PowerFlex 520-Series Adjustable Frequency AC Drive User Manual

Preface

This manual provides information for installing, starting up, and troubleshooting the PowerFlex 520-Series Adjustable Frequency AC Drive.

About This Publication

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.

Download Firmware, AOP, EDS, and Other Files

Firmware, associated files (such as AOP, EDS, and DTM), and product release notes can be downloaded from the Product Compatibility and Download Center at rok.auto/pcdc.

Summary of Changes

This publication contains new or updated information, including changes to tables, parameter descriptions, and EMC requirements.

Who Should Use this Manual

This manual is intended for qualified personnel familiar with programming and operating Adjustable Frequency AC Drive devices, and who understand parameter settings and functions.

Additional Resources

Recommended documentation is available online at rok.auto/literature. This includes general drive information, specific PowerFlex 520-Series information, and network communications information.

Manual Conventions

The manual uses specific terms for drives (e.g., "drive", "PowerFlex 520-series") and parameter formats (e.g., P 031 [Motor NP Volts]). It also defines terms like "Can", "Cannot", "May", "Must", "Shall", "Should", "Should Not" with specific meanings.

Drive Frame Sizes

PowerFlex 520-series drive sizes are grouped into frame sizes (A through E) for simplification. A cross-reference of catalog numbers and frame sizes is provided in Appendix B.

General Precautions

ATTENTION: The drive contains high voltage capacitors that take time to discharge after power removal. Wait three minutes and verify voltage levels before servicing. Only qualified personnel should perform installation and maintenance. ESD precautions are required. Incorrect application or installation can lead to component damage or reduced product life. The bus regulator function can cause uncommanded speed changes or longer deceleration times; it can be disabled via parameter A550 [Bus Reg Enable]. Do not disassemble the drive chassis.

Catalog Number Explanation

The catalog number structure defines various attributes of the drive, including series (25A/25B), voltage rating, phase, enclosure type, EMC filter, braking, and output current/frame size.

Chapter 1: Installation/Wiring

Mounting Considerations

Drives should be mounted upright on a flat, vertical, and level surface. Ensure adequate clearances for ventilation. Protect the cooling fan from dust and metallic particles. Avoid corrosive atmospheres, moisture, and direct sunlight.

Minimum Mounting Clearances

Specific clearances are required for vertical mounting (with and without zero stacking) and horizontal mounting (with control module fan kit). For example, 50 mm (2.0 in.) is typically required above and below the drive, with 25 mm (1.0 in.) on the sides for vertical mounting. Frame E with a fan kit requires 95 mm (3.7 in.) clearance above/below in some configurations. Consult the detailed diagrams in the original manual for precise requirements.

AC Supply Source Considerations

ATTENTION: Drives installed on ungrounded or resistance-grounded distribution systems must have MOVs (Metal Oxide Varistors) disconnected by removing a specific jumper. Removing MOVs in drives with an embedded filter also disconnects the filter capacitor from earth ground.

Input power conditions like low line impedance, large supply transformers, power factor correction capacitors, frequent power interruptions, or noise spikes may require corrective actions such as installing a line reactor or isolation transformer.

General Grounding Requirements

The drive's Safety Ground (PE) must be connected to system ground according to national and local codes. Ground impedance must be checked periodically. For network grounds (C1, C2), connect to clean earth ground for noise immunity. Shield termination (SHLD) for motor cables should be connected to the motor frame and the drive's safety ground terminal using a clamp or terminating kit. Control and signal wire shields should be grounded at the source end only.

Fuses and Circuit Breakers

The drive requires external branch short-circuit protection. Tables are provided listing recommended fuses (Class CC, T, RK1, J for UL; GG or equivalent for IEC) and circuit breakers (inverse time, instantaneous trip, or combination motor controllers) based on drive rating and voltage. National and local codes may dictate specific requirements.

Power and Control Module

Drives consist of a Power Module and a Control Module, which can be separated for installation. Separation involves releasing catches and sliding covers. Reconnection involves aligning connectors and securing the modules.

Control Module Cover

To access control terminals, DSI port, and Ethernet port, the front cover slides down after pressing a release arrow.

Power Module Terminal Guard

To access power terminals, the terminal guard is removed by pressing catches and releasing a locking tab.

Power Wiring

ATTENTION: Comply with national and local codes for wire types, sizes, and protection. Unused wires in conduit must be grounded at both ends to prevent induced voltages. Motor cable length restrictions apply; consult publication DRIVES-IN001. Use copper wire only. Shielded or armored cable is recommended for noise containment, especially in installations with sensitive equipment or high EMC regulations. Shielded cable construction can affect performance; use recommended types like Belden 295xx.

Reflected Wave Protection: For 240V ratings and lower, reflected wave effects are not a concern. For higher voltages and long motor cables, external protection devices may be needed.

Output Disconnect: Do not use a device that routinely disconnects/reapplies output power for starting/stopping. Use control input signals. If power must be disconnected during operation, use an auxiliary contact to disable the drive.

Power Terminal Block

Terminals are provided for AC Line Input (R/L1, S/L2, T/L3), Motor Phase Connection (U/T1, V/T2, W/T3), DC Bus Connection (DC-, DC+), Dynamic Brake Resistor Connection (BR+, BR-), and Safety Ground (PE). Terminal screws must be tightened to specified torque.

Common Bus/Precharge Notes

If drives share a common DC bus with a disconnect switch, an auxiliary contact must link the disconnect to a digital input set to "Precharge En" (parameter t062, t063, etc.) to ensure proper precharge interlock.

I/O Wiring

Use copper wire with a 600V or greater insulation rating. Separate control/signal wires from power wires by at least 0.3 m (1 ft). I/O terminals labeled "Common" are isolated from safety ground. ATTENTION: Driving the 4-20 mA analog input from a voltage source can cause damage; verify configuration.

Control I/O Terminal Block

Detailed diagrams and terminal designations are provided for PowerFlex 523 (Series A, Series B) and PowerFlex 525 Control I/O Terminal Blocks. These include digital inputs/outputs, analog inputs/outputs, relay outputs, Safe-Torque-Off (PowerFlex 525), and communication ports (RJ45 for Ethernet). Key parameters like P045 [Stop Mode], P046/P048/P050 [Start Source x], and t062/t063 [DigIn TermBlk xx] configure I/O functions.

Jumper Note: A jumper between I/O Terminals 01 and 11 allows keypad/comms start by default. Remove this jumper if I/O Terminal 01 is used as a stop or enable input.

Start and Speed Reference Control

Start and speed commands can originate from various sources (keypad, digital inputs, serial/DSI, network). Parameter groups P046-P051 define the primary and secondary sources. Override priority is detailed in logic diagrams.

CE Conformity

Compliance with Low Voltage Directive (2014/35/EU) and EMC Directive (2014/30/EU) is demonstrated via EN standards. Drives must be installed in pollution degree 1 or 2 environments. EMC compliance requires specific installation practices, including shielded cables, proper grounding, and potentially external filters or enclosures, depending on the EMC category (C1, C2, C3).

ATTENTION: Drives produce leakage current exceeding 3.5 mA AC or 10 mA DC, potentially affecting RCDs/RCMs of type A or AC. Only Type B RCDs/RCMs are allowed on the supply side.

EMC Directive Requirements: Use shielded motor cables (75%+ coverage) or metal conduit, with low-impedance termination at both ends. Control wiring also requires shielding. Motor cable length must not exceed specified limits for EMC compliance.

General Considerations

For CE compliance, drives must meet EN 61800-5-1 and EN 61800-3 requirements. Motor cable length should be minimized. Line filters are not recommended for ungrounded systems. Input power for CE installations must be a balanced Wye with center ground.

Connections and Grounding

Illustrates typical shielded enclosure setups with EMI filters, conduit, and EMC cores for RF emission compliance. Placement of EMC cores is critical and depends on drive frame size and filter type.

RF Emission Compliance and Installation Requirements

Details requirements for meeting EN61800-3 Categories C1, C2, and C3, specifying enclosure types, conduit/shielded cable, and EMC core usage based on drive frame size and filter configuration.

Chapter 2: Start Up

Prepare for Drive Startup

A task list guides the user through pre-startup checks: disconnecting power, verifying voltage, inspecting wiring, setting control schemes (SNK/SRC), wiring I/O and power, collecting motor data, verifying grounding, resetting defaults, configuring basic parameters, completing autotune, applying backup configurations, and verifying operation.

Start, Stop, Direction, and Speed Control

Factory defaults allow keypad control. Motor tuning via autotune (P040) is recommended for SVC mode. V/Hz mode may require boost adjustment (A530).

Display and Control Keys

The drive features control keys (FWD, Esc, Sel, Enter, Up, Down) and an LCD display. The display shows parameter groups like Basic Display, Basic Program, Terminal Blocks, Communications, Logic, Advanced Display, Advanced Program, Network, Modified, Fault and Diagnostic, AppView, and CustomView. Network status LEDs (ENET LINK, FAULT) are also present on PowerFlex 525.

Viewing and Editing Parameters

Navigation involves using Esc to move between parameter groups and lists, Sel/Enter to select parameters, and Up/Down arrows to change values. Program mode is entered by pressing Enter/Sel.

Drive Programming Tools

Recommends using Connected Components Workbench (v5.0+), Logix Designer (v21.0+), or RSLogix 5000 (v17.0+) for full functionality. Older tools have limited support.

Language Support

The drive supports multiple languages for keypad/LCD display and programming software.

Smart Startup with Basic Program Group Parameters

Key parameters for initial setup are in the Basic Program Group. These include Language (P030), Motor Nameplate Data (P031-P037), Torque Performance Mode (P039), Autotune (P040), Accel/Decel/Min/Max Frequencies (P041-P044), Stop Mode (P045), Start Sources (P046, P048, P050), and Speed References (P047, P049, P051).

LCD Display with QuickView Technology

QuickView technology allows text scrolling on the LCD for easy configuration and troubleshooting. Text scroll speed is adjustable via A556 [Text Scroll].

Using the USB Port

The USB port allows firmware upgrades and parameter configuration uploads/downloads using the PF52XUSB.EXE utility. MainsFree programming enables configuration without powering the control module.

Using Drive Startup in CCW or Logix Designer application

The PowerFlex 525 Startup Wizard in Connected Components Workbench simplifies configuration. It requires specific firmware and Add-on Profile versions.

Chapter 3: Programming and Parameters

About Parameters

Parameters are configured via keypad, software, or communication. They are categorized as ENUM (selection from options), Numeric, or Bit parameters. Some parameters are 32-bit and may be displayed across multiple parameters or software fields.

Parameter Groups

Parameters are organized into groups: Basic Display, Basic Program, Terminal Block, Communications, Logic (PF525 only), Advanced Display, Advanced Program, Network, Modified, Fault and Diagnostic, AppView, and CustomView. Each group contains specific parameters related to its function.

Basic Display Group

This group shows real-time drive status, including Output Frequency (b001), Commanded Frequency (b002), Output Current (b003), Voltage (b004), DC Bus Voltage (b005), Drive Status (b006), Fault Codes (b007-b009), Process Display (b010, b011), Control Source (b012), Digital Input Status (b013, b014), Output RPM/Speed (b015, b016), Power/Energy metrics (b017-b026), and Software Version (b029).

Basic Program Group

Contains essential parameters for drive setup: Language (P030), Motor Nameplate Data (P031-P037), Torque Performance Mode (P039), Autotune (P040), Acceleration/Deceleration Times (P041, P042), Minimum/Maximum Frequency (P043, P044), Stop Mode (P045), Start Sources (P046, P048, P050), Speed References (P047, P049, P051), Average kWh Cost (P052), and Reset to Defaults (P053).

Terminal Block Group

Defines the function of programmable digital inputs (t062, t063, t065-t068) and outputs (t069, t072 for Opto Outputs; relay outputs). Options include start/stop commands, speed references, jog functions, fault handling, and logic functions.

Communications Group

Parameters for configuring communication settings, such as communication mode, data rates, node addresses, and loss actions for various communication protocols (RS485, EtherNet/IP, etc.).

Logic Group (PowerFlex 525 only)

Includes parameters for StepLogic, Timer, and Counter functions, allowing for advanced control sequences and automation.

Advanced Display Group

Provides more detailed operational data and status indicators, including analog input values, elapsed times, temperatures, and various status bits.

Advanced Program Group

Contains a comprehensive set of parameters for fine-tuning drive performance, motor control, protection features, and application-specific functions like PID control, skip frequencies, and positioning.

Network Parameter Group

Parameters specific to network communication cards, allowing configuration of IP addresses, subnet masks, gateway settings, and data mapping.

Modified Parameter Group

Lists parameters whose values have been changed from their factory defaults.

Fault and Diagnostic Group

Contains parameters that log fault codes, fault times, bus voltages, frequencies, currents, and status information, aiding in troubleshooting.

AppView Parameter Groups

Pre-configured parameter sets for common applications like Conveyor, Mixer, Compressor, Centrifugal Pump, Blower/Fan, Extruder, Textile/Fiber, and Positioning, simplifying setup.

CustomView Parameter Group

Allows users to create a personalized group of frequently accessed parameters.

Parameter Cross Reference by Name

An alphabetical listing of all parameters for quick lookup.