Allen-Bradley PowerFlex 525 User manual

PowerFlex 525 Adjustable Frequency AC Drive
User Manual
Original Instructions

Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
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.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Installation/Wiring
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
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 52
LCD & Scrolling Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 3
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

4Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Table of Contents
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
Chapter 4
Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 138
Appendix A
Supplemental Drive Information
Drives, Fuse & Circuit Breaker Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Appendix C
RS485 (DSI) Protocol
Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 180
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Appendix D
Velocity StepLogic, Basic Logic and
Timer/Counter Functions
Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 182
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 5
Table of Contents
Appendix E
Encoder/Pulse Train Usage and
Position StepLogic Application
Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 189
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Appendix F
PID Set Up
PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Appendix G
Safe-Torque-Off Function
PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 207
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 211
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 211
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 217
Appendix H
EtherNet/IP
Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 219
Appendix I
Control Diagrams
Induction Motor Tuning Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Index

6Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Table of Contents
Notes:

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 7
Preface
Overview
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.
Who Should Use this Manual 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.
Recommended
Documentation
All the recommended documentation listed in this section is available online at
http://www.rockwellautomation.com/literature.
The following publications provide general drive information:
The following publications provide specific PowerFlex 520-Series information on
drive installation, features, specifications, and service:
For information on… See page…
Who Should Use this Manual 7
Recommended Documentation 7
Manual Conventions 8
Drive Frame Sizes 9
General Precautions 9
Catalog Number Explanation 10
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
Title Publication
PowerFlex 525 AC Drive Specifications 520-TD001
PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

8Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Preface Overview
The following publications provide specific Network Communications
information:
Manual Conventions •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.
•Specific drives within the PowerFlex 520-Series may be referred to as:
– PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
•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.
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
P 031 [Motor NP Volts]
Name
Number
Group
b
P
t
C
L
d
A
M
N
G
F
= Basic Display
= Basic Program
= Terminal Blocks
= Communications
= Logic
= Advanced Display
= Advanced Program
= Modified
= Network
= AppView and CustomView
= Fault and Diagnostic
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

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 9
Overview Preface
Drive Frame Sizes 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.
General Precautions ATTENTION: The drive contains high voltage capacitors which take time to
discharge after removal of mains supply. Before working on drive, ensure
isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three
minutes for capacitors to discharge to safe voltage levels. Failure to do so may
result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have discharged to
safe voltage levels.
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. Staticcontrol precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
ATTENTION: The bus regulator function is extremely useful for preventing
nuisance overvoltage faults resulting from aggressive decelerations,
overhauling loads, and eccentric loads. However, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in inputvoltage 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.

10 Rockwell Automation Publication 520-UM001A-EN-E - February 2013
Preface Overview
Catalog Number Explanation
Code Braking
4Standard
Code EMC Filter
0NoFilter
1Filter
Code Interface Module
1Standard
Code Enclosure
N IP 20 NEMA/Open
Code Voltage Phase
V120VAC1
A240VAC1
B240VAC3
D480VAC3
E600VAC3
Code Type
25B PowerFlex 525
* Normal and Heavy duty ratings are
available for drives above 15 HP / 11 kW.
1-3 4 5 6-8 9 10 11 12 13 14
25B - B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash
Output Current @ 1 Phase, 100...120V Input
Code Amps Frame ND HD
HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4
4P8 4.8 B 1.0 0.75 1.0 0.75
6P0 6.0 B 1.5 1.1 1.5 1.1
Output Current @ 1 Phase, 200...240V Input
Code Amps Frame ND HD
HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4
4P8 4.8 A 1.0 0.75 1.0 0.75
8P0 8.0 B 2.0 1.5 2.0 1.5
011 11.0 B 3.0 2.2 3.0 2.2
Output Current @ 3Phase, 200...240V Input
Code Amps Frame ND HD
HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4
5P0 5.0 A 1.0 0.75 1.0 0.75
8P0 8.0 A 2.0 1.5 2.0 1.5
011 11.0 A 3.0 2.2 3.0 2.2
017 17.5 B 5.0 3.7 5.0 3.7
024 24.0 C 7.5 5.5 7.5 5.5
032 32.2 D 10.0 7.5 10.0 7.5
048 48.3 E 15.0 11.0 15.0 11.0
062 62.1 E20.0 15.0 15.0 11.0
Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD
HP kW HP kW
1P4 1.4 A 0.5 0.4 0.5 0.4
2P3 2.3 A 1.0 0.75 1.0 0.75
4P0 4.0 A 2.0 1.5 2.0 1.5
6P0 6.0 A 3.0 2.2 3.0 2.2
010 10.5 B 5.0 4.0 5.0 4.0
013 13.0 C 7.5 5.5 7.5 5.5
017 17.0 C 10.0 7.5 10.0 7.5
024 24.0 D 15.0 11.0 15.0 11.0
030 30.0 D20.0 15.0 15.0 11.0
037 37.0 E25.0 18.5 20.0 15.0
043 43.0 E30.0 22.0 25.0 18.5
Output Current @ 3 Phase, 525...600V Input
Code Amps Frame ND HD
HP kW HP kW
0P9 0.9 A 0.5 0.4 0.5 0.4
1P7 1.7 A 1.0 0.75 1.0 0.75
3P0 3.0 A 2.0 1.5 2.0 1.5
4P2 4.2 A 3.0 2.2 3.0 2.2
6P6 6.6 B 5.0 3.7 5.0 3.7
9P9 9.9 C 7.5 5.5 7.5 5.5
012 12.0 C 10.0 7.5 10.0 7.5
019 19.0 D 15.0 11.0 15.0 11.0
022 22.0 D20.0 15.0 15.0 11.0
027 27.0 E25.0 18.5 20.0 15.0
032 32.0 E30.0 22.0 25.0 18.5