Rockwell Automation Allen-Bradley PowerFlex 520 Series Manual de usuario

PowerFlex 520-series

Adjustable Frequency AC Drive

Bulletin Numbers 25A series B, 25B

User Manual Original Instructions

2Rockwell Automation Publication 520-UM001K-EN-E - August 2021

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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

SHOCKHAZARD:Labelsmaybeonor insidetheequipment,forexample,adriveormotor,toalertpeoplethatdangerousvoltage

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.

ARCFLASHHAZARD:Labelsmaybeonorinsidetheequipment,forexample,amotor controlcenter,toalertpeopletopotentialArc

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).

Rockwell Automation Publication 520-UM001K-EN-E - August 2021 3

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

Installation/Wiring 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

4Rockwell Automation Publication 520-UM001K-EN-E - August 2021

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

Chapter 2

Start Up 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

Chapter 3

Programming and Parameters 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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Table of Contents

Chapter 4

Troubleshooting 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

Appendix A

Supplemental Drive Information Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Appendix B

Accessories and Dimensions 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

Appendix C

RS485 (DSI) Protocol 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

Appendix D

Velocity StepLogic, Basic Logic

and Timer/Counter Functions

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

Position StepLogic Application

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

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

6Rockwell Automation Publication 520-UM001K-EN-E - August 2021

Table of Contents

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 Set Up 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

Safe Torque Off Function 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-UM001K-EN-E - August 2021 7

Table of Contents

Appendix H

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

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

Appendix I

Control Diagrams Induction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Appendix J

PowerFlex 525 PM Motor

Configuration

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

Appendix K

PowerFlex 525 Synchronous

Reluctance Motor Configuration

SynRM Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

SynRM Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

8Rockwell Automation Publication 520-UM001K-EN-E - August 2021

Table of Contents

Notes:

Rockwell Automation Publication 520-UM001K-EN-E - August 2021 9

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.

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 Page

Summary of Changes 9

Additional Resources 10

Manual Conventions 11

Drive Frame Sizes 12

General Precautions 13

Catalog Number Explanation 14

Topic Page

Removed column “Min Enclosure Vol” from Fuses and Circuit Breaker tables 24…27

Updated C2 and C3 categories external requirements in PowerFlex 520-Series RF Emission

Compliance and Installation Requirements table 54

Added footnote on EMC enclosure dimension 55

Corrected PCR with ID 1018 on description of P043 [Minimum Freq] 85

Corrected PCR with ID 1539 on fractional parameters.

• Added t071 [Opto Out1 LevelF] and t074 [Opto Out2 LevelF]

• Added t078 [RelayOut1 LevelF] and t083 [RelayOut2 LevelF]

• Added L201 [Step Units F 0], L203 [Step Units F 1], L205 [Step Units F 2], L207 [Step Units F

3], L209 [Step Units F 4], L2011 [Step Units F 5], L213 [Step Units F6], and L215 [Step Units F 7]

• Updated d366 [Timer StatusF]

• Updated d377 [Speed Feedback F]

• Updated d379 [Encoder Speed F]

• Updated d389 [Units Traveled L]

108

109

110

111

112

Corrected PCR with ID 1541 on parameter reference t105 [Safety Open En] for Fault F059 160

Added Efficiency Class certification based on Ecodesign Regulation (EU) 2019/1781 165

Updated Input Current Scaling section and table to improve clarity 171

Added column “For 150 m” to EMC Line Filters table 175

10 Rockwell Automation Publication 520-UM001K-EN-E - August 2021

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:

The following publications provide specific PowerFlex 520-Series information

on drive installation, features, specifications, and service:

The following publications provide specific Network Communications

information:

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.

Title Publication

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001

Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001

Safety Guidelines for the Application, Installation, and Maintenance of solid-state Control SGI-1.1

Guarding Against Electrostatic Damage 8000-SB001

Title Publication

PowerFlex 520-Series AC Drive Specifications 520-TD001

PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001

PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

Title Publication

PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001

PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002

PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM003

PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004

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