Allen-Bradley PowerFlex 527 User manual

PowerFlex 527 Adjustable Frequency AC Drive
Catalog Number 25C
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 Software, Rockwell Automation, PowerFlex, CompactLogix, Connected Components Workbench, ControlLogix, GuardLogix, Logix5000, RSLinx, Studio 5000, Studio 5000 Logix Designer, and
TechConnect 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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 3
Summary of Changes
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added footnotes to indicate the overload capacity of catalogs. 12, 21...24
Updated Motor Phase Connection description in Power Terminal Block. 32
Added wiring information about Terminals 01 and 11. 33, 34
Updated descriptions for several terminals in the Control I/O Terminal Designations table. 35
Updated Network Configuration section. 47
Updated Real-time Information Display section. 49
Updated Configure the PowerFlex 527 Drive section with additional controllers. 59
Updated Test the Axes section. 83
Updated Tune the Axes section. 85
Updated PHF Data section. 89
Updated Operation of Hardwired Safe Torque-Off section. 97
Updated Compatible Safety Controllers section. 103
Updated Network Safe Torque-off Specifications section. 104
Added INIT FLT M22 – ILLEGAL ADDRESS to INIT FLT Fault Codes table. 125
Updated INHIBIT Fault Codes table. 125
Updated information on configurable stopping actions in Logix5000 Controller and Drive Behavior. 129
Updated Drive Behavior, FLT Sxx Fault Codes table. 131
Updated Control table in Technical Specifications. 135
Removed Bandwidth specification from Control Inputs table in Technical Specifications. 137
UpdatedMotion Group Base Update Rate graphic. 165
Updated Encoder Signal – Single-Ended, Dual Channel connection example graphic. 170

4Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Summary of Changes
Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 5
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table of Contents
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Environmental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
Installation/Wiring
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Understanding the PowerFlex 527 Display and Indicators . . . . . . . . . . . 44
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Using the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 3
Configuring the PowerFlex 527 Drive
with Integrated Motion
Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Configure the Logix Designer Application Project . . . . . . . . . . . . . . . . . . 52
Add a PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configure the PowerFlex 527 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Apply Power to the PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Test and Tune the Axes – Velocity and Position Control Modes . . . . . 83

6Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Table of Contents
Chapter 4
PowerFlex 527 Integrated Safe
Torque-Off
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . . 89
Safe Torque-Off (STO) Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Out-of-Box (OOB) Safety State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Safe Torque-Off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Chapter 5
Hardwired Control of Safe Torque-Off
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Safe Torque-Off Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Wire the Safe Torque-Off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safe Torque-Off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 6
Network Control of Safe Torque-Off
Understanding Integrated Safety Drive Replacement. . . . . . . . . . . . . . . 107
Replacing an Integrated Safety Drive in a GuardLogix System . . . . . . . 107
Motion Direct Commands in Motion Control Systems . . . . . . . . . . . . 114
Functional Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Chapter 7
Troubleshooting
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Logix5000 Controller and Drive Behavior. . . . . . . . . . . . . . . . . . . . . . . . . 129
Appendix A
Supplemental Drive Information
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Appendix C
Out-of-Box Configuration
Recommended Out-of-Box Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Setting the ACO/AVO Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Appendix D
Encoder Option Card Usage
Installing the Encoder Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 7
Table of Contents
Removing the Encoder Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Encoder Option Card Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Index

8Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Table of Contents
Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 9
Preface
Overview
The purpose of this manual is to provide you with the basic information needed
to install, start-up and troubleshoot the PowerFlex® 527 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
a working knowledge and understanding of ControlLogix®/Studio 5000® and
CIP Motion.
If you do not have a basic understanding of the PowerFlex 527 drives, contact
your local Rockwell Automation sales representative for information on available
training courses.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/literature. To order paper copies of
For information on… See page…
Who Should Use this Manual 9
Additional Resources 9
Manual Conventions 10
Drive Frame Sizes 10
General Precautions 11
Catalog Number Explanation 12
Title Publication
GuardLogix 5570 Controllers User Manual 1756-UM022
GuardLogix 5570 Controller Systems Safety Reference Manual 1756-RM099
CompactLogix 5370 Controllers User Manual 1769-UM021
ControlLogix 5580 Controllers User Manual 1756-UM543
Compact GuardLogix 5370 Controllers User Manual 1769-UM022
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001
Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual MOTION-UM003
Integrated Motion on the EtherNet/IP Network MOTION-RM003
PowerFlex DB (Dynamic Braking) Resistor Calculator PFLEX-AT001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1
Guarding Against Electrostatic Damage 8000-4.5.2

10 Rockwell Automation Publication 520-UM002B-EN-E - December 2017
Preface Overview
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Manual Conventions •In this manual we refer to PowerFlex 527 Adjustable Frequency AC Drive
as: drive, PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive.
•Specific drives within the PowerFlex 520-series may be referred to as:
– PowerFlex 523, PowerFlex 523 drive or PowerFlex 523 AC drive.
– PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.
– PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive
•The following words are used throughout the manual to describe an
action:
•The Studio 5000 Automation Engineering and Design Environment™
(formerly RSLogix 5000) combines engineering and design elements into
one standard framework that enables optimized productivity and reduced
time to commission. As part of the Studio 5000 environment, Logix
Designer™ is the tool used to program Logix programmable automation
controllers for process, batch, discrete, drives, safety and motion-based
systems. The Studio 5000 environment is the foundation for system
engineering design tools and capabilities — it is the one tool for engineers
to design and develop all the elements of their control system.
These conventions are used throughout this manual:
•Bulleted lists such as this one provide information, not procedural steps.
•Numbered lists provide sequential steps or hierarchical information.
Drive Frame Sizes The PowerFlex 527 AC drive belongs to the new generation of PowerFlex 520-
series drives which also consist of PowerFlex 523 and PowerFlex 525 drives.
Similar PowerFlex 520-series drive sizes are grouped into frame sizes to simplify
spare parts ordering, dimensioning, etc. A cross reference of drive catalog
numbers and their respective frame sizes is provided in Appendix B.
Product Environmental
Information
Rockwell Automation maintains current product environmental information on
its website at
http://www.rockwellautomation.com/rockwellautomation/about-us/
sustainability-ethics/product-environmentalcompliance.page
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