Allen-Bradley PowerFlex 525 Manuel utilisateur

PowerFlex 525 Adjustable Frequency AC Drive

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, 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.

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.

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 3

Table of Contents

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

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

4Rockwell Automation Publication 520-UM001A-EN-E - February 2013

Table of Contents

Advanced Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Network Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Fault and Diagnostic Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Parameter Cross Reference by Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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

Timer/Counter Functions

Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 182

Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Counter Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 5

Table of Contents

Appendix E

Encoder/Pulse Train Usage and

Position StepLogic Application

Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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

Index

6Rockwell Automation Publication 520-UM001A-EN-E - February 2013

Table of Contents

Notes:

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 7

Preface

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.

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 7

Recommended Documentation 7

Manual Conventions 8

Drive Frame Sizes 9

General Precautions 9

Catalog Number Explanation 10

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

Title Publication

PowerFlex 525 AC Drive Specifications 520-TD001

PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001

PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

8Rockwell Automation Publication 520-UM001A-EN-E - February 2013

Preface Overview

The following publications provide specific Network Communications

information:

Manual Conventions •In this manual we refer to PowerFlex 520-Series Adjustable Frequency AC

Drive as; drive, PowerFlex 520, PowerFlex 520 Drive or PowerFlex 520 AC

drive.

•Specific drives within the PowerFlex 520-Series may be referred to as:

– PowerFlex 525, PowerFlex 525 drive or PowerFlex 525 AC drive.

•Parameter numbers and names are shown in this format:

•The following words are used throughout the manual to describe an

action:

•The Studio 5000™ Engineering and Design Environment combines

engineering and design elements into a common environment. The first

element in the Studio 5000 environment is the Logix Designer

application. The Logix Designer application is the rebranding of

RSLogix 5000 software and will continue to be the product to program

Logix 5000 controllers for discrete, process, batch, motion, safety, and

drive-based solutions. The Studio 5000 environment is the foundation for

the future of Rockwell Automation engineering design tools and

capabilities. It is the one place for design engineers to develop all the

elements of their control system.

Title Publication

PowerFlex 525 Embedded EtherNet/IP Adapter (including dual port Ethernet) 520COM-UM001

PowerFlex 525 DeviceNet Adapter 520COM-UM002

PowerFlex 525 PROFIBUS DP Adapter 520COM-UM003

P 031 [Motor NP Volts]

Name

Number

Group

= Basic Display

= Basic Program

= Terminal Blocks

= Communications

= Logic

= Advanced Display

= Advanced Program

= Modified

= Network

= AppView and CustomView

= Fault and Diagnostic

Words Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not Recommended

Rockwell Automation Publication 520-UM001A-EN-E - February 2013 9

Overview Preface

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. Staticcontrol 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 inputvoltage 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.

10 Rockwell Automation Publication 520-UM001A-EN-E - February 2013

Preface Overview

Catalog Number Explanation

Code Braking

4Standard

Code EMC Filter

0NoFilter

1Filter

Code Interface Module

1Standard

Code Enclosure

N IP 20 NEMA/Open

Code Voltage Phase

V120VAC1

A240VAC1

B240VAC3

D480VAC3

E600VAC3

Code Type

25B PowerFlex 525

* Normal and Heavy duty ratings are

available for drives above 15 HP / 11 kW.

1-3 4 5 6-8 9 10 11 12 13 14

25B - B 2P3 N 1 1 4 – –

Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash

Output Current @ 1 Phase, 100...120V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 B 1.0 0.75 1.0 0.75

6P0 6.0 B 1.5 1.1 1.5 1.1

Output Current @ 1 Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

4P8 4.8 A 1.0 0.75 1.0 0.75

8P0 8.0 B 2.0 1.5 2.0 1.5

011 11.0 B 3.0 2.2 3.0 2.2

Output Current @ 3Phase, 200...240V Input

Code Amps Frame ND HD

HP kW HP kW

2P5 2.5 A 0.5 0.4 0.5 0.4

5P0 5.0 A 1.0 0.75 1.0 0.75

8P0 8.0 A 2.0 1.5 2.0 1.5

011 11.0 A 3.0 2.2 3.0 2.2

017 17.5 B 5.0 3.7 5.0 3.7

024 24.0 C 7.5 5.5 7.5 5.5

032 32.2 D 10.0 7.5 10.0 7.5

048 48.3 E 15.0 11.0 15.0 11.0

062 62.1 E20.0 15.0 15.0 11.0

Output Current @ 3 Phase, 380...480V Input

Code Amps Frame ND HD

HP kW HP kW

1P4 1.4 A 0.5 0.4 0.5 0.4

2P3 2.3 A 1.0 0.75 1.0 0.75

4P0 4.0 A 2.0 1.5 2.0 1.5

6P0 6.0 A 3.0 2.2 3.0 2.2

010 10.5 B 5.0 4.0 5.0 4.0

013 13.0 C 7.5 5.5 7.5 5.5

017 17.0 C 10.0 7.5 10.0 7.5

024 24.0 D 15.0 11.0 15.0 11.0

030 30.0 D20.0 15.0 15.0 11.0

037 37.0 E25.0 18.5 20.0 15.0

043 43.0 E30.0 22.0 25.0 18.5

Output Current @ 3 Phase, 525...600V Input

Code Amps Frame ND HD

HP kW HP kW

0P9 0.9 A 0.5 0.4 0.5 0.4

1P7 1.7 A 1.0 0.75 1.0 0.75

3P0 3.0 A 2.0 1.5 2.0 1.5

4P2 4.2 A 3.0 2.2 3.0 2.2

6P6 6.6 B 5.0 3.7 5.0 3.7

9P9 9.9 C 7.5 5.5 7.5 5.5

012 12.0 C 10.0 7.5 10.0 7.5

019 19.0 D 15.0 11.0 15.0 11.0

022 22.0 D20.0 15.0 15.0 11.0

027 27.0 E25.0 18.5 20.0 15.0

032 32.0 E30.0 22.0 25.0 18.5

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