 1 1 Active Running 0 Not Active 2 1 Cmd Forward 0 Cmd Reverse 3 1 Rotating Forward 0 Rotating Reverse 4 1 Accelerating 0 Not Accelerating 5 1 Decelerating 0 Not Decelerating 6 1 Forward Travel Position 0 Reverse Travel Position 7 1 Faulted 0 Not Faulted 8 1 At Reference 0 Not At Reference 9 1 At Position 0 Not At Position 10 1 At Home 0 Not At Home 11 1 Drive Homed 0 Not Drive Homed 12 1 Sync Hold 0 Not Sync Hold 13 1 Sync Ramp 0 Not Sync Ramp 14 1 Traverse On 0 Traverse Off 15 1 Traverse Decel 0 Not Traverse Decel 178 Rockwell Automation Publication 520 UM001B EN E February 2013 Reading 03 Drive Error Codes RS485 DSI Protocol Appendix C The PowerFlex 525 Error Code data can be read through the network by sending Function Code 03 reads to register address 2101H Drive Error Codes Drive Error Codes Logic Status Address Decimal Value Decimal Description
66. Mounting Single Drive 120 IP 30 NEMA with Control 110 Module Fan Kit 100 90 IP 20 0pen Type 80 70 60 50 Percentage of Rated Current 96 40 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Horizontal Floor Mounting Single Drive 120 with Control 110 Module Fan Kit 100 90 80 70 60 50 40 Percentage of Rated Current 96 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature C Rockwell Automation Publication 520 UM001B EN E February 2013 Percentage of Rated Current Percentage of Rated Current 2 For catalogs 25B D1P4N104 and 25B EOP9N104 the temperature listed under the Maximum Derate column is reduced by 5 C 9 F for all mounting methods For catalogs 25B D1P4N104 and 25B 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 Zero Stacking 120 IP30 NEMA 1 with Control 110 Module Fan Ki 100 90 IP 20 0pen Type 80 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 Ambient Temperature C 13 Chapter1 Installation Wiring Derating Guidelines for High Altitude The drive can be used without derating at
67. ReTC amp 05 Pulse Train Input t067 DigIn TermBlk 07 52 S Pulse In Use P047 P049 and P051 5 Speed Referencex to Common 04 E select pulse input Jumper pulsen E for DigIn TermBlk 07 Sel Era must be moved to Pulse 8 ui In 2 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing P046 Start Source 1 2 S and t062 Digln TermBlk i O 02 48 Stop Run 02 Stop Run Input must be active for the drive to run When input is opened the drive will stop as specified by Paav common P045 Stop Mode If desired a User Supplied Each digital input draws 6 mA 24V DC power source can be used Refer to the External Supply SRC example Rockwell Automation Publication 520 UM001B EN E February 2013 35 Chapter 1 36 Installation Wiring 1 0 2 Wire SNK Control Non Reversing Connection Example Internal Supply SNK 3 01 02 03 04 2 Wire SRC Control External Supply SRC Run FWD Run REV P046 Start Source 1 2 9 t062 Digln TermBIk 02 Bn 01 48 and t063 Digin 90 re 02 TermBlk 03 50 e Forward 03 op Run 04 Input must be active for Forward Sfop Run the drive to run When Reverse input
68. Read Holding Registers 06 Preset Write Single Register 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 some master devices e g Pro for others e g PanelViews Logic Command may be register address 8192 for Soft 3150 MCM SLC Modbus scanner and 8193 Writing 06 Logic Command The PowerFlex 525 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 Parameter C122 Cmd Stat Select is used to select Velocity or Position Bit Data definitions TIP Powerup Reset the drive after for the change to take effect Rockwell Automation Publication 520 UM001B EN E February 2013 selecting an option for C122 Cmd Stat Select 175 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 54 00 No Command 01 Forward Command 10 Reverse Command 11 No Command 6
69. Shear Pin2 Level 488 Step Units F 6 213 Positioning Mode 558 Skip Freq Band 1 449 Step Units F 7 215 Power Loss Mode 548 Skip Freq Band 2 451 Stop Mode 045 Power Saved 018 Skip Freq Band 3 453 Stp Logic 0 180 Preset Freq 0 410 Skip Freq Band 4 455 Stp Logic 1 181 Preset Freq 1 411 Skip Frequency 1 448 Stp Logic 2 182 Preset Freq 10 420 Skip Frequency 2 450 Stp Logic 3 183 Preset Freq 11 421 Skip Frequency 3 452 Stp Logic 4 184 Preset Freq 12 422 Skip Frequency 4 454 Stp Logic 5 185 130 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Parameter Name No Parameter Name No Parameter Name No Stp Logic 6 186 Stp Logic Time 6 196 Torque Perf Mode 039 Stp Logic 7 187 Stp Logic Time 7 197 Traverse Dec 569 Stp Logic Status 391 Sync Time 571 Traverse Inc 568 Stp Logic Time 0 190 Testpoint Data 368 Units Traveled H 388 Stp Logic Time 1 191 Testpoint Sel 483 Units Traveled L 389 Stp Logic Time 2 192 Text Scroll 556 Var PWM Disable 540 Stp Logic Time 3 193 Timer Status 365 Voltage Class 038 Stp Logic Time 4 194 Timer StatusF 366 Wake Level 103 Stp Logic Time 5 195 Torque Current 382 Wake Time 104 Rockwell Automation Publication 520 UM001B EN E February 2013 131 Chapter3 Programming and Parameters Notes 132 Rockwell Automation Publication 520 UM001B EN E February 2013 Drive Status Faults Chapter 4 Troubleshooting This chapter provides information
70. Slip Hz Meter Speed Feedback Speed Feedback F Encoder Speed Encoder Speed F DC Bus Ripple Output Powr Fctr PID 1 Preload PID 1 Invert Err PID 2 Trim Hi PID 2 Trim Lo PID 2 Trim Sel PID 2 Ref Sel PID 2 Fdback Sel PID 2 Prop Gain PID 2 Integ Time PID 2 Diff Rate PID 2 Setpoint PID 2 Deadband PID 2 Preload PID 2 Invert Err Process Disp Lo Process Disp Hi Testpoint Sel Current Limit 1 Current Limit 2 Shear Pin1 Level Shear Pin 1 Time Shear Pin2 Level Shear Pin 2 Time Load Loss Level Load Loss Time Stall Fault Time Motor OL Select Motor OL Ret Drive OL Mode IR Voltage Drop L194 L195 L196 L197 L200 L201 L202 L203 d375 d376 d377 d378 d379 d380 d381 M66 M67 M68 M69 A470 A471 A472 A473 A474 A475 A476 A477 A478 A479 A481 A482 A483 A484 A485 A486 A487 A488 A489 A490 A491 A492 A493 A494 A495 A496 Step Units 2 Step Units F 2 Step Units 3 Step Units F 3 Step Units 4 Step Units F 4 Step Units 5 Step Units F 5 Torque Current PID1 Fdbk Displ PID1 Setpnt Displ PID2 Fdbk Displ PID2 Setpnt Displ Position Status Units Traveled H Flux Current Ref Motor Rr Motor Lm Motor Lx Speed Reg Sel Freq 1 Freq 1 BW Freq 2 Freq 2 BW Freq 3 Freq 3 BW Freq 1 Kp Freq 1 Ki Freq 2 Kp Freq 2 Ki Freq 3 Kp Freq 3 Ki Boost Select Start Boost Break Voltage Break Frequency Maximum Voltage Motor Fdbk Type Encoder PPR Pulse In Scale Ki Speed Loop Kp Speed Loop Var PWM Dis
71. Winne Ai Ree Dee Batti dud hue da Md ont E As Me a Ma d 211 PowerFlex 525 Safe Torque Off Operation sseessese 211 Verify Operation sesso sib SS seater d daa he Potete 217 Connection Examples 1 coco EI a Rei uu Ea 213 PowerFlex 525 Certification for Safe Torque Off Ls 217 Appendix H Establishing A Connection With EtherNet IP usus 219 Appendix I Induction Motor Tuning DIAerdmss cv v eruoed43 ausa An QURTEEPE 221 Adjusting Speed Control Patametets e Ld eere oer ER bani 222 Rockwell Automation Publication 520 UM001B EN E February 2013 5 Table of Contents Notes 6 Rockwell Automation Publication 520 UM001B EN E February 2013 Who Should Use this Manual Recommended 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 525 Adjustable Frequency AC Drive For information on Who Should Use this Manual See page Recommended Documentation Manual Conventions Drive Frame Sizes General Precautions Catalog Number Explanation ls INO NO lOO IN IN 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
72. and the EMI filter PowerFlex 525 RF Emission Compliance and Installation Requirements 10 1 Phase Input with External EMC Filter 0 230V 3 Phase Output Filter Type Standard Limits EN61800 3 Category C1 EN61800 3 Category C2 EN61800 3 Category C3 EN61000 6 3 EN61000 6 4 Is 100 A 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 16ft 100 m 328 ft 100 m 328 ft 1 See Appendix B for more information on optional external filters Class C1 Class C2 Enclosure and Conduit Cable EMC Cores Required Endosure EMC Cores Required Input and Output A Shielded None None INPUT CORE RF A 1 OUTPUT CORE RF A 2 B Shielded OUTPUT CORE RF B 2 None INPUT CORE RF B 1 OUTPUT CORE RF B 2 200 240V AC 15 A 10 1 Phase Input with Internal EMC Filter 0 230V 3 Phase Output Shielded None B Shielded None 200 240V AC 15 10 3 Phase Input with External EMC Filter 0 230V 3 Phase Output A Shielded OUTPUT CORE RF A 2 None INPUT CORE RF A 1 OUTPUT CORE RF A 2 B Shielded OUTPUT CORE RF B 2 None INPUT CORE RF B 1 OUTPUT CORE RF B 2 C Shielded OUTPUT CORE RF C 2 None INPUT CORE RF C 1 OUTPUT CORE RF C 2 D Shielded None None INPUT CORE RF D 1 E Shielded None None INPUT CORE RF E 1
73. 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 A525 Freq 3 Kp A524 Freq 2 Ki A526 Freq 3 Ki 222 Rockwell Automation Publication 520 UM001B EN E February 2013 Numerics 2 wire inputs 40 3 wire inputs 40 A accel override priority 41 selecting 41 accessing control terminals 25 power terminals 25 applications safety 209 auxiliary contact drive 28 30 basic operation 52 drive 47 52 138 programming 52 safety 212 C circuit breakers inputs 18 ratings 18 recommended 143 common bus drive 30 communications positioning 196 configuring RS485 DSI 174 control terminals accessing 25 counter programming 181 184 D decel override priority 41 selecting 41 derating factor 108 temperature 13 digital inputs selecting 40 start source 40 dimensions mounting 12 157 disconnect output 28 drive auxiliary contact 28 30 basic operation 47 52 138 common bus
74. 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 UM001B EN E February 2013 17 Chapter1 _Installation Wiring Fuses and Circuit Breakers 18 The PowerFlex 525 drive does not provide branch short circuit protection This product should be installed with either input fu
75. certified the PowerFlex 525 Safe Torque Off function compliant with the requirements for machines defined in Annex I of the 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 Adjustable 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 41 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 fore
76. gt Values Default 0 Min Max 0 100 Display 1 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 9 100 11 12 1 1 15 16 Carrier Frequency kHz IMPORTANT gnoring 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 Reduces the frequency based on current This frequency is subtracted from the commanded output frequency Generally Slip and Droop would not both be used but if both are enabled they simply subtract from each other Typically used in load sharing schemes Values Default 0 0 Hz Min Max 0 0 10 0 Hz Display 0 1 Hz Rockwell Automation Publication 520 UM001B EN E February 2013 101 Chapter3 Programming and Parameters Advanced Program Group continued M42 Accel Time 2 Related Parameter s P044 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 Maximum Freq 0 Accel Timex amp Time Decel Time x
77. in the position regulator Values Default 8 Min Max 0 15 Display 1 A566 Pos Reg Gain Sets the gain adjustment for the position regulator Values Default 3 0 Min Max 0 0 200 0 Display 0 1 A567 Max Traverse Sets the amplitude of triangle wave speed modulation Li P Jump Max Traverse Output Freq F 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 frequency See the diagram at A567 Max Traverse Values Default 0 00s 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 Rockwell Automation Publication 520 UM001B EN E February 2013 117 Chapter3 Programming and Parameters Advanced Program Group continued 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 SyncTime Related Parameter s t062 t
78. individual parameters as show below Step Key s Example Displays 1 Press the Up Arrow or Down Arrow to scroll to TL the CustomView group GC I CED Shire ZILIN 2 Press Enter to view the parameters that can be added to the CustomView group RID l lt 3 Press the Up Arrow or Down Arrow to scroll A FT Bi through the list of parameters a gt Ca m ttu LIE 4 Press Enter to add the parameter to the CustomView group The LCD display will show a X y y X y confirmation To delete parameters from the CustomView parameter group Step Key s Example Displays 1 Press the Up Arrow or Down Arrow to scroll to 5 ren n the CustomView group GC a gt y A LI LA LI LIC PA ES 2 Press Enter to view the parameters that are in Nie the CustomView group aol TIT lt L1L LI utr 3 Pressthe Up Arrow or Down Arrow to scroll to Si the command GC 52 a ng p NEN LIL vas 4 Press Enter or Sel to view the parameters that nn are stored in the CustomView group Mise LILIE 5 Pressthe Up Arrow or Down Arrow to scroll N14 through the list of parameters a gt ZAD w ee PITTI LILIL PROGRAMA 6 Press Enter to delete the parameter from the CustomView group The LCD display will show a tt w w E 4 confirmation lt H TIP The Connected Components Workbench software can be used to speed up this process w
79. is opened the drive Sfop Run will stop as specified by Reverse 24 Common P045 Stop Mode Each digital input draws 6 mA 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 01 R 02 Forward 03 5 04 Stop Run Reverse 3 Wire SRC Control External Supply SRC Non Reversing P046 Start Source 1 2 and t062 Digln TermBIk 9 0 02 49 01 90 A momentary input will 02 04 start the drive A stop lt input to 1 0 Terminal 01 d A will stop the drive as 24V Common specified by P045 Stop Mode Each digital input draws 6 mA 3 Wire SNK Control Internal Supply SNK Non Reversing Se le 9 04 S Rockwell Automation Publication 520 UM001B EN E February 2013 Installation Wiring Chapter 1 1 0 Connection Example 3 Wire SRC Control Internal Supply SRC External Supply SRC Reversing ii P046 Start Source 1 2 Ls t062 DigIn TermBlk 02 le b 49 and t063 Digln ists Es a TermBlk 03 51 2 A momentary input will amp ome start the drive A stop D Direction input to 1 0 Terminal 01 Direction l l will stop the drive as 4X Common specified by P045 Stop iii Model 1 0 Terminal 03 Each digital input draws 6 mA determines direction 3 Wire SNK Control Internal Supply SNK Reversing
80. 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 operation of other drives that share the same 0 Common connection may occur Multiple Analog Connections oooooooo Qpgooooooo poooooooQ 1213 14 13 14 13 14 00909900000 009900000 000000000 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 UM001B EN E February 2013 Installation Wiring Chapter 1 Start and Speed Reference Start Source and Speed Reference Selection Control The start and drive speed command can be obtained from a number of different sources By default start source is determined by P046 Start Source 1 and drive speed source is determined by P047 Speed Reference1 However various inputs can override this selectio
81. made Options 1 Parameters 2 BOOTP Default C129 EN IP Addr Cfg 1 C130 EN IP Addr Cfg 2 C131 EN IP Addr Cfg 3 C132 EN IP Addr Cfg 4 Sets the bytes in the IP address A reset or power cycle is required after selection is made 192 168 1 62 Related Parameter s C128 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 C133 EN Subnet Cfg 1 C134 EN Subnet Cfg 2 C135 EN Subnet Cfg 3 C136 EN Subnet Cfg 4 Sets the bytes of the subnet mask A reset or power cycle is required after selection is made 255 255 255 0 Related Parameter s C128 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 Values Default 0 Min Max 0 255 Display 1 86 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Communications Group continued C137 EN Gateway Cfg 1 Related Parameter s C128 C138 EN Gateway Cfg 2 C139 EN Gateway Cfg 3 C140 EN Gateway Cfg 4 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
82. 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 W 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 Values Default Read Only Min Max 0 65535 Display 1 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Display Group continued d368 Testpoint Data Displays the present value of the 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 0 150 096 Display 0 196 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 d378 Encoder Speed Ny 32
83. not recognize Cycle power the power module Hash with newer firmware version Replace drive if fault cannot be cleared F107 Replaced C P 2 The control module was mounted toa Set P053 Reset To Defalts to any of the power module with a different power reset options rating F109 Mismatch C P 2 The control module was mounted toa Set P053 Reset To Defalts to any ofthe different drive type power module reset options F110 Keypad Membrane 2 Keypad membrane failure Cyde power disconnected e Replace control module if fault cannot be cleared F111 Safety Hardware 2 Safety input enable hardware e Check safety input signals If not malfunction One of the safety inputs is using safety verify and tighten not enabled jumper for 1 0 terminals 1 2 and 4 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 UM001B EN E February 2013 137 Chapter4 Troubleshooting Common Symptoms and Corrective Actions 138 Fault Types Descriptions and Actions No Fault Type Description Action F122 1 0 Board Fail 2 Failure has been detected in the drive Cycle power control and 1 0 section e Replace drive or control module if fault cannot be cleared F125 Flash Update Req 2 The firmware in the drive is corrupt Perform a firm
84. specifications NFPA 70 US National Electrical Code NEMA ICS 3 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems IEC 146 International Electrical Code Rockwell Automation Publication 520 UM001B EN E February 2013 Supplemental Drive Information Appendix A Category Specifications Protection Bus Overvoltage Trip 100 120V AC Input 405V DC bus equivalent to 150V AC incoming line 200 240V AC Input 405V DC bus equivalent to 290V AC incoming line 380 480V AC Input 810V DC bus equivalent to 575V AC incoming line 525 600V AC Input 1005V DC bus equivalent to 711V AC incoming line Bus Undervoltage Trip 100 120V AC Input 190V DC bus equivalent to 75V AC incoming line 200 240V AC Input 190V DC bus equivalent to 150V AC incoming line 380 480V AC Input 390V DC bus equivalent to 275V AC incoming line 525 600V AC Input P038 3 600V 487V DC bus equivalent to 344V AC incoming line P038 2 480V 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 Protection I2t protection 150 for 60 s 200 for 3 s Provides Class 10 protection 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 Environment Alti
85. 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 Esc PARS StartUp Chapter2 Key s Example Display an 7 7 r1 VOLTS Ein e j LJ a J J u VOLTS p JE DPA L L A FU Some features in the PowerFlex 525 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 3 0 or greater to enjoy a richer full featured configuration experience Description Catalog Number Release Version Connected Components Workbench Version 3 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 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 param
86. 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 525 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 Rockwell Automation Publication 520 UM001B EN E February 2013 41 Chapter1 Installation Wiring 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 Adjustable speed electrical power drive systems Part 3 EMC requirements and specific test methods Machinery Directive 2006 42 EC EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 2 2008 Safety of machinery Safety related par
87. to guide you in troubleshooting the PowerFlex 525 drive Included is a listing and description of drive faults with possible solutions when applicable For information on See page Drive Status 133 Faults 133 Fault Descriptions 135 Common Symptoms and Corrective Actions 138 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 49 for information on drive status indicators and controls A 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 UM001B EN E February 2013 133 Chapter4 Troubleshooting Fa
88. 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 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 UM001B EN E February 2013 81 Chapter3 Programming and Parameters Terminal Block Group continued t094 Anlg In V Loss Related Parameter s P043 P044 A426 M27 Sets the response to a loss of input When the 0 10V input or 10 to 10V is used for any reference any input less than 1V is reported as a signal loss Input must exceed 1 5V for the signal loss condition to end If enabled this function affects any input that is being used as a speed reference PID reference or PID setpoint in the drive 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 A Ww N t095 Anlg In4 20m
89. 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 1068 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 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 UM001B EN E February 2013 Encoder and Position Feedback Encoder Pulse Train
90. with a 162 ms time constant Given a 0 100 step input from a steady state the output of Filter A takes 500 ms to get to 95 of maximum 810 ms to get to 99 and 910 ms to get to 100 Values Default 0 Min Max 0 23 Display 1 80 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t089 Analog Out High Scales the maximum output value V or mA when the source setting is at maximum Values Default 100 Min Max 0 800 Display 1 t090 Anlg Out Setpt Related Parameter s t088 Sets the percentage of output desired when t088 Analog Out Sel is set to 6 14 or 22 Analog Setpoint Values Default 0 0 Min Max 0 0 100 0 Display 0 1 t091 Anlg In 0 10V Lo Related Parameter s P043 t092 t093 O Kay 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 ignored Values Default 0 096 Min Max 0 0 200 096 Display 0 196 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
91. 063 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 DigIn TermBlk xx 32 Sync Enable r Sync Time y I New Drive 2 Reference 5 New Drive 1 Reference Speed Sync Bit L Fiber Status Change Ref s Drive 1 and 2 Sync Enable Input Time Values Default 0 0s Min Max 0 0 3200 0 s Display 0 15 A572 Speed Ratio O Ray drive before changing this parameter Scales the drive speed command Values Default 1 00 Min Max 0 01 99 99 Display 0 01 Network Parameter Group This group contains parameters for the network option card that is installed Refer to the network option card s user manual for more information on the available parameters 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 118 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 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 F6
92. 08 Step Units 4 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 The following is a listing of the available settings for each digit Rockwell Automation Publication 520 UM001B EN E February 2013 Encoder Pulse Train Usage and Position StepLogic Application Appendix E
93. 09 Minimum Freq 043 Fault 1 BusVolts 651 Fault 9 Current 649 MOP Freq 427 Fault 1 Code 007 Fault 9 Freq 639 MOP Preload 429 Fault 1 Current 641 Fault 9 Time hr 619 MOP Reset Sel 428 Fault 1 Freq 631 Fault 9 Time min 629 MOP Time 430 Fault 1 Time hr 611 Fault Clear 551 Motor Fdbk Type 535 Fault 1 Time min 621 Fault10 BusVolts 660 Motor Lm 499 Fault 2 BusVolts 652 Fault10 Code 610 Motor Lx 500 Fault 2 Code 008 Fault10 Current 650 Motor NP FLA 034 Fault 2 Current 642 Fault10 Freq 640 Motor NP Hertz 032 Fault 2 Freq 632 Fault10 Time hr 620 Motor NP Poles 035 Fault 2 Time hr 612 Fault10 Time min 630 Motor NP Power 037 Fault 2 Time min 622 Fiber Status 390 Motor NP RPM 036 Fault 3 BusVolts 653 Find Home Dir 563 Motor NP Volts 031 Fault 3 Code 009 Find Home Freq 562 Motor OL Current 033 Fault 3 Current 643 Flux Current Ref 497 Motor OL Level 369 Fault 3 Freq 633 Flying Start En 545 Motor OL Ret 494 Fault 3 Time hr 613 FlyStrt CurLimit 546 Motor OL Select 493 Fault 3 Time min 623 Freq 1 510 Motor Rr 498 Fault 4 BusVolts 654 Freq 1 BW 511 MultiDrv Sel 169 Fault 4 Code 604 Freq 1 Ki 522 Opt Data In 1 161 Fault 4 Current 644 Freq 1 Kp 521 Opt Data In 2 162 Fault 4 Freq 634 Freq 2 512 Opt Data In 3 163 Fault 4 Time hr 614 Freq 2 BW 513 Opt Data In 4 164 Fault 4 Time min 624 Freq 2 Ki 524 Opt Data Out 1 165 Fault 5 BusVolts 655 Freq 2 Kp 523 Opt Data Out 2 166 Fault 5 Code 605 Freq 3 514 Opt Data Out 3 167 Fault 5 Current 645 Freq 3 BW 515 Opt Data Out 4 168 Fa
94. 097 A410 A456 A457 A459 A460 A461 A462 t096 t097 A410 A456 A457 A459 A460 A461 A462 t095 t096 t097 d375 d376 d378 A410 A492 A535 L212 L214 d375 d376 d378 d388 d389 A410 A411 A412 A413 A414 A415 A416 A417 A418 A431 d375 d390 A410 A431 A432 A439 A544 A548 A549 A550 Programming and Parameters PID 1 Diff Rate PID 1 Setpoint PID 1 Deadband PID 1 Preload Auto Rstrt Tries Auto Rstrt Delay Start At PowerUp Reverse Disable PID 1 Diff Rate PID 1 Setpoint PID 1 Deadband PID 1 Preload Auto Rstrt Tries Auto Rstrt Delay Start At PowerUp Reverse Disable Flying Start En Encoder PPR Pulse In Scale Ki Speed Loop Kp Speed Loop Power Loss Mode Half Bus Enable Jog Accel Decel DB Threshold S Curve 96 Motor Fdbk Type Encoder PPR Pulse In Scale Ki Speed Loop Kp Speed Loop Bus Reg Enable Positioning Mode Counts Per Unit Enh Control Word Find Home Freq Find Home Dir Encoder Pos Tol Pos Reg Filter Pos Reg Gain Max Traverse Traverse Inc Traverse Dec P Jump SyncTime Speed Ratio Chapter 3 M63 M64 M65 M66 A541 A542 A543 A544 M63 M64 M65 M66 A541 A542 A543 A544 A545 A536 A537 A538 A539 A548 A549 M32 A438 A439 A535 A536 A537 A538 A539 A550 A558 A559 A560 A562 A563 A564 A565 A566 A567 A568 A569 A570 A571 A572 61 Chapter 3 Programming and Parameters CustomView Parameter Group PowerFlex 525 drives include a CustomView pa
95. 1 Force Keypad Control 0 Not Force Keypad Control T 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 176 Rockwell Automation Publication 520 UM001B EN E February 2013 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 12 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 Fr
96. 1 indicates positive or negative position in relation to Home rn nmn LALAN LALJ LI 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 W7 32 bit parameter Displays the number of user defined units traveled from the home position See d387 Position Status for direction of travel Values Default Read Only Min Max 0 64000 Display 1 d389 Units Traveled L Related Parameter s d387 S drive before changing this parameter 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 96 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Display Group continued d390 Fiber Status Present status of the Fibers features MMT LALALALA LA 1 Condition True 0 Condition False Sync Hold Digit 1 Sync Ramp Digit 2 Traverse On Digit 3 Traverse Dec Digit4 Not Used Values Default Read Only Min Max 0000 1111 Display 0000 d391 Stp Logic Status Related Parameter s P047 L180 L18
97. 10 1 Phase Input with EMC Filter 0 230V 3 Phase Output 0 5 0 4 0 5 0 4 2 5 170 264 A 25 PM2 A2P5 1 0 0 75 1 0 0 75 48 170 264 A 25 PM2 A4P8 2 0 1 5 2 0 1 5 8 0 170 264 B 25 PM2 A8P0 3 0 22 3 0 22 11 0 170 264 B 25 PM2 A011 200 240V AC 15 10 3 Phase Input 0 230V 3 Phase Output 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 37 5 0 3 7 17 5 170 264 B 25 PM1 B017 7 5 5 5 7 5 5 5 24 0 170 264 C 25 PM1 B024 10 0 7 5 10 0 75 32 2 170 264 D 25 PM1 B032 15 0 11 0 15 0 11 0 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 40 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 D024 20 0 15 0 15 0 11 0 30 0 323 528 D 25 PM1 D030 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
98. 10 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 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 Fault5 Time min F626 Fault 6 Time min F627 Fault7 Time min F628 Fault 8 Time min F629 Fault9Time min F630 Fault10 Time min 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 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 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 F
99. 1321 3R4 A 1321 3RM A 1321 3R4 A 1321 3RM A 20 15 20 115 1321 3R8 A 1321 3RA8 A 1321 3R8 A 1321 3RA8 A 30 22 30 122 1321 3R12 A 1321 3RA12 A 1321 3R12 A 1321 3RA12 A 50 37 5 0 37 13213R18 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 17 5 1321 3R35 A 1321 3RA35 A 1321 3R35 A 1321 3RA35 A 15 0 110 150 110 13213R45 A 1321 3RM5 A 1321 3R45 A 1321 3RM5 A 20 0 15 0 150 111 0 380 480V 50 60 Hz 3 Phase 1321 3R55 A ND 1321 3R45 A HD 1321 3RA55 A ND 1321 3R55 A 1321 3RA45 A HD 1321 3RA55 A 0 5 04 05 0 4 1321 3R1 C 1321 3RA1 C 1321 3R2 B 1321 3RA2 B 1 0 075 10 0 75 1321 3R2 A 1321 3RA2 A 1321 3R2 A 1321 3RA2 A 2 0 1 5 2 0 1 5 1321 3R4 B 1321 3RM B 1321 3R4 B 1321 3RM B 3 0 22 3 0 22 1321 3R8 C 1321 3RA8 C 1321 3R8 C 1321 3RA8 C 50 40 50 40 1321 3R8 B 1321 3RA8 B 1321 3R8 B 1321 3RA8 B 75 5 5 75 5 5 1321 3R12 B 1321 3RA12 B 1321 3R12 B 1321 3RA12 B Rockwell Automation Publication 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B Bulletin 1321 3R Series Line Reactors Output Ratings Input Line Reactor 20 Output Line Reactor 20 IP00 IP11 IP00 IP11 Normal Duty Heavy Duty OpenStyle NEMA UL Type 1 Open Style NEMA UL Type 1 HP kW HP kW Catalog No Catalog No Catalog No Catalog No 100 7 5 100 17 5 1321 3R18 B 1321 3RA18 B 1321 3R18 B 1321 3RA18 B 15 0
100. 2 1 1 1 1 1 Preset Setting 0 is only available if P047 P049 or P051 Speed Referencex is set to 7 Preset Freq Values Defaults Preset Freq 0 0 00 Hz Preset Freq 1 5 00 Hz Preset Freq 2 10 00 HZ Preset Freq 3 20 00 Hz Preset Freq 4 30 00 Hz Preset Freq 5 40 00 Hz Preset Freq 6 50 00 Hz Preset Freq 7 15 60 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz 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 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 98 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Adv
101. 3 65 Ib in e Protect the cooling fan by avoiding dust or metallic particles Rockwell Automation Publication 520 UM001B EN E February 2013 11 Chapter1 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 25mm 4 1 0 in ARA HARARE 4 25 mm 50 mm 50 mm 1 0in 2 0 in 2 0 in IT p m oin 50 Oin TT a r eme mm ES LM doo em H 0 g D Te PS 7 TU Ty Horizontal with Control Module Fan
102. 30 mount 11 programming 48 51 safety 211 drive damage preventing 15 ungrounded distribution systems 15 encoder programming 187 wiring 188 environment storage 14 Ethernet programming 219 F fault monitoring ground 17 fuses rating 18 recommended 143 G ground fault monitoring 17 motor 17 RFI filter 17 safety 17 shielding 17 homing automatic 194 manual 194 programming 194 inputs 2 wire 40 3 wire 40 circuit breakers 18 power 16 logic basic 181 182 timed steps 181 182 M Rockwell Automation Publication 520 UM001B EN E February 2013 223 224 Modbus reading 177 179 180 writing 175 177 180 motor ground 17 start 28 stop 28 mount drive 11 mounting dimensions 12 157 noise immunity wiring 31 174 0 output disconnect 28 override priority accel 41 decel 41 speed reference 39 start source 39 P parameters AppView 60 126 CustomView 127 programming 50 54 PID programming 201 positioning communications 196 programming 189 190 power inputs 16 power and control module separating 22 power terminals accessing 25 preventing drive damage 15 programming 52 basic logic 181 182 counter 181 184 drive 48 51 encoder 187 Ethernet 219 homing 194 parameters 50 54 PID 201 positioning 189 190 pulse train 187 timed steps 181 182 timer 181 183 tools 51 pulse train programming 187 rating fuses 18
103. 4 Digital Common 05 Digin TermBlk 05 Preset Freq Program with t065 DigIn TermBlk 05 t065 06 Digin TermBlk 06 Preset Freq Program with t066 DigIn TermBlk 06 t066 07 Digin TermBIk 07 Start Source 2 Program with t067 DigIn TermBIk 07 Also functions as a Pulse t067 Pulse In Speed Train input for reference or speed feedback The maximum Reference2 _ frequency is 100 kHz 08 Digin TermBlk 08 Jog Forward Program with t068 DigIn TermBlk 08 1068 a ca This terminal is tied directly to the RJ 45 and USB shields on the Keypad printed circuit board PCB Ties this shield to earth 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 Safety 2 Safety input 2 Current consumption is 6 mA S Safety 24V 24V supply for safety circuit Internally tied to the 24VDC 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 Rockwell Automation Publication 520 UM001B EN E February 2013 33 Chapter1 _Installation Wiring Control 1 0 Terminal Designations No Signal Defaul
104. 60P500 3 Phase 2 0 1 5 120 360 AK R2 360P500 3 0 2 2 120 120 AK R2 120P1K2 5 0 3 7 82 120 AK R2 120P1K2 7 5 5 5 65 120 AK R2 120P1K2 10 0 17 5 65 120 AK R2 120P1K2 15 0 110 165 60 AK R2 120P1K2 20 0 150 165 60 AK R2 120P1K2 250 18 5 60 60 AK R2 120P1K2 300 122 0 38 40 AK R2 120P1K2 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 Rockwell Automation Publication 520 UM001B EN E February 2013 151 Appendix B 152 Accessories and Dimensions EMC Line Filters Drive Ratings Input Voltage 100 120V 50 60 Hz 1 Phase 200 240V 50 60 Hz 1 Phase 200 240V 50 60 Hz 3 Phase 380 480V 50 60 Hz 3 Phase 525 600V 50 60 Hz 3 Phase HP kW Current A Frame Size Catalog No 05 10 4 25 A 25 RFO11 AL 10 075 48 B 25 RF023 BL 1 5 11 6 0 B 25 RF023 BL 05 10 4 25 A 25 RFO11 AL 10 075 48 A 25 RFO11 AL 2 0 15 8 0 B 25 RF023 BL 30 22 11 0 B 25 RF023 BL 05 10 4 25
105. 7 y 32 bit parameter 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 Rockwell Automation Publication 520 UM001B EN E February 2013 97 Chapter3 Programming and Parameters Advanced Program Group A410 Preset Freq 0 M11 Preset Freq 1 M12 Preset Freq 2 M13 Preset Freq 3 A414 Preset Freq 4 M15 Preset Freq 5 A416 Preset Freq 6 M17 Preset Freq 7 A418 Preset Freq 8 A419 Preset Freq 9 A420 Preset Freq 10 M21 Preset Freq 11 A422 Preset Freq 12 A423 Preset Freq 13 A424 Preset Freq 14 M25 Preset Freq 15 Sets the frequency of the drive outputs to the programmed value when selected Default Accel Decel Used Preset Input 1 Preset Input 2 Preset Input 3 Preset Input 4 DigIn TermBlk 05 Digln TermBIk 06 DigIn TermBIk 07 DigIn TermBlk 08 Preset Setting 0 1 0 0 0 0 Preset Setting 1 1 1 0 0 0 Preset Setting 2 2 0 1 0 0 Preset Setting 3 2 1 1 0 0 Preset Setting 4 1 0 0 1 0 Preset Setting 5 1 1 0 1 0 Preset Setting 6 2 0 1 1 0 Preset Setting 7 2 1 1 1 0 Preset Setting 8 1 0 0 0 1 Preset Setting 9 1 1 0 0 1 Preset Setting 10 2 0 1 0 1 Preset Setting 11 2 1 1 0 1 Preset Setting 12 1 0 0 1 1 Preset Setting 13 1 1 0 1 1 Preset Setting 14 2 0 1 1 1 Preset Setting 15
106. 9 32 WOPL SLI 7090 NOvL SC SL c12 001 V OL S 0 OL vLLNSdvV 8Sc 9L 30 WOvL SLI Z090 NOPL SZ Y S10 L10 f SAY SSVD 910 3O WOvL SL ca90 norL H4 SL 719 001 V OL SLO OL vOLNSdPV gSC 012 3 WOtL OLD 2090 NOVL SL Y S1d 110 f SAY SSVID 012 30 WOtL OLD 2090 NOFL SL 0L 602 001 V SO vo SO viINSdCV 8SC 012 3 WOt L OLD Z090 NOVL SL H S10 110 Sy SSY 012 30 WOvL OLD 2090 NOFL SL 0L 602 001 V SO vo SO vOLNSdCV 8SC WorL orL1n NOvL 68h 1n ON Gojeyey sser Worl forL Buey xew Huey uw on Bojeye sduy dH MA dH ON boje s1ayeasg INDI Gurney xew sasny s1ayeaig UNUI sasng 0Pe3U0 oue kyng Aaeay ynq jeuuoy suoljerijddy 1n suore iddy 10 uoN 531 sbuney yndu sPuney 1nding C 3831 WOYL 07 180 W0rL 01L 42 Worl 0 Ca9q novL S7 7090 N0rL C15 O90 0vL WOvL orL1n novL srv 1n saayearg HINDI 0S 4 S10 140 f SYY SSY Op u S10 140 f SYY SSY 0c 4 S10 110 f SYY SSY oN 5ojee sser Burney xew sesnj suoneiiddy 10 C 383 WOY1 020 380 WOT 1 01 3O WOvL g V sau sana uoiajo4g 1nduJ asbyq AOFZ 00 opcm os oe coo aj ove zef ooj ri sif vif si vooaoicase scrcase nort o moj aj cel se sej sro ot sro ot vosavicasc coton oe s woj v os ef se voj soj vof sofromsaras wort mori Buneuxew Buneu utw oN Bore sewegamup sng PEO g V sau sana uoiajo4g 1nduJ asbuq AOz 1 001 suone idd
107. A 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 o 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 0 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 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 N AJ BS Ww N 82 Rockwell Automation Publication 520 UM001B EN E Februa
108. 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 100 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 0 Min Max 10 0 110 0 Display 0 1 100 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued M39 S Curve Enables a fixed shape S Curve that is applied to the acceleration and deceleration ramps including jog S Curve Time Accel or Decel Time x S Curve Setting in percentage 100 S Curve 50 S Curve Example Accel Time 10 s Target l Target y l LE S Curve Setting 3096 j S Curve Time 10x 0 3 2 35 EE uu l l 4 S Curve Time Accel Time l 4 S Curve Time A Total Time to Accelerate Accel Time S Curve Time Total Time to Accelerate Accel Time S Curve Time
109. 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 134 Rockwell Automation Publication 520 UM001B EN E February 2013 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 faults are allowed to be reset Certain faults Type 2 that indicate possible drive component malfunction are not resettable Fault types are listed in the table Fault Types on page 133 See Fault Descriptions on page 135 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 l
110. Accel Time 1 P041 Analog Out Sel t088 Preset Freq 0 A410 Commanded Freq b002 Decel Time 1 P042 Analog Out High t089 Auto Rstrt Tries A541 Motor NP Volts P031 Minimum Freq P043 Anlg Out Setpt t090 Auto Rstrt Delay A542 60 Rockwell Automation Publication 520 UM001B EN E February 2013 t097 d375 M10 M31 M32 A439 A544 t096 t097 A410 A492 A543 A544 A548 A549 Centrifugal Pump Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Blower Fan Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Extruder Language Output Freq Commanded Freq Output Current Motor NP Volts Positioning Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Textile Fiber Language Output Freq Commanded Freq Motor NP Volts Motor NP Hertz Motor OL Current P030 b001 b002 P031 P032 P030 b001 b002 P031 P032 P030 b001 b002 b003 P031 P030 b001 b002 P031 P032 P033 P034 P035 P040 P041 P042 P043 P044 P030 b001 b002 P031 P032 P033 Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Motor OL Current Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Motor NP Hertz Motor OL Current Motor NP FLA Motor NP Poles Auto
111. Auto Rstrt Tries F038 Phase U to Gnd 2 A phase to ground fault has been e Check the wiring between the drive detected between the drive and motor and motor ee eee Vto Grid in this phase e Check motor for grounded phase F040 Phase W to Gnd Replace drive if fault cannot be cleared F041 Phase UV Short 2 Excessive current has been detected e Check the motor and drive output F042 Phase UW Short between these two output terminals p for a shorted F043 Phase VW Short Replace drive if fault cannot be cleared F048 Params Defaulted 1 The drive was commanded to write Clear the fault or cycle power to the default values to EEPROM drive Program the drive parameters as 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 Mnt for 1 0 terminals 51 2 and F063 SW OverCurrent 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 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 Cycle power Replace drive if fault cannot be cl
112. B PowerFlex 525 No Filter 1 Filter V 120VAC 1 A 240V AC 1 1 Standard B 240VAC 3 D 480VAC 3 E 3 600V AC IP 20 NEMA Open 2P5 25 A 05 04 05 10 4 A 4P8 48 B 10 10 75 1 0 075 253 23 A 10 10 75 10 0 75 6P0 6 0 B 15 11 15 11 1 4P0 40 A 20 15 12 0 11 5 6P0 6 0 A 30 22 13 0 22 010 1105 B 5 0 40 15 0 40 013 113 0 IC 7 5 55 17 5 5 5 A 017 117 0 C 10 0 75 110 0 7 5 are 48 n 10 0 75 10 075 i a xs E Normal and Heavy duty ratings are 8P0 80 B 20 15 20 11 5 oe aes available for drives above 15 HP 11 kW on ho IB 30 122 130 2 037 370 JE 25 0 18 5 20 0 15 0 043 430 JE 30 0 22 0 25 0 18 5 25 las la o5 los los 04 spo 50 IA 10 ozs mo ozs 2 M9 A 05 04 05 04 E WE TRE GEERT ME ER PTS 7 hz amp ho oz L0 075 on no A 30 22 30 22 NO 9 uA ipn 9 ic T9 o7 vs B 50 37 so p 2 39922 3 0 22 o4 a0 E s lss z5 s5 6 66 JB 50 37 0 B7 02 322 D 10 0175 100 75 39 33 C foc LES 048 483 E polio liso mo 02 779 C 10 0173 110 0 Z5 ENERO eo p sojo 150 110 o2 220 D 2001150 150110 o7 xo t 2501185 20 01150 032 320 E 3001220 125 01185 10 Rockwell Automation Publication 520 UM001B EN E February 2013 Mounting Considerations Installation Wiring This chapter provides information on mounti
113. 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 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 re
114. Digln 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 4417 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 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 0200 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
115. GBT 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 The functionis suitable for performing mechanical work on the drive system or affected area of a machine only It does not provide electrical safety Rockwell Automation Publication 520 UM001B EN E February 2013 207 AppendixG Safe Torque Off Function EC Type Examination Certification EMC Instructions Using PowerFlex 525 Safe Torque Off 208 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
116. Half 100Mbps Full 100Mbps Half Dup IP Addr Disabled Di my A w N Rockwell Automation Publication 520 UM001B EN E February 2013 121 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F686 DSI 1 0 Act Displays the Drives that are active in Multi Drive mode Tomiu l 1 Drive Inactive 0 Drive Active 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 F687 HW Addr 1 F688 HW Addr 2 F689 HW Addr 3 F690 HW Addr 4 F691 HW Addr 5 F692 HW Addr 6 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 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 1 122 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F697 EN Subnet Act 1 F698 EN Subnet Act 2 F699 EN Subnet Act 3 F700 EN
117. J0peju0 2UiEJj Ayng Aneay Ayng euuoN suoneddy 10 suone iuddy 10 uoN 41 sbuney 3nduj sBuney 3nding JV SUDI sa aq uoiajoJg Indu asbuq A009 67 21 Rockwell Automation Publication 520 UM001B EN E February 2013 Chapter1 Installation Wiring Power and Control Module PowerFlex 525 drives consists of a Power Module and Control Module Separating the Power and Control Module 1 Press and hold down the catch on both sides of the frame cover then pull out and swing upwards to remove Frames B E only 2 Press down and slide out the top cover of the Control Module to unlock it from the Power Module 22 Rockwell Automation Publication 520 UM001B EN E February 2013 Installation Wiring Chapter 1 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 Rockwell Automation Publication 520 UM001B EN E February 2013 23 Installation Wiring Chapter 1 2 Push the top cover of the Control Module towards the Power Module to lock it 3 Insert the catch at the top of the frame cover into the Power Module then
118. 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 12 Rockwell Automation Publication 520 UM001B EN E February 2013 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 Type 1 29 0 4 oF 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 PTT TET EN e sema L Sal 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 3 4 Catalogs 25B D1P4N104 and 25B E0P9N104 cannot be mounted using either of the horizontal mounting methods S Requires installation of the PowerFlex 520 Series Control Module Fan Kit catalog number 25 FANx 70C Current Derating Curves Vertical
119. L215 d389 d390 d391 A543 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 59 Chapter3 Programming and Parameters Fault and Diagnostic Fault 5 Time min F625 Fault10 Current F650 EN Rate Act F685 Drv 1 Reference Fault 6 Time min F626 Fault 1 BusVolts F651 DSI 1 0 Act F686 Drv 1 Logic Sts ta Fault 7 Time min F627 Fault 2 BusVolts F652 HW Addr 1 F687 Drv 1 Feedback Fault 8 Time min F628 Fault 3 BusVolts F653 HW Addr 2 F688 Drv 2 Logic Cmd Fault 4 Code F604 Fault 9 Time min F629 Fault 4 BusVolts F654 HW Addr 3 F689 Drv 2 Reference Fault 5 Code F605 Fault10 Time min F630 Fault 5 BusVolts F655 HW Addr 4 F690 Drv 2 Logic Sts Fault 6 Code F606 Fault 1 Freq F631 Fault 6 BusVolts F656 HW Addr 5 F691 Drv 2 Feedback Fault 7 Code F607 Fault 2 Freq F632 Fault 7 BusVolts F657 HW Addr 6 F692 Drv3 Logic Cmd Fault 8 Code F608 Fault 3 Freq F633 Fault 8 BusVolts F658 EN IP Addr Act 1 F693 Drv 3 Reference Fault 9 Code F609 Fault 4 Freq F634 Fault 9 BusVolts F659 EN IP Addr Act 2 F694 Drv 3 Logic Sts Fault10 Code F610 Fault 5 Freq F635 Fault10 BusVolts F660 EN IP Addr Act 3 F695 Drv3 Feedback Fault 1 Time hr F611 Fault 6 Freq F636 Status Fault 1 F661 EN IP Addr Act 4 F696 Drv 4 Logic Cmd Fault 2 Time hr F612 Fault7 Freq F637 Status Fault 2 F662 ENSubnet Act 1 F697 Drv 4 Reference Fault 3 Time hr F613 Fault 8 Freq F638 Status Faul
120. Program Group P030 Language Language Support Selects the language displayed A reset or power cycle is required after selection is made HIM LCD Display RSLogix 5000 Connected Logix Designer Components Workbench Y Options English Default Francais Espafiol 1 2 3 4 Italiano 5 Deutsch 6 7 8 9 lt lt lt lt lt lt lt x xx Japanese Portugu s Y lt lt lt lt lt lt lt lt Chinese Chinese Simplified Reserved 10 Reserved 11 Korean Y 12 Polish Y 13 Reserved 14 Turkish Y 15 Czech Y P031 Motor NP Volts Related Parameter s b004 A530 A531 A532 A533 O Kay 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 Ray 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 fau
121. Subnet Act 4 Shows the actual subnet mask used by the embedded EtherNet IP interface at the time This will indicate 0 if no address is set 255 255 255 255 EN Subnet Act 1 EN Subnet Act 2 EN Subnet Act 3 EN Subnet Act 4 Values Default Read Only Min Max 0 255 Display 1 F701 EN Gateway Act 1 F702 EN Gateway Act 2 F703 EN Gateway Act 3 F704 EN Gateway Act 4 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 Rockwell Automation Publication 520 UM001B EN E February 2013 123 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F706 Drv 0 Reference F710 Drv 1 Reference F714 Drv 2 Reference F718 Drv 3 Reference F722 Drv 4 Ref
122. T 45 0 VT 0 0 no IR 0 0 Default for 400V and 600V drives 5 HP and above 7 2 5 CT Default for 200V drives 5 HP and above 8 5 0 CT Default for drives below 5 HP Boost Voltage 96 of Base Constant Torque 9 15CT 10 10 0 CT 11 125 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT Fan Pump Curves Variable Torque al m wl N 110 Rockwell Automation Publication 520 UM001B EN E February 2013 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 i Break Voltage Start Boost di Pd Frequency de de 1 Break Frequency Motor NP Hertz T F Minimum Freq Maximum Freq Values Default 2 596 Min Max 0 0 25 096 Display 0 196 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
123. 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 TT mgri gc p E d Digit 4 Defines the action during the step currently executing Setting a 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 Program Normal Stop End Program Coast to Stop eSlwololwnl alulalwl rn alo End Program and Fault F002 Rockwell Automation Publication 520 UM001B EN E February 2013 185 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
124. UL Type 1 Frame C Dimensions are in millimeters and inches a N idou IP 30 NEMA 1 UL Type 1 top panel 90 5 3 56 1 184 0 7 24 M F _ R Q LI pu eo E Ly CC LN ej N C C Ke C C V oo Y 33 8 SSS o e Cc Ni N N 3 CC N CL in C 3 C Eh PowerFlex Ao 2 CL CL 525 30 o C5 C5 anoaann an n e L L S SS SS CI Rr ee 3 m SS C5 rx ER 8 AllenBrediey V p T c ES 6 0 0 24 bodad rs NN E 80 5 3 17 IP 30 NEMA 1 UL Type 1 conduit box I 66 5 2 62 4 34 5 1 36 26 5 1 04 I UUUUUUU 21 5 20 85 F x 27 5 21 08 amp 123 3 4 85 ine Sm 3 0578 i Rockwell Automation Publication
125. ULTCO WS p Basic Program Commonly used programmable functions ore o So Terminal Blocks p Programmable terminal functions r Communications L Programmable communication functions Logic L Programmable logic functions Advanced Display Advanced drive operating conditions Advanced Program Remaining programmable functions f Fault and Diagnostic Consists of list of codes for specific fault conditions hl Network Ju Network functions that are shown only when a comm card is used M Modified E Functions from the other groups with values changed from default E AppView and CustomView LJ Functions from the other groups organized for specific applications Control and Navigation Keys Display Display State Description ENET 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 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 Key Name Description Up Arrow Scroll through user selectable display parameters or groups 24 v Down Arrow Incr
126. UT CORE RF C 1 OUTPUT CORE RF C 2 D Shielded None None INPUT CORE RF D 1 OUTPUT CORE RF D 2 E Shielded None Shielded None 1 EMC cores are included with product Recommended Placement of EMC Cores with EMC Plate Frame A Frame B Frame C Frame D Frame E 4 Input cable to drive Shielded or Unshielded CORE INPUT CORE INPUT CORE INPUT CORE INPUT CORE INPUT 2 CORE OUTPUT CORE OUTPUT CORE OUTPUT CORE OUTPUT n n CORE OUTPUT 2 V Output cable from drive Shielded Sy Shows contact to Shows cable zip tie for pL shielded layer securing EMC Core Recommended Placement of EMC Cores Relative to External Filter All Frame sizes Incoming power EMC Filter Drive Motor IMPORTANT 46 CORE INPUT 1 2 CORE OUTPUT 1 2 The grounded shielded cable 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 only pass through EMC CORE E 2 e 600V drives with external filters where the grounded output cable must not pass through the EMC core s Rockwell Automation Publication 520 UM001B EN E February 2013 Chapter 2 Start Up This chapter describes how to start up the PowerFlex 525 drive To simplify drive setup the most commonly programmed parameters are organized in a single Basic Program Group For info
127. Usage and Position StepLogic Application Appendix E point too quickly it will then reverse direction at 1 10th A562 Find Home Freq to the point where the Home Limit switch reactivates Approximately one second after the routine finds home the drive will stop Alternately the Find Home Freq and or Home Limit bits in A560 Enh Control Word can be activated instead of utilizing a digital input The inputs or bits should be returned to inactive after the routine is complete 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 Feedback F is the value to the right of the decimal the portion less than 1 ico 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 Encode
128. User Manual Allen Bradley PowerFlex 525 Adjustable Frequency AC Drive 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 ofthis 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 respect to use of information circuits equipment or software described in this manual Reproduction
129. Values Default 10 00 s Min Max 0 00 600 00 s Display 0 015 A443 Decel Time 2 Related Parameter s P044 Time for the drive to ramp from P044 Maximum Freq to 0 0 Hz if Decel Time 2 is selected Decel Rate Maximum Freq Decel Time Values Default 10 005 Min Max 0 00 600 00 s Display 0 015 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 A450 Skip Frequency 2 A452 Skip Frequency 3 M54 Skip Frequency 4 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 102 Rockwell Automation Publication 520 UM001B EN E February 2013 Advanced Program Group continued A449 Skip Freq Band 1 A451 Skip Freq Band 2 A453 Skip Freq Band 3 A455 Skip Freq Band 4 Determines the band around A448 A450 A452 and A454 Skip Frequency x Frequency Command pi requency Drive Output AFfequency 2x Sk
130. 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 UM001B EN E February 2013 197 AppendixE Encoder Pulse Train Usage and Position StepLogic Application Notes 198 Rockwell Automation Publication 520 UM001B EN E February 2013 PID Loop Appendix F PID Set Up The PowerFlex 525 drive has two built in PID proportional integral derivative control loops of which only one can be in use at any time The PID loop is used to maintain a process feedback such as pressure flow or tension at a desired set point The PID loop works by subtracting the PID feedback from a reference and generating an error value The PID loop reacts to the error based on the PID Gains and outputs a frequency to try to reduce the error value to 0 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 spee
131. 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 41 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 10 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 _ w 60 m e 100 g 5 2 9 s g Fi sg g 5 70 e 60 S 30 5 5 a 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 drive is 70 C 14 Rockwell Automation Publication 520 UM001B EN E February 2013 AC Supply Source Considerations Installation Wiring Chapter 1
132. able Auto Rstrt Tries Auto Rstrt Delay This group contains parameters for the network option card that is installed See the network option card s user manual for more information on the available parameters This group contains parameters that have their values changed from the factory default When a parameter has its default value changed it is automatically added to this group When a parameter has its value changed back to the factory default it is automatically removed from this group Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters L204 L205 L206 L207 L208 L209 L210 L211 d382 d383 d384 d385 d386 d387 d388 M97 A498 A499 A500 A509 A510 A511 A512 A513 A514 A515 A521 A522 A523 A524 A525 A526 A530 A531 A532 A533 A534 A535 A536 A537 A538 A539 A540 A541 A542 Step Units 6 Step Units F 6 Step Units 7 Step Units F 7 Units Traveled L Fiber Status Stp Logic Status Start At PowerUp Reverse Disable Flying Start En FlyStrt CurLimit Compensation Power Loss Mode Half Bus Enable Bus Reg Enable Fault Clear Program Lock Program Lock Mod Drv Ambient Sel Reset Meters Text Scroll Out Phas Loss En Positioning Mode Counts Per Unit Enh Control Word Home Save Find Home Freq Find Home Dir Encoder Pos Tol Pos Reg Filter Pos Reg Gain Max Traverse Traverse Inc Traverse Dec P Jump Sync Time Speed Ratio Chapter 3 L212 L213 L214
133. ach digit See Appendix D for more information BOO d 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 Dece 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 Jump 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 Decel2 On NoOupu Settings Digit 2 and 1 Positioning Settings Digit 4 Setting Description 0 Skip Step Jump Immediately Seng Param Used OuputState FromHome Command 1 SEP Based on StpLogicTimex 7 heel Deel 0f ND Msoue 2 Step if Logic In 1 is Aane 1 Accel Decel 1 off FWD ncremental 3 Step if Magee is Active 7 Accel Decel 1 Of REV Absolute 4 Step if Logic In 1 is Not Active 3 Accel
134. al 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 Provides an internal fixed value for process setpoint when PID mode is enabled Values Default 0 0 Min Max 0 0 100 0 Display 0 1 A465 PID 1 Deadband M77 PID 2 Deadband Sets the lower limit of the PID output Values Default 0 0 Min Max 0 0 10 0 Display 0 1 Rockwell Automation Publication 520 UM001B EN E February 2013 105 Chapter3 Programming and Parameters Advanced Program Group continued M66 PID 1 Preload A478 PID 2 Preload Sets the value used to preload the integral component on start or enable Values Default 0 0Hz Min Max 0 0 500 0 Hz Display 0 1Hz M67 PID 1 Invert Err A479 PID 2 Invert Err Changes the sign of the PID error Options 0 Normal Default 1 Inverted 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 Freg Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A483 Testpoint Sel Used by R
135. al input transitions 7 LogicIn 2 This provides and identical function as the Logic In2 Digital Input option This bit is logically ORed with a digital input t062 t063 1065 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 Determines whether the current position is saved on power down Options 0 HomeReset Default Position resets to zero on power up 1 Home Saved A562 Find Home Freq Sets the maximum frequency the drive uses when Find Home is issued Values Default 10 0 Hz Min Max 0 1 500 0 Hz Display 0 1 Hz A563 Find Home Dir O Ray drive before changing this parameter Sets the direction the drive commands when Find Home is issued Options 0 Forward Default 1 Reverse 116 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A564 Encoder Pos Tol 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 Sets the error signal filter
136. alid 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 Example 2 Safe Torque Off Connection with Controlled Stop Action SIL 2 PL d Stop Category 1 Controlled 9 ACline I input power GuardMaster PF 525 Trojan i 24V DC I i 3 Stop 1 top i 24V i ro Start seban rH ou Vi ra tart l 552512 522 37 l Minotaur l eel Gate control 1 ower SU MSR138DP r E EM T A AQ XT D 1X3 D 39 Y40 38 zx j LI CI LI l 24V DC i Common Gate contro druit 4 CB S1 l S2 i 1 Safety relay and PowerFlex 525 must be installed in the same enclosure Rockwell Automation Publication 520 UM001B EN E February 2013 Safe Torque Off Function Appendix G 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 inpu
137. ameters 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 3 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 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 58 Parameter Groups 58 Basic Display Group 63 Basic Program Group 68 Terminal Block Group 13 Communications Group 85 Logic Group 91 Advanced Display Group 94 Advanced Program Group 98 Network Parameter Group 118 Modified Parameter Group 118 Fault and Diagnostic Group 119 AppView Parameter Groups 126 CustomView Parameter Group 127 Parameter Cross Reference by Name 128 Rockwell Automation Publication 520 UM001B EN E February 2013 57 Chapter3 Programming and Parameters About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of paramete
138. 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 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 Rockwell Automation Publication 520 UM001B EN E February 2013 91 Chapter3 Programming and Parameters 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 e
139. anced Program Group continued 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 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 Related Parameter s P044 Sets the output frequency when a jog command is issued 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 10 005 Min Max 0 01 600 00 s Display 0 015 M33 Purge Frequency Related Parameter s t062 t063 t065 t068 Provides a fixed frequency command value when 1062 1063 1065 1068 Digln TermBlk xx is set to 40 Purge Values Default 5 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz M34 DC Brake Time Sets the length of time that DC brake current is injected into the motor Related Parameter s P045 A435 Values Default 0 05 Min Max 0 0 99 9 s Display 0 15 Rockwell Automation Publication 520 UM001B EN E February 2013 99 Chapter3 Programming and Parameters Advanced Program Gr
140. and the Low Voltage Directive e 600V PowerFlex 525 drives can only be used on a center grounded supply system for altitudes up to and including 2000 m 6562 ft e When used at altitudes above 2000 m 6562 ft up to a maximum of 4800 m 15 748 ft PowerFlex 525 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 14 e PowerFlex 525 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 earthing conductor which may reduce the ability of RCD s residual current operated protective devices or RCM 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 PowerFlex 525 drives produce DC current in the protective Rockwell Automation Publication 520 UM001B EN E February 2013 43 Chapter1 Installation Wiring Installation Requirements Related to EN 61800 3 and the EMC Directive e The drive must be earth
141. ard have been Reinstall option card in drive interrupted Modify using C125 Comm Loss Action Replace wiring port expander option card or control module F083 EN Comm Loss 2 Internal communications between the Cycle power drive and the embedded EtherNet IP_ e Check EtherNet IP setting adapter have been interrupted Check drive s 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 If P047 P049 P051 Speed missing Referencex 16 Positioning and A535 Motor Fdbk Type 5 Quad 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 control module could
142. at each step L200 L202 L204 L206 L208 L210 L212 and L214 Step Units x are the number value to the left of the 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 Rockwell Automation Publication 520 UM001B EN E February 2013 191 Appendix E 192 Encoder Pulse Train Usage and Position StepLogic Application 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 Step Source Position Source A410 Preset Freq 0 L180 Stp Logic 0 L200 Step Units 0 A411 Preset Freq 1 L181 Stp Logic 1 L202 Step Units 1 A412 Preset Freq 2 L182 Stp Logic 2 L204 Step Units 2 A413 Preset Freq 3 L183 Stp Logic 3 L206 Step Units 3 A414 Preset Freq 4 L184 Stp Logic 4 L2
143. ated 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 FLA Filter A d382 5 TstData 0 10 0 10V 0V 0000 65535 Hex FFFF None 6 Setpnt0 10 0 10V 0V 096 100 096 Setpoint setting None 1090 7 DCVolt 0 10 0 10V 0V 0V 100 0 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 FLA 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 FLA 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 FLA 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 FLA Filter A d382 21 TstData 4 20 4 20 mA 4 mA 0000 65535 Hex FFFF None 22 Setpnt 4 20 4 20 m 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 Ais a single pole digital filter
144. ation Publication 520 UM001B EN E February 2013 Drive Frame Sizes General Precautions Overview Preface Similar PowerFlex 525 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 A ATTENTION The drive contains high voltage capacitors which take time to discharge after removal of mains supply Before working on drive ensure isolation of mains supply from line inputs R S T L1 L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any
145. ay 0 015 A490 Load Loss Level Related Parameter s A491 Provides a software trip Load Loss fault when the current drops below this level for the time specified in A491 Load Loss Time Values Default 0 0A Min Max 0 0 Drive Rated Amps Display 0 1A A491 Load Loss Time Related Parameter s A490 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 240 Seconds 360 Seconds 480 Seconds Fit Disabled Wm e w N Rockwell Automation Publication 520 UM001B EN E February 2013 107 Chapter3 Programming and Parameters Advanced Program Group continued M93 Motor OL Select Related Parameter s P032 P033 Drive provides Class 10 overload protection Settings 0 2 select the derating factor for the P t overload function No Derate Min Derate Max Derate _ 10 1r _ 100 _ 100 E 80 E 80 E 80 e 0 a 6 a 6 i 40 EH 40 H 40 5 20 5 20 S 20 s x amp 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
146. bien wa te es UE Rag 184 Velocity StepLogic Parameters wis eeus civdwel ow Er Re ere EE nne 185 Rockwell Automation Publication 520 UM001B EN E February 2013 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 iid aee ePi US 187 Willing Notes sic castes Ceo tise eta CIN eta doe oo aya esos 188 Positioning Overview samaisena R 998 Gan PIG UAM SES ETER 189 Common Guidelines for All Applications lsseeesesee 189 Positioning Operations des su Deuce cete bue eiit cele e 190 Homing BOUUhess ec al acca ee elated uo ton Epp Una 194 Encoder and Position Feedback uuuuuesuss 195 Use Over Communications 0c cece cece ccc hh nn 196 Setup INOLGS acus awk eRe os piala d PEP d ero EST dedita Rs 197 Appendix F PS BOO cR tos teins ol eR EE 199 PID Reference and Feedback 2 cee eee eee ee eee eneee 201 Analog PID Reference Signals e Sen Rx n Per RES 201 Appendix G PowerFlex 525 Safe Torque Off Overview esseeuuees 207 EC Type Examination Certification 212eezeecu d du d Rer RUN 208 EMG Instr ctl ns iov RpxevepOT CUI ERR oes EV UE I ERES 208 Using PowerFlex 525 Safe Torque Off us couduida Sc EE ore ete oo 208 Safety COD ceps esto eee Sete EI S IO E YR DU quen iss 209 Enabling PowerFlex 525 Safe Torque On ouis ecce tee reke rnv 211
147. bit parameter 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 41 0VDC 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 Default Read Only Min Max 0 0 18 0 deg Display 0 1 deg Rockwell Automation Publication 520 UM001B EN E February 2013 95 Chapter3 Programming and Parameters Advanced Display Group continued d382 Torque Current Displays the current value ofthe 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 d385 PID2 Fdbk Displ Displays the active PID Feedback value Values Default Read Only Min Max 0 0 100 096 Display 0 196 d384 PID1 Setpnt Displ d386 PID2 Setpnt Displ Displays the active PID Setpoint value Values Default Read Only Min Max 0 0 100 096 Display 0 196 d387 Position Status Displays the present operating condition of the drive When in Positioning mode Bit
148. ced Program Group continued A522 Freq1 Ki Related Parameter s A509 A510 A524 Freq2 Ki A526 Freq3 Ki 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 Speed Reg Sel is set to 1 Manual these parameters can be changed See the control diagrams in Appendix for more information Values Default 0 100 s Min Max 0 000 10 000 s Display 0 001 s A530 Boost Select Related Parameter s b004 P031 P032 P039 Sets the boost voltage of P031 Motor NP Volts and redefines the V Hz curve Only used for V Hz and SVC control modes Maximum Voltage can be set anywhere If itis gt Motor NP Volts then it defines a point on the V Hz curve 100 l Maximum Voltage can be setanywhere Fo i If itis lt Motor NP Volts then it functions as a limit only does not change the V Hz curve l a I l l i i a 1 2 Motor NP Volts I I Jls l I s l E i i z a l I J i i v E a I l Settings t j 5 14 E rm Motor NP Hertz 2 50 1 w Maximum Freq can be set anywhere 4 Maximum Freq can be set anywhere If itis lt Motor NP Hertz then it functions as a limit only i If itis gt Motor NP Hertz then it defines a does not change the V Hz curve point on the V Hz curve Options 0 Custom V Hz 1 30 0 VT 35 0 VT 40 0 V
149. ceeds the value set in t070 or t073 Opto 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 2mA 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 NonRec Fault Value set in A541 Auto Rstrt Tries is exceeded or None A541 Auto Rstrt Tries is not enabled or 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
150. chieve 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 f 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 provided 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 8396 DC 62 596 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 the configured Stop Type is 100 ms maximum Rockwe
151. cted 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 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 UM001B EN E February 2013 Installation Wiring Chapter 1 Power Terminal Block Power Terminal Block Frame A B C amp D Frame E LR LD S BA TU TN BAW a LI R L2 5 L3 T T U T2 N T3 W XR lt p GDH S V hup P M AB SHEA AS Pi DC DG BR od n B BR BR Terminal Description L1 R L2 S L3 T Input Line Voltage Connection T1 U T2 V T3 W Motor Phase Connection Switch any two motor leads to change GG forward direction DC DC DC Bus Connection BR BR Dynamic Brake Resistor Connection Safety Ground PE IMPORTANT Terminal screws may become loose during shipment Ensure that all terminal screws are tightened to the recommended torqu
152. ctromechanical EM Brake Control Mode is enabled with P045 Stop Mode Minimum Freq gt iani M bed Off armia CRIAM Drive stops Values Default 2 005 Min Max 0 00 10 00 s Display 0 015 Rockwell Automation Publication 520 UM001B EN E February 2013 79 Chapter3 Programming and Parameters Terminal Block Group continued t087 EM Brk On Delay Related Parameter s P045 Sets the time the drive remains at minimum frequency after releasing the brake coil relay before stopping if EM Brake Control Mode is enabled with P045 Stop Mode EM Brk On Delay EM Brk Off Delay 2 j T i uv v S 4 5 Minimum Freq gt memecenesce PN Time PN PN P Start EM Brk Stop EM Brk Drive stops commanded energized Off commanded de energized On Values Default 2 005 Min Max 0 00 10 00 s Display 0 015 t088 Analog Out Sel 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 Parameter 0 OutFreq 0 10 0 10V 0V 0Hz Maximum Freq None b001 1 OutCurr 0 10 0 10V OV 0A 200 Drive Rated FLA Filter A b003 2 OutVolt 0 10 0 10V 0v zov 12096 Drive R
153. d Parameters Table of Contents Important User Information c eoe d ee et e 2 Preface Who Should Use this Manual enue ete vu doa tt Ia ee 7 Recommended Documentation c nei sea 7 Manual Conventions o 95 62 Sut eisernen pe resto dul iaaa 8 Drive Frame o WE MM Im 9 General Precautions s er oor aT EE SEEE sqq as RI ERE MES oy 9 Catalog Number Explanation 4 edit sees pec e vea t e MER E Y 10 Chapter 1 Mounting Considerations duces ee eot e xA PENES 11 AC Supply Source Considerations 235 22 c0cctaxchdecyensay Reneba 15 General Grounding Requirements n eese curo n ei ner en DAR 16 Fuses and Circuit Breakers soci aceon cede tasto E eeu te eus 18 Power and Control Module 2 52 eye bere EH Y 22 Control Module Covet cose set roue t raa EROR dur wad eames 25 Power Module Terminal Guard i2 et eroe eds ot tUe ER eue 25 Power Wh ice ey tenerte ex WE PRMPYSEPELUFETAR eee REPES 26 Power Terminal BIGck 2255 utens ponte esas pd a ose aes 29 Common Bus Prechatpe Notes 1ecbeeriec ete rere Es 30 DA SVN tats Coca oe by gi avare bte ded Dress dade pot eei cuins 30 Control I O Terminal Bloke nicer et o OR Pb dem 22 Start and Speed Reference Control 4 ente Later tdem 39 GE Conformity oo sob la debeas pcdes se aiunt robs coed 4l Chapter 2 Prepare for Drive Start W pity ootss sce ree sega daw eee 47 Display and Control Keys ire verseocice reas RR EET Sod ghe 49 Viewing and Editing Parametetss vise vastus vodsve wees eat sates 50 Drive P
154. d reference activated 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 1 PID Loop i _ PID Ref gt PID Prop Gain p do Qm E rror utput F Accel Decel Freq PID Fdbk PID Integ Time Gu gt Ramp gt 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 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 e The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow Rockwell Automation Publication 520 UM001B EN E February 2013 199 Appendix F 200 PID Set Up e When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference
155. ded 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 2 A current path to earth ground has been Check the motor and external wiring to detected at one or more of the drive the drive output terminals for a output terminals grounded condition Rockwell Automation Publication 520 UM001B EN E February 2013 135 Chapter 4 136 Troubleshooting Fault Types Descriptions and Actions No Fault Type Description Action F015 Load Loss 2 The output torque current is below the e Verify connections between motor value programmed in A490 Load Loss Level for a time period greater than the time programmed in A491 Load Loss Time and load Verify level and time requirements F021 Output Ph Loss 2 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 Check for broken loose connections signal loss A signal loss has occurred at inputs Configure with t094 Anlg In V Loss or Check parameters 1097 Anlg In mA Loss F033 Auto Rstrt 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
156. ded 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 aluminum foil combination shield and 29501 29507 or equivalent tinned copper drain wire e PVCjacket 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 refle
157. drive 4 ae is power cycled 5 Deutsch 6 Japanese 7 Portugu s 8 Chinese 9 Reserved 10 Reserved 11 Korean 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 x 2 10 1 A Based on Drive Rating Sets the motor nameplate overload current P034 Motor NP FLA 0 0 Drive Rated Ampsx2 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 1 rpm 1750 rpm 9 Sets the rated nameplate rpm of motor P037 Motor NP Power 0 00 Drive Rated Power 0 01 kW Drive Rated Power Sets the motor nameplate power 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 l NC 2 Economize 3 Vector P040 Autotune 0 2 0 Ready Idle 0 a 1 Static Tune Enables a static not spinning or dynamic motor E Spinning autotune 2 Rotate Tune 52 Rockwell Automation Publication 520 UM001B EN E February 2013 LCD amp Scrolling Description
158. e Error 127 DSI Flash Update Required The PowerFlex 525 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 UM001B EN E February 2013 Appendix D Velocity StepLogic Basic Logic and Timer Counter Functions Four PowerFlex 525 logic functions provide the capability to program simple logic functions without a separate controller e Velocity StepLogic Function Steps through up to eight preset speeds based on programmed logic Programmed logic can include conditions that 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 sta
159. e 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 Ib in C 8 4 mm 8 AWG 2 1 mm 14 AWG 1 76 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 UM001B EN E February 2013 29 Chapter1 _Installation Wiring Common Bus Precharge Notes 1 0 Wiring 30 If drives are used with a disconnect switch to the common DC bus then an auxiliary contact on the disconnect must be connected to a digital input of the drive The corresponding input parameter t062 t063 t065 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 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
160. e control shown For three wire control use a momentary input eo 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 1076 R2 Relay 1 Common Fault Common for output relay Em R5 Relay2 Common Motor Running Common for output relay T R6 Relay 2 N C Motor Running Normally closed contact for output relay ge 01 Stop Coast Three wire stop However it functions as a stop under all input po45 modes and cannot be disabled 02 Digin TermBlk 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 TermBlk P048 P050 02 as three wire Start Dir with Stop or two wire Run FWD A544 t062 Run REV control 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 Return for digital 1 0 Electrically isolated along with the digital 1 0 from the rest of the drive 0
161. e is ready for operation Opto outputs are inactive when power is removed or a fault occurs Hysteresis None occurring 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 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 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 093 10V Bipolar EnbI is set to 1 Bi Polar In 11 Above PF Ang Power Factor angle ex
162. e 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 068 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 1068 DigIn TermBlk xx It can be used to move through the Step Logic functions speed or Rockwell Automation Publication 520 UM001B EN E February 2013 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 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
163. e that a Reset Timer input is not required for this example since the Timer Start input both clears and starts the timer 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 Out1 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 Anaccumulator 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 position 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 Rockwell Automation Publication 520 UM001B EN E February 2013 Velocity StepLogic Parameters Output Frequency Start Relay Out Photo Eye Digin
164. ea pue jeuuov 1 Z 384 Worl 09 110SSVD 7 384 WOvL 05 99H NorL 09 1 001 J SZ O7 OOE voLNZEOJ aSZ 7 384 WOrl 0s 1J0 SSVD 7 384 WOvL S 99H NorL 0S 0 001 1 007 S8 OSc vOLNLCOJ 8SC 09 110fSSVD 7 384 WOvL S 9H NovL 09 0 001 q OSL OSL 0 02 vOLNCCO3 8SC 0s LJ0 SSVD 0 384 WOPL 0 99H NOvL 0S 0 001 d OSL O LL O SL POLN6LOI 57 91 32 WOrL O M S10 1406 SAY SSVD 9L 32 WOPL 029 090 NObL oE 2 001 QOL SZ OOL POLNZLOI 857 91 32 WOrl STHSIO L406 SHSSWDD 91230 WovL S1I 090 NOvL St 91 001 SL SS SL v0LN6d63 8SC 012 3O WOrL 0Z 4 S10 L40 f SAY SSVD 012 3O WovL 019 090 NOvL z 602 001 q US LE OS POLN9d93 aSz 98 30 WOFL Sl 4 S10 140 f SAY SSVD 98 3O WOvL 089 090 NOFL SL 602 001 V Oe TT 0t POLNZdbI aS7 0v8 32 WO0bL OL 4 S10 140 SYY SSVD 0vg 3C WOPL 054 090 NOFL OL 602 001 V 07 SL Oc vOLNOdEJ 8SC 24 32 WObL 9 4 S10 L40 f SAY SSVD S74 3Z WOPL 0 4 090 NOPL 9 602 001 V OL SLO OL vOLN dI3 8SC 79 32 WOPL 9 4 S10 110 f SAY SSVD 74 32 WOPL 074 090 NOPL 9 602 001 V SO v0 S O POLN6d03 8S7 Wort OPL1N NOL 68h 1n ON Bojeyey sep WOtL Nobl Guney xew Guney uiy oy Bojeze azis sdu yaj sduy MA dH MA dH ON boeze SAayeaig N11 Buney xew sasnj SJo ea1g N11 Sosnj
165. eared 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 cards e Cycle power remote network has been interrupted Check communications cabling e Check network adapter setting e Check external network status F073 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 cancelled by the user or failed Rockwell Automation Publication 520 UM001B EN E February 2013 Troubleshooting Chapter 4 Fault Types Descriptions and Actions No Fault Type Description Action F081 DSI Comm Loss 2 Communications between the drive and 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 Connecting 1 0 terminals C1 and C2 to ground may improve noise immunity Replace wiring Modbus master device or control module F082 Opt Comm Loss 2 Communications between the drive and Cycle power the network option c
166. earth Rockwell Automation Publication 520 UM001B EN E February 2013 31 Chapter1 Installation Wiring Control 1 0 Terminal Block 32 Control 1 0 Wiring Block Diagram Typical Typical 1 stop SRCwiring SNK wiring Safety 1 S1 u ig Hue k 02 5 2 lo elc Start Run FWD Safe Torque Off Safety 2 2 3 Sa A i igin TermBlk 03 G 7 Safety 24V 03 irection Run REV 3 4 Gal SNK s SRC m igital Common VY igin TermBlk 05 am o4 m igIn TermBlk 06 sl ee 07 igIn TermBlk 07 Pulse Pe eee m igIn TermBIk 08 Gr aes x 7 PAD Relay 1 N 0 RII pos iW 10V DC Relay 1 Common R2 LT l 2 a 0 10V or 10V Input Relay 2 Common R5 7 Analog Common x aM Ing tame NS i 0 10V 2W min Analog Output i 0 4 20mA 16 M Opto Output 1 BE OT d Opto Output 2 Common 3 DC w 8 50mA Non inductive 9 Opto Common a RJ45 Shield Q Comm Common V V V 0 4 20mA amp Pulse In SNK 5 S s EH Z sh s E lt ki e 0 10V amp Digital SRC Vy amp Input Vy b d m R2 R R6 01 02 03 04 05 06 07 08 a o CS CS ASA AISIA AlS Z SZ X CN
167. eceiver 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 e Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 525 RF Emission Compliance and Installation Requirements on page 45 for compliance with radio frequency emission limits for the specific standard and installation environment 44 Rockwell Automation Publication 520 UM001B EN E February 2013 Additional Installation Requirements Frame Size 200 240V AC 15 Installation Wiring Chapter 1 Connections and Grounding Shielded enclosure e ES IP 30 NEMA 1 UL Type 1 fe A ji j option kit or EMC kit Pek Ei BHEN EM EMI fittings and metal conduit EMI filter ele ou BRE L un b uv B ir UE ze E y Enclosure ground connection Shielded motor cable Building structure steel 1 Some installations require a shielded enclosure Keep wire length as short as possible between the enclosure entry point
168. ed grounded as described in Connections and Grounding on page 45 See General Grounding Requirements on page 16 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 EMC1 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 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 r
169. eferencex See Start and Speed Reference Control on page 39 for more information QOO Example a a Source Digit Display reads Description 2 Digln TrmBlk Parameters t062 1063 t065 t068 2004 Start source comes from Network Opt and Frequency source is Purge Fs ee t 113 Start source comes from Serial DSI and Frequency source comes from PID1 Output 5 EtherNet I 155 Start source and Frequency source comes from EtherNet IP Paquet Command Source Digit2 amp 3 052 Start source comes from Digln TrmBlk and Frequency source from 0 10V Input 01 ety 011 Start source comes from Keypad and Frequency source comes from Drive Pot 03 Serial DSI 04 Network Opt 05 0 10V n 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 IP 16 Positioning Frequency Command Source Digit 4 o MT Digit 2 amp 3 are used Digit 4 is not shown Jo 2 Purge Not Used Values Default Read Only Min Max 0000 2165 Display 0000 64 Rockwell Automation Publication 520 UM001B EN E February 2013 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 con
170. ejno Rockwell Automation Publication 520 UM001B EN E February 2013 217 AppendixG Safe Torque Off Function Notes 218 Rockwell Automation Publication 520 UM001B EN E February 2013 Establishing A Connection With EtherNet IP Appendix H EtherNet IP This section contains only basic information to setup an EtherNet IP connection with your PowerFlex 525 drive For comprehensive information about EtherNet IP single and dual port and how to use it refer to PowerFlex 525 Embedded EtherNet IP Adapter publication 20COM UMO01 There are two methods for configuring the embedded EtherNet IP adapter 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 BootP is enabled by default 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 IMPORTANT Ifyou are setting your network addresses manually using parameters you must set C128 EN Addr Sel to 1 Parameters 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 th
171. elded 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 INO001 Consideration should be 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 7596 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 10096 coverage foil and an 8596 coverage copper braided shield with drain wire surrounded by a PVC jacket 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 Rockwell Automation Publication 520 UM001B EN E February 2013 27 Chapter 1 28 Installation Wiring the overall drive performance Unless specified in the individual distance tables as tested with the drive these cables are not recommen
172. ement values 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 Select a digit when viewing parameter value Enter Advance one step in programming menu e Save a change to a parameter value Rockwell Automation Publication 520 UM001B EN E February 2013 49 Chapter2 Start Up Viewing and Editing Parameters 50 Key Name Reverse Description Used to reverse direction of the drive Default is active Controlled by parameters P046 P048 and P050 Start Source x and A544 Reverse Disable Start Used to start the drive Default is active Controlled by parameters P046 P048 and P050 Start Source x ea D 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 characters The display then defaults to that parameter s current value Example shows the value of b001 Output Freq with the drive stopped Pr
173. en remove and reapply power to or reset the adapter Rockwell Automation Publication 520 UM001B EN E February 2013 219 AppendixH EtherNet IP Notes 220 Rockwell Automation Publication 520 UM001B EN E February 2013 Appendix Induction Motor Tuning Diagrams Control Diagrams This chapter contains various diagrams on the PowerFlex 525 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 ASTS Freq3 BW 7 ss a8 oE ee BS AS13 Freq2BW gt a5 nun at EO ASI Freq 1 BW A510 I NUN A512 Freq Hz i Freq 2 4514 Freq 3 Low Speed Mid Speed High Speed Control Mode Control Mode Control Mode Speed Controller Gain m A525 Freq 3 Kpl H J AS26 Freq3 Ki pir eg s w 2 A523 Freq 2Kp RE A524 Freq 2 Ki as E A521 Freq 1 Kp A522 Freq 1 Ki A y Fed asi Freq Hz f AMI Freq 2 A514 TIO Rockwell Automation Publication 520 UM001B EN E February 2013 B Leu Freq 3 221 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
174. eness of the position regulator For faster response the filter should be reduced and or the gain should be increased For smoother response with less Rockwell Automation Publication 520 UM001B EN E February 2013 193 AppendixE _Encoder Pulse Train Usage and Position StepLogic Application Homing Routine 194 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 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
175. eq 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 525 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 525 Logic Status data can be read through the network by sending Function Code 03 reads to register address 2100H Logic Status Rockwell Automation Publication 520 UM001B EN E February 2013 177 AppendixC RS485 DSI Protocol Parameter C122 Cmd Stat Select is used to select Velocity or Position Bit definitions Velocity Bit Definitions Comm Logic Status C122 0 Velocity Address Decimal 2100H 8448 Position Bit Definitions Comm Logic Status C122 1 Position Bit s Description 0 1 Ready 0 Not Ready 1 1 Active Running 0 Not Active 2 1 Cmd Forward 0 Cmd Reverse 3 1 Rotating Forward 0 Rotating Reverse 4 1 Accelerating 0 Not Accelerating 5 1 Decelerating 0 Not Decelerating 6 Not Used 7 1 Faulted 0 Not Faulted 8 1 At Reference 0 Not At Reference 9 1
176. erence In multi drive mode this 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 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 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 A count of the number of receive packets reported by the embedded EtherNet IP interface Values Default Read Only Min Max 0 65535 Display 1 F727
177. erence and Datalink values transmitted to the drive will be held at their last value 4 Send Flt Cfg Note The Logic Reference and Datalink values will be transmitted to the drive as configured in C145 C146 and C147 C150 C145 EN Fit Cfg Logic Related Parameter s C143 C144 ird 32 bit parameter Sets the Logic Command 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 See Writing 06 Logic Command Data on page 175 for more information Values Default 0000 Min Max 0000 FFFF Display 0000 C146 EN Fit Cfg Ref Related Parameter s C143 C144 id 32 bit parameter 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 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 Fi
178. es Frame A Frame B S Frame C S y N N 72 0 28 3 870 84 5 109 0 4 29 57 5 2 26 S 72 5 2 85 4 e 90 5 3 56 e q 1 LC B m i amp 3 S So S 2 2 Q E N o e 2 2 N i Y Y 7 T iN Ke n 2 a e co i 2 amp PORTO MO Powerflex Ep PowerFlex S an0a0nnannanas T a B Allen Bradiey VW Frame D Frame E A A S 196 0 7 72 N 130 0 5 12 185 0 7 28 116 0 4 57 s 160 0 6 30 52 0 2 05 x e FALTO gt 5 i A N U CY i J Y Y E N 3 UUU gx o n UU port PowerFlex E NANA AAA 280 0 11 02 d hl j Allen Bradley Allen Bradley Rockwell Automation Publication 520 UM001B EN E February 2013 161 AppendixB
179. ess 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 ii ririri LILI Lle NIZ sn L riri LILI LTT Ex i bu LI siz CAC gt e PIT 4 pri LaL v Pa 18 S p NI ai ju x ESI Co 3M PROER BN Rockwell Automation Publication 520 UM001B EN E February 2013 Drive Programming Tools Language Support Step 10 If desired press Sel to move from digit to digit or bit to bit The digit or bit that 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
180. eter groups AppView CustomView and CopyCat functionality is limited to the linear parameter list Communications option cards are not accessible using the remote HIM Language HIM LCD Display RSLogix 5000 Connected Components Version 17 0 or greater Workbench Logix Designer Version 3 0 or greater Version 21 0 or greater 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 UM001B EN E February 2013 51 Chapter2 Start Up Language HIM LCD Display RSLogix 5000 Connected Components Version 17 0 or greater Workbench Logix Designer Version 3 0 or greater Version 21 0 or greater Polish Y Turkish Y Czech Y Smart Start Up with Basic The PowerFlex 525 drive is designed so that start up is simple and efficient The Basic Program Group contains the most commonly used parameters See Program Group Parameters Programming and Parameters on page 57 for detailed descriptions of the parameters listed here as well as the full list of available parameters Stop drive before changing this parameter No Parameter Min Max Display Options Default P030 Language 1 15 1 English 1 Selects the language displayed m E Important The setting takes effect after the
181. eter s P044 A43 Sets the time for the drive to accelerate from 0 Hz to P044 Maximum Freq Accel Rate Maximum Freq Accel Time x Maximum Freq 9 0 Accel Timex amp Time Decel Time x la 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 Accel Time x la Time Decel Timex Values Default 10 005 Min Max 0 00 600 00 s Display 0 015 P043 Minimum Freq Related Parameter s b001 b002 b013 P044 A530 A531 O Ray drive before changing this parameter Sets the lowest frequency the drive outputs Values Default 0 00 Hz Min Max 0 00 500 00 Hz Display 0 01 Hz P044 Maximum Freq Related Parameter s b001 b002 b013 b016 P043 A530 A531 so 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 70 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Basic Program Group continued P045 Stop Mode Related Parameter s t086 t087 A434 M35 Determines the stopping mode used by the drive when a stop is i
182. eters 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 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 Rockwell Automation Publication 520 UM001B EN E February 2013 183 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Counter Function 184 P049 Speed Reference2 7 Preset Freq t062 DigIn TermBlk 02 1 Speed Ref 2 t063 DigIn TermBlk 03 19 Timer Start t076 Relay Out Sel 25 Timer Out t077 Relay Out1 Level 20 0 Secs A411 Preset Freq 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 aT n 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 Not
183. ex 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 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 Limitation in Exporting pf5 Configuration Files with Connected Components Workbench Export of pf5 configuration files in Connected Components Workbench is limited to non multidrive configurations Rockwell Automation Publication 520 UM001B EN E February 2013 55 Chapter2 Start Up Notes 56 Rockwell Automation Publication 520 UM001B EN E February 2013 Chapter 3 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 525 parameters Par
184. f 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 Rockwell Automation Publication 520 UM001B EN E February 2013 85 Chapter3 Programming and Parameters 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 E 1 RTU 8 0 1 RTU 8 N 2 RTU 8 E 2 RTU 8 0 2 n e wj N C128 EN Addr Sel Related Parameter s C129 C132 C133 C136 C137 C140 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 cyde is required after selection is
185. f 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 T in F an AppView group G1 G8 a gt lt a gt e j LI ALI d LIIIN 2 Press Enter or Sel to enter a group The right EE most digit of the last viewed parameter in that aol Hl j group will flash or LJ We j A 3 Press the Up Arrow or Down Arrow to scroll to C CS r1 P aa the command G1 gt GC h L2 UP LIL 18 4 Press Enter or Sel to add all the parameters in this AppView group to the CustomView group X Ww y x X The LCD display will show a confirmation or 126 Rockwell Automation Publication 520 UM001B EN E February 2013 CustomView Parameter Group Programming and Parameters Chapter 3 Use the CustomView parameter group to e store frequently used parameters for your application for quicker access e select only those parameters needed for your application and if required hide all other parameters with A552 Program Lock 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 above or add
186. 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 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 Description 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 Parameters t091 Anlg In 0 10V Lo and 1092 Anlg In 0 10V Hi are used to scale or invert an analog PID Reference or PID Feedback Scale Function For a 0 5V signal the fol
187. fter 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 208 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 Fault F111 Ready Run Safety Open En Safety Hardware Safety Hardware Safety Channel Operation Safety Input S1 No Power Applied Power Applied No Power Applied 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 UM001B EN E February 2013 Safe Torque Off Function Appendix G
188. guring Parameters for DSI Network Parameter Details Reference P046 Start Source 1 Set to 3 Serial DSI if Start is controlled from the network page 71 P047 Speed Reference Set to 3 Serial DSI if the Speed Reference is controlled from the network page 7 E C123 RS485 Data Rate Setsthe data rate for the RS485 DSI Port All nodes on the network must be set to the same data rate co D ico un un C124 RS485 Node Addr Sets the node address for the drive on the network Each device on the age 8 network requires a unique node address C125 Comm Loss Action Selects the drive s response to communication problems 126 Comm Loss Time Sets the time that the drive will remain in communication loss before the drive implements C125 Comm Loss Action C127 Comm Format Sets the transmission mode data bits parity and stop bits for the RS485 DSI page 8 Port All nodes on the network must be set to the same setting io H E C121 Comm Write Mode Set to 0 Save when programming drive Set to 1 RAM only to only write to volatile memory Rockwell Automation Publication 520 UM001B EN E February 2013 Supported Modbus Function Codes the Modbus function codes Supported Modbus Function Codes RS485 DSI Protocol Appendix C The peripheral interface DSI used on PowerFlex 525 drives supports some of Modbus Function Code Decimal Command 03
189. hey contain power etc for other Rockwell Automation peripheral devices Wiring terminations on the master controller will vary depending on the master controller used and TxRxD and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations 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 on the PowerFlex 525 drive must also be connected to PE ground there are two PE terminals on the drive See Control I O Terminal Designations on page 33 for more information I O Terminal C2 Comm Common is internally tied to Network Common and NOT to RJ45 Shield Tying I O Terminal C2 to PE ground may improve noise immunity in some applications The following PowerFlex 525 parameters are used to configure the drive to operate on a DSI network Confi
190. hin the PowerFlex 520 Series may be referred to as 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 MM Name Number Group b Basic Display P Basic Program t Terminal Blocks C Communications L Logic d Advanced Display A Advanced Program M Modified N Network G AppView and CustomView F Fault and Diagnostic e The following words are used throughout the manual to describe an action Words Meaning 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 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 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 Rockwell Autom
191. ical 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 i ATTENTION National Codes and standards NEC VDE BSI etc and local codes 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 hazard from cross coupled power leads 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 UM001B EN E February 2013 Installation Wiring Chapter 1 UL installations above 50 C ambient must use 600V 90
192. ications Encoder Pulse Train Usage and Position StepLogic Application Appendix E IMPORTANT A quadrature 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 and swap the A and A NOT encoder channels or 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 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 A535 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 enc
193. imary benefit of this mode is increased speed accuracy when compared to open loop slip compensation It does not provide speed bandwidth improvement 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 UM001B EN E February 2013 187 Appendix E Wiring Notes 188 Encoder Pulse Train Usage and Position StepLogic Application No Signal Description V U A JEncoder A E ingle channel pulse train or quadrature A input Cm A EncoderA NOT j p B B Encoder B T uadrature B input A B Encoder B NOT P d Cm Power Return A ma Internal power source 250 mA isolated V 5 12V Power 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 IMPORTANT A quadrature 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
194. imeters 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 72 0 2 83 54 0 2 13 ys 20 22 Li L2 L3 6 66 234 0 9 21 223 0 8 78 LI L2 L3 n fark mt aci tack e ibi 55022 54 0 2 13 Filter can be mounted onto the back of the drive 87 0 3 43 58 0 2 28 05 5 20 22 e Li max Bae 55 0 22 58 0 2 28 Rockwell Automation Publication 520 UM001B EN E February 2013 167 Appendix B Accessories and Dimensions 168 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 me
195. ing 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 e 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 characteristics 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 See the control diagrams in Appendix for more information Motor operation is unstable Cause s Motor data was incorrectly entered Indication 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 See the control diagrams in Appendix for more information Drive will not reverse motor direction 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 73 Choose correct input and program for reversing mode Digital input is incorrectly wired None Check input wiring See page 34 Motor wiring is improperly phased for reverse None Switch two motor leads 140 Rock
196. ip Frequency Band Ww Skip Frequency gt Programming and Parameters Chapter 3 Related Parameter s A448 A450 A452 M54 Time Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz M56 PID 1 Trim Hi M68 PID 2 Trim Hi Scales the upper value of the trim frequency when trim is active Values Default 60 0 Hz Min Max 0 0 500 0 Hz Display 0 1Hz A457 PID 1 Trim Lo A469 PID 2 Trim Lo Scales the lower value of the trim frequency when trim is active Values Default 0 0 Hz Min Max 0 0 500 0 Hz Display 0 1Hz Rockwell Automation Publication 520 UM001B EN E February 2013 103 Chapter3 Programming and Parameters Advanced Program Group continued A458 PID 1 Trim Sel M70 PID 2 Trim Sel O Bay drive before changing this parameter Sets the PID output as trim to the source reference Options 0 Disabled Default PID Trim is disabled TrimOn Pot TrimOn Keypd TrimOn DSI TrimOn NetOp TrimOn 0 10V TrimOn 4 20 TrimOn Prset TrimOn AnMIt wo Co NI cu A wl N TrimOn MOP ce TrimOn Pulse TrimOn Slgic No TrimOn Encdr w TrimOn ENet M59 PID 1 Ref Sel M71 PID 2 Ref Sel S drive before changing this parameter Selects the source of the PID reference Options 0 PIDSetpoi
197. 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 525 AC Drive Specifications 520 TD001 PowerFlex Dynamic Braking Resistor Calculator PFLEX ATOO1 PowerFlex AC Drives in Common Bus Configurations DRIVES ATO02 Rockwell Automation Publication 520 UM001B EN E February 2013 Preface Overview Manual Conventions The following publications provide specific Network Communications information Title Publication PowerFlex 525 Embedded EtherNet IP Adapter including dual port Ethernet 520COM UM001 PowerFlex 525 DeviceNet Adapter 520COM UM002 PowerFlex 525 PROFIBUS DP Adapter 520COM UM003 e In this manual we refer to PowerFlex 520 Series Adjustable Frequency AC Drive as drive PowerFlex 520 PowerFlex 520 Drive or PowerFlex 520 AC drive e Specific drives wit
198. ith drag and drop functionality Rockwell Automation Publication 520 UM001B EN E February 2013 127 Chapter3 Programming and Parameters Parameter Cross Reference by Name Parameter Name No Parameter Name No Parameter Name No 10V Bipolar Enbl 093 DB Resistor Sel 437 DSI Errors 731 2 Wire Mode 064 DB Threshold 438 DSI 1 0 Act 686 Accel Time 1 041 DC Brake Level 435 DSI 1 0 Cfg 175 Accel Time 2 442 DC Brake Time 434 Elapsed kWh 021 Accel Time 3 444 DC Brk Time Strt 436 Elapsed MWh 022 Accel Time 4 446 DC Bus Ripple 380 Elapsed Run Time 019 Accum C02 Sav 026 DC Bus Voltage 005 Elapsed Time hr 362 Accum Cost Sav 025 Decel Time 1 042 Elapsed Time min 363 Accum kWh Sav 024 Decel Time 2 443 EM Brk Off Delay 086 Analog In 0 10V 360 Decel Time 3 445 EM Brk On Delay 087 Analog In 4 20mA 361 Decel Time 4 447 EN Addr Sel 128 Analog In Filter 099 Dig In Status 014 EN Addr Src 684 Analog Out High 089 Digln TermBlk 02 062 EN Comm Fit Actn 143 Analog Out Sel 088 Digln TermBlk 03 063 EN Data In 1 153 Anlg In 0 10V Hi 092 Digln TermBlk 05 065 EN Data In 2 154 Anlg In 0 10V Lo 091 Digln TermBlk 06 066 EN Data In 3 155 Anlg In mA Loss 097 Digln TermBlk 07 067 EN Data In 4 156 Anlg In V Loss 094 Digln TermBlk 08 068 EN Data Out 1 157 Anlg In4 20mA Hi 096 Drive OL Mode 495 EN Data Out 2 158 Anlg In4 20mA Lo 095 Dr
199. itional 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 45 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 e PowerFlex 525 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 ofthe distribution network operator have been met Consultation with the network operator and Rockwell Automation may be necessary e 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 e The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents e Use of line filters in ungrounded systems is not recommended e In CE installations input power must be a Balanced Wye with Center Ground configuration for EMC compliance Installation Requirements Related to EN 61800 5 1
200. itions 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 e Install Line Reactor Greater than 120 kVA supply transformer e orlsolation Transformer Line has power factor correction capacitors Install Line Reactor e 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 Ungrounded distribution system 240V open delta configuration stinger leg Install Line Reactor 1 For drives applied on an open delta with a middle phase grounded neutral system the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the stinger leg high leg red leg etc This leg should be identified throughout the system with red or orange tape on the wire a
201. ive Status 006 EN Data Out 3 159 Anlg Loss Delay 098 Drive Temp 027 EN Data Out 4 160 Anlg Out Setpt 090 Drive Type 367 EN Fit Cfg DL 1 147 Auto Rstrt Delay 542 Droop Hertz FLA 441 EN Flt Cfg DL 2 148 Auto Rstrt Tries 541 Drv 0 Feedback 708 EN Fit Cfg DL 3 149 Autotune 040 Drv 0 Logic Cmd 705 EN Fit Cfg DL 4 150 Average kWh Cost 052 Drv 0 Logic Sts 707 EN Flt Cfg Logic 145 Average Power 020 Drv 0 Reference 706 EN Fit Cfg Ref 146 Boost Select 530 Drv 1 Addr 171 EN Gateway Act 1 701 Break Frequency 533 Drv 1 Feedback 712 EN Gateway Act 2 702 Break Voltage 532 Drv 1 Logic Cmd 709 EN Gateway Act 3 703 Bus Reg Enable 550 Drv 1 Logic Sts 711 EN Gateway Act 4 704 Cmd Stat Select 122 Drv 1 Reference 710 EN Gateway Cfg 1 137 Com Sts Emb Enet 683 Drv 2 Addr 172 EN Gateway Cfg 2 138 Comm Loss Action 125 Drv 2 Feedback 716 EN Gateway Cfg 3 139 Comm Loss Time 126 Drv 2 Logic Cmd 713 EN Gateway Cfg 4 140 Comm Sts DSI 681 Drv 2 Logic Sts 715 EN Idle Fit Actn 144 Comm Sts Opt 682 Drv 2 Reference 714 EN IP Addr Act 1 693 Comm Write Mode 121 Drv 3 Addr 173 EN IP Addr Act 2 694 Commanded Freq 002 Drv 3 Feedback 720 EN IP Addr Act 3 695 Compensation 547 Drv 3 Logic Cmd 717 EN IP Addr Act 4 696 Contrl In Status 013 Drv 3 Logic Sts 719 EN IP Addr Cfg 1 129 Control Source 012 Drv 3 Reference 718 EN IP Addr Cfg 2 130 Control SW Ver 029 Drv 4 Addr 174 EN IP Addr Cfg 3 131 Control Temp 028 Drv 4 Feedback 724 EN IP Addr Cfg 4 132 Counter Status 364 Drv 4 Logic Cmd 721 EN Mi
202. ive exceeds 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 t070 or t073 Opto 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 2mA 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 Value set in A541 Auto Rstrt Tries is exceeded or None e A541 Auto Rstrt Tries is not enabled or Anon resettab
203. k xx must be configured for 2 Wire or 3 Wire control for the drive to function properly Start Source x 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 UM001B EN E February 2013 Installation Wiring Chapter 1 CE Conformity 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 Accel Decel always Purge Input Enabled RN a Accel Decel 1 AND Active Accel Decel from Jog Acc Dec Terminal Block Jog Yes Drive stopped Input Enabled AND NOT running No Input s is programmed as Acc Dec 2 3 4 Accel Decel 2 is active when input is selected by Accel and Decel input No Accel Decel 1 2 3 4 is selected by the default Preset Freq x setting ls speed controlled by Preset Freq x Active Accel Decel 1 or 2 is Speed Referencex selected according omms to Comms Active Accel Decel 1 2 3 4 is Speed Referencex selected according to 13 Step Logic Step Logic Drive uses Accel 1 and Decel 1 Compliance with
204. le 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 one 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 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 Drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with A564 Encoder Pos Tol 28 At Home Drive is i
205. lemental Drive Information PowerFlex 525 Estimated Watts Loss Rated Load Speed amp PWM Voltage Output Current A Total Watts Loss 380 480V 14 27 0 50 60 Hz 3 Phase 23 370 4 0 80 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 ae a IT 4 0 81 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 0 525 600V 0 9 22 0 50 60 Hz 3 Phase 17 320 3 0 50 0 4 2 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 0 148 Rockwell Automation Publication 520 UM001B EN E February 2013 Appendix B Accessories and Dimensions Product Selection Catalog Number Description 25B V 25 N 1 0 4 Drive VoltageRating Rating Enclosure HIM Emission Class Version PowerFlex 525 Drives Output Ratings Normal Duty Heavy Duty Output Input Frame Catalog No HP kW HP kW Current A Voltage Range Size 100 120V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25B V2P5N104 0 5 0 4 0 5 0 4 25 85 132 A 25B V4P8N104 1 0 0 75 1 0 075 148 85 132 B 25B V6PON104 15 1 1 1 5 1 1 6 0 85 132 B 200 240V AC 15 10 1 Phase Input 0 230V 3 Phase Output 25B A2P5N104 0 5 0 4 0 5 0 4 2 5 170 264 A 25B A4P8N104 1 0 0 75 1 0 075 148 170 264 A 25B
206. lex 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 61508 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 A Functional Safety The test report no 968 M 365 00 12 dated 2012 09 24 is an integral part of this FS The holder of a valid licence certificate for the product tested is authorized to Q T VRheinland FE Berlin 2012 09 24 Tel 49 30 7562 1557 F ax 49 30 7562 1370 E Mail tuvatfde tuv com TOV Rheinland Industrie Service GmbH Alboinstr 56 12103 Berlin Germany Certification Body for Machinery NB 0035 Dipl Ing Eberhard Fr
207. ll Automation Publication 520 UM001B EN E February 2013 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 terminals 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 R R5 R6 01 02 03 04 05 06 07 08 S1919 9989189188 eleleleioielelelelele e 1 s2 St 12 B WM 15 16 17 18 19 V p 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
208. lowing European Directives C EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Standards applied EN 61800 3 2004 EN 61800 5 1 2007 TUV iauart gepri T V Rheinland AO T V Rheinland Standards applied EN ISO 13849 1 2008 EN ISO 13849 2 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 Safety FS when used with embedded Safe Torque Off function ATEX Certified to ATEX directive 94 9 EC Group II Category 2 GD Applications with ATEX Approved Motors x lI 2 GD 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 EPRI Electric Power Research Institute PQ Certified compliant with the following standards nd CET000 4 34 Lloyds Register 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
209. lowing 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 1092 Anlg In 0 10V Hi 50 0 201 AppendixF PID Set Up e A459 PID 1 Ref Sel 5 0 10V Input Input Volts M 4 D co 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 t092 Anlg In4 20mA Lo 100 096 t096 Anlg In4 20mA Hi 0 0 e A459 PID 1 Ref Sel 6 4 20mA Input 24 0 Er Lt L En amp DEF N 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 202 Rockwell Automation Publication 520 UM001B EN E February 2013 PID SetUp Appendix F drive s frequency command to initially jump to that preload frequenc
210. lt 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 P034 Motor NP FLA Related Parameter s P040 Sets the motor nameplate FLA Used to assist the Autotune routine and motor control Values Default Based on Drive Rating Min Max 0 1 Drive Rated Amps x 2 Display 0 1A 68 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Basic Program Group continued 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 Bay 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 Sets the motor nameplate power Values Default Drive Rated Power Min Max 0 00 Drive Rated Power Display 0 01 kW P038 Voltage Class O Ray 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 Bay drive before changing this parameter Selects the mo
211. m kWh Sav b024 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 Ue 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 08 t068 Relay Out LevelF t078 Analog Out Sel t088 Anlg Loss Delay t098 Opto Out1 Sel t069 Relay 1 0n Time t079 Analog Out High t089 Analog In Filter t099 ka Opto Outi Level t070 Relay 1 Off Time t080 Anlg Out Setpt t090 Sleep Wake Sel t100 Opto Out1 LevelF t071 Relay Out2 Sel t081 Anlg In 0 10V Lo t091 Sleep Level t101 Digln TermBlk 02 1062 Opto Out2 Sel t072 Relay Out2 Level 1082 Anlg In 0 10V Hi 1092 Sleep Time t102 Digln TermBlk 03 1063 Opto Out2 Level t073 Relay Out2 LevelF 1083 10V Bipolar Enbl t093 Wake Level t103 2 Wire Mode t064 Opto Out2 LevelF t074 Relay 2 On Time t084 Anlg In V Loss t094 Wake Time t104 Digln TermBlk 05 t065 Opto Out Logic t075 Relay 2 Off Time t085 AnlgIn4 20mA Lo 1095 Safety Open En t105 Digln TermBlk 06 t066 Relay Out1 Sel t076 EM Brk Off Delay t086 Anlg In4 20mA Hi t096 Digln TermBlk 07 t067 Relay Out Level t077 EM Brk On Delay 1087 AnlgIn mA Loss t097 Communicatio
212. m keypad access but can still be accessed over communications All parameters are locked and hidden except custom group and Program Lock All parameters are locked and hidden except custom group and Program Lock from keypad access but can still be accessed over communications 114 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued 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 JA wl N A555 Reset Meters Related Parameter s b019 b021 b022 b023 b024 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 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 a
213. mended Signal Wire Signal Type Belden Wire Type s 7 Description Min Insulation Where Used or equivalent Rating eT UU UEM DRE TP PENNE oe a aaa TE RR Analog 1 0 amp PTC 8760 9460 0 750 mm 18 AWG twisted pair 300V 100 shield with drain 60 C 140 F Remote Pot 8770 0 750 mm 18 AWG 3 conductor shielded Encoder Pulse 1 0 9728 9730 0 196 mm 24 AWG individually shielded pairs 1 Stranded or solid wire 2 If the 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 10 750 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 If using the RS485 DSI port I O Terminal C1 should also be connected to ground terminal protective earth Additionally communication noise immunity can also be improved by connecting I O Terminal C2 to ground terminal protective
214. meter 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 ofthe drive that is in multi drive mode A reset or power cyde 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 with 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 Rockwell Automation Publication 520 UM001B EN E February 2013 89 Chapter3 Programming and Parameters Communications Group continued 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
215. n 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 S Yes Block REV terminal 03 AND Active NOT running Comms OR FWD REV determined by Jog FWD Jog REV command Run as specified by Preset Freq x Preset Inputs Active Gesn rditm commands come from 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 Start and Direction command from Start Source 2 2 Run as specified by _ Start S 2 Speed Reference2 Start Source 2 select Speed Reference2 select 1 Run as specified by Start and Direction command from Speed Reference1 Start Source 1 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 40 for information on selecting the correct digital input Rockwell Automation Publication 520 UM001B EN E February 2013 39 Chapter 1 40 Installation Wiring 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 TermBl
216. n 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 Relay Out Sel 0 Relay Out2 Sel 2 Min Max 0 29 Display 1 78 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Terminal Block Group continued t077 Relay Out Level t082 Relay Out2 Level Related Parameter s t076 t081 W 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 0 100 18 T0 1809 7 0 180 16 0 1 9999 s 20 0 1 8 10 815V 17 1 9999 counts 26 0 150 Values Default 0 Min Max 0 9999 Display 1 t079 Relay 1 On Time t084 Relay 2 On Time 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 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 Delay 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 Ele
217. n 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 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 co
218. ng and wiring the PowerFlex 525 Chapter 1 drive For information on See page Mounting Considerations 11 AC Supply Source Considerations 15 General Grounding Requirements 16 Fuses and Circuit Breakers 18 Power and Control Module 22 Control Module Cover 25 Power Module Terminal Guard 25 Power Wiring 26 Power Terminal Block 29 Common Bus Precharge Notes 30 1 0 Wiring 30 Control 1 0 Terminal Block 32 Start and Speed Reference Control 39 CE Conformity 41 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 Screw Size Screw Torque A M5 10 24 1 56 1 96 Nm 14 17 Ib in B M5 10 24 1 56 1 96 Nm 14 17 Ib in C M5 10 24 1 56 1 96 Nm 14 17 Ib in D M5 10 24 2 45 2 94 Nm 22 26 Ib in E M8 5 16 in 6 0 7 4 Nm 5
219. nitiated 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 DCBrkAuto CF DC Injection Braking Stop with Auto Shutoff ii DC Injection Braking for value set in A434 DC Brake Time e 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 current limit is exceeded 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 command clears Provides a method to stop at a constant distance instead of a fixed rate active fault 5 top 11 PointStop PointStop Maximum Freq Speed Calculated Stop Time DecelTimex gt Time P046 Start Source 1 Related Parameter s b012 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 factor
220. ns EN Addr Sel C128 EN Gateway Cfg 3 C139 EN Data In 1 C153 Opt Data In 4 C164 EN IP Addr Cfg 1 C129 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 3 C155 Opt Data Out 2 166 EN IP Addr Cfg 3 C131 EN Comm Fit Actn C143 EN Data In 4 C156 Opt Data Out 3 167 Comm Write Mode C121 EN IP 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 Flt Cfg Logic C145 EN Data Out 2 C158 MultiDrv Sel C169 RS485 Data Rate C123 EN Subnet Cfg 2 C134 EN Flt Cfg Ref C146 EN Data Out 3 C159 Drv 1 Addr 171 RS485 Node Addr C124 EN Subnet Cfg 3 C135 EN Flt Cfg DL 1 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 C173 Comm Loss Time C126 EN Gateway Cfg 1 C137 EN Flt Cfg DL 3 C149 Opt Data In 2 C162 Drv4 Addr C174 RS485 Format C127 EN Gateway Cfg 2 C138 EN Flt Cfg DL 4 C150 Opt Data In 3 C163 DSII 0 Cfg C175 58 Rockwell Automation Publication 520 UM001B EN E February 2013 Logic ra Stp Logic 0 Stp Logic 1 Stp Logic 2 Stp Logic 3 Advanced Display Analog In 0 10V Analog In 4 20mA Elapsed Time hr Advanced Program Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Preset Freq 8 Preset Freq 9 Preset Freq 10 Preset Freq 11 Preset Freq 12 Preset Freq 13 Preset Freq 14 Preset F
221. nt Default Drive Pot Keypad Freq Serial DSI Network Opt 0 10V Input 4 20mA Input Preset Freq Anigin Multi wo CO N BD HM A wl N MOP Freq ce Pulse Input Step Logic N Encoder i w EtherNet IP 104 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued A460 PID 1 Fdback Sel M72 PID 2 Fdback Sel 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 treated as zero 1 4 20mA Input Serial DSI Network Opt Pulse Input Encoder EtherNet IP Di wm eA w N A461 PID 1 Prop Gain Related Parameter s A459 A471 A473 PID 2 Prop Gain 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 A462 PID 1 Integ Time Related Parameter s A459 A471 A474 PID 2 Integ Time 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 Sets the value in 1 second for the PID differenti
222. o RS232 DSI Cable Connected Components Workbench software Includes e DSI to RS232 serial converter 1 e 1203 SFC serial cable 1 22 RJ45CBL C20 cable 1 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 programming and configuring Allen Bradley drives and other Rockwell Automation products Compatibility Windows XP Windows Vista and Windows 7 Bulletin 1321 3R Series Line Reactors http ab rockwellautomation co m programmable controllers connected components workbench software Output Ratings Input Line Reactor Output Line Reactor 25 IP00 IP11 IP00 IP11 Normal Duty Heavy Duty OpenStyle NEMA UL Type 1 Open Style NEMA UL Type 1 HP kW HP kW CatalogNo Catalog No Catalog No Catalog No 200 240V 50 60 Hz 3 Phase 05 04 0 5 10 4 1321 3R2 D 13213RA2 D 1321 3R2 D 1321 3RA2 D 10 1075 10 1075
223. ockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Fault and Diagnostic Group continued F682 Comm Sts Opt Displays the status of the internal communication to the drive DEDERE EI Digit 3 Internal Com option 1 Condition True 0 Condition False Not Active no connection Rx Digit 1 Internal option connected active Tx 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 F683 Com Sts Emb Enet Displays the status of the embedded EtherNet IP interface to the drive AGGIE Digit 3 Embedded EtherNet IP 1 Condition True 0 Condition False 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 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 Displays the network data rate currently used by the embedded EtherNet IP interface Options 0 NoLink Read Only 1 10Mbps Full 10Mbps
224. ockwell Automation field service personnel Values Default 400 Min Max 0 FFFF Display 1 A484 Current Limit 1 Maximum output current allowed before current limiting occurs Related Parameter s P033 Values Default Drive Rated Amps x 1 1 Normal 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 Maximum output current allowed before current limiting occurs Related Parameter s P033 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 106 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Advanced Program Group continued M86 Shear Pin1 Level Related Parameter s A487 A489 A488 Shear Pin2 Level 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 M87 Shear Pin 1 Time Related Parameter s A486 A488 A489 Shear Pin 2 Time 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 Displ
225. oder 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 isa 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 Rockwell Automation Publication 520 UM001B EN E February 2013 189 AppendixE _ Encoder Pulse Train Usage and Position StepLogic Application Positioning Operation 190 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 results t
226. 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 gt eee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley Rockwell Automation Rockwell Software PowerFlex Connected Components Workbench Studio 5000 DriveTools SP AppView CustomView MainsFree Programming and PointStop are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Overview Installation Wiring Start Up Programming an
227. ol requires Run Forward Run Reverse or Jog f 2 wire or 3 wire mode is used verify that t062 DigIn TermBIk 02 and t063 DigIn input TermBlk 03 are set properly e 3wire 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 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 TermBIk 02 03 is set incorrectly None Check parameter settings Incorrect input wiring See page 34 for wiring examples 2wire control requires Run Forward Run Reverse or Jog input e 3wire 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 UM001B EN E Februar
228. ommunication 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 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 enabl
229. only 309g 2 5g Screw only Conformal Coating Complies with IEC 60721 3 3 to level 3C2 chemical gases only See Pollution Degree Ratings According to EN 61800 5 1 on page 42 for descriptions All enclosures acceptable Rockwell Automation Publication 520 UM001B EN E February 2013 145 AppendixA X Supplemental Drive Information Category Specifications Environment Sound Pressure Level A weighted Measurements are taken 1 m from the drive Frame A amp B Maximum 53 dBA Frame C Maximum 57 dBA Frame D Maximum 64 dBA Frame E Maximum 68 dBA Electrical 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 Control Method Sinusoidal PWM Volts Hertz Sensorless Vector Control Economizer SVC motor control and Closed Loop Velocity Vector Control Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency 10 Bit resolution Analog Output 2 of full scale 10 Bit resolution Speed Regulation Open Loop
230. or 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 5 Verify that the Stop input is present or the drive will not start IMPORTANT If1 0 Terminal 01 is used as a stop input the jumper between 1 0 Terminals 01 and 11 must be removed Applying Power to the Drive 6 Apply AC power and control voltages to the drive Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from the keypad No programming is required to start stop change direction and control speed directly from the keypad IMPORTANT To disable reverse operation see A544 Reverse Disable If a fault appears on power up see Fault Descriptions on page 135 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 UM001B EN E February 2013 Display and Control Keys StartUp Chapter 2 Allen Bradley Menu Parameter Group and Description L Basic Display J Commonly viewed drive operating conditions boo i Lee d FA
231. other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations overhauling loads and eccentric loads However it can also cause either of the following two conditions to occur 1 Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes 2 Actual deceleration times can be longer than commanded deceleration times However a Stall Fault is generated if the drive remains in this state for 1 minute If this condition is unacceptable the bus regulator must be disabled see parameter A550 Bus Reg Enable In addition installing a properly sized dynamic brake resistor will provide equal or better performance in most cases ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis Rockwell Automation Publication 520 UM001B EN E February 2013 9 Preface Overview Catalog Number Explanation 13 4 5 6 8 9 10 11 12 13 14 N 1 1 4 amp B Voltage Rating 4 Standard 25
232. oup continued 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 EE cs E 4 E a 6 A Speed S DC Brake Time Ege Magnitude s Magnitude depends on depends on P3 Time DC Brake Level Time DC Brake Level Stop Command 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 5 Min Max 0 0 Drive Rated Amps x 1 8 Display 0 1A M36 DC Brk Time Strt Related Parameter s P045 A435 Sets the length of time that DC brake current is injected into the motor after a valid start command is received Volts Speed DC Brk Time Strt DC Brake Level Start ent Time Values Default 0 0s Min Max 0 0 99 9 s Display 0 15 M37 DB Resistor Sel S drive before changing this parameter Enables disables external dynamic braking and selects the level of resistor protection Options 0 Disabled Default 1 Norml RA Res 5 2 NoProtection 100 3 99 3 99 DutyCycle A438 DB Threshold Related Parameter s
233. out 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 so drive before changing this parameter Enables disables drive start on power up without a start command being cycled 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 Disabled Default 1 Enabled A544 Reverse Disable Related Parameter s b006 O Ray 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 a
234. ow 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 e Increase P041 A442 A444 A446 decelerate motor Accel Time x or reduce load so drive output current does not exceed the current set by parameter A484 A485 Current Limit x for too long e Check for overhauling load F007 Motor Overload 1 Internal electronic overload trip An excessive 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 HeatsinkOvrTmp 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 exceeds a e Check product ambient temperature predefined value e Check for airflow obstruction e Check for dirt or debris Check fan F012 HW OverCurrent 2 The drive output current has excee
235. p Units 3 Step Units 4 Step Units 5 Digln TermBlk 02 Digln TermBlk 03 Opto Out Sel Opto Out2 Sel Relay Outi Sel Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 20mA Hi Anlg In mA Loss P046 P047 t076 t088 t089 t090 t091 t092 t095 P046 P047 t076 t088 t089 t090 t091 t092 t095 P045 P046 P047 t076 t088 t089 t090 t091 t092 L185 L186 L187 L190 L191 L192 L193 L194 L195 L196 L197 L200 L202 L204 L206 L208 L210 t062 t063 t069 t072 t076 t091 t092 t095 t096 t097 Anlg In4 20mA Hi Anlg In mA Loss Preset Freq 0 PID 1 Trim Hi PID 1 Trim Lo PID 1 Ref Sel PID 1 Fdback Sel PID 1 Prop Gain PID 1 Integ Time Anlg In4 20mA Hi Anlg In mA Loss Preset Freq 0 PID 1 Trim Hi PID 1 Trim Lo PID 1 Ref Sel PID 1 Fdback Sel PID 1 Prop Gain PID 1 Integ Time Anlg In4 20mA Lo Anlg In4 20mA Hi Anlg In mA Loss Slip Hz Meter Speed Feedback Encoder Speed Preset Freq 0 Stall Fault Time Motor Fdbk Type Step Units 6 Step Units 7 Slip Hz Meter Speed Feedback Encoder Speed Units Traveled H Units Traveled L Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Preset Freq 8 Jog Frequency Slip Hz Meter Fiber Status Preset Freq 0 Jog Frequency Jog Accel Decel S Curve Reverse Disable Power Loss Mode Half Bus Enable Bus Reg Enable Rockwell Automation Publication 520 UM001B EN E February 2013 t096 t
236. plete 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 UM001B EN E February 2013 Copyright O 2013 Rockwell Automation Inc All rights reserved
237. pplication 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 so drive before changing this parameter 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 A559 Counts Per Unit Sets the number of encoder counts equal to one user defined unit Values Default 4096 Min Max 1 32000 Display 1 Rockwell Automation Publication 520 UM001B EN E February 2013 115 Chapter3 Programming and Parameters Advanced Program Group continued A560 Enh Control Word Related Parameter s t062 t063 t065 t068 A571 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 LIBI 00 0 000 1 Input Present 0 Input Not Present Home Limit Digit 1 Find Home Digit 2
238. put of the integral gain component would integrate up to 100 of max frequency when the PID error is 100 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 Rockwell Automation Publication 520 UM001B EN E February 2013 203 Appendix F 204 PID Set Up e A463 and A475 PID x Diff Rate The Differential gain units of 1 seconds affects the rate of change of the PID output The differential gain is multiplied by the difference between the previous error and current error Thus with a large error the D has a large effect and with a small error the D has less of an effect This parameter is scaled so that when it is set to 1 00 the process response is 0 1 of P044 Maximum Freq when the process error is changing at 1 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 slo
239. r 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 Rockwell Automation Publication 520 UM001B EN E February 2013 Encoder Pulse Train Usage and Position StepLogic Application Appendix E 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 of the 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 drive will move directly to whatever step is cur
240. r 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 of the 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 homed either manually or automatically It will remain active until the next power down Rockwell Automation Publication 520 UM001B EN E February 2013 195 AppendixE _Encoder Pulse Train Usage and Position StepLogic Application Use Over Communications 196 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 c
241. r local codes may require different ratings Fusing If fuses are chosen as the desired protection method refer to the recommended types listed Fuses and Circuit Breakers on page 18 If available amp ratings do not match the tables provided the closest fuse rating that exceeds the drive rating should be chosen e IEC BS88 British Standard Parts 1 amp 27 EN60269 1 Parts 1 amp 2 type GG or equivalent should be used e UL UL fuses must match those shown in Fuses and Circuit Breakers 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 2 Typical designations include Type CC KTI R FNQ R Type J JKS LPJ Type T JS JJN Circuit Breakers Refer to listings in Fuses and Circuit Breakers on page 18 for recommended circuit breakers inverse time or instantaneous trip and 140M Self Protecting Motor Starters Rockwell Automation Publication 520 UM001B EN E February 2013 143 AppendixA Supplemental Drive Information Specifications 144 Category Certifications PowerFlex 525 c UL us Listed to UL508C and CAN CSA C22 2 No 14 05 is 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 CE In conformity with the fol
242. rameter group for you to store frequently used parameters for your application See CustomView Parameter Group on page 127 for more information Custom Group 62 This group can store up to 100 parameters Rockwell Automation Publication 520 UM001B EN E February 2013 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 command can come from a number of sources See Start and Speed Reference Control on page 39 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 DC Bus Voltage Filtered DC bus voltage level of the drive
243. ransition 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 182 Rockwell Automation Publication 520 UM001B EN E February 2013 Velocity StepLogic Basic Logic and Timer Counter Functions Appendix D 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 Step2 Step 3 Frequency Logic In 1 gt Logic In 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 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 Out1 Level t082 Relay Out2 Level t070 Opto Out1 Level and t073 Opto Out2 Level are used to set the desired time in seconds Param
244. rently commanded by A410 A425 Preset Freq x and L200 L214 Step Units x This is useful when an application 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 selected 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
245. req 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 Rockwell Automation Publication 520 UM001B EN E February 2013 119 Chapter3 Programming and Parameters Fault and Diagnostic Group continued F641 Fault 1 Current F642 Fault 2 Current Related Parameter s b003 F643 Fault 3 Current 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 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 Fault 6 BusVolts F657 Fault 7 BusVolts F658 Fault 8 BusVolts F659 Fault 9 BusVolts F660 Fault10 BusVolts 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
246. req 15 Keypad Freq MOP Freq MOP Reset Sel MOP Preload MOP Time Jog Frequency Jog Accel Decel Purge Frequency DC Brake Time DC Brake Level Network Modified L180 L181 L182 L183 d360 d361 d362 M10 A411 A412 A413 A414 A415 A416 A417 A418 A419 A420 A421 A422 A423 A424 M25 M26 M27 A428 A429 M30 M31 M32 M33 M34 M35 Stp Logic 4 Stp Logic 5 Stp Logic 6 Stp Logic 7 Stp Logic Time 0 Stp Logic Time 1 Stp Logic Time 2 Stp Logic Time 3 Elapsed Time min Counter Status Timer Status Timer StatusF Drive Type Testpoint Data Motor OL Level DC Brk Time Strt DB Resistor Sel DB Threshold S Curve PWM Frequency Droop Hertz FLA Accel Time 2 Decel Time 2 Accel Time 3 Decel Time 3 Accel Time 4 Decel Time 4 Skip Frequency 1 Skip Freq Band 1 Skip Frequency 2 Skip Freq Band 2 Skip Frequency 3 Skip Freq Band 3 Skip Frequency 4 Skip Freq Band 4 PID 1 Trim Hi PID 1 Trim Lo PID 1 Trim Sel PID 1 Ref Sel PID 1 Fdback Sel PID 1 Prop Gain PID 1 Integ Time PID 1 Diff Rate PID 1 Setpoint PID 1 Deadband L184 L185 L186 L187 L190 L191 L192 L193 d363 d364 d365 d366 d367 d368 d369 M36 M37 M38 M39 A440 A441 A442 A443 A444 A445 A446 A447 A448 A449 A450 A451 A452 A453 A454 A455 A456 A457 A458 A459 A460 A461 A462 A463 A464 A465 Stp Logic Time 4 Stp Logic Time 5 Stp Logic Time 6 Stp Logic Time 7 Step Units 0 Step Units F 0 Step Units 1 Step Units F 1
247. ring 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 i 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 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 2 Custom Only 3 KeyPd Custom All parameters are locked except Program Lock fro
248. rmation on See page Prepare for Drive Start Up 47 Display and Control Keys 49 Viewing and Editing Parameters 50 Drive Programming Tools 51 Smart Start Up with Basic Program Group Parameters 52 LCD amp Scrolling Description 53 USB 54 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 i ATTENTION Power must be applied to the drive to perform the following Prepare for Drive Start Up Before Applying Power to the Drive 1 Confirm that all inputs are connected to the correct terminals and are secure 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Verify that any digital control power is 24 volts Rockwell Automation Publication 520 UM001B EN E February 2013 47 Chapter 2 48 Start Up 4 Verify that the Sink SNK Source SRC jumper is set to match your control wiring scheme See the Control I O Wiring Block Diagram on page 32 f
249. rogramming Tools os vated un d verat adress wid dare 51 Language SUP POLES Sou cd vat rbi doro E ahd E id ois 51 Smart Start Up with Basic Program Group Parameters 52 LCD amp Scrolling Description 2254 91 ERR RA RES ETREMUS 53 US C 54 Chapter 3 About Parameters eo sanc deu i us Ta ee e bemus Dd d AER BP NEN PA 58 Parameter Groups deret torera n met ERE AFER vis wea PARURE 58 Basic Display Group e iet ab ane cores Vert ta eee taeet oka 63 Basic Program GEDUD S s Ou ome eS qase Op um VEU TU EN 68 Terminal Block Group desde geste de omoes EO bon tob ed rris 73 Communications GIolpess igre hd i e e Ne p epus d hires 85 Lote Grop eroi dau g d tepUF CUN MONI aoa aaa DR HS ERU eaters 91 Advanced Display Group coc 9555 anes satan o EAS os PRNATS 94 Rockwell Automation Publication 520 UM001B EN E February 2013 3 Table of Contents Troubleshooting Supplemental Drive Information Accessories and Dimensions RS485 DSI Protocol Velocity StepLogic Basic Logic and Timer Counter Functions Advanced Program Group si c cree t c Ya RN sees ee 98 Network Parameter Group pcdes cence el elena Seis 118 Modified Parameter Group oris eae tea e Doce peo ea ets 118 Fault and Diagnostic Group eios et teresa Ese Peor roe LUE RSS 119 App View Parameter Groups vs 15er er nex denar a EX SERERE HE 126 Custom View Parameter Group sii eH NP PER RR Ee 127 Parameter Cross Reference by Name
250. rs 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 e 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 Ny 32 bit parameter Parameters marked 32 bit will have two parameter 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 Parameter Groups For an alphabetical listing of parameters see Parameter Cross Reference by Name on page 128 Basic Display Output Voltage b004 Process Fract b011 Power Saved b018 Accum Cost Sav b025 DC Bus Voltage b005 Control Source b012 Elapsed Run Time b019 Accum C02 Sav b026 Ue Drive Status b006 Contrl In Status b013 Average Power b020 Drive Temp b027 Fault 1 Code b007 Dig In Status b014 Elapsed kWh b021 Control Temp b028 Output Freq b001 Fault 2 Code b008 Output RPM b015 Elapsed MWh b022 Control SW Ver b029 Commanded Freq b002 Fault 3 Code b009 Output Speed b016 Energy Saved b023 Output Current b003 Process Display b010 Output Power b017 Accu
251. ry 2013 Programming and Parameters Chapter 3 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 05 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 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 Sleep Level the drive wakes and ramps to the commanded 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
252. s Default 0 Min Max 0 9999 Display 1 t075 Opto Out Logic 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 Rockwell Automation Publication 520 UM001B EN E February 2013 77 Chapter3 Programming and Parameters Terminal Block Group continued t076 Relay Out1 Sel t081 Relay Out2 Sel Determines the operation of the programmable output relay Related Parameter s P046 P048 P050 t070 t073 t077 t082 t086 t087 t093 t094 t097 A541 A564 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 occurring 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 6 Above Freq Dr
253. s activated If it passes this point it then runs in the 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 36 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 position 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 37 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 39 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
254. sed on time Values Default 30 0 s 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 vA 32 bit parameter Sets the position in user defined units the drive must reach at each step Values Default 0 Min Max 0 6400 Display 1 Rockwell Automation Publication 520 UM001B EN E February 2013 93 Chapter3 Programming and Parameters Advanced Display Group d360 Analog In 0 10V Related Parameter s t091 t09 Displays the 0 10V analog input as a percent of full scale 1092 Values Default Read Only Min Max 0 0 100 096 Display 0 196 d361 Analog In 4 20mA Displays the 4 20 mA analog input as a percent of full scale Related Parameter s t095 t096 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
255. seeable operational and environmental characteristics of the machine to which it is to be fitted Rockwell Automation Publication 520 UM001B EN E February 2013 Safety Concept Safe Torque Off Function Appendix G A safety analysis of the machine section controlled by the drive is required to determine how often the safety function should be tested for proper operation during the life of the machine installation Rockwell Automation cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation f ATTENTION The following information is merely a guide for proper 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 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
256. ses or an input circuit breaker National and local industrial safety regulations and or electrical codes may determine additional requirements for these 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 Fusing The ratings in the tables that follow are the recommended values for use with each drive rating The devices listed in this table are provided to serve as a guide Rockwell Automation Publication 520 UM001B EN E February 2013 Chapter 1 Installation Wiring MA LL dH SL adoge sanup 104 ajqeiene ave sbunei Kanp Kaea pue RWJON L SCL L40 SSVI 0ZD d8H WOYL 06 99H NOPL Scl 04 7Z 001 3 OSL OSL OOc vOLNCO08 8GC aa 06 110f SSYD St 384 WObL 0 2 09H fOvL 06 09 099 001 E OSL OLL OSL vOLN8vOS dSC Sy 384 WOF 0Z 4 S10 L40 f SAY SSVT Sp2 384 WOFL 099 99H N0Y L OL Sy v 001 d 0 0L S Q0 O0L vOLNCEOS gSC C 2 383 WOt L 9H OvL 09 110fSSVD ZED 384 WOYL SE 29H fl0vL 09 St 1 001 GL
257. spective 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 Time x and Logic In 2 is not active logically false TIMED OR F Use logic programmed in Digit 1 IGNORE 186 Rockwell Automation Publication 520 UM001B EN E February 2013 Encoder and Pulse Train Usage Appendix E Encoder Pulse Train Usage and Position StepLogic Application The PowerFlex 525 drive includes a pulse train input built into the terminal block and an encoder option card The pulse
258. splay 0 01 P053 Reset To Defalts O Bay drive before changing this parameter Resets all parameters to their factory default values After a Reset command the value of this parameter returns to zero Options 0 Ready ldle Default 1 Param Reset Does not reset custom group or P030 Language parameter 2 Factory Rset Restore drive to factory condition 3 PowerReset Resets only power parameters Can be used when swapping power modules 72 Rockwell Automation Publication 520 UM001B EN E February 2013 Terminal Block Group t062 Digln TermBlk 02 t065 Digln TermBlk 05 t067 Digln TermBlk 07 O Ray 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 Programming and Parameters Chapter 3 t063 Digln TermBlk 03 Related Parameter s b012 b013 b014 P045 P046 P048 P049 P050 P051 t064 t066 Digin TermBlk 06 t086 A410 A425 A427 A431 A432 A433 A434 A435 t068 Digin TermBlk 08 A442 A443 A488 A535 A560 A562 A563 A567 A571 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 SpeedRef2 Selects P049 Speed Reference2 as drive s speed command 2 SpeedRef3
259. splay 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 UM001B EN E February 2013 Programming and Parameters Chapter 3 Basic Display Group continued b025 Accum Cost Sav Related Parameter s b024 P052 A555 Total approximate accumulated cost savings of the drive compared to using an across the line starter Accum Cost Sav Average kWh cost x Accum kWh Sav Values Default Read Only Min Max 0 0 6553 5 Display 0 1 b026 Accum 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 UM001B EN E February 2013 Chapter3 Programming and Parameters Basic
260. ssed 10 Pkt 730 Counts Per Unit 559 Drv 4 Logic Sts 723 EN Rate Act 685 Current Limit 1 484 Drv 4 Reference 722 EN Rate Cfg 141 Current Limit 2 485 Drv Ambient Sel 554 EN Rx Errors 727 128 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Parameter Name No Parameter Name No Parameter Name No EN Rx Overrruns 725 Fault 6 Current 646 HW Addr 2 688 EN Rx Packets 726 Fault 6 Freq 636 HW Addr 3 689 EN Subnet Act 1 697 Fault 6 Time hr 616 HW Addr 4 690 EN Subnet Act 2 698 Fault 6 Time min 626 HW Addr 5 691 EN Subnet Act 3 699 Fault 7 BusVolts 657 HW Addr 6 692 EN Subnet Act 4 700 Fault 7 Code 607 IR Voltage Drop 496 EN Subnet Cfg 1 133 Fault 7 Current 647 Jog Accel Decel 432 EN Subnet Cfg 2 134 Fault 7 Freq 637 Jog Frequency 431 EN Subnet Cfg 3 135 Fault 7 Time hr 617 Keypad Freq 426 EN Subnet Cfg 4 136 Fault 7 Time min 627 Ki Speed Loop 538 EN Tx Errors 729 Fault 8 BusVolts 658 Kp Speed Loop 539 EN Tx Packets 728 Fault 8 Code 608 Language 30 Encoder Pos Tol 564 Fault 8 Current 648 Load Loss Level 490 Encoder PPR 536 Fault 8 Freq 638 Load Loss Time 491 Encoder Speed 378 Fault 8 Time hr 618 Max Traverse 567 Encoder Speed F 379 Fault 8 Time min 628 Maximum Freq 044 Energy Saved 023 Fault 9 BusVolts 659 Maximum Voltage 534 Enh Control Word 560 Fault 9 Code 6
261. st to stop Drive will restart after a Stop command when Stop is removed and Start is held active 1 0 Terminal 03 Run REV is maintained the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop 1 ATTENTION Hazard of injury exists due to unintended operation When set to option 3 and the Run input 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 e 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 Rockwell Automation Publication 520 UM001B EN E February 2013 75 Chapter 3 t069 Opto Out1 Sel t072 Opto Out2 Sel Programming and Parameters Terminal Block Group continued Related Parameter s P046 P048 P050 t070 t073 t077 t082 1086 t087 1093 t094 t097 A541 A564 Determines the operation of the programmable digital outputs Options 0 Ready Fault Setting Output Changes State When Opto outputs are active when power is applied Indicates that the driv
262. t 3 F663 EN Subnet Act 2 F698 Drv 4 Logic Sts Fault 4 Time hr F614 Fault 9 Freq F639 Status Fault 4 F664 EN Subnet Act 3 F699 Drv 4 Feedback Fault 5 Time hr F615 Fault10 Freq F640 Status Fault 5 F665 EN Subnet Act 4 F700 EN Rx Overruns Fault 6 Time hr F616 Fault 1 Current F641 Status Fault 6 F666 EN Gateway Act 1 F701 EN Rx Packets Fault 7 Time hr F617 Fault2 Current F642 Status Fault 7 F667 EN Gateway Act 2 F702 EN Rx Errors Fault 8 Time hr F618 Fault3 Current F643 Status Fault 8 F668 EN Gateway Act 3 F703 EN Tx Packets Fault 9 Time hr F619 Fault 4 Current F644 Status Fault 9 F669 EN Gateway Act 4 F704 EN Tx Errors Fault10 Time hr F620 Fault5 Current F645 Status Fault10 F670 Drv 0 Logic Cmd F705 EN Missed IO Pkt Fault 1 Time min F621 Fault6 Current F646 Comm Sts DSI F681 Drv 0 Reference F706 DSI Errors Fault 2 Time min F622 Fault7 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 Fault9 Current F649 EN Addr Src F684 Drv 1 Logic Cmd F709 AppView Parameter Groups F710 F711 F712 F713 F714 F715 F716 F717 F718 F719 F720 F721 F722 F723 F724 F725 F726 F727 F728 F729 F730 F731 PowerFlex 525 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 126 for more information
263. t 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 88 Rockwell Automation Publication 520 UM001B EN E February 2013 Programming and Parameters Chapter 3 Communications Group continued C153 EN Data In 1 C154 EN Data In 2 C155 EN Data In 3 C156 EN Data In 4 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 Datalink parameter number whose value is read 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 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 para
264. t Description Parameter 13 x10VIn Not Active For external 0 10V unipolar or 10V bipolar input supply or P047 P049 potentiometer wiper 1062 t063 Input impedance 1065 1066 1093 A459 Voltage source 100 kQ Allowable potentiometer resistance range 1 10 KQ MH 14 Analog Common Return for the analog 1 0 Electrically isolated along with the analog 1 0 from the rest of the drive 15 4 20mA In Not Active For external 4 20 mA input supply P047 P049 Input impedance 250 Q 1062 t063 1065 t066 A459 M71 16 Analog Output OutFreq0 10 The default analog output is 0 10V To convert a current value t088 t089 change the Analog Output 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 Opto Common The emitters of the Optocoupler Outputs 1 and 2 are tied together at Optocoupler Common Electrically isolated from the rest of the drive 1 See Footnote 1 on page 32 Control 1 0 Terminal Block Wire Specifications A E 1 3 mm 16 AWG 0 13 mm 26 AWG 0
265. t actual RPM Options 0 Disabled Default 1 Enabled Catch and ramp to commanded speed at every drive start A546 FlyStrt CurLimit Used to determine when the drive has matched the motor frequency if flying start is enabled Values Default 6596 Min Max 30 20096 Display 196 Rockwell Automation Publication 520 UM001B EN E February 2013 113 Chapter3 Programming and Parameters Advanced Program Group continued A547 Compensation Enables disables correction options that may improve problems with motor instability Options 0 Disabled 1 Electrical Default No compensation 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 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 du
266. t circuits S11 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 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 the loss of the safety function Rockwell Automation Publication 520 UM001B EN E February 2013 215 AppendixG 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 ACine input power i PF 525 External 24V DC 24V DC Stop Start Open i oe Gate control power supply T bd E 211822 Closed Gate contro circuit 4 0 1
267. t 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 156 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 UM001B EN E February 2013 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 connected to one of the ground terminals on the drive Shield Termination SHLD Either of the safety ground terminals located on the power terminal
268. ted are for 3 impedance 5 impedance reactor types are also available See publication 1321 TD001 3 Input line reactors were sized based on the NEC fundamental motor amps Output line reactors were sized based on the VFD rated output currents The PowerFlex 525 drive is available in five frame sizes See PowerFlex 525 Drives on page 149 for information on power ratings Product Dimensions PowerFlex 525 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 Rockwell Automation Publication 520 UM001B EN E February 2013 157 AppendixB Accessories and Dimensions IP 20 0pen Type Frame A Dimensions are in millimeters and inches H 72 0 2 83 4 9 172 0 6 77 57 5 2 26 c Alen Bradey c 2 E gt gt gt c gt o ES SSS E FALTO _ Te o C gt C gt n c 1 c 5 cut A o c gt c gt a gt gt A C gt c gt C gt 2 ww L il Povverti f 6 0 0 24 IP 20 0pen Type Frame B Dimensions are in millimeters and inches 87 0 3 43 72 5 2 85 al 172 0 6 77 KA Y 180 0 7 09
269. the three speed reference sources parameter Timed St eps 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 Step0 Step1 Step2 Step3 Step4 Step5 Step6 Step7 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 Digital input ind digital ia R can E ud te us use logic to transition to the next step Logic In 1 and Logic In 2 are defined by programming Basic Logic Functions 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 e T
270. tion adapter interface connector into the Control Module Make sure the indicator line on the connector is aligned with the surface of the Control Module Communication adapter interface connector SA 2 Align the connectors on the communication adapter to the communication adapter interface connector then push the back cover down 3 Press along the edges of the back cover until it snaps firmly into place Communication adapter interface f connector Bo 170 Rockwell Automation Publication 520 UM001B EN E February 2013 Accessories and Dimensions Appendix B 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 in r Zu g OEE f AAAA Rockwell Automation Publication 520 UM001B EN E February 2013 171 AppendixB Accessories and Dimensions Notes 172 Rockwell Automation Publication 520 UM001B EN E February 2013 Network Wiring Appendix C RS485 DSI Protocol PowerFlex 525 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 525 drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode PowerFlex 520 Series Drive Network
271. to the drive and swap the A and A NOT encoder channels or swap any two motor leads Drive will fault when an encoder is incorrectly wired and A535 Motor Fdbk Type is set to 5 Quad Check Encoder Wiring Examples 1 0 Connection Example 1 0 Connection Example Encoder Power 12VDC Encoder Power Internal Drive v Jopa External 3 Power 2 amp emm Power Source LE A B HOJ tosui LD z M d External Internal drive 4 HO Power 12V DC 250mA i Encoder Signal to Power Supply Encoder Signal Single Ended wie i Differential Dual Channel nile Dual Channel miO B NOT wen B s B JO A B r febr T i M He dej i fe to SHLD 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 Rockwell Automation Publication 520 UM001B EN E February 2013 Positioning Overview Common Guidelines for All Appl
272. to your PC with a USB Type B cable and you will benefit from MainsFree programming Connecting PowerFlex 525 to a PC Control Module USB port USB Type B cable SX Connect to PC Connect to Control Module When connected the drive appears on the PC and contains two files e GUIDE PDF This file contains links to relevant product documentation and software downloads PFS2XUSB 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 UM001B EN E February 2013 StartUp Chapter 2 Double click on the PFS2XUSB 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 Upload a configuration from the drive or peripheral Download 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 ind
273. tor control mode Options 0 V Hz 1 SVC Default 2 Economize Related Parameter s P040 A530 A531 A532 A533 3 Vector P040 Autotune so drive before changing this parameter Related Parameter s P034 P039 A496 A497 DIY E 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 30 s 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 Idle Default 1 Static Tune Static Autotune runs at next start command 2 Rotate Tune Static Dynamic Autotune runs at next start command Use Rotate Tune for best performance Rockwell Automation Publication 520 UM001B EN E February 2013 69 Chapter3 Programming and Parameters Basic Program Group continued P041 Accel Time 1 Related Param
274. 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 Speed Referencel 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 P047 Speed Referencel when the PID Feedback or PID Reference are set to use an encoder then the PID function will use the encoder or pulse train input 3 If not enabled by P047 Speed Referencel or the PID parameters then if 4535 Motor Fdbk Type is set the encoder or pulse train is used 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 pr
275. trol 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 Values Default Read Only Min Max 0000 1111 Display 0000 b014 Dig In Status Related Parameter s t065 t068 State ofthe programmable digital inputs LiB Ld 1 Closed State 0 Open State Digln TBIk 5 Digit 1 Digln TBIk 6 Digit 2 Digln TBIK 7 Digit 3 Dighn TBIK 8 Digit 4 Not Used 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
276. ts of control systems Part 2 Validation EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements 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 For CE compliance drives must satisfy installation requirements related to both EN 61800 5 1 and EN 61800 3 provided in this document PowerFlex 525 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 42 for descriptions of each pollution degree rating PowerFlex 525 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 ofan entire machine or installation and compliance of the drive itself does not ensure compliance of all applications 42 Rockwell Automation Publication 520 UM001B EN E February 2013 Installation Wiring Chapter 1 e PowerFlex 525 drives are not intended to be used on public low voltage networks which supply domestic premises Without add
277. tude Without derating 1000 m 3300 ft max With derating Up to 4000 m 13 200 ft max with the exception of 600V drives at 2000 m 6600 ft max See Current Derating Curves on page 13 for derating guidelines Max Surrounding Air Temperature Without derating 20 50 C 4 122 F With derating 20 60 C 4 140 F or 20 70 C 4 158 F with optional Control Module Fan kit See Current Derating Curves on page 13 for derating guidelines 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 Surrounding Environment Pollution Degree Pollution Degree 1 amp 2 Operating and Nonoperating Nonoperating Transportation Frame Force Force Size Shock Vibration Mounting Type Shock Vibration Mounting Type A 15g 2g DIN rail orscrew 30g 2 5g Screw only B 15g 2g DIN rail orscrew 30g 2 5g Screw only C 15g 2g DIN rail orscrew 30g 2 5g Screw only D 15g 2g Screw only 309g 2 5g Screw only E 15g 15g Screw
278. tune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 Digln TermBlk 02 Digln TermBlk 03 Digln TermBlk 05 Digln TermBlk 06 Opto Out Sel Opto Out2 Sel Relay Out Sel EM Brk Off Delay EM Brk On Delay Stp Logic 0 Stp Logic 1 Stp Logic 2 Stp Logic 3 Stp Logic 4 Motor NP FLA Motor NP Poles Autotune Accel Time 1 Decel Time 1 Minimum Freq Maximum Freq Stop Mode Start Source 1 Speed Reference1 P033 P034 P035 P040 P041 P042 P043 P044 P045 P033 P034 P035 P040 P041 P042 P043 P044 P045 P032 P033 P034 P035 P040 P041 P042 P043 P044 P045 P046 P047 t062 t063 t065 t066 t069 t072 t076 t086 t087 L180 L181 L182 L183 L184 P034 P035 P040 P041 P042 P043 P044 P045 P046 P047 Start Source 1 Speed Reference1 Relay Out Sel Analog Out Sel Analog Out High Anlg Out Setpt Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Start Source 1 Speed Reference1 Relay Outi Sel Analog Out Sel Analog Out High Anlg Out Setpt Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Stop Mode Start Source 1 Speed Reference1 Relay Out Sel Analog Out Sel Analog Out High Anlg Out Setpt Anlg In 0 10V Lo Anlg In 0 10V Hi Stp Logic 5 Stp Logic 6 Stp Logic 7 Stp Logic Time 0 Stp Logic Time 1 Stp Logic Time 2 Stp Logic Time 3 Stp Logic Time 4 Stp Logic Time 5 Stp Logic Time 6 Stp Logic Time 7 Step Units 0 Step Units 1 Step Units 2 Ste
279. tus of a digital output can also be controlled based on the step being executed e Basic Logic Function 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 Connected Components Workbench to simplify setup instead of manually configuring the parameters Rockwell Automation Publication 520 UM001B EN E February 2013 181 AppendixD Velocity StepLogic Basic Logic and Timer Counter Functions Velocity StepLogic Using To activate this function set one of
280. ult 5 Freq 635 Freq 3 Ki 526 Opto Out Logic 075 Fault 5 Time hr 615 Freq 3 Kp 525 Opto Out Level 070 Fault 5 Time min 625 Half Bus Enable 549 Opto Out LevelF 071 Fault 6 BusVolts 656 Home Save 561 Opto Out Sel 069 Fault 6 Code 606 HW Addr 1 687 Opto Out2 Level 073 Rockwell Automation Publication 520 UM001B EN E February 2013 129 Chapter3 Programming and Parameters Parameter Name No Parameter Name No Parameter Name No Output Voltage 004 Preset Freq 13 423 Sleep Level 101 Opto Out2 LevelF 074 Preset Freq 14 424 Sleep Time 102 Opto Out Sel 072 Preset Freq 15 425 Sleep Wake Sel 100 Out Phas Loss En 557 Preset Freq 2 412 Slip Hz Meter 375 Output Current 003 Preset Freq 3 413 Speed Feedback 376 Output Freq 001 Preset Freq 4 414 Speed Feedback F 377 Output Power 017 Preset Freq 5 415 Speed Ratio 572 Output Powr Fctr 381 Preset Freq 6 416 Speed Reference1 047 Output RPM 015 Preset Freq 7 417 Speed Reference2 049 Output Speed 016 Preset Freq 8 418 Speed Reference3 051 PJump 570 Preset Freq 9 419 Speed Reg Sel 509 PID 1 Deadband 465 Process Disp Hi 482 Stall Fault Time 492 PID 1 Diff Rate 463 Process Disp Lo 481 Start At PowerUp 543 PID 1 Fdback Sel 460 Process Display 010 Start Boost 531 PID 1 Integ Time 462 Process Fract 011 Start Source 1 046 PID 1 Invert Err 467 Program Lock 552 Start Source 2 048
281. ult Indication Condition Display Drive is indicating a fault SISIA IY The integral LCD display provides visual notification of a fault condition by displaying the 4 i y following PAPAE LISTS e Flashing fault number 7 Flashing fault indicator LED FAULT GP Press the Esc key to regain control of the display lt gt 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 cleared See Fault Types Descriptions and Actions on page 135 3 After corrective action has been taken clear the fault by one of these methods 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
282. une the application first The autotune routine can be completed to further improve the drive motor performance 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 525 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 motor 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 othe
283. unless disabled by A544 Reverse Disable Q If Digln TrmBIk is selected ensure that the digital inputs are properly configured P047 Speed Reference 1 16 1 Drive Pot P047 1 m Sets the default speed command ofthe drive unless Pipe E overridden by P049 Speed Reference2 or P051 era i E Speed Reference3 4 Network Opt 5 0 10V Input 6 4 20mA Input 7 Preset Freq 8 Anlg In Mult 9 MOP 10 Pulse Input 11 PID1 Output 12 PID2 Output 13 Step Logic 14 Encoder 15 Ethernet IP 16 Positioning P052 Average kWh Cost 0 00 655 35 0 01 0 00 Sets the average cost per kWh P053 Reset To Defalts 0 3 0 Ready Idle 0 Resets parameters to their factory defaults values Hora paid After a Reset command the value of this parameter 3 Pos ak s returns to zero ONET nese 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 51 for the languages supported by PowerFlex 525 Rockwell Automation Publication 520 UM001B EN E February 2013 53 Chapter 2 USB 54 Start Up The PowerFlex 525 drive has a USB port that connects to a PC for the purpose of upgrading drive firmware or uploading downloading a parameter configuration You do not need to power up the control module Simply connect the PowerFlex 525 drive
284. unter 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 Logic In 140 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 220 Logic function input number 2 May be used to control the relay or opto outputs t076 t081 Relay Outx Sel and t069 t072 Opto Outx Sel options 11 14 May be used in conjunction with StepLogic parameters L180 L187 Stp Logic x 26 Current Lmt2 When active A485 Current Limit 2 determines the drive current limit level Rockwell Automation Publication 520 UM001B EN E February 2013 73 Chapter3 Programming and Parameters Options 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 20m4A 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
285. w increase A461 or A473 PID x Prop Gain Ifthe response is too quick and or unstable see Unstable Response on page 205 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 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 page 205 or the PID Feedback does not become equal to the PID Reference decrease A462 or A474 PID x Integ Time If there is a lot of oscillation in the PID Feedback before settling out see Oscillation Under Damped on page 205 increase A462 or A474 PID x Integ Time At this 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 Rockwell Automation Publication 520 UM001B EN E February 2013 PID SetUp Appendix F Unstable Response PID Reference PID Feedback Time Slow Response Over Damped PID Reference _ PID Feedback Time
286. ware flash update mismatched or incompatible with the operation to attempt to load a valid set hardware of firmware F126 NonRecoverablErr 2 A non recoverable firmware or e Clear fault or cycle power to the hardware error was detected The drive drive was automatically stopped and reset e Replace drive or control module if fault cannot be cleared F127 DSIFlashUpdatReq 2 A critical problem with the firmware Perform a firmware flash update 1 See Fault Types for more information was detected and the drive is running using backup firmware that only supports DSI communications operation using DSI communications to attempt to load a valid set of firmware The drive is designed to start from the keypad when shipped For a basic test of drive operation 1 Remove all user I O wire Ee NS Verify safety terminals S1 S2 and S jumper is in place and tightened Verify wire jumper is in place between I O terminals 01 and 11 Verify that the three jumpers are in their proper default positions on the control board See Control I O Wiring Block Diagram on page 32 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 UM001B EN E February 2013 Cause s No output voltage to the motor
287. well Automation Publication 520 UM001B EN E February 2013 Cause s No input power to drive Troubleshooting Chapter 4 Drive does not power up Indication Corrective Action None e Check the power circuit 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 is 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 UM001B EN E February 2013 141 Chapter4 Troubleshooting Notes 142 Rockwell Automation Publication 520 UM001B EN E February 2013 Drives Fuse amp Circuit Breaker Ratings Appendix A Supplemental Drive Information For information on Drives Fuse amp Circuit Breaker Ratings Specifications 144 The tables found in Fuses and Circuit Breakers on page 18 provide drive ratings and recommended AC line input fuse and circuit breaker information Both types of short circuit protection are acceptable for UL and IEC requirements Sizes listed are the recommended sizes based on 40 degree C and the U S N E C Other country state o
288. with Slip Compensation 1 of base speed across a 80 1 speed range With Encoder 0 3 of base speed across a 80 1 speed range 0 05 of base speed across a 20 1 speed range Output Voltage Range OV to rated motor voltage Output Frequency Range 0 500 Hz programmable Efficiency 97 5 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 150 for up to 3 s Heavy Duty 150 Overload capability for up to 60 s 180 for up to 3 s 200 programmable Control Inputs Digital Bandwidth 10 Rad s for open and closed loop Quantity 1 Dedicated for stop 6 Programmable Current 6 mA Type Source Mode SRC 18 24V ON 0 6V OFF Sink Mode SNK 0 6V ON 18 24V OFF Analog Quantity 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 146 Rockwell Automation Publication 520 UM001B EN E February 2013 Supplemental Drive Information Appendix A Category Specifications Encoder Type Incremental dual channel Supply 12V 250 mA Quadrature 90
289. y 0 1 mH A509 Speed Reg Sel Related Parameter s A521 A522 A523 A524 A525 A526 Determines if PI gain of the Vector control mode speed regulator is set automatically or manually Parameters A521 A526 are set automatically by this parameter Seethe control diagrams in Appendix for more information Options 0 Automatic Default 1 Manual A510 Freq 1 A512 Freq2 A514 Freq3 Sets the Vector control mode frequency See the control diagrams in Appendix for more information Values Default Freq 1 8 3396 Freq 2 15 0096 Freq 3 20 00 Min Max 0 00 200 00 Display 0 01 A511 Freq 1 BW A513 Freq 2 BW A515 Freq 3 BW Speed control loop bandwidth for Vector control mode See the control diagrams in Appendix for more information Values Default 10 Hz Min Max 0 40 Hz Display 1Hz A521 Freq 1 Kp Related Parameter s A509 A510 A523 Freq 2 Kp A525 Freq 3 Kp 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 See the control diagrams in Appendix for more information Values Default 100 0 Min Max 0 0 500 0 Display 0 1 Rockwell Automation Publication 520 UM001B EN E February 2013 109 Chapter3 Programming and Parameters Advan
290. y and the PID loop starts regulating from there PID Enabled PID Pre load Value 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 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 of the error The proportional component of the PID regulator outputs a speed command proportional to the PID error For example a proportional gain of 1 would output 100 of max frequency when the PID error is 100 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 e 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 out
291. y 2013 139 Chapter4 Troubleshooting Drive does not respond to changes in speed command Cause s Indication The drive Run indicator is Corrective Action Vo value is coming from the source of the command lit and output is 0 Hz e Check b012 Control Source for correct source e Ifthe source is an analog input check wiring and use a meter to check for presence of signal Check 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 e Check b014 Dig In Status to see if inputs are selecting an alternate source Verify settings for t062 t063 t065 t068 DigIn TermBlk xx e Check P047 P049 P051 Speed Referencex for the source of the speed reference Reprogram as necessary Review the Speed Reference Control chart on page 39 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 sett
292. y 310 uoN 531 suey ynduy alan a anf on ore sBuney 1nding 19 Rockwell Automation Publication 520 UM001B EN E February 2013 Installation Wiring Chapter 1 MA LL dH SL adoge santp 104 a qejreae ave sbunei Kanp Kaea pue euioN L Sy 384 WOvL 08 110fSSYD Sv 384 WOvL 099 99H NOrL 08 09 001 3 Osc Occ OOE PLLNEVOd aSz Sp 383 WOvL 0L 110f SSY S 384 WObL 05 9H NOFL OL 00L 3 007 S8L QOSc vLLNZEOQ aSC 0L L140fSSVD Sv2 383 WOvL 059 99H NOPL 0 v 001 q OSL OSL 0 07 PLLNOEOG aSz 0L L140fSSVD Sv 484 WOPL 05 99H NOPL 0L 00L q OSL OSL 00c vOLNOEOQ SC E 09 1J0 SSVI c 0 383 WOVL 0v2 09H fOvL 09 L 001 l OSL OLL O SL YLLNYZOQ 9S7 09 1406 SSVID c 0 384 WOvL 0 99H NOFL 09 Z 001 d OSL OIL OSL vOLNVCOQ GSC 020 380 WOvL 0p 1406 SSYD 079 380 WOPL S7 090 NOFL Ov O 001 J ool GL 0 0L vLLNZLOQ 8SC 02 380 WOTL 0 110 f SSYD 070 380 WOVL S73 EQ9A N0Y1 Ov O 001 ool SL 00L POLNZLOG asz 02 38d W0rL SE 140fSSY1 00 380 WOvL S73 EQ9A N0Y L SE 7 00L GL GS SL VLLNELOQ 8SC 02 48d W0rL B Sc L1Jo0 SSvI 00 380 WOvL SC a90 n0vL SE O 001 GL GS SL VOLNELOQ 8SC 91 3O WOtL Og 4 S10 L40 f SAY SSVD 912 3O WOrL SL9 090 NOPL 0 001 g os 0t 0 S vLLNOLOQ 8SC 91 3O WOtL OEwST0 1J0 cyH SSVD
293. y default start source unless overridden See Start and Speed Reference Control on page 39 for more information Options 1 Keypad Start Source 1 default 2 Digln TrmBlk Start Source 2 default 3 Serial DSI 4 Network Opt 5 EtherNet IP Start Source 3 default Rockwell Automation Publication 520 UM001B EN E February 2013 71 Chapter3 Programming and Parameters Basic Program Group continued 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 39 for more information Options 1 Drive Pot Speed Reference1 default Keypad Freq Serial DSI 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 wo Co NI cu m N N 15 EtherNet IP Speed Reference3 default 16 Positioning Referencing from A558 Positioning Mode P052 Average kWh Cost Related Parameter s b025 Sets the average cost per kWh Values Default 0 00 Min Max 0 00 655 35 Di

520-UM001B-EN-E PowerFlex 525 Adjustable Frequency AC Drive

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