Rockwell Automation B Series User manual

PowerFlex 520-Series Adjustable Frequency AC Drive
PowerFlex 523 Catalog Number 25A, Series B
PowerFlex 525 Catalog Number 25B
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, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree
Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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-UM001I-EN-E - July 2016 3
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preface
Overview
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Installation/Wiring
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 2
Start Up
Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 65
LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . . 67
Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Table of Contents
Chapter 3
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Chapter 4
Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162
Appendix A
Supplemental Drive Information
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Appendix B
Accessories and Dimensions
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Appendix C
RS485 (DSI) Protocol
Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 208
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 5
Table of Contents
Appendix D
Velocity StepLogic, Basic Logic and
Timer/Counter Functions
Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 210
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Appendix E
Encoder/Pulse Train Usage and
Position StepLogic Application
Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Appendix F
PID Set Up
PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Appendix G
Safe-Torque-Off Function
PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 235
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 239
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 239
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 245
Appendix H
EtherNet/IP
Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 247
Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248

6Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Table of Contents
Appendix I
Control Diagrams
Induction Motor Tuning Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Appendix J
PowerFlex 525 PM Motor
Configuration
Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Automatic Configuration Using Drive Startup Wizard. . . . . . . . . . . . . 254
Manual Configuration Using Drive Keypad . . . . . . . . . . . . . . . . . . . . . . . 261
Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Optional Parameter Adjustments for Optimum Performance . . . . . . . 266
Index

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 7
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added footnote to indicate that circuit breaker selection is not available for certain drive
ratings. 24...27
Added PowerFlex 523 series B to Control I/O Wiring Block Diagram. 38
Added PowerFlex 523 series B to Control I/O Terminal Designations. 40
Added PowerFlex 523 series B I/O wiring examples for analog input and analog output. 45
Added note to PowerFlex 525 I/O wiring example for pulse train input. 46
Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with Basic
Program Group Parameters. 67
Added new sub topic for 32-bit parameters. 72
Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later. Chapter 3
Updated descriptions for parameters that are available in PowerFlex 523 FRN 3.xxx and later.
Added formula for calculating scaled process value to parameter b010 [Process Display]. 79
Added recommendation to perform rotate tune when using VVC mode to parameter P040
[Autotune]. 85
Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [Dig
Out Status]. 114
Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband]. 123
Added corrective action to fault F114 (uC Failure). 162
Added analog output to PowerFlex 523 drives. 171
Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution” to Appendix E. 217
Updated information to verify operation of the safety inputs in Appendix G. 240
General maintenance updates. Throughout manual

8Rockwell Automation Publication 520-UM001I-EN-E - July 2016
Summary of Changes
Notes:

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 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® 520-Series 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 9
Recommended Documentation 9
Manual Conventions 10
Drive Frame Sizes 11
General Precautions 12
Catalog Number Explanation 13
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 520-Series AC Drive Specifications 520-TD001
PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

10 Rockwell Automation Publication 520-UM001I-EN-E - July 2016
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-series, PowerFlex 520-series drive or
PowerFlex 520-series 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.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Title Publication
PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001
PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002
PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM003
PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004
P 031 [Motor NP Volts]
Name
Number
Group
b
P
t
C
L
d
A
N
M
f
G
= Basic Display
= Basic Program
= Terminal Blocks
= Communications
= Logic
= Advanced Display
= Advanced Program
= Network
= Modified
= Fault and Diagnostic
= AppView and CustomView
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