520 UM001I EN E PowerFlex 520 Series Adjustable Frequency AC Drive User Manual

Transcript

1 User Manual PowerFlex 520-Series Adjustable Frequency AC Drive PowerFlex 523 Catalog Number 25A, Series B PowerFlex 525 Catalog Number 25B Original Instructions

2 Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety SGI-1.1 Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication 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. for illustrative purposes. Because of the many variables and The examples and diagrams in this manual are included solely 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. Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, WARNING: which may lead to personal injury or de ath, 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. e, a drive or motor, to alert people that dangerous SHOCK HAZARD: Labels may be on or inside the equipment, for exampl voltage may be present. a drive or motor, to alert people that surfaces may BURN HAZARD: Labels may be on or inside the equipment, for example, reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for ex ample, 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). ssful application and understanding of the product. Identifies information that is critical for succe IMPORTANT Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logi x 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.

3 Table of Contents Important User Information . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . . . New and Updated Information. . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . . . . Summary of Changes Preface Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Overview Recommended Documentation . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . . . . . . . . . Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Catalog Number Explanation . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . Chapter 1 Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation/Wiring AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . Control Module Cover . . . . . . . . . . . . . . . . . . . . . . 31 Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . . . . . . . . . . . . Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Common Bus/Precharge Notes I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . . . . . . . . . . . . . . Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Chapter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Prepare for Drive Start-Up . . . . . . Start Up Display and Control Keys . . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . . . . . . . . . Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Smart Start-Up with Basic Pro gram Group Parameters . . . . . . . . . . . . . . 65 LCD Display with QuickView Techn ology. . . . . . . . . . . . . . . . . . . . . . . . . 67 Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 n 520-UM001I-EN-E - July 2016 3 Rockwell Automation Publicatio

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

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

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

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

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

9 Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex® 520-Series Adjustable Fre quenc y AC Dri ve. For information on... See page... 9 Who Should Use this Manual Recommended Documentation 9 10 Manual Conventions Drive Frame Sizes 11 12 General Precautions Catalog Number Explanation 13 rsonnel. You must be able to program This manual is intended for qualified pe Who Should Use this Manual and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions. All the recommended documentation listed in this section is available online at Recommended http://www.rockwellautomation.com/literature/ . Documentation The following publications provide general drive information: 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, Instal lation and Maintenance of Solid State Control SGI-1.1 100-2.10 A Global Reference Guide for Reading Schematic Diagrams 8000-4.5.2 Guarding Against Electrostatic Damage The following publications provide specific PowerFlex 520-Series information on drive installation, features, specifications, and service: 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 n 520-UM001I-EN-E - July 2016 9 Rockwell Automation Publicatio

10 Preface Overview The following publications provide specific Network Communications information: Title Publication PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001 PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002 520COM-UM003 PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM004 PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter • In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC Manual Conventions 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: P 031 [Motor NP Volts] Name Number Group b = Basic Display = Basic Program P t = Terminal Blocks = Communications C L = Logic = Advanced Display d A = Advanced Program N = Network = Modified M = Fault and Diagnostic f = AppView and CustomView G The following words are used throughout the manual to describe an • action: 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 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 10

11 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. Similar PowerFlex 520-series drive sizes are grouped into frame sizes to simplify Drive Frame Sizes spare parts ordering, dimensioning, etc. A cross reference of drive catalog . numbers and their respective frame sizes is provided in Appendix B n 520-UM001I-EN-E - July 2016 11 Rockwell Automation Publicatio

12 Preface Overview General Precautions AT T E NT IO N : capacitors which take time to The drive contains high voltage 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. L1, L2, L3 (Line to Line and Line to After three minutes, verify AC voltage Ground) to ensure mains power has been disconnected. Measure DC voltage across DC- and 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. AT T E NT IO N : 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. AT T E NT IO N : This drive contains ESD (Electrostatic Discharge) sensitive parts are required when installing, testing, and assemblies. Static control precautions servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If yo u 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. AT T E NT IO N : 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. AT T E NT IO N : 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 voltag e or imbalanced input voltages can cause uncommanded positive speed changes; 2. Actual deceleration times can be lo nger 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 Re g Enable]). In addition, in stalling a properly sized dynamic brake resistor will provide prop er stopping requirements based on braking resistor sizing. AT T E NT IO N : Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 12

13 Overview Preface Catalog Number Explanation 4 5 6-8 13 10 11 12 1-3 14 9 25B – B 2P3 N 1 1 4 – – Emission Class eserved Dash Dash Reserved Drive Dash Voltage Rating Rating Enclosure R Code Braking 4Standard Type Code EMC Filter Code 25A PowerFlex 523 0 No Filter PowerFlex 525 1Filter 25B Interface Module Code Voltage Phase Code 1Standard V120V AC1 A240V AC1 Enclosure Code B240V AC3 IP20 NEMA / Open N D480V AC3 E600V AC3 Output Current @ 3 Phase, 380...480V Input Output Current @ 1 Phase, 100...120V Input ND Code Amps Code Amps Frame ND HD HD Frame HP kW HP kW HP kW HP kW (1) 1.4 A 0.5 0.4 0.5 1P6 1P4 0.4 1.6 A 0.25 0.2 0.25 0.2 2P3 0.75 1.0 0.75 1.0 A 2.3 0.4 0.5 0.4 0.5 2.5 A 2P5 4P0 A 4.0 1.5 2.0 1.5 2.0 0.75 0.75 1.0 B 4.8 4P8 1.0 2.2 3.0 A 2.2 6.0 6P0 3.0 1.1 1.5 1.5 B 6.0 6P0 1.1 4.0 5.0 B 10.5 4.0 5.0 010 Output Current @ 1 Phase, 200...240V Input 7.5 5.5 013 5.5 7.5 13.0 C Code Amps Frame ND HD 10.0 C 17.0 017 7.5 10.0 7.5 kW HP kW HP 11.0 D 024 15.0 11.0 15.0 24.0 (1) 1.6 A 0.25 0.2 0.25 0.2 1P6 (2) 11.0 20.0 15.0 D 30.0 15.0 030 2P5 0.5 0.4 0.5 A 2.5 0.4 (2) 18.5 25.0 E 37.0 15.0 037 20.0 1.0 1.0 0.75 A 0.75 4.8 4P8 (2) 043 43.0 E 30.0 22.0 25.0 18.5 8P0 2.0 1.5 2.0 1.5 B 8.0 Output Current @ 3 Phase, 525...600V Input 2.2 011 11.0 B 2.2 3.0 3.0 HD ND Frame Amps Code Output Current @ 3Phase, 200...240V Input kW HP HP kW ND Frame Amps Code HD 0.5 A 0.9 0P9 0.4 0.5 0.4 HP kW HP kW 1P7 0.75 1.0 0.75 1.0 A 1.7 (1) 0.2 A 1.6 0.2 0.25 0.25 1P6 2.0 1.5 2.0 A 3.0 3P0 1.5 0.5 0.4 2P5 0.4 2.5 A 0.5 A 4.2 4P2 3.0 2.2 2.2 3.0 0.75 5P0 5.0 A 1.0 0.75 1.0 4.0 5.0 6P6 6.6 B 5.0 4.0 2.0 2.0 1.5 8.0 8P0 1.5 A 5.5 7.5 5.5 7.5 C 9.9 9P9 A 3.0 2.2 3.0 11.0 011 2.2 7.5 12.0 C 10.0 7.5 10.0 012 17.5 5.0 5.0 017 4.0 B 4.0 019 19.0 D 15.0 11.0 15.0 11.0 5.5 7.5 C 24.0 024 7.5 5.5 (2) 022 22.0 D 20.0 15.0 15.0 11.0 032 32.2 D 10.0 10.0 7.5 7.5 (2) 15.0 027 27.0 E 25.0 18.5 20.0 (2) 10.0 11.0 15.0 E 48.3 7.5 048 (2) 25.0 032 32.0 E 30.0 22.0 18.5 (2) 15.0 11.0 62.1 E 20.0 062 15.0 This rating is only available for PowerFlex 523 drives. (1) Normal and Heavy Duty ratings are available for this drive. (2) n 520-UM001I-EN-E - July 2016 13 Rockwell Automation Publicatio

14 Preface Overview Notes: 14 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

15 Chapter 1 Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 520- series drives. For information on... See page... 15 Mounting Considerations 19 AC Supply Source Considerations General Grounding Requirements 20 Fuses and Circuit Breakers 23 28 Power and Control Module Control Module Cover 31 Power Module Terminal Guard 31 Power Wiring 32 Power Terminal Block 35 Common Bus/Precharge Notes 36 I/O Wiring 36 Control I/O Terminal Block 37 Start and Speed Reference Control 49 CE Conformity 52 Most start-up 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. The following information is merely a guide for proper AT T E NT IO N : 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. Mount the drive upright on a flat, vertical and level surface. • Mounting Considerations Screw Size Screw Torque Frame A M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) B M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) C M5 (#10...24) 1.56...1.96 Nm (14...17 lb-in.) M5 (#10...24) 2.45...2.94 Nm (22...26 lb-in.) D M8 (5/16 in.) 6.0...7.4 Nm (53...65 lb-in.) E Protect the cooling fan by avoiding dust or metallic particles. • n 520-UM001I-EN-E - July 2016 15 Rockwell Automation Publicatio

16 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. Vertical, Zero Stacking with Vertical Vertical with Control Module Fan Kit Vertical, Zero Stacking Control Module Fan Kit No clearance between drives. No clearance between drives. 50 mm 50 mm 50 mm 50 mm (1) (1) (2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.) 25 mm (1.0 in.) Sel Sel Sel Sel Esc Esc Esc Esc Sel Sel Esc Esc Sel Sel Esc Esc 25 mm (2) 50 mm 50 mm 50 mm 50 mm (1.0 in.) (2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.) 50 mm 50 mm (2.0 in.) (2.0 in.) 50 mm 50 mm (1) (2.0 in.) (1) Esc (2.0 in.) 50 mm E Se s c 50 mm l S e l (2.0 in.) (2.0 in.) (2) E s c Esc S e l S el 25 mm (1.0 in.) 50 mm 50 mm (2.0 in.) (2.0 in.) Horizontal, Zero Stacking with Horizontal with Control Module Fan Kit Control Module Fan Kit No clearance between drives. , clearance of 95 mm (3.7 in.) is required. For Frame E with Control Module Fan Kit only (1) (2) For Frame E with Control Module Fan Kit only , clearance of 12 mm (0.5 in.) is required. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 16

17 Chapter 1 Installation/Wiring Ambient Operating Temperatures Appendix B for option kits. See (1) Ambient Temperature Mounting Enclosure Rating (2) Maximum with Minimum Maximum (Derate) Maximum (No Derate) (3)(5) Control Module Fan Kit (Derate) 50 Vertical ° IP 20/Open Type ° F) 60 ° C (140 ° F) 70 ° C (158 ° F) C (122 – F) ° C (131 IP 30/NEMA 1/UL Type 1 45 ° C (113 ° F) 55 ° ° ° F) ° Vertical, Zero Stacking IP 20/Open Type 45 C (149 C (113 ° F) 55 ° C (131 ° F) 65 50 ° 40 ° C (104 F) IP 30/NEMA 1/UL Type 1 ° C (122 ° F) – -20 ° C (-4 ° F) F) ° C (158 ° IP 20/Open Type 50 ° C (122 ° F) – 70 Horizontal with (4)(5) Control Module Fan Kit F) C (149 ° 65 IP 20/Open Type ° Horizontal, Zero Stacking 45 C (113 ° F) – ° (4)(5) with Control Module Fan Kit 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 n (1) umber 25-JBAx. ed under the Maximum (Derate) column is reduced by 5 °C (9 ° F) for all mounting methods. For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature list (2) (3) For catalogs 25x-D1P4N104 and 25x-E0P9N104, the temperature listed under the Maximum with Control Module Fan Kit (Derate) co lumn 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 moun ted 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 Zero Stacking 120 120 with Control with Control IP 30/NEMA 1 IP 30/NEMA 1 Module Fan Kit Module Fan Kit 110 110 100 100 90 90 IP 20/Open Type IP 20/Open Type 80 80 70 70 60 60 50 50 40 40 Percentage of Rated Current (%) Percentage of Rated Current (%) 65 70 75 80 80 65 70 75 60 60 55 40 30 45 45 50 55 35 50 30 35 40 Ambient Temperature (°C) Ambient Temperature (°C) Horizontal/Floor Mounting Zero Stacking Single Drive 120 120 with Control with Control Module Fan Kit Module Fan Kit 110 110 100 100 90 90 IP 20/Open Type IP 20/Open Type 80 80 70 70 60 60 50 50 40 40 Percentage of Rated Current (%) Percentage of Rated Current (%) 70 75 80 30 35 60 65 50 55 40 45 75 80 70 65 30 35 40 45 55 50 60 Ambient Temperature (°C) Ambient Temperature (°C) n 520-UM001I-EN-E - July 2016 17 Rockwell Automation Publicatio

18 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 ° ° F) for every • C (9 additional 1000 m (3300 ft), subject to limits listed in the Altitude Limit table below. (Based on Voltage) 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) Corner Ground, Impedance Center Ground (Wye Neutral) Drive Rating Ground, or Ungrounded 6000 m 100...120V 1-Phase 6000 m 200...240V 1-Phase 2000 m 2000 m 6000 m 2000 m 200...240V 3-Phase 2000 m 380...480V 3-Phase 4000 m 525...600V 3-Phase 2000 m 2000 m High Altitude 120 60 110 100 50 90 80 40 70 60 30 50 Ambient Temperature (°C) 40 20 Percentage of Rated Current (%) 4000 4000 3000 1000 0 0 2000 3000 1000 2000 Altitude (m) Altitude (m) Debris Protection Take precautions to prevent debris from falling through the vents of the drive housing during installation. Storage (1) . ° Store within an ambient temperature range of -40...85 • C • Store within a relative humidity range of 0...95%, noncondensing. Do not expose to a corrosive atmosphere. • ° C. The maximum ambient temperature for storing a Frame E drive is 70 (1) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 18

19 Installation/Wiring Chapter 1 Ungrounded Distribution Systems AC Supply Source Considerations PowerFlex 520-series drives contain protective MOVs that are AT T E NT IO N : referenced to ground. These devices mu st be disconnected if the drive is stive grounded di stribution system. installed on an ungrounded or resi Removing MOVs in drives with an embedded filter will also AT T E NT IO N : 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. Pull the jumper completely out of the drive chassis. 2. Tighten the screw to keep it in place. 3. Jumper Location (Typical) Power Module Tighten screw after jumper removal. IMPORTANT Phase to Ground MOV Removal R/L1 Three-Phase S/L2 AC Input T/L3 123 4 Jumper n 520-UM001I-EN-E - July 2016 19 Rockwell Automation Publicatio

20 Installation/Wiring Chapter 1 Input Power Conditioning The drive is suitable for direct connection to input power within the rated page 169 voltage of the drive (see ). 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. quired. It should be mounted closest to Only one device per branch circuit is re IMPORTANT the branch and sized to handle the total current of the branch circuit. Input Power Conditions Input Power Condition Corrective Action (2) • Low Line Impedance (less than 1% line reactance) Install Line Reactor • or Isolation Transformer Greater than 120 kVA supply transformer (2) Install Line Reactor • Line has power factor correction capacitors or Isolation Transformer • Line has frequent power interruptions in excess of 6000V (lightning) Line has intermittent noise spikes Remove MOV jumper to ground. Phase to ground voltage exceeds 125% of normal line to line voltage • or Install Isolation Transformer with • Ungrounded distribution system grounded secondary if necessary. B-phase grounded distribution system (1) (2) • Install Line Reactor 240V open delta configuration (stinger leg) in For drives applied on an open delta with a middle phase gr (1) ounded neutral system, the phase opposite the phase that is tapped the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identifi ed throughout e B ion point. The stinger leg should be connected to the center Phas the system with red or orange tape on the wire at each connect on the reactor. See Bulletin 1321-3R Series Line Reactors on page 183 for specific line reactor part numbers. for accessory ordering information. See (2) Appendix B General Grounding The drive Safety Ground - (PE) must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial Requirements safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. Typical Grounding l S e E s c R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 SHLD Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 20

21 Installation/Wiring Chapter 1 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. 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 topolog y (EtherNet/IP) or daisy-chain (RS485). It is acceptable to ground both C1 and C2 terminals. Connect terminal CS1 or CS2 to a clean ground when using a network with a ring topolog y (EtherNet/IP). Ground Connections for For more information on EtherNet/IP networks, see EtherNet/IP Networks . on page 248 Network Wiring For more information on RS485 networks, see on page 201 . 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. Th e earthing plate or conduit box option may be used with a cable clamp for a grounding point for the cable shield. control and signal wiring , the shield should be When shielded cable is used for grounded at the source end only, not at the drive end. n 520-UM001I-EN-E - July 2016 21 Rockwell Automation Publicatio

22 Chapter 1 Installation/Wiring RFI Filter Grounding Using a drive with filter may result in relatively high ground leakage currents. filter must only be used in installations with grounded AC Therefore, the 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 flex ible 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 22

23 Installation/Wiring Chapter 1 The PowerFlex 520-series drive does not provide branch short circuit protection. Fuses and Circuit Breakers 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. 24 The tables found on pages 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. (1) , EN60269-1, Parts 1 & 2, • IEC – BS88 (British Standard) Parts 1 & 2 type GG or equivalent should be used. • UL – UL Class CC, T, RK1, or J should be used. Circuit Breakers ... 27 include inverse time 24 The “non-fuse” listings in the tables found on pages 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 br eakers and the specified 140M self- protected combination motor controllers are acceptable for UL installations. Bulletin 140M (Self-Protected Combinat ion 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. without • Bulletin 140M can be used up stream from the drive the need for fuses. (1) 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. n 520-UM001I-EN-E - July 2016 23 Rockwell Automation Publicatio

24 Chapter 1 Installation/Wiring ) ) 3 3 – – – – – – – – – – – – – – Vol. (in. Enclosure Enclosure Vol. (in. Min. Min. B63 B63 C25 C25 -B63 (2)(3)(4) (2)(3)(4) 140M-C2E 140M 140M 140M-F8E- 140M-F8E- 140M-C2E- 140M-C2E- 140M-C2E-C16 140M-C2E-C16 140M-D8E-C20 140M-C2E-C10 140M-C2E-C10 140M-C2E-C10 140M-F8E-C25 140M-F8E-C25 140M-F8E-C25 0 0 2 30 -C15 -C15 -C25 (5) (5) 140U-D6D2 140U-D6D2-C 140U-D6D2-C25 140U-D6D2-C25 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-B80 140U-D6D2-C1 140U-D6D2-C1 140U/140G 140U/140G 140U-D6C2-C1 – – 140U-D6D2 140U-D6D2 Circuit Breakers Circuit Breakers Class / Catalog No. Class / Catalog No. CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-15 UL Applications UL Applications CLASS RK5, CC, J, or T / DLS-R-25 CLASS RK5, CC, J, or T / DLS-R-50 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-20 Fuses (Max. Rating) Fuses (Max. Rating) CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 CLASS RK5, CC, J, or T / DLS-R-25 CLASS RK5, CC, J, or T / DLS-R-40 CLASS CC, J, or T / 50 CLASS CC, J, or T / 50 ground, or high-resistance ground systems. 2E-B63 2E-B63 . 140M 140M 140M-C 140M-C 140M-C2E-C16 140M-F8E-C25 140M-C2E-C10 140M-C2E-C10 140M-C2E-C10 140M-C2E-B63 140M-F8E-C25 140M-F8E-C25 140M-C2E-C16 140M-F8E-C25 140M-F8E-C25 140M-D8E-C20 140U/140G 140U/140G 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-C15 140U-D6D2-C10 140U-D6D2-C10 140U-D6D2-B80 140U-D6D2-C30 140U-D6D2-C12 140U-D6D2-C25 140U-D6D2-C25 140U-D6D2-C15 Circuit Breakers Circuit Breakers 140U-D6D2-C25 140G-G6C3-C35 140G-G6C3-C35 use on 480V or 600V Delta/Delta, corner rip. Max. Max. 10 10 25 16 16 16 50 20 40 40 25 40 50 50 ion Devices – Frames A...B ion Devices – Frames A...B Min. Min. IEC Applications (Non-UL) IEC Applications (Non-UL) Fuses (Rating) Fuses (Rating) Catalog No. Catalog No. Contactor Contactor nge that the device will not t 100-C09 6 100-C09 6 100-C12 16 100-C09 10 100-C09 10 100-C09 10 100-C23 32 100-C12 16 100-C23 25 100-C23 25 100-C12 16 100-C23 25 100-C37 32 100-C37 32 Frame Size Frame Size A A A A A A B A B B A B B B (1) (1) Bulletin 140M Motor Protection Circuit Breakers Application Ratings 5.3 5.3 10.7 6.5 6.5 24.0 6.4 18.0 18.0 Amps Max Amps Max 9.6 10.7 19.2 22.9 22.9 kVA kVA 1.4 1.4 2.8 Input Input 1.7 1.7 0.8 3.2 Ratings Ratings 4.8 4.8 1.3 2.8 2.5 6.0 6.0 Amps Amps 100...120V 1-Phase Input Protect 200...240V 1-Phase Input Protect Fuses and Circuit Breakers for PowerFlex 520-Series Drives 1.6 1.6 4.8 2.5 2.5 1.6 6.0 8.0 8.0 2.5 4.8 4.8 11.0 11.0 rrent trip set to the minimum ra refer to the drive nameplate for drive input current rating. kW kW 0.2 0.2 0.75 0.4 0.4 0.2 1.1 1.5 1.5 0.75 0.4 0.75 2.2 2.2 HP HP 0.25 0.25 HD HD 1.0 0.25 0.5 0.5 2.0 2.0 1.5 1.0 0.5 1.0 3.0 3.0 kW kW 0.2 0.2 0.75 0.2 0.4 0.4 1.1 1.5 1.5 0.75 0.4 0.75 2.2 2.2 Output Ratings Output Ratings HP HP 0.25 0.25 ND ND 0.25 PF 525 PF 525 Circuit breaker selection is not available for this drive rating. When the drive is controlling motors with lower amp ratings, Bulletin 140M with adjustable current range should have the cu Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See 25A-A4P8N104 25B-A4P8N104 1.0 25A-A1P6N114 – 25A-A2P5N114 25B-A2P5N114 0.5 25A-A011N104 25B-A011N104 3.0 25A-A8P0N114 25B-A8P0N114 2.0 25A-A4P8N114 25B-A4P8N114 1.0 25A-A8P0N104 25B-A8P0N104 2.0 25A-A2P5N104 25B-A2P5N104 0.5 25A-V4P8N104 25B-V4P8N104 1.0 25A-A011N114 25B-A011N114 3.0 25A-V2P5N104 25B-V2P5N104 0.5 PF 523 25A-V6P0N104 25B-V6P0N104 1.5 PF 523 25A-A1P6N104 – Catalog No. Catalog No. 25A-V1P6N104 – (5) (4) (2) (1) (3) Rockwell Automation Publication 520-UM001I-EN-E - July 2016 24

25 Chapter 1 Installation/Wiring ) 3 (6) – – – – – – – Vol. (in. Enclosure – 1416.0 – Min. al 25 -C25 (3)(4)(5) 0M-C2E-B40 (7) 14 140M-C2E-B 140M 140M-C2E-B63 140M-F8E-C45 140M-C2E-C10 140M-F8E-C32 – 140M-F8E-C45 140M-C2E-C16 140M-F8E 0 B80 C15 (7) (7) (7) (7) 140U-D6D3- 140U-D6D3- 140U-D6D3-B40 140U-D6D3-B30 140U-D6D3-C1 140U/140G – – 140U-D6D3-C25 – – Circuit Breakers mum volume specified in this column. Application specific therm Class / Catalog No. CLASS RK5, CC, J, or T / DLS-R-15 UL Applications CLASS CC, J, or T / 90 CLASS CC, J, or T / 125 CLASS RK5, CC, J, or T / DLS-R-6 CLASS RK5, CC, J, or T / DLS-R-30 CLASS RK5, CC, J, or T / DLS-R-15 CLASS RK5, CC, J, or T / DLS-R-70 CLASS RK5, CC, J, or T / DLS-R-20 Fuses (Max. Rating) CLASS CC, J, or T / 60 CLASS CC, J, or T / 45 ground, or high-resistance ground systems. (continued) -B25 (7) . 140M 140M-C2E 140M-F8E-C45 – 140M-F8E-C45 140M-C2E-C16 140M-C2E-B40 140M-C2E-C10 140M-C2E-B63 140M-F8E-C32 140M-F8E-C25 B40 6D3-B80 -G6C3-C60 140U/140G 140U-D6D3-B30 140G 140U-D6D3- 140U-D 140G-G6C3-C70 140G-G6C3-C90 140U-D6D3-C15 140U-D6D3-C10 Circuit Breakers 140U-D6D3-C25 140G-G6C3-C35 talled in a ventilated or non-ventilated enclosure with the mini use on 480V or 600V Delta/Delta, corner rip. 6 Max. 70 6 16 125 90 32 20 45 63 ion Devices – Frames A...E r PowerFlex 520-Series Drives Min. 63 70 IEC Applications (Non-UL) Fuses (Rating) Catalog No. Contactor nge that the device will not t 100-C09 3 100-C43 45 100-C09 6 100-C09 10 100-C23 20 100-C72 100-C60 100-C12 16 100-C23 32 100-C37 35 Frame Size A D A A A E E A B C (2) Bulletin 140M Motor Protection Circuit Breakers Application Ratings 1.9 34.8 2.7 5.8 Amps 56.0 44.0 Max 13.8 9.5 21.1 26.6 kVA 0.9 15.9 1.2 2.7 20.1 Ratings 25.6 Input 6.3 4.3 9.6 12.2 Amps Controller with this drive power rating, the drive must be ins Fuses and Circuit Breakers fo 200...240V 3-Phase Input Protect 1.6 32.2 48.3 62.1 2.5 5.0 11.0 8.0 17.5 24.0 rrent trip set to the minimum ra refer to the drive nameplate for drive input current rating. kW 7.5 11.0 0.2 7.5 0.4 0.75 2.2 1.5 4.0 5.5 HP 10.0 15.0 HD 0.25 10.0 0.5 1.0 3.0 2.0 5.0 7.5 kW 11.0 15.0 0.2 7.5 0.75 0.4 2.2 1.5 4.0 5.5 HP Output Ratings 15.0 20.0 ND 0.25 25B-B062N104 25B-B048N104 PF 525 (1) Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive. considerations may require a larger enclosure. When using a Manual Self-Protected (Type E) Combination Motor Circuit breaker selection is not available for this drive rating. When the drive is controlling motors with lower amp ratings, Bulletin 140M with adjustable current range should have the cu Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See 25A-B032N104 25B-B032N104 10.0 PF 523 25A-B062N104 25A-B048N104 Catalog No. 25A-B1P6N104 – 25A-B5P0N104 25B-B5P0N104 1.0 25A-B2P5N104 25B-B2P5N104 0.5 25A-B011N104 25B-B011N104 3.0 25A-B024N104 25B-B024N104 7.5 25A-B8P0N104 25B-B8P0N104 2.0 25A-B017N104 25B-B017N104 5.0 (7) (6) (5) (2) (1) (3) (4) 25 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

26 Installation/Wiring Chapter 1 ) 3 (6) (6) (6) (6) Min. – – – – – – – – – – – – – – 656.7 656.7 Vol. (in. Enclosure – – 656.7 656.7 al (3)(4)(5) 140M 140M-F8E-C45 140M-D8E-C20 140M-C2E-B25 140M-F8E-C45 140M-D8E-C20 140M-C2E-C10 140M-D8E-C20 140M-F8E-C45 140M-C2E-B25 140M-C2E-C16 140M-C2E-B40 140M-D8E-C20 140M-C2E-C16 140M-C2E-B40 140M-F8E-C45 140M-C2E-C10 140M-F8E-C32 140M-C2E-B63 140M-F8E-C32 140M-C2E-B63 (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) – – – – 140U/140G – – – – – – – – – – – – Circuit Breakers – – – – mum volume specified in this column. Application specific therm Fuses (Max. Rating) Class / Catalog No. UL Applications CLASS CC, J, or T / 70 CLASS CC, J, or T / 80 CLASS CC, J, or T / 70 CLASS CC, J, or T / 70 CLASS CC, J, or T / 35 CLASS CC, J, or T / 60 CLASS CC, J, or T / 60 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-10 CLASS RK5, CC, J, or T / DLS-R-10 CLASS CC, J, or T / 35 CLASS CC, J, or T / 40 CLASS CC, J, or T / 40 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-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 ground, or high-resistance ground systems. (continued) . 140M 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45 140M-F8E-C45 140M-F8E-C32 140M-F8E-C32 140M-D8E-C20 140M-C2E-B63 140M-C2E-B63 140M-D8E-C20 140M-D8E-C20 140M-D8E-C20 140M-C2E-B40 140M-C2E-B40 140M-C2E-C10 140M-C2E-C10 140M-C2E-B25 140M-C2E-B25 140M-C2E-C16 140M-C2E-C16 140U/140G Circuit Breakers 140G-G6C3-C50 140G-G6C3-C50 140G-G6C3-C50 140G-G6C3-C60 140G-G6C3-C40 140G-G6C3-C40 140U-D6D3-C25 140U-D6D3-B60 140U-D6D3-C10 140U-D6D3-C10 140U-D6D3-B60 140U-D6D3-C25 140U-D6D3-C25 140U-D6D3-C25 140U-D6D3-B60 140U-D6D3-B60 140U-D6D3-B30 140U-D6D3-B30 140U-D6D3-C15 140U-D6D3-C15 talled in a ventilated or non-ventilated enclosure with the mini use on 480V or 600V Delta/Delta, corner rip. Max. 63 70 63 70 70 80 35 16 16 16 16 35 40 40 10 10 6 6 32 32 ion Devices – Frames A...E r PowerFlex 520-Series Drives Min. 45 45 IEC Applications (Non-UL) 50 45 Fuses (Rating) Catalog No. 7 35 7 35 Contactor nge that the device will not t 100-C3 100-C43 100-C43 100-C60 100-C43 100-C23 20 100-C3 100-C09 10 100-C09 10 100-C09 10 100-C09 10 100-C23 20 100-C09 6 100-C09 6 100-C09 3 100-C09 3 100-C23 25 100-C23 25 100-C23 20 100-C23 20 Frame Size D D E E D C D A A A A C A A A A C C B B (2) Bulletin 140M Motor Protection Circuit Breakers Application Ratings 26.4 33.0 33.0 Max 33.7 38.9 Amps 15.4 26.4 5.7 7.5 5.7 7.5 15.4 3.2 3.2 1.9 1.9 18.4 18.4 13.8 13.8 kVA 35.6 Ratings 30.2 30.2 30.8 Input 24.1 14.1 24.1 6.9 5.2 5.2 6.9 14.1 1.7 1.7 2.9 2.9 16.8 16.8 12.6 12.6 Amps Controller with this drive power rating, the drive must be ins Fuses and Circuit Breakers fo 380...480V 3-Phase Input Protect 30.0 43.0 30.0 37.0 24.0 13.0 24.0 13.0 4.0 6.0 4.0 6.0 17.0 17.0 10.5 10.5 1.4 1.4 2.3 2.3 rrent trip set to the minimum ra refer to the drive nameplate for drive input current rating. kW 11.0 15.0 11.0 18.5 11.0 5.5 11.0 1.5 1.5 2.2 2.2 5.5 0.4 0.4 4.0 4.0 0.75 0.75 7.5 7.5 HP 15.0 15.0 25.0 20.0 HD 15.0 7.5 15.0 2.0 3.0 2.0 3.0 7.5 1.0 1.0 10.0 10.0 0.5 0.5 5.0 5.0 kW 15.0 22.0 18.5 15.0 11.0 5.5 11.0 2.2 2.2 1.5 1.5 0.75 0.75 5.5 0.4 0.4 7.5 7.5 4.0 4.0 HP 20.0 30.0 25.0 20.0 Output Ratings ND 25B-D030N114 25B-D030N104 25B-D043N114 25B-D037N114 PF 525 (1) Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive. considerations may require a larger enclosure. When using a Manual Self-Protected (Type E) Combination Motor Circuit breaker selection is not available for this drive rating. When the drive is controlling motors with lower amp ratings, Bulletin 140M with adjustable current range should have the cu Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See 25A-D024N104 25B-D024N104 15.0 25A-D017N104 25B-D017N104 10.0 PF 523 25A-D6P0N104 25B-D6P0N104 3.0 25A-D010N104 25B-D010N104 5.0 25A-D6P0N114 25B-D6P0N114 3.0 25A-D4P0N104 25B-D4P0N104 2.0 25A-D1P4N114 25B-D1P4N114 0.5 25A-D4P0N114 25B-D4P0N114 2.0 25A-D013N104 25B-D013N104 7.5 25A-D013N114 25B-D013N114 7.5 25A-D2P3N114 25B-D2P3N114 1.0 25A-D2P3N104 25B-D2P3N104 1.0 25A-D010N114 25B-D010N114 5.0 25A-D017N114 25B-D017N114 10.0 25A-D043N114 25A-D030N114 25A-D037N114 25A-D1P4N104 25B-D1P4N104 0.5 25A-D030N104 Catalog No. 25A-D024N114 25B-D024N114 15.0 (7) (6) (5) (3) (2) (1) (4) Rockwell Automation Publication 520-UM001I-EN-E - July 2016 26

27 Installation/Wiring Chapter 1 ) 3 (7) (7) (7) (7) – – – – – – 656.7 Vol. (in. Enclosure 1416.0 656.7 – 1416.0 Min. al (6) (3)(4)(5) 140M 140M-D8E-C16 140M-D8E-B63 140M-F8E-C32 140M-F8E-C25 140M-D8E-C16 140M-D8E-C10 140M-C2E-B25 140M-C2E-B40 140M-F8E-C32 140M-C2E-B25 140M-F8E-C32 (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) 140U/140G – – – – – – – – Circuit Breakers – – – mum volume specified in this column. Application specific therm Class / Catalog No. UL Applications CLASS CC, J, or T / 50 CLASS CC, J, or T / 60 CLASS CC, J, or T / 60 CLASS RK5, CC, J, or T / DLS-R-30 Fuses (Max. Rating) CLASS RK5, CC, J, or T / DLS-R-15 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-20 CLASS RK5, CC, J, or T / DLS-R-6 CLASS CC, J, or T / 50 CLASS RK5, CC, J, or T / DLS-R-25 ground, or high-resistance ground systems. (continued) . 140M 140M-F8E-C32 140M-F8E-C32 140M-F8E-C32 140M-F8E-C25 140M-C2E-C16 140M-C2E-C10 140M-C2E-C16 140M-C2E-B40 140M-C2E-B63 140M-C2E-B25 140M-C2E-B25 -D6D3-C20 140U/140G 140U 140G-G6C3-C35 140G-G6C3-C35 140G-G6C3-C50 140G-G6C3-C30 140U-D6D3-C10 140U-D6D3-B50 140U-D6D3-B20 140U-D6D3-B80 Circuit Breakers 140U-D6D3-B30 140U-D6D3-C15 the minimum size of 457.2 x 457.2 x 269.8 mm (18 x 18 x 10.62 in.). talled in a ventilated or non-ventilated enclosure with the mini use on 480V or 600V Delta/Delta, corner rip. Max. 32 50 50 63 63 20 10 6 16 6 25 ion Devices – Frames A...E r PowerFlex 520-Series Drives Min. Fuses (Rating) 35 35 IEC Applications (Non-UL) 40 Catalog No. 0 32 Contactor nge that the device will not t 100-C23 20 100-C3 100-C37 100-C30 100-C30 100-C09 3 100-C09 6 100-C09 10 100-C09 10 100-C09 3 100-C16 16 Frame Size C D E D E A B A A A C (2) Bulletin 140M Motor Protection Circuit Breakers Application Ratings 13.5 24.7 29.2 Max Amps 27.3 24.0 3.8 1.2 5.3 8.0 2.3 11.2 kVA 15.4 28.2 33.4 31.2 Ratings Input 27.4 9.1 4.3 6.1 12.8 1.4 2.6 Amps be installed in a ventilated or non-ventilated enclosure with Controller with this drive power rating, the drive must be ins 525...600V 3-Phase Input Protect Fuses and Circuit Breakers fo 12.0 32.0 27.0 22.0 19.0 4.2 9.9 6.6 3.0 0.9 1.7 rrent trip set to the minimum ra refer to the drive nameplate for drive input current rating. kW 11.0 15.0 18.5 7.5 11.0 4.0 1.5 2.2 5.5 0.75 0.4 HP 25.0 20.0 15.0 10.0 HD 15.0 3.0 2.0 5.0 7.5 0.5 1.0 kW 22.0 18.5 15.0 7.5 11.0 2.2 4.0 0.75 1.5 5.5 0.4 HP 20.0 30.0 25.0 Output Ratings 10.0 ND 15.0 2.0 3.0 5.0 7.5 1.0 0.5 25B-E022N104 25B-E032N104 25B-E027N104 PF 525 25B-E012N104 25B-E019N104 25B-E3P0N104 25B-E9P9N104 25B-E4P2N104 25B-E1P7N104 25B-E6P6N104 25B-E0P9N104 (1) Normal Duty (ND) and Heavy Duty (HD) ratings are available for this drive. considerations may require a larger enclosure. When using a Manual Self-Protected (Type E) Combination Motor Circuit breaker selection is not available for this drive rating. When the drive is controlling motors with lower amp ratings, Bulletin 140M with adjustable current range should have the cu When used with the 140M circuit breaker, the 25A-E9P9104 must Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 480Y/277 and 600Y/347 AC input. Not UL listed for The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See 25A-E9P9N104 PF 523 25A-E1P7N104 25A-E012N104 25A-E3P0N104 25A-E019N104 25A-E4P2N104 25A-E6P6N104 Catalog No. 25A-E027N104 25A-E032N104 25A-E022N104 25A-E0P9N104 (8) (7) (6) (5) (2) (3) (1) (4) 27 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

28 Chapter 1 Installation/Wiring PowerFlex 520-series drives consist of a Power Module and Control Module. Power and Control Module Separating the Power and Control Module AT T E NT IO N : Perform this action only when drive is NOT powered. Press and hold down the catch on both sides of the frame cover, then pull 1. 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 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 28

29 Installation/Wiring Chapter 1 Hold the sides and top of the Control Module firmly, then pull out to 3. separate it from the Power Module. Connecting the Power and Control Module Align the connectors on the Power Module and Control Module, then 1. push the Control Module firmly onto the Power Module. n 520-UM001I-EN-E - July 2016 29 Rockwell Automation Publicatio

30 Chapter 1 Installation/Wiring Push the top cover of the Control Module towards the Power Module to 2. lock it. Insert the catch at the top of the frame cover into the Power Module, then 3. swing the frame cover to snap the side catches onto the Power Module (Frames B...E only). Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 30

31 Installation/Wiring Chapter 1 To access the control terminals, DSI port, and Ethernet port, the front cover must Control Module Cover be removed. To remove: 1. Press and hold down the arrow on the front of the cover. 2. Slide the front cover down to remove from the Control Module. 1 2 Re-attach the front cover when wiring is complete. To access the power terminals, the terminal guard must be removed. To remove: Power Module Terminal Guard 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). n 520-UM001I-EN-E - July 2016 31 Rockwell Automation Publicatio

32 Chapter 1 Installation/Wiring Press and hold down the locking tab on the terminal guard. 2. 3. Slide the terminal guard down to remove from the Power Module. 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. Power Wiring AT T E NT IO N : 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. To avoid a possible shock hazard caused by induced voltages, AT T E NT IO N : unused wires in the conduit must be grounded at both ends. For the same g serviced or installed, all drives using reason, if a drive sharing a conduit is bein will help minimize the possible shock this conduit should be disabled. This hazard from “cross coupled” power leads. Motor Cable Types Acceptable fo r 100...600 Volt Installations A variety of cable types are acceptable for drive installations. For many te, provided it can be separated from installations, unshielded cable is adequa sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for long parallel runs must be avoided. Do every 10 m (32.8 ft) of length. In all cases, ess less than 15 mils (0.4 mm/0.015 in.). not use cable with an insulation thickn 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 32

33 Chapter 1 Installation/Wiring 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. Use copper wire only. Wire gauge requirements and recommendations are based on 75 ° C. Do not reduce wire gauge when using higher temperature wire. The distance between the drive and motor must not exceed the WARNING: 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. AT T E NT IO N : 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. Refer to Reflected Wave in “Wiring and Grounding Guide, (PWM) AC Drives,” DRIVES-IN001 publication . 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 (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. n 520-UM001I-EN-E - July 2016 33 Rockwell Automation Publicatio

34 Chapter 1 Installation/Wiring 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 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 Rating/Type Description Location 600V, 90 • F) XHHW2/RHW-2 ° C (194 ° rs with XLPE insulation. Standard (Option 1) Four tinned copper conducto Anixter B209500-B209507, Belden • Copper braid/aluminum foil combination shield and 29501-29507, or equivalent tinned copper drain wire. • PVC jacket. Three tinned copper conductors with XLPE insulation. • ° Standard (Option 2) F) Tray rated 600V, 90 C (194 ° • RHH/RHW-2 Anixter OLF-7xxxxx or 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield. equivalent • PVC jacket. F) Class I & II; Three bare copper conductors with XLPE insulation • Tray rated 600V, 90 ° C (194 ° and impervious corrugated continuously welded RHH/RHW-2 Anixter 7V-7xxxx-3G or Division I & II equivalent 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). Refer to 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). Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 34

35 Installation/Wiring Chapter 1 Power Terminal Block Power Terminal Block Frame E Frame A, B, C & D T/L3 S/L2 R/L1 U/T1 W/T3 V/T2 U/T1 V/T2 T/L3 S/L2 R/L1 W/T3 BR- DC+ DC- DC+ DC- BR- BR+ BR+ Terminal Description 1-Phase Input Line Voltage Connection R/L1, S/L2 R/L1, S/L2, T/L3 3-Phase Input Line Voltage Connection = Switch any two motor leads to change U/T1, V/T2, W/T3 Motor Phase Connection forward direction. DC+, DC- DC Bus Connection (except for 110V 1-Phase) BR+, BR- Dynamic Brake Resistor Connection Safety Ground - PE Terminal screws may become loose during shipment. Ensure that all terminal IMPORTANT screws are tightened to the recommended torque before applying power to the drive. Power Terminal Block Wire Specifications (1) (1) Minimum Wire Size Maximum Wire Size To rque Frame 2 2 A5.3 mm 1.76...2.16 Nm (15.6...19.1 lb-in.) (18 AWG) 0.8 mm (10 AWG) 2 2 1.76...2.16 Nm (15.6...19.1 lb-in.) 2.1 mm (8 AWG) (14 AWG) B8.4 mm 2 2 1.76...2.16 Nm (15.6...19.1 lb-in.) (8 AWG) 2.1 mm (14 AWG) C8.4 mm 2 2 D13.3 mm (10 AWG) 5.3 mm (6 AWG) 1.76...2.16 Nm (15.6...19.1 lb-in.) 2 2 8.4 mm (3 AWG) 3.09...3.77 Nm (27.3...33.4 lb-in.) (8 AWG) E26.7 mm k will accept – these are not recommendations. Maximum/minimum sizes that the terminal bloc (1) n 520-UM001I-EN-E - July 2016 35 Rockwell Automation Publicatio

36 Chapter 1 Installation/Wiring If drives are used with a disconnect switch to the common DC bus, then an Common Bus/Precharge auxiliary contact on the disconnect must be connected to a digital input of the Notes drive. The corresponding input (parameter t062 , t065 ... t068 [DigIn , t063 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 . DRIVES-AT002 Bus Configurations, publication Motor Start/Stop Precautions I/O Wiring AT T E NT IO N : 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 to use control input signals that will hardware damage. The drive is designed start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur. The drive start/stop control circuitry includes solid-state AT T E NT IO N : 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). I/O terminals labeled “Common” are not referenced to the safety ground (PE) IMPORTANT terminal and are designed to greatly reduce common mode interference. Driving the 4-20 mA analog input from a voltage source could AT T E NT IO N : cause component damage. Verify proper configuration prior to applying input signals. Signal and Control Wire Types ° C ambient temperature. Recommendations are for 50 ° C ambient temperature. C wire must be used for 60 ° 75 C ambient temperature. ° C wire must be used for 70 ° 90 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 36

37 Chapter 1 Installation/Wiring Recommended Signal Wire (1) Description Belden Wire Type(s) Signal Type/ Min. Insulation (or equivalent) Where Used Rating 2 300V, Analog I/O & PTC 8760/9460 0.750 mm (18 AWG), twisted pair, (2) F) ° 60 ° 100% shield with drain C (140 2 (18 AWG), 3 conductor, shielded Remote Pot 8770 0.750 mm 2 (24 AWG), individually shielded pairs 9728/9730 0.196 mm Encoder/Pulse I/O Stranded or solid wire. (1) (2) ecessary, If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be n but is always recommended. Recommended Control Wire for Digital I/O Min. Insulation Description Wire Type(s) Type Rating Per US NEC or applicable Unshielded 300V, – national or local code F) 60 ° C (140 ° 2 (18 AWG), 3 conductor, shielded. Multi-conductor shielded 0.750 mm Shielded cable such as Belden 8770 (or equivalent) 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 Bl ock Wire Specifications Control I/O Terminal Block (1) (1) Frame Maximum Wire Size Minimum Wire Size Torque 2 2 0.71...0.86 Nm (6.2...7.6 lb-in.) (26 AWG) 0.13 mm (16 AWG) A...E 1.3 mm k will accept – these are not recommendations. Maximum/minimum sizes that the terminal bloc (1) n 520-UM001I-EN-E - July 2016 37 Rockwell Automation Publicatio

38 Chapter 1 Installation/Wiring PowerFlex 523 Control I/O Terminal Block PowerFlex 523 Control I/O Wiring Block Diagram Series A Typical Typical (1) SNK wiring SRC wiring Stop 01 DigIn TermBlk 02/ (2) Start/Run FWD 02 DigIn TermBlk 03/ Direction/Run REV 03 Digital Common SRC SNK 04 DigIn TermBlk 05/Pulse 05 DigIn TermBlk 06 06 +24V +24V DC 11 Relay N.O. R1 +10V DC +10V 12 Relay Common R2 0-10V Input Relay N.C. 13 R3 Analog Common 14 Pot must be 4-20mA Input 1...10 k ohm 15 2 W min. RJ45 Shield C1 Comm Common C2 J7 J8 RS485 Pulse In SNK (DSI) 81 Digital In SRC Digital Input DigIn TermBlk 05 Sel 01 02 03 04 05 06 R2 R1 13 C1 15 14 C2 12 R3 11 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 38

39 Chapter 1 Installation/Wiring Series B Typical Typical (1) SRC wiring SNK wiring Stop 01 DigIn TermBlk 02/ (2) Start/Run FWD 02 DigIn TermBlk 03/ Direction/Run REV 03 Digital Common SRC SNK 04 DigIn TermBlk 05/Pulse 05 DigIn TermBlk 06 06 Relay N.O. R1 Relay Common +24V R2 +24V DC 11 Relay N.C. R3 +10V DC +10V 12 0-10V Analog Input 13 13 4-20 mA Analog Common 14 14 (4) (3) 0-10V Pot must be 4-20 mA Analog Output 15 source 1...10 k ohm 0/4-20 mA 2 W min. RJ45 Shield C1 Comm Common C2 J7 J8 J13 J4 RS485 Pulse In 0/4-20 mA 4-20 mA SNK (DSI) 81 Digital In Analog In Analog Out 0-10V 0-10V Digital SRC Input DigIn TermBlk 05 Sel R1 01 02 03 04 05 06 R2 12 13 14 C2 C1 15 R3 11 Control I/O Wiring Block Diagram Notes Digital Input Selection for Start Source for more information on configuring the digital inputs. (1) See on page 50 I/O Terminal 01 is always a stop input. The stopping mode is determined by the IMPORTANT drive setting. See the tables below for more information. Start Method Stop Method Normal Stop I/O Terminal 01 Stop P046, P048, P050 [Start Source x] Per P045 1 “Keypad” Coast [Stop Mode] below See t062, t063 [DigIn TermBlk xx] 2 “DigIn TrmBlk” 3 “Serial/DSI” Coast 4 “Network Opt” Coast (1) Coast 5 “Ethernet/IP” Setting is specific to PowerFlex 525 drives only. (1) 39 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

40 Chapter 1 Installation/Wiring Stop Method Start Method I/O Terminal 01 Stop Normal Stop t062, t063 [DigIn TermBlk xx] t064 [2-Wire Mode] is set to: 48 “2-Wire FWD” Per P045 [Stop Mode] 0, 1, or 2 = Coast • • 3 = per P045 [Stop Mode] 49 “3-Wire Start” Per P045 [Stop Mode] t064 [2-Wire Mode] is set to: 50 “2-Wire REV” 0, 1, or 2 = Coast • 3 = per P045 [Stop Mode] • Per P045 [Stop Mode] 51 “3-Wire Dir” alled between I/O Terminals 01 and 11. The drive is shipped with a jumper inst IMPORTANT Remove this jumper when using I/O Term inal 01 as a stop or enable input. Two wire control shown. For three wire control use a mome (2) ntary input on I/O Terminal 02 to command a start. Use a for I/O Terminal 03 to change direction. maintained input (3) Analog output (terminal 15) is only available on PowerFlex 523 series B drive, and requires firmware 3.001 and later to conf igure 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. If more than one reference is connected at the same time, an (5) Only one analog frequency source may be connected at a time. undetermined frequency reference will result. Control I/O Terminal Designations No. Signal Description Parameter Default R1 Relay N.O. Fault Normally open contact for output relay. t076 Relay Common Fault Common for output relay. R2 Relay N.C. Motor Running Normally closed contact for output relay. t081 R3 (2) Stop Coast Three wire stop. However, it functions as a stop under all input 01 P045 modes and cannot be disabled. 02 Run FWD Used to initiate motion and also can be used as a programmable DigIn TermBlk 02/ P045 , P046 , , Start/Run FWD digital input. It can be programmed with t062 [DigIn TermBlk P048 , P050 , t062 A544 02] as three wire (Start/Dir with Stop) or two wire (Run FWD/ Run REV) control. Current consumption is 6 mA. DigIn TermBlk 03/ t063 Run REV Used to initiate motion and al so can be used as a programmable 03 digital input. It can be programmed with t063 [DigIn TermBlk Dir/Run REV 03] as three wire (Start/Dir with Stop) or two wire (Run FWD/ Run REV) control. Current consumption is 6 mA. 04 Digital Common – Return for digital I/O. Elec trically isolated (along with the digital – I/O) from the rest of the drive. DigIn TermBlk 05/ Preset Freq Program with t065 [DigIn TermBlk 05]. 05 t065 Pulse In Also functions as a Pulse Trai n input for reference or speed feedback. Requires an NPN pulse input. The maximum ent consumption is 6 mA. frequency is 100 kHz. Curr 06 DigIn TermBlk 06 Preset Freq Program with t066 [DigIn TermBlk 06]. t066 Current consumption is 6 mA. – 11 +24V DC – Referenced to Digital Common. Drive supplied power for digital inputs. Maximum output current is 100 mA. P049 , 12 +10V DC – Referenced to Analog Common. P047 Drive supplied power for 0...10V external potentiometer. Maximum output current is 15 mA. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 40

41 Installation/Wiring Chapter 1 Control I/O Terminal Designations Parameter No. Signal Default Description For Series A 13 Not Active For external 0-10V (unipolar) input supply or potentiometer , P049 , P047 (1) t063 wiper. t062 , , 0-10V In , t065 , t066 Input impedance: t093 , A459 , Voltage source = 100 k Ω A471 Allowable potentiometer resistance range = 1...10 k Ω External anal For Series B og input supply, selectable by Analog Input Not Active , P049 , P047 jumper. Default is 0-10V (unipolar) input supply or , t062 , t063 Analog Input , t065 potentiometer wiper. , t066 , , A459 t093 Input impedance: A471 Ω Voltage source = 100 k Allowable potentiometer resistance range = 1...10 k Ω Change Analog Input jumper to 4-20 mA for external 4-20 mA Ω input supply. Input impedance = 250 – Return for th e analog I/O. Electrically isolated (along with the 14 – Analog Common analog I/O) from the rest of the drive. , For external 4-20 mA input supply. P047 , P049 Not Active For Series A 15 (1) t062 , t063 , Ω Input impedance = 250 4-20mA In , t065 , t066 A459 , A471 For Series B 0-10V. To convert a current value, t089 , OutFreq 0-10 The default analog output is t088 change the Analog Output jumper to 0-20 mA. Program with Analog Output t088 [Analog Out Sel]. Maximum analog value can be scaled with t089 [Analog Out High]. 4-20 mA = 525 Ω (10.5V) Maximum Load: (10 mA) 0-10V = 1 k Ω C1 – This terminal is tied to the RJ-45 port shield. Tie this terminal to – C1 a clean ground in order to improve noise immunity when using external communication peripherals. – This is the signal common for the communication signals. – C2 C2 If more than one reference is connected at the same time, an Only one analog frequency source may be connected at a time. (1) undetermined frequency reference will result. (2) See Footnote (1) on page 39 . n 520-UM001I-EN-E - July 2016 41 Rockwell Automation Publicatio

42 Chapter 1 Installation/Wiring PowerFlex 525 Control I/O Terminal Block PowerFlex 525 Control I/O Wiring Block Diagram Typical Typical (1) SRC wiring SNK wiring Stop 01 Safety 1 DigIn TermBlk 02/ (2) S1 Start/Run FWD Safe-Torque-Off 02 Safety 2 DigIn TermBlk 03/ S2 Direction/Run REV 03 Safety +24V S+ Digital Common SRC SNK 04 DigIn TermBlk 05 05 DigIn TermBlk 06 06 DigIn TermBlk 07/Pulse 07 DigIn TermBlk 08 08 +24V +24V DC 11 Relay 1 N.O. R1 +10V DC +10V 12 Relay 1 Common R2 0-10V (or ±10V) Input 13 Relay 2 Common Analog Common R5 14 Pot must be Relay 2 N.C. 4-20mA Input R6 1...10 k ohm 15 2 W min. 0-10V Analog Output 16 0/4-20 mA Opto Output 1 24V 17 (3) Common Opto Output 2 18 30V DC 50 mA Opto Common Non-inductive 19 RJ45 Shield C1 Comm Common C2 J9 J5 J10 Pulse In 0/4-20mA SNK Digital In Analog Out 0-10V SRC Digital Input DigIn TermBlk 07 Sel 06 R2 01 02 03 04 05 R6 07 08 C1 C2 R1 R5 11 12 13 14 15 16 17 18 19 S1 S2 S+ Control I/O Wiring Block Diagram Notes See for more information on configuring the digital inputs. Digital Input Selection for Start Source (1) on page 50 I/O Terminal 01 is always a stop input. The stopping mode is determined by the IMPORTANT drive setting. See the tables below for more information. Start Method Stop Method P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop Coast Per P045 1 “Keypad” [Stop Mode] below 2 “DigIn TrmBlk” t062, t063 [DigIn TermBlk xx] See Coast 3 “Serial/DSI” 4 “Network Opt” Coast 5 “EtherNet/IP” Coast Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 42

43 Installation/Wiring Chapter 1 Stop Method Start Method t062, t063 [DigIn TermBlk xx] Normal Stop I/O Terminal 01 Stop t064 [2-Wire Mode] is set to: Per P045 48 “2-Wire FWD” [Stop Mode] 0, 1, or 2 = Coast • 3 = per P045 [Stop Mode] • Per P045 [Stop Mode] 49 “3-Wire Start” 50 “2-Wire REV” t064 [2-Wire Mode] is set to: • 0, 1, or 2 = Coast • 3 = per P045 [Stop Mode] Per P045 [Stop Mode] 51 “3-Wire Dir” alled between I/O Terminals 01 and 11. The drive is shipped with a jumper inst IMPORTANT inal 01 as a stop or enable input. Remove this jumper when using I/O Term on I/O Terminal 02 to command a start. Use a ntary input Two wire control shown. For three wire control use a mome (2) for I/O Terminal 03 to change direction. maintained input o prevent When using an opto output with an inductive load such as a re (3) lay, install a recovery diode parallel to the relay as shown, t damage to the output. Control I/O Terminal Designations No. Signal Default Description Parameter R1 Relay 1 N.O. Fault Normally open contact for output relay. t076 R2 Relay 1 Common Fault Common for output relay. R5 g Common for output relay. Motor Runnin Relay 2 Common t081 R6 Relay 2 N.C. Motor Running Normally closed contact for output relay. (1) Coast Three wire stop. However, it functions as a stop under all input Stop P045 01 modes and cannot be disabled. 02 DigIn TermBlk 02/ Run FWD Used to initiate motion and also can be used as a programmable P045 , P046 , P048 , Start/Run FWD digital input. It can be programmed with t062 [DigIn TermBlk P050 , 02] as three wire (Start/Dir with Stop) or two wire (Run FWD/ , t062 A544 Run REV) control. Current consumption is 6 mA. DigIn TermBlk 03/ Used to initiate motion and al so can be used as a programmable 03 Run REV t063 digital input. It can be programmed with t063 [DigIn TermBlk Dir/Run REV 03] as three wire (Start/Dir with Stop) or two wire (Run FWD/ Run REV) control. Current consumption is 6 mA. Digital Common – Return for digital I/O. Elec trically isolated (along with the digital – 04 I/O) from the rest of the drive. 05 DigIn TermBlk 05 Program with t065 [DigIn TermBlk 05]. Preset Freq t065 Current consumption is 6 mA. 06 Preset Freq Program with t066 [DigIn TermBlk 06]. DigIn TermBlk 06 t066 Current consumption is 6 mA. DigIn TermBlk 07/ Start Source 2 t067 Program with t067 [DigIn TermBlk 07]. 07 Pulse In Also functions as a Pulse Trai + Speed n input for reference or speed feedback. Requires an NPN pulse input. Maximum frequency is Reference2 100 kHz. Current consumption is 6 mA. DigIn TermBlk 08 Program with t068 [DigIn TermBlk 08]. t068 08 Jog Forward Current consumption is 6 mA. C1 – This terminal is tied to the RJ-45 port shield. Tie this terminal to – C1 a clean ground in order to improve noise immunity when using external communication peripherals. C2 C2 – This is the signal common for the communication signals. – S1 – Safety input 1. Current consumption is 6 mA. – Safety 1 S2 Safety 2 – Safety input 2. Current consumption is 6 mA. – S+ Safety +24V – +24V supply for safety circ uit. Internally tied to the +24V DC – source (Pin 11). – Referenced to Digital Common. – 11 +24V DC Drive supplied power for digital inputs. Maximum output current is 100 mA. n 520-UM001I-EN-E - July 2016 43 Rockwell Automation Publicatio

44 Chapter 1 Installation/Wiring Control I/O Terminal Designations Parameter No. Signal Default Description Referenced to Analog Common. P047 12 +10V DC – , P049 Drive supplied power for 0...10V external potentiometer. Maximum output current is 15 mA. 13 ±10V In Not Active , P047 , P049 For external 0-10V (unipolar) or ±10V (bipolar) input supply or , potentiometer wiper. t063 t062 , t065 t066 , , Input impedance: t093 , A459 , Ω Voltage source = 100 k A471 Ω Allowable potentiometer resistance range = 1...10 k Return for th e analog I/O. Electrically isolated (along with the 14 – Analog Common – analog I/O) from the rest of the drive. , P049 , Not Active 4-20mA In 15 P047 For external 4-20 mA input supply. t062 , t063 , Ω Input impedance = 250 , , t065 t066 A471 A459 , , t089 Analog Output OutFreq 0-10 16 The default analog output is 0-10V. To convert a current value, t088 change the Analog Output jumper to 0-20 mA. Program with analog value can be scaled t088 [Analog Out Sel]. Maximum with t089 [Analog Out High]. (10.5V) 4-20 mA = 525 Maximum Load: Ω (10 mA) Ω 0-10V = 1 k Motor Running Program with t069 [Opto Out1 Sel]. , t069 17 t070 , Opto Output 1 t075 Each Opto-Output is rated 30V DC 50 mA (Non-inductive). Program with t072 [Opto Out1 Sel]. 18 t072 , At Frequency , Opto Output 2 t073 t075 Each Opto-Output is rated 30V DC 50 mA (Non-inductive). – The emitters of the Optocoupler Outputs (1 and 2) are tied 19 Opto Common – together at Optocoupler Common. Electrically isolated from the rest of the drive. (1) See Footnote (1) on page 39 . Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 44

45 Chapter 1 Installation/Wiring I/O Wiring Examples I/O Connection Example [Speed Reference1] = 5 “0-10V Input” P047 Potentiometer Pot. Ω 1...10k Recommended 12 (2 W minimum) 13 14 Bipolar Analog Input Unipolar (Voltage) [Speed Reference1] = 5 “0-10V Input” P047 [Speed Reference1] = 5 “0-10V Input” impedance 0-10V, 100k P047 Ω and t093 [10V Bipolar Enbl] = 1 “Bi-Polar In” 4-20 mA, 250 Ω impedance 13 13 + ±10V 14 14 Common Common Unipolar (Current) [Speed Reference1] = 6 “4-20mA Input” P047 PowerFlex 523 Series B PowerFlex 523 Series A, PowerFlex 525 13 + 4-20 mA 14 14 Common Common 15 + Analog In 0-10V matched to the PTC Hot Resistance) to I/O Analog Input, PTC Wire the PTC and External Resistor (typically Terminals 12, 13, 14. For Drive Fault Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11. [DigIn TermBlk 05] = 12 “Aux Fault” t065 [Relay Out 2 Sel] = 10 “Above Anlg V” t081 [Relay Out 2 Level] = % Voltage Trip t082 R5 R6 11 12 R e R PTC (hot) 13 %V X 100 = Trip R + R PTC (hot) e 14 R PTC 05 n 520-UM001I-EN-E - July 2016 45 Rockwell Automation Publicatio

46 Installation/Wiring Chapter 1 I/O Connection Example Pulse Train Input PowerFlex 525 PowerFlex 523 PowerFlex 523 t065 [DigIn TermBlk 05] = 52 Pulse In Pulse In PowerFlex 525 t067 [DigIn TermBlk 07] Common Common 04 04 = 52 Pulse In 05 Pulse In Digital Digital Input Input DigIn TermBlk 07 Sel DigIn TermBlk 05 Sel 07 Use P047, P049 and P051 [Speed Referencex] to select pulse input. The device connected to terminal 5 (for PowerFlex 523) or terminal 7 (for PowerFlex 525) Jumper for DigIn TermBlk needs to be NPN or push-pull output driver. 05 or 07 Sel must be moved to Pulse In. External Supply (SRC) Internal Supply (SRC) 2 Wire SRC Control - Non-Reversing 11 P046 [Start Source 1] = 2 01 and t062 [DigIn TermBlk 01 02 02] = 48 Stop-Run Stop-Run 02 Input must be active for 04 the drive to run. When input is opened, the drive Common +24V will stop as specified by [Stop Mode]. P045 If desired, a User Supplied Each digital input draws 6 mA. 24V DC power source can be used. Refer to the “External Supply (SRC)” example. 2 Wire SNK Control - Internal Supply (SNK) Non-Reversing 01 02 Stop-Run 03 04 2 Wire SRC Control - External Supply (SRC) Internal Supply (SRC) Run FWD/Run REV 11 P046 [Start Source 1] = 2, 01 t062 [DigIn TermBlk 02] 01 02 02 = 48 and t063 [DigIn Stop-Run 03 Forward 03 TermBlk 03] = 50 Stop-Run 04 Forward Input must be active for Stop-Run Reverse the drive to run. When input is opened, the drive Stop-Run Reverse +24V Common will stop as specified by P045 [Stop Mode]. Each digital input draws 6 mA. If both Run Forward and Run Reverse inputs are closed at the same time, an undetermined state could occur. Internal Supply (SNK) 2 Wire SNK Control - Run FWD/Run REV 01 02 Stop-Run 03 Forward 04 Stop-Run Reverse Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 46

47 Installation/Wiring Chapter 1 Connection Example I/O 3 Wire SRC Control - External Supply (SRC) Internal Supply (SRC) Non-Reversing P046 [Start Source 1] = 2, Stop 11 Stop 01 t062 [DigIn TermBlk 02] 02 = 49 and t063 [DigIn 01 Start 02 TermBlk 03] = 51 Start 04 A momentary input will start the drive. A stop +24V Common input to I/O Terminal 01 will stop the drive as specified by [Stop P045 Each digital input draws 6 mA. Mode]. 3 Wire SNK Control - Internal Supply (SNK) Non-Reversing Stop 01 02 Start 04 External Supply (SRC) Internal Supply (SRC) 3 Wire SRC Control - Reversing 11 P046 [Start Source 1] = 2, Stop 01 t062 [DigIn TermBlk 02] Stop 01 02 = 49 and t063 [DigIn 02 03 TermBlk 03] = 51 Start 03 04 Start A momentary input will Direction start the drive. A stop Direction input to I/O Terminal 01 Common +24V will stop the drive as [Stop specified by P045 Each digital input draws 6 mA. Mode]. I/O Terminal 03 determines direction. 3 Wire SNK Control - Internal Supply (SNK) Reversing Stop 01 02 03 Start 04 Direction (1) Opto-Output 1 Opto Output (1 & 2) t069 [Opto Out1 Sel] determines Opto-Output 1 (I/O Terminal 17) operation. [Opto Out2 Sel] t072 determines Opto-Output 2 17 (I/O Terminal 18) operation. CR 19 When using Opto-Output with an inductive load +24V Common such as a relay, install a Each Opto-Output is rated 30V DC 50 mA (Non-inductive). recovery diode parallel to the relay as shown, to prevent damage to the output. n 520-UM001I-EN-E - July 2016 47 Rockwell Automation Publicatio

48 Chapter 1 Installation/Wiring I/O Connection Example (2) Analog Output [Analog Out Sel] = 0 through 23 t088 t088 [Analog Out Sel] match the analog output signal mode set in The Analog Output Select jumper must be set to determines analog output [Analog Out Sel]. t088 type and drive conditions. PowerFlex 523 Series B PowerFlex 525 0-10V, 1k Ω minimum 0-20 mA/4-20 mA, 525 Ω maximum 14 14 Common Common 15 + 16 + Feature is specific to PowerFlex 525 drives only (1) (2) Feature is not applicable to PowerFlex 523 series A drives. Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input 04 02 02 04 04 02 Connections Customer Inputs can be wired per External Supply (SRC). Customer Inputs Optional Ground Connection Stop, Reverse or Preset Speeds to multiple When connecting a single input such as Run, 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 13 14 13 14 13 14 12 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 each drive. All drives must be powered up (potentiometer wiper) should be daisy-chained to for the analog signal to be read correctly. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 48

49 Installation/Wiring Chapter 1 Start Source and Speed Reference Selection Start and Speed Reference Control 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 P047 speed source is determined by [Speed Reference1]. However, various inputs can override this selection, See below for the override priority. Drive will start and run at Purge Speed. Ye s Purge Input Enabled AND Active Direction is always FORWARD. No Drive will start and run at Jog Speed. Direction is from Terminal Ye s Ye s Drive stopped Jog Input Enabled Block REV terminal (03), (NOT running) AND Active Comms, OR FWD/REV determined by No Jog FWD/Jog REV command. No [Speed Referencex] = 11 or 12 (PIDx Output) Ye s Ye s Preset Inputs Active AND [PID x Ref Sel] = 7 (Preset Freq) No Run as specified by Run as specified by No [Preset Freq x]. [PIDx Output]. Start and Direction Start and Direction commands come from commands come from [Start Source x]. [Start Source x]. Start and Direction Ye s Ye s Run as specified by [Start Source 3] [Speed Reference3] command from [Speed Reference3]. (1) (1) (2) select select [Start Source 3]. No No Start and Direction Ye s Ye s Run as specified by [Start Source 2] [Speed Reference2] command from [Speed Reference2]. (1) (1) select select (2) [Start Source 2]. No No Start and Direction Run as specified by command from [Speed Reference1]. [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 50 for information on selecting the correct digital input. 49 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

50 Installation/Wiring Chapter 1 Digital Input Select ion for Start Source P048 P046 , P050 or If [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 and Direction [DigIn TermBlk [Start Source x] Ye s Ye s 02/03] = 48/49/50/51 command from = 2 (DigIn TrmBlk) (2-Wire or Terminal Block. 3-Wire) No No Drive will not start. Start and Direction command from [Start Source x]. 50 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

51 Installation/Wiring Chapter 1 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]. Alternative Accel/Decel rates can be made through digital inputs, communications and/or parameters. See below for the override priority. Ye s Accel/Decel always Purge Input Enabled Accel/Decel 1. AND Active No Ye s [Sync Time] is used Active [DigIn TermBlk xx] for Accel/Decel rate = 32 (Sync Enable) No Traverse Inc/Dec Traverse active if Ye s is used for [Max Traverse] > 0 Hz Accel/Decel rate No Terminal Block Jog Accel/Decel from Ye s Ye s Drive stopped Input Enabled AND [Jog Acc/Dec]. (NOT running) Active No No Input(s) is Accel/Decel 2 is active Ye s programmed as when input is selected Acc/Dec by Accel and Decel input. (2/3/4) No Accel/Decel 1/2/3/4 is Ye s Is speed controlled selected by the default by [Preset Freq x] [Preset Freq x] setting. No Active [Speed Referencex] = Comms Accel/Decel 1 or 2 is and Ye s selected according [Start Source x] = 3 “Serial/DSI” or to Comms. 4 “Network Opt” or 5 “EtherNet/IP” No Active Accel/Decel 1/2/3/4 is Ye s [Speed Referencex] selected according to (1) = 13 (Step Logic) Step Logic No Drive uses Accel 1 and Decel 1. Setting is specific to PowerFlex 525 drives only. (1) Rockwell Automation Publicatio 51 n 520-UM001I-EN-E - July 2016

52 Chapter 1 Installation/Wiring Compliance with the Low Voltage Directive and Electromagnetic Compatibility CE Conformity 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. ty are available online at: CE Declarations of Conformi http://www.rockwellautomation.com/products/certification/ . Low Voltage Directive (2006/95/EC and 2014/35/EU) • EN 61800-5-1 Adjustable speed electrical power drive systems – Part 5-1: Safety requirements – Electrical, thermal and energ y. Pollution Degree Ratings According to EN 61800-5-1 Pollution Description Degree 1 No pollution or only dry, non-conductive po llution occurs. The pollution has no influence. 2 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. 08/EC and 2014/30/EU) EMC Directive (2004/1 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 – Func tional 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 Appendix G Refer to for installation consideration related to Machinery Directive. ATEX Directive (94/9/EC and 2014/34/EU) EN 50495 – Safety devices required for the safe functioning of equipment • with respect to explosion risks. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 52

53 Installation/Wiring Chapter 1 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 on page 52 for descriptions of Degree Ratings According to EN 61800-5-1 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 low- voltage 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 55 ) to prevent interference, in addition to the installation requirements of this document. either be installed in a NEMA/UL Open Type drives must ATTENTION: supplementary enclosure or equipped with a “NEMA Type 1 Kit” to be CE compliant with respect to prot ection 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. 61800-5-1 and the Low Voltage Directive Installation Requirements Related to EN • 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). n 520-UM001I-EN-E - July 2016 53 Rockwell Automation Publicatio

54 Chapter 1 Installation/Wiring 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 Derating to maintain compliance with the CE LV Directive. See on page 18 . Guidelines for High Altitude • 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. to EN 61800-3 and the EMC Directive Installation Requirements Related • The drive must be earthed (grounded) as described in Connections and on page 55 General Grounding Requirements . See on page 20 Grounding 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 conduit box, or the shield may be conjunction with a conduit plate or clamped to an “EMC plate.” Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 54

55 Chapter 1 Installation/Wiring 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 on page 55 for compliance with radio frequency Installation Requirements emission limits for the specific standard and installation environment. Connections and Grounding (1) Shielded enclosure IP 30/NEMA 1/UL Type 1 l e S c s E option kit or EMC kit EMI fittings and metal conduit EMI filter U/T1 R/L1 L1' L1 V/T2 S/L2 L2' L2 W/T3 T/L3 L3' L3 Shielded motor cable Enclosure ground connection Building structure steel (1) the ible between the enclosure entry point and osure. Keep wire length as short as poss Some installations require a shielded encl EMI filter. PowerFlex 520-Series RF Emission Comp liance and Installation Requirements Standard/Limits Filter Type EN61800-3 Category C1 EN61800-3 Category C2 EN61800-3 Category C3 (I ≤ 100 A) EN61000-6-3 EN61000-6-4 CISPR11 Group 1 Class A CISPR11 Group 1 Class B CISPR11 Group 1 Class A (Input power > 20 kVA) (Input power ≤ 20 kVA) Internal – 10 m (33 ft) 20 m (66 ft) (1) 100 m (328 ft) 30 m (16 ft) 100 m (328 ft) External optional external filters. (1) See Appendix B for more information on Additional Installation Requirements This section provides information on additional requirements for category C1 and C2 installation, such as enclosures and EMC cores. EMC cores are included with: IMPORTANT al EMC filter (25x-xxxxN114) • drives that have an intern external EMC filter accessory kit (25-RFxxx) • An enclosure, shielded input cable, and EMC cores are not required to meet IMPORTANT category C3 requirements. n 520-UM001I-EN-E - July 2016 55 Rockwell Automation Publicatio

56 Chapter 1 Installation/Wiring Additional Installation Requirements Frame Category C2 Category C1 Size Enclosure Conduit or Shielded Conduit or Shielded EMC Cores Required EMC Cores Required Enclosure Cable @ Input (Included with product) Cable @ Input (Included with product) External EMC Filter, 0...120V 1-Phase Output 100...120V AC (-15%, +10%) – 1-Phase Input with ANoNo No NoNo No No BNoNo No NoNo 200...240V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...230V 3-Phase Output Yes No No No Input/Output A Yes Yes B Output only No No Input/Output Yes (1) 200...240V AC (-15%, +10%) – 1-Phase Input with Internal EMC Filter, 0...230V 3-Phase Output A* * * Yes No No B* * Yes No No * External EMC Filter, 0...230V 3-Phase Output 200...240V AC (-15%, +10%) – 3-Phase Input with Yes Yes Output only No No Input/Output A Yes Yes Output only No No Input/Output B C Yes Yes Output only No No Input/Output DYes No No No Input only Yes E Yes Yes Output only No No Input only 380...480V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...460V 3-Phase Output No A Yes Yes No No Input/Output B Yes No No Input/Output Yes No No Input only No Yes CYes No Yes Output only No No Input/Output D Yes Yes Yes No Yes No Input/Output E (1) Internal EMC Filter, 0...460V 3-Phase Output 380...480V AC (-15%, +10%) – 3-Phase Input with A * * * No No Input/Output * * * No No Input/Output B * * * Input/Output No No C D * * No No Input/Output * * E * No No Input/Output * 525...600V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...575V 3-Phase Output A Yes Yes No No No Input/Output B Yes No No No Input/Output Yes C Yes Yes No No No Input/Output D Yes Yes No No No Input/Output No E Yes Yes No Yes No An (*) indicates that EMC requirements are not met. (1) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 56

57 Installation/Wiring Chapter 1 Recommended Placement of EMC Cores Frame B Frame C Frame D Frame E Frame A With optional EMC plate (25-EMC-Fx) Ground cable CORE-E-1 CORE-E-3 CORE-xx-D-1 CORE-xx-B-1 CORE-xx-A-1 CORE-xx-C-1 CORE-E-2 CORE-xx-D-2 CORE-E-4 CORE-xx-B-2 CORE-xx-A-2 CORE-xx-C-2 Without EMC plate Ground cable CORE-E-3 CORE-E-1 CORE-E-4 CORE-E-2 CORE-xx-x-1 CORE-xx-x-2 Output cable from drive (Shielded) Input cable to drive (Shielded or Unshielded) Secure EMC core by Shows contact to using cable/zip ties shielded layer The ground cable/shield for both input and output must pass through the EMC core(s), except for the following: IMPORTANT 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 n 520-UM001I-EN-E - July 2016 57 Rockwell Automation Publicatio

58 Chapter 1 Installation/Wiring Notes: 58 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

59 2 Chapter Start Up 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. For information on... See page... Prepare for Drive Start-Up 59 62 Display and Control Keys 63 Viewing and Editing Parameters Drive Programming Tools 64 65 Smart Start-Up with Basic Program Group Parameters LCD Display with QuickView Technology 67 Using the USB Port 67 Read the section before proceeding. General Precautions IMPORTANT AT T E NT IO N : 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 ha zard 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. Drive Startup Task List Prepare for Drive Start-Up 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. n 520-UM001I-EN-E - July 2016 59 Rockwell Automation Publicatio

60 Start Up Chapter 2 6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your control wiring scheme. See the PowerFlex 523 Control I/O Wiring Block on page 38 and Diagram PowerFlex 525 Control I/O Wiring Block Diagram on page 42 for location. The default control scheme is Source (SRC). The Stop terminal is jumpered to IMPORTANT allow starting from the keypad or comms. If the control scheme is changed to Sink (SNK), the jumper must be remo ved 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. Wire the power input and output terminals. 8. 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? • Verify the input voltage to the drive. Verify if the drive is on a grounded 11. system. Ensure the MOV jumpers are in the correct position. See AC for more information. on page 19 Supply Source Considerations Apply power and reset the drive and communication adapters to factory 12. 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. Configure the basic program parameters related to the motor. See 13. Smart Start-Up with Basic Program Group Parameters on page 65 . Complete the autotune procedure for the drive. See parameter P040 14. [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 US B Por t on page 67 for more information. Otherwise, set the necessary parameters for your application using the LCD keypad interface, Connected Components Workbench, or RSLogix or Logix Designer 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 60

61 Chapter 2 Start Up 16. Verify the drive and motor perform as specified. • Verify that the Stop input is present or the drive will not start. If I/O Terminal 01 is used as a stop input, the jumper between I/O IMPORTANT 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. • Save a backup of the drive settings using the USB utility application. See 17. Using the US B Por t on page 67 for more information. 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. To disable reverse operation, see A544 [Reverse Disable]. IMPORTANT Fault Descriptions on page 159 If a fault appears on power up, see 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. 61 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

62 Chapter 2 Start Up Display and Control Keys PowerFlex 523 Menu Parameter Group and Description Basic Display Commonly viewed drive operating conditions. Basic Program D W F Commonly used programmable functions. Termi na l Bl o cks Programmable terminal functions. Communications Programmable communication functions. l e S s c E Logic (PowerFlex 525 only) Programmable logic functions. Advanced Display Advanced drive operating conditions. Advanced Program PowerFlex 525 Remaining programmable functions. Network Network functions that are shown only when a comm F W D card is used. ENET LINK Modified EtherNet/IP Functions from the other groups with values changed from default. Fault and Diagnostic Consists of list of codes for specific fault conditions. l e S E s c AppView and CustomView Functions from the other groups organized for specific applications. Control and Navigation Keys Display Description Display State ENET (PowerFlex 525 only) Off Adapter is not connected to the network. Adapter is connected to the network and drive is controlled Steady through Ethernet. Flashing Adapter is connected to the network but drive is not controlled through Ethernet. Off Adapter is not connected to the network. LINK (PowerFlex 525 only) 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. Description Name Key Scroll through user-selectable display parameters or groups. Up Arrow Increment values. Down Arrow Back one step in programming menu. Escape Cancel a change to a parameter value and exit Program Mode. s c E Advance one step in programming menu. Select e l S Select a digit when viewing parameter value. Advance one step in programming menu. Enter Save a change to a parameter value. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 62

63 Chapter 2 Start Up Key Description Name Used to reverse direction of the drive. Default is active. Reverse P048 and P050 [Start Source x] Controlled by parameters P046, and A544 [Reverse Disable]. Start 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. Stop 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]. The following is an example of basic integral keypad and display functions. This Viewing and Editing example provides basic navigation instructions and illustrates how to program Parameters a parameter. Step Example Display Key(s) 1. the last user-selected When power is applied, F W D Basic Display Group parameter number is briefly ER Z H T displayed with flashing characters. The display rameter’s current value. then defaults to that pa (Example shows the value of b001 [Output Freq] with the drive stopped.) 2. Press Esc to display the Basic Display Group parameter number shown on power-up. The F W D parameter number will flash. E s c Press Esc to enter the parameter group list. The 3. parameter group letter will flash. F W D E s c 4. Press the Up Arrow or Down Arrow to scroll or through the group list (b, P, t, C, L, d, A, f and F D W Gx). 5. Press Enter or Sel to enter a group. The right digit of the last viewed parameter in that group D F W or S e l will flash. Press the Up Arrow or Down Arrow to scroll 6. or through the parameter list. F D W 7. Press Enter to view the value of the parameter. VOLTS D F W Or Press Esc to return to the parameter list. Press Enter or Sel to enter Program Mode and 8. VOLTS edit the value. The right digit will flash and the D W F or e S l word Program on the LCD display will light up. PROGR A M 9. Press the Up Arrow or Down Arrow to change VOLTS or the parameter value. D F W A M PROGR n 520-UM001I-EN-E - July 2016 63 Rockwell Automation Publicatio

64 Chapter 2 Start Up Key(s) Step Example Display 10. If desired, press Sel to move from digit to digit VOLTS l S e or bit to bit. The digit or bit that you can change F D W will flash. M A PROGR 11. Press Esc to cancel a change and exit Program VOLTS F W D Mode. Or or c s E or Press Enter to save a change and exit Program VOLTS W D F Mode. The digit will stop flashing and the word Program on the LCD display will turn off. 12. Press Esc to return to the parameter list. Continue to press Esc to back out of the D W F programming menu. E c s change the display, then If pressing Esc does not b001 [Output Freq] is displayed. Press Enter or Sel to enter the group list again. Some features in the PowerFlex 520-series drive are not supported by older Drive Programming Tools configuration software tools. It is strongly recommended that customers using such tools migrate to RSLogix 5000 (version 17.0 or greater) or Logix Designer (version 21.0 or greater) with Add-On-Profile (AOP), or Connected Components Workbench (version 5.0 or greater) to enjoy a richer, full-featured configuration experience. For Automatic Device Configuration (ADC) support, RSLogix 5000 version 20.0 or greater is required. Description Catalog Nu mber/Release Version (1) Connected Components Workbench Version 5.0 or greater Logix Designer Version 21.0 or greater RSLogix 5000 Version 17.0 or greater – Built-in USB software tool (2) 22-SCM-232 Serial Converter Module (2) 1203-USB USB Converter Module (2) 22-HIM-C2S Remote Panel Mount, LCD Display (2) 22-HIM-A3 Remote Handheld, LCD Display Available as a free download at (1) http://ab.rockwellautomation.com/program mable-controllers/connected-components- . workbench-software limited to the linear c parameter groups (AppView, CustomView), and Co Does not support the new dynami (2) pyCat functionality is parameter list. Language Support Language RSLogix 5000/ Connected Components Keypad/LCD Display Workbench Logix Designer English Y Y Y French Y Y Y Spanish Y Y Y Italian Y Y Y German Y Y Y Japanese – Y – Portuguese Y Y – Chinese Simplified – Y Y Y – – Korean Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 64

65 Start Up Chapter 2 Connected Components RSLogix 5000/ Keypad/LCD Display Language Logix Designer Workbench (1) Y–– Polish (1) Y–– Tu r ki s h (1) Y–– Czech Due to a limitation of the LCD Display, some of the ch aracters for Polish, Turkish, and Czech will be modified. (1) The PowerFlex 520-series drive is designed so that start up is simple and efficient. Smart Start-Up with Basic The Basic Program Group contains the most commonly used parameters. See Program Group Parameters Programming and Parameters on page 71 for detailed descriptions of the parameters listed here, as well as the full list of available parameters. = Stop drive before changing this parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only. No. Parameter Min/Max Display/Options Default P030 [Language] 1/15 1 = English 1 2= Français Selects the language displayed. 3= Español Important: The setting takes effect after the drive 4 = Italiano is power cycled. 5= Deutsch = Reserved 6 7 = Português = Reserved 8 = Reserved 9 10 = Reserved 11 = Reserved 12 = Polish 13 = Reserved 14 = Turkish 15 = Czech [Motor NP Volts] Based on Drive Rating 1V P031 10V (for 200V Drives), 20V (for 400V Drives), 25V (for 600V Drives)/Drive Rated Volts Sets the motor nameplate rated volts. P032 [Motor NP Hertz] 15/500 Hz 1 Hz 60 Hz Sets the motor nameplate rated frequency. 0.1 A P033 [Motor OL Current] 0.0/(Drive Rated Amps x 2) Based on Drive Rating Sets the motor nameplate overload current. [Motor NP FLA] 0.0/(Drive Rated Amps x 2) 0.1 A Drive Rated Amps P034 Sets the motor nameplate FLA. 2/40 [Motor NP Poles] 4 1 P035 Sets the number of poles in the motor. P036 [Motor NP RPM] 0/24000 rpm 1 rpm 1750 rpm Sets the rated nameplate rpm of motor. Drive Rated Power P037 [Motor NP Power] 0.00/Drive Rated Power 0.01 kW PF 525 Sets the motor nameplate power. Used in PM regulator. 2 = “480V” P038 [Voltage Class] 2/3 3 3 = “600V” Sets the voltage class of 600V drives. Only applicable to 600V drives. n 520-UM001I-EN-E - July 2016 65 Rockwell Automation Publicatio

66 Start Up Chapter 2 = Stop drive before changing this parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only. No. Default Display/Options Min/Max Parameter P039 1 0 = “V/Hz” 0/4 [Torque Perf Mode] 1 = “SVC” Selects the motor control mode. 2 = “Economize” (1) 3 = “Vector” Setting is specific to PowerFlex 525 drives only. (1) (1)(2)(3) 4 = “PM Control” Setting is available in PowerFlex 525 FRN 5.xxx and (2) later. When P039 [Torque Perf Mode] is set to 4 and (3) 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. [Autotune] 0/2 0 = “Ready/Idle” 0 P040 1 = “Static Tune” Enables a static (not spinning) or dynamic (motor 2 = “Rotate Tune” spinning) autotune. 0.00/600.00 s [Accel Time 1] P041 0.01 s 10.00 s Sets the time for the drive to accel from 0 Hz to [Maximum Freq]. 10.00 s 0.01 s 0.00/600.00 s [Decel Time 1] P042 Sets the time for the drive to decel from [Maximum Freq] to 0 Hz. [Minimum Freq] 0.00/500.00 Hz 0.01 Hz 0.00 Hz P043 Sets the lowest frequency the drive outputs. 60.00 Hz 0.01 Hz 0.00/500.00 Hz [Maximum Freq] P044 Sets the highest frequency the drive outputs. (1) 0 0/11 0 = “Ramp, CF” P045 [Stop Mode] (1) 1= “Coast, CF” Stop command for normal stop. (1) = “DC Brake, CF” 2 (1) I/O Terminal 01 is always a stop input. Important: = “DCBrkAuto,CF” 3 The stopping mode is determined by the drive 4= “Ramp” setting. 5= “Coast” Important: The drive is shipped with a jumper 6= “DC Brake” installed between I/O Terminals 01 and 11. Remove 7= “DC BrakeAuto” (1) this jumper when using I/O Terminal 01 as a stop or 8= “Ramp+EM B,CF” enable input. 9= “Ramp+EM Brk” (1) 10 = “PointStp,CF” (1) Stop input also clears active fault. 11 = “PointStop” (1) 1 = “Keypad” 1/5 [Start Source 1] P046, P046 = 1 (2) P048 = 2 2 = “DigIn TrmBlk” P048, Sets the default control scheme used to start the P050 P050 = 3 (PowerFlex 523) 3 = “Serial/DSI” drive unless overriden by P048 [Start Source 2] or 4 = “Network Opt” 5 (PowerFlex 525) P050 [Start Source 3]. (3) 5 = “Ethernet/IP” When active, the Reverse key is also active unless (1) disabled by A544 [Reverse Disable]. ed, ensure that the digital If “DigIn TrmBlk” is select (2) inputs are properly configured. (3) Setting is specific to PowerFlex 525 drives only. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 66

67 Chapter 2 Start Up = Stop drive before changing this parameter. PF 525 = Parameter is specific to PowerFlex 525 drives only. Min/Max No. Parameter Display/Options Default P047, P047 = 1 = “Drive Pot” 1 1/16 [Speed Reference1] 2= “Keypad Freq” P049 = 5 P049, Sets the default speed command of the drive unless 3= “Serial/DSI” P051 = 3 (PowerFlex 523) P051 overridden by P049 [Speed Reference2] or P051 4= “Network Opt” 15 (PowerFlex 525) [Speed Reference3]. 5 = “0-10V Input” 6 = “4-20mA Input” Setting is specific to PowerFlex 525 drives only. (1) 7= “Preset Freq” (1) 8 = “Anlg In Mult” 9= “MOP” 10 = “Pulse Input” 11 = “PID1 Output” (1) 12 = “PID2 Output” (1) 13 = “Step Logic” (1) 14 = “Encoder” (1) 15 = “Ethernet/IP” (1) 16 = “Positioning” [Average kWh Cost] 0.00 0.00/655.35 0.01 P052 Sets the average cost per kWh. 0 [Reset To Defalts] 0 = “Ready/Idle” 0/4 P053 1 = “Param Reset” r factory defaults values. Resets parameters to thei 2 = “Factory Rset” After a Reset command, the value of this parameter 3 = “Power Reset” returns to zero. (1)(2)(3) 4 = “Module Reset” parameters are reset. NO Power cycle of the drive, (1) Setting is available in (2) PowerFlex 525 FRN 5.xxx and later. PowerFlex 523 FRN 3.xxx and Setting is available in (3) later. QuickView™ technolog y enables text to scroll across the LCD display of the LCD Display with QuickView PowerFlex 520-series drive. This allows you to easily configure parameters, Technology 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 on the display. Select 0 “Off ” to turn off text scrolling. See Language Support page 64 for the languages supported by the PowerFlex 520-series drive. The PowerFlex 520-series drive has a USB port that connects to a PC for the Using the USB Port purpose of upgrading drive firmware or uploading/downloading a parameter configuration. To use the USB feature of the PowerFlex 520-series drive, Microsoft .Net IMPORTANT Framework 2.0 and Windows XP or later is required. MainsFree Programming The MainsFree™ 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. n 520-UM001I-EN-E - July 2016 67 Rockwell Automation Publicatio

68 Chapter 2 Start Up Connecting a PowerFlex 520-series drive to a PC Control Module USB port USB Type B cable 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. Double-click on 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. Make sure your PC is powered by an AC power outlet or has a fully charged IMPORTANT battery before starting any operation. This prevents the operation from terminating before completion due to insufficient power. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 68

69 Start Up Chapter 2 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. n 520-UM001I-EN-E - July 2016 69 Rockwell Automation Publicatio

70 Chapter 2 Start Up Notes: 70 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

71 Chapter 3 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex 520- series drive parameters. Parameters are programmed (viewed/edited) using either the drive’s built-in keypad, RSLogix 5000 version 17.0 or greater, Logix Designer version 21.0 or greater, o r Connected Components Workbench version 5.0 or greater software. 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 (DriveTools SP™). When using these methods, the parameter list can only be displayed linearly, and there is no access to communications option card programming. For information on... See page... About Parameters 71 73 Parameter Groups Basic Display Group 78 Basic Program Group 83 Terminal Block Group 89 Communications Group 101 Logic Group 107 110 Advanced Display Group 115 Advanced Program Group Network Parameter Group 141 Modified Parameter Group 142 Fault and Diagnostic Group 142 AppView Parameter Groups 150 CustomView Parameter Group 151 152 Parameter Cross Reference by Name To configure a drive to operate in a specific way, drive parameters may have to be About Parameters set. Three types of parameters exist: •ENUM 2 or more items. Each item is ENUM parameters allow a selection from represented by a number. •Numeric Parameters These parameters have a single numerical value (0.1V ). n 520-UM001I-EN-E - July 2016 71 Rockwell Automation Publicatio

72 Programming and Parameters Chapter 3 •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. Some parameters are marked as follows. = Stop drive before changing this parameter. 2 3 = 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 for um la , ([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freqp]) Scaled Process Value (PV) = [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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 72

73 Chapter 3 Programming and Parameters Parameter Cross Reference by Name For an alphabetical listing of parameters, see Parameter Groups . on page 152 Basic Display Output Voltage b004 b012 Control Source Elapsed Run Time b019 b026 Accum CO2 Sav b005 DC Bus Voltage Contrl In Status b013 b020 Average Power b027 Drive Temp b006 Drive Status Dig In Status b014 b021 Elapsed kWh b028 Control Temp Fault 1 Code b007 Output RPM b015 b022 Elapsed MWh Control SW Ver b029 b001 Output Freq Fault 2 Code b008 b016 Output Speed b023 Energy Saved Commanded Freq b002 b009 Fault 3 Code b017 Output Power b024 Accum kWh Sav b003 Output Current Process Display b010 Power Saved b018 Accum Cost Sav b025 P038 Voltage Class Maximum Freq P044 P050 Start Source 3 Motor NP Hertz Basic Program P032 P039 Torque Perf Mode Stop Mode P045 P051 Speed Reference3 Motor OL Current P033 Autotune P040 Start Source 1 P046 Average kWh Cost P052 P034 Motor NP FLA Accel Time 1 P041 Speed Reference1 P047 P053 Reset To Defalts P035 Motor NP Poles P030 Language Decel Time 1 P042 Start Source 2 P048 P036 Motor NP RPM (1) P031 Motor NP Volts P037 Minimum Freq P043 P049 Speed Reference2 Motor NP Power (2) (1) t067 Analog Out High t089 t079 Relay 1 On Time Terminal Blocks Anlg Loss Delay t098 DigIn TermBlk 07 (1) (2) t068 Anlg Out Setpt t090 DigIn TermBlk 08 Relay 1 Off Time t080 t099 Analog In Filter (1) (1) t081 t069 Opto Out1 Sel t091 Anlg In 0-10V Lo Relay Out2 Sel t100 Sleep-Wake Sel (1) (1) t082 Relay Out2 Level t070 Opto Out1 Level t092 Anlg In 0-10V Hi t101 Sleep Level (1) (1) (1) DigIn TermBlk 02 t062 t084 Relay 2 On Time Opto Out2 Sel t072 t093 10V Bipolar Enbl Sleep Time t102 (1) (1) DigIn TermBlk 03 t063 t073 t085 Relay 2 Off Time Opto Out2 Level Anlg In V Loss t094 t103 Wake Level (1) t064 2-Wire Mode t075 EM Brk Off Delay Opto Out Logic t086 t095 Anlg In4-20mA Lo Wake Time t104 (1) DigIn TermBlk 05 t065 t105 t087 EM Brk On Delay Relay Out1 Sel t076 t096 Anlg In4-20mA Hi Safety Open En (1)(3) (2) DigIn TermBlk 06 t066 t106 t088 Relay Out1 Level SafetyFlt RstCfg t077 Analog Out Sel Anlg In mA Loss t097 (1) (1) (1) EN Gateway Cfg 3 EN Data In 1 Communications C153 Opt Data In 4 C164 C139 C128 EN Addr Sel (1) (1) (1) C140 C129 C154 EN Data In 2 EN Gateway Cfg 4 EN IP Addr Cfg 1 Opt Data Out 1 C165 (1) (1) (1) C130 EN Data In 3 C155 C141 EN Rate Cfg EN IP Addr Cfg 2 Opt Data Out 2 C166 (1) (1) (1) C131 C143 EN Comm Flt Actn EN Data In 4 C156 EN IP Addr Cfg 3 Opt Data Out 3 C167 (1) (1) (1) Comm Write Mode C121 C157 C132 C144 EN Idle Flt Actn EN IP Addr Cfg 4 EN Data Out 1 Opt Data Out 4 C168 (1) (1) (1) (1) C122 Cmd Stat Select C145 EN Data Out 2 C133 EN Flt Cfg Logic C158 EN Subnet Cfg 1 MultiDrv Sel C169 (1) (1) (1) C123 RS485 Data Rate C146 EN Subnet Cfg 2 EN Flt Cfg Ref C134 C159 EN Data Out 3 C171 Drv 1 Addr (1) (1) (1) RS485 Node Addr C124 C135 C147 C160 EN Flt Cfg DL 1 EN Subnet Cfg 3 EN Data Out 4 Drv 2 Addr C172 (1) (1) C125 Comm Loss Action EN Flt Cfg DL 2 C148 C136 EN Subnet Cfg 4 Opt Data In 1 C161 C173 Drv 3 Addr (1) (1) C126 Comm Loss Time Opt Data In 2 EN Gateway Cfg 1 C162 EN Flt Cfg DL 3 C137 C149 C174 Drv 4 Addr (1) (1) RS485 Format C127 C138 C150 C163 EN Flt Cfg DL 4 EN Gateway Cfg 2 Opt Data In 3 DSI I/O Cfg C175 (1) L182 Stp Logic 2 L190 Stp Logic Time 0 Logic L196 Stp Logic Time 6 Step Units 4 L208 Stp Logic 3 L183 L191 Stp Logic Time 1 Stp Logic Time 7 L197 L210 Step Units 5 Stp Logic 4 L184 Stp Logic Time 2 L192 L200 Step Units 0 Step Units 6 L212 Stp Logic 5 L185 L193 Stp Logic Time 3 Step Units 1 L202 Step Units 7 L214 Stp Logic 0 L180 L186 Stp Logic 6 Stp Logic Time 4 L194 Step Units 2 L204 L181 Stp Logic 1 Stp Logic 7 L187 L195 Stp Logic Time 5 Step Units 3 L206 (1) (2)(4) d385 d392 RdyBit Mode Act PID2 Fdbk Displ Advanced Display d363 Elapsed Time-min d376 Speed Feedback (2)(3) (2) (1) PID2 Setpnt Disp Drive Status 2 d386 d393 d378 Counter Status d364 Encoder Speed (2)(3) (1) d394 d387 Position Status Dig Out Status DC Bus Ripple d380 Timer Status d365 (1) d388 Units Traveled H Output Powr Fctr d381 d367 Drive Type (1) d360 Analog In 0-10V Units Traveled L d389 To rq u e Cu r re n t d 3 8 2 Testpoint Data d368 d361 Analog In 4-20mA d390 Fiber Status d383 PID1 Fdbk Displ d369 Motor OL Level (1) Elapsed Time-hr d362 d391 Stp Logic Status PID1 Setpnt Disp d384 Slip Hz Meter d375 n 520-UM001I-EN-E - July 2016 73 Rockwell Automation Publicatio

74 Chapter 3 Programming and Parameters (1)(3) (1) Advanced Program A519 A478 PID 2 Preload PM HIFI NS Cur A442 Accel Time 2 Reset Meters A555 (1) (1)(3) PID 2 Invert Err PM Bus Reg Kd A520 A479 Decel Time 2 A443 Te x t S c ro l l A 5 5 6 (1) Freq 1 Kp A481 Process Disp Lo A521 A444 Accel Time 3 Out Phas Loss En A557 (1) (1) A522 A558 Process Disp Hi A482 Freq 1 Ki A445 Decel Time 3 Positioning Mode (1) (1) A410 Preset Freq 0 A559 A523 Freq 2 Kp Counts Per Unit Testpoint Sel A483 A446 Accel Time 4 (1) (1) Preset Freq 1 A411 A524 A560 Freq 2 Ki Enh Control Word A484 Current Limit 1 A447 Decel Time 4 (1) (1) (1) Preset Freq 2 A412 A525 A485 A561 Freq 3 Kp Home Save Current Limit 2 A448 Skip Frequency 1 (1) (1) A413 Preset Freq 3 Find Home Freq Freq 3 Ki A486 Shear Pin1 Level A526 A562 Skip Freq Band 1 A449 (1)(3) (1) Preset Freq 4 A414 A527 A563 A487 Shear Pin 1 Time Find Home Dir PM FWKn 1 Kp Skip Frequency 2 A450 (1) (1) (1)(3) A415 Preset Freq 5 A528 A564 Encoder Pos Tol PM FWKn 2 Kp A488 Shear Pin2 Level Skip Freq Band 2 A451 (1) (1) (1)(3) (1) A416 Preset Freq 6 Shear Pin 2 Time A489 A452 A529 PM Control Cfg Pos Reg Filter A565 Skip Frequency 3 (1) (1) (1) A417 Preset Freq 7 A490 A453 A566 Pos Reg Gain Load Loss Level Skip Freq Band 3 Boost Select A530 (1) (1) (1) A418 Preset Freq 8 Max Traverse A454 Skip Frequency 4 A567 Load Loss Time A491 A531 Start Boost (1) (1) A419 Preset Freq 9 Skip Freq Band 4 A455 A492 Stall Fault Time A 5 6 8 Tr ave r s e I n c Break Voltage A532 (1) A420 Preset Freq 10 A 5 6 9 A456 PID 1 Trim Hi A493 Motor OL Select Tr ave r s e D e c A533 Break Frequency (1) Preset Freq 11 A421 PID 1 Trim Lo A494 A570 Motor OL Ret P Jump A457 A534 Maximum Voltage (1) (2) A422 Preset Freq 12 A535 A458 Drive OL Mode Sync Time A571 PID 1 Trim Sel A495 Motor Fdbk Type (1) (1) A423 Preset Freq 13 A536 Encoder PPR IR Voltage Drop PID 1 Ref Sel A459 Speed Ratio A572 A496 (1) (2)(5) A424 Preset Freq 14 A537 A573 Pulse In Scale Mtr Options Cfg A497 Flux Current Ref PID 1 Fdback Sel A460 (1) (2)(4) (1) (2) Preset Freq 15 A425 A498 A574 A538 Ki Speed Loop RdyBit Mode Cfg A461 PID 1 Prop Gain Motor Rr (2)(3) (2) (1) Keypad Freq A426 A575 A499 A539 Kp Speed Loop Flux Braking En Motor Lm PID 1 Integ Time A462 (2)(3) (1) MOP Freq A427 Var PWM Disable Phase Loss Level Motor Lx A576 A540 A500 PID 1 Diff Rate A463 (1)(3) (1)(3) A428 MOP Reset Sel PM IR Voltage A580 Current Loop BW Auto Rstrt Tries A501 A541 A464 PID 1 Setpoint (1)(3) (1)(3) A429 MOP Preload A581 A502 PM Stable 1 Freq A542 Auto Rstrt Delay PM IXd Voltage A465 PID 1 Deadband (1)(3) (1)(3) A430 MOP Time A582 A503 PM Stable 2 Freq PM IXq Voltage A543 Start At PowerUp PID 1 Preload A466 (1)(3) (1)(3) A431 Jog Frequency A583 PM BEMF Voltage PM Stable 1 Kp A504 Reverse Disable A544 A467 PID 1 Invert Err (1) (1) (1)(3) A432 Jog Accel/Decel A584 A509 A468 Speed Reg Sel PM Stable 2 Kp A545 Flying Start En PID 2 Trim Hi (1) (1)(3) (1) Purge Frequency A433 A469 A510 A585 PID 2 Trim Lo Freq 1 PM Stable Brk Pt FlyStrt CurLimit A546 (1) (1)(3) (1) A434 DC Brake Time A470 PM Stepload Kp A511 A586 PID 2 Trim Sel Freq 1 BW Compensation A547 (1)(3) (1) (1) A435 DC Brake Level A587 A471 A512 Freq 2 PM 1 Efficiency PID 2 Ref Sel A548 Power Loss Mode (1)(3) (1) (1) DC Brk [email protected] A436 PID 2 Fdback Sel PM 2 Efficiency A588 A472 Freq 2 BW A513 Half Bus Enable A549 (1) (1) (1)(3) A437 DB Resistor Sel A514 PM Algor Sel A473 A589 PID 2 Prop Gain Freq 3 Bus Reg Enable A550 (1) (1) DB Threshold A438 A474 A515 PID 2 Integ Time Freq 3 BW A551 Fault Clear (1)(3) (1) A439 S Curve % A516 A475 PM Initial Sel PID 2 Diff Rate Program Lock A552 (1) (1)(3) PWM Frequency A440 PID 2 Setpoint A476 A517 PM DC Inject Cur Program Lock Mod A553 (1) (1)(3) (1) A441 Droop [email protected] FLA A518 A477 PID 2 Deadband PM Align Time A554 Drv Ambient Sel 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 th eir values changed from the factory default. a parameter has its value changed back to the When a parameter has its default value changed, it is automatica lly added to this group. When factory default, it is automatically removed from this group. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 74

75 Chapter 3 Programming and Parameters (1) (1) Fault and Diagnostic F685 F625 Fault 5 Time-min F650 EN Rate Act Fault10 Current Drv 1 Reference F710 (1) Fault 1 BusVolts F651 DSI I/O Act F626 Fault 6 Time -min F686 F711 Drv 1 Logic Sts (1) (1) HW Addr 1 Fault 7 Time -min Fault 2 BusVolts F627 F687 F652 F712 Drv 1 Feedback (1) (1) F628 F688 Fault 3 BusVolts F653 Fault 8 Time -min HW Addr 2 Drv 2 Logic Cmd F713 (1) (1) Fault 4 Code F604 HW Addr 3 F689 F629 Fault 9 Time -min Fault 4 BusVolts F654 F714 Drv 2 Reference (1) (1) F605 Fault 5 Code F630 F690 HW Addr 4 Fault10 Time-min Fault 5 BusVolts F655 F715 Drv 2 Logic Sts (1) (1) Fault 6 Code F606 F656 F691 F631 HW Addr 5 Fault 1 Freq Fault 6 BusVolts Drv 2 Feedback F716 (1) (1) Fault 7 Code F607 HW Addr 6 Fault 7 BusVolts F657 F692 Fault 2 Freq F632 F717 Drv 3 Logic Cmd (1) (1) Fault 8 Code F608 F693 F658 EN IP Addr Act 1 Fault 8 BusVolts F633 Fault 3 Freq F718 Drv 3 Reference (1) (1) Fault 9 Code F609 Fault 9 BusVolts F659 EN IP Addr Act 2 F694 Fault 4 Freq F634 Drv 3 Logic Sts F719 (1) (1) Fault10 Code F610 F660 EN IP Addr Act 3 Fault10 BusVolts F695 F635 Fault 5 Freq Drv 3 Feedback F720 (1) (1) Fault 1 Time-hr F611 F696 F636 F661 EN IP Addr Act 4 Status @ Fault 1 Fault 6 Freq F721 Drv 4 Logic Cmd (1) (1) Fault 2 Time-hr F612 F697 EN Subnet Act 1 F637 Fault 7 Freq F662 Status @ Fault 2 Drv 4 Reference F722 (1) (1) F613 Fault 3 Time-hr Fault 8 Freq F698 EN Subnet Act 2 F638 F663 Status @ Fault 3 Drv 4 Logic Sts F723 (1) (1) F614 Fault 4 Time-hr F699 F639 EN Subnet Act 3 Fault 9 Freq Status @ Fault 4 F664 Drv 4 Feedback F724 (1) (1) (1) Fault 5 Time-hr F615 F725 Fault10 Freq EN Subnet Act 4 F640 F700 F665 Status @ Fault 5 EN Rx Overruns (1) (1) (1) (1) F616 Fault 6 Time-hr EN Gateway Act 1 F666 F701 F641 Fault 1 Current EN Rx Packets F726 Status @ Fault 6 (1) (1) (1) (1) F617 Fault 7 Time-hr F702 F727 F667 F642 Fault 2 Current EN Gateway Act 2 EN Rx Errors Status @ Fault 7 (1) (1) (1) (1) F618 Fault 8 Time-hr F703 EN Tx Packets F668 EN Gateway Act 3 F728 Status @ Fault 8 F643 Fault 3 Current (1) (1) (1) (1) Fault 9 Time-hr F619 Status @ Fault 9 F704 F669 F729 EN Gateway Act 4 EN Tx Errors Fault 4 Current F644 (1) (1) (1) F620 Fault10 Time-hr F670 F730 F705 Status @ Fault10 Drv 0 Logic Cmd EN Missed IO Pkt F645 Fault 5 Current (1) F621 Fault 1 Time-min DSI Errors F681 Comm Sts - DSI F731 F646 Drv 0 Reference F706 Fault 6 Current (1) F622 Fault 2 Time-min F647 F682 Comm Sts - Opt Fault 7 Current F707 Drv 0 Logic Sts (1) (1) Fault 3 Time-min F623 F683 F648 Fault 8 Current Com Sts-Emb Enet Drv 0 Feedback F708 (1) (1) Fault 4 Time-min F624 Fault 9 Current EN Addr Src F649 F684 F709 Drv 1 Logic Cmd (1) Parameter is specific to PowerFlex 525 drives only. PowerFlex 523 FRN 3.xxx and later. (2) Parameter is also available in (3) Parameter is available in PowerFlex 525 FRN 5.xxx and later. Parameter is available in PowerFlex 525 FRN 3.xxx and later. (4) Parameter is available in PowerFlex 525 FRN 2.xxx and later. (5) n 520-UM001I-EN-E - July 2016 75 Rockwell Automation Publicatio

76 Programming and Parameters Chapter 3 AppView Parameter Groups 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 for more on page 150 information. Conveyor Motor NP Volts P031 P042 Decel Time 1 t063 DigIn TermBlk 03 t097 Anlg In mA Loss P032 Motor NP Hertz P043 Minimum Freq Opto Out1 Sel t069 Slip Hz Meter d375 P033 Motor OL Current Maximum Freq P044 Relay Out1 Sel t076 Preset Freq 0 A410 P034 Motor NP FLA Stop Mode P045 t091 Anlg In 0-10V Lo Jog Frequency A431 Language P030 P035 Motor NP Poles Start Source 1 P046 Anlg In 0-10V Hi t092 A432 Jog Accel/Decel b001 Output Freq P040 Autotune Speed Reference1 P047 t095 Anlg In4-20mA Lo S Curve % A439 Commanded Freq b002 Accel Time 1 P041 DigIn TermBlk 02 t062 Anlg In4-20mA Hi t096 A544 Reverse Disable Commanded Freq b002 Mixer P035 Motor NP Poles Stop Mode P045 Anlg In4-20mA Lo t095 b003 Output Current Autotune P040 Start Source 1 P046 Anlg In4-20mA Hi t096 P031 Motor NP Volts P041 Accel Time 1 Speed Reference1 P047 t097 Anlg In mA Loss P032 Motor NP Hertz P042 Decel Time 1 t076 Relay Out1 Sel A410 Preset Freq 0 P030 Language P033 Motor OL Current Minimum Freq P043 t091 Anlg In 0-10V Lo A492 Stall Fault Time b001 Output Freq P034 Motor NP FLA Maximum Freq P044 t092 Anlg In 0-10V Hi Compressor Motor NP Hertz P032 Maximum Freq P044 t091 Anlg In 0-10V Lo A543 Start At PowerUp P033 Motor OL Current P045 Stop Mode t092 Anlg In 0-10V Hi Reverse Disable A544 P034 Motor NP FLA P046 Start Source 1 Anlg In4-20mA Lo t095 A548 Power Loss Mode P035 Motor NP Poles Speed Reference1 P047 t096 Anlg In4-20mA Hi A549 Half Bus Enable Language P030 Autotune P040 Relay Out1 Sel t076 t097 Anlg In mA Loss b001 Output Freq Accel Time 1 P041 t088 Analog Out Sel Preset Freq 0 A410 b002 Commanded Freq P042 Decel Time 1 t089 Analog Out High Auto Rstrt Tries A541 Motor NP Volts P031 Minimum Freq P043 t090 Anlg Out Setpt A542 Auto Rstrt Delay Centrifugal Pump P033 Motor OL Current P046 Start Source 1 Anlg In4-20mA Hi t096 A463 PID 1 Diff Rate P034 Motor NP FLA P047 Speed Reference1 t097 Anlg In mA Loss PID 1 Setpoint A464 P035 Motor NP Poles Relay Out1 Sel t076 A410 Preset Freq 0 PID 1 Deadband A465 P040 Autotune t088 Analog Out Sel PID 1 Trim Hi A456 A466 PID 1 Preload P030 Language Accel Time 1 P041 t089 Analog Out High A457 PID 1 Trim Lo Auto Rstrt Tries A541 b001 Output Freq P042 Decel Time 1 t090 Anlg Out Setpt A459 PID 1 Ref Sel Auto Rstrt Delay A542 b002 Commanded Freq Start At PowerUp A543 P043 Minimum Freq Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 P031 Motor NP Volts Reverse Disable A544 Maximum Freq P044 t092 Anlg In 0-10V Hi A461 PID 1 Prop Gain P032 Motor NP Hertz Stop Mode P045 t095 Anlg In4-20mA Lo PID 1 Integ Time A462 P033 Motor OL Current Blower/Fan Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463 Motor NP FLA P034 P047 Speed Reference1 Anlg In mA Loss t097 PID 1 Setpoint A464 P035 Motor NP Poles t076 Relay Out1 Sel A410 Preset Freq 0 PID 1 Deadband A465 P040 Autotune Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466 P030 Language Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541 Output Freq b001 P042 Decel Time 1 t090 Anlg Out Setpt PID 1 Ref Sel A459 Auto Rstrt Delay A542 b002 Commanded Freq Minimum Freq P043 Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 A543 Start At PowerUp P031 Motor NP Volts P044 Maximum Freq t092 Anlg In 0-10V Hi A461 PID 1 Prop Gain Reverse Disable A544 Motor NP Hertz P032 Stop Mode P045 t095 Anlg In4-20mA Lo PID 1 Integ Time A462 A545 Flying Start En Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 76

77 Programming and Parameters Chapter 3 Extruder P032 Motor NP Hertz Stop Mode P045 t095 Anlg In4-20mA Lo A536 Encoder PPR P033 Motor OL Current Start Source 1 P046 t096 Anlg In4-20mA Hi Pulse In Scale A537 Motor NP FLA P034 P047 Speed Reference1 Anlg In mA Loss t097 A538 Ki Speed Loop Motor NP Poles P035 Relay Out1 Sel t076 d375 Slip Hz Meter A539 Kp Speed Loop P030 Language Autotune P040 Analog Out Sel t088 d376 Speed Feedback Power Loss Mode A548 b001 Output Freq P041 Accel Time 1 Analog Out High t089 d378 Encoder Speed A549 Half Bus Enable b002 Commanded Freq Decel Time 1 P042 t090 Anlg Out Setpt A410 Preset Freq 0 b003 Output Current Minimum Freq P043 t091 Anlg In 0-10V Lo Stall Fault Time A492 P031 Motor NP Volts Maximum Freq P044 t092 Anlg In 0-10V Hi A535 Motor Fdbk Type (1) Stop Mode P045 Stp Logic 5 L185 Positioning L212 Step Units 6 Jog Accel/Decel A432 Start Source 1 P046 L186 Stp Logic 6 L214 Step Units 7 A438 DB Threshold Speed Reference1 P047 Stp Logic 7 L187 d375 Slip Hz Meter S Curve % A439 DigIn TermBlk 02 t062 Stp Logic Time 0 L190 Speed Feedback d376 Motor Fdbk Type A535 P030 Language t063 DigIn TermBlk 03 Stp Logic Time 1 L191 Encoder Speed d378 A536 Encoder PPR b001 Output Freq t065 DigIn TermBlk 05 Stp Logic Time 2 L192 d388 Units Traveled H A537 Pulse In Scale Commanded Freq b002 t066 DigIn TermBlk 06 Stp Logic Time 3 L193 Units Traveled L d389 Ki Speed Loop A538 P031 Motor NP Volts Opto Out1 Sel t069 L194 Stp Logic Time 4 A410 Preset Freq 0 Kp Speed Loop A539 Motor NP Hertz P032 Opto Out2 Sel t072 Stp Logic Time 5 L195 A411 Preset Freq 1 Bus Reg Enable A550 Motor OL Current P033 Relay Out1 Sel t076 Stp Logic Time 6 L196 A412 Preset Freq 2 A558 Positioning Mode P034 Motor NP FLA EM Brk Off Delay t086 L197 Stp Logic Time 7 Preset Freq 3 A413 Counts Per Unit A559 Motor NP Poles P035 t087 EM Brk On Delay Step Units 0 L200 A414 Preset Freq 4 A560 Enh Control Word Autotune P040 L180 Stp Logic 0 Step Units 1 L202 Preset Freq 5 A415 Find Home Freq A562 P041 Accel Time 1 L181 Stp Logic 1 L204 Step Units 2 Preset Freq 6 A416 A563 Find Home Dir Decel Time 1 P042 L182 Stp Logic 2 Step Units 3 L206 A417 Preset Freq 7 Encoder Pos Tol A564 P043 Minimum Freq Stp Logic 3 L183 L208 Step Units 4 Preset Freq 8 A418 A565 Pos Reg Filter P044 Maximum Freq Stp Logic 4 L184 L210 Step Units 5 A431 Jog Frequency Pos Reg Gain A566 Text il e/Fiber P034 Motor NP FLA DigIn TermBlk 02 t062 d375 Slip Hz Meter A567 Max Traverse P035 Motor NP Poles t063 DigIn TermBlk 03 Fiber Status d390 A 5 6 8 Tr ave r s e I n c Autotune P040 t069 Opto Out1 Sel Preset Freq 0 A410 A 5 6 9 Tr ave r s e D e c Accel Time 1 P041 Opto Out2 Sel t072 A431 Jog Frequency P Jump A570 P030 Language Decel Time 1 P042 t076 Relay Out1 Sel A432 Jog Accel/Decel Sync Time A571 b001 Output Freq P043 Minimum Freq Anlg In 0-10V Lo t091 S Curve % A439 Speed Ratio A572 b002 Commanded Freq Maximum Freq P044 t092 Anlg In 0-10V Hi Reverse Disable A544 P031 Motor NP Volts P045 Stop Mode Anlg In4-20mA Lo t095 A548 Power Loss Mode Motor NP Hertz P032 Start Source 1 P046 t096 Anlg In4-20mA Hi A549 Half Bus Enable P033 Motor OL Current P047 Speed Reference1 t097 Anlg In mA Loss A550 Bus Reg Enable This AppView parameter group is specific to PowerFlex 525 drives only. (1) CustomView Parameter Group PowerFlex 520-series drives include a CustomView™ parameter group for you to store frequently used parameters for your application. See CustomView on page 151 for more information. Parameter Group Custom Group This group can store up to 100 parameters. n 520-UM001I-EN-E - July 2016 77 Rockwell Automation Publicatio

78 Chapter 3 Programming and Parameters Basic Display Group , b002 , b010 , P043 , P044 , b001 Related Parameter(s): P050 , P052 [Output Freq] P048 , V & W). Does not include slip frequency. Output frequency present at T1, T2 & T3 (U Values Default: Read Only 0.00/[Maximum Freq] Min/Max: 0.01 Hz Display: [Commanded Freq] Related Parameter(s): b001 , b013 , P043 , b002 , P048 , P050 , P052 P044 Value of the active frequency command even if the drive is not running. on page 49 Start and Speed Reference Control The frequency command can come from a number of sources. See for more information. IMPORTANT Read Only Default: Values Min/Max: 0.00/[Maximum Freq] Display: 0.01 Hz [Output Current] b003 Output current present at T1, T2 & T3 (U, V & W). Read Only Default: Values Min/Max: 0.00/(Drive Rated Amps x 2) Display: 0.01 A [Output Voltage] Related Parameter(s): P031 , A530 , A534 b004 Output voltage present at T1, T2 & T3 (U, V & W). Values Default: Read Only Min/Max: 0.0/Drive Rated Volts Display: 0.1V b005 [DC Bus Voltage] Filtered DC bus voltage level of the drive. Default: Read Only Values Min/Max: 0/1200VDC Display: 1VDC b006 [Drive Status] Related Parameter(s): A544 Present operating condition of the drive. 1 = True/Active, 0 = False/Inactive Digit 1 Running For ward Digit 2 Accelerating Digit 3 Decelerating Digit 4 (1) SafetyActive Digit 5 (1) Setting is specific to PowerFlex 525 drives only. Read Only Default: Values 00000/11111 Min/Max: 00000 Display: Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 78

79 Programming and Parameters Chapter 3 (continued) Basic Display Group b007 Related Parameter(s): F604 - F610 [Fault 1 Code] b008 [Fault 2 Code] [Fault 3 Code] b009 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. Fault and Diagnostic Group for more information. See Default: Values Read Only F0/F127 Min/Max: F0 Display: b010 Related Parameter(s): b001 , A481 , A482 [Process Display] 32 32 bit parameter. Output frequency scaled by [Process Disp Lo] and A482 [Process Disp Hi]. A481 Scaled Process Value (PV) = (([Process Disp inimum Freq]) Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [M Values Default: Read Only Min/Max: 0.00/9999.00 0.01 Display: b012 [Control Source] Related Parameter(s): P046 , P047 , P048 , P049 , P050 , P051 , t062 A425 t063 , t065 - t068 , L180 - L187 , A410 - , [Speed Referencex]. , Active source of the Start Command and Frequenc y Command. Normally defined by the settings of P046 , P048 , P050 [Start Source x] and P047 P051 P049 , for more information. on page 49 See Start and Speed Reference Control Example Start Command Source Digit 1 Display reads... Description 1 = Keypad 2004 Start source comes from Network Opt and Frequency source is Purge. t065 , t063 , - t068 ) t062 2 = DigIn TrmBlk (Parameters 3 = Serial/DSI d Frequency source comes from PID1 Output. Start source comes from Serial/DSI an 113 (1) 4 = Network Opt (2) Start source and Frequency source comes from EtherNet/IP. 155 5 = EtherNet/IP Start source comes from DigIn TrmBlk and Frequency source from 0-10V Input. 052 Frequency Command Source Digit 2 & 3 00 = Other 011 Start source comes from Keypad and Frequency source comes from Drive Pot. 01 = Drive Pot 02 = Keypad 03 = Serial/DSI (1) 04 = Network Opt 05 = 0-10V Input 06 = 4-20mA Input - ) A425 07 = Preset Freq (Parameters A410 (2) 08 = Anlg In Mult 09 = MOP 10 = Pulse Input 11 = PID1 Output (2) 12 = PID2 Output (1) ) L180 13 = Step Logic (Parameters - L187 (2) 14 = Encoder (2) 15 = EtherNet/IP (2) 16 = Positioning Digit 4 Frequency Command Source 0 = Other (Digit 2 & 3 are used. Digit 4 is not shown.) 1 = Jog 2 = Purge Not Used Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or (1) 25-COMM-P adapters as the Start source and/or Frequency source. (2) Setting is specific to PowerFlex 525 drives only. Values Default: Read Only 0000/2165 Min/Max: Display: 0000 79 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

80 Programming and Parameters Chapter 3 Basic Display Group (continued) Related Parameter(s): b002 , P044 , P045 [Contrl In Status] b013 DB transistor. State of the digital terminal bl ocks 1...3 and Actual control commands may come from a source other than the control terminal block. IMPORTANT 1 = Closed State, 0 = Open State Digit 1 DigIn TBlk 1 DigIn TBlk 2 Digit 2 DigIn TBlk 3 Digit 3 (1) DB Trans On Digit 4 Not Used (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. Read Only Default: Values Min/Max: 0000/1111 0000 Display: t065 - t068 Related Parameter(s): [Dig In Status] b014 State of the programmable digital inputs. 1 = Closed State, 0 = Open State DigIn TBlk 5 Digit 1 Digit 2 DigIn TBlk 6 (1) DigIn TBlk 7 Digit 3 (1) DigIn TBlk 8 Digit 4 Not Used (1) Setting is specific to PowerFlex 525 drives only. Default: Values Read Only 0000/1111 Min/Max: 0000 Display: b015 [Output RPM] P035 Related Parameter(s): P035 Current output frequency in rpm. Scale is based on [Motor NP Poles]. Values Default: Read Only 0/24000 rpm Min/Max: 1 rpm Display: b016 [Output Speed] Related Parameter(s): P044 Current output frequency in %. Scale is 0% at 0.00 Hz to 100% at P044 [Maximum Freq]. Values Read Only Default: Min/Max: 0.0/100.0% Display: 0.1% b017 [Output Power] Related Parameter(s): b018 Output power present at T1, T2 & T3 (U, V & W). Values Default: Read Only Min/Max: 0.00/(Drive Rated Power x 2) Display: 0.01 kW Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 80

81 Programming and Parameters Chapter 3 (continued) Basic Display Group Related Parameter(s): b017 b018 [Power Saved] ive compared to an across the line starter. Instantaneous power savings of using this dr Values Read Only Default: Min/Max: 0.00/655.35 kW Display: 0.01 kW b019 [Elapsed Run time] Related Parameter(s): A555 Accumulated time drive is outputting power. Time is displayed in 10 hour increments. Default: Values Read Only 0/65535 x 10 hr Min/Max: 1 = 10 hr Display: [Average Power] Related Parameter(s): A555 b020 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 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: Values Read Only Min/Max: 0.0/100.0 kWh Display: 0.1 kWh [Elapsed MWh] b022 b021 Related Parameter(s): Accumulated output energy of the drive. Values Default: Read Only Min/Max: 0.0/6553.5 MWh Display: 0.1 MWh b023 Related Parameter(s): A555 [Energy Saved] Total energy savings of using this drive compared to an across the line starter since the last reset of the meters. Values Default: Read Only Min/Max: 0.0/6553.5 kWh Display: 0.1 kWh b024 [Accum kWh Sav] Related Parameter(s): b025 Total approximate accumulated energy savings of the dr ive compared to using an across the line starter. Values Default: Read Only Min/Max: 0.0/6553.5 kWh Display: 0.1 = 10 kWh n 520-UM001I-EN-E - July 2016 81 Rockwell Automation Publicatio

82 Chapter 3 Programming and Parameters (continued) Basic Display Group [Accum Cost Sav] Related Parameter(s): b024 , P052 b025 A555 , 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] Values Default: Read Only Min/Max: 0.0/6553.5 Display: 0.1 b026 [Accum CO2 Sav] Related Parameter(s): A555 Total approximate accumulated CO2 savings of the dr ive compared to using an across the line starter. Values Default: Read Only Min/Max: 0.0/6553.5 kg Display: 0.1 kg b027 [Drive Temp] Present operating temperature of th e drive heatsink (inside module). Default: Values Read Only Min/Max: 0/120 ° C Display: ° C 1 b028 [Control Temp] Present operating temperature of the drive control. Values Default: Read Only Min/Max: ° C 0/120 Display: 1 ° C b029 [Control SW Ver] Current drive firmware version. Values Default: Read Only 0.000/65.535 Min/Max: 0.001 Display: Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 82

83 Programming and Parameters Chapter 3 Basic Program Group [Language] P030 Language Support Keypad/ RSLogix 5000/ Selects the language displayed. A reset or power cycle is required after selection is made. Connected Components Logix Designer LCD Display Workbench 1 English (Default) Y Y Y Options YYY 2Français 3Español YYY 4Italiano YYY 5Deutsch YYY – Y 6Japanese – 7 Português Y – Y Chinese 8 – Y Y Chinese Simplified 9Reserved 10 Reserved 11 Korean – Y – (1) 12 Polish Y–– 13 Reserved (1) 14 Turkish Y–– (1) 15 Czech Y–– and Czech will be modified. (1) Due to a limitation of the LCD Display, some of the ch aracters for Polish, Turkish, , A533 P031 [Motor NP Volts] Related Parameter(s): b004 , A530 , A531 , A532 Stop drive before changing this parameter. Sets the motor nameplate rated volts. Values Default: Drive Rated Volts Min/Max: 10V (for 230V Drives), 20V (for 460V Dr ives), 25V (for 600V Drives)/Drive Rated Volts Display: 1V P032 [Motor NP Hertz] Related Parameter(s): A493 , A530 , A531 , A532 , A533 Stop drive before changing this parameter. Sets the motor nameplate rated frequency. Values Default: 60 Hz Min/Max: 15/500 Hz Display: 1 Hz P033 [Motor OL Current] Related Parameter(s): t069 , t072 , t076 , t081 , A484 , A485 , A493 Sets the motor nameplate overload current. Used to determine moto r overload conditions and can be set from 0.1 A to 200% of dri ve rated current. otection according to NEC article this parameter is exceeded based on class 10 motor overload pr The drive will fault on an F007 “Motor Overload” if the value of IMPORTANT 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572 Drive Rated Amps Default: Values Min/Max: 0.0/(Drive Rated Amps x 2) Display: 0.1 A n 520-UM001I-EN-E - July 2016 83 Rockwell Automation Publicatio

84 Chapter 3 Programming and Parameters Basic Program Group (continued) P040 [Motor NP FLA] P034 Related Parameter(s): st the Autotune routine and motor control. Sets the motor nameplate FLA. Used to assi Default: Based on Drive Rating Values Min/Max: 0.1/(Drive Rated Amps x 2) 0.1 A Display: P035 [Motor NP Poles] Related Parameter(s): b015 Sets the number of poles in the motor. Default: 4 Values Min/Max: 2/40 1 Display: [Motor NP RPM] P036 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 thi s parameter closer to the motor synchronous speed. Values 1750 rpm Default: 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. Values Default: Drive Rated Power Min/Max: 0.00/Drive Rated Power Display: 0.01 kW P038 [Voltage Class] Stop drive before changing this parameter. Sets the voltage class of 600V drives. Only applicable to 600V drives. 2 “480V” Options 3 “600V” (Default) [Torque Perf Mode] Related Parameter(s): P040 , P039 , A531 , A532 , A533 , A535 A530 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” Options 1 “SVC” (Default) 2 “Economize” (1) 3“Vector” (2) (1) 3, the drive is in open loop PM motor When P039 [Torque Perf Mode] is set to 4 and A535 [Motor Fdbk Type] is set to 0, 1, 2 or 4“PM Control” control mode. [Motor Fdbk Type] is set to 4 or 5, the drive is in closed loop PM motor control When P039 [Torque Perf Mode] is set to 4 and A535 mode. Setting is specific to PowerFlex 525 drives only. (1) Setting is available in PowerFlex 525 FRN 5.xxx and later. (2) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 84

85 Programming and Parameters Chapter 3 Basic Program Group (continued) P040 [Autotune] Related Parameter(s): P034 , P039 , A496 , A497 Stop drive before changing this parameter. er value to a one or two, then issue a valid “Start” Enables a static (not spinning) or dynamic (motor spinning) autotune to automatically set the motor parameters. Set the paramet command to begin the routine. After the routine is complete the parameter resets to a zero. A failure (such as if a motor is no t connected) results in an Autotune Fault. It is recommended to perform a full rotate tune when using VVC mode. oup must be set before running the routine. If a start command is not given (or a s All motor parameters in the Basic Program gr top command is given) within IMPORTANT 30 s, the parameter automatically returns to a zero and an Autotune Fault occurs. AT T E N T I O N : this procedure. To guard against possible injury and/or equipm ent damage, it is Rotation of the motor in an undesired direction can occur during recommended that the motor be disconnected from the load before proceeding. Options 0 “Ready/Idle” (Default) A496 “Static Tune” A temporary command that initiates a non-rotational motor stator resistance test for the best possible automatic setting of 1 [IR Voltage Drop]. A start command is required following initiati on of this setting. The parameter returns to 0 “Ready/Idle” following the test, at which time another start transition is re quired operate the drive in norm al mode. Used when motor cannot be uncoupled from the load. 2 A497 followed by a rotational test A temporary command that initiates a “Static Tune” for the best possible automatic “Rotate Tune” setting of ter returns to 0 “Ready/Idle” ion of this setting. The parame [Flux Current Ref ]. A start command is required following initiat n following the test, at which time another start transition is requ ired to operate the drive in normal mode. Important: Used whe if a load is coupled to the motor during this procedure. motor is uncoupled from the load. Results may not be valid P044 , A439 P041 [Accel Time 1] Related Parameter(s): [Maximum Freq]. accelerate from 0 Hz to Sets the time for the drive to P044 Accel Rate = [Maximum Freq] / [Accel Time x] [Maximum Freq] Deceleration Speed Acceleration 0 [Accel Time x] [Decel Time x] Time 0 Default: 10.00 s Values Min/Max: 0.00/600.00 s 0.01 s Display: P042 [Decel Time 1] Related Parameter(s): P044 , A439 P044 [Maximum Freq] to 0 Hz. Sets the time for the drive to decelerate from Decel Rate = [Maximum Freq] / Decel Time x] [Maximum Freq] Deceleration Speed Acceleration 0 [Accel Time x] [Decel Time x] Time 0 Default: 10.00 s Values Min/Max: 0.00/600.00 s 0.01 s Display: n 520-UM001I-EN-E - July 2016 85 Rockwell Automation Publicatio

86 Chapter 3 Programming and Parameters (continued) Basic Program Group [Minimum Freq] Related Parameter(s): b001 , b002 , b013 , P044 , A530 , A531 P043 Stop drive before changing this parameter. Sets the lowest frequency the drive outputs. Values Default: 0.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz P044 [Maximum Freq] Related Parameter(s): b001 , b002 , b013 , b016 , P043 , A530 , A531 Stop drive before changing this parameter. Sets the highest frequency the drive outputs. This value must be greater than th e value set in P043 [Minimum Freq]. IMPORTANT 60.00 Hz Default: Values Min/Max: 0.00/500.00 Hz Display: 0.01 Hz A550 P045 [Stop Mode] Related Parameter(s): t086 , t087 , A434 , A435 , Determines the stopping mode used by the drive when a stop is initiated. Options 0 Ramp to Stop. Stop command clears active fault. “Ramp, CF” (Default) “Coast, CF” Coast to Stop. Stop command clears active fault. 1 2 DC Injection Braking Stop. Stop command clears active fault. “DC Brake, CF” 3 “DC BrkAuto,CF” DC Injection Br aking 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. • A434 Standard DC Injection Braking for value set in [DC Brake Time]. OR Drive shuts off if the drive detects that the motor is stopped. • 8 “Ramp+EM B,CF” Ramp to Stop with EM Brake Control. Stop command clears active fault. Ramp to Stop with EM Brake Control. 9 “Ramp+EM Brk” 10 “PointStp,CF” PointStop. Stop command clears Provides a method to stop at a constant distance instead of a fixed rate. active fault. When a Stop command is given, the distance required for the machine to travel to standstill based on the progra mmed maximum speed and decelera tion time is calculated. PointStop. 11 “PointStop” m speed, the function will apply a calculated If the drive is running slower than the maximu deceleration time that allows th e 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 [Maximum Freq] Speed Calculated Stop Time Time [Decel Time x] Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 86

87 Programming and Parameters Chapter 3 (continued) Basic Program Group C125 b012 , t064 P046 [Start Source 1] Related Parameter(s): , [Start Source 2] P048 P050 [Start Source 3] Stop drive before changing this parameter. ] is the factory default start source unless overridden. Configures the start source of the drive. Changes to these inputs take effect as soon as they are entered. P046 [Start Source 1 for more information. on page 49 Start and Speed Reference Control See For all settings except when t064 [2-Wire Mode] is set to 1 “Lev el Sense”, the drive must receive a leading edge from the start input for the drive to start after a IMPORTANT stop input, loss of power, or fault condition. “Keypad” 1 Options [Start Source 1] default [Start Source 2] default 2 “DigIn TrmBlk” [Start Source 3] default for PowerFlex 523 3 “Serial/DSI” (1) “Network Opt” 4 (2) [Start Source 3] default for PowerFlex 525 5“EtherNet/IP” onal PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the start source. Select this setting if using the opti (1) Setting is specific to PowerFlex 525 drives only. (2) P047 [Speed Reference1] Related Parameter(s): C125 P049 [Speed Reference2] P051 [Speed Reference3] as soon as they are entered. P047 [Speed Selects the source of speed command for the dr ive. Changes to these inputs take effect Reference1] is the factor y default speed reference unless overridden. on page 49 for more information. See Start and Speed Reference Control 1 [Speed Reference1] default Options “Drive Pot” 2“Keypad Freq” 3 “Serial/DSI” [Speed Referenc e3] default for PowerFlex 523 (1) 4 “Network Opt” “0-10V Input” 5 [Speed Reference2] default “4-20mA Input” 6 7 “Preset Freq” (2) 8 “Anlg In Mult” 9“MOP” 10 “Pulse Input” 11 “PID1 Output” (2) 12 “PID2 Output” (2) 13 “Step Logic” (2) 14 “Encoder” (2) 15 “EtherNet/IP” [Speed Reference3] default for PowerFlex 525 (2) [Positioning Mode] Referencing from A558 16 “Positioning” (1) al PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the speed reference. Select this setting if using the option (2) Setting is specific to PowerFlex 525 drives only. P052 [Average kWh Cost] Related Parameter(s): b025 Sets the average cost per kWh. Values Default: 0.00 0.00/655.35 Min/Max: 0.01 Display: n 520-UM001I-EN-E - July 2016 87 Rockwell Automation Publicatio

88 Chapter 3 Programming and Parameters (continued) Basic Program Group P053 [Reset To Defalts] Stop drive before changing this parameter. fault values. After a Reset command, the va Resets all parameters to their factory de lue of this parameter returns to zero. Parameters that are NOT Reset when P053 = 1 Parameters that are Reset when P053 = 3 Parameter Name Parameter Parameter Parameter P031 [Motor NP Volts] P030 [Language] C138 [EN Gateway Cfg 2] C159 [EN Data Out 3] P033 [Motor OL] Current C160 [EN Data Out 4] C139 [EN Gateway Cfg 3] C121 [Comm Write Mode] C122 [Cmd Stat Select] P034 [Motor NP FLA] C161 [Opt Data In 1] C140 [EN Gateway Cfg 4] C123 [RS485 Data Rate] P035 [Motor NP Poles] C162 [Opt Data In 2] C141 [EN Rate Cfg] C143 [EN Comm Flt Actn] C124 [RS485 Node Addr] C163 [Opt Data In 3] P038 [Voltage Class] C164 [Opt Data In 4] A435 [DC Brake Level] C124 [Comm Loss Action] C144 [EN Idle Flt Actn] C165 [Opt Data Out 1] C126 [Comm Loss Time] A484 [Current Limit 1] C145 [EN Flt Cfg Logic] C146 [EN Flt Cfg Ref ] C127 [RS485 Format] A485 [Current Limit 2] C166 [Opt Data Out 2] C147 [EN Flt Cfg DL 1] C128 [EN Addr Sel] A486 [Shear Pin1 Level] C167 [Opt Data Out 3] A488 [Shear Pin2 Level] C168 [Opt Data Out 4] C129 [EN IP Addr Cfg 1] C148 [EN Flt Cfg DL 2] A490 [Load Loss Level] C149 [EN Flt Cfg DL 3] C169 [MultiDrv Sel] C130 [EN IP Addr Cfg 2] C150 [EN Flt Cfg DL 4] C131 [EN IP Addr Cfg 3] A496 [IR Voltage Drop] C171 [Drv 1 Addr] A497 [Flux Current Ref ] C132 [EN IP Addr Cfg 4] C153 [EN Data In 1] C172 [Drv 2 Addr] C154 [EN Data In 2] C173 [Drv 3 Addr] A530 [Boost Select] C133 [EN Subnet Cfg 1] A531 [Start Boost] C134 [EN Subnet Cfg 2] C155 [EN Data In 3] C174 [Drv 4 Addr] A532 [Break Voltage] C135 [EN Subnet Cfg 3] C156 [EN Data In 4] C175 [DSI I/O Cfg] A533 [Break Frequency] C136 [EN Subnet Cfg 4] C157 [EN Data Out 1] GC [Parameters in Custom Group] A534 [Maximum] Voltage C158 [EN Data Out 2] C137 [EN Gateway Cfg 1] Options 0 “Ready/Idle” (Default) 1 “Param Reset” Does not reset custom groups, parame ter P030 [Language], and communication parameters. 2 “Factory Rset” Restore drive to factory condition. Resets only power parameters. 3 Can be used when swapping power modules. “Power Reset” (1) (2) “Module Reset” 4 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 88

89 Programming and Parameters Chapter 3 Te rm in a l B l oc k G ro up , , t064 t063 [DigIn TermBlk 03] , P051 Related Parameter(s): b012 , b013 , b014 , t062 [DigIn TermBlk 02] P046 , P048 , P049 , P050 , P045 [DigIn TermBlk 06] t066 [DigIn TermBlk 05] t065 t086 , A410 - A425 , A427 , A431 , A432 , A433 , A434 , A435 , A442 , A443 , A488 , A535 , A560 , A562 , A563 , A567 , A571 t067 [DigIn TermBlk 07] t068 [DigIn TermBlk 08] PF 525 PowerFlex 525 only. 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 s election that is only usable on one input, no other input can be set for the same selection. Options “Not Used” Terminal has no function but can be read over network communications with b013 0 b014 [Dig In Status]. [Contrl In Status] and Selects P049 1 “Speed Ref 2” [Speed Reference2] as drive's speed command. “Speed Ref 3” Selects P051 [Speed Reference3] as drive's speed command. 2 “Start Src 2” Selects P048 3 [Start Source 2] as control source to start the drive. 4 Selects P050 “Start Src 3” [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” Selects combination of P051 [Speed Reference3] and [Start Source 3] as speed command with control source to start P050 the drive. 7 “Preset Freq” [DigIn TermBlk 05] and [DigIn TermBlk 06] default. A425 ... [Preset Freq x]. A410 [Speed Referencex] = 1...15). See P051 , P049 , P047 • Selects a preset frequency in Velocity mode ( [Speed Referencex] = 16). Selects a preset frequency and position in Positioning mode ( , • P047 , P049 P051 (PF523: only for DigIn TermBlk 03, 05, See L200 ... [Step Units x] (only for PowerFlex 525 drives). L214 and 06) (PF525: only for DigIn TermBlk 05...08) when programmed as Preset Speed and are active. Digital Inputs have priority for frequency control IMPORTANT Start Source and Speed Reference Selection on page 49 for more information. See A432 When input is present, drive accelerates according to the value set in • 8“Jog” [Jog Accel/Decel] and ramps to the value set in [Jog Frequency]. A431 • [Jog Accel/Decel]. A432 When input is removed, drive ramps to a stop according to the value set in override this input. A valid Start command will • 9 [DigIn TermBlk 08] default. “Jog Forward” A431 [Jog Accel/Decel] and ramps to a stop when input becomes A432 [Jog Frequency] according to Drive accelerates to inactive. A valid Start command will override this input. 10 “Jog Reverse” A431 Drive accelerates to [Jog Frequency] according to [Jog Accel/Decel] and ramps to a stop when input becomes A432 inactive. A valid Start command will override this input. (1) 11 “Acc/Dec Sel2” will be used for all ramp rates except jog. If active, determines which Accel/Decel time [Accel Time 2] for more information. A442 Can be used with option 29 “Acc/Dec Sel3” for additional Accel/Decel times. See “Auxiliary Input” fault will occur when the input is removed. 12 “Aux Fault” When enabled, an F002 13 “Clear Fault” When active, clears an active fault. 14 “RampStop,CF” P045 Causes drive to immediatel y ramp to a stop regardless of how [Stop Mode] is set. 15 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of how P045 [Stop Mode] is set. Causes drive to immediately P045 16 “DCInjStop,CF” begin a DC Injection stop regardless of how [Stop Mode] is set. 17 “MOP Up” Increases the value of A427 [MOP Time]. A430 [MOP Freq] at the rate set in A427 18 “MOP Down” Decreases the value of [MOP Freq] at the rate set in A430 [MOP Time]. (1) 19 “Timer Start” used to control the relay or opto outputs. Clears and starts the timer function. May be (1) 20 “Counter In” Starts the counter function. May be used to control the relay or opto outputs. 21 “Reset Timer” d365 Resets the internal active timer, [Timer Status]. For more information, see . Timer Function on page 211 Resets the count in the d364 22 “Reset Countr” accumulated internal active counter, Counter Function [Counter Status]. For more information, see on page 212 . timer and accumulated internal active counter. Resets both the internal active 23 “Rset Tim&Cnt” (1)(2) 24 “Logic In 1” t076 , t081 [Relay Outx Sel] and Logic function input number 1. May be used to control the relay or opto outputs ( L180 ... L187 [Stp Logic x]. t069 , t072 [Opto Outx Sel], options 11...14). May be used in conjunction with StepLogic parameters (1)(2) 25 “Logic In 2” t081 [Relay Outx Sel] and , t076 Logic function input number 2. May be used to control the relay or opto outputs ( L180 ... L187 [Stp Logic x]. t069 , t072 [Opto Outx Sel], options 11...14). May be used in conjunction with StepLogic parameters n 520-UM001I-EN-E - July 2016 89 Rockwell Automation Publicatio

90 Chapter 3 Programming and Parameters (2) 26 “Current Lmt2” Options When active, A485 [Current Limit 2] determines the drive current limit level. 27 “Anlg Invert” Inverts the scaling of the analog input levels set in t091 t092 [Anlg In 0-10V Hi] or [Anlg In 0-10V Lo] and [Anlg In4-20mA Lo] and t096 [Anlg In4-20mA Hi]. t095 28 “EM Brk Rlse” If EM brake function is enab led, 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. (1) 29 “Acc/Dec Sel3” If active, determines which Accel/Decel time is used for all ramp rates except jog. Option Description Accel/Decel times listed in this table. Used with option 11 “Acc/Dec Sel2” for the 29 11 0 Acc/Dec 1 0 0 1 Acc/Dec 2 Acc/Dec 3 1 0 1 1 Acc/Dec 4 rolled by auxiliary contact on the disconnect at the DC input to the drive. If this Forces drive into precharge state. Typically cont 30 “Precharge En” to close and for the drive to run. If it is de-energized, the input is assigned, it must be energized for the pre-charge relay pre- charge relay opens and the drive coasts to a stop. 31 “Inertia Dcel” Forces drive into Inertia Ride-Through state. Th e drive attempts to regulate the DC bus at the current level. 32 “Sync Enable” Must be used in order to hold the existing freque ncy when Sync Time is set to en able speed synchronization. When this input is released the drive accelerates to the commanded frequency in A571 [Sync Time]. 33 “Traverse Dis” When an input is programmed the traverse function is disabled while this input is active. See A567 [Max Traverse]. (2) 34 “Home Limit” for more information on Positioning. Appendix E In Positioning mode, indicates the drive is at the home position. See (2) 35 “Find Home” the Home position when a Start command is issued. In Positioning mode, causes the drive to return to [Find Home Freq] and A563 [Find Home Dir] until the “Home Limit” input is activated. If it passes this point, it then A562 Uses 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. On ce the Find Home routine has finished, the drive stops. See Appendix E for more information on Positioning. (2) 36 “Hold Step” 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 the drive must see any required digital inputs transition (even if they already run. Therefore, when the Hold is removed, for more information on Positioning. Appendix E transitioned during the hold), but it does not reset any timer. See (2) In Positioning mode, resets the home position to the current position of the machine. See 37 “Pos Redefine” Appendix E for more information on Positioning. A435 38 “Force DC” If the drive is not running, causes the drive to apply a DC Holding current ( [DC Brake Time]) A434 [DC Brake Level], ignoring while the input is applied. 39 “Damper Input” When active, drive is allowed to run normally. When inactive, drive is forced into sleep mode an d is prevented from accelerating to command speed. (1) 40 “Purge” A433 [Purge Frequency] regardless of the selected control source. Supersedes the keypad Control function as Starts the drive at 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 sour ce selection. If a valid stop (other than from comms or SW t start on the purge input transition. enable) is present, the drive will no If a hazard of injury due to movement of equipment or material exists, an auxiliary ATTENTION: mechanical braking device must be used. 41 “Freeze-Fire” 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 42 “SW Enable” has to be active for the drive to run. 43 “SherPin1 Dis” 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. 44 Reserved 45 Reserved 46 Reserved 47 Reserved Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 90

91 Programming and Parameters Chapter 3 ct 2-Wire FWD for this input. 48 “2-Wire FWD” [DigIn TermBlk 02] default. Sele Options (only for DigIn TermBlk 02) Select this option and set P046 , P050 [Start Source x] to 2 “DigIn TrmBlk” to P048 or t064 [2-Wire Mode] for configure [Start Source x] to a 2-wire run forward mode. Also see level trigger settings. Drive Start Condition 49 “3-Wire Start” Select 3-Wire Start for this input. Matrix for t062 and t063 (only for DigIn TermBlk 02) P048 or , [Start Source x] to 2 “DigIn TrmBlk” to P046 Select this option and set P050 configure [Start Source x] to a 3-wire start mode. t062 Setting ct 2-Wire REV for this input. 50 “2-Wire REV” [DigIn TermBlk 03] default. Sele 3-Wire t063 2-Wire (only for DigIn TermBlk 03) [Start Source x] to 2 “DigIn TrmBlk” to , Select this option and set or P050 P046 P048 Start FWD Setting configure [Start Source x] to a 2-wire run reverse mode. Also see t064 [2-Wire Mode] for level Drive will OK 2-Wire trigger settings. REV not start disabled If [DigIn TermBlk 03] is set to For PowerFlex 523 drives, this setting will be OK 3-Wire Drive will 7 “Preset Freq”. Dir not start Select 3-Wire Dir for this input. 51 “3-Wire Dir” (only for DigIn TermBlk 03) , P048 Select this option and set P046 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”. 52 “Pulse Train” Select pulse train for this input. and [Speed Referencex] to select pulse input. P051 P049 , P047 Use (PF523: only for DigIn TermBlk 05) Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In. (PF525: only for DigIn TermBlk 07) This function may be tied to one input only. (1) Setting is specific to PowerFlex 525 drives only. (2) [2-Wire Mode] Related Parameter(s): P045 , P046 , P048 t064 P050 , t062 , t063 , Stop drive before changing this parameter. t063 Programs the mode of trigger only for t062 [DigIn TermBlk 02] and [Start Source x]. [DigIn TermBlk 03] when 2-wire option is being selected as P046 , P048 or P050 Options “Edge Trigger” (Default) Standard 2-Wire operation. 0 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” • AT T E N TI O N : 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 ed only when the Stop input is active (open). the drive to run again. A Stop function is provid AT T E N TI O N : When operating in 2-Wire Level Sense (Run Level), the PowerFlex 523 and PowerFlex 525 drive should only be controlled from This should NOT be used with any the Digital Input Terminal Blocks. other DSI or Network device. 2 “Hi-Spd Edge” There is greater potential voltage on the output terminals when using this option. IMPORTANT • Outputs are kept in a ready-to-run state. The driv e will respond to a Start command within 10 ms. • I/O Terminal 01 “Stop” = Coast to stop. • I/O Terminal 03 “Run REV” 3“Momentary” 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). • P045 I/O Terminal 01 “Stop” = Stop according to the value set in [Stop Mode]. n 520-UM001I-EN-E - July 2016 91 Rockwell Automation Publicatio

92 Chapter 3 Programming and Parameters [Opto Out1 Sel] Related Parameter(s): P046 , P048 , P050 , t070 , t073 , t077 , t082 , t069 t072 [Opto Out2 Sel] t086 t097 t087 t093 , , , , , A541 , A564 t094 PF 525 PowerFlex 525 only. Determines the operation of the programmable digital outputs. Setting Output Changes State When... Options Hysteresis 0 “Ready/Fault” None dicates that the drive is ready for operation. Opto outputs are Opto outputs are active when power is applied. In inactive when power is removed or a fault occurs. “At Frequency” Drive reaches commanded frequency. 0.5 Hz above; 1.0 Hz below 1 “MotorRunning” Motor is receiving power from the drive. 2 None 3 “Reverse” Drive is commanded to run in reverse direction. None Motor overload condition exists. 4 “Motor Overld” 100 ms time delay on or off 5 100 ms time delay on or off Ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or overvoltage fault from “Ramp Reg” occurring. t070 6 “Above Freq” Drive exceeds the frequency (Hz) value set in or 100 ms time delay on or off t073 [Opto Outx Level]. t070 7 “Above Cur” Drive exceeds the current (% Amps) value set in or 100 ms time delay on or off t073 [Opto Outx Level]. Value for t070 or t073 [Opto Outx Level] must be entered in percent of drive rated output IMPORTANT current. or [Opto Outx Level]. t073 100 ms time delay on or off 8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t070 Value set in 9 A541 “Retries Exst” None [Auto Rstrt Tries] is exceeded. -10V input) exceeds the value set in Analog input voltage (0 10 “Above Anlg V” t070 or t073 [Opto Outx Level]. 100 ms time delay on or off t093 Do not use if [10V Bipolar Enbl] is set to 1 “Bi-Polar In”. IMPORTANT t070 Power Factor angle exceeds the value set in 11 “Above PF Ang” t073 or 100 ms time delay on or off [Opto Outx Level]. Analog input loss has occurred. Program 12 “Anlg In Loss” t094 [Anlg In V Loss] or t097 [Anlg In mA Loss] for desired action when On, 2 mA / ±1V input loss occurs. Off, 3 mA / ±1.5V Output is directly controlled by the state of the t070 13 “ParamControl” t073 [Opto Outx Level]. A value of 0 causes the output to None or turn off. A value of 1 or greater in this parameter causes the output to turn on. 14 “NonRec Fault” • Value set in A541 [Auto Rstrt Tries] is exceeded or None A541 [Auto Rstrt Tries] is not enabled or • A non-resettable fault has occurred. • 15 “EM Brk Cntrl” EM Brake is energized. Program t087 [EM Brk On Delay] and t086 [EM Brk Off Delay] for desired action. None 16 “Thermal OL” Relay energizes when thermal Moto r overload counter is above the value set in t077 or t082 [Relay Outx Level]. It None also energizes if the drive is within 5 ° C of the drive overheat trip point. 17 “Amb OverTemp” Relay energizes when control module over temperature occurs. None P046 Active when drive 18 “Local Active” [Start Source x] is in local keypad control. P050 or , P048 None Active when communication is lost from any comm source with reference or control. None 19 “Comm Loss” 20 “Logic In 1” An input is programmed as “Logic Input 1” and is active. None None 21 “Logic In 2” An input is programmed as “Logic Input 2” and is active. 22 “Logic 1 & 2” Both Logic inputs are programmed and active. None 23 “Logic 1 or 2” One or both Logic inputs ar e programmed and one or both is active. None 24 “StpLogic Out” Drive enters StepLogic step with Command Word set to enable Logic output. None Timer has reached the value set in t070 25 “Timer Out” or [Opto Outx Level] or not timing. t073 None 26 “Counter Out” Counter has reached the value set in t070 or t073 [Opto Outx Level] or not counting. None Drive is in Positionin g mode and has reached the commanded position. Tolerance is adjusted with 27 “At Position” A564 – [Encoder Pos Tol]. A564 28 “At Home” Drive is in Positioning mode and has reac hed the home position. Tolerance is adjusted with [Encoder Pos Tol]. – – Both safe-off inputs are active. 29 “Safe-Off ” (1) 30 “SafeTqPermit” – Both safe-off inputs are inactive (closed). (1) 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – Values Default: 2 Opto Out1 Sel: 1 Opto Out2 Sel: Min/Max: 0/31 Display: 1 in FRN 5.xxx and later. Setting is available (1) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 92

93 Programming and Parameters Chapter 3 (continued) Terminal Block Group [Opto Out1 Level] Related Parameter(s): t069 , t072 t070 t073 [Opto Out2 Level] 2 3 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: 16: 0.1...9999 s 20: 0/1 10: 0...100% 0...500 Hz 11 7: 0...180% 26: 0...150% 0/1 17: 1...9999 counts 8: 13 18: 0...180 0...800 0...815V – ° Values Default: 0.0 0.0/9999.0 Min/Max: Display: 0.1 t075 [Opto Out Logic] PF 525 PowerFlex 525 only. Determines the logic (Normally Open/NO or Norm ally Closed/NC) of the digital outputs only. Setting Digital Out 1 Logic Digital Out 2 Logic NO 0NO NO 1NC NC 2NO NC 3NC 0 Default: Values 0/3 Min/Max: 1 Display: n 520-UM001I-EN-E - July 2016 93 Rockwell Automation Publicatio

94 Chapter 3 Programming and Parameters t087 A564 , , P048 , P050 , t070 , t073 , t077 , t082 , t086 , A541 , t093 , t094 , t097 , t076 Related Parameter(s): P046 [Relay Out1 Sel] t081 [Relay Out2 Sel] PF 525 PowerFlex 525 only. Determines the operation of th e programmable output relay. Options Output Relay Changes State When... Hysteresis None 0 o Relay changes state when power is applied. Indicates that the drive is ready for operation. Relay returns drive t “Ready/Fault” shelf state when power is removed or a fault occurs. “At Frequency” 1 Drive reaches commanded frequency. 0.5 Hz above; 1.0 Hz below Motor is receiving power from the drive. None “MotorRunning” 2 3 “Reverse” Drive is commanded to run in reverse direction. None 4 “Motor Overld” Motor overload condition exists. 100 ms time delay on or off 5 “Ramp Reg” Ramp regulator is modifying the programmed accel/ decel times to avoid an overcurrent or overvoltage fault from 100 ms time delay on or off occurring. t077 6 “Above Freq” Drive exceeds the frequency (Hz) value set in or t082 100 ms time delay on or off [Relay Outx Level]. 7 “Above Cur” Drive exceeds the current (% Amps) value set in t077 t082 or [Relay Outx Level]. 100 ms time delay on or off Value for t077 or t082 [Relay Outx Level] must be entered in percent of drive rated output IMPORTANT current. or t082 [Relay Outx Level]. 100 ms time delay on or off 8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t077 9 “Retries Exst” Value set in A541 [Auto Rstrt Tries] is exceeded. None t077 Analog input voltage (0 -10V input) exceeds the value set in 10 “Above Anlg V” t082 100 ms time delay on or off [Relay Outx Level]. or [10V Bipolar Enbl] is set to 1 “Bi-Polar In”. t093 Do not use if IMPORTANT t082 [Relay Outx Level]. 100 ms time delay on or off or 11 “Above PF Ang” Power Factor angle exceeds the value set in t077 t094 12 “Anlg In Loss” Analog input loss has occurred. Program [Anlg In V Loss] or On, 2 mA / ±1V [Anlg In mA Loss] for desired action when t097 input loss occurs. Off, 3 mA / ±1.5V 13 “ParamControl” Output will be directly controlled by the state of the t077 t082 [Relay Outx Level]. A value of 0 causes the output None or to turn off. A value of 1 or greater in th is parameter causes the output to turn on. 14 “NonRec Fault” • Value set in A541 [Auto Rstrt Tries] is exceeded or None A541 [Auto Rstrt Tries] is not enabled or • • A non-resettable fault has occurred. 15 “EM Brk Cntrl” EM Brake is energized. Program t087 [EM Brk On Delay] and [EM Brk Off Delay] for desired action. None t086 16 “Thermal OL” Relay energizes when thermal Moto r overload counter is above the value set in t077 or t082 [Relay Outx Level]. It None ° C of the drive overheat trip point. also energizes if the drive is within 5 17 “Amb OverTemp” Relay energizes when control module over temperature occurs. None 18 “Local Active Active when drive P046 or P050 None [Start Source x] is in local keypad control. , P048 None 19 “Comm Loss” Active when communication is lost from any comm source with reference or control. (1) 20 “Logic In 1” An input is programmed as “Log None ic Input 1” and is active. (1) 21 “Logic In 2” ic Input 2” and is active. None An input is programmed as “Log (1) 22 “Logic 1 & 2” Both Logic inputs are programmed and active. None (1) 23 “Logic 1 or 2” One or both Logic inputs are programm ed and one or both is active. None (1) 24 “StpLogic Out” Drive enters StepLogic step with Command Word set to enable Logic output. None 25 “Timer Out” Timer has reached the value set in t077 [Relay Outx Level] or not timing. or t082 None t077 26 “Counter Out” Counter has reached the value set in or [Relay Outx Level] or not counting. None t082 (1) 27 “At Position” Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with A564 [Encoder – Pos Tol]. (1) 28 “At Home” A564 [Encoder Pos Tol]. – Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with (1) 29 “Safe-Off ” Both safe-off inputs are active. – (1)(2) 30 “SafeTqPermit” – Both safe-off inputs are inactive (closed). (1)(2) 31 “AutoRst Ctdn” Drive is counting down to an automatic restart. – Values Default: 0 Relay Out1 Sel: Relay Out2 Sel: 2 0/31 Min/Max: Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 94

95 Programming and Parameters Chapter 3 (1) Setting is specific to PowerFlex 525 drives only. in FRN 5.xxx and later. Setting is available (2) , t081 t077 [Relay Out1 Level] Related Parameter(s): t076 [Relay Out2 Level] t082 PF 525 PowerFlex 525 only. 32 32 bit parameter. Determines the on/off point [Relay Outx Sel] is set to the values shown below. for the output relay when t076 or t081 Min/Max Value Range Based On [Relay Outx Sel] Setting 6: 0...500 Hz 10: 0...100% 16: 0.1...9999 s 20: 0/1 26: 0...150% 7: 0...180% 11: 0/1 17: 1... 9999 counts 8: ° 0...815V 18: 0...180 13: 0...800 – 0.0 Default: Values 0.0/9999.0 Min/Max: 0.1 Display: t079 [Relay 1 On Time] t084 [Relay 2 On Time] PF 525 PowerFlex 525 only. Sets the delay time before Relay ener gizes after required condition is met. Values 0.0 s Default: Min/Max: 0.0/600.0 s Display: 0.1 s [Relay 1 Off Time] t080 [Relay 2 Off Time] t085 PF 525 PowerFlex 525 only. Sets the delay time before Relay de-ene rgizes after required condition ceases. Default: 0.0 s Values 0.0/600.0 s Min/Max: 0.1 s Display: t086 [EM Brk Off Delay] Related Parameter(s): P045 Sets the time the drive remains at minimum frequency before ramp ing up to the commanded frequenc y (and engaging the brake coil relay) if Electromechanical (EM) Brake Control Mode is enabled with [Stop Mode]. P045 Frequency Ramp decel [EM Brk Off Delay] [EM Brk On Delay] Ramp accel [Minimum Freq] Time Stop EM Brk Drive stops Start EM Brk energized (Off) commanded commanded de-energized (On) Values 2.00 s Default: 0.00/10.00 s Min/Max: 0.01 s Display: n 520-UM001I-EN-E - July 2016 95 Rockwell Automation Publicatio

96 Chapter 3 Programming and Parameters Terminal Block Group (continued) t087 P045 Related Parameter(s): [EM Brk On Delay] P045 [Stop Mode]. 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 Frequency Ramp decel [EM Brk Off Delay] [EM Brk On Delay] Ramp accel [Minimum Freq] Time EM Brk Stop Start EM Brk Drive stops energized (Off) commanded de-energized (On) commanded Default: 2.00 s Values Min/Max: 0.00/10.00 s 0.01 s Display: Related Parameter(s): t090 [Analog Out Sel] t088 ide a signal proportional to several drive conditions. This par ameter also selects which analog calibration parameters The 0-10V, 0-20 mA or 4-2 0 mA analog output can be used to prov (1) to use. (1) Output Range Maximum Output Value = Minimum Output Value Options Filter Related [Analog Out High] t089 Parameter 0 “OutFreq 0-10” 0-10V 0V = 0 Hz [Maximum Freq] None b001 1 “OutCurr 0-10” 0-10V 0V = 0 A 200% Drive Rated Current Filter A b003 2 0-10V 0V = 0V 120% Drive Rated Output Volts None b004 “OutVolt 0-10” b017 “OutPowr 0-10” 0-10V 0V = 0 kW 200% Drive Rated Power Filter A 3 Filter A 200% Drive Rated Current 0V = 0 A d382 4 “OutTorq 0-10” 0-10V “TstData 0-10” – None 65535 (Hex FFFF) 0V = 0000 5 0-10V 6 0V = 0% 100.0% Setpoint setting None t090 0-10V “Setpnt 0-10” “DCVolt 0-10” 0-10V 0V = 0V 100.0% of trip value None b005 7 0 mA = 0 Hz “OutFreq 0-20” 0-20 mA None [Maximum Freq] 8 b001 b003 9 0-20 mA 0 mA = 0 A 200% Drive Rated Current Filter A “OutCurr 0-20” 10 “OutVolt 0-20” 0-20 mA 0 mA = 0V 120% Drive Rated Output Volts None b004 b017 11 “OutPowr 0-20” 0-20 mA 0 mA = 0 kW 200% Drive Rated Power Filter A 0-20 mA 200% Drive Rated Current d382 Filter A 0 mA = 0 A 12 “OutTorq 0-20” 13 “TstData 0-20” 0 mA = 0000 65535 (Hex FFFF) None – 0-20 mA 14 “Setpnt 0-20” 0-20 mA 0 mA = 0% 100.0% Setpoint setting None t090 15 “DCVolt 0-20” 0-20 mA 0 mA = 0V 100.0% of trip value None b005 [Maximum Freq] 16 “OutFreq 4-20” 4 mA = 0 Hz 4-20 mA None b001 17 “OutCurr 4-20” 4 mA = 0 A 200% Drive Rated Current Filter A b003 4-20 mA 18 “OutVolt 4-20” 4-20 mA 4 mA = 0V 120% Drive Rated Output Volts None b004 19 “OutPowr 4-20” 4-20 mA 4 mA = 0 kW 200% Drive Rated Power Filter A b017 4 mA = 0 A 200% Drive Rated Current d382 Filter A 4-20 mA 20 “OutTorq 4-20” 4 mA = 0000 21 “TstData 4-20” 65535 (Hex FFFF) – None 4-20 mA t090 None 100.0% Setpoint setting 4 mA = 0% 4-20 mA 22 “Setpnt 4-20” b005 100.0% of trip value 4 mA = 0V 4-20 mA 23 “DCVolt 4-20” None 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 o (1) utput 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%. Values Default: 0 0/23 Min/Max: Display: 1 (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 96

97 Programming and Parameters Chapter 3 (continued) Terminal Block Group t089 [Analog Out High] (1) Scales the maximum ou tput value (V or mA) when the source setting is at maximum. 100% Values Default: 0/800% Min/Max: Display: 1% (1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 series B drive is required. [Anlg Out Setpt] Related Parameter(s): t088 t090 (1) t088 [Analog Out Sel] is set to 6, 14 or 22 “Analog Setpoint”. Sets the percentage of output desired when Values 0.0% Default: 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] Related Parameter(s): P043 , t092 , t093 Stop drive before changing this parameter. applied to the 0-10V analog input used to represent Sets the percentage (based on 10V) of input voltage [Minimum Freq]. P043 [Anlg In 0-10V Hi]. Analog inversion can be accomplished by setting this value larger than t092 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”, this parameter is ignored. If t093 Default: 0.0% Values Min/Max: 0.0/200.0% Display: 0.1% [Anlg In 0-10V Hi] Related Parameter(s): P044 , t091 , t093 t092 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 t091 [Anlg In 0-10V Lo]. by setting this value smaller than same value applies to positive and negative voltage. [10V Bipolar Enbl] is set to 1 “Bi-Polar In”, the t093 If Values Default: 100.0% Min/Max: 0.0/200.0% Display: 0.1% , t092 t093 [10V Bipolar Enbl] Related Parameter(s): t091 PF 525 PowerFlex 525 only. Enables/disables bi-polar control. In bi-polar mode di rection is commanded by the polarity of the voltage. [Anlg In 0-10V Lo] are ignored. t091 [Minimum Freq] and P043 If bi-polar control is enabled, Options 0 “Uni-Polar In” (Default) 0-10V only 1 “Bi-Polar In” ±10V n 520-UM001I-EN-E - July 2016 97 Rockwell Automation Publicatio

98 Chapter 3 Programming and Parameters (continued) Terminal Block Group [Anlg In V Loss] Related Parameter(s): P043 , P044 , A426 , A427 t094 –10 to +10V) is used for any reference, any input less than 1V i Sets the response to a loss of input. When the 0-10V input (or put must exceed 1.5V for the s reported as a signal loss. In 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 Options 0 “Disabled” (Default) 1 “Fault (F29)” 2“Stop” 3“Zero Ref” 4“Min Freq Ref” 5“Max Freq Ref” 6“Key Freq Ref” 7“MOP Freq Ref” 8 “Continu Last” t095 [Anlg In4-20mA Lo] Related Parameter(s): P043 , t096 Stop drive before changing this parameter. applied to the 4-20 mA analog input used to represent P043 [Minimum Freq]. Sets the percentage (based on 4-20 mA) of input current Analog inversion can be accomplished by setting this value larger than t096 [Anlg In4-20mA Hi]. Values Default: 0.0% Min/Max: 0.0/100.0% Display: 0.1% [Anlg In4-20mA Hi] , t095 P044 t096 Related Parameter(s): Stop drive before changing this parameter. P044 [Maximum Freq]. Sets the percentage (based on 4-20 mA) of input current applied to the 4-20 mA analog input used to represent [Anlg In4-20mA Lo]. t095 Analog inversion can be accomplished by setting this value smaller than Values Default: 100.0% Min/Max: 0.0/200.0% Display: 0.1% t097 [Anlg In mA Loss] Related Parameter(s): P043 , P044 , A426 , A427 Sets the response to a loss of input. When the 4-20mA input is used for any reference, any input less than 2 mA is reported as ceed 3 mA for the signal loss a signal loss. Input must ex 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 dri ve. Options 0 “Disabled” (Default) 1 “Fault (F29)” 2“Stop” 3“Zero Ref” 4“Min Freq Ref” 5“Max Freq Ref” 6“Key Freq Ref” 7“MOP Freq Ref” “Continu Last” 8 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 98

99 Programming and Parameters Chapter 3 (continued) Terminal Block Group [Anlg Loss Delay] Related Parameter(s): t094 , t097 t098 Sets the length of time after power-up during which the drive detects no analog signal loss. signal loss is set in t094 or Response to an analog [Analog In x Loss]. t097 Values Default: 0.0 s Min/Max: 0.0 /20.0 s Display: 0.1 s t099 [Analog In Filter] Sets the level of additional filtering of the analog input sign als. 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 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 disp lay flashes to indicate the drive is in “sleep” mode. When the appropriate analog input rises above the set [Wake Le vel], the drive “wakes” and ramps to the commanded frequency. [Wake Level]. Inversion can be accomplished by setting [Sleep Level] to a higher setting than t103 AT T E N T I O N : injury uipment damage and/or personal eration during the Wake mode. Eq Enabling the Sleep-Wake function can cause unexpected machine op onal codes, standards, regulations or ation. In addition, all applicable local, national and internati can result if this parameter is used in an inappropriate applic industry guidelines must be considered. “Disabled” (Default) Options 0 1 Sleep enabled from 0-10V Analog Input 1 “0-10V Input” Sleep enabled from 4-20 mA Analog Input 2 “4-20mA Input” 2 3 “Command Freq” Sleep enabled based on drive commanded frequency t101 [Sleep Level] Sets the analog input level the drive must reach to enter sleep mode. Values 10.0% Default: 0.0/100.0% Min/Max: 0.1% Display: t102 [Sleep Time] Sets the analog input time the drive must stay below to enter sleep mode. Values Default: 0.0 s 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. Values Default: 15.0% 0.0/100.0% Min/Max: 0.1% Display: n 520-UM001I-EN-E - July 2016 99 Rockwell Automation Publicatio

100 Programming and Parameters Chapter 3 Terminal Block Group (continued) [Wake Time] t104 Sets the analog input time the drive must stay above to wake from sleep mode. Values Default: 0.0 s Min/Max: 0.0/600.0 s Display: 0.1 s [Safety Open En] t105 PF 525 PowerFlex 525 only. ts (Safety 1 and Safety 2) are disabled (de-energized – no power is applied). Sets the action when both safety inpu Options 0“FaultEnable” (Default) 1 “FaultDisable” [SafetyFlt RstCfg] t106 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Sets the method of resetting fault F111 “Safety Hardware” ei ther by means of a power cycle or fault clear operation. “PwrCycleRset” (Default) Options 0 Reset fault F111 using power cycle. 1 “FltClr Reset” Reset fault F111 using fa ult clear mechanism without power cycle. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 100

101 Programming and Parameters Chapter 3 Communications Group [Comm Write Mode] C121 AM) or in drive non-vola tile memory (EEPROM). Saves parameter values in active drive memory (R default value of 0 “Save”. rameter must remain at its AT T E N T I O N : If Automatic Drive Configuration (ADC) is used, this pa Parameter values set prior to setting 1 “RAM only” are saved in RAM. IMPORTANT 0“Save” (Default) Options 1“RAM only” C122 [Cmd Stat Select] PF 525 PowerFlex 525 only. ork. See on page 203 Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use over a communication netw Writing (06) Logic Command Data be changed when an I/O connection is es or the drive’s embedded EtherNet/IP port. tablished through the communication adapter for more information. This parameter cannot Options 0“Velocity” (Default) 1“Position” C123 [RS485 Data Rate] (bits/second) for the RS485 port. A reset or po Sets the communications baud rate wer cycle is required after selection is made. Options 0 “1200” 1 “2400” 2 “4800” 3 “9600” (Default) 4 “19,200” 5 “38,400” C124 [RS485 Node Addr] (address) for the RS485 port if using a network connection. A reset or power cycle is require d after selection is made. Sets the Modbus drive node number Values Default: 100 Min/Max: 1/247 1 Display: [Comm Loss Action] Related Parameter(s): P045 C125 Sets the drive's response to a loss of connection or excessive communication errors on the RS485 port. 0“Fault” (Default) Options 1 “Coast Stop” Stops drive using “Coast to stop”. 2 Stops drive using P045 “Stop” [Stop Mode] setting. 3 “Continu Last” Drive continues operating at communication commanded speed saved in RAM. C126 [Comm Loss Time] Related Parameter(s): C125 for more information. 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 ls the drive is transmitted through the RS485 port. This setting is effective only if I/O that contro IMPORTANT Default: 5.0 s Values 0.1/60.0 s Min/Max: Display: 0.1 s n 520-UM001I-EN-E - July 2016 101 Rockwell Automation Publicatio

102 Chapter 3 Programming and Parameters (continued) Communications Group C127 [RS485 Format] ed by the drive. A reset or power cycle is required after sele ction is made. Determines the details related to the specific Modbus protocol us Options “RTU 8-N-1” (Default) 0 1“RTU 8-E-1” 2 “RTU 8-O-1” 3 “RTU 8-N-2” 4“RTU 8-E-2” 5 “RTU 8-O-2” C136 C128 [EN Addr Sel] Related Parameter(s): C129 - C132 , C133 - - , C137 C140 PF 525 PowerFlex 525 only. t with a BOOTP server. Identifies attempted on a reset or power cycle. A reset or power the connections that would be Enables the IP address, subnet mask and gateway address to be se cycle is required after selection is made. Options 1 “Parameters” 2“BOOTP” (Default) C129 [EN IP Addr Cfg 1] Related Parameter(s): C128 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] C128 [EN Addr Sel] must be set to 1 “Parameters”. IMPORTANT Default: 0 Values 0/255 Min/Max: Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 102

103 Programming and Parameters Chapter 3 (continued) Communications Group C133 [EN Subnet Cfg 1] Related Parameter(s): C128 C134 [EN Subnet Cfg 2] [EN Subnet Cfg 3] C135 [EN Subnet Cfg 4] C136 PF 525 PowerFlex 525 only. Sets the bytes of the subnet mask. A reset or po wer 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] C128 [EN Addr Sel] must be set to 1 “Parameters”. IMPORTANT Default: 0 Values 0/255 Min/Max: 1 Display: C137 [EN Gateway Cfg 1] Related Parameter(s): C128 [EN Gateway Cfg 2] C138 [EN Gateway Cfg 3] C139 C140 [EN Gateway Cfg 4] PF 525 PowerFlex 525 only. power cycle is required after selection is made. Sets the bytes of the gateway address. A reset or 192.168.1.1 [EN Gateway Cfg 1] [EN Gateway Cfg 2] [EN Gateway Cfg 3] [EN Gateway Cfg 4] C128 [EN Addr Sel] must be set to 1 “Parameters”. IMPORTANT 0 Values Default: Min/Max: 0/255 1 Display: 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. Options 0 “Auto detect” (Default) “10Mbps Full” 1 2 “10Mbps Half ” 3 “100Mbps Full” 4 “100Mbps Half ” 103 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

104 Chapter 3 Programming and Parameters (continued) Communications Group [EN Comm Flt Actn] Related Parameter(s): P045 , C145 , C146 , C147 - C150 C143 PF 525 PowerFlex 525 only. if the EtherNet/IP interface detects that Ethernet communication s have been disrupted. Sets the action that the EtherNet/IP interface and drive takes This setting is effective only if I/O that controls th e drive is transmitted through the EtherNet/IP interface. IMPORTANT the action of the EtherNet/IP i nterface and ATTENTION: Risk of injury or equipment damage exists. Parameter C143 [EN Co mm Flt Actn] lets you determine t the drive continues to run. connected drive if communications are disrupted. By default, this parameter faults the drive. You can set this parameter so tha the setting of this parameter does not crea te a risk of injury or equipment damage. Precautions should be taken to ensure that When commissioning the drive, verify that your system responds correctly to various situations (for example, a disconnected drive). Options 0“Fault” (Default) 1 “Stop” Drive stops per P045 [Stop Mode] setting. Note: The Reference and Datalink values transmitted to the drive will be set to “0”. 2 “Zero Data” 3 “Hold Last” Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value. C146, and 4 “Send Flt Cfg” Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, C147...C150. C150 C147 C144 [EN Idle Flt Actn] Related Parameter(s): P045 , C145 , C146 , - 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 be cause the controller was switched to program mode. nterface and le Flt Actn] lets you determine the action of the EtherNet/IP i Risk of injury or equipment damage exists. Parameter C144 [EN Id ATTENTION: ve continues to run. Precautions r faults the drive. you can set this parameter so that the dri connected drive if the scanner is idle. By default, this paramete should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage. When commiss ioning the drive, verify that ations (for example, a disconnected drive). your system responds correctly to various situ Options 0“Fault” (Default) 1 “Stop” Drive stops per P045 [Stop Mode] setting. “Zero Data” Note: The Reference and Datalink values transmitted to the drive will be set to “0”. 2 Note: The Logic Command, Reference, and Datalink values transmitted to the drive will be held at their last value. 3 “Hold Last” Note: The Logic Command, Reference, and Datalink values will be transmitted to the drive as configured in C145, 4 C146, and “Send Flt Cfg” C147...C150. C145 [EN Flt Cfg Logic] Related Parameter(s): C143 , C144 2 3 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” an d the scanner is put into Program or Test mode. for more information. on page 203 Writing (06) Logic Command Data See Values Default: 0000 Min/Max: 0000/FFFF Display: 0000 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 104

105 Chapter 3 Programming and Parameters (continued) Communications Group 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. d the scanner is put into Program or Test mode. [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” an C144 – Default: 0 Values Min/Max: 0/50000 1 Display: 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 se nt 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. [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” an d the scanner is put into Program or Test mode. – C144 Default: Values 0 Min/Max: 0/65535 1 Display: C153 [EN Data In 1] C154 [EN Data In 2] [EN Data In 3] C155 [EN Data In 4] C156 PF 525 PowerFlex 525 only. d EtherNet/IP data table. This parameter cannot be changed whe n an I/O connection is established through the Datalink parameter number whose value is written from the embedde drive’s embedded EtherNet/IP port. Values 0 Default: Min/Max: 0/800 1 Display: C157 [EN Data Out 1] C158 [EN Data Out 2] C159 [EN Data Out 3] [EN Data Out 4] C160 PF 525 PowerFlex 525 only. Datalink parameter number whose value is re ad from the embedded EtherNet/IP data table. This parameter cannot be changed when a n I/O connection is established through the drive’s embedded EtherNet/IP port. Values Default: 0 Min/Max: 0/800 Display: 1 105 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

106 Chapter 3 Programming and Parameters (continued) Communications Group C161 [Opt Data In 1] C162 [Opt Data In 2] [Opt Data In 3] C163 C164 [Opt Data In 4] Speed Drive Serial Interface (HSDSI) data table. This parameter cannot be changed when an I/O connection is Datalink parameter number whose value is written from the High communication adapter. established through the Default: 0 Values 0/800 Min/Max: 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 re ad from the HSDSI data table. This parame ter cannot be changed when an I/O connectio n is established through the communication adapter. Values Default: 0 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. ll function as a Options 0 “Disabled” (Default) No multi-drive master from the internal netw ork option module or embedded Ethernet port. The drive can sti multi-drive slave or as a single drive (no multi-drive used). 1 up to four slave tion as a multi-drive master. The host drive is “Drive 0” and “Network Opt” Multi-drive is enabled with the internal network op drives can be daisy-chai ned from its RS485 port. (1) 2“EtherNet/IP” Multi-drive is enabled with the embedded Ethernet port as the multi-drive master. The host drive is “Drive 0” and up to four sl ave drives can be daisy-chai ned from its RS485 port. (1) Setting is specific to PowerFlex 525 drives only. C171 [Drv 1 Addr] Related Parameter(s): C169 C172 [Drv 2 Addr] C173 [Drv 3 Addr] C174 [Drv 4 Addr] [MultiDrv Sel] is set to 1 “Network Opt” or 2 “EtherNet/IP”. A reset or power cycle is required after Sets the corresponding no de addresses of the dais y-chained drives when C169 selection is made. Default: Values Drv 1 Addr: 2 Drv 2 Addr: 3 Drv 3 Addr: 4 5 Drv 4 Addr: Min/Max: 1/247 Display: 1 C175 [DSI I/O Cfg] Sets the configuration of the Drives that are active in the mu lti-drive mode. Identifies the connections that would be attempte d on a reset or power cycle. A reset or power cycle is required after selection is made. “Drive 0” (Default) Options 0 1“Drive 0-1” 2“Drive 0-2” 3“Drive 0-3” 4“Drive 0-4” Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 106

107 Programming and Parameters Chapter 3 Logic Group [Stp Logic 0] L180 [Stp Logic 1] Related Parameter(s): L181 L182 [Stp Logic 3] [Stp Logic 2] L183 [Stp Logic 4] L185 [Stp Logic 5] L184 [Stp Logic 6] L186 L187 [Stp Logic 7] Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Default: Values 00F1 Min/Max: 0000/FAFF 0001 Display See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic. P047 , Parameters L180...L187 , or P051 [Speed Referencex] is set to 13 “Step Logic” or 16 “Positioning ”. These parameters can be used to create a custom profile of are only active if P049 d on time, status of a Logic input or a combination of time and the status of a Logi c input. frequency commands. Each “step” can be base ter must be programmed according to the desi red profile. A Logic input is established by setting a digita l input, parameters t062 , t063 , Digits 1...4 for each [Stp Logic x] parame ... [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]. t068 t065 ble below for related parameters. [Stp Logic Time x]. See the ta ... L197 A time interval between steps ca L190 n be programmed using parameters ... [Preset Freq x]. The speed for any step is programmed using parameters A417 A410 Step StepLogic Parameter Related Preset Frequency Parameter Related StepLogic Time Parameter (Can be activated independent of StepLogic Parameters) (Active when L180...L187 Digit 1 or 2 are set to 1, b, C, d or E) L180 [Stp Logic 0] A410 [Preset Freq 0] L190 [Stp Logic Time 0] 0 L191 [Stp Logic Time 1] A411 [Preset Freq 1] L181 [Stp Logic 1] 1 A412 [Preset Freq 2] L182 [Stp Logic 2] 2 L192 [Stp Logic Time 2] 3 L183 [Stp Logic 3] A413 [Preset Freq 3] L193 [Stp Logic Time 3] 4 L184 [Stp Logic 4] A414 [Preset Freq 4] L194 [Stp Logic Time 4] A415 [Preset Freq 5] L185 [Stp Logic 5] 5 L195 [Stp Logic Time 5] 6 A416 [Preset Freq 6] L196 [Stp Logic Time 6] L186 [Stp Logic 6] 7 L187 [Stp Logic 7] A417 [Preset Freq 7] L197 [Stp Logic Time 7] The position for any step is programmed using parameters L200 ... L214 [Step Units x]. Step StepLogic Position Parameter L200 [Step Units 0] & L201 [Step Units F 0] 0 1 L202 [Step Units 1] & L203 [Step Units F 1] 2 L204 [Step Units 2] & L205 [Step Units F 2] L206 [Step Units 3] & L207 [Step Units F 3] 3 L208 [Step Units 4] & L209 [Step Units F 4] 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 st ep. When the condition is met the program ad vances 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 ogram overrides Digit 0 and jumps to the step defined by Digit 3. For all settings other than F, when the condition is met, the pr Digit 3: Different step to jump When the condition for Digit 2 is me t, this digit setting de termines 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 the condition of different StepLogic commands. opto output, but you can not control different outputs based on n 520-UM001I-EN-E - July 2016 107 Rockwell Automation Publicatio

108 Chapter 3 Programming and Parameters StepLogic Settings r each StepLogic parameter. The following is a listing of the av Appendix D The logic for each function is de ailable settings for each digit. See termined by the four digits fo for more information. Logic for next step Digit 1 Digit 2 Logic to jump to a different step Different step to jump Digit 3 Step settings Digit 4 Not Used Settings (Digit 3) Velocity Control Settings (Digit 4) Accel/Decel Commanded Required Setting Description StepLogic Output State Param. Used Setting Direction 0Jump to Step 0 Off FWD Accel/Decel 1 0 1Jump to Step 1 1 Accel/Decel 1 Off REV 2Jump to Step 2 Off No Output 2 Accel/Decel 1 3Jump to Step 3 3 Accel/Decel 1 On FWD 4Jump to Step 4 On 4 Accel/Decel 1 REV 5Jump to Step 5 Accel/Decel 1 On No Output 5 6Jump to Step 6 Off Accel/Decel 2 6 FWD 7Jump to Step 7 7 REV Accel/Decel 2 Off 8 End Program (Normal Stop) 8 Accel/Decel 2 No Output Off 9 End Program (Coast to Stop) On FWD 9 Accel/Decel 2 A End Program and Fault (F2) REV On Accel/Decel 2 A No Output On Accel/Decel 2 b Settings (Digit 2 and 1) Setting Description Positioning Settings (Digit 4) 0 Skip Step (Jump Immediately) Required StepLogic Type of Accel/Decel Direction Step Based on [Stp Logic Time x] 1 Param. Used Command Setting From Home Output State 2 Step if “Logic In 1” is Active FWD 0 Accel/Decel 1 Off Absolute Step if “Logic In 2” is Active 3 1 Accel/Decel 1 Incremental FWD Off 4 Step if “Logic In 1” is Not Active Accel/Decel 1 Absolute REV Off 2 Step if “Logic In 2” is Not Active 5 Incremental 3 Accel/Decel 1 Off REV Step if either “Logic In 1” or “Logic In 2” is Active 6 On Absolute Accel/Decel 1 FWD 4 Step if both “Logic In 1” and “Logic In 2” are Active 7 Incremental Accel/Decel 1 On 5 FWD 8 Step if neither “Logic In 1” nor “Logic In 2” is Active Absolute REV On Accel/Decel 1 6 Step if “Logic In 1” is Active and “Logic In 2” is Not Active 9 On REV 7 Incremental Accel/Decel 1 A Step if “Logic In 2” is Active and “Logic In 1” is Not Active Absolute FWD Off Accel/Decel 2 8 b Step after [Stp Logic Time x] and “Logic In 1” is Active Accel/Decel 2 9 Incremental Off FWD Step after [Stp Logic Time x] and “Logic In 2” is Active C Accel/Decel 2 Off REV Absolute A d Step after [Stp Logic Time x] and “Logic In 1” is Not Active b Incremental REV Off Accel/Decel 2 E Step after [Stp Logic Time x] and “Logic In 2” is Not Active Accel/Decel 2 Absolute FWD C On Do Not Step/Ignore Digit 2 Settings F Incremental FWD On Accel/Decel 2 d E Absolute REV On Accel/Decel 2 Incremental On Accel/Decel 2 F REV Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 108

109 Programming and Parameters Chapter 3 Logic Group (continued) L190 [Stp Logic Time 0] L191 [Stp Logic Time 1] [Stp Logic Time 2] L192 L193 [Stp Logic Time 3] L195 [Stp Logic Time 5] [Stp Logic Time 4] L194 [Stp Logic Time 6] L196 L197 [Stp Logic Time 7] PF 525 PowerFlex 525 only. Sets the time to remain in each step if the corres ponding command word is set to “Step based on time”. Values Default: 30.0 s Min/Max: 0.0/999.9 s Display: 0.1 s L200 [Step Units 0] [Step Units 1] L202 [Step Units 2] L204 L206 [Step Units 3] L208 [Step Units 4] L210 [Step Units 5] [Step Units 6] L212 L214 [Step Units 7] 3 2 32 bit parameter. PF 525 PowerFlex 525 only. Sets the position in user-defined units the drive must reach at each step. Values Default: 0.00 Min/Max: 0.00/6400.00 Display: 0.01 n 520-UM001I-EN-E - July 2016 109 Rockwell Automation Publicatio

110 Chapter 3 Programming and Parameters Advanced Display Group d360 t091 , t092 [Analog In 0-10V] Related Parameter(s): Displays the 0-10V analog input as a percent of full scale. Default: Values Read Only Min/Max: 0.0/100.0% 0.1% Display: d361 Related Parameter(s): t095 , t096 [Analog In 4-20mA] Displays the 4-20 mA analog input as a percent of full scale. Default: Values Read Only 0.0/100.0% Min/Max: 0.1% Display: d362 [Elapsed Time-hr] Related Parameter(s): A555 Displays the total elapsed powered-up time (in hours) since ti mer reset. The timer stops when it reaches the maximum value. Values Default: Read Only Min/Max: 0/32767 hr Display: 1 hr d363 [Elapsed Time-min] Related Parameter(s): d362 , A555 Displays the total elapsed powered-up time (in minutes) since timer reset. Resets to e is reached and inc rements d362 [Elapsed Time-hr] by one. zero when maximum valu Default: Values Read Only Min/Max: 0.0/60.0 min 0.1 min Display: d364 [Counter Status] Displays the current value of the counter if enabled. Values Default: Read Only Min/Max: 0/65535 Display: 1 d365 [Timer Status] 32 32 bit parameter. Displays the current value of the timer if enabled. Values Default: Read Only Min/Max: 0.0/9999.0 s 0.1 s Display: d367 [Drive Type] Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non Rockwell Auto mation technical personnel). Values Default: Read Only Min/Max: 0/65535 Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 110

111 Programming and Parameters Chapter 3 (continued) Advanced Display Group d368 Related Parameter(s): A483 [Testpoint Data] Displays the present value of the function selected in A483 [Testpoint Sel]. Values Default: Read Only 0/FFFF Min/Max: Display: 1 d369 [Motor OL Level] Displays the motor overload counter. Default: Read Only Values 0.0/150.0% Min/Max: 0.1% Display: [Slip Hz Meter] Related Parameter(s): P032 d375 n the setting for P032 [Motor NP Hertz]. Displays the current amount of slip or droop (absolute value) being applied to the motor frequency. Drives applies slip based o Default: Read Only Values Min/Max: 0.0/25.0 Hz Display: 0.1 Hz d376 [Speed Feedback] 2 3 32 bit parameter. Displays the value of the actual motor speed whether me asured by encoder/pulse train feedback or estimated. Default: Read Only Values 0.0/64000.0 rpm Min/Max: Display: 0.1 rpm d378 [Encoder Speed] 32 32 bit parameter. (1) Provides a monitoring point that reflects the speed measured fr eed even if not used directly to control motor speed. om the feedback device. This sh ows the encoder or pulse train sp Values Default: Read Only Min/Max: 0.0/64000.0 rpm Display: 0.1 rpm (1) PowerFlex 523 FRN 3.xxx and later. Parameter is also available in d380 [DC Bus Ripple] Displays the real-time value of the DC bus ripple voltage. Values Default: Read Only for 460VAC drives; 1025VDC for 600VAC drives Min/Max: 0/410VDC for 230V AC drives; 820VDC Display: 1V DC d381 [Output Powr Fctr] Displays the angle in electrical degrees between motor voltage and motor current. Values Default: Read Only 0.0/180.0 deg Min/Max: 0.1 deg Display: n 520-UM001I-EN-E - July 2016 111 Rockwell Automation Publicatio

112 Chapter 3 Programming and Parameters (continued) Advanced Display Group d382 [Torque Current] Displays the current value of the motor torque current measured by the drive. Values Default: Read Only 0.00/(Drive Rated Amps x 2) Min/Max: 0.01 A Display: d383 [PID1 Fdbk Displ] [PID2 Fdbk Displ] d385 PF 525 PowerFlex 525 only. Displays the active PID Feedback value. Default: Read Only Values 0.0/100.0% Min/Max: Display: 0.1% d384 [PID1 Setpnt Disp] d386 [PID2 Setpnt Disp] PF 525 PowerFlex 525 only. Displays the active PID Setpoint value. Values Default: Read Only Min/Max: 0.0/100.0% Display: 0.1% 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. 1 = Condition True, 0 = Condition False Dir Positive Digit 1 Digit 2 At Position Digit 3 At Home Digit 4 Drive Homed Not Used Values Read Only Default: Min/Max: 0000/1111 0000 Display: d388 [Units Traveled H] Related Parameter(s): d387 Stop drive before changing this parameter. 2 3 32 bit parameter. PF 525 PowerFlex 525 only. s traveled from the home position. See d387 [Position Status] for direction of travel. Displays the number of user-defined unit Values Default: Read Only Min/Max: 0/64000 Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 112

113 Programming and Parameters Chapter 3 Advanced Display Group (continued) d389 [Units Traveled L] Related Parameter(s): d387 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. d387 [Position Status] for direction of travel. Displays the number of user-defined unit s traveled from the home position. See Values Default: Read Only Min/Max: 0.00/0.99 0.01 Display: [Fiber Status] d390 Present status of the Fibers features. 1 = Condition True, 0 = Condition False Sync Hold Digit 1 Sync Ramp Digit 2 D i g i t 3 Trave r s e O n D i g i t 4 Trave r s e D e c Not Used Read Only Default: Values Min/Max: 0000/1111 0000 Display: [Stp Logic Status] Related Parameter(s): P047 , L180 - L187 d391 PF 525 PowerFlex 525 only. L180 ... L187 [Step Logic x] when P047 [Speed Reference1] is set to 13 “Step Logic” or 16 “Positioning”. Displays the current step of the Step Logic profile as defined by parameters Default: Values Read Only Min/Max: 0/8 Display: 1 d392 [RdyBit Mode Act] Related Parameter(s): A574 (With PowerFlex 525 FRN 3.xxx and later.) (With PowerFlex 523 FRN 3.xxx and later.) [RdyBit Mode Cfg]. Displays the value of A574 Values Default: Read Only Min/Max: 0/1 Display: 1 n 520-UM001I-EN-E - July 2016 113 Rockwell Automation Publicatio

114 Programming and Parameters Chapter 3 (continued) Advanced Display Group 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. (1) (1) (1) (1) DC Braking Safety S1 Auto Tuning At Freq EM Braking AutoRst Ctdn Curr Limit Safety S2 F111 Status Jogging SafeTqPermit Flux Braking Motor Overld x 0 0 0 0 x x 0 0 00 0 0 0 0 0 1 = Condition True 0 = Condition False 8 11 12 1 3 14 15 7 9 6 5 3 2 1 0 10 4 x = Reserved Nibble Nibble 4 3 Nibble 2 Nibble 1 Bit # * Enhanced Control 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. Status Bit Value = 1 Bit Value = 0 Rly1 Status Digit 1 Not activated Activated (Relay 1 closed) (Relay 1 open) Relay 1 status (Normally Open) (1) Rly2 Status Digit 2 Activated (Relay 2 open) Relay 2 status (Normally Closed) Not activated (Relay 2 closed) (1) Opto1 Status Digit 3 (1) Not activated Activated Opto 1 status Digit 4 Opto2 Status Activated Not activated Opto 2 status Not Used (1) Setting is specific to PowerFlex 525 drives only. Values Default: Read Only Min/Max: 0/15 Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 114

115 Programming and Parameters Chapter 3 Advanced Program Group A410 [Preset Freq 0] A411 [Preset Freq 1] A413 [Preset Freq 3] A412 [Preset Freq 2] A415 [Preset Freq 5] A414 [Preset Freq 4] A416 A417 [Preset Freq 6] [Preset Freq 7] [Preset Freq 8] A418 [Preset Freq 9] A419 [Preset Freq 10] A420 A421 [Preset Freq 11] A422 [Preset Freq 12] [Preset Freq 13] A423 [Preset Freq 14] A424 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 Preset Input 4 Default Accel/Decel Used Preset Input 1 Preset Input 2 Preset Input 3 (DigIn TermBlk 05) (DigIn TermBlk 08) (DigIn TermBlk 06) (DigIn TermBlk 07) (1) Preset Setting 0 10000 0 1 1 Preset Setting 1 0 0 0 Preset Setting 2 1 0 2 0 Preset Setting 3 1 1 0 0 2 0 0 1 Preset Setting 4 1 0 0 1 1 Preset Setting 5 0 1 0 1 1 0 2 Preset Setting 6 0 2 Preset Setting 7 1 1 1 1 1 0 0 0 Preset Setting 8 1 1 1 0 0 Preset Setting 9 Preset Setting 10 0 1 1 0 2 0 1 1 1 2 Preset Setting 11 0 1 Preset Setting 12 0 1 1 Preset Setting 13 1 0 1 1 1 1 2 0 1 1 Preset Setting 14 2 Preset Setting 15 1 1 1 1 For PowerFlex 523 Preset Input 3 Default Accel/Decel Used Preset Input 1 Preset Input 2 – (DigIn TermBlk 05) (DigIn TermBlk 03) (DigIn TermBlk 06) (1) Preset Setting 0 1000 0 1 Preset Setting 1 1 0 0 Preset Setting 2 0 1 2 Preset Setting 3 2 1 1 0 – Preset Setting 4 0 1 1 0 Preset Setting 5 1 1 0 1 1 Preset Setting 6 2 0 1 1 1 2 Preset Setting 7 1 (1) P051 [Speed Referencex] is set to 7 “Preset Freq”. Preset Setting 0 is only available if P047, P049 or Values Defaults: Preset Freq 0: 0.00 Hz Preset Freq 1: 5.00 Hz 10.00 HZ Preset Freq 2: 20.00 Hz Preset Freq 3: Preset Freq 4: 30.00 Hz 40.00 Hz Preset Freq 5: Preset Freq 6: 50.00 Hz Preset Freq 7...15: 60.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz n 520-UM001I-EN-E - July 2016 115 Rockwell Automation Publicatio

116 Chapter 3 Programming and Parameters (continued) Advanced Program Group [Keypad Freq] Related Parameter(s): P047 , P049 , P051 A426 g the built-in keypad navigation. When Provides the drive frequency command usin , P049 or P051 [Speed Referencex] selects 2 “Keypad Freq”, the value set in this parameter P047 controls the frequency of the drive. The valu e of this parameter can also be changed wh en navigating with the keypad by pressin g the Up or Down arrow keys. Values Default: 60.00 Hz Min/Max: 0.00/500.00 Hz 0.01 Hz Display: A427 [MOP Freq] Provides the drive frequency command using the built-in Motor Operated Potentiometer (MOP). powered-down. If both MOP Up and MOP Down are applied at the sa me time, the inputs are Frequency is not written to non-volatile storage until drive is IMPORTANT ignored and the frequency is unchanged. 60.00 Hz Values Default: 0.00/500.00 Hz Min/Max: 0.01 Hz Display: A428 [MOP Reset Sel] Determines if the current MOP reference command is saved on power down. Options 0 Resets the MOP frequency to zero on power down and stop. “Zero MOP Ref ” “Save MOP Ref ” (Default) 1 [MOP Preload] A429 Determines the operatio n of the MOP function. 0 “No preload” (Default) Options “Preload” Bumpless Transfer: whenever MOP mode is selected, the current ou tput value of the speed is loaded. 1 A430 [MOP Time] Sets the rate of change of the MOP reference. Values Default: 10.0 s Min/Max: 0.1/600.0 s Display: 0.1 s A431 [Jog Frequency] Related Parameter(s): P044 Sets the output frequency when a jog command is issued. Values Default: 10.00 Hz Min/Max: 0.00/[Maximum Freq] Display: 0.01 Hz A432 [Jog Accel/Decel] Sets the acceleration and deceleration time used when in jog mode. Values Default: 10.00 s 0.01/600.00 s Min/Max: 0.01 s Display: Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 116

117 Programming and Parameters Chapter 3 (continued) Advanced Program Group [Purge Frequency] Related Parameter(s): t062 , t063 , t065 - t068 A433 t062 , t063 , t065 - t068 Provides a fixed frequency command value when [DigIn TermBlk xx] is set to 40 “Purge”. Values Default: 5.00 Hz Min/Max: 0.00/500.00 Hz Display: 0.01 Hz A434 [DC Brake Time] Related Parameter(s): P045 , A435 Sets the length of time that DC brake current is “injected” into the motor. Values Default: 0.0 s Min/Max: 0.0/99.9 s Display: 0.1 s [DC Brake Level] A435 Related Parameter(s): P045 [Stop Mode] is set to either 4 “Ramp” or 6 “DC Brake”. P045 Defines the maximum DC brake current, in amps, applied to the motor when Ramp-to-Stop Mode DC Injection Stop Mode [DC Brake Time] Voltage Voltage Speed Speed [DC Brake Time] Magnitude Magnitude Volts/Speed Volts/Speed depends on depends on [DC Brake Level] [DC Brake Level] Time Time Stop Command Stop Command s feature should ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used. Thi rs may be demagnetized during braking. not be used with synchronous motors. Moto Drive Rated Amps x 0.05 Values Default: Min/Max: 0.00/(Drive Rated Amps x 1.80) Display: 0.01 A A436 [DC Brk [email protected]] Related Parameter(s): P045 , A435 d” into the motor after a valid start command is received. Sets the length of time that DC brake current is “injecte Voltage [DC Brk [email protected]] Speed Volts/Speed [DC Brake Level] Time Start Command 0.0 s Values Default: 0.0/99.9 s Min/Max: 0.1 s Display: n 520-UM001I-EN-E - July 2016 117 Rockwell Automation Publicatio

118 Programming and Parameters Chapter 3 (continued) Advanced Program Group Related Parameter(s): A438 , A550 A437 [DB Resistor Sel] Stop drive before changing this parameter. Enables/disables external dyna mic braking and selects the level of resistor protection. e greater than “0”, the value set in parameter A550 When A437 [DB Resistor Sel] is set to a valu ll not take effect. [Bus Reg Enable] wi IMPORTANT “Disabled” (Default) 0 Options 1 “Norml RA Res” 5% 100% “NoProtection” 2 “3...99% DutyCycle” 3...99 A438 [DB Threshold] Related Parameter(s): A437 Sets the DC bus voltage threshold for Dynamic Brake operation. If nction more DC bus voltage rises above this level, Dynamic Brake turns on . Lower values makes the dyna mic braking fu responsive but may result in nuisance Dynamic Brake activation (IGBT can modulate continuously). power. Parameter ter is set to a value that causes the dynamic braking resistor to dissipate excessive ATTENTION: Equipment damage may result if this parame wattage rating is not exceede that the Dynamic Brake resistor's settings less than 100% should be carefully evaluated to ensure d. 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 “NoProtect ion”. Default: 100.0% Values 10.0/110.0% Min/Max: 0.1% Display: [S Curve %] A439 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) Example: 100% S-Curve 50% S-Curve Accel Time = 10 s Target Target vel vel S-Curve Setting = 30% S-Curve Time = 10 x 0.3 = 3 s Target vel/2 S-Curve Time S-Curve Time = Accel Time Total Time to Accelerate = Accel Time + S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time 0% Default: Values 0/100% Min/Max: Display: 1% Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 118

119 Chapter 3 Programming and Parameters Advanced Program Group (continued) A440 [PWM Frequency] Related Parameter(s): A540 es based on the PWM frequency setting. Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelin 100 96 92 88 84 80 Note: If Vector mode (open loop) is selected and 16 kHz is selected, 76 the drive will forcibly reduce the carrier frequency to 8 kHz. 72 68 64 % Output Curent (A) 60 56 50 7 14 13 16 8 6 15 10 11 5 4 3 2 1 12 9 Carrier Frequency (kHz) Ignoring derating guidelines can cause re duced drive performance. The drive may auto matically reduce the PWM carrier frequency at low output speeds, IMPORTANT unless prevented from doing so by A540 [Var PWM Disable]. 4.0 kHz Default: Values Min/Max: 2.0/16.0 kHz 0.1 kHz Display: [Droop [email protected] FLA] A441 PF 525 PowerFlex 525 only. Reduces the frequency based on current. This frequency is subtra cted from the commanded output frequency. Generally Slip and Dr oop would not both be used, but if both are enabled Typically used in load sharing schemes. they simply subtract from each other. Default: 0.0 Hz Values Min/Max: 0.0/10.0 Hz 0.1 Hz Display: A442 [Accel Time 2] Related Parameter(s): P044 [Maximum Freq] if Accel Time 2 is selected. Time for the drive to ramp from 0.0 Hz to P044 Accel Rate = [Maximum Freq] / [Accel Time] [Maximum Freq] Deceleration Speed Acceleration 0 [Accel Time x] [Decel Time x] Time 0 Values 10.00 s Default: 0.00/600.00 s Min/Max: 0.01 s Display: A443 [Decel Time 2] Related Parameter(s): P044 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] Values Default: 10.00 s 0.00/600.00 s Min/Max: 0.01 s Display: n 520-UM001I-EN-E - July 2016 119 Rockwell Automation Publicatio

120 Chapter 3 Programming and Parameters (continued) Advanced Program Group [Accel Time 3] A444 A446 [Accel Time 4] Sets the rate of acceleration for all speed increases when selected by digital inputs. Default: 10.00 s Values 0.00/600.00 s Min/Max: Display: 0.01 s A445 [Decel Time 3] A447 [Decel Time 4] Sets the rate of deceleration for all speed decreases when selected by digital inputs. Values Default: 10.00 s Min/Max: 0.00/600.00 s Display: 0.01 s A448 [Skip Frequency 1] Related Parameter(s): A449 , A451 , A453 , A455 A450 [Skip Frequency 2] A452 [Skip Frequency 3] A454 [Skip Frequency 4] PF 525 PowerFlex 525 only. Works in conjunction with A453 A449 , A451 , s at which the drive does not operate continuously. and A455 [Skip Freq Band x] creating a range of frequencie Values 0.0 Hz (Disabled) Default: Min/Max: 0.0/500.0 Hz Display: 0.1 Hz [Skip Freq Band 1] A448 Related Parameter(s): A449 , A450 , A452 , A454 [Skip Freq Band 2] A451 A453 [Skip Freq Band 3] [Skip Freq Band 4] A455 PF 525 PowerFlex 525 only. and A448 , A450 , A452 Determines the band around A454 [Skip Frequency x]. Command Frequency Frequency Drive Output Frequency 2x Skip Skip Frequency Frequency Band Time 0.0 Hz Default: Values 0.0/30.0 Hz Min/Max: 0.1 Hz Display: Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 120

121 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. Values Default: 60.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.1 Hz [PID 1 Trim Lo] A457 A469 [PID 2 Trim Lo] PF 525 PowerFlex 525 only. Scales the lower value of the trim frequency when trim is active. Values Default: 0.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.1 Hz A458 [PID 1 Trim Sel] [PID 2 Trim Sel] A470 PF 525 PowerFlex 525 only. Stop drive before changing this parameter. Sets the PID output as trim to the source reference. Options 0 “Disabled” (Default) PID Trim is disabled. 1“TrimOn Pot” 2 “TrimOn Keypd” 3“TrimOn DSI” 4“TrimOn NetOp” 5 “TrimOn 0-10V” 6 “TrimOn 4-20” 7“TrimOn Prset” (1) 8“TrimOn AnMlt” 9“TrimOn MOP” 10 “TrimOn Pulse” (1) 11 “TrimOn Slgic” (1) 12 “TrimOn Encdr” (1) 13 “TrimOn ENet” (1) Setting is specific to PowerFlex 525 drives only. 121 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

122 Chapter 3 Programming and Parameters Advanced Program Group (continued) 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. Options 0“PID Setpoint” (Default) 1“Drive Pot” 2“Keypad Freq” 3 “Serial/DSI” 4 “Network Opt” 5 “0-10V Input” 6 “4-20mA Input” 7 “Preset Freq” (1) 8 “AnlgIn Multi” 9“MOP Freq” 10 “Pulse Input” (1) 11 “Step Logic” (1) 12 “Encoder” (1) 13 “EtherNet/IP” (1) Setting is specific to PowerFlex 525 drives only. [PID 1 Fdback Sel] A460 [PID 2 Fdback Sel] A472 PF 525 PowerFlex 525 only. Selects the source of the PID feedback. Options 0 “0-10V Input” (Default) Note: PID does not function with bipo lar input. Negative voltages are ignored and treated as zero. 1 “4-20mA Input” 2 “Serial/DSI” “Network Opt” 3 4“Pulse Input” (1) 5“Encoder” (1) 6“EtherNet/IP” (1) Setting is specific to PowerFlex 525 drives only. , A471 A461 [PID 1 Prop Gain] Related Parameter(s): A459 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: Values 0.01 Min/Max: 0.00/99.99 Display: 0.01 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 122

123 Programming and Parameters Chapter 3 (continued) Advanced Program Group A462 [PID 1 Integ Time] Related Parameter(s): A459 A471 , A474 [PID 2 Integ Time] PF 525 PowerFlex 525 only. component when PID mode is enabled. Sets the value for the PID integral Values Default: 2.0 s Min/Max: 0.0/999.9 s 0.1 s Display: A463 Related Parameter(s): A459 , A471 [PID 1 Diff Rate] A475 [PID 2 Diff Rate] PF 525 PowerFlex 525 only. rential component when PID mode is enabled. Sets the value (in 1/second) for the PID diffe Values Default: 0.00 Min/Max: 0.00/99.99 Display: 0.01 A459 A464 [PID 1 Setpoint] Related Parameter(s): , A471 A476 [PID 2 Setpoint] PF 525 PowerFlex 525 only. ess setpoint when PID mode is enabled. Provides an internal fixed value for proc Values 0.0% Default: 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 PI D Reference, that the PID output will ignore. Default: 0.0% Values 0.0/10.0% Min/Max: 0.1% Display: A466 [PID 1 Preload] A478 [PID 2 Preload] PF 525 PowerFlex 525 only. tegral component on start or enable. Sets the value used to preload the in Values Default: 0.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.1 Hz [PID 1 Invert Err] A467 [PID 2 Invert Err] A479 PF 525 PowerFlex 525 only. Changes the sign of the PID error. Options 0“Normal” (Default) 1“Inverted” n 520-UM001I-EN-E - July 2016 123 Rockwell Automation Publicatio

124 Chapter 3 Programming and Parameters (continued) Advanced Program Group A481 b010 , P043 [Process Disp Lo] Related Parameter(s): [Process Display] when the drive is running at P043 [Minimum Freq]. b010 Sets the value displayed in Default: 0.00 Values 0.00/99.99 Min/Max: Display: 0.01 A482 [Process Disp Hi] Related Parameter(s): , P044 b010 Sets the value displayed in b010 [Process Display] when the drive is running at P044 [Maximum Freq]. Values 0.00 Default: Min/Max: 0.00/99.99 Display: 0.01 A483 [Testpoint Sel] Used by Rockwell Automation field service personnel. Values Default: 400 Min/Max: 0/FFFF Display: 1 P033 A484 [Current Limit 1] Related Parameter(s): Maximum output current allowed be fore current limiting occurs. Values Default: Drive Rated Amps x 1.1 (Normal Duty); Drive Rated Amps x 1.5 (Heavy Duty) Min/Max: 0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty) 0.1 A Display: A485 P033 Related Parameter(s): [Current Limit 2] PF 525 PowerFlex 525 only. Maximum output current allowed be fore current limiting occurs. Drive Rated Amps x 1.1 Values Default: 0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty) Min/Max: Display: 0.1 A A486 [Shear Pin1 Level] Related Parameter(s): A487 , A489 [Shear Pin2 Level] A488 PF 525 PowerFlex 525 only. r pin fault occurs after the time set in this function. , A489 [Shear Pin x Time]. Setting the valu e at 0.0 A disables Sets the value of current at which the shea A487 Default: 0.0 A (Disabled) Values Min/Max: 0.0/(Drive Rated Amps x 2) Display: 0.1 A , A488 A487 [Shear Pin 1 Time] Related Parameter(s): A486 [Shear Pin 2 Time] A489 PF 525 PowerFlex 525 only. [Shear Pinx Level] before a shear pin fault occurs. Sets the continuous time the drive mu st be at or above the value set in A486 , A488 Values Default: 0.00 s Min/Max: 0.00/30.00 s Display: 0.01 s n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 124

125 Programming and Parameters Chapter 3 Advanced Program Group (continued) [Load Loss Level] Related Parameter(s): A491 A490 PF 525 PowerFlex 525 only. A491 [Load Loss Time]. is level for the time specified in Provides a software trip (Load Loss fault) when the current drops below th Values Default: 0.0 A 0.0/Drive Rated Amps Min/Max: 0.1 A Display: A491 [Load Loss Time] Related Parameter(s): A490 PF 525 PowerFlex 525 only. [Load Loss Level] before a Load Loss fault occurs. Sets the required time for the current to be below A490 0 s Values Default: 0/9999 s Min/Max: Display: 1 s A492 [Stall Fault Time] Sets the time that the drive remains in stall mode before a fault is issued. 0 “60 Seconds” (Default) Options “120 Seconds” 1 2 “240 Seconds” 3 “360 Seconds” 4 “480 Seconds” 5“Flt Disabled” A493 [Motor OL Select] Related Parameter(s): P032 , P033 2 Drive provides Class 10 overload protection. Settings 0...2 select the derating factor for the I t overload function. No Derate Max Derate Min Derate 100 100 100 80 80 80 60 60 60 40 40 40 20 20 20 % of [Motor OL Curent] % of [Motor OL Curent] % of [Motor OL Curent] 0 0 0 175 175 150 200 150 200 75 0 25 50 125 100 25 50 100 0 125 75 175 200 150 50 125 0 100 75 25 % of [Motor NP Hertz] % of [Motor NP Hertz] % of [Motor NP Hertz] Options 0“No Derate” (Default) 1“Min. Derate” “Max. Derate” 2 A494 [Motor OL Ret] Selects whether the motor overload counter is saved on power-down or reset on power-up. Options 0“Reset” (Default) 1“Save” n 520-UM001I-EN-E - July 2016 125 Rockwell Automation Publicatio

126 Chapter 3 Programming and Parameters (continued) Advanced Program Group A495 [Drive OL Mode] Determines how the drive handles overload conditio ns that would otherwise cause the drive to fault. Options 0“Disabled” 1“Reduce CLim” “Reduce PWM” 2 “Both-PWM 1st” (Default) 3 A496 [IR Voltage Drop] Related Parameter(s): P040 Value of volts dropped across the resistance of the motor stator (autotune) for induction motor. Values Default: Based on Drive Rating Min/Max: 0.0/600.0VAC Display: 0.1VAC A497 [Flux Current Ref ] Related Parameter(s): P040 This is the current necessary for full motor flux. The value sh ould be set to the full speed no-load current of the motor. Values Default: Based on Drive Rating 0.00/(Drive Rated Amps x 1.4) Min/Max: Display: 0.01 A 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. Values Based on Drive Rating Default: Min/Max: 0.00/655.35 ohm 0.01 ohm Display: A499 [Motor Lm] PF 525 PowerFlex 525 only. Mutual Inductance of induction motor. The value of this pa rameter will populate when a full rotate tune is performed. Values Default: Based on Drive Rating Min/Max: 0.0/6553.5 mH Display: 0.1 mH [Motor Lx] A500 PF 525 PowerFlex 525 only. Leakage Inductance of induction motor. The value of this parameter will populate when a full rotate tune is performed. Based on Drive Rating Values Default: Min/Max: 0.0/6553.5 mH Display: 0.1 mH [PM IR Voltage] A501 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Voltage across the stator resistance of the PM motor at the rated motor current displayed in line-to-line rms value. Values Default: 11.50V Min/Max: 0.00/655.35V Display: 0.01V n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 126

127 Programming and Parameters Chapter 3 Advanced Program Group (continued) A502 [PM IXd Voltage] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) in line-to-line rms value. the rated motor current and the rated motor frequency displayed Voltage across the d-axis stator inductance of the PM motor at Values Default: 17.91V Min/Max: 0.00/655.35V 0.01V Display: 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 motor at in line-to-line rms value. the rated motor current and the rated motor frequency displayed Values Default: 53.21V 0.00/655.35V Min/Max: 0.01V Display: A504 [PM BEMF Voltage] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Back electromotive force (EMF) voltage. Values 1640.0 Drive Rated Volts Default: Min/Max: 0.0/6000.0 Drive Rated Volts Display: 0.1V A509 [Speed Reg Sel] Related Parameter(s): A521 , A522 , A523 , A524 , A525 , A526 PF 525 PowerFlex 525 only. d regulator is set automatica lly or manually. Parameters A521 ... A526 Determines if PI gain of the “Vector” control mode spee 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: 8.33% Freq 1: Freq 2: 15.00% Freq 3: 20.00% Min/Max: 0.00/200.00% Display: 0.01% 127 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

128 Chapter 3 Programming and Parameters (continued) Advanced Program Group 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. Values Default: 10 Hz Min/Max: 0/40 Hz Display: 1 Hz [PM Initial Sel] A516 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) PM initial angle detect. Options 0“Align” (Default) “HFI” High Frequency Injection to detect initial angle. 1 2“Six Pulse” A517 [PM DC Inject Cur] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Maximum DC current in amps applie d to the motor in order to reset the rotor position of a PM motor. 30% Values Default: Min/Max: 0/300% 1% Display: A518 [PM Align Time] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Magnetic pole reorientation time. Values Default: 0.7 s Min/Max: 0.0/60.0 s Display: 0.1 s [PM HFI NS Cur] A519 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) High Frequency Injection (HFI) North South Current to detect N/S Magnet. 100% Values Default: Min/Max: 0/300% Display: 1% [PM Bus Reg Kd] A520 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Derivative gain for bus regulator. Default: Values 2 Min/Max: 0/500 Display: 1 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 128

129 Programming and Parameters Chapter 3 (continued) Advanced Program Group [Freq 1 Kp] Related Parameter(s): A509 , A510 A521 [Freq 2 Kp] A523 A525 [Freq 3 Kp] PF 525 PowerFlex 525 only. in frequency region 1, 2 or 3 for faster speed response during dynamic-state where mo tor is still accelerating. If A509 [Speed Reg Sel] is set Sets P-gain of “Vector” control mode when to 1 “Manual”, these parameters can be changed. Values Default: 100.0% Min/Max: 0.0/500.0% Display: 0.1% Related Parameter(s): A522 [Freq 1 Ki] A510 A509 , [Freq 2 Ki] A524 A526 [Freq 3 Ki] 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 mot or is at its rated speed. If A509 [Speed Reg Sel] is set to 1 “Manual”, these parameters can be changed. Values Default: 0.100 s Min/Max: 0.000/10.000 s 0.001 s Display: [PM FWKn 1 Kp] A527 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) The gain to ensure good performance in field weakening region. Default: Values 250% Min/Max: 0/2000% 1% Display: A528 [PM FWKn 2 Kp] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) The gain to ensure robustness unde r step load in weakening region. Values Default: 100% Min/Max: 100/8000% Display: 1% 129 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

130 Programming and Parameters Chapter 3 (continued) Advanced Program Group A529 [PM Control Cfg] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Torque Per Amp (MTPA), and Load Disturbance Observer (LDOB). Control configuration for Feed Forward Decouple (FFD), Maximum 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 00111 Default: Values 00000/00111 Min/Max: 00000 Display: P032 A530 [Boost Select] Related Parameter(s): b004 , P031 , P039 , 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) 1/2 [Motor NP Volts] 50 4 3 2 1 % [Motor NP Volts] 1/2 Settings 5...14 [Motor NP Hertz] % [Motor NP Hertz] 0 50 100 [Maximum Freq] can be set anywhere. [Maximum Freq] can be set anywhere. If it is > [Motor NP Hertz] then it defines a If it is < [Motor NP Hertz] then it functions as a limit only point on the V/Hz curve (does not change the V/Hz curve) Options “Custom V/Hz” 0 “30.0, VT” 1 “35.0, VT” 2 Fan/Pump Curves (Variable Torque) 3 “40.0, VT” 4 “45.0, VT” 5 “0.0, no IR” 6“0.0” (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” Boost Voltage (% of Base) (Constant Torque) (Default for drives below 5 HP) 9“7.5, CT” 10 “10.0, CT” 11 “12.5, CT” 12 “15.0, CT” 13 “17.5, CT” 14 “20.0, CT” Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 130

131 Programming and Parameters Chapter 3 (continued) Advanced Program Group [Start Boost] Related Parameter(s): P031 , A531 , P039 , A530 P032 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] Frequency [Break Frequency] [Motor NP Hertz] [Minimum Freq] [Maximum Freq] Values 2.5% Default: 0.0/25.0% Min/Max: 0.1% Display: , A532 [Break Voltage] Related Parameter(s): P031 , P032 , P039 , A530 A533 Sets the voltage (in percent of [Base Frequency]) at the A533 A530 [Boost Select] is set to 0 “Custom V/Hz”. [Break Frequency] if Default: Values 25.0% Min/Max: 0.0/100.0% Display: 0.1% A533 [Break Frequency] Related Parameter(s): P031 , P032 , P039 , A530 , A532 Sets the frequency where [Break Voltage] is applied if A530 [Boost Select] is set to 0 “Custom V/Hz”. A532 Values Default: 15.0 Hz Min/Max: 0.0/500.0 Hz Display: 0.1 Hz A534 [Maximum Voltage] Related Parameter(s): b004 Sets the highest voltage the drive outputs. Values Default: Drive Rated Volts Min: 10V AC (on 230V AC Drives); 20V AC (on 460V AC Drives); 25V AC (on 600V AC Drives) V AC Drives); 637.5V AC (on 600V AC Drives) Max: 255V AC (on 230V AC Drives); 510V AC (on 460 1V AC Display: n 520-UM001I-EN-E - July 2016 131 Rockwell Automation Publicatio

132 Chapter 3 Programming and Parameters Advanced Program Group (continued) P039 , A535 Related Parameter(s): [Motor Fdbk Type] A537 Stop drive before changing this parameter. (1) Selects the encoder type. AT TE N T I O N : appropriate precautions to guard against The loss of analog input, encoder or other feedback may cause un intended speed or motion. Take possible unintended speed or motion. Allowable Control Modes (See P039 [Torque Perf Mode]) Hardware Inputs 0 Options V/Hz, SVC, Economize, Vector, PM Control – “None” (Default) [DigIn TermBlk 05] for PowerFlex 523 ntrol V/Hz, SVC, Economize, PM Co “Pulse Train” 1 [DigIn TermBlk 07] for PowerFlex 525 (2) 2“Single Chan” V/Hz, SVC, Economize, PM Control (2) 3“Single Check” V/Hz, SVC, Economize, PM Control Optional incremental encoder card (2) (catalog number 25-ENC-1) 4“Quadrature” V/Hz, SVC, Economize, Vector, PM Control (2) 5“Quad Check” V/Hz, SVC, Economize, Vector, PM Control PowerFlex 523 FRN 3.xxx and later. Parameter is also available in (1) (2) Setting is specific to PowerFlex 525 drives only. 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 cont rol, a minimum of 1 024 PPR encoder is re commended. The maximum encoder pulse is 250 kHz. on page 217 . For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution Default: 1024 PPR Values Min/Max: 1/20000 PPR Display: 1 PPR Related Parameter(s): t065 [Pulse In Scale] t067 , A535 A537 , t065 Sets the scale factor/gain for the Pulse Input when t067 [DigIn TermBlk 07] is set to 52 “Pulse Train”, or A535 [Motor Fdbk Type] is set to 1 “Pulse Train”. [DigIn TermBlk 05] or Input frequency (Hz) / Pulse in Scale = Output frequency (Hz) Values Default: 64 Min/Max: 0/20000 Display: 1 A538 [Ki Speed Loop] (1) Sets the I-gain used in the PI calculation of loop control only. the speed loop when feedback is used. Ap plicable to V/Hz and SVC modes in closed Default: Values 2.0 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] (1) 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. Values Default: 5.0 Min/Max: 0.0/200.0 Display: 0.1 Parameter is also available in PowerFlex 523 FRN 3.xxx and later. (1) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 132

133 Programming and Parameters Chapter 3 (continued) Advanced Program Group [Var PWM Disable] Related Parameter(s): A440 A540 Stop drive before changing this parameter. frequency for the PWM output waveform defined by A440 Enables/disables a feature that varies the carrier [PWM Frequency]. Options 0 “Enabled” (Default) 1“Disabled” A541 [Auto Rstrt Tries] Related Parameter(s): A542 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”. A542 [Auto Rstrt Delay] to a value other than “0”. 2. Set Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A541 [Auto Rstrt Tries] to a value other than “0”. [Auto Rstrt Delay] to “0”. 2. Set A542 unction without Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this f AT T E N T I O N : codes, standards, regulation s or industry guidelines. considering applicable local, national and international 0 Values Default: 0/9 Min/Max: 1 Display: A542 [Auto Rstrt Delay] Related Parameter(s): A541 Sets the time between restart attempts if A541 [Auto Rstrt Tries] is not zero. Default: Values 1.0 s Min/Max: 0.0/120.0 s 0.1 s Display: [Start At PowerUp] A543 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. unction without Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this f AT T E N T I O N : considering applicable local, national and international codes, standards, regulation s or industry guidelines. “Disabled” (Default) Options 0 1“Enabled” [Reverse Disable] Related Parameter(s): b006 A544 Stop drive before changing this parameter. Enables/disables the function that allows the direction of motor rotation to be changed. Options “Rev Enabled” (Default) 0 1 “Rev Disabled” A545 [Flying Start En] Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM. Options 0 “Disabled” (Default) “Enabled” Catch and ramp to commanded speed at every drive start. 1 n 520-UM001I-EN-E - July 2016 133 Rockwell Automation Publicatio

134 Chapter 3 Programming and Parameters (continued) Advanced Program Group [FlyStrt CurLimit] A546 Used to determine when the drive has matched the motor frequency if flying start is enabled. Values Default: 150% 30/200% Min/Max: 1% Display: A547 [Compensation] Enables/disables correction options that may improve problems with motor instability. Options 0 “Disabled” No compensation. 1 “Electrical” (Default) Some drive/motor combinations have inhere nt instabilities which are exhibited as non-sinusodial motor cu rrents. This setting attempts to correct this condition “Mechanical” Some motor/load combinations have mechanical resonances which can be excited by the drive current regulator. 2 This setting slows down the current regulator re sponse and attempts to correct this condition. 3“Both” A548 [Power Loss Mode] Sets the reaction to a loss of input power. Options 0 “Coast” (Default) Drive faults and motor coasts to a stop. 1 “Decel” Drive decelerates and attempts to keep the DC bus voltage above the undervoltage level. A549 [Half Bus Enable] ge during short-term Enables/disables the power ride through func tion which allows the drive to maintain power to the motor at 50% drive input volta power sag conditions. AT TE N T I O N : To guard against drive damage, a minimum line impedance must be provided to limit inru sh current when the power line recovers. The input ng if Half Bus is enabled. impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive's input VA rati Options “Disabled” (Default) 0 1“Enabled” [Bus Reg Enable] Related Parameter(s): A437 A550 Enables/disables the bus regulator. Options 0“Disabled” 1 “Enabled” (Default) A551 [Fault Clear] Stop drive before changing this parameter. Resets a fault and clears the fault queue. Options 0 “Ready/Idle” (Default) 1 “Reset Fault” Resets the active faul t but does not clear any fault buffer. 2 “Clear Buffer” Resets the active fault and clears all fault buffers to “0”. A552 [Program Lock] Related Parameter(s): A553 Protects parameters against change by unau thorized personnel wi th a 4-digit password. Values Default: 0000 0000/9999 Min/Max: 1111 Display: Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 134

135 Programming and Parameters Chapter 3 (continued) Advanced Program Group A553 [Program Lock Mod] Related Parameter(s): A552 A552 [Program Lock]. When set to 2 or 3, A552 [Program Lock] is added to the custom group to allow unlocking of parameters. Determines the lock mode used in parameter 0 “Full Lock” (Default) All parameters are locked except [Program Lock]. Options “Keypad Lock” All parameters are locked except [Program Lock] fr om keypad access but can still be accessed over communications. 1 2 “Custom Only” All parameters are locked and hidden except custom group and [Program Lock]. 3 “KeyPd Custom” All parameters are locked an d hidden except custom group and [Program Lo ck] from keypad access but can still be accessed over communications. [Drv Ambient Sel] A554 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. Options 0“Normal” (Default) 1“55C” 2“60C” 3 “65C +Fan Kit” Fan kit required. 4 “70C +Fan Kit” Related Parameter(s): A555 [Reset Meters] b019 , b021 , b022 , b023 , b024 , b025 d363 , , b026 , d362 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 kW h, Cost, and CO2 Sav parameter values. 2 “Reset Time” Resets min, hr, and x10 hr. A556 [Text Scroll] Sets the scrolling speed of the text in the LCD display. 0“Off” Options No scroll. 1“Low Speed” “Mid Speed” (Default) 2 3 “High Speed” A557 [Out Phas Loss En] Enable/disable output phase loss detection. unction without Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this f AT T E N T I O N : codes, standards, regulations or industry guidelines. considering applicable local, national and international 0“Disable” (Default) Options 1“Enable” [Positioning Mode] A558 Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Defines the positioning transition mode used for the position steps. Options 0 “Time Steps” (Default) Steps based on time. Preset inputs directly commands a given step. 1 “Preset Input” 2 “Step Logic” Use Step Logic Commands. Always start from Step 0. 3 “Preset StpL” Use Preset Inputs to determ ine starting step then Step Logic commands. 4 “StpLogic-Lst” Use Step Logic commands from last Step Logic step at last drive stop. n 520-UM001I-EN-E - July 2016 135 Rockwell Automation Publicatio

136 Chapter 3 Programming and Parameters (continued) Advanced Program Group A559 [Counts Per Unit] PF 525 PowerFlex 525 only. Sets the number of encoder counts equal to one user-defined unit. Values 4096 Default: Min/Max: 1/32000 Display: 1 [Enh Control Word] , t062 , t063 , t065 - t068 A560 A571 Related Parameter(s): PF 525 PowerFlex 525 only. Allows control of positioning and other fu ital input options and fu nction in the same way. nctions through parameter control for use ov er comms. The functions replicate the dig 1 = Input Present, 0 = Input Not Present Digit 1 Home Limit Find Home Digit 2 Hold Step Digit 3 Pos Redefine Digit 4 Sync Enable Digit 5 Trave r s e D i s D i g i t 6 Logic In 1 Digit 7 Logic In 2 Digit 8 Not Used Values Default: 0000 0000 0000 0000/1111 1111 Min/Max: Display: 0000 0000 dicates the drive is Digits 0 “Home Limit” at the home position In Positioning mode, this in ne. “Find Home” When set, the next start command causes the drive to find home. Set this bit to 0 after completing the homing routi 1 In Positioning mode, this input over-rides other inpu 2 ts and causes the drive to remain at its current step (running at zero speed “Hold Step” once it reaches its position) until released. 3 “Pos Redefine” In Positioning mode, this input resets the home po sition to the current position of the machine. Set this bit to 0 after completing the homing routine. this bit is reset 4 “Sync Enable” Must be used in order to hold set to enable speed synchronization. When the existing frequency when Sync Time is to zero the drive accelerates to the new commanded frequency based on A571 [Sync Time] setting. 5 “Traverse Dis” When set the traverse function is disabled. ital input 6 “Logic In 1” This provides an identical function as the “Logic In1” Digital Input option. This bi t is logically ORed with a dig t062 t063 , , t068 t065 - to move through the Step-Logic functions (speed or position) [DigIn TermBlk xx] set to 24 “Logic In1”. It can be used using comms control without requiring actual digital input transitions. , t063 , This provides and identical function as the “Logic “Logic In 2” 7 t062 gital input on. This bit is logically ORed with a di In2” Digital Input opti t065 to move through the Step-Logic functions (speed or position) [DigIn TermBlk xx] set to 25 “Logic In2”. It can be used - t068 using comms control without requiring actual digital input transitions. A561 [Home Save] PF 525 PowerFlex 525 only. Determines whether the current po sition is saved on power down. Options 0 “Home Reset” (Default) Position resets to zero on power up. 1“Home Saved” Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 136

137 Programming and Parameters Chapter 3 (continued) Advanced Program Group A562 [Find Home Freq] PF 525 PowerFlex 525 only. Sets the maximum frequency the drive uses when “Find Home” is issued. 10.0 Hz Values Default: Min/Max: 0.1/500.0 Hz 0.1 Hz Display: A563 [Find Home Dir] Stop drive before changing this parameter. PF 525 PowerFlex 525 only. Sets the direction the drive comma nds when “Find Home” is issued. Options 0“Forward” (Default) 1“Reverse” A564 [Encoder Pos Tol] PF 525 PowerFlex 525 only. et encoder unit value to Sets the “At Position” and the “At Home’ tolerance around the enco der count. The value is added to and subtracted from the targ create the tolerance range. Default: 100 Values Min/Max: 1/50000 Display: 1 A565 [Pos Reg Filter] PF 525 PowerFlex 525 only. in the position regulator. Sets the error signal filter 8 Values Default: Min/Max: 0/15 Display: 1 [Pos Reg Gain] A566 PF 525 PowerFlex 525 only. Sets the gain adjustment for the position regulator. 3.0 Values Default: Min/Max: 0.0/200.0 Display: 0.1 n 520-UM001I-EN-E - July 2016 137 Rockwell Automation Publicatio

138 Programming and Parameters Chapter 3 (continued) Advanced Program Group A567 [Max Traverse] Sets the amplitude of triang le wave speed modulation. [P Jump] [Max Traverse] [Output Freq] Hertz Traverse Bit [Fiber Status] Traverse Enable Bit Seconds 0.00 Hz Default: Values Min/Max: 0.00/300.00 Hz 0.01 Hz Display: A568 [Traverse Inc] Related Parameter(s): A567 Sets the time required for the Traverse function to accelerate traverse frequency. See the diag ram at A567 [Max Traverse]. from the minimum to the maximum Values Default: 0.00 s Min/Max: 0.00/300.00 s Display: 0.01 s A569 [Traverse Dec] Related Parameter(s): A567 from the maximum to the minimum Sets the time required for the Traverse function to decelerate traverse frequency. See the diag ram at A567 [Max Traverse]. Values Default: 0.00 s 0.00/300.00 s Min/Max: Display: 0.01 s [P Jump] Related Parameter(s): A567 A570 cted from the commanded freq A567 Sets the frequency amplitude that is added to or subtra [Max Traverse]. uency. See the diagram at Values Default: 0.00 Hz Min/Max: 0.00/300.00 Hz Display: 0.01 Hz A571 [Sync Time] Related Parameter(s): t062 , t063 , t065 - t068 , A560 - [DigIn TermBlk xx] 32 “Sync Enable”. Enables the function that holds the drive at the current frequency even if the commanded frequency changes. Used with t062 , t063 , t065 t068 [Sync Time] New Drive #2 Reference New Drive #1 Reference Hertz Speed Sync Bit [Fiber Status] Change Ref's Drive #1 and #2 Sync Enable Input Time Default: 0.0 s Values Min/Max: 0.0/3200.0 s 0.1 s Display: n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 138

139 Programming and Parameters Chapter 3 (continued) Advanced Program Group [Speed Ratio] A572 Stop drive before changing this parameter. Scales the drive speed command. Default: 1.00 Values Min/Max: 0.01/99.99 0.01 Display: 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. Description Options 1 = Enabled, 0 = Disabled ty reference for improved current limiting. Set to Limits the rate of change to the veloci Jerk Select ations with fast Accel or Decel times. 0 “Disabled” for positioning type applic Digit 1 Jerk Select ZeroSpd Slip Digit 2 ZeroSpd Slip Sets slip compensation to 0.0 Hz when the following conditions are met: • Commanded speed = 0.00 Hz Not Used • Status of drive = “At speed” Not Used • ZeroSpd Slip = 1 “Enabled” Not Used 11 Default: Values 00/11 Min/Max: 00 Display: 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 (Net work Logic Status bit 1) to go low (0). A reset or power cycl e is required after selection is made. (2) Ready Bit Status Stop Conditions Standard Enhanced Drive fault 0 0 Stop digital input terminal 01/11 open 1 0 the Remote DSI HIM Stop button 0 1 Holding down the drive’s keypad or 1 0 Stop commanded through Comms (Stop bit = 1) Software (SW) Enable digital input terminal open 1 0 (1) 00 05 [Safety Open En] set to 1 “FaultDisabled” Safe-Torque-Off (STO) condition with value of t1 (1) Condition is specific to PowerFlex 525 drives only. 1 = Active, 0 = Inactive (2) 0“Standard” (Default) Options 1“Enhanced” A575 [Flux Braking En] Related Parameter(s): A550 (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” n 520-UM001I-EN-E - July 2016 139 Rockwell Automation Publicatio

140 Chapter 3 Programming and Parameters (continued) Advanced Program Group [Phase Loss Level] A576 (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. Decrea sing this parameter's value lowers sensitivity. 25.0% for Induction motor; 4.0% for PM motor Default: Values 0.0/100.0% Min/Max: Display: 0.1% [Current Loop BW] A580 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Current loop bandwidth (0 = Automatically calculate the control gain of current loop). Values 0 Hz Default: Min/Max: 0/65535 Hz 1 Hz Display: 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]). Values Default: 0% Min/Max: 0/100% Display: 1% [PM Stable 2 Freq] A582 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) [Motor NP Hertz] x A582 [PM Stable 2 Freq]). Stabilization function will return to normal output after this frequency ( P032 Values Default: 45% Min/Max: 0/100% Display: 1% [PM Stable 1 Kp] A583 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) [PM Stable 2 Kp]. Percentage of the gain for stabilization loop. The gain is set in A584 Values Default: 40% Min/Max: 0/100% Display: 1% [PM Stable 2 Kp] A584 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) The gain for stabilization loop. Default: Values 250% Min/Max: 0/2000% Display: 1% n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 140

141 Programming and Parameters Chapter 3 (continued) Advanced Program Group A585 [PM Stable Brk Pt] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) P037 [Motor NP Power] for the gain of ( A584 [PM Stable 2 Kp] x A583 [PM Stable 1 Kp]). Percentage of rated power Values 40% Default: Min/Max: 0/100% Display: 1% A586 [PM Stepload Kp] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) r step load in low speed region. The gain to ensure robustness unde Values Default: 0% Min/Max: 0/1000% 1% Display: A587 [PM 1 Efficiency] PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Reduce full load current. Values Default: 120% 0/2000% Min/Max: Display: 1% [PM 2 Efficiency] A588 PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) Reduce no load current. 500% Values Default: Min/Max: 0/2000% Display: 1% A550 A589 Related Parameter(s): [PM Algor Sel] Stop drive before changing this parameter. PF 525 PowerFlex 525 only. (With FRN 5.xxx and later.) M motor. Selects the algorithm to use with your motor. Check with the manufacturer of your moto r to determine whether it is an iPM or sP “Algorithm 1” (Default) Options Suggested for most motors. 0 1 “Algorithm 2” Enable an embedded algorithm to reduce oscillation in output waveform (u se with sPM motor only, do not enable for iPM motor). This group contains parameters for the network option card that is installed. Network Parameter Group Refer to the network option card’s user manual for more information on the available parameters. n 520-UM001I-EN-E - July 2016 141 Rockwell Automation Publicatio

142 Chapter 3 Programming and Parameters This group contains parameters that have their values changed from the factory Modified Parameter Group 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 [Fault 4 Code] Related Parameter(s): b007 - b009 F604 [Fault 5 Code] F605 F606 [Fault 6 Code] [Fault 7 Code] F607 F608 [Fault 8 Code] F609 [Fault 9 Code] F610 [Fault10 Code] A code that represents a drive fault. The codes appear in these cur (b007 [Fault 1 Code] = the m ost recent fault). Repetitive fa ults are only recorded once. parameters in the order they oc Values Default: Read Only Min/Max: F0/F127 Display: F0 F612 F611 [Fault 1 Time-hr] d362 Related Parameter(s): [Fault 2 Time-hr] F614 [Fault 4 Time-hr] [Fault 3 Time-hr] F613 [Fault 5 Time-hr] F615 [Fault 7 Time-hr] F617 F616 [Fault 6 Time-hr] [Fault 9 Time-hr] F619 F618 [Fault 8 Time-hr] F620 [Fault10 Time-hr] PF 525 PowerFlex 525 only. Displays the value of d362 [Elapsed Time-hr] when the fault occurs. Values Default: Read Only 0/32767 hr Min/Max: Display: 1 hr Related Parameter(s): F621 d363 [Fault 1 Time-min] [Fault 2 Time-min] F622 [Fault 3 Time-min] F623 F624 [Fault 4 Time-min] F625 [Fault 5 Time-min] [Fault 7 Time-min] F627 [Fault 6 Time-min] F626 F629 [Fault 9 Time-min] F628 [Fault 8 Time-min] F630 [Fault10 Time-min] PF 525 PowerFlex 525 only. [Elapsed Time-min] when the fault occurs. Displays the value of d363 Read Only Default: Values Min/Max: 0.0/320.0 min Display: 0.1 min Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 142

143 Programming and Parameters Chapter 3 Fault and Diagnostic Group (continued) b001 Related Parameter(s): [Fault 2 Freq] F632 [Fault 1 Freq] F631 [Fault 3 Freq] F633 F634 [Fault 4 Freq] F635 [Fault 5 Freq] [Fault 7 Freq] F637 [Fault 6 Freq] F636 [Fault 9 Freq] F639 [Fault 8 Freq] F638 [Fault10 Freq] F640 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] stor hird most recent fault. es the second most recent fault and [Fault 3 Freq] stores the t Default: Values Read Only Min/Max: 0.00/500.00 Hz Display: 0.01 Hz F642 F641 [Fault 1 Current] b003 Related Parameter(s): [Fault 2 Current] [Fault 3 Current] F643 [Fault 4 Current] F644 F645 [Fault 5 Current] [Fault 7 Current] F647 F646 [Fault 6 Current] [Fault 9 Current] F649 F648 [Fault 8 Current] [Fault10 Current] F650 PF 525 PowerFlex 525 only. [Output Current] with the most recent 10 faults occurred. Displays and stores the value of b003 [Fault 1 Current] stores the most recent fault, [Fault 2 Current] stores the second most recent fault and [Fault 3 Current] sto res the third most recent fault. Values Default: Read Only Min/Max: 0.00/(Drive Rated Amps x 2) Display: 0.01 A Related Parameter(s): b005 [Fault 2 BusVolts] F652 F651 [Fault 1 BusVolts] [Fault 3 BusVolts] F653 F654 [Fault 4 BusVolts] F655 [Fault 5 BusVolts] [Fault 7 BusVolts] F657 [Fault 6 BusVolts] F656 F659 [Fault 9 BusVolts] F658 [Fault 8 BusVolts] F660 [Fault10 BusVolts] PF 525 PowerFlex 525 only. Displays and stores the value of b005 [DC Bus Voltage] with the most recent 10 faults occurred. ] stores the second most recent fault and [Fault 3 BusVolts] s tores the third most recent fault. [Fault 1 BusVolts] stores the most recent fault, [Fault2 BusVolts Values Default: Read Only Min/Max: 0/1200VDC Display: 1VDC 143 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

144 Chapter 3 Programming and Parameters (continued) Fault and Diagnostic Group [Status @ Fault 2] Related Parameter(s): b006 F662 [Status @ Fault 1] F661 [Status @ Fault 3] F663 [Status @ Fault 4] F664 [Status @ Fault 5] F665 F667 [Status @ Fault 7] [Status @ Fault 6] F666 [Status @ Fault 9] F669 F668 [Status @ Fault 8] F670 [Status @ Fault10] PF 525 PowerFlex 525 only. b006 Displays the value of [Drive Status] with the most recent 10 faults occurred. fault and [[email protected] res the third most recent fault. stores the second most recent [[email protected] Fault 1] stores the most recent fault, [[email protected] Fault 2] Fault 3] sto 1 = Condition True, 0 = Condition False Running Digit 1 Digit 2 For ward Accelerating Digit 3 Decelerating Digit 4 (1) SafetyActive Digit 5 Setting is specific to PowerFlex 525 drives only. (1) Read Only Default: Values Min/Max: 0/0x1F 1 Display: [Comm Sts - DSI] F681 Displays the status of the RS485 serial (DSI) port to the drive. Digit 3 (Connection Status) 1 = Condition True, 0 = Condition False 0 “Not Active” 1 “Modbus slave network (external Modbus master)” Rx Digit 1 Tx D igi t 2 “Modbus multi-drive w/ internal com option master” 2 (1) Status Digit 3 3 “Modbus multi-drive w/ embedded com master” “DSI peripheral connected” 4 Error Digit 4 Not Used 5...8 “Reserved” “RS-485 network faulted” 9 (1) Setting is specific to PowerFlex 525 drives only. Values Default: Read Only Min/Max: 0000/1911 0000 Display: F682 [Comm Sts - Opt] Displays the status of the inte rnal communication to the drive. Digit 3 = “Internal Com option” 1 = Condition True, 0 = Condition False “Not Active (no connection)” 0 Rx Digit 1 1 “Internal option connected/active” Tx D igi t 2 2...8 “Reserved” Digit 3 Status 9 “Internal com option faulted” Error Digit 4 Not Used Read Only Default: Values Min/Max: 0000/1911 Display: 0000 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 144

145 Programming and Parameters Chapter 3 (continued) Fault and Diagnostic Group F683 [Com Sts-Emb Enet] PF 525 PowerFlex 525 only. Displays the status of the embedded EtherNet/IP interface to the drive. Digit 3 = “Embedded EtherNet/IP” 1 = Condition True, 0 = Condition False “Not Active (no connection)” 0 Rx Digit 1 “Embedded EtherNet/IP active” 1 Tx D igi t 2 2-8 “Reserved” Status Digit 3 “Embedded EtherNet/IP faulted” 9 Digit 4 Error Not Used Values Read Only Default: Min/Max: 0000/1911 Display: 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). Options 1 “Parameters” Read Only 2“BOOTP” [EN Rate Act] F685 PF 525 PowerFlex 525 only. Displays the network data rate currently used by the embedded EtherNet/IP interface. 0 “No Link” Read Only Options “10Mbps Full” 1 2 “10Mbps Half ” 3 “100Mbps Full” 4 “100Mbps Half ” 5 “Dup IP Addr” 6“Disabled” F686 [DSI I/O Act] Displays the Drives that are active in Multi-Drive mode. 1 = Drive Active, 0 = Drive Inactive Digit 1 Drive 0 Actv Digit 2 Drive 1 Actv Drive 2 Actv Digit 3 Drive 3 Actv Digit 4 Digit 5 Drive 4 Actv Read Only Default: Value 00000/11111 Min/Max: 00000 Display: n 520-UM001I-EN-E - July 2016 145 Rockwell Automation Publicatio

146 Chapter 3 Programming and Parameters (continued) Fault and Diagnostic Group F687 [HW Addr 1] F688 [HW Addr 2] [HW Addr 3] F689 [HW Addr 4] F690 F691 [ HW Addr 5] [ HW Addr 6] F692 PF 525 PowerFlex 525 only. Shows the MAC address for the embedded EtherNet/IP interface. Values Default: Read Only Min/Max: 0/255 1 Display: 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 in terface 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 Read Only Default: 0/255 Min/Max: Display: 1 F697 [EN Subnet Act 1] F698 [EN Subnet Act 2] F699 [EN Subnet Act 3] [EN Subnet Act 4] F700 PF 525 PowerFlex 525 only. Shows the actual subnet mask used by the embedded EtherNet/IP inte rface 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] Read Only Default: Values Min/Max: 0/255 Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 146

147 Programming and Parameters Chapter 3 (continued) Fault and Diagnostic Group 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] Default: Read Only Values Min/Max: 0/255 Display: 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 th e drive (whether HS-DSI, EtherNet/IP, or DSI) at the time. If c omms control is NOT being used, and the drive is in single- drive mode, then this parameter will show 0. Default: Values Read Only Min/Max: 0/FFFF 1 Display: [Drv 0 Reference] F706 F710 [Drv 1 Reference] F714 [Drv 2 Reference] [Drv 3 Reference] F718 [ Drv 4 Reference] F722 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 dr ive (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. Values Default: Read Only Min/Max: 0.00/500.00 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 lo gic status of the drive at the time. Values Default: Read Only 0/FFFF Min/Max: 1 Display: n 520-UM001I-EN-E - July 2016 147 Rockwell Automation Publicatio

148 Chapter 3 Programming and Parameters (continued) Fault and Diagnostic Group F708 [Drv 0 Feedback] F712 [Drv 1 Feedback] F716 [Drv 2 Feedback] [Drv 3 Feedback] F720 F724 [Drv 4 Feedback] In multi-drive mode, this is the feedba ck being received from drive 0/1/2/3/4. In single-drive mode, this is the feedback of the drive at the time. Values Default: Read Only Min/Max: 0.00/500.00 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. Values Default: Read Only Min/Max: 0/65535 Display: 1 F726 [EN Rx Packets] PF 525 PowerFlex 525 only. A count of the number of receive packets re ported by the embedded EtherNet/IP interface. Values Read Only Default: Min/Max: 0/65535 1 Display: 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 [EN Tx Packets] F728 PF 525 PowerFlex 525 only. A count of the number of transmitted packets re ported by the embedded EtherNet/IP interface. Read Only Values Default: Min/Max: 0/65535 Display: 1 [EN Tx Errors] F729 PF 525 PowerFlex 525 only. A count of the number of transmit errors reported by the embedded EtherNet/IP interface. Read Only Values Default: Min/Max: 0/65535 Display: 1 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 148

149 Programming and Parameters Chapter 3 (continued) Fault and Diagnostic Group F730 [EN Missed IO Pkt] PF 525 PowerFlex 525 only. The number of I/O packets missed. Values Default: Read Only 0/65535 Min/Max: 1 Display: F731 [DSI Errors] The number of total DSI errors. Values Default: Read Only Min/Max: 0/65535 Display: 1 n 520-UM001I-EN-E - July 2016 149 Rockwell Automation Publicatio

150 Chapter 3 Programming and Parameters AppView parameter groups provide a simple starting point for using the AppView Parameter Groups 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 : Example Displays Key(s) Step 1. Press the Up Arrow or Down Arrow to scroll to or an AppView group (G1...G8). D W F 2. Press Enter or Sel to enter a group. The right most digit of the last viewed parameter in that D F W or S e l group will flash. Press the Up Arrow or Down Arrow to scroll to 3. or the command G1->GC. W D F Press Enter or Sel to add all the parameters in 4. this AppView group to the CustomView group. or S e l The LCD display will show a confirmation. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 150

151 Chapter 3 Programming and Parameters CustomView allows you to quickly access only the parameters needed for your CustomView Parameter parameter group. Add your frequently application by storing them in a custom Group used parameters to this group, th A552 en hide all other parameters with [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 or add individual parameters as show below. page 150 group as shown on Key(s) Example Displays Step 1. Press the Up Arrow or Down Arrow to scroll to or the CustomView group (GC). W D F 2. Press Enter to view the parameters that can be F W D added to the CustomView group. Press the Up Arrow or Down Arrow to scroll 3. or through the list of parameters. W F D PROGR A M Press Enter to add the parameter to the 4. CustomView group. The LCD display will show a confirmation. To delete parameters from the CustomView parameter group: Example Displays Step Key(s) 1. Press the Up Arrow or Down Arrow to scroll to or the CustomView group (GC). D W F Press Enter to view the parameters that are in 2. the CustomView group. F D W 3. Press the Up Arrow or Down Arrow to scroll to or the command GC---. W F D 4. Press Enter or Sel to view the parameters that F W D are stored in the CustomView group. or e l S Press the Up Arrow or Down Arrow to scroll 5. or through the list of parameters. D F W PROGR A M 6. Press Enter to delete the parameter from the CustomView group. The LCD display will show a confirmation. The Connected Components Workbench software can be used to speed up this TIP process with drag and drop functionality. n 520-UM001I-EN-E - July 2016 151 Rockwell Automation Publicatio

152 Chapter 3 Programming and Parameters Parameter Cross Reference by Name No. Parameter Name No. Parameter Name Parameter Name No. (1)(3) (1) 093 580 Drv 4 Logic Sts 723 Current Loop BW 10V Bipolar Enbl DB Resistor Sel 437 Drv 4 Reference 722 2-Wire Mode 064 DB Threshold Accel Time 1 Drv Ambient Sel 554 041 438 DC Brake Level 731 DSI Errors 442 Accel Time 2 435 444 434 DSI I/O Act 686 Accel Time 3 DC Brake Time 446 DC Brk [email protected] 436 DSI I/O Cfg 175 Accel Time 4 026 Accum CO2 Sav Elapsed kWh 021 DC Bus Ripple 380 DC Bus Voltage 022 Elapsed MWh 025 Accum Cost Sav 005 024 042 Elapsed Run Time 019 Accum kWh Sav Decel Time 1 360 Decel Time 2 443 Elapsed Time-hr 362 Analog In 0-10V 361 445 Elapsed Time-min 363 Decel Time 3 Analog In 4-20mA 099 Decel Time 4 447 EM Brk Off Delay 086 Analog In Filter (2) 089 Dig In Status 014 EM Brk On Delay 087 Analog Out High (2) (2)(3) (1) 394 EN Addr Sel 128 088 Dig Out Status Analog Out Sel (1) 684 DigIn TermBlk 02 062 EN Addr Src Anlg In 0-10V Hi 092 (1) DigIn TermBlk 03 063 EN Comm Flt Actn Anlg In 0-10V Lo 091 143 (1) 153 Anlg In mA Loss DigIn TermBlk 05 065 EN Data In 1 097 (1) 154 066 EN Data In 2 Anlg In V Loss 094 DigIn TermBlk 06 (1) (1) DigIn TermBlk 07 Anlg In4-20mA Hi 096 EN Data In 3 067 155 (1) (1) 156 068 EN Data In 4 DigIn TermBlk 08 095 Anlg In4-20mA Lo (1) 157 Drive OL Mode EN Data Out 1 098 Anlg Loss Delay 495 (2) (1) Anlg Out Setpt Drive Status 006 EN Data Out 2 090 158 (2)(3) (1) 393 EN Data Out 3 159 Auto Rstrt Delay 542 Drive Status 2 (1) 160 Auto Rstrt Tries 541 Drive Temp 027 EN Data Out 4 (1) Autotune 367 040 Drive Type EN Flt Cfg DL 1 147 (1) (1) 441 EN Flt Cfg DL 2 148 Droop [email protected] FLA 052 Average kWh Cost (1) 149 708 020 Average Power EN Flt Cfg DL 3 Drv 0 Feedback (1) Drv 0 Logic Cmd EN Flt Cfg DL 4 530 Boost Select 705 150 (1) 145 Drv 0 Logic Sts 707 EN Flt Cfg Logic 533 Break Frequency (1) 146 706 Break Voltage Drv 0 Reference EN Flt Cfg Ref 532 (1) 701 171 Drv 1 Addr 550 Bus Reg Enable EN Gateway Act 1 (1) (1) 712 EN Gateway Act 2 Drv 1 Feedback 702 122 Cmd Stat Select (1) (1) Drv 1 Logic Cmd 709 EN Gateway Act 3 683 703 Com Sts-Emb Enet (1) 704 Comm Loss Action Drv 1 Logic Sts 711 EN Gateway Act 4 125 (1) 137 710 EN Gateway Cfg 1 Comm Loss Time 126 Drv 1 Reference (1) 138 Drv 2 Addr 172 EN Gateway Cfg 2 Comm Sts - DSI 681 (1) 139 Comm Sts - Opt Drv 2 Feedback EN Gateway Cfg 3 682 716 (1) 140 121 713 EN Gateway Cfg 4 Comm Write Mode Drv 2 Logic Cmd (1) 144 Drv 2 Logic Sts EN Idle Flt Actn 002 Commanded Freq 715 (1) 693 714 Drv 2 Reference 547 EN IP Addr Act 1 Compensation (1) 694 173 EN IP Addr Act 2 Contrl In Status 013 Drv 3 Addr (1) 695 Drv 3 Feedback 720 EN IP Addr Act 3 Control Source 012 (1) 696 Control SW Ver 717 EN IP Addr Act 4 Drv 3 Logic Cmd 029 (1) Drv 3 Logic Sts 719 EN IP Addr Cfg 1 Control Temp 129 028 (1) 130 Drv 3 Reference 718 EN IP Addr Cfg 2 Counter Status 364 (1) (1) 131 559 Drv 4 Addr 174 EN IP Addr Cfg 3 Counts Per Unit (1) Current Limit 1 484 Drv 4 Feedback 724 EN IP Addr Cfg 4 132 (1) (1) EN Missed IO Pkt 721 730 485 Drv 4 Logic Cmd Current Limit 2 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 152

153 Programming and Parameters Chapter 3 No. Parameter Name No. Parameter Name No. Parameter Name (1) (1) EN Rate Act 685 656 Fault 6 BusVolts 549 Half Bus Enable (1) (1) (1) 606 Home Save Fault 6 Code 561 141 EN Rate Cfg (1) (1) (1) 646 727 687 Fault 6 Current HW Addr 1 EN Rx Errors (1) (1) (1) 636 688 Fault 6 Freq 725 EN Rx Overruns HW Addr 2 (1) (1) (1) 616 726 Fault 6 Time-hr HW Addr 3 689 EN Rx Packets (1) (1) (1) 690 HW Addr 4 626 Fault 6 Time-min 697 EN Subnet Act 1 (1) (1) (1) 691 698 Fault 7 BusVolts 657 HW Addr 5 EN Subnet Act 2 (1) (1) (1) Fault 7 Code 699 HW Addr 6 EN Subnet Act 3 607 692 (1) (1) 647 496 Fault 7 Current 700 IR Voltage Drop EN Subnet Act 4 (1) (1) 432 133 Fault 7 Freq Jog Accel/Decel 637 EN Subnet Cfg 1 (1) (1) 431 134 Fault 7 Time-hr 617 Jog Frequency EN Subnet Cfg 2 (1) (1) Fault 7 Time-min 426 135 627 Keypad Freq EN Subnet Cfg 3 (1) (2) (1) 136 538 658 Ki Speed Loop Fault 8 BusVolts EN Subnet Cfg 4 (1) (2) (1) 539 Kp Speed Loop Fault 8 Code 729 EN Tx Errors 608 (1) (1) Language 728 648 30 Fault 8 Current EN Tx Packets (1) (1) (1) 490 Load Loss Level 638 564 Fault 8 Freq Encoder Pos Tol (1) (1) (1) Encoder PPR Fault 8 Time-hr 618 Load Loss Time 536 491 (1) (2) Max Traverse 567 Fault 8 Time-min 628 378 Encoder Speed (1) Maximum Freq 044 659 Energy Saved 023 Fault 9 BusVolts (1) (1) Enh Control Word 609 560 Fault 9 Code 534 Maximum Voltage (1) 649 043 Minimum Freq Fault 9 Current 651 Fault 1 BusVolts (1) MOP Freq 427 639 007 Fault 1 Code Fault 9 Freq (1) 641 Fault 9 Time-hr Fault 1 Current 429 MOP Preload 619 (1) 629 MOP Reset Sel 428 631 Fault 9 Time-min Fault 1 Freq 551 Fault Clear 611 Fault 1 Time-hr MOP Time 430 (1) (2) 660 Motor Fdbk Type 535 Fault 1 Time-min 621 Fault10 BusVolts (1) (1) Motor Lm 499 610 Fault 2 BusVolts Fault10 Code 652 (1) (1) 500 Motor Lx 650 Fault10 Current 008 Fault 2 Code (1) Fault 2 Current 642 Fault10 Freq 034 640 Motor NP FLA (1) Motor NP Hertz 620 032 Fault 2 Freq Fault10 Time-hr 632 (1) Motor NP Poles 035 630 Fault 2 Time-hr 612 Fault10 Time-min (1) 037 Fault 2 Time-min Motor NP Power 622 390 Fiber Status (1) 563 Motor NP RPM 036 Find Home Dir Fault 3 BusVolts 653 (1) 562 031 Motor NP Volts Find Home Freq 009 Fault 3 Code (2)(3) Motor OL Current 033 575 643 Fault 3 Current Flux Braking En Motor OL Level 369 633 497 Flux Current Ref Fault 3 Freq Motor OL Ret 494 545 613 Fault 3 Time-hr Flying Start En 546 Motor OL Select 493 Fault 3 Time-min 623 FlyStrt CurLimit (1) (1) 498 510 Motor Rr Fault 4 BusVolts Freq 1 654 (1) (2)(5) 511 Mtr Options Cfg 573 Fault 4 Code Freq 1 BW 604 (1) 169 522 MultiDrv Sel 644 Fault 4 Current Freq 1 Ki (1) Opt Data In 1 161 521 Fault 4 Freq 634 Freq 1 Kp (1) 512 Opt Data In 2 162 614 Freq 2 Fault 4 Time-hr (1) 513 163 Opt Data In 3 Freq 2 BW 624 Fault 4 Time-min (1) 655 Fault 5 BusVolts Freq 2 Ki 524 Opt Data In 4 164 (1) 165 523 Opt Data Out 1 Fault 5 Code Freq 2 Kp 605 (1) 514 166 Opt Data Out 2 Freq 3 Fault 5 Current 645 (1) Opt Data Out 3 635 Freq 3 BW Fault 5 Freq 515 167 (1) Opt Data Out 4 168 526 615 Freq 3 Ki Fault 5 Time-hr (1) (1) Opto Out Logic 075 525 Freq 3 Kp 625 Fault 5 Time-min n 520-UM001I-EN-E - July 2016 153 Rockwell Automation Publicatio

154 Chapter 3 Programming and Parameters No. Parameter Name No. Parameter Name No. Parameter Name (1)(3) (1) (1) Opto Out1 Level 527 070 PM FWKn 1 Kp 084 Relay 2 On Time (1)(3) (1) (1) 528 Relay Out2 Level 069 082 PM FWKn 2 Kp Opto Out1 Sel (1)(3) (1) (1) 073 519 081 Relay Out2 Sel PM HIFI NS Cur Opto Out2 Level (1)(3) (1) 072 PM Initial Sel Opto Out2 Sel 516 Reset Meters 555 (1)(3) 053 Reset to Defalts 501 PM IR Voltage Out Phas Loss En 557 (1)(3) 544 502 Reverse Disable Output Current 003 PM IXd Voltage (1)(3) 503 RS485 Data Rate 123 PM IXq Voltage Output Freq 001 (1)(3) RS485 Format PM Stable 1 Freq 127 017 Output Power 581 (1)(3) RS485 Node Addr 583 124 Output Powr Fctr PM Stable 1 Kp 381 (1)(3) 439 582 S Curve % Output RPM PM Stable 2 Freq 015 (1) (1)(3) 584 016 Output Speed Safety Open En PM Stable 2 Kp 105 (1)(3) (1)(3) SafetyFlt RstCfg 585 106 Output Voltage 004 PM Stable Brk Pt (1)(3) 586 Shear Pin 1 Time 487 PM Stepload Kp P Jump 570 (1) (2)(3) 486 576 565 Phase Loss Level Pos Reg Filter Shear Pin1 Level (1) (1) Shear Pin 2 Time 566 489 Pos Reg Gain 465 PID 1 Deadband (1) (1) 387 488 Shear Pin2 Level 463 PID 1 Diff Rate Position Status (1) PID 1 Fdback Sel 460 Positioning Mode 558 Skip Freq Band 1 449 451 462 548 Power Loss Mode PID 1 Integ Time Skip Freq Band 2 (1) 453 467 Power Saved 018 Skip Freq Band 3 PID 1 Invert Err (1) Skip Freq Band 4 PID 1 Preload Preset Freq 0 410 466 455 411 PID 1 Prop Gain 461 Skip Frequency 1 Preset Freq 1 448 Skip Frequency 2 412 Preset Freq 2 459 PID 1 Ref Sel 450 (1) 452 464 Preset Freq 3 413 Skip Frequency 3 PID 1 Setpoint (1) 454 Skip Frequency 4 456 Preset Freq 4 414 PID 1 Trim Hi Sleep Level 101 Preset Freq 5 457 PID 1 Trim Lo 415 416 Sleep Time 102 PID 1 Trim Sel 458 Preset Freq 6 417 Preset Freq 7 383 Sleep-Wake Sel PID1 Fdbk Displ 100 (1) 418 Slip Hz Meter 375 384 PID1 Setpnt Disp Preset Freq 8 (1) (1) PID 2 Deadband 419 Speed Feedback 477 Preset Freq 9 376 (1) (1) Speed Ratio 420 Preset Freq 10 475 572 PID 2 Diff Rate (1) (1) 047 472 421 Preset Freq 11 Speed Reference1 PID 2 Fdback Sel (1) (1) 049 474 Preset Freq 12 422 Speed Reference2 PID 2 Integ Time (1) (1) Speed Reference3 051 Preset Freq 13 423 479 PID 2 Invert Err (1) (1) (1) Preset Freq 14 424 Speed Reg Sel 509 478 PID 2 Preload (1) (1) Stall Fault Time 492 Preset Freq 15 473 425 PID 2 Prop Gain (1) Start At PowerUp 543 471 Process Disp Hi 482 PID 2 Ref Sel (1) Process Disp Lo 531 481 Start Boost 476 PID 2 Setpoint (1) Process Display 468 Start Source 1 046 010 PID 2 Trim Hi (1) 552 Start Source 2 048 469 Program Lock PID 2 Trim Lo (1) Start Source 3 050 Program Lock Mod 470 553 PID 2 Trim Sel (1) Pulse In Scale 537 385 661 Status @ Fault 1 PID2 Fdbk Displ (1) 433 Purge Frequency 662 386 Status @ Fault 2 PID2 Setpnt Disp (1)(3) Status @ Fault 3 663 587 PWM Frequency 440 PM 1 Efficiency (1)(3) (2)(4) RdyBit Mode Act 664 588 392 Status @ Fault 4 PM 2 Efficiency (1)(3) (2)(4) PM Algor Sel Status @ Fault 5 665 589 574 RdyBit Mode Cfg (1)(3) (1) Status @ Fault 6 518 666 Relay 1 Off Time 080 PM Align Time (1)(3) (1) 504 667 Relay 1 On Time Status @ Fault 7 079 PM BEMF Voltage (1)(3) (1) Relay Out1 Level 668 520 Status @ Fault 8 PM Bus Reg Kd 077 (1) (1)(3) Status @ Fault 9 529 669 Relay Out1 Sel 076 PM Control Cfg (1) (1) (1)(3) 670 517 Relay 2 Off Time 085 Status @ Fault10 PM DC Inject Cur Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 154

155 Programming and Parameters Chapter 3 No. Parameter Name No. Parameter Name No. Parameter Name (1) (1) Step Units 0 Stp Logic 5 200 185 483 Testpoint Sel (1) (1) 186 556 202 Text Scroll Stp Logic 6 Step Units 1 (1) (1) 365 Timer Status Stp Logic 7 204 187 Step Units 2 (1) (1) Torque Current 382 Stp Logic Status 206 Step Units 3 391 (1) (1) Torque Perf Mode 039 Stp Logic Time 0 208 190 Step Units 4 (1) (1) Traverse Dec 569 191 210 Stp Logic Time 1 Step Units 5 (1) (1) Stp Logic Time 2 212 192 Traverse Inc 568 Step Units 6 (1) (1) (1) Units Traveled H Stp Logic Time 3 214 193 Step Units 7 388 (1) (1) 194 389 Units Traveled L Stop Mode 045 Stp Logic Time 4 (1) (1) 180 540 Stp Logic Time 5 Var PWM Disable 195 Stp Logic 0 (1) (1) Voltage Class 038 Stp Logic Time 6 196 Stp Logic 1 181 (1) (1) 182 Wake Level 103 Stp Logic Time 7 197 Stp Logic 2 (1) Wake Time 104 183 Sync Time 571 Stp Logic 3 (1) 184 368 Stp Logic 4 Testpoint Data (1) Parameter is specific to PowerFlex 525 drives only. (2) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. Parameter is available in PowerFlex 525 FRN 5.xxx and later. (3) Parameter is available in PowerFlex 525 FRN 3.xxx and later. (4) (5) Parameter is available in PowerFlex 525 FRN 2.xxx and later. n 520-UM001I-EN-E - July 2016 155 Rockwell Automation Publicatio

156 Chapter 3 Programming and Parameters Notes: 156 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

157 4 Chapter Troubleshooting 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. For information on... See page... 157 Drive Status Faults 157 Fault Descriptions 159 Common Symptoms and Corrective Actions 162 Risk of injury or equipment damage exists. Drive does not contain AT T E NT IO N : user-serviceable components. Do not disassemble drive chassis. The condition or state of your drive is constantly monitored. Any changes will be Drive Status indicated through the integral LCD display. Display and Control Keys See for information on drive status on page 62 indicators and controls. A fault is a condition that stops the drive. There are two fault types. Faults Fault Types Fault Description Type [Auto Rstrt Tries] is set to a value greater than Auto-Reset/Run When this type of fault occurs, and A541 1 “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 cond ition 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 2 Non-Resettable errors. The cause of the fault must be corrected before the fault can be cleared. n 520-UM001I-EN-E - July 2016 157 Rockwell Automation Publicatio

158 Chapter 4 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. D F W The integral LCD display provides visual notification of a fault condition by displaying the following. Flashing fault number • FAU LT Flashing fault indicator (LED) • control of the display. Press the Esc key to regain l e S E c s Manually Clearing Faults Step Key(s) 1. Press Esc to acknowledge the fault. The faul t information will be removed so that you can use the integral keypad. [Fault 1 Code] to view the most recent fault information. b007 Access E c s 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. P045 [Stop Mode] is set to a value between “0” and “3”. • Press Stop if • Cycle drive power. [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”. A551 Set • [DigIn TermBlk xx] is set to • Cycle digital input if t062 , t063 , t065 ... t068 13 “Clear Fault”. 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”. [Auto Rstrt Delay] to a value other than “0”. 2. Set A542 Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set [Auto Rstrt Tries] to a value other than “0”. A541 A542 [Auto Rstrt Delay] to “0”. 2. Set Equipment damage and/or personal injury may result if these AT T E NT IO N : 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 158

159 Troubleshooting Chapter 4 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 Fault Descriptions on page 159 on page 157 . See for more information. Use caution when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming. Fault Descriptions Fault Types, Descriptions and Actions (2) Type No. Description Action Fault No Fault No fault present. – – F000 Auxiliary Input Check remote wiring. External trip (Auxiliary) input. • F002 1 • Verify communications programming for intentional fault. F003 Power Loss Single phase operation detected with 2 • Monitor the incoming AC line for low excessive load. voltage or line power interruption. • Check input fuses. • Reduce load. F004 UnderVoltage 1 DC bus voltage fell below the minimum Monitor the incoming AC line for low value. voltage or line power interruption. F005 OverVoltage 1 DC bus vo ltage exceeded maximum Monitor the AC line fo r high line voltage value. or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. , A446 A442 , A444 , F006 Motor Stalled 1 Drive is unable to accelerate or P041 • Increase [Accel Time x] or reduce load so drive decelerate motor. output current does not exceed the , A485 A484 current set by parameter [Current Limit x] for too long. • Check for overhauling load. Motor Overload 1 Internal electronic overload trip. • An excessive motor load exists. F007 Reduce load so drive output current does not exceed the current set by [Motor OL Current]. parameter P033 • Verify A530 [Boost Select] setting. F008 Heatsink OvrTmp 1 Heatsink/Power Module temperature Check for blocked or dirty heat sink • exceeds a predefined value. fins. Verify that ambient temperature has not exceeded the rated ambient temperature. Check fan. • CC OvrTmp 1 Control module temperature exceeds a • F009 Check product ambient temperature. predefined value. • Check for airflow obstruction. • Check for dirt or debris. • Check fan. F012 HW OverCurrent 2 The drive output current has exceeded Check programming. Check for excess [Boost Select] the hardware current limit. load, improper A530 setting, DC brake volts set too high or other causes of excess current. (3) Check the motor and external wiring to A current path to earth ground has been Ground Fault 1 F013 the drive output terminals for a detected at one or more of the drive grounded condition. output terminals. n 520-UM001I-EN-E - July 2016 159 Rockwell Automation Publicatio

160 Chapter 4 Troubleshooting Fault Types, Descriptions and Actions (2) No. Fault Type Action Description (1) F015 2 Load Loss The output torque current is below the • Verify connections between motor value programmed in A490 and load. [Load Loss Verify level and time requirements Level] for a time period greater than the • A491 time programmed in [Load Loss Time]. Verify motor wiring. • 1 Output Ph Loss F021 Output Phase Loss (if enabled). • Verify motor. [Out Phas Loss En]. A557 Configure with • Check for broken/loose connections F029 Analog In Loss 1 An analog input is configured to fault on at inputs. signal loss. A signal loss has occurred. Check parameters. • [Anlg In V Loss] or Configure with t094 t097 [Anlg In mA Loss]. Correct the cause of the fault and Drive unsuccessfully attempted to reset 2 Auto Rstrt Tries F033 manually clear. a fault and resume running for the [Auto programmed number of A541 Rstrt Tries]. 2 • Check the wiring between the drive F038 Phase U to Gnd A phase to ground fault has been and motor. detected between the drive and motor F039 Phase V to Gnd • in this phase. Check motor for grounded phase. F040 Phase W to Gnd • Replace drive if fault cannot be cleared. • Check the motor and drive output Excessive current has been detected 2 Phase UV Short F041 terminal wiring for a shorted between these two output terminals. Phase UW Short F042 condition. Phase VW Short F043 Replace drive if fault cannot be • cleared. Clear the fault or cycle power to the 1 Params Defaulted The drive was commanded to write • F048 default values to EEPROM. drive. • Program the drive parameters as needed. (1) Safety Open 1 Both of the safety inputs (Safety 1, Check safety input signals. If not • F059 Safety 2) are not enabled. using safety, verify and tighten jumper for I/O terminals S1, S2 and [Safety Open En]. t105 Configure with S+. A486 SW OverCurrent F063 Programmed 1 • , [Shear Pinx A488 Verify connections between motor Level] has been exceeded for a time and load. • period greater than the time Verify level and time requirements. programmed in , [Shear Pin x A489 A487 Time]. F064 Drive Overload 2 Drive overload rating has been Reduce load or extend Accel Time. exceeded. een detected in the drive • Check maximum ambient 2 F070 Power Unit Failure has b power section. temperature has not been exceeded. • Cycle power. Replace drive if fault cannot be • cleared. DSI Net Loss 2 Cycle power. Control over the Modbus or DSI F071 • Check communications cabling. • communication link has been • Check Modbus or DSI setting. interrupted. Check Modbus or DSI status. • 2 Cycle power. Control over the network option card’s F072 Opt Net Loss • remote network has been interrupted. Check communications cabling. • Check network adapter setting. • Check external network status. • (1) Cycle power. EN Net Loss • 2 Control through the embedded F073 Check communications cabling. EtherNet/IP adapter has been • Check EtherNet/IP setting. • interrupted. Check external network status. • F080 Autotune Failure 2 Restart procedure. The autotune function was either cancelled by the user or failed. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 160

161 Troubleshooting Chapter 4 Fault Types, Descriptions and Actions (2) No. Fault Type Action Description Communicati Cycle power. 2 DSI Comm Loss F081 ons between the drive and • Check communications cabling. the Modbus or DSI master device have • been interrupted. Check Modbus or DSI setting. • Check Modbus or DSI status. • Modify using C125 • [Comm Loss Action]. Connecting I/O terminals C1 and C2 • to ground may improve noise immunity. • Replace wiring, Modbus master device, or control module. • 2 Communications between the drive and F082 Opt Comm Loss Cycle power. the network option card have been • Reinstall option card in drive. [Comm Loss Modify using interrupted. C125 • Action]. Replace wiring, port expander, • option card, or control module. (1) 2 • Cycle power. Internal communications between the EN Comm Loss F083 drive and the embedded EtherNet/IP • Check EtherNet/IP setting. • adapter have been interrupted. Check drive’s Ethernet settings and diagnostic parameters. C125 Modify using [Comm Loss • Action]. Replace wiring, Ethernet switch, or • control module. (1) F091 • 2 Requires differential encoder. Check Wiring. Encoder Loss , P047 , P051 [Speed • If P049 One of the 2 encoder channel signals is Referencex] = 16 “Positioning” and missing. A535 [Motor Fdbk Type] = 5 “Quad Check”, swap the Encoder channel inputs or swap any two motor leads. • Replace encoder. “Freeze-Fire” (Function Loss) input is 2 Function Loss F094 Close input to the terminal and cycle inactive, input to the programmed power. terminal is open. [Reset To Defalts] to 2 “Factor y Set Parameter Chksum 2 P053 F100 Drive parameter non-volatile storage is Rset”. corrupted. P053 External non-volatile storage has failed. Set 2 External Storage F101 [Reset To Defalts] to 2 “Factor y Rset”. F105 Clear fault and verify all parameter C Connect Err 2 Control modu le was disconnected while settings. Do not remove or install the drive was powered. control module while power is applied. 2 • Change to a different power module. F106 The PowerFlex 525 control module does Incompat C-P • not support power modules with 0.25 Change to a PowerFlex 523 control module. HP power rating. • F107 Change to a different power module. Replaced C-P 2 The control module could not recognize Replace control module if changing • the power module. Hardware failure. power module does not work. [Reset To Defalts] to 3 “Power P053 The control module was mounted to a F109 Mismatch C-P Set 2 Reset”. different drive type power module. Keypad Membrane 2 Keypad membrane failure / Cycle power. F110 • Replace control module if fault • disconnected. cannot be cleared. (1) Safety Hardware 2 • Check safety input signals. If not Safety input enable hardware F111 malfunction. One of the safety inputs is using safety, verify and tighten not enabled. jumper for I/O terminals S1, S2 and S+. Replace control module if fault • cannot be cleared. n 520-UM001I-EN-E - July 2016 161 Rockwell Automation Publicatio

162 Chapter 4 Troubleshooting Fault Types, Descriptions and Actions (2) Action Type Fault No. Description uC Failure F114 Microprocessor failure. • Cycle power. 2 Verify grounding requirements. See • on General Grounding Requirements for more information. page 20 • Replace control module if fault cannot be cleared. I/O Board Fail 2 Failure has been detected in the drive • Cycle power. F122 Replace drive or control module if control and I/O section. • fault cannot be cleared. Perform a firmware flash update F125 Flash Update Req 2 The firmware in the drive is corrupt, operation to attempt to load a valid set mismatched, or incompatible with the of firmware. hardware. Clear fault or cycle power to the F126 NonRecoverablErr 2 • A non-recoverable firmware or drive. hardware error was detected. The drive Replace drive or control module if • was automatically stopped and reset. fault cannot be cleared. F127 A critical problem with the firmware Perform a firmware flash update DSIFlashUpdatReq 2 was detected and the drive is running operation using DSI communications to attempt to load a valid set of firmware. using backup firmware that only supports DSI communications. (1) le to PowerFlex 523 drives. This fault is not applicab (2) See Fault Types for more information. This fault may be cleared by the auto-restart routine and will be attempted only once. It ignores the value set in parameter A541 (3) [Auto Rstrt Tries]. The drive is designed to start from the keypad when shipped. For a basic test of Common Symptoms and drive operation: Corrective Actions Remove all user I/O wire. 1. 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. Verif y that the three jumpers are in their proper default positions on the 4. PowerFlex 525 Control I/O Wiring Block Diagram control board. See on page 42 for more information. 5. P053 Reset default parameter values by setting [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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 162

163 Troubleshooting Chapter 4 Motor does not Start. Indication Corrective Action Cause(s) None Check the power circuit. No output voltage to the motor. 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. • [Start Source x] matches your configuration. , P048 , P050 Verify that • P046 Verify that A544 [Reverse Disable] is not prohibiting movement. • • Verify that safety inputs (Safety 1 and Safety 2) are active. Improper boost setting at initial start-up. None Set A530 [Boost Select] to 2 “35.0, VT”. Drive is Faulted Clear fault. Flashing red status light [Stop Mode] is set to a value between “0” and “3”. Press Stop if P045 • • 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”. [Control Source]. b012 None Check setting for Incorrect programming. , P050 [Start Source x] is set incorrectly. , P048 P046 • • None Wire inputs correctly and/or install jumper. Incorrect input wiring. • If the PowerFlex 525 Safe-Torque-Off function is used, verify that inputs are active. for wiring examples. page 45 See t062 If 2-wire or 3-wire mode is used, verify that • [DigIn TermBlk 02] and t063 [DigIn • 2 wire control requires Run Forward, Run Reverse or Jog TermBlk 03] are set properly. input. • 3 wire control requires Start and Stop inputs Stop input is always required. • Non e Set switch to match wiring scheme. Incorrect Sink/Source jumper setting. Drive does not Start from Start or Run Inputs wired to the terminal block. Cause(s) Indication Corrective Action Flashing red status light Clear fault. Drive is Faulted [Stop Mode] is set to a value between “0” and “3”. Press Stop if P045 • • Cycle drive power. [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”. • Set A551 • Cycle digital input if t062 , t063 , t065 ... t068 [DigIn TermBlk xx] is set to 13 “Clear Fault”. Check parameter settings. None Incorrect programming. , [Start Source x] is set incorrectly. P048 , P050 P046 • t063 [DigIn TermBlk 02/03] is set incorrectly. • t062 , Wire inputs correctly and/or install jumper. • None Incorrect input wiring. is used, verify that inputs are active. If the PowerFlex 525 Safe-Torque-Off function • for wiring examples. See page 45 2 wire control requires Run Forward, Run Reverse or Jog • input. 3 wire control requires Start and Stop inputs • • Stop input is always required. Set switch to match wiring scheme. Incorrect Sink/Source jumper setting. None n 520-UM001I-EN-E - July 2016 163 Rockwell Automation Publicatio

164 Chapter 4 Troubleshooting Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action [Control Source] for correct source. • Check No value is coming from the source of the command. The drive “Run” indicator is b012 If the source is an analog input, check wiring and use a meter to check for presence of • lit and output is 0 Hz. signal. [Commanded Freq] to verify correct command. b002 • Check [Control Source] for correct source. None • Check b012 Incorrect reference source is being selected by remote device or • Check b014 [Dig In Status] to see if inputs are selecting an alternate source. Verify digital inputs. [DigIn TermBlk xx]. settings for t062 , t063 , t065 - t068 • , P049 , P051 [Speed Referencex] for the source of the speed reference. P047 Check Reprogram as necessary. Review the Speed Reference Control chart on page 49 . • Verify communications if used. • Motor and/or drive will not accelerate to commanded speed. Indication Corrective Action Cause(s) , A442 , A444 , A446 [Accel Time x]. P041 Acceleration time is excessive. None Reprogram [Output Current] with A484 , A485 [Current Limit x]. None Excess load or short acceleration times force the drive into • Compare b003 P041 A446 , , • Remove excess load or reprogram [Accel Time x]. A442 , A444 current limit, slowing or stopping acceleration. • A530 [Boost Select] setting. Check for improper None b002 Verify Speed command source or value is not as expected. • [Commanded Freq]. Check b012 [Control Source] for the proper Speed Command. • [Maximum Freq] to ensure that speed is not limited by programming. drive output from exceeding • None Programming is preventing the Check P044 Verify programming of A572 [Speed Ratio]. • limiting values. [Motor NP FLA]. None • Set motor nameplate full load amps in parameter P034 Torque performance does not match motor characteristics. • Per form P040 [Autotune] “Static Tune” or “Rotate Tune” procedure. [Torque Perf Mode] to 0 “V/Hz”. P039 • Set Motor operation is unstable. Indication Corrective Action Cause(s) . P033 and P032 , P031 1. Co None Motor data was incorrectly entered. rrectly enter motor nameplate data into 2. Enable A547 [Compensation]. 3. Use A530 [Boost Select] to reduce boost level. Drive will not reverse motor direction. Cause(s) Indication Corrective Action [Reverse Disable]. Reverse is disabled. Check A544 None ). Choose correct input and program for reversing control. None Check [DigIn TermBlk xx] (See page 89 Digital input is not selected for reversing mode. ). Digital input is incorrectly wire d. None Check input wiring (See page 45 Switch two motor leads. None r reverse. Motor wiring is improperly phased fo Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 164

165 Chapter 4 Troubleshooting Drive does not power up. Cause(s) Indication Corrective Action No input power to drive. None • Check the power circuit. • Check the supply voltage. Check all fuses and disconnects. • Control module is not connected properly to power module. None 1. Remove power. 2. Verify that the control module is properly and fully installed on the power module. 3. Reapply power. slip frequency is not correct. Motor is rotating at zero Hz or Cause(s) Indication Corrective Action [Motor NP Hertz]. Improper speed. • Verify P032 Incorrect speed calculation. • Reduce boost with A530 [Boost Select]. [Motor NP RPM] to motor synchronous speed. Set P036 • n 520-UM001I-EN-E - July 2016 165 Rockwell Automation Publicatio

166 Chapter 4 Troubleshooting Notes: 166 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

167 Appendix A Supplemental Drive Information For information on... See page... 167 Certifications Environmental Specifications 168 169 Technical Specifications Power Specifications 172 Certifications Certifications PowerFlex 523 PowerFlex 525 c-UL-us Listed to UL508C and CAN/CSA-C22.2 No. 14-05. RCM Australian Communications and Media Authority In conformity with the following: Radiocommunications Act: 1992 Radiocommunications Standard: 2008 Radiocommunications Labelling Notice: 2008 Standards applied: EN 61800-3 CE 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) Standards applied: EN 61800-3 EN 61800-5-1 TUV (Applicable to PowerFlex 525 drives only) Functional TÜV Rheinland afety S Type Standards applied: Approved www.tuv.com EN ISO 13849-1 ID 0600000000 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) AT E X Certified to ATEX Directive 2014/34/EU II (2) G D Group II Category (2) GD Applications with ATEX Approved Motors TUV 12 ATEX 7199 X Korean Registration of Broadcasting and Communications Equipment KCC Compliant with the following standards: Article 58-2 of Radio Waves Act, Clause 3 Standards applied: EAC Low Voltage TP TC 004/2011 EMC TP TC 020/2011 n 520-UM001I-EN-E - July 2016 167 Rockwell Automation Publicatio

168 Appendix A Supplemental Drive Information Certifications PowerFlex 523 PowerFlex 525 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification AC 156 Testing of Nonstructural Components and 2003 International Building Code for worst-case seismic level for USA excluding site class F Electric Power Research Institute SEMI F47 Certified compliant with the following standards: SEMI F47 IEC 61000-4-11 IEC 61000-4-34 (Applicable to PowerFlex 525 drives only) Lloyds Register Lloyd’s Register Type Approval Certificate 12/10068(E1) on of Hazardous Substances” Directive Compliant with the European “Restricti RoHS 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 PowerFlex 523 PowerFlex 525 on page 17 for derating guidelines. Altitude: See Current Derating Curves 1000 m (3300 ft) max. Without derating: Up to 4000 m (13,200 ft) max., with the exce ption of 600V drives at 2000 m (6600 ft) With derating: max. for derating guidelines. on page 17 Max. Surrounding Air See Current Derating Curves Te m p e r a t u re -20...50 ° C (-4...122 ° F) Without derating: F) or -20...70 C (-4...158 -20...60 ° C (-4...140 ° F) with optional Control Module Fan ° ° kit. With derating: Storage Temperature: Frame A...D: ° C (-40...185 ° F) -40...85 -40...70 °C (-40...158 °F) Frame E: Atmosphere: Drive must not be installed in an area where the ambient atmosphere contains volatile or IMPORTANT ing to be installed for a period of time, it must corrosive gas, vapors or dust. If the drive is not go be stored in an area where it will not be exposed to a corrosive atmosphere. ...95% noncondensing Relative Humidity: 0 Complies with IEC 60068-2-27 Shock: Complies with IEC 60068-2-6:1995 Vibration: noperating (Transportation) No Operating and Nonoperating Frame Force Force Size Mounting Type (Shock/Vibration) (Shock/Vibration) Mounting Type A 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only B 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only C 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only D 15 g / 2 g Screw only 30 g/ 2.5 g Screw only 30 g/ 2.5 g Screw only Screw only E 15 g / 1.5 g Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 168

169 Appendix A Supplemental Drive Information Specifications PowerFlex 523 PowerFlex 525 Conformal Coating: Complies with: IEC 60721-3-3 to level 3C2 (chemical and gases only) on page 52 See Pollution Degree Ratings According to EN 61800-5-1 Surrounding Environment for descriptions. Pollution Degree All enclosures acceptable. Pollution Degree 1 & 2: Sound Pressure Level Measurements are taken 1 m from the drive. (A-weighted) Frame A & B: Maximum 53 dBA Maximum 57 dBA Frame C: Frame D: Maximum 64 dBA Frame E: Maximum 68 dBA Protection Technical Specifications Specifications PowerFlex 523 PowerFlex 525 Bus Overvoltage Trip 100...120V AC Input: 405V DC bus (equivalent to 150V AC incoming line) 200...240V AC Input: 405V DC bus (equivalent to 290V AC incoming line) 380...480V AC Input: 810V DC bus (equivalent to 575V AC incoming line) 525...600V AC Input: 1005V DC bus (equivalent to 711V AC incoming line) Bus Undervoltage Trip 100...120V AC Input: 190V DC bus (equivalent to 75V AC incoming line) 200...240V AC Input: 190V DC bus (equivalent to 150V AC incoming line) 380...480V AC Input: 390V DC bus (equivalent to 275V AC incoming line) 525...600V AC Input P038 = 3 “600V”: 487V DC bus (equivalent to 344V AC incoming line) P038 = 2 “480V”: 390V DC bus (equivalent to 275V AC incoming line) 100 ms Power Ride-Thru: Logic Control Ride-Thru: 0.5 s minimum, 2 s typical Electronic Motor Overload Provides class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). Protection: UL 508C File 29572. Overcurrent: 200% hardware limit, 300% instantaneous fault Ground Fault Trip: Phase-to-ground on drive output Short Circuit Trip: Phase-t o-phase on drive output Electrical Specifications PowerFlex 525 PowerFlex 523 Voltage Tolerance: -15% / +10% Frequency Tolerance: 47...63 Hz Input Phases: Three-phase input provides full ra ting. Single-phase input provides 35% rating on three-phase drives. Displacement Power Factor: 0.98 across entire speed range Maximum Short Circ uit Rating: 100,000 Amps Symmetrical Actual Short Circuit Rating: Determined by AI C Rating of installed fuse/circuit breaker Tra n s i s to r Ty p e : I s o l ate d G ate B i p o l a r Tra n s i s to r ( I G BT ) Only for Frame E drive ratings Internal DC Bus Choke 200...240V AC Input: 11 kW (15 HP) 15...18.5 kW (20...25 HP) – Heavy Duty 380...480V AC Input: 525...600V AC Input: 15...18.5 kW (20...25 HP) – Heavy Duty n 520-UM001I-EN-E - July 2016 169 Rockwell Automation Publicatio

170 Supplemental Drive Information Appendix A Control PowerFlex 525 Specifications PowerFlex 523 Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor Method control, Closed Loop Velocity Vector Control, Surface Mount and Interior Permanent Permanent Magnet Motor (with encoder) Magnet Motor (without encoder), Interior (Closed Loop Velocity Vector Control and PM motor control are not applicable to PowerFlex 523 drives) Carrier Frequency 2...16 kHz, Dr ive rating based on 4 kHz Frequency Accuracy Within ±0.05% of set output frequency Digital Input: Analog Input: Within 0.5% of maximum output frequency, 10-Bit resolution Analog Output: ±2% of full scale, 10-Bit resolution Performance ±1% of base speed across a 60:1 speed range V/Hz (Volts per Hertz): ±0.5% of base speed across a 100:1 speed range SVC (Sensorless Vector): ±0.5% of base speed across a 100:1 speed range SVC Economizer: (Applicable to PowerFlex 525 drives only) ±0.5% of base speed across a 60:1 speed range VVC (Velocity Vector Control): (1) : ±0.5% of base speed, up to a 20:1 speed range PM Motor (Applicable to PowerFlex 525 drives only) Performance with Encoder (2) ±0.1% of base speed across a 100:1 speed range SVC (Sensorless Vector): (2) ±0.1% of base speed across a 100:1 speed range SVC Economizer: (2) ±0.1% of base speed across a 1000:1 speed range VVC (Velocity Vector Control): ±0.1% of base speed, up to a 60:1 speed range PM Motor (iPM motor, 10 HP (1) : rating and below) Output Voltage Range: 0V to rated motor voltage 0...500 Hz (programmable) Output Frequency Range: Efficiency: 97.5% (typical) Multiple programmable stop mo Stop Modes: des including – Ramp, Coast, DC-Brake, and Ramp-to-Stop Accel/Decel: Four independently programmable accel and decel times. Each time may be programmed from 0...600 s in 0.01 s increments. Intermittent Overload 110% Overload capability for up to 60 s, 150% for up to 3 s Normal Duty: 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) Heavy Duty: article “PowerFlex 525 PM Motor Performance Testing Summary”. For details on specific motor performance, see Knowledge Base (1) . Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution For more information, see (2) on page 217 170 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

171 Supplemental Drive Information Appendix A Control Inputs PowerFlex 525 Specifications PowerFlex 523 Bandwidth: 10 Rad/s for open and closed loop Digital Quantity: (1) Dedicated for stop (1) Dedicated for stop (6) Programmable (4) Programmable 6 mA Current: Ty p e Source Mode (SRC): 18...24V = ON, 0...6V = OFF Sink Mode (SNK): 0...6V = ON, 18...24V = OFF Pulse Train Quantity: rammable digital input terminals. (1) Shared with one of the prog Transistor contact (open collector) Input Signal: Input Frequency: 0...100 kHz Current Consumption: 7 mA @ 24V DC maximum (2) Isolated, -10-10V and 4-20mA Analog: Quantity: (1) Isolated, 0-10V and 4-20mA Specification Resolution: 10-bit 0-10V DC Analog: 100k ohm input impedance 4-20mA Analog: 250 ohm input impedance External Pot: 1...10k ohm, 2 W minimum Control Outputs PowerFlex 525 Specifications PowerFlex 523 (1) Programmable Form (2) 1 Programmable Form A and C Relay: Quantity: 1 Programmable Form B Specification Resistive Rating: 3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC Inductive Rating: 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC Opto: Quantity: – (2) Programmable Specification: 30V DC, 50 mA Non-inductive (1) Analog Quantity: (1) Non-Isolated 0-10V or 4-20 mA Specification 10-bit Resolution: 1 k ohm minimum 0-10V DC Analog: 4-20 mA Analog: 525 ohm maximum Feature is not applicable to PowerFlex 523 series A drives. (1) Encoder Specifications PowerFlex 523 PowerFlex 525 – Incremental, dual channel Type: Supply: 12V, 250 mA Quadrature: 90 ° , ±27 ° @ 25 ° C Duty Cycle: 50%, +10% Requirements: 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 mini mum of 10 mA per channel. ximum frequency of 250 kHz. The Allowable input is DC up to a ma encoder I/O automatically scales to allow 5V, 12V and 24V DC nominal voltages. n 520-UM001I-EN-E - July 2016 171 Rockwell Automation Publicatio

172 Appendix A Supplemental Drive Information Watts Loss Power Specifications PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Total Watts Loss Output Current (A) Voltage 20.0 1.6 100...120V, 50/60 Hz 1-Phase 2.5 27.0 4.8 53.0 6.0 67.0 1.6 20.0 200...240V, 50/60 Hz 1-Phase 2.5 29.0 4.8 50.0 81.0 8.0 111.0 11.0 20.0 1.6 200...240V, 50/60 Hz 1-Phase 2.5 29.0 w/ EMC Filter 53.0 4.8 8.0 84.0 11.0 116.0 200...240V, 1.6 20.0 50/60 Hz 3-Phase 2.5 29.0 5.0 50.0 8.0 79.0 11.0 107.0 17.5 148.0 259.0 24.0 323.0 32.2 48.3 584.0 62.1 708.0 27.0 1.4 380...480V, 50/60 Hz 3-Phase 2.3 37.0 62.0 4.0 6.0 86.0 10.5 129.0 13.0 170.0 17.0 221.0 24.0 303.0 387.0 30.0 380...480V, 1.4 27.0 50/60 Hz 3-Phase 2.3 37.0 w/ EMC Filter 4.0 63.0 6.0 88.0 10.5 133.0 13.0 175.0 17.0 230.0 24.0 313.0 30.0 402.0 37.0 602.0 43.0 697.0 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 172

173 Supplemental Drive Information Appendix A PowerFlex 520-Series Estimated Watts Loss (Rated Load, Speed & PWM) Total Watts Loss Voltage Output Current (A) 22.0 525...600V, 0.9 50/60 Hz 3-Phase 1.7 32.0 3.0 50.0 4.2 65.0 6.6 95.0 138.0 9.9 12.0 164.0 290.0 19.0 22.0 336.0 466.0 27.0 32.0 562.0 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 3.2 amps. See the PowerFlex 520-Series Input on page 173 table for more Current Rating Scaled by the Motor FLA information. PowerFlex 520-Series Input Current Rating Scaled by the Motor FLA Output Current: Motor FLA Input Drive Current Rating PowerFlex 523 PowerFlex 525 Catalog NumberCatalog Number12345678 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 1.3 1.0 0.8 6.4 5.2 4.0 3.2 – 25A-V1P6N104 1.6 2.5 2.0 1.6 1.3 9.6 7.7 6.2 4.8 25A-V2P5N104 25B-V2P5N104 25B-V4P8N104 4.8 3.1 2.4 19.2 15.4 12.5 9.6 25A-V4P8N104 3.8 6.0 25A-V6P0N104 3.0 24.0 19.2 15.6 12.0 4.8 25B-V6P0N104 3.9 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 4.3 1.0 0.8 5.3 1.3 3.4 2.7 25A-A1P6N104 – 1.6 2.5 2.0 1.6 1.3 25A-A2P5N104 5.2 4.2 3.3 25B-A2P5N104 6.5 25B-A4P8N104 3.8 3.1 2.4 10.7 8.6 7.0 5.4 25A-A4P8N104 4.8 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0 25A-A8P0N104 25B-A8P0N104 25B-A011N104 11.0 8.8 7.2 5.5 22.9 18.3 14.9 11.5 25A-A011N104 with EMC Filter, 0...230V 3-Phase Output 200...240V AC (-15%, +10%) – 1-Phase Input 1.6 25A-A1P6N114 0.8 5.3 4.3 3.4 2.7 1.3 – 1.0 2.5 1.6 1.3 6.5 5.2 4.2 3.3 25B-A2P5N114 25A-A2P5N114 2.0 4.8 3.8 3.1 2.4 10.7 25A-A4P8N114 7.0 5.4 25B-A4P8N114 8.6 25B-A8P0N114 6.4 5.2 4.0 18.0 14.4 11.7 9.0 25A-A8P0N114 8.0 18.3 25B-A011N114 7.2 5.5 22.9 8.8 14.9 11.5 25A-A011N114 11.0 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output – 1.6 1.3 1.0 0.8 1.9 1.5 1.2 1.0 25A-B1P6N104 25B-B2P5N104 25A-B2P5N104 1.6 1.3 2.7 2.2 1.8 1.4 2.5 2.0 25B-B5P0N104 4.0 3.2 2.5 5.8 4.6 3.8 2.9 25A-B5P0N104 5.0 25B-B8P0N104 8.0 6.4 5.2 4.0 9.5 7.6 6.2 4.8 25A-B8P0N104 25B-B011N104 8.8 7.2 5.5 13.8 11.0 9.0 6.9 11.0 25A-B011N104 25B-B017N104 17.5 14.0 11.4 8.8 21.1 16.9 13.7 10.6 25A-B017N104 n 520-UM001I-EN-E - July 2016 173 Rockwell Automation Publicatio

174 Appendix A Supplemental Drive 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 NumberCatalog Number12345678 2 24.0 26.6 21.3 17.3 13.3 25B-B024N104 25A-B024N104 15.6 19. 12.0 20.9 25. 27.8 22.6 17.4 32.2 25B-B032N104 25A-B032N104 16.1 8 34.8 44.0 24.2 28.6 22.0 31.4 35.2 25A-B048N104 6 38. 48.3 25B-B048N104 25A-B062N104 56.0 44.8 36.4 28.0 25B-B062N104 62.1 49. 7 40.4 31.1 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output 0.7 1.9 1.5 25A-D1P4N104 1.0 25B-D1P4N104 1.4 1.1 0.9 1.2 1.5 3.2 2.6 2.1 1.6 25A-D2P3N104 25B-D2P3N104 2.3 1.8 1.2 2.0 2.9 4.6 3.7 2.6 25A-D4P0N104 25B-D4P0N104 4.0 3.2 5.7 3.9 7.5 6.0 4.9 3.8 4.8 6.0 25B-D6P0N104 25A-D6P0N104 3.0 6.8 5.3 13.8 25A-D010N104 9.0 6.9 25B-D010N104 10.5 8.4 11.0 10.4 6.5 15.4 12.3 10.0 7.7 25A-D013N104 25B-D013N104 13.0 8.5 11.1 17.0 14.7 12.0 9.2 25B-D017N104 25A-D017N104 8.5 13.6 18.4 12.0 21.1 17.2 13.2 15.6 26.4 25A-D024N104 25B-D024N104 19.2 24.0 15.0 25A-D030N104 26.4 21.5 16.5 25B-D030N104 30.0 24.0 19.5 33.0 with EMC Filter, 0...460V 3-Phase Output 380...480V AC (-15%, +10%) – 3-Phase Input 0.9 0.7 1.9 1.5 25A-D1P4N114 1.0 25B-D1P4N114 1.4 1.1 1.2 1.8 1.2 3.2 2.6 2.1 1.6 25A-D2P3N114 25B-D2P3N114 2.3 1.5 2.6 3.7 5.7 4.6 3.2 2.9 25A-D4P0N114 25B-D4P0N114 4.0 2.0 4.8 3.0 7.5 6.0 4.9 3.8 6.0 25B-D6P0N114 25A-D6P0N114 3.9 8.4 6.8 5.3 13.8 11.0 9.0 6.9 25A-D010N114 25B-D010N114 10.5 10.4 13.0 15.4 12.3 10.0 7.7 25B-D013N114 25A-D013N114 8.5 6.5 11.1 17.0 14.7 12.0 9.2 25B-D017N114 25A-D017N114 8.5 13.6 18.4 12.0 21.1 17.2 3.2 15.6 26.4 19.2 24.0 25B-D024N114 25A-D024N114 25A-D030N114 33.0 26.4 21.5 16.5 25B-D030N114 30.0 24.0 19.5 15.0 24.1 18.5 33.7 27.0 21.9 25A-D037N114 25B-D037N114 37.0 29.6 16.9 34.4 21.5 38.9 31.1 25.3 19.5 25A-D043N114 25B-D043N114 43.0 28.0 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 0.7 0.5 1.2 1.0 0.9 0.6 0.8 25A-E0P9N104 25B-E0P9N104 0.6 1.1 0.9 2.3 1.8 1.5 1.2 1.7 25B-E1P7N104 25A-E1P7N104 1.4 2.4 2.0 1.5 3.8 3.0 2.5 1.9 25A-E3P0N104 25B-E3P0N104 3.0 3.4 4.2 5.3 4.2 3.4 2.7 25B-E4P2N104 25A-E4P2N104 2.7 2.1 4.3 8.0 6.4 5.2 4.0 5.3 3.3 25A-E6P6N104 25B-E6P6N104 6.6 6.4 5.0 11.2 9.0 7.3 25A-E9P9N104 25B-E9P9N104 9.9 7.9 5.6 9.6 6.0 13.5 10.8 7.8 6.8 12.0 25B-E012N104 25A-E012N104 8.8 15.2 12.4 9.5 24.0 19.2 15.6 12.0 25A-E019N104 25B-E019N104 19.0 17.6 11.0 27.3 21.8 17.7 13.7 14.3 25A-E022N104 25B-E022N104 22.0 21.6 17.6 13.5 24.7 19.8 16.1 12.4 25A-E027N104 25B-E027N104 27.0 14.6 25.6 16.0 29.2 23.4 19.0 20.8 32.0 25B-E032N104 25A-E032N104 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 174

175 Appendix B Accessories and Dimensions Catalog Number Description Product Selection V N 1 0 4 - 2P5 25B Enclosure HIM Emission Class Drive Voltage Rating Rating Version PowerFlex 520-Series Drive Ratings Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Input Frame Output Current (A) HP kW HP Size Voltage Range Catalog No. kW Catalog No. 100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output (2) – 1.6 85...132 A 25A-V1P6N104 0.25 0.25 0.2 0.2 0.5 85...132 2.5 0.4 A 25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.75 0.75 4.8 85...132 B 25A-V4P8N104 25B-V4P8N104 1.0 1.0 1.1 1.5 1.1 6.0 85...132 B 25A-V6P0N104 25B-V6P0N104 1.5 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output (2) – 0.2 1.6 170...264 A 25A-A1P6N104 0.25 0.25 0.2 0.4 0.5 2.5 170...264 A 25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.75 0.75 4.8 170...264 A 25A-A4P8N104 25B-A4P8N104 1.0 1.0 1.5 2.0 1.5 8.0 170...264 B 25A-A8P0N104 25B-A8P0N104 2.0 2.2 3.0 2.2 11.0 170...264 B 25A-A011N104 25B-A011N104 3.0 with EMC Filter, 0...230V 3-Phase Output 200...240V AC (-15%, +10%) – 1-Phase Input 0.2 0.25 0.2 1.6 170...264 A 25A-A1P6N114 – 0.25 0.4 0.5 0.4 2.5 170...264 A 25A-A2P5N114 25B-A2P5N114 0.5 1.0 0.75 1.0 0.75 4.8 170...264 A 25A-A4P8N114 25B-A4P8N114 2.0 2.0 1.5 1.5 8.0 170...264 B 25A-A8P0N114 25B-A8P0N114 3.0 2.2 2.2 11.0 170...264 B 25A-A011N114 25B-A011N114 3.0 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output (2) – 0.25 170...264 A 25A-B1P6N104 0.2 0.2 1.6 0.25 0.5 0.4 2.5 170...264 A 25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.75 1.0 0.75 5.0 170...264 A 25A-B5P0N104 25B-B5P0N104 1.0 1.5 2.0 1.5 8.0 170...264 A 25A-B8P0N104 25B-B8P0N104 2.0 2.2 170...264 2.2 11.0 3.0 A 25A-B011N104 25B-B011N104 3.0 5.0 5.0 4.0 17.5 170...264 B 25A-B017N104 25B-B017N104 4.0 7.5 5.5 7.5 5.5 24.0 170...264 C 25A-B024N104 25B-B024N104 10.0 7.5 32.2 170...264 D 25A-B032N104 25B-B032N104 10.0 7.5 11.0 10.0 7.5 48.3 170...264 E 25A-B048N104 25B-B048N104 15.0 25A-B062N104 15.0 11.0 62.1 170...264 E 15.0 25B-B062N104 20.0 (1) 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output (2) (2) 0.5 0.4 1.4 323...528 A 25A-D1P4N104 0.5 25B-D1P4N104 0.4 1.0 1.0 0.75 2.3 323...528 A 25A-D2P3N104 25B-D2P3N104 0.75 2.0 1.5 2.0 1.5 4.0 323...528 A 25A-D4P0N104 25B-D4P0N104 3.0 2.2 3.0 2.2 6.0 323...528 A 25A-D6P0N104 25B-D6P0N104 25B-D010N104 25A-D010N104 B 5.0 4.0 5.0 4.0 10.5 323...528 n 520-UM001I-EN-E - July 2016 175 Rockwell Automation Publicatio

176 Accessories and Dimensions Appendix B PowerFlex 520-Series Drive Ratings Output Ratings PowerFlex 523 PowerFlex 525 Normal Duty Heavy Duty Input Output Frame Size Voltage Range Catalog No. Current (A) HP kW HP kW Catalog No. 25B-D013N104 25A-D013N104 C 323...528 13.0 5.5 7.5 5.5 7.5 25A-D017N104 10.0 7.5 10.0 25B-D017N104 323...528 17.0 7.5 C 25B-D024N104 25A-D024N104 D 323...528 24.0 11.0 15.0 11.0 15.0 25B-D030N104 D 323...528 30.0 11.0 15.0 15.0 20.0 25A-D030N104 with EMC Filter, 0...460V 3-Phase Output 380...480V AC (-15%, +10%) – 3-Phase Input 323...528 25A-D1P4N114 A 25B-D1P4N114 1.4 0.4 0.5 0.4 0.5 323...528 2.3 25A-D2P3N114 0.75 1.0 0.75 1.0 A 25B-D2P3N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 323...528 A 25A-D4P0N114 25B-D6P0N114 3.0 3.0 2.2 2.2 6.0 323...528 A 25A-D6P0N114 25A-D010N114 5.0 4.0 5.0 4.0 10.5 323...528 B 25B-D010N114 25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 323...528 C 7.5 10.0 7.5 10.0 17.0 323...528 C 25A-D017N114 25B-D017N114 25A-D024N114 15.0 11.0 15.0 11.0 24.0 323...528 D 25B-D024N114 20.0 25B-D030N114 25A-D030N114 D 323...528 30.0 11.0 15.0 15.0 25A-D037N114 E 25.0 18.5 20.0 25B-D037N114 15.0 323...528 37.0 E 323...528 30.0 18.5 25.0 22.0 25B-D043N114 25A-D043N114 43.0 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output (2) (2) 25B-E0P9N104 0.4 0.9 446...660 A 25A-E0P9N104 0.5 0.4 0.5 25B-E1P7N104 25A-E1P7N104 A 446...660 1.7 0.75 1.0 1.0 0.75 A 25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 446...660 25B-E4P2N104 25A-E4P2N104 A 446...660 4.2 2.2 3.0 2.2 3.0 B 5.0 4.0 5.0 446...660 6.6 4.0 25A-E6P6N104 25B-E6P6N104 25B-E9P9N104 25A-E9P9N104 C 446...660 9.9 5.5 7.5 5.5 7.5 25A-E012N104 25B-E012N104 10.0 7.5 10.0 446...660 12.0 7.5 C 25B-E019N104 15.0 11.0 15.0 11.0 19.0 446...660 D 25A-E019N104 25A-E022N104 20.0 15.0 15.0 11.0 22.0 446...660 D 25B-E022N104 25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 446...660 E 446...660 E 22.0 25.0 18.5 32.0 30.0 25A-E032N104 25B-E032N104 (1) 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 ava ilable, ication will support a filtered drive. however you must verify that the appl a heatsink cooling fan and are in accordance with design specifications. These drive ratings do not come with (2) Dynamic Brake Resistors Minimum Drive Ratings Resistance Resistance Input Voltage HP kW (1)(2) Catalog No. ±10% Ω Ω ±5% AK-R2-091P500 100...120V 91 0.25 0.2 56 50/60 Hz 0.5 0.4 56 91 AK-R2-091P500 1-Phase 1.00.755691AK-R2-091P500 AK-R2-091P500 1.1 1.5 41 91 91 200...240V 0.25 0.2 56 AK-R2-091P500 50/60 Hz 0.4 56 91 AK-R2-091P500 0.5 1-Phase 1.00.755691AK-R2-091P500 2.0 1.5 AK-R2-091P500 91 41 3.0 2.2 32 47 AK-R2-047P500 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 176

177 Accessories and Dimensions Appendix B Dynamic Brake Resistors Drive Ratings Minimum Resistance Resistance HP Input Voltage kW (1)(2) Ω ±5% ±10% Ω Catalog No. 200...240V 0.25 0.2 56 91 AK-R2-091P500 50/60 Hz 0.4 0.5 AK-R2-091P500 56 91 3-Phase 1.00.755691AK-R2-091P500 2.0 1.5 41 91 AK-R2-091P500 3.0 2.2 32 47 AK-R2-047P500 5.0 4.0 18 47 AK-R2-047P500 7.5 5.5 16 30 AK-R2-030P1K2 30 14 AK-R2-030P1K2 10.0 7.5 (3) 14 15 AK-R2-030P1K2 11.0 15.0 (3) 15.0 10 15 AK-R2-030P1K2 20.0 380...480V 0.5 0.4 89 360 AK-R2-360P500 50/60 Hz 89 360 1.0 0.75 AK-R2-360P500 3-Phase AK-R2-360P500 2.0 1.5 89 360 89 120 AK-R2-120P1K2 2.2 3.0 47 4.0 AK-R2-120P1K2 120 5.0 7.5 5.5 47 120 AK-R2-120P1K2 AK-R2-120P1K2 10.0 7.5 47 120 (3) 60 AK-R2-120P1K2 15.0 11.0 43 (3) 20.0 15.0 AK-R2-120P1K2 43 60 (4) 27 18.5 AK-R2-120P1K2 25.0 40 (4) 27 40 AK-R2-120P1K2 30.0 22.0 525...600V 0.4 112 360 AK-R2-360P500 0.5 50/60 Hz 1.0 AK-R2-360P500 0.75 112 360 3-Phase AK-R2-360P500 1.5 112 360 2.0 3.0 2.2 112 120 AK-R2-120P1K2 AK-R2-120P1K2 120 5.0 4.0 86 7.5 5.5 59 120 AK-R2-120P1K2 120 AK-R2-120P1K2 10.0 7.5 59 (3) 15.0 60 AK-R2-120P1K2 59 11.0 (3) 59 60 AK-R2-120P1K2 20.0 15.0 (3) 18.5 53 60 AK-R2-120P1K2 25.0 (4) 30.0 22.0 34 40 AK-R2-120P1K2 (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. Al ternative resistors may be used, however, ca re must be taken when making a selectio n. See the PowerFlex Dynamic Braking Resist or Calculator, publication PFLEX-AT001. Requires two resistors wired in parallel. (3) (4) Requires three resistors wired in parallel. EMC Line Filters Short Circuit Current Rating = 100 kA Drive Ratings Input Voltage HP kW Current (A) Frame Size Catalog No. A 1.6 25-RF011-AL 0.25 100...120V 0.2 50/60 Hz 0.5 25-RF011-AL A 2.5 0.4 1-Phase 25-RF023-BL 4.8 0.75 1.0 B 1.1 6.0 B 25-RF023-BL 1.5 n 520-UM001I-EN-E - July 2016 177 Rockwell Automation Publicatio

178 Appendix B Accessories and Dimensions EMC Line Filters Short Circuit Current Rating = 100 kA Drive Ratings Current (A) Frame Size Catalog No. Input Voltage HP kW 25-RF011-AL 1.6 0.2 0.25 200...240V A 50/60 Hz 25-RF011-AL 0.5 0.4 A 2.5 1-Phase 0.75 1.0 25-RF011-AL 4.8 A 25-RF023-BL B 8.0 1.5 2.0 25-RF023-BL 11.0 2.2 3.0 B 200...240V 0.25 0.2 1.6 A 25-RF014-AL 50/60 Hz 0.5 0.4 2.5 25-RF014-AL A 3-Phase 0.75 5.0 1.0 A 25-RF014-AL A 8.0 1.5 2.0 25-RF014-AL 11.0 A 25-RF014-AL 3.0 2.2 B 5.0 4.0 17.5 25-RF021-BL 24.0 25-RF027-CL 7.5 5.5 C 10.0 25-RF035-DL D 32.2 7.5 48.3 11.0 25-RF056-EL E 15.0 25-RF056-EL E 62.1 15.0 20.0 25-RF7P5-AL 380...480V 0.5 0.4 1.4 A 50/60 Hz A 1.0 0.75 25-RF7P5-AL 2.3 3-Phase A 1.5 25-RF7P5-AL 2.0 4.0 25-RF7P5-AL 6.0 2.2 3.0 A 4.0 10.5 B 25-RF014-BL 5.0 25-RF018-CL C 13.0 5.5 7.5 7.5 25-RF018-CL 10.0 17.0 C 25-RF033-DL D 24.0 11.0 15.0 30.0 15.0 D 20.0 25-RF033-DL 25-RF039-EL E 37.0 18.5 25.0 (1) E 22.0 30.0 25-RF039-EL 43.0 (2) 525...600V 0.5 0.4 0.9 A 25-RF8P0-BL 50/60 Hz (2) 0.75 1.0 1.7 A 25-RF8P0-BL 3-Phase (2) 2.0 25-RF8P0-BL A 3.0 1.5 (2) 25-RF8P0-BL 4.2 2.2 3.0 A 4.0 6.6 B 25-RF8P0-BL 5.0 25-RF014-CL C 9.9 5.5 7.5 7.5 25-RF014-CL 10.0 12.0 C 15.0 11.0 19.0 D 25-RF027-DL 20.0 15.0 22.0 D 25-RF027-DL 25-RF029-EL E 27.0 18.5 25.0 (1) 32.0 E 25-RF029-EL 30.0 22.0 page 26 for more information. page 27 and EMC Line Filter size is based on the input current of the drive. See the tables on (1) This 600V drive rating needs to be matched with a frame B EMC Line Filter. (2) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 178

179 Accessories and Dimensions Appendix B EMC Plates Frame Item Description Size Catalog No. Optional grounding plate for shielded cables. A 25-EMC1-FA EMC Plate 25-EMC1-FB B C 25-EMC1-FC D 25-EMC1-FD E 25-EMC1-FE Human Interface Module (HIM) Option Kits and Accessories Item Description Catalog No. LCD Display, Remote Panel Digital speed control 22-HIM-C2S Mount CopyCat capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.0 meter cable LCD Display, Remote Digital speed control 22-HIM-A3 Handheld Full numeric keyboard CopyCat capable IP 30 (NEMA Type 1) Includes 1.0 meter cable Panel mount with optional Bezel Kit 22-HIM-B1 Bezel Kit Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1) Includes 2.0 m DSI cable 22-HIM-H10 DSI HIM Cable 1.0 m (3.3 ft) (DSI HIM to RJ45 cable) 2.9 m (9.51 ft) 22-HIM-H30 IP 30/NEMA 1/UL Type 1 Kit Frame Item Size Catalog No. Description Converts drive to IP 30/NEMA 1/UL Type 1 A25-JBAA IP 30/NEMA 1/UL Type 1 Kit Field installed kit. enclosure. Includes conduit bo x with mounting screws and B25-JBAB plastic top panel. C25-JBAC D25-JBAD E25-JBAE Control Module Fan Kit Frame Size Item Description Catalog No. 25-FAN1-70C For use with drive in environments with ambient A...D Control Module Fan Kit temperatures up to 70 ° C or horizontal mounting. E 25-FAN2-70C Incremental Encoder Input Option Item Description Catalog No. 25-ENC-1 Incremental Encoder Incremental en coder input option board. Only the 25-ENC-1 Encoder will work properly in the PowerFlex 525 WARNING: drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-2 will cause damage to the PowerFlex 525 drive. n 520-UM001I-EN-E - July 2016 179 Rockwell Automation Publicatio

180 Appendix B Accessories and Dimensions Bulletin 160 to PowerFlex 520-Se ries Mounting Adapter Plate B160 Frame Size Catalog No. Description Item For use with drive when replacing Bulletin 160 drives in A 25-MAP-FA Mounting Adapter Plate existing installations to a PowerFlex 520-Series drive. Select 25-MAP-FB B the catalog number based on the frame size of your Bulletin 160 drive. Replacement Parts PowerFlex 520-Series Power Module Description Item PowerFlex 520-Series PowerFlex 520-Series drives. Includes: Replacement power module for use with Power Module • Power Module • Power Module Front Cover • Power Terminal Guard • Heatsink Fan Output Ratings Normal Duty Heavy Duty Output Input Frame kW Current (A) HP Voltage Range HP Size Catalog No. kW 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 25-PM1-V1P6 0.4 0.5 0.4 2.5 85...132 A 25-PM1-V2P5 0.5 1.0 1.0 0.75 4.8 85...132 B 25-PM1-V4P8 0.75 1.1 1.5 6.0 85...132 B 25-PM1-V6P0 1.5 1.1 200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output 0.25 0.25 0.2 1.6 170...264 A 25-PM1-A1P6 0.2 0.4 0.5 0.4 0.5 170...264 A 25-PM1-A2P5 2.5 1.0 1.0 0.75 4.8 170...264 A 25-PM1-A4P8 0.75 1.5 2.0 1.5 8.0 170...264 B 25-PM1-A8P0 2.0 3.0 2.2 3.0 2.2 11.0 170...264 B 25-PM1-A011 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 25-PM2-A1P6 0.5 0.4 0.4 2.5 170...264 A 25-PM2-A2P5 0.5 0.75 1.0 4.8 170...264 A 25-PM2-A4P8 1.0 0.75 1.5 1.5 8.0 170...264 B 25-PM2-A8P0 2.0 2.0 2.2 3.0 2.2 11.0 170...264 B 25-PM2-A011 3.0 200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output 0.25 0.25 0.2 1.6 170...264 A 25-PM1-B1P6 0.2 0.4 2.5 0.4 0.5 170...264 A 25-PM1-B2P5 0.5 1.0 1.0 0.75 5.0 170...264 A 25-PM1-B5P0 0.75 2.0 1.5 2.0 1.5 8.0 170...264 A 25-PM1-B8P0 3.0 2.2 2.2 11.0 170...264 A 25-PM1-B011 3.0 4.0 170...264 4.0 17.5 5.0 B 25-PM1-B017 5.0 7.5 7.5 5.5 24.0 170...264 C 25-PM1-B024 5.5 10.0 7.5 10.0 7.5 32.2 170...264 D 25-PM1-B032 15.0 10.0 7.5 48.3 170...264 E 25-PM1-B048 11.0 20.0 15.0 15.0 11.0 62.1 170...264 E 25-PM1-B062 380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output A 323...528 25-PM1-D1P4 0.5 0.4 0.5 0.4 1.4 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 180

181 Accessories and Dimensions Appendix B Output Ratings Normal Duty Heavy Duty Input Frame Output Catalog No. Voltage Range kW Size Current (A) HP kW HP 25-PM1-D2P3 A 323...528 2.3 0.75 1.0 0.75 1.0 4.0 2.0 2.0 323...528 25-PM1-D4P0 1.5 1.5 A 2.2 25-PM1-D6P0 A 323...528 6.0 3.0 3.0 2.2 4.0 5.0 10.5 323...528 25-PM1-D010 5.0 B 4.0 25-PM1-D013 C 323...528 13.0 5.5 7.5 5.5 7.5 323...528 C 25-PM1-D017 10.0 7.5 10.0 7.5 17.0 D 15.0 11.0 25-PM1-D024 323...528 24.0 11.0 15.0 15.0 D 323...528 25-PM1-D030 30.0 11.0 15.0 20.0 with EMC Filter, 0...460V 3-Phase Output 380...480V AC (-15%, +10%) – 3-Phase Input 1.4 323...528 A 25-PM2-D1P4 0.5 0.4 0.5 0.4 25-PM2-D2P3 1.0 0.75 1.0 0.75 2.3 323...528 A A 25-PM2-D4P0 4.0 2.0 1.5 2.0 1.5 323...528 3.0 25-PM2-D6P0 A 323...528 6.0 2.2 2.2 3.0 5.0 323...528 10.5 4.0 B 25-PM2-D010 4.0 5.0 25-PM2-D013 C 323...528 13.0 5.5 7.5 5.5 7.5 17.0 323...528 C 25-PM2-D017 10.0 7.5 10.0 7.5 25-PM2-D024 24.0 15.0 11.0 15.0 11.0 323...528 D 323...528 20.0 15.0 15.0 11.0 25-PM2-D030 D 30.0 15.0 37.0 323...528 E 25-PM2-D037 25.0 18.5 20.0 25-PM2-D043 E 323...528 43.0 18.5 25.0 22.0 30.0 525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output 0.5 0.5 0.4 446...660 A 25-PM1-E0P9 0.4 0.9 1.0 25-PM1-E1P7 A 446...660 1.7 0.75 0.75 1.0 1.5 2.0 446...660 1.5 A 3.0 25-PM1-E3P0 2.0 25-PM1-E4P2 A 446...660 4.2 2.2 3.0 2.2 3.0 6.6 446...660 B 25-PM1-E6P6 5.0 4.0 5.0 4.0 7.5 5.5 7.5 5.5 9.9 446...660 C 25-PM1-E9P9 7.5 25-PM1-E012 12.0 C 446...660 10.0 7.5 10.0 25-PM1-E019 D 446...660 19.0 11.0 15.0 11.0 15.0 11.0 22.0 446...660 D 25-PM1-E022 20.0 15.0 15.0 25-PM1-E027 E 446...660 27.0 15.0 20.0 18.5 25.0 18.5 25.0 30.0 22.0 E 25-PM1-E032 32.0 446...660 PowerFlex 520-Series Control Module Frame Item Description Size Catalog No. A...E 25A-CTM1 PowerFlex 523 Control Replacement control module for use with Module PowerFlex 520-Series drives. Includes: • Control Module 25B-CTM1 PowerFlex 525 Control Control Module Front Cover • Module Other Parts Frame Catalog No. Description Item Size Replacement cover for the control module I/O terminals, 25A-CTMFC1 A...E PowerFlex 523 Control EtherNet/IP and DSI ports. Module Front Cover PowerFlex 525 Control 25B-CTMFC1 Module Front Cover n 520-UM001I-EN-E - July 2016 181 Rockwell Automation Publicatio

182 Appendix B Accessories and Dimensions Other Parts Frame Item Description Catalog No. Size B Replacement cover for the PowerFlex 520-Series power 25-PMFC-FB PowerFlex 520-Series module. Power Module Front Cover 25-PMFC-FC C 25-PMFC-FD D 25-PMFC-FE E A Replacement finger guard for power terminals. PowerFlex 520-Series 25-PTG1-FA Power Terminal Guard 25-PTG1-FB B 25-PTG1-FC C 25-PTG1-FD D 25-PTG1-FE E 25-FAN1-FA Replacement fan for drive power module. PowerFlex 520-Series A Heatsink Fan Kit 25-FAN1-FB B 25-FAN1-FC C 25-FAN1-FD D 25-FAN1-FE E PowerFlex 520-Series EMC A Replacement EMC cores 25-CORE-A Cores 25-CORE-RF-A B 25-CORE-B 25-CORE-RF-B C 25-CORE-C 25-CORE-RF-C 25-CORE-D D 25-CORE-RF-D E 25-CORE-E 25-CORE-RF-E Communication Option Kits and Accessories Catalog No. Item Description Communication Adapters cation options for use with the Embedded communi PowerFlex 520-Series drives: 25-COMM-D DeviceNet™ • • Dual Port EtherNet/IP™ 25-COMM-E2P PROFIBUS™ DP-V1 • 25-COMM-P Three channel 1769-SM2 Compact I/O Module 1203-USB Universal Serial Bus™ (USB) Provides serial communication with DF1 protocol for use with Converter Module Connected Components Workbench software. Includes: 2 m USB cable (1) • 20-HIM-H10 cable (1) • • 22-HIM-H10 cable (1) Serial Converter Module Provides serial communication with DF1 protocol for use with 22-SCM-232 Connected Components Workbench software. Includes: (RS485 to RS232) • DSI to RS232 serial converter (1) • 1203-SFC serial cable (1) • 22-RJ45CBL-C20 cable (1) 22-RJ45CBL-C20 2.0 m RJ45 to RJ45 cable, male to male connectors. DSI Cable 2.0 m serial cable with a locking low profile connector to 1203-SFC Serial Cable connect to the serial converter and a 9-pin sub-miniature D female connector to connect to a computer. AK-U0-RJ45-SC1 litter cable (Modbus only) RJ45 one to two port sp Splitter Cable Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 182

183 Accessories and Dimensions Appendix B Communication Option Kits and Accessories Catalog No. Item Description AK-U0-RJ45-TR1 Terminating Resistors RJ45 120 Ohm resistors (2 pieces) Terminal Block AK-U0-RJ45-TB2P RJ45 Two position terminal block (5 pieces) Windows-based software packages for programming and Connected Components http:// configuring Allen-Bradley drives and other Rockwell Workbench Software ab.rockwellautomation.co m/programmable- Automation products. (Download or DVD-ROM) controllers/connected- Compatibility: components-workbench- Windows XP, Windows Vista and Windows 7 software Bulletin 1321-3R Series Line Reactors (1) (3)(4) (3)(4) Input Line Reactor Output Ratings Output Line Reactor IP11 IP00 IP00 IP11 (Open Style) (Open Style) (NEMA/UL Type 1) Normal Duty (NEMA/UL Type 1) Heavy Duty kW HP Catalog No. Catalog No. Catalog No. kW HP Catalog No. (2) 200...240V 50/60 Hz 1-Phase 0.2 1321-3R4-A 1321-3RA4-A 0.25 1321-3RA2-D 1321-3R2-D 0.2 0.25 0.4 1321-3R8-A 1321-3RA8-A 1321-3R2-D 1321-3RA2-D 0.4 0.5 0.5 1.0 0.75 1321-3R8-A 1321-3RA8-A 1321-3R4-A 1321-3RA4-A 1.0 0.75 1.5 2.0 1321-3R18-A 1321-3RA18-A 1321-3R8-A 1321-3RA8-A 2.0 1.5 3.0 2.2 1321-3RA18-A 1321-3R12-A 1321-3RA12-A 3.0 2.2 1321-3R18-A 200...240V 50/60 Hz 3-Phase 0.25 1321-3R2-D 1321-3RA2-D 0.2 1321-3RA2-D 1321-3R2-D 0.25 0.2 0.4 1321-3R2-D 1321-3RA2-D 1321-3R2-D 1321-3RA2-D 0.4 0.5 0.5 1.0 0.75 1321-3R4-A 1321-3RA4-A 1321-3R4-A 1321-3RA4-A 1.0 0.75 2.0 1.5 1321-3R8-A 1321-3RA8-A 1321-3R8-A 1321-3RA8-A 2.0 1.5 3.0 1321-3R12-A 1321-3RA12-A 1321-3R12-A 1321-3RA12-A 2.2 2.2 3.0 5.0 4.0 1321-3R18-A 1321-3RA18-A 5.0 1321-3RA18-A 4.0 1321-3R18-A 5.5 7.5 5.5 1321-3R25-A 1321-3RA25-A 1321-3R25-A 1321-3RA25-A 7.5 7.5 10.0 7.5 1321-3R35-A 1321-3RA35-A 1321-3R35-A 1321-3RA35-A 10.0 11.0 15.0 1321-3R45-A 1321-3RA45-A 1321-3R45-A 1321-3RA45-A 10.0 7.5 15.0 11.0 20.0 1321-3RA55-A (ND) 15.0 1321-3R55-A (ND) 1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3RA45-A (HD) 1321-3R45-A (HD) 1321-3RA45-A (HD) 1321-3R45-A (HD) 380...480V 50/60 Hz 3-Phase 0.4 0.5 1321-3RA2-B 1321-3R2-B 1321-3RA2-B 0.4 0.5 1321-3R2-B 1.0 0.75 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C 1.0 0.75 2.0 1.5 1321-3R4-B 1321-3RA4-B 1321-3R4-B 1321-3RA4-B 2.0 1.5 3.0 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C 2.2 2.2 3.0 5.0 4.0 1321-3R12-B 1321-3RA12-B 5.0 1321-3RA12-B 4.0 1321-3R12-B 5.5 7.5 5.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B 7.5 7.5 10.0 7.5 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B 10.0 11.0 15.0 1321-3R25-B 1321-3RA25-B 1321-3R25-B 1321-3RA25-B 15.0 11.0 15.0 20.0 11.0 1321-3RA35-B (ND) 15.0 1321-3R35-B (ND) 1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3RA25-B (HD) 1321-3RA25-B (HD) 1321-3R25-B (HD) 1321-3R25-B (HD) 20.0 15.0 25.0 1321-3RA35-B 1321-3R35-B 1321-3RA35-B 18.5 1321-3R35-B 22.0 25.0 18.5 1321-3R45-B (ND) 1321-3RA45-B (ND) 30.0 1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R35-B (HD) 1321-3R35-B (HD) 1321-3RA35-B (HD) 1321-3RA35-B (HD) 525...600V 50/60 Hz 3-Phase 0.5 0.5 0.4 1321-3R1-C 1321-3RA1-C 1321-3R1-C 1321-3RA1-C 0.4 0.75 1.0 0.75 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B 1.0 1321-3R4-C 1.5 1.5 1321-3R4-C 1321-3RA4-C 2.0 1321-3RA4-C 2.0 n 520-UM001I-EN-E - July 2016 183 Rockwell Automation Publicatio

184 Accessories and Dimensions Appendix B Bulletin 1321-3R Series Line Reactors (1) (3)(4) (3)(4) Output Line Reactor Input Line Reactor Output Ratings IP00 IP11 IP00 IP11 Heavy Duty (NEMA/UL Type 1) (NEMA/UL Type 1) (Open Style) (Open Style) Normal Duty Catalog No. HP kW HP kW Catalog No. Catalog No. Catalog No. 1321-3R4-B 1321-3RA4-B 3.0 2.2 3.0 2.2 1321-3R4-B 1321-3RA4-B 1321-3RA8-C 1321-3R8-C 5.0 4.0 5.0 4.0 1321-3R8-C 1321-3RA8-C 1321-3R12-B 7.5 5.5 7.5 1321-3RA12-B 1321-3RA12-B 1321-3R12-B 5.5 10.0 7.5 1321-3RA12-B 1321-3R12-B 1321-3RA12-B 1321-3R12-B 7.5 10.0 1321-3RA18-B 15.0 11.0 15.0 11.0 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3R25-B (ND) 20.0 1321-3RA25-B (ND) 15.0 15.0 1321-3RA25-B (ND) 11.0 1321-3R25-B (ND) 1321-3RA18-B (HD) 1321-3RA18-B (HD) 1321-3R18-B (HD) 1321-3R18-B (HD) 20.0 25.0 1321-3RA35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C (ND) 1321-3R35-C (ND) 15.0 18.5 1321-3RA25-C (HD) 1321-3RA25-C (HD) 1321-3R25-C (HD) 1321-3R25-C (HD) 1321-3RA35-C (ND) 25.0 18.5 1321-3R35-C (ND) 22.0 1321-3R35-C (ND) 30.0 1321-3RA35-C (ND) 1321-3R25-B (HD) 1321-3RA25-B (HD) 1321-3R25-B (HD) 1321-3RA25-B (HD) ve. (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) dri (2) r 1-phase applications by routing each of the two supply conductors through an outsi de Standard 3-phase reactors can be used fo coil and leaving the center open. impedance reactor types are al 1321-TD001 so available. See publication Catalog numbers listed are for 3% impedance at 60 Hz. 5% (3) . ed the NEC fundamental motor amps. Output line reactors were sized based on the VFD rat Input line reactors were sized based on (4) output currents. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 184

185 Appendix B Accessories and Dimensions The PowerFlex 520-series drive is available in five frame sizes. See the PowerFlex Product Dimensions 520-Series Drive Ratings for information on power ratings. on page 175 PowerFlex 520-Series Drive Weight Frame Size Weight (kg/lb) A1.1 / 2.4 B1.6 / 3.5 C2.3 / 5.0 D3.9 / 8.6 12.9 / 28.4 E IP 20/Open Type – Frame A Dimensions are in millimeters and (inches) 72.0 (2.83) 172.0 (6.77) 57.5 (2.26) l e S E s c 152.0 (5.98) 92.7 (3.65) 140.0 (5.51) 6.0 (0.24) n 520-UM001I-EN-E - July 2016 185 Rockwell Automation Publicatio

186 Accessories and Dimensions Appendix B IP 20/Open Type – Frame B Dimensions are in millimeters and (inches) 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) l S e c E s 180.0 (7.09) 168.0 (6.61) 92.7 (3.65) 6.0 (0.24) IP 20/Open Type – Frame C Dimensions are in millimeters and (inches) 184.0 (7.24) 109.0 (4.29) 90.5 (3.56) l S e E c s 220.0 (8.66) 207.0 (8.15) 92.7 (3.65) 6.0 (0.24) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 186

187 Appendix B Accessories and Dimensions IP 20/Open Type – Frame D Dimensions are in millimeters and (inches) 212.0 (8.35) 130.0 (5.12) 116.0 (4.57) e S l E s c 260.0 (10.24) 247.0 (9.72) 6.0 (0.24) IP 20/Open Type – Frame E llimeters and (inches) Dimensions are in mi 185.0 (7.28) 279.0 (10.98) 160.0 (6.30) S e l s c E 300.0 (11.81) 280.0 (11.02) 7.6 (0.30) n 520-UM001I-EN-E - July 2016 187 Rockwell Automation Publicatio

188 Appendix B Accessories and Dimensions Control Module Fan Kit 25-FAN2-70C 25-FAN1-70C 25-FAN1-70C Specifications 25-FAN2-70C Rated Voltage 24V DC Operation Voltage 14...27.6V DC 0.15 A Input Current 0.1 A 4500 ± 10% rpm Speed (Reference) 7000 rpm 3 3 /min 1.574 m /min 0.575 m Maximum Air Flow (At zero static pressure) t zero air flow) 7.70 mmH Maximum Air Pressure (A O 9.598 mmH O 2 2 Acoustical Noise 46.0 dB-A 40.5 dB-A Insulation Type UL Class A Frame Size Frame A...D Frame E 2 (22 AWG) 0.32 mm Wire Size Torque 0.29...0.39 Nm (2.6...3.47 lb-in.) IP 20/Open Type with Control Module Fan Kit – Frame A...C Dimensions are in millimeters and (inches) Frame B Frame A Frame C 72.0 (2.83) 87.0 (3.43) 109.0 (4.29) 72.5 (2.85) 57.5 (2.26) 90.5 (3.56) 32.0 (1.26) 32.0 (1.26) 32.0 (1.26) l e S c E s S l e E s c l e S c E s 180.0 (7.09) 152.0 (5.98) 220.0 (8.66) 140.0 (5.51) 168.0 (6.61) 207.0 (8.15) An external 24V DC power source is required when using IMPORTANT the Control Module Fan Kit with drive frames A, B, and C. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 188

189 Appendix B Accessories and Dimensions IP 20/Open Type with Control Module Fan Kit – Frame D...E Dimensions are in mi llimeters and (inches) Frame E Frame D 196.0 (7.72) 185.0 (7.28) 130.0 (5.12) 160.0 (6.30) 116.0 (4.57) 32.0 (1.26) 52.0 (2.05) e S l c s E S e l s E c 260.0 (10.24) 300.0 (11.81) 247.0 (9.72) 280.0 (11.02) ilt-in 24V supply on drive fr ames D and E for use with the Remove the label to access the bu IMPORTANT Control Module Fan Kit. n 520-UM001I-EN-E - July 2016 189 Rockwell Automation Publicatio

190 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame A Dimensions are in mi llimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 72.0 (2.83) 172.0 (6.77) 57.5 (2.26) 15.0 (0.59) 219.0 (8.62) e l S s E c 152.0 (5.98) 92.7 (3.65) 140.0 (5.51) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 51.1 (2.01) 21.0 (0.82) ø21.5 (ø0.85) 135.4 (5.33) 111.9 (4.41) 88.2 (3.47) 64.7 (2.55) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 190

191 Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame B Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 87.0 (3.43) 172.0 (6.77) 72.5 (2.85) 15.0 (0.59) S e l s E c 218.0 (8.58) 180.0 (7.09) 168.0 (6.61) 92.7 (3.65) 6.1 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 66.1 (2.60) 63.1 (2.48) 33.5 (1.32) 23.9 (0.94) ø21.5 (ø0.85) ø27.5 (ø1.08) 128.5 (5.06) 108.5 (4.27) 88.3 (3.48) 67.3 (2.65) n 520-UM001I-EN-E - July 2016 191 Rockwell Automation Publicatio

192 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame C Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 109.0 (4.29) 90.5 (3.56) 184.0 (7.24) 15.0 (0.59) e S l c E s 255.0 (10.04) 222.0 (8.66) 207.0 (8.15) 92.7 (3.65) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 80.5 (3.17) 66.5 (2.62) 34.5 (1.36) 26.5 (1.04) ø21.5 (ø0.85) ø27.5 (ø1.08) 123.3 (4.85) 82.2 (3.24) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 192

193 Accessories and Dimensions Appendix B IP 30/NEMA 1/UL Type 1 – Frame D Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 130.0 (5.12) 212.0 (8.35) 116.0 (4.57) 15.0 (0.59) e l S c s E 295.0 (11.61) 260.0 (10.24) 247.0 (9.72) 6.0 (0.24) IP 30/NEMA 1/ UL Type 1 conduit box 96.0 (3.78) 70.0 (2.76) 44.0 (1.73) 30.0 (1.18) ø21.5 (ø0.85) ø33.5 (ø1.32) 153.3 (6.04) 109.8 (4.32) 193 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

194 Appendix B Accessories and Dimensions IP 30/NEMA 1/UL Type 1 – Frame E Dimensions are in millimeters and (inches) IP 30/NEMA 1/ UL Type 1 top panel 185.0 (7.28) 160.0 (6.30) 279.0 (10.98) 15.0 (0.59) e l S c E s 350.0 (13.78) 300.0 (11.81) 280.0 (11.02) 7.6 (0.30) IP 30/NEMA 1/ UL Type 1 conduit box 127.5 (5.02) 82.5 (3.25) 62.5 (2.46) 42.5 (1.67) ø21.5 (ø0.85) ø43.7 (ø1.72) 212.0 (8.35) 181.0 (7.13) 164.0 (6.46) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 194

195 Accessories and Dimensions Appendix B EMC Line Filter – Frame A Dimensions are in millimeters and (inches) can be mounted onto the back of the drive. Filter 55.0 (2.17) 72.0 (2.83) 30.0 (1.18) 54.0 (2.13) ø5.5 (ø0.22) 234.0 (9.21) 223.0 223.0 (8.78) (8.78) 23.0 (0.91) 20.0 (0.79) 5.5 (0.22) 54.0 (2.13) EMC Line Filter – Frame B can be mounted onto the back of the drive. Filter Dimensions are in millimeters and (inches) 70.0 (2.76) 87.0 (3.43) 35.0 (1.38) 58.0 (2.28) ø5.5 (ø0.22) 270.0 (10.63) 258.0 258.0 (10.16) (10.16) 5.5 (0.22) 24.0 (0.94) 25.0 (0.98) 58.0 (2.28) n 520-UM001I-EN-E - July 2016 195 Rockwell Automation Publicatio

196 Accessories and Dimensions Appendix B EMC Line Filter – Frame C Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 70.0 (2.76) 109.0 (4.29) 37.0 (1.46) 76.0 (2.99) ø5.5 (ø0.22) 275.0 (10.83) 263.0 263.0 (10.35) (10.35) 25.0 (0.98) 28.0 (1.10) 5.5 (0.22) 76.0 (2.99) EMC Line Filter – Frame D Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive. 80.0 (3.15) 130.0 (5.12) 33.0 (1.30) 28.0 (1.10) 90.0 (3.54) ø5.5 (ø0.22) 310.0 (12.20) 298.0 298.0 (11.73) (11.73) 28.0 (1.10) 33.0 (1.30) 5.5 (0.22) 90.0 (3.54) Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 196

197 Accessories and Dimensions Appendix B EMC Line Filter – Frame E llimeters and (inches) Dimensions are in mi 80.0 (3.15) 155.0 (6.10) 28.0 (1.10) 33.0 (1.30) 110.0 (4.33) ø5.5 (ø0.22) 390.0 (15.35) 375.0 375.0 (14.76) (14.76) 33.0 (1.30) 28.0 (1.10) 5.5 (0.22) 110.0 (4.33) n 520-UM001I-EN-E - July 2016 197 Rockwell Automation Publicatio

198 Accessories and Dimensions Appendix B Installing a Communication Adapter Optional Accessories and Kits 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 Align the connectors on the communication adapter to the 2. communication adapter interface connector, then push the back cover down. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 198

199 Accessories and Dimensions Appendix B 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. n 520-UM001I-EN-E - July 2016 199 Rockwell Automation Publicatio

200 Appendix B Accessories and Dimensions Notes: 200 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

201 C Appendix RS485 (DSI) Protocol 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 e l S l S e l l S e e S s E E s c E s c E s c c 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 Network Wiring from node to node. AT T E NT IO N : Never attempt to connect a Power over Ethernet (PoE) cable to the RS485 port. Doing so may damage the circuitry. Network Wiring Diagram Example PowerFlex 525 PowerFlex 525 PowerFlex 523 Master Node “n” Node 2 Node 1 TxRxD+ TxRxD+ FRONT 120 ohm resistor TxRxD+ 4 4 4 120 ohm resistor TxRxD- TxRxD- TxRxD- 5 5 5 Shield Shield Shield PIN 1 PIN 8 X X X C1 C2 C1 C2 RS485 RS485 (DSI) (DSI) AK-U0-RJ45-TB2P TxRxD+ TxRxD+ TxRxD - TxRxD - W/T3 R/L1 W/T3 V/T2 T/L3 S/L2 R/L1 U/T1 V/T2 T/L3 U/T1 S/L2 DC+ DC+ DC- DC- BR- BR- BR+ BR+ The shield is connected at ONLY ONE end of each cable segment. IMPORTANT n 520-UM001I-EN-E - July 2016 201 Rockwell Automation Publicatio

202 Appendix C RS485 (DSI) Protocol 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 on page 40 and for more page 43 information. The following PowerFlex 520-series drive parameters are used to configure the Parameter Configuration drive to operate on a DSI network. Configuring Parameters for DSI Network Parameter Details Reference [Start Source 1] Set to 3 “Serial/DSI” if Start is controlled from the network. page 87 P046 P047 [Speed Reference1] e Speed Reference is controlled from the network. page 87 Set to 3 “Serial/DSI” if th [RS485 Data Rate] 485 (DSI) Port. All nodes on the network must be C123 page 101 Sets the data rate for the RS set to the same data rate. C124 Sets the node address for th e drive on the network. Each device on the page 101 [RS485 Node Addr] network requires a unique node address. C125 [Comm Loss Action] Selects the drive’s response to communication problems. page 101 page 101 C126 Sets the time that the drive wi ll remain in communication loss before the [Comm Loss Time] C125 [Comm Loss Action]. drive implements C127 [Comm Format] Sets the transmission mode, data bi ts, parity and stop bits for the RS485 (DSI) page 102 Port. All nodes on the network must be set to the same setting. page 101 [Comm Write Mode] Set to 0 “Save” when programming drive. C121 Set to 1 “RAM only” to only write to volatile memory. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 202

203 RS485 (DSI) Protocol Appendix C The peripheral interface (DSI) used on PowerFlex 520-series drives supports Supported Modbus Function some of the Modbus function codes. Codes Supported Modbus Function Codes Modbus Function Code (Decimal) Command Read Holding Registers 03 06 Preset (Write) Single Register Preset (Write) Multiple Registers 16 (10 Hexadecimal) Modbus devices can be 0-based (registers are numbered starting at 0) or 1- IMPORTANT based (registers are numbered starting at 1). Depending on the Modbus Master used, the register addresses list ed on the following pages may need to be offset by +1. For example, Logic Co mmand may be register address 8192 for some master devices (e.g. ProSoft 31 50-MCM SLC Modbus scanner) and 8193 for others (e.g. PanelViews). The PowerFlex 520-series drive can be controlled through the network by Writing (06) Logic Command sending Function Code 06 writes to register address 2000H (Logic Command). Data 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. [Cmd Stat Select] to select either C122 PowerFlex 525 drives can use Parameter Velocity or Position bit definitions. Powerup/Reset the drive after selecting an option for C122 [Cmd Stat Select] TIP for the change to take effect. n 520-UM001I-EN-E - July 2016 203 Rockwell Automation Publicatio

204 Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Command – C122 = 0 “Velocity” Bit(s) Description Address (Decimal) 2000H (8192) 0 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 1 = Jog, 0 = No Jog 2 31 = Clear Faults, 0 = Not Clear Faults 5, 4 00 = No Command 01 = Forward Command 10 = Reverse Command 11 = No Command 6 1 = Force Keypad Control, 0 = Not Force Keypad Control 7 1 = MOP Increment, 0 = Not Increment 9, 8 00 = No Command 01 = Accel Rate 1 Enable 10 = Accel Rate 2 Enable 11 = Hold Accel Rate Selected 11, 10 00 = No Command 01 = Decel Rate 1 Enable 10 = Decel Rate 2 Enable 11 = Hold Decel Rate Selected 14, 13, 12 000 = 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] 15 1 = MOP Decrement, 0 = Not Decrement Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 204

205 Appendix C RS485 (DSI) Protocol Position Bit Definitions Comm Logic Command – C122 = 1 “Position” Address (Decimal) Bit(s) Description 2000H (8192) 1 = Stop, 0 = Not Stop 0 1 1 = Start, 0 = Not Start 2 1 = Jog, 0 = No Jog 3 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 5, 4 01 = Forward Command 10 = Reverse Command 11 = No Command 61 = Logic In 1 71 = Logic In 2 10, 9, 8 000 = 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 11 1 = Hold Step 12 13 1 = Pos Redefine 1 = Sync Enable 14 15 1 = Traverse Disable The PowerFlex 520-series drive Comm Frequency Command can be controlled Writing (06) Comm through the network by sending Function Code 06 writes to register address Frequency Command 2001H (Comm Frequency Command). Comm Frequency Command Reference Address (Decimal) Description 2001H (8193) ntrol the reference of the drive. In units of Used by internal comm modules to co 0.01 Hz. The PowerFlex 520-series drive Logic Status data can be read through the Reading (03) Logic Status network by sending Function Code 03 reads to register address 2100H (Logic Data Status). PowerFlex 523 drives support only Velocity bit definitions. C122 PowerFlex 525 drives can use Parameter [Cmd Stat Select] to select either Velocity or Position bit definitions. n 520-UM001I-EN-E - July 2016 205 Rockwell Automation Publicatio

206 Appendix C RS485 (DSI) Protocol Velocity Bit Definitions Comm Logic Status – C122 = 0 “Velocity” Description Address (Decimal) Bit(s) 0 1 = Ready, 0 = Not Ready 2100H (8448) 1 1 = Active (Running), 0 = Not Active 2 1 = Cmd Forward, 0 = Cmd Reverse 3 1 = Rotating Forward, 0 = Rotating Reverse 4 1 = Accelerating, 0 = Not Accelerating 5 1 = Decelerating, 0 = Not Decelerating 6Not Used 1 = Faulted, 0 = Not Faulted 7 1 = At Reference, 0 = Not At Reference 8 9 1 = Main Freq Controlled by Active Comm 1 = Operation Cmd Controlled by Active Comm 10 1 = Parameters have been locked 11 12 Digital Input 1 Status (DigIn TermBlk 05) 13 Digital Input 2 Status (DigIn TermBlk 06) 14 Digital Input 3 Status (DigIn TermBlk 07) 15 Digital Input 4 Status (DigIn TermBlk 08) Position Bit Definitions Comm Logic Status – C122 = 1 “Position” Bit(s) Description Address (Decimal) 2100H (8448) 0 1 = Ready, 0 = Not Ready 1 1 = Active (Running), 0 = Not Active 2 1 = Cmd Forward, 0 = Cmd Reverse 3 1 = Rotating Forward, 0 = Rotating Reverse 4 1 = Accelerating, 0 = Not Accelerating 5 1 = Decelerating, 0 = Not Decelerating 6 1 = Forward Travel Position, 0 = Reverse Travel Position 7 1 = Faulted, 0 = Not Faulted 8 1 = At Reference, 0 = Not At Reference 9 1 = At Position, 0 = Not At Position 10 1 = At Home, 0 = Not At Home 11 1 = Drive Homed, 0 = Not Drive Homed 12 1 = Sync Hold, 0 = Not Sync Hold 13 1 = Sync Ramp, 0 = Not Sync Ramp 14 1 =Traverse On, 0 = Traverse Off 15 1 = Traverse Decel, 0 = Not Traverse Decel Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 206

207 RS485 (DSI) Protocol Appendix C The PowerFlex 520-series Error Code data can be read through the network by Reading (03) Drive Error sending Function Code 03 reads to register address 2101H (Drive Error Codes). Codes Drive Error Codes Logic Status Address (Decimal) Value (Decimal) Description 0 2101H (8449) No Fault 2 Auxiliary Input 3Power Loss 4Undervoltage 5Overvoltage 6 Motor Stalled 7 Motor Overload 8 Heatsink Overtemperature 9 Control Module Overtemperature 12 HW Overcurrent (300%) 13 Ground Fault 15 Load Loss 21 Output Phase Loss 29 Analog Input Loss 33 Auto Restart Tries 38 Phase U to Ground Short 39 Phase V to Ground Short 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short Parameters Defaulted 48 Safety Open 59 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 71 DSI Network Loss 72 Option Card Network Loss 73 Embedded EtherNet/IP Adapter Network Loss 80 AutoTune Fail 81 DSI Communication Loss 82 Option Card Communication Loss 83 Embedded EtherNet/IP Adapter Communication Loss 91 Encoder Loss 94 Function Loss 100 Parameter Checksum Error 101 External Storage 105 Control Module Connect Error 106 Incompatible Control-Power Module 107 Unrecognized Control-Power Module 109 Mismatched Control-Power Module 110 Keypad Membrane 111 Safety Hardware Microprocessor Failure 114 I/O Board Fail 122 n 520-UM001I-EN-E - July 2016 207 Rockwell Automation Publicatio

208 Appendix C RS485 (DSI) Protocol Drive Error Codes Logic Status Value (Decimal) Address (Decimal) Description Flash Update Required 125 2101H (8449) Non Recoverable Error 126 DSI Flash Update Required 127 The PowerFlex 520-series Drive Operational Values can be read through the Reading (03) Drive network by sending Function Code 03 reads to register addresses Operational Values 2102H...210AH. Drive Operational Values Reference Description Address (Decimal) 2102H (8450) Frequency Command (xxx.xx Hz) Output Fr 2103H (8451) equency (xxx.xx Hz) Current (xxx.xx A) Output 2104H (8452) S Voltage (xxxV) DC-BU 2105H (8453) Output Voltage (xxx.xV) 2106H (8454) To access drive parameters, the Modbus register address equals the parameter Reading (03) and Writing number. For example, a decimal “1” is used to address Parameter b001 [Output (06) Drive Parameters Freq] and decimal “41” is used to address Parameter P041 [Accel Time 1]. http://www.ab.com/drives/ See for additional information. Additional Information Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 208

209 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 to simplify setup instead TIP of manually configuring the parameters. n 520-UM001I-EN-E - July 2016 209 Rockwell Automation Publicatio

210 c and Timer/Counter Functions Appendix D Velocity StepLogic, Basic Logi Velocity StepLogic Using This function is specific to PowerFlex 525 drives only. IMPORTANT Timed Steps 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 7 Step 2 Step 3 Step 4 Step 5 Step 1 Step 0 Step 6 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 This function is specific to PowerFlex 525 drives only. IMPORTANT Basic Logic Functions 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 TermBlk xx] to 24 “Logic In 1” or parameters t062...t063, t065...t068 [DigIn 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”. n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 210

211 Velocity StepLogic, Basic Logi Appendix D c and Timer/Counter Functions • 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. • 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. Step 3 Step 2 Step 1 Step 0 Start 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. Step 0 Start Step 1 Frequency Logic In 1 Logic In 2 Time Digital inputs and outputs control the timer function and are configured with Timer Function TermBlk xx] set to 19 “Timer Start” parameters t062...t063, t065...t068 [DigIn 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. n 520-UM001I-EN-E - July 2016 211 Rockwell Automation Publicatio

212 Appendix D Velocity StepLogic, Basic Logi c and Timer/Counter Functions 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” t076 [Relay Out1 Sel] = 25 “Timer Out” – t077 [Relay Out1 Level] = 20.0 Secs – 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. Digital inputs and outputs control the counter function and are configured with Counter Function TermBlk xx] set to 20 “Counter In” parameters t062...t063, t065...t068 [DigIn 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 5 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 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 212

213 Velocity StepLogic, Basic Logi c and Timer/Counter Functions Appendix D Output Frequency Start Relay Out Photo Eye DigIn TermBlk 05 Counter In DigIn TermBlk 06 Reset Counter Limit Switch Code Descriptions for Parameters L180...L187 Velocity StepLogic Digit 4 Digit 3 Digit 2 Digit 1 Parameters 00F1 Digit 4 – Defines the action during the step currently executing Setting Accel/Decel Parameter Commanded Direction StepLogic Output State Used 01OffFWD 11OffREV 21OffNo Output 31OnFWD 41OnREV 5 1 No Output On 62OffFWD 72OffREV 82OffNo Output 92OnFWD A2OnREV b 2 On No Output Digit 3 – Defines what step to jump to or how to end program when the lo gic conditions specified in Digit 2 are met. Logic Setting 0Jump to Step 0 1Jump to Step 1 2Jump to Step 2 3Jump to Step 3 4Jump to Step 4 5Jump to Step 5 6Jump to Step 6 7Jump to Step 7 8 End Program (Normal Stop) End Program (Coast to Stop) 9 End Program and Fault (F002) A n 520-UM001I-EN-E - July 2016 213 Rockwell Automation Publicatio

214 Appendix D Velocity StepLogic, Basic Logi c and Timer/Counter Functions Digit 2 – Defines what logic must be met to jump to a step other than the very next step. Setting Description Logic SKIP Skip Step (jump immediately) 0 Step based on the time programmed in the resp ective [Stp Logic Time x] parameter. TIMED 1 2 TRUE Step if “Logic In 1” is active (logically true) 3 Step if “Logic In 2” is active (logically true) TRUE 4 Step if “Logic In 1” is not active (logically false) FALSE 5 Step if “Logic In 2” is not active (logically false) FALSE 6 Step if either “Logic In 1” or “Logic In 2” is active (logically true) OR 7 Step if both “Logic In 1” and “Logic In 2” is active (logically true) AND Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR 8 9 d “Logic In 2” is not active (logically false) XOR Step if “Logic In 1” is active (logically true) an A Step if “Logic In2” is active (logically true) and “Logic In 1” is not active (logically false) XOR b Step after [Stp Logic Time x] and “Logic In 1” is active (logically true) TIMED AND C TIMED AND Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) d Step after [Stp Logic Time x] and “Logic In 1” is not active (logically false) TIMED OR E Step after [Stp Logic Time x] and “Logic In 2” is not active (logically false) TIMED OR F Do not step OR no “jump to”, so use Digit 0 logic IGNORE Digit 1 – Defines what logic must be met to jump to the very next step. Setting Logic Description Skip Step (jump immediately) 0 SKIP 1 Step based on the time programmed in the resp ective [Stp Logic Time x] parameter. TIMED 2 Step if “Logic In 1” is active (logically true) TRUE Step if “Logic In 2” is active (logically true) 3 TRUE 4 FALSE Step if “Logic In 1” is not active (logically false) Step if “Logic In 2” is not active (logically false) 5 FALSE 6 Step if either “Logic In 1” or “Logic In 2” is active (logically true) OR 7 Step if both “Logic In 1” and “Logic In 2” is active (logically true) AND 8 Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR Step if “Logic In 1” is active (logically true) an d “Logic In 2” is not active (logically false) 9 XOR A Step if “Logic In 2” is active (logically true) an d “Logic In 1” is not active (logically false) XOR b Step after [Stp Logic Time x] and “Logic In 1” is active (logically true) TIMED AND C TIMED AND Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) d Step after [Stp Logic Time x] and “Logic In 1” is not active (logically false) TIMED OR E Step after [Stp Logic Time x] and “Logic In 2” is not active (logically false) TIMED OR Use logic programmed in Digit 1 IGNORE F Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 214

215 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application The PowerFlex 520-series drives include a pulse train input built into the Encoder and Pulse Train terminal block. PowerFlex 525 drives also support an optional encoder card. The Usage 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, 12 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 A459 train can be used with the PID function if enabled by or A471 [PID A460 x Ref Sel], or A472 or [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 [Kp Speed Loop] are used in this control loop. The primary benefit A539 of this mode is increased speed accuracy when compared to open-loop slip compensation. It does not provide speed bandwidth improvement. The encoder usage, and position StepLogic application covered in this chapter IMPORTANT is specific to PowerFlex 525 drives only. n 520-UM001I-EN-E - July 2016 215 Rockwell Automation Publicatio

216 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Encoder Interface The incremental encoder option card can source 5 or 12 volt power and accept 5, 12 or 24 volt single ended or differential inputs. See Appendix B for ordering information. operly in the PowerFlex 525 drive. Only the 25-ENC-1 Encoder will work pr IMPORTANT ch as the PowerFle Installing an incorrect encoder card, su x 527 25-ENC-2 will cause damage to the PowerFlex 525 drive. Description Signal No. (1)(2) +V +V 5...12V Power Internal power source 250 mA (isolated). Cm Power Return Cm B- Encoder B (NOT) B- Quadrature B input. B B Encoder B A- A- Encoder A (NOT) A Single channel, pulse train or quadrature A input. Encoder A A   Output DIP switch selects 12 or 5 volt power supplied at terminals “+V” and “Cm” 5V 12V for the encoder. When using 12V Encoder power, 24V I/O power, maximum output current at I/O Terminal 11 is 50 mA. (1) If Encoder requires 24V power, it must be supplied by an external power source. (2) Encoder Wiring Examples I/O I/O Connection Example Connection Example Encoder Power Encoder Power +12V DC (250 mA) +V – Internal Drive – External Cm Power Power Source Common to B- + Common SHLD B to SHLD External A- Power Internal (drive) A Supply 12V DC, 250mA Encoder Signal Encoder Signal to Power Supply Common – Differential, – Single-Ended, to SHLD +V +V Dual Channel Dual Channel Cm Cm B NOT B NOT B- B- B B B B A NOT A NOT A- A- A A A A to SHLD The encoder option card can supply 5V or 12V power (250 mA maximum) for Wiring Notes 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. n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 216

217 sition StepLogic Application Appendix E Encoder/Pulse Train Usage and Po A quadrature encoder provides rotor speed and direction. Therefore, the IMPORTANT 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”. Use the following formula to determine the encoder pulse per revolution (PPR) Determine Encoder Pulse Per specification based on the speed resolution. Revolution (PPR) 1 x pole pairs Specification Based on Speed Speed resolution (Hz) = encoder pulse number x 4 Resolution -3 10 sec The operating speed range will depend on the motor control mode selected TIP on Performance with Encoder (SVC or VVC). For more information, see page 170 . 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: 1 x 2 0.06 Hz = encoder pulse number x 4 -3 10 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: 1 x 2 Speed resolution (Hz) = 1024 x 4 -3 10 sec = 0.49 Hz Therefore, using a 1024 PPR quadrature encoder will give a speed resolution of 0.49 Hz. n 520-UM001I-EN-E - July 2016 217 Rockwell Automation Publicatio

218 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application The PowerFlex 525 drive includes a simple position regulator which can be used Positioning Overview in a variety of position applications without the need for multiple limit switches or photo-eyes. This can be used as a stand-alone 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. The position regulator can be configured for operation appropriate for a variety Common Guidelines for All of applications. Certain parameters will need to be adjusted in all cases. Applications P047 [Speed Reference1] must be set to 16 “Positioning”. A535 [Motor Fdbk Type] must be set to the match the feedback device. [Motor Fdbk Type] option 4. Positioning mode must use A535 A535 [Motor Fdbk Type] Options indicates no encoder is used. This can not be used for 0 “None” 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 results, tune the application first. The autotune routine can be completed to further improve the drive-motor performance. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 218

219 Encoder/Pulse Train Usage and Po Appendix E sition StepLogic Application 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. [DB Resistor Sel] default setting is 0 “Disabled”. If improved deceleration A437 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 1cm 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 one 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. n 520-UM001I-EN-E - July 2016 219 Rockwell Automation Publicatio

220 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application Parameter A558 [Positioning Mode] must be set to properly match the desired Positioning Operation operation of the positioning function. A558 [Positioning Mode] Options uses Step Logic times. This mode ignores the Step Logic 0 “Time Steps” 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 Step Logic Commands settings and instead the drive will move directly to whatever step is currently commanded by A410 [Preset ... A425 ... L214 [Step Units x]. This is useful when an application Fre q x] an d L200 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. Advanced Step Logic options such as incremental move are not IMPORTANT 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 Step Logic 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 220

221 sition StepLogic Application Encoder/Pulse Train Usage and Po Appendix E In all position modes, the following parameters will control the characteristics at each step: L200 L204 , L206 , L208 , L210 , L212 and L214 [Step Units x] are the , L202 , 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 [Preset Freq x] are the parameters that define the maximum ... A417 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. Step Source Position Source Frequency Source [Stp Logic 0] [Preset Freq 0] L200 [Step Units 0] L180 A410 L202 [Preset Freq 1] [Stp Logic 1] L181 [Step Units 1] A411 A412 [Preset Freq 2] [Step Units 2] L182 [Stp Logic 2] L204 [Stp Logic 3] L206 L183 [Step Units 3] [Preset Freq 3] A413 [Stp Logic 4] [Step Units 4] L208 [Preset Freq 4] L184 A414 A415 [Preset Freq 5] L185 [Stp Logic 5] L210 [Step Units 5] [Step Units 6] L212 [Stp Logic 6] L186 [Preset Freq 6] A416 [Step Units 7] [Stp Logic 7] L187 [Preset Freq 7] L214 A417 [Preset Freq 0] is 0.00 Hz. This value needs to be A410 The default value for IMPORTANT changed or the drive will not be able to move during Step 0. ... L197 [Stp Logic Time x] are the parameters that define the time the drive L190 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 ... allow additional flexibility and [Stp Logic x] are the parameters that L187 control various aspects of each step when a positioning mode is selected that utilizes the Step Logic 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: n 520-UM001I-EN-E - July 2016 221 Rockwell Automation Publicatio

222 Encoder/Pulse Train Usage and Position StepLogic Application Appendix E Logic for next step Digit 1 Logic to jump to a different step Digit 2 Different step to jump Digit 3 Step settings Digit 4 Not Used Settings (Digit 3) Velocity Control Settings (Digit 4) Commanded StepLogic Setting Description Required Accel/Decel Setting Output State Direction Param. Used 0Jump to Step 0 Accel/Decel 1 0 FWD Off 1Jump to Step 1 1 Accel/Decel 1 Off REV 2Jump to Step 2 2 No Output Accel/Decel 1 Off 3Jump to Step 3 On FWD 3 Accel/Decel 1 4Jump to Step 4 On REV Accel/Decel 1 4 5Jump to Step 5 Accel/Decel 1 On No Output 5 6Jump to Step 6 FWD 6 Accel/Decel 2 Off 7Jump to Step 7 Accel/Decel 2 REV 7 Off 8 End Program (Normal Stop) No Output 8 Off Accel/Decel 2 9 End Program (Coast to Stop) FWD 9 Accel/Decel 2 On A End Program and Fault (F2) Accel/Decel 2 On REV A Accel/Decel 2 On b No Output Settings (Digit 2 and 1) Setting Description Positioning Settings (Digit 4) Skip Step (Jump Immediately) 0 StepLogic Direction Required Accel/Decel Type of 1 Step Based on [Stp Logic Time x] Param. Used Command Setting Output State From Home 2 Step if “Logic In 1” is Active FWD Off Accel/Decel 1 0 Absolute 3 Step if “Logic In 2” is Active Incremental FWD Off Accel/Decel 1 1 4 Step if “Logic In 1” is Not Active Off REV Absolute 2 Accel/Decel 1 5 Step if “Logic In 2” is Not Active REV Incremental Off 3 Accel/Decel 1 6 Step if either “Logic In 1” or “Logic In 2” is Active Absolute 4 Accel/Decel 1 On FWD 7 Step if both “Logic In 1” and “Logic In 2” are Active On Accel/Decel 1 5 Incremental FWD 8 Step if neither “Logic In 1” nor “Logic In 2” is Active Absolute REV On Accel/Decel 1 6 Step if “Logic In 1” is Active and “Logic In 2” is Not Active 9 7 Accel/Decel 1 On REV Incremental A Step if “Logic In 2” is Active and “Logic In 1” is Not Active FWD Accel/Decel 2 Off 8 Absolute Step after [Stp Logic Time x] and “Logic In 1” is Active b Incremental FWD Off Accel/Decel 2 9 Step after [Stp Logic Time x] and “Logic In 2” is Active C A Accel/Decel 2 Off REV Absolute d Step after [Stp Logic Time x] and “Logic In 1” is Not Active Accel/Decel 2 Off REV Incremental b Step after [Stp Logic Time x] and “Logic In 2” is Not Active E FWD Accel/Decel 2 C Absolute On Do Not Step/Ignore Digit 2 Settings F Incremental Accel/Decel 2 On FWD d Accel/Decel 2 E Absolute REV On REV F Accel/Decel 2 On Incremental Use the Wizard in Connected Components Workbench to simplify setup instead TIP 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 222

223 Encoder/Pulse Train Usage and Po Appendix E sition StepLogic Application 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. This drive supports incremental encoders only. Therefore, when the drive powers Homing Routine 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 Homing–Program the following drive parameters: t062 , t063 [DigIn TermBlk xx] = 37 “Pos Redefine” , t065 ... t068 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, 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. [Enh Control Word] can be Alternately, the “Pos Redefine” bit in A560 toggled instead of utilizing a digital input. The “Pos Redefine” input or bit must be returned to inactive before IMPORTANT starting the position routine. Otherwise the drive will continuously read a position of “0” (home) and the position routine will not function correctly. Automatic Homing to Limit Switch–Program the following drive 2. parameters: t062 t063 t068 [DigIn TermBlk xx] = 35 “Find Home” , ... , t065 Program one of the digital inputs to 35 “Find Home”. t062 = t068 [DigIn TermBlk xx] t065 34 “Home Limit” , t063 ... , 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. n 520-UM001I-EN-E - July 2016 223 Rockwell Automation Publicatio

224 Encoder/Pulse Train Usage and Position StepLogic Application Appendix E 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 [Find Home Freq] A562 point too quickly it will then reverse direction at 1/10th 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. After the position is reached the drive will stop. If the Find Home is removed IMPORTANT before the homing is complete, the drive will begin running the position case Home will not be reset and the routine without the proper home. In this position will be in relation to the power up position. d376 [Speed Feedback] indicates the measured speed feedback or the calculated Encoder and Position speed feedback when no feedback device is selected. Parameter d376 [Speed Feedback 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). [Encoder Speed] indicates the measured speed of the feedback device. This d378 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 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). [Position Status] indicates the status of the positioning functions. The d387 indication bits are: Bit 0 “Dir Positive” indicates the current direction the drive has moved from Home. indicates whether the drive is at its commanded Bit 1 “At Position” 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 A564 within [Encoder Pos Tol] of “Home”, this bit will be active. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 224

225 sition StepLogic Application Appendix E Encoder/Pulse Train Usage and Po 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 in active until the next power down. manually or automatically. It will rema If 8 steps are not adequate for the application or if dynamic program changes are Use Over Communications 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. Parameter values set prior to setting 1 “RAM only” are saved in RAM. IMPORTANT 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. 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. n 520-UM001I-EN-E - July 2016 225 Rockwell Automation Publicatio

226 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application 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 Step Logic 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 t062 with setting 25 “Logic In 2” for t065 ... , t063 , [DigIn TermBlk t068 xx]. It can be used to move through the Step Logic 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 Step Logic 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) can make setup of Setup Notes the positioning functions much easier. Refer to the latest versions for additional tools or wizards which can aid in the setup. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 226

227 Appendix F PID Set Up The PowerFlex 520-series drive features built-in PID (proportional, integral, PID Loop 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. P047 To enable the PID loop, , P049 or P051 [Speed Referencex] must be set to 11 “PID1 Output” or 12 “PID2 Output”, and the corresponding speed reference activated. PowerFlex 523 has one PID control loop. IMPORTANT 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 or A458 becomes the entire Freq Command. Exclusive Control is used when This configuration does not require a [PID x Trim Sel] is set to option 0. A470 master reference, only a desired set point, such as a flow rate for a pump. PID Loop PID Ref PID Prop Gain PID PID + + Output Error + – Freq Accel/Decel PID Fdbk PID Integ Time Command Ramp + PID Diff Rate PID Selected 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. n 520-UM001I-EN-E - July 2016 227 Rockwell Automation Publicatio

228 PID Set Up Appendix F • The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow. • When the PID Control Loop is disabled, the Commanded Speed is the Ramped Speed Reference. l e S E s c PID Feedback = Pressure Transducer Signal Pump 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 A458 Control is used when [PID x Trim Sel] is set to any option other A470 or than 0. [Speed Referencex] PID Loop Accel/Decel Ramp PID Ref PID Prop Gain PID PID + + + Error Output – + + Output PID Fdbk PID Integ Time Freq + PID Diff Rate PID Selected 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 228

229 Appendix F PID Set Up As tension increases or decreases during winding, the Speed Reference is • trimmed to compensate. Tension is maintained near the Equilibrium set point. 0V PID Reference = PID Feedback = Equilibrium Set Point Dancer Pot Signal l S e s E c 10V [Speed Referencex] PID mode is enabled by setting P047 [Speed Referencex] to P051 or , P049 PID Reference and Feedback 11 “PID1 Output” or 12 “PID2 Output”, and activating the corresponding speed reference. PowerFlex 523 has one PID control loop. IMPORTANT PowerFlex 525 has two PID control loops, of which only one can be in use at any time. A459 If A471 or [PID x Ref Sel] is not set to 0 “PID Setpoint”, PID can still be t063 , , t062 disabled by select programmable digital input options (parameters [DigIn TermBlk xx]) such as “Purge”. t068 ... t065 A459, A471 [PID x Ref Sel] Options Options Description 0 be used to set the value of the PID Reference. A464 or A476 [PID x Setpoint] will “PID Setpoint“ 1 The drive potentiometer will be used to set the value of the PID Reference. “Drive Pot” 2 “Keypad Freq” The drive keypad will be used to set the value of the PID Reference. 2 ”Serial/DSI” The reference word from the Serial/D SI communication network becomes the PID Reference. 4 “Network Opt” The reference word from a communication network option becomes the PID Reference. 5 “0-10V Input” Selects the 0-10V Input. Note that the PID wi ll not function with a bipo lar analog input. It will ignore any negative voltages and treat them like a zero. 6 “4-20mA Input” Selects the 4-20 mA Input. 7 Freq x] will be used as an input for the PID Reference. “Preset Freq” A410...A425 [Preset (1) The product of the 0-10V and 4-20 mA Inputs will be used as an input for the PID Reference. “AnlgIn Multi” 8 9 “MOP Freq” 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. 10 ”Pulse Input” (1) Step Logic will be used as an input for the PID Reference. 11 “Step Logic” (1) input for the PID Reference. Encoder will be used as an 12 “Encoder” (1) The reference word from the Ethernet/IP communication network becomes the PID Reference. 13 “Ethernet/IP” Setting is specific to PowerFlex 525 drives only. (1) n 520-UM001I-EN-E - July 2016 229 Rockwell Automation Publicatio

230 PID Set Up Appendix F 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 Description 0 “0-10V Input” Selects the 0-10V Input (def the PID will not function ault setting). Note that with a bipolar analog voltages and treat them like a zero. input. It will ignore any negative “4-20mA Input“ Selects the 4-20 mA Input. 1 “Serial/DSI” 2 ll be used as an input for the PID Feedback. Serial/DSI wi 3 “Network Opt” The reference word from a communication network option becomes the PID Reference. as an input for the PID Feedback. Pulse train will be used “Pulse Input” 4 (1) Encoder will be used as an input for the PID Feedback. 5“Encoder” (1) Ethernet/IP will be used as an input for the PID Feedback. 6“Ethernet/IP” Setting is specific to PowerFlex 525 drives only. (1) t091 [Anlg In 0-10V Hi] are used to Parameters t092 [Anlg In 0-10V Lo] and Analog PID Reference Signals 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 Input Volts 2 8 010203040506070 90 100 0 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% n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio 230

231 PID Set Up Appendix F • A459 [PID 1 Ref Sel] = 6 “4-20mA Input” 24 20 16 12 8 4-20 mA Input 4 0 10203040506070 8 0 90 100 PID Reference (%) PID Deadband Parameters A465 and [PID x Deadband] are used to set a range, in percent, A477 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% 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 Pre-load Value PID Output Freq Cmd PID Pre-load Value > 0 PID Limits [PID x Trim Hi] and [PID x Trim Lo] are used A469 and A457 A468 and A456 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 n 520-UM001I-EN-E - July 2016 231 Rockwell Automation Publicatio

232 Appendix F PID Set Up 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 [PID x Prop Gain] A473 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 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 Unstab le R esp onse on ), decrease A461 or A473 [PID x Prop Gain]. page 233 – Typically, A461 or A473 [PID x Prop Gain] is set to some value below the point where the PID begins to go unstable. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 232

233 Appendix F PID Set Up 2. Adjust the integral gain (leave the proportional gain set as in Step 1). After a step change in the PID Feedback: on If the response is too slow (see Slow Response – Over Damped – page 233 ), 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 ), increase A462 or on page 233 Oscillation – Under Damped (see 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 Oscillation – Under Damped PID Reference PID Feedback Time n 520-UM001I-EN-E - July 2016 233 Rockwell Automation Publicatio

234 Appendix F PID Set Up Good Response – Critically Damped PID Reference PID Feedback Time 234 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

235 Appendix G Safe-Torque-Off Function 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. See page... For information on... 235 PowerFlex 525 Safe-Torque-Off Overview 236 EC Type Examination Certification 236 EMC Instructions Using PowerFlex 525 Safe-Torque-Off 236 239 Enabling PowerFlex 525 Safe-Torque-Off 239 Wiring Verify Operation 240 PowerFlex 525 Safe-Torque-Off Operation 239 Connection Examples 241 PowerFlex 525 Certification for Safe-Torque-Off 245 The Safe-Torque-Off function covered in this chapter is specific to IMPORTANT PowerFlex 525 drives only. The PowerFlex 525 Safe-Torque-Off function: PowerFlex 525 Safe-Torque- • Provides the Safe-Torque-Off (STO) function defined in Off Overview 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 Category 3 / PL (d) according to EN ISO 13849-1 and SIL CL2 according to EN 62061, IEC 61508, and EN 61800-5-2. The function is suitable for performing mechanical work on the drive system or IMPORTANT affected area of a machine only. It does not provide electrical safety. n 520-UM001I-EN-E - July 2016 235 Rockwell Automation Publicatio

236 Safe-Torque-Off Function Appendix G AT T E NT IO N : 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 EC Type Examination compliant with the requirements for machines defined in Annex I of the Certification 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: www.rockwellautomation.com/products/certification/ . PowerFlex 525 Safe-Torque-Off function requires CE Conformity as described EMC Instructions on page 52 . The PowerFlex 525 Safe-Torque-Off function is intended to be part of the safety Using PowerFlex 525 Safe- related control system of a machine. Before use, a risk assessment should be To rq ue - O ff 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 236

237 Safe-Torque-Off Function Appendix G 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. AT T E NT IO N : 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 equipmen t. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation. AT T E NT IO N : 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. AT T E NT IO N : 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 2-pole motor ° before torque production in the motor ceases. The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety Safety Concept applications up to and including Category 3 / PL(d) according to EN ISO 13849-1 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 safety-related applications where the de-energized state is considered to be the safe state. All of the examples in this manual are based on achieving de-energization 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. • • programming the application software and the safety option configurations in accordance with the information in this manual. n 520-UM001I-EN-E - July 2016 237 Rockwell Automation Publicatio

238 Appendix G Safe-Torque-Off Function • access control to the system, including password handling. • analyzing all configuration settings and choosing the proper setting to achieve the required safety rating. When applying Functional Safety, restrict access to qualified, authorized IMPORTANT personnel who are trained and experienced. AT T E NT IO N : When designing your system, co nsider 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 calculations are based on the equations from Part 6 of EN 61508. PFD and PFH 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 Value PFD 6.62E-05 (MTTF = 3593 years) 8.13E-10 PFH D SFF 83% DC 62.5% CAT 3 HFT 1 (1oo2) 20 YEARS PTI Hardware Type 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). Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 238

239 Safe-Torque-Off Function Appendix G 1. Remove all power to the drive. Enabling PowerFlex 525 Safe-Torque-Off To avoid an electric shock hazard, verify that the voltage AT T E NT IO N : before performing any work on on the bus capacitors has discharged 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. Loosen the screw of terminals Safety 1, Safety 2 and Safety +24V 2. (S1, S2, S+) on the control I/O terminal block. 3. Remove the protective jumper. 02 01 08 07 06 05 R6 R5 03 04 R1 R2 18 17 16 15 14 13 12 11 S+ S2 S1 19 Safe-Torque-Off function is now enabled and the terminals are ready to 4. function as safety inputs. Important points to remember about wiring : 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 (1) Wire Type Min. Insulation Description Type Rating 2 C (140 ° 300V, 60 (18 AWG), ° F) Shielded Multi-conductor shielded cable such as Belden 8770 (or equiv.) 0.750 mm 3 conductor, shielded. C ambient temperature. (1) Recommendations are for 50 ° ° C wire must be used for 60 C ambient temperature. ° 75 C ambient temperature. 90 ° C wire must be used for 70 ° on page 36 Control I/O for wiring recommendations and See I/O Wiring on page 43 Te r m i n a l D e s i g n a t i o n s 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. The PowerFlex 525 Safe-Torque-Off function disables the drive’s output IGBT’s PowerFlex 525 Safe-Torque- by breaking the link with the drive microcontroller. When used in combination Off Operation 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. n 520-UM001I-EN-E - July 2016 239 Rockwell Automation Publicatio

240 Safe-Torque-Off Function Appendix G 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 me et EN ISO 13849 operation, both safety channels must be de-energized. Refer to the following examples for more information. By itself, the Safe-Torque-Off function initiates a coast to stop action. IMPORTANT Additional protective measures will need to be applied when an application requires a change to the stop action. Test the safety function for proper operation after the initial setup of the Verify Operation PowerFlex 525 Safe-Torque-Off function. Retest the safety function at the . page 236 intervals determined by the safety analysis described on Verif y that both safety channels are functioning according to the table below. Channel Operation and Verification Safety Function Drive Drive In Drive In Drive In Safe State Safe State Safe State Able To Run Status Configured by t105 Ready/Run Drive Status Fault F111 Fault F111 (Safety Hardware) [Safety Open En] (Safety Hardware) Safety Channel Operation Power Applied No Power Applied Power Applied Safety Input S1 No Power Applied Power Applied Safety Input S2 No Power Applied Power Applied No Power Applied If an external fault is present on the wi ring or circuitry controlling the Safety 1 IMPORTANT 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 240

241 Appendix G Safe-Torque-Off Function Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action, Connection Examples SIL 2/PL d Stop Category 0 – Coast AC line input power PF 525 +24V DC +24V DC GuardMaster Gate Trojan Stop Stop Start Start S21 S11 S52 41 13 23 33 A1 Gate control MSR E-Stop power supply latching button 42 14 A2 34 24 S22 S14 S34 24V DC Gate control common circuit S1 S2 (1) M AC line input power PF 525 +24V DC GuardMaster Gate Trojan Stop Stop Start Start Gate control E-Stop power supply latching button Gate control circuit S1 S2 (2) M st be considered as described in EN ISO 13849-2. Enclosure or Enclosure Recommended. Note: External wiring failure modes mu (1) ould be used. failure modes sh other measure to exclude these (2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure. 241 n 520-UM001I-EN-E - July 2016 Rockwell Automation Publicatio

242 Appendix G Safe-Torque-Off Function Stop Category 0 – Coast with Two PowerFlex 525 Drives (1) 24V DC Supply AC line Reset input power PF 525 AC line input power E-Stop +24V DC Stop A1 PF 525 L12 Stop S11 Start L11 Start +24V DC SI S21 Dig. comm Stop Y32 Stop S12 Gate control Start Reset S34 power supply 0 Start S22 Dig. comm AM MM Gate control Gate control power supply circuit 13 (2) 14 S1 Gate control circuit 23 S2 (2) 24 S1 A2 S2 24V DC COM M M (1) st be considered as described in EN ISO 13849-2. Enclosure or Enclosure Recommended. Note: External wiring failure modes mu failure modes sh ould be used. other measure to exclude these (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 & S21- S22) to the Minotaur 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 242

243 Appendix G Safe-Torque-Off Function Example 2 – Safe-Torque-Off Connecti on with Controlled Stop Action, SIL 2/PL d Stop Category 1 – Controlled (1) AC line input power PF 525 GuardMaster Trojan +24V DC Gate Stop Stop +24V DC Start Start S34 S33 23 13 S12 S52 S21 A1 S11 S22 57 47 37 Gate control Minotaur power supply MSR138DP 14 48 38 Y40 Y39 X4 X3 A2 X1 X2 Y1 58 Y2 24 24V DC Gate control Common circuit S1 S2 M Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other (1) measure to exclude these fa ilure 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 & S21- S22) 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. n 520-UM001I-EN-E - July 2016 243 Rockwell Automation Publicatio

244 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) AC line input power PF 525 External +24V DC +24V DC Stop Reset Start COM Open 23 A1 S11 S52 S12 13 33 41 Gate control power supply MSR127TP 14 24 S21 S22 S34 A2 42 34 Closed Gate control circuit S1 S2 X1 AUX 13 23 33 X2 A1 Coil 14 24 34 A2 External 100-C 24V DC COM 100S-C contactor M (1) Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or other ilure modes should be used. measure to exclude these fa 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 & S21- S22) 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 244

245 Safe-Torque-Off Function Appendix G Certification information can be viewed at PowerFlex 525 Certification http://www.rockwellautomation.com/global/certification/ for Safe-Torque-Off Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 245

246 Appendix G Safe-Torque-Off Function Notes: 246 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

247 Appendix H 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 . AT T E NT IO N : PowerFlex 523 drives support only the 25-COMM-E2P dual-port EtherNet/IP adapter. PowerFlex 525 drives support both the embedded E2P dual-port EtherNet/IP adapter. EtherNet/IP adapter and the 25-COMM- 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. There are three methods for configuring the Ethernet IP address: Establishing A Connection – Use BootP if you prefer to control the IP addresses of •BootP Server With EtherNet/IP 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. Dynamic Host Configuration Protocol ) (only with PowerFlex ( •DHCP 25-COMM-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. If you are setting your network addr esses manually using parameters, you IMPORTANT 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. n 520-UM001I-EN-E - July 2016 247 Rockwell Automation Publicatio

248 EtherNet/IP Appendix H Regardless of the method used to set the adapter IP address, each node on the IMPORTANT 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. Connect terminal C1 to a clean ground when using a network with a star Ground Connections for topolog y. It is acceptable to ground both C1 and C2 terminals. EtherNet/IP Networks PowerFlex 525 Embedded Ethernet/IP Adapter F W D ENET LINK EtherNet/IP l e S E s c Te r m i n a l s C 1 / C 2 Terminal Description C1 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 ex ternal communication peripherals. This is the signal common for the communication C2 signals. Connect terminal CS1 or CS2 to a clean ground when using a network with a ring topolog y. PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter Terminal Description Provides a clean ground for the communication bus CS1/CS2 cable shields. CS1 or CS2 should be connected to a clean ground or PE ground on the drive. Terminals CS1/CS2 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 248

249 I Appendix Control Diagrams This chapter contains various diagrams on the PowerFlex 520-series drive functions and behaviors. [Speed Reg Sel] Diagrams For Motor Tuning Induction Motor Tuning Low Speed Mid Speed High Speed Diagrams Control Mode Control Mode Control Mode Speed Controller Gain A515 [Freq 3 BW] A513 [Freq 2 BW] A511 [Freq 1 BW] Gain set automatically A509 [Speed Reg Sel] = 0 A510 Freq (Hz) [Freq 1] A512 [Freq 2] A514 [ Freq 3] High Speed Mid Speed Low Speed Control Mode Control Mode Control Mode Speed Controller Gain A525 [Freq 3 Kp] A526 [Freq 3 Ki] A523 [Freq 2 Kp] A524 [Freq 2 Ki] Gain set manually A521 [Freq 1 Kp] A509 [Speed Reg Sel] = 1 A522 [Freq 1 Ki] A510 Freq (Hz) [Freq 1] A512 [Freq 2] A514 [Freq 3] n 520-UM001I-EN-E - July 2016 249 Rockwell Automation Publicatio

250 Appendix I Control Diagrams These settings show how to adjust the speed control for motor tuning. Adjusting Speed Control Parameters Speed Loop Bandwidth: Increase the bandwidth to obtain A511 [Freq 1 BW] = 10 Hz faster speed response. If oscillation A513 [Freq 2 BW] = 10 Hz occurs, decrease the bandwidth. A515 [Freq 3 BW] = 10 Hz For [Freq x Kp], gradually increase by 1% For [Freq x Ki], gradually increase by 0.1 s Set A509 A509 = 1 (Manual) For general use, set A509 [Speed Reg Sel] [Speed Reg Sel] to 0 (Automatic) A509 = 0 (Automatic) Set Speed Controller Gain Set Speed Controller Gain manually: automatically 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 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 250

251 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. See page... For information on... 252 Download Files 254 Automatic Configuration Using Drive Startup Wizard Manual Configuration Using Drive Keypad 261 262 Additional PM Motor Configuration Optional Parameter Adjustme nts for Optimum Performance 266 AT T E NT IO N : 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 tion cannot assume responsibility or particular installation, Rockwell Automa 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 soft ware described in this document. Rockwell changes to this document without prior Automation reserves the right to make notice. When using examples in this document the user recognizes that Rockwell any damage or claims. Because there are Automation cannot be made liable for 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, you also need to install version 1.05 or later Ad d-on profile (AOP) and update to the latest drive database for Connected Components Workbench. These files are available for download at the Rockwell Automation Product Compatibility and Download Center. For instructions, see Download Files on page 252 . n 520-UM001I-EN-E - July 2016 251 Rockwell Automation Publicatio

252 Appendix J PowerFlex 525 PM Motor Configuration Follow these steps to download the files for your PowerFlex 525 drive. Download Files 1. Go to the Rockwell Automation Product Compatibility and Download Center at http://www.rockwellautomation.com/rockwellautomation/support/ pcdc.page You must sign in to the Rockwell Automation website before IMPORTANT downloading a firmware revision. 2. Click the Find Downloads link. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 252

253 PowerFlex 525 PM Motor Configuration Appendix J 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 . 5. Click the Show Downloads icon, then click the links to download the firmware revision and AOP files to your computer. 6. Go back to step 2 and enter “AB Drives” into the Product Search field. The results appear in the box below. 7. Select both entries, then click Downloads . Click the Show Downloads icon, then click the links to download the 8. database files to your computer. n 520-UM001I-EN-E - July 2016 253 Rockwell Automation Publicatio

254 PowerFlex 525 PM Motor Configuration Appendix J To use the PowerFlex 525 Startup Wizard in Connected Components Automatic Configuration Workbench to automatically configure the parameters, make sure you have Using Drive Startup Wizard installed the following : • PowerFlex 525 drive firmware revision 5.001 or later. • PowerFlex 525 drive Add-on Profile 1.05 or later. Latest drive database for Connected Components Workbench. • . on page 252 For instructions, see Download Files Alternatively, you can manually configure the parameters by using the drive keypad. For instructions, see Manual Configuration Using Drive Keypad on page 261 . From Connected Components Workbench software, click the Wizard 1. Browser icon. In the Available Wizards dialog box, click on PowerFlex 525 Startup 2. Wizard, then click Select. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 254

255 PowerFlex 525 PM Motor Configuration Appendix J 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. Follow the Startup Wizard steps exactly. If not, unexpected results can IMPORTANT occur. 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”. n 520-UM001I-EN-E - July 2016 255 Rockwell Automation Publicatio

256 Appendix J PowerFlex 525 PM Motor Configuration Motor Data Key in the details of your Motor Nameplate. Feedback If you are configuring a closed loop PM motor control, key in the details of your incremental encoder. Note the following: IMPORTANT • 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 256

257 PowerFlex 525 PM Motor Configuration Appendix J Stop Mode/Brake Type Key in the details of your configuration. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 257

258 Appendix J PowerFlex 525 PM Motor Configuration Direction Test When configuring a PM motor, it is required to perform a Direction Test before IMPORTANT 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 th e feedback polarity. The test confirms motor rotation and feedback polarity. After the test is completed, a change can be made, if required. If the drive was never operated before (new installation), verify that safeguards IMPORTANT are in place to remove power safely from the drive during an unstable situation where the drive can produce undesired motion. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 258

259 PowerFlex 525 PM Motor Configuration Appendix J Auto Tune Ensure the load is uncoupled and perform a Rotate Tune test. 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. • 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. n 520-UM001I-EN-E - July 2016 259 Rockwell Automation Publicatio

260 PowerFlex 525 PM Motor Configuration Appendix J 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. If the drive was never operated before (new installation), verify AT T E NT IO N : 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 encounte r 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. Additional PM Motor Configuration See for instructions. on page 262 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 260

261 PowerFlex 525 PM Motor Configuration Appendix J Besides using the PowerFlex 525 Startup Wizard in Connected Components Manual Configuration Using Workbench, you can also manually configure the parameters by using the drive Drive Keypad keypad. Make sure you have installed the PowerFlex 525 drive firmware revision Download Files 5.001 or later. For instructions, see . on page 252 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” Enter Motor nameplate data 3. • 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) Set A535 [Motor Fdbk Type] 5. • = 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” Press the Start button (Take note of your Start Source settings P046, P048, and P050. Default setting of P046 = 1 “Keypad”) If the drive was never operated before (new installation), verify AT T E NT IO N : 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. n 520-UM001I-EN-E - July 2016 261 Rockwell Automation Publicatio

262 Appendix J PowerFlex 525 PM Motor Configuration For an open loop system (A535 [Motor Fdbk Type] = 0 “None”), you may need to adjust two parameters if you encounte r 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 262 for instructions. After completing the initial configuration, there are additional steps that need to Additional PM Motor be performed to complete the whole PM motor setup. Configuration 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. If the motor reverses, repeat steps 2 and 3. 7. 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 262

263 PowerFlex 525 PM Motor Configuration Appendix J Flowchart for Open Loop PM Motor (iPM and sPM) Setup Basic setting P053 [Reset to Defalts] Load Default = 2 (Factory Reset) P039 [Torque Perf Mode] Control Mode = 4 (PM Control) Selection P031 [Motor NP Volts] P032 [Motor NP Hertz] P033 [Motor OL Current] P034 [Motor NP FLA] Set Motor P035 [Motor NP Poles] Parameters P036 [Motor NP RPM] P037 [Motor NP Power] P043 [Minimum Freq] P044 [Maximum Freq] A440 [PWM Frequency] A535 [Motor Fdbk Type] Set PG = 0 (None) P040 [Autotune] Set Autotune = 2 (Rotate Tune) Start Autotune A501 [PM IR Voltage] A502 [PM IXd Voltage] Obtain Parameters A503 [PM IXq Voltage] from Autotune A504 [PM BEMF Voltage] P041 [Accel Time 1] Set Accel and P042 [Decel Time 1] Decel Time A439 [S Curve %] Perform a test run at Reverse Startup command frequency Check Repeat steps 2 and 3 of Additional Setup for Open Loop PM Motor Do you see reverse startup? Ye s No Drive is aligned and ready to run n 520-UM001I-EN-E - July 2016 263 Rockwell Automation Publicatio

264 PowerFlex 525 PM Motor Configuration Appendix J Additional Setup for Cl osed 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 : Uncouple the load. 1. 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, and so on. Set the Start Source. 4. Check the setting for P046 [Start Source 1]. Start source can be from POT, control panel of Connected Components Workbench, 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 TIP drive is power cycled or re-tuned. The PM angle alignment has failed when fault F012 (HW Overcurrent) or IMPORTANT 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”. Increase A517 [PM DC Inject Cur] by 50%. 2. Increase A518 [PM Align Time] by 0.2 s. 3. Repeat the 4. Align the PM Angle instructions again, beginning from step 3. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 264

265 Appendix J PowerFlex 525 PM Motor Configuration Flowchart for Closed Loop PM Motor (iPM) Setup Basic setting P053 [Reset to Defalts] Load Default = 2 (Factory Reset) P039 [Torque Perf Mode] Control Mode = 4 (PM Control) Selection P031 [Motor NP Volts] P032 [Motor NP Hertz] P033 [Motor OL Current] P034 [Motor NP FLA] Set Motor P035 [Motor NP Poles] Parameters P036 [Motor NP RPM] P037 [Motor NP Power] P043 [Minimum Freq] P044 [Maximum Freq] PLACEHOLDER A440 [PWM Frequency] A535 [Motor Fdbk Type] = 4 (Quadrature) or 5 (Quad Check) Set PG A536 [Encoder PPR] A518 [Align Time] A517 [PM DC Inject Cur] P040 [Autotune] Set Autotune = 2 (Rotate Tune) Start Autotune A501 [PM IR Voltage] A502 [PM IXd Voltage] Obtain Parameters A503 [PM IXq Voltage] from Autotune A504 [PM BEMF Voltage] P041 [Accel Time 1] Set Accel and P042 [Decel Time 1] Decel Time A439 [S Curve %] Set alignment Set Alignment Align the PM Angle See See Adjustments if PM Angle Alignment has Failed Does drive align successfully? No (Fault F012 or F013 is observed during acceleration and deceleration.) Ye s Drive is aligned and ready to run n 520-UM001I-EN-E - July 2016 265 Rockwell Automation Publicatio

266 Appendix J PowerFlex 525 PM Motor Configuration There are a few parameters that you can use to obtain optimum performance Optional Parameter during the test run. Usually, the default value of these parameters work well, but Adjustments for Optimum you may need to adjust them under different conditions. Per formance 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. A518 [PM Align Time] 2. 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. Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016 266

267 PowerFlex 525 PM Motor Configuration Appendix J 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. n 520-UM001I-EN-E - July 2016 267 Rockwell Automation Publicatio

268 Appendix J PowerFlex 525 PM Motor Configuration Notes: 268 Rockwell Automation Publicatio n 520-UM001I-EN-E - July 2016

269 Index output 34 , Numerics drive 2-wire auxiliary contact 36 , 34 , inputs 50 , basic operation , , 60 65 , 162 3-wire common bus 36 , inputs , 50 mount , 15 programming 64 61 , , safety , 239 A drive damage preventing accel 19 , ungrounded distribution systems 19 , override priority , 51 selecting , 51 accessing E control terminals 31 , encoder power terminals , 31 applications programming , 215 wiring , 216 safety , 237 environment auxiliary contact storage , 18 drive 34 , 36 , Ethernet programming 247 , B 65 , basic operation F drive , 162 , 60 , 65 fault monitoring programming , 65 safety , 240 ground , 21 fuses rating 23 , C circuit breakers G inputs 23 , ratings , 23 ground common bus fault monitoring 21 , drive 36 , motor 21 , communications RFI filter , 22 safety , 21 positioning , 225 shielding , 21 configuring RS485(DSI) , 202 control terminals H accessing , 31 homing counter automatic , 223 programming , 212 , 209 manual , 223 , 223 programming D decel I override priority , 51 inputs selecting 51 , 2-wire 50 , derating 3-wire 50 , factor 125 , 23 , circuit breakers temperature , 17 power 20 , digital inputs selecting , 50 , 50 start source L dimensions logic mounting , 185 , 16 basic 210 , 209 , disconnect , 210 209 , timed steps 269 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

270 Index timed steps 209 , , 210 M timer 211 , 209 , Modbus 64 , tools reading , 207 205 , 208 , pulse train writing 208 , 203 , 205 , programming , 215 motor ground , 21 R start , 34 34 , stop rating mount fuses 23 , drive , 15 ratings mounting circuit breakers 23 , dimensions 16 , 185 , reading Modbus , 207 , 205 , 208 recommended N wiring 239 , 36 , noise immunity reflected wiring 202 , 37 , wave protection , 34 RFI filter ground , 22 O RS485(DSI) output configuring 202 , disconnect , 34 override priority accel , 51 S decel 51 , safety speed reference , 49 applications 237 , start source 49 , basic operation , 240 drive , 239 ground 21 , P testing 238 , parameters wiring 239 , AppView , 76 , 150 selecting CustomView , 151 accel 51 , programming , 63 67 , decel , 51 PID digital inputs , 50 programming , 229 speed reference , 49 positioning , 49 start source communications separating 225 , programming , 220 , 218 power and control module , 28 power shielded inputs , 20 wiring 33 , power and control module shielding separating , 28 ground 21 , power terminals speed reference accessing , 31 override priority , 49 preventing selecting 49 , drive damage , 19 start programming , 65 motor 34 , start source basic logic , 210 , 209 counter 212 , 209 , digital inputs 50 , , 61 64 drive , override priority 49 , encoder , 215 selecting , 49 Ethernet , 247 stop homing , 223 motor 34 , parameters 67 , 63 , storage PID 229 , environment , 18 positioning 220 , 218 , pulse train 215 , Rockwell Automation Publication 520-UM001I-EN-E - July 2016 270

271 Index V T voltage reflections temperature derating wiring , 17 34 , wiring 33 , testing W safety , 238 timer wave protection programming 211 , 209 , reflected , 34 tools wiring programming , 64 encoder , 216 noise immunity 202 , 37 , , 36 239 , recommended U RS485 (DSI) , 201 safety , 239 unshielded , 33 shielded wiring , 33 temperature 33 , unshielded , 33 voltage reflections , 34 writing Modbus , 208 , 203 , 205 271 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

272 Index Notes: 272 Rockwell Automation Publication 520-UM001I-EN-E - July 2016

273

274 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At , you can find technical manuals, a knowledge base of FAQs, technical and http://www.rockwellautomation.com/support/ application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. Rockwell Automation provides compliance certification support at [email protected] . . [email protected] .rockwell.com Rockwell Automation provides environmental compliance support at Rockwell Automation provides country of origin certificates at [email protected] . For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer TechConnect support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/ . Installation Assistance If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running. 1.440.646.3434 United States or Canada , or contact your local Rockwell at http://www.rockwellautomation.com/support/americas/phone_en.html Wor ldwide Locator Use the Outside United States or Canada Automation representative. New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures. United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain o ne) to your distributor to complete the return process. Outside United States Please contact your local Rockwell Automation representative for the return procedure. Documentation Feedback better. If you have any suggestions on how to improve this Your comments will help us serve your documentation needs document, complete this form, publication . http://www.rockwellautomation.com/literature/ , available at RA-DU002 Rockwell Automation maintains current product environmental information on its website at . http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page www.rockwe automation.com l l Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382. 4444 Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852 ) 2508 1846 *PN-386600* PN-386600 PN-386600 Publication 520-UM001I-EN-E – July 2016 on, Inc. All rights reserved. Copyright © 2016 Rockwell Automati Supersedes Publication 520-UM001H-EN-E – April 2016

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