Rockwell Automation B Series Bedienungsanleitung

PowerFlex 520-Series Adjustable Frequency AC Drive

PowerFlex 523 Catalog Number 25A, Series B

PowerFlex 525 Catalog Number 25B

User Manual

Original Instructions

Important User Information

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

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

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

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

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

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

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

use or application of this equipment.

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

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

liability for actual use based on the examples and diagrams.

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

software described in this manual.

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

Inc., is prohibited.

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

Allen-Bradley, Rockwell Automation, Rockwell Software, PowerFlex, Connected Components Workbench, Studio 5000, Studio 5000 Logix Designer, DriveTools SP, AppView, CustomView, QuickView, MainsFree

Programming, PointStop, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

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

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

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

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

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

voltage may be present.

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

reach dangerous temperatures.

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

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

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

IMPORTANT

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

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 3

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Summary of Changes

New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Preface

Overview

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1

Installation/Wiring

Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 2

Start Up

Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Display and Control Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Smart Start-Up with Basic Program Group Parameters . . . . . . . . . . . . . . 65

LCD Display with QuickView Technology. . . . . . . . . . . . . . . . . . . . . . . . . 67

Using the USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

4Rockwell Automation Publication 520-UM001I-EN-E - July 2016

Table of Contents

Chapter 3

Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Basic Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Terminal Block Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Communications Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Chapter 4

Troubleshooting

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162

Appendix A

Supplemental Drive Information

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Appendix B

Accessories and Dimensions

Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Appendix C

RS485 (DSI) Protocol

Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Supported Modbus Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 205

Reading (03) Logic Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 208

Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 5

Table of Contents

Appendix D

Velocity StepLogic, Basic Logic and

Timer/Counter Functions

Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 210

Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Appendix E

Encoder/Pulse Train Usage and

Position StepLogic Application

Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Determine Encoder Pulse Per Revolution (PPR) Specification Based on

Speed Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 218

Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Setup Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Appendix F

PID Set Up

PID Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Appendix G

Safe-Torque-Off Function

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

EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

EMC Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 239

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

PowerFlex 525 Safe-Torque-Off Operation . . . . . . . . . . . . . . . . . . . . . . . 239

Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

PowerFlex 525 Certification for Safe-Torque-Off. . . . . . . . . . . . . . . . . . 245

Appendix H

EtherNet/IP

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

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

6Rockwell Automation Publication 520-UM001I-EN-E - July 2016

Table of Contents

Appendix I

Control Diagrams

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

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

Appendix J

PowerFlex 525 PM Motor

Configuration

Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Automatic Configuration Using Drive Startup Wizard. . . . . . . . . . . . . 254

Manual Configuration Using Drive Keypad . . . . . . . . . . . . . . . . . . . . . . . 261

Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Optional Parameter Adjustments for Optimum Performance . . . . . . . 266

Index

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 7

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Added footnote to indicate that circuit breaker selection is not available for certain drive

ratings. 24...27

Added PowerFlex 523 series B to Control I/O Wiring Block Diagram. 38

Added PowerFlex 523 series B to Control I/O Terminal Designations. 40

Added PowerFlex 523 series B I/O wiring examples for analog input and analog output. 45

Added note to PowerFlex 525 I/O wiring example for pulse train input. 46

Added footnote to enum “4” for P053 [Reset to Defalts] under Smart Start-Up with Basic

Program Group Parameters. 67

Added new sub topic for 32-bit parameters. 72

Added footnotes to parameters that are available in PowerFlex 523 FRN 3.xxx and later. Chapter 3

Updated descriptions for parameters that are available in PowerFlex 523 FRN 3.xxx and later.

Added formula for calculating scaled process value to parameter b010 [Process Display]. 79

Added recommendation to perform rotate tune when using VVC mode to parameter P040

[Autotune]. 85

Added footnote to indicate which settings are PowerFlex 525 only for parameter d394 [Dig

Out Status]. 114

Updated descriptions for parameters A465 [PID 1 Deadband] and A477 [PID 2 Deadband]. 123

Added corrective action to fault F114 (uC Failure). 162

Added analog output to PowerFlex 523 drives. 171

Added new topic “Determine Encoder Pulse Per Revolution (PPR) Specification Based on

Speed Resolution” to Appendix E. 217

Updated information to verify operation of the safety inputs in Appendix G. 240

General maintenance updates. Throughout manual

8Rockwell Automation Publication 520-UM001I-EN-E - July 2016

Summary of Changes

Notes:

Rockwell Automation Publication 520-UM001I-EN-E - July 2016 9

Preface

Overview

The purpose of this manual is to provide you with the basic information needed

to install, start-up and troubleshoot the PowerFlex® 520-Series Adjustable

Frequency AC Drive.

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

Documentation

All the recommended documentation listed in this section is available online at

http://www.rockwellautomation.com/literature/.

The following publications provide general drive information:

The following publications provide specific PowerFlex 520-Series information on

drive installation, features, specifications, and service:

For information on… See page…

Who Should Use this Manual 9

Beliebte Industrieanlagen Handbücher anderer Marken

ABB

ABB Unifix AD Handbuch

Mark 7

Mark 7 Evolution Bedienungsanleitung

Husky

Husky HyPET Bedienungsanleitung

bora

bora PM-1800 Bedienungsanleitung

Grizzly

Grizzly T32428 Bedienungsanleitung

Siemens

Siemens 8MF1 Series Bedienungsanleitung

ABB

ABB HT610965 Bedienungsanleitung

ABB

ABB SafeLink Bedienungsanleitung

Phoenix

Phoenix PHX-150 Bedienungsanleitung

ABB

ABB A165-L32 Bedienungsanleitung

ABB

ABB HT842936 Bedienungsanleitung

Hermetica

Hermetica 10 Series Bedienungsanleitung

HORNER

HORNER OEE Solution Bedienungsanleitung

Hammerhead

Hammerhead HG375 Bedienungsanleitung

SCHUNK

SCHUNK VERO-S NSE-A3 138 Gebrauchsanweisung

ABB

ABB HT566657 Bedienungsanleitung

Webasto

Webasto GSE CAN Bedienungsanleitung

ABB

ABB HT614003 Bedienungsanleitung