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

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PowerFlex 520-Series Adjustable Frequency AC DrivePowerFlex 523 Catalog Number 25A, Series BPowerFlex 525 Catalog Number 25BUser ManualOriginal InstructionsImportant User InformationSolid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.Throughout this manual, when necessary, we use notes to make you aware of safety considerations.Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).IMPORTANTIdentifies information that is critical for successful application and understanding of the product.Rockwell Automation Publication 520-UM001I-EN-E - July 20163Table of ContentsImportant User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Summary of ChangesNew and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7PrefaceOverviewWho Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Chapter 1Installation/WiringMounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15AC Supply Source Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19General Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Power and Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Power Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Control I/O Terminal Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Chapter 2Start UpPrepare for Drive Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Viewing and Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Language Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 65LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . . 67Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674Rockwell Automation Publication 520-UM001I-EN-E - July 2016Table of ContentsChapter 3Programming and ParametersAbout Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Parameter Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Basic Display Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Basic Program Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Chapter 4TroubleshootingDrive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162Appendix ASupplemental Drive InformationCertifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Appendix BAccessories and DimensionsProduct Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Optional Accessories and Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Appendix CRS485 (DSI) ProtocolNetwork Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 205Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Reading (03) Drive Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 208Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Rockwell Automation Publication 520-UM001I-EN-E - July 20165Table of ContentsAppendix DVelocity StepLogic, Basic Logic and Timer/Counter FunctionsVelocity StepLogic Using Timed Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 210Timer Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Appendix EEncoder/Pulse Train Usage and Position StepLogic ApplicationEncoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218Positioning Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Homing Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226Appendix FPID Set UpPID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227PID Reference and Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Analog PID Reference Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Appendix GSafe-Torque-Off FunctionPowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 235EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237Enabling PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . 239Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 239Verify Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 245Appendix HEtherNet/IPEstablishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 247Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 248

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