Allen-Bradley PowerFlex 527 User manual

PowerFlex 527 Adjustable Frequency AC Drive

Catalog Number 25C

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 Software, Rockwell Automation, PowerFlex, CompactLogix, Connected Components Workbench, ControlLogix, GuardLogix, Logix5000, RSLinx, Studio 5000, Studio 5000 Logix Designer, 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-UM002B-EN-E - December 2017 3

Summary of Changes

This manual contains new and updated information. Changes throughout this

revision are marked by change bars, as shown to the right of this paragraph.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Added footnotes to indicate the overload capacity of catalogs. 12, 21...24

Updated Motor Phase Connection description in Power Terminal Block. 32

Added wiring information about Terminals 01 and 11. 33, 34

Updated descriptions for several terminals in the Control I/O Terminal Designations table. 35

Updated Network Configuration section. 47

Updated Real-time Information Display section. 49

Updated Configure the PowerFlex 527 Drive section with additional controllers. 59

Updated Test the Axes section. 83

Updated Tune the Axes section. 85

Updated PHF Data section. 89

Updated Operation of Hardwired Safe Torque-Off section. 97

Updated Compatible Safety Controllers section. 103

Updated Network Safe Torque-off Specifications section. 104

Added INIT FLT M22 – ILLEGAL ADDRESS to INIT FLT Fault Codes table. 125

Updated INHIBIT Fault Codes table. 125

Updated information on configurable stopping actions in Logix5000 Controller and Drive Behavior. 129

Updated Drive Behavior, FLT Sxx Fault Codes table. 131

Updated Control table in Technical Specifications. 135

Removed Bandwidth specification from Control Inputs table in Technical Specifications. 137

UpdatedMotion Group Base Update Rate graphic. 165

Updated Encoder Signal – Single-Ended, Dual Channel connection example graphic. 170

4Rockwell Automation Publication 520-UM002B-EN-E - December 2017

Summary of Changes

Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 5

Table of Contents

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

Summary of Changes

New and Updated Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table of Contents

Preface

Overview

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

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Product Environmental Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

Installation/Wiring

Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power and Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 2

Start Up

Prepare for Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Understanding the PowerFlex 527 Display and Indicators . . . . . . . . . . . 44

Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Using the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Chapter 3

Configuring the PowerFlex 527 Drive

with Integrated Motion

Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Configure the Logix Designer Application Project . . . . . . . . . . . . . . . . . . 52

Add a PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Configure the PowerFlex 527 Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Apply Power to the PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Test and Tune the Axes – Velocity and Position Control Modes . . . . . 83

6Rockwell Automation Publication 520-UM002B-EN-E - December 2017

Table of Contents

Chapter 4

PowerFlex 527 Integrated Safe

Torque-Off

Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . . 89

Safe Torque-Off (STO) Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Out-of-Box (OOB) Safety State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Safe Torque-Off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Chapter 5

Hardwired Control of Safe Torque-Off

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Safe Torque-Off Connector Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Wire the Safe Torque-Off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Safe Torque-Off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Chapter 6

Network Control of Safe Torque-Off

Understanding Integrated Safety Drive Replacement. . . . . . . . . . . . . . . 107

Replacing an Integrated Safety Drive in a GuardLogix System . . . . . . . 107

Motion Direct Commands in Motion Control Systems . . . . . . . . . . . . 114

Functional Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Chapter 7

Troubleshooting

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Interpret Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Logix5000 Controller and Drive Behavior. . . . . . . . . . . . . . . . . . . . . . . . . 129

Appendix A

Supplemental Drive Information

Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Power Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Appendix B

Accessories and Dimensions

Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Product Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Appendix C

Out-of-Box Configuration

Recommended Out-of-Box Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Setting the ACO/AVO Attribute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Appendix D

Encoder Option Card Usage

Installing the Encoder Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 7

Table of Contents

Removing the Encoder Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Encoder Option Card Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Index

8Rockwell Automation Publication 520-UM002B-EN-E - December 2017

Table of Contents

Notes:

Rockwell Automation Publication 520-UM002B-EN-E - December 2017 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® 527 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

a working knowledge and understanding of ControlLogix®/Studio 5000® and

CIP Motion.

If you do not have a basic understanding of the PowerFlex 527 drives, contact

your local Rockwell Automation sales representative for information on available

training courses.

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http://www.rockwellautomation.com/literature. To order paper copies of

For information on… See page…

Who Should Use this Manual 9

Additional Resources 9

Manual Conventions 10

Drive Frame Sizes 10

General Precautions 11

Catalog Number Explanation 12

Title Publication

GuardLogix 5570 Controllers User Manual 1756-UM022

GuardLogix 5570 Controller Systems Safety Reference Manual 1756-RM099

CompactLogix 5370 Controllers User Manual 1769-UM021

ControlLogix 5580 Controllers User Manual 1756-UM543

Compact GuardLogix 5370 Controllers User Manual 1769-UM022

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001

Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001

Integrated Motion on the EtherNet/IP Network Configuration and Startup User Manual MOTION-UM003

Integrated Motion on the EtherNet/IP Network MOTION-RM003

PowerFlex DB (Dynamic Braking) Resistor Calculator PFLEX-AT001

Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1

Guarding Against Electrostatic Damage 8000-4.5.2

10 Rockwell Automation Publication 520-UM002B-EN-E - December 2017

Preface Overview

technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

Manual Conventions •In this manual we refer to PowerFlex 527 Adjustable Frequency AC Drive

as: drive, PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive.

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

– PowerFlex 523, PowerFlex 523 drive or PowerFlex 523 AC drive.

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

– PowerFlex 527, PowerFlex 527 drive or PowerFlex 527 AC drive

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

action:

•The Studio 5000 Automation Engineering and Design Environment™

(formerly RSLogix 5000) combines engineering and design elements into

one standard framework that enables optimized productivity and reduced

time to commission. As part of the Studio 5000 environment, Logix

Designer™ is the tool used to program Logix programmable automation

controllers for process, batch, discrete, drives, safety and motion-based

systems. The Studio 5000 environment is the foundation for system

engineering design tools and capabilities — it is the one tool for engineers

to design and develop all the elements of their control system.

These conventions are used throughout this manual:

•Bulleted lists such as this one provide information, not procedural steps.

•Numbered lists provide sequential steps or hierarchical information.

Drive Frame Sizes The PowerFlex 527 AC drive belongs to the new generation of PowerFlex 520-

series drives which also consist of PowerFlex 523 and PowerFlex 525 drives.

Similar PowerFlex 520-series 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.

Product Environmental

Information

Rockwell Automation maintains current product environmental information on

its website at

http://www.rockwellautomation.com/rockwellautomation/about-us/

sustainability-ethics/product-environmentalcompliance.page

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

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