520-UM002D-EN-E PowerFlex 527 Adjustable Frequency AC Drive

User Manual

Original Instructions

PowerFlex 527 Adjustable

Frequency AC Drive

Bulletin Number 25C

2 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

PowerFlex 527 Adjustable Frequency AC Drive User Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize

themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to

be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

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.

These labels may also be on or inside the equipment to provide specific precautions.

The following icon may appear in the text of this document.

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.

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

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).

Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 3

Table of Contents

Preface

About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 7

Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Drive Frame Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 1

Installation/Wiring Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ambient Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Current Derating Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Debris Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Ungrounded Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Input Power Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

Ground Fault Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safety Ground - (PE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Motor Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

RFI Filter Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

Fusing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuses and Circuit Breakers for PowerFlex 527 . . . . . . . . . . . . . . . . . . 21

Power and Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Motor Cable Types Acceptable for 100…600 Volt Installations . . . . 30

Reflected Wave Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Output Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Motor Start/Stop Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Signal and Control Wire Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Maximum Control Wire Recommendations. . . . . . . . . . . . . . . . . . . . 34

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

PowerFlex 527 Control I/O Removable Terminal Block . . . . . . . . . . 35

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Table of Contents

Low Voltage Directive (2014/35/EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

ATEX Directive (2014/34/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

UKCA Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Electrical Equipment (Safety) Regulations (2016 No. 1101) . . . . . . . 38

Electromagnetic Compatibility Regulations (2016 No. 1091). . . . . . 38

Supply of Machinery (Safety) Regulations (2008 No. 1597) . . . . . . . 38

Equipment and Protective Systems Intended for Use in Potentially

Explosive Atmospheres Regulations (2016 No. 1107) . . . . . . . . . . . . . 38

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chapter 2

Start Up Prepare for Drive Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Drive Startup Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Start, Stop, Direction, and Speed Control . . . . . . . . . . . . . . . . . . . . . . 46

Understanding the PowerFlex 527 Display and Indicators. . . . . . . . . . . 46

Startup Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Device and Axis States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Information Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Real-time Information Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Using the Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 3

Configuring the PowerFlex 527

Drive with Integrated Motion

Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Set the Network Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Configure the Logix Designer Application Project . . . . . . . . . . . . . . . . . . 54

Configure the Logix 5000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Add a PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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

Configure Drive with Hardwired Safety Connections . . . . . . . . . . . 60

Configure Drive with Integrated Safety Connections . . . . . . . . . . . 61

Continue Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Configure the Motion Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Configure Axis Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Download the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Apply Power to the PowerFlex 527 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Test and Tune the Axes – Velocity and Position Control Modes . . . . . . 80

Test the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Tune the Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 5

Table of Contents

Chapter 4

PowerFlex 527 Integrated Safe

Torque-Off

Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Category 3 Requirements According to ISO 13849 . . . . . . . . . . . . . . . 85

Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Performance Level (PL) and Safety Integrity Level (SIL) . . . . . . . . . 86

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Probability of Dangerous Failure Per Hour (PFH) . . . . . . . . . . . . . . . . . . 86

PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Safe Torque-Off (STO) Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Safe Torque-Off Feature Bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

As-Shipped Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Out-of-Box (OOB) Safety State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Recognizing the Out-of-Box State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Restoring the Drive to the Out-of-Box State . . . . . . . . . . . . . . . . . . . . 88

Safe Torque-Off Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Axis Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Safety Supervisor State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Propose TUNID Blocked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Safe Torque-Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Safe Torque-Off Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Chapter 5

Hardwired Control of Safe

Torque-Off

Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Selection of Hardwired Safe Torque-Off . . . . . . . . . . . . . . . . . . . . . . . 93

Operation of Hardwired Safe Torque-Off . . . . . . . . . . . . . . . . . . . . . . 93

Troubleshoot the Safe Torque-Off Function . . . . . . . . . . . . . . . . . . . . 94

Safe Torque-Off Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Wire the Safe Torque-Off Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Safe Torque-Off Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . 96

Safe Torque-Off Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Chapter 6

Network Control of Safe Torque-

Off

Compatible Safety Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Selection of Network Safe Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 99

Safety Application Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Network Safe Torque-off Specifications . . . . . . . . . . . . . . . . . . . . . . 100

Safe Torque-off Assembly Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

STO Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Troubleshoot Network Safe Torque-Off. . . . . . . . . . . . . . . . . . . . . . . 102

Understanding Integrated Safety Drive Replacement. . . . . . . . . . . . . . 103

Replacing an Integrated Safety Drive in a GuardLogix System. . . . . . 103

Replacement with “Configure Only When No Safety Signature

Exists” Enabled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Replacement with “Configure Always” Enabled . . . . . . . . . . . . . . . . 108

Motion Direct Commands in Motion Control Systems. . . . . . . . . . . . . 109

6 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Table of Contents

Understanding STO Bypass When Using Motion Direct Commands

110

Logix Designer Application Warning Messages. . . . . . . . . . . . . . . . 110

Torque Permitted in a Multi-workstation Environment . . . . . . . . 112

Warning Icon and Text in Axis Properties. . . . . . . . . . . . . . . . . . . . . 112

Functional Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Chapter 7

Troubleshooting Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Interpret Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

PowerFlex 527 Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . 120

General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Logix 5000 Controller and Drive Behavior . . . . . . . . . . . . . . . . . . . . . . . . 123

PowerFlex 527 Drive Exception Behavior. . . . . . . . . . . . . . . . . . . . . . 124

Appendix A

Supplemental Drive Information Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Appendix B

Accessories and Dimensions Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Replacing the PowerFlex 527 Control Module Internal Fan. . . . . . 157

Appendix C

Out-of-Box Configuration Recommended Out-of-Box Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Setting the ACO/AVO Attribute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Appendix D

Encoder Option Card Usage Installing the Encoder Option Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Removing the Encoder Option Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Encoder Option Card Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Encoder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

HTL/TTL DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 7

Preface

About This Publication The purpose of this manual is to provide you with the basic information that is

needed to install, startup, and troubleshoot the PowerFlex® 527 Adjustable

Frequency AC Drive.

Rockwell Automation recognizes that some of the terms that are currently

used in our industry and in this publication are not in alignment with the

movement toward inclusive language in technology. We are proactively

collaborating with industry peers to find alternatives to such terms and

making changes to our products and content. Please excuse the use of such

terms in our content while we implement these changes.

Download Firmware, AOP,

EDS, and Other Files

Download firmware, associated files (such as AOP, EDS, and DTM), and access

product release notes from the Product Compatibility and Download Center at

rok.auto/pcdc.

Summary of Changes This publication contains the following new or updated information. This list

includes substantive updates only and is not intended to reflect all changes.

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.

Topic Page

Who Should Use this Manual 7

Additional Resources 8

Manual Conventions 8

Drive Frame Sizes 9

General Precautions 10

Catalog Number Explanation 11

Topic Page

Updated template Throughout

Added Inclusive Language acknowledgment 7

Added topic UKCA Conformity 13, 38

Added footnotes to table Altitude Limit (Based on Voltage) 16

Updated section Fuses and Circuit Breakers 20

Updated Fuse and Circuit Breaker tables for 140M/140MT and UL 61800-5-1 applications 21…25

Updated section General Considerations for UK LV Regulations 39, 40

Updated table PFD and PFH Data 87

Updated Certifications 127, 128

Updated table Dynamic Brake Resistors 138

Updated table EMC Line Filters in Appendix B 139

8 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Preface

Additional Resources All recommended documentation that is listed in this section is available

online at rok.auto/literature.

The following publications provide general information:

The following publications provide information on the use and configuration

of GuardLogix® 5570, CompactLogix™ 5370, ControlLogix 5580, GuardLogix

5580, and Compact GuardLogix 5370.

The following publications provide information on the use and configuration

of PowerFlex 527 drives on an EtherNet/IP network.

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:

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

Guarding Against Electrostatic Damage 8000-4.5.2

Industrial Automation Wiring and Grounding Guidelines 1770-4.1

Product Certifications website, rok.auto/certifications

Title Publication

GuardLogix 5570 Controllers User Manual 1756-UM022

GuardLogix 5570 and Compact GuardLogix 5370 Safety Reference Manual 1756-RM099

CompactLogix 5370 Controllers User Manual 1769-UM021

ControlLogix 5580 and GuardLogix 5580 Controllers User Manual 1756-UM543

Compact GuardLogix 5370 Controllers User Manual 1769-UM022

PowerFlex Dynamic Braking Resistor Calculator Application Technique PFLEX-AT001

Title Publication

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

Integrated Motion on the EtherNet/IP Network MOTION-RM003

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-UM002D-EN-E - January 2023 9

Preface

• 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,

Studio 5000 Logix Designer® application is the tool that is 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

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 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, and so on. A cross-reference of

drive catalog numbers and their respective frame sizes is provided in

Appendix B on page 137

10 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Preface

General Precautions

ATTENTION: The drive contains high-voltage capacitors, which take time to

discharge after removal of mains supply. Before working on drive, verify

isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three

minutes for capacitors to discharge to safe voltage levels (DC Bus voltage is

less than 50V DC). 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. Static control 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 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 input voltage or imbalanced input voltages can

cause uncommanded positive speed changes.

2. Actual deceleration times can be longer than commanded deceleration

times.

However, a “Decel Override” fault is generated if the drive remains in this

state for one minute. If this condition is unacceptable, the bus regulator

must be disabled by setting the Bus Regulator Action in the Logix Designer

application. In addition, installing a properly sized dynamic brake resistor

provides equal or better performance in most cases. See Dynamic Brake

Resistors on page 138 to select an appropriate resistor for your drive rating.

ATTENTION: Risk of injury or equipment damage exists. Drive does not

contain user-serviceable components. Do not disassemble drive chassis.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 11

Preface

Catalog Number Explanation

Code Type

25C PowerFlex 527

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

25C – 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

(1)

2.5 A 0.50.40.50.4

4P8

(1)

4.8 B 1.0 0.75 1.0 0.75

6P0

(1)

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

(1)

2.5 A 0.50.40.50.4

4P8

(1)

4.8 A 1.0 0.75 1.0 0.75

8P0

(1)

8.0 B 2.0 1.5 2.0 1.5

011

(1)

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

(1)

2.5 A 0.50.40.50.4

5P0

(1)

5.0 A 1.0 0.75 1.0 0.75

8P0

(1)

8.0 A 2.0 1.5 2.0 1.5

011

(1)

11.0 A 3.0 2.2 3.0 2.2

017

(1)

17.5 B 5.0 4.0 5.0 4.0

024

(1)

24.0 C 7.5 5.5 7.5 5.5

032

(1)

32.2 D 10.0 7.5 10.0 7.5

048

(2)

48.3 E 15.0 11.0 10.0 7.5

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

Code Amps Frame

ND HD

HP kW HP kW

1P4

(1)

1.4 A 0.5 0.4 0.5 0.4

2P3

(1)

2.3 A 1.0 0.75 1.0 0.75

4P0

(1)

4.0 A 2.0 1.5 2.0 1.5

6P0

(1)

6.0 A 3.0 2.2 3.0 2.2

010

(1)

10.5 B 5.0 4.0 5.0 4.0

013

(1)

13.0 C 7.5 5.5 7.5 5.5

017

(1)

17.0 C 10.0 7.5 10.0 7.5

024

(1)

24.0 D 15.0 11.0 15.0 11.0

030

(2)

30.0 D 20.0 15.0 15.0 11.0

037

(2)

37.0 E 25.0 18.5 20.0 15.0

043

(2)

43.0 E 30.0 22.0 25.0 18.5

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

Code Amps Frame

ND HD

HP kW HP kW

0P9

(1)

0.9 A 0.5 0.4 0.5 0.4

1P7

(1)

1.7 A 1.0 0.75 1.0 0.75

3P0

(1)

3.0 A 2.0 1.5 2.0 1.5

4P2

(1)

4.2 A 3.0 2.2 3.0 2.2

6P6

(1)

6.6 B 5.0 4.0 5.0 4.0

9P9

(1)

9.9 C 7.5 5.5 7.5 5.5

012

(1)

12.0 C 10.0 7.5 10.0 7.5

019

(1)

19.0 D 15.0 11.0 15.0 11.0

022

(2)

22.0 D 20.0 15.0 15.0 11.0

Code Voltage Phase

V120V AC1

A240V AC1

B240V AC3

D480V AC3

E600V AC3

Code Enclosure

NIP20 NEMA / Open

Code Interface Module

1Standard

Code EMC Filter

0 No Filter

1 Filter

Code Braking

4Standard

(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(2) 110% Overload capability for up to 60 s, 150% for up to 3 s.

12 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Preface

Notes:

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 13

Chapter

Chapter 1

Installation/Wiring

This chapter provides information on mounting and wiring the PowerFlex 527

drives.

Most startup difficulties are the result of incorrect wiring. Every precaution

must be taken to verify that the wiring is done as instructed. All items must be

read and understood before the actual installation begins.

Mounting Considerations • Mount the drive upright on a flat, vertical, and level surface.

• Protect the cooling fan by avoiding dust or metallic particles.

• Do not expose to a corrosive atmosphere.

• Protect from moisture and direct sunlight.

Topic Page

Mounting Considerations 13

AC Supply Source Considerations 17

General Grounding Requirements 18

Fuses and Circuit Breakers 20

Power and Control Module 26

Control Module Cover 29

Power Module Terminal Guard 29

Power Wiring 30

Power Terminal Block 33

I/O Wiring 33

Control I/O Terminal Block 34

CE Conformity 37

UKCA Conformity 38

ATTENTION: The following information is merely a guide for proper

installation. Rockwell Automation cannot assume responsibility for the

compliance or the noncompliance to any code, national, local or otherwise

for the proper installation of this drive or associated equipment. A hazard of

personal injury and/or equipment damage exists if codes are ignored during

installation.

Frame Screw Size Screw Torque

A M5 (#10…24) 1.56…1.96 N•m (14…17 lb•in)

B M5 (#10…24) 1.56…1.96 N•m (14…17 lb•in)

C M5 (#10…24) 1.56…1.96 N•m (14…17 lb•in)

D M5 (#10…24) 2.45…2.94 N•m (22…26 lb•in)

E M8 (5/16 in) 6.0…7.4 N•m (53…65 lb•in)

14 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Minimum Mounting Clearances

For mounting dimensions, see Product Dimensions on page 144.

(1) For Frame E with Control Module Fan Kit only, clearance of 95 mm (3.7 in.) is required.

(2) For Frame E with Control Module Fan Kit only, clearance of 12 mm (0.5 in.) is required.

Vertical, Zero Stacking

No clearance between drives.

Horizontal, Zero Stacking with

Control Module Fan Kit

No clearance between drives.

Vertical Vertical, Zero Stacking with

Control Module Fan Kit

No clearance between drives.

Vertical with Control Module Fan Kit

Horizontal with Control Module Fan Kit

25 mm

(1.0 in.)

25 mm

(1.0 in.)

(2)

25 mm

(1.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

(1)

50 mm

(2.0 in.)

(1)

50 mm

(2.0 in.)

(1)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

(1)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 15

Chapter 1 Installation/Wiring

Ambient Operating Temperatures

For optional accessories and kits, see Accessories and Dimensions on page 137.

Current Derating Curves

Vertical Mounting

Horizontal/Floor Mounting

Mounting Enclosure Rating

(1)

Ambient Temperature

Minimum Maximum (No Derate) Maximum (Derate)

(2)

Maximum with

Control Module Fan Kit (Derate)

(3)(5)

Vertical

IP 20/Open Type

-20 °C (-4 °F)

50 °C (122 °F) — 70 °C (158 °F)

IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) –

Vertical, Zero Stacking IP 20/Open Type 45 °C (113 °F) — 65 °C (149 °F)

Horizontal with

Control Module Fan Kit

(4)(5)

IP 20/Open Type 50 °C (122 °F) — 70 °C (158 °F)

Horizontal, Zero Stacking

with Control Module Fan Kit

(4)(5)

IP 20/Open Type 45 °C (113 °F) — 65 °C (149 °F)

(1) IP 30/NEMA 1/UL Type 1 rating requires installation of the PowerFlex 520-Series IP 30/NEMA 1/UL Type 1 option kit, catalog number 25-JBAx.

(2) For catalogs 25C-D1P4N104 and 25C-E0P9N104, the temperature that is listed under the Maximum (Derate) column is reduced by 5 °C (9 °F) for all mounting methods.

(3) For catalogs 25C-D1P4N104 and 25C-E0P9N104, the temperature that is listed under the Maximum with Control Module Fan Kit (Derate) column is reduced by 10 °C (18 °F) for vertical and

vertical with zero stacking mounting methods only.

(4) Catalogs 25C-D1P4N104 and 25C-E0P9N104 cannot be mounted using either of the horizontal mounting methods.

(5) Requires installation of the PowerFlex 520-Series Control Module Fan Kit, catalog number 25-FANx-70C.

Single Drive Zero Stacking

Ambient Temperature (°C)

100

110

120

45403530

60 65 70 75 80

5550

Percentage of Rated Current (%)

IP 30/NEMA 1

with Control

Module Fan Kit

IP 20/Open Type

Ambient Temperature (°C)

100

110

120

45403530

60 65 70 75 80

5550

Percentage of Rated Current (%)

with Control

Module Fan Kit

IP 20/Open Type

Single Drive Zero Stacking

Ambient Temperature (°C)

100

120

110

30 35

70 75 80

60 6550 5540 45

Percentage of Rated Current (%)

with Control

Module Fan Kit

IP 20/Open Type

Ambient Temperature (°C)

100

120

110

30 35

70 75 80

60 6550 5540 45

Percentage of Rated Current (%)

with Control

Module Fan Kit

IP 20/Open Type

16 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Derating Guidelines for High Altitude

The drive can be used without derating at a maximum altitude of

1000 m (3300 ft). If the drive is used above 1000 m (3300 ft):

• Derate the maximum ambient temperature by 5 °C (9 °F) for every

additional 1000 m (3300 ft), subject to limits listed in Table 1

• Derate the output current by 10% for every additional 1000 m (3300 ft),

up to 3000 m (9900 ft), subject to limits listed in Table 1

High Altitude

Debris Protection

Take precautions to prevent debris from falling through the vents of the drive

housing during installation.

Storage

• Store within an ambient temperature range of -40…+85 °C

(-140…+185 °F)

(1)

• Store within a relative humidity range of 0…95%, noncondensing.

• Do not expose to a corrosive atmosphere.

Table 1 - Altitude Limit (Based on Voltage)

Drive Rating

Center Ground (Wye Neutral)

(1)

(1) The circuit breaker that is used in the drive may have different altitude specifications. See publications 140UT-TD001 and

140-TD005

for more information.

Corner Ground, Impedance Ground,

or Ungrounded

(1)(2)

(2) Impedance Ground and Ungrounded limits are not evaluated as part of UL specifications.

100…120V 1-Phase 6000 m 6000 m

200…240V 1-Phase 2000 m 2000 m

200…240V 3-Phase 6000 m 2000 m

380…480V 3-Phase 4000 m 2000 m

525…600V 3-Phase 2000 m 2000 m

(1) The maximum ambient temperature for storing a Frame E drive is 70 °C (158 °F).

Altitude (m)

Percentage of Rated Current (%)

100

110

120

4000

300020001000

Altitude (m)

Ambient Temperature (°C)

4000

300020001000

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 17

Chapter 1 Installation/Wiring

AC Supply Source

Considerations

Ungrounded Distribution Systems

Disconnecting MOVs

To help prevent drive damage, the MOVs connected to ground shall be

disconnected if the drive is installed on an ungrounded distribution system (IT

mains) where the line-to-ground voltages on any phase could exceed 125% of

the nominal line-to-line voltage. To disconnect these devices, remove the

jumper that is shown in the following diagrams.

1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.

3. Tighten the screw to keep it in place.

Jumper Location (Typical)

Phase to Ground MOV Removal

ATTENTION:

• PowerFlex 527 drives contain protective MOVs that are referenced to ground.

These devices must be disconnected if the drive is installed on an

ungrounded or resistive grounded distribution system.

• Removing MOVs in drives with an embedded filter will also disconnect the

filter capacitor from earth ground.

IMPORTANT Tighten screw after jumper removal.

Power module

R/L1

S/L2

T/L3

1234

3-phase

AC input

Jumper

18 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated

voltage of the drive (see Technical Specifications

on page 129). Listed in Table 2

are certain input power conditions which may cause component damage or

reduction in product life. If any of these conditions exist, install one of the

devices that are listed under the heading Corrective Action on the line side of

the drive.

General Grounding

Requirements

The drive Safety Ground - (PE) must be connected to system ground.

Ground impedance must conform to the requirements of national and local

industrial safety regulations and/or electrical codes. The integrity of all ground

connections should be periodically checked.

Typical Grounding

Ground Fault Monitoring

If a system ground fault monitor (RCD) is to be used, only Type B (adjustable)

devices should be used to avoid nuisance tripping.

IMPORTANT Only one device per branch circuit is required. It should be mounted

closest to the branch and sized to handle the total current of the branch

circuit.

Table 2 - Input Power Conditions

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance)

• Install Line Reactor.

(1)

• Install Isolation Transformer.

(1) See Accessories and Dimensions on page 137 for accessory ordering information.

Greater than 120 kVA supply transformer

Line has power factor correction capacitors

• Install Line Reactor.

(1)

• Install Isolation Transformer.

Line has frequent power interruptions

Line has intermittent noise spikes in excess of 6000V (lightning)

Phase to ground voltage exceeds 125% of normal line-to-line voltage • Remove MOV jumper to ground.

• Install Isolation Transformer with

grounded secondary if necessary.

Ungrounded distribution system

240V open delta configuration (stinger leg)

(2)

(2) For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is

tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” and so on. This leg should

be identified throughout the system with red or orange tape on the wire at each connection point. The stinger leg should be

connected to the center Phase B on the reactor. See Bulletin 1321-3R Series Line Reactors

on page 143 for specific line

reactor part numbers.

• Install Line Reactor.

(1)

SHLD

U/T1

V/T2

W/T3

R/L1

S/L2

T/L3

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 19

Chapter 1 Installation/Wiring

Safety Ground - (PE)

This is the safety ground for the drive that is required by code. One of these

points must be connected to adjacent building steel (girder, joist), a floor

ground rod, or busbar. Grounding points must comply with national and local

industrial safety regulations and/or electrical codes.

Motor Ground

The motor ground must be connected to one of the ground terminals on the

drive.

Shield Termination - SHLD

Either of the safety ground terminals that are located on the power terminal

block provides a grounding point for the motor cable shield. The motor cable

shield connected to one of these terminals (drive end) should also be

connected to the motor frame (motor end). Use a shield terminating or EMI

clamp to connect the shield to the safety ground terminal. The earthing plate

or conduit box option may be used with a cable clamp for a grounding point

for the cable shield.

When shielded cable is used for control and signal wiring, the shield should be

grounded at the source end only, not at the drive end.

RFI Filter Grounding

Using a drive with filter may result in relatively high ground leakage currents.

Therefore, the filter must only be used in installations with grounded AC

supply systems and be permanently installed and solidly grounded (bonded)

to the building power distribution ground. Verify that the incoming supply

neutral is solidly connected (bonded) to the same building power distribution

ground. Grounding must not rely on flexible cables and should exclude any

form of plug or socket that would permit inadvertent disconnection. Some

local codes may require redundant ground connections. The integrity of all

connections should be periodically checked.

20 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Fuses and Circuit Breakers The PowerFlex 527 drive does not provide branch short circuit protection. This

product should be installed with either input fuses or an input circuit breaker.

National and local industrial safety regulations and/or electrical codes may

determine additional requirements for these installations.

The tables under Fuses and Circuit Breakers for PowerFlex 527

on page 21

provide recommended AC line input fuse and circuit breaker information. See

Fusing and Circuit Breakers below for UL and IEC requirements. Sizes that are

listed are the recommended sizes based on 40 °C(104 °F) and the U.S. N.E.C.

Other country, state, or local codes may require different ratings.

Fusing

The recommended fuse types are listed in the tables under Fuses and Circuit

Breakers for PowerFlex 527 on page 21. If available current ratings do not

match those listed in the tables provided, choose the next higher fuse rating.

• IEC – BS88 (British Standard) Parts 1 & 2

(1)

, EN60269-1, Parts 1 & 2, type

GG or equivalent should be used.

• UL – UL Class CC, T, or J should be used.

Circuit Breakers

The “non-fuse” listings in the tables under Fuses and Circuit Breakers for

PowerFlex 527 on page 21 include inverse time circuit breakers, instantaneous

trip circuit breakers (motor circuit protectors), and 140M/140MT self-protected

combination motor controllers. If one of these is chosen as the desired

protection method, the following requirements apply:

• IEC – Both types of circuit breakers and 140M/140MT self-protected

combination motor controllers are acceptable for IEC installations.

• UL – Only inverse time circuit breakers and the specified 140M/140MT

self-protected combination motor controllers are acceptable for UL

installations.

Bulletin 140M/140MT (Self-Protected Combination Controller)/UL489 Circuit Breakers

When using Bulletin 140M/140MT or UL489 rated circuit breakers, the

following guidelines that are listed must be followed to meet the NEC

requirements for branch circuit protection.

• Bulletin 140M/140MT can be used in single motor applications.

• Bulletin 140M/140MT can be used up stream from the drive without the

need for fuses.

If the DC Bus terminals or the Dynamic Brake terminals are used, the drive

must be installed in an enclosure and fuses must be used for input protection

(for CE applications only). The ventilated enclosure needs to be IP 20 rating or

higher and at least 1.5x size larger than the drive.

(1) Typical designations include, but may not be limited to the following;

Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 21

Chapter 1 Installation/Wiring

Fuses and Circuit Breakers for PowerFlex 527

100...120V 1-Phase Input Protection Devices – Frames A...B — IEC (Non-UL) Applications

Catalog No.

(1)

Output Ratings Input Ratings

Frame Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current A

(2)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U

140M/140MT

(3)(4)(5)

25C-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 15 20 140U-D6D2-C12

140M-C2E-C10

140MT-D9E-C10

25C-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 25 40 140U-D6D2-C25

140M-D8E-C20

140MT-D9E-C20

25C-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 30 50 140U-D6D2-C30 140M-F8E-C25

(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

100...120V 1-Phase Input Protection Devices – Frames A...B — UL 61800-5-1 Applications

Catalog No.

(1)

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

UL 61800-5-1 Applications

ND HD

AkVA

Max Current A

(2)

Fuses (Max. Rating) Circuit Breakers

Hp kW Hp kW Class / Catalog No. 140UT

140M/140MT

(3)(4)(5)

25C-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 CLASS CC, J, or T/20 140UT-D7D2-C12

140MT-C3E-C10

140MT-D9E-C10

25C-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 CLASS CC, J, or T/40

—

(6)

140MT-D9E-C20

25C-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 CLASS CC, J, or T/50

—

(6)

140M-F8E-C25

(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(6) Circuit breaker selection is not available for this drive rating.

200...240V 1-Phase Input Protection Devices – Frames A...B — IEC (Non-UL) Applications

Catalog No.

(1)

Output Ratings Input Ratings

Frame Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current A

(2)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U

140M/140MT

(3)(4)(5)

25C-A2P5N104 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 15 140U-D6D2-C10

140M-C2E-C10

140MT-D9E-C10

25C-A2P5N114 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 15 140U-D6D2-C10

140M-C2E-C10

140MT-D9E-C10

25C-A4P8N104 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 15 25 140U-D6D2-C15

140M-C2E-C16

140MT-D9E-C16

25C-A4P8N114 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 15 25 140U-D6D2-C15

140M-C2E-C16

140MT-D9E-C16

25C-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140U-D6D2-C25 140M-F8E-C25

25C-A8P0N114 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140U-D6D2-C25 140M-F8E-C25

25C-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25

25C-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 30 50 140U-H6C2-C35 140M-F8E-C25

(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

22 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

200...240V 1-Phase Input Protection Devices – Frames A...B — UL 61800-5-1 Applications

Catalog No.

(1)

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

UL 61800-5-1 Applications

ND HD

AkVA

Max

Current

(2)

Fuses (Max. Rating) Circuit Breakers

Hp kW Hp kW Class / Catalog No. 140UT

140M/140MT

(3)(4)(5)

25C-A2P5N104 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 CLASS CC, J, or T/15 140UT-D7D2-C10 140MT-D9E-C10

25C-A2P5N114 0.5 0.4 0.5 0.4 2.5 1T.7 6.5 A 100-C09 CLASS CC, J, or T/15 140UT-D7D2-C10 140MT-D9E-C10

25C-A4P8N104 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 CLASS CC, J, or T/25 140UT-D7D2-C15 140MT-D9E-C16

25C-A4P8N114 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 CLASS CC, J, or T/25 140UT-D7D2-C15 140MT-D9E-C16

25C-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 CLASS CC, J, or T/40

—

(6)

140M-F8E-C25

25C-A8P0N114 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 CLASS CC, J, or T/40

—

(6)

140M-F8E-C25

25C-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 CLASS CC, J, or T/50

—

(6)

140M-F8E-C25

25C-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 CLASS CC, J, or T/50

—

(6)

140M-F8E-C25

(1) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(2) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(6) Circuit breaker selection is not available for this drive rating.

200...240V 3-Phase Input Protection Devices – Frames A...B — IEC (Non-UL) Applications

Catalog No.

Output Ratings Input Ratings

Frame Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current

(1)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U

140M/140MT

(2)(3)(4)

25C-B2P5N104

(5)

0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C07 6 6 140U-D6D3-B40

140M-C2E-B40

140MT-D9E-B40

25C-B5P0N104

(5)

1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 10 15 140U-D6D3-B80

140M-C2E-B63

140MT-D9E-B63

25C-B8P0N104

(5)

2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 15 20 140U-D6D3-C10

140M-C2E-C10

140MT-D9E-C10

25C-B011N104

(5)

3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 20 30 140U-D6D3-C15

140M-C2E-C16

140MT-D9E-C16

25C-B017N104

(5)

5.0 4.0 5.0 4.0 17.5 9.6 21.1 B 100-C23 30 45 140U-D6D3-C25 140M-F8E-C25

25C-B024N104

(5)

7.5 5.5 7.5 5.5 24.0 12.2 26.6 C 100-C37 35 60 140U-H6C3-C35 140M-F8E-C32

25C-B032N104

(5)

10.0 7.5 10.0 7.5 32.2 15.9 34.8 D 100-C43 45 70 140U-H6C3-C60 140M-F8E-C45

25C-B048N104

(6)

15.0 11.0 10.0 7.5 48.3 20.1 44.0 E 100-C60 60 90 140U-H6C3-C70 140M-F8E-C45

25C-B062N104

(6)

20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 70 125 140U-H6C3-C90 140M-H8P-C70

(1) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(2) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(3) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(4) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(5) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(6) 110% Overload capability for up to 60 s, 150% for up to 3 s.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 23

Chapter 1 Installation/Wiring

200...240V 3-Phase Input Protection Devices – Frames A...E — UL 61800-5-1 Applications

Catalog No.

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

UL 61800-5-1 Applications

ND HD

AkVA

Max Current

(1)

Fuses (Max. Rating) Circuit Breakers

Hp kW Hp kW Class / Catalog No. 140UT

140M/140MT

(2)(3)(4)

25C-B2P5N104

(5)

0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C07 CLASS CC, J, or T/6 140UT-D7D3-B40 140MT-D9E-B40

25C-B5P0N104

(5)

1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 CLASS CC, J, or T/15 140UT-D7D3-B80 140MT-D9E-B63

25C-B8P0N104

(5)

2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 CLASS CC, J, or T/20 140UT-D7D3-C10 140MT-D9E-C10

25C-B011N104

(5)

3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 CLASS CC, J, or T/30 140UT-D7D3-C15 140MT-D9E-C16

25C-B017N104

(5)

5.0 4.0 5.0 4.0 17.5 9.6 21.1 B 100-C23 CLASS CC, J, or T/45 140UT-D7D3-C25 140M-F8E-C25

25C-B024N104

(5)

7.5 5.5 7.5 5.5 24.0 12.2 26.6 C 100-C37 CLASS CC, J, or T/60

—

(6)

140M-F8E-C32

25C-B032N104

(5)

10.0 7.5 10.0 7.5 32.2 15.9 34.8 D 100-C43 CLASS CC, J, or T/70

—

(6)

140M-F8E-C45

25C-B048N104

(7)

15.0 11.0 10.0 7.5 48.3 20.1 44.0 E 100-C60 CLASS CC, J, or T/90

—

(6)

140M-F8E-C45

25C-B062N104

(7)

20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 CLASS CC, J, or T/125

—

(6)

140M-H8P-C70

(1) When the drive is controlling motors with lower amp ratings, refer to the drive nameplate for drive input current rating.

(2) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(3) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(4) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(5) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(6) Circuit breaker selection is not available for this drive rating.

(7) 110% Overload capability for up to 60 s, 150% for up to 3 s.

380...480V 3-Phase Input Protection Devices – Frames A...E— IEC (Non-UL) Applications

Catalog No

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current A

(1)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U

140M/MT

(2)(3)(4)

25C-D1P4N104

(5)

0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30

140M-C2E-B25

140MT-C3E-B25

25C-D1P4N114

(5)

0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 3 6 140U-D6D3-B30

140M-C2E-B25

140MT-C3E-B25

25C-D2P3N104

(5)

1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60

140M-C2E-B40

140MT-C3E-B40

25C-D2P3N114

(5)

1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 6 10 140U-D6D3-B60

140M-C2E-B40

140MT-C3E-B40

25C-D4P0N104

(5)

2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60

140M-C2E-B63

40MT-C3E-B63

25C-D4P0N114

(5)

2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 15 140U-D6D3-B60

140M-C2E-B63

40MT-C3E-B63

25C-D6P0N104

(5)

3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10

140M-C2E-C10

140MT-C3E-C10

25C-D6P0N114

(5)

3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 15 140U-D6D3-C10

140M-C2E-C10

140MT-C3E-C10

25C-D010N104

(5)

5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15

140M-C2E-C16

140MT-D9E-C16

25C-D010N114

(5)

5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 30 140U-D6D3-C15

140M-C2E-C16

140MT-D9E-C16

25C-D013N104

(5)

7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25

140M-D8E-C20

140MT-D9E-C20

25C-D013N114

(5)

7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35 140U-D6D3-C25

140M-D8E-C20

140MT-D9E-C20

25C-D017N104

(5)

10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25

140M-D8E-C20

140MT-D9E-C20

25C-D017N114

(5)

10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140U-D6D3-C25

140M-D8E-C20

140MT-D9E-C20

25C-D024N104

(5)

15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32

25C-D024N114

(5)

15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 60 140U-H6C3-C40 140M-F8E-C32

25C-D030N104

(6)

20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45

25C-D030N114

(6)

20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45

25C-D037N114

(6)

25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 45 70 140U-H6C3-C50 140M-F8E-C45

25C-D043N114

(6)

30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 50 80 140U-H6C3-C60 140M-F8E-C45

24 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

(1) When the drive is controlling motors with lower ampere ratings, see the drive nameplate for drive input current rating.

(2) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005 or 140M-TD002.

(3) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(4) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(5) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(6) 110% Overload capability for up to 60 s, 150% for up to 3 s.

380…480V 3-Phase Input Protection Devices – Frames A…E — UL 61800-5-1 Applications

Catalog No.

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

UL 61800-5-1 Applications

ND HD

AkVA

Max Current A

(1)

Fuses (Max Rating) Circuit Breakers

Hp kW Hp kW Class/Catalog No.

140UT

(2)

140M/MT

(3)(4)(5)

25C-D1P4N104

(6)

0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 CLASS CC, J, or T/6 — 140MT-C3E-B25

25C-D1P4N114

(6)

0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C07 CLASS CC, J, or T/6 — 140MT-C3E-B25

25C-D2P3N104

(6)

1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 CLASS CC, J, or T/10 — 140MT-C3E-B40

25C-D2P3N114

(6)

1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C07 CLASS CC, J, or T/10 — 140MT-C3E-B40

25C-D4P0N104

(6)

2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 CLASS CC, J, or T/15 — 140MT-C3E-B63

25C-D4P0N114

(6)

2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 CLASS CC, J, or T/15 — 140MT-C3E-B63

25C-D6P0N104

(6)

3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 CLASS CC, J, or T/15 — 140MT-C3E-C10

25C-D6P0N114

(6)

3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 CLASS CC, J, or T/15 — 140MT-C3E-C10

25C-D010N104

(6)

5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 CLASS CC, J, or T/30 — 140MT-D9E-C16

25C-D010N114

(6)

5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 CLASS CC, J, or T/30 — 140MT-D9E-C16

25C-D013N104

(6)

7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 CLASS CC, J, or T/35 — 140MT-D9E-C20

25C-D013N114

(6)

7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 CLASS CC, J, or T/35 — 140MT-D9E-C20

25C-D017N104

(6)

10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 CLASS CC, J, or T/40 — 140MT-D9E-C20

25C-D017N114

(6)

10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 CLASS CC, J, or T/40 — 140MT-D9E-C20

25C-D024N104

(6)

15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 CLASS CC, J, or T/60 — 140M-F8E-C32

25C-D024N114

(6)

15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 CLASS CC, J, or T/60 — 140M-F8E-C32

25C-D030N104

(7)

20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 CLASS CC, J, or T/70 — 140M-F8E-C45

25C-D030N114

(7)

20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 CLASS CC, J, or T/70 — 140M-F8E-C45

25C-D037N114

(7)

25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 CLASS CC, J, or T/70 — 140M-F8E-C45

25C-D043N114

(7)

30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 CLASS CC, J, or T/80 — 140M-F8E-C45

(1) When the drive is controlling motors with lower ampere ratings, see the drive nameplate for drive input current rating.

(2) Circuit breaker selection is not available for this drive rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(6) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(7) 110% Overload capability for up to 60 s, 150% for up to 3 s.

525…600V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications

Catalog No.

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current A

(1)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U/140G

140M/MT

(2)(3)(4)

25C-E0P9N104

(5)

0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 3 6 140U-D6D3-B20

140M-C2E-B25

140MT-C3E-B25

25C-E1P7N104

(5)

1.0 0.75 1.0 0.75 1.7 2.6 2.3 A 100-C09 3 6 140U-D6D3-B30

140M-C2E-B25

140MT-C3E-B25

25C-E3P0N104

(5)

2.0 1.5 2.0 1.5 3.0 4.3 3.8 A 100-C09 6 10 140U-D6D3-B50

140M-C2E-B40

140MT-C3E-B40

25C-E4P2N104

(5)

3.0 2.2 3.0 2.2 4.2 6.1 5.3 A 100-C09 10 15 140U-D6D3-B80

140M-C2E-B63

140MT-D9E-B63

25C-E6P6N104

(5)

5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 10 20 140U-D6D3-C10

140M-C2E-C10

140MT-D9E-C10

25C-E9P9N104

(5)

7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 15 25 140U-D6D3-C15

140M-C2E-C16

140MT-D9E-C16

25C-E012N104

(5)

10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 20 30 140U-D6D3-C20

140M-C2E-C16

140MT-D9E-C16

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 25

Chapter 1 Installation/Wiring

25C-E019N104

(5)

15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 30 50 140U-H6C3-C30 140M-F8E-C25

25C-E022N104

(6)

20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 35 60 140U-H6C3-C35 140M-F8E-C32

25C-E027N104

(6)

25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 35 50 140U-H6C3-C35 140M-F8E-C32

25C-E032N104

(6)

30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 40 60 140U-H6C3-C50 140M-F8E-C32

(1) When the drive is controlling motors with lower ampere ratings, see the drive nameplate for drive input current rating.

(2) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(3) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(4) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 480Y/277 and 600Y/347 AC input. Not UL Listed for use on 480V or 600V Delta/Delta, corner ground, or high-

resistance ground systems.

(5) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(6) 110% Overload capability for up to 60 s, 150% for up to 3 s.

525…600V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications (Continued)

Catalog No.

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

IEC (Non-UL) Applications

ND HD

AkVA

Max Current A

(1)

Fuses (Rating) Circuit Breakers

Hp kW Hp kW Min Max 140U/140G

140M/MT

(2)(3)(4)

525…600V 3-Phase Input Protection Devices – Frames A…E — UL 61800-5-1 Applications

Catalog No.

Output Ratings Input Ratings

Frame

Size

Contactor

Cat. No.

UL 61800-5-1 Applications

ND HD

AkVA

Max Current A

(1)

Fuses (Max Rating) Circuit Breakers

Hp kW Hp kW Class/Catalog No.

140UT

(2)

140M/MT

(3)(4)(5)

25C-E0P9N104

(6)

0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 CLASS CC, J, or T/6 — 140MT-C3E-B25

25C-E1P7N104

(6)

1.0 0.75 1.0 0.75 1.7 2.6 2.3 A 100-C09 CLASS CC, J, or T/6 — 140MT-C3E-B25

25C-E3P0N104

(6)

2.0 1.5 2.0 1.5 3.0 4.3 3.8 A 100-C09 CLASS CC, J, or T/10 — 140MT-C3E-B40

25C-E4P2N104

(6)

3.0 2.2 3.0 2.2 4.2 6.1 5.3 A 100-C09 CLASS CC, J, or T/15 — 140MT-D9E-B63

25C-E6P6N104

(6)

5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 CLASS CC, J, or T/20 — 140MT-D9E-C10

25C-E9P9N104

(6)

7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 CLASS CC, J, or T/25 — 140MT-D9E-C16

25C-E012N104

(6)

10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 CLASS CC, J, or T/30 — 140MT-D9E-C16

25C-E019N104

(6)

15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 CLASS CC, J, or T/50 — 140M-F8E-C25

25C-E022N104

(7)

20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 CLASS CC, J, or T/60 — 140M-F8E-C32

25C-E027N104

(7)

25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 CLASS CC, J, or T/50 — 140M-F8E-C32

25C-E032N104

(7)

30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 CLASS CC, J, or T/60 — 140M-F8E-C32

(1) When the drive is controlling motors with lower ampere ratings, see the drive nameplate for drive input current rating.

(2) Circuit breaker selection is not available for this drive rating.

(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication 140-TD005

or 140M-TD002.

(4) Bulletin 140M/MT with adjustable current range should have the current trip set to the minimum range that the device will not trip.

(5) Manual Self-Protected (Type E) Combination Motor Controller, UL Listed for 208V Wye or Delta, 240V Wye or Delta, 480V Y/277 or 600V Y/347. Not UL Listed for use on 480V or 600V Delta/

Delta, corner ground, or high-resistance ground systems.

(6) 150% Overload capability for up to 60 s, 180% for up to 3 s.

(7) 110% Overload capability for up to 60 s, 150% for up to 3 s.

26 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Power and Control Module

PowerFlex 527 drives consist of a Power Module and Control Module. This

section describes how to separate the two modules and reconnect them back

together, and also how to access the power terminals and control terminals. It

is assumed that your drive is new and has not been installed.

Separating the Power and Control Module

1. Press and hold down the catch on both sides of the frame cover, then pull

out and swing upwards to remove (Frames B…E only).

2. Press down and slide out the top cover of the Control Module to unlock it

from the Power Module.

ATTENTION: If you are performing these steps on a drive that has been

installed, verify that the drive is powered down and the DC Bus voltage is

less than 50V DC before proceeding.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 27

Chapter 1 Installation/Wiring

3. Hold the sides and top of the Control Module firmly, then pull out to

separate it from the Power Module.

Connecting the Power and Control Module

1. Align the connectors on the Power Module and Control Module, then

push the Control Module firmly onto the Power Module.

28 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

2. Push the top cover of the Control Module towards the Power Module to

lock it.

3. Insert the catch at the top of the frame cover into the Power Module, then

swing the frame cover to snap the side catches onto the Power Module

(Frames B...E only).

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 29

Chapter 1 Installation/Wiring

Control Module Cover To access the control terminals, the front cover must be removed. To remove:

1. Press and hold down the arrow on the front of the cover.

2. Slide the front cover down to remove from the Control Module.

Reattach the front cover when wiring is complete.

Power Module Terminal

Guard

To access the power terminals, the terminal guard must be removed. To

remove:

1. Press and hold down the catch on both sides of the frame cover, then pull

out and swing upwards to remove (Frames B…E only).

2. Press and hold down the locking tab on the terminal guard.

30 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

3. Slide the terminal guard down to remove from the Power Module.

Reattach the terminal guard when wiring is complete.

To access the power terminals for Frame A, you need to separate the Power and

Control Modules. See Separating the Power and Control Module

on page 26 for

instructions.

Power Wiring For general wiring and grounding practices, see the Wiring and Grounding for

Pulse Width Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

Motor Cable Types Acceptable for 100…600 Volt Installations

A variety of cable types are acceptable for drive installations. For many

installations, unshielded cable is adequate, provided it can be separated from

sensitive circuits. As an approximate guide, allow a spacing of 0.3 m (1 ft) for

every 10 m (32.8 ft) of length. In all cases, long parallel runs must be avoided.

Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015

in.). Do not route more than three sets of motor leads in one conduit to

minimize “cross talk”. If more than three drive/motor connections per conduit

are required, shielded cable must be used.

• UL installations above 50 °C (122 °F) ambient must use 600V, 90 °C

(194 °F) wire.

• UL installations in 50 °C (122 °F) ambient must use 600V, 75 °C or 90 °C

(167 °F or 194 °F) wire.

• UL installations in 40 °C (104 °F) ambient should use 600V, 75 °C or 90 °C

(167 °F or 194 °F) wire.

ATTENTION:

• National Codes and standards (NEC, VDE, BSI, and so on) and local codes

outline provisions for safely installing electrical equipment. Installation must

comply with specifications regarding wire types, conductor sizes, branch

circuit protection, and disconnect devices. Failure to do so may result in

personal injury and/or equipment damage.

• To avoid a possible shock hazard that is caused by induced voltages, unused

wires in the conduit must be grounded at both ends. For the same reason, if

a drive sharing a conduit is being serviced or installed, all drives using this

conduit should be disabled. This will help minimize the possible shock

hazard from “cross coupled” power leads.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 31

Chapter 1 Installation/Wiring

Use copper wire only. Wire gauge requirements and recommendations are

tables that are provided on 75 °C (167 °F). Do not reduce wire gauge when using

higher temperature wire.

Unshielded

THHN, THWN, or similar wire is acceptable for drive installation in dry

environments provided adequate free air space and/or conduit fill rate limits

are provided. Any wire that is chosen must have a minimum insulation

thickness of 15 mils and should not have large variations in insulation

concentricity.

Shielded/Armored Cable

Shielded cable contains all the general benefits of multi-conductor cable with

the added benefit of a copper braided shield that can contain much of the noise

that is generated by a typical AC Drive. Strong consideration for shielded cable

should be given in installations with sensitive equipment such as weigh scales,

capacitive proximity switches, and other devices that may be affected by

electrical noise in the distribution system. Applications with large numbers of

drives in a similar location, imposed EMC regulations or a high degree of

communications / networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing

currents for some applications. In addition, the increased impedance of

shielded cable may help extend the distance that the motor can be located from

the drive without the addition of motor protective devices such as terminator

networks. See Reflected Wave in the Wiring and Grounding for Pulse Width

Modulated (PWM) AC Drives Installation Instructions,

publication DRIVES-IN001

Consideration should be given to all general specifications dictated by the

environment of the installation, including temperature, flexibility, moisture

characteristics, and chemical resistance. In addition, a braided shield should

be included and be specified by the cable manufacturer as having coverage of

at least 75%. An additional foil shield can greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx determines

gauge). This cable has four XLPE insulated conductors with a 100% coverage

foil and an 85% coverage copper braided shield surrounded by a PVC jacket.

Other types of shielded cable are available, but the selection of these types may

limit the allowable cable length. Particularly, some of the newer cables twist

four conductors of THHN wire and wrap them tightly with a foil shield. This

construction can greatly increase the cable charging current required and

reduce the overall drive performance. Unless specified in the individual

distance tables as tested with the drive, these cables are not recommended and

their performance against the lead length limits supplied is not known.

ATTENTION: The distance between the drive and motor must not exceed the

maximum cable length that is stated in the Motor Cable Length Restrictions

Tables in the Wiring and Grounding for Pulse Width Modulated (PWM) AC

Drives Installation Instructions, publication DRIVES-IN001

ATTENTION: Do not use THHN or similarly coated wire in wet areas.

32 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Reflected Wave Protection

The drive should be installed as close to the motor as possible. Installations

with long motor cables may require the addition of external devices to limit

voltage reflections at the motor (reflected wave phenomena). See Reflected

Wave in the Wiring and Grounding for Pulse Width Modulated (PWM) AC

Drives Installation Instructions, publication DRIVES-IN001

The reflected wave data applies to all carrier frequencies 2…8 kHz.

Note: For 240V ratings and lower, reflected wave effects do not need to be

considered.

Output Disconnect

The drive is intended to be commanded by motion commands that will start

and stop the motor. A device that routinely disconnects then reapplies output

power to the motor for starting and stopping the motor should not be used. If

it is necessary to disconnect power to the motor with the drive outputting

power, use the Logix Designer application to disable the drive (Aux Fault or

Coast to Stop).

Recommended Shielded Wire

Location Rating/Type Description

Standard (Option 1)

600V, 90 °C (194 °F) XHHW2/RHW-2

Anixter B209500-B209507, Belden

29501-29507, or equivalent

• Four tinned copper conductors with XLPE insulation.

• Copper braid/aluminum foil combination shield and

tinned copper drain wire.

• PVC jacket.

Standard (Option 2)

Tray rated 600V, 90 °C (194 °F)

RHH/RHW-2 Anixter OLF-7xxxxx or

equivalent

• Three tinned copper conductors with XLPE

insulation.

• 5 mil single helical copper tape (25% overlap min.)

with three bare copper grounds in contact with

shield.

• PVC jacket.

Class I & II;

Division I & II

Tray rated 600V, 90 °C (194 °F)

RHH/RHW-2 Anixter 7V-7xxxx-3G or

equivalent

• Three bare copper conductors with XLPE insulation

and impervious corrugated continuously welded

aluminum armor.

• Black sunlight resistant PVC jacket overall.

• Three copper grounds on #10 AWG and smaller.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 33

Chapter 1 Installation/Wiring

Power Terminal Block Power Terminal Block

I/O Wiring Motor Start/Stop Precautions

Important points to remember about I/O wiring:

• Always use copper wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Control and signal wires should be separated from power wires by at

least 0.3 m (1 ft).

Terminal Description

R/L1, S/L2 1-Phase Input Line Voltage Connection

R/L1, S/L2, T/L3 3-Phase Input Line Voltage Connection

U/T1, V/T2, W/T3 Motor Phase Connection =

Switch any two motor leads to change

forward direction or change the

Motion Polarity within Studio 5000

Logix Designer application > Axis

Properties > Polarity category.

DC+, DC- DC Bus Connection

BR+, BR- Dynamic Brake Resistor Connection

Safety Ground - PE

IMPORTANT Terminal screws may become loose during shipment. Verify that all

terminal screws are tightened to the recommended torque before

applying power to the drive.

Power Terminal Block Wire Specifications

Frame

Maximum Wire Size

(1)

(1) Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

Minimum Wire Size

(1)

Torque

5.3 mm

(10 AWG) 0.8 mm

(18 AWG)

1.76…2.16 N•m (15.6…19.1 lb•in)

8.4 mm

(8 AWG) 2.1 mm

(14 AWG)

1.76…2.16 N•m(15.6…19.1 lb•in)

8.4 mm

(8 AWG) 2.1 mm

(14 AWG)

1.76…2.16 N•m (15.6…19.1 lb•in)

13.3 mm

(6 AWG) 5.3 mm

(10 AWG)

1.76…2.16 N•m (15.6…19.1 lb•in)

26.7 mm

(3 AWG) 8.4 mm

(8 AWG)

3.09…3.77 N•m (27.3…33.4 lb•in)

V/T2T/L3S/L2R/L1 U/T1 W/T3

BR+

BR-

DC- DC+

BR+

BR-

DC-

DC+

Frame A, B, C & D Frame E

ATTENTION: A contactor or other device that routinely disconnects and

reapplies the AC line to the drive to start and stop the motor can cause drive

hardware damage. The drive is designed to use control input signals that will

start and stop the motor. If used, the input device must not exceed one

operation per minute or drive damage can occur.

IMPORTANT I/O terminals labeled “Common” are not referenced to the safety ground

(PE) terminal and are designed to greatly reduce common mode

interference.

34 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Signal and Control Wire Types

Recommendations are for 50 °C (122 °F) ambient temperature.

75 °C (167 °F) wire must be used for 60 °C (140 °F) ambient temperature.

90 °C (194 °F) wire must be used for 70 °C (158 °F) ambient temperature.

Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 m (100 ft). Control signal cable

length is highly dependent on electrical environment and installation

practices. To improve noise immunity, the I/O terminal block Common may be

connected to ground terminal/protective earth.

Control I/O Terminal Block

ATTENTION: Driving the 4-20 mA analog input from a voltage source could

cause component damage. Verify proper configuration before applying

input signals.

ATTENTION: Due to its control circuitry difference from the PowerFlex 523

and PowerFlex 525 drives, connecting Terminals 01 and 11 on the PowerFlex

527 drive causes an internal short and results in some internal components

incurring damage to the control module I/O circuitry.

Recommended Signal Wire

Signal Type/

Where Used

Belden Wire Types

(1)

(or equivalent)

(1) Stranded or solid wire.

Description Min. Insulation

Rating

Analog I/O 8760/9460

0.750 mm

(18 AWG), twisted pair,

100% shield with drain

(2)

(2) If the wires are short and contained within a cabinet, which has no sensitive circuits, the use of shielded wire may not be

necessary, but is always recommended.

300V,

60 °C

(140 °F)

Remote Pot 8770

0.750 mm

(18 AWG), 3 conductor, shielded

Encoder 9728/9730

0.196 mm

(24 AWG), individually shielded pairs

Recommended Control Wire for Digital I/O

Type Wire Types Description Min. Insulation

Rating

Unshielded

Per US NEC or applicable

national or local code

–

300V,

60 °C

(140 °F)

Shielded

Multi-conductor shielded

cable such as Belden

8770 (or equivalent)

0.750 mm

(18 AWG), 3 conductor, shielded

Control I/O Terminal Block Wire Specifications

Frame

Maximum Wire Size

(1)

(1) Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

Minimum Wire Size

(1)

Torque

A…E

1.3 mm

(16 AWG) 0.13 mm

(26 AWG)

0.71...0.86 N•m (6.2...7.6 lb•in)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 35

Chapter 1 Installation/Wiring

PowerFlex 527 Control I/O Removable Terminal Block

PowerFlex 527 Control I/O Wiring Block Diagram

(1) When using an opto output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to

help prevent damage to the output.

(2) Do not short across Terminals 01 and 11.

Control I/O Terminal Designations

No. Signal Description

R1 Relay 1 N.O. These are the Normally Open (N.O.), Common, and Normally Closed (N.C.) contacts for

the programmable relay output.

Resistive: 1.0 A @ 30V DC/ 0.2 A @ 125V AC/ 0.1 A @ 230V AC

Inductive: 0.5 A @ 30V DC/0.1 A @ 125V AC/ 0.1 A @ 230V AC

Rated minimum current is 5 mA or less @ 24V DC.

Note: These are general-purpose outputs and do not have the same functionality as

system outputs when compared to chassis or remote I/O products. See the

Logix 5000® Controllers General Instructions Reference Manual, publication

1756-RM003, for important information regarding execution conditions and action

that is taken for the respective instructions used to control the digital outputs on

the drive.

R2 Relay 1 Common

R5 Relay 2 Common

R6 Relay 2 N.C.

01 Digital Common

The return for digital I/O. It is electrically isolated (along with the digital I/O) from the

rest of the drive, except for the communications port.

(2)

12 13 14 15 16 17

R2 R5 R6 01

(2)

02 03 04 05 06 07

C1 C2

Digital Common

Digital In 1

Digital In 2

Digital In 3

Digital In 4

S+

Relay 1 N.O.

Relay 1 Common

+24V DC

+10V DC

±10V Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

(1)

Opto Output 2

(1)

Ethernet

Comm Common

Opto Common

+24V

+10V

Safety 1

Safety 2

Safety +24V

Typical

SNK wiring

Typical

SRC wiring

Pot must be

1...10 k ohm

2 W min.

0-10V

0/4-20 mA

SNK

Digital In

Analog Out

SRC

ACO

AVO

SRC

SNK

Relay 2 Common

Relay 2 N.C.

Common

(1)

24V

36 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

02 Digital In 1

Configurable to Home, Registration 1, Drive Enable, Positive

Overtravel, and Negative Overtravel.

If programmed as unassigned, this becomes a general-

purpose input.

Set the Digital In

jumper (J1) as shown.

03 Digital In 2

Configurable to Registration 2, Drive Enable, Positive

Overtravel, and Negative Overtravel.

If programmed as unassigned, this becomes a general-

purpose input.

04 Digital In 3

Configurable to Drive Enable, Positive Overtravel, and

Negative Overtravel.

If programmed as unassigned, this becomes a general-

purpose input.

05 Digital In 4

Configurable to Drive Enable, Positive Overtravel, and

Negative Overtravel.

If programmed as unassigned, this becomes a general-

purpose input.

06 Opto Output 1 Programmable digital output.

Note: These are general-purpose outputs and do not have the same functionality as

system outputs when compared to chassis or remote I/O products. See the

Logix 5000 Controllers General Instructions Reference Manual, publication

1756-RM003

, for important information regarding execution conditions and action

that is taken for the respective instructions used to control the digital outputs on

the drive.

07 Opto Output 2

C1 Ethernet

This terminal is tied to the Ethernet port shield. Tie this terminal to a clean ground in

order to improve noise immunity when using external communication peripherals.

C2 Comm Common This is the signal common for the communication signals.

S1 Safety 1 Safety input 1

S2 Safety 2 Safety input 2

S+ Safety +24V +24V supply for safety circuit. This is internally tied to the +24V DC source (Pin-11).

11 +24V DC

+24V DC (+/-10%) supply for digital inputs. It is rated to supply at least 100 mA and

will use Digital Common as the return. It will also be short-circuit protected (not

damaged if tied to a Common or GND), for a short duration, and will not be damaged

if connected to the +24V DC source of a different drive.

12 +10V DC

+10V DC (-0% / +6%) supply for potentiometer or 0-10V input. It is rated to supply at

least 15 mA and will use Analog Common as the return. It will also be short-circuit

protected (not damaged if tied to a Common or GND) and will not be damaged if

connected to the +10V DC source of a different drive.

13 ±10V In

±10V bipolar analog input optically isolated from the drive to avoid ground loops.

This input has approximately 100K Ω input impedance. If a remote potentiometer is

used with this input the maximum pot impedance is 10K Ω and the minimum

impedance and the maximum is still 10K Ω. The A/D resolution will be 10-bit or better.

The drive will not be damaged if up to ±27V DC or Voltage surge up to 1 kV is applied

to this port. The input bandwidth shall be about 100 Hz.

14 Analog Common

This is the return for the analog I/O. It is electrically isolated (along with the analog

I/O) from the rest of the drive.

15 4-20mA In

4-20 mA analog input optically isolated from the drive to allow daisy chain

configurations and to avoid ground loops. The input impedance for the 4-20 mA

analog input is approximately 250 Ω. The A/D resolution will be 10-bit or better.

16 Analog Output

Configurable to a 0-20 mA or 0-10V analog output signal. Set

the Analog Out jumper (J2) as shown, then set the ACO/AVO

attribute. See Setting the ACO/AVO Attribute

on page 162 for

instructions.

17 Opto Common

The emitters of the Optocoupler Outputs (1 and 2) are tied together at Optocoupler

Common. They are therefore electrically isolated from the rest of the drive.

Control I/O Terminal Designations (Continued)

No. Signal Description

SNK

Digital In

SRC

SNK

Digital In

SRC

Sink Source

Analog Out

ACO

AVO

Analog Out

ACO

AVO

0-10V 0-20 mA

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 37

Chapter 1 Installation/Wiring

CE Conformity Compliance with the Low Voltage Directive and Electromagnetic

Compatibility Directive has been demonstrated using harmonized European

Norm (EN) standards that are published in the Official Journal of the

European Communities. PowerFlex 520-series drives comply with the EN

standards that are listed below when installed according to the installation

instructions in this manual.

Product certifications and Declarations of Conformity (DoC) are available

online at rok.auto/certifications

Low Voltage Directive (2014/35/EU)

• EN 61800-5-1 Adjustable speed electrical power drive systems – Part 5-1:

Safety requirements – Electrical, thermal, and energy.

EMC Directive (2014/30/EU)

• EN 61800-3 – Adjustable speed electrical power drive systems - Part 3:

EMC requirements and specific test methods.

Machinery Directive (2006/42/EC)

• EN ISO 13849-1 – Safety of machinery – safety-related parts of control

systems -Part 1: General principles for design.

• EN 61800-5-2 – Adjustable speed electrical power drive systems - Part 5-2:

Safety requirement – Functional.

• EN 62061 – Safety of machinery – Functional safety of safety-related

electrical, electronic, and programmable electronic control systems.

Tag Attributes in Logix Designer for Inputs and Outputs

No. Signal Tag Attribute

Analog Input

13 ±10V In <axis tag>.AnalogInput1

15 4-20mA In <axis tag>.AnalogInput2

Analog Output

16 Analog Output <axis tag>.AnalogOutput1

Digital Input

02 Digital In 1 <axis tag>.DigitalInput0

03 Digital In 2 <axis tag>.DigitalInput1

04 Digital In 3 <axis tag>.DigitalInput2

05 Digital In 4 <axis tag>.DigitalInput3

Digital Output

(1)

06 Opto Output 1 <axis tag>.DigitalOutput0

07 Opto Output 2 <axis tag>.DigitalOutput1

R1 Relay 1 N.O. <axis tag>.DigitalOutput2

R6 Relay 2 N.C. <axis tag>.DigitalOutput3

(1) These are general-purpose outputs and do not have the same functionality as system outputs when compared to chassis or

remote I/O products. See the Logix 5000 Controllers General Instructions Reference Manual, publication 1756-RM003

, for

important information regarding execution conditions and action that is taken for the respective instructions used to control

the digital outputs on the drive.

Pollution Degree Ratings According to EN 61800-5-1

Pollution Degree Description

1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence.

Normally, only non-conductive pollution occurs. Occasionally, however, a temporary

conductivity caused by condensation is to be expected, when the drive is out of operation.

38 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

• EN 60204-1 – Safety of machinery – Electrical equipment of machines -

Part 1: General requirements.

• EN 61508 Part 1-7 Functional safety of electrical/electronic/

programmable electronic safety-related systems – Parts 1-7.

ATEX Directive (2014/34/EU)

• EN 50495 – Safety devices that are required for the safe functioning of

equipment with respect to explosion risks.

UKCA Conformity Compliance with application Statutory Regulations has been demonstrated

using harmonized standards published in the UK list of Designated standards.

PowerFlex 520-series drives comply with the EN standards listed below when

installed according to the installation instructions in this manual.

UK Declarations of Conformity are available online at rok.auto/certifications

Electrical Equipment (Safety) Regulations (2016 No. 1101)

• EN 61800-5-1 Adjustable speed electrical power drive systems – Part 5-1:

Safety requirements – Electrical, thermal, and energy.

Electromagnetic Compatibility Regulations (2016 No. 1091)

• EN 61800-3 Adjustable speed electrical power drive systems – Part 3: EMC

requirements and specific test methods.

Supply of Machinery (Safety) Regulations (2008 No. 1597)

• EN ISO 13849-1 – Safety of machinery – Safety related parts of control

systems -Part 1: General principles for design.

• EN 61800-5-2 – Adjustable speed electrical power drive systems – Part 5-2:

Safety requirement – Functional.

• EN 62061 – Safety of machinery – Functional safety of safety-related

electrical, electronic, and programmable electronic control systems.

• EN 60204-1 – Safety of machinery – Electrical equipment of machines –

Part 1: General requirements.

• EN 61508 Part 1-7 Functional safety of electrical, electronic, and

programmable electronic safety-related systems – Part 1-7.

Equipment and Protective Systems Intended for Use in Potentially

Explosive Atmospheres Regulations (2016 No. 1107)

• EN 50495 – Safety devices required for the safe functioning of

equipment with respect to explosion risks.

Pollution Degree Ratings According to EN 61800-5-1

Pollution

Degree

Description

1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence.

Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity

that is caused by condensation is to be expected, when the drive is out of operation.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 39

Chapter 1 Installation/Wiring

General Considerations

• For CE and UK compliance, drives must satisfy installation requirements

that are related to both EN 61800-5-1 and EN 61800-3 provided in this

document.

• PowerFlex 520-series drives must be installed in a pollution degree 1 or 2

environment to be compliant with the CE LV Directive and UK LV

Regulations. See Pollution Degree Ratings According to EN 61800-5-1

page 37 for descriptions of each pollution degree rating.

• PowerFlex 520-series drives comply with the EMC requirements of EN

61800-3 when installed according to good EMC practices and the

instructions that are provided in this document. However, many factors

can influence the EMC compliance of an entire machine or installation,

and compliance of the drive itself does not ensure compliance of all

applications.

• PowerFlex 520-series drives are not intended to be used on public low-

voltage networks that supply domestic premises. Without additional

mitigation, radio frequency interference is expected if used on such a

network. The installer is responsible for taking measures such as a

supplementary line filter and enclosure (see Connections and Grounding

on page 41) to prevent interference, in addition to the installation

requirements of this document.

• PowerFlex 520-series drives generate harmonic current emissions on the

AC supply system. When operated on a public low-voltage network it is

the responsibility of the installer or user to verify that applicable

requirements of the distribution network operator have been met.

Consultation with the network operator and Rockwell Automation may

be necessary.

• If the optional NEMA 1 kit is not installed, the drive must be installed in

an enclosure with side openings less than 12.5 mm (0.5 in.) and top

openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV

Directive and UK LV Regulations.

• The motor cable should be kept as short as possible to avoid

electromagnetic emission and capacitive currents.

• Use of line filters in ungrounded systems is not recommended.

• In CE and UK installations, input power must be a Balanced wye with

Center Ground configuration for EMC compliance.

• If the DC Bus terminals or the Dynamic Brake terminals are used, the

drive must be installed in an enclosure and fuses must be used for input

protection. The ventilated enclosure needs to be IP 20 rating or higher

and at least 1.5x size larger than the drive.

Installation Requirements Related to EN 61800-5-1 and the Low Voltage Directive/UK LV

Regulations

• 600V PowerFlex 520-series drives can only be used on a “center

grounded” supply system for altitudes up to and including

2000 m (6562 ft).

• When used at altitudes above 2000 m (6562 ft) up to a maximum of

4800 m (15,748 ft), PowerFlex 520-series drives of voltage classes up to

480V may not be powered from a “corner-earthed” supply system to

maintain compliance with the CE LV Directive and UK LV Regulations.

See Derating Guidelines for High Altitude

on page 16.

ATTENTION: NEMA/UL Open Type drives must either be installed in a

supplementary enclosure or equipped with a “NEMA Type 1 Kit” to be

CE and UK compliant with respect to protection against electrical

shock.

40 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

• PowerFlex 520-series drives produce leakage current in the protective

earthing conductor, which exceeds 3.5 mA AC and/or 10 mA DC. The

minimum size of the protective earthing (grounding) conductor that is

used in the application must comply with local safety regulations for high

protective earthing conductor current equipment.

Installation Requirements Related to EN 61800-3 and the EMC Directive and UK EMC

Regulations

• The drive must be earthed (grounded) as described in Connections and

Grounding on page 41. See General Grounding Requirements on page 18

for additional grounding recommendations.

• Output power wiring to the motor must employ cables with a braided

shield providing 75% or greater coverage, or the cables must be housed in

metal conduit, or equivalent shield must be provided. Continuous

shielding must be provided from the drive enclosure to the motor

enclosure. Both ends of the motor cable shield (or conduit) must

terminate with a low-impedance connection to earth.

Drive Frames A...E: At the drive end of the motor, either

a. The cable shield must be clamped to a properly installed “EMC Plate”

for the drive, kit number 25-EMC1-Fx.

b. The cable shield or conduit must terminate in a shielded connector

that is installed in an EMC plate, conduit box, or similar.

• At the motor end, the motor cable shield or conduit must terminate in a

shielded connector, which must be properly installed in an earthed

motor wiring box that is attached to the motor. The motor wiring box

cover must be installed and earthed.

• All control (I/O) and signal wiring to the drive must use cable with a

braided shield providing 75% or greater coverage, or the cables must be

housed in metal conduit, or equivalent shielding must be provided.

When shielded cable is used, the cable shield should be terminated with a

low impedance connection to earth at only one end of the cable,

preferably the end where the receiver is located. When the cable shield is

terminated at the drive end, it may be terminated either by using a

shielded connector in conjunction with a conduit plate or conduit box, or

the shield may be clamped to an “EMC plate.”

• Motor cabling must be separated from control and signal wiring

wherever possible.

• Maximum motor cable length must not exceed the maximum length that

is indicated in Table 3

for compliance with radio frequency emission

limits for the specific standard and installation environment.

ATTENTION: PowerFlex 520-series drives produce DC current in the

protective earthing conductor which may reduce the ability of RCD’s

(residual current-operated protective devices) or RCM’s (residual

current-operated monitoring devices) of type A or AC to provide

protection for other equipment in the installation.

Where an RCD or RCM is used for protection in case of direct or

indirect contact, only an RCD or RCM of Type B is allowed on the

supply side of this product.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 41

Chapter 1 Installation/Wiring

Connections and Grounding

(1) Some installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and

the EMI filter.

Additional Installation Requirements

This section provides information on additional requirements for Class C1 and

C2 installation, such as enclosures and EMC cores.

Table 3 - PowerFlex 527 RF Emission Compliance and Installation Requirements

Filter Type Standard/Limits

EN61800-3 Category C1

EN61000-6-3

CISPR11 Group 1 Class B

EN61800-3 Category C2

EN61000-6-4

CISPR11 Group 1 Class A

(Input power ≤ 20 kVA)

EN61800-3 Category C3

(I ≤ 100 A)

CISPR11 Group 1 Class A

(Input power > 20 kVA)

Internal – 10 m (33 ft) 20 m (66 ft)

External

(1)

(1) See Accessories and Dimensions on page 137 for more information on optional external filters.

30 m (16 ft) 100 m (328 ft) 100 m (328 ft)

IMPORTANT EMC cores are included with:

• Drives that have an internal EMC filter (25x-xxxxN114)

• External EMC filter accessory kit (25-RFxxx)

IMPORTANT An enclosure, shielded input cable, and EMC cores are not required to

meet Class C3 requirements.

R/L1

S/L2

T/L3

U/T1

V/T2

W/T3

EMI ttings and metal conduit

IP 30/NEMA 1/UL Type 1

option kit or EMC kit

Shielded enclosure

(1)

Building structure steel

Enclosure ground connection

EMI lter

L1'

L2'

L3'

Shielded motor cable

Additional Installation Requirements

Frame

Size

Class C1 Class C2

Enclosure Conduit or Shielded

Cable @ Input

EMC Cores Required

(Included with product)

Enclosure Conduit or Shielded

Cable @ Input

EMC Cores Required

(Included with product)

100...120V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...120V 1-Phase Output

ANoNo No NoNo No

BNoNo No NoNo No

200...240V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...230V 3-Phase Output

A Yes Yes No No No Input/Output

B Yes Yes Output only No No Input/Output

200...240V AC (-15%, +10%) – 1-Phase Input with Internal EMC Filter, 0...230V 3-Phase Output

(1)

A* * * Yes No No

B* * * Yes No No

42 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

200...240V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...230V 3-Phase Output

A Yes Yes Output only No No Input/Output

B Yes Yes Output only No No Input/Output

C Yes Yes Output only No No Input/Output

DYes Yes No No No Input only

E Yes Yes Output only No No Input only

380...480V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...460V 3-Phase Output

A Yes Yes No No No Input/Output

B Yes Yes No No No Input/Output

CYes Yes No No No Input only

D Yes Yes Output only No No Input/Output

E Yes Yes No Yes No Input/Output

380...480V AC (-15%, +10%) – 3-Phase Input with Internal EMC Filter, 0...460V 3-Phase Output

(1)

A * * * No No Input/Output

B * * * No No Input/Output

C * * * No No Input/Output

D * * * No No Input/Output

E * * * No No Input/Output

525...600V AC (-15%, +10%) – 3-Phase Input with External EMC Filter, 0...575V 3-Phase Output

A Yes Yes No No No Input/Output

B Yes Yes No No No Input/Output

C Yes Yes No No No Input/Output

D Yes Yes No No No Input/Output

E Yes Yes No Yes No No

(1) An (*) indicates that EMC requirements are not met.

Additional Installation Requirements (Continued)

Frame

Size

Class C1 Class C2

Enclosure Conduit or Shielded

Cable @ Input

EMC Cores Required

(Included with product)

Enclosure Conduit or Shielded

Cable @ Input

EMC Cores Required

(Included with product)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 43

Chapter 1 Installation/Wiring

Chapter

Recommended Placement of EMC Cores with Optional EMC Plate

Frame A Frame B Frame C Frame D Frame E

With Optional EMC Plate (25-EMC-Fx)

Without EMC Plate

CORE-xx-A-1

CORE-xx-A-2

CORE-xx-B-1

CORE-xx-B-2

CORE-xx-C-1

CORE-xx-C-2

CORE-xx-D-1

CORE-xx-D-2

CORE-E-1

CORE-E-2

CORE-E-3

CORE-E-4

Ground

cable

CORE-xx-x-1 CORE-xx-x-2

CORE-E-1

CORE-E-2

CORE-E-3

CORE-E-4

Ground

cable

Shows contact to

shielded layer

Secure EMC core by

using cable/zip ties

Input cable to drive (Shielded or Unshielded) Output cable from drive (Shielded)

IMPORTANT The ground cable/shield for both input and output must pass through the EMC core(s), except for the following:

• Frame E drives with internal filters where the grounded input cable must not pass through EMC CORE-E-1.

• 600V drives with external filters where the grounded output cable must not pass through the EMC core(s).

Recommended Placement of EMC Cores Relative to External Filter

Input core Output core

Incoming power

EMC filter Drive Motor

All Frame Sizes

44 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 1 Installation/Wiring

Notes:

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 45

Chapter

Chapter 2

Start Up

This chapter describes how to start up the PowerFlex 527 drive.

Prepare for Drive Startup Before starting up the drive, it is recommended to perform the startup tasks

described below to achieve a smooth startup and drive operation. Verify that

the drive is not powered (check that DC Bus voltage is less than 50V DC) before

proceeding with the startup task list.

Drive Startup Task List

1. Disconnect and lock out power to the machine.

2. Verify that AC line power at the disconnect device is within the rated

value of the drive.

3. If replacing a drive, verify the current catalog number of the drive. Verify

all options installed on the drive.

4. Verify that any digital control power is 24 volts.

5. Inspect grounding, wiring, connections, and environmental

compatibility.

6. Verify that the Sink (SNK)/Source (SRC) jumper is set to match your

control wiring scheme. See the PowerFlex 527 Control I/O Wiring Block

Diagram on page 35 for location.

7. Wire I/O as required for the application.

8. Wire the power input and output terminals.

9. Confirm that all inputs are connected to the correct terminals and are

secure.

Topic Page

Prepare for Drive Startup 45

Understanding the PowerFlex 527 Display and Indicators 46

Drive Programming Tools 51

Language Support 52

Using the Ethernet Port 52

IMPORTANT Read General Precautions on page 10 before proceeding.

ATTENTION: Power must be applied to the drive to perform the following

startup procedures. Some of the voltages present are at incoming line

potential. To avoid electric shock hazard or damage to equipment, only

qualified service personnel should perform the following procedure.

Thoroughly read and understand the procedure before beginning. If an event

does not occur while performing this procedure, Do Not Proceed. Remove

All Power including user supplied control voltages. User supplied voltages

may exist even when main AC power is not applied to the drive. Correct the

malfunction before continuing.

46 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 2 Start Up

10. Collect and record motor nameplate and encoder or feedback device

information. Verify motor connections.

• Is the motor uncoupled?

• What direction will the motor need to turn for the application?

11. Verify the input voltage to the drive. Verify if the drive is on a grounded

system. Verify that the MOV jumpers are in the correct position. See AC

Supply Source Considerations on page 17 for more information.

12. Apply AC power to the drive.

• You need to establish a connection with a Logix controller and verify

that the drive is enabled using a Logix motion instruction (for example

MSO command) and no “START INHIBIT” condition exists. See

Configuring the PowerFlex 527 Drive with Integrated Motion

page 53 for instructions.

• Verify that the drive is receiving start and stop commands correctly.

• Verify that input currents are balanced.

• Verify that motor currents are balanced.

Start, Stop, Direction, and Speed Control

Start, Stop, Direction, and Speed Control are done using Logix motion

instructions (for example, Motion Drive Start (MDS)). See the Logix 5000

Motion Controllers Instructions Reference Manual, publication MOTION-

RM002 for more information.

Understanding the

PowerFlex 527 Display and

Indicators

The PowerFlex 527 drive has four status indicators, a fault indicator, an LCD

display, and a membrane keypad for navigation. The display is used to view

information such as motor information, axis states, faults, and set the network

configuration. The indicators are used to monitor the module and network

status, and troubleshoot faults.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 47

Chapter 2 Start Up

PowerFlex 527 Drive LCD Display and Status Indicators

For detailed descriptions of the Fault, MOD, NET, and LINK A/B status

indicators, see PowerFlex 527 Drive Status Indicators

on page 120.

Display Display State Description

ENET

Off Drive is not connected to the network.

Steady Drive is connected to the network.

LINK

Off Drive has not established a controller connection.

Steady

Drive is connected to the network and a controller connection

has been established.

LED LED State Description

FAULT Steady

Indicates that drive is faulted. See Fault Codes

on page 116 for

more information.

Key Name Description

Up Arrow

Down Arrow

Pressing either arrow moves the selection to the next (or

previous) item. When changing values, pressing the Up arrow

increments the highlighted value. Values rollover after

reaching the end of the list.

Escape

Press to go back. Pressing enough times results in the HOME

screen.

Select Press to select a menu item.

Enter Press to confirm the selection and go to submenu items.

LED LED State Description

MOD Steady Green Drive is operational and no fault exists.

NET Steady Green Drive is online and has connections in the established state.

LINK A (Ethernet Port 1)

LINK B (Ethernet Port 2)

Steady Green Drive is connected to the network but not transmitting data.

ENET and LINK display

Fault status indicator

Module status indicator

Network status indicator

Link A status indicator (Ethernet Port 1)

Link B status indicator (Ethernet Port 2)

Navigation keypad

Esc

Sel

48 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 2 Start Up

Startup Sequence

On power-up, the drive will initialize and

status information will scroll across the

LCD display.

After initialization, the Device/Axis state

will be shown on the LCD display. In this

example, the current state is STANDBY.

Device and Axis States

Table 4 and Table 5 list the possible Device and Axis states and their

descriptions.

If a boot fault occurs during initialization, a

fault number shows up on the screen with

the format, “BFxxx”, where “BF” represents

boot fault and “xxx” refers to the fault code.

In this example, fault BF003 is shown.

For a list of other types of possible faults, see

Fault Codes

on page 116.

Table 4 - Device States

Device State Description

STANDBY The drive is waiting to receive configuration information from the controller.

CONNECTING The drive is trying to establish communication with the EtherNet/IP™ controller.

CONFIGURING The drive is receiving configuration information from the controller.

SYNCING The drive is waiting for a successful Group Sync service.

CONN_TIMEOUT

The drive is trying to establish communication with the EtherNet/IP controller but

the connection has timed out.

DUPLICATE_IP The drive has detected another device on the network with the same IP address.

FWUPDATE The drive is updating the firmware.

Table 5 - Axis States

Axis State Description

INITIALIZING The drive is initializing the motion connection.

PRECHARGE The drive is ready for mains input power.

STOPPED The drive is in the Stopped state and awaiting a motion command.

STARTING

The drive has received a motion command and is transitioning to the Running state

from the Stopped state.

RUNNING The drive is enabled and/or running.

TESTING The drive is actively executing a test procedure, for example, a hookup test.

STOPPING The drive is decelerating to a stop as the result of a disable.

ABORTING The drive is decelerating to a stop as the result of a fault or an abort request.

MAJOR FAULTED The drive is faulted due to an existing or past fault condition.

START INHIBITED The drive has an active condition that inhibits it from being enabled.

SHUTDOWN The drive has been shut down.

VOLTS

AMPS

HERTZ

RUN

FWD

REV

PROGRAM

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 49

Chapter 2 Start Up

Information Display

From the axis state screen, press Select or the Down arrow to

access the following information menu:

Network Configuration

Through the settings option, you can configure the drive IP address. There are

two methods for configuring the drive IP address:

• Static IP – Use Static IP when you want to manually configure the IP

address, subnet mask, and gateway addresses.

• DHCP (Dynamic Host Configuration Protocol) – Use DHCP when you

want convenience and ease-of-use compared to Static IP. The IP address,

subnet mask, and gateway addresses will be assigned automatically by

the DHCP server.

Screen Option Description

Example Display

(1)

(1) The LCD only accommodates up to five characters. Text strings that are more than five characters are scrolled.

Version Info

Provides information on the hardware and software

versions.

HW Ver 01.002 FW Ver 01.102

Device Info

Provides information on the drive type, network

configuration, and IP address.

PowerFlex 527 Static IP 192.168.1.180

or PowerFlex 527 DHCP

192.168.1.180

(2)

(2) If “0.0.0.0” is displayed and DHCP is enabled, it means that the IP address has not been assigned by the DHCP server. Check

your network settings.

Settings

Allows configuration of network settings, changing

the display language, and resetting the drive.

See Network Configuration for

instructions on how to configure the

IP address.

Navigating the Settings Menu

Settings Menu

Selections

Sub Menu

Selections

Attributes Default Description

Protected Mode

(1)

(1) This setting is only available in PowerFlex 527 firmware revision 2.001 or later.

Reset

ENABLED

DISABLED

ENABLED

When Enabled (default), identity

object resets are not possible when a

controller connection is open.

Network

Config

ENABLED

DISABLED

ENABLED

When Enabled (default), network

configuration changes are not

possible when a controller

connection is open.

Flash Update

ENABLED

DISABLED

ENABLED

When Enabled (default), firmware

updates are not possible when a

controller connection is open.

Device Config

ENABLED

DISABLED

ENABLED

When Enabled (default), only attribute

writes are possible when a controller

connection is open.

Network

Static IP

IP address 192.168.1.180 Indicates current IP address.

Subnet mask 255.255.255.0 Indicates current subnet mask.

Gateway 192.168.1.1 Indicates current gateway.

DHCP

IP address

Automatically

assigned by the

DHCP server.

Indicates current IP address.

Subnet mask Indicates current subnet mask.

Gateway Indicates current gateway.

Web

(1)

Enabled Enables the web server.

->Disabled

(2)

(2) An arrow (->) appears in front of the chosen attribute indicating that this attribute is currently configured. This is also the

factory default setting.

Disables the web server.

Sel

50 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 2 Start Up

IMPORTANT Regardless of the method used to set the adapter IP address, each node

on the EtherNet/IP network must have a unique IP address. To change

an IP address, you must set the new value and then power cycle the

drive.

You can also use the Reset function, however all safety connections will

have to be disabled before this option is available.

You must enter a valid IP address configuration. With firmware 1.008 or

later, if an illegal IP address configuration exists upon power-up, for

example, if the IP address and gateway address are identical, the drive

faults and exhibits INIT FLT M22 - ILLEGAL ADDRESS on the display and

the IP address configuration changes to DHCP.

Configuring Network Settings

Step Keys Example Display

1. On the Device/Axis state screen, press the Down

arrow to go to the Settings menu.

2. Press Enter to display the Network Settings screen.

3. Press the Up or Down arrow to select either DHCP or

Static IP, then press Enter.

If you choose DHCP, go to step 4

If you choose Static IP, go to step 5.

4. Press Enter to confirm DHCP as the network

configuration option. Choosing DHCP automatically

configures the IP settings for your drive.

This completes the network configuration for your

drive.

5. Choosing Static IP enables you to manually configure

the IP address, subnet mask, and gateway address for

your drive. Press the Up or Down arrow to scroll

through the settings.

6. In this example, we will start by configuring the IP

address. Select IP address, then press Enter to display

the first octet of the IP address.

7. Press the Up or Down arrow to scroll through the four

octets of the IP address.

8. Press Sel to edit an octet. The rightmost digit of the

octet will flash.

9. Press the Up or Down arrow to change the digit.

Press Sel to edit the digits on the left.

10. Press ESC to cancel a change and exit the edit mode.

Press Enter to save a change and exit the edit mode.

Sel

Esc

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 51

Chapter 2 Start Up

Real-time Information Display

Once the drive is enabled and running and connected to a controller, the

following information can be accessed through the LCD screen.

Note: See Integrated Motion on the EtherNet/IP Network Reference Manual,

publication MOTION-RM003

, for complete motion attribute description.

Drive Programming Tools Some features in the PowerFlex 527 drive are not supported by older

configuration software tools. It is strongly recommended that customers

using such tools migrate to Studio 5000 Logix Designer application (version 24

or later) with Add-on Profile (AOP) to enjoy a richer, full-featured

configuration experience.

11. Repeat step 7 to step 10 to edit the values of the other

octets.

After you have finished configuring the IP address.

Press ESC to go back to the Static IP menu.

12. Repeat step 5

to step 11 to configure the subnet mask

and gateway address.

13. Power cycle the drive to store the new IP settings.

This completes the network configuration for your

drive.

IMPORTANT You must cycle power to make network configuration changes

persistent. An asterisk (*) is shown next to the network configuration

when viewing the Device Info screen option to signify that a change has

been made but has not taken effect.

For example, after changing the network configuration from Static IP to

DHCP, when viewing the Device Info screen option, an asterisk (*)

appears next to the text “DHCP” on the LCD display.

The change takes effect and the asterisk is removed

after you cycle power to the drive.

Display configuration changes take effect

immediately.

Real-time Information Description Example Display

Velocity Feedback

Displays the value of the velocity feedback in

units/sec. See motion attribute 454.

VELOCITY FDBK 0.0

Motor Current

Displays the value of the motor current in

% motor rated. See motion attribute 529.

MOTOR CURT 0.0

Motor Utilization

Displays the value of the motor utilization in %.

See motion attribute 635.

MOTOR UTIL 0.0

DC Bus Voltage

Displays the value of the DC Bus voltage in VDC.

See motion attribute 620.

DC BUS VLTG 0.0

Current Command

Displays the value of the torque current in

% motor rated. See motion attribute 524.

CURRENT CMD 0.0

Output Current

Displays the value of Output Current in Amps RMS.

See motion attribute 601.

OUTPUT CURT 0.0

Configuring Network Settings (Continued)

Step Keys Example Display

Esc

52 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 2 Start Up

Language Support

Using the Ethernet Port

The PowerFlex 527 drive has dual embedded Ethernet ports that connect the

drive to an EtherNet/IP network. This enables communication with a Logix

based control system for drive control using CIP Motion commands. You can

also upgrade the drive firmware or upload/download a configuration easily

using the Studio 5000 Logix Designer application.

The EtherNet/IP network offers a full suite of control, configuration, and data

collection services by layering the Common Industrial Protocol (CIP™) over the

standard protocols used by the Internet (TCP/IP and UDP). EtherNet/IP uses

TCP/IP for general messaging/information exchange services and UDP/IP for

I/O messaging services for control applications.

Liner, Star, and Device Level Ring network topologies are supported by the

PowerFlex 527 drive. Plus, the application of the CIP Safety™ protocol enables

the simultaneous transmission of safety and standard control data and

diagnostics information.

Language Keypad/LCD Display Logix Designer Application

English Y Y

French Y Y

Spanish Y Y

Italian Y Y

German Y Y

Japanese – Y

Portuguese Y Y

Simplified Chinese – Y

Korean – Y

Polish

(1)

(1) Due to a limitation of the LCD display, some of the characters for Polish, Turkish, and Czech will be modified.

Y–

Turkish

(1)

Y–

Czech

(1)

Y–

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 53

Chapter 3

Chapter

Configuring the PowerFlex 527 Drive with

Integrated Motion

This chapter describes procedures on how to configure Integrated Motion on

the EtherNet/IP network control by using a PowerFlex 527 Drive.

Configure the Drive You can include the drive in your Studio 5000 Logix Designer application by

adding it to a configured EtherNet/IP module or controller and adding it

under the I/O configuration tree. After setting the network configuration, you

can view the drive status information in the Studio 5000 environment and use

it in your Studio 5000 Logix Designer application.

Set the Network Configuration

You can set the network configuration by using the LCD display and drive

keypad.

1. When the LCD display is showing the Device/Axis state, use the keypad

to navigate to SETTINGS -> NETWORK. Then choose either STATIC IP

or DHCP.

The default setting is STATIC IP.

2. If you chose STATIC IP, then you must configure the following settings:

• IP address

• Gateway

•Subnet mask

If you chose DHCP, the three settings above are configured automatically

by the DHCP server.

Settings are stored in nonvolatile memory. IP addressing can also be changed

through the Module Configuration dialog box in RSLinx® software. Changes to

the IP addressing take effect after power is cycled or reset. The drive is factory

programmed to static IP address of 192.168.1.180.

See Configuring Network Settings

on page 50 for help on configuring the IP

settings.

Topic Page

Configure the Drive 53

Configure the Logix Designer Application Project 54

Add a PowerFlex 527 Drive 58

Configure the PowerFlex 527 Drive 59

Apply Power to the PowerFlex 527 Drive 79

Test and Tune the Axes – Velocity and Position Control Modes 80

Before you begin, make sure that you know the catalog number for each drive

component, the Logix module and/or controller used in your motion control

application.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

Configure the Logix

Designer Application

Project

These procedures assume that you have wired your PowerFlex 527 drive

system. In this example, the CompactLogix 5370 controller is used.

For help with using the Studio 5000 Logix Designer application (version 24 or

later) application as it applies to configuring the ControlLogix or

CompactLogix controllers, see Additional Resources

on page 8.

Configure the Logix 5000 Controller

Follow these steps to configure the controller.

1. Apply power to your controller and open your Logix Designer

application.

2. From the Create menu, choose New Project.

The New Project dialog box appears.

If using a safety or non-safety ControlLogix controller, you must also use a

1756-EN2T, 1756-EN2TR, or 1756-EN3TR EtherNet/IP module. If using a

CompactLogix 5370 controller, it has dual embedded EtherNet/IP ports.

IMPORTANT If you are configuring a PowerFlex 527 drive for integrated safety in a

safety application, you must use a GuardLogix safety controller.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

In this example, the typical dialog boxes for 1756-L7xS GuardLogix 5570 safety

controllers and CompactLogix 5370 controllers are shown.

Follow these steps to configure your Logix 5000 controller.

1. Expand the Logix 5000 controller family and select your controller.

2. Type the file name.

3. Click Next.

The New Project dialog box appears.

4. From the Revision pull-down menu, choose your software revision.

5. Click Finish.

The new controller appears in the Controller Organizer under the I/O

Configuration folder.

6. Right-click I/O Configuration in the Controller Organizer and choose

New Module.

The Select Module Type dialog box appears.

IMPORTANT If your project includes a ControlLogix or GuardLogix controller, you need

to add an Ethernet communication module to your Bulletin 1756 chassis

and configure it for use in your application.

• For ControlLogix or GuardLogix controllers, go to step 6

• For CompactLogix 5370 controllers, go to step 13.

See the EtherNet/IP Network Configuration User Manual, publication,

ENET-UM001

for more information.

Controller Organizer with

GuardLogix 1756-7xS controller

Controller Organizer with

CompactLogix 5370 controller

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

7. By using the filters, check Communication and Allen-Bradley, and select

1756-EN2T, 1756-EN2TR, or 1756-EN3TR as appropriate for your actual

hardware configuration.

In this example, the 1756-EN2T module is selected.

8. Click Create.

The New Module dialog box appears.

a. Configure the new module.

b. Type the module Name.

c. Enter the Logix EtherNet/IP module slot (leftmost slot = 0).

d. Select an Ethernet Address option.

In this example, the Private Network address is selected.

e. Enter the address of your EtherNet/IP module.

In this example, the last octet of the address is 1.

f. Click Change in the Module Definition area.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

The Module Definition dialog box opens.

9. From the Time Sync Connection pull-down menu, choose Time Sync and

Motion.

10. Click OK to close the Module Definition dialog box.

11. Click Yes when prompted to confirm your module definition changes.

12. Click OK to close the New Module dialog box.

13. From the Edit menu, choose Controller Properties.

The Controller Properties dialog box appears.

14. Click the Date/Time tab.

15. Check Enable Time Synchronization.

IMPORTANT Time Sync functionality is what enables motion control on an

Ethernet network. Without this setting, you won’t be able to run

your motion application.

Your new 1756-ENxT Ethernet

module appears under the I/O

configuration folder in the

Controller Organizer.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

The motion modules set their clocks to the module you assign as the

Grandmaster.

16. Click OK.

Add a PowerFlex 527 Drive Follow these instructions to add the PowerFlex 527 drive to your project.

1. Right-click the Ethernet network (node) and choose New Module…

2. Clear the small ‘select all’ check boxes, Module Type Category and Vendor

Filters.

Alternatively, you can simply type “527” into the search box and choose

the drive.

3. In the Module Type Category Filters window, check Drive.

In the Module Type Vendors Filters window, check Allen-Bradley.

IMPORTANT Check Enable Time Synchronization for all controllers that

participate in CIP Sync™. The overall CIP Sync network

automatically promotes a Grandmaster clock, unless the priority

is set in the Advanced tab.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

4. Choose the PowerFlex 527 drive and click Create.

The Module Properties dialog box appears.

5. Configure the new drive.

a. Type the drive Name.

b. Type a Description, if desired.

c. Select an Ethernet Address option.

In this example, the Private Network address is selected.

d. Enter the address of your PowerFlex 527 drive.

In this example, the last octet of the address is 180.

6. Proceed to Configure the PowerFlex 527 Drive

to continue configuring

your drive.

Configure the PowerFlex

527 Drive

After you have added a PowerFlex 527 drive to your project, you will need to

configure the type of safety connection suitable for your application. See the

following sections for instructions on configuring the drive for the different

types of safety connections.

• Configure Drive with Hardwired Safety Connections

on page 60

• Configure Drive with Integrated Safety Connections on page 61

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

Configure Drive with Hardwired Safety Connections

Follow these steps to configure the PowerFlex 527 drives with hardwired

safety.

1. Verify that you have done the steps in Add a PowerFlex 527 Drive

page 58 before proceeding.

2. Under Module Definition, click Change.

The Module Definition dialog box appears.

a. From the Electronic Keying pull-down menu, choose an option.

b. From the Connection pull-down menu, choose the Connection mode

for your motion application.

In this example, choose Motion only.

Connection Mode Controller Needed Description

Motion only

ControlLogix 5570,

GuardLogix 5570,

CompactLogix 5370,

ControlLogix 5580,

CompactLogix 5380, or

Compact GuardLogix 5370

(1)

• Hard-wired Safe Torque Off (STO) connections are

possible.

• This controller manages Motion.

• Another controller that has a Safety only

connection to the drive manages Safety.

Motion and Safety

GuardLogix 5570,

GuardLogix 5580,

Compact GuardLogix 5370

(1)

, or

Compact GuardLogix 5380

This controller manages Motion and Safety.

Safety only

GuardLogix 5570,

GuardLogix 5580,

Compact GuardLogix 5370, or

Compact GuardLogix 5380

• This controller manages Safety.

• Another controller that has a Motion only

connection to the drive manages Motion.

(1) Catalog numbers containing the letter M.

IMPORTANT To configure PowerFlex 527 drives, you must use the Logix Designer

application, version 24.00 or later.

WARNING: When using motion modules, the electronic keying must be

either “Exact Match” or “Compatible Keying”.

Never use “Disable Keying” with motion modules.

When ‘Safety’ appears in the Connection mode, integrated safety is

implied.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

c. From the Power Structure pull-down menu, choose the catalog

number that matches your power structure.

d. Check the Verify Power Rating on Connection checkbox to confirm

that the proper power structure that is defined in the profile is the

same as the connected drive. If the two do not match, a connection

error occurs, which indicates a power mismatch.

Verify Power Rating on Connection is checked by default. It is enabled

in offline mode.

3. Click OK to close the Module Definition dialog box.

4. Click OK to close the Module Properties dialog box.

5. Proceed to Continue Drive Configuration

on page 64 to continue

configuring your drive.

Configure Drive with Integrated Safety Connections

Follow these steps to configure PowerFlex 527 drives with integrated safety.

1. Verify that you have done the steps in Add a PowerFlex 527 Drive

page 58 before proceeding.

2. Under Module Definition, click Change.

The Module Definition dialog box appears.

Your PowerFlex 527 drive appears in

the Controller Organizer under the

Ethernet controller in the I/O

configuration folder.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

a. From the Electronic Keying pull-down menu, choose an option.

b. From the Connection pull-down menu, choose the Connection mode

for your motion application.

In this example, choose Motion and Safety.

The Safety Network Number (SNN) field populates automatically when

the Connection mode includes an integrated Motion and Safety or

Safety-only connection. For a detailed explanation of the safety network

number, see the GuardLogix 5570 and Compact GuardLogix 5370

Reference Manual, publication 1756-RM099

c. From the Power Structure pull-down menu, choose the catalog

number that matches your power structure.

d. Check the Verify Power Rating on Connection check box to confirm

that the proper power structure that is defined in the profile is the

same as the connected drive. If the two do not match, a connection

error occurs, which indicates a power mismatch.

Verify Power Rating on Connection is checked by default. It is enabled

in offline mode.

3. Click OK to close the Module Definition dialog box.

WARNING: When using motion modules, the electronic keying must be

either “Exact Match” or “Compatible Keying”.

Never use “Disable Keying” with motion modules.

When ‘Safety’ appears in the Connection mode, integrated safety is

implied.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

4. Click the Safety tab.

The connection between the controller and the PowerFlex 527 drive is

based on the following:

Drive catalog number must be 527 (integrated)

• Drive catalog number must be PowerFlex 527 (integrated)

• Drive Safety Network Number (SNN)

•GuardLogix slot number

• GuardLogix safety network number

• Path from the GuardLogix controller to the PowerFlex 527 drive

• Configuration signature

If any differences are detected, the connection between the GuardLogix

controller and the PowerFlex 527 drive is lost, and the yellow icon appears

in the controller project tree after you download the program.

5. Click Advanced.

The Advanced Connection Reaction Time Limit Configuration dialog box

appears.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

Analyze each safety channel to determine the appropriate settings. The

smallest Input RPI allowed is 6 ms. Selecting small RPI values consumes

network bandwidth and can cause nuisance trips because other devices

cannot get access to the network.

For more information about the Advanced Connection Reaction Time

Limit Configuration, see the GuardLogix 5570 Controllers User Manual,

publication 1756-UM022

6. Click OK to close the Advanced Connection Reaction Time Limit

Configuration dialog box.

7. Click OK to close the Module Properties dialog box.

8. Proceed to Continue Drive Configuration

to continue configuring your

drive.

Continue Drive Configuration

After you have established your PowerFlex 527 drive in the Logix Designer

application, the remaining configuration steps are the same regardless of the

drive catalog number.

1. Right-click the PowerFlex 527 drive you created and choose Properties.

The Module Properties dialog box appears.

2. Click the Associated Axes tab.

3. Click New Axis.

Your PowerFlex 527 drive appears

in the Controller Organizer under

the Ethernet controller in the I/O

Configuration folder.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

The New Tag dialog box appears.

4. Type the axis Name.

AXIS_CIP_DRIVE is the default Data Type.

5. Click Create.

6. Click Apply.

The axis (Axis_1 in this example) appears

in the Controller Organizer under Motion

Groups > Ungrouped Axes and is

assigned as Axis 1.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

7. Click the Power tab.

8. From the pull-down menu, choose the power options appropriate for

your actual hardware configuration.

9. Click OK.

10. Repeat step 1

through step 9 for each PowerFlex 527 drive.

Attribute Menu Description

PWM Frequency

•2 kHz

• 4 kHz (Default)

•8 kHz

The value sets the carrier frequency for the Pulse Width

Modulation (PWM) output to the motor.

See the PWM Frequency Chart

on page 67 for derating

guidlines.

Bus Regulator Action

Disabled

This selection disables the internal DC bus voltage regulation

feature of the drive. Select this option if there is an external

regenerative brake or regenerative line supply that is

connected to the drive DC bus.

Shunt Regulator

This selection is used when either an external shunt resistor is

connected to the drive or the internal IGBT will be controlling

the power dissipation to the resistor (the type of shunt resistor

is selected below).

Adjustable Frequency

(Default)

This selection allows the drive to either change the torque

limits or ramp rate of the velocity to control the DC bus voltage.

This option is not recommended for positioning applications

because it will override the velocity and the system will

overshoot or may not stop.

Shunt then Adjustable

Frequency

This selection allows the shunt resistor to absorb as much

energy as it is designed for, then transitions to adjustable

frequency control if the limit of the resistor has been reached.

Adjustable Frequency

then Shunt

This selection allows for adjustable frequency control of the DC

bus. If adjustable frequency control cannot maintain the DC

bus within limits, the shunt resistor will be activated.

Shunt Regulator Resistor

Type

Internal Not applicable for PowerFlex 527 drives.

External Enables the external shunt (internal shunt option is disabled).

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

PWM Frequency Chart

Configure the Motion Group

Follow these steps to configure the motion group.

1. In the Controller Organizer, right-click Motion Groups and choose New

Motion Group.

The New Tag dialog box appears.

2. Type the new motion group Name.

3. Click Create.

IMPORTANT Ignoring derating guidelines can cause reduced drive performance. The

drive may automatically reduce the PWM carrier frequency at low output

speeds, unless prevented from doing so.

100

54321

% Output Current (A)

Carrier Frequency (kHz)

Your new motion group appears in the Controller

Organizer under the Motion Groups folder.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

4. Right-click the new motion group and choose Properties.

The Motion Group Properties dialog box appears.

5. Click the Axis Assignment tab and move your axes (created earlier) from

Unassigned to Assigned.

6. Click the Attribute tab and edit the default values as appropriate for your

application.

7. Click OK.

Configure Axis Properties

Axis configuration depends on the motor or other devices (for example, an

external encoder) associated with each axis. This section provides guidelines

for configuring induction motors.

• Configure Induction Motor Axis Properties (Frequency Control)

• Configure Induction Motors Axis Properties (Velocity Loop) on page 72

• Configure Induction Motors Axis Properties (Position Loop) on page 76

Configure Induction Motor Axis Properties (Frequency Control)

The PowerFlex 527 drives support basic Volts/Hertz (V/Hz), Fan/Pump Volts/

Hertz, Sensorless Vector Control (SVC), and Sensorless Vector Control (SVC)

Economy frequency control methods.

Follow these steps to configure the induction motor axis properties.

1. In the Controller Organizer, right-click an axis and choose Properties.

Your axis moves to the new motion group.

To get the minimum motion group base update

rate, see Motion Group Base Update Rate

page 161.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

2. Select the General category.

The General and Associated Module dialog box appears.

3. From the Axis Configuration pull-down menu, choose Frequency

Control.

4. From the Module pull-down menu, choose your PowerFlex 527 drive.

The Module Type and Power Structure fields populate with the chosen

drive catalog number.

5. Click Apply.

6. Select the Motor category.

The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Nameplate Datasheet.

This is the default setting.

8. From the Motor Type pull-down menu, choose Rotary Induction.

9. From the motor Nameplate / Datasheet, enter the Phase to Phase values.

10. Click Apply.

11. Select the Frequency Control category.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

The Frequency Control dialog box appears.

12. From the Frequency Control Method pull-down menu, choose the

method appropriate for your application.

13. If you chose the Basic Volts/Hertz method, enter the nameplate data for

your motor in the Basic Volts/Hertz fields.

If you chose the Sensorless Vector method, the Basic Volts/Hertz fields

are dimmed.

14. Click Apply.

15. If you chose the Sensorless Vector or Sensorless Vector Economy

method, select the Motor > Analyzer category.

The Analyze Motor to Determine Motor Model dialog box appears.

16. Click the Static Motor Test tab.

17. Click Start to run the test and measure Motor Stator Resistance.

If you chose the Basic Volts/Hertz category, you can skip this test.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

18. Select the Actions category.

The Actions to Take Upon Conditions dialog box appears.

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

Some out-of-box (OOB) settings will need to be applied here. See

Recommended Out-of-Box Settings

on page 159 for more information.

19. Select the Parameter List category.

The Motion Axis Parameters dialog box appears.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

To obtain the best performance from the drive regardless of which

control method you are using, you should configure the recommended

out-of-box settings as described in Recommended Out-of-Box Settings

on page 159 first before configuring further for your application.

20. Click OK.

21. Repeat step 1

through step 20 for each induction motor axis.

Configure Induction Motors Axis Properties (Velocity Loop)

Follow these steps to configure the induction motor axis properties.

1. In the Controller Organizer, right-click an axis and choose Properties.

2. Select the General category.

The General and Associated Module dialog box appears.

3. From the Axis Configuration pull-down menu, choose Velocity Loop.

4. From the Module pull-down menu, choose your PowerFlex 527 drive.

The Module Type and Power Structure fields populate with the chosen

drive catalog number.

5. Click Apply.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

6. Select the Motor category.

The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Nameplate Datasheet.

This is the default setting.

8. From the Motor Type pull-down menu, choose Rotary Induction.

9. From the motor Nameplate / Datasheet, enter the Phase to Phase values.

10. Click Apply.

11. Select the Motor Feedback category.

12. Enter the specifications of your encoder into the fields.

13. Click Apply.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

14. Select the Scaling category and edit the values as appropriate for your

application.

15. Click Apply if you make changes.

16. Select the Actions category.

The Actions to Take Upon Conditions dialog box appears.

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

Some out-of-box (OOB) settings will need to be applied here. See

Recommended Out-of-Box Settings

on page 159 for more information.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

17. Select the Parameter List category.

The Motion Axis Parameters dialog box appears.

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

To obtain the best performance from the drive regardless of which

control method you are using, you should configure the recommended

out-of-box settings as described in Recommended Out-of-Box Settings

on page 159 first before configuring further for your application.

18. Click OK.

19. Repeat step 1

through step 18 for each induction motor axis.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

Configure Induction Motors Axis Properties (Position Loop)

Follow these steps to configure the induction motor axis properties.

1. In the Controller Organizer, right-click an axis and choose Properties.

2. Select the General category.

The General and Associated Module dialog box appears.

3. From the Axis Configuration pull-down menu, choose Position Loop.

4. From the Module pull-down menu, choose your PowerFlex 527 drive.

The Module Type and Power Structure fields populate with the chosen

drive catalog number.

5. Click Apply.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

6. Select the Motor category.

The Motor Device Specification dialog box appears.

7. From the Data Source pull-down menu, choose Nameplate Datasheet.

This is the default setting.

8. From the Motor Type pull-down menu, choose Rotary Induction.

9. From the motor Nameplate / Datasheet, enter the Phase to Phase values.

10. Click Apply.

11. Select the Motor Feedback category.

12. Enter the specifications of your encoder into the fields.

13. Click Apply.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

14. Select the Scaling category and edit the values as appropriate for your

application.

15. Click Apply if you make changes.

16. Select the Actions category.

The Actions to Take Upon Conditions dialog box appears.

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

Some out-of-box (OOB) settings will need to be applied here. See

Recommended Out-of-Box Settings

on page 159 for more information.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

17. Select the Parameter List category.

The Motion Axis Parameters dialog box appears.

From this dialog box, you can program actions and change the action for

exceptions (faults). See Logix 5000 Controller and Drive Behavior

page 123 for more information.

To obtain the best performance from the drive regardless of which

control method you are using, you should configure the recommended

out-of-box settings as described in Recommended Out-of-Box Settings

on page 159 first before configuring further for your application.

18. Click OK.

19. Repeat step 1

through step 18 for each induction motor axis.

Download the Program

After completing the Logix Designer application and saving the file, you must

download your program to the Logix 5000 controller.

Apply Power to the

PowerFlex 527 Drive

This procedure assumes that you have done the following:

• Wired and configured your PowerFlex 527 system and your Logix 5000

controller.

• Downloaded the project to the controller.

• Connected the Ethernet port to the drive.

If you have not done the steps that are listed above, you will achieve a different

result in step 5

SHOCK HAZARD: To avoid hazard of electrical shock, perform all mounting

and wiring of the PowerFlex 527 drives before applying power. Once power is

applied, connector terminals can have voltage present even when not in use.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

Follow these steps to apply power to the PowerFlex 527 system.

1. Disconnect the load to the motor.

2. Apply AC power.

The LCD display begins the startup sequence. See Startup Sequence

page 48 for more information.

3. When the startup sequence completes, verify that the MOD and NET

status indicators are steady green.

If the two status indicators are not solid green, see PowerFlex 527 Drive

Status Indicators on page 120 for more information.

4. Monitor the DC Bus voltage on the LCD display. See Real-time

Information Display on page 51 for more information.

If the DC Bus does not reach the expected voltage level, check the 3-phase

input power connections. Also it can take as many as 1.8 seconds after

input power is applied before the drive can accept motion commands.

5. Verify that the axis state changes to STOPPED.

If the axis state does not change to STOPPED, see Fault Codes

page 116.

Test and Tune the Axes –

Velocity and Position

Control Modes

This procedure assumes that you have configured your PowerFlex 527 drive,

your Logix 5000 controller, and applied power to the system.

For help using the Logix Designer application as it applies to testing and

tuning your axes with ControlLogix EtherNet/IP modules or CompactLogix

5370 controllers, see Additional Resources

on page 8.

Test the Axes

Note: In the following example, the Axis Configuration is set to Position Loop.

Follow these steps to test the axes.

1. Verify that the load was removed from each axis.

2. In your Motion Group folder, right-click an axis and choose Properties.

The Axis Properties dialog box appears.

ATTENTION: To avoid personal injury or damage to the equipment,

disconnect the load to the motor. Make sure that each motor is free of

all linkages when initially applying power to the system.

IMPORTANT Before proceeding with testing and tuning your axes, verify that the MOD

and NET status indicators are operating as described in PowerFlex 527

Drive Status Indicators on page 120.

ATTENTION: Verify if drive I/O connection is in the running state and the

axis is in a stopped state.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

3. Click the Hookup Tests category.

4. In the Test Distance field, type 2.0 as the number of revolutions for the

test.

5. Click the Motor Feedback tab.

6. Click Start.

7. Manually move the motor to the specific test distance. In this case, Step 4

dictated 2 revolutions.

8. Click the Motor and Feedback tab.

The Marker and Motor Feedback tests are not supported in Frequency

Control mode.

9. Click Start.

The Logix Designer - Motor and Feedback Test dialog box appears. The

Test State is Executing. TESTING appears on the drive LCD display.

Test Description

Marker Verifies marker detection capability as you rotate the motor shaft.

Motor Feedback Verifies feedback connections are wired correctly as you rotate the motor shaft.

Motor and Feedback

Verifies motor power and feedback connections are wired correctly as you command the

motor to rotate.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

When the test completes successfully, the Test State changes from

Executing to Passed.

10. Click OK.

This dialog box appears asking if the direction was correct.

11. Click Yes.

12. Click Accept Test Results.

13. If the test fails, this dialog box appears.

Tune the Axes

Tuning the Axes is not applicable when using the Frequency Control method.

Follow these steps to tune the axes.

1. Verify that the load is still removed from the axis being tuned.

ATTENTION: Verify if drive I/O connection is in the running state and the

axis is in a stopped state.

ATTENTION: To reduce the possibility of unpredictable motor

response, tune your motor with the load removed first, then reattach

the load and perform the tuning procedure again to provide an

accurate operational response.

a. Click OK.

b. Verify the DC Bus voltage.

c. Verify unit values entered in the

Scaling category.

d. Return to step 9

and run the test

again.

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Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

2. Click the Autotune category.

3. Type values for Travel Limit and Speed.

In this example, Travel Limit = 5 and Speed = 10. The actual value of

programmed units depending on your application.

4. From the Direction pull-down menu, choose a setting appropriate for

your application.

The default setting is Forward Uni-directional.

5. Edit other fields as appropriate for your application.

6. Click Start.

The Logix Designer - Autotune dialog box appears. When the test

completes, the Test State changes from Executing to Success.

Tuned values populate the Loop and Load Parameters tables. Actual

bandwidth values (Hz) depend on your application and can require

adjustment once motor and load are connected.

7. Click Accept Tuned Values.

8. Click OK to close the Logix Designer - Autotune dialog box.

84 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 3 Configuring the PowerFlex 527 Drive with Integrated Motion

9. Click OK to close the Axis Properties dialog box.

10. If the test fails, this dialog box appears.

11. Repeat Test and Tune the Axes for each axis.

a. Click OK.

b. Make an adjustment to motor velocity.

c. See the Integrated Motion on the

EtherNet/IP Network: Configuration

and Startup User Manual, publication

MOTION-UM003

for more

information.

d. Return to step 6

and run the test again.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 85

Chapter 4

Chapter

PowerFlex 527 Integrated Safe Torque-Off

This chapter introduces you to how the PowerFlex 527 integrated safe torque-

off feature meets the requirements of Performance Level e (PLe), Category 3

according to EN ISO 13849, and SIL CL3 according to IEC 61508,

EN 61800-5-2, and EN 62061.

Certification The TÜV Rheinland group has approved PowerFlex 527 drives with integrated

safe torque-off for use in safety-related applications up to PLe, Category 3

according to EN ISO 13849, and SIL CL3 according to IEC 61508, EN 61800-5-2,

and EN 62061, in which removing the motion-producing power is considered

to be the safe state.

See CE Conformity

on page 37 for more information regarding certification.

Important Safety Considerations

The system user is responsible for the following:

• Validation of any sensors or actuators connected to the system.

• Completing a machine-level risk assessment.

• Certification of the machine to the desired EN ISO 13849 performance

level or EN 62061 SIL level.

• Project management and proof testing performed in accordance with

EN ISO 13849.

Category 3 Requirements According to ISO 13849

Safety-related parts are designed with these attributes:

• A single fault in any of these parts does not lead to the loss of the safety

function.

• A single fault is detected whenever reasonably practicable.

• Accumulation of undetected faults can lead to the loss of the safety

function and a failure to remove motion producing power from the

motor.

Topic Page

Certification 85

Description of Operation 86

Probability of Dangerous Failure Per Hour (PFH) 86

Safe Torque-Off (STO) Feature 87

Out-of-Box (OOB) Safety State 88

Safe Torque-Off Status 90

Explicit Messages 91

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Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

Stop Category Definition

Stop category 0 as defined in EN 60204 or Safe Torque-Off as defined by

EN 61800 5 2 is achieved with immediate removal of motion-producing power

to the actuator.

Performance Level (PL) and Safety Integrity Level (SIL)

For safety-related control systems, Performance Level (PL), according to

EN ISO 13849, and SIL levels, according to EN 61508 and EN 62061, include a

rating of the system's ability to perform its safety functions. All of the safety-

related components of the control system must be included in both a risk

assessment and the determination of the achieved levels.

Refer to the EN ISO 13849, EN 61508, and EN 62061 standards for complete

information on requirements for PL and SIL determination.

Description of Operation The Safe Torque-Off (STO) feature provides a method, with sufficiently low

probability of failure, to force the power-transistor control signals to a disabled

state. When the command to allow torque ceases, all of the drive output-power

transistors are released from the On state. This results in a condition where the

motor is coasting (stop category 0). Disabling the power transistor output does

not provide mechanical isolation of the electrical output that is required for

some applications.

The PowerFlex 527 drive STO function response time is less than 12 ms.

Response time is the delay between the time the drive STO function receives

the STO request and the time when motion producing power is removed from

the motor.

Probability of Dangerous

Failure Per Hour (PFH)

Safety-related systems are classified as operating in a High-demand/

continuous mode where the frequency of demands for operation made on a

safety-related system is greater than once per year.

The SIL value for a High-demand/continuous mode safety-related system is

directly related to the probability of a dangerous failure occurring per

hour (PFH).

PFH Data

This PFH calculation is based on the equations from EN 61508 and show worst-

case values.

Determination of safety parameters is based on the assumptions that the

system operates in High-demand mode and that the safety function is

requested at least once a year.

IMPORTANT In the event of a malfunction, the most likely stop category is category 0.

When designing the machine application, timing and distance must be

considered for a coast to stop. For more information regarding stop

categories, refer to EN 60204-1.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 87

Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

Table 6 provides data for a 20-year proof test interval and demonstrates the

worst-case effect of various configuration changes on the data.

Safe Torque-Off (STO)

Feature

The safe torque-off circuit, when used with suitable safety components,

provides protection according to EN ISO 13849 (PLe), Category 3 or according

to IEC EN 61508, EN 61800-5-2, and EN 62061 (SIL CL3). All components in the

system must be chosen and applied correctly to achieve the desired level of

operator safeguarding.

The safe torque-off circuit is designed to safely turn off all of the output-power

transistors. You can use the safe torque-off circuit in combination with other

safety devices to achieve the stop and protection-against-restart as specified in

IEC 60204-1.

Safe Torque-Off Feature Bypass

PowerFlex 527 drives do not operate without a safety circuit or safety bypass

wiring. For applications that do not require the safe torque-off feature, you

must install jumper wires to bypass the safe torque-off circuitry.

PowerFlex 527 drives ship with the safety control in the out-of-box state and

with a safety bypass jumper in place. In this configuration, the PowerFlex 527

safe torque-off function is disabled.

IMPORTANT Determination of safety parameters is based on the assumptions that

the system operates in High-demand mode and that the safety function

is requested at least once every three months.

Table 6 - PFD and PFH Data

Attribute Value (Hardwired and Network)

PFD (average) 1.53E-4

PFH 1.91E-9

SIL CL 3

PL e

Category 3

MTTFd (years) 166

DCavg (%) 90 (medium)

HFT 1 (1oo2)

Mission time (years) 20

ATTENTION: This option is suitable only for performing mechanical work on

the drive system or affected area of a machine. It does not provide

electrical safety.

SHOCK HAZARD: In Safe Torque-Off mode, hazardous voltages can still be

present at the drive. To avoid an electric shock hazard, disconnect power to

the system and verify that the voltage is zero before performing any work on

the drive.

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Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

Safe Torque-Off Bypass Wiring

As-Shipped Safety Configuration

The PowerFlex 527 drive is shipped with:

• Safety control in out-of-box state

• Safety Bypass Jumper installed

In this configuration, the PowerFlex 527 safe torque-off function is disabled.

Out-of-Box (OOB) Safety

State

The PowerFlex 527 drives ship in the out-of-box safety state.

Recognizing the Out-of-Box State

The safety control state can be read from the axis tag AxisSafetyState, or by

using a MSG command in the Logix Designer application to read the Safety

Supervisor State.

If the state is “Waiting for TUNID” (8) or “Waiting for TUNID with Torque

Permitted” (51), then the safety control is in the out-of-box state.

Restoring the Drive to the Out-of-Box State

After the integrated safety connection configuration is applied to the

PowerFlex 527 drive at least once, you can follow these steps to restore your

PowerFlex 527 drive to the out-of-box state.

IMPORTANT If safe torque-off is not required, the drive must be returned to the

as-shipped safety configuration to allow operation.

IMPORTANT If the Safety Bypass Jumper is misplaced, it is acceptable to wire the S1,

S2, and S+ input terminals together.

S1 S2 S+

Safety Bypass Jumper

Hardwired Safety Inputs

Table 7 - Safety Supervisor State: Values

Value Definition Definition Mode

2 Idle No active connections Network

4 Executing Normal running state Network

7 Configuring Transition state Network

8 Waiting for TUNID Out-of-Box state Hardwired

Waiting for TUNID with Torque

Permitted

Out-of-Box state Hardwired

52 Executing with Torque Permitted STO Bypass state Network

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Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

1. Right-click the PowerFlex 527 drive you created, and choose Properties.

Click the Connection tab.

The Connection tab appears.

2. Check Inhibit Module.

3. Click Apply, then click the Safety tab.

The Safety tab appears.

4. In the Configuration Ownership field, click Reset Ownership.

The safety connection must be inhibited before the reset is attempted. If

any active connection to the drive is detected, the reset is rejected.

5. Cycle drive power.

IMPORTANT Only authorized personnel should attempt Reset Ownership.

90 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

The drive is in the out-of-box state.

6. On power-up, make sure that the drive does not have a safety connection.

Safe Torque-Off Status This section describes the safety-related status that is available to the motion

controller.

Axis Tags

When a PowerFlex 527 Add-On-Profile (AOP) is added to a Logix I/O tree, Axis

tags are added to the controller tags.

Table 8

lists the safety-related STANDARD tags that are added when a new

AXIS_CIP_DRIVE axis is defined.

IMPORTANT If power to the drive is not cycled after step 4, the drive does not

transition to the out-of-box state and maintains STO function.

IMPORTANT When the drive returns to the out-of-box state, the STO function

reverts to hardwired control.

ATTENTION: The status data described in this section is STANDARD data

(not SAFETY data) and may not be used as part of a safety function.

Table 8 - Safety-Related Axis Tags

Logix Designer Tag Name Attribute

[bit]

Type Description

AxisFault 34 DINT

GuardFaultStatus [5] BOOL STO Fault - Hardwired

SafetyFaultStatus [8] BOOL STO Fault - Network

GuardStatus

(1)

980 DINT

GuardOKStatus [0] BOOL Not STO Fault - Hardwired

GuardGateDriveOutputStatus [2] BOOL Torque Permitted - Hardwired

GuardStopInputStatus [3] BOOL Safety Inputs Enabled

GuardStopRequestStatus [4] BOOL Torque Disabled - Hardwired

GuardFault

(1)

981 DINT

GuardStopInputFault [9] BOOL STO Fault - Hardwired

GuardGateDriveFault [2] BOOL Internal STO Circuit Fault - Hardwired

CIPAxisFaultsRA 903 LINT

SafetyModuleCommunicationErrorFault [28] BOOL Loss of communications to Safety Control

CIPAxisAlarmsRA 904 LINT

SafetyModuleCommunicationErrorAlarm [28] BOOL Loss of communications to Safety Control

CIPInitializationFaultsRA 910 DINT

InvalidSafetyFirmwareFault [14] BOOL Invalid Safety Control Firmware

CIPStartInhibits 676 INT

SafeTorqueOffActiveInhibit [5] BOOL Torque Disabled - Network

CIPStartInhibitsRA 912 INT

SafeTorqueOffInhibit [5] BOOL Torque Disabled - Hardwired

AxisSafetyState 760 INT Safety Supervisor State

AxisSafetyStatus

(1)

761 DINT

SafetyFaultStatus [0] BOOL Status of SI.SafetyFault

SafetyResetRequestStatus [1] BOOL Status of SO.ResetRequest

SafetyResetRequiredStatus [2] BOOL Status of SI.ResetRequired

SafeTorqueOffActiveStatus [3] BOOL Status of SO.SafeTorqueOff

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Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

Explicit Messages Explicit messages can be used to obtain additional diagnostic information

from the safety control using a MSG instruction.

Safety Supervisor State

The Safety Supervisor State provides information on the state of the CIP Safety

connection and the mode of operation.

Propose TUNID Blocked

The attribute Propose TUNID Blocked can be used to check if the drive is in a

state where it will accept a safety connection. If the drive is enabled, it will not

accept a safety connection.

SafeTorqueDisabledStatus [4] BOOL Status of SI.TorqueDisabled

SafetyOutputConnectionClosed [30] BOOL 1 if all output connections are closed

SafetyOutputConnectionIdleStatus [31] BOOL 1 if output controller is in program mode

AxisSafetyFaults

(1)

763 DINT

SafetyCoreFault [1] BOOL Loss of communications to Safety Control

SafeTorqueOffFault [3] BOOL Status of SI.SafetyFault

(1) Bits not shown are always zero.

Table 8 - Safety-Related Axis Tags (Continued)

Logix Designer Tag Name Attribute

[bit]

Type Description

Safety Supervisor State: MSG

Parameter Value Description

Service Code 0x0E Get Attribute Single

Class 0x39 Safety Supervisor

Instance 1 —

Attribute 0x0B Device Status

Data Type SINT Unsigned Short Integer

Safety Supervisor State: Values

Value Definition Definition Mode

2 Idle No Active Connections Network

4 Executing Normal Running State Network

7 Configuring Transition State Network

8 Waiting for TUNID Out-of-Box State Hardwired

Waiting for TUNID

with Torque Permitted

Out-of-Box State Hardwired

Executing

with Torque Permitted

STO Bypass State Network

Propose TUNID Blocked: MSG

Parameter Value Description

Service Code 0x0E Get Attribute Single

Class 0x5A Safety Stop Functions

Instance 0 Class Attribute

Attribute 0x65 STO Mode

Data Type SINT Unsigned Short Integer

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Chapter 4 PowerFlex 527 Integrated Safe Torque-Off

Safe Torque-Off Mode

The attribute STO Mode can be used to check if the PowerFlex 527 is in STO

Bypass Mode.

Safe Torque-Off Faults

When a safety fault is indicated in any of the following tags:

• SI.SafetyFault

• Axis.SafetyFaultStatus

• Axis.SafetyTorqueOffFault

The cause of the fault can be read using an explicit message.

Safe Torque-Off Mode: Values

Value Definition

0 Accept a Safety Connection

1 Block a Safety Connection

Safe Torque-Off Mode: MSG

Parameter Value Description

Service Code 0x0E Get Attribute Single

Class 0x5A Safety Stop Functions

Instance 1 Axis Number

Attribute 0x104 STO Mode

Data Type SINT Unsigned Short Integer

Safe Torque-Off Mode: Values

Value Definition

1 Normal Operation

2 STO Bypass Mode

Safe Torque-Off Fault Type: MSG

Parameter Value Description

Service Code 0x0E Get Attribute Single

Class 0x5A Safety Stop Functions

Instance 1 Axis Number

Attribute 0x108 STO Fault Type

Data Type SINT Unsigned Short Integer

Safe Torque-Off Fault Type: Values

Value Definition

1No Fault

3 Circuit Error

102 Hardwired Input Discrepancy

104 Hardwired Input in Network Mode

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 93

Chapter 5

Hardwired Control of Safe Torque-Off

This chapter introduces you to how the PowerFlex 527 integrated safe torque-

off feature is configured for hardwired control of safe torque-off.

Description of Operation The safe torque-off feature provides a method, with sufficiently low probability

of failure, to force the power-transistor control signals to a disabled state. If

either hardwired safety input is de-energized, all drive output-power

transistors are released from the On state. This results in a condition where the

drive is coasting (stop category 0). Disabling the power transistor output does

not provide mechanical isolation of the electrical output that is required for

some applications.

Selection of Hardwired Safe Torque-Off

To select hardwired control of safe torque-off (STO):

• The safety control must be in the out-of-box state.

• The Safety Bypass Jumper must be removed.

• An appropriate safety device must be connected to terminals S1, S2, and

01 (Digital Common).

Operation of Hardwired Safe Torque-Off

Under normal operation, the safe torque-off inputs are energized. If either of

the safety enable inputs are de-energized, then all output power transistors

turn off. The safe torque-off response time is less than 12 ms.

Topic Pages

Description of Operation 93

Safe Torque-Off Connector Data 96

Wire the Safe Torque-Off Circuit 96

Safe Torque-Off Specifications 97

ATTENTION: If any of the safety enable inputs de-energize, the Start Inhibit

field indicates SafeTorqueOffInhibit and the GuardStopRequestStatus bit of

the axis GuardStatus tag are set to 1. Both inputs must be de-energized

within 1 second and re-energized within 1 second to avoid

GuardStopInputFault conditions.

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Chapter 5 Hardwired Control of Safe Torque-Off

System Operation when Inputs are Meeting Timing Requirements

Troubleshoot the Safe Torque-Off Function

Event Description

1 At least one input is switched off. GuardStopRequestStatus bit is set to 1.

Second input is switched off within 1 second. This must always occur within 1 second to help

prevent a GuardStopInputFault condition.

3 First input is switched on.

4 Second input is switched on within 1 second of event 3.

Both inputs are in the ON state simultaneously within 1 second. As a result, the GuardStopInputFault

is not posted.

The GuardStopRequestStatus bit is set back to 0 if both inputs are in the ON state for 100 ms

continuously (100 ms debounce time).

(Safety Input) S1

13456

Start Permitted

Permit Torque

Torque Permitted

(Safety Input) S2

GuardFault

SafeTorqueOInhibit

GuardOKStatus

GuardGateDriveOutputStatus

GuardStopInputStatus

GuardStopRequestStatus

GuardStopInputFault

100 ms Debounce Time

1 second Discrepancy Limit

Start Inhibit

Torque Disabled

Disable Torque

No Fault

Torque Disabled

PowerFlex 527 Drive Troubleshooting

Exception Code on Drive Display

Fault Message

Logix Designer

Problem Possible Solutions

SAFE FLT 09 - SS IN GuardStopInputFault

Safe torque-off function mismatch. System does

not allow motion. Safe torque-off mismatch is

detected when safety inputs are in a different

state for more than 1.0 second.

• Verify safety wiring and connections:

– Wire terminations at safe torque-off (STO)

connector

– Cable/header not seated correctly

– +24V power

• Check state of safety inputs.

• Reset error and run proof test.

• Return drive for repair if fault continues.

SAFE FLT 01 - GUARD INTERNALFAULT

CPUWatchdogFault

(1)

Drive safety diagnostic detected internal STO

design failure.

•Cycle power.

• Return drive for repair if fault continues.

SAFE FLT 03 - GUARD GATE DRIVE

FAULT

SafeTorqueOffFault

(2)

Drive safety diagnostic detected internal STO

design failure.

•Cycle power.

• Execute STO function.

• Return drive for repair if fault continues.

Hardwired safe torque off input energized when

drive is in network safety mode.

Reset the drive to out-of-box settings, hardwired

safety mode. See Restoring the Drive to the Out-

of-Box State on page 88 for instructions.

(1) Displayed in the LCD display as Module Fault.

(2) Displayed in the LCD display as Safety Fault.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 95

Chapter 5 Hardwired Control of Safe Torque-Off

Figure 1 demonstrates when the safe torque-off mismatch is detected and a

GuardStopInputFault is posted.

Figure 1 - System Operation in the Event that the Safety Enable Inputs Mismatch

When one safety input is turned off, the second input must also be turned off,

otherwise a fault is asserted (See Figure 2 on page 95). The fault is asserted

even if the first safety input is turned on again.

Figure 2 - System Operation in the Event that the Safety Enable Inputs Mismatch Momentarily

ATTENTION: The safe torque-off fault is detected upon demand of the safe

torque-off function. After troubleshooting, a safety function must be

executed to verify correct operation.

IMPORTANT The Safe Torque-Off fault can be reset only if both inputs are in the Off

state for more than 1 second. After the fault reset requirement is

satisfied, an MASR command in the Logix Designer application must be

issued to reset the GuardFault and GuardStopInputFault conditions.

(Safety Input) S1

1 second Discrepancy Limit

No Fault Faulted

Start Inhibited

OK Not OK

Torque Disabled

Stop Requested

Start Permitted

Torque Permitted

(Safety Input) S2

GuardFault

SafeTorqueOInhibit

GuardOKStatus

GuardGateDriveOutputStatus

GuardStopInputStatus

GuardStopRequestStatus

GuardStopInputFault

(Safety Input) S1

1 second

Start Inhibit

Torque Disabled

(Safety Input) S2

GuardFault

SafeTorqueOInhibit

GuardOKStatus

GuardGateDriveOutputStatus

GuardStopInputStatus

GuardStopRequestStatus

GuardStopInputFault

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Chapter 5 Hardwired Control of Safe Torque-Off

Safe Torque-Off Connector

Data

PowerFlex 527 terminals S1, S2, and 01 are used for hardwired control of safe

torque-off.

Terminals for Safe Torque-Off (STO) Connection

Wire the Safe Torque-Off

Circuit

This section provides guidelines for wiring safe torque-off connections to your

PowerFlex 527 drive.

Safe Torque-Off Wiring Requirements

The safe torque-off (STO) connection wire must be copper with 75 °C (167 °F)

minimum rating.

Safe Torque-Off (STO) Connector Pinouts Control

STO Pin Signal Description

01 Digital Common

The return for digital I/O. It is electrically isolated (along with the digital inputs

and encoder power) from the rest of the drive.

S1 Safety 1 Safety input 1.

S2 Safety 2 Safety input 2.

S+ Safety +24V

+24V supply for safety circuit. This is internally tied to the +24V DC source

(terminal 11).

IMPORTANT Digital Common (terminal 01) is common for the digital inputs, the safety

inputs, and the encoder power supply (optional).

11 12 13 14 15 16 17

R2 R5 R6 01 02 03 04 05 06 07

S1 S2 S+

Safety Bypass Jumper

Hardwired Safety Inputs

IMPORTANT The National Electrical Code and local electrical codes take precedence

over the values and methods provided.

IMPORTANT Pin S+ (Safety +24V) is used to disable the safe torque-off function.

When wiring to the STO connector, use an external 24V supply for the

external safety device that triggers the safe torque-off request. To avoid

jeopardizing system performance, do not use pin S+ as a power supply

for the external safety device.

IMPORTANT The National Electrical Code and local electrical codes take precedence

over the values and methods provided.

IMPORTANT Stranded wires must terminate with ferrules to help prevent short

circuits, per table D.7 of EN ISO 13849-2.

Safe Torque-Off (STO) Terminal Wiring

Maximum Wire Size

(1)

(1) Maximum and minimum sizes that the terminal block will accept. These are not recommended wire sizes.

Minimum Wire Size

(1)

Torque

1.3 mm

(16 AWG) 0.13 mm

(26 AWG)

0.71…0.86 N•m (6.2…7.6 lb•in)

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Chapter 5 Hardwired Control of Safe Torque-Off

Safe Torque-Off

Specifications

To maintain their safety rating, PowerFlex 527 drives must be installed inside

protected control panels or cabinets appropriate for the environmental

conditions of the industrial location. The protection class of the panel or

cabinet must be IP54 or higher.

Safe Torque-Off Signal Specifications

Attribute Value

Safety inputs

(per channel)

Input current < 10 mA

Input ON voltage, max 18…26.4V DC

Input OFF voltage, max 5V DC

Input ON current 10 mA

Input OFF current 500 µA

Pulse rejection width 700 µs

External power supply SELV/PELV

Input type Optically isolated and reverse voltage protected

98 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 5 Hardwired Control of Safe Torque-Off

Notes:

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 99

Chapter

Chapter 6

Network Control of Safe Torque-Off

This chapter describes network control of the safe torque-off function. This

example uses a 1756-L7xS GuardLogix safety controller to issue the safe torque-

off (STO) command over the EtherNet/IP network and the PowerFlex 527 drive

executes the STO command.

Compatible Safety Controllers

The Studio 5000 Logix Designer application:

• Version 24.00 or later, provides support for programming,

commissioning, and maintaining the 1756-L7xS GuardLogix safety

controller.

• Version 28.00 or later, provides support for programming,

commissioning, and maintaining the Compact GuardLogix 5370 safety

controller.

A 1756-L7xS GuardLogix or Compact GuardLogix 5370 safety controller is

required for network control of the PowerFlex 527 safe torque-off function.

The PowerFlex 527 safety connection can originate from a safety controller that

provides both safety and motion control.

The PowerFlex 527 safety connection can originate from a safety controller that

controls only the safety, while a separate Logix processor controls motion.

Selection of Network Safe Torque-Off

To select network control of safe torque-off:

1. The PowerFlex 527 drive must be added to a 1756-EN2T, 1756-EN2TR,

1756-EN2F, 1756-EN3T, or 1756-EN3TR EtherNet/IP bridge in a 1756-L7xS

GuardLogix controller I/O tree.

2. The 1756-EN2T, 1756-EN2TR, 1756-EN2F, 1756-EN3T, or 1756-EN3TR

EtherNet/IP bridge must be configured for “Safety Only” or “Motion and

Safety”.

3. Download the new configuration to the controller.

The drive display may show fault code “SAFE FLT 03 - GUARD GATE

DRIVE FAULT”.

4. Turn off incoming power to the drive.

Topic Page

Understanding Integrated Safety Drive Replacement 103

Replacing an Integrated Safety Drive in a GuardLogix System 103

Motion Direct Commands in Motion Control Systems 109

Functional Safety Considerations 114

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Chapter 6 Network Control of Safe Torque-Off

5. Remove the Safety Bypass jumper.

6. Turn on incoming power to the drive.

Any display fault should now be cleared.

Safety Application Requirements

Creating, recording, and verifying the safety signature is also a required part

of the safety application development process. Safety signatures are created by

the safety controller. The safety signature consists of an identification

number, date, and time that uniquely identifies the safety portion of a project.

This signature covers all safety logic, data, and safety I/O configuration.

For safety system requirements, including information on the safety network

number (SNN), verifying the safety signature, and functional verification

tests, see the GuardLogix 5570 and Compact GuardLogix 5370 Reference

Manual, publication 1756-RM099

Network Safe Torque-off Specifications

Safe Torque-off Assembly Tags

With network control, a 1756-L7xS GuardLogix safety controller controls the

PowerFlex STO function through the SO.SafeTorqueOff tag in the safety

output assembly.

The SO.Command tags are sent from the GuardLogix safety output assembly

to the PowerFlex 527 to control the safe torque-off function.

The SI.Status tags are sent from the PowerFlex 527 to the GuardLogix safety

input assembly and indicate the PowerFlex 527 safety control status.

The SI.ConnectionStatus tags indicate the status of the safety input

connection.

Table 9 on page 101

lists the SAFETY tags added to the controller tags when a

PowerFlex 527 drive is added to a GuardLogix I/O configuration and the

connection is configured for “Motion and Safety” or for “Safety only”.

IMPORTANT You must read, understand, and fulfill the requirements that are detailed

in this publication before operating a safety system that uses a

GuardLogix controller and PowerFlex 527 drive.

Safe Torque-off Network Specifications

Attribute Value

Safety connection RPI, minimum 6 ms

Input assembly connections 1

Output assembly connections 1

Integrated safety open request support Type 1 and Type 2 requests

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Chapter 6 Network Control of Safe Torque-Off

The “Attribute” values that are listed are the Assembly Object attribute values.

STO Fault Reset

If a PowerFlex 527 drive safety control detects a fault, the input assembly tag

SI.SafetyFault is set to 1. A transition from logic 0 to 1 of the SO.Reset tag is

required after the SO.SafeTorqueOff tag has transitioned from logic 0 to 1.

To reset Axis.SafetyFault, a MAFR command must be issued.

See Figure 3 on page 102 for an understanding of the PowerFlex 527 STO Fault

reset functionality.

Table 9 - Safe Torque-off Assembly Tags

Logix Designer Tag Name

Attribute

[bit]

Type Description

SI.ConnectionStatus

(1)(2)

(1) Bits not listed are always zero.

(2) ConnectionStatus is determined by the Safety Validator in the GuardLogix controller. For more information, see the Safety

Connection Status table in the GuardLogix 5570 and Compact GuardLogix 5370 Reference Manual, publication 1756-RM099

DINT

SI.RunMode [0] BOOL

See Table 10

SI.ConnectionFaulted [1] BOOL

SI.Status

(1)(3)

(3) The Status is sent from the drive to the controller using the CIP Safety protocol.

0x1A0 SINT

SI.TorqueDisabled [0] BOOL 0 = Torque Permitted; 1 = Torque Disabled

SI.SafetyFault [6] BOOL 1 = STO Fault present

SI.ResetRequired [7] BOOL 1 = A reset is required

SO.Command

(1)(4)

(4) The Command is sent from the controller to the drive using the CIP Safety protocol.

0x180 SINT

SO.SafeTorqueOff [0] BOOL 0 = Disable Permit; 1 = Permit Torque

SO.Reset [7] BOOL

0→1 = Reset STO Fault

ATTENTION: Only data that is listed in Table 10 is SAFETY data with SIL 3

integrity.

Table 10 - Safety Connection Status

RunMode Status

ConnectionFaulted

Status

Safety Connection Operation

1 = Run 0 = Valid

Data is actively being controlled by the producing device. The

producing device is in Run mode.

0 = Idle 0 = Valid

The connection is active and the producing device is in the Idle

state. The safety data is reset to zero.

0 = Idle 1 = Faulted

The safety connection is faulted. The state of the producing

device is unknown. The safety data is reset to zero.

11Invalid state.

IMPORTANT Transition of the SO.SafeTorqueOff tag to logic 1 must always be

executed before transition of the SO.Reset tag to logic 1.

IMPORTANT PowerFlex 527 drives enter the STO Fault state if any STO function fault

is detected. See Table 11 on page 102

for integrated safety

troubleshooting.

IMPORTANT An STO Fault sets the Axis.SafetyFault tag. After the STO Fault is reset, a

MAFR command must be issued by the motion controller to clear the

Axis.SafetyFault tag to enable motion.

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Chapter 6 Network Control of Safe Torque-Off

Figure 3 - Reset Safe Torque-Off Fault Diagram

Troubleshoot Network Safe Torque-Off

Drv:SO.SafeTorqueO

Disable Torque Permit Torque

Faulted

SO.ResetRequest

No Fault

Faulted (cleared by MAFR)

No Fault

Start Inhibited

Reset Not Required

Reset Not Required Reset Required

Torque Disabled

Start Permitted

Torque Permitted

Torque Disabled

Torque Permitted

Drv:SO.ResetRequest

Drv:SI.TorqueDisabled

Drv:SI.SafetyFault

DrvSI:ResetRequired

Axis.SafetyFault

Axis.SafeTorqueOActiveInhibit

Axis.SafetyFaultStatus

Axis.SafetyResetRequestStatus

Axis.SafetyResetRequiredStatus

Axis.SafeTorqueOActiveStatus

Axis.SafeTorqueODisabledStatus

Axis.SafeTorqueOFault

Permit Torque Disable Torque

Table 11 - PowerFlex 527 Drive Troubleshooting

Exception Code on Drive Display

Fault Message

Logix Designer

Problem Possible Solutions

SAFE FLT 01 - GUARD INTERNAL FAULT

CPUWatchDogFault

(1)

Drive safety diagnostic detected internal

STO design failure.

• Cycle power.

• Return drive for repair if fault

continues.

FLT AXIS FLT M28 - SAFETY COMM

SafetyModuleCommunicationErrorFault

(1)

Drive safety diagnostic detected internal

STO design failure.

• Cycle power.

• Return drive for repair if fault

continues.

SAFE FLT 03 - GUARD GATE DRIVE FAULT

(STO Fault Type = 3)

SafeTorqueOffFault

(2)

Drive safety diagnostic detected internal

STO design failure

• Cycle power.

• Execute STO function.

• Return drive for repair if fault

continues.

SAFE FLT 03 - GUARD GATE DRIVE FAULT

(STO Fault Type = 104)

SafeTorqueOffFault

(2)

Hardwired input energized in network

mode.

• Remove power.

• Remove any connection to hardwired

safety inputs.

• Restore power.

INIT FLT M14 - INVALID SAFETY FIRMWARE

InvalidSafeyFirmwareFault

(2)

The safety firmware is not compatible

with the drive firmware, or the main

safety firmware is missing.

• Cycle power.

• Upgrade drive firmware.

• Return drive for repair if fault

continues.

(1) Displayed in the LCD display as Module Fault.

(2) Displayed in the LCD display as Safety Fault.

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Chapter 6 Network Control of Safe Torque-Off

Understanding Integrated

Safety Drive Replacement

GuardLogix controllers retain I/O device configuration onboard and are able

to download the configuration to the replacement device.

Replacing a PowerFlex 527 drive that sits on an integrated safety network is

more complicated than replacing standard devices because of the Safety

Network Number (SNN). The device number and SNN make up the safety

device's DeviceID. Safety devices require this more complex identifier to make

sure that duplicate device numbers do not compromise communication

between the correct safety devices. The SNN is also used to provide integrity

on the initial download to the PowerFlex 527 drive.

When the Logix Designer application is online, the Safety tab of the Module

Properties dialog box displays the current configuration ownership. When the

opened project owns the configuration, Local is displayed.

A communication error is displayed if the module read fails. See Replacing an

Integrated Safety Drive in a GuardLogix System for integrated safety drive

replacement examples.

Replacing an Integrated

Safety Drive in a

GuardLogix System

If you are relying on a portion of the integrated safety system to maintain SIL 3

behavior during drive replacement and functional testing, do not use the

Configure Always feature.

Use the Configure Always feature when you are not relying on the entire

routable integrated safety control system to maintain PLe/SIL 3 behavior

during the replacement and functional testing of a PowerFlex 527 drive. Drive

replacement is configured on the Safety tab of the GuardLogix controller.

Setting the SNN with a GuardLogix Controller

IMPORTANT If the replacement PowerFlex 527 drive was used previously, clear its

existing configuration before installing it on a safety network by

resetting the drive to its out-of-box condition. To see how this is done,

see Out-of-Box (OOB) Safety State

on page 88.

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Chapter 6 Network Control of Safe Torque-Off

Replacement with “Configure Only When No Safety Signature Exists”

Enabled

When a PowerFlex 527 drive is replaced and the DeviceID of the new drive

matches the original, you can download the configuration from the safety

controller. The DeviceID is a combination of the node/IP address and the

safety network number (SNN), and is updated whenever the SNN is set.

If the project is configured as Configure Only When No Safety Signature

Exists, follow the appropriate instructions in Table 12

to replace a PowerFlex

527 drive based on your scenario. Once you have completed the steps correctly

and the DeviceID matches the original, the safety controller can download the

proper drive configuration and re-establish the safety connection.

Scenario 1 – Replacement Integrated Safety Drive Is Out-of-Box and Safety Signature

Exists

1. Remove and replace the existing integrated safety drive.

2. Right-click the replacement drive and choose Properties.

The General tab appears in the Module Properties dialog box.

Table 12 - Replacing a PowerFlex 527 Drive

GuardLogix Safety

Signature Exists

GuardLogix Safety Signature Exists Action Required

No No SNN (out-of-box)

None. The module is ready for use.

Yes or No Same SNN as original safety task configuration

Yes No SNN (out-of-box) See Scenario 1 on page 104

Yes

Different SNN than original safety task

configuration

See Scenario 2 on page 106

No See Scenario 3 on page 108

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Chapter 6 Network Control of Safe Torque-Off

3. Click to the right of the Safety Network Number (SNN).

The Safety Network Number dialog box appears.

4. Click Set.

5. Verify that the Network Status (NET) status indicator is alternating red/

green on the correct drive.

6. Click Yes to set the SNN and accept the replacement drive.

7. Power cycle the drive.

8. Follow your company-prescribed procedures to functionally test the

replacement drive and system and to authorize the system for use.

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Chapter 6 Network Control of Safe Torque-Off

Scenario 2 – Replacement Integrated Safety Drive SNN is Different from Original and

Safety Signature Exists

1. Remove and replace the existing integrated safety drive.

2. Right-click the replacement drive and choose Properties.

3. Click the Safety tab.

4. Click Reset Ownership.

5. Click OK.

6. Right-click the replacement drive and chooses Properties.

The General tab appears in the Module Properties dialog box.

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Chapter 6 Network Control of Safe Torque-Off

7. Click to the right of the Safety Network Number (SNN).

The Safety Network Number dialog box appears.

8. Click Set.

9. Verify that the Network Status (NET) status indicator is alternating red/

green on the correct drive.

10. Power cycle the drive.

11. Follow your company-prescribed procedures to functionally test the

replacement drive and system and to authorize the system for use.

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Chapter 6 Network Control of Safe Torque-Off

Scenario 3 – Replacement Integrated Safety Drive SNN is Different from Original and no

Safety Signature Exists

1. Remove and replace the existing integrated safety drive.

2. Right-click the replacement drive and choose Properties.

3. Click the Safety tab.

4. Click Reset Ownership.

5. Click OK.

6. Power cycle the drive.

7. Follow your company-prescribed procedures to functionally test the

replacement drive and system and to authorize the system for use.

Replacement with “Configure Always” Enabled

When the Configure Always feature is enabled, the controller automatically

checks for and connects to a replacement drive that meets all the following

requirements:

• The controller has configuration data for a compatible drive at that

network address.

• The drive is in the Out-of-box condition or has an SNN that matches the

configuration.

If the project is configured for Configure Always, follow the appropriate steps

to replace a PowerFlex 527 drive.

ATTENTION: Enable the Configure Always feature only if the entire

integrated safety control system is not being relied on to maintain SIL 3

behavior during the replacement and functional testing of a PowerFlex 527

drive. Do not place drives that are in the Out-of-box condition on an

integrated safety network when the Configure Always feature is enabled,

except while following this replacement procedure.

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Chapter 6 Network Control of Safe Torque-Off

Follow these steps when the Configure Always feature is enabled.

1. Remove and replace the existing integrated safety drive.

2. Right-click the replacement drive and choose Properties.

3. Click the Safety tab.

4. Click Reset Ownership.

5. Click OK.

6. Follow your company-prescribed procedures to functionally test the

replacement drive and system and to authorize the system for use.

Motion Direct Commands in

Motion Control Systems

You can use the Motion Direct Command (MDC) feature to initiate motion

while the controller is in Program mode, independent of application code that

is executed in Run mode. These commands let you perform a variety of

functions, for example, move an axis, jog an axis, or home an axis. See the

Logix 5000 Controllers Motion Instructions Reference Manual, publication

MOTION-RM002

for more information.

A typical use might involve a machine integrator testing different parts of the

motion system while the machine is being commissioned, or a maintenance

engineer, under certain restricted scenarios in accordance with safe machine

operating procedures, wanting to move an axis (like a conveyor) to clear a jam

before resuming normal operation.

If Then

The drive is in the Out-of-box condition

Go to step 6.

No action is needed for the GuardLogix controller to take

ownership of the drive.

An SNN mismatch error occurs Go to the next step to reset the drive to the Out-of-box condition.

ATTENTION: To avoid personal injury or damage to equipment, follow these

rules regarding Run mode and Program mode.

• Only authorized, trained personnel with knowledge of safe machine

operation should be allowed to use Motion Direct Commands.

• Additional supervisory methods, like removing the controller keyswitch,

should be used to maintain the safety integrity of the system after returning

the safety controller to RUN mode.

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Chapter 6 Network Control of Safe Torque-Off

Understanding STO Bypass When Using Motion Direct Commands

If a Safety-only connection between the GuardLogix safety controller and the

PowerFlex 527 drive was established at least once after the drive was received

from the factory, the drive does not allow motion while the safety controller is

in Program mode by default.

This is because the safety task is not executed while the GuardLogix safety

controller is in Program mode. This applies to applications running in a single

safety controller (with Motion and Safety connections). When an integrated

safety drive has a Motion connection to a standard controller and a separate

Safety connection to a dual-safety controller, the standard controller can

transition to Program mode while the safety controller stays in Run mode and

continues to execute the safety task.

However, PowerFlex 527 drive systems are designed with a bypass feature for

the STO function in single-safety controller configurations. You can use the

MDC feature to allow motion while following all necessary and prescribed

steps per your machine's safety operating procedures.

Logix Designer Application Warning Messages

When the controller is in Run mode, executing safety functions, the

PowerFlex 527 drive follows the commands that it receives from the safety

controller. The controller will report Safety state = Running and Axis state =

Stopped/Running, as shown in Figure 4

Figure 4 - Safety State Indications When Controller is in Run Mode (Safety Task Executing)

ATTENTION: Consider the consequences of allowing motion through the use

of MDC when the controller is in Program mode. You must acknowledge

warning messages in the Logix Designer application that warn of the drive

bypassing the STO function and unintended motion can occur. The

integrated safety drive does not respond to requests of the STO function if

MDC mode is entered.

ATTENTION: It is your responsibility to maintain machine safety integrity

while executing motion direct commands. One alternative is to provide

ladder logic for Machine Maintenance mode that leaves the controller in Run

mode with safety functions executing.

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Chapter 6 Network Control of Safe Torque-Off

When the controller transitions to Program mode, the integrated safety drive

is in the safe state and torque is not permitted. The controller will report Safety

state = Not Running and Axis state = Start Inhibited, as shown in Figure 5

Figure 5 - Safety State Indications After Controller Transitions to Program Mode

When you issue a motion direct command to an axis to produce torque in

Program mode, for example MSO or MDS, with the safety connection present

to the drive, a warning message is presented before the motion direct

command is executed, as shown in Figure 6

Figure 6 - STO Bypass Prompt When the Safety Controller is in Program Mode

The warning in Figure 6 is displayed the first time a motion direct command is

issued.

After you acknowledge the warning message by clicking Yes, torque is

permitted by the drive and a warning message is indicated in the software as

shown in Figure 7 on page 112

. The controller will report Safety state = Not

Running (Torque Permitted), Axis state = Stopped/Running, and Persistent

Warning = Safe Torque Off Bypassed.

IMPORTANT Switch the controller to Run mode to exit Motion Direct Command mode

and end the bypass of the STO function.

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Chapter 6 Network Control of Safe Torque-Off

Figure 7 - Safety State Indications After Controller Transitions to Program Mode (MDC Executing)

Torque Permitted in a Multi-workstation Environment

The warning in Figure 8 is displayed to notify a second user working in a

multi-workstation environment that the first user has placed the integrated

safety drive in the STO state and that the current action is about to bypass the

STO state and permit torque.

Figure 8 - STO Bypass Prompt When MDC is Issued in Multi-workstation Environment

Warning Icon and Text in Axis Properties

In addition to the other warnings that require your acknowledgment, the

Logix Designer application also provides warning icons and persistent

warning messages in other Axis Properties dialog boxes when the integrated

safety drive is in STO Bypass mode.

IMPORTANT The persistent warning message text Safe Torque Off bypassed appears

when a motion direct command is executed.

The warning message persists - even after the dialog is closed and

reopened - as long as the integrated safety drive is in STO Bypass mode.

The persistent warning message is removed only after the integrated

safety drive is restored to the Safe state.

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Chapter 6 Network Control of Safe Torque-Off

Axis and Safe State Indications on the Hookup Services Dialog Box

Axis and Safe State Indications on Motion Direct Commands Dialog Box

Axis and Safe State Indications on the Motion Console Dialog Box

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Chapter 6 Network Control of Safe Torque-Off

Functional Safety

Considerations

ATTENTION: Before maintenance work can be performed in Program mode,

the developer of the application must consider the implications of allowing

motion through motion direct commands and should consider developing

logic for runtime maintenance operations to meet the requirements of

machine safety operating procedures.

ATTENTION: Motion is allowed and the STO function is not available when

motion direct commands are used in Program mode.

Motion direct commands that are issued when the controller is in Program

mode cause the drive to bypass the STO Active condition.

It is your responsibility to implement additional preventive measures to

maintain safety integrity of the machinery during execution of motion direct

commands in Program mode.

ATTENTION: To avoid personal injury and damage to equipment in the event

of unauthorized access or unexpected motion during authorized access,

return the controller to Run mode and remove the key before leaving the

machine unattended.

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Chapter 7

Chapter

Troubleshooting

This chapter provides troubleshooting tables and related information for your

PowerFlex 527 drive.

Safety Precautions Observe the following safety precautions when troubleshooting your

PowerFlex 527 drive.

Interpret Status Indicators See these troubleshooting tables to identify faults, potential causes, and the

appropriate actions to resolve the fault. If the fault persists after attempting to

troubleshoot the system, contact your Rockwell Automation sales

representative for further assistance.

Display Interface

The LCD display provides fault messages and troubleshooting information by

using the soft menu items and navigation buttons. See Understanding the

PowerFlex 527 Display and Indicators on page 46 for more information.

Topic Page

Safety Precautions 115

Interpret Status Indicators 115

General Troubleshooting 122

Logix 5000 Controller and Drive Behavior 123

ATTENTION: Capacitors on the DC bus can retain hazardous voltages after

input power has been removed. Before working on the drive, measure the DC

bus voltage to verify it has reached less than 50V DC, or wait three minutes.

Failure to observe this precaution could result in severe bodily injury or loss

of life.

ATTENTION: Do not attempt to defeat or override the drive fault circuits.

You must determine the cause of a fault and correct it before you attempt to

operate the system. Failure to correct the fault could result in personal

injury and/or damage to equipment as a result of uncontrolled machine

operation.

ATTENTION: Provide an earth ground for test equipment (oscilloscope) used

in troubleshooting. Failure to ground the test equipment could result in

personal injury.

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Chapter 7 Troubleshooting

Fault Codes

The fault code tables are designed to help you determine the source of the fault

or exception. When a fault condition is detected, the drive performs the

appropriate fault action, the fault is displayed, and the fault is added to a

persistent fault log (along with diagnostics data). The earlier faults have

priority to be displayed.

The drive removes the fault text from the display when a Fault Reset service is

sent from the controller and the fault is no longer active. If a fault is still active

following a Fault Reset service, the fault is again posted to the display and

written to the fault log.

See Troubleshoot the Safe Torque-Off Function

on page 94 for information on

troubleshooting SAFE FLT fault codes.

Fault Code Summary

Fault Code Type Description

FLT Sxx

Standard runtime axis exceptions.

FLT Mxx

INIT FLT Sxx

Exceptions that prevent normal operation and occur during the initialization process.

INIT FLT Mxx

INHIBIT Sxx

Exceptions that prevent normal operation and indicate whenever the drive is active.

INHIBIT Mxx

NODE FLTxx Exceptions that prevent normal operation of the drive.

NODE ALARM xx

Exceptions that prevent normal operation of the drive, but do not result in any action

other than reporting the alarm to the controller.

Fault codes triggered by conditions that fall outside factory set limits

are identified by FL at the end of the display message. For example,

FLT S07 – MTR OVERLOAD FL.

Fault codes triggered by conditions that fall outside user set limits are

identified by UL at the end of the display message. For example,

FLT S08 – MTR OVERLOAD UL.

INIT FLT S03 NVMEM CHKSUM

Fault type

Fault code

Fault description

When the drive enters a fault or

inhibit scenario, the fault information

will be shown and scrolled across the

LCD display.

FLT Sxx Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

FLT S03 – MTR OVERSPEED FL Motor Overspeed Factory Limit Fault Motor speed has exceeded 590 Hz. Check control loop tuning.

FLT S04 – MTR OVERSPEED UL Motor Overspeed User Limit Fault

Motor speed has exceeded the user-

defined speed limit that is given by Motor

Overspeed User Limit.

Check control loop tuning.

FLT S07 – MTR OVERLOAD FL

Motor Thermal Overload Factory Limit

Fault

The motor thermal model has exceeded its

factory set thermal capacity limit of 110%.

Modify the command profile to reduce

speed or increase time.

FLT S08 – MTR OVERLOAD UL Motor Thermal Overload User Limit Fault

The motor thermal model has exceeded

the thermal capacity limit that is given by

Motor Thermal Overload User Limit.

• Modify the command profile.

• Increase the Motor Thermal Overload UL

attribute value.

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Chapter 7 Troubleshooting

FLT S10 – INV OVERCURRENT Inverter Overcurrent Fault

Inverter current has exceeded the

instantaneous current limit (determined by

hardware).

• Check motor power cable for shorts.

• Verify that motor windings are not

shorted.

• Verify motor power wire gauge.

• Operate within the continuous power

rating.

• Reduce acceleration times.

FLT S11 – INV OVERTEMP FL

Inverter Overtemperature Factory Limit

Fault

The measured inverter temperature has

exceeded the factory set temperature

limit.

• Modify the command profile to reduce

speed or increase time.

• Reduce drive ambient temperature.

• Verify that airflow through drive is not

obstructed.

FLT S13 – INV OVERLOAD FL

Inverter Thermal Overload Factory Limit

Fault

The thermal model for the power

transistors indicates that the temperature

has exceeded the factory set thermal

capacity rating of 110%.

Modify the command profile to reduce

speed or increase time.

FLT S16 – GROUND CURRENT Ground Current Factory Limit Fault

The sensing circuitry in the power stage

has detected excessive ground current.

• Check motor power wiring; check power

cable for shorts.

• Replace motor if the fault persists.

FLT S23 – AC PHASE LOSS AC Single Phase Loss Fault

A single AC input phase was lost while the

drive was enabled.

Check AC input voltage on all phases.

FLT S25 – PRECHARGE FAILURE Pre-charge Failure Fault

The pre-charge circuit monitoring

algorithm detected that the DC bus did not

reach a factory set voltage level after

charging for a period of time.

• Check AC input voltage on all phases.

• Check input power wiring.

• Replace drive if fault persists.

FLT S29 – BUS OVERLOAD FL

Bus Regulator Thermal Overload Factory

Limit Fault

The shunt thermal model has exceeded its

factory set thermal capacity limit.

• Modify the duty cycle of the application.

• Add external shunt for additional

capacity.

• Add capacitor module if needed.

FLT S34 – BUS UNDERVOLT UL Bus Undervoltage User Limit Fault

DC Bus voltage level is below the user set

limit as given by Bus Undervoltage User

Limit.

• Verify voltage level of the incoming AC.

• Monitor AC power source for glitches or

line droop.

• Install UPS on AC input.

• Decrease Bus Undervoltage UL attribute

value.

FLT S35 – BUS OVERVOLT FL Bus Overvoltage Factory Limit Fault

DC Bus voltage level is above the factory

set limit as determined by the configured

input voltage.

• Change the deceleration or motion

profile of all drives that are connected to

the DC bus.

• Unplug the shunt connector and

measure the resistance of the shunt.

• Replace drive if shunt resistor is open.

FLT S37 – BUS POWER LOSS Bus Power Loss

DC Bus voltage level is below the Bus

Power Loss Threshold for more than the

timeout period specified Bus Power Loss

Time value.

• Verify voltage level of the incoming AC.

• Monitor AC power source for glitches or

line droop.

• Install UPS on AC input.

FLT S41 – FDBK SIGNAL NOISE FL Feedback Signal Noise Fault

Noise induced A/B channel state changes

(illegal states) from a feedback device

were detected by the drive. Specifically,

the number of these noise events that

have occurred on this channel has

exceeded the Feedback Noise Factory

Limit. The offending feedback channel

number is encoded in the associated

Fault/Alarm Sub Code.

• Check motor feedback cable and

connector.

• Cycle power.

• Check feedback shield connection.

• Reduce shock and vibration to motor.

• Replace motor if fault continues.

• Verify all HTL/TTL DIP switches on the

25-ENC-2/B encoder are set in the same

position.

FLT S43 – FDBK SIG FL

Feedback Signal Loss Factory Limit

Fault

The absolute value of the differential A/B

signals is below a factory limit.

• Check motor feedback cable and

connector.

• Check that motor power cable and

feedback wire shields are secured

correctly.

• Check that motor frame is grounded

correctly.

FLT S50 – HARDWARE OVERTRAVEL

POSITIVE

Hardware Overtravel Positive

Axis moved beyond the physical travel

limits in the positive direction and

activated the Positive Overtravel limit

switch.

•Check wiring.

• Verify motion profile.

• Verify axis configuration in software.

FLT Sxx Fault Codes (Continued)

Exception Code on Display Exception Text Problem Possible Solutions

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Chapter 7 Troubleshooting

FLT S51 – HARDWARE OVERTRAVEL

NEGATIVE

Hardware Overtravel Negative

Axis moved beyond the physical travel

limits in the negative direction and

activated the Negative Overtravel limit

switch.

•Check wiring.

• Verify motion profile.

• Verify axis configuration in software.

FLT S54 – POSN ERROR Excessive Position Error Fault

The position error of the position control

loop has exceeded the value that is given

by Position Error Tolerance for a time

period that is given by Position Error

Tolerance Time.

• Check position loop tuning.

• Increase the feedforward gain.

• Verify sizing of the drive and motor.

• Check motor power wiring.

• Increase Position Error Tolerance and/

or Position Error Tolerance Time

attribute values.

FLT S55 – VEL ERROR Excessive Velocity Error Fault

The velocity error of the velocity control

loop has exceeded the value that is given

by Velocity Error Tolerance for a time

period that is given by Velocity Error

Tolerance Time.

• Check velocity loop tuning.

• Reduce acceleration.

• Verify sizing of the drive and motor.

• Check motor power wiring.

• Increase Velocity Error Tolerance and/or

Velocity Error Tolerance Time attribute

values.

FLT S56 – OVERTORQUE LIMIT Overtorque Limit Fault

Motor torque has risen above user-defined

maximum torque level that is given by

Overtorque Limit for a time period that is

given by Overtorque Limit Time.

• Verify Torque Trim value.

• Verify motion profile.

• Verify sizing of the drive and motor.

• Increase Overtorque Limit and/or

Overtorque Limit Time attribute values.

FLT S57 – UNDERTORQUE LIMIT Undertorque Limit Fault

Motor torque has dropped below user-

defined minimum torque level that is given

by Undertorque Limit for a time period that

is given by Undertorque Limit Time.

• Verify motion profile.

• Verify sizing of the drive and motor.

• Decrease Undertorque Limit and/or

Undertorque Limit Time attribute values.

FLT S61 – ENABLE INPUT DEACTIVATED Enable Input Deactivated

Enable Input has been deactivated while

the axis power structure is in Running

state, enabled, and supplying current to

the DC Bus or motor.

• Verify Enable Input level.

• Check Enable Input wiring.

FLT Sxx Fault Codes (Continued)

Exception Code on Display Exception Text Problem Possible Solutions

FLT Mxx Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

FLT M10 – CONTROL MODULE

OVERTEMPERATURE FL

Control Module Overtemperature Fault

The temperature sensor on the Main

Control Board detected excessive heat.

• Reduce drive ambient temperature.

• Verify that airflow through drive is not

obstructed.

• Check control module internal fan.

Replace if error persists.

FLT M19 – DECEL OVERRIDE Decel Override

The drive is not following a commanded

deceleration because it is attempting to

limit bus voltage.

• Reprogram Bus Regulator Action to

eliminate any “Adjustable Freq”

selection.

• Reprogram Bus Regulator Action to

Shunt Regulator and add external shunt.

•Correct AC input line instability or add an

isolation transformer.

• Reset drive.

FLT M21 – MOTOR TEST FAILURE Motor Test Failure The Motor Test procedure has failed.

• Verify sizing of the drive and motor.

• Verify motor data.

• Check motor power wiring.

FLT M26 – RUNTIME ERROR Runtime Error

The drive firmware encountered an

unrecoverable runtime error.

•Cycle power.

• Reset the drive.

• Return drive for repair if fault continues.

FLT M28 – SAFETY MODULE COM ERROR Safety Module Communication Error

Error in communicating to the Safety

module.

•Cycle power.

• Replace module.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 119

Chapter 7 Troubleshooting

INIT FLT Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

INIT FLT S03 – NVMEM CHKSUM Nonvolatile Memory Checksum Error

Data in the nonvolatile memory has a

checksum error.

•Cycle power.

• Reset the drive.

• Return drive for repair if fault continues.

INIT FLT M14 – INVALID SAFETY

FIRMWARE

Invalid Safety Firmware

The safety firmware is not compatible with

the drive firmware, or the main safety

firmware is missing.

•Cycle power.

• Upgrade drive firmware.

• Return drive for repair if fault continues.

INIT FLT M15 – POWER BOARD Power Board Checksum Error The power board has a checksum error.

•Cycle power.

• Reset the drive.

• Return drive for repair if fault continues.

INIT FLT M22 – ILLEGAL ADDRESS Illegal IP Address Configuration

Invalid Ethernet IP Address configuration

or device Node Address is out of range

(>254)

For example, this fault will occur when the

IP address and Gateway address are

identical.

When this fault occurs, IP address

configuration will be changed to DHCP.

Change IP address, subnet mask, and

gateway address to a legal configuration

and cycle power.

INHIBIT Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

INHIBIT S01 – AXIS ENABLE INPUT Axis Enable Input Axis Enable Input is not active.

• Verify Enable Input level.

• Check Enable Input wiring.

INHIBIT S02 – MOTOR NOT CONFIGURED Motor Not Configured

The motor has not been properly

configured for use.

Verify motor configuration in the Studio

5000 Logix Designer application.

INHIBIT S05 – SAFE TORQUE OFF

(1)

Start Inhibit – Safe Torque Off

The safety function has disabled the power

structure.

• Check that Ethernet components such

as cables are secured and switches are

operational.

• Check state of safety devices.

INHIBIT M05 – SAFE TORQUE OFF

(2)

Start Inhibit – Safe Torque Off

The safety function has disabled the power

structure.

• Check safety input wiring.

• Check state of safety devices.

(1) Network STO.

(2) Hardwired STO.

NODE FLT Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

NODE FLT 01 – LATE CTRL UPDATE Control Connection Update Fault

Several consecutive updates from the

controller have been lost.

• Remove unnecessary network devices

from the motion network.

• Change network topology so that fewer

devices share common paths.

• Use high-performance network

equipment.

• Use shielded cables.

• Separate signal wiring from power

wiring.

NODE FLT 02 – PROC WATCHDOG nn Processor Watchdog Fault

The processor on the power board or

control board failed to update in a certain

amount of time.

The nn sub-codes 00…05 are internal and

result in the same possible solution.

•Cycle power.

• Update the drive firmware.

• Return drive for repair if fault continues.

NODE FLT 03 – HARDWARE 00 Hardware Fault - PwrIF

Communication with the power board

could not be established.

•Cycle power.

• Update the drive firmware.

• Return drive for repair if fault continues.

NODE FLT 03 – HARDWARE 01 Hardware Fault - Piccolo HW DSP chip on the power board failure.

•Cycle power.

• Return motor for repair if fault

continues.

NODE FLT 05 – CLOCK SKEW FLT Clock Skew Fault

The controller time and the drive system

time are not the same.

•Cycle power.

• Check controller and Ethernet switch

operation.

120 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 7 Troubleshooting

PowerFlex 527 Drive Status Indicators

The fault status indicator is located between the LCD display and keypad.

There are also four status indicators that are located at the bottom right of the

drive and can be seen through the front cover of the control module.

NODE FLT 06 – LOST CTRL CONN Lost Controller Connection Fault

Communication with the controller has

been lost.

• Check Ethernet connection.

• Check controller and Ethernet switch

operation.

NODE FLT 07 – CLOCK SYNC Clock Sync Fault

Drive local clock has lost synchronization

with controller's clock and was not able to

resynchronize within allotted time.

• Check Ethernet connection.

• Check controller and Ethernet switch

operation.

NODE FLT 09 – DUPLICATE IP ADDRESS Duplicate IP Address Fault

Several consecutive updates from the

controller have been lost.

Select an IP address not already in use on

the network.

NODE FLT Fault Codes (Continued)

Exception Code on Display Exception Text Problem Possible Solutions

NODE ALARM Fault Codes

Exception Code on Display Exception Text Problem Possible Solutions

NODE ALARM 01 – LATE CTRL UPDATE Control Connection Update Alarm

Updates from the controller have been

late.

• Remove unnecessary network devices

from the motion network.

• Change network topology so that fewer

devices share common paths.

• Use high-performance network

equipment.

• Use shielded cables.

• Separate signal wiring from power

wiring.

NODE ALARM 03 – CLOCK JITTER Clock Jitter Alarm

The sync variance has exceeded the sync

threshold while the device is running in

sync mode.

• Check the Ethernet connection.

• Check controller and Ethernet switch

operation.

NODE ALARM 04 – CLOCK SKEW ALARM Clock Skew Alarm

The controller time and the drive system

time are not the same.

• Check the Ethernet connection.

• Check controller and Ethernet switch

operation.

NODE ALARM 05 – CLOCK SYNC ALARM Clock Sync Alarm

Drive local clock has lost synchronization

with controller's clock for a short time

during synchronous operation.

• Check the Ethernet connection.

• Check controller and Ethernet switch

operation.

Module status

Network status

Link A status (Ethernet port 1)

Link B status (Ethernet port 2)

Fault status

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 121

Chapter 7 Troubleshooting

Fault Status Indicator

Condition Safety Supervisor State CIP Motion Axis State Governing Object Identity State

Steady Red

Any State

(1)

Aborting Motion Axis

Major Recoverable or

Major Unrecoverable

Steady Red

Any State

(1)

Major Faulted Motion Axis

Major Recoverable or

Major Unrecoverable

Steady Red Abort

Any State

(1)

Safety Supervisor Major Recoverable

Steady Red Critical Fault

Any State

(1)

Safety Supervisor Major Unrecoverable

(1) “Any State” means any state that has lower precedence.

Module Status Indicator

Condition Safety Supervisor State CIP Motion Axis State Governing Object Identity State

Flashing Green/Red Self-Testing

Any State

(1)

Safety Supervisor Device Self-Testing

Flashing Green/Red

Any State

(1)

Self-Testing Motion Axis Device Self-Testing

Steady Red Self-Test Exception

Any State

(1)

Safety Supervisor Major Unrecoverable

Flashing Green/Red

Waiting for TUNID

(2)

Any State

(1)

Safety Supervisor Standby

Flashing Green/Red Configuring

Any State

(1)

Safety Supervisor Standby

Flashing Green Idle

Any State

(1)

Safety Supervisor Standby

Flashing Green

• Waiting for TUNID with Torque

Permitted

(2)(3)

•Executing

• Executing with Torque

Permitted

(4)

• Initializing

• Pre-Charge

•Shutdown

•Start Inhibit

Motion Axis Standby

Steady Green

• Stopped

• Stopping

•Starting

• Running

•Testing

Motion Axis Operational

Flashing Red or Steady Red

Any State

(1)

Aborting Motion Axis

Major Recoverable or

Major Unrecoverable

Flashing Red

Any State

(1)

Major Faulted Motion Axis

Major Recoverable or

Major Unrecoverable

Flashing Red Abort

Any State

(1)

Safety Supervisor Major Recoverable

Steady Red Critical Fault

Any State

(1)

Safety Supervisor Major Unrecoverable

(1) “Any State” means any state that has lower precedence.

(2) After Propose_TUNID service request, the Network Status indicator flashes Green/Red (fast flash) until successful Apply_TUNID.

(3) Unlike many safety I/O devices, a CIP Motion safety drive is free to operate in its “Out-of-Box” state. This behavior is made explicit by the device specific Safety Supervisor state, Waiting for

TUNID with Torque Permitted. In this “Out-of-Box” state, operation of the CIP Motion safety drive is the same as that of a CIP Motion drive to facilitate commissioning.

(4) Unlike many safety I/O devices, a CIP Motion safety drive may be operated when the safety output assemblies Run/Idle bit is set to Idle. If in the Executing state, the Run/Idle bit is set to Idle,

the device is forced to a Safe State. However, if in this condition, the safety controller sends a Mode_Change service request with Torque Permitted to the Safety Stop Functions object, drive

operation is permitted while the Run/Idle bit remains Idle. See the Safety Stop Function object for details on the Mode_Change service.

Network Status Indicator

Condition Status

Off No power applied to the drive or IP address is not configured.

Flashing Green Drive connection is not established, but has obtained an IP address.

Steady Green Drive is online and has connections in the established state.

Flashing Red One or more Exclusive Owner connections has timed out.

Steady Red Duplicate IP address. IP address that is specified is already in use.

Flashing Green/Red (slow flash) The drive performs self-test during powerup.

Flashing Green/Red (fast flash) Safety Supervisor is waiting for “Apply TUNID” service request.

122 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 7 Troubleshooting

General Troubleshooting These conditions do not always result in a fault code, but can require

troubleshooting to improve performance.

Link A Status Indicator (Ethernet Port 1)

Condition Status

Off Drive is not connected to the network.

Steady Green Drive is connected to the network but not transmitting data.

Flashing Green Drive is connected to the network and transmitting data.

Link A Status Indicator (Ethernet Port 2)

Condition Status

Off Drive is not connected to the network.

Steady Green Drive is connected to the network but not transmitting data.

Flashing Green Drive is connected to the network and transmitting data.

General Troubleshooting

Condition Potential Cause Possible Resolution

Axis or system is unstable.

The position feedback device is incorrect or open. Check wiring.

Motor tuning limits are set too high. Run Tune in the Logix Designer application.

Position loop gain or position controller accel/decel rate is improperly

set.

Run Tune in the Logix Designer application.

Improper grounding or shielding techniques are causing noise to be

transmitted into the position feedback or velocity command lines,

causing erratic axis movement.

Check wiring and ground.

Motor Data is incorrectly set (induction motor is not matched to axis

module).

• Check setups.

• Run Motor Test in the Logix Designer application.

Mechanical resonance.

Notch filter or output filter can be required (refer to Axis

Properties dialog box, Output tab in the Logix Designer

application).

You cannot obtain the motor

acceleration/deceleration that you

want.

Torque Limit limits are set too low. Verify that torque limits are set properly.

Incorrect motor selected in configuration.

Select the correct motor and run Tune in the Logix Designer

application again.

The system inertia is excessive.

• Check motor size versus application need.

• Review induction system sizing.

The system friction torque is excessive. Check motor size versus application need.

Available current is insufficient to supply the correct accel/decel rate.

• Check motor size versus application need.

• Review induction system sizing.

Acceleration limit is incorrect. Verify limit settings and correct them, as necessary.

Velocity Limit limits are incorrect. Verify limit settings and correct them, as necessary.

Motor does not respond to a

command.

The motor wiring is open. Check the wiring.

The motor cable shield connection is improper.

• Check feedback connections.

• Check cable shield connections.

The motor has malfunctioned. Repair or replace the motor.

The coupling between motor and machine has broken (for example, the

motor moves, but the load/machine does not).

Check and correct the mechanics.

Primary operation mode is set incorrectly. Check and properly set the limit.

Velocity or torque limits are set incorrectly. Check and properly set the limits.

Brake connector not wired Check brake wiring.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 123

Chapter 7 Troubleshooting

Logix 5000 Controller and

Drive Behavior

By using the Logix Designer application, you can configure how the

PowerFlex 527 drives respond when a drive fault/exception occurs.

The drive supports fault action for Ignore, Alarm, Minor Fault, and Major Fault

as defined in Table 13

. See the drive behavior tables beginning on page 125 for

information on how the fault and stopping actions apply to each of the

exception fault codes.

The drive supports these configurable stopping actions

(1)

• Disable and Coast

• Current Decel and Disable

• Ramped Decel and Disable

(1) Disable and Coast and Current Decel and Disable are available in Frequency Control, Velocity Loop and Position Loop.

Ramped Decel and Disable is available in Frequency Control and Velocity Loop only and is not supported in Position Loop.

Presence of noise on command or

motor feedback signal wires.

Recommended grounding per installation instructions have not been

followed.

• Verify grounding.

• Route wire away from noise sources.

• See the System Design for Control of Electrical Noise

Reference Manual, publication GMC-RM001

Line frequency can be present.

• Verify grounding.

• Route wire away from noise sources.

Variable frequency can be velocity feedback ripple or a disturbance that

is caused by gear teeth or ballscrew, and so forth. The frequency can be

a multiple of the motor power transmission components or ballscrew

speeds resulting in velocity disturbance.

• Decouple the motor for verification.

• Check and improve mechanical performance, for

example, the gearbox or ballscrew mechanism.

No rotation

The motor connections are loose or open. Check motor wiring and connections.

Foreign matter is lodged in the motor. Remove foreign matter.

The motor load is excessive. Verify the induction system sizing.

The bearings are worn. Return the motor for repair.

The motor brake is engaged (if supplied).

• Check brake wiring and function.

• Return the motor for repair.

The motor is not connected to the load. Check coupling.

Motor overheating

The duty cycle is excessive.

Change the command profile to reduce accel/decel or

increase time.

The rotor is partially demagnetized causing excessive motor current. Return the motor for repair.

Abnormal noise

Motor tuning limits are set too high. Run Tune in the Logix Designer application.

Loose parts are present in the motor.

• Remove the loose parts.

• Return motor for repair.

• Replace motor.

Through bolts or coupling is loose. Tighten bolts.

The bearings are worn. Return motor for repair.

Mechanical resonance.

Notch filter can be required (See the Axis Properties dialog

box, Output tab in the Logix Designer application).

Erratic operation - Motor locks into

position, runs without control or

with reduced torque.

Motor power phases U and V, U and W, or V and W reversed. Check and correct motor power wiring.

General Troubleshooting (Continued)

Condition Potential Cause Possible Resolution

The INIT FLT xxx faults are always generated after powerup, but before

the drive is enabled, so the stopping behavior does not apply.

NODE ALARM xxx faults do not apply because they do not trigger stopping

behavior.

124 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 7 Troubleshooting

PowerFlex 527 Drive Exception Behavior

For PowerFlex 527 drives, you can configure exception behavior in the

Logix Designer application from the Axis Properties dialog box, Actions

category.

Only selected drive exceptions are configurable. In the fault behavior tables,

the controlling attribute is given for programmable fault actions.

Logix Designer Axis Properties - Actions Category

Table 13 - PowerFlex 527 Drive Exception Action Definitions

Exception Action Definition

Ignore

The controller completely ignores the exception condition. For some exceptions

that are fundamental to the operation of the planner, Ignore is not an available

option.

Alarm

The controller sets the associated bit in the Motion Alarm Status word, but does not

otherwise affect axis behavior. Like Ignore, if the exception is so fundamental to

the drive, Alarm is not an available option. When an exception action is set to

Alarm, the Alarm goes away by itself when the exceptional condition has cleared.

Fault Status Only – Minor Fault

Like Alarm, Fault Status Only instructs the controller to set the associated bit in the

Motion Fault Status word, but does not otherwise affect axis behavior. However,

unlike Alarm an explicit Fault Reset is required to clear the fault once the

exceptional condition has cleared.

Like Ignore and Alarm, if the exception is so fundamental to the drive, Fault Status

Only is not an available option.

Stop Planner – Minor Fault

The controller sets the associated bit in the Motion Fault Status word and instructs

the Motion Planner to perform a controlled stop of all planned motion at the

configured maximum deceleration rate and holds at zero speed. An explicit Fault

Reset is required to clear the fault once the exceptional condition has cleared. If

the exception is so fundamental to the drive, Stop Planner is not an available

option.

Stop Drive – Major Fault

When the exception occurs, the associated bit in the Fault Status word is set and

the axis comes to a stop by using the stopping action that is defined by the drive

for the particular exception that occurred. There is no controller based

configuration to specify what the stopping action is, the stopping action is device

dependent.

Shutdown – Major Fault

When the exception occurs, the drive brings the motor to a stop by using the

stopping action defined by the drive (as in Stop Drive) and the power module is

disabled. An explicit Shutdown Reset is required to restore the drive to operation.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 125

Chapter 7 Troubleshooting

Drive Behavior, FLT Sxx Fault Codes

Exception Fault Code Exception Text

Induction

Motor

Fault Action

Best Available Stopping

Action (applies to major

faults)

Ignore Alarm

Minor

Fault

Major

Fault

FLT S03 – MTR OVERSPEED FL Motor Overspeed Factory Limit Fault X X Disable and Coast

FLT S04 – MTR OVERSPEED UL Motor Overspeed User Limit Fault X XXXXDisable and Coast

FLT S07 – MTR OVERLOAD FL Motor Thermal Overload Factory Limit Fault X X Disable and Coast

FLT S08 – MTR OVERLOAD UL Motor Thermal OverLoad User Limit Fault X XXXXDisable and Coast

FLT S10 – INV OVERCURRENT Inverter Overcurrent Fault X X Disable and Coast

FLT S11 – INV OVERTEMP FL Inverter Overtemperature Factory Limit Fault X X Disable and Coast

FLT S13 – INV OVERLOAD FL Inverter Thermal Overload Factory Limit Fault X X Disable and Coast

FLT S16 – GROUND CURRENT Ground Current Factory Limit Fault X X Disable and Coast

FLT S23 – AC PHASE LOSS AC Single Phase Loss Fault X XXXXDisable and Coast

FLT S25 – PRECHARGE FAILURE Pre-charge Failure Fault X X Disable and Coast

FLT S29 – BUS OVERLOAD FL

Bus Regulator Thermal OverLoad Factory Limit

Fault

XXDisable and Coast

FLT S34 – BUS UNDERVOLT UL Bus Undervoltage User Limit Fault X XXXXDisable and Coast

FLT S35 – BUS OVERVOLT FL Bus Overvoltage Factory Limit Fault X X Disable and Coast

FLT S37 – BUS POWER LOSS Bus Power Loss X XXXXDisable and Coast

FLT S41 – FDBK SIGNAL NOISE FLFeedback Signal Noise Fault X XXXXDisable and Coast

FLT S43 – FDBK SIG FL Feedback Signal Loss Factory Limit Fault X XXXXDisable and Coast

FLT S50 – HARDWARE OVERTRAVEL

POSITIVE

Hardware Overtravel Positive X XXXXCurrent Decel and Disable

FLT S51 – HARDWARE OVERTRAVEL

NEGATIVE

Hardware Overtravel Negative X XXXXCurrent Decel and Disable

FLT S54 – POSN ERROR Excessive Position Error Fault X XXXXDisable and Coast

FLT S55 – VEL ERROR Excessive Velocity Error Fault X XXXXDisable and Coast

FLT S56 – OVERTORQUE LIMITOvertorque Limit Fault X XXXXDisable and Coast

FLT S57 – UNDERTORQUE LIMIT Undertorque Limit Fault X XXXXDisable and Coast

FLT S61 – ENABLE INPUT

DEACTIVATED

Enable Input Deactivated X XXXXDisable and Coast

Drive Behavior, FLT Mxx Fault Codes

Exception Fault Code Exception Text

Induction

Motor

Fault Action

Best Available Stopping

Action (applies to major

faults)

Ignore Alarm

Minor

Fault

Major

Fault

FLT M10 – CONTROL MODULE

OVERTEMPERATURE FL

Control Module Overtemperature Fault X X Disable and Coast

FLT M19 – DECEL OVERRIDE Decel Override X XXXXDisable and Coast

FLT M21 – MOTOR TEST FAILURE Motor Test Failure X X Disable and Coast

FLT M26 – RUNTIME ERROR Runtime Error X X Disable and Coast

FLT M28 – SAFETY COMM Safety Module Communication Error X X Disable and Coast

Drive Behavior, NODE FLT xx Fault Codes

Exception Fault Code Exception Text

Induction

Motor

Fault Action

Best Available Stopping

Action (applies to major

faults)

Ignore Alarm

Minor

Fault

Major

Fault

NODE FLT 01 –

LATE CTRL UPDATE

Control Connection Update Fault X X Current Decel and Disable

NODE FLT 02 – PROC WATCHDOG Processor Watchdog Fault X X Disable and Coast

NODE FLT 03 – HARDWARE Hardware Fault X X Disable and Coast

NODE FLT 05 – CLOCK SKEW FLT Clock Skew Fault X X Disable and Coast

126 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Chapter 7 Troubleshooting

NODE FLT 06 – LOST CTRL CONN Lost Controller Connection Fault X X Current Decel and Disable

NODE FLT 07 – CLOCK SYNC Clock Sync Fault X X Disable and Coast

NODE FLT 09 –

DUPLICATE IP ADDRESS

Duplicate IP Address Fault X X Disable and Coast

Drive Behavior, NODE FLT xx Fault Codes (Continued)

Exception Fault Code Exception Text

Induction

Motor

Fault Action

Best Available Stopping

Action (applies to major

faults)

Ignore Alarm

Minor

Fault

Major

Fault

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 127

Appendix A

Supplemental Drive Information

Certifications

Topic Page

Certifications 127

Environmental Specifications 128

Technical Specifications 129

Power Specifications 132

Certifications

Certifications PowerFlex 527

c-UL-us

Listed to UL61800 and CAN/CSA-C22.2 No. 14-05.

RCM Australian Communications and Media Authority

In conformity with the following:

Radiocommunications Act: 1992 (including amendments up to 2018)

Radiocommunications (Electromagnetic Compatibility) Standard: 2017

Radiocommunications Labeling (Electromagnetic Compatibility) Notice: 2017

Standards applied:

EN 61800-3

CE In conformity with the following European Directives:

2014/35/EU Low Voltage Directive (LVD)

2014/30/EU EMC Directive (EMC)

2014/34/EU ATEX Directive (ATEX)

2006/42/EC Machinery Directive (MD)

2011/65/EU RoHS Directive (RoHS)

Standards applied:

EN 61800-5-1

EN 61800-3

EN 50495

UKCA In conformity with the following UK Regulations:

2016 No. 1101 Electrical Equipment (Safety) Regulations (LV)

2016 No. 1091 Electromagnetic Compatibility Regulations (EMC)

2016 No. 1107 Equipment and Protective Systems Intended for Use in Potentially

Explosive Atmospheres Regulations (Ex)

2008 No. 1597 Supply of Machinery (Safety) Regulations (MD)

2012 No. 3032 Restriction of the Use of Certain Hazardous Substances in Electrical

and Electronic Equipment Regulations (RoHS)

2021 No. 745 Ecodesign for Energy-Related Products and Energy Information

Regulations (Eco)

Standards applied:

EN 61800-5-1

EN 61800-3

EN 50495

128 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix A Supplemental Drive Information

Environmental

Specifications

Functional Safety TÜV Rheinland

Standards applied:

EN ISO 13849-1

EN 61800-5-2

EN 62061

EN 60204-1

IEC 61508 Part 1-7

Certified to ISO 13849-1 SIL3/PLe with embedded Safe Torque-Off function

Certified to ISO 61800-5-2 and EN 62061 SIL3/PLe with Network Torque-Off function

Meets Functional Safety (FS) when used with embedded Safe Torque-Off function

ATEX

TÜV 15 ATEX 7696 X

TUV 21 UKEX 7033 X

Certified to ATEX Directive 2014/34/EU

Group II Category (2) GD Applications with ATEX Approved Motors

Certified to UK Equipment and Protective Systems Intended for Use in Potentially

Explosive Atmospheres Regulations (2016 No. 1107)

Group II Category (2) GD Applications with ATEX Approved Motors

KCC Korean Registration of Broadcasting and Communications Equipment

Compliant with the following standards:

Article 58-2 of Radio Waves Act, Clause 3

EAC

Customs Union:

Low Voltage TR CU 004/2011

EMC TR CU 020/2011

AC 156 Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic

Qualification Testing of Nonstructural Components and 2003 International Building

Code for worst-case seismic level for USA excluding site class F

SEMI F47 Electric Power Research Institute

Certified compliant with the following standards:

SEMI F47

IEC 61000-4-34

ODVA

ODVA conformance tested to EtherNet/IP specifications

Lloyd’s Register Lloyd’s Register Type Approval Certificate 15/80016(E1)

IEEE P1668 Product meets the requirements of IEEE P1668

RoHS Compliant with the European “Restriction of Hazardous Substances” Directive

The drive is also designed to meet the appropriate portions of the following specifications:

NFPA 70 - US National Electrical Code

NEMA ICS 7.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable

Speed Drive Systems.

Certifications (Continued)

Certifications PowerFlex 527

Functional

Safety

Typ e

Approved

www.tuv.com

ID 0600000000

II (2) G D

Environmental Specifications

Specifications PowerFlex 527

Altitude

Without derating

With derating

See Current Derating Curves

on page 15 for derating guidelines.

1000 m (3300 ft) max.

Up to 4000 m (13,200 ft) max., with the exception of 600V drives @ 2000 m (6600 ft)

max.

Max. Surrounding Air

Temperature

Without derating

With derating

See Current Derating Curves

on page 15 for derating guidelines.

-20…+50 °C (-4…+22 °F)

-20…+60 °C (-4…+140 °F) or -20…+70 °C (-4…+158 °F) with optional Control Module

Fan kit

Storage Temperature

Frame A…D

Frame E

-40…+85 °C (-40…+185 °F)

-40…+70 °C (-40…+158 °F)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 129

Appendix A Supplemental Drive Information

Technical Specifications

Atmosphere

Relative Humidity 0…95% noncondensing

Shock Complies with IEC 60068-2-27

Vibration Complies with IEC 60068-2-6:2007

Conformal Coating

Complies with:

IEC 60721-3-3 to level 3C2 (chemical and gases only)

Surrounding Environment

Pollution Degree

Pollution Degree 1 & 2

See Pollution Degree Ratings According to EN 61800-5-1

on page 37

for descriptions.

All enclosures acceptable.

Sound Pressure Level

(A-weighted)

Frame A & B

Frame C

Frame D

Frame E

Measurements are taken 1 m from the drive.

Maximum 53 dBA

Maximum 57 dBA

Maximum 64 dBA

Maximum 68 dBA

Environmental Specifications (Continued)

Specifications PowerFlex 527

IMPORTANT Drive must not be installed in an area where

the ambient atmosphere contains volatile or

corrosive gas, vapors or dust. If the drive is not

going to be installed for a period of time, it

must be stored in an area where it will not be

exposed to a corrosive atmosphere.

Frame

Size

Operating and Nonoperating Nonoperating (Transportation)

Force

(Shock/Vibration) Mounting Type

Force

(Shock/Vibration) Mounting Type

A 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only

B 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only

C 15 g / 2 g DIN rail or screw 30 g/ 2.5 g Screw only

D 15 g / 2 g Screw only 30 g/ 2.5 g Screw only

E 15 g / 1.5 g Screw only 30 g/ 2.5 g Screw only

Protection

Specifications PowerFlex 527

Bus Overvoltage Trip

100…120V AC Input

200…240V AC Input

380…480V AC Input

525…600V AC Input

405V DC bus (equivalent to 150V AC incoming line)

405V DC bus (equivalent to 290V AC incoming line)

810V DC bus (equivalent to 575V AC incoming line)

1005V DC bus (equivalent to 711V AC incoming line)

Bus Undervoltage Trip

100…120V AC Input

200…240V AC Input

380…480V AC Input

525…600V AC Input

190V DC bus (equivalent to 75V AC incoming line)

190V DC bus (equivalent to 150V AC incoming line)

390V DC bus (equivalent to 275V AC incoming line)

487V DC bus (equivalent to 344V AC incoming line)

Power Ride-Thru 100 ms

Logic Control Ride-Thru 0.5 s minimum, 2 s typical

Electronic Motor Overload

Protection

Provides class 10 motor overload protection according to NEC article 430 and

motor over-temperature protection according to NEC article 430.126 (A) (2).

UL 508C File 29572.

Overcurrent 200% hardware limit, 300% instantaneous fault

Ground Fault Trip Phase-to-ground on drive output

Short Circuit Trip Phase-to-phase on drive output

130 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix A Supplemental Drive Information

Electrical

Specifications PowerFlex 527

Voltage Tolerance -15% / +10%

Frequency Tolerance 47…63 Hz

Input Phases

3-Phase input provides full rating. 1-Phase input provides 35% rating on 3-phase

drives.

Displacement Power Factor 0.98 across entire speed range

Maximum Short Circuit Rating 100,000 Amps Symmetrical

Actual Short Circuit Rating Determined by AIC Rating of installed fuse/circuit breaker

Transistor Type Isolated Gate Bipolar Transistor (IGBT)

Internal DC Bus Choke

200…240V AC Input

380…480V AC Input

525…600V AC Input

Only for Frame E drive ratings

11 kW (15 HP)

15…18.5 kW (20…25 HP) – Heavy Duty

Control

Specifications PowerFlex 527

Method

• Frequency Control:

– Basic Volts/Hertz

– Fan/Pump Volts/Hertz

– Sensorless Vector Control (SVC)

– Sensorless Vector Control (SVC) Economizer

• Position Loop:

– Closed Loop Position Vector Control (with optional encoder card)

• Velocity Loop:

– Closed Loop Velocity Vector Control (with optional encoder card)

Carrier Frequency 2...8 kHz, Drive rating based on 4 kHz

Frequency Accuracy Within ±0.05% of set output frequency

Performance

V/Hz (Volts per Hertz)

SVC (Sensorless Vector)

SVC Economizer

±1% of base speed across a 60:1 speed range

±0.5% of base speed across a 100:1 speed range

Performance with Encoder

Closed Loop Velocity Vector

Control ±0.1% of base speed across a 100:1 speed range

Output Voltage Range 0V to rated motor voltage

Output Frequency Range 0…590 Hz (programmable)

Efficiency 97.5% (typical)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 131

Appendix A Supplemental Drive Information

Stop Modes

Multiple programmable stop modes including – Disable and Coast, Current Decel

and Disable, and Ramped Decel and Disable

Accel/Decel

“REAL” tag programmable with Studio 5000 motion instructions.

For more information, see the Logix 5000 Controllers Motion Instructions

Reference Manual, publication MOTION-RM002

Intermittent Overload

Normal Duty

Heavy Duty

110% Overload capability for up to 60 s, 150% for up to 3 s

Applies to following drives:

•25C-B048*

•25C-B062*

• 25C-D030*

•25C-D037*

•25C-D043*

• 25C-E022*

•25C-E027*

•25C-E032*

150% Overload capability for up to 60 s, 180% for up to 3 s

Applies to following drives:

• 25C-V2P5*

• 25C-V4P8*

•25C-V6P0*

• 25C-A2P5*

•25C-A4P8*

•25C-A8P0*

•25C-A011*

• 25C-B2P5*

• 25C-B5P0*

•25C-B8P0*

•25C-B011*

•25C-B017*

•25C-B024*

•25C-B032*

•25C-D1P4*

•25C-D2P3*

•25C-D4P0*

•25C-D6P0*

• 25C-D010*

•25C-D013*

•25C-D017*

•25C-D024*

•25C-E0P9*

•25C-E1P7*

•25C-E3P0*

•25C-E4P2*

•25C-E6P6*

• 25C-E9P9*

•25C-E012*

•25C-E019*

Control Inputs

Specifications PowerFlex 527

Digital

Quantity (4) Programmable

Current 6 mA

Type

Source Mode (SRC)

Sink Mode (SNK)

18…24V = ON, 0…6V = OFF

0…6V = ON, 18…24V = OFF

Analog

Quantity (2) Isolated, ±10V and 4-20mA

Specification

Resolution

±10V DC Analog

4-20mA Analog

External Pot

10-bit

100k ohm input impedance

250 ohm input impedance

1…10k ohm, 2 W minimum

Control (Continued)

Specifications PowerFlex 527

132 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix A Supplemental Drive Information

Power Specifications Watts Loss

Safety

(per

channel)

Input Current <10 mA

Input ON Voltage, max 18…26.4V DC

Input OFF Voltage, max 5V DC

Input ON Current 10 mA

Input OFF Current 500 µA

Pulse Rejection Width 700 µs

External Power Supply SELV/PELV

Input Type Optically isolated and reverse voltage protected

Control Outputs

Specifications PowerFlex 527

Relay

Quantity (2) 1 Programmable Form A and 1 Programmable Form B

Specification

Resistive Rating

Inductive Rating

3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC

0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC

Opto

Quantity (2) Programmable

Specification 30V DC, 50 mA Non-inductive

Analog

Quantity

(1) Non-Isolated 0-10V or 0-20 mA

See Analog Output

on page 36 for instructions on setting the jumper.

See Setting the ACO/AVO Attribute on page 162 for instructions on setting the

attribute.

Specification

Resolution

0-10V DC Analog

0-20 mA Analog

10-bit

1 k Ω minimum

525 Ω maximum

Encoder

Specifications PowerFlex 527

Type Incremental, dual channel

Supply 5V, 12V, 250 mA

Quadrature 90°, ±27 ° @ 25 °C

Duty Cycle 50%, +10%

Requirements

Encoders must be line driver type, quadrature (dual channel), 3.5…26V DC output, single-

ended or differential and capable of supplying a minimum of 10 mA per channel.

Allowable input is DC up to a maximum frequency of 250 kHz. The encoder I/O automatically

scales to allow 5V, 12V, and 24V DC nominal voltages.

Control Inputs (Continued)

Specifications PowerFlex 527

PowerFlex 527 Estimated Watts Loss (Rated Load, Speed and PWM)

Voltage Output Current (A) Total Watts Loss

100...120V,

50/60 Hz 1-Phase

2.5 27.0

4.8 53.0

6.0 67.0

200...240V,

50/60 Hz 1-Phase

2.5 29.0

4.8 50.0

8.0 81.0

11.0 111.0

200...240V,

50/60 Hz 1-Phase

w/ EMC Filter

2.5 29.0

4.8 53.0

8.0 84.0

11.0 116.0

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 133

Appendix A Supplemental Drive Information

Input Current Scaling

200...240V,

50/60 Hz 3-Phase

2.5 29.0

5.0 50.0

8.0 79.0

11.0 107.0

17.5 148.0

24.0 259.0

32.2 323.0

48.3 584.0

62.1 708.0

380...480V,

50/60 Hz 3-Phase

1.4 27.0

2.3 37.0

4.0 62.0

6.0 86.0

10.5 129.0

13.0 170.0

17.0 221.0

24.0 303.0

30.0 387.0

380...480V,

50/60 Hz 3-Phase

w/ EMC Filter

1.4 27.0

2.3 37.0

4.0 63.0

6.0 88.0

10.5 133.0

13.0 175.0

17.0 230.0

24.0 313.0

30.0 402.0

37.0 602.0

43.0 697.0

525…600V,

50/60 Hz 3-Phase

0.9 22.0

1.7 32.0

3.0 50.0

4.2 65.0

6.6 95.0

9.9 138.0

12.0 164.0

19.0 290.0

22.0 336.0

27.0 466.0

32.0 562.0

PowerFlex 527 Input Current Scaled By Motor Current

Catalog Number

Output Input

12345678

100…120V AC (-15%, +10%) – 1-Phase Input, 0…230V 3-Phase Output

25C-V2P5N104 2.5 2.0 1.6 1.3 9.6 7.7 6.2 4.8

25C-V4P8N104 4.8 3.8 3.1 2.4 19.2 15.4 12.5 9.6

25C-V6P0N104 6.0 4.8 3.9 3.0 24.0 19.2 15.6 12.0

PowerFlex 527 Estimated Watts Loss (Rated Load, Speed and PWM) (Continued)

Voltage Output Current (A) Total Watts Loss

134 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix A Supplemental Drive Information

200…240V AC (-15%, +10%) – 1-Phase Input, 0…230V 3-Phase Output

25C-A2P5N104 2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3

25C-A4P8N104 4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4

25C-A8P0N104 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0

25C-A011N104 11.0 8.8 7.2 5.5 22.9 18.3 14.9 11.5

200…240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0…230V 3-Phase Output

25C-A2P5N114 2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3

25C-A4P8N114 4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4

25C-A8P0N114 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0

25C-A011N114 11.0 8.8 7.2 5.5 22.9 18.3 14.9 11.5

200…240V AC (-15%, +10%) – 3-Phase Input, 0…230V 3-Phase Output

25C-B2P5N104 2.5 2.0 1.6 1.3 2.7 2.2 1.8 1.4

25C-B5P0N104 5.0 4.0 3.2 2.5 5.8 4.6 3.8 2.9

25C-B8P0N104 8.0 6.4 5.2 4.0 9.5 7.6 6.2 4.8

25C-B011N104 11.0 8.8 7.2 5.5 13.8 11.0 9.0 6.9

25C-B017N104 17.5 14.0 11.4 8.8 21.1 16.9 13.7 10.6

25C-B024N104 24.0 19.2 15.6 12.0 26.6 21.3 17.3 13.3

25C-B032N104 32.2 25.8 20.9 16.1 34.8 27.8 22.6 17.4

25C-B048N104 48.3 38.6 31.4 24.2 44.0 35.2 28.6 22.0

25C-B062N104 62.1 49.7 40.4 31.1 56.0 44.8 36.4 28.0

380…480V AC (-15%, +10%) – 3-Phase Input, 0…460V 3-Phase Output

25C-D1P4N104 1.4 1.1 0.9 0.7 1.9 1.5 1.2 1.0

25C-D2P3N104 2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6

25C-D4P0N104 4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9

25C-D6P0N104 6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8

25C-D010N104 10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9

25C-D013N104 13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7

25C-D017N104 17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2

25C-D024N104 24.0 19.2 15.6 12.0 26.4 21.1 17.2 13.2

25C-D030N104 30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5

380…480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0…460V 3-Phase Output

25C-D1P4N114 1.4 1.1 0.9 0.7 1.9 1.5 1.2 1.0

25C-D2P3N114 2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6

25C-D4P0N114 4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9

25C-D6P0N114 6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8

25C-D010N114 10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9

25C-D013N114 13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7

25C-D017N114 17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2

25C-D024N114 24.0 19.2 15.6 12.0 26.4 21.1 17.2 3.2

25C-D030N114 30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5

25C-D037N114 37.0 29.6 24.1 18.5 33.7 27.0 21.9 16.9

25C-D043N114 43.0 34.4 28.0 21.5 38.9 31.1 25.3 19.5

525…600V AC (-15%, +10%) – 3-Phase Input, 0…575V 3-Phase Output

25C-E0P9N104 0.9 0.7 0.6 0.5 1.2 1.0 0.8 0.6

25C-E1P7N104 1.7 1.4 1.1 0.9 2.3 1.8 1.5 1.2

25C-E3P0N104 3.0 2.4 2.0 1.5 3.8 3.0 2.5 1.9

25C-E4P2N104 4.2 3.4 2.7 2.1 5.3 4.2 3.4 2.7

25C-E6P6N104 6.6 5.3 4.3 3.3 8.0 6.4 5.2 4.0

25C-E9P9N104 9.9 7.9 6.4 5.0 11.2 9.0 7.3 5.6

25C-E012N104 12.0 9.6 7.8 6.0 13.5 10.8 8.8 6.8

PowerFlex 527 Input Current Scaled By Motor Current (Continued)

Catalog Number

Output Input

12345678

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 135

Appendix A Supplemental Drive Information

Appendix

25C-E019N104 19.0 15.2 12.4 9.5 24.0 19.2 15.6 12.0

25C-E022N104 22.0 17.6 14.3 11.0 27.3 21.8 17.7 13.7

25C-E027N104 27.0 21.6 17.6 13.5 24.7 19.8 16.1 12.4

25C-E032N104 32.0 25.6 20.8 16.0 29.2 23.4 19.0 14.6

PowerFlex 527 Input Current Scaled By Motor Current (Continued)

Catalog Number

Output Input

12345678

136 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix A Supplemental Drive Information

Notes:

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 137

Appendix B

Accessories and Dimensions

Product Selection

Catalog Number Description

25C - V 2P5 N 1 0 4

Drive Voltage Rating Rating Enclosure HIM Emission Class Version

PowerFlex 527 Drive Ratings

Output Ratings

Input

Voltage Range

Frame

Size

Catalog No.Normal Duty Heavy Duty

Output

Current (A)

HP kW HP kW

100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 85...132 A 25C-V2P5N104

1.0 0.75 1.0 0.75 4.8 85...132 B 25C-V4P8N104

1.5 1.1 1.5 1.1 6.0 85...132 B 25C-V6P0N104

200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170...264 A 25C-A2P5N104

1.0 0.75 1.0 0.75 4.8 170...264 A 25C-A4P8N104

2.0 1.5 2.0 1.5 8.0 170...264 B 25C-A8P0N104

3.0 2.2 3.0 2.2 11.0 170...264 B 25C-A011N104

200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170...264 A 25C-A2P5N114

1.0 0.75 1.0 0.75 4.8 170...264 A 25C-A4P8N114

2.0 1.5 2.0 1.5 8.0 170...264 B 25C-A8P0N114

3.0 2.2 3.0 2.2 11.0 170...264 B 25C-A011N114

200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170...264 A 25C-B2P5N104

1.0 0.75 1.0 0.75 5.0 170...264 A 25C-B5P0N104

2.0 1.5 2.0 1.5 8.0 170...264 A 25C-B8P0N104

3.0 2.2 3.0 2.2 11.0 170...264 A 25C-B011N104

5.0 4.0 5.0 4.0 17.5 170...264 B 25C-B017N104

7.5 5.5 7.5 5.5 24.0 170...264 C 25C-B024N104

10.0 7.5 10.0 7.5 32.2 170...264 D 25C-B032N104

15.0 11.0 10.0 7.5 48.3 170...264 E 25C-B048N104

20.0 15.0 15.0 11.0 62.1 170...264 E 25C-B062N104

380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output

(1)

0.5 0.4 0.5 0.4 1.4 323...528 A 25C-D1P4N104

1.0 0.75 1.0 0.75 2.3 323...528 A 25C-D2P3N104

2.0 1.5 2.0 1.5 4.0 323...528 A 25C-D4P0N104

3.0 2.2 3.0 2.2 6.0 323...528 A 25C-D6P0N104

5.0 4.0 5.0 4.0 10.5 323...528 B 25C-D010N104

7.5 5.5 7.5 5.5 13.0 323...528 C 25C-D013N104

10.0 7.5 10.0 7.5 17.0 323...528 C 25C-D017N104

15.0 11.0 15.0 11.0 24.0 323...528 D 25C-D024N104

138 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

20.0 15.0 15.0 11.0 30.0 323...528 D 25C-D030N104

380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output

0.5 0.4 0.5 0.4 1.4 323...528 A 25C-D1P4N114

1.0 0.75 1.0 0.75 2.3 323...528 A 25C-D2P3N114

2.0 1.5 2.0 1.5 4.0 323...528 A 25C-D4P0N114

3.0 2.2 3.0 2.2 6.0 323...528 A 25C-D6P0N114

5.0 4.0 5.0 4.0 10.5 323...528 B 25C-D010N114

7.5 5.5 7.5 5.5 13.0 323...528 C 25C-D013N114

10.0 7.5 10.0 7.5 17.0 323...528 C 25C-D017N114

15.0 11.0 15.0 11.0 24.0 323...528 D 25C-D024N114

20.0 15.0 15.0 11.0 30.0 323...528 D 25C-D030N114

25.0 18.5 20.0 15.0 37.0 323...528 E 25C-D037N114

30.0 22.0 25.0 18.5 43.0 323...528 E 25C-D043N114

525...600V AC (-15%, +10%) – 3-Phase Input, 0...575V 3-Phase Output

0.5 0.4 0.5 0.4 0.9 446...660 A 25C-E0P9N104

1.0 0.75 1.0 0.75 1.7 446...660 A 25C-E1P7N104

2.0 1.5 2.0 1.5 3.0 446...660 A 25C-E3P0N104

3.0 2.2 3.0 2.2 4.2 446...660 A 25C-E4P2N104

5.0 4.0 5.0 4.0 6.6 446...660 B 25C-E6P6N104

7.5 5.5 7.5 5.5 9.9 446...660 C 25C-E9P9N104

10.0 7.5 10.0 7.5 12.0 446...660 C 25C-E012N104

15.0 11.0 15.0 11.0 19.0 446...660 D 25C-E019N104

20.0 15.0 15.0 11.0 22.0 446...660 D 25C-E022N104

25.0 18.5 20.0 15.0 27.0 446...660 E 25C-E027N104

30.0 22.0 25.0 18.5 32.0 446...660 E 25C-E032N104

(1) A non-filtered drive is not available for 380…480V AC 25 HP (18.5 kW) and 30 HP (22.0 kW) ratings. Filtered drives are

available, however you must verify that the application supports a filtered drive.

Dynamic Brake Resistors

Drive Ratings Minimum

Resistance,

Ω ±10%

Resistance,

Ω ±5%

Catalog No.

(1)(2)

Dynamic Brake

Fuse Rating, A

(3)

Fuse Model

Number

(4)

Input Voltage HP kW

100...120V

50/60 Hz

1-Phase

0.25 0.2 56 91 AK-R2-091P500 15 PV-15A10F

0.5 0.4 56 91 AK-R2-091P500 15 PV-15A10F

1.0 0.75 56 91 AK-R2-091P500 15 PV-15A10F

1.5 1.1 41 91 AK-R2-091P500 15 PV-15A10F

200...240V

50/60 Hz

1-Phase

0.25 0.2 56 91 AK-R2-091P500 15 PV-15A10F

0.5 0.4 56 91 AK-R2-091P500 15 PV-15A10F

1.0 0.75 56 91 AK-R2-091P500 15 PV-15A10F

2.0 1.5 41 91 AK-R2-091P500 32 PV-32ANH1

3.0 2.2 32 47 AK-R2-047P500 32 PV-32ANH1

PowerFlex 527 Drive Ratings (Continued)

Output Ratings

Input

Voltage Range

Frame

Size

Catalog No.Normal Duty Heavy Duty

Output

Current (A)

HP kW HP kW

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 139

Appendix B Accessories and Dimensions

200...240V

50/60 Hz

3-Phase

0.25 0.2 56 91 AK-R2-091P500 20 PV-20A10F

0.5 0.4 56 91 AK-R2-091P500 20 PV-20A10F

1.0 0.75 56 91 AK-R2-091P500 20 PV-20A10F

2.0 1.5 41 91 AK-R2-091P500 20 PV-20A10F

3.0 2.2 32 47 AK-R2-047P500 20 PV-20A10F

5.0 4.0 18 47 AK-R2-047P500 32 PV-32ANH1

7.5 5.5 16 30 AK-R2-030P1K2 40 PV-40ANH1

10.0 7.5 14 30 AK-R2-030P1K2 50 1000GH-040

15.0 11.0 14 15

AK-R2-030P1K2

(5)

80 1000GH-050

20.0 15.0 10 15

AK-R2-030P1K2

(5)

80 1000GH-050

380...480V

50/60 Hz

3-Phase

0.5 0.4 89 360 AK-R2-360P500 10 PV-10A10F

1.0 0.75 89 360 AK-R2-360P500 10 PV-10A10F

2.0 1.5 89 360 AK-R2-360P500 10 PV-10A10F

3.0 2.2 89 120 AK-R2-120P1K2 10 PV-10A10F

5.0 4.0 47 120 AK-R2-120P1K2 20 PV-20A10F

7.5 5.5 47 120 AK-R2-120P1K2 32 PV-32ANH1

10.0 7.5 47 120 AK-R2-120P1K2 32 PV-32ANH1

15.0 11.0 43 60

AK-R2-120P1K2

(5)

50 1000GH-025

20.0 15.0 43 60

AK-R2-120P1K2

(5)

50 1000GH-025

25.0 18.5 27 40

AK-R2-120P1K2

(6)

63 1000GH-040

30.0 22.0 27 40

AK-R2-120P1K2

(6)

63 1000GH-040

525...600V

50/60 Hz

3-Phase

0.5 0.4 112 360 AK-R2-360P500 10 PV-10A10F

1.0 0.75 112 360 AK-R2-360P500 10 PV-10A10F

2.0 1.5 112 360 AK-R2-360P500 10 PV-10A10F

3.0 2.2 112 120 AK-R2-120P1K2 10 PV-10A10F

5.0 4.0 86 120 AK-R2-120P1K2 12 PV-12A10F

7.5 5.5 59 120 AK-R2-120P1K2 20 PV-20A10F

10.0 7.5 59 120 AK-R2-120P1K2 20 PV-20A10F

15.0 11.0 59 60

AK-R2-120P1K2

(5)

40 1000GH-025

20.0 15.0 59 60

AK-R2-120P1K2

(5)

40 1000GH-025

25.0 18.5 53 60

AK-R2-120P1K2

(5)

40 1000GH-040

30.0 22.0 34 40

AK-R2-120P1K2

(6)

40 1000GH-040

(1) The resistors that are listed in this table are rated for 5% duty cycle.

(2) Use of Rockwell Automation resistors is always recommended. The resistors that are listed have been carefully selected to

optimize performance in various applications. Alternative resistors may be used, however, care must be taken when making

a selection. See the PowerFlex Dynamic Braking Resistor Calculator Application Technique, publication PFLEX-AT001

(3) Connect a 1000V DC fuse links at BR+ terminal in series with the dynamic brake resistor.

(4) PV-xxxxxx fuses are from Bussman. 1000GH-xxx fuses are from Hinode.

(5) Requires two resistors that are wired in parallel.

(6) Requires three resistors that are wired in parallel.

EMC Line Filters

Short-circuit Current Rating = 100 kA

Drive Ratings

Frame Size

For 100 m

Catalog No.

For 150 m

(1)

Catalog No.

Input Voltage HP kW Current (A)

100...120V

50/60 Hz

1-Phase

0.25 0.2 1.6 A 25-RF011-AL —

0.5 0.4 2.5 A 25-RF011-AL —

1.0 0.75 4.8 B 25-RF023-BL —

1.5 1.1 6.0 B 25-RF023-BL —

Dynamic Brake Resistors (Continued)

Drive Ratings Minimum

Resistance,

Ω ±10%

Resistance,

Ω ±5%

Catalog No.

(1)(2)

Dynamic Brake

Fuse Rating, A

(3)

Fuse Model

Number

(4)

Input Voltage HP kW

140 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

200...240V

50/60 Hz

1-Phase

0.25 0.2 1.6 A 25-RF011-AL

0.5 0.4 2.5 A 25-RF011-AL

1.0 0.75 4.8 A 25-RF011-AL

2.0 1.5 8.0 B 25-RF023-BL

3.0 2.2 11.0 B 25-RF023-BL

200...240V

50/60 Hz

3-Phase

0.25 0.2 1.6 A 25-RF014-AL 25-RF021-BL

0.5 0.4 2.5 A 25-RF014-AL 25-RF021-BL

1.0 0.75 5.0 A 25-RF014-AL 25-RF021-BL

2.0 1.5 8.0 A 25-RF014-AL 25-RF021-BL

3.0 2.2 11.0 A 25-RF014-AL 25-RF021-BL

5.0 4.0 17.5 B 25-RF021-BL

7.5 5.5 24.0 C 25-RF027-CL

10.0 7.5 32.2 D 25-RF035-DL

15.0 11.0 48.3 E 25-RF056-EL

20.0 15.0 62.1 E 25-RF056-EL

380...480V

50/60 Hz

3-Phase

0.5 0.4 1.4 A 25-RF7P5-AL 25-RF014-BL

1.0 0.75 2.3 A 25-RF7P5-AL 25-RF014-BL

2.0 1.5 4.0 A 25-RF7P5-AL 25-RF014-BL

3.0 2.2 6.0 A 25-RF7P5-AL 25-RF014-BL

5.0 4.0 10.5 B 25-RF014-BL

7.5 5.5 13.0 C 25-RF018-CL

10.0 7.5 17.0 C 25-RF018-CL

15.0 11.0 24.0 D 25-RF033-DL

20.0 15.0 30.0 D 25-RF033-DL

25.0 18.5 37.0 E 25-RF039-EL

30.0 22.0 43.0 E 25-RF039-E

525...600V

50/60 Hz

3-Phase

0.5 0.4 0.9 A

25-RF8P0-BL

(2)

—

1.0 0.75 1.7 A

25-RF8P0-BL

(2)

—

2.0 1.5 3.0 A

25-RF8P0-BL

(2)

—

3.0 2.2 4.2 A

25-RF8P0-BL

(2)

—

5.0 4.0 6.6 B 25-RF8P0-BL —

7.5 5.5 9.9 C 25-RF014-CL —

10.0 7.5 12.0 C 25-RF014-CL —

15.0 11.0 19.0 D 25-RF027-DL —

20.0 15.0 22.0 D 25-RF027-DL —

25.0 18.5 27.0 E 25-RF029-EL —

30.0 22.0 32.0 E 25-RF029-EL —

(1) Requires Series B filters to achieve 150 m rating.

(2) The 600V drive rating must be matched with a frame B Line Filter.

EMC Plates

Item Description

Frame

Size

Catalog No.

EMC Plate Optional grounding plate for shielded cables.

A 25-EMC1-FA

B 25-EMC1-FB

C 25-EMC1-FC

D 25-EMC1-FD

E 25-EMC1-FE

EMC Line Filters (Continued)

Short-circuit Current Rating = 100 kA

Drive Ratings

Frame Size

For 100 m

Catalog No.

For 150 m

(1)

Catalog No.

Input Voltage HP kW Current (A)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 141

Appendix B Accessories and Dimensions

Replacement Parts

IP 30/NEMA 1/UL Type 1 Kit

Item Description

Frame

Size

Catalog No.

IP 30/NEMA 1/UL Type 1 Kit

Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1

enclosure. Includes conduit box with mounting screws and

plastic top panel.

A25-JBAA

B25-JBAB

C25-JBAC

D25-JBAD

E25-JBAE

Control Module Fan Kit

Item Description

Frame

Size

Catalog No.

Control Module Fan Kit

For use with drive in environments with ambient

temperatures up to 70 °C or horizontal mounting.

A…D 25-FAN1-70C

E 25-FAN2-70C

Incremental Encoder Input Option

Item Description Catalog No.

Incremental Encoder

Board

Interface to an external incremental encoder. 25-ENC-2

Bulletin 160 to PowerFlex 527 Mounting Adapter Plate

Item Description

B160

Frame

Size

Catalog No.

Mounting Adapter Plate

For use with drive when replacing Bulletin 160 drives in

existing installations to a PowerFlex 520-Series drive. Select

the catalog number based on the frame size of your Bulletin

160 drive.

A25-MAP-FA

B25-MAP-FB

PowerFlex 527 Power Module

Item Description

PowerFlex 527

Power Module

Replacement power module for use with PowerFlex 527 drive.

Includes:

• Power Module

• Power Module Front Cover

• Power Terminal Guard

•Heatsink Fan

PowerFlex 527 Power Module

Output Ratings

Input

Voltage Range

Frame

Size

Catalog No.Normal Duty Heavy Duty

Output

Current (A)

HP kW HP kW

100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 85…132 A 25-PM1-V2P5

1.0 0.75 1.0 0.75 4.8 85…132 B 25-PM1-V4P8

1.51.1 1.51.1 6.0 85…132B25-PM1-V6P0

200…240V AC (-15%, +10%) – 1-Phase Input, 0…230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170…264 A 25-PM1-A2P5

1.0 0.75 1.0 0.75 4.8 170…264 A 25-PM1-A4P8

2.0 1.5 2.0 1.5 8.0 170…264 B 25-PM1-A8P0

3.0 2.2 3.0 2.2 11.0 170…264 B 25-PM1-A011

200…240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0…230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170…264 A 25-PM2-A2P5

1.0 0.75 1.0 0.75 4.8 170…264 A 25-PM2-A4P8

142 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

2.0 1.5 2.0 1.5 8.0 170…264 B 25-PM2-A8P0

3.0 2.2 3.0 2.2 11.0 170…264 B 25-PM2-A011

200…240V AC (-15%, +10%) – 3-Phase Input, 0…230V 3-Phase Output

0.5 0.4 0.5 0.4 2.5 170…264 A 25-PM1-B2P5

1.0 0.75 1.0 0.75 5.0 170…264 A 25-PM1-B5P0

2.0 1.5 2.0 1.5 8.0 170…264 A 25-PM1-B8P0

3.0 2.2 3.0 2.2 11.0 170…264 A 25-PM1-B011

5.0 4.0 5.0 4.0 17.5 170…264 B 25-PM1-B017

7.5 5.5 7.5 5.5 24.0 170…264 C 25-PM1-B024

10.0 7.5 10.0 7.5 32.2 170…264 D 25-PM1-B032

15.0 11.0 10.0 7.5 48.3 170…264 E 25-PM1-B048

20.0 15.0 15.0 11.0 62.1 170…264 E 25-PM1-B062

380…480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output

0.5 0.4 0.5 0.4 1.4 323…528 A 25-PM1-D1P4

1.0 0.75 1.0 0.75 2.3 323…528 A 25-PM1-D2P3

2.0 1.5 2.0 1.5 4.0 323…528 A 25-PM1-D4P0

3.0 2.2 3.0 2.2 6.0 323…528 A 25-PM1-D6P0

5.0 4.0 5.0 4.0 10.5 323…528 B 25-PM1-D010

7.5 5.5 7.5 5.5 13.0 323…528 C 25-PM1-D013

10.0 7.5 10.0 7.5 17.0 323…528 C 25-PM1-D017

15.0 11.0 15.0 11.0 24.0 323…528 D 25-PM1-D024

20.0 15.0 15.0 11.0 30.0 323…528 D 25-PM1-D030

380…480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output

0.5 0.4 0.5 0.4 1.4 323…528 A 25-PM2-D1P4

1.0 0.75 1.0 0.75 2.3 323…528 A 25-PM2-D2P3

2.0 1.5 2.0 1.5 4.0 323…528 A 25-PM2-D4P0

3.0 2.2 3.0 2.2 6.0 323…528 A 25-PM2-D6P0

5.0 4.0 5.0 4.0 10.5 323…528 B 25-PM2-D010

7.5 5.5 7.5 5.5 13.0 323…528 C 25-PM2-D013

10.0 7.5 10.0 7.5 17.0 323…528 C 25-PM2-D017

15.0 11.0 15.0 11.0 24.0 323…528 D 25-PM2-D024

20.0 15.0 15.0 11.0 30.0 323…528 D 25-PM2-D030

25.0 18.5 20.0 15.0 37.0 323…528 E 25-PM2-D037

30.0 22.0 25.0 18.5 43.0 323…528 E 25-PM2-D043

525…600V AC (-15%, +10%) – 3-Phase Input, 0…575V 3-Phase Output

0.5 0.4 0.5 0.4 0.9 446…660 A 25-PM1-E0P9

1.0 0.75 1.0 0.75 1.7 446…660 A 25-PM1-E1P7

2.0 1.5 2.0 1.5 3.0 446…660 A 25-PM1-E3P0

3.0 2.2 3.0 2.2 4.2 446…660 A 25-PM1-E4P2

5.0 4.0 5.0 4.0 6.6 446…660 B 25-PM1-E6P6

7.5 5.5 7.5 5.5 9.9 446…660 C 25-PM1-E9P9

10.0 7.5 10.0 7.5 12.0 446…660 C 25-PM1-E012

15.0 11.0 15.0 11.0 19.0 446…660 D 25-PM1-E019

20.0 15.0 15.0 11.0 22.0 446…660 D 25-PM1-E022

25.0 18.5 20.0 15.0 27.0 446…660 E 25-PM1-E027

30.0 22.0 25.0 18.5 32.0 446…660 E 25-PM1-E032

PowerFlex 527 Power Module (Continued)

Output Ratings

Input

Voltage Range

Frame

Size

Catalog No.Normal Duty Heavy Duty

Output

Current (A)

HP kW HP kW

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 143

Appendix B Accessories and Dimensions

PowerFlex 527 Control Module

Item Description

Frame

Size

Catalog No.

PowerFlex 527

Control Module

Replacement control module for use with PowerFlex 527 drives.

Includes:

• Control Module

• Control Module Front Cover

A…E 25C-CTM1

Other Parts

Item Description

Frame

Size

Catalog No.

PowerFlex 527 Control

Module Front Cover

Replacement cover for the control module I/O terminals and

EtherNet/IP ports.

A...E 25C-CTMFC1

PowerFlex 520-Series

Power Module Front

Cover

Replacement cover for the PowerFlex 520-Series power

module.

B25-PMFC-FB

C25-PMFC-FC

D25-PMFC-FD

E25-PMFC-FE

PowerFlex 520-Series

Power Terminal Guard

Replacement finger guard for power terminals.

A25-PTG1-FA

B25-PTG1-FB

C25-PTG1-FC

D25-PTG1-FD

E25-PTG1-FE

PowerFlex 527

Removable Terminal

Blocks Kit

Replacement terminal blocks for control wiring. A…E 25C-RCTB

PowerFlex 527 Control

Module Internal Fan Kit

Replacement internal fan for the control module. A…E 25C-FAN2-INT

PowerFlex 520-Series

Heatsink Fan Kit

Replacement fan for drive power module.

A25-FAN1-FA

B25-FAN1-FB

C25-FAN1-FC

D25-FAN1-FD

E25-FAN1-FE

Bulletin 1321-3R Series Line Reactors

Output Ratings

(1)

Input Line Reactor

(2)(3)

Output Line Reactor

Normal Duty Heavy Duty

IP00

(Open Style)

IP11

(NEMA/UL Type 1)

IP00

(Open Style)

IP11

(NEMA/UL Type 1)

HP kW HP kW Catalog No. Catalog No. Catalog No. Catalog No.

200…240V 50/60 Hz 1-Phase

(4)

0.25 0.2 0.25 0.2 1321-3R4-A 1321-3RA4-A 1321-3R2-D 1321-3RA2-D

0.5 0.4 0.5 0.4 1321-3R8-A 1321-3RA8-A 1321-3R2-D 1321-3RA2-D

1.0 0.75 1.0 0.75 1321-3R8-A 1321-3RA8-A 1321-3R4-A 1321-3RA4-A

2.0 1.5 2.0 1.5 1321-3R18-A 1321-3RA18-A 1321-3R8-A 1321-3RA8-A

3.0 2.2 3.0 2.2 1321-3R18-A 1321-3RA18-A 1321-3R12-A 1321-3RA12-A

200...240V 50/60 Hz 3-Phase

0.25 0.2 0.25 0.2 1321-3R2-D 1321-3RA2-D 1321-3R2-D 1321-3RA2-D

0.5 0.4 0.5 0.4 1321-3R2-D 1321-3RA2-D 1321-3R2-D 1321-3RA2-D

1.0 0.75 1.0 0.75 1321-3R4-A 1321-3RA4-A 1321-3R4-A 1321-3RA4-A

2.0 1.5 2.0 1.5 1321-3R8-A 1321-3RA8-A 1321-3R8-A 1321-3RA8-A

3.0 2.2 3.0 2.2 1321-3R12-A 1321-3RA12-A 1321-3R12-A 1321-3RA12-A

5.0 4.0 5.0 4.0 1321-3R18-A 1321-3RA18-A 1321-3R18-A 1321-3RA18-A

7.5 5.5 7.5 5.5 1321-3R25-A 1321-3RA25-A 1321-3R25-A 1321-3RA25-A

10.0 7.5 10.0 7.5 1321-3R35-A 1321-3RA35-A 1321-3R35-A 1321-3RA35-A

15.0 11.0 10.0 7.5 1321-3R45-A 1321-3RA45-A 1321-3R45-A 1321-3RA45-A

144 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

Product Dimensions The PowerFlex 527 drive is available in five frame sizes. See the PowerFlex 527

Drive Ratings on page 137 for information on power ratings.

20.0 15.0 15.0 11.0

1321-3R55-A (ND)

1321-3R45-A (HD)

1321-3RA55-A (ND)

1321-3RA45-A (HD)

1321-3R55-A (ND)

1321-3R45-A (HD)

1321-3RA55-A (ND)

1321-3RA45-A (HD)

380…480V 50/60 Hz 3-Phase

0.5 0.4 0.5 0.4 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B

1.0 0.75 1.0 0.75 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C

2.0 1.5 2.0 1.5 1321-3R4-B 1321-3RA4-B 1321-3R4-B 1321-3RA4-B

3.0 2.2 3.0 2.2 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C

5.0 4.0 5.0 4.0 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B

7.5 5.5 7.5 5.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B

10.0 7.5 10.0 7.5 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B

15.0 11.0 15.0 11.0 1321-3R25-B 1321-3RA25-B 1321-3R25-B 1321-3RA25-B

20.0 15.0 15.0 11.0

1321-3R35-B (ND)

1321-3R25-B (HD)

1321-3RA35-B (ND)

1321-3RA25-B (HD)

1321-3R35-B (ND)

1321-3R25-B (HD)

1321-3RA35-B (ND)

1321-3RA25-B (HD)

25.0 18.5 20.0 15.0 1321-3R35-B 1321-3RA35-B 1321-3R35-B 1321-3RA35-B

30.0 22.0 25.0 18.5

1321-3R45-B (ND)

1321-3R35-B (HD)

1321-3RA45-B (ND)

1321-3RA35-B (HD)

1321-3R45-B (ND)

1321-3R35-B (HD)

1321-3RA45-B (ND)

1321-3RA35-B (HD)

525…600V 50/60 Hz 3-Phase

0.5 0.4 0.5 0.4 1321-3R1-C 1321-3RA1-C 1321-3R1-C 1321-3RA1-C

1.0 0.75 1.0 0.75 1321-3R2-B 1321-3RA2-B 1321-3R2-B 1321-3RA2-B

2.0 1.5 2.0 1.5 1321-3R4-C 1321-3RA4-C 1321-3R4-C 1321-3RA4-C

3.0 2.2 3.0 2.2 1321-3R4-B 1321-3RA4-B 1321-3R4-B 1321-3RA4-B

5.0 4.0 5.0 4.0 1321-3R8-C 1321-3RA8-C 1321-3R8-C 1321-3RA8-C

7.5 5.5 7.5 5.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B

10.0 7.5 10.0 7.5 1321-3R12-B 1321-3RA12-B 1321-3R12-B 1321-3RA12-B

15.0 11.0 15.0 11.0 1321-3R18-B 1321-3RA18-B 1321-3R18-B 1321-3RA18-B

20.0 15.0 15.0 11.0

1321-3R25-B (ND)

1321-3R18-B (HD)

1321-3RA25-B (ND)

1321-3RA18-B (HD)

1321-3R25-B (ND)

1321-3R18-B (HD)

1321-3RA25-B (ND)

1321-3RA18-B (HD)

25.0 18.5 20.0 15.0

1321-3R35-C (ND)

1321-3R25-C (HD)

1321-3RA35-C (ND)

1321-3RA25-C (HD)

1321-3R35-C (ND)

1321-3R25-C (HD)

1321-3RA35-C (ND)

1321-3RA25-C (HD)

30.0 22.0 25.0 18.5

1321-3R35-C (ND)

1321-3R25-B (HD)

1321-3RA35-C (ND)

1321-3RA25-B (HD)

1321-3R35-C (ND)

1321-3R25-B (HD)

1321-3RA35-C (ND)

1321-3RA25-B (HD)

(1) Normal Duty and Heavy Duty ratings for 15 HP (11 kW) and below are identical except for 200…240V 3-Phase 15 HP (11 kW)

drive.

(2) Catalog numbers that are listed are for 3% impedance at 60 Hz. 5% impedance reactor types are also available. See the 1321

Power Conditioning Products Technical Data, publication 1321-TD001.

(3) Input line reactors were sized based on the NEC fundamental motor amps. Output line reactors were sized based on the VFD

rated output currents.

(4) Standard 3-phase reactors can be used for 1-phase applications by routing each of the two supply conductors through an

outside coil and leaving the center open.

Bulletin 1321-3R Series Line Reactors (Continued)

Output Ratings

(1)

Input Line Reactor

(2)(3)

Output Line Reactor

Normal Duty Heavy Duty

IP00

(Open Style)

IP11

(NEMA/UL Type 1)

IP00

(Open Style)

IP11

(NEMA/UL Type 1)

HP kW HP kW Catalog No. Catalog No. Catalog No. Catalog No.

PowerFlex 527 Drive Weight

Frame Size Weight (kg/lb)

A1.1 / 2.4

B1.6 / 3.5

C2.3 / 5.0

D3.9 / 8.6

E 12.9 / 28.4

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 145

Appendix B Accessories and Dimensions

IP 20/Open Type – Frame A

IP 20/Open Type – Frame B

72.0 (2.83)

57.5 (2.26)

172.0 (6.77)

140.0 (5.51)

152.0 (5.98)

92.7 (3.65)

6.0 (0.24)

Dimensions are in millimeters and (inches)

87.0 (3.43)

72.5 (2.85)

172.0 (6.77)

6.0 (0.24)

92.7 (3.65)

168.0 (6.61)

180.0 (7.09)

Dimensions are in millimeters and (inches)

146 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

IP 20/Open Type – Frame C

IP 20/Open Type – Frame D

109.0 (4.29)

90.5 (3.56)

207.0 (8.15)

220.0 (8.66)

184.0 (7.24)

6.0 (0.24)

92.7 (3.65)

Dimensions are in millimeters and (inches)

130.0 (5.12)

116.0 (4.57)

247.0 (9.72)

260.0 (10.24)

6.0 (0.24)

212.0 (8.35)

Dimensions are in millimeters and (inches)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 147

Appendix B Accessories and Dimensions

IP 20/Open Type – Frame E

185.0 (7.28)

160.0 (6.30)

279.0 (10.98)

280.0 (11.02)

300.0 (11.81)

7.6 (0.30)

Dimensions are in millimeters and (inches)

148 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

Control Module Fan Kit

IP 20/Open Type with Control Module Fan Kit – Frame A...C

Specifications 25-FAN1-70C 25-FAN2-70C

Rated Voltage 24V DC

Operation Voltage 14…27.6V DC

Input Current 0.1 A 0.15 A

Speed (Reference) 7000 rpm 4500 ± 10% rpm

Maximum Air Flow (At zero static pressure)

0.575 m

/min 1.574 m

/min

Maximum Air Pressure (At zero air flow)

7.70 mmH

O 9.598 mmH

Acoustical Noise 40.5 dBA 46.0 dBA

Insulation Type UL Class A

Frame Size Frame A…D Frame E

Wire Size

0.32 mm

(22 AWG)

Torque 0.29…0.39 N•m (2.6…3.47 lb•in)

25-FAN1-70C 25-FAN2-70C

72.0 (2.83)

32.0 (1.26)

140.0 (5.51)

152.0 (5.98)

57.5 (2.26)

87.0 (3.43)

32.0 (1.26)

180.0 (7.09)

168.0 (6.61)

72.5 (2.85)

109.0 (4.29)

32.0 (1.26)

220.0 (8.66)

207.0 (8.15)

90.5 (3.56)

Frame A Frame B

Dimensions are in millimeters and (inches)

Frame C

IMPORTANT An external 24V DC power source is required when

using the Control Module Fan Kit with drive frames

A, B, and C.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 149

Appendix B Accessories and Dimensions

IP 20/Open Type with Control Module Fan Kit – Frame D…E

130.0 (5.12)

32.0 (1.26)

260.0 (10.24)

247.0 (9.72)

116.0 (4.57)

185.0 (7.28)

196.0 (7.72)

52.0 (2.05)

300.0 (11.81)

280.0 (11.02)

160.0 (6.30)

Dimensions are in millimeters and (inches)

Frame D Frame E

IMPORTANT Remove the label to access the built-in 24V supply on drive frames D and E for use with the

Control Module Fan Kit.

150 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame A

72.0 (2.83)

172.0 (6.77)

6.0 (0.24)

51.1 (2.01)

21.0 (0.82)

57.5 (2.26)

15.0 (0.59)

219.0 (8.62)

92.7 (3.65)

140.0 (5.51)

135.4 (5.33)

111.9 (4.41)

88.2 (3.47)

64.7 (2.55)

152.0 (5.98)

ø21.5 (ø0.85)

Dimensions are in millimeters and (inches)

IP 30/NEMA 1/ UL Type 1 conduit box

IP 30/NEMA 1/ UL Type 1 top panel

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 151

Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame B

87.0 (3.43)

172.0 (6.77)

6.1 (0.24)

72.5 (2.85)

66.1 (2.60)

63.1 (2.48)

33.5 (1.32)

23.9 (0.94)

15.0 (0.59)

92.7 (3.65)

218.0 (8.58)

180.0 (7.09)

168.0 (6.61)

128.5 (5.06)

108.5 (4.27)

88.3 (3.48)

67.3 (2.65)

ø21.5 (ø0.85)

ø27.5 (ø1.08)

Dimensions are in millimeters and (inches)

IP 30/NEMA 1/ UL Type 1 conduit box

IP 30/NEMA 1/ UL Type 1 top panel

152 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame C

109.0 (4.29)

184.0 (7.24)

15.0 (0.59)

207.0 (8.15)

123.3 (4.85)

82.2 (3.24)

222.0 (8.66)

92.7 (3.65)

255.0 (10.04)

90.5 (3.56)

80.5 (3.17)

66.5 (2.62)

34.5 (1.36)

26.5 (1.04)

6.0 (0.24)

ø21.5 (ø0.85)

ø27.5 (ø1.08)

Dimensions are in millimeters and (inches)

IP 30/NEMA 1/ UL Type 1 conduit box

IP 30/NEMA 1/ UL Type 1 top panel

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 153

Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame D

130.0 (5.12)

212.0 (8.35)

6.0 (0.24)

260.0 (10.24)

295.0 (11.61)

15.0 (0.59)

247.0 (9.72)

109.8 (4.32)

153.3 (6.04)

116.0 (4.57)

96.0 (3.78)

44.0 (1.73)

30.0 (1.18)

70.0 (2.76)

ø21.5 (ø0.85)

ø33.5 (ø1.32)

Dimensions are in millimeters and (inches)

IP 30/NEMA 1/ UL Type 1 top panel

IP 30/NEMA 1/ UL Type 1 conduit box

154 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame E

185.0 (7.28)

160.0 (6.30)

127.5 (5.02)

82.5 (3.25)

62.5 (2.46)

42.5 (1.67)

279.0 (10.98)

15.0 (0.59)

350.0 (13.78)

300.0 (11.81)

280.0 (11.02)

212.0 (8.35)

181.0 (7.13)

164.0 (6.46)

7.6 (0.30)

ø21.5 (ø0.85)

ø43.7 (ø1.72)

Dimensions are in millimeters and (inches)

IP 30/NEMA 1/ UL Type 1 conduit box

IP 30/NEMA 1/ UL Type 1 top panel

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 155

Appendix B Accessories and Dimensions

EMC Line Filter – Frame A

EMC Line Filter – Frame B

ø5.5 (ø0.22)

72.0 (2.83)

54.0 (2.13)

5.5 (0.22)

54.0 (2.13)

23.0 (0.91)20.0 (0.79)

30.0 (1.18)

55.0 (2.17)

234.0

(9.21)

223.0

(8.78)

223.0

(8.78)

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.

ø5.5 (ø0.22)

87.0 (3.43)

58.0 (2.28)

270.0

(10.63)

58.0 (2.28)

5.5 (0.22)

258.0

(10.16)

258.0

(10.16)

24.0 (0.94)25.0 (0.98)

35.0 (1.38)

70.0 (2.76)

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.

156 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

EMC Line Filter – Frame C

EMC Line Filter – Frame D

ø5.5 (ø0.22)

263.0

(10.35)

263.0

(10.35)

25.0 (0.98) 28.0 (1.10)

76.0 (2.99)

5.5 (0.22)

275.0

(10.83)

109.0 (4.29)

70.0 (2.76)

76.0 (2.99)

37.0 (1.46)

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.

ø5.5 (ø0.22)

80.0 (3.15)

130.0 (5.12)

90.0 (3.54)

33.0 (1.30)

28.0 (1.10)

298.0

(11.73)

298.0

(11.73)

310.0

(12.20)

90.0 (3.54)

5.5 (0.22)

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 157

Appendix B Accessories and Dimensions

EMC Line Filter – Frame E

Replacing the PowerFlex 527 Control Module Internal Fan

To replace the internal fan, you must separate the control module from the

power module. Do not perform this operation while the drive is running. See

the PowerFlex 527 Control Module Internal Fan Kit Installation Instructions,

publication 520-IN014

for detailed instructions.

ATTENTION:

• Temperature inside the control module may exceed 80 °C (176 °F) when the

internal fan is not working. Wait for the control module to cool down before

replacing the internal fan.

• Take caution when replacing the internal fan as static damage may occur to

sensitive components inside the drive.

80.0 (3.15)

28.0 (1.10)

155.0 (6.10)

110.0 (4.33)

33.0 (1.30)

28.0 (1.10)33.0 (1.30)

375.0

(14.76)

375.0

(14.76)

390.0

(15.35)

ø5.5 (ø0.22)

5.5 (0.22)

Dimensions are in millimeters and (inches)

158 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix B Accessories and Dimensions

Notes:

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 159

Appendix

Appendix C

Out-of-Box Configuration

This section describes the recommended settings for configuring your

PowerFlex 527 drive to obtain the best performance from the drive. You should

apply these out-of-box settings first before configuring for your application.

Recommended Out-of-Box

Settings

Out-of-Box Settings

Setting in Logix Designer Example Recommended Configuration

Ramp Velocity Limits

120% of Motor Rated Speed for induction

motors

Current Vector Limit 180% of Motor Rated Current

160 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix C Out-of-Box Configuration

Torque Limits 200% of Motor Rated Torque

Velocity Error Tolerance Change Action to Alarm

Feedback Tap 16

Out-of-Box Settings (Continued)

Setting in Logix Designer Example Recommended Configuration

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 161

Appendix C Out-of-Box Configuration

Application Type setting in

Velocity Loop

Constant Speed

Motion Group Base Update Rate 4 ms

Out-of-Box Settings (Continued)

Setting in Logix Designer Example Recommended Configuration

162 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix C Out-of-Box Configuration

Setting the ACO/AVO

Attribute

The attribute ACO/AVO (Analog Current Output/Analog Voltage Output) can

be used to set the analog output of the PowerFlex 527 drive to either

current (mA) or voltage (V).

Verify that the Analog Out jumper (J2) is also set to the same value. See Analog

Output on page 36 for instructions.

ACO/AVO: MSG

Parameter Value Description

Service Code 0x10 Set Attribute Single

Class 0x42 Analog Output

Instance 1 –

Attribute 0xA64 Voltage/Current Mode

Data Type SINT Unsigned Short Integer

ACO/AVO: Values

Value Definition

0 Voltage (V)

1Current (mA)

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 163

Appendix

Appendix D

Encoder Option Card Usage

Installing the Encoder

Option Card

To install the encoder option card:

1. Separate the power module and control module. See Separating the

Power and Control Module on page 26 for instructions.

2. Place the encoder option card on the back of the control module. Verify

that the tabs on the encoder option card are aligned with the slots on the

control module.

3. Press down firmly on the encoder option card until it snaps together with

the control module.

164 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix D Encoder Option Card Usage

Removing the Encoder

Option Card

To remove the encoder option card:

1. Hold the top of the encoder option card firmly as shown below and pull

out to remove.

Encoder Option Card Usage PowerFlex 527 drives support an optional encoder card. The encoder supports

up to 250 kHz dual channel at 5V, 12V, or 24V and requires the optional

encoder board to be installed.

When the axis configuration is set to Position or Velocity loop, the Feedback

Configuration is enabled.

IMPORTANT Do not remove the encoder option card from the bottom as it may

damage the card and the locking mechanism on the control module.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 165

Appendix D Encoder Option Card Usage

In the Motor Feedback configuration, enter the resolution of the encoder used.

Encoder Interface

The incremental encoder option card can source 5V or 12V power and accept

5V, 12V, or 24V single ended or differential inputs. See Appendix B for ordering

information.

B-

Z-

A-

12V 5V



HTL TTL (ON)



No. Signal Description

5...12V Power

(1)(2)

(1) When using 12V Encoder power, 24V I/O power, maximum output current at I/O Terminal 11 is 50 mA.

(2) If Encoder requires 24V power, it must be supplied by an external power source.

Internal power source 250 mA (isolated).

Cm Power Return

Z- Marker Z (NOT)

Marker pulse

ZMarker Z

B- Encoder B (NOT)

Quadrature B input.

BEncoder B

A- Encoder A (NOT)

Quadrature A input.

AEncoder A

 Output

DIP switch selects 12V or 5V power that is supplied at terminals “+V” and

“Cm” for the encoder.



HTL/TTL DIP

switches

Set the position of the DIP switches based on the type of encoder signal

used. You must set all switches to the same position.

IMPORTANT A quadrature encoder provides rotor speed and direction. Therefore, the

encoder must be wired such that the forward direction matches the

motor forward direction. If the drive is reading encoder speed but the

position regulator or other encoder function is not working properly,

remove power to the drive and swap the A and A (NOT) encoder channels

or swap any two motor leads.

166 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Appendix D Encoder Option Card Usage

HTL/TTL DIP Switches

This feature is only available on 25-ENC-2/B encoders. Set the three switches to

HTL (default) or TTL (On) based on the type of encoder signal you are using in

your application. You must set all switches to the same position.

Wiring Notes The encoder option card can supply 5V or 12V power (250 mA maximum) for an

encoder. Verify that the DIP switch is set properly for the encoder. In general,

12V provides higher noise immunity.

The encoder can handle 5V, 12V, or 24V inputs. The inputs automatically adjust

to the voltage applied and no additional drive adjustment is necessary.

Encoder Wiring Examples

I/O Connection Example I/O Connection Example

Encoder Power

– Internal Drive

Power

Internal (drive)

12V DC, 250 mA

Encoder Power

– External

Power Source

Encoder Signal

– Single-Ended,

Dual Channel

Encoder Signal

– Differential,

Dual Channel

Compatible Encoder Output Voltage

Switch Position Low Level (UL) High Level (UH)

TTL <1.5V >2.5V

HTL <3.5V >5V

Common

+12V DC

(250 mA)

A-

B-

Z-

to SHLD

Common

External

Power

Supply

SHLD

Marker Z

Marker

Z NOT

to SHLD

to Power Supply

Common

A-

B-

Z-

to SHLD

A NOT

B NOT

Marker

Z NOT

Marker Z

A-

B-

Z-

IMPORTANT A quadrature encoder provides rotor speed and direction. Therefore, the

encoder must be wired such that the forward direction matches the

motor forward direction. If the drive is reading encoder speed but the

position regulator or other encoder function is not working properly,

remove power to the drive and swap the A and A (NOT) encoder channels

or swap any two motor leads.

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 167

Index

accessing

control terminals

power terminals

auxiliary contact

drive

basic operation

drive

circuit breakers

inputs

ratings 20

control terminals

accessing

derating

temperature

dimensions

mounting

14, 144

disconnect

output

drive

auxiliary contact

basic operation 45

mount

programming

drive damage

preventing

ungrounded distribution systems

encoder

wiring

166

environment

storage

fault monitoring

ground

fuses

rating

ground

fault monitoring

motor

RFI filter

safety

shielding

inputs

circuit breakers

power

motor

ground

start 32

stop

mount

drive

mounting

dimensions

14, 144

noise immunity

wiring

output

disconnect

power

inputs

power and control module

separating

power terminals

accessing

preventing

drive damage

programming

drive

tools

rating

fuses

ratings

circuit breakers

recommended

wiring

33, 34

reflected

wave protection

RFI filter

ground

safety

ground

separating

power and control module

168 Rockwell Automation Publication 520-UM002D-EN-E - January 2023

Index

shielded

wiring

shielding

ground

start

motor

stop

motor

storage

environment

temperature

derating

wiring

tools

programming

unshielded

wiring

voltage reflections

wiring

wave protection

reflected

wiring

encoder

166

noise immunity

recommended

33, 34

shielded 31

temperature

unshielded

voltage reflections 32

Rockwell Automation Publication 520-UM002D-EN-E - January 2023 169

PowerFlex 527 Adjustable Frequency AC Drive User Manual

Publication 520-UM002D-EN-E - January 2023

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