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Rockwell Automation Allen-Bradley PowerFlex 520 Series User Manual

Rockwell Automation Allen-Bradley PowerFlex 520 Series
272 pages
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PowerFlex 520-series
Adjustable Frequency AC Drive
Bulletin Numbers 25A series B, 25B
User Manual
Original Instructions

Table of Contents

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Rockwell Automation Allen-Bradley PowerFlex 520 Series Specifications

General IconGeneral
Input Voltage200-240V AC
Output Voltage0 to Input Voltage
Power Range0.4 kW to 22 kW (0.5 HP to 30 HP)
Control MethodSensorless Vector Control
Communication OptionsEtherNet/IP
Enclosure TypeIP20
Protection FeaturesOvercurrent, Overvoltage, Undervoltage, Ground Fault, Short Circuit
Humidity5% to 95% (non-condensing)
DimensionsVaries by frame size. See documentation for specific dimensions.
WeightVaries by frame size. See documentation for specific weights.

Summary

Important User Information

Preface

About This Publication

Explains the purpose and content of the manual.

Download Firmware and Resources

Guides users on obtaining necessary software, files, and related documentation.

General Information and Precautions

Covers manual conventions, drive frame sizes, and essential safety precautions.

Catalog Number Explanation

Details the breakdown and meaning of the catalog numbers for drives.

Chapter 1 Installation/Wiring

Mounting and Environmental Considerations

Covers drive mounting, clearances, ambient conditions, storage, and protection from debris.

Power Supply and Grounding

Details AC supply considerations, input power conditioning, and grounding requirements.

Protection Devices and Wiring

Information on fuses, circuit breakers, and various wiring types including motor and control wiring.

I/O and Control Terminal Configuration

Explains I/O wiring, terminal blocks, start/stop controls, and signal types.

Start and Speed Reference Control

Explains how to select start sources and speed references for drive operation.

CE Conformity and Directives

Outlines compliance with European directives like Low Voltage, EMC, Machinery, and ATEX.

Chapter 2 Start Up

Prepare for Drive Startup

Provides a task list and essential precautions before starting the drive.

Drive Interface and Navigation

Explains the drive's display, control keys, and parameter navigation.

Drive Configuration Methods

Covers programming tools, language support, and startup wizards.

Chapter 3 Programming and Parameters

Parameter Overview

Introduces parameter types, groups, and cross-referencing.

Basic Display and Program Parameters

Details parameters for displaying basic drive operating conditions and status.

Terminal Block and Communications Parameters

Covers parameters for digital/analog I/O, relay outputs, and network settings.

Logic and Advanced Parameters

Explains parameters for logic functions, advanced display, and motor control tuning.

AppView and CustomView Parameter Groups

Describes pre-defined and custom parameter groups for application setup.

Chapter 4 Troubleshooting

Drive Status and Faults

Explains drive status indicators, fault types, and how to clear faults.

Fault Descriptions and Actions

Lists and describes various drive faults with their causes and recommended corrective actions.

Common Symptoms and Corrective Actions

Provides troubleshooting guidance for common drive issues like motor not starting or responding.

Appendix A Supplemental Drive Information

Certifications

Lists the various certifications and standards the drive complies with.

Environmental Specifications

Details operating and storage conditions, including altitude, temperature, humidity, shock, and vibration.

Technical Specifications

Provides electrical and protection specifications for the drive.

Appendix B Accessories and Dimensions

Product Selection and Catalog Numbers

Lists available drive ratings and corresponding catalog numbers.

Mounting Adapter Plates and EMC Filters

Details adapter plates for mounting and EMC line filters.

Drive Components and Kits

Lists replacement control/power modules, fans, EMC cores, and jumper kits.

Communication Adapters and Cables

Details communication adapters, cables, and terminal blocks.

Drive and Accessory Dimensions

Provides physical dimensions for drives, fan kits, and adapter plates.

Installing and Removing Communication Adapters

Step-by-step instructions for installing and removing communication adapters.

Appendix C RS485 (DSI) Protocol

Network Wiring and Configuration

Covers RS485 network wiring practices and parameter configuration for DSI network.

Supported Modbus Function Codes

Details the Modbus function codes supported by the Drive Serial Interface.

Reading Drive Data via Modbus

Explains how to read logic status, error codes, and operational values using Modbus.

Appendix D Logic Functions

Velocity StepLogic Function

Explains Velocity StepLogic with timed steps and basic logic functions.

Timer and Counter Functions

Details the configuration and usage of timer and counter functions.

Appendix E Encoder and Position Control

Encoder and Pulse Train Usage

Discusses the use of pulse train input and optional encoder card for speed and position feedback.

Positioning Overview and Guidelines

Introduces the drive's position regulator, common guidelines, and operation.

Homing Routine and Setup Notes

Explains homing routines and suggests setup tools.

Use Over Communications

Discusses controlling positioning functions via communication networks.

Appendix F PID Set Up

PID Loop Configurations

Explains PID loop, Exclusive Control, and Trim Control configurations.

PID Reference and Feedback Setup

Details how to select PID reference sources and feedback inputs.

PID Tuning and Gains

Covers PID deadband, preload, limits, gains, and adjustment guidelines.

Appendix G Safe Torque Off Function

PowerFlex 525 Safe-Torque-Off Overview

Introduces the Safe-Torque-Off (STO) function and its purpose.

Safety Considerations and Requirements

Covers certifications, EMC instructions, safety concepts, and critical considerations.

Enabling and Verifying Safe-Torque-Off

Step-by-step instructions for enabling, wiring, and verifying the STO function.

Connection Examples

Provides diagrams for safe-torque-off connections with different stop actions.

Appendix H EtherNet/IP

Establishing an EtherNet/IP Connection

Explains methods for configuring Ethernet IP addresses.

Ground Connections for EtherNet/IP Networks

Details proper grounding procedures for EtherNet/IP networks.

Appendix I Control Diagrams

Induction Motor Tuning Diagrams

Visual representations of speed controller gain adjustments for motor tuning.

Adjusting Speed Control Parameters

Guides on how to adjust speed control parameters for optimal motor tuning.

Appendix J PowerFlex 525 PM Motor Configuration

Motor Control and Data Setup

Covers selecting control mode and entering motor nameplate data.

Feedback and Stop Mode Configuration

Details encoder feedback setup and drive stop modes.

Motor Tuning Procedures

Explains direction test, autotune, and manual configuration steps.

PM Motor Specific Setup

Provides additional setup for open-loop and closed-loop PM motors.

Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration

SynRM Structure and Control Diagram

Describes the structure, control diagram, and basic operation of SynRM control.

SynRM Control Configuration

Step-by-step guide for configuring SynRM control using the drive keypad.

Startup Adjustment Procedures

Outlines procedures for adjusting parameters during no-load and load testing.

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