Rockwell Automation Pub. 520-UM001I-EN-E: PowerFlex 520 Drives Install & Wiring Guide, Lecture notes of Logic

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PowerFlex 520-Series Adjustable Frequency AC Drive

PowerFlex 523 Catalog Number 25A, Series B

PowerFlex 525 Catalog Number 25B

User Manual

Original Instructions

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from

your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some

important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,

and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment

must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the

use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

• Important User Information
• Summary of Changes New and Updated Information.
• Overview Who Should Use this Manual Preface
  • Recommended Documentation
  • Manual Conventions
  • Drive Frame Sizes
  • General Precautions
  • Catalog Number Explanation
  • Chapter
• Installation/Wiring Mounting Considerations.
  • AC Supply Source Considerations
  • General Grounding Requirements
  • Fuses and Circuit Breakers
  • Power and Control Module
  • Control Module Cover
  • Power Module Terminal Guard
  • Power Wiring.
  • Power Terminal Block
  • Common Bus/Precharge Notes
  • I/O Wiring
  • Control I/O Terminal Block
  • Start and Speed Reference Control
  • CE Conformity
  • Chapter
• Start Up Prepare for Drive Start-Up
  • Display and Control Keys
  • Viewing and Editing Parameters
  • Drive Programming Tools
  • Language Support
  • Smart Start-Up with Basic Program Group Parameters
  • LCD Display with QuickView Technology.
  • Using the USB Port
  • Chapter Table of Contents
• Programming and Parameters About Parameters
  • Parameter Groups
  • Basic Display Group
  • Basic Program Group
  • Terminal Block Group.
  • Communications Group.
  • Logic Group
  • Advanced Display Group
  • Advanced Program Group
  • Network Parameter Group.
  • Modified Parameter Group
  • Fault and Diagnostic Group.
  • AppView Parameter Groups
  • CustomView Parameter Group.
  • Parameter Cross Reference by Name
  • Chapter
• Troubleshooting Drive Status
  • Faults
  • Fault Descriptions.
  • Common Symptoms and Corrective Actions
• Supplemental Drive Information Certifications Appendix A
  • Environmental Specifications
  • Technical Specifications
  • Power Specifications.
• Accessories and Dimensions Product Selection Appendix B
  • Product Dimensions.
  • Optional Accessories and Kits
• RS485 (DSI) Protocol Network Wiring Appendix C
  • Parameter Configuration
  • Supported Modbus Function Codes
  • Writing (06) Logic Command Data
  • Writing (06) Comm Frequency Command.
  • Reading (03) Logic Status Data.
  • Reading (03) Drive Error Codes
  • Reading (03) Drive Operational Values
  • Reading (03) and Writing (06) Drive Parameters
  • Additional Information.

Table of Contents

Appendix D

Velocity StepLogic, Basic Logic and

Timer/Counter Functions

Velocity StepLogic Using Timed Steps............................ 210 Velocity StepLogic Using Basic Logic Functions................... 210 Timer Function................................................. 211 Counter Function............................................... 212 Velocity StepLogic Parameters................................... 213

Appendix E

Encoder/Pulse Train Usage and

Position StepLogic Application

Encoder and Pulse Train Usage................................... 215 Wiring Notes................................................... 216 Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution................................................ 217 Positioning Overview............................................ 218 Common Guidelines for All Applications......................... 218 Positioning Operation........................................... 220 Homing Routine................................................ 223 Encoder and Position Feedback.................................. 224 Use Over Communications...................................... 225 Setup Notes..................................................... 226

Appendix F

PID Set Up PID Loop....................................................... 227

PID Reference and Feedback..................................... 229 Analog PID Reference Signals.................................... 230

Appendix G

Safe-Torque-Off Function PowerFlex 525 Safe-Torque-Off Overview........................ 235

EC Type Examination Certification.............................. 236 EMC Instructions............................................... 236 Using PowerFlex 525 Safe-Torque-Off............................ 236 Safety Concept.................................................. 237 Enabling PowerFlex 525 Safe-Torque-Off......................... 239 Wiring......................................................... 239 PowerFlex 525 Safe-Torque-Off Operation....................... 239 Verify Operation................................................ 240 Connection Examples........................................... 241 PowerFlex 525 Certification for Safe-Torque-Off.................. 245

Appendix H

EtherNet/IP Establishing A Connection With EtherNet/IP.................... 247

Ground Connections for EtherNet/IP Networks.................. 248

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page Added footnote to indicate that circuit breaker selection is not available for certain drive ratings.

Added PowerFlex 523 series B to Control I/O Wiring Block Diagram. 38 Added PowerFlex 523 series B to Control I/O Terminal Designations. 40 Added PowerFlex 523 series B I/O wiring examples for analog input and analog output. 45 Added note to PowerFlex 525 I/O wiring example for pulse train input. 46 Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with Basic Program Group Parameters.

Added new sub topic for 32-bit parameters. 72 Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later. Chapter 3 Updated descriptions for parameters that are available in PowerFlex 523 FRN 3.xxx and later. Added formula for calculating scaled process value to parameter b010 [Process Display]. 79 Added recommendation to perform rotate tune when using VVC mode to parameter P [Autotune].

Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [Dig Out Status].

Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband]. 123 Added corrective action to fault F114 (uC Failure). 162 Added analog output to PowerFlex 523 drives. 171 Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution” to Appendix E.

Updated information to verify operation of the safety inputs in Appendix G. 240 General maintenance updates. Throughout manual

Summary of Changes

Notes:

Preface Overview

The following publications provide specific Network Communications

information:

Manual Conventions •^ In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC

Drive as; drive, PowerFlex 520-series, PowerFlex 520-series drive or

PowerFlex 520-series AC drive.

• Specific drives within the PowerFlex 520-series may be referred to as:
  • PowerFlex 523, PowerFlex 523 drive or PowerFlex 523 AC drive.
  • PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.
• Parameter numbers and names are shown in this format:
• The following words are used throughout the manual to describe an

action:

Title Publication PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM

P 031 [Motor NP Volts]

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

Words Meaning Can Possible, able to do something Cannot Not possible, not able to do something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not Recommended

Overview Preface

• 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 5000 controllers for discrete, process, batch, motion,

safety, and drive-based solutions. The Studio 5000 environment is the

foundation for the future of Rockwell Automation engineering design

tools and capabilities. It is the one place for design engineers to develop all

the elements of their control system.

Drive Frame Sizes Similar PowerFlex 520-series drive sizes are grouped into frame sizes to simplify

spare parts ordering, dimensioning, etc. A cross reference of drive catalog

numbers and their respective frame sizes is provided in Appendix B.

Overview Preface

Catalog Number Explanation

Code Type 25A PowerFlex 523 25B PowerFlex 525

25B – B 2P3 N 1 1 4 – – Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash

Output Current @ 1 Phase, 100...120V Input Code Amps Frame ND HD HP kW HP kW 1P6 (1)^ 1.6 A 0.25 0.2 0.25 0. 2P5 2.5 A 0.5 0.4 0.5 0. 4P8 4.8 B 1.0 0.75 1.0 0. 6P0 6.0 B 1.5 1.1 1.5 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. 2P5 2.5 A 0.5 0.4 0.5 0. 4P8 4.8 A 1.0 0.75 1.0 0. 8P0 8.0 B 2.0 1.5 2.0 1. 011 11.0 B 3.0 2.2 3.0 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. 2P5 2.5 A 0.5 0.4 0.5 0. 5P0 5.0 A 1.0 0.75 1.0 0. 8P0 8.0 A 2.0 1.5 2.0 1. 011 11.0 A 3.0 2.2 3.0 2. 017 17.5 B 5.0 4.0 5.0 4. 024 24.0 C 7.5 5.5 7.5 5. 032 32.2 D 10.0 7.5 10.0 7. 048 (2)^ 48.3 E 15.0 11.0 10.0 7. 062 (2)^ 62.1 E 20.0 15.0 15.0 11.

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. 2P3 2.3 A 1.0 0.75 1.0 0. 4P0 4.0 A 2.0 1.5 2.0 1. 6P0 6.0 A 3.0 2.2 3.0 2. 010 10.5 B 5.0 4.0 5.0 4. 013 13.0 C 7.5 5.5 7.5 5. 017 17.0 C 10.0 7.5 10.0 7. 024 24.0 D 15.0 11.0 15.0 11. 030 (2)^ 30.0 D 20.0 15.0 15.0 11. 037 (2)^ 37.0 E 25.0 18.5 20.0 15. 043 (2)^ 43.0 E 30.0 22.0 25.0 18. 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. 1P7 1.7 A 1.0 0.75 1.0 0. 3P0 3.0 A 2.0 1.5 2.0 1. 4P2 4.2 A 3.0 2.2 3.0 2. 6P6 6.6 B 5.0 4.0 5.0 4. 9P9 9.9 C 7.5 5.5 7.5 5. 012 12.0 C 10.0 7.5 10.0 7. 019 19.0 D 15.0 11.0 15.0 11. 022 (2)^ 22.0 D 20.0 15.0 15.0 11. 027 (2)^ 27.0 E 25.0 18.5 20.0 15. 032 (2)^ 32.0 E 30.0 22.0 25.0 18.

Code Voltage Phase V 120V AC 1 A 240V AC 1 B 240V AC 3 D 480V AC 3 E 600V AC 3

Code Enclosure N IP20 NEMA / Open

Code Interface Module 1 Standard

Code EMC Filter 0 No Filter 1 Filter

Code Braking 4 Standard

(1) This rating is only available for PowerFlex 523 drives. (2) Normal and Heavy Duty ratings are available for this drive.

Preface Overview

Notes:

Chapter 1 Installation/Wiring

• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.

Minimum Mounting Clearances

See Appendix B for mounting dimensions.

(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.

25 mm (1.0 in.)

25 mm (1.0 in.) (2)

(2)

25 mm (1.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)(1)^

50 mm (2.0 in.)(1)

50 mm (2.0 in.)(1)

50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

Esc Sel Esc Sel Esc Sel Esc Sel

50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

50 mm (2.0 in.)

Esc (^) Sel

Esc (^) Sel

50 mm (2.0 in.)

50 mm (2.0 in.) 50 mm (2.0 in.) (^) (2.0 in.)50 mm

50 mm (2.0 in.) (1)

Esc (^) Sel

Esc (^) Sel

Esc Sel Esc Sel Esc Sel Esc Sel

Vertical, Zero Stacking No clearance between drives.

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

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

Vertical with Control Module Fan Kit

Horizontal with Control Module Fan Kit

Installation/Wiring Chapter 1

Ambient Operating Temperatures

See Appendix B for option kits.

Current Derating Curves

Vertical Mounting

Horizontal/Floor Mounting

Mounting Enclosure Rating(1)^ Ambient Temperature Minimum Maximum (No Derate) Maximum (Derate) (2)^ Maximum with Control Module Fan Kit (Derate) (3)(5) Vertical IP 20/Open Type

-20 °C (-4 °F)

50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F)

IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) – Vertical, Zero Stacking IP 20/Open Type 45 °C (113 °F) 55 °C (131 °F) 65 °C (149 °F) IP 30/NEMA 1/UL Type 1 40 °C (104 °F) 50 °C (122 °F) – Horizontal with Control Module Fan Kit(4)(5)^

IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F)

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

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.

Ambient Temperature (°C)

40

100 90

110

120

80 70 60 50 Percentage of Rated Current (%) 30 35 404550 5560 65 70 75 80

(^) IP 30/NEMA 1 with Control Module Fan Kit

IP 20/Open Type

Ambient Temperature (°C)

40

100 90

110

120

80 70 60 50 Percentage of Rated Current (%) 30 35 4045505560 65 70 75 80

(^) IP 30/NEMA 1 with Control Module Fan Kit

IP 20/Open Type

Single Drive Zero Stacking

Ambient Temperature (°C)

40

100 90

120 110

80 70 60 50 Percentage of Rated Current (%) 30 35 40 4550 5560 6570 75 80

with Control Module Fan Kit

IP 20/Open Type

Ambient Temperature (°C)

40

100 90

120 110

80 70 60 50 Percentage of Rated Current (%) 30 35 40 4550 5560 6570 75 80

(^) with Control Module Fan Kit

IP 20/Open Type

Single Drive Zero Stacking

Installation/Wiring Chapter 1

AC Supply Source

Considerations

Ungrounded Distribution Systems

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)

Phase to Ground MOV Removal

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.

IMPORTANT Tighten screw after jumper removal.

Power Module

R/L S/L T/L 1 2 3 4

Three-Phase AC Input

Jumper

Chapter 1 Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated

voltage of the drive (see page 169). 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.

General Grounding

Requirements

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

IMPORTANT Only one device per branch circuit is required. It should be mounted closest to

the branch and sized to handle the total current of the branch circuit.

Input Power Conditions

Input Power Condition Corrective Action Low Line Impedance (less than 1% line reactance) • Install Line Reactor(2)

- or Isolation Transformer

(2) See Appendix B for accessory ordering information.

Greater than 120 kVA supply transformer Line has power factor correction capacitors • Install Line Reactor(2) Line has frequent power interruptions^ •^ or Isolation Transformer Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage • Remove MOV jumper to ground.

- or Install Isolation Transformer with Ungrounded distribution system grounded secondary if necessary. B-phase grounded distribution system 240V open delta configuration (stinger leg)(1) (1) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire 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. - Install Line Reactor(2)

SHLD

U/T V/T W/T

R/L S/L T/L

Esc Sel