520 Um001 - en e PDF
520 Um001 - en e PDF
Original Instructions
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, DriveTools SP, AppView, CustomView, MainsFree Programming, and PointStop are trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
Overview Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Installation/Wiring Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 2
Start Up Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Display and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 52
LCD & Scrolling Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
USB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 3
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Chapter 4
Troubleshooting Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 138
Appendix A
Supplemental Drive Information Drives, Fuse & Circuit Breaker Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Appendix B
Accessories and Dimensions Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Appendix C
RS485 (DSI) Protocol Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 180
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Appendix D
Velocity StepLogic, Basic Logic and Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Timer/Counter Functions Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 182
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Appendix E
Encoder/Pulse Train Usage and Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Position StepLogic Application Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 189
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Appendix F
PID Set Up PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Appendix G
Safe-Torque-Off Function PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 207
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 211
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 211
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PowerFlex 525 Certification for Safe-Torque-Off . . . . . . . . . . . . . . . . . . 217
Appendix H
EtherNet/IP Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . 219
Appendix I
Control Diagrams Induction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Notes:
Overview
The purpose of this manual is to provide you with the basic information needed
to install, start-up and troubleshoot the PowerFlex® 525 Adjustable Frequency
AC Drive.
For information on… See page…
Who Should Use this Manual 7
Recommended Documentation 7
Manual Conventions 8
Drive Frame Sizes 9
General Precautions 9
Catalog Number Explanation 10
Who Should Use this Manual This manual is intended for qualified personnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must have
an understanding of the parameter settings and functions.
Recommended All the recommended documentation listed in this section is available online at
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, Installation and Maintenance of Solid State Control SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams 100-2.10
Guarding Against Electrostatic Damage 8000-4.5.2
Name
Number
Group
b = Basic Display
P = Basic Program
t = Terminal Blocks
C = Communications
L = Logic
d = Advanced Display
A = Advanced Program
M = Modified
N = Network
G = AppView and CustomView
F = Fault and Diagnostic
Drive Frame Sizes Similar PowerFlex 525 drive sizes are grouped into frame sizes to simplify spare
parts ordering, dimensioning, etc. A cross reference of drive catalog numbers and
their respective frame sizes is provided in Appendix B.
General Precautions ATTENTION: The drive contains high voltage capacitors which take time to
discharge after removal of mains supply. Before working on drive, ensure
isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three
minutes for capacitors to discharge to safe voltage levels. Failure to do so may
result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have discharged to
safe voltage levels.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
ATTENTION: The bus regulator function is extremely useful for preventing
nuisance overvoltage faults resulting from aggressive decelerations,
overhauling loads, and eccentric loads. However, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages can cause
uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded deceleration times
However, a “Stall Fault” is generated if the drive remains in this state for 1
minute. If this condition is unacceptable, the bus regulator must be disabled
(see parameter A550 [Bus Reg Enable]). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most cases.
ATTENTION: Risk of injury or equipment damage exists. Drive does not contain
user-serviceable components. Do not disassemble drive chassis.
Code Braking
4 Standard
Code Type
25B PowerFlex 525 Code EMC Filter
0 No Filter
1 Filter
Code Voltage Phase
V 120V AC 1 Code Interface Module
A 240V AC 1 1 Standard
B 240V AC 3
D 480V AC 3
E 600V AC 3 Code Enclosure
N IP 20 NEMA/Open
Output Current @ 1 Phase, 100...120V Input Output Current @ 3 Phase, 380...480V Input
Code Amps Frame ND HD Code Amps Frame ND HD
HP kW HP kW HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4 1P4 1.4 A 0.5 0.4 0.5 0.4
4P8 4.8 B 1.0 0.75 1.0 0.75 2P3 2.3 A 1.0 0.75 1.0 0.75
6P0 6.0 B 1.5 1.1 1.5 1.1 4P0 4.0 A 2.0 1.5 2.0 1.5
6P0 6.0 A 3.0 2.2 3.0 2.2
Output Current @ 1 Phase, 200...240V Input
010 10.5 B 5.0 4.0 5.0 4.0
Code Amps Frame ND HD
013 13.0 C 7.5 5.5 7.5 5.5
HP kW HP kW
017 17.0 C 10.0 7.5 10.0 7.5
2P5 2.5 A 0.5 0.4 0.5 0.4
024 24.0 D 15.0 11.0 15.0 11.0
4P8 4.8 A 1.0 0.75 1.0 0.75 * Normal and Heavy duty ratings are
030 30.0 D 20.0 15.0 15.0 11.0
8P0 8.0 B 2.0 1.5 2.0 1.5 available for drives above 15 HP / 11 kW.
037 37.0 E 25.0 18.5 20.0 15.0
011 11.0 B 3.0 2.2 3.0 2.2
043 43.0 E 30.0 22.0 25.0 18.5
Output Current @ 3Phase, 200...240V Input
Output Current @ 3 Phase, 525...600V Input
Code Amps Frame ND HD
Code Amps Frame ND HD
HP kW HP kW
HP kW HP kW
2P5 2.5 A 0.5 0.4 0.5 0.4
0P9 0.9 A 0.5 0.4 0.5 0.4
5P0 5.0 A 1.0 0.75 1.0 0.75
1P7 1.7 A 1.0 0.75 1.0 0.75
8P0 8.0 A 2.0 1.5 2.0 1.5
3P0 3.0 A 2.0 1.5 2.0 1.5
011 11.0 A 3.0 2.2 3.0 2.2
4P2 4.2 A 3.0 2.2 3.0 2.2
017 17.5 B 5.0 3.7 5.0 3.7
6P6 6.6 B 5.0 3.7 5.0 3.7
024 24.0 C 7.5 5.5 7.5 5.5
9P9 9.9 C 7.5 5.5 7.5 5.5
032 32.2 D 10.0 7.5 10.0 7.5
012 12.0 C 10.0 7.5 10.0 7.5
048 48.3 E 15.0 11.0 15.0 11.0
019 19.0 D 15.0 11.0 15.0 11.0
062 62.1 E 20.0 15.0 15.0 11.0
022 22.0 D 20.0 15.0 15.0 11.0
027 27.0 E 25.0 18.5 20.0 15.0
032 32.0 E 30.0 22.0 25.0 18.5
Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex 525
drive.
For information on... See page...
Mounting Considerations 11
AC Supply Source Considerations 15
General Grounding Requirements 16
Fuses and Circuit Breakers 18
Power and Control Module 22
Control Module Cover 25
Power Module Terminal Guard 25
Power Wiring 26
Power Terminal Block 29
Common Bus/Precharge Notes 30
I/O Wiring 30
Control I/O Terminal Block 32
Start and Speed Reference Control 39
CE Conformity 41
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.
Mounting Considerations • Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque
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.)
D M5 (#10...24) 2.45...2.94 Nm (22...26 lb-in.)
E M8 (5/16 in.) 6.0...7.4 Nm (53...65 lb-in.)
50 mm 50 mm 50 mm 50 mm
(2.0 in.) 25 mm (2.0 in.) (2.0 in.)(1) (2.0 in.)(1)
(1.0 in.)
25 mm (2)
50 mm 50 mm 50 mm (1.0 in.) 50 mm
(2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.)
50 mm 50 mm
(2.0 in.) 50 mm (2.0 in.)
(2.0 in.)(1) 50 mm
50 mm (2.0 in.)(1)
Esc
50 mm
Esc
Sel
(2)
Esc
Esc
Sel
25 mm
Sel
(1.0 in.)
50 mm 50 mm
(2.0 in.) (2.0 in.)
Horizontal with Control Module Fan Kit Horizontal, Zero Stacking with
Control Module Fan Kit
No clearance between drives.
(1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required.
(2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.
110 Module Fan Kit Percentage of Rated Current (%) 110 Module Fan Kit
100 100
90 IP 20/Open Type 90 IP 20/Open Type
80 80
70 70
60 60
50 50
40 40
30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80
Ambient Temperature (°C) Ambient Temperature (°C)
Horizontal/Floor Mounting
Single Drive Zero Stacking
120 with Control 120 with Control
Percentage of Rated Current (%)
Percentage of Rated Current (%)
High Altitude
120 60
Percentage of Rated Current (%)
110
Debris Protection
Take precautions to prevent debris from falling through the vents of the drive
housing during installation.
Storage
• Store within an ambient temperature range of -40...85°C(1).
• Store within a relative humidity range of 0...95%, noncondensing.
• Do not expose to a corrosive atmosphere.
(1) The maximum ambient temperature for storing a Frame E drive is 70 °C.
Disconnecting MOVs
Jumper 1 2 3 4
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in the Input Power Conditions
table below are certain input power conditions which may cause component
damage or reduction in product life. If any of these conditions exist, install one of
the devices listed under the heading Corrective Action on the line side of the
drive.
IMPORTANT Only one device per branch circuit is required. It should be mounted closest to
the branch and sized to handle the total current of the branch circuit.
General Grounding The drive Safety Ground - (PE) must be connected to system ground. Ground
Requirements impedance must conform to the requirements of national and local industrial
safety regulations and/or electrical codes. The integrity of all ground connections
should be periodically checked.
Typical Grounding
Esc Sel
R/L1 U/T1
S/L2 V/T2
T/L3 W/T3
SHLD
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.
Motor Ground
The motor ground must be connected to one of the ground terminals on the
drive.
Either of the safety ground terminals located on the power terminal block
provides a grounding point for the motor cable shield. The motor cable shield
connected to one of these terminals (drive end) should also be connected to the
motor frame (motor end). Use a shield terminating or EMI clamp to connect the
shield to the safety ground terminal. The earthing plate or conduit box option
may be used with a cable clamp for a grounding point for the cable shield.
When shielded cable is used for control and signal wiring, the shield should be
grounded at the source end only, not at the drive end.
Using a drive with filter may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded AC
supply systems and be permanently installed and solidly grounded (bonded)
to the building power distribution ground. Ensure that the incoming supply
neutral is solidly connected (bonded) to the same building power distribution
ground. Grounding must not rely on flexible cables and should not include any
form of plug or socket that would permit inadvertent disconnection. Some local
codes may require redundant ground connections. The integrity of all
connections should be periodically checked.
Fuses and Circuit Breakers The PowerFlex 525 drive does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit breaker.
National and local industrial safety regulations and/or electrical codes may
determine additional requirements for these installations.
When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed
below must be followed in order to meet the NEC requirements for branch
circuit protection.
• Bulletin 140M can be used in single motor applications.
• Bulletin 140M can be used up stream from the drive without the need for
fuses.
Fusing
The ratings in the tables that follow are the recommended values for use with
each drive rating. The devices listed in this table are provided to serve as a guide.
25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 70 125 140U-H6C3-C90 140M-H8P-C70 CLASS J or T / 125 – –
(1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.
19
Chapter 1
20
380...480V 3-Phase Input Protection Devices – Frames A...E
Output Ratings Input Ratings IEC (Non-UL Applications) UL Applications
Chapter 1
Normal Duty Heavy Duty Frame Contactor Fuses Circuit Breakers Fuses (Max. Rating) Circuit Breakers
Catalog No.(1) HP kW HP kW Amps kVA Amps Size Catalog No. Min. Rating Max. Rating 140U 140M Class / Catalog No. UL 489 (140U) UL 140 (140M)
25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25
25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30 140M-C2E-B25 CLASS RK5, J or T / DLS-R-6 – 140M-C2E-B25
25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60 140M-C2E-B40 CLASS RK5, J or T / DLS-R-10 – 140M-C2E-B40
Installation/Wiring
25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60 140M-C2E-B40 CLASS RK5, J or T / DLS-R-10 – 140M-C2E-B40
25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-B63
25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60 140M-C2E-B63 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-B63
25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10
25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10 140M-C2E-C10 CLASS RK5, J or T / DLS-R-15 – 140M-C2E-C10
25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16
25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15 140M-C2E-C16 CLASS RK5, J or T / DLS-R-30 – 140M-C2E-C16
25B-D013N104 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 35 – 140M-D8E-C20
25B-D013N114 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 35 – 140M-D8E-C20
25B-D017N104 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 40 – 140M-D8E-C20
25B-D017N114 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25 140M-D8E-C20 CLASS J or T / 40 – 140M-D8E-C20
25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32 CLASS J or T / 60 – –
25B-D024N114 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32 CLASS J or T / 60 – –
25B-D030N104 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – –
25B-D030N114 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – –
25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45 CLASS J or T / 70 – 140M-F8E-C45
25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 50 80 140U-H6C3-C60 140M-F8E-C45 CLASS J or T / 80 – 140M-F8E-C45
(1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.
(1) Normal and Heavy duty ratings are available for drives above 15 HP / 11 kW.
21
Chapter 1
Chapter 1 Installation/Wiring
Power and Control Module PowerFlex 525 drives consists of a Power Module and Control Module.
1. Press and hold down the catch on both sides of the frame cover, then pull
out and swing upwards to remove (Frames B...E only).
2. Press down and slide out the top cover of the Control Module to unlock it
from the Power Module.
3. Hold the sides and top of the Control Module firmly, then pull out to
separate it from the Power Module.
1. Align the connectors on the Power Module and Control Module, then
push the Control Module firmly onto the Power Module.
2. Push the top cover of the Control Module towards the Power Module to
lock it.
3. Insert the catch at the top of the frame cover into the Power Module, then
swing the frame cover to snap the side catches onto the Power Module
(Frames B...E only).
Control Module Cover To access the control terminals, DSI port, and Ethernet port, the front cover must
be removed. To remove:
1. Press and hold down the arrow on the front of the cover.
2. Slide the front cover down to remove from the Control Module.
Power Module Terminal To access the power terminals, the terminal guard must be removed. To remove:
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).
2. Press and hold down the locking tab on the terminal guard.
3. Slide the terminal guard down to remove from the Power Module.
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 22 for
instructions.
Power Wiring ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes
outline provisions for safely installing electrical equipment. Installation must
comply with specifications regarding wire types, conductor sizes, branch circuit
protection and disconnect devices. Failure to do so may result in personal injury
and/or equipment damage.
ATTENTION: To avoid a possible shock hazard caused by induced voltages,
unused wires in the conduit must be grounded at both ends. For the same
reason, if a drive sharing a conduit is being serviced or installed, all drives using
this conduit should be disabled. This will help minimize the possible shock
hazard from “cross coupled” power leads.
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated from
sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for
every 10 m (32.8 ft) of length. In all cases, long parallel runs must be avoided. Do
not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.).
Do not route more than three sets of motor leads in a single conduit to minimize
“cross talk”. If more than three drive/motor connections per conduit are required,
shielded cable must be used.
Unshielded
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,”
publication DRIVES-IN001.
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
Location Rating/Type Description
Standard (Option 1) 600V, 90 °C (194 °F) XHHW2/RHW-2 • Four tinned copper conductors with XLPE insulation.
Anixter B209500-B209507, Belden • Copper braid/aluminum foil combination shield and
29501-29507, or equivalent tinned copper drain wire.
• PVC jacket.
Standard (Option 2) Tray rated 600V, 90 °C (194 °F) • Three tinned copper conductors with XLPE insulation.
RHH/RHW-2 Anixter OLF-7xxxxx or • 5 mil single helical copper tape (25% overlap min.)
equivalent with three bare copper grounds in contact with shield.
• PVC jacket.
Class I & II; Tray rated 600V, 90 °C (194 °F) • Three bare copper conductors with XLPE insulation
Division I & II RHH/RHW-2 Anixter 7V-7xxxx-3G or and impervious corrugated continuously welded
equivalent aluminum armor.
• Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.
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).
Terminal Description
L1/R, L2/S, L3/T Input Line Voltage Connection
T1/U, T2/V, T3/W Motor Phase Connection = Switch any two motor leads to change
forward direction.
IMPORTANT Terminal screws may become loose during shipment. Ensure that all terminal
screws are tightened to the recommended torque before applying power to the
drive.
Common Bus/Precharge If drives are used with a disconnect switch to the common DC bus, then an
auxiliary contact on the disconnect must be connected to a digital input of the
Notes drive. The corresponding input (parameter t062, t063, t065...t068 [DigIn
TermBlk xx]) must be set to 30, “Precharge En” This provides the proper
precharge interlock, guarding against possible damage to the drive when
connected to a common DC bus.
IMPORTANT I/O terminals labeled “Common” are not referenced to the safety ground (PE)
terminal and are designed to greatly reduce common mode interference.
ATTENTION: Driving the 4-20 mA analog input from a voltage source could
cause component damage. Verify proper configuration prior to applying input
signals.
(2) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary,
but is always recommended.
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. If using the RS485 (DSI) port, I/O Terminal
C1 should also be connected to ground terminal/protective earth. Additionally,
communication noise immunity can also be improved by connecting I/O
Terminal C2 to ground terminal/protective earth.
RJ45 Shield
C1
Comm Common
C2
DigIn TermBlk 07 Sel
Digital In
S1 S2 S+ 11 12 13 14 15 16 17 18 19
IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is determined by the
drive setting. See the tables below for more information.
P046, P048, P050 [Start Source x] Normal Stop I/O Terminal 01 Stop
1 “Keypad” Per P045 Coast
2 “DigIn TrmBlk” [Stop Mode] See t062, t063 [DigIn TermBlk xx] below
3 “Serial/DSI” Coast
4 “Network Opt” Per P045 [Stop Mode]
5 “EtherNet/IP” Per P045 [Stop Mode]
t062, t063 [DigIn TermBlk xx] Normal Stop I/O Terminal 01 Stop
48 “2-Wire FWD” Per P045 See t064 [2-Wire Mode] below
49 ”3-Wire Start” [Stop Mode] Per P045 [Stop Mode]
50 “2-Wire REV” See t064 [2-Wire Mode] below
51 “3-Wire Dir” Per P045 [Stop Mode]
IMPORTANT The drive is shipped with a jumper installed between I/O Terminals 01 and 11.
Remove this jumper when using I/O Terminal 01 as a stop or enable input.
(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a
maintained input for I/O Terminal 03 to change direction.
(3) When using an opto output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to prevent
damage to the output.
±10V 13 + 13
Common 14 Common 14 Common 14
+ 15
Analog Input, PTC Wire the PTC and External Resistor (typically matched to the PTC Hot Resistance) to I/O
For Drive Fault Terminals 12, 13, 14.
Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11.
t065 [DigIn TermBlk 05] = 12 “Aux Fault”
t081 [Relay Out 2 Sel] = 10 “Above Anlg V”
t082 [Relay Out 2 Level] = % Voltage Trip
R5
R6
11
Re 12
13 RPTC (hot)
%VTrip = X 100
14 RPTC (hot) + Re
RPTC
05
Pulse In
Use P047, P049 and P051
[Speed Referencex] to Common 04
select pulse input. Jumper Pulse In
for DigIn TermBlk 07 Sel Digital
Input
must be moved to Pulse 07
In.
2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Non-Reversing
P046 [Start Source 1] = 2 11
and t062 [DigIn TermBlk 01
02] = 48 01 02
Stop-Run 02 Stop-Run
Input must be active for 04
the drive to run. When
input is opened, the drive
will stop as specified by +24V Common
P045 [Stop Mode].
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.
Start and Speed Reference Start Source and Speed Reference Selection
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
speed source is determined by P047 [Speed Reference1]. However, various inputs
can override this selection, See below for the override priority.
No
Drive will start and run at
Jog Speed.
Run as specified by
[Preset Freq x].
Yes
Preset Inputs Active Start and Direction
commands come from
[Start Source x].
No
No No
No No
(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 40 for information on selecting the correct digital input.
If P046, P048 or P050 [Start Source x] has been set to 2, “DigIn TermBlk”, then
t062 and t063 [DigIn TermBlk xx] must be configured for 2-Wire or 3-Wire
control for the drive to function properly.
[Start Source x]
No No
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.
No
No
Accel/Decel 1/2/3/4 is
Is speed controlled Yes
selected by the default
by [Preset Freq x] [Preset Freq x] setting.
No
Active Accel/Decel 1 or 2 is
[Speed Referencex] Yes
selected according
= Comms to Comms.
No
No
CE Conformity Compliance with the Low Voltage Directive and Electromagnetic Compatibility
Directive has been demonstrated using harmonized European Norm (EN)
standards published in the Official Journal of the European Communities.
PowerFlex 525 drives comply with the EN standards listed below when installed
according to the installation instructions in this manual.
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 525 drives must be installed in a pollution degree 1 or 2
environment to be compliant with the CE LV Directive. See Pollution
Degree Ratings According to EN 61800-5-1 on page 42 for descriptions of
each pollution degree rating.
• PowerFlex 525 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.
Shielded enclosure(1)
(1) Some installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the
EMI filter.
Ground
cable
CORE-INPUT-1
CORE-OUTPUT-1
CORE-INPUT CORE-INPUT CORE-INPUT CORE-INPUT
CORE-OUTPUT CORE-INPUT-2 CORE-OUTPUT-2
CORE-OUTPUT CORE-OUTPUT CORE-OUTPUT
Output cable from drive (Shielded)
Shows contact to Shows cable/zip tie for
shielded layer securing EMC Core
Incoming power
EMC Filter Drive Motor
CORE-INPUT-1/2 CORE-OUTPUT-1/2
IMPORTANT The grounded/shielded cable for both input and output must pass through the EMC core(s), except for the following:
• Frame E drives with internal filters where the grounded input cable must only pass through EMC CORE-E-2.
• 600V drives with external filters where the grounded output cable must not pass through the EMC core(s).
Start Up
This chapter describes how to start up the PowerFlex 525 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 47
Display and Control Keys 49
Viewing and Editing Parameters 50
Drive Programming Tools 51
Smart Start-Up with Basic Program Group Parameters 52
LCD & Scrolling Description 53
USB 54
1. Confirm that all inputs are connected to the correct terminals and are
secure.
2. Verify that AC line power at the disconnect device is within the rated value
of the drive.
3. Verify that any digital control power is 24 volts.
4. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your
control wiring scheme. See the Control I/O Wiring Block Diagram on
page 32 for location.
IMPORTANT The default control scheme is Source (SRC). The Stop terminal is jumpered to
allow starting from the keypad or comms. If the control scheme is changed to
Sink (SNK), the jumper must be removed from I/O Terminals 01 and 11 and
installed between I/O Terminals 01 and 04.
5. Verify that the Stop input is present or the drive will not start.
IMPORTANT If I/O Terminal 01 is used as a stop input, the jumper between I/O Terminals 01
and 11 must be removed.
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.
If a fault appears on power up, see Fault Descriptions on page 135 for an
explanation of the fault code.
Viewing and Editing The following is an example of basic integral keypad and display functions. This
example provides basic navigation instructions and illustrates how to program
Parameters a parameter.
Step Key(s) Example Display
1. When power is applied, the last user-selected
Basic Display Group parameter number is briefly FWD
HERTZ
displayed with flashing characters. The display
then defaults to that parameter’s current value.
(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 FWD
parameter number will flash. Esc
Esc
PROGRAM
Or Esc or
or
Press Enter to save a change and exit Program VOLTS
Mode. FWD
Drive Programming Tools Some features in the PowerFlex 525 drive are not supported by older
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 3.0 or greater) to enjoy a richer, full-featured
configuration experience.
Description Catalog Number/Release Version
Connected Components Workbench(1) Version 3.0 or greater
Logix Designer Version 21.0 or greater
RSLogix 5000 Version 17.0 or greater
Built-in USB software tool –
Serial Converter Module 22-SCM-232
USB Converter Module 1203-USB
Remote Panel Mount, LCD Display(2) 22-HIM-C2S
Remote Handheld, LCD Display(2) 22-HIM-A3
(1) Available as a free download at http://ab.rockwellautomation.com/programmable-controllers/connected-components-
workbench-software.
(2) Does not support the new dynamic parameter groups (AppView, CustomView), and CopyCat functionality is limited to the linear
parameter list. Communications option cards are not accessible using the remote HIM.
Smart Start-Up with Basic The PowerFlex 525 drive is designed so that start up is simple and efficient. The
Basic Program Group contains the most commonly used parameters. See
Program Group Parameters Programming and Parameters on page 57 for detailed descriptions of the
parameters listed here, as well as the full list of available parameters.
= Stop drive before changing this parameter.
No. Parameter Min/Max Display/Options Default
P030 [Language] 1/15 1 = English 1
Selects the language displayed. 2 = Français
3 = Español
Important: The setting takes effect after the drive 4 = Italiano
is power cycled. 5 = Deutsch
6 = Japanese
7 = Português
8 = Chinese
9 = Reserved
10 = Reserved
11 = Korean
12 = Polish
13 = Reserved
14 = Turkish
15 = Czech
P031 [Motor NP Volts] 10V (for 200V Drives), 20V 1V Based on Drive Rating
(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.
P033 [Motor OL Current] 0.0/(Drive Rated Amps × 2) 0.1 A Based on Drive Rating
Sets the motor nameplate overload current.
P034 [Motor NP FLA] 0.0/(Drive Rated Amps x 2) 0.1 A Drive Rated Amps
Sets the motor nameplate FLA.
P035 [Motor NP Poles] 2/40 1 4
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.
P037 [Motor NP Power] 0.00/Drive Rated Power 0.01 kW Drive Rated Power
Sets the motor nameplate power.
P038 [Voltage Class] 2/3 2 = “480V” 3
Sets the voltage class of 600V drives. Only applicable 3 = “600V”
to 600V drives.
P039 [Torque Perf Mode] 0/3 0 = “V/Hz” 1
Selects the motor control mode. 1 = “SVC”
2 = “Economize”
3 = “Vector”
P040 [Autotune] 0/2 0 = “Ready/Idle” 0
Enables a static (not spinning) or dynamic (motor 1 = “Static Tune”
spinning) autotune. 2 = “Rotate Tune”
LCD & Scrolling Description Use parameter A556 [Text Scroll] to set the speed at which the text scrolls across
the display. Select 0 “Off ” to turn off text scrolling. See Language Support on
page 51 for the languages supported by PowerFlex 525.
USB The PowerFlex 525 drive has a USB port that connects to a PC for the purpose of
upgrading drive firmware or uploading/downloading a parameter configuration.
You do not need to power up the control module. Simply connect the PowerFlex
525 drive to your PC with a USB Type B cable, and you will benefit from
MainsFree™ programming.
USB port
USB Type B cable
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.
IMPORTANT Make sure your PC is powered by an AC power outlet or has a fully charged
battery before starting any operation. This prevents the operation from
terminating before completion due to insufficient power.
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.
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.
Notes:
This chapter provides a complete listing and description of the PowerFlex 525
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, or Connected Components Workbench version 3.0 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).
About Parameters To configure a drive to operate in a specific way, drive parameters may have to be
set. Three types of parameters exist:
• ENUM
ENUM parameters allow a selection from 2 or more items. Each item is
represented by a number.
• Numeric Parameters
These parameters have a single numerical value (0.1V).
• Bit Parameters
Bit parameters have five individual digits associated with features or
conditions. If the digit is 0, the feature is off or the condition is false. If the
digit is 1, the feature is on or the condition is true.
Parameter Groups For an alphabetical listing of parameters, see Parameter Cross Reference by Name
on page 128.
Basic Display Output Voltage b004 Process Fract b011 Power Saved b018 Accum Cost Sav b025
DC Bus Voltage b005 Control Source b012 Elapsed Run Time b019 Accum CO2 Sav b026
Drive Status b006 Contrl In Status b013 Average Power b020 Drive Temp b027
Fault 1 Code b007 Dig In Status b014 Elapsed kWh b021 Control Temp b028
Output Freq b001 Fault 2 Code b008 Output RPM b015 Elapsed MWh b022 Control SW Ver b029
Commanded Freq b002 Fault 3 Code b009 Output Speed b016 Energy Saved b023
Output Current b003 Process Display b010 Output Power b017 Accum kWh Sav b024
Basic Program Motor NP Hertz P032 Voltage Class P038 Maximum Freq P044 Start Source 3 P050
Motor OL Current P033 Torque Perf Mode P039 Stop Mode P045 Speed Reference3 P051
Motor NP FLA P034 Autotune P040 Start Source 1 P046 Average kWh Cost P052
Motor NP Poles P035 Accel Time 1 P041 Speed Reference1 P047 Reset To Defalts P053
Language P030 Motor NP RPM P036 Decel Time 1 P042 Start Source 2 P048
Motor NP Volts P031 Motor NP Power P037 Minimum Freq P043 Speed Reference2 P049
Terminal Blocks DigIn TermBlk 08 t068 Relay Out1 LevelF t078 Analog Out Sel t088 Anlg Loss Delay t098
Opto Out1 Sel t069 Relay 1 On Time t079 Analog Out High t089 Analog In Filter t099
Opto Out1 Level t070 Relay 1 Off Time t080 Anlg Out Setpt t090 Sleep-Wake Sel t100
Opto Out1 LevelF t071 Relay Out2 Sel t081 Anlg In 0-10V Lo t091 Sleep Level t101
DigIn TermBlk 02 t062 Opto Out2 Sel t072 Relay Out2 Level t082 Anlg In 0-10V Hi t092 Sleep Time t102
DigIn TermBlk 03 t063 Opto Out2 Level t073 Relay Out2 LevelF t083 10V Bipolar Enbl t093 Wake Level t103
2-Wire Mode t064 Opto Out2 LevelF t074 Relay 2 On Time t084 Anlg In V Loss t094 Wake Time t104
DigIn TermBlk 05 t065 Opto Out Logic t075 Relay 2 Off Time t085 Anlg In4-20mA Lo t095 Safety Open En t105
DigIn TermBlk 06 t066 Relay Out1 Sel t076 EM Brk Off Delay t086 Anlg In4-20mA Hi t096
DigIn TermBlk 07 t067 Relay Out1 Level t077 EM Brk On Delay t087 Anlg In mA Loss t097
Communications EN Addr Sel C128 EN Gateway Cfg 3 C139 EN Data In 1 C153 Opt Data In 4 C164
EN IP Addr Cfg 1 C129 EN Gateway Cfg 4 C140 EN Data In 2 C154 Opt Data Out 1 C165
EN IP Addr Cfg 2 C130 EN Rate Cfg C141 EN Data In 3 C155 Opt Data Out 2 C166
EN IP Addr Cfg 3 C131 EN Comm Flt Actn C143 EN Data In 4 C156 Opt Data Out 3 C167
Comm Write Mode C121 EN IP Addr Cfg 4 C132 EN Idle Flt Actn C144 EN Data Out 1 C157 Opt Data Out 4 C168
Cmd Stat Select C122 EN Subnet Cfg 1 C133 EN Flt Cfg Logic C145 EN Data Out 2 C158 MultiDrv Sel C169
RS485 Data Rate C123 EN Subnet Cfg 2 C134 EN Flt Cfg Ref C146 EN Data Out 3 C159 Drv 1 Addr C171
RS485 Node Addr C124 EN Subnet Cfg 3 C135 EN Flt Cfg DL 1 C147 EN Data Out 4 C160 Drv 2 Addr C172
Comm Loss Action C125 EN Subnet Cfg 4 C136 EN Flt Cfg DL 2 C148 Opt Data In 1 C161 Drv 3 Addr C173
Comm Loss Time C126 EN Gateway Cfg 1 C137 EN Flt Cfg DL 3 C149 Opt Data In 2 C162 Drv 4 Addr C174
RS485 Format C127 EN Gateway Cfg 2 C138 EN Flt Cfg DL 4 C150 Opt Data In 3 C163 DSI I/O Cfg C175
Logic Stp Logic 4 L184 Stp Logic Time 4 L194 Step Units 2 L204 Step Units 6 L212
Stp Logic 5 L185 Stp Logic Time 5 L195 Step Units F 2 L205 Step Units F 6 L213
Stp Logic 6 L186 Stp Logic Time 6 L196 Step Units 3 L206 Step Units 7 L214
Stp Logic 7 L187 Stp Logic Time 7 L197 Step Units F 3 L207 Step Units F 7 L215
Stp Logic 0 L180 Stp Logic Time 0 L190 Step Units 0 L200 Step Units 4 L208
Stp Logic 1 L181 Stp Logic Time 1 L191 Step Units F 0 L201 Step Units F 4 L209
Stp Logic 2 L182 Stp Logic Time 2 L192 Step Units 1 L202 Step Units 5 L210
Stp Logic 3 L183 Stp Logic Time 3 L193 Step Units F 1 L203 Step Units F 5 L211
Advanced Display Elapsed Time-min d363 Slip Hz Meter d375 Torque Current d382 Units Traveled L d389
Counter Status d364 Speed Feedback d376 PID1 Fdbk Displ d383 Fiber Status d390
Timer Status d365 Speed Feedback F d377 PID1 Setpnt Displ d384 Stp Logic Status d391
Timer StatusF d366 Encoder Speed d378 PID2 Fdbk Displ d385
Analog In 0-10V d360 Drive Type d367 Encoder Speed F d379 PID2 Setpnt Displ d386
Analog In 4-20mA d361 Testpoint Data d368 DC Bus Ripple d380 Position Status d387
Elapsed Time-hr d362 Motor OL Level d369 Output Powr Fctr d381 Units Traveled H d388
Advanced Program DC Brk Time@Strt A436 PID 1 Preload A466 Flux Current Ref A497 Start At PowerUp A543
DB Resistor Sel A437 PID 1 Invert Err A467 Motor Rr A498 Reverse Disable A544
DB Threshold A438 PID 2 Trim Hi A468 Motor Lm A499 Flying Start En A545
S Curve % A439 PID 2 Trim Lo A469 Motor Lx A500 FlyStrt CurLimit A546
Preset Freq 0 A410 PWM Frequency A440 PID 2 Trim Sel A470 Speed Reg Sel A509 Compensation A547
Preset Freq 1 A411 Droop Hertz@ FLA A441 PID 2 Ref Sel A471 Freq 1 A510 Power Loss Mode A548
Preset Freq 2 A412 Accel Time 2 A442 PID 2 Fdback Sel A472 Freq 1 BW A511 Half Bus Enable A549
Preset Freq 3 A413 Decel Time 2 A443 PID 2 Prop Gain A473 Freq 2 A512 Bus Reg Enable A550
Preset Freq 4 A414 Accel Time 3 A444 PID 2 Integ Time A474 Freq 2 BW A513 Fault Clear A551
Preset Freq 5 A415 Decel Time 3 A445 PID 2 Diff Rate A475 Freq 3 A514 Program Lock A552
Preset Freq 6 A416 Accel Time 4 A446 PID 2 Setpoint A476 Freq 3 BW A515 Program Lock Mod A553
Preset Freq 7 A417 Decel Time 4 A447 PID 2 Deadband A477 Freq 1 Kp A521 Drv Ambient Sel A554
Preset Freq 8 A418 Skip Frequency 1 A448 PID 2 Preload A478 Freq 1 Ki A522 Reset Meters A555
Preset Freq 9 A419 Skip Freq Band 1 A449 PID 2 Invert Err A479 Freq 2 Kp A523 Text Scroll A556
Preset Freq 10 A420 Skip Frequency 2 A450 Process Disp Lo A481 Freq 2 Ki A524 Out Phas Loss En A557
Preset Freq 11 A421 Skip Freq Band 2 A451 Process Disp Hi A482 Freq 3 Kp A525 Positioning Mode A558
Preset Freq 12 A422 Skip Frequency 3 A452 Testpoint Sel A483 Freq 3 Ki A526 Counts Per Unit A559
Preset Freq 13 A423 Skip Freq Band 3 A453 Current Limit 1 A484 Boost Select A530 Enh Control Word A560
Preset Freq 14 A424 Skip Frequency 4 A454 Current Limit 2 A485 Start Boost A531 Home Save A561
Preset Freq 15 A425 Skip Freq Band 4 A455 Shear Pin1 Level A486 Break Voltage A532 Find Home Freq A562
Keypad Freq A426 PID 1 Trim Hi A456 Shear Pin 1 Time A487 Break Frequency A533 Find Home Dir A563
MOP Freq A427 PID 1 Trim Lo A457 Shear Pin2 Level A488 Maximum Voltage A534 Encoder Pos Tol A564
MOP Reset Sel A428 PID 1 Trim Sel A458 Shear Pin 2 Time A489 Motor Fdbk Type A535 Pos Reg Filter A565
MOP Preload A429 PID 1 Ref Sel A459 Load Loss Level A490 Encoder PPR A536 Pos Reg Gain A566
MOP Time A430 PID 1 Fdback Sel A460 Load Loss Time A491 Pulse In Scale A537 Max Traverse A567
Jog Frequency A431 PID 1 Prop Gain A461 Stall Fault Time A492 Ki Speed Loop A538 Traverse Inc A568
Jog Accel/Decel A432 PID 1 Integ Time A462 Motor OL Select A493 Kp Speed Loop A539 Traverse Dec A569
Purge Frequency A433 PID 1 Diff Rate A463 Motor OL Ret A494 Var PWM Disable A540 P Jump A570
DC Brake Time A434 PID 1 Setpoint A464 Drive OL Mode A495 Auto Rstrt Tries A541 Sync Time A571
DC Brake Level A435 PID 1 Deadband A465 IR Voltage Drop A496 Auto Rstrt Delay A542 Speed Ratio A572
Network
This group contains parameters for the network option card that is installed.
See the network option card’s user manual for more information on the available parameters.
Modified
This group contains parameters that have their values changed from the factory default.
When a parameter has its default value changed, it is automatically added to this group. When a parameter has its value changed back to the
factory default, it is automatically removed from this group.
Fault and Diagnostic Fault 5 Time-min F625 Fault10 Current F650 EN Rate Act F685 Drv 1 Reference F710
Fault 6 Time-min F626 Fault 1 BusVolts F651 DSI I/O Act F686 Drv 1 Logic Sts F711
Fault 7 Time-min F627 Fault 2 BusVolts F652 HW Addr 1 F687 Drv 1 Feedback F712
Fault 8 Time-min F628 Fault 3 BusVolts F653 HW Addr 2 F688 Drv 2 Logic Cmd F713
Fault 4 Code F604 Fault 9 Time-min F629 Fault 4 BusVolts F654 HW Addr 3 F689 Drv 2 Reference F714
Fault 5 Code F605 Fault10 Time-min F630 Fault 5 BusVolts F655 HW Addr 4 F690 Drv 2 Logic Sts F715
Fault 6 Code F606 Fault 1 Freq F631 Fault 6 BusVolts F656 HW Addr 5 F691 Drv 2 Feedback F716
Fault 7 Code F607 Fault 2 Freq F632 Fault 7 BusVolts F657 HW Addr 6 F692 Drv 3 Logic Cmd F717
Fault 8 Code F608 Fault 3 Freq F633 Fault 8 BusVolts F658 EN IP Addr Act 1 F693 Drv 3 Reference F718
Fault 9 Code F609 Fault 4 Freq F634 Fault 9 BusVolts F659 EN IP Addr Act 2 F694 Drv 3 Logic Sts F719
Fault10 Code F610 Fault 5 Freq F635 Fault10 BusVolts F660 EN IP Addr Act 3 F695 Drv 3 Feedback F720
Fault 1 Time-hr F611 Fault 6 Freq F636 Status @ Fault 1 F661 EN IP Addr Act 4 F696 Drv 4 Logic Cmd F721
Fault 2 Time-hr F612 Fault 7 Freq F637 Status @ Fault 2 F662 EN Subnet Act 1 F697 Drv 4 Reference F722
Fault 3 Time-hr F613 Fault 8 Freq F638 Status @ Fault 3 F663 EN Subnet Act 2 F698 Drv 4 Logic Sts F723
Fault 4 Time-hr F614 Fault 9 Freq F639 Status @ Fault 4 F664 EN Subnet Act 3 F699 Drv 4 Feedback F724
Fault 5 Time-hr F615 Fault10 Freq F640 Status @ Fault 5 F665 EN Subnet Act 4 F700 EN Rx Overruns F725
Fault 6 Time-hr F616 Fault 1 Current F641 Status @ Fault 6 F666 EN Gateway Act 1 F701 EN Rx Packets F726
Fault 7 Time-hr F617 Fault 2 Current F642 Status @ Fault 7 F667 EN Gateway Act 2 F702 EN Rx Errors F727
Fault 8 Time-hr F618 Fault 3 Current F643 Status @ Fault 8 F668 EN Gateway Act 3 F703 EN Tx Packets F728
Fault 9 Time-hr F619 Fault 4 Current F644 Status @ Fault 9 F669 EN Gateway Act 4 F704 EN Tx Errors F729
Fault10 Time-hr F620 Fault 5 Current F645 Status @ Fault10 F670 Drv 0 Logic Cmd F705 EN Missed IO Pkt F730
Fault 1 Time-min F621 Fault 6 Current F646 Comm Sts - DSI F681 Drv 0 Reference F706 DSI Errors F731
Fault 2 Time-min F622 Fault 7 Current F647 Comm Sts - Opt F682 Drv 0 Logic Sts F707
Fault 3 Time-min F623 Fault 8 Current F648 Com Sts-Emb Enet F683 Drv 0 Feedback F708
Fault 4 Time-min F624 Fault 9 Current F649 EN Addr Src F684 Drv 1 Logic Cmd F709
PowerFlex 525 drives include various AppView™ parameter groups that groups
certain parameters together for quick and easy access based on different types of
applications. See AppView Parameter Groups on page 126 for more information.
Conveyor Motor NP Volts P031 Decel Time 1 P042 DigIn TermBlk 03 t063 Anlg In mA Loss t097
Motor NP Hertz P032 Minimum Freq P043 Opto Out1 Sel t069 Slip Hz Meter d375
Motor OL Current P033 Maximum Freq P044 Relay Out1 Sel t076 Preset Freq 0 A410
Motor NP FLA P034 Stop Mode P045 Anlg In 0-10V Lo t091 Jog Frequency A431
Language P030 Motor NP Poles P035 Start Source 1 P046 Anlg In 0-10V Hi t092 Jog Accel/Decel A432
Output Freq b001 Autotune P040 Speed Reference1 P047 Anlg In4-20mA Lo t095 S Curve % A439
Commanded Freq b002 Accel Time 1 P041 DigIn TermBlk 02 t062 Anlg In4-20mA Hi t096 Reverse Disable A544
Mixer Output Current b003 Autotune P040 Start Source 1 P046 Anlg In4-20mA Hi t096
Motor NP Volts P031 Accel Time 1 P041 Speed Reference1 P047 Anlg In mA Loss t097
Motor NP Hertz P032 Decel Time 1 P042 Relay Out1 Sel t076 Preset Freq 0 A410
Motor OL Current P033 Minimum Freq P043 Anlg In 0-10V Lo t091 Stall Fault Time A492
Language P030 Motor NP FLA P034 Maximum Freq P044 Anlg In 0-10V Hi t092
Output Freq b001 Motor NP Poles P035 Stop Mode P045 Anlg In4-20mA Lo t095
Compressor Motor NP Hertz P032 Maximum Freq P044 Anlg In 0-10V Lo t091 Start At PowerUp A543
Motor OL Current P033 Stop Mode P045 Anlg In 0-10V Hi t092 Reverse Disable A544
Motor NP FLA P034 Start Source 1 P046 Anlg In4-20mA Lo t095 Power Loss Mode A548
Motor NP Poles P035 Speed Reference1 P047 Anlg In4-20mA Hi t096 Half Bus Enable A549
Language P030 Autotune P040 Relay Out1 Sel t076 Anlg In mA Loss t097
Output Freq b001 Accel Time 1 P041 Analog Out Sel t088 Preset Freq 0 A410
Commanded Freq b002 Decel Time 1 P042 Analog Out High t089 Auto Rstrt Tries A541
Motor NP Volts P031 Minimum Freq P043 Anlg Out Setpt t090 Auto Rstrt Delay A542
Centrifugal Pump Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464
Motor NP Poles P035 Relay Out1 Sel t076 Preset Freq 0 A410 PID 1 Deadband A465
Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466
Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541
Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542
Commanded Freq b002 Minimum Freq P043 Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544
Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 PID 1 Integ Time A462
Blower/Fan Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464
Motor NP Poles P035 Relay Out1 Sel t076 Preset Freq 0 A410 PID 1 Deadband A465
Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466
Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541
Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542
Commanded Freq b002 Minimum Freq P043 Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544
Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 PID 1 Integ Time A462 Flying Start En A545
Extruder Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 Encoder PPR A536
Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 Pulse In Scale A537
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 Ki Speed Loop A538
Motor NP Poles P035 Relay Out1 Sel t076 Slip Hz Meter d375 Kp Speed Loop A539
Language P030 Autotune P040 Analog Out Sel t088 Speed Feedback d376 Power Loss Mode A548
Output Freq b001 Accel Time 1 P041 Analog Out High t089 Encoder Speed d378 Half Bus Enable A549
Commanded Freq b002 Decel Time 1 P042 Anlg Out Setpt t090 Preset Freq 0 A410
Output Current b003 Minimum Freq P043 Anlg In 0-10V Lo t091 Stall Fault Time A492
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 Motor Fdbk Type A535
Positioning Stop Mode P045 Stp Logic 5 L185 Step Units 6 L212 Jog Accel/Decel A432
Start Source 1 P046 Stp Logic 6 L186 Step Units 7 L214 DB Threshold A438
Speed Reference1 P047 Stp Logic 7 L187 Slip Hz Meter d375 S Curve % A439
DigIn TermBlk 02 t062 Stp Logic Time 0 L190 Speed Feedback d376 Motor Fdbk Type A535
Language P030 DigIn TermBlk 03 t063 Stp Logic Time 1 L191 Encoder Speed d378 Encoder PPR A536
Output Freq b001 DigIn TermBlk 05 t065 Stp Logic Time 2 L192 Units Traveled H d388 Pulse In Scale A537
Commanded Freq b002 DigIn TermBlk 06 t066 Stp Logic Time 3 L193 Units Traveled L d389 Ki Speed Loop A538
Motor NP Volts P031 Opto Out1 Sel t069 Stp Logic Time 4 L194 Preset Freq 0 A410 Kp Speed Loop A539
Motor NP Hertz P032 Opto Out2 Sel t072 Stp Logic Time 5 L195 Preset Freq 1 A411 Bus Reg Enable A550
Motor OL Current P033 Relay Out1 Sel t076 Stp Logic Time 6 L196 Preset Freq 2 A412 Positioning Mode A558
Motor NP FLA P034 EM Brk Off Delay t086 Stp Logic Time 7 L197 Preset Freq 3 A413 Counts Per Unit A559
Motor NP Poles P035 EM Brk On Delay t087 Step Units 0 L200 Preset Freq 4 A414 Enh Control Word A560
Autotune P040 Stp Logic 0 L180 Step Units 1 L202 Preset Freq 5 A415 Find Home Freq A562
Accel Time 1 P041 Stp Logic 1 L181 Step Units 2 L204 Preset Freq 6 A416 Find Home Dir A563
Decel Time 1 P042 Stp Logic 2 L182 Step Units 3 L206 Preset Freq 7 A417 Encoder Pos Tol A564
Minimum Freq P043 Stp Logic 3 L183 Step Units 4 L208 Preset Freq 8 A418 Pos Reg Filter A565
Maximum Freq P044 Stp Logic 4 L184 Step Units 5 L210 Jog Frequency A431 Pos Reg Gain A566
Textile/Fiber Motor NP FLA P034 DigIn TermBlk 02 t062 Slip Hz Meter d375 Max Traverse A567
Motor NP Poles P035 DigIn TermBlk 03 t063 Fiber Status d390 Traverse Inc A568
Autotune P040 Opto Out1 Sel t069 Preset Freq 0 A410 Traverse Dec A569
Accel Time 1 P041 Opto Out2 Sel t072 Jog Frequency A431 P Jump A570
Language P030 Decel Time 1 P042 Relay Out1 Sel t076 Jog Accel/Decel A432 Sync Time A571
Output Freq b001 Minimum Freq P043 Anlg In 0-10V Lo t091 S Curve % A439 Speed Ratio A572
Commanded Freq b002 Maximum Freq P044 Anlg In 0-10V Hi t092 Reverse Disable A544
Motor NP Volts P031 Stop Mode P045 Anlg In4-20mA Lo t095 Power Loss Mode A548
Motor NP Hertz P032 Start Source 1 P046 Anlg In4-20mA Hi t096 Half Bus Enable A549
Motor OL Current P033 Speed Reference1 P047 Anlg In mA Loss t097 Bus Reg Enable A550
PowerFlex 525 drives include a CustomView™ parameter group for you to store
frequently used parameters for your application. See CustomView Parameter
Group on page 127 for more information.
Custom Group
This group can store up to 100 parameters.
b002 [Commanded Freq] Related Parameter(s): b001, b013, P043, P044, P048, P050, P052
Value of the active frequency command even if the drive is not running.
IMPORTANT The frequency command can come from a number of sources. See Start and Speed Reference Control on page 39 for more information.
1 = True/Active, 0 = False/Inactive
Running Digit 1
Forward Digit 2
Accelerating Digit 3
Decelerating Digit 4
SafetyActive Digit 5
b012 [Control Source] Related Parameter(s): P046, P047, P048, P049, P050, P051,
t062, t063, t065-t068, L180-L187, A410-A425
Active source of the Start Command and Frequency Command. Normally defined by the settings of P046, P048, P050 [Start Source x] and P047, P049, P051 [Speed Referencex].
See Start and Speed Reference Control on page 39 for more information.
Example
Start Command Source Digit 1 Display reads... Description
1 = Keypad
2 = DigIn TrmBlk (Parameters t062,t063,t065-t068) 2004 Start source comes from Network Opt and Frequency source is Purge.
3 = Serial/DSI 113 Start source comes from Serial/DSI and Frequency source comes from PID1 Output.
4 = Network Opt
5 = EtherNet/IP 155 Start source and Frequency source comes from EtherNet/IP.
Frequency Command Source Digit 2 & 3 052 Start source comes from DigIn TrmBlk and Frequency source from 0-10V Input.
00 = Other
01 = Drive Pot 011 Start source comes from Keypad and Frequency source comes from Drive Pot.
02 = Keypad
03 = Serial/DSI
04 = Network Opt
05 = 0-10V Input
06 = 4-20mA Input
07 = Preset Freq (Parameters A410-A425)
08 = Anlg In Mult
09 = MOP
10 = Pulse Input
11 = PID1 Output
12 = PID2 Output
13 = Step Logic (Parameters L180-L187)
14 = Encoder
15 = EtherNet/IP
16 = Positioning
Frequency Command Source Digit 4
0 = Other (Digit 2 & 3 are used. Digit 4 is not shown.)
1 = Jog
2 = Purge
Not Used
P031 [Motor NP Volts] Related Parameter(s): b004, A530, A531, A532, A533
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 Drives), 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 motor overload conditions and can be set from 0.1 A to 200% of drive rated current.
IMPORTANT The drive will fault on an F007 “Motor Overload” if the value of this parameter is exceeded by 150% for 60 s.
P039 [Torque Perf Mode] Related Parameter(s): P040, A530, A531, A532, A533
Stop drive before changing this parameter.
Selects the motor control mode.
Options 0 “V/Hz”
1 “SVC” (Default)
2 “Economize”
3 “Vector”
ATTENTION: Rotation of the motor in an undesired direction can occur during this procedure. To guard against possible injury and/or equipment damage, it is
recommended that the motor be disconnected from the load before proceeding.
Dec
n
o
rati
ele
Speed
ele
ra
tion
A cc
0
[Accel Time x] Time [Decel Time x]
0
Values Default: 10.00 s
Min/Max: 0.00/600.00 s
Display: 0.01 s
ele
Speed
ele
rati
Acc
on
0
[Accel Time x] Time [Decel Time x]
0
Values Default: 10.00 s
Min/Max: 0.00/600.00 s
Display: 0.01 s
P043 [Minimum Freq] Related Parameter(s): b001, b002, b013, P044, A530, A531
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.
IMPORTANT This value must be greater than the value set in P043 [Minimum Freq].
Speed
IMPORTANT Digital Inputs have priority for frequency control when programmed as Preset Speed and are active. See
Start Source and Speed Reference Selection on page 39 for more information.
8 “Jog” • When input is present, drive accelerates according to the value set in A432 [Jog Accel/Decel] and ramps to the value set in A431
[Jog Frequency].
• When input is removed, drive ramps to a stop according to the value set in A432 [Jog Accel/Decel].
• A valid Start command will override this input.
9 “Jog Forward” [DigIn TermBlk 08] default.
Drive accelerates to A431 [Jog Frequency] according to A432 [Jog Accel/Decel] and ramps to a stop when input becomes inactive. A
valid Start command will override this input.
10 “Jog Reverse” Drive accelerates to A431 [Jog Frequency] according to A432 [Jog Accel/Decel] and ramps to a stop when input becomes inactive. A
valid Start command will override this input.
11 “Acc/Dec Sel2”(1) If active, determines which Accel/Decel time will be used for all ramp rates except jog. Can be used with option 29 “Acc/Dec Sel3”
for additional Accel/Decel times. See A442 [Accel Time 2] for more information.
12 “Aux Fault” When enabled, an F002 “Auxiliary Input” fault will occur when the input is removed.
13 “Clear Fault” When active, clears an active fault.
14 “RampStop,CF” Causes drive to immediately ramp to a stop regardless of how P045 [Stop Mode] is set.
15 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of how P045 [Stop Mode] is set.
16 “DCInjStop,CF” Causes drive to immediately begin a DC Injection stop regardless of how P045 [Stop Mode] is set.
17 “MOP Up” Increases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time].
18 “MOP Down” Decreases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time].
19 “Timer Start”(1) Clears and starts the timer function. May be used to control the relay or opto outputs.
20 “Counter In”(1) Starts the counter function. May be used to control the relay or opto outputs.
21 “Reset Timer” Clears the active timer.
22 “Reset Countr” Clears the active counter.
23 “Rset Tim&Cnt” Clear the active timer and counter.
24 “Logic In 1”(1) Logic function input number 1. May be used to control the relay or opto outputs (t076, t081 [Relay Outx Sel] and t069, t072 [Opto
Outx Sel], options 11...14). May be used in conjunction with StepLogic parameters L180...L187 [Stp Logic x].
25 “Logic In 2”(1) Logic function input number 2. May be used to control the relay or opto outputs (t076, t081 [Relay Outx Sel] and t069, t072 [Opto
Outx Sel], options 11...14). May be used in conjunction with StepLogic parameters L180...L187 [Stp Logic x].
26 “Current Lmt2” When active, A485 [Current Limit 2] determines the drive current limit level.
Options 27 “Anlg Invert” Inverts the scaling of the analog input levels set in
t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] or
t095 [Anlg In4-20mA Lo] and t096 [Anlg In4-20mA Hi].
28 “EM Brk Rlse” If EM brake function is enabled, this input releases the brake. See t086 [EM Brk Off Delay] for more information.
29 “Acc/Dec Sel3”(1) If active, determines which Accel/Decel time is used for all ramp rates except jog.
Used with option 11 “Acc/Dec Sel2” for the Accel/Decel times listed in this table. Option Description
29 11
0 0 Acc/Dec 1
0 1 Acc/Dec 2
1 0 Acc/Dec 3
1 1 Acc/Dec 4
30 “Precharge En” Forces drive into precharge state. Typically controlled by auxiliary contact on the disconnect at the DC input to the drive. If this
input is assigned, it must be energized for the pre-charge relay to close and for the drive to run. If it is de-energized, the pre-charge
relay opens and the drive coasts to a stop.
31 “Inertia Dcel” Forces drive into Inertia Ride-Through state. The drive attempts to regulate the DC bus at the current level.
32 “Sync Enable” Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization. When this input is
released the drive accelerates to the commanded frequency in A571 [Sync Time].
33 “Traverse Dis” When an input is programmed the traverse function is disabled while this input is active. See A567 [Max Traverse].
34 “Home Limit” In Positioning mode, indicates the drive is at the home position. See Appendix E for more information on Positioning.
35 “Find Home” In Positioning mode, causes the drive to return to the Home position when a Start command is issued.
Uses A562 [Find Home Freq] and A563 [Find Home Dir] until the “Home Limit” input is activated. If it passes this point, it then runs
in the reverse direction at 1/10th the frequency of [Find Home Freq] until the “Home Limit” is activated again. As long as this input
is active, any start command causes the drive to enter the homing routine. Only functions if in Positioning mode. Once the Find
Home routine has finished, the drive stops. See Appendix E for more information on Positioning.
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
run. Therefore, when the Hold is removed, the drive must see any required digital inputs transition (even if they already
transitioned during the hold), but it does not reset any timer. See Appendix E for more information on Positioning.
37 “Pos Redefine” In Positioning mode, resets the home position to the current position of the machine. See Appendix E for more information on
Positioning.
38 “Force DC” If the drive is not running, causes the drive to apply a DC Holding current (A435 [DC Brake Level], ignoring A434 [DC Brake Time])
while the input is applied.
39 “Damper Input” When active, drive is allowed to run normally.
When inactive, drive is forced into sleep mode and is prevented from accelerating to command speed.
40 “Purge”(1) Starts the drive at A433 [Purge Frequency] regardless of the selected control source. Supersedes the keypad Control function as
well as any other control command to take control of the drive. Purge can occur, and is operational, at any time whether the drive is
running or stopped regardless of the selected logic source selection. If a valid stop (other than from comms or SW enable) is
present, the drive will not start on the purge input transition.
41 “Freeze-Fire” When inactive, will cause an immediate F094 “Function Loss” fault. Use to safely bypass the drive with an external switching
device.
42 “SW Enable” Works like an interlock that 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
Options 47 Reserved
48 “2-Wire FWD” [DigIn TermBlk 02] default. Selects 2-Wire FWD for this input.
(only for DigIn TermBlk 02) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to configure [Start Source x] to a 2-wire run
forward mode. Also see t064 [2-Wire Mode] for level trigger settings.
49 “3-Wire Start” Select 3-Wire Start for this input.
(only for DigIn TermBlk 02) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to configure [Start Source x] to a 3-wire start
mode.
50 “2-Wire REV” [DigIn TermBlk 03] default. Selects 2-Wire REV for this input.
(only for DigIn TermBlk 03) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to configure [Start Source x] to a 2-wire run
reverse mode. Also see t064 [2-Wire Mode] for level trigger settings.
51 “3-Wire Dir” Select 3-Wire Dir for this input.
(only for DigIn TermBlk 03) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn TrmBlk” to change the direction of [Start Source x].
52 “Pulse Train” Selects pulse train for this input.
(only for DigIn TermBlk 07) Use P047, P049 and P051 [Speed Referencex] to select pulse input. Jumper for DigIn TermBlk 07 Sel must be moved to Pulse In.
(1) This function may be tied to one input only.
t064 [2-Wire Mode] Related Parameter(s): P045, P046, P048, P050, t062, t063
Stop drive before changing this parameter.
Programs the mode of trigger only for t062 [DigIn TermBlk 02] and t063 [DigIn TermBlk 03] when 2-wire option is being selected as P046, P048 or P050 [Start Source x].
Options 0 “Edge Trigger” (Default) Standard 2-Wire operation.
1 “Level Sense” • I/O Terminal 01 “Stop” = Coast to stop. Drive will restart after a Stop command when:
– Stop is removed
and
– Start is held active
• I/O Terminal 03 “Run REV”
ATTENTION: Hazard of injury exists due to unintended operation. When set to option 3, and the Run input
is maintained, the Run inputs do not need to be toggled after a Stop input for the drive to run again. A Stop
function is provided only when the Stop input is active (open).
2 “Hi-Spd Edge”
IMPORTANT There is greater potential voltage on the output terminals when using this option.
• Outputs are kept in a ready-to-run state. The drive will respond to a Start command within 10 ms.
• I/O Terminal 01 “Stop” = Coast to stop.
• I/O Terminal 03 “Run REV”
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).
• I/O Terminal 01 “Stop” = Stop according to the value set in P045 [Stop Mode].
t069 [Opto Out1 Sel] Related Parameter(s): P046, P048, P050, t070, t073, t077, t082,
t072 [Opto Out2 Sel] t086, t087, t093, t094, t097, A541, A564
Determines the operation of the programmable digital outputs.
Options Setting Output Changes State When... Hysteresis
0 “Ready/Fault” Opto outputs are active when power is applied. Indicates that the drive is ready for operation. Opto outputs are None
inactive when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency. 0.5 Hz above; 1.0 Hz below
2 “MotorRunning” Motor is receiving power from the drive. None
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.
6 “Above Freq” Drive exceeds the frequency (Hz) value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
7 “Above Cur” Drive exceeds the current (% Amps) value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
IMPORTANT Value for t070 or t073 [Opto Outx Level] must be entered in percent of drive rated output
current.
8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
9 “Retries Exst” Value set in A541 [Auto Rstrt Tries] is exceeded. None
10 “Above Anlg V” Analog input voltage (0-10V input) exceeds the value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”.
11 “Above PF Ang” Power Factor angle exceeds the value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
12 “Anlg In Loss” Analog input loss has occurred. Program 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
13 “ParamControl” Output is directly controlled by the state of the t070 or t073 [Opto Outx Level]. A value of 0 causes the output to None
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 Motor 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
18 “Local Active” Active when drive P046, P048 or P050 [Start Source x] is in local keypad control. None
19 “Comm Loss” Active when communication is lost from any comm source with reference or control. None
20 “Logic In 1” An input is programmed as “Logic Input 1” and is active. None
21 “Logic In 2” An input is programmed as “Logic Input 2” and is active. None
22 “Logic 1 & 2” Both Logic inputs are programmed and active. None
23 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is active. None
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 t070 or t073 [Opto Outx Level] or not timing. None
26 “Counter Out” Counter has reached the value set in t070 or t073 [Opto Outx Level] or not counting. None
27 “At Position” Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with A564 [Encoder –
Pos Tol].
28 “At Home” Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 [Encoder Pos Tol]. –
29 “Safe-Off” Both safe-off inputs are active. –
Values Default:
Opto Out1 Sel: 2
Opto Out2 Sel: 1
Min/Max: 0/29
Display: 1
Values Default: 0
Min/Max: 0/9999
Display: 1
Values Default: 0
Min/Max: 0/3
Display: 1
IMPORTANT Value for t077 or t082 [Relay Outx Level] must be entered in percent of drive rated output
current.
8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t077 or t082 [Relay Outx Level]. 100 ms time delay on or off
9 “Retries Exst” Value set in A541 [Auto Rstrt Tries] is exceeded. None
10 “Above Anlg V” Analog input voltage (0-10V input) exceeds the value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”.
11 “Above PF Ang” Power Factor angle exceeds the value set in t077 or t082 [Relay Outx Level]. 100 ms time delay on or off
12 “Anlg In Loss” Analog input loss has occurred. Program 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
13 “ParamControl” Output will be directly controlled by the state of the t077 or t082 [Relay Outx Level]. A value of 0 causes the output None
to 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 Motor 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
18 “Local Active Active when drive P046, P048 or P050 [Start Source x] is in local keypad control. None
19 “Comm Loss” Active when communication is lost from any comm source with reference or control. None
20 “Logic In 1” An input is programmed as “Logic Input 1” and is active. None
21 “Logic In 2” An input is programmed as “Logic Input 2” and is active. None
22 “Logic 1 & 2” Both Logic inputs are programmed and active. None
23 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is active. None
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 or t082 [Relay Outx Level] or not timing. None
26 “Counter Out” Counter has reached the value set in t077 or t082 [Relay Outx Level] or not counting. None
27 “At Position” Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with A564 [Encoder –
Pos Tol].
28 “At Home” Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 [Encoder Pos Tol]. –
29 “Safe-Off” Both safe-off inputs are active. –
Values Default:
Relay Out1 Sel: 0
Relay Out2 Sel: 2
Min/Max: 0/29
Display: 1
Values Default: 0
Min/Max: 0/9999
Display: 1
pd
ece
pa
l
Ram
[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Values Default: 2.00 s
Min/Max: 0.00/10.00 s
Display: 0.01 s
l
cce
pd
ece
pa
Ram l
[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Values Default: 2.00 s
Min/Max: 0.00/10.00 s
Display: 0.01 s
Values Default: 0
Min/Max: 0/23
Display: 1
ATTENTION: Enabling the Sleep-Wake function can cause unexpected machine operation during the Wake mode. Equipment damage and/or personal injury
can result if this parameter is used in an inappropriate application. In addition, all applicable local, national and international codes, standards, regulations or
industry guidelines must be considered.
Communications Group
C121 [Comm Write Mode]
Saves parameter values in active drive memory (RAM) or in drive non-volatile memory (EEPROM).
ATTENTION: If Automatic Drive Configuration (ADC) is used, this parameter must remain at its default value of 0 “Save”.
IMPORTANT Parameter values set prior to setting 1 “RAM only” are saved in RAM.
IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the RS485 port.
Values Default: 0
Min/Max: 0/255
Display: 1
Values Default: 0
Min/Max: 0/255
Display: 1
Values Default: 0
Min/Max: 0/255
Display: 1
C143 [EN Comm Flt Actn] Related Parameter(s): P045, C145, C146, C147-C150
Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that Ethernet communications have been disrupted.
IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the EtherNet/IP interface.
ATTENTION: Risk of injury or equipment damage exists. Parameter C143 [EN Comm Flt Actn] lets you determine the action of the EtherNet/IP interface and
connected drive if communications are disrupted. By default, this parameter faults the drive. You can set this parameter so that the drive continues to run.
Precautions should be taken to ensure that the setting of this parameter does not create a risk of injury or equipment damage. When commissioning the drive,
verify that your system responds correctly to various situations (for example, a disconnected drive).
Logic Group
L180 [Stp Logic 0] L181 [Stp Logic 1] Related Parameter(s):
L182 [Stp Logic 2] L183 [Stp Logic 3]
L184 [Stp Logic 4] L185 [Stp Logic 5]
L186 [Stp Logic 6] L187 [Stp Logic 7]
Stop drive before changing this parameter.
Values Default: 00F1
Min/Max: 0000/FAFF
Display 0001
See Appendix D and Appendix E for more information on applying Step Logic and Position StepLogic.
Parameters L180...L187 are only active if P047, P049, or P051 [Speed Referencex] is set to 13 “Step Logic” or 16 “Positioning”. These parameters can be used to create a custom profile of
frequency commands. Each “step” can be based on time, status of a Logic input or a combination of time and the status of a Logic input.
Digits 1...4 for each [Stp Logic x] parameter must be programmed according to the desired profile. A Logic input is established by setting a digital input, parameters t062, t063,
t065...t068 [DigIn TermBlk xx] to 24 “Logic In 1” and/or 25 “Logic In 2” or by using Bits 6 and 7 of A560 [Enh Control Word].
A time interval between steps can be programmed using parameters L190...L197 [Stp Logic Time x]. See the table below for related parameters.
The speed for any step is programmed using parameters A410...A417 [Preset Freq x].
Step StepLogic Parameter 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)
0 L180 [Stp Logic 0] A410 [Preset Freq 0] L190 [Stp Logic Time 0]
1 L181 [Stp Logic 1] A411 [Preset Freq 1] L191 [Stp Logic Time 1]
2 L182 [Stp Logic 2] A412 [Preset Freq 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]
5 L185 [Stp Logic 5] A415 [Preset Freq 5] L195 [Stp Logic Time 5]
6 L186 [Stp Logic 6] A416 [Preset Freq 6] L196 [Stp Logic Time 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
0 L200 [Step Units 0] & L201 [Step Units F 0]
1 L202 [Step Units 1] & L203 [Step Units F 1]
2 L204 [Step Units 2] & L205 [Step Units F 2]
3 L206 [Step Units 3] & L207 [Step Units F 3]
4 L208 [Step Units 4] & L209 [Step Units F 4]
5 L210 [Step Units 5] & L211 [Step Units F 5]
6 L212 [Step Units 6] & L213 [Step Units F 6]
7 L214 [Step Units 7] & L215 [Step Units F 7]
How StepLogic Works
The StepLogic sequence begins with a valid start command. A normal sequence always begins with L180 [Stp Logic 0].
Digit 1: Logic for next step
This digit defines the logic for the next step. When the condition is met the program advances to the next step. Step 0 follows Step 7. Example: Digit 1 is set to 3. When “Logic In 2”
becomes active, the program advances to the next step.
Digit 2: Logic to jump to a different step
For all settings other than F, when the condition is met, the program overrides Digit 0 and jumps to the step defined by Digit 3.
Digit 3: Different step to jump
When the condition for Digit 2 is met, this digit setting determines the next step or to end the program.
Digit 4: Step settings
This digit defines additional characteristics of each step.
Any StepLogic parameter can be programmed to control a relay or opto output, but you can not control different outputs based on the condition of different StepLogic commands.
StepLogic Settings
The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. See Appendix D for more
information.
Values Defaults:
Preset Freq 0: 0.00 Hz
Preset Freq 1: 5.00 Hz
Preset Freq 2: 10.00 HZ
Preset Freq 3: 20.00 Hz
Preset Freq 4: 30.00 Hz
Preset Freq 5: 40.00 Hz
Preset Freq 6: 50.00 Hz
Preset Freq 7...15: 60.00 Hz
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz
IMPORTANT Frequency is not written to non-volatile storage until drive is powered-down. If both MOP Up and MOP Down are applied at the same time, the inputs are
ignored and the frequency is unchanged.
Volts/Speed
Vo
lta
ge Speed
Spee [DC Brake Time]
d
Magnitude Magnitude
depends on depends on
Time [DC Brake Level] Time [DC Brake Level]
Stop Command Stop Command
ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used. This feature should
not be used with synchronous motors. Motors may be demagnetized during braking.
ge
lta
Vo
[DC Brk Time@Strt] d
Spee
[DC Brake Level]
Time
Start Command
Values Default: 0.0 s
Min/Max: 0.0/99.9 s
Display: 0.1 s
ATTENTION: Equipment damage may result if this parameter is set to a value that causes the dynamic braking resistor to dissipate excessive power. Parameter
settings less than 100% should be carefully evaluated to ensure that the Dynamic Brake resistor's wattage rating is not exceeded. In general, values less than
90% are not needed. This parameter's setting is especially important if parameter A437 [DB Resistor Sel] is set to 2 “NoProtection”.
88
84
80
76
72
68
64
60
56
50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Carrier Frequency (kHz)
IMPORTANT Ignoring derating guidelines can cause reduced drive performance. The drive may automatically reduce the PWM carrier frequency at low output speeds,
unless prevented from doing so by A540 [Var PWM Disable].
Dec
n
o
rati
ele
Speed
ele
ra
tion
A cc
0
[Accel Time x] Time [Decel Time x]
0
Values Default: 10.00 s
Min/Max: 0.00/600.00 s
Display: 0.01 s
Time
Values Default: 0.0 Hz
Min/Max: 0.0/30.0 Hz
Display: 0.1 Hz
% of [Motor OL Curent]
% of [Motor OL Curent]
80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
% of [Motor NP Hertz] % of [Motor NP Hertz] % of [Motor NP Hertz]
Options 0 “No Derate” (Default)
1 “Min. Derate”
2 “Max. Derate”
A509 [Speed Reg Sel] Related Parameter(s): A521, A522, A523, A524, A525, A526
Determines if PI gain of the “Vector” control mode speed regulator is set automatically or manually. Parameters A521...A526 are set automatically by this parameter.
See the control diagrams in Appendix I for more information.
Options 0 “Automatic” (Default)
1 “Manual”
A510 [Freq 1]
A512 [Freq 2]
A514 [Freq 3]
Sets the “Vector” control mode frequency. See the control diagrams in Appendix I for more information.
Values Default:
Freq 1: 8.33%
Freq 2: 15.00%
Freq 3: 20.00%
Min/Max: 0.00/200.00%
Display: 0.01%
Settings
5...14
% [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 functions as a limit only If it is > [Motor NP Hertz] then it defines a
(does not change the V/Hz curve) point on the V/Hz curve
[Motor NP Volts]
Voltage
[Break Voltage]
[Start Boost]
Frequency
[Break Frequency] [Motor NP Hertz]
[Minimum Freq] [Maximum Freq]
Values Default: 2.5%
Min/Max: 0.0/25.0%
Display: 0.1%
A532 [Break Voltage] Related Parameter(s): P031, P032, P039, A530, A533
Sets the voltage (in percent of [Base Frequency]) at the A533 [Break Frequency] if A530 [Boost Select] is set to 0 “Custom V/Hz”.
Values Default: 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 A532 [Break Voltage] is applied if A530 [Boost Select] is set to 0 “Custom V/Hz”.
Values Default: 15.0 Hz
Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz
ATTENTION: The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against
possible unintended speed or motion.
ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without
considering applicable local, national and international codes, standards, regulations or industry guidelines.
Values Default: 0
Min/Max: 0/9
Display: 1
ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without
considering applicable local, national and international codes, standards, regulations or industry guidelines.
ATTENTION: To guard against drive damage, a minimum line impedance must be provided to limit inrush current when the power line recovers. The input
impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive's input VA rating if Half Bus is enabled.
A555 [Reset Meters] Related Parameter(s): b019, b021, b022, b023, b024,
b025, b026, d362, d363
Resets the values stored in the parameters that track fault times and energy usage.
Options 0 “Ready/Idle” (Default)
1 “Reset Meters” Resets kWh, MWh, Accum kWh, Cost, and CO2 Sav parameter values.
2 “Reset Time” Resets min, hr, and x10 hr.
ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without
considering applicable local, national and international codes, standards, regulations or industry guidelines.
[P Jump]
[Max Traverse]
[Output Freq]
Hertz
Traverse Bit
[Fiber Status]
A571 [Sync Time] Related Parameter(s): t062, t063, t065 - t068, A560
Enables the function that holds the drive at the current frequency even if the commanded frequency changes. Used with t062, t063, t065-t068 [DigIn TermBlk xx] 32 “Sync Enable”.
[Sync Time]
New Drive #2 Reference
Hertz
Network Parameter Group This group contains parameters for the network option card that is installed.
Refer to the network option card’s user manual for more information on the
available parameters.
Modified Parameter Group This group contains parameters that have their values changed from the factory
default.
When a parameter has its default value changed, it is automatically added to this
group. When a parameter has its value changed back to the factory default, it is
automatically removed from this group.
AppView Parameter Groups PowerFlex 525 drives include various AppView parameter groups that groups
certain parameters together for quick and easy access based on different types of
applications. These applications include:
• Conveyor
• Mixer
• Compressor
• Centrifugal Pump
• Blower/Fan
• Extruder
• Positioning
• Textile/Fiber
You cannot add or remove parameters to or from the AppView parameter groups.
If you require quick access to additional parameters to what is already included in
the different AppView parameter groups, use the CustomView parameter group
instead.
The parameters in the AppView parameter groups can be quickly added to the
CustomView parameter group by doing the following:
Step Key(s) Example Displays
1. Press the Up Arrow or Down Arrow to scroll to
an AppView group (G1...G8). or
FWD
PROGRAM
or Sel
PROGRAM
TIP The Connected Components Workbench software can be used to speed up this
process with drag and drop functionality.
Notes:
Troubleshooting
ATTENTION: Risk of injury or equipment damage exists. Drive does not contain
user-serviceable components. Do not disassemble drive chassis.
Drive Status The condition or state of your drive is constantly monitored. Any changes will be
indicated through the integral LCD display.
See Display and Control Keys on page 49 for information on drive status
indicators and controls.
Faults A fault is a condition that stops the drive. There are two fault types.
Fault Types
Type Fault Description
1 Auto-Reset/Run When this type of fault occurs, and A541 [Auto Rstrt Tries] is set to a value greater than
“0,” a user-configurable timer, A542 [Auto Rstrt Delay], begins. When the timer reaches
zero, the drive attempts to automatically reset the fault. If the condition that caused the
fault is no longer present, the fault will be reset and the drive will be restarted.
2 Non-Resettable This type of fault may require drive or motor repair, or is caused by wiring or programming
errors. The cause of the fault must be corrected before the fault can be cleared.
Fault Indication
Condition Display
Drive is indicating a fault.
The integral LCD display provides visual notification of a fault condition by displaying the FWD
following.
• Flashing fault number
• Flashing fault indicator (LED) FAULT
Esc Sel
The Auto Restart feature provides the ability for the drive to automatically
perform a fault reset followed by a start attempt without user or application
intervention. This allows remote or “unattended” operation. Only certain faults
are allowed to be reset. Certain faults (Type 2) that indicate possible drive
component malfunction are not resettable. Fault types are listed in the table
Fault Types on page 133. See Fault Descriptions on page 135 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.
Common Symptoms and The drive is designed to start from the keypad when shipped. For a basic test of
drive operation:
Corrective Actions
1. Remove all user I/O wire.
2. Verify safety terminals (S1, S2 and S+) jumper is in place and tightened.
3. Verify wire jumper is in place between I/O terminals 01 and 11.
4. Verify that the three jumpers are in their proper default positions on the
control board. See Control I/O Wiring Block Diagram on page 32 for
more information.
5. Reset default parameter values by setting P053 [Reset Defalts] to 2
“Factory Rset”.
6. If safe to do so for your application, press Start on drive keypad. Drive will
run according to the speed potentiometer.
Drive does not Start from Start or Run Inputs wired to the terminal
block.
Cause(s) Indication Corrective Action
Drive is Faulted Flashing red status light Clear fault.
• Press Stop if P045 [Stop Mode] is set to a value between “0” and “3”.
• Cycle drive power.
• Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”.
• Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to
13 “Clear Fault”.
Incorrect programming. None Check parameter settings.
• P046, P048, P050 [Start Source x] is set incorrectly.
• t062, t063 [DigIn TermBlk 02/03] is set incorrectly.
Incorrect input wiring. None • Wire inputs correctly and/or install jumper.
See page 34 for wiring examples. • If the PowerFlex 525 Safe-Torque-Off function is used, verify that inputs are active.
• 2 wire control requires Run Forward, Run Reverse or Jog
input.
• 3 wire control requires Start and Stop inputs
• Stop input is always required.
Incorrect Sink/Source jumper setting. None Set switch to match wiring scheme.
Notes:
Drives, Fuse & Circuit Breaker The tables found in Fuses and Circuit Breakers on page 18 provide drive ratings
and recommended AC line input fuse and circuit breaker information. Both
Ratings types of short circuit protection are acceptable for UL and IEC requirements.
Sizes listed are the recommended sizes based on 40 degree C and the U.S.
N.E.C. Other country, state or local codes may require different ratings.
Fusing
Circuit Breakers
Category Specifications
Protection 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)
Power Ride-Thru: 100 ms
Logic Control Ride-Thru: 0.5 s minimum, 2 s typical
Electronic Motor Overload Protection: I2t protection – 150% for 60 s, 200% for 3 s (Provides Class
10 protection)
Overcurrent: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Environment Altitude:
Without derating: 1000 m (3300 ft) max.
With derating: Up to 4000 m (13,200 ft) max., with the exception of 600V
drives at 2000 m (6600 ft) max. See Current Derating Curves
on page 13 for derating guidelines.
Max. Surrounding Air Temperature
Without derating: -20...50 °C (-4...122 °F)
With derating: -20...60 °C (-4...140 °F) or -20...70 °C (-4...158 °F) with
optional Control Module Fan kit. See Current Derating
Curves on page 13 for derating guidelines.
Storage Temperature:
Frame A...D: -40...85 °C (-40...185 °F)
Frame E: -40...70 °C (-40...158 °F)
Atmosphere:
IMPORTANT Drive must not be installed in an area where the ambient atmosphere
contains volatile or corrosive gas, vapors or dust. If the drive is not going to be
installed for a period of time, it must be stored in an area where it will not be
exposed to a corrosive atmosphere.
Relative Humidity: 0...95% noncondensing
Shock: Complies with IEC 60068-2-27
Vibration: Complies with IEC 60068-2-6:1995
Category Specifications
Environment Sound Pressure Level (A-weighted) Measurements are taken 1 m from the drive.
Frame A & B: Maximum 53 dBA
Frame C: Maximum 57 dBA
Frame D: Maximum 64 dBA
Frame E: Maximum 68 dBA
Electrical Voltage Tolerance: -15% / +10%
Frequency Tolerance: 47...63 Hz
Input Phases: Three-phase input provides full rating. Single-phase input
provides 35% rating on three-phase drives.
Displacement Power Factor: 0.98 across entire speed range
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit breaker
Transistor Type: Isolated Gate Bipolar Transistor (IGBT)
Control Method Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control,
Economizer SVC motor control and Closed Loop Velocity
Vector Control
Carrier Frequency 2...16 kHz, Drive rating based on 4 kHz
Frequency Accuracy
Digital Input: Within ±0.05% of set output frequency
Analog Input: Within 0.5% of maximum output frequency, 10-Bit
resolution
Analog Output: ±2% of full scale, 10-Bit resolution
Speed Regulation
Open Loop with Slip Compensation: ±1% of base speed across a 80:1 speed range
With Encoder: ±0.3% of base speed across a 80:1 speed range
±0.05% of base speed across a 20:1 speed range
Output Voltage Range: 0V to rated motor voltage
Output Frequency Range: 0...500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes 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
Normal Duty: 110% Overload capability for up to 60 s, 150% for up to 3 s
Heavy Duty: 150% Overload capability for up to 60 s, 180% for up to 3 s
(200% programmable)
Control Inputs Digital Bandwidth: 10 Rad/s for open and closed loop
Quantity: (1) Dedicated for stop
(6) Programmable
Current: 6 mA
Type
Source Mode (SRC): 18...24V = ON, 0...6V = OFF
Sink Mode (SNK): 0...6V = ON, 18...24V = OFF
Analog: Quantity: (2) Isolated, -10-10V 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
Category Specifications
Encoder Type: Incremental, dual channel
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
minimum of 10 mA per channel. Allowable input is DC up to
a maximum frequency of 250 kHz. The encoder I/O
automatically scales to allow 5V, 12V and 24V DC nominal
voltages.
Control Relay: Quantity: (2) 1 Programmable Form A and 1 Programmable Form B
Outputs 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
Analog Quantity: (1) Non-Isolated 0-10V or 4-20 mA
Specification
Resolution: 10-bit
0-10V DC Analog: 1 k ohm minimum
4-20 mA Analog: 525 ohm maximum
PowerFlex 525 Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage Output Current (A) Total Watts Loss
100...120V, 2.5 27.0
50/60 Hz 1-Phase 4.8 53.0
6.0 67.0
200...240V, 2.5 29.0
50/60 Hz 1-Phase 4.8 50.0
8.0 81.0
11.0 111.0
200...240V, 2.5 29.0
50/60 Hz 1-Phase 4.8 53.0
w/ EMC Filter
8.0 84.0
11.0 116.0
200...240V, 2.5 29.0
50/60 Hz 3-Phase 5.0 50.0
8.0 79.0
11.0 107.0
17.5 148.0
24.0 259.0
32.2 323.0
48.3 584.0
62.1 708.0
PowerFlex 525 Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage Output Current (A) Total Watts Loss
380...480V, 1.4 27.0
50/60 Hz 3-Phase 2.3 37.0
4.0 80.0
6.0 86.0
10.5 129.0
13.0 170.0
17.0 221.0
24.0 303.0
30.0 387.0
380...480V, 1.4 27.0
50/60 Hz 3-Phase 2.3 37.0
w/ EMC Filter
4.0 81.0
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
525...600V, 0.9 22.0
50/60 Hz 3-Phase 1.7 32.0
3.0 50.0
4.2 65.0
6.6 95.0
9.9 138.0
12.0 164.0
19.0 290.0
22.0 336.0
27.0 466.0
32.0 562.0
25B - V 2P5 N 1 0 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Version
EMC Plates
Frame
Item Description Size Catalog No.
EMC Plate Optional grounding plate for shielded cables. A 25-EMC1-FA
B 25-EMC1-FB
C 25-EMC1-FC
D 25-EMC1-FD
E 25-EMC1-FE
Replacement Parts
PowerFlex 520-Series Power Module
Item Description
PowerFlex 525 Power Replacement power module for use with PowerFlex 520-Series drives. Includes:
Module • Power Module
• Power Module Front Cover
• Power Terminal Guard
• Heatsink Fan
Output Ratings
Normal Duty Heavy Duty Output Input Frame
HP kW HP kW Current (A) Voltage Range Size Catalog No.
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.5 0.4 0.5 0.4 2.5 85...132 A 25-PM1-V2P5
1.0 0.75 1.0 0.75 4.8 85...132 B 25-PM1-V4P8
1.5 1.1 1.5 1.1 6.0 85...132 B 25-PM1-V6P0
200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM1-A2P5
1.0 0.75 1.0 0.75 4.8 170...264 A 25-PM1-A4P8
2.0 1.5 2.0 1.5 8.0 170...264 B 25-PM1-A8P0
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
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM2-A2P5
1.0 0.75 1.0 0.75 4.8 170...264 A 25-PM2-A4P8
2.0 1.5 2.0 1.5 8.0 170...264 B 25-PM2-A8P0
3.0 2.2 3.0 2.2 11.0 170...264 B 25-PM2-A011
200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output
0.5 0.4 0.5 0.4 2.5 170...264 A 25-PM1-B2P5
1.0 0.75 1.0 0.75 5.0 170...264 A 25-PM1-B5P0
2.0 1.5 2.0 1.5 8.0 170...264 A 25-PM1-B8P0
3.0 2.2 3.0 2.2 11.0 170...264 A 25-PM1-B011
5.0 3.7 5.0 3.7 17.5 170...264 B 25-PM1-B017
7.5 5.5 7.5 5.5 24.0 170...264 C 25-PM1-B024
10.0 7.5 10.0 7.5 32.2 170...264 D 25-PM1-B032
15.0 11.0 15.0 11.0 48.3 170...264 E 25-PM1-B048
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
0.5 0.4 0.5 0.4 1.4 323...528 A 25-PM1-D1P4
1.0 0.75 1.0 0.75 2.3 323...528 A 25-PM1-D2P3
2.0 1.5 2.0 1.5 4.0 323...528 A 25-PM1-D4P0
3.0 2.2 3.0 2.2 6.0 323...528 A 25-PM1-D6P0
5.0 4.0 5.0 4.0 10.5 323...528 B 25-PM1-D010
7.5 5.5 7.5 5.5 13.0 323...528 C 25-PM1-D013
10.0 7.5 10.0 7.5 17.0 323...528 C 25-PM1-D017
15.0 11.0 15.0 11.0 24.0 323...528 D 25-PM1-D024
20.0 15.0 15.0 11.0 30.0 323...528 D 25-PM1-D030
380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output
0.5 0.4 0.5 0.4 1.4 323...528 A 25-PM2-D1P4
1.0 0.75 1.0 0.75 2.3 323...528 A 25-PM2-D2P3
2.0 1.5 2.0 1.5 4.0 323...528 A 25-PM2-D4P0
3.0 2.2 3.0 2.2 6.0 323...528 A 25-PM2-D6P0
Output Ratings
Normal Duty Heavy Duty Output Input Frame
HP kW HP kW Current (A) Voltage Range Size Catalog No.
5.0 4.0 5.0 4.0 10.5 323...528 B 25-PM2-D010
7.5 5.5 7.5 5.5 13.0 323...528 C 25-PM2-D013
10.0 7.5 10.0 7.5 17.0 323...528 C 25-PM2-D017
15.0 11.0 15.0 11.0 24.0 323...528 D 25-PM2-D024
20.0 15.0 15.0 11.0 30.0 323...528 D 25-PM2-D030
25.0 18.5 20.0 15.0 37.0 323...528 E 25-PM2-D037
30.0 22.0 25.0 18.5 43.0 323...528 E 25-PM2-D043
525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output
0.5 0.4 0.5 0.4 0.9 446...660 A 25-PM1-E0P9
1.0 0.75 1.0 0.75 1.7 446...660 A 25-PM1-E1P7
2.0 1.5 2.0 1.5 3.0 446...660 A 25-PM1-E3P0
3.0 2.2 3.0 2.2 4.2 446...660 A 25-PM1-E4P2
5.0 3.7 5.0 3.7 6.6 446...660 B 25-PM1-E6P6
7.5 5.5 7.5 5.5 9.9 446...660 C 25-PM1-E9P9
10.0 7.5 10.0 7.5 12.0 446...660 C 25-PM1-E012
15.0 11.0 15.0 11.0 19.0 446...660 D 25-PM1-E019
20.0 15.0 15.0 11.0 22.0 446...660 D 25-PM1-E022
25.0 18.5 20.0 15.0 27.0 446...660 E 25-PM1-E027
30.0 22.0 25.0 18.5 32.0 446...660 E 25-PM1-E032
Other Parts
Frame
Item Description Size Catalog No.
PowerFlex 525 Control Replacement cover for the control module I/O terminals, A...E 25B-CTMFC1
Module Front Cover EtherNet/IP and DSI ports.
PowerFlex 520-Series Replacement cover for the PowerFlex 520-Series power B 25-PMFC-FB
Power Module Front Cover module. C 25-PMFC-FC
D 25-PMFC-FD
E 25-PMFC-FE
PowerFlex 520-Series Replacement finger guard for power terminals. A 25-PTG1-FA
Power Terminal Guard B 25-PTG1-FB
C 25-PTG1-FC
D 25-PTG1-FD
E 25-PTG1-FE
PowerFlex 520-Series Replacement fan for drive power module. A 25-FAN1-FA
Heatsink Fan Kit B 25-FAN1-FB
C 25-FAN1-FC
D 25-FAN1-FD
E 25-FAN1-FE
Product Dimensions The PowerFlex 525 drive is available in five frame sizes. See PowerFlex 525 Drives
on page 149 for information on power ratings.
152.0 (5.98)
Esc Sel
140.0 (5.51)
92.7 (3.65)
6.0 (0.24)
Esc Sel
168.0 (6.61)
92.7 (3.65)
6.0 (0.24)
220.0 (8.66)
Esc Sel
207.0 (8.15)
92.7 (3.65)
6.0 (0.24)
Esc Sel
247.0 (9.72)
6.0 (0.24)
300.0 (11.81)
Esc Sel
280.0 (11.02)
7.6 (0.30)
32.0 (1.26)
32.0 (1.26)
32.0 (1.26)
72.0 (2.83) 87.0 (3.43) 109.0 (4.29)
57.5 (2.26) 72.5 (2.85) 90.5 (3.56)
220.0 (8.66)
180.0 (7.09)
152.0 (5.98)
168.0 (6.61)
207.0 (8.15)
140.0 (5.51)
Frame D Frame E
196.0 (7.72)
32.0 (1.26)
52.0 (2.05)
260.0 (10.24)
Esc Sel
Esc Sel
300.0 (11.81)
247.0 (9.72)
280.0 (11.02)
15.0 (0.59)
72.0 (2.83) IP 30/NEMA 1/ UL Type 1 top panel
219.0 (8.62)
Esc Sel
152.0 (5.98)
92.7 (3.65)
140.0 (5.51) 6.0 (0.24)
51.1 (2.01)
IP 30/NEMA 1/ UL Type 1 conduit box
21.0 (0.82)
ø21.5 (ø0.85)
135.4 (5.33)
111.9 (4.41)
88.2 (3.47)
64.7 (2.55)
15.0 (0.59)
87.0 (3.43) IP 30/NEMA 1/ UL Type 1 top panel
218.0 (8.58)
Esc Sel
180.0 (7.09)
168.0 (6.61)
92.7 (3.65)
6.1 (0.24)
66.1 (2.60)
IP 30/NEMA 1/ UL Type 1 conduit box
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)
15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
109.0 (4.29)
90.5 (3.56) 184.0 (7.24)
255.0 (10.04)
Esc Sel
222.0 (8.66)
207.0 (8.15)
92.7 (3.65)
6.0 (0.24)
80.5 (3.17)
IP 30/NEMA 1/ UL Type 1 conduit box
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)
15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
130.0 (5.12) 212.0 (8.35)
116.0 (4.57)
295.0 (11.61)
Esc Sel
260.0 (10.24)
247.0 (9.72)
6.0 (0.24)
ø21.5 (ø0.85)
ø33.5 (ø1.32)
153.3 (6.04)
109.8 (4.32)
15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
185.0 (7.28)
160.0 (6.30) 279.0 (10.98)
350.0 (13.78)
Esc Sel
300.0 (11.81)
280.0 (11.02)
7.6 (0.30)
ø21.5 (ø0.85)
ø43.7 (ø1.72)
212.0 (8.35)
181.0 (7.13)
164.0 (6.46)
234.0
223.0 (9.21) 223.0
(8.78) (8.78)
270.0
(10.63)
258.0 258.0
(10.16) (10.16)
275.0
(10.83)
263.0 263.0
(10.35) (10.35)
310.0
(12.20)
298.0 298.0
(11.73) (11.73)
390.0
(15.35)
375.0 375.0
(14.76) (14.76)
Communication
adapter interface
connector
Communication
adapter interface
connector
1. Insert a finger into the slot at the top of the back cover. Lift to separate the
back cover from the Control Module.
Notes:
PowerFlex 525 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 525 drives can be
multi-dropped on an RS485 network using Modbus protocol in RTU mode.
Controller
Network Wiring Network wiring consists of a shielded 2-conductor cable that is daisy-chained
from node to node.
ATTENTION: Never attempt to connect a Power over Ethernet (PoE) cable to the
RS485 port. Doing so may damage the circuitry.
AK-00-RJ45-TB2P
TxRxD- TxRxD-
TxRxD+ TxRxD+
L1/R L2/S L3/T T1/U T2/V T3/W L1/R L2/S L3/T T1/U T2/V T3/W
IMPORTANT The shield is connected at ONLY ONE end of each cable segment.
Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the
PowerFlex 525 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.
I/O Terminal C1 (RJ45 Shield) on the PowerFlex 525 drive must also be
connected to PE ground (there are two PE terminals on the drive). See Control
I/O Terminal Designations on page 33 for more information.
Parameter Configuration The following PowerFlex 525 parameters are used to configure the drive to
operate on a DSI network.
Configuring Parameters for DSI Network
Parameter Details Reference
P046 [Start Source 1] Set to 3 “Serial/DSI” if Start is controlled from the network. page 71
P047 [Speed Reference1] Set to 3 “Serial/DSI” if the Speed Reference is controlled from the network. page 72
C123 [RS485 Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes on the network must be page 85
set to the same data rate.
C124 [RS485 Node Addr] Sets the node address for the drive on the network. Each device on the page 85
network requires a unique node address.
C125 [Comm Loss Action] Selects the drive’s response to communication problems. page 85
C126 [Comm Loss Time] Sets the time that the drive will remain in communication loss before the page 85
drive implements C125 [Comm Loss Action].
C127 [Comm Format] Sets the transmission mode, data bits, parity and stop bits for the RS485 (DSI) page 86
Port. All nodes on the network must be set to the same setting.
C121 [Comm Write Mode] Set to 0 “Save” when programming drive. page 85
Set to 1 “RAM only” to only write to volatile memory.
Supported Modbus Function The peripheral interface (DSI) used on PowerFlex 525 drives supports some of
the Modbus function codes.
Codes
Supported Modbus Function Codes
Modbus Function Code (Decimal) Command
03 Read Holding Registers
06 Preset (Write) Single Register
16 (10 Hexadecimal) Preset (Write) Multiple Registers
Writing (06) Logic Command The PowerFlex 525 drive can be controlled through the network by sending
Function Code 06 writes to register address 2000H (Logic Command). P046
Data [Start Source 1] must be set to 3 “Serial/DSI” in order to accept the commands.
Parameter C122 [Cmd Stat Select] is used to select Velocity or Position Bit
definitions.
TIP Powerup/Reset the drive after selecting an option for C122 [Cmd Stat Select]
for the change to take effect.
Writing (06) Comm The PowerFlex 525 drive Comm Frequency Command can be controlled
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) Used by internal comm modules to control the reference of the drive. In units of
0.01 Hz.
Reading (03) Logic Status The PowerFlex 525 Logic Status data can be read through the network by
sending Function Code 03 reads to register address 2100H (Logic Status).
Data
Parameter C122 [Cmd Stat Select] is used to select Velocity or Position Bit
definitions.
Velocity Bit Definitions
Comm Logic Status – C122 = 0 “Velocity”
Address (Decimal) Bit(s) Description
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 Not Used
7 1 = Faulted, 0 = Not Faulted
8 1 = At Reference, 0 = Not At Reference
9 1 = Main Freq Controlled by Active Comm
10 1 = Operation Cmd Controlled by Active Comm
11 1 = Parameters have been locked
12 Digital Input 1 Status
13 Digital Input 2 Status
14 Digital Input 3 Status
15 Digital Input 4 Status
Reading (03) Drive Error The PowerFlex 525 Error Code data can be read through the network by sending
Function Code 03 reads to register address 2101H (Drive Error Codes).
Codes
Drive Error Codes
Logic Status
Address (Decimal) Value (Decimal) Description
2101H (8449) 0 No Fault
2 Auxiliary Input
3 Power Loss
4 Undervoltage
5 Overvoltage
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
48 Parameters Defaulted
59 Safety Open
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
114 Microprocessor Failure
122 I/O Board Fail
Reading (03) Drive The PowerFlex 525 Drive Operational Values can be read through the network
by sending Function Code 03 reads to register addresses 2102H...210AH.
Operational Values
Drive Operational Values
Reference
Address (Decimal) Description
2102H (8450) Frequency Command (xxx.xx Hz)
2103H (8451) Output Frequency (xxx.xx Hz)
2104H (8452) Output Current (xxx.xx A)
2105H (8453) DC-BUS Voltage (xxxV)
2106H (8454) Output Voltage (xxx.xV)
Reading (03) and Writing To access drive parameters, the Modbus register address equals the parameter
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].
Four PowerFlex 525 logic functions provide the capability to program simple
logic functions without a separate controller.
• Velocity StepLogic™ 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”.
TIP Use the Wizard in Connected Components Workbench to simplify setup instead
of manually configuring the parameters.
Velocity StepLogic Using 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
Timed Steps 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].
Forward
0
Reverse
Time
Velocity StepLogic Using 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
Basic Logic Functions parameters t062...t063, t065...t068 [DigIn TermBlk xx] to 24 “Logic In 1” or
25 “Logic In 2”.
Example
• Run at Step 0.
• Transition to Step 1 when Logic In 1 is true.
Logic senses the edge of Logic In 1 when it transitions from off to on.
Logic In 1 is not required to remain “on”.
• Transition to Step 2 when both Logic In 1 and Logic In 2 are true.
The drive senses the level of both Logic In 1 and Logic In 2 and transitions
to Step 2 when both are on.
Frequency
Logic In 1
Logic In 2
Time
The step time value and the basic logic may be used together to satisfy machine
conditions. For instance, the step may need to run for a minimum time period
and then use the basic logic to trigger a transition to the next step.
Start Step 0 Step 1
Frequency
Logic In 1
Logic In 2
Time
Timer Function Digital inputs and outputs control the timer function and are configured with
parameters t062...t063, t065...t068 [DigIn TermBlk xx] set to 19 “Timer Start”
and 21 “Reset Timer”.
Digital outputs (relay and opto type) define a preset level and indicate when the
level is reached. Level parameters t077 [Relay Out1 Level], t082[Relay Out2
Level], t070 [Opto Out1 Level] and t073 [Opto Out2 Level] are used to set the
desired time in seconds.
Parameters t076 [Relay Out1 Sel], t081 [Relay Out2 Sel], t069 [Opto Out1 Sel]
and t072 [Opto Out2 Sel] are set to 25 “Timer Out” and causes the output to
change state when the preset level is reached.
Example
• Drive starts up and accelerates to 30 Hz.
• After 30 Hz has been maintained for 20 seconds, a 4-20 mA analog input
becomes the reference signal for speed control.
• The timer function is used to select a preset speed with a 20 second run
time that overrides the speed reference while the digital input is active.
• Parameters are set to the following options:
– P047 [Speed Reference1] = 6 “4-20mA Input”
Note that a “Reset Timer” input is not required for this example since the “Timer
Start” input both clears and starts the timer.
Counter Function Digital inputs and outputs control the counter function and are configured with
parameters t062...t063, t065...t068 [DigIn TermBlk xx] set to 20 “Counter In”
and 22 “Reset Countr”.
Digital outputs (relay and opto type) define a preset level and indicate when the
level is reached. Level parameters t077 [Relay Out1 Level], t082[Relay Out2
Level], t070 [Opto Out1 Level] and t073 [Opto Out2 Level] are used to set the
desired count value.
Parameters t076 [Relay Out1 Sel], t081 [Relay Out2 Sel], t069 [Opto Out1 Sel]
and t072 [Opto Out2 Sel] are set to 26 “Counter Out” which causes the output
to change state when the level is reached.
Example
• A photo eye is used to count packages on a conveyor line.
• An accumulator holds the packages until 5 are collected.
• A diverter arm redirects the group of 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
Output
Frequency
Start
Relay Out
Photo Eye
DigIn TermBlk 05
Counter In
DigIn TermBlk 06
Reset Counter
Limit Switch
Digit 3 – Defines what step to jump to or how to end program when the logic conditions specified
in Digit 2 are met.
Setting Logic
0 Jump to Step 0
1 Jump to Step 1
2 Jump to Step 2
3 Jump to Step 3
4 Jump to Step 4
5 Jump to Step 5
6 Jump to Step 6
7 Jump to Step 7
8 End Program (Normal Stop)
9 End Program (Coast to Stop)
A End Program and Fault (F002)
Digit 2 – Defines what logic must be met to jump to a step other than the very next step.
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] parameter. TIMED
2 Step if “Logic In 1” is active (logically true) 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
8 Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR
9 Step if “Logic In 1” is active (logically true) and “Logic In 2” is not active (logically false) XOR
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 Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) TIMED AND
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 Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] parameter. TIMED
2 Step if “Logic In 1” is active (logically true) 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
8 Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR
9 Step if “Logic In 1” is active (logically true) and “Logic In 2” is not active (logically false) XOR
A Step if “Logic In 2” 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 Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) TIMED AND
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 Use logic programmed in Digit 1 IGNORE
Encoder and Pulse Train The PowerFlex 525 drive includes a pulse train input built into the terminal
block, and an encoder option card. The pulse train and encoder can be used for
Usage 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):
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.
IMPORTANT A quadrature encoder provides rotor speed and direction. Therefore, the
encoder must be wired such that the forward direction matches the motor
forward direction. If the drive is reading encoder speed but the position
regulator or other encoder function is not working properly, remove power to
the drive and swap the A and A (NOT) encoder channels or swap any two motor
leads. Drive will fault when an encoder is incorrectly wired and A535 [Motor
Fdbk Type] is set to 5 “Quad Check”.
Common
Power Cm Common Power Source
B- to
+
B SHLD
to SHLD External
A-
Internal (drive) A
Power
Supply
12V DC, 250mA
to SHLD
Wiring Notes The encoder option card can supply 5V or 12V power (250 mA maximum) for
an encoder. Be sure the DIP switch is set properly for the encoder. In general, 12V
will provide higher noise immunity.
The encoder can handle 5V, 12V, or 24V inputs, but the pulse train can handle
only 24V inputs. The inputs will automatically adjust to the voltage applied and
no additional drive adjustment is necessary. If a single-channel input is used, it
must be wired between the A (signal) and A- (signal common) channels.
IMPORTANT A quadrature encoder provides rotor speed and direction. Therefore, the
encoder must be wired such that the forward direction matches the motor
forward direction. If the drive is reading encoder speed but the position
regulator or other encoder function is not working properly, remove power to
the drive and swap the A and A (NOT) encoder channels or 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”.
Positioning Overview The PowerFlex 525 drive includes a simple position regulator which can be used
in a variety of position applications without the need for multiple limit switches
or photo-eyes. This can be used as a 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.
Common Guidelines for All The position regulator can be configured for operation appropriate for a variety
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.
Positioning mode must use A535 [Motor Fdbk Type] option 4.
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.
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.
P035 [Motor NP Poles] must be set to match the number of motor poles on the
motor driven by the PowerFlex 525 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.
Positioning Operation Parameter A558 [Positioning Mode] must be set to properly match the desired
operation of the positioning function.
0 “Time Steps” uses Step Logic times. This mode ignores the Step Logic
settings and moves through the steps (Step 0 to Step 7 and back to Step 0)
based on the times programmed into L190...L197 [Stp Logic Time x].
This can be used when the desired position is based only on time. In
addition, this mode only accepts absolute positions in a positive direction
from “home”. This option provides an easy way to implement a simple
positioning program or to test the basic positioning setup. For additional
flexibility one of the other settings should be used.
IMPORTANT Advanced Step Logic options such as incremental move are not
available in this mode.
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.
In all position modes, the following parameters will control the characteristics at
each step:
L200, L202, L204, L206, L208, L210, L212 and L214 [Step Units x] are the
number value to the left of the decimal (whole number) of the 8 positions desired
for an application, beginning with Step 0 (L200) and continuing with each step
until Step 7 (L214). For example, enter 2 into this parameter if you would like a
commanded position of 2.77.
L201, L203, L205, L207, L209, L211, L213 and L215 [Step Units F x] are the
number value to the right of the decimal (the portion less than 1) of the 8
positions desired for an application, beginning with Step 0 (L201) and
continuing with each step until Step 7 (L215). For example, enter 0.77 into this
parameter if you would like a commanded position of 2.77.
A410...A417 [Preset Freq x] are the parameters that define the maximum
frequency the drive will run at during the corresponding step. For example, if
[Preset Freq 2] is set to 40 Hz, the drive will accelerate to 40 Hz maximum when
moving to Position 2.
Frequency Source Step Source Position Source
A410 [Preset Freq 0] L180 [Stp Logic 0] L200 [Step Units 0]
A411 [Preset Freq 1] L181 [Stp Logic 1] L202 [Step Units 1]
A412 [Preset Freq 2] L182 [Stp Logic 2] L204 [Step Units 2]
A413 [Preset Freq 3] L183 [Stp Logic 3] L206 [Step Units 3]
A414 [Preset Freq 4] L184 [Stp Logic 4] L208 [Step Units 4]
A415 [Preset Freq 5] L185 [Stp Logic 5] L210 [Step Units 5]
A416 [Preset Freq 6] L186 [Stp Logic 6] L212 [Step Units 6]
A417 [Preset Freq 7] L187 [Stp Logic 7] L214 [Step Units 7]
IMPORTANT The default value for A410 [Preset Freq 0] is 0.00 Hz. This value needs to be
changed or the drive will not be able to move during Step 0.
L190...L197 [Stp Logic Time x] are the parameters that define the time the drive
will remain in each corresponding step if that step is time-based. For example, if
L192 [Stp Logic Time 2] is set to 5.0 seconds and that step is time-based, the
drive will remain in Step 2 for 5.0 seconds. Note that this is the total time in that
step, not the time at that position. Therefore, it will include the time needed to
accelerate, run, and decelerate to that position.
L180...L187 [Stp Logic x] are the parameters that allow additional flexibility and
control various aspects of each step when a positioning mode is selected that
utilizes the 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:
TIP Use the Wizard in Connected Components Workbench to simplify setup instead
of manually configuring the parameters.
Note: Incremental move commands will cause the drive to move the amount
specified based on the current position. Absolute commands are always with
reference to “Home”.
A565 [Pos Reg Filter] provides a low pass filter at the input of the position
regulator.
A566 [Pos Reg Gain] is a single adjustment for increasing or decreasing the
responsiveness of the position regulator. For faster response, the filter should be
reduced and/or the gain should be increased. For smoother response with less
overshoot, the filter should be increased and/or the gain should be reduced. In
general, the gain will have a larger effect on most systems than the filter.
Homing Routine This drive supports incremental encoders only. Therefore, when the drive powers
up it will reset the current position to zero. If this is known to be correct the
position routine can be started without further adjustment. However, in most
applications the drive will need to be “homed” after each power-up and prior to
starting the position routine.
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.
Alternately, the “Pos Redefine” bit in A560 [Enh Control Word] can be
toggled instead of utilizing a digital input.
IMPORTANT The “Pos Redefine” input or bit must be returned to inactive before
starting the position routine. Otherwise the drive will continuously read
a position of “0” (home) and the position routine will not function
correctly.
A562 [Find Home Freq] sets the frequency the drive will use while it is
moving to the home position during the automatic homing routine.
A563 [Find Home Dir] sets the direction the drive will use while it is
moving to the home position during the automatic homing routine.
To begin the automatic homing routine, activate the “Find Home” input and
then initiate a valid start command. The drive will then ramp to the speed set in
A562 [Find Home Freq] and in the direction set in A563 [Find Home Dir] until
the digital input defined as “Home Limit” is activated. If the drive passes this
point too quickly it will then reverse direction at 1/10th A562 [Find Home Freq]
to the point where the Home Limit switch reactivates. Approximately one second
after the routine finds home the drive will stop. Alternately, the “Find Home
Freq” and/or “Home Limit” bits in A560 [Enh Control Word] can be activated
instead of utilizing a digital input. The inputs or bits should be returned to
inactive after the routine is complete.
IMPORTANT After the position is reached the drive will stop. If the Find Home is removed
before the homing is complete, the drive will begin running the position
routine without the proper home. In this case Home will not be reset and the
position will be in relation to the power up position.
Encoder and Position d376 [Speed Feedback] indicates the measured speed feedback or the calculated
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).
d378 [Encoder Speed] indicates the measured speed of the feedback device. This
is useful if the encoder is not used for motor speed control. However, the encoder
must be used for some purpose in order for d378 [Encoder Speed] to indicate a
value. Parameter d378 [Encoder Speed] is the number value to the left of the
decimal (whole number) and d379 [Encoder Speed F] is the number to the right
of the decimal (the portion less than 1).
d388, d389 [Units Traveled x] indicate the current position of the system in
terms of units away from Home. Parameter d388 [Units Traveled H] is the
number value to the left of the decimal (whole number) and d389 [Units
Traveled L] is the number to the right of the decimal (the portion less than 1).
d387 [Position Status] indicates the status of the positioning functions. The
indication bits are:
Bit 0 “Dir Positive” indicates the current direction the drive has moved
from Home.
Bit 2 “At Home” indicates whether the drive is at Home. If the drive is
within A564 [Encoder Pos Tol] of “Home”, this bit will be active.
Bit 3 “Drive Homed” indicates whether the drive has been homed since
power-up. This bit will be active once the drive has been homed either
manually or automatically. It will remain active until the next power down.
Use Over Communications If 8 steps are not adequate for the application or if dynamic program changes are
required, many of the positioning functions can be controlled through an active
communication network. The following parameters will allow this control.
IMPORTANT Parameter values set prior to setting 1 “RAM only” are saved in RAM.
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.
Setup Notes The RA computer tool (Connected Components Workbench) can make setup of
the positioning functions much easier. Refer to the latest versions for additional
tools or wizards which can aid in the setup.
Notes:
PID Set Up
PID Loop The PowerFlex 525 drive has two built-in PID (proportional, integral, derivative)
control loops, of which only one can be in use at any time. The PID loop is used
to maintain a process feedback (such as pressure, flow or tension) at a desired set
point. The PID loop works by subtracting the PID feedback from a reference and
generating an error value. The PID loop reacts to the error, based on the PID
Gains, and outputs a frequency to try to reduce the error value to 0. To enable the
PID loop, P047, P049 or P051 [Speed Referencex] must be set to 11 “PID1
Output” or 12 “PID2 Output”, and the corresponding speed reference activated.
Exclusive Control and Trim Control are two basic configurations where the PID
loop may be used.
Exclusive Control
In Exclusive Control, the Speed Reference becomes 0, and the PID Output
becomes the entire Freq Command. Exclusive Control is used when A458 or
A470 [PID x Trim Sel] is set to option 0. This configuration does not require a
master reference, only a desired set point, such as a flow rate for a pump.
PID Loop
PID Ref PID Prop Gain
+ PID + PID
– Error + Output Accel/Decel Freq
PID Fdbk PID Integ Time Ramp Command
+
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.
• 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.
Esc Sel
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
Control is used when A458 or A470 [PID x Trim Sel] is set to any option other
than 0.
[Speed Referencex]
PID Loop Accel/Decel
PID Ref Ramp
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.
• As tension increases or decreases during winding, the Speed Reference is
trimmed to compensate. Tension is maintained near the Equilibrium set
point.
0V
10V
[Speed Referencex]
PID Reference and Feedback PID mode is enabled by setting P047, P049 or P051 [Speed Referencex] to
11 “PID1 Output” or 12 “PID2 Output”, and activating the corresponding speed
reference.
If A459 or A471 [PID x Ref Sel] is not set to 0 “PID Setpoint”, PID can still be
disabled by select programmable digital input options (parameters t062, t063,
t065...t068 [DigIn TermBlk xx]) such as “Purge”.
A459, A471 [PID x Ref Sel] Options
Options Description
0 “PID Setpoint“ A464 or A476 [PID x Setpoint] will be used to set the value of the PID Reference.
1 “Drive Pot” The drive potentiometer will be used to set the value of the PID Reference.
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/DSI 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 will not function with a bipolar 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 “Preset Freq” A410...A425 [Preset Freq x] will be used as an input for the PID Reference.
8 “AnlgIn Multi” The product of the 0-10V and 4-20mA Inputs will be used as an input for the PID Reference.
9 “MOP Freq” A427 [MOP Freq] will be used as an input for the PID Reference.
10 ”Pulse Input” Pulse train will be used as an input for the PID Reference.
11 “Step Logic” Step Logic will be used as an input for the PID Reference.
12 “Encoder” Encoder will be used as an input for the PID Reference.
13 “Ethernet/IP” The reference word from the Ethernet/IP communication network becomes the PID Reference.
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 (default setting). Note that the PID will not function with a bipolar analog
input. It will ignore any negative voltages and treat them like a zero.
1 “4-20mA Input“ Selects the 4-20 mA Input.
2 “Serial/DSI” Serial/DSI will be used as an input for the PID Feedback.
3 “Network Opt” The reference word from a communication network option becomes the PID Reference.
4 “Pulse Input” Pulse train will be used as an input for the PID Feedback.
5 “Encoder” Encoder will be used as an input for the PID Feedback.
6 “Ethernet/IP” Ethernet/IP will be used as an input for the PID Feedback.
Analog PID Reference Signals Parameters t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] are used to
scale or invert an analog PID Reference or PID Feedback.
Scale Function
For a 0...5V signal, the following parameter settings are used so that a 0V signal =
0% PID Reference and a 5V signal = 100% PID Reference.
• t091 [Anlg In 0-10V Lo] = 0.0%
• t092 [Anlg In 0-10V Hi] = 50.0%
Input Volts
6
4
2
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
Invert Function
For a 4-20 mA signal, the following parameter settings are used so that a 20 mA
signal = 0% PID Reference and a 4 mA signal = 100% PID Reference.
• t092 [Anlg In4-20mA Lo] = 100.0%
• t096 [Anlg In4-20mA Hi] = 0.0%
• A459 [PID 1 Ref Sel] = 6 “4-20mA Input”
24
20
4-20 mA Input
16
12
8
4
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
PID Deadband
Parameters A465 and A477 [PID x Deadband] are used to set a range, in percent,
of the PID Reference that the drive will ignore.
Example
• A465 [PID 1 Deadband] = 5.0%
• The PID Reference is 25.0%
• The PID Regulator will not act on a PID Error that falls between 20.0 and
30.0%
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
Freq Cmd
PID Pre-load Value > 0
PID Limits
A456 and A468 [PID x Trim Hi] and A457 and A469 [PID x Trim Lo] are used
to limit the PID output and are only used in trim mode. [PID x Trim Hi] sets the
maximum frequency for the PID output in trim mode. [PID x Trim Lo] sets the
reverse frequency limit for the PID output in trim mode. Note that when the
PID reaches the Hi or Lo limit, the PID regulator stops integrating so that
windup does not occur.
PID Gains
The proportional, integral, and differential gains make up the PID regulator.
• A461 and A473 [PID x Prop Gain]
The proportional gain (unitless) affects how the regulator reacts to the
magnitude of the error. The proportional component of the PID regulator
outputs a speed command proportional to the PID error. For example, a
proportional gain of 1 would output 100% of max frequency when the
PID error is 100% of the analog input range. A larger value for [PID x
Prop Gain] makes the proportional component more responsive, and a
smaller value makes it less responsive. Setting [PID x Prop Gain] to 0.00
disables the proportional component of the PID loop.
• A462 and A474 [PID x Integ Time]
The integral gain (units of seconds) affects how the regulator reacts to
error over time and is used to get rid of steady state error. For example, with
an integral gain of 2 seconds, the output of the integral gain component
would integrate up to 100% of max frequency when the PID error is 100%
for 2 seconds. A larger value for [PID x Integ Time] makes the integral
component less responsive, and a smaller value makes it more responsive.
Setting [PID x Integ Time] to 0.0 disables the integral component of the
PID loop.
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
PID Reference
PID Feedback
Time
PID Reference
PID Feedback
Time
PID Reference
PID Feedback
Time
Notes:
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.
For information on... See page...
PowerFlex 525 Safe-Torque-Off Overview 207
EC Type Examination Certification 208
EMC Instructions 208
Using PowerFlex 525 Safe-Torque-Off 208
Enabling PowerFlex 525 Safe-Torque-Off 211
Wiring 211
Verify Operation 212
PowerFlex 525 Safe-Torque-Off Operation 211
Connection Examples 213
PowerFlex 525 Certification for Safe-Torque-Off 217
IMPORTANT The function is suitable for performing mechanical work on the drive system or
affected area of a machine only. It does not provide electrical safety.
ATTENTION: Electric Shock Hazard. Verify that all sources of AC and DC power
are de-energized and locked out or tagged out in accordance with the
requirements of ANSI/NFPA 70E, Part II.
To avoid an electric shock hazard, verify that the voltage on the bus capacitors has
discharged before performing any work on the drive. Measure the DC bus voltage
at the +DC and -DC terminals or test points (refer to your drive’s User Manual for
locations). The voltage must be zero.
In safe-off mode, hazardous voltages may still be present at the motor. To avoid an
electric shock hazard, disconnect power to the motor and verify that the voltage is
zero before performing any work on the motor.
EC Type Examination TÜV Rheinland has certified the PowerFlex 525 Safe-Torque-Off function
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 13849-1:2008 Safety of machinery – Safety related parts of
control systems – Part 1: General principles for design.
(PowerFlex 525 STO achieves Category 3 / PL(d))
• EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part
5-2 Safety requirements – Functional.
(PowerFlex 525 STO achieves SIL CL 2)
• EN 62061:2005 Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control systems.
• IEC 61508 Part 1-7:2010 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.
Using PowerFlex 525 Safe- The PowerFlex 525 Safe-Torque-Off function is intended to be part of the safety
related control system of a machine. Before use, a risk assessment should be
Torque-Off 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.
Safety Concept The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety
applications up to and including Category 3 / PL(d) according to
EN ISO 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.
ATTENTION: When designing your system, consider how personnel will exit
the machine if the door locks while they are in the machine. Additional
safeguarding devices may be required for your specific application.
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 calculations are based on the equations from Part 6 of EN 61508.
This table provides data for a 20-year proof test interval and demonstrates the
worst-case effect of various configuration changes on the data.
The safety reaction time from an input signal condition that triggers a safe stop,
to the initiation of the configured Stop Type, is 100 ms (maximum).
S1 S2 S+ 11 12 13 14 15 16 17 18 19
See I/O Wiring on page 30 for wiring recommendations and Control I/O
Terminal Designations on page 33 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.
PowerFlex 525 Safe-Torque- The PowerFlex 525 Safe-Torque-Off function disables the drive’s output IGBT’s
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.
Under normal drive operation, both safety inputs (Safety 1 and Safety 2) are
energized, and the drive is able to run. If either input is de-energized, the gate
control circuit becomes disabled. To meet EN ISO 13849 operation, both safety
channels must be de-energized. Refer to the following examples for more
information.
Verify Operation Test the safety function for proper operation after the initial setup of the
PowerFlex 525 Safe-Torque-Off function. Retest the safety function at the
intervals determined by the safety analysis described on page 208.
Verify that both safety channels are functioning according to the table below.
Channel Operation and Verification
Safety Function Drive In Drive In Drive In Drive
Status Safe State Safe State Safe State Able To Run
Drive Status Configured by t105 Fault F111 Fault F111 Ready/Run
[Safety Open En] (Safety Hardware) (Safety Hardware)
Safety Channel Operation
Safety Input S1 No Power Applied Power Applied No Power Applied Power Applied
Safety Input S2 No Power Applied No Power Applied Power Applied Power Applied
IMPORTANT If an external fault is present on the wiring or circuitry controlling the Safety 1
or Safety 2 inputs for a period of time, the Safe-Torque-Off function may not
detect this condition. When the external fault condition is removed the Safe-
Torque-Off function will allow an enable condition. Fault in the external wiring
shall either be detected by external logic, or excluded (wiring must be
protected by cable ducting or armoring), according to EN ISO 13849-2.
+24V DC PF 525
+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
A1 S21 S11 S52 41 13 23 33 Start
S1
S2
(1)
AC line
input power
PF 525
+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
Start
Gate control
circuit
S1
S2
(2)
(1) Safety relay and PowerFlex 525 must be installed in the same enclosure.
(2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.
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.
GuardMaster PF 525
Trojan
Gate +24V DC
Stop
Stop
+24V DC Start
Start
A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34
Gate control
Minotaur power supply
MSR138DP
A2 X1 X2 X3 X4 Y39 Y40 38 48 58 14 24 Y2 Y1
24V DC
Common Gate control
circuit
S1
S2
(1) Safety relay and PowerFlex 525 must be installed in the same enclosure.
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.
PF 525
External +24V DC
+24V DC
Stop
Reset Start
Open COM
A1 S11 S52 S12 13 23 33 41
Gate control
MSR127TP power supply
S1
S2
(1)
X1 AUX
X2 13 23 33
A1 Coil 14 24 34
A2
24V DC COM External 100-C
contactor 100S-C
(1) Safety relay and PowerFlex 525 must be installed in the same enclosure.
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.
Notes:
EtherNet/IP
Establishing A Connection There are two methods for configuring the embedded EtherNet/IP adapter
IP address:
With EtherNet/IP
• BootP Server – Use BootP if you prefer to control the IP addresses of
devices using a server. The IP address, subnet mask, and gateway addresses
will then be provided by the BootP server. BootP is enabled by default.
• 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.
IMPORTANT If you are setting your network addresses manually using parameters, you
must set C128 [EN Addr Sel] to 1 “Parameters”.
IMPORTANT Regardless of the method used to set the adapter IP address, each node on the
EtherNet/IP network must have a unique IP address. To change an IP address,
you must set the new value and then remove and reapply power to (or reset)
the adapter.
Notes:
Control Diagrams
Induction Motor Tuning [Speed Reg Sel] Diagrams For Motor Tuning
Adjusting Speed Control These settings show how to adjust the speed control for motor tuning.
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
A509 = 0 (Automatic)
Run
B F
basic operation, 52 fault monitoring
drive, 47, 52, 138 ground, 17
programming, 52 fuses
safety, 212 rating, 18
recommended, 143
C
circuit breakers G
inputs, 18 ground
ratings, 18 fault monitoring, 17
recommended, 143 motor, 17
common bus RFI filter, 17
drive, 30 safety, 17
communications shielding, 17
positioning, 196
configuring
RS485(DSI), 174
H
control terminals homing
accessing, 25 automatic, 194
counter manual, 194
programming, 181, 184 programming, 194
D I
decel inputs
override priority, 41 2-wire, 40
selecting, 41 3-wire, 40
derating circuit breakers, 18
power, 16
factor, 108
temperature, 13
digital inputs L
selecting, 40
start source, 40 logic
dimensions basic, 181, 182
timed steps, 181, 182
mounting, 12, 157
disconnect
output, 28 M
drive
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Installation Assistance
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manual. You can contact Customer Support for initial help in getting your product up and running.
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manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
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