Rockwell Automation PowerFlex 520-Series Adjustable Frequency AC Drive Datasheet

Datasheet for Rockwell Automation models including: PowerFlex 520
520-UM001J-EN-E PowerFlex 520-Series Adjustable Frequency AC Drive User Manual

25A series B, 25B

"25A series B, 25B"

Rockwell Automation

520-UM001 - Literature Library | Rockwell Automation

PowerFlex 520-Series Adjustable Frequency AC Drive. PowerFlex 523 Catalog Number 25A, Series B. PowerFlex 525 Catalog Number 25B. User Manual.
520-UM001I-EN-E PowerFlex 520-Series Adjustable...

User Manual. PowerFlex 520-Series Adjustable Frequency AC Drive. ... The examples and diagrams in this manual are included solely for illustrative purposes.
520-UM001

PowerFlex 520-Series. Adjustable Frequency AC Drive. Catalog Number 25A series B, 25B. User Manual. Original Instructions ...
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PowerFlex 520-Series Adjustable Frequency AC Drive
Catalog Number 25A series B, 25B

User Manual

Original Instructions

PowerFlex 520-Series Adjustable Frequency AC Drive User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 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.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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).

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Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Installation/Wiring

Table of Contents

Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 9 Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drive Frame Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 1
Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ambient Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Current Derating Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Debris Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ungrounded Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Input Power Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Ground Fault Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Safety Ground - (PE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Network Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Motor Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Shield Termination - SHLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 RFI Filter Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuses and Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuses and Circuit Breakers for PowerFlex 520-Series Drives . . . . . 24
Power and Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motor Cable Types Acceptable for 100...600 Volt Installations . . . . 32 Reflected Wave Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Output Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Motor Start/Stop Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Signal and Control Wire Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Maximum Control Wire Recommendations. . . . . . . . . . . . . . . . . . . . 37

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

3

Table of Contents

Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PowerFlex 523 Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . 37 PowerFlex 525 Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . 41 I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Start Source and Speed Reference Selection. . . . . . . . . . . . . . . . . . . . 48 Accel/Decel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Low Voltage Directive (2014/35/EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 ATEX Directive (2014/34/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Start Up

Chapter 2
Prepare for Drive Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Drive Startup Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Start, Stop, Direction, and Speed Control . . . . . . . . . . . . . . . . . . . . . . 59 Variable Torque Fan/Pump Applications . . . . . . . . . . . . . . . . . . . . . . . 59
Display and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Control and Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Smart Startup with Basic Program Group Parameters . . . . . . . . . . . . . . 63 LCD Display with QuickView Technology . . . . . . . . . . . . . . . . . . . . . . . . . 65 Using the USB Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
MainsFree Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Using Drive Startup in CCW or Logix Designer application . . . . . . . . . 66

Programming and Parameters

Chapter 3
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Basic Program Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Terminal Block Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Communications Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Advanced Display Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Network Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Fault and Diagnostic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 AppView Parameter Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 CustomView Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Troubleshooting

Table of Contents
Chapter 4
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Automatically Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162

Supplemental Drive Information

Appendix A
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Accessories and Dimensions

Appendix B
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Adapter Plate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Installing a Communication Adapter . . . . . . . . . . . . . . . . . . . . . . . . 200 Removing a Communication Adapter . . . . . . . . . . . . . . . . . . . . . . . . 201

RS485 (DSI) Protocol

Appendix C
Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Supported Modbus Function Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 207 Reading (03) Logic Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 210 Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Velocity StepLogic, Basic Logic and Timer/Counter Functions

Appendix D
Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Velocity StepLogic Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 212 Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Appendix E

Encoder/Pulse Train Usage and Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Position StepLogic Application

Encoder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

5

Table of Contents
PID Set Up Safe Torque Off Function
6

HTL/TTL DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 220 Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Setup Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Appendix F
PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Exclusive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Trim Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Scale Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Invert Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 PID Deadband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 PID Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 PID Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 PID Gains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Guidelines for Adjusting the PID Gains . . . . . . . . . . . . . . . . . . . . . . . 234
Appendix G
PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 237 EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Functional Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 PFD and PFH Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 241 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 PowerFlex 525 Safe-Torque-Off Operation. . . . . . . . . . . . . . . . . . . . . . . . 242 Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Discrepancy Time of the Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . 242 Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Example 1  Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Example 2  Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 Example 3  Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e . . . . . . . . . . . . . . . . . . . . . . . 246 PowerFlex 525 Certification for Safe-Torque-Off . . . . . . . . . . . . . . . . . . 246
Rockwell Automation Publication 520-UM001J-EN-E - April 2021

EtherNet/IP

Table of Contents
Appendix H
Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . . 247 Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248

Control Diagrams

Appendix I
Induction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

PowerFlex 525 PM Motor Configuration

Appendix J
Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Stop Mode/Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Direction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Auto Tune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Manual Configuration Using Drive Keypad. . . . . . . . . . . . . . . . . . . . . . . 256 Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Additional Setup for Open Loop PM Motor . . . . . . . . . . . . . . . . . . . . 257 Additional Setup for Closed Loop PM Motor. . . . . . . . . . . . . . . . . . . 259 Optional Parameter Adjustments for Optimum Performance . . . . . . 261

PowerFlex 525 Synchronous Reluctance Motor Configuration

Appendix K
SynRM Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
SynRM Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Index

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

7

Table of Contents
Notes:

8

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Preface

About This Publication

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.

Topic

Page

Summary of Changes

9

Additional Resources

10

Manual Conventions

11

Drive Frame Sizes

12

General Precautions

13

Catalog Number Explanation

14

Download Firmware, AOP, EDS, and Other Files

Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes from the Product Compatibility and Download Center at rok.auto/pcdc.
See Download Files on page 10 to download the files for your PowerFlex 525 drive.

Summary of Changes

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.

Topic Updated to new template Updated and corrected parameter values (see the corresponding change bars for details) Moved and updated downloading files procedure Changed Circuit Breakers Bulletin 140M-C2E-C16 to 140M-D8E-C16 for 380...480V 3-Phase Input Protection Devices Corrected PCR with ID 774 on designation of the R3 terminal Updated CE conformity directives Updated AOP version to 5.07 and moved related information to Chapter 2 from Appendix J Added synchronous reluctance motor control parameters to [P039] options Corrected PCR with ID 1076 on parameter description for A434 and A435 Corrected PCR with ID 1055 and 872 on parameter values from 150% to 65% Corrected PCR with ID 742. Changed "password" to "access code" Updated Certifications table Added new drives jumper and communication adapter spare kits Added PowerFlex 4/40/40P to PowerFlex 520-series drives product selection table for the mounting plate Added Bulletin 160 to PowerFlex 520-series mounting adapter plate dimensions Added PowerFlex 4/40/40P to PowerFlex 520-series mounting adapter plate dimensions Added new feature HTL/TTL DIP switches for 25-ENC-1 encoder card Updated information on PowerFlex 525 PM motor (see corresponding change bars for details) Added new appendix and related parameters for synchronous reluctance motor

Page throughout throughout
10
26
39 51 66 83, 140 116 133 133, 240 165 177
178, 179, 180
197 198 218 251 72, 140, 263

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

9

Preface
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.

Additional Resources

All recommended documentation that is listed in this section is available online at rok.auto/literature.

The following publications provide general drive information:

Title Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Preventive Maintenance of Industrial Control and Drive System Equipment Safety Guidelines for the Application, Installation, and Maintenance of solid-state Control Guarding Against Electrostatic Damage

Publication DRIVES-IN001 DRIVES-TD001 SGI-1.1 8000-SB001

The following publications provide specific PowerFlex 520-Series information on drive installation, features, specifications, and service:

Title PowerFlex 520-Series AC Drive Specifications PowerFlex Dynamic Braking Resistor Calculator PowerFlex AC Drives in Common Bus Configurations

Publication 520-TD001 PFLEX-AT001 DRIVES-AT002

The following publications provide specific Network Communications information:

Title PowerFlex 525 Embedded EtherNet/IP Adapter PowerFlex 25-COMM-D DeviceNet Adapter PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter

Publication 520COM-UM001 520COM-UM002 520COM-UM003 520COM-UM004

Download Files

Follow these steps to download the files for your PowerFlex 525 drive. 1. Go to the Rockwell Automation Product Compatibility and Download Center at rok.auto/pcdc.

10

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Preface
IMPORTANT You must sign in to the Rockwell Automation website before downloading a firmware revision.
2. Click the Find Downloads link. 3. Enter "PowerFlex 525" into the Product Search field.
The results appears in the box below.

4. Select the entry and the firmware revision, then click Downloads.

Manual Conventions

5. Click the Show Downloads icon, then click the links to download the firmware revision and AOP files to your computer.
· 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.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

11

Preface
Drive Frame Sizes

· Parameter numbers and names are shown in this format:
P 031 [Motor NP Volts]

Name Number Group
b = Basic Display P = Basic Program t = Terminal Blocks C = Communications L = Logic d = Advanced Display A = Advanced Program N = Network M = Modified f = Fault and Diagnostic G = AppView and CustomView

· The following words are used throughout the manual to describe an action:

Words Can Cannot May Must Shall Should Should Not

Meaning Possible, able to do something Not possible, not able to do something Permitted, allowed Unavoidable, you must do this Required and necessary Recommended Not Recommended

· The Studio 5000® Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Studio 5000 Logix Designer® application is the rebranding of RSLogix 5000® software and will continue to be the product to program Logix 5000TM 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.

Similar PowerFlex 520-series drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, and so on. A cross-reference of drive catalog numbers and their respective frame sizes is provided in Appendix B.

12

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

General Precautions

Preface
ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. After power has been removed from the drive, wait three minutes to make sure DC bus capacitors are discharged. After three minutes, verify AC voltage L1, L2, L3 (Line to Line and Line to Ground) to ensure mains power has been disconnected. Measure DC voltage across DCand DC+ bus terminals to verify DC Bus has discharged to zero volts. Measure DC voltage from L1, L2, L3, T1, T2, T3 DC  and DC+ terminals to ground and keep the meter on the terminals until the voltage discharges to zero volts. The discharge process may take several minutes to reach zero volts. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, "Guarding Against Electrostatic Damage" or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system. ATTENTION: The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, 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 proper stopping requirements based on braking resistor sizing. ATTENTION: Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

13

Preface

Catalog Number Explanation

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

Code Type 25A PowerFlex 523 25B PowerFlex 525

Code Voltage Phase

V

120V AC 1

A

240V AC 1

B

240V AC 3

D

480V AC 3

E

600V AC 3

Code EMC Filter

0

No Filter

1

Filter

Code Interface Module

1

Standard

Code Enclosure

N

IP20 NEMA / Open

Code Braking

4

Standard

Output Current @ 1 Phase, 100...120V Input

Code Amps Frame ND

HD

HP kW HP kW

1P6(1) 1.6

A

0.25 0.2 0.25 0.2

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

1P6(1) 1.6

A

0.25 0.2 0.25 0.2

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

1P6(1) 1.6

A

0.25 0.2 0.25 0.2

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 4.0 5.0 4.0

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(2) 48.3 E

15.0 11.0 10.0 7.5

062(2) 62.1 E

20.0 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(2) 30.0 D

20.0 15.0 15.0 11.0

037(2) 37.0 E

25.0 18.5 20.0 15.0

043(2) 43.0 E

30.0 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 4.0 5.0 4.0

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(2) 22.0 D

20.0 15.0 15.0 11.0

027(2) 27.0 E

25.0 18.5 20.0 15.0

032(2) 32.0 E

30.0 22.0 25.0 18.5

(1) This rating is only available for PowerFlex 523 drives.

(2)

Normal and Heavy-Duty ratings are available for this drive.

14

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Installation/Wiring

1 Chapter

This chapter provides information on mounting and wiring the PowerFlex 520-series drives.

Topic

Page

Mounting Considerations

15

AC Supply Source Considerations

19

General Grounding Requirements

20

Fuses and Circuit Breakers

22

Power and Control Module

28

Control Module Cover

30

Power Module Terminal Guard

31

Power Wiring

32

Power Terminal Block

35

Common Bus/Precharge Notes

35

I/O Wiring

36

Control I/O Terminal Block

37

Start and Speed Reference Control

48

CE Conformity

51

Most startup 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.

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.

Mounting Considerations

· Mount the drive upright on a flat, vertical, and level surface.

Frame A B C D E

Screw Size M5 (#10...24) M5 (#10...24) M5 (#10...24) M5 (#10...24) M8 (5/16 in.)

Screw Torque 1.56...1.96 N·m (14...17 lb·in) 1.56...1.96 N·m (14...17 lb·in) 1.56...1.96 N·m (14...17 lb·in) 2.45...2.94 N·m (22...26 lb·in) 6.0...7.4 N·m (53...65 lb·in)

· Protect the cooling fan by avoiding dust or metallic particles. · Do not expose to a corrosive atmosphere. · Protect from moisture and direct sunlight.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

15

Chapter 1 Installation/Wiring

Vertical

50 mm (2.0 in.)
Esc Sel

25 mm (1.0 in.)
Esc Sel

Minimum Mounting Clearances

See Product Dimensions on page 184 for mounting dimensions.

Vertical, Zero Stacking No clearance between drives.

Vertical with Control Module Fan Kit

Vertical, Zero Stacking with Control Module Fan Kit No clearance between drives.

50 mm (2.0 in.)

50 mm (2.0 in.)(1)

50 mm (2.0 in.)(1)

Esc Sel

Esc Sel

Esc Sel

Esc Sel

Esc Sel

Esc Sel

50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

25 mm (1.0 in.)

(2)
50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

Esc Sel

50 mm (2.0 in.)(1)

Esc Sel

25 mm (1.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)
(2)

50 mm (2.0 in.)

Esc Sel

50 mm (2.0 in.)(1)

Esc Sel

50 mm (2.0 in.)

Horizontal with Control Module Fan Kit

Horizontal, Zero Stacking with Control Module Fan Kit No clearance between drives.

(1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required. (2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.

16

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 Installation/Wiring

Ambient Operating Temperatures

For optional accessories and kits, see Accessories and Dimensions on page 173.

Mounting
Vertical
Vertical, Zero Stacking Horizontal with Control Module Fan Kit(4)(5) Horizontal, Zero Stacking with Control Module Fan Kit(4)(5)

Enclosure Rating(1)
IP 20/Open Type IP 30/NEMA 1/UL Type 1 IP 20/Open Type IP 30/NEMA 1/UL Type 1
IP 20/Open Type

Ambient Temperature
Minimum Maximum (No Derate)
50 °C (122 °F) 45 °C (113 °F) 45 °C (113 °F) -20 °C (-4 °F) 40 °C (104 °F) 50 °C (122 °F)

Maximum (Derate)(2)
60 °C (140 °F) 55 °C (131 °F) 55 °C (131 °F) 50 °C (122 °F)


Maximum with Control Module Fan Kit (Derate)(3)(5) 70 °C (158 °F)  65 °C (149 °F) 
70 °C (158 °F)

IP 20/Open Type

45 °C (113 °F)



65 °C (149 °F)

(1) IP 30/NEMA 1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx. (2) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Maximum (Derate) column is reduced by 5 °C (9 °F) for all mounting methods. (3) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Maximum with Control Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and vertical with zero
stacking mounting methods only. (4) Catalogs 25x-D1P4N104 and 25x-E0P9N104 cannot be mounted using either of the horizontal mounting methods. (5) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.

Current Derating Curves

Vertical Mounting

Single Drive

Percentage of Rated Current (%)

120

IP 30/NEMA 1

with Control

110

Module Fan Kit

100

90

IP 20/Open Type

80

70

60

50

40 30 35 40 45 50 55 60 65 70 75 80

Ambient Temperature (°C)

Horizontal/Floor Mounting

Single Drive

Percentage of Rated Current (%)

120

with Control

110

Module Fan Kit

100

90

80

IP 20/Open Type

70

60

50

40 30 35 40 45 50 55 60 65 70 75 80

Ambient Temperature (°C)

Percentage of Rated Current (%)

Percentage of Rated Current (%)

Zero Stacking

120

IP 30/NEMA 1

with Control

110

Module Fan Kit

100

90

IP 20/Open 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/Open Type

70

60

50

40 30 35 40 45 50 55 60 65 70 75 80

Ambient Temperature (°C)

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

17

Chapter 1 Installation/Wiring

Derating Guidelines for High Altitude

The drive can be used without derating at a maximum altitude of 1000 m (3300 ft). If the drive is used above 1000 m (3300 ft):
· Derate the maximum ambient temperature by 5 °C (9 °F for every additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit (Based on Voltage) table below. Or
· 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
100...120V 1-Phase 200...240V 1-Phase 200...240V 3-Phase 380...480V 3-Phase 525...600V 3-Phase

Center Ground (Wye Neutral)
6000 m 2000 m 6000 m 4000 m 2000 m

Corner Ground, Impedance Ground, or Ungrounded 6000 m 2000 m 2000 m 2000 m 2000 m

High Altitude

Percentage of Rated Current (%) Ambient Temperature (°C)

120 110 100 90 80 70 60 50 40
0 1000 2000 3000 4000
Altitude (m)

60 50 40 30 20
0 1000 2000 3000 4000 Altitude (m)

Debris Protection
Take precautions to prevent debris from falling through the vents of the drive housing during installation.

Storage
· Store within an ambient temperature range of -40...85 °C(1). · Store within a relative humidity range of 0...95%, noncondensing. · Do not expose to a corrosive atmosphere.
(1) The maximum ambient temperature for storing a Frame E drive is 70 °C.

18

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

AC Supply Source Considerations

Chapter 1 Installation/Wiring
Ungrounded Distribution Systems
ATTENTION: PowerFlex 520-series drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. ATTENTION: Removing MOVs in drives with an embedded filter will also disconnect the filter capacitor from earth ground.
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 AC Input

R/L1 S/L2

T/L3

Jumper

123 4

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

19

Chapter 1 Installation/Wiring
General Grounding Requirements

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see page 167). Listed in the Input Power Conditions table below are certain input power conditions which may cause component damage or reduction in product life. If any of these conditions exist, install one of the devices listed under the heading Corrective Action on the line side of the drive.

IMPORTANT Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Input Power Conditions

Input Power Condition Low Line Impedance (less than 1% line reactance) Greater than 120 kVA supply transformer Line has power factor correction capacitors 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 Ungrounded distribution system B-phase grounded distribution system 240V open delta configuration (stinger leg)(2)

Corrective Action · Install Line Reactor(1) · or Isolation Transformer
· Install Line Reactor(1) · or Isolation Transformer
· Remove MOV jumper to ground. · or Install Isolation Transformer with
grounded secondary if necessary.
· Install Line Reactor(1)

(1) See Appendix B for accessory ordering information. (2) 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 at each connection point. The stinger leg should be connected to the center Phase B on the reactor. See Bulletin 1321-3R Series Line Reactors on page 183 for specific line reactor part numbers.

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 of all ground connections should be periodically checked.
Typical Grounding

Esc Sel

R/L1

U/T1

S/L2

V/T2

T/L3

W/T3

SHLD

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.

20

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 Installation/Wiring
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.
Network Ground
Connect terminal C1 to a clean earth ground when using a network with a star topology (EtherNet/IPTM) or daisy-chain (RS485). It is acceptable to ground both C1 and C2 terminals.
Note: Grounding C1 and C2 helps noise immunity for non-network applications.
Connect terminal CS1 or CS2 to a clean ground when using a network with a ring topology (EtherNet/IP).
For more information on EtherNet/IP networks, see Ground Connections for EtherNet/IP Networks on page 248.
For more information on RS485 networks, see Network Wiring on page 203.
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 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.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

21

Chapter 1 Installation/Wiring

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.

Fuses and Circuit Breakers

The PowerFlex 520-series drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.
The tables found on pages 24...27 provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 °C (104 °F) and the U.S. N.E.C. Other country, state or local codes may require different ratings.

Fusing
The recommended fuse types are listed in the tables found on pages 24...27. If available current ratings do not match those listed in the tables provided, choose the next higher fuse rating.
· IEC  BS88 (British Standard) Parts 1 & 2(a), EN60269-1, Parts 1 & 2, type GG or equivalent should be used.
· UL  UL Class CC, T, RK1, or J should be used.

Circuit Breakers
The "non-fuse" listings in the tables found on pages 24...27 include inverse time circuit breakers, instantaneous trip circuit breakers (motor circuit protectors) and 140M self-protected combination motor controllers. If one of these is chosen as the desired protection method, the following requirements apply:
· IEC  Both types of circuit breakers and 140M self-protected combination motor controllers are acceptable for IEC installations.
· UL  Only inverse time circuit breakers and the specified 140M selfprotected combination motor controllers are acceptable for UL installations.

(a) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

22

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 Installation/Wiring
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.
· Bulletin 140M can be used in single motor applications. · Bulletin 140M can be used up stream from the drive without the need for
fuses.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

23

Chapter 1 Installation/Wiring

24

Fuses and Circuit Breakers for PowerFlex 520-Series Drives

100...120V 1-Phase Input Protection Devices  Frames A...B

Catalog No.

Output Ratings

PF 523

PF 525

ND

HD

HP kW HP kW

25A-V1P6N104 

0.25 0.2 0.25 0.2 1.6

25A-V2P5N104 25B-V2P5N104 0.5 25A-V4P8N104 25B-V4P8N104 1.0 25A-V6P0N104 25B-V6P0N104 1.5

0.4 0.5 0.75 1.0 1.1 1.5

0.4 2.5 0.75 4.8 1.1 6.0

Amps kVA Frame Size Contactor Catalog No.

Input Ratings
Max Amps(1)
0.8 6.4 A 1.3 9.6 A 2.5 19.2 B 3.2 24.0 B

IEC Applications (Non-UL)

UL Applications

Fuses (Rating)

Circuit Breakers

Fuses (Max. Rating)

Circuit Breakers

Min. Max. 140U/140G 140M

Class / Catalog No.

140U/140G

140M(2)(3)(4)

100-C09 10 16 140U-D6D2-B80 140M-C2E-B63 CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D2-B80 140M-C2E-B63

100-C12 16 20 140U-D6D2-C12 140M-C2E-C10 CLASS RK5, CC, J, or T / DLS-R-20 140U-D6C2-C12 140M-C2E-C10

100-C23 25 40 140U-D6D2-C25 140M-D8E-C20 CLASS RK5, CC, J, or T / DLS-R-40 140U-D6D2-C25 140M-D8E-C20

100-C23 32 50 140U-D6D2-C30 140M-F8E-C25 CLASS RK5, CC, J, or T / DLS-R-50 140U-D6D2-C30 140M-F8E-C25

Min. Enclosure Vol. (in.3)
-

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

200...240V 1-Phase Input Protection Devices  Frames A...B

Catalog No.

Output Ratings

PF 523

PF 525

ND

HD

HP kW HP kW

25A-A1P6N104 

0.25 0.2 0.25 0.2 1.6

25A-A1P6N114 

0.25 0.2 0.25 0.2 1.6

25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.5 0.4 2.5

25A-A2P5N114 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5

25A-A4P8N104 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8

25A-A4P8N114 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8

25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0

25A-A8P0N114 25B-A8P0N114 2.0 1.5 2.0 1.5 8.0

25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0

25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0

Amps kVA Frame Size Contactor Catalog No.

Input Ratings
Max Amps(1)
1.4 5.3 A 1.4 5.3 A 1.7 6.5 A 1.7 6.5 A 2.8 10.7 A 2.8 10.7 A 4.8 18.0 B 4.8 18.0 B 6.0 22.9 B
6.0 22.9 B

IEC Applications (Non-UL)

Fuses (Rating)

Circuit Breakers

Min. Max. 140U/140G 140M

100-C09 6 100-C09 6 100-C09 10 100-C09 10 100-C12 16 100-C12 16 100-C23 25 100-C23 25

10 140U-D6D2-C10 140M-C2E-B63 10 140U-D6D2-C10 140M-C2E-B63 16 140U-D6D2-C10 140M-C2E-C10 16 140U-D6D2-C10 140M-C2E-C10 25 140U-D6D2-C15 140M-C2E-C16 25 140U-D6D2-C15 140M-C2E-C16 40 140U-D6D2-C25 140M-F8E-C25 40 140U-D6D2-C25 140M-F8E-C25

100-C37 32 50 140G-G6C3-C35 140M-F8E-C25

100-C37 32 50 140G-G6C3-C35 140M-F8E-C25

UL Applications
Fuses (Max. Rating)
Class / Catalog No. CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-25 CLASS RK5, CC, J, or T / DLS-R-25 CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 CLASS CC, J, or T / 50 CLASS CC, J, or T / 50

Circuit Breakers

140U/140G
140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C15 140U-D6D2-C15 140U-D6D2-C25 140U-D6D2-C25 (5) (5)

140M(2)(3)(4) 140M-C2E-B63 140M-C2E-B63 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25
140M-F8E-C25

Min. Enclosure Vol. (in.3)
-
-
-

(1) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating. (2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques,
publication 140M-AT002. (3) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip. (4) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground
systems. (5) Circuit breaker selection is not available for this drive rating.

200...240V 3-Phase Input Protection Devices  Frames A...E

Catalog No.(1)

Output Ratings

Input Ratings

PF 523

PF 525

ND

HD

HP kW HP kW

Max Amps(2)

25A-B1P6N104 

0.25 0.2 0.25 0.2 1.6 0.9 1.9 A

25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A

25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 2.7 5.8 A

25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 4.3 9.5 A

25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 6.3 13.8 A

25A-B017N104 25B-B017N104 5.0 4.0 5.0 4.0 17.5 9.6 21.1 B

25A-B024N104 25B-B024N104 7.5 5.5 7.5 5.5 24.0 12.2 26.6 C

25A-B032N104 25B-B032N104 10.0 7.5 10.0 7.5 32.2 15.9 34.8 D

25A-B048N104 25B-B048N104 15.0 11.0 10.0 7.5 48.3 20.1 44.0 E

25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E

Amps kVA Frame Size Contactor Catalog No.

IEC Applications (Non-UL)

Fuses (Rating)

Circuit Breakers

Min. Max. 140U/140G 140M

100-C09 3 6 140U-D6D3-B30 140M-C2E-B25 100-C09 6 6 140U-D6D3-B40 140M-C2E-B40 100-C09 10 16 140U-D6D3-B80 140M-C2E-B63 100-C12 16 20 140U-D6D3-C10 140M-C2E-C10 100-C23 20 32 140U-D6D3-C15 140M-C2E-C16 100-C23 32 45 140U-D6D3-C25 140M-F8E-C25

100-C37 35 63 140G-G6C3-C35 140M-F8E-C32

100-C43 45 70 140G-G6C3-C60 140M-F8E-C45

100-C60 63 90 140G-G6C3-C70 140M-F8E-C45

100-C72 70 125 140G-G6C3-C90 (7)

UL Applications

Fuses (Max. Rating)

Circuit Breakers

Class / Catalog No.

140U/140G

CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D3-B30

CLASS RK5, CC, J, or T / DLS-R-6 140U-D6D3-B40

CLASS RK5, CC, J, or T / DLS-R-15 140U-D6D3-B80

CLASS RK5, CC, J, or T / DLS-R-20 140U-D6D3-C10

CLASS RK5, CC, J, or T / DLS-R-30 140U-D6D3-C15

CLASS CC, J, or T / 45

140U-D6D3-C25

CLASS CC, J, or T / 60

(7)

CLASS RK5, CC, J, or T / DLS-R-70 (7)

CLASS CC, J, or T / 90

(7)

CLASS CC, J, or T / 125

(7)

140M(3)(4)(5) 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-F8E-C25 140M-F8E-C32
140M-F8E-C45
140M-F8E-C45 (7)

Min. Enclosure Vol. (in.3)
-
1416.0(6) -

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

(1)

Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques,

publication 140M-AT002.

(4) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground

systems.

(6) When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume

specified in this column. Application specific thermal considerations may require a larger enclosure.

(7) Circuit breaker selection is not available for this drive rating.

Chapter 1 Installation/Wiring

25

Chapter 1 Installation/Wiring

26

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

380...480V 3-Phase Input Protection Devices  Frames A...E
380...480V 3-Phase Input Protection Devices  Frames A...E

Amps kVA Frame Size Contactor Catalog No.

Catalog No.(1)

PF 523

PF 525

Output Ratings

ND

HD

HP kW HP kW

Input Ratings
Max Amps(2)

IEC Applications (Non-UL)

Fuses (Rating)

Circuit Breakers

Min. Max. 140U/140G 140M

25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 3 6 140U-D6D3-B30 140M-C2E-B25

25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 3 6 140U-D6D3-B30 140M-C2E-B25

25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 6 10 140U-D6D3-B60 140M-C2E-B40

25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 6 10 140U-D6D3-B60 140M-C2E-B40

25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 16 140U-D6D3-B60 140M-C2E-B63

25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 16 140U-D6D3-B60 140M-C2E-B63

25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 16 140U-D6D3-C10 140M-C2E-C10

25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 16 140U-D6D3-C10 140M-C2E-C10

25A-D010N104 25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 32 140U-D6D3-C15 140M-C2E-C16

25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 32 140U-D6D3-C15 140M-C2E-C16

25A-D013N104 25B-D013N104 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25 140M-D8E-C20

25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25 140M-D8E-C20

25A-D017N104 25B-D017N104 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20

25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20

25A-D024N104 25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 63 140G-G6C3-C40 140M-F8E-C32

25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 63 140G-G6C3-C40 140M-F8E-C32

25A-D030N104 25B-D030N104 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45

25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45

25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45

25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 50 80 140G-G6C3-C60 140M-F8E-C45

UL Applications
Fuses (Max. Rating)
Class / Catalog No. CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-10 CLASS RK5, CC, J, or T / DLS-R-10 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-30 CLASS RK5, CC, J, or T / DLS-R-30 CLASS CC, J, or T / 35 CLASS CC, J, or T / 35 CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 CLASS CC, J, or T / 60 CLASS CC, J, or T / 60 CLASS CC, J, or T / 70 CLASS CC, J, or T / 70 CLASS CC, J, or T / 70 CLASS CC, J, or T / 80

Circuit Breakers

140U/140G 140M(3)(4)(5)

(7)

140M-C2E-B25

(7)

140M-C2E-B25

(7)

140M-C2E-B40

(7)

140M-C2E-B40

(7)

140M-C2E-B63

(7)

140M-C2E-B63

(7)

140M-C2E-C10

(7)

140M-C2E-C10

(7)

140M-D8E-C16

(7)

140M-D8E-C16

(7)

140M-D8E-C20

(7)

140M-D8E-C20

(7)

140M-D8E-C20

(7)

140M-D8E-C20

(7)

140M-F8E-C32

(7)

140M-F8E-C32

(7)

140M-F8E-C45

(7)

140M-F8E-C45

(7)

140M-F8E-C45

(7)

140M-F8E-C45

Min. Enclosure Vol. (in.3)
656.7(6) 656.7(6) 656.7(6) 656.7(6) -

(1)

Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques,

publication 140M-AT002.

(4) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground

systems.

(6) When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume

specified in this column. Application specific thermal considerations may require a larger enclosure.

(7) Circuit breaker selection is not available for this drive rating.

525...600V 3-Phase Input Protection Devices  Frames A...E

Amps kVA Frame Size Contactor Catalog No.

Catalog No.(1)

PF 523

PF 525

Output Ratings

ND

HD

HP kW HP kW

Input Ratings
Max Amps(2)

IEC Applications (Non-UL)

Fuses (Rating)

Circuit Breakers

Min. Max. 140U/140G 140M

25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 1.4 1.2

A 100-C09 3 6 140U-D6D3-B20 140M-C2E-B25

25A-E1P7N104 25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 2.6 2.3

A 100-C09 3 6 140U-D6D3-B30 140M-C2E-B25

25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 4.3 3.8

A 100-C09 6 10 140U-D6D3-B50 140M-C2E-B40

25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 6.1 5.3

A 100-C09 10 16 140U-D6D3-B80 140M-C2E-B63

25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 10 20 140U-D6D3-C10 140M-C2E-C10

25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 16 25 140U-D6D3-C15 140M-C2E-C16

25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 20 32 140U-D6D3-C20 140M-C2E-C16

25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 32 50 140G-G6C3-C30 140M-F8E-C25

25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 35 63 140G-G6C3-C35 140M-F8E-C32

25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 35 50 140G-G6C3-C35 140M-F8E-C32

25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 40 63 140G-G6C3-C50 140M-F8E-C32

UL Applications

Fuses (Max. Rating) Class / Catalog No.

Circuit Breakers 140U/140G 140M(3)(4)(5)

Min. Enclosure Vol. (in.3)

CLASS RK5, CC, J, or T / DLS-R-6 (8)

140M-C2E-B25 -

CLASS RK5, CC, J, or T / DLS-R-6 (8)

140M-C2E-B25 -

CLASS RK5, CC, J, or T / DLS-R-10 (8)

140M-C2E-B40 -

CLASS RK5, CC, J, or T / DLS-R-15 (8)

140M-D8E-B63 -

CLASS RK5, CC, J, or T / DLS-R-20 (8)

140M-D8E-C10 -

CLASS RK5, CC, J, or T / DLS-R-25 (8)

140M-D8E-C16(6) -

CLASS RK5, CC, J, or T / DLS-R-30 (8)

140M-D8E-C16 -

CLASS CC, J, or T / 50

(8)

140M-F8E-C25 656.7(7)

CLASS CC, J, or T / 60

(8)

140M-F8E-C32 656.7(7)

CLASS CC, J, or T / 50

(8)

140M-F8E-C32 1416.0(7)

CLASS CC, J, or T / 60

(8)

140M-F8E-C32 1416.0(7)

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(1)

Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. SeeSee the Use of Motor Protection Circuit Breakers with Variable-Frequency Drives Application Techniques,

publication 140M-AT002.

(4) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground

systems.

(6) When used with the 140M circuit breaker, the 25A-E9P9104 must be installed in a ventilated or non-ventilated enclosure with the minimum size of 457.2 x 457.2 x 269.8 mm (18 x 18 x 10.62 in.).

(7) When using a Manual Self-Protected (Type E) Combination Motor Controller with this drive power rating, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume

specified in this column. Application specific thermal considerations may require a larger enclosure.

(8) Circuit breaker selection is not available for this drive rating.

Chapter 1 Installation/Wiring

27

Chapter 1 Installation/Wiring
Power and Control Module

PowerFlex 520-series drives consist of a Power Module and Control Module.
Separating the Power and Control Module

ATTENTION: Perform this action only when drive is NOT powered. 1. Press and hold down the catch on both sides of the frame cover, then pull
out and swing upwards to remove (Frames B...E only).

2. Press down and slide out the top cover of the Control Module to unlock it from the Power Module.
1 2

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Chapter 1 Installation/Wiring
3. Hold the sides and top of the Control Module firmly, then pull out to separate it from the Power Module.
Connecting the Power and Control Module
1. Align the connectors on the Power Module and Control Module, then push the Control Module firmly onto the Power Module.

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Chapter 1 Installation/Wiring

2. Push the top cover of the Control Module towards the Power Module to lock it.

3. Insert the catch at the top of the frame cover into the Power Module, then swing the frame cover to snap the side catches onto the Power Module (Frames B...E only).

Control Module Cover

To access the control terminals, DSI port, and Ethernet port, the front cover must be removed. To remove:
1. Press and hold down the arrow on the front of the cover.

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Chapter 1 Installation/Wiring
2. Slide the front cover down to remove from the Control Module.

1

Power Module Terminal Guard

2
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).

2. Press and hold down the locking tab on the terminal guard.

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Chapter 1 Installation/Wiring

3. Slide the terminal guard down to remove from the Power Module.

Power Wiring
32

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 28 for instructions.
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock 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. UL installations above 50 °C ambient must use 600V, 90 °C wire. UL installations in 50 °C ambient must use 600V, 75 °C or 90 °C wire. UL installations in 40 °C ambient should use 600V, 75 °C or 90 °C wire.
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Chapter 1 Installation/Wiring
Use copper wire only. Wire gauge requirements and recommendations are based on 75 °C. Do not reduce wire gauge when using higher temperature wire.
WARNING: The distance between the drive and motor must not exceed the maximum cable length stated in the Motor Cable Length Restrictions Tables in "Wiring and Grounding Guide, (PWM) AC Drives," publication DRIVES-IN001.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.
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 of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. See Reflected Wave in "Wiring and Grounding Guide, (PWM) AC Drives," publication DRIVES-IN001.
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 75%. An additional foil shield can greatly improve noise containment.
A good example of recommended cable is Belden 295xx (xx determines gauge). This cable has four XLPE insulated conductors with a 100% coverage foil and an 85% 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 the overall drive performance. Unless specified in the individual

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Chapter 1 Installation/Wiring

distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.

Recommended Shielded Wire

Location Standard (Option 1) Standard (Option 2) Class I & II; Division I & II

Rating/Type 600V, 90 °C (194 °F) XHHW2/RHW-2 Anixter B209500-B209507, Belden 29501-29507, or equivalent Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter OLF-7xxxxx or equivalent
Tray rated 600V, 90 °C (194 °F) RHH/RHW-2 Anixter 7V-7xxxx-3G or equivalent

Description
· Four tinned copper conductors with XLPE insulation. · Copper braid/aluminum foil combination shield and
tinned copper drain wire. · PVC jacket.
· Three tinned copper conductors with XLPE insulation. · 5 mil single helical copper tape (25% overlap min) with
three bare copper grounds in contact with shield. · PVC jacket.
· Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded 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). See Reflected Wave in "Wiring and Grounding Guide, (PWM) AC Drives," publication DRIVES-IN001.
The reflected wave data applies to all carrier frequencies 2...16 kHz.
For 240V ratings and lower, reflected wave effects do not need to be considered.

Output Disconnect
The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not 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).

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Power Terminal Block

Power Terminal Block
Frame A, B, C & D
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

Chapter 1 Installation/Wiring
Frame E R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

Common Bus/Precharge Notes

DC- DC+ BRBR+

Terminal R/L1, S/L2 R/L1, S/L2, T/L3

Description 1-Phase Input Line Voltage Connection 3-Phase Input Line Voltage Connection

U/T1, V/T2, W/T3 Motor Phase Connection =

DC+, DCBR+, BR-

DC Bus Connection (except for 110V 1-Phase) Dynamic Brake Resistor Connection Safety Ground - PE

DC- DC+ BRBR+
Switch any two motor leads to change forward direction.

IMPORTANT Terminal screws may become loose during shipment. Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive.

Power Terminal Block Wire Specifications

Frame A B C D E

Maximum Wire Size(1) 5.3 mm2 (10 AWG) 8.4 mm2 (8 AWG) 8.4 mm2 (8 AWG) 13.3 mm2 (6 AWG) 26.7 mm2 (3 AWG)

Minimum Wire Size(1) 0.8 mm2 (18 AWG) 2.1 mm2 (14 AWG) 2.1 mm2 (14 AWG) 5.3 mm2 (10 AWG) 8.4 mm2 (8 AWG)

Torque 1.76...2.16 N·m (15.6...19.1 lb·in) 1.76...2.16 N·m (15.6...19.1 lb·in) 1.76...2.16 N·m (15.6...19.1 lb·in) 1.76...2.16 N·m (15.6...19.1 lb·in) 3.09...3.77 N·m (27.3...33.4 lb·in)

(1) Maximum/minimum sizes that the terminal block will accept  these are not recommendations.

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...t068 [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. For more information, see Drives in Common Bus Configurations, publication DRIVES-AT002.

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Chapter 1 Installation/Wiring
I/O Wiring

Motor Start/Stop Precautions
ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur. ATTENTION: The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. When the AC 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.
Important points to remember about I/O wiring: · Always use copper wire. · Wire with an insulation rating of 600V or greater is recommended.
Control and signal wires should be separated from power wires by at least 0.3 m (1 ft).
IMPORTANT I/O terminals labeled "Common" are not referenced to the safety ground (PE) terminal and are designed to greatly reduce common mode interference.
ATTENTION: Driving the 4...20 mA analog input from a voltage source could cause component damage. Verify proper configuration prior to applying input 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.

Recommended Signal Wire

Signal Type/ Where Used

Belden Wire Type(s)(1) (or equivalent)

Description

Min. Insulation Rating

Analog I/O & PTC 8760/9460

Remote Pot

8770

0.750 mm2 (18 AWG), twisted pair, 100% shield with drain(2)
0.750 mm2 (18 AWG), 3 conductor, shielded

300V, 60 °C (140 °F)

Encoder/Pulse I/O 9728/9730

0.196 mm2 (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 I/O

Type Unshielded Shielded

Wire Type(s)

Description

Per US NEC or applicable national or local code



Multi-conductor shielded cable such as Belden 8770 0.750 mm2 (18 AWG), 3 conductor, shielded. (or equivalent)

Min. Insulation Rating 300V, 60 °C (140 °F)

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Chapter 1 Installation/Wiring
Maximum Control Wire Recommendations
Do not exceed control wiring length of 30 m (100 ft). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal block Common may be connected to ground terminal/protective earth.

Control I/O Terminal Block

Control I/O Terminal Block Wire Specifications

Frame A...E

Maximum Wire Size(1) 1.3 mm2 (16 AWG)

Minimum Wire Size(1) 0.13 mm2 (26 AWG)

Torque 0.71...0.86 N·m (6.2...7.6 lb·in)

(1) Maximum/minimum sizes that the terminal block will accept  these are not recommendations.

PowerFlex 523 Control I/O Terminal Block
PowerFlex 523 Series A Control I/O Wiring Block Diagram

Series A

SNK

SRC

Stop (1)

01 02

DStiagrInt/TReurnmFBWlkD02/(2) DigIn TermBlk 03/

03 Direction/Run REV

Typical Typical SRC wiring SNK wiring

Digital Common 04

DigIn TermBlk 05/Pulse 05

DigIn TermBlk 06 06

Relay N.O. R1 Relay Common R2
Relay N.C. R3

+24V

+24V DC

11

+10V

+10V DC 12

0-10V Input 13

Analog Common 14

15 4-20mA Input

C1 RJ45 Shield

Comm Common C2

Pot must be 1...10 k ohm 2 W min.

Digital In DigIn TermBlk 05 Sel

J8

J7

SNK

Pulse In

RS485

(DSI)

81

R1 R2

SRC

Digital

Input

01 02 03 04 05 06

R3

11 12 13 14 15 C1 C2

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PowerFlex 523 Series B Control I/O Wiring Block Diagram

Series B
Relay N.O. R1 Relay Common R2
Relay N.C. R3

SNK

SRC

01 02

Stop (1) DStiagrInt/TReurnmFBWlkD02/(2) DigIn TermBlk 03/

03 Direction/Run REV

Typical Typical SRC wiring SNK wiring

04 Digital Common

DigIn TermBlk 05/Pulse 05

DigIn TermBlk 06 06

+24V 11
+10V 12 0-10V
13 4-20 mA
14 0-10V
15 0/4-20 mA
C1
C2

+24V DC +10V DC Analog Input Analog Common Analog Output (3) RJ45 Shield Comm Common

13
14
Pot must be (4) 4-20 mA 1...10 k ohm source 2 W min.

Analog In Analog Out Digital In DigIn TermBlk 05 Sel

J4

J13 J8

J7

4-20 mA 0/4-20 mA SNK Pulse In

RS485

(DSI)

81

0-10V R1 R2

0-10V SRC

Digital Input

01 02 03 04 05 06

R3

11 12 13 14 15 C1 C2

Control I/O Wiring Block Diagram Notes
(1) See Digital Input Selection for Start Source on page 49 for more information on configuring the digital inputs.

IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is determined by the drive setting. See the tables below for more information.

Start Method P046, P048, P050 [Start Source x] 1 "Keypad" 2 "DigIn TrmBlk" 3 "Serial/DSI" 4 "Network Opt" 5 "EtherNet/IP" (1)

Stop Method I/O Terminal 01 Stop Coast See t062, t063 [DigIn TermBlk xx] below Coast Coast Coast

(1) Setting is specific to PowerFlex 525 drives only.

Normal Stop Per P045 [Stop Mode]

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Start Method t062, t063 [DigIn TermBlk xx] 48 "2-Wire FWD" 49 "3-Wire Start" 50 "2-Wire REV" 51 "3-Wire Dir"

Stop Method
I/O Terminal 01 Stop
t064 [2-Wire Mode] is set to: · 0, 1, or 2 = Coast · 3 = per P045 [Stop Mode]
Per P045 [Stop Mode]
t064 [2-Wire Mode] is set to: · 0, 1, or 2 = Coast · 3 = per P045 [Stop Mode]
Per P045 [Stop Mode]

Normal Stop Per P045 [Stop Mode]

IMPORTANT The drive is shipped with a jumper installed between I/O Terminals 01 and 11. Remove this jumper when using I/O Terminal 01 as a stop or enable input.

(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a
maintained input for I/O Terminal 03 to change direction. (3) Analog output (terminal 15) is only available on PowerFlex 523 series B drive, and requires firmware 3.001 and later to configure the
analog output parameters (t088, t089, and t090).
(4) Potentiometer connection is only applicable when the 0...10V setting (default) is selected for jumper J4.
(5) Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an undetermined frequency reference will result.

Control I/O Terminal Designations

No. Signal R1 Relay N.O. R2 Relay Common R3 Relay N.C.
01 Stop

Default Fault Fault Fault
Coast

02

DigIn TermBlk 02/ Start/Run FWD

Run FWD

03

DigIn TermBlk 03/ Dir/Run REV

Run REV

04 Digital Common 

05

DigIn TermBlk 05/ Pulse In

Preset Freq

06 DigIn TermBlk 06 Preset Freq

11 +24V DC



12 +10V DC



Description

Parameter

Normally open contact for output relay.

Common for output relay.

t076

Normally closed contact for output relay.

Three wire stop. However, it functions as a stop under all input modes and cannot be disabled.

P045(1)

Used to initiate motion and also can be used as a programmable digital input. It can be programmed with t062 P045, P046, [DigIn TermBlk 02] as three wire (Start/Dir with Stop) or two P048, P050, wire (Run FWD/Run REV) control. Current consumption is 6 A544, t062 mA.

Used to initiate motion and also can be used as a programmable digital input. It can be programmed with t063 [DigIn TermBlk 03] as three wire (Start/Dir with Stop) or two t063 wire (Run FWD/Run REV) control. Current consumption is 6 mA.

Return for digital I/O. Electrically isolated (along with the digital I/O) from the rest of the drive.



Program with t065 [DigIn TermBlk 05]. Also functions as a Pulse Train input for reference or speed feedback. Requires an NPN pulse input. The maximum t065 frequency is 100 kHz. Current consumption is 6 mA.

Program with t066 [DigIn TermBlk 06]. Current consumption is 6 mA.

t066

Referenced to Digital Common.

Drive supplied power for digital inputs.



Maximum output current is 100 mA.

Referenced to Analog Common. Drive supplied power for 0...10V external potentiometer. Maximum output current is 15 mA.

P047, P049

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Control I/O Terminal Designations (Continued)

No. Signal For Series A 0...10V In(2)
13 For Series B Analog Input
14 Analog Common For Series A 4...20 mA In(2)
15 For Series B Analog Output
C1 C1 C2 C2

Default

Description

Parameter

Not Active

For external 0...10V (unipolar) input supply or potentiometer P047, P049,

wiper.

t062, t063,

Input impedance:

t065, t066,

Voltage source = 100 k

t093, A459,

Allowable potentiometer resistance range = 1...10 k A471

Not Active

External analog input supply, selectable by Analog Input

jumper. Default is 0...10V (unipolar) input supply or potentiometer wiper. Input impedance:
Voltage source = 100 k Allowable potentiometer resistance range = 1...10 k Change Analog Input jumper to 4...20 mA for external 4...20

P047, P049, t062, t063, t065, t066, t093, A459, A471

mA input supply. Input impedance = 250 



Return for the analog I/O. Electrically isolated (along with the analog I/O) from the rest of the drive.



Not Active

For external 4...20 mA input supply. Input impedance = 250 

P047, P049, t062, t063, t065, t066, A459, A471

The default analog output is 0...10V. To convert a current

value, change the Analog Output jumper to 0...20 mA.

Program with t088 [Analog Out Sel]. Maximum analog value

OutFreq 0...10 can be scaled with t089 [Analog Out High].

t088, t089

Maximum Load:

4...20 mA = 525  (10.5V)

0...10V = 1 k (10 mA)

This terminal is tied to the RJ-45 port shield. Tie this



terminal to a clean ground in order to improve noise



immunity when using external communication peripherals.



This is the signal common for the communication signals. 

(1) Setting is specific to PowerFlex 525 drives only. (2) Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an
undetermined frequency reference will result.

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PowerFlex 525 Control I/O Terminal Block

PowerFlex 525 Control I/O Wiring Block Diagram

Safety 1 S1 Safety 2 S2 Safety +24V S+

Safe-Torque-O

Relay 1 N.O. R1 Relay 1 Common R2
Relay 2 Common R5 Relay 2 N.C. R6

J10 0/4-20mA

J9 Pulse In

SNK

SRC

+24V +10V
0-10V 0/4-20 mA 30V DC 50 mA Non-inductive

01 02

Stop (1) DStiagrInt/TReurnmFBWlkD02/(2) DigIn TermBlk 03/

03 Direction/Run REV

Typical Typical SRC wiring SNK wiring

04 Digital Common

DigIn TermBlk 05 05

DigIn TermBlk 06 06

07 DigIn TermBlk 07/Pulse

08 DigIn TermBlk 08

+24V DC 11
+10V DC 12
0-10V (or ±10V) Input 13
Analog Common 14
4-20mA Input 15
Analog Output 16
Opto Output 1 17
Opto Output 2 18
19 Opto Common

Pot must be 1...10 k ohm 2 W min.
24V (3) Common

C1 RJ45 Shield C2 Comm Common J5 SNK

Analog Out DigIn TermBlk 07 Sel
Digital In

0-10V

Digital SRC

Input

R1 R2 R5 R6

01 02 03 04 05 06 07 08

C1 C2

S1 S2 S+ 11 12 13 14 15 16 17 18 19
Control I/O Wiring Block Diagram Notes
(1) See Digital Input Selection for Start Source on page 49 for more information on configuring the digital inputs.
IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is determined by the drive setting. See the tables below for more information.

Start Method P046, P048, P050 [Start Source x] 1 "Keypad" 2 "DigIn TrmBlk" 3 "Serial/DSI" 4 "Network Opt" 5 "EtherNet/IP"

Stop Method I/O Terminal 01 Stop Coast See t062, t063 [DigIn TermBlk xx] below Coast Coast Coast

Normal Stop Per P045 [Stop Mode]

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Chapter 1 Installation/Wiring 42

C
Start Method t062, t063 [DigIn TermBlk xx] 48 "2-Wire FWD" 49 "3-Wire Start" 50 "2-Wire REV" 51 "3-Wire Dir"

Stop Method
I/O Terminal 01 Stop
t064 [2-Wire Mode] is set to: · 0, 1, or 2 = Coast · 3 = per P045 [Stop Mode]
Per P045 [Stop Mode]
t064 [2-Wire Mode] is set to: · 0, 1, or 2 = Coast · 3 = per P045 [Stop Mode]
Per P045 [Stop Mode]

Normal Stop Per P045 [Stop Mode]

IMPORTANT The drive is shipped with a jumper installed between I/O Terminals 01 and 11. Remove this jumper when using I/O Terminal 01 as a stop or enable input.

(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a maintained input for I/O 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 I/O Terminal Designations

No. Signal R1 Relay 1 N.O. R2 Relay 1 Common R5 Relay 2 Common R6 Relay 2 N.C.
01 Stop

02

DigIn TermBlk 02/ Start/Run FWD

03

DigIn TermBlk 03/ Dir/Run REV

04 Digital Common 05 DigIn TermBlk 05 06 DigIn TermBlk 06

07

DigIn TermBlk 07/ Pulse In

08 DigIn TermBlk 08

C1 C1
C2 C2 S1 Safety 1 S2 Safety 2 S+ Safety +24V

11 +24V DC

Default

Description

Parameter

Fault

Normally open contact for output relay.

Fault

Common for output relay.

t076

Motor Running Common for output relay.

t081

Motor Running Normally closed contact for output relay.

Coast

Three wire stop. However, it functions as a stop under all input modes and cannot be disabled.

P045(1)

Run FWD

Used to initiate motion and also can be used as a programmable digital input. It can be programmed with t062 P045, P046, [DigIn TermBlk 02] as three wire (Start/Dir with Stop) or two P048, P050, wire (Run FWD/Run REV) control. Current consumption is 6 A544, t062 mA.

Run REV

Used to initiate motion and also can be used as a programmable digital input. It can be programmed with t063 [DigIn TermBlk 03] as three wire (Start/Dir with Stop) or two t063 wire (Run FWD/Run REV) control. Current consumption is 6 mA.



Return for digital I/O. Electrically isolated (along with the digital I/O) from the rest of the drive.



Preset Freq

Program with t065 [DigIn TermBlk 05]. Current consumption is 6 mA.

t065

Preset Freq

Program with t066 [DigIn TermBlk 06]. Current consumption is 6 mA.

t066

Start Source 2 + Speed Reference2

Program with t067 [DigIn TermBlk 07]. Also functions as a Pulse Train input for reference or speed feedback. Requires an NPN pulse input. Maximum frequency is 100 kHz. Current consumption is 6 mA.

t067

Jog Forward

Program with t068 [DigIn TermBlk 08]. Current consumption is 6 mA.

t068

This terminal is tied to the RJ-45 port shield. Tie this



terminal to a clean ground in order to improve noise



immunity when using external communication peripherals.



This is the signal common for the communication signals. 



Safety input 1. Current consumption is 6 mA.





Safety input 2. Current consumption is 6 mA.





+24V supply for safety circuit. Internally tied to the +24V DC source (Pin 11).



Referenced to Digital Common.



Drive supplied power for digital inputs.



Maximum output current is 100 mA.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 Installation/Wiring

Control I/O Terminal Designations (Continued)

No. Signal 12 +10V DC 13 ±10V In 14 Analog Common 15 4...20mA In
16 Analog Output
17 Opto Output 1 18 Opto Output 2 19 Opto Common

Default

Description

Parameter

Referenced to Analog Common.



Drive supplied power for 0...10V external potentiometer. P047, P049

Maximum output current is 15 mA.

Not Active

For external 0...10V (unipolar) or ±10V (bipolar) input supply or potentiometer wiper. Input impedance:
Voltage source = 100 k Allowable potentiometer resistance range = 1...10 k

P047, P049, t062, t063, t065, t066, t093, A459, A471



Return for the analog I/O. Electrically isolated (along with the analog I/O) from the rest of the drive.



Not Active

For external 4...20 mA input supply. Input impedance = 250 

P047, P049, t062, t063, t065, t066, A459, A471

The default analog output is 0...10V. To convert a current

value, change the Analog Output jumper to 0...20 mA.

Program with t088 [Analog Out Sel]. Maximum analog value

OutFreq 0...10 can be scaled with t089 [Analog Out High].

t088, t089

Maximum Load:

4...20 mA = 525  (10.5V)

0...10V = 1 k (10 mA)

Motor Running

Program with t069 [Opto Out1 Sel]. Each Opto-Output is rated 30V DC 50 mA (Non-inductive).

t069, t070, t075

At Frequency

Program with t072 [Opto Out1 Sel]. Each Opto-Output is rated 30V DC 50 mA (Non-inductive).

t072, t073, t075

The emitters of the Optocoupler Outputs (1 and 2) are tied



together at Optocoupler Common. Electrically isolated from 

the rest of the drive.

(1) Setting is specific to PowerFlex 525 drives only.

I/O Wiring Examples

I/O

Connection Example

P047 [Speed Reference1] = 5 "0-10V Input"

12

Potentiometer

13

1...10 k Pot.

14

Recommended

(2 W minimum)

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

43

Chapter 1 Installation/Wiring

I/O Wiring Examples (Continued)

I/O (Continued)

Connection Example Bipolar P047 [Speed Reference1] = 5 "0-10V Input" and t093 [10V Bipolar Enbl] = 1 "Bi-Polar In"

Unipolar (Voltage) P047 [Speed Reference1] = 5 "0-10V Input"

±10V 13 Common 14

+ 13 Common 14

Analog Input 0...10V, 100k  impedance 4...20 mA, 250  impedance

Unipolar (Current) P047 [Speed Reference1] = 6 "4-20mA Input"

PowerFlex 523 Series A, PowerFlex 525

PowerFlex 523 Series B

Common 14 + 15

+ 13 Common 14

Analog In

4-20 mA 0-10V

Wire the PTC and External Resistor (typically matched to the PTC Hot Resistance) to I/O Terminals 12, 13, 14. Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11. t065 [DigIn TermBlk 05] = 12 "Aux Fault" t081 [Relay Out 2 Sel] = 10 "Above Anlg V" t082 [Relay Out 2 Level] = % Voltage Trip

Analog Input, PTC For Drive Fault
Re RPTC

R5 R6
11 12 13 14

%VTrip

=

RPTC (hot) RPTC (hot) + Re

X 100

05

Pulse Train Input PowerFlex 523

PowerFlex 523

PowerFlex 525

t065 [DigIn TermBlk 05]

= 52

DigIn TermBlk 05 Sel DigIn TermBlk 07 Sel

PowerFlex 525

t067 [DigIn TermBlk 07]

Pulse In

Pulse In

= 52

Common

04

Common

04

Use P047, P049 and P051 Pulse In [Speed Referencex] to select pulse input.

05 Digital Input

Pulse In

Digital

07

Input

Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse

The device connected to terminal 5 (for PowerFlex 523) or terminal 7 (for PowerFlex 525) needs to be NPN or push-pull output driver.

In.

44

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

I/O Wiring Examples (Continued)

I/O (Continued)

Connection Example

2 Wire SRC Control - Internal Supply (SRC)

Non-Reversing

P046 [Start Source 1] = 2

and t062 [DigIn TermBlk

02] = 48 Input must be active for

11

the drive to run. When

01

input is opened, the

Stop-Run

02

drive will stop as

specified by P045 [Stop

Mode].

If desired, a User

Supplied 24V DC power

source can be used. See

the "External Supply

(SRC)" example.

Internal Supply (SNK)

01

2 Wire SNK Control Non-Reversing

Stop-Run

02 03 04

2 Wire SRC Control - Internal Supply (SRC)

Run FWD/Run REV

P046 [Start Source 1] =

2, t062 [DigIn TermBlk

02]

= 48 and t063 [DigIn

11

TermBlk 03] = 50

Input must be active for

01

the drive to run. When

02

input is opened, the

Stop-Run

03

drive will stop as

Forward

specified by P045 [Stop

Mode].

Stop-Run

If both Run Forward and

Reverse

Run Reverse inputs are

closed at the same time,

an undetermined state

could occur.

Internal Supply (SNK)

01

2 Wire SNK Control Run FWD/Run REV

Stop-Run Forward

02 03 04

Stop-Run Reverse

3 Wire SRC Control - Internal Supply (SRC)

Non-Reversing

P046 [Start Source 1] =

2, t062 [DigIn TermBlk

Stop 11

02]

= 49 and t063 [DigIn TermBlk 03] = 51

Start

01 02

A momentary input will

start the drive. A stop

input to I/O Terminal 01

will stop the drive as

specified by P045 [Stop

Mode].

Chapter 1 Installation/Wiring
External Supply (SRC)
01 02 Stop-Run 04 +24V Common
Each digital input draws 6 mA.

External Supply (SRC)

01

02

Stop-Run Forward

03

04

Stop-Run Reverse

+24V Common

Each digital input draws 6 mA.

External Supply (SRC)

Stop

01

02

Start

04

+24V Common

Each digital input draws 6 mA.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

45

Chapter 1 Installation/Wiring 46

I/O Wiring Examples (Continued)

I/O (Continued)

Connection Example Internal Supply (SNK)

Stop

01

3 Wire SNK Control -

02

Non-Reversing

Start

04

3 Wire SRC Control - Internal Supply (SRC)

Reversing

P046 [Start Source 1] =

2, t062 [DigIn TermBlk

11

02]

= 49 and t063 [DigIn

Stop

01

TermBlk 03] = 51

02

A momentary input will

start the drive. A stop

Start

03

input to I/O Terminal 01 will stop the drive as

Direction

specified by P045 [Stop

Mode]. I/O Terminal 03

determines direction.

Internal Supply (SNK)

Stop

01

3 Wire SNK Control -

02

Reversing

Start

03 04

Direction

External Supply (SRC)

Stop

01

02

Start

03 04

Direction

+24V Common

Each digital input draws 6 mA.

Opto Output (1 & 2)(1) Opto-Output 1

t069 [Opto Out1 Sel]

determines Opto-Output

1 (I/O Terminal 17)

operation.

t072 [Opto Out2 Sel]

determines Opto-Output

2 (I/O Terminal 18)

17

operation. When using Opto-Output

CR

19

with an inductive load such as a relay, install a +24V Common

recovery diode parallel

to the relay as shown, to prevent damage to the

Each Opto-Output is rated 30V DC 50 mA (Non-inductive).

output.

Analog Output(2) t088 [Analog Out Sel] determines analog output type and drive conditions. 0...10V,1k  min 0...20 mA/4...20 mA, 525  0...20 mA/ 4...20 mA, 525  max

t088 [Analog Out Sel] = 0...23 The Analog Output Select jumper must be set to match the analog output signal mode set in t088 [Analog Out Sel].

PowerFlex 523 Series B

PowerFlex 525

Common 14 + 15

Common 14 + 16

(1) Feature is specific to PowerFlex 525 drives only. (2) Feature is not applicable to PowerFlex 523 series A drives.

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Typical Multiple Drive Connection Examples

Input/Output

Connection Example
02 04

02 04

Chapter 1 Installation/Wiring
02 04

Multiple Digital Input Connections Customer Inputs can be wired per External Supply (SRC).

Customer Inputs

Optional Ground Connection

When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O 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 I/O Terminal 04 should be connected.

ATTENTION: I/O 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 I/O Common connection may occur.

Multiple Analog Connections

12 13 14

13 14

13 14

Remote Potentiometer

Optional Ground Connection

When connecting a single potentiometer to multiple drives it is important to connect I/O Terminal 14 common together for all drives. I/O Terminal 14 common and I/O 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.

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47

Chapter 1 Installation/Wiring

Start and Speed Reference Control

Start Source and Speed Reference Selection
The start and drive speed command can be obtained from a number of different sources. By default, start source is determined by P046 [Start Source 1] and drive speed source is determined by P047 [Speed Reference1]. However, various inputs can override this selection, See below for the override priority.

Purge Input Enabled Yes AND Active

Drive will start and run at Purge Speed.
Direction is always FORWARD.

No
Jog Input Enabled Yes AND Active No No

Drive stopped (NOT running)

Drive will start and run at Jog Speed.

Yes

Direction is from Terminal Block REV terminal (03),

Comms,

OR

FWD/REV determined by

Jog FWD/Jog REV command.

Preset Inputs Active Yes

[Speed Referencex] = 11 or 12 (PIDx Output)
AND [PID x Ref Sel] = 7 (Preset Freq)

No

No

Run as specified by [Preset Freq x].

Start and Direction commands come from
[Start Source x].

Yes
Run as specified by [PIDx Output].
Start and Direction commands come from
[Start Source x].

Run as specified by Yes [Speed Reference3]

[Speed Reference3].

select(1)

[Start Source 3]

Yes

Start and Direction command from

select(1)

[Start Source 3].(2)

No

No

Run as specified by Yes [Speed Reference2]

[Speed Reference2].

select(1)

[Start Source 2]

Yes

Start and Direction command from

select(1)

[Start Source 2].(2)

No

No

Run as specified by [Speed Reference1].

Start and Direction command from [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 49 for information on selecting the correct digital input.

48

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 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 TermBlk xx] must be configured for 2-Wire or 3-Wire control for the drive to function properly.
[Start Source x]

[Start Source x] = 2 (DigIn TrmBlk)

Yes

[DigIn TermBlk 02/03] = 48/49/50/51

Yes

(2-Wire or

Start and Direction command from Terminal Block.

3-Wire)

No

No

Start and Direction command from [Start Source x].

Drive will not start.

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].

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49

Chapter 1 Installation/Wiring

Alternative Accel/Decel rates can be made through digital inputs, communications and/or parameters. See below for the override priority.

Purge Input Enabled Yes Accel/Decel always

AND Active

Accel/Decel 1.

No

Active [DigIn TermBlk xx] Yes [Sync Time] is used

= 32 (Sync Enable)

for Accel/Decel rate

No

Traverse active if [Max Traverse] > 0 Hz

Yes

Traverse Inc/Dec is used for

Accel/Decel rate

No

Terminal Block Jog Input Enabled AND
Active
No
Input(s) is programmed as
Acc/Dec (2/3/4)
No

Yes

Drive stopped

Yes Accel/Decel from

(NOT running)

[Jog Acc/Dec].

No

Yes

Accel/Decel 2 is active when input is selected

by Accel and Decel input.

Is speed controlled by [Preset Freq x]

Yes

Accel/Decel 1/2/3/4 is selected by the default

[Preset Freq x] setting.

No
Active [Speed Referencex]
= Comms and
[Start Source x] = 3"Serial/DSI"or
4"Network Opt"or 5 "EtherNet/IP"
No

Yes

Accel/Decel 1 or 2 is selected according

to Comms.

Active [Speed Referencex] = 13 (Step Logic)(1)
No
Drive uses Accel 1 and Decel 1.

Yes

Accel/Decel 1/2/3/4 is selected according to

Step Logic

(1) Setting is specific to PowerFlex 525 drives only.

50

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

CE Conformity

Chapter 1 Installation/Wiring
Compliance with the Low Voltage Directive and Electromagnetic Compatibility Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex 520-series drives comply with the EN standards listed below when installed according to the installation instructions in this manual.
CE Declarations of Conformity are available online at: rok.auto/certifications.

Low Voltage Directive (2014/35/EU)

· 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 Degree 1
2

Description
No pollution or only dry, non-conductive pollution occurs. The pollution has no influence. 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 (2014/30/EU)
· EN 61800-3  Adjustable speed electrical power drive systems - Part 3: EMC requirements and specific test methods
Machinery Directive (2006/42/EC)
· EN ISO 13849-1  Safety of machinery  Safety related parts of control systems -Part 1: General principles for design
· EN 62061  Safety of machinery  Functional safety of safety-related electrical, electronic and programmable electronic control systems
· EN 60204-1  Safety of machinery  Electrical equipment of machines Part 1: General requirements
· EN 61800-5-2  Adjustable speed electrical power drive systems - Part 5-2: Safety requirement  Functional
See Appendix G for installation consideration related to Machinery Directive.

ATEX Directive (2014/34/EU)
· EN 50495  Safety devices required for the safe functioning of equipment with respect to explosion risks.

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51

Chapter 1 Installation/Wiring

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 520-series drives must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive. See Pollution Degree Ratings According to EN 61800-5-1 on page 51 for descriptions of each pollution degree rating.
· PowerFlex 520-series drives comply with the EMC requirements of EN 61800-3 when installed according to good EMC practices and the instructions provided in this document. However, many factors can influence the EMC compliance of an entire machine or installation, and compliance of the drive itself does not ensure compliance of all applications.
· PowerFlex 520-series drives are not intended to be used on public lowvoltage networks which supply domestic premises. Without additional mitigation, radio frequency interference is expected if used on such a network. The installer is responsible for taking measures such as a supplementary line filter and enclosure (see Connections and Grounding on page 54) to prevent interference, in addition to the installation requirements of this document.
ATTENTION: NEMA/UL Open Type drives must either be installed in a supplementary enclosure or equipped with a "NEMA Type 1 Kit" to be CE compliant with respect to protection against electrical shock.
· PowerFlex 520-series drives generate harmonic current emissions on the AC supply system. When operated on a public low-voltage network it is the responsibility of the installer or user to ensure that applicable requirements of the distribution network operator have been met. Consultation with the network operator and Rockwell Automation may be necessary.
· If the optional NEMA 1 kit is not installed, the drive must be installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV Directive.
· The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents.
· Use of line filters in ungrounded systems is not recommended. · In CE installations, input power must be a Balanced Wye with Center
Ground configuration for EMC compliance.
Installation Requirements Related to EN 61800-5-1 and the Low Voltage Directive
· 600V PowerFlex 520-series drives can only be used on a "center grounded" supply system for altitudes up to and including 2000 m (6562 ft).
· When used at altitudes above 2000 m (6562 ft) up to a maximum of 4800 m (15,748 ft), PowerFlex 520-series drives of voltage classes up to 480V may not be powered from a "corner-earthed" supply system in order to maintain compliance with the CE LV Directive. See Derating Guidelines for High Altitude on page 18.

52

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 1 Installation/Wiring
· PowerFlex 520-series drives produce leakage current in the protective earthing conductor which exceeds 3.5 mA AC and/or 10 mA DC. The minimum size of the protective earthing (grounding) conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment.
ATTENTION: PowerFlex 520-series drives produce DC current in the protective earthing conductor which may reduce the ability of RCD's (residual current-operated protective devices) or RCM's (residual current-operated monitoring devices) of type A or AC to provide protection for other equipment in the installation. Where an RCD or RCM is used for protection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed on the supply side of this product.
Installation Requirements Related to EN 61800-3 and the EMC Directive
· The drive must be earthed (grounded) as described in Connections and Grounding on page 54. See General Grounding Requirements on page 20 for additional grounding recommendations.
· Output power wiring to the motor must employ cables with a braided shield providing 75% 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.
· 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.
· All control (I/O) and signal wiring to the drive must use cable with a braided shield providing 75% 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 receiver is located. When the cable shield is terminated at the drive end, it may be terminated either by using a shielded connector in conjunction with a conduit plate or conduit box, or the shield may be clamped to an "EMC plate."
· Motor cabling must be separated from control and signal wiring wherever possible.
· Maximum motor cable length must not exceed the maximum length indicated in PowerFlex 520-Series RF Emission Compliance and Installation Requirements on page 54 for compliance with radio frequency emission limits for the specific standard and installation environment.

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Chapter 1 Installation/Wiring

Connections and Grounding
Shielded enclosure(1)
Esc Sel

IP 30/NEMA 1/UL Type 1 option kit or EMC kit

EMI filter L1 L1' R/L1 L2 L2' S/L2 L3 L3' T/L3 Enclosure ground connection

EMI fittings and metal conduit U/T1 V/T2 W/T3
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 and the EMI filter.
PowerFlex 520-Series RF Emission Compliance and Installation Requirements

Filter Type
Internal External(1)

Standard/Limits EN61800-3 Category C1 EN61000-6-3 CISPR11 Group 1 Class B  30 m (16 ft)

EN61800-3 Category C2 EN61000-6-4 CISPR11 Group 1 Class A (Input power  20 kVA) 10 m (33 ft) 100 m (328 ft)

EN61800-3 Category C3 (I  100 A) CISPR11 Group 1 Class A (Input power > 20 kVA) 20 m (66 ft) 100 m (328 ft)

(1) See EMC Line Filters on page 175 and page 195 for more information on optional external filters.

Additional Installation Requirements

This section provides information on additional requirements for category C1 and C2 installation, such as enclosures and EMC cores.
IMPORTANT EMC cores are included with: · drives that have an internal EMC filter (25x-xxxxN114) · external EMC filter accessory kit (25-RFxxx)

IMPORTANT An enclosure, shielded input cable, and EMC cores are not required to meet category C3 requirements.

Additional Installation Requirements

Frame Category C1 Size Enclosure

Conduit or Shielded EMC Cores Required

Cable @ Input

(Included with product)

Category C2 Enclosure

100...120V AC (-15%, +10%)  1-Phase Input with External EMC Filter, 0...120V 1-Phase Output

A

No

No

No

No

B

No

No

No

No

200...240V AC (-15%, +10%)  1-Phase Input with External EMC Filter, 0...230V 3-Phase Output

A

Yes

Yes

No

No

B

Yes

Yes

Output only

No

200...240V AC (-15%, +10%)  1-Phase Input with Internal EMC Filter, 0...230V 3-Phase Output(1)

A

*

*

*

Yes

B

*

*

*

Yes

Conduit or Shielded EMC Cores Required

Cable @ Input

(Included with product)

No

No

No

No

No

Input/Output

No

Input/Output

No

No

No

No

54

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Chapter 1 Installation/Wiring

Additional Installation Requirements (Continued)

Category C1 Frame Size Enclosure

Conduit or Shielded EMC Cores Required

Cable @ Input

(Included with product)

Category C2 Enclosure

200...240V AC (-15%, +10%)  3-Phase Input with External EMC Filter, 0...230V 3-Phase Output

A

Yes

Yes

Output only

No

B

Yes

Yes

Output only

No

C

Yes

Yes

Output only

No

D

Yes

Yes

No

No

E

Yes

Yes

Output only

No

380...480V AC (-15%, +10%)  3-Phase Input with External EMC Filter, 0...460V 3-Phase Output

A

Yes

Yes

No

No

B

Yes

Yes

No

No

C

Yes

Yes

No

No

D

Yes

Yes

Output only

No

E

Yes

Yes

No

Yes

380...480V AC (-15%, +10%)  3-Phase Input with Internal EMC Filter, 0...460V 3-Phase Output(1)

A

*

*

*

No

B

*

*

*

No

C

*

*

*

No

D

*

*

*

No

E

*

*

*

No

525...600V AC (-15%, +10%)  3-Phase Input with External EMC Filter, 0...575V 3-Phase Output

A

Yes

Yes

No

No

B

Yes

Yes

No

No

C

Yes

Yes

No

No

D

Yes

Yes

No

No

E

Yes

Yes

No

Yes

(1) An (*) indicates that EMC requirements are not met.

Recommended Placement of EMC Cores

Frame A

Frame B

With optional EMC plate (25-EMC-Fx)

Frame C

Frame D

Conduit or Shielded EMC Cores Required

Cable @ Input

(Included with product)

No

Input/Output

No

Input/Output

No

Input/Output

No

Input only

No

Input only

No

Input/Output

No

Input/Output

No

Input only

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

Input/Output

No

No

Frame E
Ground cable

CORE-xx-A-1 CORE-xx-A-2
Without EMC plate

CORE-xx-B-1 CORE-xx-B-2

CORE-xx-C-1 CORE-xx-C-2

CORE-xx-D-1 CORE-xx-D-2

CORE-E-1 CORE-E-2

Ground cable

CORE-xx-x-1

CORE-xx-x-2

Input cable to drive (Shielded or Unshielded)

Shows contact to shielded layer

CORE-E-1
CORE-E-2
Output cable from drive (Shielded) Secure EMC core by using cable/zip ties

CORE-E-3 CORE-E-4
CORE-E-3 CORE-E-4

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55

Chapter 1 Installation/Wiring

IMPORTANT The ground cable/shield for both input and output must pass through the EMC core(s), except for the following: · Frame E drives with internal filters where the grounded input cable must not pass through EMC CORE-E-1. · 600V drives with external filters where the grounded output cable must not pass through the EMC core(s).

Recommended Placement of EMC Cores Relative to External Filter

All Frame sizes

Incoming power

EMC Filter

Drive

Motor

Input core

Output core

56

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Start Up

2 Chapter

This chapter describes how to start up the PowerFlex 520-series drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group.

Topic

Page

Prepare for Drive Startup

57

Display and Control Keys

59

Viewing and Editing Parameters

61

Drive Programming Tools

62

Smart Startup with Basic Program Group Parameters

63

LCD Display with QuickView Technology

65

Using the USB Port

65

IMPORTANT Read the General Precautions on page 13 section before proceeding.

ATTENTION: Power must be applied to the drive to perform the following 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.

Prepare for Drive Startup

Drive Startup Task List
1. Disconnect and lock out power to the machine. 2. Verify that AC line power at the disconnect device is within the rated
value of the drive. 3. If replacing a drive, verify the current drive's catalog number. Verify all
options installed on the drive. 4. Verify that any digital control power is 24 volts. 5. Inspect grounding, wiring, connections, and environmental
compatibility. 6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your
control wiring scheme. See the PowerFlex 523 Control I/O Terminal Block on page 37 and PowerFlex 525 Control I/O Terminal Block on page 41 for location.

IMPORTANT

The default control scheme is Source (SRC). The Stop terminal is jumpered to allow starting from the keypad or comms. If the control scheme is changed to Sink (SNK), the jumper must be removed from I/O Terminals 01 and 11 and installed between I/O Terminals 01 and 04.

7. Wire I/O as required for the application.

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Chapter 2 Start Up

8. Wire the power input and output terminals. 9. Confirm that all inputs are connected to the correct terminals and are
secure. 10. Collect and record motor nameplate and encoder or feedback device
information. Verify motor connections. · Is the motor uncoupled? · What direction will the motor need to turn for the application? 11. Verify the input voltage to the drive. Verify if the drive is on a grounded system. Ensure the MOV jumpers are in the correct position. See AC Supply Source Considerations on page 19 for more information. 12. Apply power and reset the drive and communication adapters to factory default settings. To reset the drive, see parameter P053 [Reset to Defalts]. To reset the communication adapters, see the user manual of the adapter for more information. 13. Configure the basic program parameters related to the motor. See Smart Startup with Basic Program Group Parameters on page 63. 14. Complete the autotune procedure for the drive. See parameter P040 [Autotune] for more information. 15. If you are replacing a drive and have a backup of the parameter settings obtained using the USB utility application, use the USB utility application to apply the backup to the new drive. See Using the USB Port on page 65 for more information.
Otherwise, set the necessary parameters for your application using the LCD keypad interface, Connected Components WorkbenchTM software, or RSLogixTM, or Studio 5000 Logix Designer application if using an Add-on Profile through EtherNet/IP.
· Configure the communication parameters needed for the application (node number, IP address, Datalinks in and out, communication rate, speed reference, start source, and so on). Record these settings for your reference.
· Configure the other drive parameters needed for the drive analog and digital I/O to work correctly. Verify the operation. Record these settings for your reference.
16. Verify the drive and motor perform as specified. · Verify that the Stop input is present or the drive will not start.
IMPORTANT If I/O Terminal 01 is used as a stop input, the jumper between I/O Terminals 01 and 11 must be removed.
· Verify the drive is receiving the speed reference from the correct place and that the reference is scaled correctly.
· Verify the drive is receiving start and stop commands correctly. · Verify input currents are balanced. · Verify motor currents are balanced. 17. Save a backup of the drive settings using the USB utility application. See Using the USB Port on page 65 for more information.

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Chapter 2 Start Up
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 159 for an explanation of the fault code.

Variable Torque Fan/Pump Applications
For improved motor and drive performance, tune the motor in SVC mode using parameter P040 [Autotune]. If V/Hz mode is selected, use parameter A530 [Boost Select] to adjust the boost.

Display and Control Keys

PowerFlex 523

FWD

Esc Sel
PowerFlex 525
FWD
ENET LINK EtherNet/IP
Esc Sel

Menu Parameter Group and Description Basic Display Commonly viewed drive operating conditions. Basic Program Commonly used programmable functions. Terminal Blocks Programmable terminal functions. Communications Programmable communication functions. Logic (PowerFlex 525 only) Programmable logic functions. Advanced Display Advanced drive operating conditions. Advanced Program Remaining programmable functions. Network Network functions that are shown only when a comm card is used. Modified Functions from the other groups with values changed from default. Fault and Diagnostic Consists of list of codes for specific fault conditions. AppView and CustomView Functions from the other groups organized for specific applications.

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Chapter 2 Start Up

Control and Navigation Keys

Display ENET (PowerFlex 525 only) LINK (PowerFlex 525 only)

Display State Description

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.

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. Down Arrow Increment values.

Esc

Escape

Back one step in programming menu. Cancel a change to a parameter value and exit Program Mode.

Sel

Select

Advance one step in programming menu. Select a digit when viewing parameter value.

Enter

Advance one step in programming menu. Save a change to a parameter value.

Reverse Start Stop

Used to reverse direction of the drive. Default is active. Controlled by parameters P046, P048, and P050 [Start Source x] and A544 [Reverse Disable]. Used to start the drive. Default is active. Controlled by parameters P046, P048, and P050 [Start Source x]. Used to stop the drive or clear a fault. This key is always active. Controlled by parameter P045 [Stop Mode].

Used to control speed of drive. Default is active. Potentiometer Controlled by parameters P047, P049, and P051
[Speed Referencex].

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Viewing and Editing Parameters

Chapter 2 Start Up

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

Key

When power is applied, the last userselected Basic Display Group parameter number is briefly displayed with flashing 1. characters. The display then defaults to that parameter's current value. (Example shows the value of b001 [Output Freq] with the drive stopped.)

Example Display
FWD HERTZ

Press Esc to display the Basic Display

2. Group parameter number shown on power- Esc

FWD

up. The parameter number will flash.

3.

Press Esc to enter the parameter group list. The parameter group letter will flash.

Esc

Press the Up Arrow or Down Arrow to scroll 4. through the group list (b, P, t, C, L, d, A, f
and Gx). Press Enter or Sel to enter a group. The 5. right digit of the last viewed parameter in that group will flash.

or or Sel

6.

Press the Up Arrow or Down Arrow to scroll through the parameter list.

or

Press Enter to view the value of the

7.

parameter. Or

Press Esc to return to the parameter list.

Press Enter or Sel to enter Program Mode

8.

and edit the value. The right digit will flash and the word Program on the LCD display

will light up.

or Sel

9.

Press the Up Arrow or Down Arrow to change the parameter value.

If desired, press Sel to move from digit to 10. digit or bit to bit. The digit or bit that you
can change will flash. Press Esc to cancel a change and exit Program Mode. Or 11. Press Enter to save a change and exit Program Mode. The digit will stop flashing and the word Program on the LCD display will turn off. Press Esc to return to the parameter list. Continue to press Esc to back out of the programming menu. 12. If pressing Esc does not change the display, then b001 [Output Freq] is displayed. Press Enter or Sel to enter the group list again.

or Sel Esc or
Esc

FWD
FWD
FWD
FWD
VOLTS FWD
VOLTS FWD
PROGRAM
VOLTS FWD
PROGRAM VOLTS
FWD PROGRAM VOLTS
FWD
or
VOLTS FWD
FWD

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Chapter 2 Start Up
Drive Programming Tools

Some features in the PowerFlex 520-series drive are not supported by older configuration software tools. It is strongly recommended that customers using such tools migrate to RSLogix 5000 software (version 17.0 or greater) or Studio 5000 Logix Designer (version 21.0 or greater) application with Add-on Profile (AOP), or Connected Components Workbench software version 5.0 or later to enjoy a richer, full-featured configuration experience. For Automatic Device Configuration (ADC) support, RSLogix 5000 software version 20.0 or greater is required.

Description Connected Components Workbench(1) software Logix Designer application RSLogix 5000 software Built-in USB software tool Serial Converter Module(2) USB Converter Module(2) Remote Panel Mount, LCD Display(2) Remote Handheld, LCD Display(2)

Catalog Number/Release Version Version 5.0 or later Version 21.0 or later Version 17.0 or later  22-SCM-232 1203-USB 22-HIM-C2S 22-HIM-A3

(1) Available to download at rok.auto/ccw. (2) Does not support the new dynamic parameter groups (AppView®, CustomViewTM), and CopyCat functionality is limited to the linear
parameter list.

Language Support

Language
English French Spanish Italian German Japanese Portuguese Chinese Simplified Korean Polish(1) Turkish(1) Czech(1)

Keypad/LCD Display
Y Y Y Y Y  Y   Y
Y
Y

RSLogix 5000/

Connected Components

Logix Designer application Workbench software

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y



Y



Y

Y

Y















(1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified.

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Chapter 2 Start Up

Smart Startup with Basic Program Group Parameters

The PowerFlex 520-series drive is designed so that start up is simple and efficient. The Basic Program Group contains the most commonly used parameters. See Programming and Parameters on page 69 for detailed descriptions of the parameters listed here and the full list of available parameters.
Basic Program Group Parameters

= Stop drive before changing this parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only.

No. Parameter

Min/Max

Display/Options

[Language]

1/15

P030

Selects the language displayed. Important: The setting takes effect after the

drive is power cycled.

1 = English 2 = Français 3 = Español 4 = Italiano 5 = Deutsch 6 = Reserved 7 = Português 8 = Reserved 9 = Reserved 10 = Reserved 11 = Reserved 12 = Polish 13 = Reserved 14 = Turkish 15 = Czech

P031 [Motor NP Volts]

10V (for 200V Drives), 20V (for 400V Drives), 25V (for 600V Drives)/Drive Rated 1V Volts

Sets the motor nameplate rated volts.

P032 [Motor NP Hertz] 15/500 Hz

Sets the motor nameplate rated frequency.

1 Hz

P033

[Motor OL Current] 0.0/(Drive Rated Amps x 2) Sets the motor nameplate overload current.

0.1 A

P034

[Motor NP FLA] 0.0/(Drive Rated Amps x 2) Sets the motor nameplate FLA.

0.1 A

P035

[Motor NP Poles] 2/40 Sets the number of poles in the motor.

1

P036 [Motor NP RPM] 0/24000 rpm

Sets the rated nameplate rpm of motor.

1 rpm

P037 [Motor NP Power] 0.00/Drive Rated Power

PF 525

Sets the motor nameplate power. Used in PM regulator.

0.01 kW

[Torque Perf Mode]

0/4

Selects the motor control mode.

0 = "V/Hz"

(1) Setting is specific to PowerFlex 525 drives only. 1 = "SVC" P039 (2) Setting is available in PowerFlex 525 FRN 5.xxx 2 = "Economize"

and later. (3) When P039 [Torque Perf Mode] is set to 4 and
A535 [Motor Fdbk Type] is set to 0, 1, 2 or 3, the drive is in open loop PM motor control mode.

3 = "Vector"(1) 4 = "PM Control"(1)(2)(3) 5 = "SynRM"

When P039 [Torque Perf Mode] is set to 4 and

A535 [Motor Fdbk Type] is set to 4 or 5, the drive

is in closed loop PM motor control mode.

P040 [Autotune]

0/2

Enables a static (not spinning) or dynamic

(motor spinning) autotune.

0 = "Ready/Idle" 1 = "Static Tune" 2 = "Rotate Tune"

[Accel Time 1] 0.00/600.00 s P041 Sets the time for the drive to accel from 0 Hz 0.01 s
to [Maximum Freq].

Default
1
Based on Drive Rating 60 Hz Based on Drive Rating Drive Rated Amps 4 1750 rpm Drive Rated Power
1
0 10.00 s

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Chapter 2 Start Up 64

Basic Program Group Parameters (Continued)

= Stop drive before changing this parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only.

No. Parameter

Min/Max

Display/Options

[Decel Time 1] 0.00/600.00 s

P042 Sets the time for the drive to decel from

0.01 s

[Maximum Freq] to 0 Hz.

P043 [Minimum Freq] 0.00/500.00 Hz Sets the lowest frequency the drive outputs.

0.01 Hz

P044 [Maximum Freq] 0.00/500.00 Hz Sets the highest frequency the drive outputs.

0.01 Hz

[Stop Mode]

0/11

0= "Ramp, CF"(1)

1= "Coast, CF"(1)

Stop command for normal stop.

2= "DC Brake, CF"(1)

Important: I/O Terminal 01 is always a stop 3= "DCBrkAuto,CF"(1)

input. The stopping mode is determined by the 4= "Ramp"

P045

drive setting. Important: The drive is shipped with a jumper

5= "Coast" 6= "DC Brake"

installed between I/O Terminals 01 and 11.

7= "DC BrakeAuto"

Remove this jumper when using I/O Terminal 01 as a stop or enable input.

8= "Ramp+EM B,CF"(1) 9= "Ramp+EM Brk"

(1) Stop input also clears active fault.

10= "PointStp,CF"(1)

11= "PointStop"

[Start Source 1] 1/5

Sets the default control scheme used to start P046, the drive unless overriden by P048 [Start P048, Source 2] or P050 [Start Source 3]. P050 (1) When active, the Reverse key is also active
unless disabled by A544 [Reverse Disable]. (2) If "DigIn TrmBlk" is selected, ensure that the
digital inputs are properly configured. (3) Setting is specific to PowerFlex 525 drives only.

1 = "Keypad"(1) 2 = "DigIn TrmBlk"(2) 3 = "Serial/DSI" 4 = "Network Opt" 5 = "EtherNet/IP"(3)

[Speed Reference1]

1/16

P047, P049, P051

Sets the default speed command of the drive unless overridden by P049 [Speed Reference2] or P051 [Speed Reference3].

(1) Setting is specific to PowerFlex 525 drives only.

1= "Drive Pot" 2= "Keypad Freq" 3= "Serial/DSI" 4= "Network Opt" 5= "0-10V Input" 6= "4-20mA Input" 7= "Preset Freq" 8= "Anlg In Mult"(1) 9= "MOP" 10= "Pulse Input" 11= "PID1 Output" 12= "PID2 Output"(1) 13= "Step Logic"(1) 14= "Encoder"(1) 15= "EtherNet/IP"(1) 16= "Positioning"(1)

[Average kWh P052 Cost]

0.00/655.35

0.01

Sets the average cost per kWh.

[Reset To Defalts] 0/4

Resets parameters to their factory defaults values. After a Reset command, the value of P053 this parameter returns to zero.
(1) Power cycle of the drive, NO parameters are reset.
(2) Setting is available in PowerFlex 525 FRN 5.xxx and later.
(3) Setting is available in PowerFlex 523 FRN 3.xxx and later.

0 = "Ready/Idle" 1 = "Param Reset" 2 = "Factory Rset" 3 = "Power Reset" 4 = "Module Reset"(1)(2)(3)

Default 10.00 s 0.00 Hz 60.00 Hz
0
P046 = 1 P048 = 2 P050 = 3 (PowerFlex 523) 5 (PowerFlex 525)
P047 = 1 P049 = 5 P051 = 3 (PowerFlex 523) 15 (PowerFlex 525)
0.00 0

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Chapter 2 Start Up

LCD Display with QuickView Technology

QuickView® technology enables text to scroll across the LCD display of the PowerFlex 520-series drive. This allows you to easily configure parameters, troubleshoot faults and view diagnostic items without using a separate device.

Use parameter A556 [Text Scroll] to set the speed at which the text scrolls across the display. Select 0 "Off" to turn off text scrolling. See Language Support on page 62 for the languages supported by the PowerFlex 520-series drive.

Using the USB Port

The PowerFlex 520-series drive has a USB port that connects to a PC for the purpose of upgrading drive firmware or uploading/downloading a parameter configuration.
IMPORTANT PowerFlex 525 with firmware revision 7.001 and later supports the USB application with Windows® 8 and 10.

MainsFree Programming

The MainsFreeTM programming feature allows you to quickly configure your PowerFlex 520-series drive without having to power up the control module or install additional software. Simply connect the control module to your PC with a USB Type B cable and you can download a parameter configuration to your drive. You can also easily upgrade your drive with the latest firmware.

Connecting a PowerFlex 520-series drive to a PC
Control Module

USB Type B cable

USB port

Connect to PC

Connect to Control Module

When connected, the drive appears on the PC and contains two files:

· GUIDE.PDF This file contains links to relevant product documentation and software downloads.

·

PF52XUSB.EXE

This file is an application to flash upgrade firmware or upload/download

a parameter configuration.

It is not possible to delete these files or add more to the drive.

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Chapter 2 Start Up

Double-click the PF52XUSB.EXE file to launch the USB utility application. The main menu is displayed. Follow the program instructions to upgrade the firmware or upload/download configuration data.

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. Also, the drive type of the .pf5 file must match the drive.
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.

Using Drive Startup in CCW or Logix Designer application

To use the PowerFlex 525 Startup Wizard in Connected Components Workbench software to automatically configure the parameters, make sure you have installed the following:
· PowerFlex 525 drive firmware revision 5.001 or later. · PowerFlex 525 drive Add-on Profile 5.07 or later. · Latest drive database for Connected Components Workbench software.
For instructions, see Using Drive Startup in CCW or Logix Designer application on page 66.
Alternatively, you can manually configure the parameters by using the drive keypad. For instructions, see Manual Configuration Using Drive Keypad on page 256.

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Chapter 2 Start Up
1. From Connected Components Workbench software, click the Wizard Browser icon.

2. In the Available Wizards dialog box, click PowerFlex 525 Startup Wizard, then click Select.
3. Before tuning the drive, it is recommended to reset all parameters to their default values. Select the option shown below.

4. Complete each step in the Startup Wizard to configure the drive. IMPORTANT Follow the Startup Wizard steps exactly. If not, unexpected results can occur.

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Chapter 2 Start Up
Notes:

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Rockwell Automation Publication 520-UM001J-EN-E - April 2021

About Parameters

Programming and Parameters

3 Chapter

This chapter provides a complete listing and description of the PowerFlex 520series drive parameters. Parameters are programmed (viewed/edited) using either the drive's built-in keypad, RSLogix 5000 software version 17.0 or greater, Studio 5000 Logix Designer application version 21.0 or greater, or Connected Components Workbench software version 5.0 or later. 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 (DriveToolsTM SP). When using these methods, the parameter list can only be displayed linearly, and there is
no access to communications option card programming.

Topic

Page

About Parameters

69

Parameter Groups

71

Basic Display Group

76

Basic Program Group

82

Terminal Block Group

88

Communications Group

100

Logic Group

106

Advanced Display Group

109

Advanced Program Group

114

Network Parameter Group

142

Modified Parameter Group

142

Fault and Diagnostic Group

142

AppView Parameter Groups

150

CustomView Parameter Group

151

Parameter Cross Reference by Name

152

To configure a drive to operate in a specific way, drive parameters may have to be set. Three types of parameters exist:
· ENUM ENUM parameters allow a selection from two or more items. Each item is represented by a number.
· Numeric Parameters These parameters have a single numerical value (0.1V).
· 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.

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Chapter 3 Programming and Parameters

Some parameters are marked as follows.
= Stop drive before changing this parameter. 32 = 32 bit parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only.

32-bit Parameters

Parameters marked 32-bit will have two parameter numbers when using RS485 communications and programming software. For example, parameters b010 [Process Display] and b011 [Process Fract] are scaled and displayed as follows.
· P043 [Minimum Freq] = 0 Hz · P044 [Maximum Freq] = 60 Hz · A481 [Process Display Lo] = 0 · A482 [Process Display Hi] = 10

Using the formula
Scaled Process Value (PV) =

([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freqp]) [Maximum Freq] - [Minimum Freq]

when the drive is running at 10 Hz, the Process Value will be 1.66. On the drive LCD display, only parameter b010 [Process Display] is shown.

In Connected Components Workbench software, parameter b010 [Process Display] and b011 [Process Fract] are shown separately.

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Chapter 3 Programming and Parameters

Parameter Groups
Parameters List

For an alphabetical listing of parameters, see Parameter Cross Reference by Name on page 152.

Basic Display
Output Freq Commanded Freq Output Current

Output Voltage DC Bus Voltage Drive Status Fault 1 Code b001 Fault 2 Code b002 Fault 3 Code b003 Process Display

b004 Process Fract b005 Control Source b006 Contrl In Status b007 Dig In Status b008 Output RPM b009 Output Speed b010 Output Power

b011 Power Saved

b018 Accum Cost Sav

b025

b012 Elapsed Run Time

b019 Accum CO2 Sav

b026

b013 Average Power

b020 Drive Temp

b027

b014 Elapsed kWh

b021 Control Temp

b028

b015 Elapsed MWh

b022 Control SW Ver

b029

b016 Energy Saved

b023

b017 Accum kWh Sav

b024

Basic Program

Motor NP Hertz

P032 Torque Perf Mode

P039 Stop Mode

P045 Speed Reference3

P051

Motor OL Current

P033 Autotune

P040 Start Source 1

P046 Average kWh Cost

P052

Motor NP FLA

P034 Accel Time 1

P041 Speed Reference1

P047 Reset To Defalts

P053

Motor NP Poles

P035 Decel Time 1

P042 Start Source 2

P048 Display Param

P054

Language Motor NP Volts

P030 Motor NP RPM P031 Motor NP Power(1)

P036 Minimum Freq P037 Maximum Freq

P043 Speed Reference2

P049

P044 Start Source 3

P050

Terminal Blocks
DigIn TermBlk 02 DigIn TermBlk 03 2-Wire Mode

Opto Out1 Sel(1) Opto Out1 Level(1) Opto Out1 LevelF Opto Out2 Sel(1) t062 Opto Out2 Level(1) t063 Opto Out2 LevelF t064 Opto Out Logic(1)

t069 Relay 1 Off Time t070 Relay Out2 Sel(1) t071 Relay Out2 Level(1) t072 Relay Out2 LevelF(1) t073 Relay 2 On Time(1) t074 Relay 2 Off Time(1) t075 EM Brk Off Delay

t080 Anlg In 0-10V Lo t081 Anlg In 0-10V Hi t082 10V Bipolar Enbl(1) t083 Anlg In V Loss t084 Anlg In4-20mA Lo t085 Anlg In4-20mA Hi t086 Anlg In mA Loss

t091 Sleep Time

t102

t092 Wake Level

t103

t093 Wake Time

t104

t094 Safety Open En(1)

t105

t095 SafetyFlt RstCfg(1)(3)

t106

t096

t097

DigIn TermBlk 05

t065 Relay Out1 Sel

t076 EM Brk On Delay

t087 Anlg Loss Delay

t098

DigIn TermBlk 06

t066 Relay Out1 Level

t077 Analog Out Sel(2)

t088 Analog In Filter

t099

DigIn TermBlk 07(1)

t067 Relay Out1 LevelF

t078 Analog Out High(2)

t089 Sleep-Wake Sel

t100

DigIn TermBlk 08(1)

t068 Relay 1 On Time

t079 Anlg Out Setpt(2)

t090 Sleep Level

t101

Communications

EN Addr Sel(1)

C128 EN Gateway Cfg 3(1)

C139 EN Data In 1(1)

C153 Opt Data In 4

C164

EN IP Addr Cfg 1(1)

C129 EN Gateway Cfg 4(1)

C140 EN Data In 2(1)

C154 Opt Data Out 1

C165

EN IP Addr Cfg 2(1)

C130 EN Rate Cfg(1)

C141 EN Data In 3(1)

C155 Opt Data Out 2

C166

EN IP Addr Cfg 3(1)

C131 EN Comm Flt Actn(1)

C143 EN Data In 4(1)

C156 Opt Data Out 3

C167

Comm Write Mode

C121 EN IP Addr Cfg 4(1)

C132 EN Idle Flt Actn(1)

C144 EN Data Out 1(1)

C157 Opt Data Out 4

C168

Cmd Stat Select(1)

C122 EN Subnet Cfg 1(1)

C133 EN Flt Cfg Logic(1)

C145 EN Data Out 2(1)

C158 MultiDrv Sel

C169

RS485 Data Rate

C123 EN Subnet Cfg 2(1)

C134 EN Flt Cfg Ref(1)

C146 EN Data Out 3(1)

C159 Drv 1 Addr

C171

RS485 Node Addr

C124 EN Subnet Cfg 3(1)

C135 EN Flt Cfg DL 1(1)

C147 EN Data Out 4(1)

C160 Drv 2 Addr

C172

Comm Loss Action

C125 EN Subnet Cfg 4(1)

C136 EN Flt Cfg DL 2(1)

C148 Opt Data In 1

C161 Drv 3 Addr

C173

Comm Loss Time

C126 EN Gateway Cfg 1(1)

C137 EN Flt Cfg DL 3(1)

C149 Opt Data In 2

C162 Drv 4 Addr

C174

RS485 Format

C127 EN Gateway Cfg 2(1)

C138 EN Flt Cfg DL 4(1)

C150 Opt Data In 3

C163 DSI I/O Cfg

C175

Logic(1)

Stp Logic 4

L184 Stp Logic Time 4

L194 Step Units 1

L202 Step Units 5

L210

Stp Logic 5

L185 Stp Logic Time 3

L193 Step Units F 1

L203 Step Units F 5

L211

Stp Logic 6

L186 Stp Logic Time 4

L194 Step Units 2

L204 Step Units 6

L212

Stp Logic 7

L187 Stp Logic Time 5

L195 Step Units F 2

L205 Step Units F 6

L213

Stp Logic 0 Stp Logic 1 Stp Logic 2 Stp Logic 3

L180 Stp Logic Time 0

L190 Stp Logic Time 6

L196 Step Units 3

L206 Step Units 7

L214

L181 Stp Logic Time 1

L191 Stp Logic Time 7

L197 Step Units F 3

L207 Step Units F 7

L215

L182 Stp Logic Time 2

L192 Step Units 0

L200 Step Units 4

L208

L183 Stp Logic Time 3

L193 Step Units F 0

L201 Step Units F 4

L209

Advanced Display
Analog In 0-10V Analog In 4-20mA Elapsed Time-hr Elapsed Time-min

Counter Status Timer Status Timer StatusF Drive Type d360 Testpoint Data d361 Motor OL Level d362 Slip Hz Meter d363 Speed Feedback

d364 Speed Feedback F

d377 PID2 Fdbk Displ(1)

d385 Fiber Status

d390

d365 Encoder Speed(2)

d378 PID2 Setpnt Disp(1)

d386 Stp Logic Status(1)

d391

d366 Encoder Speed F

d379 Position Status(1)

d387

d367 DC Bus Ripple

d380 Units Traveled H(1)

d388

d368 Output Powr Fctr

d381 Units Traveled L(1)

d389

d369 Torque Current

d382 RdyBit Mode Act(2)(4)

d392

d375 PID1 Fdbk Displ

d383 Drive Status 2(2)(3)

d393

d376 PID1 Setpnt Disp

d384 Dig Out Status(2)(3)

d394

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Chapter 3 Programming and Parameters

Parameters List (Continued)

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(1) Preset Freq 9(1) Preset Freq 10(1) Preset Freq 11(1) Preset Freq 12(1) Preset Freq 13(1) Preset Freq 14(1) Preset Freq 15(1) Keypad Freq MOP Freq MOP Reset Sel MOP Preload MOP Time Jog Frequency Jog Accel/Decel Purge Frequency DC Brake Time DC Brake Level DC Brk Time@Strt DB Resistor Sel DB Threshold S Curve % PWM Frequency Droop Hertz@ FLA(1) Accel Time 2

Decel Time 2 Accel Time 3 Decel Time 3 Accel Time 4 A410 Decel Time 4 A411 Skip Frequency 1 A412 Skip Freq Band 1 A413 Skip Frequency 2 A414 Skip Freq Band 2 A415 Skip Frequency 3(1) A416 Skip Freq Band 3(1) A417 Skip Frequency 4(1) A418 Skip Freq Band 4(1) A419 PID 1 Trim Hi A420 PID 1 Trim Lo A421 PID 1 Trim Sel A422 PID 1 Ref Sel A423 PID 1 Fdback Sel A424 PID 1 Prop Gain A425 PID 1 Integ Time A426 PID 1 Diff Rate A427 PID 1 Setpoint A428 PID 1 Deadband A429 PID 1 Preload A430 PID 1 Invert Err A431 PID 2 Trim Hi(1) A432 PID 2 Trim Lo(1) A433 PID 2 Trim Sel(1) A434 PID 2 Ref Sel(1) A435 PID 2 Fdback Sel(1) A436 PID 2 Prop Gain(1) A437 PID 2 Integ Time(1) A438 PID 2 Diff Rate(1) A439 PID 2 Setpoint(1) A440 PID 2 Deadband(1) A441 PID 2 Preload(1) A442 PID 2 Invert Err(1)

A443 Process Disp Lo A444 Process Disp Hi A445 Testpoint Sel A446 Current Limit 1 A447 Current Limit 2(1) A448 Shear Pin1 Level A449 Shear Pin 1 Time A450 Shear Pin2 Level(1) A451 Shear Pin 2 Time(1) A452 Load Loss Level(1) A453 Load Loss Time(1) A454 Stall Fault Time A455 Motor OL Select A456 Motor OL Ret A457 Drive OL Mode A458 IR Voltage Drop A459 Flux Current Ref A460 Motor Rr(1) A461 Motor Lm(1) A462 Motor Lx(1) A463 PM IR Voltage(1)(3) A464 PM IXd Voltage(1)(3) A465 PM IXq Voltage(1)(3) A466 PM BEMF Voltage(1)(3) A467 Speed Reg Sel(1) A468 Freq 1(1) A469 Freq 1 BW(1) A470 Freq 2(1) A471 Freq 2 BW(1) A472 Freq 3(1) A473 Freq 3 BW(1) A474 PM Initial Sel(1)(3) A475 PM DC Inject Cur(1)(3) A476 PM Align Time(1)(3) A477 PM HIFI NS Cur(1)(3) A478 PM Bus Reg Kd(1)(3) A479 Freq 1 Kp(1)

A481 Freq 1 Ki(1) A482 Freq 2 Kp(1) A483 Freq 2 Ki(1) A484 Freq 3 Kp(1) A485 Freq 3 Ki(1) A486 PM FWKn 1 Kp(1)(3) A487 PM FWKn 2 Kp(1)(3) A488 PM Control Cfg(1)(3) A489 Boost Select A490 Start Boost A491 Break Voltage A492 Break Frequency A493 Maximum Voltage A494 Motor Fdbk Type(2) A495 Encoder PPR(1) A496 Pulse In Scale A497 Ki Speed Loop(2) A498 Kp Speed Loop(2) A499 Var PWM Disable A500 Auto Rstrt Tries A501 Auto Rstrt Delay A502 Start At PowerUp A503 Reverse Disable A504 Flying Start En A509 FlyStrt CurLimit A510 Compensation A511 Power Loss Mode A512 Half Bus Enable A513 Bus Reg Enable A514 Fault Clear A515 Program Lock A516 Program Lock Mod A517 Drv Ambient Sel A518 Reset Meters A519 Text Scroll A520 Out Phas Loss En A521 Positioning Mode(1)

A522 Counts Per Unit(1)

A559

A523 Enh Control Word(1)

A560

A524 Home Save(1)

A561

A525 Find Home Freq(1)

A562

A526 Find Home Dir(1)

A563

A527 Encoder Pos Tol(1)

A564

A528 Pos Reg Filter(1)

A565

A529 Pos Reg Gain(1)

A566

A530 Max Traverse

A567

A531 Traverse Inc

A568

A532 Traverse Dec

A569

A533 P Jump

A570

A534 Sync Time

A571

A535 Speed Ratio

A572

A536 Mtr Options Cfg(2)(5)

A573

A537 RdyBit Mode Cfg(2)(4)

A574

A538 Flux Braking En(2)(3)

A575

A539 Phase Loss Level(2)(3)

A576

A540 Current Loop BW(1)(3)

A580

A541 PM Stable 1 Freq(1)(3)

A581

A542 PM Stable 2 Freq(1)(3)

A582

A543 PM Stable 1 Kp(1)(3)

A583

A544 PM Stable 2 Kp(1)(3)

A584

A545 PM Stable Brk Pt(1)(3)

A585

A546 PM Stepload Kp(1)(3)

A586

A547 PM 1 Efficiency(1)(3)

A587

A548 PM 2 Efficiency(1)(3)

A588

A549 PM Algor Sel(1)(3)

A589

A550 SYNRM SW Freq

A590

A551 SYNRM Flux Cur

A591

A552 SYNRM Freq1 Volt

A592

A553 SYNRM Freq1 Kp

A593

A554 SYNRM Freq1 Comp

A594

A555 SYNRM Freq2 BW

A595

A556 SYNRM Freq2 Kp

A596

A557

A558

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Chapter 3 Programming and Parameters

Parameters List (Continued)

Network

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.

Modified

This group contains parameters that have their values changed from the factory default. When a parameter has its default value changed, it is automatically added to this group. When a parameter has its value changed back to the factory default, it is automatically removed from this group.

Fault and Diagnostic

Fault 5 Time-min

F625 Fault10 Current(1)

F650 EN Rate Act(1)

F685 Drv 1 Reference

F710

Fault 6 Time-min(1)

F626 Fault 1 BusVolts

F651 DSI I/O Act

F686 Drv 1 Logic Sts

F711

Fault 7 Time-min(1)

F627 Fault 2 BusVolts

F652 HW Addr 1(1)

F687 Drv 1 Feedback

F712

Fault 8 Time-min(1)

F628 Fault 3 BusVolts

F653 HW Addr 2(1)

F688 Drv 2 Logic Cmd

F713

Fault 4 Code

F604 Fault 9 Time-min(1)

F629 Fault 4 BusVolts

F654 HW Addr 3(1)

F689 Drv 2 Reference

F714

Fault 5 Code

F605 Fault10 Time-min(1)

F630 Fault 5 BusVolts

F655 HW Addr 4(1)

F690 Drv 2 Logic Sts

F715

Fault 6 Code

F606 Fault 1 Freq

F631 Fault 6 BusVolts(1)

F656 HW Addr 5(1)

F691 Drv 2 Feedback

F716

Fault 7 Code

F607 Fault 2 Freq

F632 Fault 7 BusVolts(1)

F657 HW Addr 6(1)

F692 Drv 3 Logic Cmd

F717

Fault 8 Code

F608 Fault 3 Freq

F633 Fault 8 BusVolts(1)

F658 EN IP Addr Act 1(1)

F693 Drv 3 Reference

F718

Fault 9 Code

F609 Fault 4 Freq

F634 Fault 9 BusVolts(1)

F659 EN IP Addr Act 2(1)

F694 Drv 3 Logic Sts

F719

Fault10 Code

F610 Fault 5 Freq

F635 Fault10 BusVolts(1)

F660 EN IP Addr Act 3(1)

F695 Drv 3 Feedback

F720

Fault 1 Time-hr

F611 Fault 6 Freq(1)

F636 Status @ Fault 1

F661 EN IP Addr Act 4(1)

F696 Drv 4 Logic Cmd

F721

Fault 2 Time-hr

F612 Fault 7 Freq(1)

F637 Status @ Fault 2

F662 EN Subnet Act 1(1)

F697 Drv 4 Reference

F722

Fault 3 Time-hr

F613 Fault 8 Freq(1)

F638 Status @ Fault 3

F663 EN Subnet Act 2(1)

F698 Drv 4 Logic Sts

F723

Fault 4 Time-hr

F614 Fault 9 Freq(1)

F639 Status @ Fault 4

F664 EN Subnet Act 3(1)

F699 Drv 4 Feedback

F724

Fault 5 Time-hr

F615 Fault10 Freq(1)

F640 Status @ Fault 5

F665 EN Subnet Act 4(1)

F700 EN Rx Overruns(1)

F725

Fault 6 Time-hr(1)

F616 Fault 1 Current

F641 Status @ Fault 6(1)

F666 EN Gateway Act 1(1)

F701 EN Rx Packets(1)

F726

Fault 7 Time-hr(1)

F617 Fault 2 Current

F642 Status @ Fault 7(1)

F667 EN Gateway Act 2(1)

F702 EN Rx Errors(1)

F727

Fault 8 Time-hr(1)

F618 Fault 3 Current

F643 Status @ Fault 8(1)

F668 EN Gateway Act 3(1)

F703 EN Tx Packets(1)

F728

Fault 9 Time-hr(1)

F619 Fault 4 Current

F644 Status @ Fault 9(1)

F669 EN Gateway Act 4(1)

F704 EN Tx Errors(1)

F729

Fault10 Time-hr(1)

F620 Fault 5 Current

F645 Status @ Fault10(1)

F670 Drv 0 Logic Cmd

F705 EN Missed IO Pkt(1)

F730

Fault 1 Time-min

F621 Fault 6 Current(1)

F646 Comm Sts - DSI

F681 Drv 0 Reference

F706 DSI Errors

F731

Fault 2 Time-min

F622 Fault 7 Current(1)

F647 Comm Sts - Opt

F682 Drv 0 Logic Sts

F707

Fault 3 Time-min

F623 Fault 8 Current(1)

F648 Com Sts-Emb Enet(1)

F683 Drv 0 Feedback

F708

Fault 4 Time-min

F624 Fault 9 Current(1)

F649 EN Addr Src(1)

F684 Drv 1 Logic Cmd

F709

(1) Parameter is specific to PowerFlex 525 drives only. (2) Parameter is also available in PowerFlex 523 FRN 3.xxx and later (3) Parameter is available in PowerFlex 525 FRN 5.xxx and later. (4) Parameter is available in PowerFlex 525 FRN 3.xxx and later. (5) Parameter is available in PowerFlex 525 FRN 2.xxx and later.

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Chapter 3 Programming and Parameters

AppView Parameter Groups

Parameters Group

PowerFlex 520-series drives include various AppView parameter groups that groups certain parameters together for quick and easy access based on different types of applications. See AppView Parameter Groups on page 150 for more information.

Conveyor

Motor NP Volts

P031 Decel Time 1

P042 DigIn TermBlk 03

t063 Anlg In mA Loss

t097

Motor NP Hertz

P032 Minimum Freq

P043 Opto Out1 Sel

t069 Slip Hz Meter

d375

Motor OL Current

P033 Maximum Freq

P044 Relay Out1 Sel

t076 Preset Freq 0

A410

Motor NP FLA

P034 Stop Mode

P045 Anlg In 0-10V Lo

t091 Jog Frequency

A431

Language

P030 Motor NP Poles

P035 Start Source 1

P046 Anlg In 0-10V Hi

t092 Jog Accel/Decel

A432

Output Freq

b001 Autotune

P040 Speed Reference1

P047 Anlg In4-20mA Lo

t095 S Curve %

A439

Commanded Freq

b002 Accel Time 1

P041 DigIn TermBlk 02

t062 Anlg In4-20mA Hi

t096 Reverse Disable

A544

Mixer
Language Output Freq

Commanded Freq Output Current Motor NP Volts Motor NP Hertz P030 Motor OL Current b001 Motor NP FLA

b002 Motor NP Poles b003 Autotune P031 Accel Time 1 P032 Decel Time 1 P033 Minimum Freq P034 Maximum Freq

P035 Stop Mode

P045 Anlg In4-20mA Lo

t095

P040 Start Source 1

P046 Anlg In4-20mA Hi

t096

P041 Speed Reference1

P047 Anlg In mA Loss

t097

P042 Relay Out1 Sel

t076 Preset Freq 0

A410

P043 Anlg In 0-10V Lo

t091 Stall Fault Time

A492

P044 Anlg In 0-10V Hi

t092

Compressor

Motor NP Hertz

P032 Maximum Freq

P044 Anlg In 0-10V Lo

t091 Start At PowerUp

A543

Motor OL Current

P033 Stop Mode

P045 Anlg In 0-10V Hi

t092 Reverse Disable

A544

Motor NP FLA

P034 Start Source 1

P046 Anlg In4-20mA Lo

t095 Power Loss Mode

A548

Motor NP Poles

P035 Speed Reference1

P047 Anlg In4-20mA Hi

t096 Half Bus Enable

A549

Language

P030 Autotune

P040 Relay Out1 Sel

t076 Anlg In mA Loss

t097

Output Freq

b001 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

Centrifugal Pump

Motor OL Current

P033 Start Source 1

P046 Anlg In4-20mA Hi

t096 PID 1 Diff Rate

A463

Motor NP FLA

P034 Speed Reference1

P047 Anlg In mA Loss

t097 PID 1 Setpoint

A464

Motor NP Poles

P035 Relay Out1 Sel

t076 Preset Freq 0

A410 PID 1 Deadband

A465

Autotune

P040 Analog Out Sel

t088 PID 1 Trim Hi

A456 PID 1 Preload

A466

Language

P030 Accel Time 1

P041 Analog Out High

t089 PID 1 Trim Lo

A457 Auto Rstrt Tries

A541

Output Freq

b001 Decel Time 1

P042 Anlg Out Setpt

t090 PID 1 Ref Sel

A459 Auto Rstrt Delay

A542

Commanded Freq

b002 Minimum Freq

P043 Anlg In 0-10V Lo

t091 PID 1 Fdback Sel

A460 Start At PowerUp

A543

Motor NP Volts

P031 Maximum Freq

P044 Anlg In 0-10V Hi

t092 PID 1 Prop Gain

A461 Reverse Disable

A544

Motor NP Hertz

P032 Stop Mode

P045 Anlg In4-20mA Lo

t095 PID 1 Integ Time

A462

Blower/Fan

Motor OL Current

P033 Start Source 1

P046 Anlg In4-20mA Hi

t096 PID 1 Diff Rate

A463

Motor NP FLA

P034 Speed Reference1

P047 Anlg In mA Loss

t097 PID 1 Setpoint

A464

Motor NP Poles

P035 Relay Out1 Sel

t076 Preset Freq 0

A410 PID 1 Deadband

A465

Autotune

P040 Analog Out Sel

t088 PID 1 Trim Hi

A456 PID 1 Preload

A466

Language

P030 Accel Time 1

P041 Analog Out High

t089 PID 1 Trim Lo

A457 Auto Rstrt Tries

A541

Output Freq

b001 Decel Time 1

P042 Anlg Out Setpt

t090 PID 1 Ref Sel

A459 Auto Rstrt Delay

A542

Commanded Freq

b002 Minimum Freq

P043 Anlg In 0-10V Lo

t091 PID 1 Fdback Sel

A460 Start At PowerUp

A543

Motor NP Volts

P031 Maximum Freq

P044 Anlg In 0-10V Hi

t092 PID 1 Prop Gain

A461 Reverse Disable

A544

Motor NP Hertz

P032 Stop Mode

P045 Anlg In4-20mA Lo

t095 PID 1 Integ Time

A462 Flying Start En

A545

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Parameters Group (Continued)

Extruder

Motor NP Hertz

P032

Motor OL Current

P033

Motor NP FLA

P034

Motor NP Poles

P035

Language

P030 Autotune

P040

Output Freq

b001 Accel Time 1

P041

Commanded Freq

b002 Decel Time 1

P042

Output Current

b003 Minimum Freq

P043

Motor NP Volts

P031 Maximum Freq

P044

Positioning(1)

Stop Mode

P045

Start Source 1

P046

Speed Reference1

P047

DigIn TermBlk 02

t062

Language

P030 DigIn TermBlk 03

t063

Output Freq

b001 DigIn TermBlk 05

t065

Commanded Freq

b002 DigIn TermBlk 06

t066

Motor NP Volts

P031 Opto Out1 Sel

t069

Motor NP Hertz

P032 Opto Out2 Sel

t072

Motor OL Current

P033 Relay Out1 Sel

t076

Motor NP FLA

P034 EM Brk Off Delay

t086

Motor NP Poles

P035 EM Brk On Delay

t087

Autotune

P040 Stp Logic 0

L180

Accel Time 1

P041 Stp Logic 1

L181

Decel Time 1

P042 Stp Logic 2

L182

Minimum Freq

P043 Stp Logic 3

L183

Maximum Freq

P044 Stp Logic 4

L184

Textile/Fiber

Motor NP FLA

P034

Motor NP Poles

P035

Autotune

P040

Accel Time 1

P041

Language

P030 Decel Time 1

P042

Output Freq

b001 Minimum Freq

P043

Commanded Freq

b002 Maximum Freq

P044

Motor NP Volts

P031 Stop Mode

P045

Motor NP Hertz

P032 Start Source 1

P046

Motor OL Current

P033 Speed Reference1

P047

(1) This AppView parameter group is specific to PowerFlex 525 drives only.

Stop Mode Start Source 1 Speed Reference1 Relay Out1 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 Step Units 3 Step Units 4 Step Units 5
DigIn TermBlk 02 DigIn TermBlk 03 Opto Out1 Sel Opto Out2 Sel Relay Out1 Sel Anlg In 0-10V Lo Anlg In 0-10V Hi Anlg In4-20mA Lo Anlg In4-20mA Hi Anlg In mA Loss

Chapter 3 Programming and Parameters

P045 Anlg In4-20mA Lo

t095 Motor Fdbk Type

A535

P046 Anlg In4-20mA Hi

t096 Encoder PPR

A536

P047 Anlg In mA Loss

t097 Pulse In Scale

A537

t076 Slip Hz Meter

d375 Ki Speed Loop

A538

t088 Speed Feedback

d376 Kp Speed Loop

A539

t089 Speed Feedback F

d377 Power Loss Mode

A548

t090 Encoder Speed

d378 Half Bus Enable

A549

t091 Preset Freq 0

A410

t092 Stall Fault Time

A492

L185 Step Units 6 L186 Step Units 7 L187 Slip Hz Meter L190 Speed Feedback L191 Encoder Speed L192 Units Traveled H L193 Units Traveled L L194 Preset Freq 0 L195 Preset Freq 1 L196 Preset Freq 2 L197 Preset Freq 3 L200 Preset Freq 4 L202 Preset Freq 5 L204 Preset Freq 6 L206 Preset Freq 7 L208 Preset Freq 8 L210 Jog Frequency

L212 Jog Accel/Decel

A432

L214 DB Threshold

A438

d375 S Curve %

A439

d376 Motor Fdbk Type

A535

d378 Encoder PPR

A536

d388 Pulse In Scale

A537

d389 Ki Speed Loop

A538

A410 Kp Speed Loop

A539

A411 Bus Reg Enable

A550

A412 Positioning Mode

A558

A413 Counts Per Unit

A559

A414 Enh Control Word

A560

A415 Find Home Freq

A562

A416 Find Home Dir

A563

A417 Encoder Pos Tol

A564

A418 Pos Reg Filter

A565

A431 Pos Reg Gain

A566

t062 Slip Hz Meter

d375 Max Traverse

A567

t063 Fiber Status

d390 Traverse Inc

A568

t069 Preset Freq 0

A410 Traverse Dec

A569

t072 Jog Frequency

A431 P Jump

A570

t076 Jog Accel/Decel

A432 Sync Time

A571

t091 S Curve %

A439 Speed Ratio

A572

t092 Reverse Disable

A544

t095 Power Loss Mode

A548

t096 Half Bus Enable

A549

t097 Bus Reg Enable

A550

Custom Group

CustomView Parameter Group
PowerFlex 520-series drives include a CustomView parameter group for you to store frequently used parameters for your application. See CustomView Parameter Group on page 151 for more information.
This group can store up to 100 parameters.

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Chapter 3 Programming and Parameters

Basic Display Group

b001 [Output Freq]

Output frequency present at T1, T2 & T3 (U, V & W). Does not include slip frequency.

Default:

Read Only

Values Min/Max:

0.00/[Maximum Freq]

Display:

0.01 Hz

Related Parameter(s): b002, b010, b011, P043, P044, P048, P050, P052

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 48 for more information.

Values

Default: Min/Max: Display:

Read Only 0.00/[Maximum Freq] 0.01 Hz

b003 [Output Current] Output current present at T1, T2 & T3 (U, V & W).
Default: Values Min/Max:
Display:

Read Only 0.00/(Drive Rated Amps x 2) 0.01 A

b004 [Output Voltage] Output voltage present at T1, T2 & T3 (U, V & W).
Default: Values Min/Max:
Display:

Read Only 0.0/Drive Rated Volts 0.1V

Related Parameter(s): P031, A530, A534

b005 [DC Bus Voltage] Filtered DC bus voltage level of the drive.
Default: Values Min/Max:
Display:

Read Only 0/1200V DC 1V DC

b006 [Drive Status] Present operating condition of the drive.

Related Parameter(s): A544

Running Forward Accelerating Decelerating SafetyActive(1)

1 = True/Active, 0 = False/Inactive Digit 1 Digit 2 Digit 3 Digit 4 Digit 5

(1) Setting is specific to PowerFlex 525 drives only.

Values

Default: Min/Max: Display:

Read Only 00000/11111 00000

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Chapter 3 Programming and Parameters

Basic Display Group (continued)

b007 [Fault 1 Code] b008 [Fault 2 Code] b009 [Fault 3 Code]

Related Parameter(s): F604-F610

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.

Default:

Read Only

Values Min/Max:

F0/F127

Display:

F0

b010 [Process Display]
32 32 bit parameter.

Related Parameter(s): b001, A481, A482

Output frequency scaled by A481 [Process Disp Lo] and A482 [Process Disp Hi]. Scaled Process Value (PV) = (([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [Minimum Freq])

Default:

Read Only

Values Min/Max:

0/9999.00

Display:

0.01

b011 [Process Fract]
32 32 bit parameter.

Related Parameter(s): b001, A481, A482

Output frequency scaled by A481 [Process Disp Lo] and A482 [Process Disp Hi]. Scaled Process Value (PV) = (([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [Minimum Freq])

Default:

Read Only

Values Min/Max:

0.00/0.99

Display:

0.01

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Basic Display Group (continued)

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 Referencex]. See Start and Speed Reference Control on page 48 for more information.

Start Command Source

Digit 1

1 = Keypad

2 = DigIn TrmBlk (Parameters t062,t063,t065-t068)

3 = Serial/DSI 4 = Network Opt(1) 5 = EtherNet/IP(2)

Frequency Command Source

Digit 2 & 3

00 = Other

01 = Drive Pot

02 = Keypad

03 = Serial/DSI 04 = Network Opt(1)

05 = 0-10V Input

06 = 4-20mA Input

07 = Preset Freq (Parameters A410-A425) 08 = Anlg In Mult(2)

09 = MOP

10 = Pulse Input

11 = PID1 Output 12 = PID2 Output(2) 13 = Step Logic (Parameters L180-L187)(1) 14 = Encoder(2) 15 = EtherNet/IP(2) 16 = Positioning(2)

Frequency Command Source

Digit 4

0 = Other (Digit 2 & 3 are used. Digit 4 is not shown.)

1 = Jog

2 = Purge

Not Used

(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the Start source and/or Frequency source.
(2) Setting is specific to PowerFlex 525 drives only.

Values

Default: Min/Max: Display:

Read Only 0000/2165 0000

Example

Display reads... Description

2004

Start source comes from Network Opt and Frequency source is Purge.

113

Start source comes from Serial/DSI and Frequency source comes from PID1 Output.

155

Start source and Frequency source comes from EtherNet/IP.

052

Start source comes from DigIn TrmBlk and Frequency source from 0...10V Input.

011

Start source comes from Keypad and Frequency source comes from Drive Pot.

b013 [Contrl In Status] State of the digital terminal blocks 1...3 and DB transistor.
IMPORTANT Actual control commands may come from a source other than the control terminal block.

Related Parameter(s): b002, P044, P045

DigIn TBlk 1 DigIn TBlk 2 DigIn TBlk 3 DB Trans On(1) Not Used

1 = Closed State, 0 = Open State Digit 1 Digit 2 Digit 3 Digit 4

(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: Min/Max: Display:

Read Only 0000/1111 0000

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b014 [Dig In Status] State of the programmable digital inputs.

Basic Display Group (continued)

DigIn TBlk 5
DigIn TBlk 6 DigIn TBlk 7(1) DigIn TBlk 8(1)
Not Used

1 = Closed State, 0 = Open State Digit 1 Digit 2 Digit 3 Digit 4

(1) Setting is specific to PowerFlex 525 drives only.

Values

Default: Min/Max: Display:

Read Only 0000/1111 0000

b015 [Output RPM]

Current output frequency in rpm. Scale is based on P035 [Motor NP Poles].

Default:

Read Only

Values Min/Max:

0/24000 rpm

Display:

1 rpm

b016 [Output Speed]

Current output frequency in %. Scale is 0% at 0.00 Hz to 100% at P044 [Maximum Freq].

Default:

Read Only

Values Min/Max:

0.0/100.0%

Display:

0.1%

b017 [Output Power] Output power present at T1, T2 & T3 (U, V & W).
Default: Values Min/Max:
Display:

Read Only 0.00/(Drive Rated Power x 2) 0.01 kW

b018 [Power Saved]

Instantaneous power savings of using this drive compared to an across the line starter.

Default:

Read Only

Values Min/Max:

0.00/655.35 kW

Display:

0.01 kW

b019 [Elapsed Run time]

Accumulated time drive is outputting power. Time is displayed in 10 hour increments.

Default:

Read Only

Values Min/Max:

0/65535 x 10 hr

Display:

1 = 10 hr

Chapter 3 Programming and Parameters Related Parameter(s): t065-t068
Related Parameter(s): P035 Related Parameter(s): P044 Related Parameter(s): b018 Related Parameter(s): b017 Related Parameter(s): A555

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Basic Display Group (continued)

b020 [Average Power]

Average power used by the motor since the last reset of the meters.

Default:

Read Only

Values Min/Max:

0.00/(Drive Rated Power x 2)

Display:

0.01 kW

Related Parameter(s): A555

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.

Default:

Read Only

Values Min/Max:

0.0/100.0 kWh

Display:

0.1 kWh

b022 [Elapsed MWh] Accumulated output energy of the drive.
Default: Values Min/Max:
Display:

Read Only 0.0/6553.5 MWh 0.1 MWh

Related Parameter(s): b021

b023 [Energy Saved]

Total energy savings of using this drive compared to an across the line starter since the last reset of the meters.

Default:

Read Only

Values Min/Max:

0.0/6553.5 kWh

Display:

0.1 kWh

Related Parameter(s): A555

b024 [Accum kWh Sav]

Total approximate accumulated energy savings of the drive compared to using an across the line starter.

Default:

Read Only

Values Min/Max:

0.0/6553.5 kWh

Display:

0.1 = 10 kWh

Related Parameter(s): b025

b025 [Accum Cost Sav]

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]

Default:

Read Only

Values Min/Max:

0.0/6553.5

Display:

0.1

Related Parameter(s): b024, P052, A555

b026 [Accum CO2 Sav]

Total approximate accumulated CO2 savings of the drive compared to using an across the line starter.

Default:

Read Only

Values Min/Max:

0.0/6553.5 kg

Display:

0.1 kg

Related Parameter(s): A555

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Basic Display Group (continued)

b027 [Drive Temp]

Present operating temperature of the drive heatsink (inside module).

Default:

Read Only

Values Min/Max:

0/120 °C

Display:

1 °C

b028 [Control Temp]

Present operating temperature of the drive control.

Default:

Read Only

Values Min/Max:

0/120 °C

Display:

1 °C

b029 [Control SW Ver] Current drive firmware version.
Default: Values Min/Max:
Display:

Read Only 0.000/65.535 0.001

Chapter 3 Programming and Parameters

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Basic Program Group

P030 [Language]

Selects the language displayed. A reset or power cycle is required after selection is made.

Options

1 English (Default) 2 Français 3 Español 4 Italiano 5 Deutsch 6 Japanese 7 Português 8 Chinese 9 Reserved 10 Reserved 11 Korean 12 Polish(1) 13 Reserved 14 Turkish(1) 15 Czech(1)

Chinese Simplified

(1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified.

Language Support

Keypad/

RSLogix 5000/Logix

LCD Display Designer application

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y



Y

Y

Y



Y

Connected Components Workbench software Y Y Y Y Y   Y



Y



Y





Y





Y





P031 [Motor NP Volts]
Stop drive before changing this parameter.
Sets the motor nameplate rated volts. Default:
Values Min/Max: Display:

Related Parameter(s): b004, A530, A531, A532, A533
Drive Rated Volts 10V (for 230V Drives), 20V (for 460V Drives), 25V (for 600V Drives)/Drive Rated Volts 1V

P032 [Motor NP Hertz]
Stop drive before changing this parameter.
Sets the motor nameplate rated frequency. Default:
Values Min/Max: Display:

60 Hz 15/500 Hz 1 Hz

Related Parameter(s): A493, A530, A531, A532, A533

P033 [Motor OL Current]

Related Parameter(s): t069, t072, t076, t081, A484, A485, A493

Sets the motor nameplate overload current. Used to determine motor overload conditions and can be set from 0.1 A to 200% of drive rated current.

IMPORTANT The drive will fault on an F007 "Motor Overload" if the value of this parameter is exceeded based on class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572

Values

Default: Min/Max: Display:

Drive Rated Amps 0.0/(Drive Rated Amps x 2) 0.1 A

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Basic Program Group (continued)

P034 [Motor NP FLA]

Sets the motor nameplate FLA. Used to assist the Autotune routine and motor control.

Default:

Based on Drive Rating

Values Min/Max:

0.1/(Drive Rated Amps x 2)

Display:

0.1 A

Chapter 3 Programming and Parameters Related Parameter(s): P040

P035 [Motor NP Poles]

Sets the number of poles in the motor.

Default:

4

Values Min/Max:

2/40

Display:

1

Related Parameter(s): b015

P036 [Motor NP RPM]

Stop 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.

Default:

1750 rpm

Values Min/Max:

0/24000 rpm

Display:

1 rpm

P037 [Motor NP Power]

PF 525 PowerFlex 525 only.

Sets the motor nameplate power. Used in PM regulator.

Default:

Drive Rated Power

Values Min/Max:

0.00/Drive Rated Power

Display:

0.01 kW

P039 [Torque Perf Mode]

Related Parameter(s): P040, A530, A531, A532, A533, A535

Stop drive before changing this parameter.

Selects the motor control mode. The PowerFlex 523 and PowerFlex 525 drives are capable of performing with the following motor control modes.

0 "V/Hz"

1 "SVC" (Default)

Options

2 "Economize" 3 "Vector"(1) 4 "PM Control"(1) (2)

5 "SynRM"(3)

Voltage Vector only (cannot control torque). It is recommended to use with an encoder when using VVC mode. When P039 [Torque Perf Mode] is set to 4 and A535 [Motor Fdbk Type] is set to 0, 1, 2 or 3, the drive is in open loop PM motor control mode. When P039 [Torque Perf Mode] is set to 4 and A535 [Motor Fdbk Type] is set to 4 or 5, the drive is in closed loop PM motor control mode. Set P039 [Torque Perf Mode] to 5 to enable the use of Synchronous Reluctance Motor control.

(1) Setting is specific to PowerFlex 525 drives only. (2) Setting is available in PowerFlex 525 FRN 5.xxx and later. (3) Setting is available in PowerFlex 525 FRN 7.xxx and later.

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Basic Program Group (continued)

P040 [Autotune]

Related Parameter(s): P034, P039, A496, A497

Stop drive before changing this parameter.

Enables a static (not spinning) or dynamic (motor spinning) autotune to automatically set the motor parameters. Set the parameter value to a one or two, then issue a valid "Start" command 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. It is recommended to perform a full rotate tune when using VVC mode.

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.

0 "Ready/Idle" (Default) 1 "Static Tune"
Options 2 "Rotate Tune"

A temporary command that initiates a non-rotational motor stator resistance test for the best possible automatic setting of A496 [IR Voltage Drop]. A start command is required following initiation of this setting. The parameter returns to 0 "Ready/ Idle" following the test, at which time another start transition is required operate the drive in normal mode. Used when motor cannot be uncoupled from the load. A temporary command that initiates a "Static Tune" followed by a rotational test for the best possible automatic setting of A497 [Flux Current Ref]. A start command is required following initiation of this setting. The parameter returns to 0 "Ready/Idle" following the test, at which time another start transition is required to operate the drive in normal mode. Important: Used when motor is uncoupled from the load. Results may not be valid if a load is coupled to the motor during this procedure. If [P039 = 5], it is the same with "Static Tune"

P041 [Accel Time 1] Sets the time for the drive to accelerate from 0 Hz to P044 [Maximum Freq]. Accel Rate = [Maximum Freq] / [Accel Time x] [Maximum Freq]

Related Parameter(s): P044, A439

Acceleration

Deceleration

Speed

0 [Accel Time x] Time [Decel Time x]
0

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

P042 [Decel Time 1] Sets the time for the drive to decelerate from P044 [Maximum Freq] to 0 Hz. Decel Rate = [Maximum Freq] / Decel Time x] [Maximum Freq]

Related Parameter(s): P044, A439

Acceleration

Deceleration

Speed

0 [Accel Time x] Time [Decel Time x]
0

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

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P043 [Minimum Freq]
Stop drive before changing this parameter.
Sets the lowest frequency the drive outputs. Default:
Values Min/Max: Display:

Basic Program Group (continued)
0.00 Hz 0.00/500.00 Hz 0.01 Hz

Chapter 3 Programming and Parameters Related Parameter(s): b001, b002, b013, P044, A530, A531

P044 [Maximum Freq]
Stop 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: Min/Max: Display:

60.00 Hz 0.00/500.00 Hz 0.01 Hz

Related Parameter(s): b001, b002, b013, b016, P043, A530, A531

P045 [Stop Mode]

Related Parameter(s): t086, t087, A434, A435, A550

Determines the stopping mode used by the drive when a stop is initiated.

0 "Ramp, CF" (Default)

Ramp to Stop. Stop command clears active fault.

1 "Coast, CF"

Coast to Stop. Stop command clears active fault.

2 "DC Brake, CF"

DC Injection Braking Stop. Stop command clears active fault.

3 "DC BrkAuto,CF"

DC Injection Braking Stop with Auto Shutoff. · Standard DC Injection Braking for value set in A434 [DC Brake Time].
OR · Drive shuts off if the drive detects that the motor is stopped. Stop command clears active fault.

4 "Ramp"

Ramp to Stop.

5 "Coast"

Coast to Stop.

6 "DC Brake"

DC Injection Braking Stop.

7 "DC BrakeAuto"

DC Injection Braking Stop with Auto Shutoff. · Standard DC Injection Braking for value set in A434 [DC Brake Time].
OR · Drive shuts off if the drive detects that the motor is stopped.

Options 8 "Ramp+EM B,CF" 9 "Ramp+EM Brk"

Ramp to Stop with EM Brake Control. Stop command clears active fault. Ramp to Stop with EM Brake Control.

10 "PointStp,CF" 11 "PointStop"

PointStop. Stop command clears active fault.

Provides a method to stop at a constant distance instead of a fixed rate. When a Stop command is given, the distance required for the machine to travel to standstill based on the programmed maximum speed and deceleration time is calculated. If the drive is running slower than the maximum speed, the function will apply a calculated deceleration time that allows the machine to travel to standstill in the same distance based on the current speed. It is recommended to use braking resistors or set A550 [Bus Reg Enable] to 0 "Disabled" for better performance.

Stop

PointStop.

[Maximum Freq]

Speed

Calculated Stop Time

[Decel Time x]

Time

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Basic Program Group (continued)

P046 [Start Source 1] P048 [Start Source 2] P050 [Start Source 3]

Related Parameter(s): b012, t064, C125

Stop drive before changing this parameter.

Configures the start source of the drive. Changes to these inputs take effect as soon as they are entered. P046 [Start Source 1] is the factory default start source unless overridden. See Start and Speed Reference Control on page 48 for more information.

IMPORTANT For all settings except when t064 [2-Wire Mode] is set to 1 "Level Sense", the drive must receive a leading edge from the start input for the drive to start after a stop input, loss of power, or fault condition.

Options

1 "Keypad"
2 "DigIn TrmBlk"
3 "Serial/DSI" 4 "Network Opt"(1) 5 "EtherNet/IP"(2)

[Start Source 1] default [Start Source 2] default [Start Source 3] default for PowerFlex 523
[Start Source 3] default for PowerFlex 525

(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the start source. (2) Setting is specific to PowerFlex 525 drives only.

P047 [Speed Reference1] P049 [Speed Reference2] P051 [Speed Reference3]

Related Parameter(s): C125

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 48 for more information.

1 "Drive Pot"

[Speed Reference1] default

2 "Keypad Freq"

3 "Serial/DSI" 4 "Network Opt"(1)

[Speed Reference3] default for PowerFlex 523

5 "0-10V Input"

[Speed Reference2] default

6 "4-20mA Input"

Options

7 "Preset Freq" 8 "Anlg In Mult"(2)
9 "MOP"

10 "Pulse Input"

11 "PID1 Output" 12 "PID2 Output"(2) 13 "Step Logic"(2) 14 "Encoder"(2) 15 "EtherNet/IP"(2) 16 "Positioning"(2)

[Speed Reference3] default for PowerFlex 525 Referencing from A558 [Positioning Mode]

(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the speed reference. (2) Setting is specific to PowerFlex 525 drives only.

P052 [Average kWh Cost] Sets the average cost per kWh.
Default: Values Min/Max:
Display:

0.00 0.00/655.35 0.01

Related Parameter(s): b025

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Chapter 3 Programming and Parameters

Basic Program Group (continued)

Basic Program Group (continued)

P053 [Reset To Defalts]

Stop 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.

Parameters that are NOT Reset when P053 = 1

Parameters that are Reset when P053 = 3

Parameter P030 [Language] C121 [Comm Write Mode] C122 [Cmd Stat Select] C123 [RS485 Data Rate] C124 [RS485 Node Addr] C124 [Comm Loss Action] C126 [Comm Loss Time] C127 [RS485 Format] C128 [EN Addr Sel] C129 [EN IP Addr Cfg 1] C130 [EN IP Addr Cfg 2] C131 [EN IP Addr Cfg 3] C132 [EN IP Addr Cfg 4] C133 [EN Subnet Cfg 1] C134 [EN Subnet Cfg 2] C135 [EN Subnet Cfg 3]
C136 [EN Subnet Cfg 4]
C137 [EN Gateway Cfg 1]

Parameter C138 [EN Gateway Cfg 2] C139 [EN Gateway Cfg 3] C140 [EN Gateway Cfg 4] C141 [EN Rate Cfg] C143 [EN Comm Flt Actn] C144 [EN Idle Flt Actn] C145 [EN Flt Cfg Logic] C146 [EN Flt Cfg Ref] C147 [EN Flt Cfg DL 1] C148 [EN Flt Cfg DL 2] C149 [EN Flt Cfg DL 3] C150 [EN Flt Cfg DL 4] C153 [EN Data In 1] C154 [EN Data In 2] C155 [EN Data In 3] C156 [EN Data In 4]
C157 [EN Data Out 1]
C158 [EN Data Out 2]

Parameter C159 [EN Data Out 3] C160 [EN Data Out 4] C161 [Opt Data In 1] C162 [Opt Data In 2] C163 [Opt Data In 3] C164 [Opt Data In 4] C165 [Opt Data Out 1] C166 [Opt Data Out 2] C167 [Opt Data Out 3] C168 [Opt Data Out 4] C169 [MultiDrv Sel] C171 [Drv 1 Addr] C172 [Drv 2 Addr] C173 [Drv 3 Addr] C174 [Drv 4 Addr] C175 [DSI I/O Cfg] GC [Parameters in Custom Group]

Parameter Name P031 [Motor NP Volts] P033 [Motor OL] Current P034 [Motor NP FLA] P035 [Motor NP Poles] A435 [DC Brake Level] A484 [Current Limit 1] A485 [Current Limit 2] A486 [Shear Pin1 Level] A488 [Shear Pin2 Level] A490 [Load Loss Level] A496 [IR Voltage Drop] A497 [Flux Current Ref] A530 [Boost Select] A531 [Start Boost] A532 [Break Voltage] A533 [Break Frequency] A534 [Maximum] Voltage

Options

0 "Ready/Idle" (Default) 1 "Param Reset" 2 "Factory Rset" 3 "Power Reset" 4 "Module Reset"(1) (2)

Does not reset custom groups, parameter P030 [Language], and communication parameters. Restore drive to factory condition. Resets only power parameters. Can be used when swapping power modules. Power cycle of the drive, NO parameters are reset.

(1) Setting is available in PowerFlex 525 FRN 5.xxx and later. (2) Setting is available in PowerFlex 523 FRN 3.xxx and later.

P054 [Display Param]

Sets the parameter to display on the drive LCD display when the drive powers up.

Options

0 "Keypad Disp" (Default) 1 "Output Freq"

Without ADC = shows last selected display parameter With ADC = shows parameter b001 [Output Freq] Basic Display group parameters

Related Parameter(s): b001

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Terminal Block Group
Programmable Digital Inputs
t062 [DigIn TermBlk 02] t063 [DigIn TermBlk 03] t065 [DigIn TermBlk 05] t066 [DigIn TermBlk 06]
t067 [DigIn TermBlk 07] t068 [DigIn TermBlk 08]
PF 525 PowerFlex 525 only.

Related Parameter(s): b012, b013, b014, P045, P046, P048, P049, P050, P051, t064, t086, A410A425, A427, A431, A432, A433, A434, A435, A442, A443, A488, A535, A560, A562, A563, A567, A571

Stop 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.

0 "Not Used"

Terminal has no function but can be read over network communications with b013 [Contrl In Status] and b014 [Dig In Status].

1 "Speed Ref 2"

Selects P049 [Speed Reference2] as drive's speed command.

2 "Speed Ref 3"

Selects P051 [Speed Reference3] as drive's speed command.

3 "Start Src 2"

Selects P048 [Start Source 2] as control source to start the drive.

4 "Start Src 3"

Selects P050 [Start Source 3] as control source to start the drive.

5 "Spd + 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.

6 "Spd + Strt 3" 7 "Preset Freq" (PF523: only for DigIn TermBlk 03, 05,
and 06) (PF525: only for DigIn TermBlk 05...08)

Selects combination of P051 [Speed Reference3] and P050 [Start Source 3] as speed command with control source to start the drive.
[DigIn 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] (only for PowerFlex 525 drives).

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 48 for more information.

8 "Jog"
Options 9 "Jog Forward"
10 "Jog Reverse"
11 "Acc/Dec Sel2"(1)
12 "Aux Fault" 13 "Clear Fault" 14 "RampStop,CF" 15 "CoastStop,CF" 16 "DCInjStop,CF" 17 "MOP Up" 18 "MOP Down" 19 "Timer Start"(1) 20 "Counter In"(1) 21 "Reset Timer" 22 "Reset Countr"
23 "Rset Tim&Cnt"

· 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]. · A valid Start command will override this input. [DigIn TermBlk 08] default. Drive accelerates to A431 [Jog Frequency] according to A432 [Jog Accel/Decel] and ramps to a stop when input becomes inactive. A valid Start command will override this input. 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. 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. When enabled, an F002 "Auxiliary Input" fault will occur when the input is removed. When active, clears an active fault. Causes drive to immediately ramp to a stop regardless of how P045 [Stop Mode] is set. Causes drive to immediately coast to a stop regardless of how P045 [Stop Mode] is set. Causes drive to immediately begin a DC Injection stop regardless of how P045 [Stop Mode] is set. Increases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time]. Decreases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time]. Clears and starts the timer function. May be used to control the relay or opto outputs. Starts the counter function. May be used to control the relay or opto outputs. Resets the internal active timer, d365 [Timer Status]. For more information, see Timer Function on page 213. Resets the count in the accumulated internal active counter, d364 [Counter Status]. For more information, see Counter Function on page 214. Resets both the internal active timer and accumulated internal active counter.

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Chapter 3 Programming and Parameters

Programmable Digital Inputs (Continued)

24 "Logic In 1"(1)(2) 25 "Logic In 2"(1)(2) 26 "Current Lmt2"(2) 27 "Anlg Invert"
28 "EM Brk Rlse"

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]. 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]. When active, A485 [Current Limit 2] determines the drive current limit level. Inverts the scaling of the analog input levels set in t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] or t095 [Anlg In4-20mA Lo] and t096 [Anlg In4-20mA Hi]. If EM brake function is enabled, this input releases the brake. See t086 [EM Brk Off Delay] for more information.

ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used.

29 "Acc/Dec Sel3"(1)

30 "Precharge En"

31 "Inertia Dcel" 32 "Sync Enable"

Options

33 "Traverse Dis" 34 "Home Limit"(2) 35 "Find Home"(2)

36 "Hold Step"(2)

37 "Pos Redefine"(2) 38 "Force DC" 39 "Damper Input" 40 "Purge"(1)

If active, determines which Accel/Decel time is used for all ramp rates except jog. Used with option 11 "Acc/Dec Sel2" for the Accel/Decel times listed in this table.

Option 29 11 00 01 10 11

Description
Acc/Dec 1 Acc/Dec 2 Acc/Dec 3 Acc/Dec 4

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 deenergized, the pre-charge relay opens and the drive coasts to a stop. Forces drive into Inertia Ride-Through state. The drive attempts to regulate the DC bus at the current level. 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]. When an input is programmed the traverse function is disabled while this input is active. See A567 [Max Traverse]. In Positioning mode, indicates the drive is at the home position. See Appendix E for more information on Positioning. In Positioning mode, causes the drive to return to the Home position when a Start command is issued. Uses A562 [Find Home Freq] and A563 [Find Home Dir] until the "Home Limit" input is activated. If it passes this point, it then runs 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. 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. In Positioning mode, resets the home position to the current position of the machine. See Appendix E for more information on Positioning. 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. When active, drive is allowed to run normally. When inactive, drive is forced into sleep mode and is prevented from accelerating to command speed. Starts the drive at A433 [Purge Frequency] regardless of the selected control source. Supersedes the keypad Control function as well as any other control command to take control of the drive. Purge can occur, and is operational, at any time whether the drive is running or stopped regardless of the selected logic source selection. If a valid stop (other than from comms or SW enable) is present, the drive will not start on the purge input transition.

ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used.

41 "Freeze-Fire" 42 "SW Enable"

When inactive, will cause an immediate F094 "Function Loss" fault. Use to safely bypass the drive with an external switching device. Works like an interlock that has to be active for the drive to run.

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Programmable Digital Inputs (Continued)

43 "SherPin1 Dis" 44 Reserved 45 Reserved 46 Reserved 47 Reserved 48 "2-Wire FWD"
(only for DigIn TermBlk 02)
49 "3-Wire Start" (only for DigIn TermBlk 02)
Options 50 "2-Wire REV" (only for DigIn TermBlk 03)
51 "3-Wire Dir" (only for DigIn TermBlk 03)

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.

[DigIn TermBlk 02] default. Select 2-Wire FWD for this input. Select this option and set P046, P048 or P050 [Start Source x] to 2 "DigIn TrmBlk" to configure [Start Source x] to a 2-wire run forward mode. Also see t064 [2-Wire Mode] for level trigger settings. Select 3-Wire Start for this input. Select this option and set P046, P048 or P050 [Start Source x] to 2 "DigIn TrmBlk" to configure [Start Source x] to a 3-wire start mode. [DigIn TermBlk 03] default. Select 2-Wire REV for this input. Select this option and set P046, P048 or P050 [Start Source x] to 2 "DigIn TrmBlk" to configure [Start Source x] to a 2-wire run reverse mode. Also see t064 [2-Wire Mode] for level trigger settings. For PowerFlex 523 drives, this setting will be disabled If [DigIn TermBlk 03] is set to 7 "Preset Freq".
Select 3-Wire Dir for this input. Select this option and set P046, P048 or P050 [Start Source x] to 2 "DigIn TrmBlk" to change the direction of [Start Source x]. For PowerFlex 523 drives, this setting will be disabled If [DigIn TermBlk 03] is set to 7 "Preset Freq".

Drive Start Condition Matrix for t062 and t063

t062 Setting

t063 3-Wire 2-Wire Setting Start FWD

2-Wire REV

Drive will not start

OK

3-Wire Dir

OK

Drive will not start

52 "Pulse Train" (PF523: only for DigIn TermBlk 05) (PF525: only for DigIn TermBlk 07)
(1) This function may be tied to one input only. (2) Setting is specific to PowerFlex 525 drives only.

Select pulse train for this input. Use P047, P049 and P051 [Speed Referencex] to select pulse input. Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In.

t064 [2-Wire Mode]

Related Parameter(s): P045, P046, P048, P050, t062, t063

Stop drive before changing this parameter.

Programs the mode of trigger only for t062 [DigIn TermBlk 02] and t063 [DigIn TermBlk 03] when 2-wire option is being selected as P046, P048 or P050 [Start Source x].

0 "Edge Trigger" (Default)

Standard 2-Wire operation.

1 "Level Sense"

· I/O Terminal 01 "Stop" = Coast to stop. Drive will restart after a Stop command when:  Stop is removed and  Start is held active
· I/O Terminal 03 "Run REV"

ATTENTION: Hazard of injury exists due to unintended operation. When t064 [2-Wire Mode] is set to option 1, and the Run input is maintained, the Run inputs do not need to be toggled after a Stop input for the drive to run again. A Stop function is provided only when the Stop input is active (open).

Options 2 "Hi-Spd Edge"
3 "Momentary"

ATTENTION: When operating in 2-Wire Level Sense (Run Level), the PowerFlex 523 and PowerFlex 525 drive should only be controlled from the Digital Input Terminal Blocks. This should NOT be used with any other DSI or Network device.
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. · I/O Terminal 01 "Stop" = Coast to stop. · I/O Terminal 03 "Run REV" · Drive will start after a momentary input from either the Run FWD input (I/O Terminal 02) or the Run REV input (I/O Terminal
03). · I/O Terminal 01 "Stop" = Stop according to the value set in P045 [Stop Mode].

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Chapter 3 Programming and Parameters

Programmable Digital Outputs

t069 [Opto Out1 Sel] t072 [Opto Out2 Sel]
PF 525 PowerFlex 525 only.
Determines the operation of the programmable digital outputs.

Related Parameter(s): P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564

Options 0 "Ready/Fault"
1 "At Frequency" 2 "MotorRunning" 3 "Reverse" 4 "Motor Overld" 5 "Ramp Reg"
6 "Above Freq" 7 "Above Cur"

Setting Output Changes State When... Opto outputs are active when power is applied. Indicates that the drive is ready for operation. Opto outputs are inactive when power is removed or a fault occurs. Drive reaches commanded frequency. Motor is receiving power from the drive. Drive is commanded to run in reverse direction. Motor overload condition exists. Ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or overvoltage fault from occurring. Drive exceeds the frequency (Hz) value set in t070 or t073 [Opto Outx Level]. Drive exceeds the current (% Amps) value set in t070 or t073 [Opto Outx Level].

Hysteresis
None
0.5 Hz above; 1.0 Hz below None None 100 ms time delay on or off
100 ms time delay on or off
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.

100 ms time delay on or off

8 "Above DCVolt" 9 "Retries Exst" 10 "Above Anlg V"

Drive exceeds the DC bus voltage value set in t070 or t073 [Opto Outx Level]. Value set in A541 [Auto Rstrt Tries] is exceeded. Analog input voltage (0...10V input) exceeds the value set in t070 or t073 [Opto Outx Level].
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 "Bi-Polar In".

100 ms time delay on or off None
100 ms time delay on or off

11 "Above PF Ang" 12 "Anlg In Loss"
13 "ParamControl"
14 "NonRec Fault"
15 "EM Brk Cntrl" 16 "Thermal OL"
17 "Amb OverTemp" 18 "Local Active" 19 "Comm Loss" 20 "Logic In 1" 21 "Logic In 2" 22 "Logic 1 & 2" 23 "Logic 1 or 2" 24 "StpLogic Out" 25 "Timer Out" 26 "Counter Out" 27 "At Position"
28 "At Home"
29 "Safe-Off" 30 "SafeTqPermit"(1) 31 "AutoRst Ctdn"(1)

Power Factor angle exceeds the value set in t070 or t073 [Opto Outx Level].

100 ms time delay on or off

Analog input loss has occurred. Program t094 [Anlg In V Loss] or t097 [Anlg In mA Loss] for desired action On, 2 mA / ±1V

when input loss occurs.

Off, 3 mA / ±1.5V

Output is directly controlled by the state of the t070 or t073 [Opto 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

· Value set in A541 [Auto Rstrt Tries] is exceeded or

· A541 [Auto Rstrt Tries] is not enabled or

None

· A non-resettable fault has occurred.

EM Brake is energized. Program t087 [EM Brk On Delay] and t086 [EM Brk Off Delay] for desired action. None

Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 [Relay Outx Level]. It also energizes if the drive is within 5 °C of the drive overheat trip point.

None

Relay energizes when control module over temperature occurs.

None

Active when drive P046, P048 or P050 [Start Source x] is in local keypad control.

None

Active when communication is lost from any comm source with reference or control.

None

An input is programmed as "Logic Input 1" and is active.

None

An input is programmed as "Logic Input 2" and is active.

None

Both Logic inputs are programmed and active.

None

One or both Logic inputs are programmed and one or both is active.

None

Drive enters StepLogic step with Command Word set to enable Logic output.

None

Timer has reached the value set in t070 or t073 [Opto Outx Level] or not timing.

None

Counter has reached the value set in t070 or t073 [Opto Outx Level] or not counting.

None

Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with A564 [Encoder Pos Tol].



Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 [Encoder Pos Tol].



Both safe-off inputs are active.



Both safe-off inputs are inactive (closed).



Drive is counting down to an automatic restart.



(1) Setting is available in FRN 5.xxx and later.

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Programmable Digital Outputs (Continued)

Default:

Opto Out1 Sel:

2

Values Opto Out2 Sel:

1

Min/Max:

0/31

Display:

1

t070 [Opto Out1 Level] t073 [Opto Out2 Level]
32 32 bit parameter. PF 525 PowerFlex 525 only.
Determines the on/off point for the digital outputs when t069 or t072 [Opto Outx Sel] is set to the values shown below.

Min/Max Value Range Based On [Opto Outx Sel] Setting

6: 0...500 Hz 10: 0...100%

16: 0.1...9999 s

7: 0...180% 8: 0...815V

11 0/1 13 0...800

17:

1...9999 counts

18: 0...180°

20 :

0/1

26 :

0...150%



Values

Default: Min/Max: Display:

0.0 0.0/9999.0 0.1

t075 [Opto Out Logic]
PF 525 PowerFlex 525 only.
Determines the logic (Normally Open/NO or Normally Closed/NC) of the digital outputs only.

Setting 0 1 2 3

Digital Out 1 Logic NO NC NO NC

Digital Out 2 Logic NO NO NC NC

Default:

0

Values Min/Max:

0/3

Display:

1

Related Parameter(s): t069, t072

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Programmable Relay Outputs

t076 [Relay Out1 Sel] t081 [Relay Out2 Sel]
PF 525 PowerFlex 525 only.
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"
1 "At Frequency" 2 "MotorRunning" 3 "Reverse" 4 "Motor Overld" 5 "Ramp Reg"
6 "Above Freq" 7 "Above Cur"

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. Drive reaches commanded frequency. Motor is receiving power from the drive. Drive is commanded to run in reverse direction. Motor overload condition exists. Ramp regulator is modifying the programmed accel/ decel times to avoid an overcurrent or overvoltage fault from occurring. Drive exceeds the frequency (Hz) value set in t077 or t082 [Relay Outx Level]. Drive exceeds the current (% Amps) value set in t077 or t082 [Relay Outx Level].

Hysteresis
None
0.5 Hz above; 1.0 Hz below None None 100 ms time delay on or off
100 ms time delay on or off
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.

100 ms time delay on or off

8 "Above DCVolt" 9 "Retries Exst" 10 "Above Anlg V"

Drive exceeds the DC bus voltage value set in t077 or t082 [Relay Outx Level]. Value set in A541 [Auto Rstrt Tries] is exceeded. Analog input voltage (0...10V input) exceeds the value set in t077 or t082 [Relay Outx Level].
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 "Bi-Polar In".

100 ms time delay on or off None
100 ms time delay on or off

11 "Above PF Ang" 12 "Anlg In Loss"
13 "ParamControl"
14 "NonRec Fault"
15 "EM Brk Cntrl" 16 "Thermal OL"
17 "Amb OverTemp" 18 "Local Active 19 "Comm Loss" 20 "Logic In 1"(1) 21 "Logic In 2"(1) 22 "Logic 1 & 2"(1) 23 "Logic 1 or 2"(1) 24 "StpLogic Out"(1) 25 "Timer Out" 26 "Counter Out" 27 "At Position"(1)
28 "At Home"(1)
29 "Safe-Off"(1) 30 "SafeTqPermit"(1)(2) 31 "AutoRst Ctdn"(1)(2)

Power Factor angle exceeds the value set in t077 or t082 [Relay Outx Level].

100 ms time delay on or off

Analog input loss has occurred. Program t094 [Anlg In V Loss] or t097 [Anlg In mA Loss] for desired action On, 2 mA / ±1V

when input loss occurs.

Off, 3 mA / ±1.5V

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

· Value set in A541 [Auto Rstrt Tries] is exceeded or

· A541 [Auto Rstrt Tries] is not enabled or

None

· A non-resettable fault has occurred.

EM Brake is energized. Program t087 [EM Brk On Delay] and t086 [EM Brk Off Delay] for desired action. None

Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 [Relay Outx Level]. It also energizes if the drive is within 5 °C of the drive overheat trip point.

None

Relay energizes when control module over temperature occurs.

None

Active when drive P046, P048 or P050 [Start Source x] is in local keypad control.

None

Active when communication is lost from any comm source with reference or control.

None

An input is programmed as "Logic Input 1" and is active.

None

An input is programmed as "Logic Input 2" and is active.

None

Both Logic inputs are programmed and active.

None

One or both Logic inputs are programmed and one or both is active.

None

Drive enters StepLogic step with Command Word set to enable Logic output.

None

Timer has reached the value set in t077 or t082 [Relay Outx Level] or not timing.

None

Counter has reached the value set in t077 or t082 [Relay Outx Level] or not counting.

None

Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with A564 [Encoder Pos Tol].



Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 [Encoder Pos Tol].



Both safe-off inputs are active.



Both safe-off inputs are inactive (closed).



Drive is counting down to an automatic restart.



(1) Setting is specific to PowerFlex 525 drives only. (2) Setting is available in FRN 5.xxx and later.

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Programmable Relay Outputs (Continued)

Default:

Relay Out1 Sel:

0

Values Relay Out2 Sel:

2

Min/Max:

0/31

Display:

1

t077 [Relay Out1 Level] t082 [Relay Out2 Level]
PF 525 PowerFlex 525 only.

32 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...500 Hz

10: 0...100%

16:

7: 0...180%

11: 0/1

17:

8: 0...815V

13: 0...800

18:

0.1...9999 s 1...9999 counts 0...180 °C

20: 0/1 26: 0...150% 

Values

Default: Min/Max: Display:

0.0 0.0/9999.0 0.1

Related Parameter(s): t076, t081

t079 [Relay 1 On Time]

t084 [Relay 2 On Time]

PF 525 PowerFlex 525 only.

Sets the delay time before Relay energizes after required condition is met.

Default:

0.0 s

Values Min/Max:

0.0/600.0 s

Display:

0.1 s

t080 [Relay 1 Off Time]

t085 [Relay 2 Off Time]

PF 525 PowerFlex 525 only.

Sets the delay time before Relay de-energizes after required condition ceases.

Default:

0.0 s

Values Min/Max:

0.0/600.0 s

Display:

0.1 s

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 Electromechanical (EM) Brake Control Mode is enabled with P045 [Stop Mode].

Frequency

[EM Brk O Delay]

Ramp decel

[EM Brk On Delay]

Ramp accel

[Minimum Freq]

Values

Start commanded Default: Min/Max: Display:

Time

EM Brk

Stop

energized (O ) commanded

EM Brk de-energized (On)

2.00 s

0.00/10.00 s

0.01 s

Drive stops

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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].

Frequency

[EM Brk O Delay]

Ramp decel

[EM Brk On Delay]

Ramp accel

[Minimum Freq]

Values

Start commanded Default: Min/Max: Display:

Time

EM Brk

Stop

energized (O ) commanded

EM Brk de-energized (On)

2.00 s

0.00/10.00 s

0.01 s

Drive stops

t088 [Analog Out Sel]

Related Parameter(s): t090

The 0...10V, 0...20 mA or 4...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.(1)

Options
0 "OutFreq 0-10" 1 "OutCurr 0-10" 2 "OutVolt 0-10" 3 "OutPowr 0-10" 4 "OutTorq 0-10" 5 "TstData 0-10" 6 "Setpnt 0-10" 7 "DCVolt 0-10" 8 "OutFreq 0-20" 9 "OutCurr 0-20" 10 "OutVolt 0-20" 11 "OutPowr 0-20" 12 "OutTorq 0-20" 13 "TstData 0-20" 14 "Setpnt 0-20" 15 "DCVolt 0-20" 16 "OutFreq 4-20" 17 "OutCurr 4-20" 18 "OutVolt 4-20" 19 "OutPowr 4-20" 20 "OutTorq 4-20" 21 "TstData 4-20" 22 "Setpnt 4-20" 23 "DCVolt 4-20"

Output Range
0-10V 0-10V 0-10V 0-10V 0-10V 0-10V 0-10V 0-10V 0-20 mA 0-20 mA 0-20 mA 0-20 mA 0-20 mA 0-20 mA 0-20 mA 0-20 mA 4-20 mA 4-20 mA 4-20 mA 4-20 mA 4-20 mA 4-20 mA 4-20 mA 4-20 mA

Minimum Output Value
0V = 0 Hz 0V = 0 A 0V = 0V 0V = 0 kW 0V = 0 A 0V = 0000 0V = 0% 0V = 0V 0 mA = 0 Hz 0 mA = 0 A 0 mA = 0V 0 mA = 0 kW 0 mA = 0 A 0 mA = 0000 0 mA = 0% 0 mA = 0V 4 mA = 0 Hz 4 mA = 0 A 4 mA = 0V 4 mA = 0 kW 4 mA = 0 A 4 mA = 0000 4 mA = 0% 4 mA = 0V

Maximum Output Value = t089 [Analog Out High] [Maximum Freq] 200% Drive Rated Current 120% Drive Rated Output Volts 200% Drive Rated Power 200% Drive Rated Current 65535 (Hex FFFF) 100.0% Setpoint setting 100.0% of trip value [Maximum Freq] 200% Drive Rated Current 120% Drive Rated Output Volts 200% Drive Rated Power 200% Drive Rated Current 65535 (Hex FFFF) 100.0% Setpoint setting 100.0% of trip value [Maximum Freq] 200% Drive Rated Current 120% Drive Rated Output Volts 200% Drive Rated Power 200% Drive Rated Current 65535 (Hex FFFF) 100.0% Setpoint setting 100.0% of trip value

Filter(1)
None Filter A None Filter A Filter A None None None None Filter A None Filter A Filter A None None None None Filter A None Filter A Filter A None None None

Related Parameter b001 b003 b004 b017 d382  t090 b005 b001 b003 b004 b017 d382  t090 b005 b001 b003 b004 b017 d382  t090 b005

(1) Filter A is a single pole digital filter with a 162 ms time constant. Given a 0...100% step input from a steady state, the output of Filter A takes 500 ms to get to 95% of maximum, 810 ms to get to 99%, and 910 ms to get to 100%.

Default:

0

Values Min/Max:

0/23

Display:

1

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required.

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Terminal Block Group (continued)

t089 [Analog Out High]

Scales the maximum output value (V or mA) when the source setting is at maximum.(1)

Default:

100%

Values Min/Max:

0/800%

Display:

1%

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required.

t090 [Anlg Out Setpt]

Sets the percentage of output desired when t088 [Analog Out Sel] is set to 6, 14 or 22 "Analog Setpoint".(1)

Default:

0.0%

Values Min/Max:

0.0/100.0%

Display:

0.1%

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required.

t091 [Anlg In 0-10V Lo]

Stop 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.

Default:

0.0%

Values Min/Max:

0.0/200.0%

Display:

0.1%

t092 [Anlg In 0-10V Hi]

Stop drive before changing this parameter.

Sets the percentage (based on 10V) of input voltage applied to the 0...10V analog input used to represent P044 [Maximum Freq]. Analog inversion can be accomplished by setting this value smaller than t091 [Anlg In 0-10V Lo]. If t093 [10V Bipolar Enbl] is set to 1 "Bi-Polar In", the same value applies to positive and negative voltage.

Default:

100.0%

Values Min/Max:

0.0/200.0%

Display:

0.1%

t093 [10V Bipolar Enbl]

PF 525 PowerFlex 525 only.

Enables/disables bi-polar control. In bi-polar mode direction is commanded by the polarity of the voltage. If bi-polar control is enabled, P043 [Minimum Freq] and t091 [Anlg In 0-10V Lo] are ignored.

0 "Uni-Polar In" (Default) Options
1 "Bi-Polar In"

0...10V only ±10V

Related Parameter(s): t088 Related Parameter(s): P043, t092, t093 Related Parameter(s): P044, t091, t093
Related Parameter(s): t091, t092

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Terminal Block Group (continued)

t094 [Anlg In V Loss]

Related Parameter(s): P043, P044, A426, A427

Sets the response to a loss of input. When the 0...10V input (or 10 to +10V) is used for any reference, any input less than 1V is reported as a signal loss. Input must exceed 1.5V for the signal loss condition to end. If enabled, this function affects any input that is being used as a speed reference, PID reference or PID setpoint in the drive.

0 "Disabled" (Default)

1 "Fault (F29)"

2 "Stop"

3 "Zero Ref"

Options 4 "Min Freq Ref"

5 "Max Freq Ref"

6 "Key Freq Ref"

7 "MOP Freq Ref"

8 "Continu Last"

t095 [Anlg In4-20mA Lo]

Stop 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].

Default:

0.0%

Values Min/Max:

0.0/200.0%

Display:

0.1%

Related Parameter(s): P043, t096

t096 [Anlg In4-20mA Hi]

Stop 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].

Default:

100.0%

Values Min/Max:

0.0/200.0%

Display:

0.1%

Related Parameter(s): P044, t095

t097 [Anlg In mA Loss]

Related Parameter(s): P043, P044, A426, A427

Sets the response to a loss of input. When the 4...20 mA 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.

0 "Disabled" (Default)

1 "Fault (F29)"

2 "Stop"

3 "Zero Ref"

Options 4 "Min Freq Ref"

5 "Max Freq Ref"

6 "Key Freq Ref"

7 "MOP Freq Ref"

8 "Continu Last"

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Terminal Block Group (continued)

t098 [Anlg Loss Delay]

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].

Default:

0.0 s

Values Min/Max:

0.0 /20.0 s

Display:

0.1 s

Terminal Bl)

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 = 4x filter, and so on).

Default:

0

Values Min/Max:

0/14

Display:

1

Related Parameter(s): t094, t097

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 [Wake 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. 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.

Default:

10.0%

Values Min/Max:

0.0/100.0%

Display:

0.1%

zo

t102 [Sleep Time]

Sets the analog input time the drive must stay below to enter sleep mode.

Default:

0.0 s

Values Min/Max:

0.0/600.0 s

Display:

0.1 s

t103 [Wake Level]

Sets the analog input level the drive must reach to wake from sleep mode.

Default:

15.0%

Values Min/Max:

0.0/100.0%

Display:

0.1%

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t104 [Wake Time]

Sets the analog input time the drive must stay above to wake from sleep mode.

Default:

0.0 s

Values

0.0/600.0 s

1 "FaultDisable"

0.1 s

t105 [Safety Open En]
PF 525 PowerFlex 525 only.
Sets the action when both safety inputs (Safety 1 and Safety 2) are disabled (de-energized  no power is applied). 0 "FaultEnable" (Default)
Options 1 "FaultDisable"

t106 [SafetyFlt RstCfg]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Sets the method of resetting fault F111 "Safety Hardware" either by means of a power cycle or fault clear operation.

0 "PwrCycleRset" (Default) Options
1 "FltClr Reset"

Reset fault F111 using power cycle. Reset fault F111 using fault clear mechanism without power cycle.

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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.
0 "Save" (Default) Options
1 "RAM only"

C122 [Cmd Stat Select]
PF 525 PowerFlex 525 only.
Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use over a communication network. See Writing (06) Logic Command Data on page 205 for more information. This parameter cannot be changed when an I/O connection is established through the communication adapter or the drive's embedded EtherNet/ IP port.
0 "Velocity" (Default) Options
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.
0 "1200" 1 "2400" 2 "4800" Options 3 "9600" (Default) 4 "19,200" 5 "38,400"

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.

Default:

100

Values Min/Max:

1/247

Display:

1

C125 [Comm Loss Action]

Sets the drive's response to a loss of connection or excessive communication errors on the RS485 port.

0 "Fault" (Default)

1 "Coast Stop" Options
2 "Stop"

Stops drive using "Coast to stop". Stops drive using P045 [Stop Mode] setting.

3 "Continu Last"

Drive continues operating at communication commanded speed saved in RAM.

Related Parameter(s): P045

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 I/O that controls the drive is transmitted through the RS485 port.

Values

Default: Min/Max: Display:

5.0 s 0.1/60.0 s 0.1 s

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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.
0 "RTU 8-N-1" (Default) 1 "RTU 8-E-1" 2 "RTU 8-O-1" Options 3 "RTU 8-N-2" 4 "RTU 8-E-2" 5 "RTU 8-O-2"

C128 [EN Addr Sel]

Related Parameter(s): C129-C132, C133-C136, C137-C140

PF 525 PowerFlex 525 only.

Enables the IP address, subnet mask and gateway address to be set with a BOOTP server. Identifies the connections that would be attempted on a reset or power cycle. A reset or power cycle is required after selection is made.

1 "Parameters" Options
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]
PF 525 PowerFlex 525 only.
Sets the bytes in the IP address. A reset or power cycle is required after selection is made.
192.168.1.62

[EN IP Addr Cfg 1] [EN IP Addr Cfg 2] [EN IP Addr Cfg 3] [EN IP Addr Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 "Parameters".

Default:

0

Values Min/Max:

0/255

Display:

1

Related Parameter(s): C128

C133 [EN Subnet Cfg 1] C134 [EN Subnet Cfg 2] C135 [EN Subnet Cfg 3] C136 [EN Subnet Cfg 4]
PF 525 PowerFlex 525 only.
Sets the bytes of the subnet mask. A reset or power cycle is required after selection is made.
255.255.255.0

[EN Subnet Cfg 1] [EN Subnet Cfg 2] [EN Subnet Cfg 3] [EN Subnet Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 "Parameters".

Default:

0

Values Min/Max:

0/255

Display:

1

Related Parameter(s): C128

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Communications Group (continued)
C137 [EN Gateway Cfg 1] C138 [EN Gateway Cfg 2] C139 [EN Gateway Cfg 3] C140 [EN Gateway Cfg 4]
PF 525 PowerFlex 525 only.
Sets the bytes of the gateway address. A reset or power cycle is required after selection is made.
192.168.1.1

[EN Gateway Cfg 1] [EN Gateway Cfg 2] [EN Gateway Cfg 3] [EN Gateway Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 "Parameters".

Default:

0

Values Min/Max:

0/255

Display:

1

Related Parameter(s): C128

C141 [EN Rate Cfg]
PF 525 PowerFlex 525 only.
Sets the network data rate at which EtherNet/IP communicates. A reset or power cycle is required after selection is made. 0 "Auto detect" (Default) 1 "10Mbps Full"
Options 2 "10Mbps Half" 3 "100Mbps Full" 4 "100Mbps Half"

C143 [EN Comm Flt Actn]
PF 525 PowerFlex 525 only.

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 I/O that controls the drive is transmitted through the EtherNet/IP interface.

ATTENTION: Risk of injury or equipment damage exists. Parameter C143 [EN Comm Flt 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" 2 "Zero Data" 3 "Hold Last" 4 "Send Flt Cfg"

Drive stops per P045 [Stop Mode] setting. Note: The Reference and Datalink values transmitted to the drive will be set to "0". Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value. Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, C146, and C147...C150.

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Communications Group (continued)

C144 [EN Idle Flt Actn]

Related Parameter(s): P045, C145, C146, C147-C150

PF 525 PowerFlex 525 only.

Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that the scanner is idle because the controller was switched to program mode.

ATTENTION: Risk of injury or equipment damage exists. Parameter C144 [EN Idle Flt Actn] lets you determine the action of the EtherNet/IP interface and connected drive if the scanner is idle. By default, this parameter faults the 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" 2 "Zero Data" 3 "Hold Last" 4 "Send Flt Cfg"

Drive stops per P045 [Stop Mode] setting. Note: The Reference and Datalink values transmitted to the drive will be set to "0". Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value. Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, C146, and C147...C150.

C145 [EN Flt Cfg Logic]

32 32 bit parameter.

PF 525 PowerFlex 525 only.

Sets the Logic Command data that is sent to the drive if any of the following is true:  C143 [EN Comm Flt Actn] is set to 4 "Send Flt Cfg" and communications are disrupted.  C144 [EN Idle Flt 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 205 for more information.

Default:

0000

Values Min/Max:

0000/FFFF

Display:

0000

Related Parameter(s): C143, C144

C146 [EN Flt Cfg Ref]

32 32 bit parameter.

PF 525 PowerFlex 525 only.

Sets the Reference data that is sent to the drive if any of the following is true:  C143 [EN Comm Flt Actn] is set to 4 "Send Flt Cfg" and communications are disrupted.  C144 [EN Idle Flt Actn] is set to 4 "Send Flt Cfg" and the scanner is put into Program or Test mode.

Default:

0

Values Min/Max:

0/50000

Display:

1

Related Parameter(s): C143, C144

C147 [EN Flt Cfg DL 1] C148 [EN Flt Cfg DL 2] C149 [EN Flt Cfg DL 3] C150 [EN Flt Cfg DL 4]

PF 525 PowerFlex 525 only.

Sets the Ethernet Datalink Input data that is sent to the drive if any of the following is true:  C143 [EN Comm Flt Actn] is set to 4 "Send Flt Cfg" and communications are disrupted.  C144 [EN Idle Flt Actn] is set to 4 "Send Flt Cfg" and the scanner is put into Program or Test mode.

Default:

0

Values Min/Max:

0/65535

Display:

1

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Communications Group (continued)

C153 [EN Data In 1] C154 [EN Data In 2] C155 [EN Data In 3] C156 [EN Data In 4]

PF 525 PowerFlex 525 only.

Datalink parameter number whose value is written from the embedded EtherNet/IP data table. This parameter cannot be changed when an I/O connection is established through the drive's embedded EtherNet/IP port.

Default:

0

Values 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]

PF 525 PowerFlex 525 only.

Datalink parameter number whose value is read from the embedded EtherNet/IP data table. This parameter cannot be changed when an I/O connection is established through the drive's embedded EtherNet/IP port.

Default:

0

Values 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 I/O connection is established through the communication adapter.

Default:

0

Values Min/Max:

0/800

Display:

1

C165 [Opt Data Out 1] C166 [Opt Data Out 2] C167 [Opt Data Out 3] C168 [Opt Data Out 4]

Datalink parameter number whose value is read from the HSDSI data table. This parameter cannot be changed when an I/O connection is established through the communication adapter.

Default:

0

Values Min/Max:

0/800

Display:

1

C169 [MultiDrv Sel]

Sets the configuration of the drive that is in multi-drive mode. A reset or power cycle is required after selection is made.

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).

Options

1 "Network Opt" 2 "EtherNet/IP"(1)

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. Multi-drive is enabled with the embedded Ethernet port as the multi-drive master. The host drive is "Drive 0" and up to four slave drives can be daisy-chained from its RS485 port.

(1) Setting is specific to PowerFlex 525 drives only.

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Communications Group (continued)

C171 [Drv 1 Addr] C172 [Drv 2 Addr] C173 [Drv 3 Addr] C174 [Drv 4 Addr]

Related Parameter(s): C169

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.

Default:

Drv 1 Addr:

2

Drv 2 Addr:

3

Values

Drv 3 Addr: Drv 4 Addr:

4 5

Min/Max:

1/247

Display:

1

C175 [DSI I/O 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.
0 "Drive 0" (Default) 1 "Drive 0-1" Options 2 "Drive 0-2" 3 "Drive 0-3" 4 "Drive 0-4"

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Logic Group

StepLogic Inputs

L180 [Stp Logic 0] L182 [Stp Logic 2] L184 [Stp Logic 4] L186 [Stp Logic 6]

L181 [Stp Logic 1] L183 [Stp Logic 3] L185 [Stp Logic 5] L187 [Stp Logic 7]

Related Parameter(s):

Stop drive before changing this parameter.

PF 525 PowerFlex 525 only.

Default:

00F1

Values Min/Max:

0000/FAFF

Display

0001

See Appendix D and Appendix E for more information on applying StepLogic® function and Position StepLogic application. 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, t065...t068 [DigIn TermBlk xx] to 24 "Logic In 1" and/or 25 "Logic In 2" or by using Bits 6 and 7 of A560 [Enh Control Word]. A time interval between steps can be programmed using parameters L190...L197 [Stp Logic Time x]. See the table below for related parameters. The speed for any step is programmed using parameters A410...A417 [Preset Freq x].

Step StepLogic Parameter
0 L180 [Stp Logic 0] 1 L181 [Stp Logic 1] 2 L182 [Stp Logic 2] 3 L183 [Stp Logic 3] 4 L184 [Stp Logic 4] 5 L185 [Stp Logic 5] 6 L186 [Stp Logic 6] 7 L187 [Stp Logic 7]

Related Preset Frequency Parameter (Can be activated independent of StepLogic Parameters) A410 [Preset Freq 0] A411 [Preset Freq 1] A412 [Preset Freq 2] A413 [Preset Freq 3] A414 [Preset Freq 4] A415 [Preset Freq 5] A416 [Preset Freq 6] A417 [Preset Freq 7]

Related StepLogic Time Parameter (Active when L180...L187 Digit 1 or 2 are set to 1, b, C, d or E) L190 [Stp Logic Time 0] L191 [Stp Logic Time 1] L192 [Stp Logic Time 2] L193 [Stp Logic Time 3] L194 [Stp Logic Time 4] L195 [Stp Logic Time 5] L196 [Stp Logic Time 6] L197 [Stp Logic Time 7]

The position for any step is programmed using parameters L200...L214 [Step Units x].
Step StepLogic Position Parameter 0 L200 [Step Units 0] & L201 [Step Units F 0] 1 L202 [Step Units 1] & L203 [Step Units F 1] 2 L204 [Step Units 2] & L205 [Step Units F 2] 3 L206 [Step Units 3] & L207 [Step Units F 3] 4 L208 [Step Units 4] & L209 [Step Units F 4] 5 L210 [Step Units 5] & L211 [Step Units F 5] 6 L212 [Step Units 6] & L213 [Step Units F 6] 7 L214 [Step Units 7] & 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.

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StepLogic Inputs (Continued)
StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. See Appendix D for more information.

Logic for next step Logic to jump to a different step Different step to jump Step settings Not Used

Digit 1 Digit 2 Digit 3 Digit 4

Velocity Control Settings (Digit 4)

Required Setting 0 1 2 3 4 5 6 7 8 9 A b

Accel/Decel Param. Used Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2

StepLogic Output State Off Off Off On On On Off Off Off On On On

Commanded Direction FWD REV No Output FWD REV No Output FWD REV No Output FWD REV No Output

Positioning Settings (Digit 4)

Required Setting 0 1 2 3 4 5 6 7 8 9 A b C d E F

Accel/Decel Param. Used Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2

StepLogic Output State Off Off Off Off On On On On Off Off Off Off On On On On

Direction From Home FWD FWD REV REV FWD FWD REV REV FWD FWD REV REV FWD FWD REV REV

Type of Command Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental

Settings (Digit 3)

Setting 0 1 2 3 4 5 6 7 8 9 A

Description 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) End Program and Fault (F2)

Settings (Digit 2 and 1)

Setting 0 1 2 3 4 5 6 7 8 9 A b C d E F

Description Skip Step (Jump Immediately) Step Based on [Stp Logic Time x] Step if "Logic In 1" is Active Step if "Logic In 2" is Active Step if "Logic In 1" is Not Active Step if "Logic In 2" is Not Active Step if either "Logic In 1" or "Logic In 2" is Active Step if both "Logic In 1" and "Logic In 2" are Active Step if neither "Logic In 1" nor "Logic In 2" is Active Step if "Logic In 1" is Active and "Logic In 2" is Not Active Step if "Logic In 2" is Active and "Logic In 1" is Not Active Step after [Stp Logic Time x] and "Logic In 1" is Active Step after [Stp Logic Time x] and "Logic In 2" is Active Step after [Stp Logic Time x] and "Logic In 1" is Not Active Step after [Stp Logic Time x] and "Logic In 2" is Not Active Do Not Step/Ignore Digit 2 Settings

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Logic Group (continued)

L190 [Stp Logic Time 0] L192 [Stp Logic Time 2] L194 [Stp Logic Time 4] L196 [Stp Logic Time 6]

L191 [Stp Logic Time 1] L193 [Stp Logic Time 3] L195 [Stp Logic Time 5] L197 [Stp Logic Time 7]

PF 525 PowerFlex 525 only.

Sets the time to remain in each step if the corresponding command word is set to "Step based on time".

Default:

30.0 s

Values Min/Max:

0.0/999.9 s

Display:

0.1 s

L200 [Step Units 0] L204 [Step Units 2] L208 [Step Units 4] L212 [Step Units 6]

L202 [Step Units 1] L206 [Step Units 3] L210 [Step Units 5] L214 [Step Units 7]

32 32 bit parameter.

PF 525 PowerFlex 525 only.

Sets the position in user-defined units the drive must reach at each step.

Default:

0.00

Values Min/Max:

0.00/6400.00

Display:

0.01

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Advanced Display Group

d360 [Analog In 0-10V]

Displays the 0...10V analog input as a percent of full scale.

Default:

Read Only

Values Min/Max:

0.0/100.0%

Display:

0.1%

Chapter 3 Programming and Parameters Related Parameter(s): t091, t092

d361 [Analog In 4-20mA]

Displays the 4...20 mA analog input as a percent of full scale.

Default:

Read Only

Values Min/Max:

0.0/100.0%

Display:

0.1%

Related Parameter(s): t095, t096

d362 [Elapsed Time-hr]

Displays the total elapsed powered-up time (in hours) since timer reset. The timer stops when it reaches the maximum value.

Default:

Read Only

Values Min/Max:

0/32767 hr

Display:

1 hr

Related Parameter(s): A555

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.

Default:

Read Only

Values Min/Max:

0.0/60.0 min

Display:

0.1 min

d364 [Counter Status]

Displays the current value of the counter if enabled.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

d365 [Timer Status]
32 32 bit parameter.

Displays the current value of the timer if enabled.

Default:

Read Only

Values Min/Max:

0.0/9999.0 s

Display:

0.1 s

d366 [Timer Status]
32 32 bit parameter.

Displays the current value of the timer if enabled.

Default:

Read Only

Values Min/Max:

0.0/0.9 s

Display:

0.1 s

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Advanced Display Group (continued)

d367 [Drive Type]

Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non Rockwell Automation technical personnel).

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

d368 [Testpoint Data]

Displays the present value of the function selected in A483 [Testpoint Sel].

Default:

Read Only

Values Min/Max:

0/FFFF

Display:

1

d369 [Motor OL Level] Displays the motor overload counter.
Default: Values Min/Max:
Display:

Read Only 0.0/150.0% 0.1%

Related Parameter(s): A483

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].

Default:

Read Only

Values Min/Max:

0.0/25.0 Hz

Display:

0.1 Hz

d376 [Speed Feedback]
32 32 bit parameter.

Displays the value of the actual motor speed whether measured by encoder/pulse train feedback or estimated.

Default:

Read Only

Values Min/Max:

0.0/64000.0 rpm

Display:

0.1 rpm

d377 [Speed Feedback F]
32 32 bit parameter.

Displays the value of the actual motor speed whether measured by encoder/pulse train feedback or estimated.

Default:

Read Only

Values Min/Max:

0.0/0.9 rpm

Display:

0.1 rpm

d378 [Encoder Speed]
32 32 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.(1)

Default:

Read Only

Values Min/Max:

0.0/64000.0 rpm

Display:

0.1 rpm

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

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d379 [Encoder Speed F]
32 32 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.

Default:

Read Only

Values Min/Max:

0.0/0.9 rpm

Display:

0.1 rpm

d380 [DC Bus Ripple]

Displays the real-time value of the DC bus ripple voltage.

Default:

Read Only

Values Min/Max:

0/410V DC for 230V AC drives; 820V DC for 460V AC drives; 1025V DC for 600V AC drives

Display:

1V DC

d381 [Output Powr Fctr]

Displays the angle in electrical degrees between motor voltage and motor current.

Default:

Read Only

Values Min/Max:

0.0/180.0 deg

Display:

0.1 deg

d382 [Torque Current]

Displays the current value of the motor torque current measured by the drive.

Default:

Read Only

Values Min/Max:

0.00/(Drive Rated Amps x 2)

Display:

0.01 A

d383 [PID1 Fdbk Displ] d385 [PID2 Fdbk Displ]
PF 525 PowerFlex 525 only.
Displays the active PID Feedback value. Default:
Values Min/Max: Display:

Read Only 0.0/100.0% 0.1%

d384 [PID1 Setpnt Disp] d386 [PID2 Setpnt Disp]
PF 525 PowerFlex 525 only.
Displays the active PID Setpoint value. Default:
Values Min/Max: Display:

Read Only 0.0/100.0% 0.1%

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Advanced Display Group (continued)
d387 [Position Status]
PF 525 PowerFlex 525 only.
Displays the present operating condition of the drive. When in Positioning mode, Bit 1 indicates positive or negative position in relation to Home.

Values

1 = Condition True, 0 = Condition False

Dir Positive

Digit 1

At Position

Digit 2

At Home

Digit 3

Drive Homed

Digit 4

Not Used

Default: Min/Max: Display:

Read Only 0000/1111 0000

d388 [Units Traveled H]

Stop drive before changing this parameter. 32 32 bit parameter.

PF 525 PowerFlex 525 only.

Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.

Default:

Read Only

Values Min/Max:

0/64000

Display:

1

Related Parameter(s): d387

d389 [Units Traveled L]

Stop drive before changing this parameter.

PF 525 PowerFlex 525 only.

Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.

Default:

Read Only

Values Min/Max:

0.00/0.99

Display:

0.01

Related Parameter(s): d387

d390 [Fiber Status] Present status of the Fibers features.

Values

1 = Condition True, 0 = Condition False

Sync Hold

Digit 1

Sync Ramp

Digit 2

Traverse On

Digit 3

Traverse Dec

Digit 4

Not Used

Default: Min/Max: Display:

Read Only 0000/1111 0000

d391 [Stp Logic Status]

Related Parameter(s): P047, L180-L187

PF 525 PowerFlex 525 only.

Displays the current step of the StepLogic profile as defined by parameters L180...L187 [Step Logic x] when P047 [Speed Reference1] is set to 13 "Step Logic" or 16 "Positioning".

Default:

Read Only

Values Min/Max:

0/8

Display:

1

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d392 [RdyBit Mode Act] (With PowerFlex 525 FRN 3.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Displays the value of A574 [RdyBit Mode Cfg].
Default: Values Min/Max:
Display:

Advanced Display Group (continued)
Read Only 0/1 1

d393 [Drive Status 2] (With PowerFlex 525 FRN 5.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Displays the present operating condition of the drive.

Chapter 3 Programming and Parameters Related Parameter(s): A574

FFSSSEJCAAADMlt1aaauuouC1oMuttfff1rtgFxrooeeerBBogSttrirTreRtBLTyyianasrqqauOtktkgaSSPiimvn1iuki2eCninet(rst1(nr)1ggn)l(d1gm)gdint (1)

x x 0 0 0 0 x 0 0 0 0 0 0 0 0 0 1 =Condition True

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0=Condition False

Nibble 4

Nibble 3

Nibble 2

Nibble 1 x =Reserved

Bit #

* Enhanced C ontrol Option Only .

(1) Bit status is specific to PowerFlex 525 drives only.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

d394 [Dig Out Status] (With PowerFlex 525 FRN 5.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Displays relay output and opto output status.

Rly1 Status Rly2 Status(1) Opto1 Status(1) Opto2 Status(1) Not Used
(1) Setting is specific to PowerFlex 525 drives only.
Default:
Values Min/Max:
Display:

Digit 1 Digit 2 Digit 3 Digit 4
Read Only 0/15 1

Status Relay 1 status (Normally Open) Relay 2 status (Normally Closed) Opto 1 status Opto 2 status

Bit Value = 0 Not activated (Relay 1 open) Not activated (Relay 2 closed) Not activated Not activated

Bit Value = 1 Activated (Relay 1 closed) Activated (Relay 2 open) Activated Activated

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Advanced Program Group

A410 [Preset Freq 0] A412 [Preset Freq 2] A414 [Preset Freq 4] A416 [Preset Freq 6]

A411 [Preset Freq 1] A413 [Preset Freq 3] A415 [Preset Freq 5] A417 [Preset Freq 7]

A418 [Preset Freq 8] A420 [Preset Freq 10] A422 [Preset Freq 12] A424 [Preset Freq 14]

A419 [Preset Freq 9] A421 [Preset Freq 11] A423 [Preset Freq 13] A425 [Preset Freq 15]

PF 525 PowerFlex 525 only.

Sets the frequency of the drive outputs to the programmed value when selected.

For PowerFlex 525

Default Accel/Decel Used

Preset Input 1 (DigIn TermBlk 05)

Preset Input 2 (DigIn TermBlk 06)

Preset Setting 0(1)

1

0

0

Preset Setting 1

1

Preset Setting 2

2

Preset Setting 3

2

Preset Setting 4

1

1

0

0

1

1

1

0

0

Preset Setting 5

1

Preset Setting 6

2

Preset Setting 7

2

Preset Setting 8

1

1

0

0

1

1

1

0

0

Preset Setting 9

1

Preset Setting 10

2

Preset Setting 11

2

Preset Setting 12

1

Preset Setting 13

1

Preset Setting 14

2

Preset Setting 15

2

For PowerFlex 523

1

0

0

1

1

1

0

0

1

0

0

1

1

1

Default Accel/Decel Used

Preset Input 1 (DigIn TermBlk 05)

Preset Input 2 (DigIn TermBlk 06)

Preset Setting 0(1)

1

Preset Setting 1

1

0

0

1

0

Preset Setting 2

2

Preset Setting 3

2

Preset Setting 4

1

Preset Setting 5

1

Preset Setting 6

2

Preset Setting 7

2

0

1

1

1

0

0

1

0

0

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: Preset Freq 1: Preset Freq 2: Preset Freq 3: Preset Freq 4: Preset Freq 5: Preset Freq 6: Preset Freq 7...15: Min/Max: Display:

0.00 Hz 5.00 Hz 10.00 HZ 20.00 Hz 30.00 Hz 40.00 Hz 50.00 Hz 60.00 Hz 0.00/500.00 Hz 0.01 Hz

Preset Input 3 (DigIn TermBlk 07) 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
Preset Input 3 (DigIn TermBlk 03) 0 0 0 0 1 1 1 1

Preset Input 4 (DigIn TermBlk 08) 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1



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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A426 [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.

Default:

60.00 Hz

Values 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: Min/Max: Display:

60.00 Hz 0.00/500.00 Hz 0.01 Hz

A428 [MOP Reset Sel]

Determines if the current MOP reference command is saved on power down.

0 "Zero MOP Ref" Options
1 "Save MOP Ref" (Default)

Resets the MOP frequency to zero on power down and stop.

A429 [MOP Preload] Determines the operation of the MOP function.
0 "No preload" (Default) Options
1 "Preload"

Bumpless Transfer: whenever MOP mode is selected, the current output value of the speed is loaded.

A430 [MOP Time] Sets the rate of change of the MOP reference.
Default: Values Min/Max:
Display:

10.0 s 0.1/600.0 s 0.1 s

A431 [Jog Frequency]

Sets the output frequency when a jog command is issued.

Default:

10.00 Hz

Values Min/Max:

0.00/[Maximum Freq]

Display:

0.01 Hz

Related Parameter(s): P044

A432 [Jog Accel/Decel]

Sets the acceleration and deceleration time used when in jog mode.

Default:

10.00 s

Values Min/Max:

0.01/600.00 s

Display:

0.01 s

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A433 [Purge Frequency]

Provides a fixed frequency command value when t062, t063, t065-t068 [DigIn TermBlk xx] is set to 40 "Purge".

Default:

5.00 Hz

Values Min/Max:

0.00/500.00 Hz

Display:

0.01 Hz

Related Parameter(s): t062, t063, t065-t068

A434 [DC Brake Time]

Related Parameter(s): P045, A435

Sets the length of time that DC brake current is "injected" into the motor when P045 [Stop Mode] is set to 10 "PointStp,CF" and 11 "PointStop" or 0 "Ramp,CF" and 4 "Ramp".

Default:

0.0 s

Values Min/Max:

0.0/99.9 s

Display:

0.1 s

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 0 "Ramp,CF", 2 "DC Brake, CF", 4 "Ramp", 6 "DC Brake", 10 "PointStp,CF", or 11 "PointStop".

Ramp-to-Stop Mode

DC Injection Stop Mode

Voltage

[DC Brake Time]

Volts/Speed Volts/Speed

SpeeVdoltage

[DC Brake Time] Magnitude

depends on

Stop Command

Time

[DC Brake Level]

Speed Stop Command Time

Magnitude depends on [DC Brake Level]

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: Min/Max: Display:

Drive Rated Amps x 0.05 0.00/(Drive Rated Amps x 1.80) 0.01 A

A436 [DC Brk Time@Strt] Sets the length of time that DC brake current is "injected" into the motor after a valid start command is received.

Related Parameter(s): P045, A435

Volts/Speed

[DC Brake Level]

[DC Brk Time@Strt]

Voltage Speed

Values

Start Command Default: Min/Max: Display:

Time
0.0 s 0.0/99.9 s 0.1 s

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A437 [DB Resistor Sel]
Stop drive before changing this parameter.
Enables/disables external dynamic braking and selects the level of resistor protection.

Related Parameter(s): A438, A550

IMPORTANT When A437 [DB Resistor Sel] is set to a value greater than "0", the value set in parameter A550 [Bus Reg Enable] will not take effect.

0 "Disabled" (Default)

1 "Norml RA Res"

5%

Options

2 "NoProtection"

100%

3...99"3...99% DutyCycle"

A438 [DB Threshold]

Related Parameter(s): A437

Sets the DC bus voltage threshold for Dynamic Brake operation. If DC bus voltage rises above this level, Dynamic Brake turns on. Lower values makes the dynamic braking function more responsive but may result in nuisance Dynamic Brake activation (IGBT can modulate continuously).

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: Min/Max: Display:

100.0% 10.0/110.0% 0.1%

A439 [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

Target

Target

vel

vel

Target vel/2

Example: Accel Time = 10 s S-Curve Setting = 30% S-Curve Time = 10 x 0.3 = 3 s

S-Curve Time = Accel Time

Total Time to Accelerate = Accel Time + S-Curve Time

Default:

0%

Values Min/Max:

0/100%

Display:

1%

S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time

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Advanced Program Group (continued)

A440 [PWM Frequency]

Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting.

% Output Curent (A)

100 96 92 88 84 80 76 72 68 64 60 56 50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Note: If Vector mode (open loop) is selected and 16 kHz is selected, the drive will forcibly reduce the carrier frequency to 8 kHz.

Carrier Frequency (kHz)

Related Parameter(s): A540

IMPORTANT Ignoring 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: Min/Max: Display:

4.0 kHz 2.0/16.0 kHz 0.1 kHz

A441 [Droop Hertz@ FLA]

PF 525 PowerFlex 525 only.

Reduces the frequency based on current. This frequency is subtracted from the commanded output frequency. 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.

Default:

0.0 Hz

Values Min/Max:

0.0/10.0 Hz

Display:

0.1 Hz

A442 [Accel Time 2] Time for the drive to ramp from 0.0 Hz to P044 [Maximum Freq] if Accel Time 2 is selected. Accel Rate = [Maximum Freq] / [Accel Time] [Maximum Freq]

Related Parameter(s): P044

Acceleration

Deceleration

Speed

0 [Accel Time x] Time [Decel Time x]
0

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

A443 [Decel Time 2]

Time for the drive to ramp from P044 [Maximum Freq] to 0.0 Hz if Decel Time 2 is selected. Decel Rate = [Maximum Freq] / [Decel Time]

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

Related Parameter(s): P044

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Advanced Program Group (continued)

A444 [Accel Time 3] A446 [Accel Time 4]

Sets the rate of acceleration for all speed increases when selected by digital inputs.

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

Chapter 3 Programming and Parameters

A445 [Decel Time 3] A447 [Decel Time 4]

Sets the rate of deceleration for all speed decreases when selected by digital inputs.

Default:

10.00 s

Values Min/Max:

0.00/600.00 s

Display:

0.01 s

A448 [Skip Frequency 1] A450 [Skip Frequency 2]

Related Parameter(s): A449, A451, A453, A455

A452 [Skip Frequency 3] A454 [Skip Frequency 4]

PF 525 PowerFlex 525 only.

Works in conjunction with A449, A451, A453 and A455 [Skip Freq Band x] creating a range of frequencies at which the drive does not operate continuously.

Default:

0.0 Hz (Disabled)

Values Min/Max:

0.0/500.0 Hz

Display:

0.1 Hz

A449 [Skip Freq Band 1] A451 [Skip Freq Band 2]

A453 [Skip Freq Band 3] A455 [Skip Freq Band 4]
PF 525 PowerFlex 525 only.

Determines the band around A448, A450, A452 and A454 [Skip Frequency x].

Frequency

Drive Output Frequency

Command Frequency

Skip Frequency

2x Skip Frequency Band

Related Parameter(s): A448, A450, A452, A454

Values

Default: Min/Max: Display:

Time 0.0 Hz 0.0/30.0 Hz 0.1 Hz

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A456 [PID 1 Trim Hi]

A468 [PID 2 Trim Hi]

PF 525 PowerFlex 525 only.

Scales the upper value of the trim frequency when trim is active.

Default:

60.0 Hz

Values Min/Max:

0.0/500.0 Hz

Display:

0.1 Hz

A457 [PID 1 Trim Lo]

A469 [PID 2 Trim Lo]

PF 525 PowerFlex 525 only.

Scales the lower value of the trim frequency when trim is active.

Default:

0.0 Hz

Values Min/Max:

0.0/500.0 Hz

Display:

0.1 Hz

A458 [PID 1 Trim Sel] A470 [PID 2 Trim Sel]
PF 525 PowerFlex 525 only.

Stop drive before changing this parameter.

Sets the PID output as trim to the source reference.

0 "Disabled" (Default)

PID Trim is disabled.

1 "TrimOn Pot"

2 "TrimOn Keypd"

3 "TrimOn DSI"

4 "TrimOn NetOp"

5 "TrimOn 0-10V"

Options

6 "TrimOn 4-20"
7 "TrimOn Prset" 8 "TrimOn AnMlt"(1)

9 "TrimOn MOP"

10 "TrimOn Pulse" 11 "TrimOn Slgic"(1) 12 "TrimOn Encdr"(1) 13 "TrimOn ENet"(1)

(1) Setting is specific to PowerFlex 525 drives only.

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Chapter 3 Programming and Parameters

A459 [PID 1 Ref Sel] A471 [PID 2 Ref Sel]
PF 525 PowerFlex 525 only.

Stop drive before changing this parameter.

Selects the source of the PID reference.

0 "PID Setpoint" (Default)

1 "Drive Pot"

2 "Keypad Freq"

3 "Serial/DSI"

4 "Network Opt"

5 "0-10V Input"

Options

6 "4-20mA Input"
7 "Preset Freq" 8 "AnlgIn Multi"(1)

9 "MOP Freq"

10 "Pulse Input" 11 "Step Logic"(1) 12 "Encoder"(1) 13 "EtherNet/IP"(1)

(1) Setting is specific to PowerFlex 525 drives only.

Advanced Program Group (continued)

A460 [PID 1 Fdback Sel] A472 [PID 2 Fdback Sel]
PF 525 PowerFlex 525 only.
Selects the source of the PID feedback. 0 "0-10V Input" (Default) 1 "4-20mA Input" 2 "Serial/DSI"
Options 3 "Network Opt" 4 "Pulse Input" 5 "Encoder"(1) 6 "EtherNet/IP"(1)
(1) Setting is specific to PowerFlex 525 drives only.

Note: PID does not function with bipolar input. Negative voltages are ignored and treated as zero.

A461 [PID 1 Prop Gain]

A473 [PID 2 Prop Gain]

PF 525 PowerFlex 525 only.

Sets the value for the PID proportional component when the PID mode is enabled.

Default:

0.01

Values Min/Max:

0.00/99.99

Display:

0.01

Related Parameter(s): A459, A471

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A462 [PID 1 Integ Time]

A474 [PID 2 Integ Time]

PF 525 PowerFlex 525 only.

Sets the value for the PID integral component when PID mode is enabled.

Default:

2.0 s

Values Min/Max:

0.0/999.9 s

Display:

0.1 s

A463 [PID 1 Diff Rate]

A475 [PID 2 Diff Rate]

PF 525 PowerFlex 525 only.

Sets the value (in 1/second) for the PID differential component when PID mode is enabled.

Default:

0.00

Values Min/Max:

0.00/99.99

Display:

0.01

A464 [PID 1 Setpoint]

A476 [PID 2 Setpoint]

PF 525 PowerFlex 525 only.

Provides an internal fixed value for process setpoint when PID mode is enabled.

Default:

0.0%

Values Min/Max:

0.0/100.0%

Display:

0.1%

A465 [PID 1 Deadband]

A477 [PID 2 Deadband]

PF 525 PowerFlex 525 only.

Sets a range, in percent above and below the PID Reference, that the PID output will ignore.

Default:

0.0%

Values Min/Max:

0.0/10.0%

Display:

0.1%

A466 [PID 1 Preload]

A478 [PID 2 Preload]

PF 525 PowerFlex 525 only.

Sets the value used to preload the integral component on start or enable.

Default:

0.0 Hz

Values Min/Max:

0.0/500.0 Hz

Display:

0.1 Hz

A467 [PID 1 Invert Err] A479 [PID 2 Invert Err]
PF 525 PowerFlex 525 only.
Changes the sign of the PID error. 0 "Normal" (Default)
Options 1 "Inverted"

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Related Parameter(s): A459, A471 Related Parameter(s): A459, A471 Related Parameter(s): A459, A471

Advanced Program Group (continued)

A481 [Process Disp Lo]

Sets the value displayed in b010 [Process Display] when the drive is running at P043 [Minimum Freq].

Default:

0.00

Values Min/Max:

0.00/99.99

Display:

0.01

Chapter 3 Programming and Parameters Related Parameter(s): b010, P043

A482 [Process Disp Hi]

Sets the value displayed in b010 [Process Display] when the drive is running at P044 [Maximum Freq].

Default:

0.00

Values Min/Max:

0.00/99.99

Display:

0.01

Related Parameter(s): b010, P044

A483 [Testpoint Sel]

Used by Rockwell Automation field service personnel.

Default:

400

Values Min/Max:

0/FFFF

Display:

1

A484 [Current Limit 1]

Maximum output current allowed before current limiting occurs.

Default:

Drive Rated Amps x 1.1 (Normal Duty); Drive Rated Amps x 1.5 (Heavy Duty)

Values Min/Max:

0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty)

Display:

0.1 A

Related Parameter(s): P033

A485 [Current Limit 2]

PF 525 PowerFlex 525 only.

Maximum output current allowed before current limiting occurs.

Default:

Drive Rated Amps x 1.1

Values Min/Max:

0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty)

Display:

0.1 A

Related Parameter(s): P033

A486 [Shear Pin1 Level]

Related Parameter(s): A487, A489

A488 [Shear Pin2 Level]

PF 525 PowerFlex 525 only.

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.

Default:

0.0 A (Disabled)

Values Min/Max:

0.0/(Drive Rated Amps x 2)

Display:

0.1 A

A487 [Shear Pin 1 Time]

A489 [Shear Pin 2 Time]

PF 525 PowerFlex 525 only.

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.

Default:

0.00 s

Values Min/Max:

0.00/30.00 s

Display:

0.01 s

Related Parameter(s): A486, A488

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Advanced Program Group (continued)

A490 [Load Loss Level]

PF 525 PowerFlex 525 only.

Provides a software trip (Load Loss fault) when the current drops below this level for the time specified in A491 [Load Loss Time].

Default:

0.0 A

Values Min/Max:

0.0/Drive Rated Amps

Display:

0.1 A

Related Parameter(s): A491

A491 [Load Loss Time]

PF 525 PowerFlex 525 only.

Sets the required time for the current to be below A490 [Load Loss Level] before a Load Loss fault occurs.

Default:

0 s

Values Min/Max:

0/9999 s

Display:

1 s

Related Parameter(s): A490

A492 [Stall Fault Time] Sets the time that the drive remains in stall mode before a fault is issued.
0 "60 Seconds" (Default) 1 "120 Seconds" 2 "240 Seconds" Options 3 "360 Seconds" 4 "480 Seconds" 5 "Flt Disabled"

A493 [Motor OL Select]

Related Parameter(s): P032, P033

Drive provides Class 10 overload protection. Settings 0...2 select the derating factor for the I2t overload function.

No Derate
100

Min Derate
100

Max Derate
100

% of [Motor OL Curent] % of [Motor OL Curent] % of [Motor OL Curent]

80

80

80

60

60

60

40

40

40

20

20

20

0 0 25 50 75 100 125 150 175 200 % of [Motor NP Hertz] 0 "No Derate" (Default)

0 0 25 50 75 100 125 150 175 200 % of [Motor NP Hertz]

0 0 25 50 75 100 125 150 175 200 % of [Motor NP Hertz]

Options 1 "Min. Derate"

2 "Max. Derate"

A494 [Motor OL Ret] Selects whether the motor overload counter is saved on power-down or reset on power-up.
0 "Reset" (Default) Options
1 "Save"

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Advanced Program Group (continued)
A495 [Drive OL Mode] Determines how the drive handles overload conditions that would otherwise cause the drive to fault.
0 "Disabled" 1 "Reduce CLim" Options 2 "Reduce PWM" 3 "Both-PWM 1st" (Default)

Chapter 3 Programming and Parameters

A496 [IR Voltage Drop]

Value of volts dropped across the resistance of the motor stator (autotune) for induction motor.

Default:

Based on Drive Rating

Values Min/Max:

0.0/600.0VAC

Display:

0.1VAC

Related Parameter(s): P040

A497 [Flux Current Ref]

This is the current necessary for full motor flux. The value should be set to the full speed no-load current of the motor.

Default:

Based on Drive Rating

Values Min/Max:

0.00/(Drive Rated Amps x 1.4)

Display:

0.01 A

Related Parameter(s): P040

A498 [Motor Rr]

PF 525 PowerFlex 525 only.

Rotor resistance of induction motor. The value of this parameter will populate when a full rotate tune is performed.

Default:

Based on Drive Rating

Values Min/Max:

0.00/655.35 ohm

Display:

0.01 ohm

A499 [Motor Lm]

PF 525 PowerFlex 525 only.

Mutual Inductance of induction motor. The value of this parameter will populate when a full rotate tune is performed.

Default:

Based on Drive Rating

Values Min/Max:

0.0/6553.5 mH

Display:

0.1 mH

A500 [Motor Lx]

PF 525 PowerFlex 525 only.

Leakage Inductance of induction motor. The value of this parameter will populate when a full rotate tune is performed.

Default:

Based on Drive Rating

Values Min/Max:

0.0/6553.5 mH

Display:

0.1 mH

A501 [PM IR Voltage]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Voltage across the stator resistance of the PM or SynRM motor at the rated motor current displayed in line-to-line rms value.

Default:

11.50V

Values Min/Max:

0.00/655.35V

Display:

0.01V

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Advanced Program Group (continued)

A502 [PM IXd Voltage]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Voltage across the d-axis stator inductance of the PM or SynRM motor at the rated motor current and the rated motor frequency displayed in line-to-line rms value.

Default:

17.91V

Values Min/Max:

0.00/655.35V

Display:

0.01V

A503 [PM IXq Voltage]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Voltage across the q-axis stator inductance of the PM or SynRM motor at the rated motor current and the rated motor frequency displayed in line-to-line rms value.

Default:

53.21V

Values Min/Max:

0.00/655.35V

Display:

0.01V

A504 [PM BEMF Voltage]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Back electromotive force (EMF) voltage of the PM or SynRM motor.

Default:

328.0 V - PM, 164.0 V - SynRM

Values Min/Max:

0.0/1200.0 V

Display:

0.1V

A509 [Speed Reg Sel]

Related Parameter(s): A521, A522, A523, A524, A525, A526

PF 525 PowerFlex 525 only.

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.

0 "Automatic" (Default) Options
1 "Manual"

A510 [Freq 1] A512 [Freq 2] A514 [Freq 3]

PF 525 PowerFlex 525 only.

Sets the "Vector" control mode frequency.

Values

Default: Freq 1: Freq 2: Freq 3:

Min/Max:

Display:

8.33% 15.00% 20.00% 0.00/200.00% 0.01%

A511 [Freq 1 BW] A513 [Freq 2 BW] A515 [Freq 3 BW]

PF 525 PowerFlex 525 only.

Speed control loop bandwidth for "Vector" control mode.

Default:

10 Hz

Values Min/Max:

0/40 Hz

Display:

1 Hz

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A516 [PM Initial Sel]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) PM initial angle detect.
0 "Align" (Default) Options 1 "HFI"
2 "Six Pulse"

Advanced Program Group (continued)

Chapter 3 Programming and Parameters

High Frequency Injection to detect initial angle.

A517 [PM DC Inject Cur]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Maximum DC current in amps applied to the motor in order to reset the rotor position of a PM motor.

Default:

30%

Values Min/Max:

0/300%

Display:

1%

A518 [PM Align Time]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) Magnetic pole reorientation time.
Default: Values Min/Max:
Display:

0.7 s 0.0/60.0 s 0.1 s

A519 [PM HFI NS Cur]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) High Frequency Injection (HFI) North South Current to detect N/S Magnet.

Default:

100%

Values Min/Max:

0/300%

Display:

1%

A520 [PM Bus Reg Kd]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) Derivative gain for bus regulator.
Default: Values Min/Max:
Display:

2 0/500 1

A521 [Freq 1 Kp] A523 [Freq 2 Kp] A525 [Freq 3 Kp]

Related Parameter(s): A509, A510

PF 525 PowerFlex 525 only.

Sets P-gain of "Vector" control mode when in frequency region 1, 2 or 3 for faster speed response during dynamic-state where motor is still accelerating. If A509 [Speed Reg Sel] is set to 1 "Manual", these parameters can be changed.

Default:

100.0%

Values Min/Max:

0.0/500.0%

Display:

0.1%

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Advanced Program Group (continued)

A522 [Freq 1 Ki] A524 [Freq 2 Ki] A526 [Freq 3 Ki]

Related Parameter(s): A509, A510

PF 525 PowerFlex 525 only.

Sets I-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.

Default:

0.100 s

Values Min/Max:

0.000/10.000 s

Display:

0.001 s

A527 [PM FWKn 1 Kp]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) The gain to ensure good performance in field weakening region.

Default:

350%

Values Min/Max:

0/2000%

Display:

1%

A528 [PM FWKn 2 Kp]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) The gain to ensure robustness under step load in weakening region.

Default:

300%

Values Min/Max:

100/8000%

Display:

1%

A529 [PM Control Cfg]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) Control configuration for Feed Forward Decouple (FFD), Maximum Torque Per Amp (MTPA), and Load Disturbance Observer (LDOB).

Values

1 = Condition True, 0 = Condition False

FFD (Feed Forward Decouple)

Digit 1

MTPA (Maximum Torque Per Amp)

Digit 2

LDOB (Load Disturbance Observer)

Digit 3

Not Used

Not Used

Default: Min/Max: Display:

00111 00000/00111 00000

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Advanced Program Group (continued)

A530 [Boost Select]
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve. Only used for V/Hz control modes.
[Maximum Voltage] can be set anywhere.
If it is > [Motor NP Volts] then it defines a point on the V/Hz curve 100
[Maximum Voltage] can be set anywhere. If it is < [Motor NP Volts] then it functions as a limit only
(does not change the V/Hz curve)

% [Motor NP Volts]
1/2 [Motor NP Hertz]

1/2 [Motor NP Volts]
50
4 3 2 1

Options

Settings 5...14

0

50

[Maximum Freq] can be set anywhere. If it is < [Motor NP Hertz] then it functions as a limit only
(does not change the V/Hz curve)

% [Motor NP Hertz] 100
[Maximum Freq] can be set anywhere. If it is > [Motor NP Hertz] then it defines a
point on the V/Hz curve

0 "Custom V/Hz"

1 "30.0, VT"

2 "35.0, VT" 3 "40.0, VT"

Fan/Pump Curves (Variable Torque)

4 "45.0, VT"

5 "0.0, no IR"

6 "2.5, CT" (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 (% of Base) (Constant Torque)

9 "7.5, CT"

10 "10.0, CT"

11 "12.5, CT"

12 "15.0, CT"

13 "17.5, CT"

14 "20.0, CT"

Chapter 3 Programming and Parameters Related Parameter(s): b004, P031, P032, P039

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A531 [Start Boost]

Related Parameter(s): P031, P032, P039, A530

Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve when A530 [Boost Select] = 0 "Custom V/Hz" and P039 [Torque Perf Mode] = 0 "V/Hz".

[Maximum Voltage]

[Motor NP Volts]

Voltage

[Break Voltage] [Start Boost]

Values

[Break Frequency] [Minimum Freq]
Default:
Min/Max:
Display:

Frequency [Motor NP Hertz]
[Maximum Freq]
2.5%
0.0/25.0%
0.1%

A532 [Break Voltage]

Related Parameter(s): P031, P032, P039, A530, A533

Sets the voltage (in percent of [Base Frequency]) at the A533 [Break Frequency] if A530 [Boost Select] is set to 0 "Custom V/Hz".

Default:

25.0%

Values Min/Max:

0.0/100.0%

Display:

0.1%

A533 [Break Frequency]

Sets the frequency where A532 [Break Voltage] is applied if A530 [Boost Select] is set to 0 "Custom V/Hz".

Default:

15.0 Hz

Values Min/Max:

0.0/500.0 Hz

Display:

0.1 Hz

Related Parameter(s): P031, P032, P039, A530, A532

A534 [Maximum Voltage] Sets the highest voltage the drive outputs.
Default: Min: Values Max: Display:

Drive Rated Volts 10V AC (on 230V AC Drives); 20V AC (on 460V AC Drives); 25V AC (on 600V AC Drives) 255V AC (on 230V AC Drives); 510V AC (on 460V AC Drives); 637.5V AC (on 600V AC Drives) 1V AC

Related Parameter(s): b004

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A535 [Motor Fdbk Type]
Stop drive before changing this parameter.
Selects the encoder type.(1)

Related Parameter(s):P039, A537

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.

0 "None" (Default) 1 "Pulse Train"

Allowable Control Modes (See P039 [Torque Perf Mode]) V/Hz, SVC, Economize, Vector, PM Control
V/Hz, SVC, Economize, PM Control

Options

2 "Single Chan"(2) 3 "Single Check"(2) 4 "Quadrature"(2) 5 "Quad Check"(2)

V/Hz, SVC, Economize, PM Control V/Hz, SVC, Economize, PM Control V/Hz, SVC, Economize, Vector, PM Control V/Hz, SVC, Economize, Vector, PM Control

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. (2) Setting is specific to PowerFlex 525 drives only.

Hardware Inputs  [DigIn TermBlk 05] for PowerFlex 523 [DigIn TermBlk 07] for PowerFlex 525
Optional incremental encoder card (catalog number 25-ENC-1)

A536 [Encoder PPR]

PF 525 PowerFlex 525 only.

Specifies the encoder Pulses Per Revolution (PPR) when an encoder is used. To achieve speed range/accuracy for SVC and VVC closed loop control, a minimum of 1024 PPR encoder is recommended. The maximum encoder pulse is 250 kHz. For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on page 219.

Default:

1024 PPR

Values Min/Max:

1/20000 PPR

Display:

1 PPR

A537 [Pulse In Scale]

Related Parameter(s): t065, t067, A535

Sets the scale factor/gain for the Pulse Input when t065 [DigIn TermBlk 05] or t067 [DigIn TermBlk 07] is set to 52 "Pulse Train", or A535 [Motor Fdbk Type] is set to 1 "Pulse Train". Input frequency (Hz) / Pulse in Scale = Output frequency (Hz)

Default:

64

Values 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. Applicable to V/Hz and SVC modes in closed loop control only.(1)

Default:

2.0

Values Min/Max:

0.0/400.0

Display:

0.1

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

A539 [Kp Speed Loop]

Sets the P-gain used in the PI calculation of the speed loop when feedback is used. Applicable to V/Hz and SVC modes in closed loop control only.(1)

Default:

0.5

Values Min/Max:

0.0/200.0

Display:

0.1

(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

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Advanced Program Group (continued)
A540 [Var PWM Disable]
Stop drive before changing this parameter.
Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by A440 [PWM Frequency]. 0 "Enabled" (Default)
Options 1 "Disabled"

Related Parameter(s): A440

A541 [Auto Rstrt Tries]
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 without restarting the drive. 1. Set A541 [Auto Rstrt Tries] to a value other than "0". 2. Set A542 [Auto Rstrt Delay] to "0".

Related Parameter(s): A542

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.

Default:

0

Values Min/Max:

0/9

Display:

1

A542 [Auto Rstrt Delay]

Sets the time between restart attempts if A541 [Auto Rstrt Tries] is not zero.

Default:

1.0 s

Values Min/Max:

0.0/120.0 s

Display:

0.1 s

Related Parameter(s): A541

A543 [Start At PowerUp]
Stop drive before changing this parameter.
Enables/disables drive start on power up without a Run command being cycled. Requires a digital input configured for Run and a valid run signal.
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.
0 "Disabled" (Default) Options
1 "Enabled"

A544 [Reverse Disable]
Stop drive before changing this parameter.
Enables/disables the function that allows the direction of motor rotation to be changed. 0 "Rev Enabled" (Default)
Options 1 "Rev Disabled"

Related Parameter(s): b006

A545 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.

0 "Disabled" (Default) Options
1 "Enabled"

Catch and ramp to commanded speed at every drive start.

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Advanced Program Group (continued)

A546 [FlyStrt CurLimit]

Used to determine when the drive has matched the motor frequency if flying start is enabled.

Default:

65%

Values Min/Max:

30/200%

Display:

1%

Chapter 3 Programming and Parameters

A547 [Compensation]

Enables/disables correction options that may improve problems with motor instability.

0 "Disabled"

No compensation.

Options

1 "Electrical" (Default) 2 "Mechanical"

Some drive/motor combinations have inherent instabilities which are exhibited as non-sinusodial motor currents. This setting attempts to correct this condition 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.
0 "Coast" (Default) Options
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 50% drive input voltage during short-term power sag conditions.
ATTENTION: To guard against drive damage, a minimum line impedance must be provided to limit inrush current when the power line recovers. The input impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive's input VA rating if Half Bus is enabled.
0 "Disabled" (Default) Options
1 "Enabled"

A550 [Bus Reg Enable] Enables/disables the bus regulator.
0 "Disabled" Options
1 "Enabled" (Default)

Related Parameter(s): A437

A551 [Fault Clear]
Stop drive before changing this parameter.
Resets a fault and clears the fault queue. 0 "Ready/Idle" (Default)
Options 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]

Protects parameters against change by unauthorized personnel with a 4-digit access code.

Default:

0000

Values Min/Max:

0000/9999

Display:

1111

Related Parameter(s): A553

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Advanced Program Group (continued)

A553 [Program Lock Mod]

Related Parameter(s): A552

Determines the lock mode used in parameter A552 [Program Lock]. When set to 2 or 3, A552 [Program Lock] is added to the custom group to allow unlocking of parameters.

0 "Full Lock" (Default)

All parameters are locked except [Program Lock].

1 "Keypad Lock" Options 2 "Custom Only"

All parameters are locked except [Program Lock] from keypad access but can still be accessed over communications. All parameters are locked and hidden except custom group and [Program Lock].

3 "KeyPd Custom"

All parameters are locked and hidden except custom group and [Program Lock] from keypad access but can still be accessed over communications.

A554 [Drv Ambient Sel]

Sets the maximum expected ambient of the drive when used above 50 °C. When ambient temperature is above 50 °C, the drive will apply necessary current derating.

0 "Normal" (Default)

1 "55C"

Options 2 "60C"

3 "65C +Fan Kit" 4 "70C +Fan Kit"

Fan kit required.

A555 [Reset Meters]

Resets the values stored in the parameters that track fault times and energy usage.

0 "Ready/Idle" (Default)

Options 1 "Reset Meters"

Resets kWh, MWh, Accum kWh, Cost, and CO2 Sav parameter values.

2 "Reset Time"

Resets min, hr, and x10 hr.

Related Parameter(s): b019, b021, b022, b023, b024, b025, b026, d362, d363

A556 [Text Scroll]

Sets the scrolling speed of the text in the LCD display.

0 "Off"

No scroll.

1 "Low Speed" Options
2 "Mid Speed" (Default)

3 "High Speed"

A557 [Out Phas Loss En] Enable/disable output phase loss detection.
ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.
0 "Disable" (Default) Options
1 "Enable"

A558 [Positioning Mode]

Stop drive before changing this parameter.

PF 525 PowerFlex 525 only.

Defines the positioning transition mode used for the position steps.

0 "Time Steps" (Default)

Steps based on time.

1 "Preset Input"

Preset inputs directly commands a given step.

Options 2 "Step Logic"

Use StepLogic Commands. Always start from Step 0.

3 "Preset StpL"

Use Preset Inputs to determine starting step then StepLogic commands.

4 "StpLogic-Lst"

Use StepLogic commands from last Step Logic step at last drive stop.

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Advanced Program Group (continued)

A559 [Counts Per Unit]

PF 525 PowerFlex 525 only.

Sets the number of encoder counts equal to one user-defined unit.

Default:

4096

Values Min/Max:

1/32000

Display:

1

Chapter 3 Programming and Parameters

A560 [Enh Control Word]

Related Parameter(s): t062, t063, t065 - t068, A571

PF 525 PowerFlex 525 only.

Allows control of positioning and other functions through parameter control for use over comms. The functions replicate the digital input options and function in the same way.

1 = Input Present, 0 = Input Not Present

Home Limit

Digit 1

Find Home

Digit 2

Hold Step

Digit 3

Pos Redefine

Digit 4

Sync Enable

Digit 5

Traverse Dis

Digit 6

Logic In 1

Digit 7

Logic In 2

Digit 8

Not Used

Values

Default: Min/Max: Display: 0 "Home Limit" 1 "Find Home" 2 "Hold Step"

3 "Pos Redefine"

Digits

4 "Sync Enable"
5 "Traverse Dis" 6 "Logic In 1"

7 "Logic In 2"

0000 0000 0000 0000/1111 1111 0000 0000 In Positioning mode, this indicates the drive is at the home position When set, the next start command causes the drive to find home. Set this bit to 0 after completing the homing routine. 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. 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. 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. When set the traverse function is disabled. This provides an identical function as the "Logic In1" Digital Input option. This bit is logically ORed with a digital input t062, t063, t065-t068 [DigIn TermBlk xx] set to 24 "Logic In1". It can be used to move through the Step-Logic functions (speed or position) using comms control without requiring actual digital input transitions. This provides and identical function as the "Logic In2" Digital Input option. This bit is logically ORed with a digital input t062, t063, t065-t068 [DigIn TermBlk xx] set to 25 "Logic In2". It can be used to move through the Step-Logic functions (speed or position) using comms control without requiring actual digital input transitions.

A561 [Home Save]

PF 525 PowerFlex 525 only.

Determines whether the current position is saved on power down.

0 "Home Reset" (Default) Options
1 "Home Saved"

Position resets to zero on power up.

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Advanced Program Group (continued)

A562 [Find Home Freq]

PF 525 PowerFlex 525 only.

Sets the maximum frequency the drive uses when "Find Home" is issued.

Default:

10.0 Hz

Values Min/Max:

0.1/500.0 Hz

Display:

0.1 Hz

A563 [Find Home Dir]
Stop drive before changing this parameter. PF 525 PowerFlex 525 only.
Sets the direction the drive commands when "Find Home" is issued. 0 "Forward" (Default)
Options 1 "Reverse"

A564 [Encoder Pos Tol]

PF 525 PowerFlex 525 only.

Sets the "At Position" and the "At Home' tolerance around the encoder count. The value is added to and subtracted from the target encoder unit value to create the tolerance range.

Default:

100

Values Min/Max:

1/50000

Display:

1

A565 [Pos Reg Filter]

PF 525 PowerFlex 525 only.

Sets the error signal filter in the position regulator.

Default:

8

Values Min/Max:

0/15

Display:

1

A566 [Pos Reg Gain]

PF 525 PowerFlex 525 only.

Sets the gain adjustment for the position regulator.

Default:

3.0

Values Min/Max:

0.0/200.0

Display:

0.1

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Advanced Program Group (continued)

A567 [Max Traverse] Sets the amplitude of triangle wave speed modulation.

[Output Freq]

[P Jump] [Max Traverse]

Chapter 3 Programming and Parameters

Hertz Hertz

Values

Default: Min/Max: Display:

Traverse Bit
Seconds 0.00 Hz 0.00/300.00 Hz 0.01 Hz

[Fiber Status] Traverse Enable Bit

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].

Default:

0.00 s

Values Min/Max:

0.00/300.00 s

Display:

0.01 s

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].

Default:

0.00 s

Values Min/Max:

0.00/300.00 s

Display:

0.01 s

A570 [P Jump]

Sets the frequency amplitude that is added to or subtracted from the commanded frequency. See the diagram at A567 [Max Traverse].

Default:

0.00 Hz

Values Min/Max:

0.00/300.00 Hz

Display:

0.01 Hz

Related Parameter(s): A567

A571 [Sync Time]

Related Parameter(s): t062, t063, t065 - t068, A560

Enables the function that holds the drive at the current frequency even if the commanded frequency changes. Used with t062, t063, t065-t068 [DigIn TermBlk xx] 32 "Sync Enable".

[Sync Time]

New Drive #2 Reference

New Drive #1 Reference

Values

Speed Sync Bit Change Ref's
Time
Default: Min/Max: Display:

[Fiber Status] Drive #1 and #2 Sync Enable Input
0.0 s 0.0/3200.0 s 0.1 s

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A572 [Speed Ratio]
Stop drive before changing this parameter.
Scales the drive speed command. Default:
Values Min/Max: Display:

Advanced Program Group (continued)
1.00 0.01/99.99 0.01

A573 [Mtr Options Cfg] (With PowerFlex 525 FRN 2.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Sets the configuration of the motor option.

Jerk Select ZeroSpd Slip Not Used Not Used Not Used

1 = Enabled, 0 = Disabled Digit 1 Digit 2

Default:

11

Values Min/Max:

00/11

Display:

00

Options Description

Limits the rate of change to the velocity reference for improved current Jerk Select limiting. Set to 0 "Disabled" for positioning type applications with fast Accel
or Decel times.

Sets slip compensation to 0.0 Hz when the following conditions are met:

ZeroSpd Slip

· Commanded speed = 0.00 Hz · Status of drive = "At speed"

· ZeroSpd Slip = 1 "Enabled"

A574 [RdyBit Mode Cfg]

Related Parameter(s): d392

Stop drive before changing this parameter.

(With PowerFlex 525 FRN 3.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Determines which Stop conditions causes the drive's Ready bit (Network Logic Status bit 1) to go low (0). A reset or power cycle is required after selection is made.

Stop Conditions Drive fault Stop digital input terminal 01/11 open Holding down the drive's keypad or the Remote DSI HIM Stop button Stop commanded through Comms (Stop bit = 1) Software (SW) Enable digital input terminal open Safe-Torque-Off (STO) condition with value of t105 [Safety Open En] set to 1 "FaultDisabled"(2)
(1) 1 = Active, 0 = Inactive (2) Condition is specific to PowerFlex 525 drives only.

Ready Bit Status(1)

Standard

Enhanced

0

0

1

0

1

0

1

0

1

0

0

0

0 "Standard" (Default) Options
1 "Enhanced"

A575 [Flux Braking En] (With PowerFlex 525 FRN 5.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Enables/disables flux braking.
0 "Disable" (Default) Options
1 "Enable"

Related Parameter(s): A550

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Advanced Program Group (continued)

A576 [Phase Loss Level]

(With PowerFlex 525 FRN 5.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) Output Phase Loss Level. Sets the threshold level which is used to determine an output phase loss condition. Each motor phase must exceed this value. Decreasing this parameter's value lowers sensitivity.

Default:

25.0% for Induction motor; 4.0% for PM motor

Values Min/Max:

0.0/100.0%

Display:

0.1%

A580 [Current Loop BW]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Current loop bandwidth (0 = Automatically calculate the control gain of current loop).

Default:

0 Hz

Values Min/Max:

0/65535 Hz

Display:

1 Hz

A581 [PM Stable 1 Freq]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) The start frequency for stabilization loop (P032 [Motor NP Hertz] x A581 [PM Stable 1 Freq]).

Default:

0%

Values Min/Max:

0/100%

Display:

1%

A582 [PM Stable 2 Freq]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Stabilization function will return to normal output after this frequency (P032 [Motor NP Hertz] x A582 [PM Stable 2 Freq]).

Default:

45%

Values Min/Max:

0/100%

Display:

1%

A583 [PM Stable 1 Kp]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Percentage of the gain for stabilization loop. The gain is set in A584 [PM Stable 2 Kp].

Default:

40%

Values Min/Max:

0/100%

Display:

1%

A584 [PM Stable 2 Kp]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) The gain for stabilization loop.
Default: Values Min/Max:
Display:

250% 0/2000% 1%

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A585 [PM Stable Brk Pt]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Percentage of rated power P037 [Motor NP Power] for the gain of (A584 [PM Stable 2 Kp] x A583 [PM Stable 1 Kp]).

Default:

40%

Values Min/Max:

0/100%

Display:

1%

A586 [PM Stepload Kp]

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) The gain to ensure robustness under step load in low speed region.

Default:

0%

Values Min/Max:

0/1000%

Display:

1%

A587 [PM 1 Efficiency]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) Reduce full load current.
Default: Values Min/Max:
Display:

120% 0/2000% 1%

A588 [PM 2 Efficiency]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.) Reduce no load current.
Default: Values Min/Max:
Display:

500% 0/2000% 1%

A589 [PM Algor Sel]

Related Parameter(s): A550

Stop drive before changing this parameter.

PF 525 PowerFlex 525 only.

(With FRN 5.xxx and later.) Selects the algorithm to use with your motor. Check with the manufacturer of your motor to determine whether it is an iPM or sPM motor.

0 "Algorithm 1" (Default) Options 1 "Algorithm 2"

Suggested for most motors. Enable an embedded algorithm to reduce oscillation in output waveform (use with sPM motor only, do not enable for iPM motor).

A590 [SYNRM SW Freq]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) Switching Frequency point from Low-Speed Observer (Freq1) to High-Speed Observer (Freq2).

Values

Default: Min/Max:

10 Hz 0/600 Hz

Related Parameter(s):

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Advanced Program Group (continued)

A591 [SYNRM Flux Cur]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) SynRM Field Excitation Current. Increasing the setting enhances no loading performance but has poor efficiency. Decreasing the setting reduces no loading performance but good efficiency.

Values

Default: Min/Max:

35% 0/150%

Chapter 3 Programming and Parameters Related Parameter(s):

A592 [SYNRM Freq1 Volt]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) The Amplitude of Injected Signal of Low-Speed Observer (Freq1). Increasing the setting enhances the loading performance during Freq1 operation.

Values

Default: Min/Max:

30% 0/100%

Related Parameter(s):

A593 [SYNRM Freq1 Kp]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) The Scaling of Band Width At Low-Speed Observer (Freq1). Increasing the setting enhances the loading performance during low-speed (Freq1) operation but too high causes motor vibration. Decreasing the setting causes the motor to stall during startup and low-speed (Freq1) operation. When the motor running speed is lower than the switching frequency A590 adjust the setting.

Values

Default: Min/Max:

1.00 0.01/5.00

Related Parameter(s):

A594 [SYNRM Freq1 Comp]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) The Scaling of Mutual Inductance Compensation At Low-Speed Observer (Freq1). Increasing or decreasing the setting enhances the loading performance during Freq1 operation depending on the motor.

Values

Default: Min/Max:

1.00 0/10.00

Related Parameter(s):

A595 [SYNRM Freq2 BW]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) The Band Width At High-Speed Observer (Freq2). Increasing the setting enhances the loading performance during high-speed (Freq2) operation but too high causes vibration. Decreasing the setting causes the motor to stall during startup and high-speed (Freq2) operations. When the motor running speed is higher than the switching frequency A590, adjust the setting.

Values

Default: Min/Max:

10 Hz 0/50 Hz

Related Parameter(s):

A596 [SYNRM Freq2 Kp]

PF 525 PowerFlex 525 only.

(With FRN 7.xxx and later.) The Scaling of Magnetic linkage estimator At High-Speed Observer (Freq2). To fine tune the setting when motor is still not stable after adjustment A595. Increasing the motor setting enhances the loading performance during high-speed (Freq2) operation but too high causes vibration. Decreasing the setting causes the motor to stall during startup and high-speed (Freq2) operations. When the motor running speed is higher than the switching frequency A590, adjust the setting.

Values

Default: Min/Max:

1.00 0.1/10.00

Related Parameter(s):

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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.

Fault and Diagnostic Group

F604 [Fault 4 Code] F605 [Fault 5 Code] F606 [Fault 6 Code] F607 [Fault 7 Code] F608 [Fault 8 Code] F609 [Fault 9 Code] F610 [Fault10 Code]

Related Parameter(s): b007-b009

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.

Default:

Read Only

Values Min/Max:

F0/F127

Display:

F0

F611 [Fault 1 Time-hr] F613 [Fault 3 Time-hr] F615 [Fault 5 Time-hr]

F612 [Fault 2 Time-hr] F614 [Fault 4 Time-hr]

F616 [Fault 6 Time-hr] F618 [Fault 8 Time-hr] F620 [Fault10 Time-hr]

F617 [Fault 7 Time-hr] F619 [Fault 9 Time-hr]

PF 525 PowerFlex 525 only.

Displays the value of d362 [Elapsed Time-hr] when the fault occurs.

Default:

Read Only

Values Min/Max:

0/32767 hr

Display:

1 hr

Related Parameter(s): d362

F621 [Fault 1 Time-min] F622 [Fault 2 Time-min] F623 [Fault 3 Time-min] F624 [Fault 4 Time-min] F625 [Fault 5 Time-min]

F626 [Fault 6 Time-min] F627 [Fault 7 Time-min] F628 [Fault 8 Time-min] F629 [Fault 9 Time-min] F630 [Fault10 Time-min]

PF 525 PowerFlex 525 only.

Displays the value of d363 [Elapsed Time-min] when the fault occurs.

Default:

Read Only

Values Min/Max:

0.0/320.0 min

Display:

0.1 min

Related Parameter(s): d363

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Fault and Diagnostic Group (continued)

F631 [Fault 1 Freq] F633 [Fault 3 Freq] F635 [Fault 5 Freq]

F632 [Fault 2 Freq] F634 [Fault 4 Freq]

Related Parameter(s): b001

F636 [Fault 6 Freq] F638 [Fault 8 Freq] F640 [Fault10 Freq]

F637 [Fault 7 Freq] F639 [Fault 9 Freq]

PF 525 PowerFlex 525 only.

Displays and stores the value of b001 [Output Freq] with the most recent 10 faults occurred. [Fault 1 Freq] stores the most recent fault, [Fault 2 Freq] stores the second most recent fault and [Fault 3 Freq] stores the third most recent fault.

Default:

Read Only

Values Min/Max:

0.00/500.00 Hz

Display:

0.01 Hz

F641 [Fault 1 Current] F643 [Fault 3 Current] F645 [Fault 5 Current]

F642 [Fault 2 Current] F644 [Fault 4 Current]

Related Parameter(s): b003

F646 [Fault 6 Current] F648 [Fault 8 Current] F650 [Fault10 Current]

F647 [Fault 7 Current] F649 [Fault 9 Current]

PF 525 PowerFlex 525 only.

Displays and stores the value of b003 [Output Current] with the most recent 10 faults occurred. [Fault 1 Current] stores the most recent fault, [Fault 2 Current] stores the second most recent fault and [Fault 3 Current] stores the third most recent fault.

Default:

Read Only

Values Min/Max:

0.00/(Drive Rated Amps x 2)

Display:

0.01 A

F651 [Fault 1 BusVolts] F653 [Fault 3 BusVolts] F655 [Fault 5 BusVolts]

F652 [Fault 2 BusVolts] F654 [Fault 4 BusVolts]

Related Parameter(s): b005

F656 [Fault 6 BusVolts] F658 [Fault 8 BusVolts] F660 [Fault10 BusVolts]

F657 [Fault 7 BusVolts] F659 [Fault 9 BusVolts]

PF 525 PowerFlex 525 only.

Displays and stores the value of b005 [DC Bus Voltage] with the most recent 10 faults occurred. [Fault 1 BusVolts] stores the most recent fault, [Fault2 BusVolts] stores the second most recent fault and [Fault 3 BusVolts] stores the third most recent fault.

Default:

Read Only

Values Min/Max:

0/1200V DC

Display:

1V DC

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Fault and Diagnostic Group (continued)

F661 [Status @ Fault 1] F663 [Status @ Fault 3] F665 [Status @ Fault 5]

F662 [Status @ Fault 2] F664 [Status @ Fault 4]

Related Parameter(s): b006

F666 [Status @ Fault 6] F668 [Status @ Fault 8] F670 [Status @ Fault10]

F667 [Status @ Fault 7] F669 [Status @ Fault 9]

PF 525 PowerFlex 525 only.

Displays the value of b006 [Drive Status] with the most recent 10 faults occurred. [Status @ Fault 1] stores the most recent fault, [Status @ Fault 2] stores the second most recent fault and [Status @ Fault 3] stores the third most recent fault.

1 = Condition True, 0 = Condition False

Running

Digit 1

Forward

Digit 2

Accelerating

Digit 3

Decelerating SafetyActive(1)

Digit 4 Digit 5

(1) Setting is specific to PowerFlex 525 drives only.

Values

Default: Min/Max: Display:

Read Only 0/0x1F 1

F681 [Comm Sts - DSI] Displays the status of the RS485 serial (DSI) port to the drive.

Values

Rx Tx Status Error Not Used
Default: Min/Max: Display:

1 = Condition True, 0 = Condition False Digit 1 Digit 2 Digit 3 Digit 4

Digit 3 (Connection Status) 0 "Not Active" 1 "Modbus slave network (external Modbus master)" 2 "Modbus multi-drive w/ internal com option
master" 3 "Modbus multi-drive w/ embedded com master"(1) 4 "DSI peripheral connected" 5...8"Reserved" 9 "RS-485 network faulted"

(1) Setting is specific to PowerFlex 525 drives only.

Read Only 0000/1911 0000

F682 [Comm Sts - Opt] Displays the status of the internal communication to the drive.

Rx Tx Status Error Not Used

1 = Condition True, 0 = Condition False Digit 1 Digit 2 Digit 3 Digit 4

Digit 3 = "Internal Com option" 0 "Not Active (no connection)" 1 "Internal option connected/active" 2...8"Reserved" 9 "Internal com option faulted"

Values

Default: Min/Max: Display:

Read Only 0000/1911 0000

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Fault and Diagnostic Group (continued)
F683 [Com Sts-Emb Enet]
PF 525 PowerFlex 525 only.
Displays the status of the embedded EtherNet/IP interface to the drive.

Values

Rx Tx Status Error Not Used
Default: Min/Max: Display:

1 = Condition True, 0 = Condition False Digit 1 Digit 2 Digit 3 Digit 4

Digit 3 = "Embedded EtherNet/IP" 0 "Not Active (no connection)" 1 "Embedded EtherNet/IP active" 2-8 "Reserved" 9 "Embedded EtherNet/IP faulted"

Read Only 0000/1911 0000

F684 [EN Addr Src]

PF 525 PowerFlex 525 only.

Displays the actual source of the Ethernet configuration (IP address, subnet mask, and gateway address).

1 "Parameters" Options
2 "BOOTP"

Read Only

F685 [EN Rate Act]

PF 525 PowerFlex 525 only.

Displays the network data rate currently used by the embedded EtherNet/IP interface.

0 "No Link"

1 "10Mbps Full"

2 "10Mbps Half"

Options 3 "100Mbps Full"

Read Only

4 "100Mbps Half"

5 "Dup IP Addr"

6 "Disabled"

F686 [DSI I/O Act] Displays the Drives that are active in Multi-Drive mode.

Value

Drive 0 Actv Drive 1 Actv Drive 2 Actv Drive 3 Actv Drive 4 Actv
Default: Min/Max: Display:

1 = Drive Active, 0 = Drive Inactive Digit 1 Digit 2 Digit 3 Digit 4 Digit 5
Read Only 00000/11111 00000

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Fault and Diagnostic Group (continued)

F687 [HW Addr 1] F688 [HW Addr 2] F689 [HW Addr 3] F690 [HW Addr 4] F691 [HW Addr 5] F692 [HW Addr 6]

PF 525 PowerFlex 525 only.

Shows the MAC address for the embedded EtherNet/IP interface.

Default:

Read Only

Values 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]
PF 525 PowerFlex 525 only.
Shows the actual IP address used by the embedded EtherNet/IP interface at the time. This indicates 0 if no address is set.
255.255.255.255

[EN IP Addr Act 1] [EN IP Addr Act 2] [EN IP Addr Act 3] [EN IP Addr Act 4]

Values

Default: Min/Max: Display:

Read Only 0/255 1

F697 [EN Subnet Act 1] F698 [EN Subnet Act 2] F699 [EN Subnet Act 3] F700 [EN Subnet Act 4]
PF 525 PowerFlex 525 only.
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: Min/Max: Display:

Read Only 0/255 1

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Chapter 3 Programming and Parameters

Fault and Diagnostic Group (continued)
F701 [EN Gateway Act 1] F702 [EN Gateway Act 2] F703 [EN Gateway Act 3] F704 [EN Gateway Act 4]
PF 525 PowerFlex 525 only.
Shows the actual gateway address used by the embedded EtherNet/IP interface at the time. This will indicate 0 if no address is set.
255.255.255.255

[EN Gateway Act 1] [EN Gateway Act 2] [EN Gateway Act 3] [EN Gateway Act 4]

Values

Default: Min/Max: Display:

Read Only 0/255 1

F705 [Drv 0 Logic Cmd] F709 [Drv 1 Logic Cmd] F713 [Drv 2 Logic Cmd] F717 [Drv 3 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.

Default:

Read Only

Values Min/Max:

0/FFFF

Display:

1

F706 [Drv 0 Reference] F710 [Drv 1 Reference] F714 [Drv 2 Reference] F718 [Drv 3 Reference] F722 [Drv 4 Reference]

In multi-drive mode, 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.

Default:

Read Only

Values Min/Max:

0.00/5000.00 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.

Default:

Read Only

Values Min/Max:

0/FFFF

Display:

1

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Fault and Diagnostic Group (continued)

F708 [Drv 0 Feedback] F712 [Drv 1 Feedback] F716 [Drv 2 Feedback] F720 [Drv 3 Feedback] F724 [Drv 4 Feedback]

In multi-drive mode, this is the feedback being received from drive 0/1/2/3/4. In single-drive mode, this is the feedback of the drive at the time.

Default:

Read Only

Values Min/Max:

0.00/5000.00 Hz

Display:

0.01 Hz

F725 [EN Rx Overruns]

PF 525 PowerFlex 525 only.

A count of the number of receive overrun errors reported by the embedded EtherNet/IP interface.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

F726 [EN Rx Packets]

PF 525 PowerFlex 525 only.

A count of the number of receive packets reported by the embedded EtherNet/IP interface.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

F727 [EN Rx Errors]

PF 525 PowerFlex 525 only.

A count of the number of receive errors reported by the embedded EtherNet/IP interface.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

F728 [EN Tx Packets]

PF 525 PowerFlex 525 only.

A count of the number of transmitted packets reported by the embedded EtherNet/IP interface.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

F729 [EN Tx Errors]

PF 525 PowerFlex 525 only.

A count of the number of transmit errors reported by the embedded EtherNet/IP interface.

Default:

Read Only

Values Min/Max:

0/65535

Display:

1

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F730 [EN Missed IO Pkt]
PF 525 PowerFlex 525 only.
The number of I/O packets missed. Default:
Values Min/Max: Display:
F731 [DSI Errors] The number of total DSI errors.
Default: Values Min/Max:
Display:

Fault and Diagnostic Group (continued)
Read Only 0/65535 1
Read Only 0/65535 1

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AppView Parameter Groups

AppView parameter groups provide a simple starting point for using the PowerFlex 520-series drives by grouping certain commonly used parameters based on different types of applications. Use these parameter groups to quickly and easily setup the PowerFlex 520-series drive for your application.

AppView parameter groups are available for the following applications:
· Conveyor · Mixer · Compressor · Centrifugal Pump · Blower/Fan · Extruder · Positioning (PowerFlex 525 only) · Textile/Fiber
You cannot add or remove parameters to or from the AppView parameter groups. If you require quick access to additional parameters to what is already included in the different AppView parameter groups, use the CustomView parameter group instead.

The parameters in the AppView parameter groups can be quickly added to the CustomView parameter group by doing the following:

Step

Key(s)

Example Displays

1.

Press the Up Arrow or Down Arrow to scroll to an AppView group (G1...G8).

or

FWD

Press Enter or Sel to enter a group. The right

2. most digit of the last viewed parameter in

or Sel

FWD

that group will flash.

3.

Press the Up Arrow or Down Arrow to scroll to the command G1->GC.

or

FWD

Press Enter or Sel to add all the parameters

4.

in this AppView group to the CustomView group. The LCD display will show a

confirmation.

or Sel

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CustomView Parameter Group

Chapter 3 Programming and Parameters

CustomView allows you to quickly access only the parameters needed for your application by storing them in a custom parameter group. Add your frequently used parameters to this group, then hide all other parameters with A552 [Program Lock] to simplify your drive configuration process.

Up to 100 parameters can be stored in the CustomView parameter group. You can copy one entire AppView parameter group to the CustomView parameter group as shown on page 150 or add individual parameters as show below.

Step

Key(s)

Example Displays

1.

Press the Up Arrow or Down Arrow to scroll to the CustomView group (GC).

or

FWD

2.

Press Enter to view the parameters that can be added to the CustomView group.

FWD

3.

Press the Up Arrow or Down Arrow to scroll through the list of parameters.

or

Press Enter to add the parameter to the 4. CustomView group. The LCD display will show
a confirmation.

FWD PROGRAM

To delete parameters from the CustomView parameter group:

Step

Key(s)

Example Displays

1.

Press the Up Arrow or Down Arrow to scroll to the CustomView group (GC).

or

FWD

2.

Press Enter to view the parameters that are in the CustomView group.

FWD

3.

Press the Up Arrow or Down Arrow to scroll to the command GC---.

or

FWD

4.

Press Enter or Sel to view the parameters that are stored in the CustomView group.

or Sel

FWD

5.

Press the Up Arrow or Down Arrow to scroll through the list of parameters.

or

Press Enter to delete the parameter from the 6. CustomView group. The LCD display will show
a confirmation.

FWD PROGRAM

The Connected Components Workbench software can be used to speed up this process with drag and drop functionality.

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Parameter Cross Reference by Name

Parameters

Parameter Name

No.

Parameter Name

No.

Parameter Name

No.

10V Bipolar Enbl(1)

093

Current Loop BW(1)(2)

580

Drv 4 Logic Sts

723

2-Wire Mode

064

DB Resistor Sel

437

Drv 4 Reference

722

Accel Time 1

041

DB Threshold

438

Drv Ambient Sel

554

Accel Time 2

442

DC Brake Level

435

DSI Errors

731

Accel Time 3

444

DC Brake Time

434

DSI I/O Act

686

Accel Time 4

446

DC Brk Time@Strt

436

DSI I/O Cfg

175

Accum CO2 Sav

026

DC Bus Ripple

380

Elapsed kWh

021

Accum Cost Sav

025

DC Bus Voltage

005

Elapsed MWh

022

Accum kWh Sav

024

Decel Time 1

042

Elapsed Run Time

019

Analog In 0-10V

360

Decel Time 2

443

Elapsed Time-hr

362

Analog In 4-20mA

361

Decel Time 3

445

Elapsed Time-min

363

Analog In Filter

099

Decel Time 4

447

EM Brk Off Delay

086

Analog Out High(3)

089

Dig In Status

014

EM Brk On Delay

087

Analog Out Sel(2)

088

Dig Out Status(2)(3)

394

EN Addr Sel(1)

128

Anlg In 0-10V Hi

092

DigIn TermBlk 02

062

EN Addr Src(1)

684

Anlg In 0-10V Lo

091

DigIn TermBlk 03

063

EN Comm Flt Actn(1)

143

Anlg In mA Loss

097

DigIn TermBlk 05

065

EN Data In 1(1)

153

Anlg In V Loss

094

DigIn TermBlk 06

066

EN Data In 2(1)

154

Anlg In4-20mA Hi

096

DigIn TermBlk 07(1)

067

EN Data In 3(1)

155

Anlg In4-20mA Lo

095

DigIn TermBlk 08(1)

068

EN Data In 4(1)

156

Anlg Loss Delay

098

Drive OL Mode

495

EN Data Out 1(1)

157

Anlg Out Setpt(2)

090

Drive Status

006

EN Data Out 2(1)

158

Auto Rstrt Delay

542

Drive Status 2(2)(3)

393

EN Data Out 3(1)

159

Auto Rstrt Tries

541

Drive Temp

027

EN Data Out 4(1)

160

Autotune

040

Drive Type

367

EN Flt Cfg DL 1(1)

147

Average kWh Cost

052

Droop Hertz@ FLA(1)

441

EN Flt Cfg DL 2(1)

148

Average Power

020

Drv 0 Feedback

708

EN Flt Cfg DL 3(1)

149

Boost Select

530

Drv 0 Logic Cmd

705

EN Flt Cfg DL 4(1)

150

Break Frequency

533

Drv 0 Logic Sts

707

EN Flt Cfg Logic(1)

145

Break Voltage

532

Drv 0 Reference

706

EN Flt Cfg Ref(1)

146

Bus Reg Enable

550

Drv 1 Addr

171

EN Gateway Act 1(1)

701

Cmd Stat Select(1)

122

Drv 1 Feedback

712

EN Gateway Act 2(1)

702

Com Sts-Emb Enet(1)

683

Drv 1 Logic Cmd

709

EN Gateway Act 3(1)

703

Comm Loss Action

125

Drv 1 Logic Sts

711

EN Gateway Act 4(1)

704

Comm Loss Time

126

Drv 1 Reference

710

EN Gateway Cfg 1(1)

137

Comm Sts - DSI

681

Drv 2 Addr

172

EN Gateway Cfg 2(1)

138

Comm Sts - Opt

682

Drv 2 Feedback

716

EN Gateway Cfg 3(1)

139

Comm Write Mode

121

Drv 2 Logic Cmd

713

EN Gateway Cfg 4(1)

140

Commanded Freq

002

Drv 2 Logic Sts

715

EN Idle Flt Actn(1)

144

Compensation

547

Drv 2 Reference

714

EN IP Addr Act 1(1)

693

Contrl In Status

013

Drv 3 Addr

173

EN IP Addr Act 2(1)

694

Control Source

012

Drv 3 Feedback

720

EN IP Addr Act 3(1)

695

Control SW Ver

029

Drv 3 Logic Cmd

717

EN IP Addr Act 4(1)

696

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Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Parameters (Continued)
Parameter Name Control Temp Counter Status Counts Per Unit(1) Current Limit 1 Current Limit 2(1) EN Rate Act(1) EN Rate Cfg(1) EN Rx Errors(1) EN Rx Overruns(1) EN Rx Packets(1) EN Subnet Act 1(1) EN Subnet Act 2(1) EN Subnet Act 3(1) EN Subnet Act 4(1) EN Subnet Cfg 1(1) EN Subnet Cfg 2(1) EN Subnet Cfg 3(1) EN Subnet Cfg 4(1) EN Tx Errors(1) EN Tx Packets(1) Encoder Pos Tol(1) Encoder PPR(1) Encoder Speed(2) Energy Saved Enh Control Word(1) Fault 1 BusVolts Fault 1 Code Fault 1 Current Fault 1 Freq Fault 1 Time-hr Fault 1 Time-min Fault 2 BusVolts Fault 2 Code Fault 2 Current Fault 2 Freq Fault 2 Time-hr Fault 2 Time-min Fault 3 BusVolts Fault 3 Code Fault 3 Current Fault 3 Freq Fault 3 Time-hr Fault 3 Time-min Fault 4 BusVolts

Chapter 3 Programming and Parameters

No.

Parameter Name

No.

028

Drv 3 Logic Sts

719

364

Drv 3 Reference

718

559

Drv 4 Addr

174

484

Drv 4 Feedback

724

485

Drv 4 Logic Cmd

721

685

Fault 6 BusVolts(1)

656

141

Fault 6 Code(1)

606

727

Fault 6 Current(1)

646

725

Fault 6 Freq(1)

636

726

Fault 6 Time-hr(1)

616

697

Fault 6 Time-min(1)

626

698

Fault 7 BusVolts(1)

657

699

Fault 7 Code(1)

607

700

Fault 7 Current(1)

647

133

Fault 7 Freq(1)

637

134

Fault 7 Time-hr(1)

617

135

Fault 7 Time-min(1)

627

136

Fault 8 BusVolts(1)

658

729

Fault 8 Code(1)

608

728

Fault 8 Current(1)

648

564

Fault 8 Freq(1)

638

536

Fault 8 Time-hr(1)

618

378

Fault 8 Time-min(1)

628

023

Fault 9 BusVolts(1)

659

560

Fault 9 Code(1)

609

651

Fault 9 Current(1)

649

007

Fault 9 Freq(1)

639

641

Fault 9 Time-hr(1)

619

631

Fault 9 Time-min(1)

629

611

Fault Clear

551

621

Fault10 BusVolts(1)

660

652

Fault10 Code(1)

610

008

Fault10 Current(1)

650

642

Fault10 Freq(1)

640

632

Fault10 Time-hr(1)

620

612

Fault10 Time-min(1)

630

622

Fiber Status

390

653

Find Home Dir(1)

563

009

Find Home Freq(1)

562

643

Flux Braking En(2)(3)

575

633

Flux Current Ref

497

613

Flying Start En

545

623

FlyStrt CurLimit

546

654

Freq 1(1)

510

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Parameter Name EN IP Addr Cfg 1(1) EN IP Addr Cfg 2(1) EN IP Addr Cfg 3(1) EN IP Addr Cfg 4(1) EN Missed IO Pkt(1) Half Bus Enable Home Save(1) HW Addr 1(1) HW Addr 2(1) HW Addr 3(1) HW Addr 4(1) HW Addr 5(1) HW Addr 6(1) IR Voltage Drop Jog Accel/Decel
Jog Frequency
Keypad Freq Ki Speed Loop(2) Kp Speed Loop(2) Language Load Loss Level(1) Load Loss Time(1) Max Traverse Maximum Freq
Maximum Voltage
Minimum Freq MOP Freq
MOP Preload
MOP Reset Sel MOP Time Motor Fdbk Type(2) Motor Lm(1) Motor Lx(1) Motor NP FLA
Motor NP Hertz Motor NP Poles Motor NP Power(1) Motor NP RPM Motor NP Volts
Motor OL Current Motor OL Level Motor OL Ret Motor OL Select Motor Rr(1)

No. 129 130 131 132 730 549 561 687 688 689 690 691 692 496 432 431 426 538 539 30 490 491 567 044 534 043 427 429 428 430 535 499 500 034 032 035 037 036 031 033 369 494 493 498
153

Chapter 3 Programming and Parameters

Parameters (Continued)

Parameter Name

No.

Parameter Name

No.

Parameter Name

No.

Fault 4 Code

604

Freq 1 BW(1)

511

Mtr Options Cfg(2)(4)

573

Fault 4 Current

644

Freq 1 Ki(1)

522

MultiDrv Sel

169

Fault 4 Freq

634

Freq 1 Kp(1)

521

Opt Data In 1

161

Fault 4 Time-hr

614

Freq 2(1)

512

Opt Data In 2

162

Fault 4 Time-min

624

Freq 2 BW(1)

513

Opt Data In 3

163

Fault 5 BusVolts

655

Freq 2 Ki(1)

524

Opt Data In 4

164

Fault 5 Code

605

Freq 2 Kp(1)

523

Opt Data Out 1

165

Fault 5 Current

645

Freq 3(1)

514

Opt Data Out 2

166

Fault 5 Freq

635

Freq 3 BW(1)

515

Opt Data Out 3

167

Fault 5 Time-hr

615

Freq 3 Ki(1)

526

Opt Data Out 4

168

Fault 5 Time-min

625

Freq 3 Kp(1)

525

Opto Out Logic(1)

075

Opto Out1 Level(1)

070

PM FWKn 1 Kp(1)(3)

527

Relay 2 On Time(1)

084

Opto Out1 Sel(1)

069

PM FWKn 2 Kp(1)(3)

528

Relay Out2 Level(1)

082

Opto Out2 Level(1)

073

PM HIFI NS Cur(1)(3)

519

Relay Out2 Sel(1)

081

Opto Out2 Sel(1)

072

PM Initial Sel(1)(3)

516

Reset Meters

555

Out Phas Loss En

557

PM IR Voltage(1)(3)

501

Reset to Defalts

053

Output Current

003

PM IXd Voltage(1)(3)

502

Reverse Disable

544

Output Freq

001

PM IXq Voltage(1)(3)

503

RS485 Data Rate

123

Output Power

017

PM Stable 1 Freq(1)(3)

581

RS485 Format

127

Output Powr Fctr

381

PM Stable 1 Kp(1)(3)

583

RS485 Node Addr

124

Output RPM

015

PM Stable 2 Freq(1)(3)

582

S Curve %

439

Output Speed

016

PM Stable 2 Kp(1)(3)

584

Safety Open En(1)

105

Output Voltage

004

PM Stable Brk Pt(1)(3)

585

SafetyFlt RstCfg(1)(3)

106

P Jump

570

PM Stepload Kp(1)(3)

586

Shear Pin 1 Time

487

Phase Loss Level(2)(3)

576

Pos Reg Filter(1)

565

Shear Pin1 Level

486

PID 1 Deadband

465

Pos Reg Gain(1)

566

Shear Pin 2 Time(1)

489

PID 1 Diff Rate

463

Position Status(1)

387

Shear Pin2 Level(1)

488

PID 1 Fdback Sel

460

Positioning Mode(1)

558

Skip Freq Band 1

449

PID 1 Integ Time

462

Power Loss Mode

548

Skip Freq Band 2

451

PID 1 Invert Err

467

Power Saved

018

Skip Freq Band 3(1)

453

PID 1 Preload

466

Preset Freq 0

410

Skip Freq Band 4(1)

455

PID 1 Prop Gain

461

Preset Freq 1

411

Skip Frequency 1

448

PID 1 Ref Sel

459

Preset Freq 2

412

Skip Frequency 2

450

PID 1 Setpoint

464

Preset Freq 3

413

Skip Frequency 3(1)

452

PID 1 Trim Hi

456

Preset Freq 4

414

Skip Frequency 4(1)

454

PID 1 Trim Lo

457

Preset Freq 5

415

Sleep Level

101

PID 1 Trim Sel

458

Preset Freq 6

416

Sleep Time

102

PID1 Fdbk Displ

383

Preset Freq 7

417

Sleep-Wake Sel

100

PID1 Setpnt Disp

384

Preset Freq 8(1)

418

Slip Hz Meter

375

PID 2 Deadband(1)

477

Preset Freq 9(1)

419

Speed Feedback

376

PID 2 Diff Rate(1)

475

Preset Freq 10(1)

420

Speed Ratio

572

PID 2 Fdback Sel(1)

472

Preset Freq 11(1)

421

Speed Reference1

047

PID 2 Integ Time(1)

474

Preset Freq 12(1)

422

Speed Reference2

049

PID 2 Invert Err(1)

479

Preset Freq 13(1)

423

Speed Reference3

051

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Parameters (Continued)

Parameter Name PID 2 Preload(1) PID 2 Prop Gain(1) PID 2 Ref Sel(1) PID 2 Setpoint(1) PID 2 Trim Hi(1) PID 2 Trim Lo(1) PID 2 Trim Sel(1) PID2 Fdbk Displ(1) PID2 Setpnt Disp(1) PM 1 Efficiency(1)(3) PM 2 Efficiency(1)(3) PM Algor Sel(1)(3) PM Align Time(1)(3) PM BEMF Voltage(1)(3) PM Bus Reg Kd(1)(3) PM Control Cfg(1)(3) PM DC Inject Cur(1)(3) Step Units 0(1) Step Units 1(1) Step Units 2(1) Step Units 3(1) Step Units 4(1) Step Units 5(1) Step Units 6(1) Step Units 7(1) Stop Mode
Stp Logic 0(1) Stp Logic 1(1) Stp Logic 2(1) Stp Logic 3(1) Stp Logic 4(1) Stp Logic 5(1) Stp Logic 6(1) Stp Logic 7(1)

No.

Parameter Name

478

Preset Freq 14(1)

473

Preset Freq 15(1)

471

Process Disp Hi

476

Process Disp Lo

468

Process Display

469

Program Lock

470

Program Lock Mod

385

Pulse In Scale

386

Purge Frequency

587

PWM Frequency

588

RdyBit Mode Act(2)(5)

589

RdyBit Mode Cfg(2)(4)

518

Relay 1 Off Time

504

Relay 1 On Time

520

Relay Out1 Level

529

Relay Out1 Sel

517

Relay 2 Off Time(1)

200

Stp Logic Status(1)

202

Stp Logic Time 0(1)

Stp Logic Time 1(1)

204

Stp Logic Time 2(1)

206

Stp Logic Time 3(1)

208

Stp Logic Time 4(1)

210

Stp Logic Time 5(1)

212

Stp Logic Time 6(1)

214

Stp Logic Time 7(1)

045

Sync Time

180

SynRM SW Freq

181

SynRM Flux Cur

182

SynRM Freq1 Volt

183

SynRM Freq1 Kp

185

SynRM Freq1 Comp

186

SynRM Freq2 BW

187

SynRM Freq2 Kp

(1) Parameter is specific to PowerFlex 525 drives only. (2) Parameter is available in PowerFlex 525 FRN 5.xxx and later. (3) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. (4) Parameter is available in PowerFlex 525 FRN 2.xxx and later. (5) Parameter is available in PowerFlex 525 FRN 3.xxx and later.

Chapter 3 Programming and Parameters

No.

Parameter Name

No.

424

Speed Reg Sel(1)

509

425

Stall Fault Time

492

482

Start At PowerUp

543

481

Start Boost

531

010

Start Source 1

046

552

Start Source 2

048

553

Start Source 3

050

537

Status @ Fault 1

661

433

Status @ Fault 2

662

440

Status @ Fault 3

663

392

Status @ Fault 4

664

574

Status @ Fault 5

665

080

Status @ Fault 6(1)

666

079

Status @ Fault 7(1)

667

077

Status @ Fault 8(1)

668

076

Status @ Fault 9(1)

669

085

Status @ Fault10(1)

670

391

Testpoint Sel

483

190

Text Scroll

556

191

Testpoint Data

368

192

Timer Status

365

193

Timer StatusF

366

194

Torque Current

382

195

Torque Perf Mode

039

196

Traverse Dec

569

197

Traverse Inc

568

571

Units Traveled H(1)

388

590

Units Traveled L(1)

389

591

Var PWM Disable

540

592

Voltage Class

038

593

Wake Level

103

594

Wake Time

104

595

596

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Chapter 3 Programming and Parameters
Notes:

156

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Drive Status Faults

Troubleshooting

4 Chapter

This chapter provides information to guide you in troubleshooting the PowerFlex 520-series drive. Included is a listing and description of drive faults with possible solutions, when applicable.

Topic

Page

Drive Status

157

Faults

157

Fault Descriptions

159

Common Symptoms and Corrective Actions

162

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 59 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 2 Non-Resettable

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. 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.

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Chapter 4 Troubleshooting

Fault Indication
Condition
Drive is indicating a fault. The integral LCD display provides visual notification of a fault condition by displaying the following. · Flashing fault number · Flashing fault indicator (LED) Press the Esc key to regain control of the display.

Display
FWD
FAULT Esc Sel

Manually Clearing Faults
Step
1. Press Esc to 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.
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 159.
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".

Key(s)
Esc

Automatically Clearing Faults
Option/Step Clear a Type 1 fault and restart the drive. 1. Set A541 [Auto Rstrt Tries] to a value other than "0". 2. Set A542 [Auto Rstrt Delay] to a value other than "0".
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A541 [Auto Rstrt Tries] to a value other than "0". 2. Set A542 [Auto Rstrt Delay] to "0".
ATTENTION: Equipment damage and/or personal injury may result if these 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.

Auto Restart (Reset/Run)
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 157. See Fault Descriptions on page 159 for more information.

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Fault Descriptions

Chapter 4 Troubleshooting
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 F000 No Fault F002 Auxiliary Input F003 Power Loss F004 UnderVoltage F005 OverVoltage
F006 Motor Stalled
F007 Motor Overload
F008 Heatsink OvrTmp
F009 CC OvrTmp
F012 HW OverCurrent F013 Ground Fault F015(3) Load Loss F021 Output Ph Loss

Type(1) Description

Action



No fault present.



1

External trip (Auxiliary) input.

· Check remote wiring. · Verify communications
programming for intentional fault.

· Monitor the incoming AC line for

2

Single phase operation detected with excessive load.

low voltage or line power interruption. · Check input fuses.

· Reduce load.

1

DC bus voltage fell below the min value.

Monitor the incoming AC line for low voltage or line power interruption.

Monitor the AC line for high line

voltage or transient conditions. Bus

1

DC bus voltage exceeded max value. overvoltage can also be caused by

motor regeneration. Extend the decel

time or install dynamic brake option.

1

Drive is unable to accelerate or decelerate motor.

· Increase P041, A442, A444, A446 [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.
· Check for overhauling load.

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.

· Check for blocked or dirty heat

1

Heatsink/Power Module temperature exceeds a predefined value.

sink fins. Verify that ambient temperature has not exceeded the rated ambient temperature.

· Check fan.

· Check product ambient

1

Control module temperature exceeds a predefined value.

temperature. · Check for airflow obstruction. · Check for dirt or debris.

· Check fan.

Check programming. Check for

2

The drive output current has exceeded the hardware current limit.

excess load, improper A530 [Boost Select] setting, DC brake volts set too high or other causes of excess

current.

A current path to earth ground has Check the motor and external wiring

1(2) been detected at one or more of the to the drive output terminals for a

drive output terminals.

grounded condition.

The output torque current is below

the value programmed in A490 [Load · Verify connections between motor

2

Loss Level] for a time period greater and load.

than the time programmed in A491 · Verify level and time requirements

[Load Loss Time].

1

Output Phase Loss (if enabled).

· Verify motor wiring.

Configure with A557 [Out Phas Loss En]. · Verify motor.

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Chapter 4 Troubleshooting 160

Fault Types, Descriptions, and Actions (Continued)

No. Fault F029 Analog In Loss
F033 Auto Rstrt Tries F038 Phase U to Gnd F039 Phase V to Gnd F040 Phase W to Gnd F041 Phase UV Short F042 Phase UW Short F043 Phase VW Short F048 Params Defaulted
F059(3) Safety Open
F063 SW OverCurrent F064 Drive Overload F070 Power Unit
F071 DSI Net Loss
F072 Opt Net Loss
F073(3) EN Net Loss F080 Autotune Failure
F081 DSI Comm Loss

Type(1) Description

Action

An analog input is configured to fault

on signal loss. A signal loss has

· Check for broken/loose

1

occurred.

connections at inputs.

Configure with t094 [Anlg In V Loss] or · Check parameters.

t097 [Anlg In mA Loss].

Drive unsuccessfully attempted to

2

reset a fault and resume running for Correct the cause of the fault and the programmed number of A541 [Auto manually clear.

Rstrt Tries].

· Check the wiring between the

A phase to ground fault has been

drive and motor.

2

detected between the drive and motor · Check motor for grounded phase.

in this phase.

· Replace drive if fault cannot be

cleared.

· Check the motor and drive output

2

Excessive current has been detected between these two output terminals.

terminal wiring for a shorted condition. · Replace drive if fault cannot be

cleared.

· Clear the fault or cycle power to

1

The drive was commanded to write

the drive.

default values to EEPROM.

· Program the drive parameters as

needed.

1

Both of the safety inputs (Safety 1, Safety 2) are not enabled. Configure with t104 [Safety Open En].

· Check safety input signals. If not using safety, verify and tighten jumper for I/O terminals S1, S2, and S+.

Programmed A486, A488 [Shear Pinx

Level] has been exceeded for a time · Verify connections between motor

1

period greater than the time

and load.

programmed in A487, A489 [Shear Pin x · Verify level and time requirements.

Time].

2

Drive overload rating has been exceeded.

Reduce load or extend Accel Time.

· Check max ambient temperature

2

Failure has been detected in the drive power section.

has not been exceeded. · Cycle power. · Replace drive if fault cannot be

cleared.

Control over the Modbus or DSI

2

communication link has been

interrupted.

· Cycle power. · Check communications cabling. · Check Modbus or DSI setting. · Check Modbus or DSI status.

· Cycle power.

2

Control over the network option card's · Check communications cabling. remote network has been interrupted. · Check network adapter setting.

· Check external network status.

Control through the embedded

2

EtherNet/IP adapter has been

interrupted.

· Cycle power. · Check communications cabling. · Check EtherNet/IP setting. · Check external network status.

2

The autotune function was either cancelled by the user or failed.

Restart procedure.

· Cycle power.

· Check communications cabling.

· Check Modbus or DSI setting.

· Check Modbus or DSI status.

Communications between the drive · Modify using C125 [Comm Loss

2

and the Modbus or DSI master device Action].

have been interrupted.

· Connecting I/O terminals C1 and C2

to ground may improve noise

immunity.

· Replace wiring, Modbus master

device, or control module.

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Chapter 4 Troubleshooting

Fault Types, Descriptions, and Actions (Continued)

No. Fault

Type(1) Description

F082 Opt Comm Loss 2

Communications between the drive and the network option card have been interrupted.

F083(3) EN Comm Loss 2

Internal communications between the drive and the embedded EtherNet/IP adapter have been interrupted.

F091(3) Encoder Loss

2

Requires differential encoder. One of the 2 encoder channel signals is missing.

F094 Function Loss 2

F100

Parameter Chksum

2

F101 External Storage 2

F105 C Connect Err 2

F106 Incompat C-P 2

F107 Replaced C-P 2 F109 Mismatch C-P 2 F110 Keypad Membrane 2

"Freeze-Fire" (Function Loss) input is inactive, input to the programmed terminal is open. Drive parameter non-volatile storage is corrupted. External non-volatile storage has failed. Control module was disconnected while drive was powered.
The PowerFlex 525 control module does not support power modules with 0.25 HP power rating.
The control module could not recognize the power module. Hardware failure. The control module was mounted to a different drive type power module. Keypad membrane failure / disconnected.

F111(3) Safety Hardware 2

Safety input enable hardware malfunction. One of the safety inputs is not enabled.

F114 uC Failure

2

Microprocessor failure.

F122 I/O Board Fail

2

Failure has been detected in the drive control and I/O section.

Action
· Cycle power. · Reinstall option card in drive. · Modify using C125 [Comm Loss
Action]. · Replace wiring, port expander,
option card, or control module.
· Cycle power. · Check EtherNet/IP setting. · Check drive's Ethernet settings
and diagnostic parameters. · Modify using C125 [Comm Loss
Action]. · Replace wiring, Ethernet switch, or
control module.
· Check Wiring. · If P047, P049, P051 [Speed
Referencex] = 16 "Positioning" and A535 [Motor Fdbk Type] = 5 "Quad Check", swap the Encoder channel inputs or swap any two motor leads. · Replace encoder.
Close input to the terminal and cycle power.
Set P053 [Reset To Defalts] to 2 "Factory Rset".
Set P053 [Reset To Defalts] to 2 "Factory Rset".
Clear fault and verify all parameter settings. Do not remove or install the control module while power is applied.
· Change to a different power module.
· Change to a PowerFlex 523 control module.
· Change to a different power module.
· Replace control module if changing power module does not work.
Set P053 [Reset To Defalts] to 3 "Power Reset".
· Cycle power. · Replace control module if fault
cannot be cleared.
· Check safety input signals. If not using safety, verify and tighten jumper for I/O terminals S1, S2, and S+.
· Replace control module if fault cannot be cleared.
· Cycle power. · Verify grounding requirements.
See General Grounding Requirements on page 20 for more information. · Replace control module if fault cannot be cleared.
· Cycle power. · Replace drive or control module if
fault cannot be cleared.

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Chapter 4 Troubleshooting
Common Symptoms and Corrective Actions
Motor does not Start
Cause(s) No output voltage to the motor. Improper boost setting at initial startup. Drive is Faulted

Fault Types, Descriptions, and Actions (Continued)

No. Fault

Type(1) Description

Action

F125 Flash Update Req 2

The firmware in the drive is corrupt, Perform a firmware flash update

mismatched, or incompatible with the operation to attempt to load a valid

hardware.

set of firmware.

F126 NonRecoverablErr 2

A non-recoverable firmware or hardware error was detected. The drive was automatically stopped and reset.

· Clear fault or cycle power to the drive.
· Replace drive or control module if fault cannot be cleared.

F127 DSIFlashUpdatReq 2

A critical problem with the firmware was detected and the drive is running using backup firmware that only supports DSI communications.

Perform a firmware flash update operation using DSI communications to attempt to load a valid set of firmware.

(1) See Fault Types for more information. (2) This fault may be cleared by the auto-restart routine and will be attempted only once. It ignores the value set in parameter A541
[Auto Rstrt Tries]. (3) This fault is not applicable to PowerFlex 523 drives.

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. 2. Verify safety terminals (S1, S2, and S+) jumper is in place and tightened. 3. Verify wire jumper is in place between I/O terminals 01 and 11. 4. Verify that the three jumpers are in their proper default positions on the
control board. See PowerFlex 525 Control I/O Terminal Block on page 41 for more information. 5. Reset default parameter values by setting P053 [Reset Defalts] to 2 "Factory Rset". 6. If safe to do so for your application, press Start on drive keypad. Drive will run according to the speed potentiometer.

Indication None None Flashing red status light

Corrective Action
Check the power circuit. · Check the supply voltage. · Check all fuses and disconnects. Check the motor. · Verify that the motor is connected properly. Check the control input signals. · 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 I/O 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.
Set A530 [Boost Select] to 2 "35.0, VT".
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 [DigIn TermBlk xx] is set to
13 "Clear Fault".

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Chapter 4 Troubleshooting

Motor does not Start (Continued)
Cause(s) (Continued)
Incorrect programming. · P046, P048, P050 [Start Source x] is set incorrectly.
Incorrect input wiring. See page 43 for wiring examples. · 2 wire control requires Run Forward, Run Reverse or Jog
input. · 3 wire control requires Start and Stop inputs · Stop input is always required.
Incorrect sink/source jumper setting.

Indication None
None None

Corrective Action Check setting for b012 [Control Source].
· Wire inputs correctly and/or install jumper. · If the PowerFlex 525 Safe Torque Off function is used, verify that inputs are active. · If 2-wire or 3-wire mode is used, verify that t062 [DigIn TermBlk 02] and t063 [DigIn
TermBlk 03] are set properly.
Set switch to match wiring scheme.

Drive does not Start from Start or Run Inputs wired to the terminal block

Cause(s)
Drive is Faulted
Incorrect programming. · P046, P048, P050 [Start Source x] is set incorrectly. · t062, t063 [DigIn TermBlk 02/03] is set incorrectly. Incorrect input wiring. See page 43 for wiring examples. · 2 wire control requires Run Forward, Run Reverse or Jog
input. · 3 wire control requires Start and Stop inputs · Stop input is always required. Incorrect sink/source jumper setting.

Indication Flashing red status light

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 [DigIn TermBlk xx] is set to
13 "Clear Fault".

None

Check parameter settings.

None

· Wire inputs correctly and/or install jumper. · If the PowerFlex 525 Safe Torque Off function is used, verify that inputs are active.

None

Set switch to match wiring scheme.

Drive does not respond to changes in speed command

Cause(s) No value is coming from the source of the command.
Incorrect reference source is being selected by remote device or digital inputs.

Indication The drive "Run" indicator is lit and output is 0 Hz.
None

Corrective Action
· Check b012 [Control Source] for correct source. · If the 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.
· Check b012 [Control Source] for correct source. · Check b014 [Dig In Status] to see if inputs are selecting an alternate source. Verify
settings for t062, t063, t065-t068 [DigIn TermBlk xx]. · Check P047, P049, P051 [Speed Referencex] for the source of the speed reference.
Reprogram as necessary. · Review the Speed Reference Control chart on page 48. · Verify communications if used.

Motor and/or drive will not accelerate to commanded speed

Cause(s) Acceleration time is excessive.

Indication None

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

None

Speed command source or value is not as expected.

None

Programming is preventing the drive output from exceeding limiting values.

None

Torque performance does not match motor characteristics. None

Corrective Action
Reprogram P041, A442, A444, A446 [Accel Time x].
· Compare b003 [Output Current] with A484, A485 [Current Limit x]. · Remove excess load or reprogram P041, A442, A444, A446 [Accel Time x]. · Check for improper A530 [Boost Select] setting.
· Verify b002 [Commanded Freq]. · Check b012 [Control Source] for the proper Speed Command.
· Check P044 [Maximum Freq] to ensure that speed is not limited by programming. · Verify programming of A572 [Speed Ratio].
· Set motor nameplate full load amps in parameter P034 [Motor NP FLA]. · Perform P040 [Autotune] "Static Tune" or "Rotate Tune" procedure. · Set P039 [Torque Perf Mode] to 0 "V/Hz".

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Motor operation is unstable
Cause(s) Motor data was incorrectly entered.

Indication None

Drive will not reverse motor direction
Cause(s) Reverse is disabled. Digital input is not selected for reversing control. Digital input is incorrectly wired. Motor wiring is improperly phased for reverse.
Drive does not power up
Cause(s)
No input power to drive.

Indication None None None None
Indication None

Control module is not connected properly to power module. None

Motor is rotating at zero Hz or slip frequency is not correct

Cause(s)

Indication

Incorrect speed calculation.

Improper speed.

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.
Corrective Action Check A544 [Reverse Disable]. Check [DigIn TermBlk xx] (See page 88). Choose correct input and program for reversing mode. Check input wiring (See page 43). Switch two motor leads.
Corrective Action · Check the power circuit. · Check the supply voltage. · Check all fuses and disconnects. 1. Remove power. 2. Verify that the control module is properly and fully installed on the power module. 3. Reapply power.
Corrective Action · Verify P032 [Motor NP Hertz]. · Reduce boost with A530 [Boost Select]. · Set P036 [Motor NP RPM] to motor synchronous speed.

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Certifications

Supplemental Drive Information

A Appendix

Topic

Page

Certifications

165

Environmental Specifications

166

Technical Specifications

167

Power Specifications

170

Certifications c-UL-us

PowerFlex 523

PowerFlex 525

Listed to UL508C and CAN/CSA-C22.2 No. 14-05.

RCM
Functional Safety
Functional Safety Type Approved www.tuv.com ID 0600000000
ATEX II (2) G D
TUV 12 ATEX 7199 X KCC EAC AC 156

Australian Communications and Media Authority In conformity with the following:
Radiocommunications Act: 1992 (including amendments up to 2018) Radiocommunications Standard: 2017 Radiocommunications Labelling Notice: 2017 Standards applied: EN 61800-3 In conformity with the following European Directives: 2014/35/EU Low Voltage Directive (LVD) 2014/30/EU EMC Directive (EMC) 2014/34/EU ATEX Directive (ATEX) 2006/42/EC Machinery Directive (MD) 2011/65/EU RoHS Directive (RoHS) Standards applied: EN 61800-3 EN 61800-5-1 (Applicable to PowerFlex 525 drives only) TÜV Rheinland Standards applied: EN ISO 13849-1 EN 61800-5-2 EN 61508 PARTS 1-7 EN 62061 EN 60204-1 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
(Applicable to PowerFlex 525 drives only) Certified to ATEX Directive 2014/34/EU Group II Category (2) GD Applications with ATEX Approved Motors
Korean Registration of Broadcasting and Communications Equipment Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3 Standards applied:
Low Voltage TP TC 004/2011 EMC TP TC 020/2011 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

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Certifications

PowerFlex 523

PowerFlex 525

SEMI F47

Certified compliant with the following standards: SEMI F47 IEC 61000-4-11 IEC 61000-4-34

Lloyds Register

(Applicable to PowerFlex 525 drives only) Lloyd's Register Type Approval Certificate 12/10068(E1)

RoHS

Compliant with the European "Restriction of Hazardous Substances" 2011/65/EU Directive

The drive is also designed to meet the appropriate portions of the following specifications: NFPA 70 - US National Electrical Code NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems.

Environmental Specifications

Specifications
Altitude: Without derating: With derating:
Max. Surrounding Air Temperature
Without derating: With derating: Storage Temperature: Frame A...D: Frame E: Atmosphere:

PowerFlex 523

PowerFlex 525

See Current Derating Curves on page 17 for derating guidelines. 1000 m (3300 ft) max. Up to 4000 m (13,200 ft) max., with the exception of 600V drives at 2000 m (6600 ft) max.

See Current Derating Curves on page 17 for derating guidelines. -20...+50 °C (-4...+122 °F) -20...+60 °C (-4...+140 °F) or -20...+70 °C (-4...+158 °F) with optional Control Module Fan kit.

-40...+85 °C (-40...+185 °F) -40...+70 °C (-40...+158 °F)

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: Shock: Vibration:

0...95% noncondensing Complies with IEC 60068-2-27 Complies with IEC 60068-2-6:1995

Frame Size
A B C D E

Operating and Nonoperating

Force (Shock/Vibration)

Mounting Type

15 g / 2 g

DIN rail or screw

15 g / 2 g

DIN rail or screw

15 g / 2 g

DIN rail or screw

15 g / 2 g

Screw only

15 g / 1.5 g

Screw only

Nonoperating (Transportation)

Force (Shock/Vibration)

Mounting Type

30 g/ 2.5 g

Screw only

30 g/ 2.5 g

Screw only

30 g/ 2.5 g

Screw only

30 g/ 2.5 g

Screw only

30 g/ 2.5 g

Screw only

Conformal Coating:
Surrounding Environment Pollution Degree
Pollution Degree 1 & 2: Sound Pressure Level (A-weighted)
Frame A & B: Frame C: Frame D: Frame E:

Complies with: IEC 60721-3-3 to level 3C2 (chemical and gases only)
See Pollution Degree Ratings According to EN 61800-5-1 on page 51 for descriptions. All enclosures acceptable. Measurements are taken 1 m from the drive.
Maximum 53 dBA Maximum 57 dBA Maximum 64 dBA Maximum 68 dBA

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Technical Specifications

Appendix A Supplemental Drive Information

Protection
Specifications Bus Overvoltage Trip
100...120V AC Input: 200...240V AC Input: 380...480V AC Input: 525...600V AC Input: Bus Undervoltage Trip 100...120V AC Input: 200...240V AC Input: 380...480V AC Input: Power Ride-Thru: Logic Control Ride-Thru:
Electronic Motor Overload Protection:
Overcurrent: Ground Fault Trip: Short Circuit Trip:

PowerFlex 523

PowerFlex 525

405V DC bus (equivalent to 150V AC incoming line) 405V DC bus (equivalent to 290V AC incoming line) 810V DC bus (equivalent to 575V AC incoming line) 1005V DC bus (equivalent to 711V AC incoming line)

190V DC bus (equivalent to 75V AC incoming line) 190V DC bus (equivalent to 150V AC incoming line) 390V DC bus (equivalent to 275V AC incoming line) 100 ms 0.5 s minimum, 2 s typical Provides class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572. 200% hardware limit, 300% instantaneous fault Phase-to-ground on drive output Phase-to-phase on drive output

Electrical

Specifications Voltage Tolerance: Frequency Tolerance:
Input Phases:
Displacement Power Factor: Maximum Short Circuit Rating: Actual Short Circuit Rating: Transistor Type: Internal DC Bus Choke
200...240V AC Input: 380...480V AC Input: 525...600V AC Input:

PowerFlex 523

PowerFlex 525

-15% / +10%

47...63 Hz

Three-phase input provides full rating. Single-phase input provides 35% rating on three-phase drives.

0.98 across entire speed range

100,000 Amps Symmetrical

Determined by AIC Rating of installed fuse/circuit breaker

Isolated Gate Bipolar Transistor (IGBT)

Only for Frame E drive ratings 11 kW (15 HP) 15...18.5 kW (20...25 HP)  Heavy Duty 15...18.5 kW (20...25 HP)  Heavy Duty

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Appendix A Supplemental Drive Information

Control

Specifications
Method
Carrier Frequency Frequency Accuracy
Digital Input: Analog Input: Analog Output: Performance V/Hz (Volts per Hertz): SVC (Sensorless Vector): SVC Economizer:

PowerFlex 523

PowerFlex 525

Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor control, Closed Loop Velocity Vector Control, Surface Mount and Interior Permanent Magnet Motor (without encoder), Interior Permanent Magnet Motor (with encoder) (Closed Loop Velocity Vector Control, PM motor control, and SynRM are not applicable to PowerFlex 523 drives)

2...16 kHz, Drive rating based on 4 kHz

Within ±0.05% of set output frequency Within 0.5% of maximum output frequency, 10-Bit resolution ±2% of full scale, 10-Bit resolution

±1% of base speed across a 60:1 speed range ±0.5% of base speed across a 100:1 speed range ±0.5% of base speed across a 100:1 speed range

VVC (Velocity Vector Control): PM Motor (1): Performance with Encoder SVC (Sensorless Vector): SVC Economizer: VVC (Velocity Vector Control): PM Motor (iPM motor, 10 HP rating and below) (1): Output Voltage Range: Output Frequency Range: Efficiency:
Stop Modes:
Accel/Decel:

(Applicable to PowerFlex 525 drives only) ±0.5% of base speed across a 60:1 speed range ±0.5% of base speed, up to a 20:1 speed range
(Applicable to PowerFlex 525 drives only) ±0.1% of base speed across a 100:1 speed range(2) ±0.1% of base speed across a 100:1 speed range(2) ±0.1% of base speed across a 1000:1 speed range(2) ±0.1% of base speed, up to a 60:1 speed range
0V to rated motor voltage 0...500 Hz (programmable) 97.5% (typical) Multiple programmable stop modes including  Ramp, Coast, DC-Brake, and Ramp-to-Stop 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: Heavy Duty:

110% Overload capability for up to 60 s, 150% for up to 3 s Applies for power rating above 15 kW (20 HP) only. Based on 480V drive rating. 150% Overload capability for up to 60 s, 180% for up to 3 s (200% programmable)

(1) For details on specific motor performance, see Knowledge Base article "PowerFlex 525 PM Motor Performance Testing Summary". (2) For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on page 219.

Control Inputs

Specifications Bandwidth:

Quantity:

Digital Analog:

Current: Type
Source Mode (SRC): Sink Mode (SNK): Pulse Train Quantity: Input Signal: Input Frequency: Current Consumption: Quantity: Specification Resolution: 0...10V DC Analog: 4...20mA Analog: External Pot:

PowerFlex 523 10 Rad/s for open and closed loop (1) Dedicated for stop (4) Programmable 6 mA

PowerFlex 525 (1) Dedicated for stop (6) Programmable

18...24V = ON, 0...6V = OFF 0...6V = ON, 18...24V = OFF

(1) Shared with one of the programmable digital input terminals. Transistor contact (open collector) 0...100 kHz

7 mA @ 24V DC maximum (1) Isolated, 0...10V and 4...20mA

(2) Isolated, -10...10V and 4...20mA

10-bit 100k ohm input impedance 250 ohm input impedance 1...10k ohm, 2 W minimum

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Appendix A Supplemental Drive Information

Control Outputs

Specifications

Quantity:

Relay: Opto: Analog

Specification Resistive Rating: Inductive Rating:
Quantity: Specification: Quantity: Specification
Resolution: 0...10V DC Analog: 4...20 mA Analog:

PowerFlex 523 (1) Programmable Form C

PowerFlex 525 (2) 1 Programmable Form A and 1 Programmable Form B

3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC



(2) Programmable 30V DC, 50 mA Non-inductive

(1) Non-Isolated 0...10V or 4...20 mA(1)

10-bit 1 k ohm minimum 525 ohm maximum

(1) Feature is not applicable to PowerFlex 523 series A drives.

Encoder
Specifications Type: Supply: Quadrature: Duty Cycle:
Requirements:

PowerFlex 523 

PowerFlex 525 Incremental, dual channel 12V, 250 mA 90 °, ±27 ° @ 25 °C 50%, +10% Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 3.5...26V DC output, single-ended or differential and capable of supplying a minimum of 10 mA per channel. Allowable input is DC up to a maximum frequency of 250 kHz. The encoder I/O automatically scales to allow 5V, 12V and 24V DC nominal voltages.

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Power Specifications

Watts Loss
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

380...480V, 50/60 Hz 3-Phase

380...480V, 50/60 Hz 3-Phase w/ EMC Filter

Output Current (A) 1.6 2.5 4.8 6.0 1.6 2.5 4.8 8.0 11.0 1.6 2.5 4.8 8.0 11.0 1.6 2.5 5.0 8.0 11.0 17.5 24.0 32.2 48.3 62.1 1.4 2.3 4.0 6.0 10.5 13.0 17.0 24.0 30.0 1.4 2.3 4.0 6.0 10.5 13.0 17.0 24.0 30.0 37.0 43.0

Total Watts Loss 20.0 27.0 53.0 67.0 20.0 29.0 50.0 81.0 111.0 20.0 29.0 53.0 84.0 116.0 20.0 29.0 50.0 79.0 107.0 148.0 259.0 323.0 584.0 708.0 27.0 37.0 62.0 86.0 129.0 170.0 221.0 303.0 387.0 27.0 37.0 63.0 88.0 133.0 175.0 230.0 313.0 402.0 602.0 697.0

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Watts Loss (Continued)
Voltage
525...600V, 50/60 Hz 3-Phase

Output Current (A) 0.9 1.7 3.0 4.2 6.6 9.9 12.0 19.0 22.0 27.0 32.0

Total Watts Loss 22.0 32.0 50.0 65.0 95.0 138.0 164.0 290.0 336.0 466.0 562.0

Input Current Scaling (Optional)

You can use a higher drive rating by scaling the input current based on the output current required for your application. You can use a lower input current rating based upon the motor FLA rating. For example, if the motor has an FLA rating of 1.6, the input rating will be 6.4 amps. See the PowerFlex 520Series Input Current Rating Scaled by the Motor FLA on page 171 table for more information.
PowerFlex 520-Series Input Current Rating Scaled by the Motor FLA

PowerFlex 523 PowerFlex 525 Output Current: Motor FLA

Input Drive Current Rating

Catalog Number Catalog Number 1

2

3

4

5

6

7

8

100...120V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

25A-V1P6N104



1.6 1.3 1.0 0.8 6.4 5.2 4.0 3.2

25A-V2P5N104 25B-V2P5N104 2.5 2.0 1.6 1.3 9.6 7.7 6.2 4.8

25A-V4P8N104

25B-V4P8N104

4.8 3.8 3.1 2.4 19.2 15.4 12.5 9.6

25A-V6P0N104 25B-V6P0N104 6.0 4.8 3.9 3.0 24.0 19.2 15.6 12.0

200...240V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

25A-A1P6N104



1.6 1.3 1.0 0.8 5.3 4.3 3.4 2.7

25A-A2P5N104 25B-A2P5N104 2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3

25A-A4P8N104 25B-A4P8N104 4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4

25A-A8P0N104 25B-A8P0N104 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0

25A-A011N104

25B-A011N104

11.0 8.8 7.2 5.5 22.9 18.3 14.9 11.5

200...240V AC (-15%, +10%)  1-Phase Input with EMC Filter, 0...230V 3-Phase Output

25A-A1P6N114



1.6 1.3 1.0 0.8 5.3 4.3 3.4 2.7

25A-A2P5N114

25B-A2P5N114

2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3

25A-A4P8N114

25B-A4P8N114

4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4

25A-A8P0N114

25B-A8P0N114

8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0

25A-A011N114

25B-A011N114

11.0 8.8 7.2 5.5 22.9 18.3 14.9 11.5

200...240V AC (-15%, +10%)  3-Phase Input, 0...230V 3-Phase Output

25A-B1P6N104



1.6 1.3 1.0 0.8 1.9 1.5 1.2 1.0

25A-B2P5N104 25B-B2P5N104 2.5 2.0 1.6 1.3 2.7 2.2 1.8 1.4

25A-B5P0N104 25B-B5P0N104 5.0 4.0 3.2 2.5 5.8 4.6 3.8 2.9

25A-B8P0N104 25B-B8P0N104 8.0 6.4 5.2 4.0 9.5 7.6 6.2 4.8

25A-B011N104

25B-B011N104

11.0 8.8 7.2 5.5 13.8 11.0 9.0 6.9

25A-B017N104

25B-B017N104

17.5 14.0 11.4 8.8 21.1 16.9 13.7 10.6

25A-B024N104 25B-B024N104 24.0 19.2 15.6 12.0 26.6 21.3 17.3 13.3

25A-B032N104 25B-B032N104 32.2 25.8 20.9 16.1 34.8 27.8 22.6 17.4

25A-B048N104 25B-B048N104 48.3 38.6 31.4 24.2 44.0 35.2 28.6 22.0

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PowerFlex 520-Series Input Current Rating Scaled by the Motor FLA (Continued)

PowerFlex 523 PowerFlex 525 Output Current: Motor FLA

Input Drive Current Rating

Catalog Number Catalog Number 1

2

3

4

5

6

7

8

25A-B062N104 25B-B062N104 62.1 49.7 40.4 31.1 56.0 44.8 36.4 28.0

380...480V AC (-15%, +10%)  3-Phase Input, 0...460V 3-Phase Output

25A-D1P4N104

25B-D1P4N104

1.4 1.1

0.9 0.7 1.9 1.5 1.2 1.0

25A-D2P3N104 25B-D2P3N104 2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6

25A-D4P0N104 25B-D4P0N104 4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9

25A-D6P0N104 25B-D6P0N104 6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8

25A-D010N104

25B-D010N104

10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9

25A-D013N104

25B-D013N104

13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7

25A-D017N104

25B-D017N104

17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2

25A-D024N104 25B-D024N104 24.0 19.2 15.6 12.0 26.4 21.1 17.2 13.2

25A-D030N104 25B-D030N104 30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5

380...480V AC (-15%, +10%)  3-Phase Input with EMC Filter, 0...460V 3-Phase Output

25A-D1P4N114

25B-D1P4N114

1.4 1.1 0.9 0.7 1.9 1.5 1.2 1.0

25A-D2P3N114

25B-D2P3N114

2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6

25A-D4P0N114

25B-D4P0N114

4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9

25A-D6P0N114

25B-D6P0N114

6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8

25A-D010N114

25B-D010N114

10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9

25A-D013N114

25B-D013N114

13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7

25A-D017N114

25B-D017N114

17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2

25A-D024N114

25B-D024N114

24.0 19.2 15.6 12.0 26.4 21.1 17.2 3.2

25A-D030N114

25B-D030N114

30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5

25A-D037N114

25B-D037N114

37.0 29.6 24.1 18.5 33.7 27.0 21.9 16.9

25A-D043N114

25B-D043N114

43.0 34.4 28.0 21.5 38.9 31.1 25.3 19.5

525...600V AC (-15%, +10%)  3-Phase Input, 0...575V 3-Phase Output

25A-E0P9N104 25B-E0P9N104 0.9 0.7 0.6 0.5 1.2 1.0 0.8 0.6

25A-E1P7N104

25B-E1P7N104

1.7 1.4 1.1 0.9 2.3 1.8 1.5 1.2

25A-E3P0N104 25B-E3P0N104 3.0 2.4 2.0 1.5 3.8 3.0 2.5 1.9

25A-E4P2N104 25B-E4P2N104 4.2 3.4 2.7 2.1 5.3 4.2 3.4 2.7

25A-E6P6N104 25B-E6P6N104 6.6 5.3 4.3 3.3 8.0 6.4 5.2 4.0

25A-E9P9N104

25B-E9P9N104

9.9 7.9 6.4 5.0 11.2 9.0 7.3 5.6

25A-E012N104

25B-E012N104

12.0 9.6 7.8 6.0 13.5 10.8 8.8 6.8

25A-E019N104

25B-E019N104

19.0 15.2 12.4 9.5 24.0 19.2 15.6 12.0

25A-E022N104 25B-E022N104 22.0 17.6 14.3 11.0 27.3 21.8 17.7 13.7

25A-E027N104

25B-E027N104

27.0 21.6 17.6 13.5 24.7 19.8 16.1 12.4

25A-E032N104 25B-E032N104 32.0 25.6 20.8 16.0 29.2 23.4 19.0 14.6

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Product Selection

Accessories and Dimensions

B Appendix

Catalog Number Description

25B

-V

Drive

Voltage Rating

2P5 Rating

N Enclosure

1

0

HIM Emission Class

4 Version

PowerFlex 520-Series Drive Ratings

Output Ratings Normal Duty HP kW

Heavy Duty HP kW

Output Current (A)

Input Voltage Range

Frame PowerFlex 523 Size
Catalog No.

100...120V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

0.25 0.2 0.25 0.2 1.6

85...132

A

25A-V1P6N104(1)

0.5 0.4 0.5 0.4 2.5

85...132

A 25A-V2P5N104

1.0 0.75 1.0 0.75 4.8

85...132

B 25A-V4P8N104

1.5 1.1

1.5 1.1

6.0

85...132

B 25A-V6P0N104

200...240V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

0.25 0.2 0.25 0.2 1.6

170...264

A

25A-A1P6N104(1)

0.5 0.4 0.5 0.4 2.5

170...264

A 25A-A2P5N104

1.0 0.75 1.0 0.75 4.8

170...264

A 25A-A4P8N104

2.0 1.5 2.0 1.5 8.0

170...264

B 25A-A8P0N104

3.0 2.2 3.0 2.2 11.0

170...264

B 25A-A011N104

200...240V AC (-15%, +10%)  1-Phase Input with EMC Filter, 0...230V 3-Phase Output

0.25 0.2 0.25 0.2 1.6

170...264

A 25A-A1P6N114

0.5 0.4 0.5 0.4 2.5

170...264

A 25A-A2P5N114

1.0 0.75 1.0 0.75 4.8

170...264

A 25A-A4P8N114

2.0 1.5 2.0 1.5 8.0

170...264

B 25A-A8P0N114

3.0 2.2 3.0 2.2 11.0

170...264

B 25A-A011N114

200...240V AC (-15%, +10%)  3-Phase Input, 0...230V 3-Phase Output

0.25 0.2 0.25 0.2 1.6

170...264

A

25A-B1P6N104(1)

0.5 0.4 0.5 0.4 2.5

170...264

A 25A-B2P5N104

1.0 0.75 1.0 0.75 5.0

170...264

A 25A-B5P0N104

2.0 1.5 2.0 1.5 8.0

170...264

A 25A-B8P0N104

3.0 2.2 3.0 2.2 11.0

170...264

A 25A-B011N104

5.0 4.0 5.0 4.0 17.5

170...264

B 25A-B017N104

7.5 5.5 7.5 5.5 24.0

170...264

C 25A-B024N104

10.0 7.5 10.0 7.5 32.2

170...264

D 25A-B032N104

15.0 11.0 10.0 7.5 48.3

170...264

E 25A-B048N104

20.0 15.0 15.0 11.0 62.1

170...264

E 25A-B062N104

380...480V AC (-15%, +10%)  3-Phase Input, 0...460V 3-Phase Output(2)

0.5 0.4 0.5 0.4 1.4

323...528

A

25A-D1P4N104(1)

1.0 0.75 1.0 0.75 2.3

323...528

A 25A-D2P3N104

2.0 1.5 2.0 1.5 4.0

323...528

A 25A-D4P0N104

PowerFlex 525
Catalog No.
 25B-V2P5N104 25B-V4P8N104 25B-V6P0N104
 25B-A2P5N104 25B-A4P8N104 25B-A8P0N104 25B-A011N104
 25B-A2P5N114 25B-A4P8N114 25B-A8P0N114 25B-A011N114
 25B-B2P5N104 25B-B5P0N104 25B-B8P0N104 25B-B011N104 25B-B017N104 25B-B024N104 25B-B032N104 25B-B048N104 25B-B062N104
25B-D1P4N104(1) 25B-D2P3N104 25B-D4P0N104

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173

Appendix B Accessories and Dimensions

PowerFlex 520-Series Drive Ratings (Continued)

Output Ratings Normal Duty HP kW

Heavy Duty HP kW

Input

Frame PowerFlex 523

Output Voltage Range Size

Current (A)

Catalog No.

3.0 2.2 3.0 2.2 6.0

323...528

A 25A-D6P0N104

5.0 4.0 5.0 4.0 10.5

323...528

B 25A-D010N104

7.5 5.5 7.5 5.5 13.0

323...528

C 25A-D013N104

10.0 7.5 10.0 7.5 17.0

323...528

C 25A-D017N104

15.0 11.0 15.0 11.0 24.0

323...528

D 25A-D024N104

20.0 15.0 15.0 11.0 30.0

323...528

D 25A-D030N104

380...480V AC (-15%, +10%)  3-Phase Input with EMC Filter, 0...460V 3-Phase Output

0.5 0.4 0.5 0.4 1.4

323...528

A 25A-D1P4N114

1.0 0.75 1.0 0.75 2.3

323...528

A 25A-D2P3N114

2.0 1.5 2.0 1.5 4.0

323...528

A 25A-D4P0N114

3.0 2.2 3.0 2.2 6.0

323...528

A 25A-D6P0N114

5.0 4.0 5.0 4.0 10.5

323...528

B 25A-D010N114

7.5 5.5 7.5 5.5 13.0

323...528

C 25A-D013N114

10.0 7.5 10.0 7.5 17.0

323...528

C 25A-D017N114

15.0 11.0 15.0 11.0 24.0

323...528

D 25A-D024N114

20.0 15.0 15.0 11.0 30.0

323...528

D 25A-D030N114

25.0 18.5 20.0 15.0 37.0

323...528

E 25A-D037N114

30.0 22.0 25.0 18.5 43.0

323...528

E 25A-D043N114

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

25A-E0P9N104(1)

1.0 0.75 1.0 0.75 1.7

446...660

A 25A-E1P7N104

2.0 1.5 2.0 1.5 3.0

446...660

A 25A-E3P0N104

3.0 2.2 3.0 2.2 4.2

446...660

A 25A-E4P2N104

5.0 4.0 5.0 4.0 6.6

446...660

B 25A-E6P6N104

7.5 5.5 7.5 5.5 9.9

446...660

C 25A-E9P9N104

10.0 7.5 10.0 7.5 12.0

446...660

C 25A-E012N104

15.0 11.0 15.0 11.0 19.0

446...660

D 25A-E019N104

20.0 15.0 15.0 11.0 22.0

446...660

D 25A-E022N104

25.0 18.5 20.0 15.0 27.0

446...660

E 25A-E027N104

30.0 22.0 25.0 18.5 32.0

446...660

E 25A-E032N104

PowerFlex 525
Catalog No. 25B-D6P0N104 25B-D010N104 25B-D013N104 25B-D017N104 25B-D024N104 25B-D030N104
25B-D1P4N114 25B-D2P3N114 25B-D4P0N114 25B-D6P0N114 25B-D010N114 25B-D013N114 25B-D017N114 25B-D024N114 25B-D030N114 25B-D037N114 25B-D043N114
25B-E0P9N104(1) 25B-E1P7N104 25B-E3P0N104 25B-E4P2N104 25B-E6P6N104 25B-E9P9N104 25B-E012N104 25B-E019N104 25B-E022N104 25B-E027N104 25B-E032N104

(1) These drive ratings do not come with a heatsink cooling fan and are in accordance with design specifications. (2) A non-filtered drive is not available for 380...480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are available,
however you must verify that the application will support a filtered drive.

Dynamic Brake Resistors
Drive Ratings Input Voltage 100...120V 50/60 Hz 1-Phase
200...240V 50/60 Hz 1-Phase

Minimum Resistance HP kW  ±10% 0.25 0.2 56 0.5 0.4 56 1.0 0.75 56 1.5 1.1 41 0.25 0.2 56 0.5 0.4 56 1.0 0.75 56 2.0 1.5 41 3.0 2.2 32

Resistance  ±5%
91 91 91 91 91 91 91 91 47

Catalog No.(1)(2)
AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500

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Appendix B Accessories and Dimensions

Dynamic Brake Resistors (Continued)

Drive Ratings Input Voltage 200...240V 50/60 Hz 3-Phase
380...480V 50/60 Hz 3-Phase
525...600V 50/60 Hz 3-Phase

Minimum Resistance HP kW  ±10% 0.25 0.2 56 0.5 0.4 56 1.0 0.75 56 2.0 1.5 41 3.0 2.2 32 5.0 4.0 18 7.5 5.5 16 10.0 7.5 14 15.0 11.0 14
20.0 15.0 10 0.5 0.4 89 1.0 0.75 89 2.0 1.5 89 3.0 2.2 89 5.0 4.0 47 7.5 5.5 47 10.0 7.5 47 15.0 11.0 43
20.0 15.0 43
25.0 18.5 27
30.0 22.0 27 0.5 0.4 112 1.0 0.75 112 2.0 1.5 112 3.0 2.2 112 5.0 4.0 86 7.5 5.5 59 10.0 7.5 59 15.0 11.0 59
20.0 15.0 59
25.0 18.5 53
30.0 22.0 34

Resistance  ±5%
91 91 91 91 47 47 30 30 15
15 360 360 360 120 120 120 120 60
60
40
40 360 360 360 120 120 120 120 60
60
60
40

Catalog No.(1)(2)
AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-047P500 AK-R2-030P1K2 AK-R2-030P1K2 AK-R2-030P1K2(3) AK-R2-030P1K2(3) AK-R2-360P500 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(4) AK-R2-120P1K2(4) AK-R2-360P500 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(3) AK-R2-120P1K2(4)

(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-AT001. (3) Requires two resistors wired in parallel. (4) Requires three resistors wired in parallel.

EMC Line Filters

Short Circuit Current Rating = 100 kA

Drive Ratings

Input Voltage

HP kW Current (A)

100...120V 50/60 Hz 1-Phase

0.25 0.2 1.6 0.5 0.4 2.5 1.0 0.75 4.8 1.5 1.1 6.0

Frame Size
A A B B

Catalog No.
25-RF011-AL 25-RF011-AL 25-RF023-BL 25-RF023-BL

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175

Appendix B Accessories and Dimensions

EMC Line Filters (Continued)

Short Circuit Current Rating = 100 kA

Drive Ratings

Input Voltage

HP kW Current (A)

0.25 0.2 1.6

200...240V 50/60 Hz 1-Phase

0.5 0.4 2.5 1.0 0.75 4.8 2.0 1.5 8.0

3.0 2.2 11.0

0.25 0.2 1.6

0.5 0.4 2.5

1.0 0.75 5.0

200...240V 50/60 Hz 3-Phase

2.0 1.5 8.0 3.0 2.2 11.0 5.0 4.0 17.5 7.5 5.5 24.0

10.0 7.5 32.2

15.0 11.0 48.3

20.0 15.0 62.1

0.5 0.4 1.4

1.0 0.75 2.3

2.0 1.5 4.0

3.0 2.2 6.0

380...480V 50/60 Hz 3-Phase

5.0 4.0 10.5 7.5 5.5 13.0 10.0 7.5 17.0

15.0 11.0 24.0

20.0 15.0 30.0

25.0 18.5 37.0

30.0 22.0 43.0

0.5 0.4 0.9

1.0 0.75 1.7

2.0 1.5 3.0

3.0 2.2 4.2

525...600V 50/60 Hz 3-Phase

5.0 4.0 6.6 7.5 5.5 9.9 10.0 7.5 12.0 15.0 11.0 19.0 20.0 15.0 22.0 25.0 18.5 27.0

30.0 22.0 32.0

Frame Size
A A A B B A A A A A B C D E E A A A A B C C D D E E
A
A
A
A B C C D D E E

Catalog No.
25-RF011-AL 25-RF011-AL 25-RF011-AL 25-RF023-BL 25-RF023-BL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF014-AL 25-RF021-BL 25-RF027-CL 25-RF035-DL 25-RF056-EL 25-RF056-EL 25-RF7P5-AL 25-RF7P5-AL 25-RF7P5-AL 25-RF7P5-AL 25-RF014-BL 25-RF018-CL 25-RF018-CL 25-RF033-DL 25-RF033-DL 25-RF039-EL 25-RF039-EL(1) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL(2) 25-RF8P0-BL 25-RF014-CL 25-RF014-CL 25-RF027-DL 25-RF027-DL 25-RF029-EL 25-RF029-EL(1)

(1) EMC Line Filter size is based on the input current of the drive. See the tables on page 26 and page 27 for more information. (2) This 600V drive rating must be matched with a frame B EMC Line Filter.

EMC Plates
Item
EMC Plate

Description Optional grounding plate for shielded cables.

Frame Size A B C D E

Catalog No.
25-EMC1-FA 25-EMC1-FB 25-EMC1-FC 25-EMC1-FD 25-EMC1-FE

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Appendix B Accessories and Dimensions

Human Interface Module (HIM) Option Kits and Accessories

Item LCD Display, Remote Panel Mount
LCD Display, Remote Handheld
Bezel Kit DSI HIM Cable (DSI HIM to RJ45 cable)

Description Digital speed control CopyCat capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.0 meter cable Digital speed control Full numeric keyboard CopyCat capable IP 30 (NEMA Type 1) Includes 1.0 meter cable Panel mount with optional Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) Includes 2.0 m DSI cable 1.0 m (3.3 ft) 2.9 m (9.51 ft)

Catalog No. 22-HIM-C2S
22-HIM-A3
22-HIM-B1 22-HIM-H10 22-HIM-H30

IP 30/NEMA 1/UL Type 1 Kit

Item

Description

Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 IP 30/NEMA 1/UL Type 1 Kit enclosure. Includes conduit box with mounting screws and
plastic top panel.

Frame Size A B C D E

Catalog No.
25-JBAA 25-JBAB 25-JBAC 25-JBAD 25-JBAE

Control Module Fan Kit

Item Control Module Fan Kit

Description For use with drive in environments with ambient temperatures up to 70 °C or horizontal mounting.

Frame Size A...D E

Catalog No.
25-FAN1-70C 25-FAN2-70C

Incremental Encoder Input Option

Item Incremental Encoder

Description Incremental encoder input option board.

Catalog No. 25-ENC-1

WARNING: Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive.

PowerFlex 520-Series Drives Jumper Spare Kit

Item

Description

· · · ·

Wire Jumper MOV Jumper Protective Jumper (Control I/O terminal block) Analog/Signal Configuration Jumper

Replace the Protective Jumper from your Power module, drive Terminals Safety 1, Safety 2 and Safety +24V (S1, S2, S+) of the Control Module.

Catalog No. 25-ACCS-Drive

PowerFlex 520 Series Communication Adapter Spare Kit

Item
· PowerFlex 525 Encoder card removable Terminal Block
· PowerFlex 523/525 Communication Adapter interface connector

Description Communication adapter spare kits

Catalog No. 25-ACCS-COMM

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177

Appendix B Accessories and Dimensions

Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate

Item Mounting Adapter Plate

Description For use with drive when replacing Bulletin 160 drives in existing installations to a PowerFlex 520-Series drive. Select the catalog number based on the frame size of your Bulletin 160 drive.

B160 Frame Size A

Catalog No. 25-MAP-FA

B

25-MAP-FB

Mounting Adapter Plate for PowerFlex 4 AC Drive to PowerFlex 520-Series

Drive Ratings

PowerFlex 4

PowerFlex 520-series

Input Voltage HP

kW

Catalog No.

Frame Size

Catalog No.

Catalog No. with external EMC Filter(1)

0.3 0.2 22A-V1P5N104 A

100 ...120V,

0.5

0.4

22A-V2P3N104 A

Single-Phase, 50/60 Hz

1.0

0.8

22A-V4P5N104 B

1.5 1.1

22A-V6P0N104 B

25-AP0-FA 25-AP0-FB

25-AP1-FA 25-AP1-FB

0.3 0.2 22A-A1P5N104 A

0.5 0.4 22A-A2P3N104 A

25-AP0-FA

25-AP1-FA

1.0 0.8 22A-A4P5N104 A

2.0 1.5 22A-A8P0N104 B

25-AP0-FB

200...240V,

Single-Phase, 50/60 Hz

0.3

0.2

No Brake IGBT 22A-A1P4N103 A

0.5 0.4 22A-A2P1N103 A

25-AP0-FA

25-AP1-FB 25-AP1-FA

1.0 0.8 22A-A3P6N103 A

2.0 1.5 22A-A6P8N103 B 3.0 2.2 22A-A9P6N103 B

25-AP0-FB

25-AP1-FB

0.3 0.2 22A-A1P5N114 A

0.5 0.4 22A-A2P3N114 A

25-AP0-FA

25-AP1-FA

1.0 0.8 22A-A4P5N114 A

200...240V,

2.0 1.5

22A-A8P0N114 B

25-AP0-FB

Single-Phase,

50/60 Hz, with integral EMC

0.3

0.2

No Brake IGBT 22A-A1P4N113 A

Filter

0.5 0.4 22A-A2P1N113 A

25-AP0-FA

25-AP1-FB 25-AP1-FA

1.0 0.8 22A-A3P6N113 A

2.0 1.5 22A-A6P8N113 B 3.0 2.2 22A-A9P6N113 B

25-AP0-FB

25-AP1-FB

0.3 0.2 22A-B1P5N104 A

0.5 0.4 22A-B2P3N104 A

200...240V, Three-Phase, 50/60 Hz

1.0 2.0

0.8 1.5

22A-B4P5N104 A 22A-B8P0N104 A

3.0 2.2 22A-B012N104 B

5.0 3.7 22A-B017N104 B

25-AP0-FA 25-AP0-FB

25-AP1-FA 25-AP1-FB

0.5 0.4 22A-D1P4N104 A

380...480V,

1.0

0.8

22A-D2P3N104 A

Three-Phase 2.0 1.5 22A-D4P0N104 A

50/60 Hz

3.0 2.2 22A-D6P0N104 B

5.0 3.7 22A-D8P7N104 B

25-AP0-FA 25-AP0-FB

25-AP1-FA 25-AP1-FB

(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC filter to PowerFlex 520-series drives with external EMC filter only.

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Appendix B Accessories and Dimensions

Mounting Adapter Plate for PowerFlex 40 AC Drive to PowerFlex 520-Series

Drive Ratings

PowerFlex 40

PowerFlex 520-series

Input Voltage HP

kW

Catalog No.

Frame Size

Catalog No.

Catalog No. with external EMC Filter(1)

100 ...120V,

0.5

0.4

22B-V2P3N104 B

Single-Phase, 1.0 0.8 22B-V5P0N104 B

50/60 Hz

1.5 1.1

22B-V6P0N104 B

25-AP0-FB

25-AP1-FB

0.5 0.4 22B-A2P3N104 B

200...240V, Single-Phase, 50/60 Hz

1.0 2.0

0.8 1.5

22B-A5P0N104 B 22B-A8P0N104 B

3.0 2.2 22B-A012N104 C

25-AP0-FB 25-AP0-FC

25-AP1-FB 25-AP1-FC

200...240V, 0.5 0.4 22B-A2P3N114 B

Single-Phase, 50/60 Hz, with integral EMC

1.0 2.0

0.8 1.5

22B-A5P0N114 B 22B-A8P0N114 B

Filter

3.0 2.2 22B-A012N114 C

25-AP0-FB 25-AP0-FC

25-AP1-FB 25-AP1-FC

0.5 0.4 22B-B2P3N104 B

1.0 0.8 22B-B5P0N104 B

200...240V,

2.0 1.5

22B-B8P0N104 B

Three-Phase, 3.0 2.2 22B-B012N104 B

50/60 Hz

5.0 3.7 22B-B017104 B

25-AP0-FB

25-AP1-FB

7.5 5.5 22B-B024N104 C

25-AP0-FC

25-AP1-FC

10.0 7.5 22B-B033N104 C

25-AP0-FD

-(2)

0.5 0.4 22B-D1P4N104 B

1.0 0.8 22B-D2P3N104 B

2.0 1.5

380...480V, 3.0 2.2

Three-Phase 50/60 Hz

5.0

3.7

7.5 5.5

10.0 7.5

22B-D4P0N104 B 22B-D6P0N104 B 22B-D010N104 B 22B-D012N104 C 22B-D017N104 C

25-AP0-FB 25-AP0-FC

25-AP1-FB 25-AP1-FC

15.0 11.0 22B-D024N104 C

25-AP0-FD

-(2)

1.0 0.8 22B-E1P7N104 B

2.0 1.5

525...600V,

3.0

2.2

Three-Phase 5.0 3.7

50/60 Hz

7.5 5.5

10.0 7.5

22B-E3P0N104 B 22B-E4P2N104 B 22B-E6P6N104 B 22B-E9P9N104 C 22B-E012N104 C

25-AP0-FB 25-AP0-FC

25-AP1-FB 25-AP1-FC

15.0 11.0 22B-E019N104 C

25-AP0-FD

-(2)

(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC filter to PowerFlex 520-series drives with external EMC filter only.
(2) Mounting Adapter Plate is not required for the following ratings, as it comes with matching footprint and mounting holes. · Three-Phase 200...240V: 7.5 kW/10 HP · Three-Phase 380...480V: 11 kW/15 HP · Three-Phase 500...600V: 11 kW/15 HP

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Appendix B Accessories and Dimensions

Mounting Adapter Plate for PowerFlex 40P AC Drive to PowerFlex 520-Series

Drive Ratings

Input Voltage HP kW

0.5 0.4

1.0 0.8

200...240V,

2.0

1.5

Three-Phase, 3.0 2.2

50/60 Hz

5.0 3.7

7.5 5.5

10.0 7.5

0.5 0.4

1.0 0.8

2.0 1.5

380...480V, 3.0 2.2

Three-Phase 50/ 60 Hz

5.0

3.7

7.5 5.5

10.0 7.5

PowerFlex 40P

Catalog No.

Frame Size

22D-B2P3N104 B

22D-B5P0N104 B

22D-B8P0N104 B

22D-B012N104 B 22D-B017N104 B 22D-B024N104 C

22D-B033N104 C

22D-D1P4N104 B 22D-D2P3N104 B 22D-D4P0N104 B

22D-D6P0N104 B

22D-D010N104 B

22D-D012N104 C

22D-D017N104 C

PowerFlex 520-series

Catalog No.

Catalog No. with external EMC Filter(1)

25-AP0-FB

25-AP1-FB

25-AP0-FC 25-AP0-FD

25-AP1-FC -(2)

25-AP0-FB

25-AP1-FB

25-AP0-FC

25-AP1-FC

15.0 11.0

1.0 0.8

2.0 1.5

525...600V,

3.0

2.2

Three-Phase 50/ 5.0 3.7

60 Hz

7.5 5.5

10.0 7.5

15.0 11.0

22D-D024N104 C 22D-E1P7N104 B 22D-E3P0N104 B 22D-E4P2N104 B 22D-E6P6N104 B 22D-E9P9N104 C 22D-E012N104 C 22D-E019N104 C

25-AP0-FD 25-AP0-FB
25-AP0-FC 25-AP0-FD

-(2) 25-AP1-FB
25-AP1-FC -(2)

(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC filter to PowerFlex 520-series drives with external EMC filter only.

(2) Mounting Adapter Plate is not required for the following ratings, as it comes with matching footprint and mounting holes. · Three-Phase 200...240V: 7.5 kW/10 HP · Three-Phase 380...480V: 11 kW/15 HP · Three-Phase 500...600V: 11 kW/15 HP

Replacement Parts

PowerFlex 520-Series Power Module

Item PowerFlex 520-Series Power Module

Description
Replacement power module for use with PowerFlex 520-Series drives. Includes: · Power Module · Power Module Front Cover · Power Terminal Guard · Heatsink Fan

Output Ratings

Normal Duty

HP

kW

Heavy Duty

HP

kW

Output Current (A)

Input Voltage Range

100...120V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

0.25

0.2

0.25

0.2

1.6

85...132

0.5

0.4

0.5

0.4

2.5

85...132

1.0

0.75

1.0

0.75

4.8

85...132

1.5

1.1

1.5

1.1

6.0

85...132

200...240V AC (-15%, +10%)  1-Phase Input, 0...230V 3-Phase Output

0.25

0.2

0.25

0.2

1.6

170...264

0.5

0.4

0.5

0.4

2.5

170...264

Frame Size
A A B B
A A

Catalog No.
25-PM1-V1P6 25-PM1-V2P5 25-PM1-V4P8 25-PM1-V6P0
25-PM1-A1P6 25-PM1-A2P5

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Appendix B Accessories and Dimensions

Output Ratings (Continued)

Normal Duty

Heavy Duty

HP

kW

HP

kW

Input

Frame

Output

Voltage Range Size

Current (A)

1.0

0.75

1.0

0.75

4.8

170...264

A

2.0

1.5

2.0

1.5

8.0

170...264

B

3.0

2.2

3.0

2.2

11.0

170...264

B

200...240V AC (-15%, +10%)  1-Phase Input with EMC Filter, 0...230V 3-Phase Output

0.25

0.2

0.25

0.2

1.6

170...264

A

0.5

0.4

0.5

0.4

2.5

170...264

A

1.0

0.75

1.0

0.75

4.8

170...264

A

2.0

1.5

2.0

1.5

8.0

170...264

B

3.0

2.2

3.0

2.2

11.0

170...264

B

200...240V AC (-15%, +10%)  3-Phase Input, 0...230V 3-Phase Output

0.25

0.2

0.25

0.2

1.6

170...264

A

0.5

0.4

0.5

0.4

2.5

170...264

A

1.0

0.75

1.0

0.75

5.0

170...264

A

2.0

1.5

2.0

1.5

8.0

170...264

A

3.0

2.2

3.0

2.2

11.0

170...264

A

5.0

4.0

5.0

4.0

17.5

170...264

B

7.5

5.5

7.5

5.5

24.0

170...264

C

10.0

7.5

10.0

7.5

32.2

170...264

D

15.0

11.0

10.0

7.5

48.3

170...264

E

20.0

15.0

15.0

11.0

62.1

170...264

E

380...480V AC (-15%, +10%)  3-Phase Input, 0...460V 3-Phase Output

0.5

0.4

0.5

0.4

1.4

323...528

A

1.0

0.75

1.0

0.75

2.3

323...528

A

2.0

1.5

2.0

1.5

4.0

323...528

A

3.0

2.2

3.0

2.2

6.0

323...528

A

5.0

4.0

5.0

4.0

10.5

323...528

B

7.5

5.5

7.5

5.5

13.0

323...528

C

10.0

7.5

10.0

7.5

17.0

323...528

C

15.0

11.0

15.0

11.0

24.0

323...528

D

20.0

15.0

15.0

11.0

30.0

323...528

D

380...480V AC (-15%, +10%)  3-Phase Input with EMC Filter, 0...460V 3-Phase Output

0.5

0.4

0.5

0.4

1.4

323...528

A

1.0

0.75

1.0

0.75

2.3

323...528

A

2.0

1.5

2.0

1.5

4.0

323...528

A

3.0

2.2

3.0

2.2

6.0

323...528

A

5.0

4.0

5.0

4.0

10.5

323...528

B

7.5

5.5

7.5

5.5

13.0

323...528

C

10.0

7.5

10.0

7.5

17.0

323...528

C

15.0

11.0

15.0

11.0

24.0

323...528

D

20.0

15.0

15.0

11.0

30.0

323...528

D

25.0

18.5

20.0

15.0

37.0

323...528

E

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

0.5

0.4

0.5

0.4

0.9

446...660

A

1.0

0.75

1.0

0.75

1.7

446...660

A

2.0

1.5

2.0

1.5

3.0

446...660

A

3.0

2.2

3.0

2.2

4.2

446...660

A

5.0

4.0

5.0

4.0

6.6

446...660

B

7.5

5.5

7.5

5.5

9.9

446...660

C

10.0

7.5

10.0

7.5

12.0

446...660

C

15.0

11.0

15.0

11.0

19.0

446...660

D

Catalog No.
25-PM1-A4P8 25-PM1-A8P0 25-PM1-A011
25-PM2-A1P6 25-PM2-A2P5 25-PM2-A4P8 25-PM2-A8P0 25-PM2-A011
25-PM1-B1P6 25-PM1-B2P5 25-PM1-B5P0 25-PM1-B8P0 25-PM1-B011 25-PM1-B017 25-PM1-B024 25-PM1-B032 25-PM1-B048 25-PM1-B062
25-PM1-D1P4 25-PM1-D2P3 25-PM1-D4P0 25-PM1-D6P0 25-PM1-D010 25-PM1-D013 25-PM1-D017 25-PM1-D024 25-PM1-D030
25-PM2-D1P4 25-PM2-D2P3 25-PM2-D4P0 25-PM2-D6P0 25-PM2-D010 25-PM2-D013 25-PM2-D017 25-PM2-D024 25-PM2-D030 25-PM2-D037 25-PM2-D043
25-PM1-E0P9 25-PM1-E1P7 25-PM1-E3P0 25-PM1-E4P2 25-PM1-E6P6 25-PM1-E9P9 25-PM1-E012 25-PM1-E019

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Appendix B Accessories and Dimensions

Output Ratings (Continued)

Normal Duty

Heavy Duty

HP

kW

HP

kW

20.0

15.0

15.0

11.0

25.0

18.5

20.0

15.0

30.0

22.0

25.0

18.5

Output Current (A)
22.0 27.0 32.0

Input

Frame

Voltage Range Size

446...660

D

446...660

E

446...660

E

Catalog No.
25-PM1-E022 25-PM1-E027 25-PM1-E032

PowerFlex 520-Series Control Module

Item
PowerFlex 523 Control Module PowerFlex 525 Control Module

Description
Replacement control module for use with PowerFlex 520-Series drives. Includes: · Control Module · Control Module Front Cover

Frame Size

Catalog No.

25A-CTM1 A...E
25B-CTM1

Other Parts
Item PowerFlex 523 Control Module Front Cover PowerFlex 525 Control Module Front Cover

Description Replacement cover for the control module I/O terminals, EtherNet/IP, and DSI ports.

PowerFlex 520-Series Replacement cover for the PowerFlex 520-Series power Power Module Front Cover module.

PowerFlex 520-Series Power Terminal Guard

Replacement finger guard for power terminals.

PowerFlex 520-Series Heatsink Fan Kit

Replacement fan for drive power module.

PowerFlex 520-Series EMC Cores

Replacement EMC cores

Frame Size

Catalog No.

25A-CTMFC1 A...E
25B-CTMFC1

B

25-PMFC-FB

C

25-PMFC-FC

D

25-PMFC-FD

E

25-PMFC-FE

A

25-PTG1-FA

B

25-PTG1-FB

C

25-PTG1-FC

D

25-PTG1-FD

E

25-PTG1-FE

A

25-FAN1-FA

B

25-FAN1-FB

C

25-FAN1-FC

D

25-FAN1-FD

E

25-FAN1-FE

A

25-CORE-A 25-CORE-RF-A

25-CORE-B

B

25-CORE-RF-B

C

25-CORE-C 25-CORE-RF-C

D

25-CORE-D

25-CORE-RF-D

E

25-CORE-E 25-CORE-RF-E

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Appendix B Accessories and Dimensions

Communication Option Kits and Accessories

Item

Description

Communication Adapters

Embedded communication options for use with the PowerFlex 520-Series drives: · DeviceNet® · Dual-port EtherNet/IP · PROFIBUS DP-V1

Compact I/OTM Module Three channels

Universal Serial Bus (USB) Converter Module

Provides serial communication with DF1 protocol for use with Connected Components Workbench software. Includes: · 2 m USB cable (1) · 20-HIM-H10 cable (1) · 22-HIM-H10 cable (1)

Serial Converter Module (RS485 to RS232)

Provides serial communication with DF1 protocol for use with Connected Components Workbench software. Includes: · DSI to RS232 serial converter (1) · 1203-SFC serial cable (1) · 22-RJ45CBL-C20 cable (1)

DSI Cable

2.0 m RJ45 to RJ45 cable, male to male connectors.

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.

Splitter Cable

RJ45 one to two port splitter cable (Modbus only)

Terminating Resistors RJ45 120 Ohm resistors (2 pieces)

Terminal Block

RJ45 Two position terminal block (5 pieces)

Connected Components Workbench Software (Download via the Software Subscription Portal or DVDROM) rok.auto/ccw

Windows-based software packages for programming and configuring Allen-Bradley® drives and other Rockwell Automation products. Compatibility:
Windows XP, Windows Vista and Windows 7

Catalog No. 25-COMM-D 25-COMM-E2P 25-COMM-P 25-ACCS-COMM 1769-SM2
1203-USB
22-SCM-232
22-RJ45CBL-C20 1203-SFC AK-U0-RJ45-SC1 AK-U0-RJ45-TR1 AK-U0-RJ45-TB2P
rok.auto/ccw

Bulletin 1321-3R Series Line Reactors

Output Ratings(1)

Input Line Reactor(2)(4)

Output Line Reactor(2)(3)

Normal Duty Heavy Duty

IP00 (Open Style)

IP11

IP00

(NEMA/UL Type 1) (Open Style)

IP11 (NEMA/UL Type 1)

HP kW HP kW Catalog No.

Catalog No.

Catalog No.

Catalog No.

200...240V 50/60 Hz 1-Phase(4)

0.25 0.2 0.25 0.2 1321-3R4-A

1321-3RA4-A

1321-3R2-D

1321-3RA2-D

0.5 0.4 0.5 0.4 1321-3R8-A

1321-3RA8-A

1321-3R2-D

1321-3RA2-D

1.0 0.75 1.0 0.75 1321-3R8-A

1321-3RA8-A

1321-3R4-A

1321-3RA4-A

2.0 1.5 2.0 1.5 1321-3R18-A

1321-3RA18-A

1321-3R8-A

1321-3RA8-A

3.0 2.2 3.0 2.2 1321-3R18-A

1321-3RA18-A

1321-3R12-A

1321-3RA12-A

200...240V 50/60 Hz 3-Phase

0.25 0.2 0.25 0.2 1321-3R2-D

1321-3RA2-D

1321-3R2-D

1321-3RA2-D

0.5 0.4 0.5 0.4 1321-3R2-D

1321-3RA2-D

1321-3R2-D

1321-3RA2-D

1.0 0.75 1.0 0.75 1321-3R4-A

1321-3RA4-A

1321-3R4-A

1321-3RA4-A

2.0 1.5 2.0 1.5 1321-3R8-A

1321-3RA8-A

1321-3R8-A

1321-3RA8-A

3.0 2.2 3.0 2.2 1321-3R12-A

1321-3RA12-A

1321-3R12-A

1321-3RA12-A

5.0 4.0 5.0 4.0 1321-3R18-A

1321-3RA18-A

1321-3R18-A

1321-3RA18-A

7.5 5.5 7.5 5.5 1321-3R25-A

1321-3RA25-A 1321-3R25-A

1321-3RA25-A

10.0 7.5 10.0 7.5 1321-3R35-A

1321-3RA35-A 1321-3R35-A

1321-3RA35-A

15.0 11.0 10.0 7.5 1321-3R45-A

1321-3RA45-A 1321-3R45-A

1321-3RA45-A

20.0 15.0 15.0 11.0

1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R45-A (HD) 1321-3RA45-A (HD) 1321-3R45-A (HD) 1321-3RA45-A (HD)

380...480V 50/60 Hz 3-Phase

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Appendix B Accessories and Dimensions

Bulletin 1321-3R Series Line Reactors (Continued)

Output Ratings(1)
Normal Duty Heavy Duty
HP kW HP kW 0.5 0.4 0.5 0.4 1.0 0.75 1.0 0.75 2.0 1.5 2.0 1.5 3.0 2.2 3.0 2.2 5.0 4.0 5.0 4.0 7.5 5.5 7.5 5.5 10.0 7.5 10.0 7.5 15.0 11.0 15.0 11.0
20.0 15.0 15.0 11.0
25.0 18.5 20.0 15.0
30.0 22.0 25.0 18.5
525...600V 50/60 Hz 3-Phase 0.5 0.4 0.5 0.4 1.0 0.75 1.0 0.75 2.0 1.5 2.0 1.5 3.0 2.2 3.0 2.2 5.0 4.0 5.0 4.0 7.5 5.5 7.5 5.5 10.0 7.5 10.0 7.5 15.0 11.0 15.0 11.0
20.0 15.0 15.0 11.0
25.0 18.5 20.0 15.0
30.0 22.0 25.0 18.5

Input Line Reactor(2)(4)

Output Line Reactor(2)(3)

IP00 (Open Style)

IP11

IP00

(NEMA/UL Type 1) (Open Style)

IP11 (NEMA/UL Type 1)

Catalog No.

Catalog No.

Catalog No.

Catalog No.

1321-3R2-B

1321-3RA2-B

1321-3R2-B

1321-3RA2-B

1321-3R4-C

1321-3RA4-C

1321-3R4-C

1321-3RA4-C

1321-3R4-B

1321-3RA4-B

1321-3R4-B

1321-3RA4-B

1321-3R8-C

1321-3RA8-C

1321-3R8-C

1321-3RA8-C

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

1321-3R12-B

1321-3RA12-B

1321-3R18-B

1321-3RA18-B

1321-3R18-B

1321-3RA18-B

1321-3R25-B

1321-3RA25-B 1321-3R25-B

1321-3RA25-B

1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R25-B (HD) 1321-3RA25-B (HD) 1321-3R25-B (HD) 1321-3RA25-B (HD)

1321-3R35-B

1321-3RA35-B 1321-3R35-B

1321-3RA35-B

1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R35-B (HD) 1321-3RA35-B (HD) 1321-3R35-B (HD) 1321-3RA35-B (HD)

1321-3R1-C 1321-3R2-B 1321-3R4-C 1321-3R4-B 1321-3R8-C 1321-3R12-B 1321-3R12-B 1321-3R18-B 1321-3R25-B (ND) 1321-3R18-B (HD) 1321-3R35-C (ND) 1321-3R25-C (HD) 1321-3R35-C (ND) 1321-3R25-B (HD)

1321-3RA1-C 1321-3RA2-B 1321-3RA4-C 1321-3RA4-B 1321-3RA8-C 1321-3RA12-B 1321-3RA12-B 1321-3RA18-B 1321-3RA25-B (ND) 1321-3RA18-B (HD) 1321-3RA35-C (ND) 1321-3RA25-C (HD) 1321-3RA35-C (ND) 1321-3RA25-B (HD)

1321-3R1-C 1321-3R2-B 1321-3R4-C 1321-3R4-B 1321-3R8-C 1321-3R12-B 1321-3R12-B 1321-3R18-B 1321-3R25-B (ND) 1321-3R18-B (HD) 1321-3R35-C (ND) 1321-3R25-C (HD) 1321-3R35-C (ND) 1321-3R25-B (HD)

1321-3RA1-C 1321-3RA2-B 1321-3RA4-C 1321-3RA4-B 1321-3RA8-C 1321-3RA12-B 1321-3RA12-B 1321-3RA18-B 1321-3RA25-B (ND) 1321-3RA18-B (HD) 1321-3RA35-C (ND) 1321-3RA25-C (HD) 1321-3RA35-C (ND) 1321-3RA25-B (HD)

(1) Normal Duty and Heavy-Duty ratings for 15 HP (11 kW) and below are identical except for 200...240V 3-Phase 15 HP (11 kW) drive. (2) Catalog numbers listed are for 3% impedance at 60 Hz. 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. (4) Standard 3-phase reactors can be used for 1-phase applications by routing each of the two supply conductors through an outside
coil and leaving the center open.

Product Dimensions

The PowerFlex 520-series drive is available in five frame sizes. See the PowerFlex 520-Series Drive Ratings on page 173 for information on power ratings.

PowerFlex 520-Series Drive Weight

Frame Size A B C D E

Weight (kg/lb) 1.1 / 2.4 1.6 / 3.5 2.3 / 5.0 3.9 / 8.6 12.9 / 28.4

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IP 20/Open Type  Frame A
Dimensions are in millimeters and (inches) 72.0 (2.83) 57.5 (2.26)
Esc Sel

Appendix B Accessories and Dimensions 172.0 (6.77)

152.0 (5.98)

92.7 (3.65)

140.0 (5.51)

IP 20/Open Type  Frame B
Dimensions are in millimeters and (inches) 87.0 (3.43) 72.5 (2.85)
Esc Sel

6.0 (0.24) 172.0 (6.77)

180.0 (7.09)

168.0 (6.61)

92.7 (3.65)

6.0 (0.24)

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

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Appendix B Accessories and Dimensions

IP 20/Open Type  Frame C
Dimensions are in millimeters and (inches) 109.0 (4.29) 90.5 (3.56)

Esc Sel

184.0 (7.24)

207.0 (8.15) 220.0 (8.66)

IP 20/Open Type  Frame D
Dimensions are in millimeters and (inches) 130.0 (5.12) 116.0 (4.57)
Esc Sel

6.0 (0.24) 212.0 (8.35)

92.7 (3.65)

260.0 (10.24)

247.0 (9.72)

6.0 (0.24)

186

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IP 20/Open Type  Frame E
Dimensions are in millimeters and (inches) 185.0 (7.28) 160.0 (6.30)
Esc Sel

Appendix B Accessories and Dimensions 279.0 (10.98)

280.0 (11.02) 300.0 (11.81)

Control Module Fan Kit
25-FAN1-70C

7.6 (0.30) 25-FAN2-70C

Specifications Rated Voltage Operation Voltage Input Current Speed (Reference) Air Flow (At zero static pressure) max
Air Pressure (At zero air flow) min Acoustical Noise Insulation Type Frame Size Wire Size Torque

25-FAN1-70C

25-FAN2-70C

24V DC

14...27.6V DC

0.1 A

0.15 A

7000 rpm

4500 ± 10% rpm

0.575 m3/min

1.574 m3/min

7.70 mm H2O

9.598 mm H2O

40.5 dB-A

46.0 dB-A

UL Class A

Frame A...D

Frame E

0.32 mm2 (22 AWG)

0.29...0.39 N·m (2.6...3.47 lb·in)

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32.0 (1.26)

207.0 (8.15) 220.0 (8.66)

Appendix B Accessories and Dimensions

IP 20/Open Type with Control Module Fan Kit  Frame A...C

Dimensions are in millimeters and (inches) Frame A

Frame B

Frame C

72.0 (2.83) 57.5 (2.26)

87.0 (3.43) 72.5 (2.85)

109.0 (4.29) 90.5 (3.56)

32.0 (1.26)

32.0 (1.26)

Esc Sel

Esc Sel

Esc Sel

168.0 (6.61) 180.0 (7.09)

140.0 (5.51) 152.0 (5.98)

IMPORTANT An external 24V DC power source is required when using the Control Module Fan Kit with drive frames A, B, and C.

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Appendix B Accessories and Dimensions

IP 20/Open Type with Control Module Fan Kit  Frame D...E

Dimensions are in millimeters and (inches) Frame D
130.0 (5.12) 116.0 (4.57)

Frame E

196.0 (7.72) 185.0 (7.28) 160.0 (6.30)

32.0 (1.26)

52.0 (2.05)

Esc Sel

Esc Sel

260.0 (10.24)

300.0 (11.81)

247.0 (9.72)

280.0 (11.02)

IMPORTANT Remove the label to access the built-in 24V supply on drive frames D and E for use with the Control Module Fan Kit.

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1  Frame A
Dimensions are in millimeters and (inches)
72.0 (2.83) 57.5 (2.26)

15.0 (0.59)

IP 30/NEMA 1/ UL Type 1 top panel 172.0 (6.77)

Esc Sel

140.0 (5.51) 152.0 (5.98) 219.0 (8.62)

92.7 (3.65)

6.0 (0.24)

51.1 (2.01) 21.0 (0.82)

IP 30/NEMA 1/ UL Type 1 conduit box ø21.5 (ø0.85)

64.7 (2.55) 88.2 (3.47) 111.9 (4.41) 135.4 (5.33)

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IP 30/NEMA 1/UL Type 1  Frame B
Dimensions are in millimeters and (inches)
87.0 (3.43) 72.5 (2.85)

15.0 (0.59)

Appendix B Accessories and Dimensions
IP 30/NEMA 1/ UL Type 1 top panel 172.0 (6.77)

Esc Sel

168.0 (6.61) 180.0 (7.09) 218.0 (8.58)

92.7 (3.65)

66.1 (2.60) 63.1 (2.48)

33.5 (1.32) 23.9 (0.94)

IP 30/NEMA 1/ UL Type 1 conduit box

ø21.5 (ø0.85) ø27.5 (ø1.08)

6.1 (0.24)

67.3 (2.65) 88.3 (3.48) 108.5 (4.27) 128.5 (5.06)

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1  Frame C
Dimensions are in millimeters and (inches)

109.0 (4.29) 90.5 (3.56)

IP 30/NEMA 1/ UL Type 1 top panel 184.0 (7.24)

15.0 (0.59)

Esc Sel

207.0 (8.15) 222.0 (8.66) 255.0 (10.04)

6.0 (0.24)

80.5 (3.17) 66.5 (2.62)

34.5 (1.36) 26.5 (1.04)

IP 30/NEMA 1/ UL Type 1 conduit box
ø21.5 (ø0.85) ø27.5 (ø1.08)

92.7 (3.65)

82.2 (3.24) 123.3 (4.85)

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IP 30/NEMA 1/UL Type 1  Frame D
Dimensions are in millimeters and (inches) 130.0 (5.12) 116.0 (4.57)
Esc Sel

15.0 (0.59)

Appendix B Accessories and Dimensions
IP 30/NEMA 1/ UL Type 1 top panel 212.0 (8.35)

247.0 (9.72) 260.0 (10.24) 295.0 (11.61)

6.0 (0.24)

96.0 (3.78) 70.0 (2.76)

44.0 (1.73) 30.0 (1.18)

IP 30/NEMA 1/ UL Type 1 conduit box

ø21.5 (ø0.85)

ø33.5 (ø1.32)

109.8 (4.32) 153.3 (6.04)

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1  Frame E
Dimensions are in millimeters and (inches)
185.0 (7.28) 160.0 (6.30)

IP 30/NEMA 1/ UL Type 1 top panel 279.0 (10.98)

15.0 (0.59)

Esc Sel

280.0 (11.02) 300.0 (11.81) 350.0 (13.78)

127.5 (5.02) 82.5 (3.25)

62.5 (2.46) 42.5 (1.67)

IP 30/NEMA 1/ UL Type 1 conduit box
ø21.5 (ø0.85) ø43.7 (ø1.72)

7.6 (0.30)

164.0 (6.46) 181.0 (7.13) 212.0 (8.35)

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EMC Line Filter  Frame A
Dimensions are in millimeters and (inches)
55.0 (2.17) 30.0 (1.18)

Appendix B Accessories and Dimensions

Filter can be mounted onto the back of the drive.

72.0 (2.83) 54.0 (2.13)

ø5.5 (ø0.22)

223.0 (8.78)

234.0 (9.21) 223.0
(8.78)

20.0 (0.79)

23.0 (0.91)

EMC Line Filter  Frame B
Dimensions are in millimeters and (inches)
70.0 (2.76) 35.0 (1.38)

54.0 (2.13)

5.5 (0.22)

Filter can be mounted onto the back of the drive.

87.0 (3.43) 58.0 (2.28)

ø5.5 (ø0.22)

258.0 (10.16)

270.0 (10.63)
258.0 (10.16)

25.0 (0.98)

24.0 (0.94)

58.0 (2.28)

5.5 (0.22)

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Appendix B Accessories and Dimensions

EMC Line Filter  Frame C
Dimensions are in millimeters and (inches)
70.0 (2.76) 37.0 (1.46)

Filter can be mounted onto the back of the drive.

109.0 (4.29) 76.0 (2.99)

ø5.5 (ø0.22)

263.0 (10.35)

275.0 (10.83)
263.0 (10.35)

25.0 (0.98)

28.0 (1.10)

EMC Line Filter  Frame D

Dimensions are in millimeters and (inches)

80.0 (3.15) 33.0 (1.30)

28.0 (1.10)

76.0 (2.99)

5.5 (0.22)

Filter can be mounted onto the back of the drive.

130.0 (5.12) 90.0 (3.54)

ø5.5 (ø0.22)

298.0 (11.73)

310.0 (12.20)
298.0 (11.73)

33.0 (1.30)

28.0 (1.10)

90.0 (3.54)

5.5 (0.22)

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EMC Line Filter  Frame E

Dimensions are in millimeters and (inches)

33.0 (1.30)

80.0 (3.15)

28.0 (1.10)

Appendix B Accessories and Dimensions

155.0 (6.10) 110.0 (4.33)

ø5.5 (ø0.22)

375.0 (14.76)

390.0 (15.35)
375.0 (14.76)

33.0 (1.30)

28.0 (1.10)

110.0 (4.33)

5.5 (0.22)

Adapter Plate Dimensions

Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate Dimensions

Dimensions are in millimeters and (inches)

Frame A 25-MAP-FA

Frame B 25-MAP-FB

80.0 (3.15)

39.2 (1.54)

92.0 (3.62)

39.2 (1.54)

198.0 (7.80) 240.0 (9.45)

20.2 (0.80)

20.2 (0.80)

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Appendix B Accessories and Dimensions

PowerFlex 4/40/40P to PowerFlex 520-Series Mounting Adapter Plate Dimension

Adapter Plate - Frame A

Dimensions are in millimeters and (inches)

80.0 (3.15) 67.0 (2.64)

Frame A 25-AP0-FA

12.0 (0.47)

Frame A 25-AP1-FA
80.0 (3.15) 60.0 (2.36)

10.6 (0.42)

139.5 (5.49) 164.0 (6.46) 207.5 (8.17) 248.0 (9.76)

Adapter Plate - Frame B
Dimensions are in millimeters and (inches)
Frame B 25-AP0-FB

100.0 (3.94) 87.0 (3.43)

12.0 (0.47)

100.0 (3.94) 78.0 (3.07)

Frame B 25-AP1-FB

10.6 (0.42)

167.5 (6.59) 192.0 (7.56) 216.0 (8.50) 270.0 (10.63)

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Adapter Plate - Frame C
Dimensions are in millimeters and (inches)
Frame C 25-AP0-FC

130.0 (5.12) 116.0 (4.57)

9.4 (0.37)

Appendix B Accessories and Dimensions

130.0 (5.12) 90.0 (3.54)

Frame C 25-AP1-FC

10.6 (0.42)

245.5 (9.67) 260.0 (10.24) 296.5 (11.67)
309.0 (12.17)

Adapter Plate - Frame D
Dimensions are in millimeters and (inches)
Frame D 25-AP0-FD
130.0 (5.12) 116.0 (4.57)

11.0 (0.43)

245.5 (9.67) 272.0 (10.71)

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Appendix B Accessories and Dimensions
Optional Accessories and Kits

Installing a Communication Adapter
1. Insert the communication adapter interface connector into the Control Module. Make sure the indicator line on the connector is aligned with the surface of the Control Module.
For PowerFlex 523
Communication adapter interface connector

For PowerFlex 525
Communication adapter interface connector

2. Align the connectors on the communication adapter to the communication adapter interface connector, then push the back cover down.

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Appendix B Accessories and Dimensions
3. Press along the edges of the back cover until it snaps firmly into place.
Communication adapter interface connector
Removing a Communication Adapter
1. Insert a finger into the slot at the top of the back cover. Lift to separate the back cover from the Control Module.

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Appendix B Accessories and Dimensions
Notes:

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Network Wiring

RS485 (DSI) Protocol

C Appendix

PowerFlex 520-series drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some Modbus functions are supported to allow simple networking. PowerFlex 520-series drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.
PowerFlex 520-Series Drive Network

Esc Sel

Esc Sel

Esc Sel

Esc Sel

Controller
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.

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Appendix C RS485 (DSI) Protocol

Network Wiring Diagram Example

Master

PowerFlex 525 PowerFlex 523 PowerFlex 525

Node 1

Node 2

Node "n"

TxRxD+

4

TxRxD+

4

TxRxD+ 4 120 ohm resistor

FRONT

TxRxD-

120 ohm resistor
5

TxRxD-

5

TxRxD- 5

Shield X

Shield X

Shield X

PIN 1 PIN 8

C1 C2 RS485 (DSI)
AK-U0-RJ45-TB2P TxRxD+ TxRxD-

C1 C2 RS485 (DSI)
TxRxD+ TxRxD-

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

DC- DC+ BRBR+

DC- DC+ BRBR+

IMPORTANT The shield is connected at ONLY ONE end of each cable segment.

Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 520-series drive's RJ45 socket must not be connected because they contain power, etc. for other Rockwell Automation peripheral devices.

Wiring terminations on the master controller will vary depending on the master controller used and "TxRxD+" and "TxRxD-" are shown for illustration purposes only. Refer to the master controller's 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.
· Termination resistors need to be applied at each end of the network cable.
· RS485 repeaters may need to be used for long cable runs, or if greater than 32 nodes are needed on the network.
· Network wiring should be separated from power wires by at least 0.3 meters (1 foot).
· Network wiring should only cross power wires at a right angle.
I/O Terminal C1 (RJ45 Shield) for the Ethernet and DSI network cables on the PowerFlex 520-series drive must also be connected to PE ground (there are two PE terminals on the drive). The shield for the network cables should be connected to PE ground at one end only.

I/O Terminal C2 (Comm Common) is internally tied to Network Common for the network signals, and NOT to RJ45 Shield. Tying I/O Terminal C2 to PE ground may improve noise immunity in some applications.

See I/O Control Terminal Designations onpage 39 and page 42 for more information.

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Parameter Configuration

Appendix C RS485 (DSI) Protocol

The following PowerFlex 520-series drive parameters are used to configure the drive to operate on a DSI network.
Configuring Parameters for DSI Network

Parameter P046 [Start Source 1] P047 [Speed Reference1]
C123 [RS485 Data Rate]
C124 [RS485 Node Addr] C125 [Comm Loss Action] C126 [Comm Loss Time]
C127 [Comm Format]
C121 [Comm Write Mode]

Details Set to 3 "Serial/DSI" if Start is controlled from the network. Set to 3 "Serial/DSI" if the Speed Reference is controlled from the network. Sets the data rate for the RS485 (DSI) Port. All nodes on the network must be set to the same data rate. Sets the node address for the drive on the network. Each device on the network requires a unique node address. Selects the drive's response to communication problems. Sets the time that the drive will remain in communication loss before the drive implements C125 [Comm Loss Action]. Sets the transmission mode, data bits, parity, and stop bits for the RS485 (DSI) Port. All nodes on the network must be set to the same setting. Set to 0 "Save" when programming drive. Set to 1 "RAM only" to only write to volatile memory.

Reference page 86 page 86
page 100
page 100 page 100 page 100
page 101
page 100

Supported Modbus Function Codes

The Drive Serial Interface (DSI) used on PowerFlex 520-series drives supports some of the Modbus function codes.
Supported Modbus Function Codes

Modbus Function Code (Decimal) 03 06 16 (10 Hexadecimal)

Command Read Holding Registers Preset (Write) Single Register Preset (Write) Multiple Registers

IMPORTANT

Modbus devices can be 0-based (registers are numbered starting at 0) or 1-based (registers are numbered starting at 1). Depending on the Modbus Master used, the register addresses listed on the following pages may need to be offset by +1. For example, Logic Command may be register address 8192 for some master devices (for example, ProSoft 3150-MCM SLCTM Modbus scanner) and 8193 for others (for example, PanelViewTM).

Writing (06) Logic Command Data

The PowerFlex 520-series drive can be controlled through the network by sending Function Code 06 writes to register address 2000H (Logic Command). P046 [Start Source 1] must be set to 3 "Serial/DSI" in order to accept the commands. PowerFlex 523 drives support only Velocity bit definitions. PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either Velocity or Position bit definitions.
Powerup/Reset the drive after selecting an option for C122 [Cmd Stat Select] for the change to take effect.

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Appendix C RS485 (DSI) Protocol

Velocity Bit Definitions

Comm Logic Command  C122 = 0 "Velocity"

Address (Decimal)

Bit(s)

0

1

2

3

5, 4

6 7

9, 8 2000H (8192)

11, 10

14, 13, 12 15

Description 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 01 = Forward Command 10 = Reverse Command 11 = No Command 1 = Force Keypad Control, 0 = Not Force Keypad Control 1 = MOP Increment, 0 = Not Increment 00 = No Command 01 = Accel Rate 1 Enable 10 = Accel Rate 2 Enable 11 = Hold Accel Rate Selected 00 = No Command 01 = Decel Rate 1 Enable 10 = Decel Rate 2 Enable 11 = Hold Decel Rate Selected 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 = A413 [Preset Freq 3] 1 = MOP Decrement, 0 = Not Decrement

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Writing (06) Comm Frequency Command

Appendix C RS485 (DSI) Protocol

Position Bit Definitions

Comm Logic Command  C122 = 1 "Position"

Address (Decimal)

Bit(s)

0

1

2

3

5, 4

6 7
2000H (8192)

10, 9, 8

11 12 13 14 15

Description 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 01 = Forward Command 10 = Reverse Command 11 = No Command 1 = Logic In 1 1 = Logic In 2 000 = 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 = Freq. and Position Step 5 110 = Freq. and Position Step 6 111 = Freq. and Position Step 7 1 = Find Home 1 = Hold Step 1 = Pos Redefine 1 = Sync Enable 1 = Traverse Disable

The PowerFlex 520-series drive Comm Frequency Command can be controlled through the network by sending Function Code 06 writes to register address 2001H (Comm Frequency Command).
Comm Frequency Command

Reference Address (Decimal)
2001H (8193)

Description Used by internal comm modules to control the reference of the drive. In units of 0.01 Hz.

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Appendix C RS485 (DSI) Protocol
Reading (03) Logic Status Data

The PowerFlex 520-series drive Logic Status data can be read through the network by sending Function Code 03 reads to register address 2100H (Logic Status). PowerFlex 523 drives support only Velocity bit definitions. PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either Velocity or Position bit definitions.

Velocity Bit Definitions

Comm Logic Status  C122 = 0 "Velocity"

Address (Decimal)

Bit(s)

0

1

2

3

4

5

6

7

2100H (8448)

8

9

10

11

12

13

14

15

Position Bit Definitions

Comm Logic Status  C122 = 1 "Position"

Address (Decimal)

Bit(s)

0

1

2

3

4

5

6

2100H (8448)

7

8

9

10

11

12

13

14

15

Description 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse 1 = Accelerating, 0 = Not Accelerating 1 = Decelerating, 0 = Not Decelerating Not Used 1 = Faulted, 0 = Not Faulted 1 = At Reference, 0 = Not At Reference 1 = Main Freq Controlled by Active Comm 1 = Operation Cmd Controlled by Active Comm 1 = Parameters have been locked Digital Input 1 Status (DigIn TermBlk 05) Digital Input 2 Status (DigIn TermBlk 06) Digital Input 3 Status (DigIn TermBlk 07) Digital Input 4 Status (DigIn TermBlk 08)
Description 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse 1 = Accelerating, 0 = Not Accelerating 1 = Decelerating, 0 = Not Decelerating 1 = Forward Travel Position, 0 = Reverse Travel Position 1 = Faulted, 0 = Not Faulted 1 = At Reference, 0 = Not At Reference 1 = At Position, 0 = Not At Position 1 = At Home, 0 = Not At Home 1 = Drive Homed, 0 = Not Drive Homed 1 = Sync Hold, 0 = Not Sync Hold 1 = Sync Ramp, 0 = Not Sync Ramp 1 =Traverse On, 0 = Traverse Off 1 = Traverse Decel, 0 = Not Traverse Decel

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Appendix C RS485 (DSI) Protocol

Reading (03) Drive Error Codes

The PowerFlex 520-series Error Code data can be read through the network by sending Function Code 03 reads to register address 2101H (Drive Error Codes).
Drive Error Codes

Logic Status Address (Decimal)
2101H (8449)
2101H (8449)

Value (Decimal) 0 2 3 4 5 6 7 8 9 12 13 15 21 29 33 38 39 40 41 42 43 48 59 63 64 70 71 72 73 80 81 82 83 91 94 100 101 105 106 107 109 110 111 114 122 125 126 127

Description No Fault Auxiliary Input Power Loss Undervoltage Overvoltage Motor Stalled Motor Overload Heatsink Overtemperature Control Module Overtemperature HW Overcurrent (300%) Ground Fault Load Loss Output Phase Loss Analog Input Loss Auto Restart Tries Phase U to Ground Short Phase V to Ground Short Phase W to Ground Short Phase UV Short Phase UW Short Phase VW Short Parameters Defaulted Safety Open Software Overcurrent Drive Overload Power Unit Fail DSI Network Loss Option Card Network Loss Embedded EtherNet/IP Adapter Network Loss AutoTune Fail DSI Communication Loss Option Card Communication Loss Embedded EtherNet/IP Adapter Communication Loss Encoder Loss Function Loss Parameter Checksum Error External Storage Control Module Connect Error Incompatible Control-Power Module Unrecognized Control-Power Module Mismatched Control-Power Module Keypad Membrane Safety Hardware Microprocessor Failure I/O Board Fail Flash Update Required Non Recoverable Error DSI Flash Update Required

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Appendix C RS485 (DSI) Protocol
Reading (03) Drive Operational Values

The PowerFlex 520-series Drive Operational Values can be read through the network by sending Function Code 03 reads to register addresses 2102H...210AH.
Drive Operational Values

Reference Address (Decimal) 2102H (8450) 2103H (8451) 2104H (8452) 2105H (8453) 2106H (8454)

Description Frequency Command (xxx.xx Hz) Output Frequency (xxx.xx Hz) Output Current (xxx.xx A) DC-BUS Voltage (xxxV) Output Voltage (xxx.xV)

Reading (03) and Writing (06) Drive Parameters

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].

Additional Information

See https://www.ab.com/drives for additional information.

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D Appendix
Velocity StepLogic, Basic Logic and Timer/ Counter Functions
Four PowerFlex 520-series logic functions provide the capability to program simple logic functions without a separate controller.
· Velocity StepLogic Function (specific to PowerFlex 525 drives only)
Steps through up to eight preset speeds based on programmed logic. Programmed logic can include conditions that need to be met from digital inputs programmed as "Logic In 1" and "Logic In 2" before stepping from one preset speed to the next. A timer is available for each of the eight steps and is used to program a time delay before stepping from one preset speed to the next. The status of a digital output can also be controlled based on the step being executed. · Basic Logic Function (specific to PowerFlex 525 drives only)
Up to two digital inputs can be programmed as "Logic In 1" and/or "Logic In 2". A digital output can be programmed to change state based on the condition of one or both inputs based on basic logic functions such as AND, OR, NOR. The basic logic functions can be used with or without StepLogic. · 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". · 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".
Use the Wizard in Connected Components Workbench software to simplify setup instead of manually configuring the parameters.

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Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions

Velocity StepLogic Using Timed Steps

IMPORTANT This function is specific to PowerFlex 525 drives only.
To activate this function, set one of the three speed reference sources, parameter P047, P049, or P051[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.
· Logic is defined using parameters L180...L187 [Stp Logic x]. · Preset Speeds are set with parameters A410...A417 [Preset Freq 0...7]. · 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
Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Forward 0
Reverse

Time

Velocity StepLogic Sequence
· Sequence begins with a valid start command. · A normal sequence begins with Step 0 and transition to the next step
when the corresponding StepLogic time has expired. · Step 7 is followed by Step 0 · Sequence repeats until a stop is issued or a fault condition occurs.

Velocity StepLogic Using Basic Logic Functions

IMPORTANT This function is specific to PowerFlex 525 drives only.
Digital input and digital output parameters can be configured to use logic to transition to the next step. Logic In 1 and Logic In 2 are defined by programming parameters t062...t063, t065...t068 [DigIn TermBlk xx] to 24 "Logic In 1" or 25 "Logic In 2".
Example · Run at Step 0. · 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". · Transition to Step 2 when both Logic In 1 and Logic In 2 are true. The drive senses the level of both Logic In 1 and Logic In 2 and transitions to Step 2 when both are on.

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Timer Function

Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions

· 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

Step 1

Step 2

Step 3

Frequency

Logic In 1

Logic In 2

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

Frequency

Logic In 1 Logic In 2
Time

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.
Parameters t076 [Relay Out1 Sel], t081 [Relay Out2 Sel], t069 [Opto Out1 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
· Drive starts up and accelerates to 30 Hz. · After 30 Hz has been maintained for 20 seconds, a 4...20 mA analog input
becomes the reference signal for speed control. · 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. · Parameters are set to the following options:
- P047 [Speed Reference1] = 6 "4-20mA Input" - P049 [Speed Reference2] = 7 "Preset Freq" - t062 [DigIn TermBlk 02] = 1 "Speed Ref 2" - t063 [DigIn TermBlk 03] = 19 "Timer Start"

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- t076 [Relay Out1 Sel] = 25 "Timer Out" - t077 [Relay Out1 Level] = 20.0 seconds - A411 [Preset Freq 1] = 30.0 Hz · The control terminal block is wired such that a start command will also trigger the timer start. · The relay output is wired to I/O Terminal 02 (DigIn TermBlk 02) so that it forces the input on when the timer starts. · After the timer is complete, the output is turned off releasing the preset speed command. The drive defaults to following the analog input reference as programmed.
Note that a "Reset Timer" input is not required for this example since the "Timer Start" input both clears and starts the timer.

Counter Function

Digital inputs and outputs control the counter function and are configured with parameters t062...t063, t065...t068 [DigIn TermBlk xx] set to 20 "Counter In" and 22 "Reset Countr".
Digital outputs (relay and opto type) define a preset level and indicate when the level is reached. Level parameters t077 [Relay Out1 Level], t082[Relay Out2 Level], t070 [Opto Out1 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 Out1 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 · A photo eye is used to count packages on a conveyor line. · An accumulator holds the packages until 5 are collected. · A diverter arm redirects the group of five packages to a bundling area. · The diverter arm returns to its original position and triggers a limit switch that resets the counter. · Parameters are set to the following options: - t065 [DigIn TermBlk 05] = 20 "Counter In" - t066 [DigIn TermBlk 06] = 22 "Reset Countr" - t076 [Relay Out1 Sel] = 26 "Counter Out" - t077 [Relay Out1 Level] = 5.0 Counts
Output Frequency
Start
Relay Out
Photo Eye
DigIn TermBlk 05 Counter In
DigIn TermBlk 06 Reset Counter Limit Switch

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Velocity StepLogic Parameters

Appendix D Velocity StepLogic, Basic Logic and Timer/Counter Functions

Code Descriptions for Parameters L180...L187

Digit 4 0

Digit 3 0

Digit 2 F

Digit 1 1

Digit 4  Defines the action during the step currently executing

Setting
0 1 2 3 4 5 6 7 8 9 A b

Accel/Decel Parameter Used 1 1 1 1 1 1 2 2 2 2 2 2

StepLogic Output State
Off Off Off On On On Off Off Off On On On

Commanded Direction
FWD REV No Output FWD REV No Output FWD REV No Output FWD REV 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 0 1 2 3 4 5 6 7 8 9 A

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) End Program and Fault (F002)

Digit 2  Defines what logic must be met to jump to a step other than the very next step

Setting 0 1 2 3 4 5 6 7 8 9 A b C

Description Skip Step (jump immediately) Step based on the time programmed in the respective [Stp Logic Time x] parameter. Step if "Logic In 1" is active (logically true) Step if "Logic In 2" is active (logically true) Step if "Logic In 1" is not active (logically false) Step if "Logic In 2" is not active (logically false) Step if either "Logic In 1" or "Logic In 2" is active (logically true) Step if both "Logic In 1" and "Logic In 2" is active (logically true) Step if neither "Logic In 1" or "Logic In 2" is active (logically true) Step if "Logic In 1" is active (logically true) and "Logic In 2" is not active (logically false) Step if "Logic In2" is active (logically true) and "Logic In 1" is not active (logically false) Step after [Stp Logic Time x] and "Logic In 1" is active (logically true) Step after [Stp Logic Time x] and "Logic In 2" is active (logically true)

Logic SKIP TIMED TRUE TRUE FALSE FALSE OR AND NOR XOR XOR TIMED AND TIMED AND

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Digit 2  Defines what logic must be met to jump to a step other than the very next step

Setting d E F

Description Step after [Stp Logic Time x] and "Logic In 1" is not active (logically false) Step after [Stp Logic Time x] and "Logic In 2" is not active (logically false) Do not step OR no "jump to", so use Digit 0 logic

Logic TIMED OR TIMED OR IGNORE

Digit 1  Defines what logic must be met to jump to the very next step

Setting 0 1 2 3 4 5 6 7 8 9 A b C d E F

Description Skip Step (jump immediately) Step based on the time programmed in the respective [Stp Logic Time x] parameter. Step if "Logic In 1" is active (logically true) Step if "Logic In 2" is active (logically true) Step if "Logic In 1" is not active (logically false) Step if "Logic In 2" is not active (logically false) Step if either "Logic In 1" or "Logic In 2" is active (logically true) Step if both "Logic In 1" and "Logic In 2" is active (logically true) Step if neither "Logic In 1" or "Logic In 2" is active (logically true) Step if "Logic In 1" is active (logically true) and "Logic In 2" is not active (logically false) Step if "Logic In 2" is active (logically true) and "Logic In 1" is not active (logically false) Step after [Stp Logic Time x] and "Logic In 1" is active (logically true) Step after [Stp Logic Time x] and "Logic In 2" is active (logically true) Step after [Stp Logic Time x] and "Logic In 1" is not active (logically false) Step after [Stp Logic Time x] and "Logic In 2" is not active (logically false) Use logic programmed in Digit 1

Logic SKIP TIMED TRUE TRUE FALSE FALSE OR AND NOR XOR XOR TIMED AND TIMED AND TIMED OR TIMED OR IGNORE

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E Appendix

Encoder/Pulse Train Usage and Position StepLogic Application

Encoder and Pulse Train Usage

The PowerFlex 520-series drives include a pulse train input built into the terminal block. PowerFlex 525 drives also support an optional encoder card. The pulse train and encoder can be used for many of the same functions, but the pulse train supports up to 100 kHz at 24V, and uses the drive built-in terminal block. The encoder supports up to 250 kHz dual channel at 5, 12V 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. If enabled by P047, P049, or P051 [Speed Referencex], the encoder or pulse train will be used directly as a commanded speed (normally used with a pulse train) or as a position reference (normally used with a quadrature encoder).
2. If not enabled by the Speed Reference parameters, the encoder or pulse train can be used with the PID function if enabled by A459 or A471 [PID x Ref Sel], or A460 or A472 [PID x Fdback Sel].
3. If not enabled by the Speed Reference or PID function parameters, the encoder or pulse train can be used with A535 [Motor Fdbk Type] for direct feedback and trim of the speed command. The normal slip compensation is not used in this case. Instead the drive will use the encoder or pulse train to determine actual output frequency and adjust the output frequency to match the command. Parameters A538 [Ki Speed Loop] and A539 [Kp Speed Loop] are used in this control loop. The primary benefit of this mode is increased speed accuracy when compared to open-loop slip compensation. It does not provide speed bandwidth improvement.
IMPORTANT The encoder usage, and position StepLogic application covered in this chapter is specific to PowerFlex 525 drives only.
Encoder Interface
The incremental encoder option card can source 5 volt or 12 volt power and accept 5, 12 or 24 volts single ended or differential inputs. See Appendix B for ordering information.
IMPORTANT Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive.

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A A- B B- Cm +V

n 12V 5V HTL

TTL (ON)

No. Signal +V 5...12V Power(1)(2) Cm Power Return B- Encoder B (NOT) B Encoder B A- Encoder A (NOT) A Encoder A

Description Internal power source 250 mA (isolated). Quadrature B input. Single channel, pulse train or quadrature A input.

 Output



HTL/TTL DIP switches

DIP switch selects 12 or 5 volt power supplied at terminals "+V" and "Cm" for the encoder. Set the position of the DIP switches based on the type of encoder signal used. You must set all switches to the same position.

(1) When using 12V Encoder power, 24V I/O power, maximum output current at I/O Terminal 11 is 50 mA. (2) If Encoder requires 24V power, it must be supplied by an external power source.

Encoder Wiring Examples

I/O

Connection Example

Encoder Power

 Internal Drive

+V Cm

Power

B-

B

Internal (drive) 12V DC, 250 mA

AA

+12V DC (250 mA) Common
to SHLD

+V
Encoder Signal Cm

 Single-Ended, B-

Dual Channel

B A-

A

to Power Supply Common
B NOT B A NOT A
to SHLD

I/O

Connection Example

+
Common

Encoder Power  External Power Source

to SHLD External Power Supply

Encoder Signal

+V Cm

 Differential, B-

Dual Channel

B A-

A

to SHLD
B NOT B A NOT A

HTL/TTL DIP Switches

This feature is available on 25-ENC-1 encoder. Set the two switches to HTL (default) or TTL (On) based on the type of encoder signal you are using in your application. You must set all switches to the same position.

Compatible Encoder Output Voltage
Switch Position TTL HTL

Low Level (UL) <1.5V <3.5V

High Level (UH) >2.5V >5V

IMPORTANT Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive.

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Wiring Notes

Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

The encoder option card can supply 5V or 12V power (250 mA maximum) for an encoder. Be sure the DIP switch is set properly for the encoder. In general, 12V will provide higher noise immunity.

The encoder can handle 5V, 12V, or 24V inputs, but the pulse train can handle only 24V inputs. The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary. If a single-channel input is used, it must be wired between the A (signal) and A- (signal common) channels.

IMPORTANT

A 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, then do one of the following: · Swap the A and A (NOT) encoder channels. · Swap the B and B (NOT) encoder channels. · 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".

Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution

Use the following formula to determine the encoder pulse per revolution (PPR) specification based on the speed resolution.

Speed resolution (Hz) =

1 encoder pulse number x 4

x pole pairs

10-3 sec

The operating speed range will depend on the motor control mode selected (SVC or VVC). For more information, see Performance with Encoder on page 168.

Example 1

To determine the PPR for quadrature encoder, to achieve 0.06 Hz of speed resolution on a 4-pole motor (2-pole pair) with a base speed of 60 Hz:

0.06 Hz =

1 x 2
encoder pulse number x 4

10-3 sec

= ~8333 pulse

Therefore, select 8333 PPR or higher for the quadrature encoder to achieve the desired speed resolution of 0.06 Hz.

Example 2

To determine the speed resolution, using a 1024 PPR quadrature incremental encoder on a 4-pole (2-pole pair) motor:

Speed resolution (Hz) =

1 x 2
1024 x 4

10-3 sec

= 0.49 Hz

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Therefore, using a 1024 PPR quadrature encoder will give a speed resolution of 0.49 Hz.

Positioning Overview

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 standalone 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.

Common Guidelines for All Applications

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 encoder is used. This can not be used for positioning.

1 "Pulse Train" is a single channel input, no direction, speed feedback only. This should not be used for positioning. The Single Channel selection is similar to a Pulse Train, but uses the standard encoder scaling parameters.

2 "Single Chan" is a single channel input, no direction, speed feedback only. This should not be used for positioning. Single channel uses the standard encoder scaling parameters.

3 "Single Check" is a single channel input with encoder signal loss detection. The drive will fault if it detects that the input pulses do not match the expected motor speed. This should not be used for positioning.

4 "Quadrature" is a dual channel encoder input with direction and speed from the encoder. This may be used for positioning control.

5 "Quad Check" is a dual channel encoder with encoder signal loss detection. The drive will fault if it detects that the encoder speed does not match the expected motor speed.

A544 [Reverse Disable] should be set to 0 "Rev Enabled" to allow bidirectional movement necessary for position control.

P039 [Torque Perf Mode] default setting is 1 "SVC". However, any mode can be used to improve the low speed torque for positioning applications. For best

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Positioning Operation

Appendix E Encoder/Pulse Train Usage and Position StepLogic Application
results, tune 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 520-series drive.
A536 [Encoder PPR] must be set to match the number of pulses per revolution of the encoder used (i.e., 1024 PPR Encoder).
A559 [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 1 cm 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 (4 x 1024 x 0.75) = 3072 counts for 1 cm of travel. Then all other positions could be setup in units of "cm".
A564 [Encoder Pos Tol] indicates the desired position tolerance for the system. This will determine how close the drive must be to the commanded position before the drive will indicate "At Home" or "At Position" in units of raw encoder pulses. This has no effect on the actual positioning control of the motor.

Parameter A558 [Positioning Mode] must be set to properly match the desired operation of the positioning function.
A558 [Positioning Mode] Options
0 "Time Steps" uses Step Logic times. This mode ignores the Step Logic settings and moves through the steps (Step 0 to Step 7 and back to Step 0) based on the times programmed into L190...L197 [Stp Logic Time x]. This can be used when the desired position is based only on time. In addition, this mode only accepts absolute positions in a positive direction from "home". This option provides an easy way to implement a simple positioning program or to test the basic positioning setup. For additional flexibility one 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 StepLogic Commands settings and instead the

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drive will move directly to whatever step is currently commanded by A410...A425 [Preset Freq x] and L200...L214 [Step Units x]. This is useful when an application 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 StepLogic 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 StepLogic 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 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.

A410...A417 [Preset Freq x] are the parameters that define the maximum frequency the drive will run at during the corresponding step. For example, if [Preset Freq 2] is set to 40 Hz, the drive will accelerate to 40 Hz maximum when moving to Position 2.

Frequency Source A410 [Preset Freq 0] A411 [Preset Freq 1] A412 [Preset Freq 2] A413 [Preset Freq 3] A414 [Preset Freq 4]

Step Source L180 [Stp Logic 0] L181 [Stp Logic 1] L182 [Stp Logic 2] L183 [Stp Logic 3] L184 [Stp Logic 4]

Position Source L200 [Step Units 0] L202 [Step Units 1] L204 [Step Units 2] L206 [Step Units 3] L208 [Step Units 4]

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Frequency Source A415 [Preset Freq 5] A416 [Preset Freq 6] A417 [Preset Freq 7]

Step Source L185 [Stp Logic 5] L186 [Stp Logic 6] L187 [Stp Logic 7]

Position Source L210 [Step Units 5] L212 [Step Units 6] 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 StepLogic 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:

Logic for next step Logic to jump to a different step Different step to jump Step settings Not Used

Velocity Control Settings (Digit 4)

Required Setting 0 1 2 3 4 5 6 7 8 9 A b

Accel/Decel Param. Used Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2

Digit 1 Digit 2 Digit 3 Digit 4
StepLogic Output State Off Off Off On On On Off Off Off On On On

Commanded Direction FWD REV No Output FWD REV No Output FWD REV No Output FWD REV No Output

Settings (Digit 3)

Setting 0 1 2 3 4 5 6 7 8 9 A

Description 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) End Program and Fault (F2)

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Positioning Settings (Digit 4)

Required Setting 0 1 2 3 4 5 6 7 8 9 A b C d E F

Accel/Decel Param. Used Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 1 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2 Accel/Decel 2

StepLogic Output State Off Off Off Off On On On On Off Off Off Off On On On On

Direction From Home FWD FWD REV REV FWD FWD REV REV FWD FWD REV REV FWD FWD REV REV

Type of Command Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental Absolute Incremental

Settings (Digit 2 and 1)

Setting 0 1 2 3 4 5 6 7 8 9
A
b
C
d
E F

Description Skip Step (Jump Immediately) Step Based on [Stp Logic Time x] Step if "Logic In 1" is Active Step if "Logic In 2" is Active Step if "Logic In 1" is Not Active Step if "Logic In 2" is Not Active Step if either "Logic In 1" or "Logic In 2" is Active Step if both "Logic In 1" and "Logic In 2" are Active Step if neither "Logic In 1" nor "Logic In 2" is Active Step if "Logic In 1" is Active and "Logic In 2" is Not Active Step if "Logic In 2" is Active and "Logic In 1" is Not Active Step after [Stp Logic Time x] and "Logic In 1" is Active Step after [Stp Logic Time x] and "Logic In 2" is Active Step after [Stp Logic Time x] and "Logic In 1" is Not Active Step after [Stp Logic Time x] and "Logic In 2" is Not Active Do Not Step/Ignore Digit 2 Settings

Use the Wizard in Connected Components Workbench software to simplify setup instead of manually configuring the parameters.

Note: Incremental move commands will cause the drive to move the amount specified based on the current position. Absolute commands are always with reference to "Home".

A565 [Pos Reg Filter] provides a low pass filter at the input of the position regulator.

A566 [Pos Reg Gain] is a single adjustment for increasing or decreasing the responsiveness of the position regulator. For faster response, the filter should be reduced and/or the gain should be increased. For smoother response with less 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.

Homing Routine
224

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 HomingProgram the following drive parameters:
t062, t063, t065...t068 [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,
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Encoder and Position Feedback

Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

or by manually moving the system into the home position. Then, toggle the "Pos Redefine" input. This will set the drive to "Home" at its current position and d388 [Units Traveled H] and d389 [Units Traveled L] are set to zero. Alternately, the "Pos Redefine" bit in A560 [Enh Control Word] can be toggled instead of utilizing a digital input.

IMPORTANT

The "Pos Redefine" input or bit must be returned to inactive before starting the position routine. Otherwise the drive will continuously read a position of "0" (home) and the position routine will not function correctly.

2. Automatic Homing to Limit SwitchProgram the following drive parameters:

t062, t063, t065...t068 [DigIn TermBlk xx] = 35 "Find Home" Program one of the digital inputs to 35 "Find Home".

t062, t063, t065...t068 [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 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).
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

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application
left of the decimal (whole number) and d379 [Encoder Speed F] is the number to the right of the decimal (the portion less than 1).
d388, d389 [Units Traveled x] indicate the current position 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.

Use Over Communications

If 8 steps are not adequate for the application or if dynamic program changes are required, many of the positioning functions can be controlled through an active communication network. The following parameters will allow this control.
C121 [Comm Write Mode] Repeated writes to parameters over a communication network can cause damage to the drive EEPROM. This parameter allows the drive to accept parameter changes without writing to the EEPROM.
IMPORTANT Parameter values set prior to setting 1 "RAM only" are saved in RAM.
C122 [Cmd Stat Select] Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use over a communication network.
A560 [Enh Control Word] This parameter allows many of the positioning functions to be completed through parameter control using an explicit message. This allows the operation over communications instead of with hardware inputs. The bits have the same functions as the digital input options of the same name. Options relating to positioning are:
Bit 0 "Home Limit" indicates the drive is at the home position.

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Setup Notes

Appendix E Encoder/Pulse Train Usage and Position StepLogic Application
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 enable speed synchronization. When this bit is deactivated the drive will accelerate to the new commanded frequency based on A571 [Sync Time].
Bit 5 "Traverse Dis" disables the traverse function when this bit is active.
Bit 6 "Logic In 1" provides an identical function and is logically ORed with setting 24 "Logic In 1" for t062, t063, t065...t068 [DigIn TermBlk xx]. It can be used to move through the StepLogic functions (speed or position) using comms control without requiring actual digital input transitions.
Bit 7 "Logic In 2" provides an identical function and is logically ORed with setting 25 "Logic In 2" for t062, t063, t065...t068 [DigIn TermBlk xx]. It can be used to move through the StepLogic functions (speed or 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 a controller external to the drive. The StepLogic 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 software) can make setup of the positioning functions much easier. See the latest versions for additional tools or wizards, which can aid in the setup.

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application
Notes:

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PID Loop

PID Set Up

F Appendix

The PowerFlex 520-series drive features built-in PID (proportional, integral, derivative) control loops. 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 speed reference activated.
IMPORTANT PowerFlex 523 has one PID control loop. PowerFlex 525 has two PID control loops, of which only one can be in use at any time.
Exclusive Control and Trim Control are two basic configurations where the PID loop may be used.

Exclusive Control

In Exclusive Control, the Speed Reference becomes 0, and the PID Output becomes the entire Freq Command. Exclusive Control is used when A458 or A470 [PID x Trim Sel] is set to option 0. This configuration does not require a master reference, only a desired set point, such as a flow rate for a pump.

PID Loop

PID Ref

+ PID

PID Fdbk 

Error

PID Prop Gain
+
PID Integ Time +

PID Output

+

PID Di Rate

PID Selected

Accel/Decel Ramp

Freq Command

Example
· In a pumping application, the PID Reference equals the Desired System Pressure set point.
· 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.
· The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value.
· The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow.

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Appendix F PID Set Up

· When the PID Control Loop is disabled, the Commanded Speed is the Ramped Speed Reference.

Esc Sel
Pump

PID Feedback = Pressure Transducer Signal

PID Reference = Desired System Pressure

Trim Control

In Trim Control, the PID Output is added to the Speed Reference. In Trim mode, the output of the PID loop bypasses the accel/decel ramp as shown. Trim Control is used when A458 or A470 [PID x Trim Sel] is set to any option other than 0.

[Speed Referencex]

PID Loop

PID Ref

+ PID

PID Fdbk 

Error

PID Prop Gain +
PID Integ Time +

PID Output

+

PID Di Rate

PID Selected

Accel/Decel Ramp

+

+

Output

Freq

Example
· In a winder application, the PID Reference equals the Equilibrium set point.
· The Dancer Pot signal provides PID Feedback to the drive. Fluctuations in tension result in a PID Error value.
· The Master Speed Reference sets the wind/unwind speed. · 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

0V
PID Feedback = Dancer Pot Signal
Esc Sel
10V [Speed Referencex]

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PID Reference and Feedback

Appendix F PID Set Up

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.
IMPORTANT PowerFlex 523 has one PID control loop. PowerFlex 525 has two PID control loops, of which only one can be in use at any time.

If A459 or A471 [PID x Ref Sel] is not set to 0 "PID Setpoint", PID can still be disabled by select programmable digital input options (parameters t062, t063, t065...t068 [DigIn TermBlk xx]) such as "Purge".
A459, A471 [PID x Ref Sel] Options

Options 0"PID Setpoint" 1"Drive Pot" 2"Keypad Freq" 2"Serial/DSI" 4"Network Opt"
5"0-10V Input"
6"4-20mA Input" 7"Preset Freq" 8"AnlgIn Multi"(1) 9"MOP Freq" 10"Pulse Input" 11"Step Logic"(1) 12"Encoder"(1) 13"EtherNet/IP"(1)

Description A464 or A476 [PID x Setpoint] will be used to set the value of the PID Reference. The drive potentiometer will be used to set the value of the PID Reference. The drive keypad will be used to set the value of the PID Reference. The reference word from the Serial/DSI communication network becomes the PID Reference. The reference word from a communication network option becomes the PID Reference. Selects the 0...10V Input. The PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero. Selects the 4...20 mA Input. A410...A425 [Preset Freq x] will be used as an input for the PID Reference. The product of the 0...10V and 4...20mA Inputs will be used as an input for the PID Reference. A427 [MOP Freq] will be used as an input for the PID Reference. Pulse train will be used as an input for the PID Reference. Step Logic will be used as an input for the PID Reference.
Encoder will be used as an input for the PID Reference.
The reference word from the EtherNet/IP communication network becomes the PID Reference.

(1) Setting is specific to PowerFlex 525 drives only.

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
0"0-10V Input"
1"4-20mA Input" 2"Serial/DSI" 3"Network Opt" 4"Pulse Input" 5"Encoder"(1) 6"EtherNet/IP"(1)

Description Selects the 0...10V Input (default setting). The PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero. Selects the 4...20 mA Input. Serial/DSI will be used as an input for the PID Feedback. The reference word from a communication network option becomes the PID Reference. Pulse train will be used as an input for the PID Feedback. Encoder will be used as an input for the PID Feedback.
EtherNet/IP will be used as an input for the PID Feedback.

(1) Setting is specific to PowerFlex 525 drives only.

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Appendix F PID Set Up
Analog PID Reference Signals

4-20 mA Input

Input Volts

Parameters t091 [Anlg In 0-10V Lo] and t092 [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 following parameter settings are used so that a 0V signal = 0% PID Reference and a 5V signal = 100% PID Reference.
· t091 [Anlg In 0-10V Lo] = 0.0% · t092 [Anlg In 0-10V Hi] = 50.0% · A459 [PID 1 Ref Sel] = 5 "0-10V Input"
12 10 8 6 4 2
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
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.
· t095 [Anlg In4-20mA Lo] = 100.0% · t096 [Anlg In4-20mA Hi] = 0.0% · A459 [PID 1 Ref Sel] = 6 "4-20mA Input"
24 20 16 12 8 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 · A465 [PID 1 Deadband] = 5.0% · The PID Reference is 25.0% · The PID Regulator will not act on a PID Error that falls between 20.0 and 30.0%

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Appendix F PID Set Up
PID Preload
The value set in A466 or A478 [PID x Preload], in Hz, will be pre-loaded into the integral component of the PID at any start or enable. This will cause the drive's frequency command to initially jump to that preload frequency, and the PID loop starts regulating from there.
PID Enabled

PID Output

PID Pre-load Value

Freq Cmd

PID Pre-load Value > 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.
· 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.
· A462 and A474 [PID x Integ Time] The integral gain (units of seconds) affects how the regulator reacts to error over time and is used to get rid of steady state error. For example, with an integral gain of 2 seconds, the output of the integral gain component would integrate up to 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.
· 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

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Appendix F PID Set Up 234

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: - If the response is too slow increase A461 or A473 [PID x Prop Gain]. - If the response is too quick and/or unstable (see Unstable Response on page 234), 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.
2. Adjust the integral gain (leave the proportional gain set as in Step 1). After a step change in the PID Feedback: - If the response is too slow (see Slow Response  Over Damped on page 234), 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 235), increase A462 or A474 [PID x Integ Time].
3. 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.
Unstable Response
PID Reference
PID Feedback
Time Slow Response  Over Damped
PID Reference
PID Feedback
Time
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Oscillation  Under Damped
PID Reference PID Feedback
Time Good Response  Critically Damped
PID Reference PID Feedback
Time

Appendix F PID Set Up

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Appendix F PID Set Up
Notes:

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PowerFlex 525 SafeTorque-Off Overview

Safe Torque Off Function

G Appendix

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.

Topic

Page

PowerFlex 525 Safe-Torque-Off Overview

237

EC Type Examination Certification

238

EMC Instructions

238

Using PowerFlex 525 Safe-Torque-Off

239

Enabling PowerFlex 525 Safe-Torque-Off

241

Wiring

241

Verify Operation

242

PowerFlex 525 Safe-Torque-Off Operation

242

Connection Examples

243

PowerFlex 525 Certification for Safe-Torque-Off

246

IMPORTANT The Safe-Torque-Off function covered in this chapter is specific to PowerFlex 525 drives only.

The PowerFlex 525 Safe-Torque-Off function:
· Provides the Safe-Torque-Off (STO) function defined in EN 61800-5-2.
· Blocks gate-firing signals from reaching the Insulated Gate Bipolar Transistor (IGBT) output devices of the drive. This prevents the IGBTs from switching in the sequence necessary to generate torque in the motor.
· Can be used in combination with other safety devices to fulfill the requirements of a system "safe torque off" function which satisfies

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Appendix G Safe Torque Off Function
EC Type Examination Certification
EMC Instructions

Category 3 / PL (d) according to EN ISO 13849-1 and SIL CL2 according to EN 62061, IEC 61508, and EN 61800-5-2.
IMPORTANT The function is suitable for performing mechanical work on the drive system or affected area of a machine only. It does not provide electrical safety.
ATTENTION: Electric Shock Hazard. Verify that all sources of AC and DC power 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. 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.
TÜV Rheinland has 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:
· EN ISO 13849-1 Safety of machinery  Safety related parts of control systems  Part 1: General principles for design. (PowerFlex 525 STO achieves Category 3 / PL(d))
· EN 61800-5-2 Adjustable speed electrical power drive systems  Part 5-2 Safety requirements  Functional. (PowerFlex 525 STO achieves SIL CL 2)
· EN 62061 Safety of machinery  Functional safety of safety-related electrical, electronic and programmable electronic control systems.
· IEC 61508 Part 1-7 Functional safety of electrical/electronic/ programmable electronic safety-related systems  Parts 1-7.
TÜV 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 TÜV Rheinland certificate may be found at: rok.auto/certifications.
PowerFlex 525 Safe-Torque-Off function requires CE Conformity as described on page 51.

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Using PowerFlex 525 SafeTorque-Off

Appendix G Safe Torque Off Function
The PowerFlex 525 Safe-Torque-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-Torque-Off function specifications and all foreseeable operational and environmental characteristics of the machine to which it is to be fitted.
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.
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 equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation. ATTENTION: In safe-off mode, hazardous voltages may still be present at the motor. To avoid an electric shock hazard, disconnect power to the motor and verify that the voltage is zero before performing any work on the motor. ATTENTION: In the event of the failure of two output IGBTs in the drive, when the PowerFlex 525 Safe-Torque-Off has controlled the drive outputs to the off state, the drive may provide energy for up to 180° of rotation in a 2pole motor before torque production in the motor ceases.

Safety Concept

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 138491 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.
In addition, the PowerFlex 525 STO may be used together with other components in a safety application to achieve an overall Category 3 / PL(e) according to EN ISO 13849-1 and SIL 3 according to EN 62061 and IEC 61508. This is illustrated in Example 3 in this appendix.
Safety requirements are based on the standards current at the time of certification.
The PowerFlex 525 Safe-Torque-Off function is intended for use in safetyrelated applications where the de-energized state is considered to be the safe state. All of the examples in this manual are based on achieving deenergization as the safe state for typical Machine Safety and Emergency Shutdown (ESD) systems.

Important Safety Considerations
The system user is responsible for: · the set-up, safety rating, and validation of any sensors or actuators connected to the system. · 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. · project management and proof testing.

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Appendix G Safe Torque Off Function

· programming the application software and the safety option configurations in accordance with the information in this manual.
· access control to the system, including access code handling. · analyzing all configuration settings and choosing the proper setting to
achieve the required safety rating.
IMPORTANT When applying Functional Safety, restrict access to qualified, authorized personnel who are trained and experienced.
ATTENTION: When designing your system, consider how personnel will exit the machine if the door locks while they are in the machine. Additional 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 PFD PFHD SFF DC CAT HFT PTI Hardware Type

Value 6.62E-05 (MTTF = 3593 years) 8.13E-10 83% 62.5% 3 1 (1oo2) 20 YEARS
Type A

Safety Reaction Time
The safety reaction time is the amount of time from a safety-related event as input to the system until the system is in the Safe State.
The safety reaction time from an input signal condition that triggers a safe stop, to the initiation of safe-torque-off, is 100 ms (maximum).

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Enabling PowerFlex 525 Safe-Torque-Off

Appendix G Safe Torque Off Function

1. Remove all power to the drive.

ATTENTION: 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 the location of the terminals). The voltage must be zero.

2. Loosen the screw of terminals Safety 1, Safety 2 and Safety +24V (S1, S2, S+) on the control I/O terminal block.
3. Remove the protective jumper.

R1 R2 R5 R6

01 02 03 04 05 06 07 08

S1 S2 S+ 11 12 13 14 15 16 17 18 19

Wiring

4. Safe-Torque-Off function is now enabled and the terminals are ready to function as safety inputs.

Important points to remember about wiring:
· Always use copper wire. · Wire with an insulation rating of 600V or greater is recommended. · Control wires should be separated from power wires by at least
0.3 m (1 ft).

Recommended Wire

Type Shielded

Wire Type(1)

Description

Min Insulation Rating

Multi-conductor shielded cable such as Belden 8770 (or equiv.)

0.750 mm2 (18 AWG), 3 conductor, shielded.

300V, 60 °C (140 °F)

(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 36 for wiring recommendations and Control I/O Terminal Designations on page 42 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.

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Appendix G Safe Torque Off Function

PowerFlex 525 Safe-Torque- The PowerFlex 525 Safe-Torque-Off function disables the drive's output IGBT's

Off Operation

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.

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. See 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.

Verify Operation

Test the safety function for proper operation after the initial setup of the PowerFlex 525 Safe-Torque-Off function. Retest the safety function at the intervals determined by the safety analysis described on page 239.

Verify that both safety channels are functioning according to the table below.

Channel Operation and Verification

Safety Function Drive In

Status

Safe State

Drive Status

Configured by t105 [Safety Open En]

Safety Channel Operation

Safety Input S1 No Power Applied

Safety Input S2 No Power Applied

Drive In Safe State Fault F111 (Safety Hardware)
Power Applied No Power Applied

Drive In Safe State Fault F111 (Safety Hardware)
No Power Applied Power Applied

Drive Able To Run Ready/Run
Power Applied Power Applied

IMPORTANT

If an 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.

Discrepancy Time of the Safety Inputs
For example, if S1 is disabled and S2 did not follow after the discrepancy time, fault F111 "Safety Hardware" will occur. However, if S1 is disable and S2 follows before the discrepancy time, fault F059 "Safety Open" will occur.
The discrepancy time is one second for PowerFlex 525 FRN 5.xxx and later. The discrepancy time is 10 milliseconds for PowerFlex 525 FRN 4.xxx and earlier.

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Connection Examples

Appendix G Safe Torque Off Function

Example 1  Safe-Torque-Off Connection with Coast-to-Stop Action, SIL 2/PL d

Stop Category 0  Coast

Gate E-Stop latching button

+24V DC GuardMaster
Trojan A1 S21 S11 S52 41 13 23 33 MSR A2 S22 S14 S34 42 14 24 34

AC line input power

PF 525

Stop Start

+24V DC Stop Start

Gate control power supply

24V DC common
(1)

Gate control circuit
S1 S2
M

Gate

GuardMaster Trojan

E-Stop latching button

AC line input power

PF 525

Stop Start

+24V DC Stop Start

Gate control power supply

Gate control circuit
S1 S2 (2)
M
(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.
(2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.

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Appendix G Safe Torque Off Function

Stop Category 0  Coast with Two PowerFlex 525 Drives

(1)
24V DC Supply Reset

AC line input power

E-Stop 24V DC COM

A1

L12

S11

SI L11
S21

S12

Y32

Reset 0 S34
S22

AM

MM

13 14 23
24 A2

PF 525

+24V DC

Stop Start

Stop Start Dig. comm

Gate control power supply

Gate control circuit
(2)
S1 S2

AC line input power

PF 525

+24V DC

Stop Start

Stop Start Dig. comm

Gate control power supply

Gate control circuit
(2)
S1 S2

M

M

(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.
(2) Each safety input draws 6 mA from the supply.
Circuit Status

Circuit shown with guard door closed and system ready for normal drive operation.

Operating Principle

This is a dual channel system with monitoring of the Safe-Torque-Off circuit and drive. Opening the guard door will switch the input circuits (S13-S14 & S21S22) to the MinotaurTM monitoring safety relay unit. The output circuits (13-14 & 23-24) will cause the Safe-Torque-Off Enable circuit to trip and the motor will coast to stop. To restart the drive, the Minotaur safety relay must first be reset followed by a valid start command to the drive.

Fault Detection

A single fault detected on the Minotaur safety input circuits will result in the lock-out of the system at the next operation and will not cause loss of the safety function.

A single fault detected on the PowerFlex 525 safety enable redundant inputs will result in the lock-out of the drive and will not cause loss of the safety function.

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Appendix G Safe Torque Off Function

Example 2  Safe-Torque-Off Connection with Controlled Stop Action, SIL 2/PL d

Stop Category 1  Controlled
(1)

GuardMaster Trojan
Gate

+24V DC

A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34

Minotaur MSR138DP

A2 X1 X2 X3 X4 Y39 Y40 38 48 58 24V DC Common

14 24

Y2 Y1

AC line input power PF 525 +24V DC Stop Stop Start Start Gate control power supply
Gate control circuit
S1 S2

M
(1) Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.
Circuit Status
Circuit shown with guard door closed and system ready for normal drive operation.
Operating Principle
This is a dual channel system with monitoring of the Safe-Torque-Off circuit and drive. Opening the guard door will switch the input circuits (S11-S12 & S21S22) 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 & 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.

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Appendix G Safe Torque Off Function

Example 3  Safe-Torque-Off Connection with Coast-to-Stop Action Using External +24V supply, SIL 3/PL e

Stop Category 0  Coast
(1)

Open Closed

External +24V DC
Reset A1 S11 S52 S12 13 23 33 41 MSR127TP S21 S22 S34 A2 14 24 34 42

AC line input power PF 525 +24V DC Stop Start COM Gate control power supply
Gate control circuit
S1 S2

24V DC COM

X1 AUX X2 A1 Coil A2

13 23 33 14 24 34

External 100-C contactor 100S-C

M

(1) Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other measure to exclude these failure modes should be used.

Circuit Status

Circuit shown with guard door closed and system ready for normal drive operation.

Operating Principle

This is a dual channel system with monitoring of the Safe-Torque-Off circuit and drive. Opening the guard door will switch the input circuits (S11-S12 & S21S22) to the Minotaur monitoring safety relay unit. The output circuits (13-14 & 23-24 & 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.

PowerFlex 525 Certification Certification information can be viewed at

for Safe-Torque-Off

rok.auto/certifications.

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H Appendix

EtherNet/IP

This section contains only basic information to setup an EtherNet/IP connection with your PowerFlex 520-series drive. For comprehensive information about EtherNet/IP (single and dual-port) and how to use it, see the following publications:
· PowerFlex 525 Embedded EtherNet/IP Adapter User Manual, publication 520COM-UM001.
· PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter User Manual, publication 520COM-UM003.
ATTENTION: PowerFlex 523 drives support only the 25-COMM-E2P dual-port EtherNet/IP adapter. PowerFlex 525 drives support both the embedded EtherNet/IP adapter and the 25-COMM-E2P dual-port EtherNet/IP adapter.
It is recommended to use Allen-Bradley Ethernet RJ45 cables, shielded or unshielded (catalog number 1585J-M8xBJM-x), for connecting your PowerFlex 520-series drive to an EtherNet/IP network.

Establishing A Connection With EtherNet/IP

There are three methods for configuring the Ethernet IP address:
· 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.
· 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.
· DHCP (Dynamic Host Configuration Protocol) (only with PowerFlex 25COMM-E2P adapter)  Use DHCP when you want additional flexibility and ease-of-use compared to BOOTP in configuring the IP address, subnet mask, and gateway address for the adapter using a DHCP server.

IMPORTANT

If you are setting your network addresses manually using parameters, you must set the appropriate drive or 25-COMM-E2P adapter parameter value to 1 "Parameters". See the respective EtherNet/IP adapter user manual for more information.

IMPORTANT Regardless of the method used to set the adapter IP address, each node on the EtherNet/IP network must have a unique IP address. To change an IP address, you must set the new value and then remove and reapply power to (or reset) the adapter.

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Appendix H EtherNet/IP
Ground Connections for EtherNet/IP Networks

Connect terminal C1 to a clean ground when using a network with a star topology. It is acceptable to ground both C1 and C2 terminals.
PowerFlex 525 Embedded Ethernet/IP Adapter

FWD ENET LINK EtherNet/IP
Esc Sel

Terminals C1/C2

Terminal C1 C2

Description This terminal is tied to the RJ-45 port shield. Tie this terminal to a clean ground in order to improve noise immunity when using external communication peripherals. This is the signal common for the communication signals.

Connect terminal CS1 or CS2 to a clean ground when using a network with a ring topology.
PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter

Terminal CS1/CS2

Description Provides a clean ground for the communication bus cable shields. CS1 or CS2 should be connected to a clean ground or PE ground on the drive.

Terminals CS1/CS2

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Control Diagrams

I Appendix

Induction Motor Tuning Diagrams

This chapter contains various diagrams on the PowerFlex 520-series drive functions and behaviors.

[Speed Reg Sel] Diagrams For Motor Tuning

Speed Controller Gain

Low Speed Control Mode

A515 [Freq 3 BW]

Mid Speed Control Mode

High Speed Control Mode

A509 [Speed Reg Sel] = 0 Gain set automatically

A513 [Freq 2 BW] A511 [Freq 1 BW]

A510 [Freq 1]

A512 [Freq 2]

A514 [ Freq 3]

Freq (Hz)

Speed Controller Gain
A525 [Freq 3 Kp] A526 [Freq 3 Ki]

Low Speed Control Mode

Mid Speed Control Mode

High Speed Control Mode

A523 [Freq 2 Kp] A524 [Freq 2 Ki]
A521 [Freq 1 Kp] A522 [Freq 1 Ki]

A510 [Freq 1]

A512 [Freq 2]

A514 [Freq 3]

Freq (Hz)

A509 [Speed Reg Sel] = 1 Gain set manually

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Appendix I Control Diagrams
Adjusting Speed Control Parameters

These settings show how to adjust the speed control for motor tuning.

Increase the bandwidth to obtain faster speed response. If oscillation occurs, decrease the bandwidth.

Speed Loop Bandwidth: A511 [Freq 1 BW] = 10 Hz A513 [Freq 2 BW] = 10 Hz A515 [Freq 3 BW] = 10 Hz

For [Freq x Kp], gradually increase by 1% For [Freq x Ki], gradually increase by 0.1 s

For general use, set A509 [Speed Reg Sel] to 0 (Automatic)

Set A509 [Speed Reg Sel]

A509 = 1 (Manual)

A509 = 0 (Automatic)
Set Speed Controller Gain automatically

Set Speed Controller Gain manually: A521 [Freq 1 Kp] A522 [Freq 1 Ki] A523 [Freq 2 Kp] A524 [Freq 2 Ki] A525 [Freq 3 Kp] A526 [Freq 3 Ki]

Run

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J Appendix
PowerFlex 525 PM Motor Configuration

This chapter contains instructions and diagrams on configuring the PowerFlex 525 drive for use with a PM motor. For more information, see the PowerFlex 525 Configuration with Permanent Magnet Motors Application Technique, publication 520-AT001.

Topic

Page

Manual Configuration Using Drive Keypad

256

Additional PM Motor Configuration

257

Optional Parameter Adjustments for Optimum Performance

261

ATTENTION: It is the responsibility of the startup engineer / end user to use proper safety precautions with any equipment used during this startup. 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 document are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation cannot assume responsibility or liability of actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to the information, circuits, equipment. Or software described in this document. Rockwell Automation reserves the right to make changes to this document without prior notice. When using examples in this document the user recognizes that Rockwell Automation cannot be made liable for any damage or claims. Because there are many application-specific variables, users MUST ensure that products are correctly used and the appropriate architecture is deployed. Reproduction of the contents of this document, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

To use PM motor control, you need to install the PowerFlex 525 drive firmware revision 5.001 or later. If you wish to perform PM motor tuning by using the PowerFlex 525 Startup Wizard in Connected Components Workbench software, and update to the latest drive database.

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Appendix J PowerFlex 525 PM Motor Configuration
Motor Control
From the Torq Perf Mode drop-down list, select "PM Motor".
This configuration can also be done by setting parameter P039 [Torq Perf Mode] to 4 "PM Motor".
Motor Data
Key in the details of your Motor Nameplate.

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Appendix J PowerFlex 525 PM Motor Configuration
Feedback
If you are configuring a closed loop PM motor control, key in the details of your incremental encoder.

IMPORTANT

Note the following: · PowerFlex 525 drive only supports incremental AB encoder (25-ENC-1). · Motor Feedback Type can be "Quadrature" or "Quad Check". · Only Interior Permanent magnet motor (iPM) is supported for closed loop
control.

Stop Mode/Brake Type
Key in the details of your configuration.

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Appendix J PowerFlex 525 PM Motor Configuration
Direction Test
IMPORTANT When configuring a PM motor or using an encoder, it is required to perform a Direction Test before proceeding to the next step (Auto Tune).
Perform a Direction Test. The direction test can be performed with or without the load attached. Consider your application requirements when deciding to have the load attached or removed from the motor. This test runs in V/Hz mode to verify the motor polarity relative to the feedback polarity. The test confirms motor rotation and feedback polarity. After the test is completed, a change can be made, if necessary.

IMPORTANT If the drive was never operated before (new installation), verify that safeguards are in place to remove power safely from the drive during an unstable situation where the drive can produce undesired motion.

Auto Tune
Ensure the load is uncoupled and perform a Rotate Tune test.
Run the drive with P040 [Autotune] = 2 "Rotate Tune" configured to complete the autotune process. This process measures and configures the following:
· A501 [PM IR Voltage] · A502 [PM IXd Voltage] · A503 [PM IXq Voltage] · A504 [PM BEMF Voltage]
The Auto Tune is used to identify the correct motor flux and stator electrical properties, including the following:
· IR volt drop, which is voltage drop over resistance. · IXd volt drop, which is voltage drop over inductance.

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Appendix J PowerFlex 525 PM Motor Configuration
· Flux current (estimated in Static Tune and measured in Rotate Tune test).
· Slip RPM, which is calculated from motor nameplate data. If an encoder is used, the Slip RPM becomes a measured value using the encoder.
Auto Tune Window

A properly tested motor and drive helps ensure higher starting torque and better performance at low speeds. Conversely, an improperly performed Auto Tune can cause the motor to exhibit instability at low speeds, uneven performances when running through the motor speed range, and can generate unnecessary faults such as overcurrent and overvoltage faults.
Static Tune
This test is used when the motor is connected to a high friction load and cannot easily be uncoupled from the motor, or when the load cannot be rotated due to mechanical constraints or a limited range of movement. The Static Tune test does not generate any motor movement. The Static tune test results may not be as accurate as the Rotate Tune test.
Rotate Tune (preferred for PM motor tuning)
This test is used when the motor is not coupled to the load or the load is low friction. Rotate tune is generally used to better identify motor flux and stator electrical properties, which are used to automatically tune the torque current loop. The Rotate Tune test causes motor rotation at different speeds while it is executing.

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Appendix J PowerFlex 525 PM Motor Configuration

ATTENTION: If the drive was never operated before (new installation), verify that safeguards are in place to remove power safely from the drive during an unstable situation where the drive can produce undesired motion.
After completing the configuration and running the Auto Tune test, you may need to perform additional configuration depending on whether you have an open loop or closed loop system.
For an open loop system (A535 [Motor Fdbk Type] = 0 "None"), you may need to adjust two parameters if you encounter momentary reverse startup after a Start command is issued.
For a closed loop system (A535 [Motor Fdbk Type] = 4 "Quadrature" or 5 "Quad Check", you must perform an angle alignment after the Auto Tune test before running the motor normally.
See Additional PM Motor Configuration on page 257 for instructions.

Manual Configuration Using Drive Keypad

Besides using the PowerFlex 525 Startup Wizard in Connected Components Workbench software, you can also manually configure the parameters by using the drive keypad. Make sure you have installed the PowerFlex 525 drive firmware revision 5.001 or later.

To configure the parameters, do the following:
1. Reset all parameters to their default values. Set P053 [Reset to Defalts] = 2 "Factory Rset"
2. Select the Control Mode Set P039 [Torque Perf Mode] = 4 "PM Control"
3. Enter Motor nameplate data · Set P031 [Motor NP Volts] · Set P032 [Motor NP Hertz] · Set P033 [Motor OL Current] · Set P034 [Motor NP FLA] · Set P035 [Motor NP Poles] · Set P036 [Motor NP RMP] · Set P037 [Motor NP Power] · Set P043 [Minimum Freq] · Set P044 [Maximum Freq]
4. Set A440 [PWM Frequency] = 4.0 kHz (default) 5. Set A535 [Motor Fdbk Type]
· = 4 "Quadrature" or 5 "Quad Check" (for Closed Loop PM) or
· = 0 "None" (for Open Loop PM) · A536 [Encoder PPR] 6. Enter Stop mode and dynamic brake data, if any. · P045 [Stop Mode] · A437 [DB Resistor Sel] 7. Ensure the load is uncoupled and perform a Rotate Tune test Set P040 [Autotune] = 2 "Rotate Tune"

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Additional PM Motor Configuration

Appendix J PowerFlex 525 PM Motor Configuration
Press the Start button (Take note of your Start Source settings P046, P048, and P050. Default setting of P046 = 1 "Keypad")
ATTENTION: If the drive was never operated before (new installation), verify that safeguards are in place to remove power safely from the drive during an unstable situation where the drive can produce undesired motion.
After completing the configuration and running the Auto Tune test, you may need to perform additional configuration depending on whether you have an open loop or closed loop system.
For an open loop system (A535 [Motor Fdbk Type] = 0 "None"), you may need to adjust two parameters if you encounter momentary reverse startup after a Start command is issued.
For a closed loop system (A535 [Motor Fdbk Type] = 4 "Quadrature" or 5 "Quad Check", you must perform an angle alignment after the Auto Tune test before running the motor normally.
See Additional PM Motor Configuration on page 257 for instructions.
After completing the initial configuration, there are additional steps that need to be performed to complete the whole PM motor setup.
For an open loop PM motor (iPM and sPM) control, some parameters need to be adjusted to prevent reverse startup. For a closed loop PM motor (iPM), an angle alignment procedure needs to be performed before the motor is run normally.
Additional Setup for Open Loop PM Motor
After performing an autotune on an open loop PM motor, a momentary "reverse startup" may occur. To prevent this from occurring, perform the following steps:
1. Set A516 [PM Initial Sel] = 1 "HFI". 2. Increase the value of A519 [PM HFI NS Cur] by 10%. 3. Perform a test run at a reference speed and check if the motor reverses. 4. If the motor reverses, repeat steps 2 and 3. 5. If A519 [PM HFI NS Cur] has reached its maximum value (200%):
· reset the value to the default (100%) · set A516 [PM Initial Sel] = 2 "Six Pulse" 6. Perform a test run at a reference speed and check if the motor reverses. 7. If the motor reverses, repeat steps 2 and 3. 8. If A519 [PM HFI NS Cur] has reached its maximum value again and a reverse motor startup still occurs, the motor setup has failed.

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Appendix J PowerFlex 525 PM Motor Configuration Flowchart for Open Loop PM Motor (iPM and sPM) Setup Basic setting

Load Default

P053 [Reset to Defalts] = 2 (Factory Reset)

Control Mode Selection
Set Motor Parameters

P039 [Torque Perf Mode] = 4 (PM Control)
P031 [Motor NP Volts] P032 [Motor NP Hertz] P033 [Motor OL Current] P034 [Motor NP FLA] P035 [Motor NP Poles] P036 [Motor NP RPM] P037 [Motor NP Power] P043 [Minimum Freq] P044 [Maximum Freq]

A440 [PWM Frequency]

Set PG

A535 [Motor Fdbk Type] = 0 (None)

Set Autotune
Obtain Parameters from Autotune

P040 [Autotune] = 2 (Rotate Tune)
A501 [PM IR Voltage] A502 [PM IXd Voltage] A503 [PM IXq Voltage] A504 [PM BEMF Voltage]

Start Autotune

Set Accel and Decel Time

P041 [Accel Time 1] P042 [Decel Time 1] A439 [S Curve %]

Reverse Startup Check

Perform a test run at command frequency

Do you see

reverse startup?

Yes

No
Drive is aligned and ready to run

Repeat steps 2 and 3 of Additional Setup for Open Loop PM Motor

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Appendix J PowerFlex 525 PM Motor Configuration
Additional Setup for Closed Loop PM Motor
After performing an autotune on an closed loop PM motor, a PM angle alignment needs to be performed to complete the setup.
Align the PM Angle
To align the PM angle, do the following: 1. Uncouple the load. 2. Set these parameters to the recommended value: · A517 [PM DC Inject Cur] = 60% (default is 30%) · A518 [PM Align Time] = 5.8 s (default is 0.7 s) · A580 [Current Loop BW] = 300 Hz (default is 0 Hz) 3. Set the desired speed (10...40 Hz recommended). Check the setting for P047 [Speed Reference 1]. Speed reference can be from POT, control panel of Connected Components Workbench software, and so on. 4. Set the Start Source. Check the setting for P046 [Start Source 1]. Start source can be from POT, control panel of Connected Components Workbench software, and so on. 5. Start the drive to run at the desired speed. 6. Drive will begin to align itself (move forward and reverse) and run to the desired speed. 7. Stop the drive. The drive is now aligned. The PM angle alignment only needs to be performed once unless the drive is power cycled or re-tuned.
IMPORTANT The PM angle alignment has failed when fault F012 (HW Overcurrent) or F013 (Ground Fault) is observed during acceleration and deceleration.
Adjustments if PM Angle Alignment has Failed
If the PM angle alignment has failed, do the following: 1. Cycle drive power or set A535 [Motor Fdbk Type] = 0 "None", then set back to 4 "Quadrature" or 5 "Quad Check". 2. Increase A517 [PM DC Inject Cur] by 50%. 3. Increase A518 [PM Align Time] by 0.2 s. 4. Repeat the Align the PM Angle instructions again, beginning from step 3.

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Appendix J PowerFlex 525 PM Motor Configuration Flowchart for Closed Loop PM Motor (iPM) Setup Basic setting

Load Default

P053 [Reset to Defalts] = 2 (Factory Reset)

Control Mode Selection

P039 [Torque Perf Mode] = 4 (PM Control)

Set Motor Parameters

P031 [Motor NP Volts] P032 [Motor NP Hertz] P033 [Motor OL Current] P034 [Motor NP FLA] P035 [Motor NP Poles] P036 [Motor NP RPM] P037 [Motor NP Power] P043 [Minimum Freq] P044 [Maximum Freq]

A440 [PWM Frequency]

Set PG

A535 [Motor Fdbk Type] = 4 (Quadrature) or 5 (Quad Check)
A536 [Encoder PPR] A518 [Align Time] A517 [PM DC Inject Cur]

Set Autotune
Obtain Parameters from Autotune

P040 [Autotune] = 2 (Rotate Tune)
A501 [PM IR Voltage] A502 [PM IXd Voltage] A503 [PM IXq Voltage] A504 [PM BEMF Voltage]

Start Autotune

Set Accel and Decel Time

P041 [Accel Time 1] P042 [Decel Time 1] A439 [S Curve %]

Set Alignment

Set alignment See Align the PM Angle

Does drive align successfully?
Yes Drive is aligned and
ready to run

See Adjustments if PM Angle Alignment has Failed
No (Fault F012 or F013 is observed during acceleration and deceleration.)

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Optional Parameter Adjustments for Optimum Performance

Appendix J PowerFlex 525 PM Motor Configuration
There are a few parameters that you can use to obtain optimum performance during the test run. Usually, the default value of these parameters work well, but you may need to adjust them under different conditions.
1. A517 [PM DC Inject Cur]
Maximum DC current in amps applied to the motor in order to reset the rotor position of a PM motor.
Alignment has failed when fault F012 (HW Overcurrent) or F013 (Ground Fault) is observed during acceleration and deceleration.
Default = 30% Increase 50 of A517 [PM DC Inject Cur] for each trial when PM speed response is slow after adding load. 2. A518 [PM Align Time]
Magnetic pole reorientation time.
Alignment failed when fault F012 (HW Overcurrent) or F013 (Ground Fault) is observed during acceleration and deceleration.
Default = 0.7 s Increase A518 [PM Align Time] to > 4.7 s. 3. A527 [PM FWKn 1 Kp]
The gain to ensure good performance in field weakening region.
Default = 450% Increase 100 of A527 [PM FWKn 1Kp] for each trial when PM speed response is slow after adding load. Decrease 100 of A527 [PM FWKn 1Kp] for each trial when speed vibration is observed after adding load. 4. A580 [Current loop BW]
Current loop bandwidth (0 = Auto calculate the control gain of current loop)
Default = 0 Hz Increase 50 of A580 [Current Loop BW] for each trial when PM speed response is slow after adding load. Decrease 50 of A580 [Current Loop BW] for each trial when speed instability is observed after adding load. 5. A584 [PM Stable 2 Kp]
The gain for stabilization loop.
Default = 250% Increase 100 of A584 [PM Stable 2 Kp] for each trial if fault F064 (Drive overload) is experienced at high load. Applicable to open loop tuning especially for sPM motor. In most cases, the default value will work.

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Appendix J PowerFlex 525 PM Motor Configuration
Notes:

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K Appendix
PowerFlex 525 Synchronous Reluctance Motor Configuration

This chapter contains instructions and diagrams on configuring the PowerFlex 525 drive for use with a Synchronous Reluctance Motor (SynRM) control.

Topic

Page

SynRM Structure

263

SynRM Control Configuration

264

PowerFlex 525 drive is enhanced with SynRM control that allows an option to pair with PF525 SynRM for energy efficiency and low effort in motor maintenance.

SynRM Structure

Control Diagram
With PowerFlex 525 drive firmware revision 7.001, SynRM control can only be configured manually using the keypad.

Speed Reference (Keyboard, 2-wire, digital ...)

Speed Loop

Speedcmd
+ -

P1 Regulator

Currentcmd
+ -

Current Loop P1 Regulator

A510 [Freq 1] A511 [Freq 1 BW]
A512 [Freq 2] A513 [Freq 2 BW] A514 [Freq 3] A515 [Freq 3 BW]

A580 [Current Loop BW]

Voltage o u t

dq/abc Motor

Current feedback

abc/dq

See Adjusting Speed Control Parameters on page 250 for more information on speed loop bandwidth adjustment.

Theta
Speed
A590 [SYNRM SW Freq] A591 [SYNRM Flux Cur] A592 [SYNRM Freq1 Volt] A593 [SYNRM Freq1 Kp] A594 [SYNRM Freq1 Comp] A595 [SYNRM Freq2 BW] A596 [SYNRM Freq2 Kp]

Speed / Theta estimated

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Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration
SynRM Control Configuration To run the motor test, make sure you have installed the PowerFlex 525 drive
firmware revision 7.001 or later. For instructions, see Download Files on page 10.
Start

Increase the bandwidth to obtain faster speed response. If oscillation occurs, decrease the bandwidth.

Select the Control Mode: Set P039 [Torque Perf Mode] = 5 "SynRm"

Set the motor parameters setting: Rated Voltage: P031 [Motor NP Volts] Rated Frequency: P032 [Motor NP Hertz] OL Current: P033 [Motor OL Current] Rated Current: P034 [Motor NP FLA] Pole Numbers: P034 [Motor NP Poles] Rated RPM: P036 [Motor NP RMP] Rated Power: P037 [Motor NP Power] Minimum Frequency: P043 [Minimum Freq] Maximum Frequency: P044 [Maximum Freq] Set A484 [Current Limit 1] recommended value: > 1.65 x Rated Motor Current

Motor Parameter Auto-Tuning: Set P040 [Autotune] = 1 "Auto Tune"
Press Run

Make sure that the motor leaves the load during auto-tuning

No SynRM parameters

Is the motor

No

auto-tuning successful?

Yes

No-Load Run

Check the following motor parameters: A501 [PM IR Voltage] A502 [PM IXd Voltage] A503 [PM IXq Voltage] A504 [PM BEMF Voltage]

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Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration Startup with No-Load adjustment procedure
No-Load Test
Frequency command setting higher than A590 [SYNRM SW Freq]

Motor starts running

· Increase A591 [SYNRM Flux Cur] · Adjust A593 [SYNRM Freq1 Kp]

Is the speed stable and does not oscillate before A590 [SYNRM SW Freq]?
Yes

No
1. The start-up direction is wrong and causes F013 fault
2. Motor stalls 3. Motor speed vibrates extremely

When the frequency operation exceeds
A590 [SYNRM SW Freq], is the speed stable and
does not oscillate?

1. Increase A591 [SYNRM Flux Cur] 2. Adjust A595 [SYNRM Freq2 BW] 3. Adjust A596 [SYNRM Freq2 Kp]
No
Frequency speed vibration

Yes

Load operation test

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265

Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration Startup with Load adjustment procedure Load operation test
Frequency command setting higher than A590 [SYNRM SW Freq]

Motor starts running
Is the speed stable and does not oscillate before A590 [SYNRM SW Freq]?
Yes

1. Adjust the ASR Bandwidth See Induction Motor Tuning Diagrams on page 249
2. Adjust the A593 [SYNRM Freq1 Kp]
Transient load: If the speed drops drastically, increase the setting to improve the response. Steady-state load: If there is extreme frequency vibration, decrease the setting.
No
1. When the motor increases the load at low frequency, the speed drop is too large
2. Output frequency low frequency flutters

High-frequency loading performance test

Did the high-frequency loading performance meet the request?
Yes

1. Adjust A595 [SYNRM Freq2 BW] 2. Adjust A596 [SYNRM Freq2 Kp] 3. Adjust ASR Bandwidth See Induction Motor Tuning Diagrams on page 249
No
Insu cient high-frequency loading performance

Finish

266

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Numerics
2-wire inputs 49
3-wire inputs 49
A
accel override priority 50 selecting 49
accessing control terminals 30 power terminals 31
applications safety 239
auxiliary contact
drive 34, 35
B
basic operation 63
drive 58, 63, 162
programming 63 safety 242
C
circuit breakers inputs 22 ratings 23
common bus drive 35
communications positioning 226
configuring RS485(DSI) 205
control terminals accessing 30
counter
programming 211, 214
D
decel override priority 50 selecting 49
derating factor 124 temperature 17
digital inputs selecting 49 start source 49
dimensions
mounting 16, 184
disconnect output 34

Index
drive
auxiliary contact 34, 35 basic operation 58, 63, 162
common bus 35 mount 15
programming 59, 62
safety 242 drive damage
preventing 19 ungrounded distribution systems 19
E
encoder programming 217 wiring 219
environment storage 18
Ethernet programming 247
F
fault monitoring ground 20
fuses rating 22
G
ground fault monitoring 20 motor 21 RFI filter 22 safety 21 shielding 21
H
homing automatic 225 manual 224 programming 224
I
inputs 2-wire 49 3-wire 49 circuit breakers 22 power 20
L
logic
basic 211, 212 timed steps 211, 212

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267

Index

M
Modbus
reading 208, 209, 210 writing 205, 207, 210
motor ground 21 start 34 stop 34
mount drive 15
mounting
dimensions 16, 184
N
noise immunity
wiring 37, 204
O
output disconnect 34
override priority accel 50 decel 50 speed reference 48 start source 48
P
parameters
AppView 74, 150
CustomView 151
programming 61, 65
PID programming 231
positioning communications 226
programming 220, 221
power inputs 20
power and control module separating 28
power terminals accessing 31
preventing drive damage 19
programming 63
basic logic 211, 212 counter 211, 214 drive 59, 62
encoder 217 Ethernet 247 homing 224
parameters 61, 65
PID 231
positioning 220, 221
pulse train 217
timed steps 211, 212 timer 211, 213
tools 62 pulse train
programming 217

R
rating fuses 22
ratings circuit breakers 23
reading
Modbus 208, 209, 210
recommended
wiring 36, 241
reflected wave protection 34
RFI filter ground 22
RS485(DSI) configuring 205
S
safety applications 239 basic operation 242 drive 242 ground 21 testing 240 wiring 241
selecting accel 49 decel 49 digital inputs 49 speed reference 48 start source 48
separating power and control module 28
shielded wiring 33
shielding ground 21
speed reference override priority 48 selecting 48
start motor 34
start source digital inputs 49 override priority 48 selecting 48
stop motor 34
storage environment 18
T
temperature derating 17 wiring 32
testing safety 240
timer
programming 211, 213
tools programming 62

268

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

Index
U
unshielded wiring 33
V
voltage reflections wiring 34
W
wave protection reflected 34
wiring encoder 219
noise immunity 37, 204 recommended 36, 241
RS485 (DSI) 203 safety 241 shielded 33 temperature 32 unshielded 33 voltage reflections 34 writing
Modbus 205, 207, 210

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269

Index
Notes:

270

Rockwell Automation Publication 520-UM001J-EN-E - April 2021

PowerFlex 520-Series Adjustable Frequency AC Drive User Manual

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271

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References

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