PowerFlex 520-series

Adjustable Frequency AC Drive

Bulletin Numbers 25A series B, 25B

User Manual Original Instructions

PowerFlex 520-series 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.

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

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).

2 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Table of Contents

Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 9
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Download Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Frame Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 1
Installation/Wiring Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ambient Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Current Derating Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Debris Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ungrounded Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Input Power Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ground Fault Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Ground - (PE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Network Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Shield Termination - SHLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RFI Filter Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuses and Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuses and Circuit Breakers for PowerFlex 520-Series Drives . . . . . 23
Power and Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control Module Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Module Terminal Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Motor Cable Types Acceptable for 100...600 Volt Installations . . . . 32
Reflected Wave Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Output Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Common Bus/Precharge Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Motor Start/Stop Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Signal and Control Wire Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maximum Control Wire Recommendations. . . . . . . . . . . . . . . . . . . . 37

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Table of Contents

Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PowerFlex 523 Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . 37
PowerFlex 525 Control I/O Terminal Block . . . . . . . . . . . . . . . . . . . . . 41
I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Start and Speed Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Start Source and Speed Reference Selection. . . . . . . . . . . . . . . . . . . . 48
Accel/Decel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Low Voltage Directive (2014/35/EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EMC Directive (2014/30/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Machinery Directive (2006/42/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ATEX Directive (2014/34/EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
UKCA Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electrical Equipment (Safety) Regulations (2016 No. 1101) . . . . . . . 52
Electromagnetic Compatibility Regulations (2016 No. 1091) . . . . . . 52
Supply of Machinery (Safety) Regulations (2008 No. 1597) . . . . . . . 52
Equipment and Protective Systems Intended for Use in Potentially
Explosive Atmospheres Regulations (2016 No. 1107) . . . . . . . . . . . . . 52
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 2
Startup Prepare for Drive Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Drive Startup Task List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Start, Stop, Direction, and Speed Control . . . . . . . . . . . . . . . . . . . . . . 59
Variable Torque Fan/Pump Applications . . . . . . . . . . . . . . . . . . . . . . . 59
Display and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control and Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Drive Programming Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Language Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Smart Startup with Basic Program Group Parameters . . . . . . . . . . . . . . 63
LCD Display with QuickView Technology . . . . . . . . . . . . . . . . . . . . . . . . . 65
Using the USB Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
MainsFree Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Using Drive Startup in CCW or Logix Designer Application . . . . . . . . . 66

Chapter 3
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
AppView Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
CustomView Parameter Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Basic Display Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Basic Program Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Terminal Block Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Communications Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Logic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Advanced Display Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Advanced Program Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Network Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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Modified Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Fault and Diagnostic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
AppView Parameter Groups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
CustomView Parameter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Parameter Cross-reference by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Chapter 4
Troubleshooting Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Fault Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Automatically Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . 162

Appendix A
Supplemental Drive Information Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Power Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Appendix B
Accessories and Dimensions Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Product Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Adapter Plate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Optional Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Installing a Communication Adapter . . . . . . . . . . . . . . . . . . . . . . . . 200
Removing a Communication Adapter . . . . . . . . . . . . . . . . . . . . . . . . 201

Appendix C
RS-485 (DSI) Protocol Network Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Parameter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Supported Modbus Function Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Writing (06) Logic Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Writing (06) Comm Frequency Command. . . . . . . . . . . . . . . . . . . . . . . . 207
Reading (03) Logic Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Reading (03) Drive Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Reading (03) Drive Operational Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . 210
Additional Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Appendix D
Velocity StepLogic, Basic Logic, Velocity StepLogic Using Timed Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
and Timer/Counter Functions Velocity StepLogic Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Velocity StepLogic Using Basic Logic Functions . . . . . . . . . . . . . . . . . . . 212
Timer Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

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Counter Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Velocity StepLogic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Appendix E
Encoder/Pulse Train Usage and Encoder and Pulse Train Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Position StepLogic Application Encoder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
HTL/TTL DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Determine Encoder Pulse Per Revolution (PPR) Specification Based on
Speed Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Positioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Common Guidelines for All Applications . . . . . . . . . . . . . . . . . . . . . . . . . 222
Positioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Encoder and Position Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Use Over Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Setup Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Appendix F
PID Set Up PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Exclusive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Trim Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
PID Reference and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Analog PID Reference Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Scale Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Invert Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
PID Deadband . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
PID Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
PID Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
PID Gains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Guidelines for Adjusting the PID Gains . . . . . . . . . . . . . . . . . . . . . . . 236

Appendix G
Safe Torque Off Function PowerFlex 525 Safe-Torque-Off Overview . . . . . . . . . . . . . . . . . . . . . . . . 239
EC Type Examination Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
UK Type Examination Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Using PowerFlex 525 Safe-Torque-Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Safety Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Functional Proof Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
PFD and PFH Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Enabling PowerFlex 525 Safe-Torque-Off . . . . . . . . . . . . . . . . . . . . . . . . . 243
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
PowerFlex 525 Safe-Torque-Off Operation. . . . . . . . . . . . . . . . . . . . . . . . 244
Verify Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Discrepancy Time of the Safety Inputs. . . . . . . . . . . . . . . . . . . . . . . . 244

6 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Table of Contents

Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action,
SIL 2/PL d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Example 2 – Safe-Torque-Off Connection with Controlled Stop
Action, SIL 2/PL d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action
Using External +24V supply, SIL 3/PL e . . . . . . . . . . . . . . . . . . . . . . . 248
PowerFlex 525 Certification for Safe-Torque-Off . . . . . . . . . . . . . . . . . . 248

Appendix H
EtherNet/IP Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . . . . 249
Ground Connections for EtherNet/IP Networks . . . . . . . . . . . . . . . . . . 250

Appendix I
Control Diagrams Induction Motor Tuning Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Adjusting Speed Control Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Appendix J
PowerFlex 525 PM Motor Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Configuration Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Stop Mode/Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Direction Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Auto Tune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Manual Configuration Using Drive Keypad. . . . . . . . . . . . . . . . . . . . . . . 258
Additional PM Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Additional Setup for Open Loop PM Motor . . . . . . . . . . . . . . . . . . . . 259
Additional Setup for Closed Loop PM Motor. . . . . . . . . . . . . . . . . . . 261
Optional Parameter Adjustments for Optimum Performance . . . . . . 263

Appendix K
PowerFlex 525 Synchronous SynRM Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Reluctance Motor Configuration Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
SynRM Control Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 7

Table of Contents

Notes:

8 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 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® 520-Series
Adjustable Frequency AC Drive.

Topic Page
Summary of Changes 9
Additional Resources 10
Manual Conventions 11
Drive Frame Sizes 12
General Precautions 13
Catalog Number Explanation 14

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, Download firmware, associated files (such as AOP, EDS, and DTM), and access
EDS, and Other Files product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.

See Download Files on page 10 to download the files for your PowerFlex 525
drive.

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.

Topic Page
Added Inclusive Language acknowledgment 9
Added PROFINET adapter manual reference to Additional Resources 10
Added footnotes to table Altitude Limit (Based on Voltage) 18
Updated section Fuses and Circuit Breakers 22
Updated Fuse and Circuit Breaker tables for UL 61800-5-1 applications 23…27
Added topic UKCA Conformity 51
Updated section General Considerations for UK LV Regulations 52…53
Updated derating diagram for parameter A493 [Motor OL Select] 124
Added UKCA certifications and updated ATEX certifications 165, 166
Updated Intermittent Overload specification 168
Updated table Dynamic Brake Resistors 174, 175
Added footnote to table EMC Line Filters 176
Added PROFINET communication option to table Communication Option Kits and Accessories 183
Added topic UK Type Examination Certification 240

Who Should Use this Manual This manual is intended for qualified personnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must
have an understanding of the parameter settings and functions.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 9

Preface

Additional Resources All recommended documentation that is listed in this section is available
online at rok.auto/literature.

The following publications provide general drive information:

Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
Preventive Maintenance Checklist 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-SB001

The following publications provide specific PowerFlex 520-Series information

on drive installation, features, specifications, and service:

Title Publication
PowerFlex 520-Series AC Drive Specifications 520-TD001
PowerFlex Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex AC Drives in Common Bus Configurations DRIVES-AT002

The following publications provide specific Network Communications

information:

Title Publication
PowerFlex 525 Embedded EtherNet/IP Adapter 520COM-UM001
PowerFlex 25-COMM-D DeviceNet Adapter 520COM-UM002
PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter 520COM-UM003
PowerFlex 25-COMM-P PROFIBUS DPV1 Adapter 520COM-UM004
PowerFlex 25-COMM-PNET2P PROFINET Adapter 520COM-UM005

Download Files Follow these steps to download the files for your PowerFlex 525 drive.
1. Go to the Rockwell Automation Product Compatibility and Download
Center at rok.auto/pcdc.

IMPORTANT You must sign in to the Rockwell Automation website before

downloading a firmware revision.

10 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Preface

2. Click the Find Downloads link.

3. Enter “PowerFlex 525” into the Product Search field.
The results appear in the box below.

4. Select the entry and the firmware revision, then click Downloads.

5. Click the Show Downloads icon, then click the links to download
the firmware revision and AOP files to your computer.

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

AC Drive as; drive, PowerFlex 520-series, PowerFlex 520-series drive or
PowerFlex 520-series 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.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 11

Preface

• Parameter numbers and names are shown in this format:

P 031 [Motor NP Volts]

Name
Number
Group
b = Basic Display
P = Basic Program
t = Terminal Blocks
C = Communications
L = Logic
d = Advanced Display
A = Advanced Program
N = Network
M = Modified
f = Fault and Diagnostic
G = AppView and CustomView

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

action:
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

• The Studio 5000® Engineering and Design Environment combines

engineering and design elements into a common environment. The
first element in the Studio 5000 environment is the Logix Designer
application. The Studio 5000 Logix Designer® application is the
rebranding of RSLogix 5000® software and will continue to be the
product to program Logix 5000® controllers for discrete, process,
batch, motion, safety, and drive-based solutions. The Studio 5000
environment is the foundation for the future of Rockwell Automation®
engineering design tools and capabilities. It is the one place for design
engineers to develop all elements of their control system.

Drive Frame Sizes 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.

12 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Preface

General Precautions
ATTENTION: The drive contains high-voltage capacitors, which take time to
discharge after removal of mains supply. After power has been removed
from the drive, wait three minutes to make sure DC bus capacitors are
discharged. After three minutes, verify AC voltage L1, L2, L3 (Line to Line and
Line to Ground) to ensure mains power has been disconnected. Measure DC
voltage across DC- and DC+ bus terminals to verify DC Bus has discharged
to zero volts. Measure DC voltage from L1, L2, L3, T1, T2, T3 DC – and DC+
terminals to ground and keep the meter on the terminals until the voltage
discharges to zero volts. The discharge process may take several minutes
to reach zero volts.
Darkened display LEDs are 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,
startup 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 Allen-Bradley® 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 “Stall Fault” is generated if the drive remains in this state for one
minute. If this condition is unacceptable, the bus regulator must be
disabled (see parameter A550 [Bus Reg Enable]). In addition, installing a
properly sized dynamic brake resistor will provide proper stopping
requirements based on braking resistor sizing.
ATTENTION: Risk of injury or equipment damage exists. Drive does not
contain user-serviceable components. Do not disassemble drive chassis.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 13

Preface

Catalog Number Explanation

1…3 4 5 6…8 9 10 11 12 13 14
25B – B 2P3 N 1 1 4 – –
Drive Dash Voltage Rating Rating Enclosure Reserved Emission Class Reserved Dash Dash

Code Braking
Code Type Code EMC Filter 4 Standard
25A PowerFlex 523 0 No Filter
25B PowerFlex 525 1 Filter

Code Voltage Phase Code Interface Module

V 120V AC 1 1 Standard
A 240V AC 1
B 240V AC 3 Code Enclosure
D 480V AC 3 N IP20 NEMA / Open
E 600V AC 3

Output Current @ 1 Phase, 100...120V Input Output Current @ 3 Phase, 380...480V Input
ND HD ND HD
Code Amps Frame Code Amps Frame
HP kW HP kW HP kW HP kW
1P6(1) 1.6 A 0.25 0.2 0.25 0.2 1P4 1.4 A 0.5 0.4 0.5 0.4
2P5 2.5 A 0.5 0.4 0.5 0.4 2P3 2.3 A 1.0 0.75 1.0 0.75
4P8 4.8 B 1.0 0.75 1.0 0.75 4P0 4.0 A 2.0 1.5 2.0 1.5
6P0 6.0 B 1.5 1.1 1.5 1.1 6P0 6.0 A 3.0 2.2 3.0 2.2
010 10.5 B 5.0 4.0 5.0 4.0
013 13.0 C 7.5 5.5 7.5 5.5
Output Current @ 1 Phase, 200...240V Input
017 17.0 C 10.0 7.5 10.0 7.5
ND HD
Code Amps Frame 024 24.0 D 15.0 11.0 15.0 11.0
HP kW HP kW
(1) 1.6 A 0.25 0.2 0.25 0.2 030(2) 30.0 D 20.0 15.0 15.0 11.0
1P6
2P5 2.5 A 0.5 0.4 0.5 0.4 037(2) 37.0 E 25.0 18.5 20.0 15.0
4P8 4.8 A 1.0 0.75 1.0 0.75 043(2) 43.0 E 30.0 22.0 25.0 18.5
8P0 8.0 B 2.0 1.5 2.0 1.5
011 11.0 B 3.0 2.2 3.0 2.2 Output Current @ 3 Phase, 525...600V Input
ND HD
Code Amps Frame
Output Current @ 3Phase, 200...240V Input HP kW HP kW
ND HD 0P9 0.9 A 0.5 0.4 0.5 0.4
Code Amps Frame
HP kW HP kW 1P7 1.7 A 1.0 0.75 1.0 0.75
1P6 (1) 1.6 A 0.25 0.2 0.25 0.2 3P0 3.0 A 2.0 1.5 2.0 1.5
2P5 2.5 A 0.5 0.4 0.5 0.4 4P2 4.2 A 3.0 2.2 3.0 2.2
5P0 5.0 A 1.0 0.75 1.0 0.75 6P6 6.6 B 5.0 4.0 5.0 4.0
8P0 8.0 A 2.0 1.5 2.0 1.5 9P9 9.9 C 7.5 5.5 7.5 5.5
011 11.0 A 3.0 2.2 3.0 2.2 012 12.0 C 10.0 7.5 10.0 7.5
017 17.5 B 5.0 4.0 5.0 4.0 019 19.0 D 15.0 11.0 15.0 11.0
024 24.0 C 7.5 5.5 7.5 5.5 022(2) 22.0 D 20.0 15.0 15.0 11.0
032 32.2 D 10.0 7.5 10.0 7.5 027(2) 27.0 E 25.0 18.5 20.0 15.0
048(2) 48.3 E 15.0 11.0 10.0 7.5 032(2) 32.0 E 30.0 22.0 25.0 18.5
062(2) 62.1 E 20.0 15.0 15.0 11.0
(1) This rating is only available for PowerFlex 523 drives.
(2) Normal and Heavy-Duty ratings are available for this drive.

14 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Chapter 1

Installation/Wiring

This chapter provides information on mounting and wiring the PowerFlex

520-series drives.

Topic Page
Mounting Considerations 15
AC Supply Source Considerations 19
General Grounding Requirements 20
Fuses and Circuit Breakers 22
Power and Control Module 28
Control Module Cover 30
Power Module Terminal Guard 31
Power Wiring 32
Power Terminal Block 35
Common Bus/Precharge Notes 35
I/O Wiring 36
Control I/O Terminal Block 37
Start and Speed Reference Control 48
CE Conformity 51
UKCA Conformity 51

Most startup difficulties are the result of incorrect wiring. Every precaution
must be taken to assure that the wiring is done as instructed. All items must be
read and understood before the actual installation begins.

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.

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

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)

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

• Do not expose to a corrosive atmosphere.
• Protect from moisture and direct sunlight.

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Chapter 1 Installation/Wiring

Minimum Mounting Clearances

See Product Dimensions on page 184 for mounting dimensions.

Vertical Vertical, Zero Stacking Vertical with Control Module Fan Kit Vertical, Zero Stacking with
No clearance between drives. Control Module Fan Kit
No clearance between drives.

50 mm 50 mm 50 mm 50 mm
(2.0 in.) 25 mm (2.0 in.) (2.0 in.)(1) (2.0 in.)(1)
(1.0 in.)

Esc Sel Esc Sel Esc Sel Esc Sel

Esc Sel Esc Sel Esc Sel Esc Sel

25 mm (2)
50 mm 50 mm 50 mm (1.0 in.) 50 mm
(2.0 in.) (2.0 in.) (2.0 in.) (2.0 in.)

50 mm 50 mm
(2.0 in.) 50 mm (2.0 in.)
(2.0 in.)(1) 50 mm
50 mm (2.0 in.)(1)
Esc

50 mm

Esc
Sel

(2.0 in.) (2.0 in.)

Sel
(2)

Esc
Esc

Sel
25 mm
Sel

(1.0 in.)

50 mm 50 mm
(2.0 in.) (2.0 in.)

Horizontal with Control Module Fan Kit Horizontal, Zero Stacking with
Control Module Fan Kit
No clearance between drives.

(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.

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 Chapter 1 Installation/Wiring

Ambient Operating Temperatures

For optional accessories and kits, see Accessories and Dimensions on page 173.

Ambient Temperature
Mounting Enclosure Rating(1) Maximum with
Minimum Maximum (No Derate) Maximum (Derate)(2)
Control Module Fan Kit (Derate)(3)(5)
IP 20/Open Type 50 °C (122 °F) 60 °C (140 °F) 70 °C (158 °F)
Vertical
IP 30/NEMA 1/UL Type 1 45 °C (113 °F) 55 °C (131 °F) –
IP 20/Open Type 45 °C (113 °F) 55 °C (131 °F) 65 °C (149 °F)
Vertical, Zero Stacking
IP 30/NEMA 1/UL Type 1 40 °C (104 °F) 50 °C (122 °F) –
-20 °C (-4 °F)
Horizontal with
IP 20/Open Type 50 °C (122 °F) – 70 °C (158 °F)
Control Module Fan Kit(4)(5)
Horizontal, Zero Stacking
IP 20/Open Type 45 °C (113 °F) – 65 °C (149 °F)
with Control Module Fan Kit(4)(5)
(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 25x-D1P4N104 and 25x-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 25x-D1P4N104 and 25x-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 25x-D1P4N104 and 25x-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.

Current Derating Curves

Vertical Mounting
Single Drive Zero Stacking
120 IP 30/NEMA 1 with Control 120 IP 30/NEMA 1 with Control
Percentage of Rated Current (%)

Percentage of Rated Current (%)

110 Module Fan Kit 110 Module Fan Kit
100 100
90 IP 20/Open Type 90 IP 20/Open Type
80 80
70 70
60 60
50 50
40 40
30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80
Ambient Temperature (°C) Ambient Temperature (°C)

Horizontal/Floor Mounting
Single Drive Zero Stacking
120 with Control 120 with Control
Percentage of Rated Current (%)
Percentage of Rated Current (%)

110 Module Fan Kit 110 Module Fan Kit

100 100
90 90
80 IP 20/Open Type 80 IP 20/Open Type
70 70
60 60
50 50
40 40
30 35 40 45 50 55 60 65 70 75 80 30 35 40 45 50 55 60 65 70 75 80
Ambient Temperature (°C) Ambient Temperature (°C)

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 17

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 the Altitude Limit
(Based on Voltage) table below.
Or
• Derate the output current by 10% for every additional 1000 m (3300 ft),
up to 3000 m (9900 ft), subject to limits listed in the Altitude Limit
(Based on Voltage) table below.
Altitude Limit (Based on Voltage)
Corner Ground, Impedance Ground,
Drive Rating Center Ground (Wye Neutral) (1)
or Ungrounded (1)(2)
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 circuit breaker that is used in the drive may have different altitude specifications. See publications 140UT-TD001 and
140-TD005 for more information.
(2) Impedance Ground and Ungrounded limits are not evaluated as part of UL specifications.

High Altitude

120 60
Percentage of Rated Current (%)

110

Ambient Temperature (°C)

100 50
90
80 40
70
60 30
50
40 20
0 1000 2000 3000 4000 0 1000 2000 3000 4000
Altitude (m) Altitude (m)

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
(-40…+185 °F)(a).
• Store within a relative humidity range of 0...95%, noncondensing.
• Do not expose to a corrosive atmosphere.

(a) The maximum ambient temperature for storing a Frame E drive is 70 °C (158 °F).
18 Rockwell Automation Publication 520-UM001M-EN-E - January 2023
 Chapter 1 Installation/Wiring

AC Supply Source Ungrounded Distribution Systems

Considerations
ATTENTION: PowerFlex 520-series 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.
ATTENTION: Removing MOVs in drives with an embedded filter will also
disconnect the filter capacitor from earth ground.

Disconnecting MOVs

To 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 diagrams below.
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)

Power Module

IMPORTANT Tighten screw after jumper removal.

Phase to Ground MOV Removal
R/L1
3-phase
S/L2
AC input T/L3

Jumper 1 2 3 4

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 19

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 page 167). Listed in the Input Power Conditions table
below 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.

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.

Input Power Conditions

Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) • Install Line Reactor.(1)
or
Greater than 120 kVA supply transformer • Install Isolation Transformer.
Line has power factor correction capacitors
• Install Line Reactor.(1)
Line has frequent power interruptions or
Line has intermittent noise spikes in excess of 6000V (lightning) • Install Isolation Transformer.
Phase to ground voltage exceeds 125% of normal line-to-line voltage • Remove MOV jumper to ground.
Ungrounded distribution system or
• Install Isolation Transformer with
B-phase grounded distribution system grounded secondary if necessary.
240V open delta configuration (stinger leg)(2) • Install Line Reactor.(1)
(1) See Appendix B for accessory ordering information.
(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 183 for specific line
reactor part numbers.

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

Esc Sel

R/L1 U/T1
S/L2 V/T2
T/L3 W/T3

SHLD

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 Chapter 1 Installation/Wiring

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.

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.

Network Ground
Connect terminal C1 to a clean earth ground when using a network with a star
topology (EtherNet/IP™) or daisy-chain (RS-485). It is acceptable to ground
both C1 and C2 terminals.

Note: Grounding C1 and C2 helps noise immunity for non-network

applications.

Connect terminal CS1 or CS2 to a clean ground when using a network with a
ring topology (EtherNet/IP).

For more information on EtherNet/IP networks, see Ground Connections for

EtherNet/IP Networks on page 250.

For more information on RS-485 networks, see Network Wiring on page 203.

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 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.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 21

Chapter 1 Installation/Wiring

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. Ensure 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 not include 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.

Fuses and Circuit Breakers The PowerFlex 520-series 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 found on pages 23...27 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 that are found on pages
23...27. If available current ratings do not match those listed in the tables that
are provided, choose the next higher fuse rating.
• IEC – BS88 (British Standard) Parts 1 & 2(a), 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 found on pages 23...27 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.

(a) 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.
22 Rockwell Automation Publication 520-UM001M-EN-E - January 2023
 Chapter 1 Installation/Wiring

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

When using Bulletin 140M or UL489 rated circuit breakers, the guidelines that
are listed below must be followed to meet the NEC requirements for branch
circuit protection.
• Bulletin 140M can be used in single motor applications.
• Bulletin 140M can be used up stream from the drive without the need
for fuses.

Fuses and Circuit Breakers for PowerFlex 520-Series Drives

100…120V 1-Phase Input Protection Devices – Frames A…B — IEC (Non-UL) Applications
Catalog No. Output Ratings Input Ratings IEC (Non-UL) Applications
ND HD Contactor Fuses (Rating) Circuit Breakers
Max Current Frame Size
PF 523 PF 525 A kVA Cat. No.
Hp kW Hp kW A(1) Min Max 140U/140G 140M/MT(2)(3)(4)

25A-V1P6N104 – 0.25 0.2 0.25 0.2 1.6 0.8 6.4 A 100-C09 10 16 140U-D6D2-B80 140M-C2E-B63
140UT-D7D2-B80 140MT-C3E-B63
140U-D6D2-C12 140M-C2E-C10
25A-V2P5N104 25B-V2P5N104 0.5 0.4 0.5 0.4 2.5 1.3 9.6 A 100-C12 16 20 140UT-D7D2-C12 140MT-C3E-C10
140U-D6D2-C25 140M-D8E-C20
25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 25 40
140UT-D7D2-C25 140MT-D9E-C20

25A-V6P0N104 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 32 50 140U-D6D2-C30 140M-F8E-C25
140UT-D7D2-C30
(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 devices with adjustable current range must have the current trip set to the minimum range that the device does not trip.
(4) 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.

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

Catalog No. Output Ratings Input Ratings UL 61800-5-1 Applications
ND HD Max Frame Contactor Fuses (Max Rating) Circuit Breakers
PF 523 PF 525 A kVA Current Size Cat. No.
Hp kW Hp kW A(1) Class/Catalog No. 140UT 140M/MT(2)(3)(4)
140MT-C3E-B63
25A-V1P6N104 — 0.25 0.2 0.25 0.2 1.6 0.8 6.4 A 100-C09 CLASS CC, J, or T/15 140UT-D7D2-B80
140MT-D9E-B63

25A-V2P5N104 25B-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
25A-V4P8N104 25B-V4P8N104 1.0 0.75 1.0 0.75 4.8 2.5 19.2 B 100-C23 CLASS CC, J, or T/40 — (5) 140MT-D9E-C20
25A-V6P0N104 25B-V6P0N104 1.5 1.1 1.5 1.1 6.0 3.2 24.0 B 100-C23 CLASS CC, J, or T/50 — (5) 140M-F8E-C25
(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 devices with adjustable current range must have the current trip set to the minimum range that the device does not trip.
(4) 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.
(5) 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. Output Ratings Input Ratings IEC (Non-UL) Applications
ND HD Frame Contactor Fuses (Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(1) Size Cat. No.
Hp kW Hp kW Min Max 140U/140G 140M/MT(2)(3)(4)

25A-A1P6N104 — 0.25 0.2 0.25 0.2 1.6 1.4 5.3 A 100-C09 6 10 140U-D6D2-C10 140M-C2E-B63
140UT-D7D2-C10 140MT-C3E-B63
140U-D6D2-C10 140M-C2E-B63
25A-A1P6N114 — 0.25 0.2 0.25 0.2 1.6 1.4 5.3 A 100-C09 6 10 140UT-D7D2-C10 140MT-C3E-B63
140U-D6D2-C10 140M-C2E-C10
25A-A2P5N104 25B-A2P5N104 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 16
140UT-D7D2-C10 140MT-C3E-C10

25A-A2P5N114 25B-A2P5N114 0.5 0.4 0.5 0.4 2.5 1.7 6.5 A 100-C09 10 16 140U-D6D2-C10 140M-C2E-C10
140UT-D7D2-C10 140MT-C3E-C10

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 23

Chapter 1 Installation/Wiring

200…240V 1-Phase Input Protection Devices – Frames A…B — IEC (Non-UL) Applications (Continued)
Catalog No. Output Ratings Input Ratings IEC (Non-UL) Applications
ND HD Frame Contactor Fuses (Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(1) Size Cat. No.
Hp kW Hp kW Min Max 140U/140G 140M/MT(2)(3)(4)

25A-A4P8N104 25B-A4P8N104 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 16 25 140U-D6D2-C15 140M-C2E-C16
140UT-D7D2-C15 140MT-C3E-C16
140U-D6D2-C15 140M-C2E-C16
25A-A4P8N114 25B-A4P8N114 1.0 0.75 1.0 0.75 4.8 2.8 10.7 A 100-C12 16 25 140UT-D7D2-C15 140MT-C3E-C16
140U-D6D2-C25
25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 25 40 140M-F8E-C25
140UT-D7D2-C25

25A-A8P0N114 25B-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
140UT-D7D2-C25
25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 32 50 140G-G6C3-C35 140M-F8E-C25
25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 32 50 140G-G6C3-C35 140M-F8E-C25
(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 devices with adjustable current range must have the current trip set to the minimum range that the device does not trip.
(4) 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.

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

Catalog No. Output Ratings Input Ratings UL 61800-5-1 Applications
ND HD Frame Contactor Fuses (Max Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(1) Size Cat. No.
Hp kW Hp kW Class/Catalog No. 140UT 140M/MT(2)(3)(4)
25A-A1P6N104 — 0.25 0.2 0.25 0.2 1.6 1.4 5.3 A 100-C09 CLASS CC, J, or T/15 140UT-D7D2-B50 140MT-D9E-B63
25A-A1P6N114 — 0.25 0.2 0.25 0.2 1.6 1.4 5.3 A 100-C09 CLASS CC, J, or T/15 140UT-D7D2-B50 140MT-D9E-B63
25A-A2P5N104 25B-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
25A-A2P5N114 25B-A2P5N114 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
25A-A4P8N104 25B-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
25A-A4P8N114 25B-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
25A-A8P0N104 25B-A8P0N104 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 CLASS CC, J, or T/40 —(5) 140M-F8E-C25
25A-A8P0N114 25B-A8P0N114 2.0 1.5 2.0 1.5 8.0 4.8 18.0 B 100-C23 CLASS CC, J, or T/40 (5) 140M-F8E-C25
—
25A-A011N104 25B-A011N104 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 CLASS CC, J, or T/50 — (5) 140M-F8E-C25
25A-A011N114 25B-A011N114 3.0 2.2 3.0 2.2 11.0 6.0 22.9 B 100-C37 CLASS CC, J, or T/50 (5) 140M-F8E-C25
—
(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 devices with adjustable current range must have the current trip set to the minimum range that the device does not trip.
(4) 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.
(5) Circuit breaker selection is not available for this drive rating.

200…240V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications
Catalog No.(1) Output Ratings Input Ratings IEC (Non-UL) Applications
ND HD Frame Contactor Fuses (Rating) Circuit Breakers
Size Cat. No.
PF 523 PF 525 A kVA Max Current A(2)
Hp kW Hp kW Min Max 140U/140G 140M/MT(3)(4)(5)
140U-D6D3-B30 140M-C2E-B25
25A-B1P6N104 — 0.25 0.2 0.25 0.2 1.6 0.9 1.9 A 100-C09 3 6 140UT-D7D3-B30 140MT-C3E-B25
140U-D6D3-B40 140M-C2E-B40
25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C09 6 6
140UT-D7D3-B40 140MT-C3E-B40

25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 10 16 140U-D6D3-B80 140M-C2E-B63
140UT-D7D3-B80 140MT-C3E-B63
140U-D6D3-C10 140M-C2E-C10
25A-B8P0N104 25B-B8P0N104 2.0 1.5 2.0 1.5 8.0 4.3 9.5 A 100-C12 16 20 140UT-D7D3-C10 140MT-C3E-C10
140U-D6D3-C15 140M-C2E-C16
25A-B011N104 25B-B011N104 3.0 2.2 3.0 2.2 11.0 6.3 13.8 A 100-C23 20 32
140UT-D7D3-C15 140MT-F8E-C16

25A-B017N104 25B-B017N104 5.0 4.0 5.0 4.0 17.5 9.6 21.1 B 100-C23 32 45 140U-D6D3-C25 140M-F8E-C25
140UT-D7D3-C25
25A-B024N104 25B-B024N104 7.5 5.5 7.5 5.5 24.0 12.2 26.6 C 100-C37 35 63 140G-G6C3-C35 140M-F8E-C32
25A-B032N104 25B-B032N104 10.0 7.5 10.0 7.5 32.2 15.9 34.8 D 100-C43 45 70 140G-G6C3-C60 140M-F8E-C45
25A-B048N104 25B-B048N104 15.0 11.0 10.0 7.5 48.3 20.1 44.0 E 100-C60 63 90 140G-G6C3-C70 140M-F8E-C45
25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 70 125 140G-G6C3-C90 —(6)

24 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Chapter 1 Installation/Wiring

(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see 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 devices with adjustable current range must have the current trip set to the minimum range that the device does 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) Circuit breaker selection is not available for this drive rating.

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

Catalog No.(1) Output Ratings Input Ratings UL 61800-5-1 Applications
Frame Contactor
ND HD Fuses (Max Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(2) Size Cat. No.
Hp kW Hp kW Class/Catalog No. 140UT 140M/MT(3)(4)(5)

25A-B1P6N104 — 0.25 0.2 0.25 0.2 1.6 0.9 1.9 A 100-C09 CLASS CC, J, or T/15 140UT-D7D3- 140MT-D9E-B25
B30
140UT-D7D3-
25A-B2P5N104 25B-B2P5N104 0.5 0.4 0.5 0.4 2.5 1.2 2.7 A 100-C09 CLASS CC, J, or T/6 B40 140MT-D9E-B40

140UT-D7D3-
25A-B5P0N104 25B-B5P0N104 1.0 0.75 1.0 0.75 5.0 2.7 5.8 A 100-C09 CLASS CC, J, or T/15 140MT-D9E-B63
B80
25A-B8P0N104 25B-B8P0N104 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
25A-B011N104 25B-B011N104 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
25A-B017N104 25B-B017N104 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
25A-B024N104 25B-B024N104 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
25A-B032N104 25B-B032N104 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
—
25A-B048N104 25B-B048N104 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
25A-B062N104 25B-B062N104 20.0 15.0 15.0 11.0 62.1 25.6 56.0 E 100-C72 CLASS CC, J, or T/125 — (6) — (6)
(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see 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 devices with adjustable current range must have the current trip set to the minimum range that the device does 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) Circuit breaker selection is not available for this drive rating.
380...480V 3-Phase Input Protection Devices – Frames A...

380…480V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications
Catalog No.(1) Output Ratings Input Ratings IEC (Non-UL) Applications
ND HD Frame Contactor Fuses (Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(2) Size Cat. No.
Hp kW Hp kW Min Max 140U/140G 140M/MT(3)(4)(5)

25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 3 6 140U-D6D3-B30 140M-C2E-B25
140UT-D7D3-B30 140MT-C3E-B25
140U-D6D3-B30 140M-C2E-B25
25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 3 6 140UT-D7D3-B30 140MT-C3E-B25
140U-D6D3-B60 140M-C2E-B40
25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 6 10
140UT-D7D3-B60 140MT-C3E-B40

25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 6 10 140U-D6D3-B60 140M-C2E-B40
140UT-D7D3-B60 140MT-C3E-B40
140U-D6D3-B60 140M-C2E-B63
25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 16
140UT-D7D3-B60 140MT-C3E-B63

25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 10 16 140U-D6D3-B60 140M-C2E-B63
140UT-D7D3-B60 140MT-C3E-B63
140U-D6D3-C10 140M-C2E-C10
25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 16 140UT-D7D3-C10 140MT-C3E-C10
140U-D6D3-C10 140M-C2E-C10
25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 10 16
140UT-D7D3-C10 140MT-C3E-C10
25A-D010N104 25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 32 140U-D6D3-C15 140M-C2E-C16
140UT-D7D3-C15 140MT-D9E-C16
140U-D6D3-C15 140M-C2E-C16
25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 20 32 140UT-D7D3-C15 140MT-D9E-C16
140U-D6D3-C25 140M-D8E-C20
25A-D013N104 25B-D013N104 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 20 35
140UT-D7D3-C25 140MT-D9E-C20

25A-D013N114 25B-D013N114 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
140UT-D7D3-C25 140MT-D9E-C20
140U-D6D3-C25 140M-D8E-C20
25A-D017N104 25B-D017N104 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40 140UT-D7D3-C25 140MT-D9E-C20
140U-D6D3-C25 140M-D8E-C20
25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 25 40
140UT-D7D3-C25 140MT-D9E-C20

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Chapter 1 Installation/Wiring

380…480V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications (Continued)
Catalog No.(1) Output Ratings Input Ratings IEC (Non-UL) Applications
Frame Contactor
ND HD Size Cat. No. Fuses (Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(2)
Hp kW Hp kW Min Max 140U/140G 140M/MT(3)(4)(5)
25A-D024N104 25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 63 140G-G6C3-C40 140M-F8E-C32
25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 35 63 140G-G6C3-C40 140M-D8E-C32
25A-D030N104 25B-D030N104 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45
25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45
25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 45 70 140G-G6C3-C50 140M-F8E-C45
25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 50 80 140G-G6C3-C60 140M-F8E-C45
(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see 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 devices with adjustable current range must have the current trip set to the minimum range that the device does 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.

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

Catalog No.(1) Output Ratings Input Ratings UL 61800-5-1 Applications
ND HD Frame Contactor Fuses (Max Rating) Circuit Breakers
Size Cat. No.
PF 523 PF 525 A kVA Max Current A(2)
Hp kW Hp kW Class/Catalog No. 140UT 140M/MT(3)(4)(5)
25A-D1P4N104 25B-D1P4N104 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 CLASS CC, J, or T/6 — (6) 140MT-C3E-B25
25A-D1P4N114 25B-D1P4N114 0.5 0.4 0.5 0.4 1.4 1.7 1.9 A 100-C09 CLASS CC, J, or T/6 — (6) 140MT-C3E-B25
25A-D2P3N104 25B-D2P3N104 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 CLASS CC, J, or T/10 — (6) 140MT-C3E-B40
25A-D2P3N114 25B-D2P3N114 1.0 0.75 1.0 0.75 2.3 2.9 3.2 A 100-C09 CLASS CC, J, or T/10 — (6) 140MT-C3E-B40
25A-D4P0N104 25B-D4P0N104 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 CLASS CC, J, or T/15 — (6) 140MT-C3E-B63
25A-D4P0N114 25B-D4P0N114 2.0 1.5 2.0 1.5 4.0 5.2 5.7 A 100-C09 CLASS CC, J, or T/15 — (6) 140MT-C3E-B63
25A-D6P0N104 25B-D6P0N104 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 CLASS CC, J, or T/15 (6) 140MT-C3E-C10
—
25A-D6P0N114 25B-D6P0N114 3.0 2.2 3.0 2.2 6.0 6.9 7.5 A 100-C09 CLASS CC, J, or T/15 — (6) 140MT-C3E-C10
25A-D010N104 25B-D010N104 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 CLASS CC, J, or T/30 (6) 140MT-D9E-C16
—
25A-D010N114 25B-D010N114 5.0 4.0 5.0 4.0 10.5 12.6 13.8 B 100-C23 CLASS CC, J, or T/30 — (6) 140MT-D9E-C16
25A-D013N104 25B-D013N104 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 CLASS CC, J, or T/35 — (6) 140MT-D9E-C20
25A-D013N114 25B-D013N114 7.5 5.5 7.5 5.5 13.0 14.1 15.4 C 100-C23 CLASS CC, J, or T/35 — (6) 140MT-D9E-C20
25A-D017N104 25B-D017N104 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 CLASS CC, J, or T/40 — (6) 140MT-D9E-C20
25A-D017N114 25B-D017N114 10.0 7.5 10.0 7.5 17.0 16.8 18.4 C 100-C23 CLASS CC, J, or T/40 (6) 140MT-D9E-C20
—
25A-D024N104 25B-D024N104 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 CLASS CC, J, or T/60 — (6) 140M-F8E-C32
25A-D024N114 25B-D024N114 15.0 11.0 15.0 11.0 24.0 24.1 26.4 D 100-C37 CLASS CC, J, or T/60 — (6) 140M-F8E-C32
25A-D030N104 25B-D030N104 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 CLASS CC, J, or T/70 (6) 140M-F8E-C45
—
25A-D030N114 25B-D030N114 20.0 15.0 15.0 11.0 30.0 30.2 33.0 D 100-C43 CLASS CC, J, or T/70 — (6) 140M-F8E-C45
25A-D037N114 25B-D037N114 25.0 18.5 20.0 15.0 37.0 30.8 33.7 E 100-C43 CLASS CC, J, or T/70 — (6) 140M-F8E-C45
25A-D043N114 25B-D043N114 30.0 22.0 25.0 18.5 43.0 35.6 38.9 E 100-C60 CLASS CC, J, or T/80 — (6) 140M-F8E-C45
(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see the drive nameplate for drive input current rating.
(3) The AIC ratings of the Bulletin 140M/MT devices can vary. See publication140-TD005 or 140M-TD002.
(4) Bulletin 140M/MT devices with adjustable current range must have the current trip set to the minimum range that the device does 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) Circuit breaker selection is not available for this drive rating.

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525…600V 3-Phase Input Protection Devices – Frames A…E — IEC (Non-UL) Applications
Catalog No.(1) Output Ratings Input Ratings IEC (Non-UL) Applications
Frame Contactor
ND HD Fuses (Rating) Circuit Breakers
Size Cat. No.
PF 523 PF 525 A kVA Max Current A(2)
Hp kW Hp kW Min Max 140U/140G 140M/MT(3)(4)(5)
140U-D6D3-B20 140M-C2E-B25
25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 3 6
140UT-D7D3-B20 140MT-C3E-B25
25A-E1P7N104 25B-E1P7N104 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
140UT-D7D3-B30 140MT-C3E-B25
140U-D6D3-B50 140M-C2E-B40
25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 4.3 3.8 A 100-C09 6 10
140UT-D7D3-B50 140MT-C3E-B40

25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 6.1 5.3 A 100-C09 10 16 140U-D6D3-B80 140M-C2E-B63
140UT-D7D3-B80 140MT-D9E-B63
140U-D6D3-C10 140M-C2E-C10
25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 10 20 140UT-D7D3-C10 140MT-D9E-C10
140U-D6D3-C15 140M-C2E-C16
25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 16 25
140UT-D7D3-C15 140MT-D9E-C16

25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 20 32 — 140M-C2E-C16
140MT-D9E-C16
25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 32 50 140G-G6C3-C30 140M-F8E-C25
25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 35 63 140G-G6C3-C35 140M-F8E-C32
25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 35 50 140G-G6C3-C35 140M-F8E-C32
25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 40 63 140G-G6C3-C50 140M-F8E-C32
(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see 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 devices with adjustable current range must have the current trip set to the minimum range that the device does 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.

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

Catalog No.(1) Output Ratings Input Ratings UL 61800-5-1 Applications
Frame Contactor
ND HD Fuses (Max Rating) Circuit Breakers
PF 523 PF 525 A kVA Max Current A(2) Size Cat. No.
Hp kW Hp kW Class/Catalog No. 140UT 140M/MT(3)(4)(5)
25A-E0P9N104 25B-E0P9N104 0.5 0.4 0.5 0.4 0.9 1.4 1.2 A 100-C09 CLASS CC, J, or T/6 — (6) 140MT-C3E-B25
25A-E1P7N104 25B-E1P7N104 1.0 0.75 1.0 0.75 1.7 2.6 2.3 A 100-C09 CLASS CC, J, or T/6 (6) 140MT-C3E-B25
—
25A-E3P0N104 25B-E3P0N104 2.0 1.5 2.0 1.5 3.0 4.3 3.8 A 100-C09 CLASS CC, J, or T/10 — (6) 140MT-C3E-B40
25A-E4P2N104 25B-E4P2N104 3.0 2.2 3.0 2.2 4.2 6.1 5.3 A 100-C09 CLASS CC, J, or T/15 — (6) 140MT-D9E-B63
25A-E6P6N104 25B-E6P6N104 5.0 4.0 5.0 4.0 6.6 9.1 8.0 B 100-C09 CLASS CC, J, or T/20 — (6) 140MT-D9E-C10
25A-E9P9N104 25B-E9P9N104 7.5 5.5 7.5 5.5 9.9 12.8 11.2 C 100-C16 CLASS CC, J, or T/25 — (6) 140MT-D9E-C16
25A-E012N104 25B-E012N104 10.0 7.5 10.0 7.5 12.0 15.4 13.5 C 100-C23 CLASS CC, J, or T/30 — (6) 140MT-D9E-C16
25A-E019N104 25B-E019N104 15.0 11.0 15.0 11.0 19.0 27.4 24.0 D 100-C30 CLASS CC, J, or T/50 — (6) 140M-F8E-C25
25A-E022N104 25B-E022N104 20.0 15.0 15.0 11.0 22.0 31.2 27.3 D 100-C30 CLASS CC, J, or T/60 (6) 140M-F8E-C32
—
25A-E027N104 25B-E027N104 25.0 18.5 20.0 15.0 27.0 28.2 24.7 E 100-C30 CLASS CC, J, or T/50 (6) 140M-F8E-C32
—
25A-E032N104 25B-E032N104 30.0 22.0 25.0 18.5 32.0 33.4 29.2 E 100-C37 CLASS CC, J, or T/60 (6) 140M-F8E-C32
—
(1) Normal and Heavy-Duty ratings are available for this drive.
(2) When the drive is controlling motors with lower ampere ratings, see 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 devices with adjustable current range must have the current trip set to the minimum range that the device does 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) Circuit breaker selection is not available for this drive rating.

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Chapter 1 Installation/Wiring

Power and Control Module PowerFlex 520-series drives consist of a Power Module and Control Module.

Separating the Power and Control Module

ATTENTION: Perform this action only when drive is NOT powered.

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.

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 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.

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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).

Control Module Cover To access the control terminals, DSI port, and Ethernet port, the front cover
must be removed. To remove:
1. Press and hold down the arrow on the front of the cover.

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 Chapter 1 Installation/Wiring

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

Reattach the front cover when wiring is complete.

Power Module Terminal To access the power terminals, the terminal guard must be removed. To
Guard 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.

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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 must separate the Power and
Control Modules. See Separating the Power and Control Module on page 28 for
instructions.

Power Wiring
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.
ATTENTION: 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 helps minimize the
possible shock hazard from “cross coupled” power leads.

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

Various 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 a single 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.

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 Chapter 1 Installation/Wiring

Use copper wire only. Wire gauge requirements and recommendations are
based on 75 °C (167 °F). Do not reduce wire gauge when using higher
temperature wire.

WARNING: 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.

Unshielded

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

environments provided adequate free air space and/or conduit fill rates 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.

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

Shielded/Armored Cable

Shielded cable contains all 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 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 (with drain wire) 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

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Chapter 1 Installation/Wiring

distance tables as tested with the drive, these cables are not recommended and
their performance against the lead length limits supplied is not known.

Recommended Shielded Wire

Location Rating/Type Description
• Four tinned copper conductors with XLPE
600V, 90 °C (194 °F) XHHW2/RHW-2 insulation.
Standard (Option 1) Anixter B209500-B209507, Belden • Copper braid/aluminum foil combination shield and
29501-29507, or equivalent tinned copper drain wire.
• PVC jacket.
• Three tinned copper conductors with XLPE
insulation.
Tray rated 600V, 90 °C (194 °F) • 5 mil single helical copper tape (25% overlap min)
Standard (Option 2) RHH/RHW-2 Anixter OLF-7xxxxx or with three bare copper grounds in contact with
equivalent shield.
• PVC jacket.
• Three bare copper conductors with XLPE insulation
Tray rated 600V, 90 °C (194 °F) and impervious corrugated continuously welded
Class I & II; aluminum armor.
RHH/RHW-2 Anixter 7V-7xxxx-3G or
Division I & II equivalent • Black sunlight resistant PVC jacket overall.
• Three copper grounds on #10 AWG and smaller.

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...16 kHz.

For 240V ratings and lower, reflected wave effects do not need to be
considered.

Output Disconnect

The drive is intended to be commanded by control input signals 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, an auxiliary contact should be used to simultaneously disable drive
(Aux Fault or Coast to Stop).

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 Chapter 1 Installation/Wiring

Power Terminal Block Power Terminal Block

Frame A, B, C & D Frame E
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

DC- DC+ BR- DC- DC+ BR-

BR+ BR+

Terminal Description
R/L1, S/L2 1-Phase Input Line Voltage Connection
R/L1, S/L2, T/L3 3-Phase Input Line Voltage Connection
Switch any two motor leads to change
U/T1, V/T2, W/T3 Motor Phase Connection = forward direction.
DC+, DC- DC Bus Connection (except for 110V 1-Phase)
BR+, BR- Dynamic Brake Resistor Connection
Safety Ground - PE

IMPORTANT Terminal screws may become loose during shipment. Ensure 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) Minimum Wire Size(1) Torque
A 5.3 mm2 (10 AWG) 0.8 mm2 (18 AWG) 1.76...2.16 N•m (15.6...19.1 lb•in)
B 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 N•m (15.6...19.1 lb•in)
C 8.4 mm2 (8 AWG) 2.1 mm2 (14 AWG) 1.76...2.16 N•m (15.6...19.1 lb•in)
D 13.3 mm2 (6 AWG) 5.3 mm2 (10 AWG) 1.76...2.16 N•m (15.6...19.1 lb•in)
E 26.7 mm2 (3 AWG) 8.4 mm2 (8 AWG) 3.09...3.77 N•m (27.3...33.4 lb•in)
(1) Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

Common Bus/Precharge If drives are used with a disconnect switch to the common DC bus, then an
Notes auxiliary contact on the disconnect must be connected to a digital input of the
drive. The corresponding input (parameter t062, t063, t065...t068 [DigIn
TermBlk xx]) must be set to 30, “Precharge En” This provides the proper
precharge interlock, guarding against possible damage to the drive when
connected to a common DC bus. For more information, see Drives in Common
Bus Configurations, publication DRIVES-AT002.

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Chapter 1 Installation/Wiring

I/O Wiring Motor Start/Stop Precautions

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.
ATTENTION: The drive start/stop control circuitry includes solid-state
components. If hazards due to accidental contact with moving machinery or
unintentional flow of liquid, gas or solids exist, an additional hardwired stop
circuit may be required to remove the AC line to the drive. When the AC line
is removed, there will be a loss of any inherent regenerative braking effect
that might be present - the motor will coast to a stop. An auxiliary braking
method may be required. Alternatively, use the drive’s safety input function.

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).

IMPORTANT I/O terminals labeled “Common” are not referenced to the safety ground
(PE) terminal and are designed to greatly reduce common mode
interference.

ATTENTION: Driving the 4…20 mA analog input from a voltage source could
cause component damage. Verify proper configuration prior to applying
input signals.

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.

Recommended Signal Wire

Signal Type/ Belden Wire Types(1) Description Min Insulation
Where Used (or equivalent) Rating
0.750 mm2 (18 AWG), twisted-pair,
Analog I/O and PTC 8760/9460
100% shield with drain(2) 300V,
Remote Pot 8770 0.750 mm2 (18 AWG), 3 conductor, shielded 60 °C (140 °F)
Encoder/Pulse I/O 9728/9730 0.196 mm2 (24 AWG), individually shielded pairs
(1) Stranded or solid wire.
(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.

Recommended Control Wire for Digital I/O

Min Insulation
Type Wire Types Description Rating
Per US NEC or applicable –
Unshielded national or local code
300V,
Multi-conductor shielded 60 °C (140 °F)
Shielded cable such as Belden 8770 0.750 mm2 (18 AWG), 3 conductor, shielded
(or equivalent)

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 Chapter 1 Installation/Wiring

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 Control I/O Terminal Block Wire Specifications
Frame Maximum Wire Size(1) Minimum Wire Size(1) Torque
A...E 1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.71...0.86 N•m (6.2...7.6 lb•in)
(1) Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

PowerFlex 523 Control I/O Terminal Block

PowerFlex 523 Series A Control I/O Wiring Block Diagram

Typical Typical
(1) SRC wiring SNK wiring
Stop
01
DigIn TermBlk 02/(2)
Start/Run FWD
Series A 02
DigIn TermBlk 03/
Direction/Run REV
03
SNK SRC Digital Common
04
DigIn TermBlk 05/Pulse
05
DigIn TermBlk 06
06

+24V +24V DC
Relay N.O. 11
R1 +10V +10V DC
Relay Common 12
R2
0-10V Input
Relay N.C. 13
R3
Analog Common
14
Pot must be
4-20mA Input 1...10 k ohm
15 2 W min.
RJ45 Shield
C1
Comm Common
C2

J8 J7
RS485
DigIn TermBlk 05 Sel

SNK Pulse In
(DSI)
Digital In

81

SRC Digital
Input
R1 R2 01 02 03 04 05 06

R3 11 12 13 14 15 C1 C2

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Chapter 1 Installation/Wiring

PowerFlex 523 Series B Control I/O Wiring Block Diagram

Typical Typical
Stop
(1) SRC wiring SNK wiring
01
DigIn TermBlk 02/(2)
Start/Run FWD
Series B 02
DigIn TermBlk 03/
Direction/Run REV
03
SNK SRC Digital Common
04
DigIn TermBlk 05/Pulse
05
DigIn TermBlk 06
06

Relay N.O.
R1
Relay Common +24V
R2 +24V DC
11
Relay N.C.
R3 +10V +10V DC
12
0-10V Analog Input 13
13
4-20 mA
Analog Common 14
14
0-10V (3) (4)
Analog Output Pot must be 4-20 mA
15 1...10 k ohm source
0/4-20 mA 2 W min.
RJ45 Shield
C1
Comm Common
C2

J4 J13 J8 J7
RS485
DigIn TermBlk 05 Sel

4-20 mA 0/4-20 mA SNK Pulse In

(DSI)
Analog Out

Digital In
Analog In

81

0-10V 0-10V SRC Digital

Input
R1 R2 01 02 03 04 05 06

R3 11 12 13 14 15 C1 C2

Control I/O Wiring Block Diagram Notes

(1) See Digital Input Selection for Start Source on page 49 for more information on configuring the digital inputs.

IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is

determined by the drive setting. See the tables below for more
information.
Start Method Stop Method
P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop
1 “Keypad” Coast
2 “DigIn TrmBlk” See t062, t063 [DigIn TermBlk xx] below
3 “Serial/DSI” Coast Per P045
[Stop Mode]
4 “Network Opt” Coast
5 “EtherNet/IP” (1) Coast
(1) Setting is specific to PowerFlex 525 drives only.

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 Chapter 1 Installation/Wiring

Start Method Stop Method

t062, t063 [DigIn TermBlk xx] I/O Terminal 01 Stop Normal Stop
t064 [2-Wire Mode] is set to:
48 “2-Wire FWD” • 0, 1, or 2 = Coast
• 3 = per P045 [Stop Mode]
49 “3-Wire Start” Per P045 [Stop Mode] Per P045
t064 [2-Wire Mode] is set to: [Stop Mode]
50 “2-Wire REV” • 0, 1, or 2 = Coast
• 3 = per P045 [Stop Mode]
51 “3-Wire Dir” Per P045 [Stop Mode]

IMPORTANT The drive is shipped with a jumper that is installed between I/O
Terminals 01 and 11. Remove this jumper when using I/O Terminal
01 as a stop or enable input.
(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a
maintained input for I/O Terminal 03 to change direction.
(3) Analog output (terminal 15) is only available on PowerFlex 523 Series B drive, and requires firmware 3.001 and later to
configure the analog output parameters (t088, t089, and t090).
(4) Potentiometer connection is only applicable when the 0…10V setting (default) is selected for jumper J4.

IMPORTANT Only one analog frequency source may be connected at a time. If

more than one reference is connected at the same time, an
undetermined frequency reference results.

Control I/O Terminal Designations

No. Signal Default Description Parameter
R1 Relay N.O. Fault Normally open contact for output relay.
R2 Relay Common Fault Common for output relay. t076
R3 Relay N.C. Fault Normally closed contact for output relay.
Three wire stop. However, it functions as a stop under all
01 Stop Coast input modes and cannot be disabled. P045(1)
Used to initiate motion and also can be used as a
programmable digital input. It can be programmed with P045, P046,
02 DigIn TermBlk 02/ Run FWD t062 [DigIn TermBlk 02] as three wire (Start/Dir with Stop) P048, P050,
Start/Run FWD or two wire (Run FWD/Run REV) control. Current A544, t062
consumption is 6 mA.
Used to initiate motion and also can be used as a
programmable digital input. It can be programmed with
03 DigIn TermBlk 03/ Run REV t063 [DigIn TermBlk 03] as three wire (Start/Dir with Stop) t063
Dir/Run REV or two wire (Run FWD/Run REV) control. Current
consumption is 6 mA.
Return for digital I/O. Electrically isolated (along with the
04 Digital Common – –
digital I/O) from the rest of the drive.
Program with t065 [DigIn TermBlk 05].
Also functions as a Pulse Train input for reference or
05 DigIn TermBlk 05/ Preset Freq speed feedback. Requires an NPN pulse input. The t065
Pulse In maximum frequency is 100 kHz. Current consumption is
6 mA.
Program with t066 [DigIn TermBlk 06].
06 DigIn TermBlk 06 Preset Freq t066
Current consumption is 6 mA.
Referenced to Digital Common.
11 +24V DC – Drive supplied power for digital inputs. –
Maximum output current is 100 mA.
Referenced to Analog Common.
12 +10V DC – Drive supplied power for 0...10V external potentiometer. P047, P049
Maximum output current is 15 mA.

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Control I/O Terminal Designations (Continued)

No. Signal Default Description Parameter
For external 0…10V (unipolar) input supply or P047, P049,
For Series A potentiometer wiper. t062, t063,
Not Active Input impedance: t065, t066,
0…10V In(2) Voltage source = 100 kΩ t093, A459,
Allowable potentiometer resistance range = 1...10 kΩ A471
External analog input supply, selectable by Analog Input
13 jumper. Default is 0…10V (unipolar) input supply or P047, P049,
potentiometer wiper.
For Series B Input impedance: t062, t063,
Not Active t065, t066,
Analog Input Voltage source = 100 kΩ t093, A459,
Allowable potentiometer resistance range = 1...10 kΩ A471
Change Analog Input jumper to 4…20 mA for external
4…20 mA input supply. Input impedance = 250 Ω
Return for the analog I/O. Electrically isolated (along with
14 Analog Common – –
the analog I/O) from the rest of the drive.
P047, P049,
For Series A For external 4…20 mA input supply. t062, t063,
Not Active
4…20 mA In(2) Input impedance = 250 Ω t065, t066,
A459, A471
The default analog output is 0…10V. To convert a current
15 value, change the Analog Output jumper to 0…20 mA.
Program with t088 [Analog Out Sel]. Maximum analog
For Series B OutFreq 0…10 value can be scaled with t089 [Analog Out High]. t088, t089
Analog Output Maximum Load:
4…20 mA = 525 Ω (10.5V)
0…10V = 1 kΩ (10 mA)
This terminal is tied to the RJ45 port shield. Tie this
C1 C1 – terminal to a clean ground to improve noise immunity –
when using external communication peripherals.
C2 C2 – This is the signal common for the communication signals. –
(1) Setting is specific to PowerFlex 525 drives only.
(2) Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an
undetermined frequency reference results.

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PowerFlex 525 Control I/O Terminal Block

PowerFlex 525 Control I/O Wiring Block Diagram
Typical Typical
Stop
(1) SRC wiring SNK wiring
Safety 1 01
S1 DigIn TermBlk 02/(2)
Safe-Torque-Off Start/Run FWD
Safety 2 02
S2 DigIn TermBlk 03/
Direction/Run REV
Safety +24V 03
S+
SNK SRC Digital Common
04
DigIn TermBlk 05
05
DigIn TermBlk 06
06
DigIn TermBlk 07/Pulse
07
DigIn TermBlk 08
08
+24V +24V DC
Relay 1 N.O. 11
R1 +10V +10V DC
Relay 1 Common 12
R2 0-10V (or ±10V) Input
13
Relay 2 Common Analog Common
R5 14
Relay 2 N.C. Pot must be
R6 4-20mA Input 1...10 k ohm
15 2 W min.
0-10V
Analog Output
0/4-20 mA 16
Opto Output 1
17 24V
(3)
Opto Output 2 Common
30V DC 18
50 mA Opto Common
Non-inductive 19

RJ45 Shield
C1
Comm Common
C2
J10 J9 J5
DigIn TermBlk 07 Sel

0/4-20mA Pulse In SNK

Analog Out

Digital In

0-10V Digital SRC

Input
R1 R2 R5 R6 01 02 03 04 05 06 07 08 C1 C2

S1 S2 S+ 11 12 13 14 15 16 17 18 19

Control I/O Wiring Block Diagram Notes

(1) See Digital Input Selection for Start Source on page 49 for more information on configuring the digital inputs.

IMPORTANT I/O Terminal 01 is always a stop input. The stopping mode is

determined by the drive setting. See the tables below for more
information.
Start Method Stop Method
P046, P048, P050 [Start Source x] I/O Terminal 01 Stop Normal Stop
1 “Keypad” Coast
2 “DigIn TrmBlk” See t062, t063 [DigIn TermBlk xx] below
Per P045
3 “Serial/DSI” Coast [Stop Mode]
4 “Network Opt” Coast
5 “EtherNet/IP” Coast

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Chapter 1 Installation/Wiring

Start Method Stop Method

t062, t063 [DigIn TermBlk xx] I/O Terminal 01 Stop Normal Stop
t064 [2-Wire Mode] is set to:
48 “2-Wire FWD” • 0, 1, or 2 = Coast
• 3 = per P045 [Stop Mode]
49 “3-Wire Start” Per P045 [Stop Mode] Per P045
t064 [2-Wire Mode] is set to: [Stop Mode]
50 “2-Wire REV” • 0, 1, or 2 = Coast
• 3 = per P045 [Stop Mode]
51 “3-Wire Dir” Per P045 [Stop Mode]

IMPORTANT The drive is shipped with a jumper that is installed between I/O
Terminals 01 and 11. Remove this jumper when using I/O Terminal
01 as a stop or enable input.

(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a
maintained input for I/O Terminal 03 to change direction.
(3) When using an opto output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to
prevent damage to the output.

Control I/O Terminal Designations

No. Signal DefaultDescription Parameter
R1 Relay 1 N.O. Fault Normally open contact for output relay.
t076
R2 Relay 1 Common Fault Common for output relay.
R5 Relay 2 Common MotorRunning
Common for output relay.
t081
R6 Relay 2 N.C. MotorRunning
Normally closed contact for output relay.
Three wire stop. However, it functions as a stop under all
01 Stop Coast input modes and cannot be disabled. P045(1)
Used to initiate motion and also can be used as a
programmable digital input. It can be programmed with P045, P046,
02 DigIn TermBlk 02/ Run FWD t062 [DigIn TermBlk 02] as three wire (Start/Dir with Stop) P048, P050,
Start/Run FWD or two wire (Run FWD/Run REV) control. Current A544, t062
consumption is 6 mA.
Used to initiate motion and also can be used as a
programmable digital input. It can be programmed with
DigIn TermBlk 03/
03 Dir/Run REV Run REV t063 [DigIn TermBlk 03] as three wire (Start/Dir with Stop) t063
or two wire (Run FWD/Run REV) control. Current
consumption is 6 mA.
Return for digital I/O. Electrically isolated (along with the
04 Digital Common – –
digital I/O) from the rest of the drive.
05 DigIn TermBlk 05 Preset Freq Program with t065 [DigIn TermBlk 05]. t065
Current consumption is 6 mA.
06 DigIn TermBlk 06 Preset Freq Program with t066 [DigIn TermBlk 06]. t066
Current consumption is 6 mA.
Start Source 2 Program with t067 [DigIn TermBlk 07].
DigIn TermBlk 07/ Also functions as a Pulse Train input for reference or
07 Pulse In + Speed t067
Reference2 speed feedback. Requires an NPN pulse input. Maximum
frequency is 100 kHz. Current consumption is 6 mA.
08 DigIn TermBlk 08 Jog Forward Program with t068 [DigIn TermBlk 08]. t068
Current consumption is 6 mA.
This terminal is tied to the RJ45 port shield. Tie this
C1 C1 – terminal to a clean ground to improve noise immunity –
when using external communication peripherals.
C2 C2 – This is the signal common for the communication signals. –
S1 Safety 1 – Safety input 1. Current consumption is 6 mA. –
S2 Safety 2 – Safety input 2. Current consumption is 6 mA. –
+24V supply for safety circuit. Internally tied to the +24V
S+ Safety +24V – –
DC source (Pin 11).
Referenced to Digital Common.
11 +24V DC – Drive supplied power for digital inputs. –
Maximum output current is 100 mA.

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Control I/O Terminal Designations (Continued)

No. Signal Default Description Parameter
Referenced to Analog Common.
12 +10V DC – Drive supplied power for 0...10V external potentiometer. P047, P049
Maximum output current is 15 mA.
For external 0…10V (unipolar) or ±10V (bipolar) input P047, P049,
supply or potentiometer wiper. t062, t063,
13 ±10V In Not Active Input impedance: t065, t066,
Voltage source = 100 kΩ t093, A459,
Allowable potentiometer resistance range = 1...10 kΩ A471
Return for the analog I/O. Electrically isolated (along with
14 Analog Common – –
the analog I/O) from the rest of the drive.
P047, P049,
For external 4…20 mA input supply. t062, t063,
15 4…20mA In Not Active Input impedance = 250 Ω t065, t066,
A459, A471
The default analog output is 0…10V. To convert a current
value, change the Analog Output jumper to 0…20 mA.
Program with t088 [Analog Out Sel]. Maximum analog
16 Analog Output OutFreq 0…10 value can be scaled with t089 [Analog Out High]. t088, t089
Maximum Load:
4…20 mA = 525 Ω (10.5V)
0…10V = 1 kΩ (10 mA)
Program with t069 [Opto Out1 Sel]. t069, t070,
17 Opto Output 1 MotorRunning Each Opto-Output is rated 30V DC 50 mA (Non-inductive). t075
At Frequency Each Opto-Output is[Opto
Program with t072 Out2 Sel]. t072, t073,
18 Opto Output 2 rated 30V DC 50 mA (Non-inductive). t075
The emitters of the Optocoupler Outputs (1 and 2) are tied
19 Opto Common – together at Optocoupler Common. Electrically isolated –
from the rest of the drive.
(1) Setting is specific to PowerFlex 525 drives only.

I/O Wiring Examples

I/O Connection Example
P047 [Speed Reference1] = 5 “0-10V Input”

12
Potentiometer 13
1...10 kΩ Pot. 14
Recommended
(2 W minimum)

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Chapter 1 Installation/Wiring

I/O Wiring Examples (Continued)

I/O (Continued) Connection Example
Bipolar
P047 [Speed Reference1] = 5 “0-10V Input” Unipolar (Voltage)
and t093 [10V Bipolar Enbl] = 1 “Bi-Polar In” P047 [Speed Reference1] = 5 “0-10V Input”

±10V 13 + 13
Common 14 Common 14

Analog Input
0…10V, 100k Ω
impedance Unipolar (Current)
4…20 mA, 250 Ω P047 [Speed Reference1] = 6 “4-20mA Input”
impedance
PowerFlex 523 Series A, PowerFlex 523 Series B
PowerFlex 525

+ 13
14 14 4-20 mA
Common Common

Analog In
+ 15

0-10V

Wire the PTC and External Resistor (typically matched to the PTC Hot Resistance) to I/O
Terminals 12, 13, 14.
Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11.
t065 [DigIn TermBlk 05] = 12 “Aux Fault”
t081 [Relay Out 2 Sel] = 10 “Above Anlg V”
t082 [Relay Out 2 Level] = % Voltage Trip

R5
Analog Input, PTC R6
For Drive Fault
11
Re 12
13 RPTC (hot)
%VTrip = X 100
14 RPTC (hot) + Re
RPTC

05

Pulse Train Input

PowerFlex 523 PowerFlex 523 PowerFlex 525
t065 [DigIn TermBlk 05]
= 52
PowerFlex 525
t067 [DigIn TermBlk 07]
DigIn TermBlk 05 Sel

DigIn TermBlk 07 Sel

Pulse In Pulse In
= 52
Common 04 Common 04
Use P047, P049, and Pulse In 05
Pulse In
P051 [Speed Digital
Input
Digital
Input
Referencex] to select 07
pulse input.
Jumper for DigIn The device connected to terminal 5 (for PowerFlex 523) or terminal 7 (for PowerFlex 525)
TermBlk 05 or 07 Sel needs to be NPN or push-pull output driver.
must be moved to Pulse
In.

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I/O Wiring Examples (Continued)

I/O (Continued) Connection Example
2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)
Nonreversing
P046 [Start Source 1] =
2 and t062 [DigIn 01
TermBlk 02] = 48 11 02
Input must be active for Stop-Run
the drive to run. When Stop-Run
01 04
02
input is opened, the
drive stops as specified +24V Common
by P045 [Stop Mode].
If desired, a User
Supplied 24V DC power
source can be used. Each digital input draws 6 mA.
See the “External
Supply (SRC)” example.
Internal Supply (SNK)

01
2 Wire SNK Control - Stop-Run
02
03
Nonreversing 04

2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)

Run FWD/Run REV
P046 [Start Source 1] =
2, t062 [DigIn TermBlk 01
02] = 48 and t063 11 Stop-Run
02
[DigIn TermBlk 03] = 50 Forward 03
Input must be active for 01 04
the drive to run. When 02 Stop-Run
Reverse
input is opened, the Stop-Run
03
drive stops as specified Forward
+24V Common
by P045 [Stop Mode].
If both Run Forward and Stop-Run
Run Reverse inputs are Reverse
closed at the same Each digital input draws 6 mA.
time, an undetermined
state could occur.
Internal Supply (SNK)

01
2 Wire SNK Control - Stop-Run
02
03
Run FWD/Run REV Forward
04
Stop-Run
Reverse

3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)

Non-Reversing
P046 [Start Source 1] = Stop 11
2, t062 [DigIn TermBlk Stop 01
02] = 49 and t063 01
02
[DigIn TermBlk 03] = 51 Start 02 Start
A momentary input 04
starts the drive. A stop
input to I/O Terminal 01 +24V Common
stops the drive as
specified by P045 [Stop
Mode]. Each digital input draws 6 mA.

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Chapter 1 Installation/Wiring

I/O Wiring Examples (Continued)

I/O (Continued) Connection Example
Internal Supply (SNK)

Stop 01
3 Wire SNK Control - 02
Non-Reversing Start
04

3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC)

Reversing
P046 [Start Source 1] = 11
2, t062 [DigIn TermBlk Stop 01
02] = 49 and t063 Stop
02
[DigIn TermBlk 03] = 51 01
Start
03
02
A momentary input 03
04
starts the drive. A stop Start Direction
input to I/O Terminal 01
stops the drive as Direction
+24V Common
specified by P045 [Stop
Mode]. I/O Terminal 03 Each digital input draws 6 mA.
determines direction.
Internal Supply (SNK)

Stop 01
3 Wire SNK Control - 02
03
Reversing Start
04
Direction

Opto Output (1 & 2)(1) Opto-Output 1

t069 [Opto Out1 Sel]
determines Opto-
Output 1 (I/O Terminal
17) operation.
t072 [Opto Out2 Sel]
determines Opto-
Output 2 (I/O Terminal 17
18) operation. CR
When using Opto-Output 19
with an inductive load
such as a relay, install a +24V Common
recovery diode parallel
to the relay as shown, to Each Opto-Output is rated 30V DC 50 mA (Non-inductive).
prevent damage to the
output.
t088 [Analog Out Sel] = 0...23
The Analog Output Select jumper must be set to match the analog output signal mode set
(2)
in t088 [Analog Out Sel].
Analog Output
t088 [Analog Out Sel] PowerFlex 523 Series B PowerFlex 525
determines analog
output type and drive
conditions.
0…10V, 1k Ω min Common 14 Common 14
0…20 mA/4…20 mA, + 15
525 Ω 0…20 mA/ + 16
4…20 mA, 525 Ω max

(1) Feature is specific to PowerFlex 525 drives only.

(2) Feature is not applicable to PowerFlex 523 series A drives.

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Typical Multiple Drive Connection Examples

Input/Output Connection Example
02 04 02 04 02 04

Customer Inputs Optional Ground Connection

Multiple Digital Input
Connections When connecting a single input such as Run, Stop, Reverse, or Preset Speeds to multiple
Customer Inputs can be drives, it is important to connect I/O Terminal 04 common together for all drives. If they
wired per External are to be tied into another common (such as earth ground or separate apparatus ground)
Supply (SRC). only one point of the daisy chain of I/O Terminal 04 should be connected.

ATTENTION: I/O Common terminals should not be tied

together when using SNK (Internal Supply) mode. In SNK
mode, if power is removed from one drive, inadvertent
operation of other drives that share the same I/O
Common connection may occur.

12 13 14 13 14 13 14

Multiple Analog
Connections
Remote Potentiometer Optional Ground Connection
When connecting a single potentiometer to multiple drives, it is important to connect I/O
Terminal 14 common together for all drives. I/O Terminal 14 common and I/O Terminal 13
(potentiometer wiper) should be daisy chained to each drive. All drives must be powered
up for the analog signal to be read correctly.

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Start and Speed Reference Start Source and Speed Reference Selection
Control
The start and drive speed command can be obtained from a number of
different sources. By default, start source is determined by P046 [Start Source
1] and drive speed source is determined by P047 [Speed Reference1]. However,
various inputs can override this selection, See below for the override priority.

Drive will start and

run at Purge Speed.
Purge Input Enabled Yes
AND Active Direction is always
FORWARD.

No
Drive will start and run at
Jog Speed.

Yes Yes Direction is from Terminal

Jog Input Enabled Drive stopped Block REV terminal (03),
AND Active (NOT running) Comms,
OR
No FWD/REV determined by
Jog FWD/Jog REV command.
No

[Speed Referencex]
Yes = 11 or 12 (PIDx Output) Yes
Preset Inputs Active AND
[PID x Ref Sel]
= 7 (Preset Freq)

No

Run as specified by Run as specified by

No
[Preset Freq x]. [PIDx Output].

Start and Direction Start and Direction

commands come from commands come from
[Start Source x]. [Start Source x].

Yes Yes Start and Direction

Run as specified by [Speed Reference3] [Start Source 3] command from
[Speed Reference3]. select(1) select(1) [Start Source 3].(2)

No No

Start and Direction

Run as specified by Yes Yes
[Speed Reference2] [Start Source 2] command from
[Speed Reference2]. select(1) select(1) [Start Source 2].(2)

No No

Run as specified by Start and Direction

[Speed Reference1]. command from
[Start Source 1].

(1) [Start Source 2/3] and [Speed Reference2/3] can be selected by the control terminal block or communication commands.
(2) See Digital Input Selection for Start Source on page 49 for information on selecting the correct digital input.

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Digital Input Selection for Start Source

If P046, P048 or P050 [Start Source x] has been set to 2, “DigIn TermBlk”, then
t062 and t063 [DigIn TermBlk xx] must be configured for 2-Wire or 3-Wire
control for the drive to function properly.

[Start Source x]

[Start Source x] Yes [DigIn TermBlk Yes

Start and Direction
= 2 (DigIn TrmBlk) 02/03] = 48/49/50/51 command from
(2-Wire or Terminal Block.
3-Wire)

No No

Start and Direction Drive will not start.

command from
[Start Source x].

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Chapter 1 Installation/Wiring

Accel/Decel Selection

The Accel/Decel rate can be obtained by various methods. The default rate is
determined by P041 [Accel Time 1] and P042 [Decel Time 1].

Alternative Accel/Decel rates can be made through digital inputs,

communications and/or parameters. See below for the override priority.

Purge Input Enabled Yes Accel/Decel always

AND Active Accel/Decel 1.

No

Active [DigIn TermBlk xx] Yes [Sync Time] is used

= 32 (Sync Enable) for Accel/Decel rate

No

Traverse active if Traverse Inc/Dec

Yes
[Max Traverse] > 0 Hz is used for
Accel/Decel rate

No

Terminal Block Jog Yes Drive stopped Yes Accel/Decel from

Input Enabled AND (NOT running) [Jog Acc/Dec].
Active
No
No

Input(s) is Accel/Decel 2 is active

programmed as Yes
when input is selected
Acc/Dec by Accel and Decel input.
(2/3/4)

No

Accel/Decel 1/2/3/4 is
Is speed controlled Yes
selected by the default
by [Preset Freq x] [Preset Freq x] setting.

No

Active
[Speed Referencex]
= Comms Accel/Decel 1 or 2 is
and Yes
[Start Source x] selected according
= 3 “Serial/DSI” or to Comms.
4 “Network Opt” or
5 “EtherNet/IP”

No

Active Accel/Decel 1/2/3/4 is

[Speed Referencex] Yes
selected according to
= 13 (Step Logic)(1) Step Logic

No

Drive uses Accel 1

and Decel 1.

(1) Setting is specific to PowerFlex 525 drives only.

50 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 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.

CE Declarations of Conformity 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.
Pollution Degree Ratings According to EN 61800-5-1
Pollution Description
Degree
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
2 caused by condensation is to be expected, when the drive is out of operation.

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 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 61800-5-2 – Adjustable speed electrical power drive systems - Part 5-
2: Safety requirement – Functional.

See Appendix G for installation consideration that is related to Machinery

Directive.

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.

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Chapter 1 Installation/Wiring

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.
Pollution Degree Ratings According to EN 61800-5-1
Pollution Description
Degree
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
2 that is caused by condensation is to be expected, when the drive is out of operation.

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 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 61800-5-2 – Adjustable speed electrical power drive systems – Part
5-2: Safety requirement – Functional.

See Appendix G for installation consideration related to the Supply of

Machinery (Safety) Regulations.

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.

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
on page 51 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.

52 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Chapter 1 Installation/Wiring

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

voltage networks, which 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 54) to prevent interference, in addition to the
installation requirements of this document.

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.
• 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 ensure 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 as well as capacitive currents.
• Use of line filters in ungrounded systems is not recommended.
• In CE installations, input power must be a Balanced Wye with Center
Ground configuration for EMC compliance.

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 18.
• 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.

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

protective earthing conductor which may reduce the ability of RCDs
(residual current-operated protective devices) or RCMs (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.

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

• The drive must be earthed (grounded) as described in Connections and
Grounding on page 54. See General Grounding Requirements on
page 20 for additional grounding recommendations.

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Chapter 1 Installation/Wiring

• 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.
or
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 PowerFlex 520-Series RF Emission Compliance and
Installation Requirements on page 55 for compliance with radio
frequency emission limits for the specific standard and installation
environment.
Connections and Grounding

Shielded enclosure(1)

Esc Sel IP 30/NEMA 1/UL Type 1

option kit or EMC kit

EMI fittings and metal conduit

EMI filter
L1 L1' R/L1 U/T1
L2 L2' S/L2 V/T2
L3 L3' T/L3 W/T3

Enclosure ground connection Shielded motor cable

Building structure steel

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

54 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Chapter 1 Installation/Wiring

PowerFlex 520-Series RF Emission Compliance and Installation Requirements

Standard/Limits
EN61800-3 Category C2 EN61800-3 Category C3
Filter Type EN61800-3 Category C1 EN61000-6-4 (I ≤ 100 A)
EN61000-6-3 CISPR11 Group 1 Class A CISPR11 Group 1 Class A
CISPR11 Group 1 Class B (Input power ≤ 20 kVA) (Input power > 20 kVA)
Internal – 10 m (33 ft) 20 m (66 ft)
(1) 30 m (16 ft) 150 m (492 ft) 150 m (492 ft)
External
(1) See EMC Line Filters on page 175 and page 195 for more information on optional external filters.

Additional Installation Requirements

This section provides information on additional requirements for category C1

and C2 installation, such as enclosures and EMC cores.

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 category C3 requirements.

Additional Installation Requirements

Category C1 Category C2
Frame
Size Conduit or Shielded EMC Cores Required Conduit or Shielded EMC Cores Required
Enclosure(1) Cable @ Input (Included with product) Enclosure(1) Cable @ Input (Included with product)
100...120V AC (-15%, +10%) – 1-Phase Input with External EMC Filter, 0...120V 1-Phase Output
A No No No No No No
B No No No No No 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(2)
A * * * Yes No No
B * * * Yes No No
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
D Yes 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
C Yes 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(2)
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

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Chapter 1 Installation/Wiring

Additional Installation Requirements (Continued)

Category C1 Category C2
Frame
Size Conduit or Shielded EMC Cores Required Conduit or Shielded EMC Cores Required
Enclosure(1) Cable @ Input (Included with product) Enclosure(1) Cable @ Input (Included with product)
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) Minimum EMC enclosure dimension (60 x 55 x 80 cm) with a shielding attenuation of at least 92 dB.
(2) An (*) indicates that EMC requirements are not met.

Recommended Placement of EMC Cores

Frame A Frame B Frame C Frame D Frame E
With optional EMC plate (25-EMC-Fx)

Ground
cable

CORE-E-1
CORE-E-3
CORE-xx-A-1 CORE-xx-B-1 CORE-xx-C-1 CORE-xx-D-1
CORE-E-2
CORE-xx-A-2 CORE-xx-B-2 CORE-xx-C-2 CORE-xx-D-2 CORE-E-4

Without EMC plate

Ground
cable

CORE-E-1 CORE-E-3
CORE-E-4
CORE-E-2
CORE-xx-x-1 CORE-xx-x-2

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

Shows contact to Secure EMC core by

shielded layer using cable/zip ties

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

All Frame sizes

Incoming power
EMC filter Drive Motor

Input core Output core

56 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Chapter 2

Startup

This chapter describes how to startup the PowerFlex 520-series drive. To

simplify drive setup, the most commonly programmed parameters are
organized in a single Basic Program Group.

Topic Page
Prepare for Drive Startup 57
Display and Control Keys 59
Viewing and Editing Parameters 61
Drive Programming Tools 62
Smart Startup with Basic Program Group Parameters 63
LCD Display with QuickView Technology 65
Using the USB Port 65

IMPORTANT Read the General Precautions on page 13 section 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.

Prepare for Drive Startup 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 drive’s catalog number. 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 523 Control I/O Terminal

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 57

Chapter 2 Startup

Block on page 37 and PowerFlex 525 Control I/O Terminal Block on

page 41 for location.

IMPORTANT The default control scheme is Source (SRC). The Stop terminal is
jumpered to allow starting from the keypad or comms. If the control
scheme is changed to Sink (SNK), the jumper must be removed from I/O
Terminals 01 and 11 and installed between I/O Terminals 01 and 04.
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.
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. Ensure the MOV jumpers are in the correct position. See AC
Supply Source Considerations on page 19 for more information.
12. Apply power and reset the drive and communication adapters to factory
default settings. To reset the drive, see parameter P053 [Reset to
Defaults]. To reset the communication adapters, see the user manual of
the adapter for more information.
13. Configure the basic program parameters that are related to the motor.
See Smart Startup with Basic Program Group Parameters on page 63.
14. Complete the autotune procedure for the drive. See parameter P040
[Autotune] for more information.
15. If you are replacing a drive and have a backup of the parameter settings
obtained using the USB utility application, use the USB utility
application to apply the backup to the new drive. See Using the USB Port
on page 65 for more information.

Otherwise, set the necessary parameters for your application using the
LCD keypad interface, Connected Components Workbench™ software,
or RSLogix™, or Studio 5000 Logix Designer application if using an
Add-on Profile through EtherNet/IP.
• Configure the communication parameters needed for the application
(node number, IP address, Datalinks in and out, communication rate,
speed reference, start source, and so on). Record these settings for
your reference.
• Configure the other drive parameters that are needed for the drive
analog and digital I/O to work correctly. Verify the operation. Record
these settings for your reference.
16. Verify that the drive and motor perform as specified.
• Verify that the Stop input is present or the drive does not start.

IMPORTANT If I/O Terminal 01 is used as a stop input, the jumper between I/O
Terminals 01 and 11 must be removed.
• Verify that the drive is receiving the speed reference from the correct
place and that the reference is scaled correctly.
• Verify that the drive is receiving start and stop commands correctly.
• Verify that input currents are balanced.
• Verify that motor currents are balanced.
17. Save a backup of the drive settings using the USB utility application. See
Using the USB Port on page 65 for more information.

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 Chapter 2 Startup

Start, Stop, Direction, and Speed Control

Factory default parameter values allow the drive to be controlled from the
keypad. No programming is required to start, stop, change direction and
control speed directly from the keypad.

IMPORTANT To disable reverse operation, see A544 [Reverse Disable].

If a fault appears on power-up, see Fault Descriptions on page 159 for an

explanation of the fault code.

Variable Torque Fan/Pump Applications

For improved motor and drive performance, tune the motor in SVC mode
using parameter P040 [Autotune]. If V/Hz mode is selected, use parameter
A530 [Boost Select] to adjust the boost.

Display and Control Keys

PowerFlex 523
Menu Parameter Group and Description
Basic Display
Commonly viewed drive operating conditions.
Basic Program
FWD

Commonly used programmable functions.

Terminal Blocks
Programmable terminal functions.
Communications
Esc Sel Programmable communication functions.
Logic (PowerFlex 525 only)
Programmable logic functions.
Advanced Display
Advanced drive operating conditions.
PowerFlex 525 Advanced Program
Remaining programmable functions.
Network
Network functions that are shown only when a
FWD comm card is used.
ENET LINK Modified
EtherNet/IP
Functions from the other groups with values
changed from default.
Fault and Diagnostic
Consists of list of codes for specific fault conditions.
Esc Sel
AppView and CustomView
Functions from the other groups organized for
specific applications.

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Chapter 2 Startup

Control and Navigation Keys

Display Display State Description
Off Adapter is not connected to the network.
Adapter is connected to the network and drive is controlled
Steady
ENET (PowerFlex 525 only) through Ethernet.
Adapter is connected to the network but drive is not controlled
Flashing through Ethernet.
Off Adapter is not connected to the network.
LINK (PowerFlex 525 only) Steady Adapter is connected to the network but not transmitting data.
Flashing Adapter is connected to the network and transmitting data.

LED LED State Description

FAULT Flashing Red Indicates that drive is faulted.

Key Name Description

Up Arrow Scroll through user-selectable display parameters or groups.
Down Arrow Increment values.

Back one step in programming menu.

Escape
Esc
Cancel a change to a parameter value and exit Program Mode.

Advance one step in programming menu.

Select
Sel Select a digit when viewing parameter value.

Advance one step in programming menu.

Enter Save a change to a parameter value.

Used to reverse direction of the drive. Default is active.

Reverse Controlled by parameters P046, P048, and P050 [Start Source x]
and A544 [Reverse Disable].
Used to start the drive. Default is active.
Start Controlled by parameters P046, P048, and P050 [Start Source x].
Used to stop the drive or clear a fault.
Stop This key is always active.
Controlled by parameter P045 [Stop Mode].
Used to control speed of drive. Default is active.
Potentiometer Controlled by parameters P047, P049, and P051
[Speed Referencex].

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 Chapter 2 Startup

Viewing and Editing The following is an example of basic integral keypad and display functions.
Parameters This example provides basic navigation instructions and illustrates how to
program a parameter.

Step Key Example Display

When power is applied, the last user-
selected Basic Display Group parameter
number is briefly displayed with flashing
1. characters. The display then defaults to FWD

that parameter’s current value. (Example

HERTZ

shows the value of b001 [Output Freq] with

the drive stopped.)

Press Esc to display the Basic Display

2. Group parameter number shown on power- Esc FWD
up. The parameter number flashes.

3. Press Esc to enter the parameter group

list. The parameter group letter flashes. Esc FWD

Press the Up Arrow or Down Arrow to scroll

4. through the group list (b, P, t, C, L, d, A, f or FWD
and Gx).

Press Enter or Sel to enter a group. The

5. right digit of the last viewed parameter in or Sel FWD
that group flashes.

6. Press the Up Arrow or Down Arrow to scroll or

through the parameter list.
FWD

Press Enter to view the value of the

parameter. VOLTS
7. FWD
Or
Press Esc to return to the parameter list.

Press Enter or Sel to enter Program Mode

8. and edit the value. The right digit flashes or Sel
VOLTS

and the word Program on the LCD display

FWD

lights up. PROGRAM

9. Press the Up Arrow or Down Arrow to or

VOLTS

change the parameter value.

FWD

PROGRAM

If desired, press Sel to move from digit to VOLTS

10. digit or bit to bit. The digit or bit that you Sel FWD
can change flashes. PROGRAM

Press Esc to cancel a change and exit VOLTS

Program Mode. FWD
Or
11. Press Enter to save a change and exit Esc or or
Program Mode. VOLTS

The digit stops flashing and the word FWD

Program on the LCD display turns off.

Press Esc to return to the parameter list.
Continue to press Esc to back out of the
programming menu.
12. If pressing Esc does not change the Esc FWD
display, then b001 [Output Freq] is
displayed. Press Enter or Sel to enter the
group list again.

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Chapter 2 Startup

Drive Programming Tools Some features in the PowerFlex 520-series drive are not supported by older
configuration software tools. It is recommended that customers using such
tools migrate to RSLogix 5000 software (version 17.0 or later) or Studio 5000
Logix Designer (version 21.0 or later) application with AOP, or Connected
Components Workbench software version 5.0 or later to enjoy a richer, full-
featured configuration experience. For Automatic Device Configuration (ADC)
support, RSLogix 5000 software version 20.0 or later is required.

Description Catalog Number/Release Version

(1) Version 5.0 or later
Connected Components Workbench software
Logix Designer application Version 21.0 or later
RSLogix 5000 software Version 17.0 or later
Built-in USB software tool –
Serial Converter Module(2) 22-SCM-232
(2) 1203-USB
USB Converter Module
(2) 22-HIM-C2S
Remote Panel Mount, LCD Display
(2) 22-HIM-A3
Remote Handheld, LCD Display
(1) Available to download at rok.auto/ccw.
(2) Does not support the new dynamic parameter groups (AppView®, CustomView™), and CopyCat functionality is limited to the
linear parameter list.

Language Support
RSLogix 5000/ Connected Components
Language Keypad/LCD Display Logix Designer Application Workbench Software
English Y Y Y
French Y Y Y
Spanish Y Y Y
Italian Y Y Y
German Y Y Y
Japanese – Y –
Portuguese Y Y –
Chinese Simplified – Y Y
Korean – Y –
Polish(1) Y – –
(1) Y – –
Turkish
(1) Y – –
Czech
(1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech will be modified.

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 Chapter 2 Startup

Smart Startup with Basic The PowerFlex 520-series drive is designed so that startup is simple and
Program Group Parameters efficient. The Basic Program Group contains the most commonly used
parameters. See Programming and Parameters on page 69 for detailed
descriptions of the parameters that are listed here and the full list of available
parameters.

Basic Program Group Parameters

= Stop drive before changing this parameter.

PF 525 = Parameter is specific to PowerFlex 525 drives only.
No. Parameter Min/Max Display/Options Default
[Language] 1/15 1 = English
2 = Français
3 = Español
4 = Italiano
5 = Deutsch
6 = Reserved
7 = Português
P030 Selects the language displayed. 8 = Reserved 1
Important: The setting takes effect after the 9 = Reserved
drive is power cycled. 10 = Reserved
11 = Reserved
12 = Polish
13 = Reserved
14 = Turkish
15 = Czech
10V (for 200V Drives), 20V
[Motor NP Volts] (for
P031 400V Drives), 25V (for
600V Drives)/Drive Rated 1V Based on Drive Rating
Volts
Sets the motor nameplate rated volts.
P032 [Motor NP Hertz] 15/500 Hz
1 Hz 60 Hz
Sets the motor nameplate rated frequency.
[Motor OL Current] 0.0/(Drive Rated Amps x 2)
P033 0.1 A Based on Drive Rating
Sets the motor nameplate overload current.
[Motor NP FLA] 0.0/(Drive Rated Amps x 2)
P034 0.1 A Drive Rated Amps
Sets the motor nameplate FLA.
[Motor NP Poles] 2/40
P035 1 4
Sets the number of poles in the motor.
P036 [Motor NP RPM] 0/24000 rpm
1 rpm 1750 rpm
Sets the rated nameplate rpm of motor.
[Motor NP Power] 0.00/Drive Rated Power
P037
PF 525 Sets the motor nameplate power. Used in PM 0.01 kW Drive Rated Power
regulator.
[Torque Perf Mode] 0/4
Selects the motor control mode.
0 = “V/Hz”
(1) Setting is specific to PowerFlex 525 drives only. 1 = “SVC”
P039 (2) Setting is available in PowerFlex 525 FRN 5.xxx 2 = “Economize”
and later. (1) 1
(3) When P039 [Torque Perf Mode] is set to 4 and 3 = “Vector”
A535 [Motor Fdbk Type] is set to 0, 1, 2 or 3, the 4 = “PM Control”(1)(2)(3)
drive is in open loop PM motor control mode. 5 = “SynRM”
When P039 [Torque Perf Mode] is set to 4 and
A535 [Motor Fdbk Type] is set to 4 or 5, the
drive is in closed loop PM motor control mode.

P040 [Autotune] 0/2 0 = “Ready/Idle”

Enables a static (not spinning) or dynamic (motor 1 = “Static Tune” 0
spinning) autotune. 2 = “Rotate Tune”
[Accel Time 1] 0.00/600.00 s
P041 Sets the time for the drive to accel from 0 Hz to 0.01 s 10.00 s
[Maximum Freq].

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Basic Program Group Parameters (Continued)

= Stop drive before changing this parameter.

= Parameter is specific to PowerFlex 525 drives only.
PF 525

No. Parameter Min/Max Display/Options Default

[Decel Time 1] 0.00/600.00 s
P042 Sets the time for the drive to decel from 0.01 s 10.00 s
[Maximum Freq] to 0 Hz.
P043 [Minimum Freq] 0.00/500.00 Hz
0.01 Hz 0.00 Hz
Sets the lowest frequency the drive outputs.
P044 [Maximum Freq] 0.00/500.00 Hz
0.01 Hz 60.00 Hz
Sets the highest frequency the drive outputs.
[Stop Mode] 0/11 0= “Ramp, CF”(1)
1= “Coast, CF”(1)
Stop command for normal stop. 2= “DC Brake, CF”(1)
Important: I/O Terminal 01 is always a stop 3= “DCBrkAuto,CF”(1)
input. The stopping mode is determined by the 4= “Ramp”
P045 drive setting. 5= “Coast” 0
Important: The drive is shipped with a jumper 6= “DC Brake”
that is installed between I/O Terminals 01 and 11. 7= “DC BrakeAuto”
Remove this jumper when using I/O Terminal 01
as a stop or enable input. 8= “Ramp+EM B,CF”(1)
9= “Ramp+EM Brk”
(1) Stop input also clears active fault. 10= “PointStp,CF”(1)
11= “PointStop”
[Start Source 1] 1/5
Sets the default control scheme that is used to (1)
P046, start the drive unless overridden by P048 [Start 1 = “Keypad” P046 = 1
P048, Source 2] or P050 [Start Source 3]. 2 = “DigIn TrmBlk”(2) P048 = 2
P050 (1) When active, the Reverse key is also active unless 3 = “Serial/DSI” P050 = 3 (PowerFlex 523)
disabled by A544 [Reverse Disable].
4 = “Network Opt” 5 (PowerFlex 525)
(3)
(2) If “DigIn TrmBlk” is selected, ensure that the digital 5 = “EtherNet/IP”
inputs are properly configured.
(3) Setting is specific to PowerFlex 525 drives only.
[Speed Reference1] 1/16 1= “Drive Pot”
2= “Keypad Freq”
3= “Serial/DSI”
4= “Network Opt”
5= “0-10V Input”
6= “4-20mA Input”
7= “Preset Freq”
P047 = 1
P047, Sets the default speed command of the drive 8= “Anlg In Mult”(1) P049 = 5
P049, unless overridden by P049 [Speed Reference2] 9= “MOP” P051 = 3 (PowerFlex 523)
P051 or P051 [Speed Reference3]. 10= “Pulse Input”
11= “PID1 Output” 15 (PowerFlex 525)
(1) Setting is specific to PowerFlex 525 drives only.
12= “PID2 Output”(1)
13= “Step Logic”(1)
14= “Encoder”(1)
15= “EtherNet/IP”(1)
16= “Positioning”(1)
[Average kWh Cost] 0.00/655.35
P052 0.01 0.00
Sets the average cost per kWh.
[Reset To Defaults] 0/4
Resets parameters to their factory defaults
values. After a Reset command, the value of this 0 = “Ready/Idle”
P053 parameter returns to zero. 1 = “Param Reset”
(1) Power cycle of the drive, NO parameters are 2 = “Factory Rset” 0
reset. 3 = “Power Reset”
(2) Setting is available in PowerFlex 525 FRN 5.xxx 4 = “Module Reset”(1)(2)(3)
and later.
(3) Setting is available in PowerFlex 523 FRN 3.xxx
and later.

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 Chapter 2 Startup

LCD Display with QuickView QuickView® technology enables text to scroll across the LCD display of the
Technology PowerFlex 520-series drive. This allows you to easily configure parameters,
troubleshoot faults, and view diagnostic items without using a separate device.

Use parameter A556 [Text Scroll] to set the speed at which the text scrolls
across the display. Select 0 “Off” to turn off text scrolling. See Language
Support on page 62 for the languages supported by the PowerFlex 520-series
drive.

Using the USB Port The PowerFlex 520-series drive has a USB port that connects to a PC for
upgrading drive firmware or uploading/downloading a parameter
configuration.

IMPORTANT PowerFlex 525 with firmware revision 7.001 and later supports the USB
application with Windows® 8 and 10.

MainsFree Programming

The MainsFree™ programming feature allows you to quickly configure your

PowerFlex 520-series drive without having to power up the control module or
install additional software. Simply connect the control module to your PC with
a USB Type B cable and you can download a parameter configuration to your
drive. You can also easily upgrade your drive with the latest firmware.

Connecting a PowerFlex 520-series drive to a PC

Control Module

USB port
USB Type B cable

Connect to PC Connect to Control Module

When connected, the drive appears on the PC and contains two files:
• GUIDE.PDF
This file contains links to relevant product documentation and software
downloads.
• PF52XUSB.EXE
This file is an application to flash upgrade firmware or upload/download
a parameter configuration.

It is not possible to delete these files or add more to the drive.

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Chapter 2 Startup

Double-click the PF52XUSB.EXE file to launch the USB utility application. The
main menu is displayed. Follow the program instructions to upgrade the
firmware or upload/download configuration data.

IMPORTANT Make sure that your PC is powered by an AC power outlet or has a fully
charged battery before starting any operation. This prevents the
operation from terminating before completion due to insufficient power.

Limitation in Downloading .pf5 Configuration Files with the USB Utility Application

Before downloading a .pf5 configuration file using the USB utility application,
parameter C169 [MultiDrv Sel] in the destination drive must match the
incoming configuration file. If it does not, set the parameter manually to
match and then cycle drive power. Also, the drive type of the .pf5 file must
match the drive.

This means you cannot apply a multi-drive configuration using the USB utility
application to a drive in single mode (parameter C169 [MultiDrv Sel] set to 0
“Disabled”), or apply a single mode configuration to a drive in multi-drive
mode.

Using Drive Startup in CCW To use the PowerFlex 525 Startup Wizard in Connected Components
or Logix Designer Workbench software to automatically configure the parameters, make sure
you have installed the following:
Application
• PowerFlex 525 drive firmware revision 5.001 or later.
• PowerFlex 525 drive Add-on Profile 5.07 or later.
• Latest drive database for Connected Components Workbench software.

For instructions, see Using Drive Startup in CCW or Logix Designer

Application on page 66.

Alternatively, you can manually configure the parameters by using the drive
keypad. For instructions, see Manual Configuration Using Drive Keypad on
page 258.

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 Chapter 2 Startup

1. From Connected Components Workbench software, click the Wizard

Browser icon.

2. In the Available Wizards dialog box, click PowerFlex 525 Startup Wizard,
then click Select.

3. Before tuning the drive, it is recommended to reset all parameters to

their default values. Select the option shown below.

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Chapter 2 Startup

4. Complete each step in the Startup Wizard to configure the drive.

IMPORTANT Follow the Startup Wizard steps exactly. If not, unexpected

results can occur.

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 Chapter 3

Programming and Parameters

This chapter provides a complete listing and description of the PowerFlex 520-
series drive parameters. Parameters are programmed (viewed/edited) using
either the drive’s built-in keypad, RSLogix 5000 software version 17.0 or later,
Studio 5000 Logix Designer application version 21.0 or later, or Connected
Components Workbench software version 5.0 or later. The Connected
Components Workbench software can be used offline (through USB) to upload
parameter configurations to the drive or online (through Ethernet
connection).

Limited functionality is also available when using the Connected Components

Workbench software online (through DSI and serial converter module), a
legacy external HIM, or legacy software online (DriveTools™ SP). When using
these methods, the parameter list can only be displayed linearly, and there is
no access to communications option card programming.

Topic Page
About Parameters 69
Parameter Groups 71
Basic Display Group 76
Basic Program Group 82
Terminal Block Group 88
Communications Group 100
Logic Group 106
Advanced Display Group 109
Advanced Program Group 114
Network Parameter Group 142
Modified Parameter Group 142
Fault and Diagnostic Group 142
AppView Parameter Groups 150
CustomView Parameter Group 151
Parameter Cross-reference by Name 152

About Parameters To configure a drive to operate in a specific way, drive parameters may have to
be set. Three types of parameters exist:
• ENUM
ENUM parameters allow a selection from two or more items. Each item
is represented by a number.
• Numeric Parameters
These parameters have a single numerical value (0.1V).
• Bit Parameters
Bit parameters have five individual digits that are associated with

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Chapter 3 Programming and Parameters

features or conditions. If the digit is 0, the feature is off or the condition

is false. If the digit is 1, the feature is on or the condition is true.

Some parameters are marked as follows.

= Stop drive before changing this parameter.

32 = 32-bit parameter.

PF 525 = Parameter is specific to PowerFlex 525 drives only.

32-bit Parameters

Parameters marked 32-bit will have two parameter numbers when using RS-
485 communications and programming software. For example, parameters
b010 [Process Display] and b011 [Process Fract] are scaled and displayed as
follows.
• P043 [Minimum Freq] = 0 Hz
• P044 [Maximum Freq] = 60 Hz
• A481 [Process Display Lo] = 0
• A482 [Process Display Hi] = 10

Using the formula

([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freqp])
Scaled Process Value (PV) =
[Maximum Freq] - [Minimum Freq]

when the drive is running at 10 Hz, the Process Value is 1.66.

On the drive LCD display, only parameter b010 [Process Display] is shown.

In Connected Components Workbench software, parameter b010 [Process

Display] and b011 [Process Fract] are shown separately.

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 Chapter 3 Programming and Parameters

Parameter Groups For an alphabetical listing of parameters, see Parameter Cross-reference by

Name on page 152.
Parameters List
Basic Display Output Voltage b004 Process Fract b011 Power Saved b018 Accum Cost Sav b025
DC Bus Voltage b005 Control Source b012 Elapsed Run Time b019 Accum CO2 Sav b026
Drive Status b006 Contrl In Status b013 Average Power b020 Drive Temp b027
Fault 1 Code b007 Dig In Status b014 Elapsed kWh b021 Control Temp b028
Output Freq b001 Fault 2 Code b008 Output RPM b015 Elapsed MWh b022 Control SW Ver b029
Commanded Freq b002 Fault 3 Code b009 Output Speed b016 Energy Saved b023
Output Current b003 Process Display b010 Output Power b017 Accum kWh Sav b024
Basic Program Motor NP Hertz P032 Voltage Class P038 Maximum Freq P044 Start Source 3 P050
Motor OL Current P033 Torque Perf Mode P039 Stop Mode P045 Speed Reference3 P051
Motor NP FLA P034 Autotune P040 Start Source 1 P046 Average kWh Cost P052
Motor NP Poles P035 Accel Time 1 P041 Speed Reference1 P047 Reset To Defalts P053
Language P030 Motor NP RPM P036 Decel Time 1 P042 Start Source 2 P048 Display Param P054
Motor NP Volts P031 Motor NP Power(1) P037 Minimum Freq P043 Speed Reference2 P049
Terminal Blocks Opto Out1 Sel(1) t069 Relay 1 Off Time t080 Anlg In 0-10V Lo t091 Sleep Time t102
Opto Out1 Level(1) t070 Relay Out2 Sel(1) t081 Anlg In 0-10V Hi t092 Wake Level t103
Opto Out1 LevelF t071 Relay Out2 Level(1) t082 10V Bipolar Enbl(1) t093 Wake Time t104
Opto Out2 Sel(1) t072 Relay Out2 LevelF(1) t083 Anlg In V Loss t094 Safety Open En(1) t105
DigIn TermBlk 02 t062 Opto Out2 Level(1) t073 Relay 2 On Time(1) t084 Anlg In4-20mA Lo t095 SafetyFlt RstCfg(1)(3) t106
DigIn TermBlk 03 t063 Opto Out2 LevelF t074 Relay 2 Off Time(1) t085 Anlg In4-20mA Hi t096
2-Wire Mode t064 Opto Out Logic(1) t075 EM Brk Off Delay t086 Anlg In mA Loss t097
DigIn TermBlk 05 t065 Relay Out1 Sel t076 EM Brk On Delay t087 Anlg Loss Delay t098
DigIn TermBlk 06 t066 Relay Out1 Level t077 Analog Out Sel(2) t088 Analog In Filter t099
DigIn TermBlk 07(1) t067 Relay Out1 LevelF t078 Analog Out High(2) t089 Sleep-Wake Sel t100
DigIn TermBlk 08(1) t068 Relay 1 On Time t079 Anlg Out Setpt(2) t090 Sleep Level t101
Communications EN Addr Sel(1) C128 EN Gateway Cfg 3(1) C139 EN Data In 1(1) C153 Opt Data In 4 C164
EN IP Addr Cfg 1(1) C129 EN Gateway Cfg 4(1) C140 EN Data In 2(1) C154 Opt Data Out 1 C165
EN IP Addr Cfg 2(1) C130 EN Rate Cfg(1) C141 EN Data In 3(1) C155 Opt Data Out 2 C166
EN IP Addr Cfg 3(1) C131 EN Comm Flt Actn(1) C143 EN Data In 4(1) C156 Opt Data Out 3 C167
Comm Write Mode C121 EN IP Addr Cfg 4(1) C132 EN Idle Flt Actn(1) C144 EN Data Out 1(1) C157 Opt Data Out 4 C168
Cmd Stat Select(1) C122 EN Subnet Cfg 1(1) C133 EN Flt Cfg Logic(1) C145 EN Data Out 2(1) C158 MultiDrv Sel C169
RS485 Data Rate C123 EN Subnet Cfg 2(1) C134 EN Flt Cfg Ref(1) C146 EN Data Out 3(1) C159 Drv 1 Addr C171
RS485 Node Addr C124 EN Subnet Cfg 3(1) C135 EN Flt Cfg DL 1(1) C147 EN Data Out 4(1) C160 Drv 2 Addr C172
Comm Loss Action C125 EN Subnet Cfg 4(1) C136 EN Flt Cfg DL 2(1) C148 Opt Data In 1 C161 Drv 3 Addr C173
Comm Loss Time C126 EN Gateway Cfg 1(1) C137 EN Flt Cfg DL 3(1) C149 Opt Data In 2 C162 Drv 4 Addr C174
RS485 Format C127 EN Gateway Cfg 2(1) C138 EN Flt Cfg DL 4(1) C150 Opt Data In 3 C163 DSI I/O Cfg C175
Logic(1) Stp Logic 4 L184 Stp Logic Time 4 L194 Step Units 1 L202 Step Units 5 L210
Stp Logic 5 L185 Stp Logic Time 3 L193 Step Units F 1 L203 Step Units F 5 L211
Stp Logic 6 L186 Stp Logic Time 4 L194 Step Units 2 L204 Step Units 6 L212
Stp Logic 7 L187 Stp Logic Time 5 L195 Step Units F 2 L205 Step Units F 6 L213
Stp Logic 0 L180 Stp Logic Time 0 L190 Stp Logic Time 6 L196 Step Units 3 L206 Step Units 7 L214
Stp Logic 1 L181 Stp Logic Time 1 L191 Stp Logic Time 7 L197 Step Units F 3 L207 Step Units F 7 L215
Stp Logic 2 L182 Stp Logic Time 2 L192 Step Units 0 L200 Step Units 4 L208
Stp Logic 3 L183 Stp Logic Time 3 L193 Step Units F 0 L201 Step Units F 4 L209
Advanced Display Counter Status d364 Speed Feedback F d377 PID2 Fdbk Displ(1) d385 Fiber Status d390
Timer Status d365 Encoder Speed(2) d378 PID2 Setpnt Disp(1) d386 Stp Logic Status(1) d391
Timer StatusF d366 Encoder Speed F d379 Position Status(1) d387
Drive Type d367 DC Bus Ripple d380 Units Traveled H(1) d388
Analog In 0-10V d360 Testpoint Data d368 Output Powr Fctr d381 Units Traveled L(1) d389
Analog In 4-20mA d361 Motor OL Level d369 Torque Current d382 RdyBit Mode Act(2)(4) d392
Elapsed Time-hr d362 Slip Hz Meter d375 PID1 Fdbk Displ d383 Drive Status 2(2)(3) d393
Elapsed Time-min d363 Speed Feedback d376 PID1 Setpnt Disp d384 Dig Out Status(2)(3) d394

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Parameters List (Continued)

Advanced Program Decel Time 2 A443 Process Disp Lo A481 Freq 1 Ki(1) A522 Counts Per Unit(1) A559
Accel Time 3 A444 Process Disp Hi A482 Freq 2 Kp(1) A523 Enh Control Word(1) A560
Decel Time 3 A445 Testpoint Sel A483 Freq 2 Ki(1) A524 Home Save(1) A561
Accel Time 4 A446 Current Limit 1 A484 Freq 3 Kp(1) A525 Find Home Freq(1) A562
Preset Freq 0 A410 Decel Time 4 A447 Current Limit 2(1) A485 Freq 3 Ki(1) A526 Find Home Dir(1) A563
Preset Freq 1 A411 Skip Frequency 1 A448 Shear Pin1 Level A486 PM FWKn 1 Kp(1)(3) A527 Encoder Pos Tol(1) A564
Preset Freq 2 A412 Skip Freq Band 1 A449 Shear Pin 1 Time A487 PM FWKn 2 Kp(1)(3) A528 Pos Reg Filter(1) A565
Preset Freq 3 A413 Skip Frequency 2 A450 Shear Pin2 Level(1) A488 PM Control Cfg(1)(3) A529 Pos Reg Gain(1) A566
Preset Freq 4 A414 Skip Freq Band 2 A451 Shear Pin 2 Time(1) A489 Boost Select A530 Max Traverse A567
Preset Freq 5 A415 Skip Frequency 3(1) A452 Load Loss Level(1) A490 Start Boost A531 Traverse Inc A568
Preset Freq 6 A416 Skip Freq Band 3(1) A453 Load Loss Time(1) A491 Break Voltage A532 Traverse Dec A569
Preset Freq 7 A417 Skip Frequency 4(1) A454 Stall Fault Time A492 Break Frequency A533 P Jump A570
Preset Freq 8(1) A418 Skip Freq Band 4(1) A455 Motor OL Select A493 Maximum Voltage A534 Sync Time A571
Preset Freq 9(1) A419 PID 1 Trim Hi A456 Motor OL Ret A494 Motor Fdbk Type(2) A535 Speed Ratio A572
Preset Freq 10(1) A420 PID 1 Trim Lo A457 Drive OL Mode A495 Encoder PPR(1) A536 Mtr Options Cfg(2)(5) A573
Preset Freq 11(1) A421 PID 1 Trim Sel A458 IR Voltage Drop A496 Pulse In Scale A537 RdyBit Mode Cfg(2)(4) A574
Preset Freq 12(1) A422 PID 1 Ref Sel A459 Flux Current Ref A497 Ki Speed Loop(2) A538 Flux Braking En(2)(3) A575
Preset Freq 13(1) A423 PID 1 Fdback Sel A460 Motor Rr(1) A498 Kp Speed Loop(2) A539 Phase Loss Level(2)(3) A576
Preset Freq 14(1) A424 PID 1 Prop Gain A461 Motor Lm(1) A499 Var PWM Disable A540 Current Loop BW(1)(3) A580
Preset Freq 15(1) A425 PID 1 Integ Time A462 Motor Lx(1) A500 Auto Rstrt Tries A541 PM Stable 1 Freq(1)(3) A581
Keypad Freq A426 PID 1 Diff Rate A463 PM IR Voltage(1)(3) A501 Auto Rstrt Delay A542 PM Stable 2 Freq(1)(3) A582
MOP Freq A427 PID 1 Setpoint A464 PM IXd Voltage(1)(3) A502 Start At PowerUp A543 PM Stable 1 Kp(1)(3) A583
MOP Reset Sel A428 PID 1 Deadband A465 PM IXq Voltage(1)(3) A503 Reverse Disable A544 PM Stable 2 Kp(1)(3) A584
MOP Preload A429 PID 1 Preload A466 PM BEMF Voltage(1)(3) A504 Flying Start En A545 PM Stable Brk Pt(1)(3) A585
MOP Time A430 PID 1 Invert Err A467 Speed Reg Sel(1) A509 FlyStrt CurLimit A546 PM Stepload Kp(1)(3) A586
Jog Frequency A431 PID 2 Trim Hi(1) A468 Freq 1(1) A510 Compensation A547 PM 1 Efficiency(1)(3) A587
Jog Accel/Decel A432 PID 2 Trim Lo(1) A469 Freq 1 BW(1) A511 Power Loss Mode A548 PM 2 Efficiency(1)(3) A588
Purge Frequency A433 PID 2 Trim Sel(1) A470 Freq 2(1) A512 Half Bus Enable A549 PM Algor Sel(1)(3) A589
DC Brake Time A434 PID 2 Ref Sel(1) A471 Freq 2 BW(1) A513 Bus Reg Enable A550 SYNRM SW Freq A590
DC Brake Level A435 PID 2 Fdback Sel(1) A472 Freq 3(1) A514 Fault Clear A551 SYNRM Flux Cur A591
DC Brk Time@Strt A436 PID 2 Prop Gain(1) A473 Freq 3 BW(1) A515 Program Lock A552 SYNRM Freq1 Volt A592
DB Resistor Sel A437 PID 2 Integ Time(1) A474 PM Initial Sel(1)(3) A516 Program Lock Mod A553 SYNRM Freq1 Kp A593
DB Threshold A438 PID 2 Diff Rate(1) A475 PM DC Inject Cur(1)(3) A517 Drv Ambient Sel A554 SYNRM Freq1 Comp A594
S Curve % A439 PID 2 Setpoint(1) A476 PM Align Time(1)(3) A518 Reset Meters A555 SYNRM Freq2 BW A595
PWM Frequency A440 PID 2 Deadband(1) A477 PM HIFI NS Cur(1)(3) A519 Text Scroll A556 SYNRM Freq2 Kp A596
Droop Hertz@ FLA(1) A441 PID 2 Preload(1) A478 PM Bus Reg Kd(1)(3) A520 Out Phas Loss En A557
Accel Time 2 A442 PID 2 Invert Err(1) A479 Freq 1 Kp(1) A521 Positioning Mode(1) A558

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Parameters List (Continued)

Network This group contains parameters for the network option card that is installed.
See the network option card’s user manual for more information on the available parameters.

Modified This group contains parameters that have their values changed from the factory default.
When a parameter has its default value changed, it is automatically added to this group. When a parameter has its value changed back
to the factory default, it is automatically removed from this group.

Fault and Diagnostic Fault 5 Time-min F625 Fault10 Current(1) F650 EN Rate Act(1) F685 Drv 1 Reference F710
Fault 6 Time-min(1) F626 Fault 1 BusVolts F651 DSI I/O Act F686 Drv 1 Logic Sts F711
Fault 7 Time-min(1) F627 Fault 2 BusVolts F652 HW Addr 1(1) F687 Drv 1 Feedback F712
Fault 8 Time-min(1) F628 Fault 3 BusVolts F653 HW Addr 2(1) F688 Drv 2 Logic Cmd F713
Fault 4 Code F604 Fault 9 Time-min(1) F629 Fault 4 BusVolts F654 HW Addr 3(1) F689 Drv 2 Reference F714
Fault 5 Code F605 Fault10 Time-min(1) F630 Fault 5 BusVolts F655 HW Addr 4(1) F690 Drv 2 Logic Sts F715
Fault 6 Code F606 Fault 1 Freq F631 Fault 6 BusVolts(1) F656 HW Addr 5(1) F691 Drv 2 Feedback F716
Fault 7 Code F607 Fault 2 Freq F632 Fault 7 BusVolts(1) F657 HW Addr 6(1) F692 Drv 3 Logic Cmd F717
Fault 8 Code F608 Fault 3 Freq F633 Fault 8 BusVolts(1) F658 EN IP Addr Act 1(1) F693 Drv 3 Reference F718
Fault 9 Code F609 Fault 4 Freq F634 Fault 9 BusVolts(1) F659 EN IP Addr Act 2(1) F694 Drv 3 Logic Sts F719
Fault10 Code F610 Fault 5 Freq F635 Fault10 BusVolts(1) F660 EN IP Addr Act 3(1) F695 Drv 3 Feedback F720
Fault 1 Time-hr F611 Fault 6 Freq(1) F636 Status @ Fault 1 F661 EN IP Addr Act 4(1) F696 Drv 4 Logic Cmd F721
Fault 2 Time-hr F612 Fault 7 Freq(1) F637 Status @ Fault 2 F662 EN Subnet Act 1(1) F697 Drv 4 Reference F722
Fault 3 Time-hr F613 Fault 8 Freq(1) F638 Status @ Fault 3 F663 EN Subnet Act 2(1) F698 Drv 4 Logic Sts F723
Fault 4 Time-hr F614 Fault 9 Freq(1) F639 Status @ Fault 4 F664 EN Subnet Act 3(1) F699 Drv 4 Feedback F724
Fault 5 Time-hr F615 Fault10 Freq(1) F640 Status @ Fault 5 F665 EN Subnet Act 4(1) F700 EN Rx Overruns(1) F725
Fault 6 Time-hr(1) F616 Fault 1 Current F641 Status @ Fault 6(1) F666 EN Gateway Act 1(1) F701 EN Rx Packets(1) F726
Fault 7 Time-hr(1) F617 Fault 2 Current F642 Status @ Fault 7(1) F667 EN Gateway Act 2(1) F702 EN Rx Errors(1) F727
Fault 8 Time-hr(1) F618 Fault 3 Current F643 Status @ Fault 8(1) F668 EN Gateway Act 3(1) F703 EN Tx Packets(1) F728
Fault 9 Time-hr(1) F619 Fault 4 Current F644 Status @ Fault 9(1) F669 EN Gateway Act 4(1) F704 EN Tx Errors(1) F729
Fault10 Time-hr(1) F620 Fault 5 Current F645 Status @ Fault10(1) F670 Drv 0 Logic Cmd F705 EN Missed IO Pkt(1) F730
Fault 1 Time-min F621 Fault 6 Current(1) F646 Comm Sts - DSI F681 Drv 0 Reference F706 DSI Errors F731
Fault 2 Time-min F622 Fault 7 Current(1) F647 Comm Sts - Opt F682 Drv 0 Logic Sts F707
Fault 3 Time-min F623 Fault 8 Current(1) F648 Com Sts-Emb Enet(1) F683 Drv 0 Feedback F708
Fault 4 Time-min F624 Fault 9 Current(1) F649 EN Addr Src(1) F684 Drv 1 Logic Cmd F709
(1) Parameter is specific to PowerFlex 525 drives only.
(2) Parameter is also available in PowerFlex 523 FRN 3.xxx and later
(3) Parameter is available in PowerFlex 525 FRN 5.xxx and later.
(4) Parameter is available in PowerFlex 525 FRN 3.xxx and later.
(5) Parameter is available in PowerFlex 525 FRN 2.xxx and later.

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AppView Parameter Groups

PowerFlex 520-series drives include various AppView parameter groups that

groups certain parameters together for quick and easy access based on
different types of applications. See AppView Parameter Groups on page 150 for
more information.
Parameters Group
Conveyor Motor NP Volts P031 Decel Time 1 P042 DigIn TermBlk 03 t063 Anlg In mA Loss t097
Motor NP Hertz P032 Minimum Freq P043 Opto Out1 Sel t069 Slip Hz Meter d375
Motor OL Current P033 Maximum Freq P044 Relay Out1 Sel t076 Preset Freq 0 A410
Motor NP FLA P034 Stop Mode P045 Anlg In 0-10V Lo t091 Jog Frequency A431
Language P030 Motor NP Poles P035 Start Source 1 P046 Anlg In 0-10V Hi t092 Jog Accel/Decel A432
Output Freq b001 Autotune P040 Speed Reference1 P047 Anlg In4-20mA Lo t095 S Curve % A439
Commanded Freq b002 Accel Time 1 P041 DigIn TermBlk 02 t062 Anlg In4-20mA Hi t096 Reverse Disable A544
Mixer Commanded Freq b002 Motor NP Poles P035 Stop Mode P045 Anlg In4-20mA Lo t095
Output Current b003 Autotune P040 Start Source 1 P046 Anlg In4-20mA Hi t096
Motor NP Volts P031 Accel Time 1 P041 Speed Reference1 P047 Anlg In mA Loss t097
Motor NP Hertz P032 Decel Time 1 P042 Relay Out1 Sel t076 Preset Freq 0 A410
Language P030 Motor OL Current P033 Minimum Freq P043 Anlg In 0-10V Lo t091 Stall Fault Time A492
Output Freq b001 Motor NP FLA P034 Maximum Freq P044 Anlg In 0-10V Hi t092
Compressor Motor NP Hertz P032 Maximum Freq P044 Anlg In 0-10V Lo t091 Start At PowerUp A543
Motor OL Current P033 Stop Mode P045 Anlg In 0-10V Hi t092 Reverse Disable A544
Motor NP FLA P034 Start Source 1 P046 Anlg In4-20mA Lo t095 Power Loss Mode A548
Motor NP Poles P035 Speed Reference1 P047 Anlg In4-20mA Hi t096 Half Bus Enable A549
Language P030 Autotune P040 Relay Out1 Sel t076 Anlg In mA Loss t097
Output Freq b001 Accel Time 1 P041 Analog Out Sel t088 Preset Freq 0 A410
Commanded Freq b002 Decel Time 1 P042 Analog Out High t089 Auto Rstrt Tries A541
Motor NP Volts P031 Minimum Freq P043 Anlg Out Setpt t090 Auto Rstrt Delay A542
Centrifugal Pump Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464
Motor NP Poles P035 Relay Out1 Sel t076 Preset Freq 0 A410 PID 1 Deadband A465
Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466
Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541
Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542
Commanded Freq b002 Minimum Freq P043 Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544
Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 PID 1 Integ Time A462
Blower/Fan Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 PID 1 Diff Rate A463
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 PID 1 Setpoint A464
Motor NP Poles P035 Relay Out1 Sel t076 Preset Freq 0 A410 PID 1 Deadband A465
Autotune P040 Analog Out Sel t088 PID 1 Trim Hi A456 PID 1 Preload A466
Language P030 Accel Time 1 P041 Analog Out High t089 PID 1 Trim Lo A457 Auto Rstrt Tries A541
Output Freq b001 Decel Time 1 P042 Anlg Out Setpt t090 PID 1 Ref Sel A459 Auto Rstrt Delay A542
Commanded Freq b002 Minimum Freq P043 Anlg In 0-10V Lo t091 PID 1 Fdback Sel A460 Start At PowerUp A543
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 PID 1 Prop Gain A461 Reverse Disable A544
Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 PID 1 Integ Time A462 Flying Start En A545

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 Chapter 3 Programming and Parameters

Parameters Group (Continued)

Extruder Motor NP Hertz P032 Stop Mode P045 Anlg In4-20mA Lo t095 Motor Fdbk Type A535
Motor OL Current P033 Start Source 1 P046 Anlg In4-20mA Hi t096 Encoder PPR A536
Motor NP FLA P034 Speed Reference1 P047 Anlg In mA Loss t097 Pulse In Scale A537
Motor NP Poles P035 Relay Out1 Sel t076 Slip Hz Meter d375 Ki Speed Loop A538
Language P030 Autotune P040 Analog Out Sel t088 Speed Feedback d376 Kp Speed Loop A539
Output Freq b001 Accel Time 1 P041 Analog Out High t089 Speed Feedback F d377 Power Loss Mode A548
Commanded Freq b002 Decel Time 1 P042 Anlg Out Setpt t090 Encoder Speed d378 Half Bus Enable A549
Output Current b003 Minimum Freq P043 Anlg In 0-10V Lo t091 Preset Freq 0 A410
Motor NP Volts P031 Maximum Freq P044 Anlg In 0-10V Hi t092 Stall Fault Time A492
Positioning(1) Stop Mode P045 Stp Logic 5 L185 Step Units 6 L212 Jog Accel/Decel A432
Start Source 1 P046 Stp Logic 6 L186 Step Units 7 L214 DB Threshold A438
Speed Reference1 P047 Stp Logic 7 L187 Slip Hz Meter d375 S Curve % A439
DigIn TermBlk 02 t062 Stp Logic Time 0 L190 Speed Feedback d376 Motor Fdbk Type A535
Language P030 DigIn TermBlk 03 t063 Stp Logic Time 1 L191 Encoder Speed d378 Encoder PPR A536
Output Freq b001 DigIn TermBlk 05 t065 Stp Logic Time 2 L192 Units Traveled H d388 Pulse In Scale A537
Commanded Freq b002 DigIn TermBlk 06 t066 Stp Logic Time 3 L193 Units Traveled L d389 Ki Speed Loop A538
Motor NP Volts P031 Opto Out1 Sel t069 Stp Logic Time 4 L194 Preset Freq 0 A410 Kp Speed Loop A539
Motor NP Hertz P032 Opto Out2 Sel t072 Stp Logic Time 5 L195 Preset Freq 1 A411 Bus Reg Enable A550
Motor OL Current P033 Relay Out1 Sel t076 Stp Logic Time 6 L196 Preset Freq 2 A412 Positioning Mode A558
Motor NP FLA P034 EM Brk Off Delay t086 Stp Logic Time 7 L197 Preset Freq 3 A413 Counts Per Unit A559
Motor NP Poles P035 EM Brk On Delay t087 Step Units 0 L200 Preset Freq 4 A414 Enh Control Word A560
Autotune P040 Stp Logic 0 L180 Step Units 1 L202 Preset Freq 5 A415 Find Home Freq A562
Accel Time 1 P041 Stp Logic 1 L181 Step Units 2 L204 Preset Freq 6 A416 Find Home Dir A563
Decel Time 1 P042 Stp Logic 2 L182 Step Units 3 L206 Preset Freq 7 A417 Encoder Pos Tol A564
Minimum Freq P043 Stp Logic 3 L183 Step Units 4 L208 Preset Freq 8 A418 Pos Reg Filter A565
Maximum Freq P044 Stp Logic 4 L184 Step Units 5 L210 Jog Frequency A431 Pos Reg Gain A566
Textile/Fiber Motor NP FLA P034 DigIn TermBlk 02 t062 Slip Hz Meter d375 Max Traverse A567
Motor NP Poles P035 DigIn TermBlk 03 t063 Fiber Status d390 Traverse Inc A568
Autotune P040 Opto Out1 Sel t069 Preset Freq 0 A410 Traverse Dec A569
Accel Time 1 P041 Opto Out2 Sel t072 Jog Frequency A431 P Jump A570
Language P030 Decel Time 1 P042 Relay Out1 Sel t076 Jog Accel/Decel A432 Sync Time A571
Output Freq b001 Minimum Freq P043 Anlg In 0-10V Lo t091 S Curve % A439 Speed Ratio A572
Commanded Freq b002 Maximum Freq P044 Anlg In 0-10V Hi t092 Reverse Disable A544
Motor NP Volts P031 Stop Mode P045 Anlg In4-20mA Lo t095 Power Loss Mode A548
Motor NP Hertz P032 Start Source 1 P046 Anlg In4-20mA Hi t096 Half Bus Enable A549
Motor OL Current P033 Speed Reference1 P047 Anlg In mA Loss t097 Bus Reg Enable A550
(1) This AppView parameter group is specific to PowerFlex 525 drives only.

CustomView Parameter Group

PowerFlex 520-series drives include a CustomView parameter group for you to

store frequently used parameters for your application. See CustomView
Parameter Group on page 151 for more information.

Custom Group
This group can store up to 100 parameters.

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Chapter 3 Programming and Parameters

Basic Display Group

b001 [Output Freq] Related Parameters: b002, b010, b011, P043, P044, P048, P050, P052
Output frequency present at T1, T2 & T3 (U, V & W). Does not include slip frequency.
Default: Read Only
Values Min/Max: 0.00/[Maximum Freq]
Display: 0.01 Hz

b002 [Commanded Freq] Related Parameters: b001, b013, P043, P044, P048, P050, P052
Value of the active frequency command even if the drive is not running.

IMPORTANT The frequency command can come from a number of sources. See Start and Speed Reference Control on page 48 for
more information.

Default: Read Only

Values Min/Max: 0.00/[Maximum Freq]
Display: 0.01 Hz

b003 [Output Current]

Output current present at T1, T2 & T3 (U, V & W).
Default: Read Only
Values Min/Max: 0.00/(Drive Rated Amps x 2)
Display: 0.01 A

b004 [Output Voltage] Related Parameters: P031, A530, A534

Output voltage present at T1, T2 & T3 (U, V & W).
Default: Read Only
Values Min/Max: 0.0/Drive Rated Volts
Display: 0.1V

b005 [DC Bus Voltage]

Filtered DC bus voltage level of the drive.
Default: Read Only
Values Min/Max: 0/1200V DC
Display: 1V DC

b006 [Drive Status] Related Parameters: A544

Present operating condition of the drive.

1 = True/Active, 0 = False/Inactive
Running Digit 1
Forward Digit 2
Accelerating Digit 3
Decelerating Digit 4
SafetyActive(1) Digit 5
(1) Setting is specific to PowerFlex 525 drives only.

Default: Read Only

Values Min/Max: 00000/11111
Display: 00000

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 Chapter 3 Programming and Parameters

Basic Display Group (continued)

b007 [Fault 1 Code] Related Parameters: F604-F610
b008 [Fault 2 Code]
b009 [Fault 3 Code]
A code that represents a drive fault. Codes appear in these parameters in the order that they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults are only
recorded once.
See Fault and Diagnostic Group for more information.
Default: Read Only
Values Min/Max: F0/F127
Display: F0

b010 [Process Display] Related Parameters: b001, A481, A482

32
32-bit parameter.
Output frequency scaled by A481 [Process Disp Lo] and A482 [Process Disp Hi].
Scaled Process Value (PV) = (([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [Minimum Freq])
Default: Read Only
Values Min/Max: 0/9999.00
Display: 0.01

b011 [Process Fract] Related Parameters: b001, A481, A482

Output frequency (fractional portion) scaled by A481 [Process Disp Lo] and A482 [Process Disp Hi].
Scaled Process Value (PV) = (([Process Disp Hi] - [Process Disp Lo]) x ([Output Freq] - [Minimum Freq])) / ([Maximum Freq] - [Minimum Freq])
Default: Read Only
Values Min/Max: 0.00/0.99
Display: 0.01

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Chapter 3 Programming and Parameters

Basic Display Group (continued)

b012 [Control Source] Related Parameters: P046, P047, P048, P049, P050, P051,
t062, t063, t065-t068, L180-L187, A410-A425
Active source of the Start Command and Frequency Command. Normally defined by the settings of P046, P048, P050 [Start Source x] and P047, P049, P051 [Speed
Referencex].
See Start and Speed Reference Control on page 48 for more information.

Start Command Source Digit 1

1 = Keypad
2 = DigIn TrmBlk (Parameters t062,t063,t065-t068) Example
3 = Serial/DSI
4 = Network Opt(1) Display Reads Description
5 = EtherNet/IP(2)
2004 Start source comes from Network Opt and Frequency source is Purge.
Frequency Command Source Digit 2 & 3
00 = Other Start source comes from Serial/DSI and Frequency source comes from
113
01 = Drive Pot PID1 Output.
02 = Keypad
03 = Serial/DSI 155 Start source and Frequency source come from EtherNet/IP.
04 = Network Opt(1) Start source comes from DigIn TrmBlk and Frequency source comes from
05 = 0-10V Input 052 0…10V Input.
06 = 4-20mA Input
07 = Preset Freq (Parameters A410-A425) Start source comes from Keypad and Frequency source comes from Drive
08 = Anlg In Mult(2)
011 Pot.
09 = MOP
10 = Pulse Input
11 = PID1 Output
12 = PID2 Output(2)
13 = Step Logic (Parameters L180-L187)(1)
14 = Encoder(2)
15 = EtherNet/IP(2)
16 = Positioning(2)
Frequency Command Source Digit 4
0 = Other (Digit 2 & 3 Digits 2 & 3 are used. Digit 4 is not
shown.)
1 = Jog
2 = Purge
Not Used
(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D,
or 25-COMM-P adapters as the Start source and/or Frequency source.
(2) Setting is specific to PowerFlex 525 drives only.

Default: Read Only

Values Min/Max: 0000/2165
Display: 0000

b013 [Contrl In Status] Related Parameters: b002, P044, P045

State of the digital terminal blocks 1...3 and DB transistor.

IMPORTANT Actual control commands may come from a source other than the control terminal block.

1 = Closed State, 0 = Open State

DigIn TBlk 1 Digit 1
DigIn TBlk 2 Digit 2
DigIn TBlk 3 Digit 3
DB Trans On(1) Digit 4
Not Used
(1) The DB Transistor “on” indication must have a 0.5 s hysteresis. It turns on
and stays on for at least 0.5 s every time the DB transistor is turned on.

Default: Read Only

Values Min/Max: 0000/1111
Display: 0000

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 Chapter 3 Programming and Parameters

Basic Display Group (continued)

b014 [Dig In Status] Related Parameters: t065-t068
State of the programmable digital inputs.

1 = Closed State, 0 = Open State

DigIn TBlk 5 Digit 1
DigIn TBlk 6 Digit 2
DigIn TBlk 7(1) Digit 3
DigIn TBlk 8(1) Digit 4
Not Used
(1) Setting is specific to PowerFlex 525 drives only.

Default: Read Only

Values Min/Max: 0000/1111
Display: 0000

b015 [Output RPM] Related Parameters: P035

Current output frequency in rpm. Scale is based on P035 [Motor NP Poles].
Default: Read Only
Values Min/Max: 0/24000 rpm
Display: 1 rpm

b016 [Output Speed] Related Parameters: P044

Current output frequency in %. Scale is 0% at 0.00 Hz to 100% at P044 [Maximum Freq].
Default: Read Only
Values Min/Max: 0.0/100.0%
Display: 0.1%

b017 [Output Power] Related Parameters: b018

Output power present at T1, T2 & T3 (U, V & W).
Default: Read Only
Values Min/Max: 0.00/(Drive Rated Power x 2)
Display: 0.01 kW

b018 [Power Saved] Related Parameters: b017

Instantaneous power savings of using this drive compared to an across the line starter.
Default: Read Only
Values Min/Max: 0.00/655.35 kW
Display: 0.01 kW

b019 [Elapsed Run time] Related Parameters: A555

Accumulated time drive is outputting power. Time is displayed in 10-hour increments.
Default: Read Only
Values Min/Max: 0/65535 x 10 hr
Display: 1 = 10 hr

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Chapter 3 Programming and Parameters

Basic Display Group (continued)

b020 [Average Power] Related Parameters: A555
Average power that is used by the motor since the last reset of the meters.
Default: Read Only
Values Min/Max: 0.00/(Drive Rated Power x 2)
Display: 0.01 kW

b021 [Elapsed kWh] Related Parameters: b022

Accumulated output energy of the drive. When the maximum value of this parameter is reached, it resets to zero and b022 [Elapsed MWh] is incremented.
Default: Read Only
Values Min/Max: 0.0/100.0 kWh
Display: 0.1 kWh

b022 [Elapsed MWh] Related Parameters: b021

Accumulated output energy of the drive.
Default: Read Only
Values Min/Max: 0.0/6553.5 MWh
Display: 0.1 MWh

b023 [Energy Saved] Related Parameters: A555

Total energy savings of using this drive compared to an across the line starter since the last reset of the meters.
Default: Read Only
Values Min/Max: 0.0/6553.5 kWh
Display: 0.1 kWh

b024 [Accum kWh Sav] Related Parameters: b025

Total approximate accumulated energy savings of the drive compared to using an across the line starter.
Default: Read Only
Values Min/Max: 0.0/6553.5 kWh
Display: 0.1 = 10 kWh

b025 [Accum Cost Sav] Related Parameters: b024, P052, A555

Total approximate accumulated cost savings of the drive compared to using an across the line starter.
[Accum Cost Sav] = [Average kWh cost] x [Accum kWh Sav]
Default: Read Only
Values Min/Max: 0.0/6553.5
Display: 0.1

b026 [Accum CO2 Sav] Related Parameters: A555

Total approximate accumulated CO2 savings of the drive compared to using an across the line starter.
Default: Read Only
Values Min/Max: 0.0/6553.5 kg
Display: 0.1 kg

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 Chapter 3 Programming and Parameters

Basic Display Group (continued)

b027 [Drive Temp]
Present operating temperature of the drive heatsink (inside module).
Default: Read Only
Values Min/Max: 0/120 °C
Display: 1 °C

b028 [Control Temp]

Present operating temperature of the drive control.
Default: Read Only
Values Min/Max: 0/120 °C
Display: 1 °C

b029 [Control SW Ver]

Current drive firmware revision.
Default: Read Only
Values Min/Max: 0.000/65.535
Display: 0.001

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Chapter 3 Programming and Parameters

Basic Program Group

P030 [Language] Language Support
Connected
Keypad/ RSLogix 5000/Logix
Selects the language displayed. A reset or power cycle is required after selection is made. Components
LCD Display Designer application Workbench software
1 English (Default) Y Y Y
2 Français Y Y Y
3 Español Y Y Y
4 Italiano Y Y Y
5 Deutsch Y Y Y
6 Japanese – Y –
7 Português Y Y –
Options 8 Chinese Simplified Chinese – Y Y
9 Reserved
10 Reserved
11 Korean – Y –
12 Polish(1) Y – –
13 Reserved
14 Turkish(1) Y – –
15 Czech(1) Y – –
(1) Due to a limitation of the LCD Display, some of the characters for Polish, Turkish, and Czech is modified.

P031 [Motor NP Volts] Related Parameters: b004, A530, A531, A532, A533
Stop drive before changing this parameter.
Sets the motor nameplate rated volts.
Default: Drive Rated Volts
Values Min/Max: 10V (for 230V Drives), 20V (for 460V Drives), 25V (for 600V Drives)/Drive Rated Volts
Display: 1V

P032 [Motor NP Hertz] Related Parameters: A493, A530, A531, A532, A533
Stop drive before changing this parameter.
Sets the motor nameplate rated frequency.
Default: 60 Hz
Values Min/Max: 15/500 Hz
Display: 1 Hz

P033 [Motor OL Current] Related Parameters: t069, t072, t076, t081, A484, A485, A493
Sets the motor nameplate overload current. Used to determine motor overload conditions and can be set from 0.1 A to 200% of drive rated current.

IMPORTANT The drive will fault on an F007 “Motor Overload” if the value of this parameter is exceeded based on 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.
Default: Drive Rated Amps
Values Min/Max: 0.0/(Drive Rated Amps x 2)
Display: 0.1 A

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 Chapter 3 Programming and Parameters

Basic Program Group (continued)

P034 [Motor NP FLA] Related Parameters: P040
Sets the motor nameplate FLA. Used to assist the Autotune routine and motor control.
Default: Based on Drive Rating
Values Min/Max: 0.1/(Drive Rated Amps x 2)
Display: 0.1 A

P035 [Motor NP Poles] Related Parameters: b015

Sets the number of poles in the motor.
Default: 4
Values Min/Max: 2/40
Display: 1

P036 [Motor NP RPM]

Stop drive before changing this parameter.
Sets the rated nameplate rpm of the motor. Used to calculate the rated slip of the motor. To reduce the slip frequency, set this parameter closer to the motor synchronous
speed.
Default: 1750 rpm
Values Min/Max: 0/24000 rpm
Display: 1 rpm

P037 [Motor NP Power]

PF 525 PowerFlex 525 only.
Sets the motor nameplate power. Used in PM regulator.
Default: Drive Rated Power
Values Min/Max: 0.00/Drive Rated Power
Display: 0.01 kW

P038 [Voltage Class]

Stop drive before changing this parameter.
Sets the voltage class of 600V drives.
2 “Low Voltage” 480V
Options
3 “High Voltage” (Default) 600V

P039 [Torque Perf Mode] Related Parameters: P040, A530, A531, A532, A533, A535
Stop drive before changing this parameter.
Selects the motor control mode.
The PowerFlex 523 and PowerFlex 525 drives are capable of performing with the following motor control modes.
0 “V/Hz”
1 “SVC” (Default)
2 “Economize”
3 “Vector”(1) Voltage Vector only (cannot control torque). It is recommended to use with an encoder when using VVC mode.
Options
4 “PM Control”(1) (2) When P039 [Torque Perf Mode] is set to 4 and A535 [Motor Fdbk Type] is set to 0, 1, 2 or 3, the drive is in open loop PM
motor control mode.
When P039 [Torque Perf Mode] is set to 4 and A535 [Motor Fdbk Type] is set to 4 or 5, the drive is in closed loop PM motor
control mode.
5 “SynRM”(3) Set P039 [Torque Perf Mode] to 5 to enable the use of Synchronous Reluctance Motor control.
(1) Setting is specific to PowerFlex 525 drives only.
(2) Setting is available in PowerFlex 525 FRN 5.xxx and later.
(3) Setting is available in PowerFlex 525 FRN 7.xxx and later.

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Chapter 3 Programming and Parameters

Basic Program Group (continued)

P040 [Autotune] Related Parameters: P034, P039, A496, A497
Stop drive before changing this parameter.
Enables a static (not spinning) or dynamic (motor spinning) autotune to automatically set the motor parameters. Set the parameter value to a one or two, then issue a valid
“Start” command to begin the routine. After the routine is complete the parameter resets to a zero. A failure (such as if a motor is not connected) results in an Autotune
Fault.
It is recommended to perform a full rotate tune when using VVC mode.

IMPORTANT All motor parameters in the Basic Program group must be set before running the routine. If a start command is not
given (or a stop command is given) within 30 s, the parameter automatically returns to a zero and an Autotune Fault
occurs.

ATTENTION: Rotation of the motor in an undesired direction can occur during this procedure. To guard against possible
injury and/or equipment damage, it is recommended that the motor be disconnected from the load before proceeding.

0 “Ready/Idle” (Default)
1 “Static Tune” A temporary command that initiates a non-rotational motor stator resistance test for the best possible automatic setting
of A496 [IR Voltage Drop]. A start command is required following initiation of this setting. The parameter returns to 0
“Ready/Idle” following the test, at which time another start transition is required to operate the drive in normal mode.
Used when motor cannot be uncoupled from the load.
Options
2 “Rotate Tune” A temporary command that initiates a “Static Tune” followed by a rotational test for the best possible automatic setting of
A497 [Flux Current Ref]. A start command is required following initiation of this setting. The parameter returns to 0
“Ready/Idle” following the test, at which time another start transition is required to operate the drive in normal mode.
Important: Used when motor is uncoupled from the load. Results may not be valid if a load is coupled to the motor during
this procedure.
If [P039 = 5], it is the same with “Static Tune”.

P041 [Accel Time 1] Related Parameters: P044, A439

Sets the time for the drive to accelerate from 0 Hz to P044 [Maximum Freq].
Accel Rate = [Maximum Freq] / [Accel Time x]
[Maximum Freq]
Dec
on
rati

ele

Speed
ele

rati
Acc

on

0
[Accel Time x] Time [Decel Time x]
0
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

P042 [Decel Time 1] Related Parameters: P044, A439

Sets the time for the drive to decelerate from P044 [Maximum Freq] to 0 Hz.
Decel Rate = [Maximum Freq] / Decel Time x]
[Maximum Freq]
Dec
on
rati

ele

Speed
ele

rati
Acc

on

0
[Accel Time x] Time [Decel Time x]
0
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

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 Chapter 3 Programming and Parameters

Basic Program Group (continued)

P043 [Minimum Freq] Related Parameters: b001, b002, b013, P044, A530, A531
Stop drive before changing this parameter.
Sets the lowest frequency the drive outputs.
Although this parameter can be set greater than P044 [Maximum Freq], the drive uses P044 [Maximum Freq] to determine the actual maximum frequency.
Default: 0.00 Hz
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

P044 [Maximum Freq] Related Parameters: b001, b002, b013, b016, P043, A530, A531
Stop drive before changing this parameter.
Sets the highest frequency the drive outputs.

IMPORTANT This value must be greater than the value set in P043 [Minimum Freq].
Default: 60.00 Hz
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

P045 [Stop Mode] Related Parameters: t086, t087, A434, A435, A550
Determines the stopping mode that is used by the drive when a stop is initiated.
0 “Ramp, CF” (Default) Ramp to Stop. Stop command clears active fault.
1 “Coast, CF” Coast to Stop. Stop command clears active fault.
2 “DC Brake, CF” DC Injection Braking Stop. Stop command clears active fault.
3 “DC BrkAuto,CF” DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A434 [DC Brake Time].
OR
• Drive shuts off if the drive detects that the motor is stopped.
Stop command clears active fault.
4 “Ramp” Ramp to Stop.
5 “Coast” Coast to Stop.
6 “DC Brake” DC Injection Braking Stop.
7 “DC BrakeAuto” DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A434 [DC Brake Time].
OR
• Drive shuts off if the drive detects that the motor is stopped.

Options 8 “Ramp+EM B,CF” Ramp to Stop with EM Brake Control. Stop command clears active fault.
9 “Ramp+EM Brk” Ramp to Stop with EM Brake Control.
10 “PointStp,CF” PointStop. Stop command clears Provides a method to stop at a constant distance instead of a fixed rate.
active fault. When a Stop command is given, the distance that is required for the machine to
travel to standstill based on the programmed maximum speed and deceleration time
11 “PointStop” is calculated. If the drive is running slower than the maximum speed, the function
applies a calculated deceleration time that allows the machine to travel to standstill
in the same distance based on the current speed.
It is recommended to use braking resistors or set A550 [Bus Reg Enable] to 0
“Disabled” for better performance.
Stop
PointStop. [Maximum Freq]

Speed

Calculated Stop Time

[Decel Time x] Time

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Chapter 3 Programming and Parameters

Basic Program Group (continued)

P046 [Start Source 1] Related Parameters: b012, t064, C125
P048 [Start Source 2]
P050 [Start Source 3]
Stop drive before changing this parameter.
Configures the start source of the drive. Changes to these inputs take effect as soon as they are entered. P046 [Start Source 1] is the factory default start source unless
overridden.
See Start and Speed Reference Control on page 48 for more information.

IMPORTANT For all settings except when t064 [2-Wire Mode] is set to 1 “Level Sense”, the drive must receive a leading edge from the
start input for the drive to start after a stop input, loss of power, or fault condition.
1 “Keypad” [Start Source 1] default
2 “DigIn TrmBlk” [Start Source 2] default
Options 3 “Serial/DSI” [Start Source 3] default for PowerFlex 523
4 “Network Opt”(1)
5 “EtherNet/IP”(2) [Start Source 3] default for PowerFlex 525
(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the start source.
(2) Setting is specific to PowerFlex 525 drives only.

P047 [Speed Reference1] Related Parameters: C125

P049 [Speed Reference2]
P051 [Speed Reference3]
Selects the source of speed command for the drive. Changes to these inputs take effect as soon as they are entered. P047 [Speed Reference1] is the factory default speed
reference unless overridden.
See Start and Speed Reference Control on page 48 for more information.
1 “Drive Pot” [Speed Reference1] default
2 “Keypad Freq”
3 “Serial/DSI” [Speed Reference3] default for PowerFlex 523
4 “Network Opt”(1)
5 “0-10V Input” [Speed Reference2] default
6 “4-20mA Input”
7 “Preset Freq”
8 “Anlg In Mult”(2)
Options
9 “MOP”
10 “Pulse Input”
11 “PID1 Output”
12 “PID2 Output”(2)
13 “Step Logic”(2)
14 “Encoder”(2)
15 “EtherNet/IP”(2) [Speed Reference3] default for PowerFlex 525
16 “Positioning”(2) Referencing from A558 [Positioning Mode]
(1) Select this setting if using the optional PowerFlex 25-COMM-E2P, 25-COMM-D, or 25-COMM-P adapters as the speed reference.
(2) Setting is specific to PowerFlex 525 drives only.

P052 [Average kWh Cost] Related Parameters: b025

Sets the average cost per kWh.
Default: 0.00
Values Min/Max: 0.00/655.35
Display: 0.01

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Basic Program Group (continued)

Basic Program Group (continued)

P053 [Reset To Defalts]

Stop drive before changing this parameter.
Resets all parameters to their factory default values. After a Reset command, the value of this parameter returns to zero.
Parameters that are NOT Reset when P053 = 1 Parameters that are Reset when P053 = 3
Parameter Parameter Parameter Parameter Name
P030 [Language] C138 [EN Gateway Cfg 2] C159 [EN Data Out 3] P031 [Motor NP Volts]
C121 [Comm Write Mode] C139 [EN Gateway Cfg 3] C160 [EN Data Out 4] P033 [Motor OL] Current
C122 [Cmd Stat Select] C140 [EN Gateway Cfg 4] C161 [Opt Data In 1] P034 [Motor NP FLA]
C123 [RS485 Data Rate] C141 [EN Rate Cfg] C162 [Opt Data In 2] P035 [Motor NP Poles]
C124 [RS485 Node Addr] C143 [EN Comm Flt Actn] C163 [Opt Data In 3] A435 [DC Brake Level]
C124 [Comm Loss Action] C144 [EN Idle Flt Actn] C164 [Opt Data In 4] A484 [Current Limit 1]
C126 [Comm Loss Time] C145 [EN Flt Cfg Logic] C165 [Opt Data Out 1] A485 [Current Limit 2]
C127 [RS485 Format] C146 [EN Flt Cfg Ref] C166 [Opt Data Out 2] A486 [Shear Pin1 Level]
C128 [EN Addr Sel] C147 [EN Flt Cfg DL 1] C167 [Opt Data Out 3] A488 [Shear Pin2 Level]
C129 [EN IP Addr Cfg 1] C148 [EN Flt Cfg DL 2] C168 [Opt Data Out 4] A490 [Load Loss Level]
C130 [EN IP Addr Cfg 2] C149 [EN Flt Cfg DL 3] C169 [MultiDrv Sel] A496 [IR Voltage Drop]
C131 [EN IP Addr Cfg 3] C150 [EN Flt Cfg DL 4] C171 [Drv 1 Addr] A497 [Flux Current Ref]
C132 [EN IP Addr Cfg 4] C153 [EN Data In 1] C172 [Drv 2 Addr] A530 [Boost Select]
C133 [EN Subnet Cfg 1] C154 [EN Data In 2] C173 [Drv 3 Addr] A531 [Start Boost]
C134 [EN Subnet Cfg 2] C155 [EN Data In 3] C174 [Drv 4 Addr] A532 [Break Voltage]
C135 [EN Subnet Cfg 3] C156 [EN Data In 4] C175 [DSI I/O Cfg] A533 [Break Frequency]
GC [Parameters in Custom A534 [Maximum] Voltage
C136 [EN Subnet Cfg 4] C157 [EN Data Out 1] Group]
C137 [EN Gateway Cfg 1] C158 [EN Data Out 2]

0 “Ready/Idle” (Default)
1 “Param Reset” Does not reset custom groups, parameter P030 [Language], and communication parameters.
Options 2 “Factory Rset” Restore drive to factory condition.
3 “Power Reset” Resets only power parameters. Can be used when swapping power modules.
4 “Module Reset”(1) (2) Power cycle of the drive, NO parameters are reset.
(1) Setting is available in PowerFlex 525 FRN 5.xxx and later.
(2) Setting is available in PowerFlex 523 FRN 3.xxx and later.

P054 [Display Param] Related Parameters: b001

Sets the parameter to display on the drive LCD display when the drive powers up.
0 “Keypad Disp” (Default) Without ADC = shows last selected display parameter
Options With ADC = shows parameter b001 [Output Freq]
1 “Output Freq” Basic Display group parameters

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Terminal Block Group

Programmable Digital Inputs
t062 [DigIn TermBlk 02] t063 [DigIn TermBlk 03] Related Parameters: b012, b013, b014, P045, P046, P048, P049, P050, P051, t064, t086, A410-
t065 [DigIn TermBlk 05] t066 [DigIn TermBlk 06] A425, A427, A431, A432, A433, A434, A435, A442, A443, A488, A535,
A560, A562, A563, A567, A571
t067 [DigIn TermBlk 07] t068 [DigIn TermBlk 08]
PF 525 PowerFlex 525 only.

Stop drive before changing this parameter.

Programmable digital input. Changes to these inputs take effect as soon as they are entered. If a digital input is set for a selection that is only usable on one input, no other
input can be set for the same selection.
0 “Not Used” Terminal has no function but can be read over network communications with b013 [Contrl In Status] and b014 [Dig In
Status].
1 “Speed Ref 2” Selects P049 [Speed Reference2] as drive's speed command.
2 “Speed Ref 3” Selects P051 [Speed Reference3] as drive's speed command.
3 “Start Src 2” Selects P048 [Start Source 2] as control source to start the drive.
4 “Start Src 3” Selects P050 [Start Source 3] as control source to start the drive.
5 “Spd + Strt 2” [DigIn TermBlk 07] default.
Selects combination of P049 [Speed Reference2] and P048 [Start Source 2] as speed command with control source to
start the drive.
6 “Spd + Strt 3” Selects combination of P051 [Speed Reference3] and P050 [Start Source 3] as speed command with control source to
start the drive.
7 “Preset Freq” [DigIn TermBlk 05] and [DigIn TermBlk 06] default.
• Selects a preset frequency in Velocity mode (P047, P049, P051 [Speed Referencex] = 1...15). See A410...A425 [Preset
(PF523: only for DigIn TermBlk 03, 05, Freq x].
and 06) • Selects a preset frequency and position in Positioning mode (P047, P049, P051 [Speed Referencex] = 16).
(PF525: only for DigIn TermBlk 05...08) See L200...L214 [Step Units x] (only for PowerFlex 525 drives).

IMPORTANT Digital Inputs have priority for frequency control when programmed as
Preset Speed and are active. See Start Source and Speed Reference
Selection on page 48 for more information.
8 “Jog” • When input is present, drive accelerates according to the value set in A432 [Jog Accel/Decel] and ramps to the value
set in A431 [Jog Frequency].
• When input is removed, drive ramps to a stop according to the value set in A432 [Jog Accel/Decel].
Options • A valid Start command overrides this input.
9 “Jog Forward” [DigIn TermBlk 08] default.
Drive accelerates to A431 [Jog Frequency] according to A432 [Jog Accel/Decel] and ramps to a stop when input
becomes inactive. A valid Start command overrides this input.
10 “Jog Reverse” Drive accelerates to A431 [Jog Frequency] according to A432 [Jog Accel/Decel] and ramps to a stop when input
becomes inactive. A valid Start command overrides this input.
11 “Acc/Dec Sel2”(1) If active, determines which Accel/Decel time is used for all ramp rates except jog.
Can be used with option 29 “Acc/Dec Sel3” for additional Accel/Decel times. See A442 [Accel Time 2] for more
information.
12 “Aux Fault” When enabled, an F002 “Auxiliary Input” fault occurs when the input is removed.
13 “Clear Fault” When active, clears an active fault.
14 “RampStop,CF” Causes drive to immediately ramp to a stop regardless of how P045 [Stop Mode] is set.
15 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of how P045 [Stop Mode] is set.
16 “DCInjStop,CF” Causes drive to immediately begin a DC Injection stop regardless of how P045 [Stop Mode] is set.
17 “MOP Up” Increases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time].
18 “MOP Down” Decreases the value of A427 [MOP Freq] at the rate set in A430 [MOP Time].
19 “Timer Start”(1) Clears and starts the timer function. May be used to control the relay or opto outputs.
20 “Counter In”(1) Starts the counter function. May be used to control the relay or opto outputs.
21 “Reset Timer” Resets the internal active timer, d365 [Timer Status]. For more information, see Timer Function on page 213.
22 “Reset Countr” Resets the count in the accumulated internal active counter, d364 [Counter Status]. For more information,
see Counter Function on page 214.
23 “Rset Tim&Cnt” Resets both the internal active timer and accumulated internal active counter.

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Programmable Digital Inputs (Continued)

24 “Logic In 1”(1)(2) Logic function input number 1. May be used to control the relay or opto outputs (t076, t081 [Relay Outx Sel] and
t069, t072 [Opto Outx Sel], options 11...14). May be used with StepLogic parameters L180...L187 [Stp Logic x].
25 “Logic In 2”(1)(2) Logic function input number 2. May be used to control the relay or opto outputs (t076, t081 [Relay Outx Sel] and
t069, t072 [Opto Outx Sel], options 11...14). May be used with StepLogic parameters L180...L187 [Stp Logic x].
26 “Current Lmt2”(2) When active, A485 [Current Limit 2] determines the drive current limit level.
27 “Anlg Invert” Inverts the scaling of the analog input levels set in t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi], or t095 [Anlg In4-
20mA Lo] and t096 [Anlg In4-20mA Hi].
28 “EM Brk Rlse” If EM brake function is enabled, this input releases the brake. See t086 [EM Brk Off Delay] for more information.

ATTENTION: If a hazard of injury due to movement of equipment or material

exists, an auxiliary mechanical braking device must be used.

29 “Acc/Dec Sel3”(1) If active, determines which Accel/Decel time is used for all ramp rates except jog.
Used with option 11 “Acc/Dec Sel2” for the Accel/Decel times listed in this table. Option
Description
29 11
0 0 Acc/Dec 1
0 1 Acc/Dec 2
1 0 Acc/Dec 3
1 1 Acc/Dec 4

30 “Precharge En” Forces drive into precharge state. Typically controlled by auxiliary contact on the disconnect at the DC input to the
drive. If this input is assigned, it must be energized for the precharge relay to close and for the drive to run. If it is de-
energized, the pre-charge relay opens and the drive coasts to a stop.
31 “Inertia Dcel” Forces drive into Inertia ride-through state. The drive attempts to regulate the DC bus at the current level.
32 “Sync Enable” Must be used to hold the existing frequency when Sync Time is set to enable speed synchronization. When this input is
released the drive accelerates to the commanded frequency in A571 [Sync Time].
33 “Traverse Dis” When an input is programmed the traverse function is disabled while this input is active. See A567 [Max Traverse].
Options 34 “Home Limit”(2) In Positioning mode, indicates that the drive is at the home position. See Appendix E for more information on
Positioning.
35 “Find Home”(2) In Positioning mode, causes the drive to return to the Home position when a Start command is issued.
Uses A562 [Find Home Freq] and A563 [Find Home Dir] until the “Home Limit” input is activated. If it passes this point, it
then runs in the reverse direction at 1/10th the frequency of [Find Home Freq] until the “Home Limit” is activated again.
As long as this input is active, any start command causes the drive to enter the homing routine. Only functions if in
Positioning mode. Once the Find Home routine has finished, the drive stops. See Appendix E for more information on
Positioning.
36 “Hold Step”(2) In Positioning mode, overrides other inputs and causes the drive to remain at its current step (running at zero speed
once it reaches its position) until released.
While in “Hold”, the drive ignores any input command that would normally result in a move to a new step. Timers
continue to run. Therefore, when the Hold is removed, the drive must see any required digital inputs transition (even if
they already transitioned during the hold), but it does not reset any timer. See Appendix E for more information on
Positioning.
37 “Pos Redefine”(2) In Positioning mode, resets the home position to the current position of the machine. See Appendix E for more
information on Positioning.
38 “Force DC” If the drive is not running, causes the drive to apply a DC Holding current (A435 [DC Brake Level], ignoring A434 [DC
Brake Time]) while the input is applied.
39 “Damper Input” When active, drive is allowed to run normally.
When inactive, drive is forced into sleep mode and is prevented from accelerating to command speed.
40 “Purge”(1) Starts the drive at A433 [Purge Frequency] regardless of the selected control source. Supersedes the keypad Control
function and any other control command to take control of the drive. Purge can occur, and is operational, at any time
whether the drive is running or stopped regardless of the selected logic source selection. If a valid stop (other than from
comms or SW enable) is present, the drive will not start on the purge input transition.

ATTENTION: If a hazard of injury due to movement of equipment or material

exists, an auxiliary mechanical braking device must be used.

41 “Freeze-Fire” When inactive, causes an immediate F094 “Function Loss” fault. Use to safely bypass the drive with an external
switching device.
42 “SW Enable” Works like an interlock that has to be active for the drive to run.

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Programmable Digital Inputs (Continued)

43 “SherPin1 Dis” Disables shear pin 1 but leaves shear pin 2 active. If A488 [Shear Pin 2 Level] is greater than 0.0 A, shear pin 2 is
enabled.
44 Reserved
45 Reserved
46 Reserved
47 Reserved
48 “2-Wire FWD” [DigIn TermBlk 02] default. Select 2-Wire FWD for this input. Drive Start Condition Matrix
(only for DigIn TermBlk 02) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn
TrmBlk” to configure [Start Source x] to a 2-wire run forward mode. Also see for t062 and t063
t064 [2-Wire Mode] for level trigger settings.
t062 Setting
49 “3-Wire Start” Select 3-Wire Start for this input.
(only for DigIn TermBlk 02) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn t063 3-Wire 2-Wire
TrmBlk” to configure [Start Source x] to a 3-wire start mode. Setting Start FWD
Options Drive
50 “2-Wire REV” [DigIn TermBlk 03] default. Select 2-Wire REV for this input. 2-Wire REV will not OK
(only for DigIn TermBlk 03) Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn start
TrmBlk” to configure [Start Source x] to a 2-wire run reverse mode. Also see
t064 [2-Wire Mode] for level trigger settings. Drive will
3-Wire Dir OK
For PowerFlex 523 drives, this setting is disabled If [DigIn TermBlk 03] is set to not start
7 “Preset Freq”.
51 “3-Wire Dir”
(only for DigIn TermBlk 03) Select 3-Wire Dir for this input.
Select this option and set P046, P048 or P050 [Start Source x] to 2 “DigIn
TrmBlk” to change the direction of [Start Source x].
For PowerFlex 523 drives, this setting is disabled If [DigIn TermBlk 03] is set to
7 “Preset Freq”.

52 “Pulse Train” Select pulse train for this input.

Use P047, P049 and P051 [Speed Referencex] to select pulse input.
(PF523: only for DigIn TermBlk 05) Jumper for DigIn TermBlk 05 or 07 Sel must be moved to Pulse In.
(PF525: only for DigIn TermBlk 07)
(1) This function may be tied to one input only.
(2) Setting is specific to PowerFlex 525 drives only.

t064 [2-Wire Mode] Related Parameters: P045, P046, P048, P050, t062, t063
Stop drive before changing this parameter.
Programs the mode of trigger only for t062 [DigIn TermBlk 02] and t063 [DigIn TermBlk 03] when 2-wire option is being selected as P046, P048 or P050 [Start Source x].
0 “Edge Trigger” (Default) Standard 2-Wire operation.
1 “Level Sense” • I/O Terminal 01 “Stop” = Coast to stop. Drive will restart after a Stop command when:
– Stop is removed
and
– Start is held active
• I/O Terminal 03 “Run REV”

ATTENTION: Hazard of injury exists due to unintended operation. When t064 [2-
Wire Mode] is set to option 1, and the Run input is maintained, the Run inputs do
not need to be toggled after a Stop input for the drive to run again. A Stop function
is provided only when the Stop input is active (open).

ATTENTION: When operating in 2-Wire Level Sense (Run Level), the PowerFlex 523
Options
and PowerFlex 525 drive should only be controlled from the Digital Input Terminal
Blocks. This should NOT be used with any other DSI or Network device.

2 “Hi-Spd Edge”
IMPORTANT There is greater potential voltage on the output terminals when using this
option.
• Outputs are kept in a ready-to-run state. The drive responds to a Start command within 10 ms.
• I/O Terminal 01 “Stop” = Coast to stop.
• I/O Terminal 03 “Run REV”
3 “Momentary” • Drive will start after a momentary input from either the Run FWD input (I/O Terminal 02) or the Run REV input (I/O
Terminal 03).
• I/O Terminal 01 “Stop” = Stop according to the value set in P045 [Stop Mode].

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Programmable Digital Outputs

t069 [Opto Out1 Sel] Related Parameters: P046, P048, P050, t070, t073, t077, t082,
t072 [Opto Out2 Sel] t086, t087, t093, t094, t097, A541, A564
PF 525 PowerFlex 525 only.
Determines the operation of the programmable digital outputs.
Options Setting Output Changes State When... Hysteresis
0 “Ready/Fault” Opto outputs are active when power is applied. Indicates that the drive is ready for operation. Opto None
outputs are inactive when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency. 0.5 Hz above; 1.0 Hz below
2 “MotorRunning” Motor is receiving power from the drive. None
3 “Reverse” Drive is commanded to run in reverse direction. None
4 “Motor Overld” Motor overload condition exists. 100 ms time delay on or off
5 “Ramp Reg” Ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or 100 ms time delay on or off
overvoltage fault from occurring.
6 “Above Freq” Drive exceeds the frequency (Hz) value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
7 “Above Cur” Drive exceeds the current (% Amps) value set in t070 or t073 [Opto Outx Level].

IMPORTANT Value for t070 or t073 [Opto Outx Level] must be entered in 100 ms time delay on or off
percent of drive rated output current.
8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
9 “Retries Exst” Value set in A541 [Auto Rstrt Tries] is exceeded. None
10 “Above Anlg V” Analog input voltage (0…10V input) exceeds the value set in t070 or t073 [Opto Outx Level].
100 ms time delay on or off
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”.
11 “Above PF Ang” Power Factor angle exceeds the value set in t070 or t073 [Opto Outx Level]. 100 ms time delay on or off
12 “Anlg In Loss” Analog input loss has occurred. Program t094 [Anlg In V Loss] or t097 [Anlg In mA Loss] for desired On, 2 mA / ±1V
action when input loss occurs. Off, 3 mA / ±1.5V
13 “ParamControl” Output is directly controlled by the state of the t070 or t073 [Opto Outx Level]. A value of 0 causes the None
output to turn off. A value of 1 or greater in this parameter causes the output to turn on.
14 “NonRec Fault” • Value set in A541 [Auto Rstrt Tries] is exceeded or
• A541 [Auto Rstrt Tries] is not enabled or None
• A non-resettable fault has occurred.
15 “EM Brk Cntrl” EM Brake is energized. Program t087 [EM Brk On Delay] and t086 [EM Brk Off Delay] for desired
None
action.
16 “Thermal OL” Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 [Relay None
Outx Level]. It also energizes if the drive is within 5 °C of the drive overheat trip point.
17 “Amb OverTemp” Relay energizes when control module over temperature occurs. None
18 “Local Active” Active when drive P046, P048 or P050 [Start Source x] is in local keypad control. None
19 “Comm Loss” Active when communication is lost from any comm source with reference or control. None
20 “Logic In 1” An input is programmed as “Logic Input 1” and is active. None
21 “Logic In 2” An input is programmed as “Logic Input 2” and is active. None
22 “Logic 1 & 2” Both Logic inputs are programmed and active. None
23 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is active. None
24 “StpLogic Out” Drive enters StepLogic step with Command Word set to enable Logic output. None
25 “Timer Out” Timer has reached the value set in t070 or t073 [Opto Outx Level] or not timing. None
26 “Counter Out” Counter has reached the value set in t070 or t073 [Opto Outx Level] or not counting. None
27 “At Position” Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with –
A564 [Encoder Pos Tol].
28 “At Home” Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 –
[Encoder Pos Tol].
29 “Safe-Off” Both safe-off inputs are active. –
30 “SafeTqPermit”(1) Both safe-off inputs are inactive (closed). –
31 “AutoRst Ctdn”(1) Drive is counting down to an automatic restart. –
(1) Setting is available in FRN 5.xxx and later.

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Programmable Digital Outputs (Continued)

Default:
Opto Out1 Sel: 2
Values Opto Out2 Sel: 1
Min/Max: 0/31
Display: 1

t070 [Opto Out1 Level] Related Parameters: t069, t072

t073 [Opto Out2 Level]
32
32-bit parameter.
PF 525 PowerFlex 525 only.
Determines the on/off point for the digital outputs when t069 or t072 [Opto Outx Sel] is set to the values shown below.
Min/Max Value Range Based on [Opto Outx Sel] Setting
6: 0...500 Hz 10: 0...100% 16: 0.1...9999 s 20 0/1
:
7: 0...180% 11 0/1 17: 1...9999 counts 26: 0...150%
8: 0...815V 13 0...800 18: 0...180 ° –

Default: 0.0
Values Min/Max: 0.0/9999.0
Display: 0.1

t071 [Opto Out1 LevelF]

t074 [Opto Out2 LevelF]
PF 525 PowerFlex 525 only.
Determines the on/off point (fractional portion) for the digital outputs.
Default: Read Only
Values Min/Max: 0.0/0.9 s
Display: 0.1 s

t075 [Opto Out Logic]

PF 525 PowerFlex 525 only.
Determines the logic (Normally Open/NO or Normally Closed/NC) of the digital outputs only.

Setting Digital Out 1 Logic Digital Out 2 Logic

0 NO NO
1 NC NO
2 NO NC
3 NC NC

Default: 0
Values Min/Max: 0/3
Display: 1

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Terminal Block Group (continued)

Programmable Relay Outputs
t076 [Relay Out1 Sel] Related Parameters: P046, P048, P050, t070, t073, t077, t082, t086, t087, t093, t094, t097, A541, A564
t081 [Relay Out2 Sel]
PF 525 PowerFlex 525 only.
Determines the operation of the programmable output relay.

Options Output Relay Changes State When... Hysteresis

0 “Ready/Fault” Relay changes state when power is applied. Indicates that the drive is ready for operation. Relay None
returns drive to shelf state when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency. 0.5 Hz above; 1.0 Hz below
2 “MotorRunning” Motor is receiving power from the drive. None
3 “Reverse” Drive is commanded to run in reverse direction. None
4 “Motor Overld” Motor overload condition exists. 100 ms time delay on or off
5 “Ramp Reg” Ramp regulator is modifying the programmed accel/ decel times to avoid an overcurrent or 100 ms time delay on or off
overvoltage fault from occurring.
6 “Above Freq” Drive exceeds the frequency (Hz) value set in t077 or t082 [Relay Outx Level]. 100 ms time delay on or off
7 “Above Cur” Drive exceeds the current (% Amps) value set in t077 or t082 [Relay Outx Level].

IMPORTANT Value for t077 or t082 [Relay Outx Level] must be entered in 100 ms time delay on or off
percent of drive rated output current.
8 “Above DCVolt” Drive exceeds the DC bus voltage value set in t077 or t082 [Relay Outx Level]. 100 ms time delay on or off
9 “Retries Exst” Value set in A541 [Auto Rstrt Tries] is exceeded. None
10 “Above Anlg V” Analog input voltage (0…10V input) exceeds the value set in t077 or t082 [Relay Outx Level].
100 ms time delay on or off
IMPORTANT Do not use if t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”.
11 “Above PF Ang” Power Factor angle exceeds the value set in t077 or t082 [Relay Outx Level]. 100 ms time delay on or off
12 “Anlg In Loss” Analog input loss has occurred. Program t094 [Anlg In V Loss] or t097 [Anlg In mA Loss] for desired On, 2 mA / ±1V
action when input loss occurs. Off, 3 mA / ±1.5V
13 “ParamControl” Output is directly controlled by the state of the t077 or t082 [Relay Outx Level]. A value of 0 causes the None
output to turn off. A value of 1 or greater in this parameter causes the output to turn on.
14 “NonRec Fault” • Value set in A541 [Auto Rstrt Tries] is exceeded or
• A541 [Auto Rstrt Tries] is not enabled or None
• A non-resettable fault has occurred.
15 “EM Brk Cntrl” EM Brake is energized. Program t087 [EM Brk On Delay] and t086 [EM Brk Off Delay] for desired action. None
16 “Thermal OL” Relay energizes when thermal Motor overload counter is above the value set in t077 or t082 [Relay Outx None
Level]. It also energizes if the drive is within 5 °C of the drive overheat trip point.
17 “Amb OverTemp” Relay energizes when control module over temperature occurs. None
18 “Local Active Active when drive P046, P048 or P050 [Start Source x] is in local keypad control. None
19 “Comm Loss” Active when communication is lost from any comm source with reference or control. None
20 “Logic In 1”(1) An input is programmed as “Logic Input 1” and is active. None
21 “Logic In 2”(1) An input is programmed as “Logic Input 2” and is active. None
22 “Logic 1 & 2”(1) Both Logic inputs are programmed and active. None
23 “Logic 1 or 2”(1) One or both Logic inputs are programmed and one or both is active. None
24 “StpLogic Out”(1) Drive enters StepLogic step with Command Word set to enable Logic output. None
25 “Timer Out” Timer has reached the value set in t077 or t082 [Relay Outx Level] or not timing. None
26 “Counter Out” Counter has reached the value set in t077 or t082 [Relay Outx Level] or not counting. None
27 “At Position”(1) Drive is in Positioning mode and has reached the commanded position. Tolerance is adjusted with –
A564 [Encoder Pos Tol].
28 “At Home”(1) Drive is in Positioning mode and has reached the home position. Tolerance is adjusted with A564 –
[Encoder Pos Tol].
29 “Safe-Off”(1) Both safe-off inputs are active. –
30 “SafeTqPermit”(1)(2) Both safe-off inputs are inactive (closed). –
31 “AutoRst Ctdn”(1)(2) Drive is counting down to an automatic restart. –
(1) Setting is specific to PowerFlex 525 drives only.
(2) Setting is available in FRN 5.xxx and later.

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Programmable Relay Outputs (Continued)

Default:
Relay Out1 Sel: 0
Relay Out2 Sel: 2
Values
Min/Max: 0/31
Display: 1

t077 [Relay Out1 Level] Related Parameters: t076, t081

t082 [Relay Out2 Level]
PF 525 PowerFlex 525 only.

32
32-bit parameter.
Determines the on/off point for the output relay when t076 or t081 [Relay Outx Sel] is set to the values shown below.
Min/Max Value Range Based On [Relay Outx Sel] Setting
6: 0...500 Hz 10: 0...100% 16: 0.1...9999 s 20: 0/1
7: 0...180% 11: 0/1 17: 1...9999 counts 26: 0...150%
8: 0...815V 13: 0...800 18: 0...180 °C –

Default: 0.0
Values Min/Max: 0.0/9999.0
Display: 0.1

t078 [RelayOut1 LevelF]

t083 [RelayOut2 LevelF]
PF 525 PowerFlex 525 only.
Determines the on/off point (fractional portion) for the output relay.
Default: Read Only
Values Min/Max: 0.0/0.9 s
Display: 0.1 s

t079 [Relay 1 On Time]

t084 [Relay 2 On Time]
PF 525 PowerFlex 525 only.
Sets the delay time before Relay energizes after required condition is met.
Default: 0.0 s
Values Min/Max: 0.0/600.0 s
Display: 0.1 s

t080 [Relay 1 Off Time]

t085 [Relay 2 Off Time]
PF 525 PowerFlex 525 only.
Sets the delay time before Relay de-energizes after required condition ceases.
Default: 0.0 s
Values Min/Max: 0.0/600.0 s
Display: 0.1 s

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Terminal Block Group (continued)

t086 [EM Brk Off Delay] Related Parameters: P045
Sets the time that the drive remains at minimum frequency before ramping up to the commanded frequency (and engaging the brake coil relay) if Electromechanical (EM)
Brake Control Mode is enabled with P045 [Stop Mode].
Frequency

[EM Brk Off Delay] Ram [EM Brk On Delay]

l
cce
pd
ece
pa
Ram l

[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Default: 2.00 s
Values Min/Max: 0.00/10.00 s
Display: 0.01 s

t087 [EM Brk On Delay] Related Parameters: P045

Sets the time that the drive remains at minimum frequency (after releasing the brake coil relay) before stopping if EM Brake Control Mode is enabled with P045 [Stop
Mode].
Frequency

[EM Brk Off Delay] Ram [EM Brk On Delay]

l
cce

pd
ece
pa

l
Ram

[Minimum Freq]
Time
Start EM Brk Stop EM Brk Drive stops
commanded energized (Off) commanded de-energized (On)
Default: 2.00 s
Values Min/Max: 0.00/10.00 s
Display: 0.01 s

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Terminal Block Group (continued)

t088 [Analog Out Sel] Related Parameters: t090
The 0…10V, 0…20 mA or 4…0 mA analog output can be used to provide a signal proportional to several drive conditions. This parameter also selects which analog
calibration parameters to use.(1)
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 Series B drive is required.

Maximum Output Value =

Options Output Range Minimum Output Value t089 [Analog Out High] Filter(1) Related Parameter
0 “OutFreq 0-10” 0-10V 0V = 0 Hz [Maximum Freq] None b001
1 “OutCurr 0-10” 0-10V 0V = 0 A 200% Drive Rated Current Filter A b003
2 “OutVolt 0-10” 0-10V 0V = 0V 120% Drive Rated Output Volts None b004
3 “OutPowr 0-10” 0-10V 0V = 0 kW 200% Drive Rated Power Filter A b017
4 “OutTorq 0-10” 0-10V 0V = 0 A 200% Drive Rated Current Filter A d382
5 “TstData 0-10” 0-10V 0V = 0000 65535 (Hex FFFF) None –
6 “Setpnt 0-10” 0-10V 0V = 0% 100.0% Setpoint setting None t090
7 “DCVolt 0-10” 0-10V 0V = 0V 100.0% of trip value None b005
8 “OutFreq 0-20” 0-20 mA 0 mA = 0 Hz [Maximum Freq] None b001
9 “OutCurr 0-20” 0-20 mA 0 mA = 0 A 200% Drive Rated Current Filter A b003
10 “OutVolt 0-20” 0-20 mA 0 mA = 0V 120% Drive Rated Output Volts None b004
11 “OutPowr 0-20” 0-20 mA 0 mA = 0 kW 200% Drive Rated Power Filter A b017
12 “OutTorq 0-20” 0-20 mA 0 mA = 0 A 200% Drive Rated Current Filter A d382
13 “TstData 0-20” 0-20 mA 0 mA = 0000 65535 (Hex FFFF) None –
14 “Setpnt 0-20” 0-20 mA 0 mA = 0% 100.0% Setpoint setting None t090
15 “DCVolt 0-20” 0-20 mA 0 mA = 0V 100.0% of trip value None b005
16 “OutFreq 4-20” 4-20 mA 4 mA = 0 Hz [Maximum Freq] None b001
17 “OutCurr 4-20” 4-20 mA 4 mA = 0 A 200% Drive Rated Current Filter A b003
18 “OutVolt 4-20” 4-20 mA 4 mA = 0V 120% Drive Rated Output Volts None b004
19 “OutPowr 4-20” 4-20 mA 4 mA = 0 kW 200% Drive Rated Power Filter A b017
20 “OutTorq 4-20” 4-20 mA 4 mA = 0 A 200% Drive Rated Current Filter A d382
21 “TstData 4-20” 4-20 mA 4 mA = 0000 65535 (Hex FFFF) None –
22 “Setpnt 4-20” 4-20 mA 4 mA = 0% 100.0% Setpoint setting None t090
23 “DCVolt 4-20” 4-20 mA 4 mA = 0V 100.0% of trip value None b005
(1) Filter A is a single pole digital filter with a 162 ms time constant. Given a 0...100% step input from a steady state, the output of Filter A takes 500 ms to get to 95% of maximum, 810 ms to
get to 99%, and 910 ms to get to 100%.

Default: 0
Values Min/Max: 0/23
Display: 1

t089 [Analog Out High]

Scales the maximum output value (V or mA) when the source setting is at maximum.(1)
Default: 100%
Values Min/Max: 0/800%
Display: 1%
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 Series B drive is required.

t090 [Anlg Out Setpt] Related Parameters: t088

Sets the percentage of output desired when t088 [Analog Out Sel] is set to 6, 14 or 22 “Analog Setpoint”.(1)
Default: 0.0%
Values Min/Max: 0.0/100.0%
Display: 0.1%
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later. PowerFlex 523 Series B drive is required.

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Terminal Block Group (continued)

t091 [Anlg In 0-10V Lo] Related Parameters: P043, t092, t093
Stop drive before changing this parameter.
Sets the percentage (based on 10V) of input voltage applied to the 0…10V analog input that is used to represent P043 [Minimum Freq].
Analog inversion can be accomplished by setting this value larger than t092 [Anlg In 0-10V Hi].
If t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”, this parameter is ignored.
Default: 0.0%
Values Min/Max: 0.0/200.0%
Display: 0.1%

t092 [Anlg In 0-10V Hi] Related Parameters: P044, t091, t093

Stop drive before changing this parameter.
Sets the percentage (based on 10V) of input voltage applied to the 0…10V analog input that is used to represent P044 [Maximum Freq].
Analog inversion can be accomplished by setting this value smaller than t091 [Anlg In 0-10V Lo].
If t093 [10V Bipolar Enbl] is set to 1 “Bi-Polar In”, the same value applies to positive and negative voltage.
Default: 100.0%
Values Min/Max: 0.0/200.0%
Display: 0.1%

t093 [10V Bipolar Enbl] Related Parameters: t091, t092

PF 525 PowerFlex 525 only.
Enables/disables bi-polar control. In bi-polar mode direction is commanded by the polarity of the voltage.
If bi-polar control is enabled, P043 [Minimum Freq] and t091 [Anlg In 0-10V Lo] are ignored.
0 “Uni-Polar In” (Default) 0…10V only
Options
1 “Bi-Polar In” ±10V

t094 [Anlg In V Loss] Related Parameters: P043, P044, A426, A427

Sets the response to a loss of input. When the 0…10V input (or –10…+10V) is used for any reference, any input less than 1V is reported as a signal loss. Input must exceed
1.5V for the signal loss condition to end.
If enabled, this function affects any input that is being used as a speed reference, PID reference or PID setpoint in the drive.
0 “Disabled” (Default)
1 “Fault (F29)”
2 “Stop”
3 “Zero Ref”
Options 4 “Min Freq Ref”
5 “Max Freq Ref”
6 “Key Freq Ref”
7 “MOP Freq Ref”
8 “Continu Last”

t095 [Anlg In4-20mA Lo] Related Parameters: P043, t096

Stop drive before changing this parameter.
Sets the percentage (based on 4…20 mA) of input current applied to the 4…20 mA analog input that is used to represent P043 [Minimum Freq].
Analog inversion can be accomplished by setting this value larger than t096 [Anlg In4-20mA Hi].
Default: 0.0%
Values Min/Max: 0.0/200.0%
Display: 0.1%

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Terminal Block Group (continued)

t096 [Anlg In4-20mA Hi] Related Parameters: P044, t095
Stop drive before changing this parameter.
Sets the percentage (based on 4…20 mA) of input current applied to the 4…20 mA analog input that is used to represent P044 [Maximum Freq].
Analog inversion can be accomplished by setting this value smaller than t095 [Anlg In4-20mA Lo].
Default: 100.0%
Values Min/Max: 0.0/200.0%
Display: 0.1%

t097 [Anlg In mA Loss] Related Parameters: P043, P044, A426, A427

Sets the response to a loss of input. When the 4…20 mA input is used for any reference, any input less than 2 mA is reported as a signal loss. Input must exceed 3 mA for
the signal loss condition to end.
If enabled, this function affects any input that is being used as a speed reference or PID reference or PID setpoint in the drive.
0 “Disabled” (Default)
1 “Fault (F29)”
2 “Stop”
3 “Zero Ref”
Options 4 “Min Freq Ref”
5 “Max Freq Ref”
6 “Key Freq Ref”
7 “MOP Freq Ref”
8 “Continu Last”

t099 [Analog In Filter] Related Parameters: t091, t092, t095, t096

Sets the level of additional filtering of the analog input signals. The higher number increases filtering and decreases bandwidth. Each setting doubles the applied filtering
(1 = 2x filter, 2= 4x filter, and so on). No additional filtering is applied when set to “0”.
Default: 0
Values Min/Max: 0 /14
Display: 1

t098 [Anlg Loss Delay] Related Parameters: t094, t097

Sets the length of time after power-up during which the drive detects no analog signal loss.
Response to an analog signal loss is set in t094 or t097 [Analog In x Loss].
Default: 0.0 s
Values Min/Max: 0.0 /20.0 s
Display: 0.1 s

t100 [Sleep-Wake Sel] Related Parameters: t101, t102, t103

Drive “sleeps” if the appropriate analog input drops below the set t101 [Sleep Level] for the time set in t102 [Sleep Time] and the drive is running. When entering sleep mode
the drive ramps to zero and the run indicator on the keypad display flashes to indicate that the drive is in “sleep” mode.
When the appropriate analog input rises above the set [Wake Level], the drive “wakes” and ramps to the commanded frequency.
Inversion can be accomplished by setting [Sleep Level] to a higher setting than t103 [Wake Level].

ATTENTION: Enabling the Sleep-Wake function can cause unexpected machine operation during the Wake mode.
Equipment damage and/or personal injury can result if this parameter is used in an inappropriate application. In addition,
all applicable local, national, and international codes, standards, regulations or industry guidelines must be considered.
0 “Disabled” (Default)
1 “0-10V Input” Sleep enabled from 0…10V Analog Input 1
Options
2 “4-20mA Input” Sleep enabled from 4…20 mA Analog Input 2
3 “Command Freq” Sleep enabled based on drive commanded frequency

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Terminal Block Group (continued)

t101 [Sleep Level]
Sets the analog input level that the drive must reach to enter sleep mode.
Default: 10.0%
Values Min/Max: 0.0/100.0%
Display: 0.1%

t102 [Sleep Time]

Sets the analog input time that the drive must stay below to enter sleep mode.
Default: 0.0 s
Values Min/Max: 0.0/600.0 s
Display: 0.1 s

t103 [Wake Level]

Sets the analog input level that the drive must reach to wake from sleep mode.
Default: 15.0%
Values Min/Max: 0.0/100.0%
Display: 0.1%

t104 [Wake Time]

Sets the analog input time that the drive must stay above to wake from sleep mode.
Default: 0.0 s
Values Min/Max: 0.0/600.0 s
Display: 0.1 s

t105 [Safety Open En]

PF 525 PowerFlex 525 only.
Sets the action when both safety inputs (Safety 1 and Safety 2) are disabled (de-energized – no power is applied).
0 “FaultEnable” (Default)
Options
1 “FaultDisable”

t106 [SafetyFlt RstCfg]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Sets the method of resetting fault F111 “Safety Hardware” either with a power cycle or fault clear operation.
0 “PwrCycleRset” (Default) Reset fault F111 using power cycle.
Options
1 “FltClr Reset” Reset fault F111 using fault clear mechanism without power cycle.

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Communications Group
C121 [Comm Write Mode]
Saves parameter values in active drive memory (RAM) or in drive nonvolatile memory (EEPROM).

ATTENTION: If Automatic Drive Configuration (ADC) is used, this parameter must remain at its default value of 0
“Save”.

IMPORTANT Parameter values set prior to setting 1 “RAM only” are saved in RAM.
0 “Save” (Default)
Options
1 “RAM only”

C122 [Cmd Stat Select]

PF 525 PowerFlex 525 only.
Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use over a communication network. See Writing (06) Logic Command
Data on page 205 for more information. This parameter cannot be changed when an I/O connection is established through the communication adapter or the drive’s
embedded EtherNet/IP port.
0 “Velocity” (Default)
Options
1 “Position”

C123 [RS485 Data Rate]

Sets the communications rate (bits/second) for the RS-485 port. A reset or power cycle is required after selection is made.
0 “1200”
1 “2400”
2 “4800”
Options
3 “9600” (Default)
4 “19,200”
5 “38,400”

C124 [RS485 Node Addr]

Sets the Modbus drive node number (address) for the RS-485 port if using a network connection. A reset or power cycle is required after selection is made.
Default: 100
Values Min/Max: 1/247
Display: 1

C125 [Comm Loss Action] Related Parameters: P045

Sets the drive's response to a loss of connection or excessive communication errors on the RS-485 port.
0 “Fault” (Default)
1 “Coast Stop” Stops drive using “Coast to stop”.
Options
2 “Stop” Stops drive using P045 [Stop Mode] setting.
3 “Continu Last” Drive continues operating at communication commanded speed that is saved in RAM.

C126 [Comm Loss Time] Related Parameters: C125

Sets the time that the drive remains in communication loss with the RS-485 port before taking the action specified in C125 [Comm Loss Action]. See Appendix C for more
information.

IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the RS-485 port.
Default: 5.0 s
Values Min/Max: 0.1/60.0 s
Display: 0.1 s

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Communications Group (continued)

C127 [RS485 Format]
Determines the details that are related to the specific Modbus protocol used by the drive. A reset or power cycle is required after selection is made.
0 “RTU 8-N-1” (Default)
1 “RTU 8-E-1”
2 “RTU 8-O-1”
Options
3 “RTU 8-N-2”
4 “RTU 8-E-2”
5 “RTU 8-O-2”

C128 [EN Addr Sel] Related Parameters: C129-C132, C133-C136, C137-C140

PF 525 PowerFlex 525 only.
Enables the IP address, subnet mask, and gateway address to be set with a BOOTP server. Identifies the connections that would be attempted on a reset or power cycle.
A reset or power cycle is required after selection is made.
1 “Parameters”
Options
2 “BOOTP” (Default)

C129 [EN IP Addr Cfg 1] Related Parameters: C128

C130 [EN IP Addr Cfg 2]
C131 [EN IP Addr Cfg 3]
C132 [EN IP Addr Cfg 4]
PF 525 PowerFlex 525 only.
Sets the bytes in the IP address. A reset or power cycle is required after selection is made.
192.168.1.62

[EN IP Addr Cfg 1]

[EN IP Addr Cfg 2]
[EN IP Addr Cfg 3]
[EN IP Addr Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 “Parameters”.

Default: 0
Values Min/Max: 0/255
Display: 1

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Communications Group (continued)

C133 [EN Subnet Cfg 1] Related Parameters: C128
C134 [EN Subnet Cfg 2]
C135 [EN Subnet Cfg 3]
C136 [EN Subnet Cfg 4]
PF 525 PowerFlex 525 only.
Sets the bytes of the subnet mask. A reset or power cycle is required after selection is made.
255.255.255.0

[EN Subnet Cfg 1]

[EN Subnet Cfg 2]
[EN Subnet Cfg 3]
[EN Subnet Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 “Parameters”.

Default: 0
Values Min/Max: 0/255
Display: 1

C137 [EN Gateway Cfg 1] Related Parameters: C128

C138 [EN Gateway Cfg 2]
C139 [EN Gateway Cfg 3]
C140 [EN Gateway Cfg 4]
PF 525 PowerFlex 525 only.
Sets the bytes of the gateway address. A reset or power cycle is required after selection is made.
192.168.1.1

[EN Gateway Cfg 1]

[EN Gateway Cfg 2]
[EN Gateway Cfg 3]
[EN Gateway Cfg 4]

IMPORTANT C128 [EN Addr Sel] must be set to 1 “Parameters”.

Default: 0
Values Min/Max: 0/255
Display: 1

C141 [EN Rate Cfg]

PF 525 PowerFlex 525 only.
Sets the network data rate at which EtherNet/IP communicates. A reset or power cycle is required after selection is made.
0 “Auto detect” (Default)
1 “10Mbps Full”
Options 2 “10Mbps Half”
3 “100Mbps Full”
4 “100Mbps Half”

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Communications Group (continued)

C143 [EN Comm Flt Actn] Related Parameters: P045, C145, C146, C147-C150
PF 525 PowerFlex 525 only.
Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that Ethernet communications have been disrupted.
IMPORTANT This setting is effective only if I/O that controls the drive is transmitted through the EtherNet/IP interface.

ATTENTION: Risk of injury or equipment damage exists. Parameter C143 [EN Comm Flt Actn] lets you determine the
action of the EtherNet/IP interface and connected drive if communications are disrupted. By default, this parameter
faults the drive. You can set this parameter so that the drive continues to run. Precautions should be taken to ensure
that the setting of this parameter does not create a risk of injury or equipment damage. When commissioning the
drive, verify that your system responds correctly to various situations (for example, a disconnected drive).

0 “Fault” (Default)
1 “Stop” Drive stops per P045 [Stop Mode] setting.
2 “Zero Data” Note: The Reference and Datalink values that are transmitted to the drive are set to “0”.
Options
3 “Hold Last” Note: The Logic Command, Reference, and Datalink values that are transmitted to the drive are held at their last value.
4 “Send Flt Cfg” Note: The Logic Command, Reference, and Datalink values are transmitted to the drive as configured in C145, C146, and
C147...C150.

C144 [EN Idle Flt Actn] Related Parameters: P045, C145, C146, C147-C150
PF 525 PowerFlex 525 only.
Sets the action that the EtherNet/IP interface and drive takes if the EtherNet/IP interface detects that the scanner is idle because the controller was switched to program
mode.

ATTENTION: Risk of injury or equipment damage exists. Parameter C144 [EN Idle Flt Actn] lets you determine the action
of the EtherNet/IP interface and connected drive if the scanner is idle. By default, this parameter faults the drive. you can
set this parameter so that the drive continues to run. Precautions should be taken to ensure that the setting of this
parameter does not create a risk of injury or equipment damage. When commissioning the drive, verify that your system
responds correctly to various situations (for example, a disconnected drive).
0 “Fault” (Default)
1 “Stop” Drive stops per P045 [Stop Mode] setting.
2 “Zero Data” Note: The Reference and Datalink values that are transmitted to the drive are set to “0”.
Options
3 “Hold Last” Note: The Logic Command, Reference, and Datalink values that are transmitted to the drive are held at their last value.
4 “Send Flt Cfg” Note: The Logic Command, Reference, and Datalink values are transmitted to the drive as configured in C145, C146, and
C147...C150.

C145 [EN Flt Cfg Logic] Related Parameters: C143, C144

32
32-bit parameter.
PF 525 PowerFlex 525 only.
Sets the Logic Command data that is sent to the drive if any of the following is true:
– C143 [EN Comm Flt Actn] is set to 4 “Send Flt Cfg” and communications are disrupted.
– C144 [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” and the scanner is put into Program or Test mode.
See Writing (06) Logic Command Data on page 205 for more information.
Default: 0000
Values Min/Max: 0000/FFFF
Display: 0000

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Communications Group (continued)

C146 [EN Flt Cfg Ref] Related Parameters: C143, C144
32
32-bit parameter.
PF 525 PowerFlex 525 only.
Sets the Reference data that is sent to the drive if any of the following is true:
– C143 [EN Comm Flt Actn] is set to 4 “Send Flt Cfg” and communications are disrupted.
– C144 [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” and the scanner is put into Program or Test mode.
Default: 0
Values Min/Max: 0/50000
Display: 1

C147 [EN Flt Cfg DL 1]

C148 [EN Flt Cfg DL 2]
C149 [EN Flt Cfg DL 3]
C150 [EN Flt Cfg DL 4]
PF 525 PowerFlex 525 only.
Sets the Ethernet Datalink Input data that is sent to the drive if any of the following is true:
– C143 [EN Comm Flt Actn] is set to 4 “Send Flt Cfg” and communications are disrupted.
– C144 [EN Idle Flt Actn] is set to 4 “Send Flt Cfg” and the scanner is put into Program or Test mode.
Default: 0
Values Min/Max: 0/65535
Display: 1

C153 [EN Data In 1]

C154 [EN Data In 2]
C155 [EN Data In 3]
C156 [EN Data In 4]
PF 525 PowerFlex 525 only.
Datalink parameter number whose value is written from the embedded EtherNet/IP data table. This parameter cannot be changed when an I/O connection is established
through the drive’s embedded EtherNet/IP port.
Default: 0
Values Min/Max: 0/800
Display: 1

C157 [EN Data Out 1]

C158 [EN Data Out 2]
C159 [EN Data Out 3]
C160 [EN Data Out 4]
PF 525 PowerFlex 525 only.
Datalink parameter number whose value is read from the embedded EtherNet/IP data table. This parameter cannot be changed when an I/O connection is established
through the drive’s embedded EtherNet/IP port.
Default: 0
Values Min/Max: 0/800
Display: 1

C161 [Opt Data In 1]

C162 [Opt Data In 2]
C163 [Opt Data In 3]
C164 [Opt Data In 4]
Datalink parameter number whose value is written from the High Speed Drive Serial Interface (HSDSI) data table. This parameter cannot be changed when an I/O
connection is established through the communication adapter.
Default: 0
Values Min/Max: 0/800
Display: 1

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Communications Group (continued)

C165 [Opt Data Out 1]
C166 [Opt Data Out 2]
C167 [Opt Data Out 3]
C168 [Opt Data Out 4]
Datalink parameter number whose value is read from the HSDSI data table. This parameter cannot be changed when an I/O connection is established through the
communication adapter.
Default: 0
Values Min/Max: 0/800
Display: 1

C169 [MultiDrv Sel]

Sets the configuration of the drive that is in multi-drive mode. A reset or power cycle is required after selection is made.
0 “Disabled” (Default) No multi-drive master from the internal network option module or embedded Ethernet port. The drive can still function as
a multi-drive slave or as a single drive (no multi-drive used).
1 “Network Opt” Multi-drive is enabled with the internal network option as a multi-drive master. The host drive is “Drive 0” and up to four
Options slave drives can be daisy chained from its RS-485 port.
2 “EtherNet/IP”(1) Multi-drive is enabled with the embedded Ethernet port as the multi-drive master. The host drive is “Drive 0” and up to
four slave drives can be daisy chained from its RS-485 port.
(1) Setting is specific to PowerFlex 525 drives only.

C171 [Drv 1 Addr] Related Parameters: C169

C172 [Drv 2 Addr]
C173 [Drv 3 Addr]
C174 [Drv 4 Addr]
Sets the corresponding node addresses of the daisy chained drives when C169 [MultiDrv Sel] is set to 1 “Network Opt” or 2 “EtherNet/IP”. A reset or power cycle is required
after selection is made.
Default:
Drv 1 Addr: 2
Drv 2 Addr: 3
Drv 3 Addr: 4
Values Drv 4 Addr: 5
Min/Max: 1/247
Display: 1

C175 [DSI I/O Cfg]

Sets the configuration of the Drives that are active in the multi-drive mode. Identifies the connections that would be attempted on a reset or power cycle. A reset or power
cycle is required after selection is made.
0 “Drive 0” (Default)
1 “Drive 0-1”
Options 2 “Drive 0-2”
3 “Drive 0-3”
4 “Drive 0-4”

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Chapter 3 Programming and Parameters

Logic Group
StepLogic Inputs
L180 [Stp Logic 0] L181 [Stp Logic 1]
L182 [Stp Logic 2] L183 [Stp Logic 3]
L184 [Stp Logic 4] L185 [Stp Logic 5]
L186 [Stp Logic 6] L187 [Stp Logic 7]
Stop drive before changing this parameter.
PF 525 PowerFlex 525 only.
Default: 00F1
Values Min/Max: 0000/FAFF
Display 0001
See Appendix D and Appendix E for more information on applying StepLogic® function and Position StepLogic application.
Parameters L180...L187 are only active if P047, P049, or P051 [Speed Referencex] is set to 13 “Step Logic” or 16 “Positioning”. These parameters can be used to create a
custom profile of frequency commands. Each “step” can be based on time, status of a Logic input or a combination of time and the status of a Logic input.
Digits 1...4 for each [Stp Logic x] parameter must be programmed according to the desired profile. A Logic input is established by setting a digital input, parameters t062,
t063, t065...t068 [DigIn TermBlk xx] to 24 “Logic In 1” and/or 25 “Logic In 2” or by using Bits 6 and 7 of A560 [Enh Control Word].
A time interval between steps can be programmed using parameters L190...L197 [Stp Logic Time x]. See the table below for related parameters.
The speed for any step is programmed using parameters A410...A417 [Preset Freq x].

Step StepLogic Parameter Related Preset Frequency Parameter Related StepLogic Time Parameter
(Can be activated independent of StepLogic Parameters) (Active when L180...L187 Digit 1 or 2 are set to 1, b, C, d, or E)
0 L180 [Stp Logic 0] A410 [Preset Freq 0] L190 [Stp Logic Time 0]
1 L181 [Stp Logic 1] A411 [Preset Freq 1] L191 [Stp Logic Time 1]
2 L182 [Stp Logic 2] A412 [Preset Freq 2] L192 [Stp Logic Time 2]
3 L183 [Stp Logic 3] A413 [Preset Freq 3] L193 [Stp Logic Time 3]
4 L184 [Stp Logic 4] A414 [Preset Freq 4] L194 [Stp Logic Time 4]
5 L185 [Stp Logic 5] A415 [Preset Freq 5] L195 [Stp Logic Time 5]
6 L186 [Stp Logic 6] A416 [Preset Freq 6] L196 [Stp Logic Time 6]
7 L187 [Stp Logic 7] A417 [Preset Freq 7] L197 [Stp Logic Time 7]

The position for any step is programmed using parameters L200...L214 [Step Units x].
Step StepLogic Position Parameter
0 L200 [Step Units 0] & L201 [Step Units F 0]
1 L202 [Step Units 1] & L203 [Step Units F 1]
2 L204 [Step Units 2] & L205 [Step Units F 2]
3 L206 [Step Units 3] & L207 [Step Units F 3]
4 L208 [Step Units 4] & L209 [Step Units F 4]
5 L210 [Step Units 5] & L211 [Step Units F 5]
6 L212 [Step Units 6] & L213 [Step Units F 6]
7 L214 [Step Units 7] & L215 [Step Units F 7]

How StepLogic Works

The StepLogic sequence begins with a valid start command. A normal sequence always begins with L180 [Stp Logic 0].
Digit 1: Logic for next step
This digit defines the logic for the next step. When the condition is met the program advances to the next step. Step 0 follows Step 7. Example: Digit 1 is set to 3. When
“Logic In 2” becomes active, the program advances to the next step.
Digit 2: Logic to jump to a different step
For all settings other than F, when the condition is met, the program overrides Digit 0 and jumps to the step defined by Digit 3.
Digit 3: Different step to jump
When the condition for Digit 2 is met, this digit setting determines the next step or to end the program.
Digit 4: Step settings
This digit defines additional characteristics of each step.
Any StepLogic parameter can be programmed to control a relay or opto output, but you cannot control different outputs based on the condition of different StepLogic
commands.

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 Chapter 3 Programming and Parameters

StepLogic Inputs (Continued)

StepLogic Settings
The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. See Appendix D
for more information.

Logic for next step Digit 1

Logic to jump to a different step Digit 2
Different step to jump Digit 3
Step settings Digit 4
Not Used

Velocity Control Settings (Digit 4) Settings (Digit 3)

Required Accel/Decel StepLogic Commanded Setting Description
Setting Param. Used Output State Direction 0 Jump to Step 0
0 Accel/Decel 1 Off FWD 1 Jump to Step 1
1 Accel/Decel 1 Off REV 2 Jump to Step 2
2 Accel/Decel 1 Off No Output 3 Jump to Step 3
3 Accel/Decel 1 On FWD 4 Jump to Step 4
4 Accel/Decel 1 On REV 5 Jump to Step 5
5 Accel/Decel 1 On No Output 6 Jump to Step 6
6 Accel/Decel 2 Off FWD 7 Jump to Step 7
7 Accel/Decel 2 Off REV 8 End Program (Normal Stop)
8 Accel/Decel 2 Off No Output 9 End Program (Coast to Stop)
9 Accel/Decel 2 On FWD A End Program and Fault (F2)
A Accel/Decel 2 On REV
b Accel/Decel 2 On No Output

Positioning Settings (Digit 4) Settings (Digit 2 and 1)

Required Accel/Decel StepLogic Direction Type of Setting Description
Setting Param. Used Output State From Home Command 0 Skip Step (Jump Immediately)
0 Accel/Decel 1 Off FWD Absolute 1 Step Based on [Stp Logic Time x]
1 Accel/Decel 1 Off FWD Incremental 2 Step if “Logic In 1” is Active
2 Accel/Decel 1 Off REV Absolute 3 Step if “Logic In 2” is Active
3 Accel/Decel 1 Off REV Incremental 4 Step if “Logic In 1” is Not Active
4 Accel/Decel 1 On FWD Absolute 5 Step if “Logic In 2” is Not Active
5 Accel/Decel 1 On FWD Incremental 6 Step if either “Logic In 1” or “Logic In 2” is Active
6 Accel/Decel 1 On REV Absolute 7 Step if both “Logic In 1” and “Logic In 2” are Active
7 Accel/Decel 1 On REV Incremental 8 Step if neither “Logic In 1” nor “Logic In 2” is Active
8 Accel/Decel 2 Off FWD Absolute 9 Step if “Logic In 1” is Active and “Logic In 2” is Not Active
9 Accel/Decel 2 Off FWD Incremental A Step if “Logic In 2” is Active and “Logic In 1” is Not Active
A Accel/Decel 2 Off REV Absolute b Step after [Stp Logic Time x] and “Logic In 1” is Active
b Accel/Decel 2 Off REV Incremental C Step after [Stp Logic Time x] and “Logic In 2” is Active
C Accel/Decel 2 On FWD Absolute d Step after [Stp Logic Time x] and “Logic In 1” is Not Active
d Accel/Decel 2 On FWD Incremental E Step after [Stp Logic Time x] and “Logic In 2” is Not Active
E Accel/Decel 2 On REV Absolute F Do Not Step/Ignore Digit 2 Settings
F Accel/Decel 2 On REV Incremental

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Chapter 3 Programming and Parameters

Logic Group (continued)

L190 [Stp Logic Time 0] L191 [Stp Logic Time 1]
L192 [Stp Logic Time 2] L193 [Stp Logic Time 3]
L194 [Stp Logic Time 4] L195 [Stp Logic Time 5]
L196 [Stp Logic Time 6] L197 [Stp Logic Time 7]
PF 525 PowerFlex 525 only.
Sets the time to remain in each step if the corresponding command word is set to “Step based on time”.
Default: 30.0 s
Values Min/Max: 0.0/999.9 s
Display: 0.1 s

L200 [Step Units 0] L202 [Step Units 1]

L204 [Step Units 2] L206 [Step Units 3]
L208 [Step Units 4] L210 [Step Units 5]
L212 [Step Units 6] L214 [Step Units 7]
32
32-bit parameter.
PF 525 PowerFlex 525 only.
Sets the position in user-defined units that the drive must reach at each step.
Default: 0.00
Values Min/Max: 0.00/6400.00
Display: 0.01

L201 [Step Units F 0] L203 [Step Units F 1]

L205 [Step Units F 2] L207 [Step Units F 3]
L209 [Step Units F 4] L211 [Step Units F 5]
L213 [Step Units F 6] L215 [Step Units F 7]
PF 525 PowerFlex 525 only.
Sets the position in user-defined units (fractional portion) the drive must reach at each step.
Default: Read Only
Values Min/Max: 0.00/0.99
Display: 0.01

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 Chapter 3 Programming and Parameters

Advanced Display Group

d360 [Analog In 0-10V] Related Parameters: t091, t092
Displays the 0…10V analog input as a percent of full scale.
Default: Read Only
Values Min/Max: 0.0/100.0%
Display: 0.1%

d361 [Analog In 4-20mA] Related Parameters: t095, t096

Displays the 4…20 mA analog input as a percent of full scale.
Default: Read Only
Values Min/Max: 0.0/100.0%
Display: 0.1%

d362 [Elapsed Time-hr] Related Parameters: A555

Displays the total elapsed powered-up time (in hours) since timer reset. The timer stops when it reaches the maximum value.
Default: Read Only
Values Min/Max: 0/32767 hr
Display: 1 hr

d363 [Elapsed Time-min] Related Parameters: d362, A555

Displays the total elapsed powered-up time (in minutes) since timer reset. Resets to zero when maximum value is reached and increments d362 [Elapsed Time-hr] by one.
Default: Read Only
Values Min/Max: 0.0/60.0 min
Display: 0.1 min

d364 [Counter Status]

Displays the current value of the counter if enabled.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

d365 [Timer Status]

32
32-bit parameter.
Displays the current value of the timer if enabled.
Default: Read Only
Values Min/Max: 0.0/9999.0 s
Display: 0.1 s

d366 [Timer StatusF]

Displays the current value of the timer (fractional portion) if enabled.
Default: Read Only
Values Min/Max: 0.0/0.9 s
Display: 0.1 s

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Chapter 3 Programming and Parameters

Advanced Display Group (continued)

d367 [Drive Type]
Displays the Drive type setting. Used by Rockwell Automation field service personnel (not write accessible by non-Rockwell Automation technical personnel).
Default: Read Only
Values Min/Max: 0/65535
Display: 1

d368 [Testpoint Data] Related Parameters: A483

Displays the present value of the function that is selected in A483 [Testpoint Sel].
Default: Read Only
Values Min/Max: 0/FFFF
Display: 1

d369 [Motor OL Level]

Displays the motor overload counter.
Default: Read Only
Values Min/Max: 0.0/150.0%
Display: 0.1%

d375 [Slip Hz Meter] Related Parameters: P032

Displays the current amount of slip or droop (absolute value) being applied to the motor frequency. Drive applies slip based on the setting for P032 [Motor NP Hertz].
Default: Read Only
Values Min/Max: 0.0/25.0 Hz
Display: 0.1 Hz

d376 [Speed Feedback]

32
32-bit parameter.
Displays the value of the actual motor speed whether measured by encoder/pulse train feedback or estimated.
Default: Read Only
Values Min/Max: 0.0/64000.0 rpm
Display: 0.1 rpm

d377 [Speed Feedback F]

Displays the value of the actual motor speed (fractional portion) whether measured by encoder/pulse train feedback or estimated.
Default: Read Only
Values Min/Max: 0.0/0.9 rpm
Display: 0.1 rpm

d378 [Encoder Speed]

32
32-bit parameter.
Provides a monitoring point that reflects the speed that is measured from the feedback device. This shows the encoder or pulse train speed even if not used directly to
control motor speed.(1)
Default: Read Only
Values Min/Max: 0.0/64000.0 rpm
Display: 0.1 rpm
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

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 Chapter 3 Programming and Parameters

Advanced Display Group (continued)

d379 [Encoder Speed F]
Provides a monitoring point that reflects the speed (fractional portion) measured from the feedback device. This shows the encoder or pulse train speed even if not used
directly to control the motor speed.
Default: Read Only
Values Min/Max: 0.0/0.9 rpm
Display: 0.1 rpm

d380 [DC Bus Ripple]

Displays the real-time value of the DC bus ripple voltage.
Default: Read Only
Values Min/Max: 0/410V DC for 230V AC drives; 820V DC for 460V AC drives; 1025V DC for 600V AC drives
Display: 1V DC

d381 [Output Powr Fctr]

Displays the angle in electrical degrees between motor voltage and motor current.
Default: Read Only
Values Min/Max: 0.0/180.0 deg
Display: 0.1 deg

d382 [Torque Current]

Displays the current value of the motor torque current that is measured by the drive.
Default: Read Only
Values Min/Max: 0.00/(Drive Rated Amps x 2)
Display: 0.01 A

d383 [PID1 Fdbk Displ]

d385 [PID2 Fdbk Displ]
PF 525 PowerFlex 525 only.
Displays the active PID Feedback value.
Default: Read Only
Values Min/Max: 0.0/100.0%
Display: 0.1%

d384 [PID1 Setpnt Disp]

d386 [PID2 Setpnt Disp]
PF 525 PowerFlex 525 only.
Displays the active PID Setpoint value.
Default: Read Only
Values Min/Max: 0.0/100.0%
Display: 0.1%

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Chapter 3 Programming and Parameters

Advanced Display Group (continued)

d387 [Position Status]
PF 525 PowerFlex 525 only.
Displays the present operating condition of the drive. When in Positioning mode, Bit 1 indicates positive or negative position in relation to Home.

1 = Condition True, 0 = Condition False

Dir Positive Digit 1
At Position Digit 2
At Home Digit 3
Drive Homed Digit 4
Not Used

Default: Read Only

Values Min/Max: 0000/1111
Display: 0000

d388 [Units Traveled H] Related Parameters: d387

Stop drive before changing this parameter.
32
32-bit parameter.
PF 525 PowerFlex 525 only.
Displays the number of user-defined units traveled from the home position. See d387 [Position Status] for direction of travel.
Default: Read Only
Values Min/Max: 0/64000
Display: 1

d389 [Units Traveled L] Related Parameters: d387

Stop drive before changing this parameter.
PF 525 PowerFlex 525 only.
Displays the number of user-defined units (fractional portion) traveled from the home position. See d387 [Position Status] for direction of travel.
Default: Read Only
Values Min/Max: 0.00/0.99
Display: 0.01

d390 [Fiber Status]

Present status of the Fibers features.

1 = Condition True, 0 = Condition False

Sync Hold Digit 1
Sync Ramp Digit 2
Traverse On Digit 3
Traverse Dec Digit 4
Not Used

Default: Read Only

Values Min/Max: 0000/1111
Display: 0000

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 Chapter 3 Programming and Parameters

Advanced Display Group (continued)

d391 [Stp Logic Status] Related Parameters: P047, L180-L187
PF 525 PowerFlex 525 only.
Displays the current step of the StepLogic profile as defined by parameters L180...L187 [Step Logic x] when P047 [Speed Reference1] is set to 13 “Step Logic” or 16
“Positioning”.
Default: Read Only
Values Min/Max: 0/8
Display: 1

d392 [RdyBit Mode Act] Related Parameters: A574

(With PowerFlex 525 FRN 3.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Displays the value of A574 [RdyBit Mode Cfg].
Default: Read Only
Values Min/Max: 0/1
Display: 1

d393 [Drive Status 2]

(With PowerFlex 525 FRN 5.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Displays the present operating condition of the drive.
Saf Statu rmit (1)

Flu or Ov tdn
Jog Brak rld
gin ing
Safety S2s(1 1)

Fre ing
(

ety )

At o Tun g

Mo oRst g
S1 (1)

Aut Braki t

x e
n

n
t C
F11 eTqPe

i
EM Lim

AutBraki

g
DC q
r
Cur
1
Saf

x x 0 0 0 0 x 0 0 0 0 0 0 0 0 0 1 = Condition True
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 = Condition False
Nibble 4 Nibble 3 Nibble 2 Nibble 1 x = Reserved
Bit # * Enhanced Control Option Only.

(1) Bit status is specific to PowerFlex 525 drives only.

Default: Read Only
Values Min/Max: 0/65535
Display: 1

d394 [Dig Out Status]

(With PowerFlex 525 FRN 5.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Displays relay output and opto output status.

Status Bit Value = 0 Bit Value = 1

Rly1 Status Digit 1 Relay 1 status (Normally Open) Not activated (Relay 1 open) Activated (Relay 1 closed)
Rly2 Status(1) Digit 2 Relay 2 status (Normally Closed) Not activated (Relay 2 closed) Activated (Relay 2 open)
Opto1 Status(1) Digit 3
Opto 1 status Not activated Activated
Opto2 Status(1) Digit 4
Not Used Opto 2 status Not activated Activated
(1) Setting is specific to PowerFlex 525 drives only.
Default: Read Only
Values Min/Max: 0/15
Display: 1

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Chapter 3 Programming and Parameters

Advanced Program Group

A410 [Preset Freq 0] A411 [Preset Freq 1]
A412 [Preset Freq 2] A413 [Preset Freq 3]
A414 [Preset Freq 4] A415 [Preset Freq 5]
A416 [Preset Freq 6] A417 [Preset Freq 7]
A418 [Preset Freq 8] A419 [Preset Freq 9]
A420 [Preset Freq 10] A421 [Preset Freq 11]
A422 [Preset Freq 12] A423 [Preset Freq 13]
A424 [Preset Freq 14] A425 [Preset Freq 15]
PF 525 PowerFlex 525 only.
Sets the frequency of the drive outputs to the programmed value when selected.
For PowerFlex 525
Preset Input 1 Preset Input 2 Preset Input 3 Preset Input 4
Default Accel/Decel Used (DigIn TermBlk 05) (DigIn TermBlk 06) (DigIn TermBlk 07) (DigIn TermBlk 08)
Preset Setting 0(1) 1 0 0 0 0
Preset Setting 1 1 1 0 0 0
Preset Setting 2 2 0 1 0 0
Preset Setting 3 2 1 1 0 0
Preset Setting 4 1 0 0 1 0
Preset Setting 5 1 1 0 1 0
Preset Setting 6 2 0 1 1 0
Preset Setting 7 2 1 1 1 0
Preset Setting 8 1 0 0 0 1
Preset Setting 9 1 1 0 0 1
Preset Setting 10 2 0 1 0 1
Preset Setting 11 2 1 1 0 1
Preset Setting 12 1 0 0 1 1
Preset Setting 13 1 1 0 1 1
Preset Setting 14 2 0 1 1 1
Preset Setting 15 2 1 1 1 1
For PowerFlex 523
Default Accel/Decel Used Preset Input 1 Preset Input 2 Preset Input 3 –
(DigIn TermBlk 05) (DigIn TermBlk 06) (DigIn TermBlk 03)
(1) 1 0 0 0
Preset Setting 0
Preset Setting 1 1 1 0 0
Preset Setting 2 2 0 1 0
Preset Setting 3 2 1 1 0
–
Preset Setting 4 1 0 0 1
Preset Setting 5 1 1 0 1
Preset Setting 6 2 0 1 1
Preset Setting 7 2 1 1 1
(1) Preset Setting 0 is only available if P047, P049, or P051 [Speed Referencex] is set to 7 “Preset Freq”.

Defaults:
Preset Freq 0: 0.00 Hz
Preset Freq 1: 5.00 Hz
Preset Freq 2: 10.00 HZ
Preset Freq 3: 20.00 Hz
Preset Freq 4: 30.00 Hz
Values Preset Freq 5: 40.00 Hz
Preset Freq 6: 50.00 Hz
Preset Freq 7...15: 60.00 Hz
Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

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 Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A426 [Keypad Freq] Related Parameters: P047, P049, P051
Provides the drive frequency command using the built-in keypad navigation. When P047, P049 or P051 [Speed Referencex] selects 2 “Keypad Freq”, the value set in this
parameter controls the frequency of the drive. The value of this parameter can also be changed when navigating with the keypad by pressing the Up or Down arrow keys.
Default: 60.00 Hz
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

A427 [MOP Freq]

Provides the drive frequency command using the built-in Motor Operated Potentiometer (MOP).

IMPORTANT Frequency is not written to non-volatile storage until drive is powered-down. If both MOP Up and MOP Down are applied
at the same time, the inputs are ignored and the frequency is unchanged.
Default: 60.00 Hz
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

A428 [MOP Reset Sel]

Determines if the current MOP reference command is saved on power down.
0 “Zero MOP Ref” Resets the MOP frequency to zero on power down and stop.
Options
1 “Save MOP Ref” (Default)

A429 [MOP Preload]

Determines the operation of the MOP function.
0 “No preload” (Default)
Options
1 “Preload” Bumpless Transfer: whenever MOP mode is selected, the current output value of the speed is loaded.

A430 [MOP Time]

Sets the rate of change of the MOP reference.
Default: 10.0 s
Values Min/Max: 0.1/600.0 s
Display: 0.1 s

A431 [Jog Frequency] Related Parameters: P044

Sets the output frequency when a jog command is issued.
Default: 10.00 Hz
Values Min/Max: 0.00/[Maximum Freq]
Display: 0.01 Hz

A432 [Jog Accel/Decel]

Sets the acceleration and deceleration time that is used when in jog mode.
Default: 10.00 s
Values Min/Max: 0.01/600.00 s
Display: 0.01 s

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A433 [Purge Frequency] Related Parameters: t062, t063, t065-t068
Provides a fixed frequency command value when t062, t063, t065-t068 [DigIn TermBlk xx] is set to 40 “Purge”.
Default: 5.00 Hz
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

A434 [DC Brake Time] Related Parameters: P045, A435

Sets the length of time that DC brake current is “injected” into the motor when P045 [Stop Mode] is set to 10 “PointStp,CF” and 11 “PointStop” or 0 “Ramp,CF” and 4 “Ramp”.
Default: 0.0 s
Values Min/Max: 0.0/99.9 s
Display: 0.1 s

A435 [DC Brake Level] Related Parameters: P045

Defines the maximum DC brake current, in amps, applied to the motor when P045 [Stop Mode] is set to either 0 “Ramp,CF”, 2 “DC Brake, CF”, 4 “Ramp”, 6 “DC Brake”, 10
“PointStp,CF”, or 11 “PointStop”.
Ramp-to-Stop Mode DC Injection Stop Mode
[DC Brake Time]
Voltage
Volts/Speed

Volts/Speed

Vo
lta
ge Speed
Spee [DC Brake Time]
d
Magnitude Magnitude
depends on depends on
Time [DC Brake Level] Time [DC Brake Level]
Stop Command Stop Command

ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking
device must be used. This feature should not be used with synchronous motors. Motors may be demagnetized during
braking.
Default: Drive Rated Amps x 0.05
Values Min/Max: 0.00/(Drive Rated Amps x 1.80)
Display: 0.01 A

A436 [DC Brk Time@Strt] Related Parameters: P045, A435

Sets the length of time that DC brake current is “injected” into the motor after a valid start command is received.

ge
Volts/Speed

lta
Vo
[DC Brk Time@Strt] d
Spee
[DC Brake Level]

Time
Start Command
Default: 0.0 s
Values Min/Max: 0.0/99.9 s
Display: 0.1 s

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 Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A437 [DB Resistor Sel] Related Parameters: A438, A550
Stop drive before changing this parameter.
Enables/disables external dynamic braking and selects the level of resistor protection.

IMPORTANT When A437 [DB Resistor Sel] is set to a value greater than “0”, the value set in parameter A550 [Bus Reg Enable] does
not take effect.
0 “Disabled” (Default)
1 “Norml RA Res” 5%
Options
2 “NoProtection” 100%
3...99“3...99% DutyCycle”

A438 [DB Threshold] Related Parameters: A437

Sets the DC bus voltage threshold for Dynamic Brake operation. If DC bus voltage rises above this level, Dynamic Brake turns on. Lower values make the dynamic braking
function more responsive but may result in nuisance Dynamic Brake activation (IGBT can modulate continuously).

ATTENTION: Equipment damage may result if this parameter is set to a value that causes the dynamic braking resistor to
dissipate excessive power. Parameter settings less than 100% should be carefully evaluated to ensure that the Dynamic
Brake resistor's wattage rating is not exceeded. In general, values less than 90% are not needed. This parameter's setting
is especially important if parameter A437 [DB Resistor Sel] is set to 2 “NoProtection”.
Default: 100.0%
Values Min/Max: 10.0/110.0%
Display: 0.1%

A439 [S Curve %]
Enables a fixed shape S-curve that is applied to the acceleration and deceleration ramps (including jog).
S-Curve Time = (Accel or Decel Time) x (S-Curve Setting in percentage)
100% S-Curve 50% S-Curve Example:
Target Target
Accel Time = 10 s
vel vel S-Curve Setting = 30%
S-Curve Time = 10 x 0.3 = 3 s
Target
vel/2

S-Curve Time = Accel Time S-Curve Time

Total Time to Accelerate = Accel Time + S-Curve Time Total Time to Accelerate = Accel Time + S-Curve Time
Default: 0%
Values Min/Max: 0/100%
Display: 1%

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Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A440 [PWM Frequency] Related Parameters: A540
Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting.
100
95
90
85
% Output Curent (A)

80
75
70 Note: If Vector mode (open loop) is selected and 16 kHz is selected, the
65 drive forcibly reduces the carrier frequency to 8 kHz.
60
55
50
45
40
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Carrier Frequency (kHz)

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 by A540 [Var PWM Disable].
Default: 4.0 kHz
Values Min/Max: 2.0/16.0 kHz
Display: 0.1 kHz

A441 [Droop Hertz@ FLA]

PF 525 PowerFlex 525 only.
Reduces the frequency based on current. This frequency is subtracted from the commanded output frequency. Generally Slip and Droop would not both be used, but if both
are enabled they simply subtract from each other. Typically used in load sharing schemes.
Default: 0.0 Hz
Values Min/Max: 0.0/10.0 Hz
Display: 0.1 Hz

A442 [Accel Time 2] Related Parameters: P044

Time for the drive to ramp from 0.0 Hz to P044 [Maximum Freq] if Accel Time 2 is selected.
Accel Rate = [Maximum Freq] / [Accel Time]
[Maximum Freq]
Dec
on
rati

ele

Speed
ele

rati
Acc

on

0
[Accel Time x] Time [Decel Time x]
0
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

A443 [Decel Time 2] Related Parameters: P044

Time for the drive to ramp from P044 [Maximum Freq] to 0.0 Hz if Decel Time 2 is selected.
Decel Rate = [Maximum Freq] / [Decel Time]
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

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 Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A444 [Accel Time 3]
A446 [Accel Time 4]
Sets the rate of acceleration for all speed increases when selected by digital inputs.
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

A445 [Decel Time 3]

A447 [Decel Time 4]
Sets the rate of deceleration for all speed decreases when selected by digital inputs.
Default: 10.00 s
Values Min/Max: 0.00/600.00 s
Display: 0.01 s

A448 [Skip Frequency 1] Related Parameters: A449, A451, A453, A455

A450 [Skip Frequency 2]
A452 [Skip Frequency 3]
A454 [Skip Frequency 4]
PF 525 PowerFlex 525 only.
Works with A449, A451, A453 and A455 [Skip Freq Band x] creating a range of frequencies at which the drive does not operate continuously.
Default: 0.0 Hz (Disabled)
Values Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz

A449 [Skip Freq Band 1] Related Parameters: A448, A450, A452, A454
A451 [Skip Freq Band 2]
A453 [Skip Freq Band 3]
A455 [Skip Freq Band 4]
PF 525 PowerFlex 525 only.
Determines the band around A448, A450, A452 and A454 [Skip Frequency x].
Frequency Command
Frequency
Drive Output
Frequency

Skip Frequency 2x Skip

Frequency Band

Time
Default: 0.0 Hz
Values Min/Max: 0.0/30.0 Hz
Display: 0.1 Hz

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Advanced Program Group (continued)

A456 [PID 1 Trim Hi]
A468 [PID 2 Trim Hi]
PF 525 PowerFlex 525 only.
Scales the upper value of the trim frequency when trim is active.
Default: 60.0 Hz
Values Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz

A457 [PID 1 Trim Lo]

A469 [PID 2 Trim Lo]
PF 525 PowerFlex 525 only.
Scales the lower value of the trim frequency when trim is active.
Default: 0.0 Hz
Values Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz

A458 [PID 1 Trim Sel]

A470 [PID 2 Trim Sel]
PF 525 PowerFlex 525 only.

Stop drive before changing this parameter.

Sets the PID output as trim to the source reference.
0 “Disabled” (Default) PID Trim is disabled.
1 “TrimOn Pot”
2 “TrimOn Keypd”
3 “TrimOn DSI”
4 “TrimOn NetOp”
5 “TrimOn 0-10V”
6 “TrimOn 4-20”
Options
7 “TrimOn Prset”
8 “TrimOn AnMlt”(1)
9 “TrimOn MOP”
10 “TrimOn Pulse”
11 “TrimOn Slgic”(1)
12 “TrimOn Encdr”(1)
13 “TrimOn ENet”(1)
(1) Setting is specific to PowerFlex 525 drives only.

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 Chapter 3 Programming and Parameters

Advanced Program Group (continued)

A459 [PID 1 Ref Sel]
A471 [PID 2 Ref Sel]
PF 525 PowerFlex 525 only.

Stop drive before changing this parameter.

Selects the source of the PID reference.
0 “PID Setpoint” (Default)
1 “Drive Pot”
2 “Keypad Freq”
3 “Serial/DSI”
4 “Network Opt”
5 “0-10V Input”
6 “4-20mA Input”
Options
7 “Preset Freq”
8 “AnlgIn Multi”(1)
9 “MOP Freq”
10 “Pulse Input”
11 “Step Logic”(1)
12 “Encoder”(1)
13 “EtherNet/IP”(1)
(1) Setting is specific to PowerFlex 525 drives only.

A460 [PID 1 Fdback Sel]

A472 [PID 2 Fdback Sel]
PF 525 PowerFlex 525 only.
Selects the source of the PID feedback.
0 “0-10V Input” (Default) Note: PID does not function with bipolar input. Negative voltages are ignored and treated as zero.
1 “4-20mA Input”
2 “Serial/DSI”
Options 3 “Network Opt”
4 “Pulse Input”
5 “Encoder”(1)
6 “EtherNet/IP”(1)
(1) Setting is specific to PowerFlex 525 drives only.

A461 [PID 1 Prop Gain] Related Parameters: A459, A471

A473 [PID 2 Prop Gain]
PF 525 PowerFlex 525 only.
Sets the value for the PID proportional component when the PID mode is enabled.
Default: 0.01
Values Min/Max: 0.00/99.99
Display: 0.01

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Advanced Program Group (continued)

A462 [PID 1 Integ Time] Related Parameters: A459, A471
A474 [PID 2 Integ Time]
PF 525 PowerFlex 525 only.
Sets the value for the PID integral component when PID mode is enabled.
Default: 2.0 s
Values Min/Max: 0.0/999.9 s
Display: 0.1 s

A463 [PID 1 Diff Rate] Related Parameters: A459, A471

A475 [PID 2 Diff Rate]
PF 525 PowerFlex 525 only.
Sets the value (in 1/second) for the PID differential component when PID mode is enabled.
Default: 0.00
Values Min/Max: 0.00/99.99
Display: 0.01

A464 [PID 1 Setpoint] Related Parameters: A459, A471

A476 [PID 2 Setpoint]
PF 525 PowerFlex 525 only.
Provides an internal fixed value for the process setpoint when PID mode is enabled.
Default: 0.0%
Values Min/Max: 0.0/100.0%
Display: 0.1%

A465 [PID 1 Deadband]

A477 [PID 2 Deadband]
PF 525 PowerFlex 525 only.
Sets a range, in percent above and below the PID Reference, that the PID output ignores.
Default: 0.0%
Values Min/Max: 0.0/10.0%
Display: 0.1%

A466 [PID 1 Preload]

A478 [PID 2 Preload]
PF 525 PowerFlex 525 only.
Sets the value that is used to preload the integral component on start or enable.
Default: 0.0 Hz
Values Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz

A467 [PID 1 Invert Err]

A479 [PID 2 Invert Err]
PF 525 PowerFlex 525 only.
Changes the sign of the PID error.
0 “Normal” (Default)
Options
1 “Inverted”

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Advanced Program Group (continued)

A481 [Process Disp Lo] Related Parameters: b010, P043
Sets the value that is displayed in b010 [Process Display] when the drive is running at P043 [Minimum Freq].
Default: 0.00
Values Min/Max: 0.00/99.99
Display: 0.01

A482 [Process Disp Hi] Related Parameters: b010, P044

Sets the value that is displayed in b010 [Process Display] when the drive is running at P044 [Maximum Freq].
Default: 0.00
Values Min/Max: 0.00/99.99
Display: 0.01

A483 [Testpoint Sel]

Used by Rockwell Automation field service personnel.
Default: 400
Values Min/Max: 0/FFFF
Display: 1

A484 [Current Limit 1] Related Parameters: P033

Maximum output current allowed before current limiting occurs.
Default: Drive Rated Amps x 1.1 (Normal Duty); Drive Rated Amps x 1.5 (Heavy Duty)
Values Min/Max: 0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty)
Display: 0.1 A

A485 [Current Limit 2] Related Parameters: P033

PF 525 PowerFlex 525 only.
Maximum output current allowed before current limiting occurs.
Default: Drive Rated Amps x 1.1
Values Min/Max: 0.0/Drive Rated Amps x 1.5 (Normal Duty); Drive Rated Amps x 1.8 (Heavy Duty)
Display: 0.1 A

A486 [Shear Pin1 Level] Related Parameters: A487, A489

A488 [Shear Pin2 Level]
PF 525 PowerFlex 525 only.
Sets the value of current at which the shear pin fault occurs after the time set in A487, A489 [Shear Pin x Time]. Setting the value at 0.0 A disables this function.
Default: 0.0 A (Disabled)
Values Min/Max: 0.0/(Drive Rated Amps x 2)
Display: 0.1 A

A487 [Shear Pin 1 Time] Related Parameters: A486, A488

A489 [Shear Pin 2 Time]
PF 525 PowerFlex 525 only.
Sets the continuous time that the drive must be at or above the value set in A486, A488 [Shear Pinx Level] before a shear pin fault occurs.
Default: 0.00 s
Values Min/Max: 0.00/30.00 s
Display: 0.01 s

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Advanced Program Group (continued)

A490 [Load Loss Level] Related Parameters: A491
PF 525 PowerFlex 525 only.
Provides a software trip (Load Loss fault) when the current drops below this level for the time specified in A491 [Load Loss Time].
Default: 0.0 A
Values Min/Max: 0.0/Drive Rated Amps
Display: 0.1 A

A491 [Load Loss Time] Related Parameters: A490

PF 525 PowerFlex 525 only.
Sets the required time for the current to be below A490 [Load Loss Level] before a Load Loss fault occurs.
Default: 0s
Values Min/Max: 0/9999 s
Display: 1s

A492 [Stall Fault Time]

Sets the time that the drive remains in stall mode before a fault is issued.
0 “60 Seconds” (Default)
1 “120 Seconds”
2 “240 Seconds”
Options
3 “360 Seconds”
4 “480 Seconds”
5 “Flt Disabled”

A493 [Motor OL Select] Related Parameters: P032, P033

Drive provides Class 10 overload protection. Settings 0...2 select the derating factor for the I2t overload function.
No Derate Min Derate Max Derate
100 100 100
95
% of [Motor OL Curent]

% of [Motor OL Curent]
% of [Motor OL Curent]

80 80 80
60 60 60
40 40 40
20 20 20
0 0 0
0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200
% of [Motor NP Hertz] % of [Motor NP Hertz] % of [Motor NP Hertz]
0 “No Derate” (Default)
Options 1 “Min Derate”
2 “Max Derate”

A494 [Motor OL Ret]

Selects whether the motor overload counter is saved on power-down or reset on power-up.
0 “Reset” (Default)
Options
1 “Save”

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Advanced Program Group (continued)

A495 [Drive OL Mode]
Determines how the drive handles overload conditions that would otherwise cause the drive to fault.
0 “Disabled”
1 “Reduce CLim”
Options
2 “Reduce PWM”
3 “Both-PWM 1st” (Default)

A496 [IR Voltage Drop] Related Parameters: P040

Value of volts dropped across the resistance of the motor stator (autotune) for induction motor.
Default: Based on Drive Rating
Values Min/Max: 0.0/600.0VAC
Display: 0.1VAC

A497 [Flux Current Ref] Related Parameters: P040

This is the current necessary for full motor flux. The value should be set to the full speed no-load current of the motor.
Default: Based on Drive Rating
Values Min/Max: 0.00/(Drive Rated Amps x 1.4)
Display: 0.01 A

A498 [Motor Rr]

PF 525 PowerFlex 525 only.
Rotor resistance of induction motor. The value of this parameter populates when a full rotate tune is performed.
Default: Based on Drive Rating
Values Min/Max: 0.00/655.35 ohm
Display: 0.01 ohm

A499 [Motor Lm]

PF 525 PowerFlex 525 only.
Mutual Inductance of induction motor. The value of this parameter populates when a full rotate tune is performed.
Default: Based on Drive Rating
Values Min/Max: 0.0/6553.5 mH
Display: 0.1 mH

A500 [Motor Lx]

PF 525 PowerFlex 525 only.
Leakage Inductance of induction motor. The value of this parameter populates when a full rotate tune is performed.
Default: Based on Drive Rating
Values Min/Max: 0.0/6553.5 mH
Display: 0.1 mH

A501 [PM IR Voltage]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Voltage across the stator resistance of the PM or SynRM motor at the rated motor current that is displayed in line-to-line rms value.
Default: 11.50V
Values Min/Max: 0.00/655.35V
Display: 0.01V

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Advanced Program Group (continued)

A502 [PM IXd Voltage]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Voltage across the d-axis stator inductance of the PM or SynRM motor at the rated motor current and the rated motor frequency that is displayed in line-to-line rms value.
Default: 17.91V
Values Min/Max: 0.00/655.35V
Display: 0.01V

A503 [PM IXq Voltage]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Voltage across the q-axis stator inductance of the PM or SynRM motor at the rated motor current and the rated motor frequency that is displayed in line-to-line rms value.
Default: 53.21V
Values Min/Max: 0.00/655.35V
Display: 0.01V

A504 [PM BEMF Voltage]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Back electromotive force (EMF) voltage of the PM or SynRM motor.
Default: 328.0 V - PM, 164.0 V - SynRM
Values Min/Max: 0.0/1200.0 V
Display: 0.1V

A509 [Speed Reg Sel] Related Parameters: A521, A522, A523, A524, A525, A526
PF 525 PowerFlex 525 only.
Determines if PI gain of the “Vector” control mode speed regulator is set automatically or manually. This parameter automatically sets parameters A521...A526.
0 “Automatic” (Default)
Options
1 “Manual”

A510 [Freq 1]
A512 [Freq 2]
A514 [Freq 3]
PF 525 PowerFlex 525 only.
Sets the “Vector” control mode frequency.
Default:
Freq 1: 8.33%
Freq 2: 15.00%
Values Freq 3: 20.00%
Min/Max: 0.00/200.00%
Display: 0.01%

A511 [Freq 1 BW]

A513 [Freq 2 BW]
A515 [Freq 3 BW]
PF 525 PowerFlex 525 only.
Speed control loop bandwidth for “Vector” control mode.
Default: 10 Hz
Values Min/Max: 0/40 Hz
Display: 1 Hz

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Advanced Program Group (continued)

A516 [PM Initial Sel]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
PM initial angle detect.
0 “Align” (Default)
Options 1 “HFI” High Frequency Injection to detect initial angle.
2 “Six Pulse”

A517 [PM DC Inject Cur]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Maximum DC current in amps applied to the motor to reset the rotor position of a PM motor.
Default: 30%
Values Min/Max: 0/300%
Display: 1%

A518 [PM Align Time]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Magnetic pole reorientation time.
Default: 0.7 s
Values Min/Max: 0.0/60.0 s
Display: 0.1 s

A519 [PM HFI NS Cur]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
High Frequency Injection (HFI) North South Current to detect N/S Magnet.
Default: 100%
Values Min/Max: 0/300%
Display: 1%

A520 [PM Bus Reg Kd]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Derivative gain for bus regulator.
Default: 2
Values Min/Max: 0/500
Display: 1

A521 [Freq 1 Kp] Related Parameters: A509, A510

A523 [Freq 2 Kp]
A525 [Freq 3 Kp]
PF 525 PowerFlex 525 only.
Sets P-gain of “Vector” control mode when in frequency region 1, 2 or 3 for faster speed response during dynamic-state where motor is still accelerating. If A509 [Speed
Reg Sel] is set to 1 “Manual”, these parameters can be changed.
Default: 100.0%
Values Min/Max: 0.0/500.0%
Display: 0.1%

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Advanced Program Group (continued)

A522 [Freq 1 Ki] Related Parameters: A509, A510
A524 [Freq 2 Ki]
A526 [Freq 3 Ki]
PF 525 PowerFlex 525 only.
Sets I-gain of “Vector” control mode when in frequency region 1, 2 or 3 for faster speed response during steady-state where motor is at its rated speed. If A509 [Speed Reg
Sel] is set to 1 “Manual”, these parameters can be changed.
Default: 0.100 s
Values Min/Max: 0.000/10.000 s
Display: 0.001 s

A527 [PM FWKn 1 Kp]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
The gain to ensure good performance in field weakening region.
Default: 350%
Values Min/Max: 0/2000%
Display: 1%

A528 [PM FWKn 2 Kp]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
The gain to ensure robustness under step load in weakening region.
Default: 300%
Values Min/Max: 100/8000%
Display: 1%

A529 [PM Control Cfg]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Control configuration for Feed Forward Decouple (FFD), Maximum Torque Per Amp (MTPA), and Load Disturbance Observer (LDOB).

1 = Condition True, 0 = Condition False

FFD (Feed Forward Decouple) Digit 1
MTPA (Maximum Torque Per Amp) Digit 2
LDOB (Load Disturbance Observer) Digit 3
Not Used
Not Used

Default: 00111
Values Min/Max: 00000/00111
Display: 00000

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Advanced Program Group (continued)

A530 [Boost Select] Related Parameters: b004, P031, P032, P039
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve. Only used for V/Hz control modes.
[Maximum Voltage] can be set anywhere.
If it is > [Motor NP Volts] then it defines a point on the V/Hz curve 100

[Maximum Voltage] can be set anywhere.

If it is < [Motor NP Volts] then it functions as a limit only
(does not change the V/Hz curve)

% [Motor NP Volts]
1/2 [Motor NP Volts]
50
4
3
2
1

[Motor NP Hertz]
1/2
Settings
5...14
% [Motor NP Hertz]
0 50 100
[Maximum Freq] can be set anywhere. [Maximum Freq] can be set anywhere.
If it is < [Motor NP Hertz] then it functions as a limit only If it is > [Motor NP Hertz] then it defines a
(does not change the V/Hz curve) point on the V/Hz curve

0 “Custom V/Hz”
1 “30.0, VT”
2 “35.0, VT”
Fan/Pump Curves (Variable Torque)
3 “40.0, VT”
4 “45.0, VT”
5 “0.0, no IR”
6 “2.5, CT”
(Default for 400V and 600V
drives, 5 HP and above)
7 “2.5, CT”
Options (Default for 200V drives, 5 HP and
above)
8 “5.0, CT”
(Default for drives below 5 HP) Boost Voltage (% of Base) (Constant Torque)
9 “7.5, CT”
10 “10.0, CT”
11 “12.5, CT”
12 “15.0, CT”
13 “17.5, CT”
14 “20.0, CT”

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Advanced Program Group (continued)

A531 [Start Boost] Related Parameters: P031, P032, P039, A530
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the V/Hz curve when A530 [Boost Select] = 0 “Custom V/Hz” and P039 [Torque Perf Mode] = 0 “V/Hz”.
[Maximum Voltage]

[Motor NP Volts]
Voltage
[Break Voltage]

[Start Boost]

Frequency
[Break Frequency] [Motor NP Hertz]
[Minimum Freq] [Maximum Freq]

Default: 2.5%
Values Min/Max: 0.0/25.0%
Display: 0.1%

A532 [Break Voltage] Related Parameters: P031, P032, P039, A530, A533
Sets the voltage (in percent of [Base Frequency]) at the A533 [Break Frequency] if A530 [Boost Select] is set to 0 “Custom V/Hz”.
Default: 25.0%
Values Min/Max: 0.0/100.0%
Display: 0.1%

A533 [Break Frequency] Related Parameters: P031, P032, P039, A530, A532
Sets the frequency where A532 [Break Voltage] is applied if A530 [Boost Select] is set to 0 “Custom V/Hz”.
Default: 15.0 Hz
Values Min/Max: 0.0/500.0 Hz
Display: 0.1 Hz

A534 [Maximum Voltage] Related Parameters: b004

Sets the highest voltage that the drive outputs.
Default: Drive Rated Volts
Min: 10V AC (on 230V AC Drives); 20V AC (on 460V AC Drives); 25V AC (on 600V AC Drives)
Values
Max: 255V AC (on 230V AC Drives); 510V AC (on 460V AC Drives); 637.5V AC (on 600V AC Drives)
Display: 1V AC

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Advanced Program Group (continued)

A535 [Motor Fdbk Type] Related Parameters:P039, A537
Stop drive before changing this parameter.

Selects the encoder type.(1)

ATTENTION: The loss of analog input, encoder, or other feedback may cause unintended speed or motion. Take
appropriate precautions to guard against possible unintended speed or motion.

Allowable Control Modes (See P039 [Torque Perf Mode]) Hardware Inputs
0 “None” (Default) V/Hz, SVC, Economize, Vector, PM Control –
1 “Pulse Train” [DigIn TermBlk 05] for PowerFlex 523
V/Hz, SVC, Economize, PM Control [DigIn TermBlk 07] for PowerFlex 525
Options 2 “Single Chan”(2) V/Hz, SVC, Economize, PM Control
3 “Single Check”(2) V/Hz, SVC, Economize, PM Control Optional incremental encoder card
4 “Quadrature”(2) V/Hz, SVC, Economize, Vector, PM Control (catalog number 25-ENC-1)
5 “Quad Check”(2) V/Hz, SVC, Economize, Vector, PM Control
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.
(2) Setting is specific to PowerFlex 525 drives only.

A536 [Encoder PPR]

PF 525 PowerFlex 525 only.
Specifies the encoder Pulses Per Revolution (PPR) when an encoder is used.
To achieve speed range/accuracy for SVC and VVC closed loop control, a minimum of 1024 PPR encoder is recommended. The maximum encoder pulse is 250 kHz.
For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on page 221.
Default: 1024 PPR
Values Min/Max: 1/20000 PPR
Display: 1 PPR

A537 [Pulse In Scale] Related Parameters: t065, t067, A535

Sets the scale factor/gain for the Pulse Input when t065 [DigIn TermBlk 05] or t067 [DigIn TermBlk 07] is set to 52 “Pulse Train”, or A535 [Motor Fdbk Type] is set to 1 “Pulse
Train”.
Input frequency (Hz) / Pulse in Scale = Output frequency (Hz)
Default: 64
Values Min/Max: 0/20000
Display: 1

A538 [Ki Speed Loop]

Sets the I-gain that is used in the PI calculation of the speed loop when feedback is used. Applicable to V/Hz and SVC modes in closed loop control only.(1)
Default: 2.0
Values Min/Max: 0.0/400.0
Display: 0.1
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

A539 [Kp Speed Loop]

Sets the P-gain that is used in the PI calculation of the speed loop when feedback is used. Applicable to V/Hz and SVC modes in closed loop control only.(1)
Default: 0.5
Values Min/Max: 0.0/200.0
Display: 0.1
(1) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.

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Advanced Program Group (continued)

A540 [Var PWM Disable] Related Parameters: A440
Stop drive before changing this parameter.
Enables/disables a feature that varies the carrier frequency for the PWM output waveform that is defined by A440 [PWM Frequency].
0 “Enabled” (Default)
Options
1 “Disabled”

A541 [Auto Rstrt Tries] Related Parameters: A542

Sets the maximum number of times the drive attempts to reset a fault and restart. See Chapter 4 for more information on faults and fault codes.
Clear a Type 1 fault and restart the drive.
1. Set A541 [Auto Rstrt Tries] to a value other than “0”.
2. Set A542 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.
1. Set A541 [Auto Rstrt Tries] to a value other than “0”.
2. Set A542 [Auto Rstrt Delay] to “0”.

ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate
application. Do not use this function without considering applicable local, national, and international codes, standards,
regulations or industry guidelines.
Default: 0
Values Min/Max: 0/9
Display: 1

A542 [Auto Rstrt Delay] Related Parameters: A541

Sets the time between restart attempts if A541 [Auto Rstrt Tries] is not zero.
Default: 1.0 s
Values Min/Max: 0.0/120.0 s
Display: 0.1 s

A543 [Start At PowerUp]

Stop drive before changing this parameter.
Enables/disables drive start on power-up without a Run command being cycled. Requires a digital input that is configured for Run and a valid run signal.

ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate
application. Do not use this function without considering applicable local, national, and international codes, standards,
regulations or industry guidelines.
0 “Disabled” (Default)
Options
1 “Enabled”

A544 [Reverse Disable] Related Parameters: b006

Stop drive before changing this parameter.
Enables/disables the function that allows the direction of motor rotation to be changed.
0 “Rev Enabled” (Default)
Options
1 “Rev Disabled”

A545 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.
0 “Disabled” (Default)
Options
1 “Enabled” Catch and ramp to commanded speed at every drive start.

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Advanced Program Group (continued)

A546 [FlyStrt CurLimit]
Used to determine when the drive has matched the motor frequency if Flying Start is enabled.
Default: 65%
Values Min/Max: 30/200%
Display: 1%

A547 [Compensation]
Enables/disables correction options that may improve problems with motor instability.
0 “Disabled” No compensation.
1 “Electrical” (Default) Some drive/motor combinations have inherent instabilities that are exhibited as non-sinusodial motor currents.
This setting attempts to correct this condition.
Options
2 “Mechanical” Some motor/load combinations have mechanical resonances that can be excited by the drive current regulator.
This setting slows down the current regulator response and attempts to correct this condition.
3 “Both”

A548 [Power Loss Mode]

Sets the reaction to a loss of input power.
0 “Coast” (Default) Drive faults and motor coasts to a stop.
Options
1 “Decel” Drive decelerates and attempts to keep the DC bus voltage above the undervoltage level.

A549 [Half Bus Enable]

Enables/disables the power ride-through function, which allows the drive to maintain power to the motor at 50% drive input voltage during short-term power sag conditions.

ATTENTION: To guard against drive damage, a minimum line impedance must be provided to limit inrush current when
the power line recovers. The input impedance should be equal or greater than the equivalent of a 5% transformer with a
VA rating 6 times the drive's input VA rating if Half Bus is enabled.
0 “Disabled” (Default)
Options
1 “Enabled”

A550 [Bus Reg Enable] Related Parameters: A437

Enables/disables the bus regulator.
0 “Disabled”
Options
1 “Enabled” (Default)

A551 [Fault Clear]

Stop drive before changing this parameter.
Resets a fault and clears the fault queue.
0 “Ready/Idle” (Default)
Options 1 “Reset Fault” Resets the active fault but does not clear any fault buffer.
2 “Clear Buffer” Resets the active fault and clears all fault buffers to “0”.

A552 [Program Lock] Related Parameters: A553

Protects parameters against change by unauthorized personnel with a 4-digit access code.
Default: 0000
Values Min/Max: 0000/9999
Display: 1111

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Advanced Program Group (continued)

A553 [Program Lock Mod] Related Parameters: A552
Determines the lock mode that is used in parameter A552 [Program Lock]. When set to 2 or 3, A552 [Program Lock] is added to the custom group to allow unlocking of
parameters.
0 “Full Lock” (Default) All parameters are locked except [Program Lock].
1 “Keypad Lock” All parameters are locked except [Program Lock] from keypad access but can still be accessed over communications.
Options 2 “Custom Only” All parameters are locked and hidden except custom group and [Program Lock].
3 “KeyPd Custom” All parameters are locked and hidden except custom group and [Program Lock] from keypad access but can still be
accessed over communications.

A554 [Drv Ambient Sel]

Sets the maximum expected ambient of the drive when used above 50 °C. When ambient temperature is above 50 °C, the drive applies necessary current derating.
0 “Normal” (Default)
1 “55C”
Options 2 “60C”
3 “65C +Fan Kit”
Fan kit required.
4 “70C +Fan Kit”

A555 [Reset Meters] Related Parameters: b019, b021, b022, b023, b024,
b025, b026, d362, d363
Resets the values that are stored in the parameters that track fault times and energy usage.
0 “Ready/Idle” (Default)
Options 1 “Reset Meters” Resets kWh, MWh, Accum kWh, Cost, and CO2 Sav parameter values.
2 “Reset Time” Resets min, hr, and x10 hr.

A556 [Text Scroll]

Sets the scrolling speed of the text in the LCD display.
0 “Off” No scroll.
1 “Low Speed”
Options
2 “Mid Speed” (Default)
3 “High Speed”

A557 [Out Phas Loss En]

Enable/disable output phase loss detection.

ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate
application. Do not use this function without considering applicable local, national, and international codes, standards,
regulations or industry guidelines.
0 “Disable” (Default)
Options
1 “Enable”

A558 [Positioning Mode]

Stop drive before changing this parameter.
PF 525 PowerFlex 525 only.
Defines the positioning transition mode that is used for the position steps.
0 “Time Steps” (Default) Steps based on time.
1 “Preset Input” Preset inputs directly commands a given step.
Options 2 “Step Logic” Use StepLogic Commands. Always start from Step 0.
3 “Preset StpL” Use Preset Inputs to determine starting step then StepLogic commands.
4 “StpLogic-Lst” Use StepLogic commands from last Step Logic step at last drive stop.

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Advanced Program Group (continued)

A559 [Counts Per Unit]
PF 525 PowerFlex 525 only.
Sets the number of encoder counts equal to one user-defined unit.
Default: 4096
Values Min/Max: 1/32000
Display: 1

A560 [Enh Control Word] Related Parameters: t062, t063, t065 - t068, A571
PF 525 PowerFlex 525 only.
Allows control of positioning and other functions through parameter control for use over comms. The functions replicate the digital input options and function in the same
way.

1 = Input Present, 0 = Input Not Present

Home Limit Digit 1
Find Home Digit 2
Hold Step Digit 3
Pos Redefine Digit 4
Sync Enable Digit 5
Traverse Dis Digit 6
Logic In 1 Digit 7
Logic In 2 Digit 8
Not Used

Default: 0000 0000

Values Min/Max: 0000 0000/1111 1111
Display: 0000 0000
0 “Home Limit” In Positioning mode, this indicates that the drive is at the home position.
1 “Find Home” When set, the next start command causes the drive to find home. Set this bit to 0 after completing the homing routine.
2 “Hold Step” In Positioning mode, this input overrides other inputs and causes the drive to remain at its current step (running at zero
speed once it reaches its position) until released.
3 “Pos Redefine” In Positioning mode, this input resets the home position to the current position of the machine. Set this bit to 0 after
completing the homing routine.
4 “Sync Enable” Must be used to hold the existing frequency when Sync Time is set to enable speed synchronization. When this bit is reset
Digits to zero the drive accelerates to the new commanded frequency based on A571 [Sync Time] setting.
5 “Traverse Dis” When set the traverse function is disabled.
6 “Logic In 1” This provides an identical function as the “Logic In1” Digital Input option. This bit is logically ORed with a digital input t062,
t063, t065-t068 [DigIn TermBlk xx] set to 24 “Logic In1”. It can be used to move through the StepLogic functions (speed or
position) using comms control without requiring actual digital input transitions.
7 “Logic In 2” This provides and identical function as the “Logic In2” Digital Input option. This bit is logically ORed with a digital input
t062, t063, t065-t068 [DigIn TermBlk xx] set to 25 “Logic In2”. It can be used to move through the StepLogic functions
(speed or position) using comms control without requiring actual digital input transitions.

A561 [Home Save]

PF 525 PowerFlex 525 only.
Determines whether the current position is saved on power down.
0 “Home Reset” (Default) Position resets to zero on power-up.
Options
1 “Home Saved”

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Advanced Program Group (continued)

A562 [Find Home Freq]
PF 525 PowerFlex 525 only.
Sets the maximum frequency that the drive uses when “Find Home” is issued.
Default: 10.0 Hz
Values Min/Max: 0.1/500.0 Hz
Display: 0.1 Hz

A563 [Find Home Dir]

Stop drive before changing this parameter.
PF 525 PowerFlex 525 only.
Sets the direction that the drive commands when “Find Home” is issued.
0 “Forward” (Default)
Options
1 “Reverse”

A564 [Encoder Pos Tol]

PF 525 PowerFlex 525 only.
Sets the “At Position” and the “At Home’ tolerance around the encoder count. The value is added to and subtracted from the target encoder unit value to create the tolerance
range.
Default: 100
Values Min/Max: 1/50000
Display: 1

A565 [Pos Reg Filter]

PF 525 PowerFlex 525 only.
Sets the error signal filter in the position regulator.
Default: 8
Values Min/Max: 0/15
Display: 1

A566 [Pos Reg Gain]

PF 525 PowerFlex 525 only.
Sets the gain adjustment for the position regulator.
Default: 3.0
Values Min/Max: 0.0/200.0
Display: 0.1

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Advanced Program Group (continued)

A567 [Max Traverse]
Sets the amplitude of triangle wave speed modulation.

[P Jump]
[Max Traverse]
[Output Freq]
Hertz

Traverse Bit
[Fiber Status]

Traverse Enable Bit

Seconds
Default: 0.00 Hz
Values Min/Max: 0.00/300.00 Hz
Display: 0.01 Hz

A568 [Traverse Inc] Related Parameters: A567

Sets the time that is required for the Traverse function to accelerate from the minimum to the maximum traverse frequency. See the diagram at A567 [Max Traverse].
Default: 0.00 s
Values Min/Max: 0.00/300.00 s
Display: 0.01 s

A569 [Traverse Dec] Related Parameters: A567

Sets the time that is required for the Traverse function to decelerate from the maximum to the minimum traverse frequency. See the diagram at A567 [Max Traverse].
Default: 0.00 s
Values Min/Max: 0.00/300.00 s
Display: 0.01 s

A570 [P Jump] Related Parameters: A567

Sets the frequency amplitude that is added to or subtracted from the commanded frequency. See the diagram at A567 [Max Traverse].
Default: 0.00 Hz
Values Min/Max: 0.00/300.00 Hz
Display: 0.01 Hz

A571 [Sync Time] Related Parameters: t062, t063, t065 - t068, A560
Enables the function that holds the drive at the current frequency even if the commanded frequency changes. Used with t062, t063, t065-t068 [DigIn TermBlk xx] 32
“Sync Enable”.
[Sync Time]
New Drive #2 Reference
Hertz

New Drive #1 Reference

Speed Sync Bit [Fiber Status]

Change Ref's Drive #1 and #2 Sync Enable Input
Time

Default: 0.0 s
Values Min/Max: 0.0/3200.0 s
Display: 0.1 s

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Advanced Program Group (continued)

A572 [Speed Ratio]
Stop drive before changing this parameter.
Scales the drive speed command.
Default: 1.00
Values Min/Max: 0.01/99.99
Display: 0.01

A573 [Mtr Options Cfg]

(With PowerFlex 525 FRN 2.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Sets the configuration of the motor option.

Options Description
1 = Enabled, 0 = Disabled Limits the rate of change to the velocity reference for improved current
Jerk Select Digit 1 Jerk Select limiting. Set to 0 “Disabled” for positioning type applications with fast Accel
ZeroSpd Slip Digit 2 or Decel times.
Not Used Sets slip compensation to 0.0 Hz when the following conditions are met:
Not Used • Commanded speed = 0.00 Hz
ZeroSpd Slip
Not Used • Status of drive = “At speed”
• ZeroSpd Slip = 1 “Enabled”

Default: 11
Values Min/Max: 00/11
Display: 00

A574 [RdyBit Mode Cfg] Related Parameters: d392

Stop drive before changing this parameter.
(With PowerFlex 525 FRN 3.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Determines which Stop conditions cause the drive’s Ready bit (Network Logic Status bit 1) to go low (0). A reset or power cycle is required after selection is made.

Ready Bit Status(1)

Stop Conditions Standard Enhanced
Drive fault 0 0
Stop digital input terminal 01/11 open 1 0
Holding down the drive’s keypad or the Remote DSI HIM Stop button 1 0
Stop commanded through Comms (Stop bit = 1) 1 0
Software (SW) Enable digital input terminal open 1 0
Safe-Torque-Off (STO) condition with value of t105 [Safety Open En] set to 1
0 0
“FaultDisabled”(2)
(1) 1 = Active, 0 = Inactive
(2) Condition is specific to PowerFlex 525 drives only.

0 “Standard” (Default)
Options
1 “Enhanced”

A575 [Flux Braking En] Related Parameters: A550

(With PowerFlex 525 FRN 5.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Enables/disables flux braking.
0 “Disable” (Default)
Options
1 “Enable”

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Advanced Program Group (continued)

A576 [Phase Loss Level]
(With PowerFlex 525 FRN 5.xxx and later.)
(With PowerFlex 523 FRN 3.xxx and later.)
Output Phase Loss Level. Sets the threshold level that is used to determine an output phase loss condition.
Each motor phase must exceed this value. Decreasing this parameter's value lowers sensitivity.
Default: 25.0% for Induction motor; 4.0% for PM motor
Values Min/Max: 0.0/100.0%
Display: 0.1%

A580 [Current Loop BW]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Current loop bandwidth (0 = Automatically calculate the control gain of current loop).
Default: 0 Hz
Values Min/Max: 0/65535 Hz
Display: 1 Hz

A581 [PM Stable 1 Freq]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
The start frequency for stabilization loop (P032 [Motor NP Hertz] x A581 [PM Stable 1 Freq]).
Default: 0%
Values Min/Max: 0/100%
Display: 1%

A582 [PM Stable 2 Freq]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Stabilization function will return to normal output after this frequency (P032 [Motor NP Hertz] x A582 [PM Stable 2 Freq]).
Default: 45%
Values Min/Max: 0/100%
Display: 1%

A583 [PM Stable 1 Kp]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Percentage of the gain for stabilization loop. The gain is set in A584 [PM Stable 2 Kp].
Default: 40%
Values Min/Max: 0/100%
Display: 1%

A584 [PM Stable 2 Kp]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
The gain for stabilization loop.
Default: 250%
Values Min/Max: 0/2000%
Display: 1%

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Advanced Program Group (continued)

A585 [PM Stable Brk Pt]
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Percentage of rated power P037 [Motor NP Power] for the gain of (A584 [PM Stable 2 Kp] x A583 [PM Stable 1 Kp]).
Default: 40%
Values Min/Max: 0/100%
Display: 1%

A586 [PM Stepload Kp]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
The gain to ensure robustness under step load in low speed region.
Default: 0%
Values Min/Max: 0/1000%
Display: 1%

A587 [PM 1 Efficiency]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Reduce full-load current.
Default: 120%
Values Min/Max: 0/2000%
Display: 1%

A588 [PM 2 Efficiency]

PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Reduce no load current.
Default: 500%
Values Min/Max: 0/2000%
Display: 1%

A589 [PM Algor Sel] Related Parameters: A550

Stop drive before changing this parameter.
PF 525 PowerFlex 525 only.
(With FRN 5.xxx and later.)
Selects the algorithm to use with your motor. Check with the manufacturer of your motor to determine whether it is an iPM or sPM motor.
0 “Algorithm 1” (Default) Suggested for most motors.
Options 1 “Algorithm 2” Enable an embedded algorithm to reduce oscillation in output waveform (use with sPM motor only, do not enable for iPM
motor).

A590 [SYNRM SW Freq]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
Switching Frequency point from Low-Speed Observer (Freq1) to High-Speed Observer (Freq2).
Default: 10 Hz
Values
Min/Max: 0/600 Hz

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Advanced Program Group (continued)

A591 [SYNRM Flux Cur]
PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
SynRM Field Excitation Current.
Increasing the setting enhances no loading performance but has poor efficiency.
Decreasing the setting reduces no loading performance but good efficiency.
Default: 35%
Values
Min/Max: 0/150%

A592 [SYNRM Freq1 Volt]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
The Amplitude of Injected Signal of Low-Speed Observer (Freq1).
Increasing the setting enhances the loading performance during Freq1 operation.
Default: 30%
Values
Min/Max: 0/100%

A593 [SYNRM Freq1 Kp]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
The Scaling of bandwidth At Low-Speed Observer (Freq1).
Increasing the setting enhances the loading performance during low-speed (Freq1) operation but too high causes motor vibration.
Decreasing the setting causes the motor to stall during startup and low-speed (Freq1) operation.
When the motor running speed is lower than the switching frequency A590 adjust the setting.
Default: 1.00
Values
Min/Max: 0.01/5.00

A594 [SYNRM Freq1 Comp]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
The Scaling of Mutual Inductance Compensation At Low-Speed Observer (Freq1).
Increasing or decreasing the setting enhances the loading performance during Freq1 operation depending on the motor.
Default: 1.00
Values
Min/Max: 0/10.00

A595 [SYNRM Freq2 BW]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
The bandwidth At High-Speed Observer (Freq2).
Increasing the setting enhances the loading performance during high-speed (Freq2) operation but too high causes vibration.
Decreasing the setting causes the motor to stall during startup and high-speed (Freq2) operations.
When the motor running speed is higher than the switching frequency A590, adjust the setting.
Default: 10 Hz
Values
Min/Max: 0/50 Hz

A596 [SYNRM Freq2 Kp]

PF 525 PowerFlex 525 only.
(With FRN 7.xxx and later.)
The Scaling of Magnetic linkage estimator At High-Speed Observer (Freq2).
To fine-tune the setting when motor is still not stable after adjustment A595.
Increasing the motor setting enhances the loading performance during high-speed (Freq2) operation but too high causes vibration.
Decreasing the setting causes the motor to stall during startup and high-speed (Freq2) operations.
When the motor running speed is higher than the switching frequency A590, adjust the setting.
Default: 1.00
Values
Min/Max: 0.1/10.00

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Network Parameter Group This group contains parameters for the network option card that is installed.

See the network option card’s user manual for more information on the
available parameters.

Modified Parameter Group This group contains parameters that have their values changed from the
factory default.

When a parameter has its default value changed, it is automatically added to

this group. When a parameter has its value changed back to the factory default,
it is automatically removed from this group.

Fault and Diagnostic Group

F604 [Fault 4 Code] Related Parameters: b007-b009
F605 [Fault 5 Code]
F606 [Fault 6 Code]
F607 [Fault 7 Code]
F608 [Fault 8 Code]
F609 [Fault 9 Code]
F610 [Fault10 Code]
A code that represents a drive fault. The codes appear in these parameters in the order that they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults are
only recorded once.
Default: Read Only
Values Min/Max: F0/F127
Display: F0

F611 [Fault 1 Time-hr] F612 [Fault 2 Time-hr] Related Parameters: d362

F613 [Fault 3 Time-hr] F614 [Fault 4 Time-hr]
F615 [Fault 5 Time-hr]
F616 [Fault 6 Time-hr] F617 [Fault 7 Time-hr]
F618 [Fault 8 Time-hr] F619 [Fault 9 Time-hr]
F620 [Fault10 Time-hr]
PF 525 PowerFlex 525 only.
Displays the value of d362 [Elapsed Time-hr] when the fault occurs.
Default: Read Only
Values Min/Max: 0/32767 hr
Display: 1 hr

F621 [Fault 1 Time-min] F622 [Fault 2 Time-min] Related Parameters: d363

F623 [Fault 3 Time-min] F624 [Fault 4 Time-min]
F625 [Fault 5 Time-min]
F626 [Fault 6 Time-min] F627 [Fault 7 Time-min]
F628 [Fault 8 Time-min] F629 [Fault 9 Time-min]
F630 [Fault10 Time-min]
PF 525 PowerFlex 525 only.
Displays the value of d363 [Elapsed Time-min] when the fault occurs.
Default: Read Only
Values Min/Max: 0.0/320.0 min
Display: 0.1 min

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Fault and Diagnostic Group (continued)

F631 [Fault 1 Freq] F632 [Fault 2 Freq] Related Parameters: b001
F633 [Fault 3 Freq] F634 [Fault 4 Freq]
F635 [Fault 5 Freq]
F636 [Fault 6 Freq] F637 [Fault 7 Freq]
F638 [Fault 8 Freq] F639 [Fault 9 Freq]
F640 [Fault10 Freq]
PF 525 PowerFlex 525 only.
Displays and stores the value of b001 [Output Freq] with the most recent 10 faults occurred.
[Fault 1 Freq] stores the most recent fault, [Fault 2 Freq] stores the second most recent fault and [Fault 3 Freq] stores the third most recent fault.
Default: Read Only
Values Min/Max: 0.00/500.00 Hz
Display: 0.01 Hz

F641 [Fault 1 Current] F642 [Fault 2 Current] Related Parameters: b003

F643 [Fault 3 Current] F644 [Fault 4 Current]
F645 [Fault 5 Current]
F646 [Fault 6 Current] F647 [Fault 7 Current]
F648 [Fault 8 Current] F649 [Fault 9 Current]
F650 [Fault10 Current]
PF 525 PowerFlex 525 only.
Displays and stores the value of b003 [Output Current] with the most recent 10 faults occurred.
[Fault 1 Current] stores the most recent fault, [Fault 2 Current] stores the second most recent fault and [Fault 3 Current] stores the third most recent fault.
Default: Read Only
Values Min/Max: 0.00/(Drive Rated Amps x 2)
Display: 0.01 A

F651 [Fault 1 BusVolts] F652 [Fault 2 BusVolts] Related Parameters: b005

F653 [Fault 3 BusVolts] F654 [Fault 4 BusVolts]
F655 [Fault 5 BusVolts]
F656 [Fault 6 BusVolts] F657 [Fault 7 BusVolts]
F658 [Fault 8 BusVolts] F659 [Fault 9 BusVolts]
F660 [Fault10 BusVolts]
PF 525 PowerFlex 525 only.
Displays and stores the value of b005 [DC Bus Voltage] with the most recent 10 faults occurred.
[Fault 1 BusVolts] stores the most recent fault, [Fault2 BusVolts] stores the second most recent fault and [Fault 3 BusVolts] stores the third most recent fault.
Default: Read Only
Values Min/Max: 0/1200V DC
Display: 1V DC

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Fault and Diagnostic Group (continued)

F661 [Status @ Fault 1] F662 [Status @ Fault 2] Related Parameters: b006
F663 [Status @ Fault 3] F664 [Status @ Fault 4]
F665 [Status @ Fault 5]
F666 [Status @ Fault 6] F667 [Status @ Fault 7]
F668 [Status @ Fault 8] F669 [Status @ Fault 9]
F670 [Status @ Fault10]
PF 525 PowerFlex 525 only.
Displays the value of b006 [Drive Status] with the most recent 10 faults occurred.
[Status @ Fault 1] stores the most recent fault, [Status @ Fault 2] stores the second most recent fault and [Status @ Fault 3] stores the third most recent fault.

1 = Condition True, 0 = Condition False

Running Digit 1
Forward Digit 2
Accelerating Digit 3
Decelerating Digit 4
SafetyActive(1) Digit 5
(1) Setting is specific to PowerFlex 525 drives only.

Default: Read Only

Values Min/Max: 0/0x1F
Display: 1

F681 [Comm Sts - DSI]

Displays the status of the RS-485 serial (DSI) port to the drive.

1 = Condition True, 0 = Condition False Digit 3 (Connection Status)

Rx Digit 1 0 “Not Active”
Tx Digit 2 1 “Modbus slave network (external Modbus master)”
Status Digit 3
2 “Modbus multi-drive w/ internal com option master”
Error Digit 4
Not Used
3 “Modbus multi-drive w/ embedded com master”(1)
4 “DSI peripheral connected”
5.…8 “Reserved”
9 “RS-485 network faulted”
(1) Setting is specific to PowerFlex 525 drives only.

Default: Read Only

Values Min/Max: 0000/1911
Display: 0000

F682 [Comm Sts - Opt]

Displays the status of the internal communication to the drive.
Digit 3 = “Internal Com option”
1 = Condition True, 0 = Condition False 0 “Not Active (no connection)”
Rx Digit 1 1 “Internal option connected/active”
Tx Digit 2
2...8 “Reserved”
Status Digit 3
Error Digit 4
9 “Internal com option faulted”
Not Used

Default: Read Only

Values Min/Max: 0000/1911
Display: 0000

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Fault and Diagnostic Group (continued)

F683 [Com Sts-Emb Enet]
PF 525 PowerFlex 525 only.
Displays the status of the embedded EtherNet/IP interface to the drive.

1 = Condition True, 0 = Condition False Digit 3 = “Embedded EtherNet/IP”

Rx Digit 1 0 “Not Active (no connection)”
Tx Digit 2 1 “Embedded EtherNet/IP active”
Status Digit 3
2…8 “Reserved”
Error Digit 4
Not Used 9 “Embedded EtherNet/IP faulted”

Default: Read Only

Values Min/Max: 0000/1911
Display: 0000

F684 [EN Addr Src]

PF 525 PowerFlex 525 only.
Displays the actual source of the Ethernet configuration (IP address, subnet mask, and gateway address).
1 “Parameters”
Options Read Only
2 “BOOTP”

F685 [EN Rate Act]

PF 525 PowerFlex 525 only.
Displays the network data rate that is currently used by the embedded EtherNet/IP interface.
0 “No Link”
1 “10Mbps Full”
2 “10Mbps Half”
Options 3 “100Mbps Full” Read Only
4 “100Mbps Half”
5 “Dup IP Addr”
6 “Disabled”

F686 [DSI I/O Act]

Displays the Drives that are active in Multi-Drive mode.

1 = Drive Active, 0 = Drive Inactive

Drive 0 Actv Digit 1
Drive 1 Actv Digit 2
Drive 2 Actv Digit 3
Drive 3 Actv Digit 4
Drive 4 Actv Digit 5

Default: Read Only

Value Min/Max: 00000/11111
Display: 00000

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Fault and Diagnostic Group (continued)

F687 [HW Addr 1]
F688 [HW Addr 2]
F689 [HW Addr 3]
F690 [HW Addr 4]
F691 [HW Addr 5]
F692 [HW Addr 6]
PF 525 PowerFlex 525 only.
Shows the MAC address for the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/255
Display: 1

F693 [EN IP Addr Act 1]

F694 [EN IP Addr Act 2]
F695 [EN IP Addr Act 3]
F696 [EN IP Addr Act 4]
PF 525 PowerFlex 525 only.
Shows the actual IP address that is used by the embedded EtherNet/IP interface at the time. This indicates 0 if no address is set.
255.255.255.255

[EN IP Addr Act 1]

[EN IP Addr Act 2]
[EN IP Addr Act 3]
[EN IP Addr Act 4]

Default: Read Only

Values Min/Max: 0/255
Display: 1

F697 [EN Subnet Act 1]

F698 [EN Subnet Act 2]
F699 [EN Subnet Act 3]
F700 [EN Subnet Act 4]
PF 525 PowerFlex 525 only.
Shows the actual subnet mask that is used by the embedded EtherNet/IP interface at the time. This indicates 0 if no address is set.
255.255.255.255

[EN Subnet Act 1]

[EN Subnet Act 2]
[EN Subnet Act 3]
[EN Subnet Act 4]

Default: Read Only

Values Min/Max: 0/255
Display: 1

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 Chapter 3 Programming and Parameters

Fault and Diagnostic Group (continued)

F701 [EN Gateway Act 1]
F702 [EN Gateway Act 2]
F703 [EN Gateway Act 3]
F704 [EN Gateway Act 4]
PF 525 PowerFlex 525 only.
Shows the actual gateway address that is used by the embedded EtherNet/IP interface at the time. This indicates 0 if no address is set.
255.255.255.255

[EN Gateway Act 1]

[EN Gateway Act 2]
[EN Gateway Act 3]
[EN Gateway Act 4]

Default: Read Only

Values Min/Max: 0/255
Display: 1

F705 [Drv 0 Logic Cmd]

F709 [Drv 1 Logic Cmd]
F713 [Drv 2 Logic Cmd]
F717 [Drv 3 Logic Cmd]
F721 [Drv 4 Logic Cmd]
In multi-drive mode, this is the logic command being transmitted to drive 0/1/2/3/4/.
In single-drive mode, this is the logic command being used by the drive (whether HS-DSI, EtherNet/IP, or DSI) at the time. If comms control is NOT being used, and the drive
is in single-drive mode, then this parameter shows 0.
Default: Read Only
Values Min/Max: 0/FFFF
Display: 1

F706 [Drv 0 Reference]

F710 [Drv 1 Reference]
F714 [Drv 2 Reference]
F718 [Drv 3 Reference]
F722 [Drv 4 Reference]
In multi-drive mode, this is the reference being transmitted to drive 0/1/2/3/4.
In single-drive mode, this is the reference being used by the drive (whether HS-DSI, EtherNet/IP, or DSI) at the time. If comms control is NOT being used, and the drive is in
single-drive mode, then this parameter shows 0.
Default: Read Only
Values Min/Max: 0.00/5000.00 Hz
Display: 0.01 Hz

F707 [Drv 0 Logic Sts]

F711 [Drv 1 Logic Sts]
F715 [Drv 2 Logic Sts]
F719 [Drv 3 Logic Sts]
F723 [Drv 4 Logic Sts]
In multi-drive mode, this is the logic status being received from drive 0/1/2/3/4.
In single-drive mode, this is the logic status of the drive at the time.
Default: Read Only
Values Min/Max: 0/FFFF
Display: 1

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Chapter 3 Programming and Parameters

Fault and Diagnostic Group (continued)

F708 [Drv 0 Feedback]
F712 [Drv 1 Feedback]
F716 [Drv 2 Feedback]
F720 [Drv 3 Feedback]
F724 [Drv 4 Feedback]
In multi-drive mode, this is the feedback being received from drive 0/1/2/3/4.
In single-drive mode, this is the feedback of the drive at the time.
Default: Read Only
Values Min/Max: 0.00/5000.00 Hz
Display: 0.01 Hz

F725 [EN Rx Overruns]

PF 525 PowerFlex 525 only.
A count of the number of receive overrun errors reported by the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

F726 [EN Rx Packets]

PF 525 PowerFlex 525 only.
A count of the number of receive packets that are reported by the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

F727 [EN Rx Errors]

PF 525 PowerFlex 525 only.
A count of the number of receive errors that are reported by the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

F728 [EN Tx Packets]

PF 525 PowerFlex 525 only.
A count of the number of transmitted packets reported by the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

F729 [EN Tx Errors]

PF 525 PowerFlex 525 only.
A count of the number of transmit errors reported by the embedded EtherNet/IP interface.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

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 Chapter 3 Programming and Parameters

Fault and Diagnostic Group (continued)

F730 [EN Missed IO Pkt]
PF 525 PowerFlex 525 only.
The number of I/O packets missed.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

F731 [DSI Errors]

The number of total DSI errors.
Default: Read Only
Values Min/Max: 0/65535
Display: 1

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Chapter 3 Programming and Parameters

AppView Parameter Groups AppView parameter groups provide a simple starting point for using the
PowerFlex 520-series drives by grouping certain commonly used parameters
based on different types of applications. Use these parameter groups to quickly
and easily set up the PowerFlex 520-series drive for your application.

AppView parameter groups are available for the following applications:

• Conveyor
• Mixer
• Compressor
• Centrifugal Pump
• Blower/Fan
• Extruder
• Positioning (PowerFlex 525 only)
• Textile/Fiber

You cannot add or remove parameters to or from the AppView parameter

groups. If you require quick access to additional parameters to what is already
included in the different AppView parameter groups, use the CustomView
parameter group instead.

The parameters in the AppView parameter groups can be quickly added to the
CustomView parameter group by doing the following:

Step Keys Example Displays

Press the Up Arrow or Down Arrow to scroll to or

1. an AppView group (G1...G8).
FWD

Press Enter or Sel to enter a group. The

2. rightmost digit of the last viewed parameter or Sel FWD
in that group flashes.

Press the Up Arrow or Down Arrow to scroll to or

3. the command G1->GC.
FWD

Press Enter or Sel to add all parameters in

4. this AppView group to the CustomView group. or Sel
The LCD display shows a confirmation.

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 Chapter 3 Programming and Parameters

CustomView Parameter CustomView allows you to quickly access only the parameters that are needed
Group for your application by storing them in a custom parameter group. Add your
frequently used parameters to this group, then hide all other parameters with
A552 [Program Lock] to simplify your drive configuration process.

Up to 100 parameters can be stored in the CustomView parameter group. You

can copy one entire AppView parameter group to the CustomView parameter
group as shown on page 150 or add individual parameters as show below.

Step Keys Example Displays

Press the Up Arrow or Down Arrow to scroll to or

1. the CustomView group (GC).
FWD

Press Enter to view the parameters that can

2. FWD
be added to the CustomView group.

Press the Up Arrow or Down Arrow to scroll or

3. through the list of parameters.
FWD

PROGRAM

Press Enter to add the parameter to the

4. CustomView group. The LCD display shows a
confirmation.

To delete parameters from the CustomView parameter group:

Step Keys Example Displays

Press the Up Arrow or Down Arrow to scroll to or

1. the CustomView group (GC).
FWD

Press Enter to view the parameters that are

2. in the CustomView group.
FWD

Press the Up Arrow or Down Arrow to scroll to or

3. the command GC---.
FWD

Press Enter or Sel to view the parameters or

4. Sel FWD
that are stored in the CustomView group.

Press the Up Arrow or Down Arrow to scroll or

5. through the list of parameters.
FWD

PROGRAM

Press Enter to delete the parameter from the

6. CustomView group. The LCD display shows a
confirmation.

The Connected Components Workbench software can be used to speed

up this process with drag-and-drop functionality.

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Chapter 3 Programming and Parameters

Parameter Cross-reference by Name

Parameters
Parameter Name No. Parameter Name No. Parameter Name No.
10V Bipolar Enbl(1) 093 Current Loop BW(1)(2) 580 Drv 4 Logic Sts 723
2-Wire Mode 064 DB Resistor Sel 437 Drv 4 Reference 722
Accel Time 1 041 DB Threshold 438 Drv Ambient Sel 554
Accel Time 2 442 DC Brake Level 435 DSI Errors 731
Accel Time 3 444 DC Brake Time 434 DSI I/O Act 686
Accel Time 4 446 DC Brk Time@Strt 436 DSI I/O Cfg 175
Accum CO2 Sav 026 DC Bus Ripple 380 Elapsed kWh 021
Accum Cost Sav 025 DC Bus Voltage 005 Elapsed MWh 022
Accum kWh Sav 024 Decel Time 1 042 Elapsed Run Time 019
Analog In 0-10V 360 Decel Time 2 443 Elapsed Time-hr 362
Analog In 4-20mA 361 Decel Time 3 445 Elapsed Time-min 363
Analog In Filter 099 Decel Time 4 447 EM Brk Off Delay 086
Analog Out High(3) 089 Dig In Status 014 EM Brk On Delay 087
Analog Out Sel(2) 088 Dig Out Status(2)(3) 394 EN Addr Sel(1) 128
Anlg In 0-10V Hi 092 DigIn TermBlk 02 062 EN Addr Src(1) 684
Anlg In 0-10V Lo 091 DigIn TermBlk 03 063 EN Comm Flt Actn(1) 143
Anlg In mA Loss 097 DigIn TermBlk 05 065 EN Data In 1(1) 153
Anlg In V Loss 094 DigIn TermBlk 06 066 EN Data In 2(1) 154
Anlg In4-20mA Hi 096 DigIn TermBlk 07(1) 067 EN Data In 3(1) 155
Anlg In4-20mA Lo 095 DigIn TermBlk 08(1) 068 EN Data In 4(1) 156
Anlg Loss Delay 098 Drive OL Mode 495 EN Data Out 1(1) 157
Anlg Out Setpt(2) 090 Drive Status 006 EN Data Out 2(1) 158
Auto Rstrt Delay 542 Drive Status 2(2)(3) 393 EN Data Out 3(1) 159
Auto Rstrt Tries 541 Drive Temp 027 EN Data Out 4(1) 160
Autotune 040 Drive Type 367 EN Flt Cfg DL 1(1) 147
Average kWh Cost 052 Droop Hertz@ FLA(1) 441 EN Flt Cfg DL 2(1) 148
Average Power 020 Drv 0 Feedback 708 EN Flt Cfg DL 3(1) 149
Boost Select 530 Drv 0 Logic Cmd 705 EN Flt Cfg DL 4(1) 150
Break Frequency 533 Drv 0 Logic Sts 707 EN Flt Cfg Logic(1) 145
Break Voltage 532 Drv 0 Reference 706 EN Flt Cfg Ref(1) 146
Bus Reg Enable 550 Drv 1 Addr 171 EN Gateway Act 1(1) 701
Cmd Stat Select(1) 122 Drv 1 Feedback 712 EN Gateway Act 2(1) 702
(1) 683 Drv 1 Logic Cmd 709 EN Gateway Act 3(1) 703
Com Sts-Emb Enet
Comm Loss Action 125 Drv 1 Logic Sts 711 EN Gateway Act 4(1) 704
Comm Loss Time 126 Drv 1 Reference 710 EN Gateway Cfg 1(1) 137
Comm Sts - DSI 681 Drv 2 Addr 172 EN Gateway Cfg 2(1) 138
Comm Sts - Opt 682 Drv 2 Feedback 716 EN Gateway Cfg 3(1) 139
Comm Write Mode 121 Drv 2 Logic Cmd 713 (1) 140
EN Gateway Cfg 4
Commanded Freq 002 Drv 2 Logic Sts 715 EN Idle Flt Actn(1) 144
Compensation 547 Drv 2 Reference 714 EN IP Addr Act 1(1) 693
Contrl In Status 013 Drv 3 Addr 173 (1) 694
EN IP Addr Act 2
Control Source 012 Drv 3 Feedback 720 EN IP Addr Act 3(1) 695
Control SW Ver 029 Drv 3 Logic Cmd 717 EN IP Addr Act 4(1) 696

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 Chapter 3 Programming and Parameters

Parameters (Continued)
Parameter Name No. Parameter Name No. Parameter Name No.
Control Temp 028 Drv 3 Logic Sts 719 EN IP Addr Cfg 1(1) 129
Counter Status 364 Drv 3 Reference 718 EN IP Addr Cfg 2(1) 130
(1) 559 Drv 4 Addr 174 EN IP Addr Cfg 3(1) 131
Counts Per Unit
Current Limit 1 484 Drv 4 Feedback 724 EN IP Addr Cfg 4(1) 132
Current Limit 2(1) 485 Drv 4 Logic Cmd 721 EN Missed IO Pkt(1) 730
(1) 685 Fault 6 BusVolts(1) 656 Half Bus Enable 549
EN Rate Act
(1) 141 Fault 6 Code(1) 606 Home Save(1) 561
EN Rate Cfg
(1) 727 Fault 6 Current(1) 646 HW Addr 1(1) 687
EN Rx Errors
EN Rx Overruns(1) 725 Fault 6 Freq(1) 636 HW Addr 2(1) 688
(1) 726 Fault 6 Time-hr(1) 616 HW Addr 3(1) 689
EN Rx Packets
EN Subnet Act 1(1) 697 Fault 6 Time-min(1) 626 HW Addr 4(1) 690
EN Subnet Act 2(1) 698 Fault 7 BusVolts(1) 657 HW Addr 5(1) 691
(1) 699 Fault 7 Code(1) 607 HW Addr 6(1) 692
EN Subnet Act 3
(1) 700 Fault 7 Current(1) 647 IR Voltage Drop 496
EN Subnet Act 4
EN Subnet Cfg 1(1) 133 Fault 7 Freq(1) 637 Jog Accel/Decel 432
(1) 134 Fault 7 Time-hr(1) 617 Jog Frequency 431
EN Subnet Cfg 2
(1) 135 Fault 7 Time-min(1) 627 Keypad Freq 426
EN Subnet Cfg 3
EN Subnet Cfg 4(1) 136 Fault 8 BusVolts(1) 658 Ki Speed Loop(2) 538
EN Tx Errors(1) 729 Fault 8 Code(1) 608 Kp Speed Loop(2) 539
(1) 728 Fault 8 Current(1) 648 Language 30
EN Tx Packets
Encoder Pos Tol(1) 564 Fault 8 Freq(1) 638 Load Loss Level(1) 490
(1) 536 Fault 8 Time-hr(1) 618 Load Loss Time(1) 491
Encoder PPR
(2) 378 Fault 8 Time-min(1) 628 Max Traverse 567
Encoder Speed
Energy Saved 023 Fault 9 BusVolts(1) 659 Maximum Freq 044
Enh Control Word(1) 560 Fault 9 Code(1) 609 Maximum Voltage 534
Fault 1 BusVolts 651 Fault 9 Current(1) 649 Minimum Freq 043
Fault 1 Code 007 Fault 9 Freq(1) 639 MOP Freq 427
Fault 1 Current 641 Fault 9 Time-hr(1) 619 MOP Preload 429
Fault 1 Freq 631 Fault 9 Time-min(1) 629 MOP Reset Sel 428
Fault 1 Time-hr 611 Fault Clear 551 MOP Time 430
Fault 1 Time-min 621 Fault10 BusVolts(1) 660 Motor Fdbk Type(2) 535
Fault 2 BusVolts 652 Fault10 Code(1) 610 Motor Lm(1) 499
Fault 2 Code 008 (1) 650 Motor Lx(1) 500
Fault10 Current
Fault 2 Current 642 Fault10 Freq(1) 640 Motor NP FLA 034
Fault 2 Freq 632 Fault10 Time-hr(1) 620 Motor NP Hertz 032
Fault 2 Time-hr 612 (1) 630 Motor NP Poles 035
Fault10 Time-min
Fault 2 Time-min 622 Fiber Status 390 Motor NP Power(1) 037
Fault 3 BusVolts 653 Find Home Dir(1) 563 Motor NP RPM 036
Fault 3 Code 009 Find Home Freq(1) 562 Motor NP Volts 031
Fault 3 Current 643 Flux Braking En(2)(3) 575 Motor OL Current 033
Fault 3 Freq 633 Flux Current Ref 497 Motor OL Level 369
Fault 3 Time-hr 613 Flying Start En 545 Motor OL Ret 494
Fault 3 Time-min 623 FlyStrt CurLimit 546 Motor OL Select 493
Fault 4 BusVolts 654 Freq 1(1) 510 Motor Rr(1) 498

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Chapter 3 Programming and Parameters

Parameters (Continued)
Parameter Name No. Parameter Name No. Parameter Name No.
Fault 4 Code 604 Freq 1 BW(1) 511 Mtr Options Cfg(2)(4) 573
Fault 4 Current 644 Freq 1 Ki(1) 522 MultiDrv Sel 169
Fault 4 Freq 634 Freq 1 Kp(1) 521 Opt Data In 1 161
Fault 4 Time-hr 614 Freq 2(1) 512 Opt Data In 2 162
Fault 4 Time-min 624 Freq 2 BW(1) 513 Opt Data In 3 163
Fault 5 BusVolts 655 Freq 2 Ki(1) 524 Opt Data In 4 164
Fault 5 Code 605 Freq 2 Kp(1) 523 Opt Data Out 1 165
Fault 5 Current 645 Freq 3(1) 514 Opt Data Out 2 166
Fault 5 Freq 635 Freq 3 BW(1) 515 Opt Data Out 3 167
Fault 5 Time-hr 615 Freq 3 Ki(1) 526 Opt Data Out 4 168
Fault 5 Time-min 625 Freq 3 Kp(1) 525 Opto Out Logic(1) 075
Opto Out1 Level(1) 070 PM FWKn 1 Kp(1)(3) 527 Relay 2 On Time(1) 084
(1) 069 PM FWKn 2 Kp(1)(3) 528 Relay Out2 Level(1) 082
Opto Out1 Sel
(1) 073 PM HIFI NS Cur(1)(3) 519 Relay Out2 Sel(1) 081
Opto Out2 Level
Opto Out2 Sel(1) 072 PM Initial Sel(1)(3) 516 Reset Meters 555
Out Phas Loss En 557 PM IR Voltage(1)(3) 501 Reset to Defalts 053
Output Current 003 PM IXd Voltage(1)(3) 502 Reverse Disable 544
Output Freq 001 PM IXq Voltage(1)(3) 503 RS485 Data Rate 123
Output Power 017 PM Stable 1 Freq(1)(3) 581 RS485 Format 127
Output Powr Fctr 381 PM Stable 1 Kp(1)(3) 583 RS485 Node Addr 124
Output RPM 015 PM Stable 2 Freq(1)(3) 582 S Curve % 439
Output Speed 016 PM Stable 2 Kp(1)(3) 584 Safety Open En(1) 105
Output Voltage 004 PM Stable Brk Pt(1)(3) 585 SafetyFlt RstCfg(1)(3) 106
P Jump 570 PM Stepload Kp(1)(3) 586 Shear Pin 1 Time 487
Phase Loss Level(2)(3) 576 Pos Reg Filter(1) 565 Shear Pin1 Level 486
PID 1 Deadband 465 Pos Reg Gain(1) 566 Shear Pin 2 Time(1) 489
PID 1 Diff Rate 463 Position Status(1) 387 Shear Pin2 Level(1) 488
PID 1 Fdback Sel 460 Positioning Mode(1) 558 Skip Freq Band 1 449
PID 1 Integ Time 462 Power Loss Mode 548 Skip Freq Band 2 451
PID 1 Invert Err 467 Power Saved 018 Skip Freq Band 3(1) 453
PID 1 Preload 466 Preset Freq 0 410 Skip Freq Band 4(1) 455
PID 1 Prop Gain 461 Preset Freq 1 411 Skip Frequency 1 448
PID 1 Ref Sel 459 Preset Freq 2 412 Skip Frequency 2 450
PID 1 Setpoint 464 Preset Freq 3 413 Skip Frequency 3(1) 452
PID 1 Trim Hi 456 Preset Freq 4 414 Skip Frequency 4(1) 454
PID 1 Trim Lo 457 Preset Freq 5 415 Sleep Level 101
PID 1 Trim Sel 458 Preset Freq 6 416 Sleep Time 102
PID1 Fdbk Displ 383 Preset Freq 7 417 Sleep-Wake Sel 100
PID1 Setpnt Disp 384 Preset Freq 8(1) 418 Slip Hz Meter 375
PID 2 Deadband(1) 477 Preset Freq 9(1) 419 Speed Feedback 376
PID 2 Diff Rate(1) 475 Preset Freq 10(1) 420 Speed Ratio 572
PID 2 Fdback Sel(1) 472 Preset Freq 11(1) 421 Speed Reference1 047
(1) 474 Preset Freq 12(1) 422 Speed Reference2 049
PID 2 Integ Time
(1) 479 Preset Freq 13(1) 423 Speed Reference3 051
PID 2 Invert Err

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 Chapter 3 Programming and Parameters

Parameters (Continued)
Parameter Name No. Parameter Name No. Parameter Name No.
(1) 478 Preset Freq 14(1) 424 Speed Reg Sel(1) 509
PID 2 Preload
PID 2 Prop Gain(1) 473 Preset Freq 15(1) 425 Stall Fault Time 492
(1) 471 Process Disp Hi 482 Start At PowerUp 543
PID 2 Ref Sel
PID 2 Setpoint(1) 476 Process Disp Lo 481 Start Boost 531
PID 2 Trim Hi(1) 468 Process Display 010 Start Source 1 046
(1) 469 Program Lock 552 Start Source 2 048
PID 2 Trim Lo
(1) 470 Program Lock Mod 553 Start Source 3 050
PID 2 Trim Sel
(1) 385 Pulse In Scale 537 Status @ Fault 1 661
PID2 Fdbk Displ
PID2 Setpnt Disp(1) 386 Purge Frequency 433 Status @ Fault 2 662
(1)(3) 587 PWM Frequency 440 Status @ Fault 3 663
PM 1 Efficiency
PM 2 Efficiency(1)(3) 588 RdyBit Mode Act(2)(5) 392 Status @ Fault 4 664
PM Algor Sel(1)(3) 589 RdyBit Mode Cfg(2)(4) 574 Status @ Fault 5 665
(1)(3) 518 Relay 1 Off Time 080 Status @ Fault 6(1) 666
PM Align Time
(1)(3) 504 Relay 1 On Time 079 Status @ Fault 7(1) 667
PM BEMF Voltage
PM Bus Reg Kd(1)(3) 520 Relay Out1 Level 077 Status @ Fault 8(1) 668
(1)(3) 529 Relay Out1 Sel 076 Status @ Fault 9(1) 669
PM Control Cfg
(1)(3) 517 Relay 2 Off Time(1) 085 Status @ Fault10(1) 670
PM DC Inject Cur
Step Units 0(1) 200 Stp Logic Status(1) 391 Testpoint Sel 483
Step Units 1(1) 202 Stp Logic Time 0(1) 190 Text Scroll 556
(1) 204 Stp Logic Time 1(1) 191 Testpoint Data 368
Step Units 2
Step Units 3(1) 206 Stp Logic Time 2(1) 192 Timer Status 365
(1) 208 Stp Logic Time 3(1) 193 Timer StatusF 366
Step Units 4
(1) 210 Stp Logic Time 4(1) 194 Torque Current 382
Step Units 5
Step Units 6(1) 212 Stp Logic Time 5(1) 195 Torque Perf Mode 039
Step Units 7(1) 214 Stp Logic Time 6(1) 196 Traverse Dec 569
Stop Mode 045 Stp Logic Time 7(1) 197 Traverse Inc 568
Stp Logic 0(1) 180 Sync Time 571 Units Traveled H(1) 388
(1) 181 SynRM SW Freq 590 Units Traveled L(1) 389
Stp Logic 1
(1) 182 SynRM Flux Cur 591 Var PWM Disable 540
Stp Logic 2
(1) 183 SynRM Freq1 Volt 592 Voltage Class 038
Stp Logic 3
Stp Logic 4(1) 184 SynRM Freq1 Kp 593 Wake Level 103
Stp Logic 5(1) 185 SynRM Freq1 Comp 594 Wake Time 104
Stp Logic 6(1) 186 SynRM Freq2 BW 595
(1) 187 SynRM Freq2 Kp 596
Stp Logic 7
(1) Parameter is specific to PowerFlex 525 drives only.
(2) Parameter is available in PowerFlex 525 FRN 5.xxx and later.
(3) Parameter is also available in PowerFlex 523 FRN 3.xxx and later.
(4) Parameter is available in PowerFlex 525 FRN 2.xxx and later.
(5) Parameter is available in PowerFlex 525 FRN 3.xxx and later.

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Chapter 3 Programming and Parameters

Notes:

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 Chapter 4

Troubleshooting

This chapter provides information to guide you in troubleshooting the

PowerFlex 520-series drive. Included is a listing and description of drive faults
with possible solutions, when applicable.

Topic Page
Drive Status 157
Faults 157
Fault Descriptions 159
Common Symptoms and Corrective Actions 162

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

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

Drive Status The condition or state of your drive is constantly monitored. Any changes are
indicated through the integral LCD display.

See Display and Control Keys on page 59 for information on drive status
indicators and controls.

Faults A fault is a condition that stops the drive. There are two fault types.

Fault Types
Type Fault Description
When this type of fault occurs, and A541 [Auto Rstrt Tries] is set to a value greater
than “0,” a user-configurable timer, A542 [Auto Rstrt Delay], begins. When the timer
1 Auto-Reset/Run reaches zero, the drive attempts to automatically reset the fault. If the condition that
caused the fault is no longer present, the fault is reset and the drive is restarted.
This type of fault may require drive or motor repair, or is caused by wiring or
2 Non-Resettable programming errors. The cause of the fault must be corrected before the fault can
be cleared.

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Chapter 4 Troubleshooting

Fault Indication
Condition Display

FWD

Drive is indicating a fault.

The integral LCD display provides visual notification of a fault condition by displaying
FAULT
the following.
• Flashing fault number
• Flashing fault indicator (LED)
Press the Esc key to regain control of the display. Esc Sel

Manually Clearing Faults

Step Keys
1. Press Esc to acknowledge the fault. The fault information is removed so that you can
use the integral keypad.
Access b007 [Fault 1 Code] to view the most recent fault information.
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared. See Fault Types, Esc
Descriptions, and Actions on page 159.
3. After corrective action has been taken, clear the fault by one of these methods.
• Press Stop if P045 [Stop Mode] is set to a value between “0” and “3”.
• Cycle drive power.
• Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”.
• Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to 13 “Clear
Fault”.

Automatically Clearing Faults

Option/Step
Clear a Type 1 fault and restart the drive.
1. Set A541 [Auto Rstrt Tries] to a value other than “0”.
2. Set A542 [Auto Rstrt Delay] to a value other than “0”.

Clear an OverVoltage, UnderVoltage, or Heatsink OvrTmp fault

without restarting the drive.
1. Set A541 [Auto Rstrt Tries] to a value other than “0”.
2. Set A542 [Auto Rstrt Delay] to “0”.

ATTENTION: Equipment damage and/or personal injury may result if these

parameters are used in an inappropriate application. Do not use this
function without considering applicable local, national, and international
codes, standards, regulations or industry guidelines.

Auto Restart (Reset/Run)

The Auto Restart feature provides the ability for the drive to automatically
perform a fault reset followed by a start attempt without user or application
intervention. This allows remote or “unattended” operation. Only certain
faults are allowed to be reset. Certain faults (Type 2) that indicate possible
drive component malfunction are not resettable. Fault types are listed in the
table Fault Types on page 157. See Fault Descriptions on page 159 for more
information.

Use caution when enabling this feature, since the drive attempts to issue its
own start command based on user selected programming.
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 Chapter 4 Troubleshooting

Fault Descriptions
Fault Types, Descriptions, and Actions
No. Fault Type(1) Description Action
F000 No Fault – No fault present. –
• Check remote wiring.
F002 Auxiliary Input 1 External trip (Auxiliary) input. • Verify communications
programming for intentional fault.
• Monitor the incoming AC line for low
Single-phase operation detected voltage or line power interruption.
F003 Power Loss 2 with excessive load. • Check input fuses.
• Reduce load.
DC bus voltage fell below the min Monitor the incoming AC line for low
F004 UnderVoltage 1 value. voltage or line power interruption.
Monitor the AC line for high line voltage
or transient conditions. Bus
DC bus voltage exceeded max
F005 OverVoltage 1 overvoltage can also be caused by
value. motor regeneration. Extend the decel
time or install dynamic brake option.
• Increase P041, A442, A444, A446
[Accel Time x] or reduce load so
Drive is unable to accelerate or drive output current does not exceed
F006 Motor Stalled 1 the current set by parameter A484,
decelerate motor.
A485 [Current Limit x] for too long.
• Check for overhauling load.
• An excessive motor load exists.
Reduce load so drive output current
F007 Motor Overload 1 Internal electronic overload trip. does not exceed the current set by
parameter P033 [Motor OL Current].
• Verify A530 [Boost Select] setting.
• Check for blocked or dirty heatsink
Heatsink/Power Module fins. Verify that ambient temperature
F008 Heatsink OvrTmp 1 temperature exceeds a has not exceeded the rated ambient
predefined value. temperature.
• Check fan.
• Check product ambient temperature.
Control module temperature • Check for airflow obstruction.
F009 CC OvrTmp 1 exceeds a predefined value. • Check for dirt or debris.
• Check fan.
Check programming. Check for excess
The drive output current has load, improper A530 [Boost Select]
F012 HW OverCurrent 2 exceeded the hardware current setting, DC brake volts set too high or
limit. other causes of excess current.
A current path to earth ground has Check the motor and external wiring to
F013 Ground Fault 1(2) been detected at one or more of the drive output terminals for a
the drive output terminals. grounded condition.
The output torque current is below
the value that is programmed in • Verify connections between motor
A490 [Load Loss Level] for a time
F015(3) Load Loss 2 period greater than the time
and load.
programmed in A491 [Load Loss • Verify level and time requirements.
Time].
Output Phase Loss (if enabled). • Verify motor wiring.
F021 Output Ph Loss 1 Configure with A557 [Out Phas
Loss En]. • Verify motor.
An analog input is configured to
fault on signal loss. A signal loss • Check for broken/loose connections
F029 Analog In Loss 1 has occurred. at inputs.
Configure with t094 [Anlg In V • Check parameters.
Loss] or t097 [Anlg In mA Loss].
Drive unsuccessfully attempted to
reset a fault and resume running Correct the cause of the fault and
F033 Auto Rstrt Tries 2 for the programmed number of manually clear.
A541 [Auto Rstrt Tries].
F038 Phase U to Gnd • Check the wiring between the drive
F039 Phase V to Gnd A phase to ground fault has been and motor.
2 detected between the drive and • Check motor for grounded phase.
F040 Phase W to Gnd motor in this phase. • Replace drive if fault cannot be
cleared.

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Chapter 4 Troubleshooting

Fault Types, Descriptions, and Actions (Continued)

No. Fault Type(1) Description Action
F041 Phase UV Short • Check the motor and drive output
F042 Phase UW Short Excessive current has been terminal wiring for a shorted
2 detected between these two condition.
F043 Phase VW Short output terminals. • Replace drive if fault cannot be
cleared.
• Clear the fault or cycle power to the
The drive was commanded to write drive.
F048 Params Defaulted 1 default values to EEPROM. • Program the drive parameters as
needed.
Both of the safety inputs (Safety 1, Check safety input signals. If not using
Safety 2) are not enabled.
F059(3) Safety Open 1 Configure with t105 [Safety Open safety, verify and tighten jumper for I/O
terminals S1, S2, and S+.
En].
Programmed A486, A488 [Shear
Pinx Level] has been exceeded for • Verify connections between motor
F063 SW OverCurrent 1 a time period greater than the and load.
time programmed in A487, A489 • Verify level and time requirements.
[Shear Pin x Time].
Drive overload rating has been
F064 Drive Overload 2 Reduce load or extend Accel Time.
exceeded.
• Check that max ambient
temperature has not been exceeded.
Failure has been detected in the • Cycle power.
F070 Power Unit 2 drive power section.
• Replace drive if fault cannot be
cleared.
• Cycle power.
Control over the Modbus or DSI • Check communications cabling.
F071 DSI Net Loss 2 communication link has been
interrupted. • Check Modbus or DSI setting.
• Check Modbus or DSI status.
• Cycle power.
Control over the network option • Check communications cabling.
F072 Opt Net Loss 2 card’s remote network has been
interrupted. • Check network adapter setting.
• Check external network status.
• Cycle power.
Control through the embedded • Check communications cabling.
F073(3) EN Net Loss 2 EtherNet/IP adapter has been
• Check EtherNet/IP setting.
interrupted.
• Check external network status.
The autotune function was either Restart procedure.
F080 Autotune Failure 2 canceled by the user or failed.
• Cycle power.
• Check communications cabling.
• Check Modbus or DSI setting.
• Check Modbus or DSI status.
Communications between the
drive and the Modbus or DSI • Modify using C125 [Comm Loss
F081 DSI Comm Loss 2 Action].
master device have been
interrupted. • Connecting I/O terminals C1 and C2
to ground may improve noise
immunity.
• Replace wiring, Modbus master
device, or control module.
• Cycle power.
• Reinstall option card in drive.
Communications between the
F082 Opt Comm Loss 2 drive and the network option card • Modify using C125 [Comm Loss
have been interrupted. Action].
• Replace wiring, port expander, option
card, or control module.
• Cycle power.
• Check EtherNet/IP setting.
Internal communications between • Check drive’s Ethernet settings and
the drive and the embedded diagnostic parameters.
F083(3) EN Comm Loss 2 EtherNet/IP adapter have been • Modify using C125 [Comm Loss
interrupted. Action].
• Replace wiring, Ethernet switch, or
control module.

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 Chapter 4 Troubleshooting

Fault Types, Descriptions, and Actions (Continued)

No. Fault Type(1) Description Action
• Check Wiring.
• If P047, P049, P051 [Speed
Requires differential encoder. Referencex] = 16 “Positioning” and
F091(3) Encoder Loss 2 One of the 2 encoder channel A535 [Motor Fdbk Type] = 5 “Quad
signals is missing. Check”, swap the Encoder channel
inputs or swap any two motor leads.
• Replace encoder.
“Freeze-Fire” (Function Loss) input Close input to the terminal and cycle
F094 Function Loss 2 is inactive, input to the power.
programmed terminal is open.
Drive parameter non-volatile Set P053 [Reset To Defalts] to 2
F100 Parameter Chksum 2 storage is corrupted. “Factory Rset”.
External non-volatile storage hasSet P053 [Reset To Defalts] to 2
F101 External Storage 2 failed. “Factory Rset”.
Control module was disconnected Clear fault and verify all parameter
F105 C Connect Err 2 settings. Do not remove or install the
while drive was powered. control module while power is applied.
The PowerFlex 525 control module • Change to a different power module.
F106 Incompat C-P 2 does not support power modules • Change to a PowerFlex 523 control
with 0.25 HP power rating. module.
The control module could not • Change to a different power module.
F107 Replaced C-P 2 recognize the power module. • Replace control module if changing
Hardware failure. power module does not work.
The control module was mounted Set P053 [Reset To Defalts] to 3 “Power
F109 Mismatch C-P 2 to a different drive type power Reset”.
module.
• Cycle power.
Keypad membrane failure /
F110 Keypad Membrane 2 • Replace control module if fault
disconnected.
cannot be cleared.
• Check safety input signals. If not
using safety, verify and tighten
Safety input enable hardware jumper for I/O terminals S1, S2, and
F111(3) Safety Hardware 2 malfunction. One of the safety S+.
inputs is not enabled.
• Replace control module if fault
cannot be cleared.
• Cycle power.
• Verify grounding requirements. See
General Grounding Requirements on
F114 uC Failure 2 Microprocessor failure. page 20 for more information.
• Replace control module if fault
cannot be cleared.
• Cycle power.
Failure has been detected in the
F122 I/O Board Fail 2 • Replace drive or control module if
drive control and I/O section.
fault cannot be cleared.
The firmware in the drive is Perform a firmware flash update
F125 Flash Update Req 2 corrupt, mismatched, or operation to attempt to load a valid set
incompatible with the hardware. of firmware.
A nonrecoverable firmware or • Clear fault or cycle power to the
hardware error was detected. The drive.
F126 NonRecoverablErr 2 drive was automatically stopped • Replace drive or control module if
and reset. fault cannot be cleared.
A critical problem with the
firmware was detected and the Perform a firmware flash update
F127 DSIFlashUpdatReq 2 drive is running using backup operation using DSI communications to
firmware that only supports DSI attempt to load a valid set of firmware.
communications.
(1) See Fault Types for more information.
(2) This fault may be cleared by the auto-restart routine and is attempted only once. It ignores the value set in parameter A541
[Auto Rstrt Tries].
(3) This fault is not applicable to PowerFlex 523 drives.

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Chapter 4 Troubleshooting

Common Symptoms and The drive is designed to start from the keypad when shipped. For a basic test of
Corrective Actions drive operation:
1. Remove all user I/O wire.
2. Verify safety terminals (S1, S2, and S+) jumper is in place and tightened.
3. Verify that wire jumper is in place between I/O terminals 01 and 11.
4. Verify that the three jumpers are in their proper default positions on the
control board. See PowerFlex 525 Control I/O Terminal Block on page 41
for more information.
5. Reset default parameter values by setting P053 [Reset Defalts] to 2
“Factory Rset”.
6. If safe to do so for your application, press Start on drive keypad. Drive
runs according to the speed potentiometer.
Motor does not Start
Causes Indication Corrective Action
Check the power circuit.
• Check the supply voltage.
• Check all fuses and disconnects.
Check the motor.
• Verify that the motor is connected properly.
Check the control input signals.
No output voltage to the motor. None • Verify that a Start signal is present. If 2-Wire control is used, verify that either the
Run Forward or Run Reverse signal is active, but not both.
• Verify that I/O Terminal 01 is active.
• Verify that P046, P048, P050 [Start Source x] matches your configuration.
• Verify that A544 [Reverse Disable] is not prohibiting movement.
• Verify that safety inputs (Safety 1 and Safety 2) are active.
Improper boost setting at initial startup. None Set A530 [Boost Select] to 2 “35.0, VT”.
Clear fault.
• Press Stop if P045 [Stop Mode] is set to a value between “0” and “3”.
• Cycle drive power.
Drive is Faulted Flashing red status light
• Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”.
• Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to
13 “Clear Fault”.
Incorrect programming.
None Check setting for b012 [Control Source].
• P046, P048, P050 [Start Source x] is set incorrectly.
Incorrect input wiring.
See page 43 for wiring examples. • Wire inputs correctly and/or install jumper.
• 2 wire control requires Run Forward, Run Reverse or Jog • If the PowerFlex 525 Safe Torque Off function is used, verify that inputs are active.
input. None
• If 2-wire or 3-wire mode is used, verify that t062 [DigIn TermBlk 02] and t063
• 3 wire control requires Start and Stop inputs [DigIn TermBlk 03] are set properly.
• Stop input is always required.
Incorrect sink/source jumper setting. None Set switch to match wiring scheme.

Drive does not start from Start or Run inputs wired to the terminal block
Causes Indication Corrective Action
Clear fault.
• Press Stop if P045 [Stop Mode] is set to a value between “0” and “3”.
Drive is Faulted Flashing red status light • Cycle drive power.
• Set A551 [Fault Clear] to 1 “Reset Fault” or 2 “Clear Buffer”.
• Cycle digital input if t062, t063, t065...t068 [DigIn TermBlk xx] is set to
13 “Clear Fault”.

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 Chapter 4 Troubleshooting

Drive does not start from Start or Run inputs wired to the terminal block (Continued)
Causes Indication Corrective Action
Incorrect programming.
• P046, P048, P050 [Start Source x] is set incorrectly. None Check parameter settings.
• t062, t063 [DigIn TermBlk 02/03] is set incorrectly.
Incorrect input wiring.
See page 43 for wiring examples.
• 2 wire control requires Run Forward, Run Reverse or Jog • Wire inputs correctly and/or install jumper.
input. None
• If the PowerFlex 525 Safe Torque Off function is used, verify that inputs are active.
• 3 wire control requires Start and Stop inputs.
• Stop input is always required.
Incorrect sink/source jumper setting. None Set switch to match wiring scheme.

Drive does not respond to changes in speed command

Causes Indication Corrective Action
• Check b012 [Control Source] for correct source.
The drive “Run” indicator • If the source is an analog input, check wiring and use a meter to check for presence
No value is coming from the source of the command. is lit and output is 0 Hz. of signal.
• Check b002 [Commanded Freq] to verify correct command.
• Check b012 [Control Source] for correct source.
• Check b014 [Dig In Status] to see if inputs are selecting an alternate source.
Verify settings for t062, t063, t065-t068 [DigIn TermBlk xx].
Incorrect reference source is being selected by remote None • Check P047, P049, P051 [Speed Referencex] for the source of the speed
device or digital inputs. reference. Reprogram as necessary.
• Review the Speed Reference Control chart on page 48.
• Verify communications if used.

Motor and/or drive will not accelerate to commanded speed

Causes Indication Corrective Action
Acceleration time is excessive. None Reprogram P041, A442, A444, A446 [Accel Time x].
• Compare b003 [Output Current] with A484, A485 [Current Limit x].
Excess load or short acceleration times force the drive into None
current limit, slowing or stopping acceleration. • Remove excess load or reprogram P041, A442, A444, A446 [Accel Time x].
• Check for improper A530 [Boost Select] setting.
• Verify b002 [Commanded Freq].
Speed command source or value is not as expected. None
• Check b012 [Control Source] for the proper Speed Command.
• Check P044 [Maximum Freq] to ensure that speed is not limited by
Programming is preventing the drive output from programming.
None
exceeding limiting values.
• Verify programming of A572 [Speed Ratio].
• Set motor nameplate full load amps in parameter P034 [Motor NP FLA].
Torque performance does not match motor characteristics. None • Perform P040 [Autotune] “Static Tune” or “Rotate Tune” procedure.
• Set P039 [Torque Perf Mode] to 0 “V/Hz”.

Motor operation is unstable

Causes Indication Corrective Action
• Correctly enter motor nameplate data into P031, P032 and P033.
Motor data was incorrectly entered. None • Enable A547 [Compensation].
• Use A530 [Boost Select] to reduce boost level.

Drive will not reverse motor direction

Causes Indication Corrective Action
Reverse is disabled. None Check A544 [Reverse Disable].
Check [DigIn TermBlk xx] (See page 88). Choose correct input and program for
Digital input is not selected for reversing control. None reversing mode.
Digital input is incorrectly wired. None Check input wiring (See page 43).
Motor wiring is improperly phased for reverse. None Switch two motor leads.

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Chapter 4 Troubleshooting

Drive does not power up

Causes Indication Corrective Action
• Check the power circuit.
No input power to drive. None • Check the supply voltage.
• Check all fuses and disconnects.
• Remove power.
• Verify that the control module is properly and fully installed on the power
Control module is not connected properly to power module. None module.
• Reapply power.

Motor is rotating at zero Hz or slip frequency is not correct

Causes Indication Corrective Action
• Verify P032 [Motor NP Hertz].
Incorrect speed calculation. Improper speed. • Reduce boost with A530 [Boost Select].
• Set P036 [Motor NP RPM] to motor synchronous speed.

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 Appendix A

Supplemental Drive Information

Topic Page
Certifications 165
Environmental Specifications 166
Technical Specifications 167
Power Specifications 169

Certifications
Certifications PowerFlex 523 PowerFlex 525
c-UL-us
Listed to UL508C and CAN/CSA-C22.2 No. 14-05.

Australian Communications and Media Authority

In conformity with the following:
RCM Radiocommunications Act: 1992 (including amendments up to 2018)
Radiocommunications Standard: 2017
Radiocommunications Labeling Notice: 2017
Standards applied:
EN 61800-3
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 61800-3
EN 61800-5-1
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)
UKCA 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 61800-3
EN 61800-5-1
(Applicable to PowerFlex 525 drives only)
TÜV Rheinland
Standards applied:
Functional Safety EN ISO 13849-1
Functional
Safety EN 61800-5-2
Type
Approved EN 61508 PARTS 1-7
www.tuv.com EN 62061
ID 0600000000
EN 60204-1
Certified to ISO 13849-1 SIL2/PLd with embedded Safe Torque Off function
Meets Functional Safety (FS) when used with embedded Safe Torque Off function

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Appendix A Supplemental Drive Information

Certifications PowerFlex 523 PowerFlex 525

ATEX (Applicable to PowerFlex 525 drives only)
II (2) G D
Certified to ATEX Directive 2014/34/EU
Group II Category (2) GD Applications with ATEX Approved Motors
TÜV 12 ATEX 7199 X
TÜV 21 UKEX 7031 X 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
Korean Registration of Broadcasting and Communications Equipment
KCC Compliant with the following standards:
Article 58-2 of Radio Waves Act, Clause 3
Standards applied:
EAC Low Voltage TP TC 004/2011
EMC TP TC 020/2011
Ecodesign regulation (EU) 2019/1781, IE2 efficiency class, refer to PowerFlex AC Drive
Efficiency Class Performance Specifications per Ecodesign Regulation (EU) 2019/1781,
publication PFLEX-TD003 for additional information.
Tested by Trentec to be compliant with AC156 Acceptance Criteria for Seismic Qualification
AC 156 Testing of Nonstructural Components and 2003 International Building Code for worst-case
seismic level for USA excluding site class F
Certified compliant with the following standards:
SEMI F47 SEMI F47
IEC 61000-4-11
IEC 61000-4-34
(Applicable to PowerFlex 525 drives only)
Lloyds Register Lloyd’s Register Type Approval Certificate 12/10068(E1)
RoHS Compliant with the European “Restriction of Hazardous Substances” 2011/65/EU 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.

Environmental
Specifications Specifications PowerFlex 523 PowerFlex 525
See Current Derating Curves on page 17 for derating guidelines.
Altitude 1000 m (3300 ft) max
Without derating Up to 4000 m (13,200 ft) max, with the exception of 600V drives at 2000 m (6600 ft)
With derating max.
Max Surrounding Air See Current Derating Curves on page 17 for derating guidelines.
Temperature -20...+50 °C (-4...+122 °F)
Without derating -20...+60 °C (-4...+140 °F) or -20...+70 °C (-4...+158 °F) with optional Control Module
With derating Fan kit
Storage Temperature
Frame A...D -40...+85 °C (-40...+185 °F)
Frame E -40...+70 °C (-40...+158 °F)

IMPORTANT Drive must not be installed in an area where

the ambient atmosphere contains volatile or
Atmosphere corrosive gas, vapors, or dust. If the drive is
not going to be installed for time, it must be
stored in an area where it will not be exposed
to a corrosive atmosphere.
Relative Humidity 0...95% noncondensing
Shock Complies with IEC 60068-2-27
Vibration Complies with IEC 60068-2-6:1995

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 Appendix A Supplemental Drive Information

Specifications PowerFlex 523 PowerFlex 525

Operating and Nonoperating Nonoperating (Transportation)

Frame
Size Force Force
Mounting Type Mounting Type
(Shock/Vibration) (Shock/Vibration)
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

Complies with:
Conformal Coating IEC 60721-3-3 to level 3C2 (chemical and gases only)
Surrounding Environment See Pollution Degree Ratings According to EN 61800-5-1 on page 51
Pollution Degree for descriptions.
Pollution Degree 1 & 2 All enclosures acceptable.
Sound Pressure Level Measurements are taken 1 m from the drive.
(A-weighted)
Frame A & B Maximum 53 dBA
Frame C Maximum 57 dBA
Frame D Maximum 64 dBA
Frame E Maximum 68 dBA

Technical Specifications Protection

Specifications PowerFlex 523 PowerFlex 525

Bus Overvoltage Trip
100...120V AC Input 405V DC bus (equivalent to 150V AC incoming line)
200...240V AC Input 405V DC bus (equivalent to 290V AC incoming line)
380...480V AC Input 810V DC bus (equivalent to 575V AC incoming line)
525...600V AC Input 1005V DC bus (equivalent to 711V AC incoming line)
Bus Undervoltage Trip
100...120V AC Input 190V DC bus (equivalent to 75V AC incoming line)
200...240V AC Input 190V DC bus (equivalent to 150V AC incoming line)
380...480V AC Input 390V DC bus (equivalent to 275V AC incoming line)
Power ride-through 100 ms
Logic Control ride-through 0.5 s minimum, 2 s typical
Provides class 10 motor overload protection according to NEC article 430 and motor
Electronic Motor Overload over-temperature protection according to NEC article 430.126 (A) (2).
Protection 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

Electrical

Specifications PowerFlex 523 PowerFlex 525

Voltage Tolerance -15% / +10%
Frequency Tolerance 47...63 Hz
Three-phase input provides full rating. Single-phase input provides 35% rating on
Input Phases three-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 Insulated gate bipolar transistor (IGBT)
Internal DC Bus Choke Only for Frame E drive ratings
200...240V AC Input 11 kW (15 HP)
380...480V AC Input 15...18.5 kW (20...25 HP) – Heavy Duty
525...600V AC Input 15...18.5 kW (20...25 HP) – Heavy Duty

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Appendix A Supplemental Drive Information

Control

Specifications PowerFlex 523 PowerFlex 525

Sinusoidal PWM, Volts/Hertz, Sensorless Vector Control, Economizer SVC motor
control, Closed Loop Velocity Vector Control, Surface Mount, and Interior
Permanent Magnet Motor (without encoder), Interior Permanent Magnet Motor
Method (with encoder)
(Closed Loop Velocity Vector Control, PM motor control, and SynRM are not
applicable to PowerFlex 523 drives)
Carrier Frequency 2...16 kHz, Drive rating based on 4 kHz
Frequency Accuracy
Digital Input Within ±0.05% of set output frequency
Analog Input Within 0.5% of maximum output frequency, 10-Bit resolution
Analog Output ±2% of full scale, 10-Bit resolution
Performance
V/Hz (Volts per Hertz) ±1% of base speed across a 60:1 speed range
SVC (Sensorless Vector) ±0.5% of base speed across a 100:1 speed range
SVC Economizer ±0.5% of base speed across a 100:1 speed range

(Applicable to PowerFlex 525 drives only)

VVC (Velocity Vector Control) ±0.5% of base speed across a 60:1 speed range
PM Motor (1) ±0.5% of base speed, up to a 20:1 speed range
Performance with Encoder (Applicable to PowerFlex 525 drives only)
SVC (Sensorless Vector)
SVC Economizer ±0.1% of base speed across a 100:1 speed range(2)
VVC (Velocity Vector Control) ±0.1% of base speed across a 100:1 speed range(2)
PM Motor (iPM motor, 10 HP ±0.1% of base speed across a 1000:1 speed range(2)
rating and below) (1) ±0.1% of base speed, up to a 60:1 speed range
Output Voltage Range 0V to rated motor voltage
Output Frequency Range 0...500 Hz (programmable)
Efficiency 97.5% (typical)
Multiple programmable stop modes including – Ramp, Coast, DC-Brake,
Stop Modes and Ramp to Stop
Four independently programmable accel and decel times. Each time may be
Accel/Decel programmed from 0...600 s in 0.01 s increments.
Intermittent Overload 110% Overload capability for up to 60 s, 150% for up to 3 s
Normal Duty Applies for power rating above 15 kW (20 HP) only. Based on 480V drive rating.
Heavy Duty 150% Overload capability for up to 60 s, 180% for up to 3 s
(1) For details on specific motor performance, see Knowledgebase article “PowerFlex 525 Drive PM Motor Performance Testing
Summary”.
(2) For more information, see Determine Encoder Pulse Per Revolution (PPR) Specification Based on Speed Resolution on
page 221.

Control Inputs
Specifications PowerFlex 523 PowerFlex 525
Bandwidth 10 Rad/s for open and closed loop
(1) Dedicated for stop (1) Dedicated for stop
Quantity (4) Programmable (6) Programmable
Current 6 mA
Type
Source Mode (SRC) 18...24V = ON, 0...6V = OFF
Digital Sink Mode (SNK) 0...6V = ON, 18...24V = OFF
Pulse Train
Quantity (1) Shared with one of the programmable digital input terminals.
Input Signal Transistor contact (open collector)
Input Frequency 0...100 kHz
Current
Consumption 7 mA @ 24V DC maximum
Quantity (1) Isolated, 0…10V and 4…20mA (2) Isolated, -10…10V and 4…20mA
Specification
Analog Resolution 10-bit
0…10V DC Analog 100k ohm input impedance
4…20mA Analog 250 ohm input impedance
External Pot 1...10k ohm, 2 W minimum

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 Appendix A Supplemental Drive Information

Control Outputs

Specifications PowerFlex 523 PowerFlex 525

(2) 1 Programmable Form A and
Quantity (1) Programmable Form C 1 Programmable Form B
Relay Specification
Resistive Rating 3.0 A @ 30V DC, 3.0 A @ 125V, 3.0 A @ 240V AC
Inductive Rating 0.5 A @ 30V DC, 0.5 A @ 125V, 0.5 A @ 240V AC
Quantity (2) Programmable
Opto –
Specification 30V DC, 50 mA Non-inductive
Quantity (1) Non-Isolated 0…10V or 4…20 mA(1)
Specification
Analog Resolution 10-bit
0…10V DC Analog 1 kΩ minimum
4…20 mA Analog 525 Ω maximum
(1) Feature is not applicable to PowerFlex 523 series A drives.

Encoder

Specifications PowerFlex 523 PowerFlex 525

Type Incremental, dual channel
Supply 12V, 250 mA
Quadrature 90 °C, ±27 °C @ 25 °CC
Duty Cycle 50%, +10%
– Encoders must be line driver type, quadrature (dual channel), or
pulse (single channel), 3.5...26V DC output, single-ended or
differential and capable of supplying a minimum of 10 mA per
Requirements 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.

Power Specifications
Watts Loss
Voltage Output Current (A) Total Watts Loss
1.6 20.0
100...120V, 2.5 27.0
50/60 Hz 1-Phase 4.8 53.0
6.0 67.0
1.6 20.0
2.5 29.0
200...240V, 4.8 50.0
50/60 Hz 1-Phase
8.0 81.0
11.0 111.0
1.6 20.0
200...240V, 2.5 29.0
50/60 Hz 1-Phase 4.8 53.0
w/ EMC Filter 8.0 84.0
11.0 116.0

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Appendix A Supplemental Drive Information

Watts Loss (Continued)

Voltage Output Current (A) Total Watts Loss
1.6 20.0
2.5 29.0
5.0 50.0
8.0 79.0
200...240V, 11.0 107.0
50/60 Hz 3-Phase 17.5 148.0
24.0 259.0
32.2 323.0
48.3 584.0
62.1 708.0
1.4 27.0
2.3 37.0
4.0 62.0
6.0 86.0
380...480V,
50/60 Hz 3-Phase 10.5 129.0
13.0 170.0
17.0 221.0
24.0 303.0
30.0 387.0
1.4 27.0
2.3 37.0
4.0 63.0
6.0 88.0
380...480V, 10.5 133.0
50/60 Hz 3-Phase 13.0 175.0
w/ EMC Filter 17.0 230.0
24.0 313.0
30.0 402.0
37.0 602.0
43.0 697.0
0.9 22.0
1.7 32.0
3.0 50.0
4.2 65.0
6.6 95.0
525...600V,
50/60 Hz 3-Phase 9.9 138.0
12.0 164.0
19.0 290.0
22.0 336.0
27.0 466.0
32.0 562.0

170 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix A Supplemental Drive Information

Input Current Scaling (Optional)

You can use a higher drive rating by scaling the input current based on the
output current that is required for your application. You can use a lower input
current rating based on the motor FLA rating. See the PowerFlex 520-Series
Input Current Rating Scaled by the Motor FLA on page 171 table for more
information.

Use the motor FLA rating in columns 1…4 and check the corresponding input
rating in columns A…D. For example when using a 25A-V1P6N104 drive, if the
motor has an FLA rating of 1.6, the input rating is 6.4 amps.

PowerFlex 520-Series Input Current Rating Scaled by the Motor FLA

PowerFlex 523 PowerFlex 525 Output Current: Motor FLA Input Drive Current Rating
Catalog Number Catalog Number 1 2 3 4 A B C D
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
25A-V1P6N104 – 1.6 1.3 1.0 0.8 6.4 5.2 4.0 3.2
25A-V2P5N104 25B-V2P5N104 2.5 2.0 1.6 1.3 9.6 7.7 6.2 4.8
25A-V4P8N104 25B-V4P8N104 4.8 3.8 3.1 2.4 19.2 15.4 12.5 9.6
25A-V6P0N104 25B-V6P0N104 6.0 4.8 3.9 3.0 24.0 19.2 15.6 12.0
200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
25A-A1P6N104 – 1.6 1.3 1.0 0.8 5.3 4.3 3.4 2.7
25A-A2P5N104 25B-A2P5N104 2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3
25A-A4P8N104 25B-A4P8N104 4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4
25A-A8P0N104 25B-A8P0N104 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0
25A-A011N104 25B-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
25A-A1P6N114 – 1.6 1.3 1.0 0.8 5.3 4.3 3.4 2.7
25A-A2P5N114 25B-A2P5N114 2.5 2.0 1.6 1.3 6.5 5.2 4.2 3.3
25A-A4P8N114 25B-A4P8N114 4.8 3.8 3.1 2.4 10.7 8.6 7.0 5.4
25A-A8P0N114 25B-A8P0N114 8.0 6.4 5.2 4.0 18.0 14.4 11.7 9.0
25A-A011N114 25B-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
25A-B1P6N104 – 1.6 1.3 1.0 0.8 1.9 1.5 1.2 1.0
25A-B2P5N104 25B-B2P5N104 2.5 2.0 1.6 1.3 2.7 2.2 1.8 1.4
25A-B5P0N104 25B-B5P0N104 5.0 4.0 3.2 2.5 5.8 4.6 3.8 2.9
25A-B8P0N104 25B-B8P0N104 8.0 6.4 5.2 4.0 9.5 7.6 6.2 4.8
25A-B011N104 25B-B011N104 11.0 8.8 7.2 5.5 13.8 11.0 9.0 6.9
25A-B017N104 25B-B017N104 17.5 14.0 11.4 8.8 21.1 16.9 13.7 10.6
25A-B024N104 25B-B024N104 24.0 19.2 15.6 12.0 26.6 21.3 17.3 13.3
25A-B032N104 25B-B032N104 32.2 25.8 20.9 16.1 34.8 27.8 22.6 17.4
25A-B048N104 25B-B048N104 48.3 38.6 31.4 24.2 44.0 35.2 28.6 22.0
25A-B062N104 25B-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
25A-D1P4N104 25B-D1P4N104 1.4 1.1 0.9 0.7 1.9 1.5 1.2 1.0
25A-D2P3N104 25B-D2P3N104 2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6
25A-D4P0N104 25B-D4P0N104 4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9
25A-D6P0N104 25B-D6P0N104 6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8
25A-D010N104 25B-D010N104 10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9
25A-D013N104 25B-D013N104 13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7
25A-D017N104 25B-D017N104 17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2
25A-D024N104 25B-D024N104 24.0 19.2 15.6 12.0 26.4 21.1 17.2 13.2
25A-D030N104 25B-D030N104 30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 171

Appendix A Supplemental Drive Information

PowerFlex 520-Series Input Current Rating Scaled by the Motor FLA (Continued)
PowerFlex 523 PowerFlex 525 Output Current: Motor FLA Input Drive Current Rating
Catalog Number Catalog Number 1 2 3 4 A B C D
380...480V AC (-15%, +10%) – 3-Phase Input with EMC Filter, 0...460V 3-Phase Output
25A-D1P4N114 25B-D1P4N114 1.4 1.1 0.9 0.7 1.9 1.5 1.2 1.0
25A-D2P3N114 25B-D2P3N114 2.3 1.8 1.5 1.2 3.2 2.6 2.1 1.6
25A-D4P0N114 25B-D4P0N114 4.0 3.2 2.6 2.0 5.7 4.6 3.7 2.9
25A-D6P0N114 25B-D6P0N114 6.0 4.8 3.9 3.0 7.5 6.0 4.9 3.8
25A-D010N114 25B-D010N114 10.5 8.4 6.8 5.3 13.8 11.0 9.0 6.9
25A-D013N114 25B-D013N114 13.0 10.4 8.5 6.5 15.4 12.3 10.0 7.7
25A-D017N114 25B-D017N114 17.0 13.6 11.1 8.5 18.4 14.7 12.0 9.2
25A-D024N114 25B-D024N114 24.0 19.2 15.6 12.0 26.4 21.1 17.2 3.2
25A-D030N114 25B-D030N114 30.0 24.0 19.5 15.0 33.0 26.4 21.5 16.5
25A-D037N114 25B-D037N114 37.0 29.6 24.1 18.5 33.7 27.0 21.9 16.9
25A-D043N114 25B-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
25A-E0P9N104 25B-E0P9N104 0.9 0.7 0.6 0.5 1.2 1.0 0.8 0.6
25A-E1P7N104 25B-E1P7N104 1.7 1.4 1.1 0.9 2.3 1.8 1.5 1.2
25A-E3P0N104 25B-E3P0N104 3.0 2.4 2.0 1.5 3.8 3.0 2.5 1.9
25A-E4P2N104 25B-E4P2N104 4.2 3.4 2.7 2.1 5.3 4.2 3.4 2.7
25A-E6P6N104 25B-E6P6N104 6.6 5.3 4.3 3.3 8.0 6.4 5.2 4.0
25A-E9P9N104 25B-E9P9N104 9.9 7.9 6.4 5.0 11.2 9.0 7.3 5.6
25A-E012N104 25B-E012N104 12.0 9.6 7.8 6.0 13.5 10.8 8.8 6.8
25A-E019N104 25B-E019N104 19.0 15.2 12.4 9.5 24.0 19.2 15.6 12.0
25A-E022N104 25B-E022N104 22.0 17.6 14.3 11.0 27.3 21.8 17.7 13.7
25A-E027N104 25B-E027N104 27.0 21.6 17.6 13.5 24.7 19.8 16.1 12.4
25A-E032N104 25B-E032N104 32.0 25.6 20.8 16.0 29.2 23.4 19.0 14.6

172 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix B

Accessories and Dimensions

Product Selection
Catalog Number Description
25B - V 2P5 N 1 0 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Version

PowerFlex 520-Series Drive Ratings

Output Ratings
Input Frame PowerFlex 523 PowerFlex 525
Normal Duty Heavy Duty Output Voltage Range Size
HP kW HP kW Current (A) Catalog No. Catalog No.
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 85...132 A 25A-V1P6N104(1) –
0.5 0.4 0.5 0.4 2.5 85...132 A 25A-V2P5N104 25B-V2P5N104
1.0 0.75 1.0 0.75 4.8 85...132 B 25A-V4P8N104 25B-V4P8N104
1.5 1.1 1.5 1.1 6.0 85...132 B 25A-V6P0N104 25B-V6P0N104
200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 170...264 A 25A-A1P6N104(1) –
0.5 0.4 0.5 0.4 2.5 170...264 A 25A-A2P5N104 25B-A2P5N104
1.0 0.75 1.0 0.75 4.8 170...264 A 25A-A4P8N104 25B-A4P8N104
2.0 1.5 2.0 1.5 8.0 170...264 B 25A-A8P0N104 25B-A8P0N104
3.0 2.2 3.0 2.2 11.0 170...264 B 25A-A011N104 25B-A011N104
200...240V AC (-15%, +10%) – 1-Phase Input with EMC Filter, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 170...264 A 25A-A1P6N114 –
0.5 0.4 0.5 0.4 2.5 170...264 A 25A-A2P5N114 25B-A2P5N114
1.0 0.75 1.0 0.75 4.8 170...264 A 25A-A4P8N114 25B-A4P8N114
2.0 1.5 2.0 1.5 8.0 170...264 B 25A-A8P0N114 25B-A8P0N114
3.0 2.2 3.0 2.2 11.0 170...264 B 25A-A011N114 25B-A011N114
200...240V AC (-15%, +10%) – 3-Phase Input, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 170...264 A 25A-B1P6N104(1) –
0.5 0.4 0.5 0.4 2.5 170...264 A 25A-B2P5N104 25B-B2P5N104
1.0 0.75 1.0 0.75 5.0 170...264 A 25A-B5P0N104 25B-B5P0N104
2.0 1.5 2.0 1.5 8.0 170...264 A 25A-B8P0N104 25B-B8P0N104
3.0 2.2 3.0 2.2 11.0 170...264 A 25A-B011N104 25B-B011N104
5.0 4.0 5.0 4.0 17.5 170...264 B 25A-B017N104 25B-B017N104
7.5 5.5 7.5 5.5 24.0 170...264 C 25A-B024N104 25B-B024N104
10.0 7.5 10.0 7.5 32.2 170...264 D 25A-B032N104 25B-B032N104
15.0 11.0 10.0 7.5 48.3 170...264 E 25A-B048N104 25B-B048N104
20.0 15.0 15.0 11.0 62.1 170...264 E 25A-B062N104 25B-B062N104
380...480V AC (-15%, +10%) – 3-Phase Input, 0...460V 3-Phase Output(2)
0.5 0.4 0.5 0.4 1.4 323...528 A 25A-D1P4N104(1) 25B-D1P4N104(1)
1.0 0.75 1.0 0.75 2.3 323...528 A 25A-D2P3N104 25B-D2P3N104
2.0 1.5 2.0 1.5 4.0 323...528 A 25A-D4P0N104 25B-D4P0N104

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 173

Appendix B Accessories and Dimensions

PowerFlex 520-Series Drive Ratings (Continued)

Output Ratings
Input Frame PowerFlex 523 PowerFlex 525
Normal Duty Heavy Duty Output Voltage Range Size
HP kW HP kW Current (A) Catalog No. Catalog No.
3.0 2.2 3.0 2.2 6.0 323...528 A 25A-D6P0N104 25B-D6P0N104
5.0 4.0 5.0 4.0 10.5 323...528 B 25A-D010N104 25B-D010N104
7.5 5.5 7.5 5.5 13.0 323...528 C 25A-D013N104 25B-D013N104
10.0 7.5 10.0 7.5 17.0 323...528 C 25A-D017N104 25B-D017N104
15.0 11.0 15.0 11.0 24.0 323...528 D 25A-D024N104 25B-D024N104
20.0 15.0 15.0 11.0 30.0 323...528 D 25A-D030N104 25B-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 25A-D1P4N114 25B-D1P4N114
1.0 0.75 1.0 0.75 2.3 323...528 A 25A-D2P3N114 25B-D2P3N114
2.0 1.5 2.0 1.5 4.0 323...528 A 25A-D4P0N114 25B-D4P0N114
3.0 2.2 3.0 2.2 6.0 323...528 A 25A-D6P0N114 25B-D6P0N114
5.0 4.0 5.0 4.0 10.5 323...528 B 25A-D010N114 25B-D010N114
7.5 5.5 7.5 5.5 13.0 323...528 C 25A-D013N114 25B-D013N114
10.0 7.5 10.0 7.5 17.0 323...528 C 25A-D017N114 25B-D017N114
15.0 11.0 15.0 11.0 24.0 323...528 D 25A-D024N114 25B-D024N114
20.0 15.0 15.0 11.0 30.0 323...528 D 25A-D030N114 25B-D030N114
25.0 18.5 20.0 15.0 37.0 323...528 E 25A-D037N114 25B-D037N114
30.0 22.0 25.0 18.5 43.0 323...528 E 25A-D043N114 25B-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 25A-E0P9N104(1) 25B-E0P9N104(1)
1.0 0.75 1.0 0.75 1.7 446...660 A 25A-E1P7N104 25B-E1P7N104
2.0 1.5 2.0 1.5 3.0 446...660 A 25A-E3P0N104 25B-E3P0N104
3.0 2.2 3.0 2.2 4.2 446...660 A 25A-E4P2N104 25B-E4P2N104
5.0 4.0 5.0 4.0 6.6 446...660 B 25A-E6P6N104 25B-E6P6N104
7.5 5.5 7.5 5.5 9.9 446...660 C 25A-E9P9N104 25B-E9P9N104
10.0 7.5 10.0 7.5 12.0 446...660 C 25A-E012N104 25B-E012N104
15.0 11.0 15.0 11.0 19.0 446...660 D 25A-E019N104 25B-E019N104
20.0 15.0 15.0 11.0 22.0 446...660 D 25A-E022N104 25B-E022N104
25.0 18.5 20.0 15.0 27.0 446...660 E 25A-E027N104 25B-E027N104
30.0 22.0 25.0 18.5 32.0 446...660 E 25A-E032N104 25B-E032N104
(1) These drive ratings do not come with a heatsink cooling fan and are in accordance with design specifications.
(2) 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 Dynamic Brake Fuse Model
Resistance,
Resistance, Catalog No.(1)(2)
Input Voltage HP kW Ω ±10% Ω ±5% Fuse Rating, A(3) Number(4)
0.25 0.2 56 91 AK-R2-091P500 15 PV-15A10F
100...120V 0.5 0.4 56 91 AK-R2-091P500 15 PV-15A10F
50/60 Hz
1-Phase 1.0 0.75 56 91 AK-R2-091P500 15 PV-15A10F
1.5 1.1 41 91 AK-R2-091P500 15 PV-15A10F
0.25 0.2 56 91 AK-R2-091P500 15 PV-15A10F
200...240V 0.5 0.4 56 91 AK-R2-091P500 15 PV-15A10F
50/60 Hz 1.0 0.75 56 91 AK-R2-091P500 15 PV-15A10F
1-Phase 2.0 1.5 41 91 AK-R2-091P500 32 PV-32ANH1
3.0 2.2 32 47 AK-R2-047P500 32 PV-32ANH1

174 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix B Accessories and Dimensions

Dynamic Brake Resistors (Continued)

Drive Ratings Minimum Dynamic Brake Fuse Model
Resistance,
Resistance, Catalog No.(1)(2)
Input Voltage HP kW Ω ±10% Ω ±5% Fuse Rating, A(3) Number(4)
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
200...240V 3.0 2.2 32 47 AK-R2-047P500 20 PV-20A10F
50/60 Hz 5.0 4.0 18 47 AK-R2-047P500 32 PV-32ANH1
3-Phase
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
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
380...480V 7.5 5.5 47 120 AK-R2-120P1K2 32 PV-32ANH1
50/60 Hz
3-Phase 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
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
525...600V 7.5 5.5 59 120 AK-R2-120P1K2 20 PV-20A10F
50/60 Hz
3-Phase 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 these tables are rated for 5% duty cycle.
(2) Use of Rockwell Automation resistors is always recommended. The resistors that are listed have been carefully selected for
optimizing performance in a variety of applications. Alternative resistors may be used, however, care must be taken when
making a selection. See the PowerFlex Dynamic Braking Resistor Calculator, 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 wired in parallel.
(6) Requires three resistors wired in parallel.

EMC Line Filters

Short-circuit Current Rating = 100 kA
Drive Ratings For 100 m For 150 m(1)
Frame Size
Input Voltage HP kW Current (A) Catalog No. Catalog No.
0.25 0.2 1.6 A 25-RF011-AL —
100...120V 0.5 0.4 2.5 A 25-RF011-AL —
50/60 Hz
1-Phase 1.0 0.75 4.8 B 25-RF023-BL —
1.5 1.1 6.0 B 25-RF023-BL —

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 175

Appendix B Accessories and Dimensions

EMC Line Filters (Continued)

Short-circuit Current Rating = 100 kA
Drive Ratings For 100 m For 150 m(1)
Frame Size
Input Voltage HP kW Current (A) Catalog No. Catalog No.
0.25 0.2 1.6 A 25-RF011-AL
200...240V 0.5 0.4 2.5 A 25-RF011-AL
50/60 Hz 1.0 0.75 4.8 A 25-RF011-AL
1-Phase 2.0 1.5 8.0 B 25-RF023-BL
3.0 2.2 11.0 B 25-RF023-BL
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
200...240V 3.0 2.2 11.0 A 25-RF014-AL 25-RF021-BL
50/60 Hz
3-Phase 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
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
380...480V 5.0 4.0 10.5 B 25-RF014-BL
50/60 Hz 7.5 5.5 13.0 C 25-RF018-CL
3-Phase 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
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) —
525...600V 5.0 4.0 6.6 B 25-RF8P0-BL —
50/60 Hz
3-Phase 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
Frame
Item Description Catalog No.
Size
A 25-EMC1-FA
B 25-EMC1-FB
EMC Plate Optional grounding plate for shielded cables. C 25-EMC1-FC
D 25-EMC1-FD
E 25-EMC1-FE

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 Appendix B Accessories and Dimensions

Human Interface Module (HIM) Option Kits and Accessories

Item Description Catalog No.
Digital speed control
LCD Display, Remote Panel Copycat capable 22-HIM-C2S
Mount IP66 (NEMA Type 4X/12) indoor use only
Includes 2.0 meter cable
Digital speed control
Full numeric keyboard
LCD Display, Remote Copycat capable 22-HIM-A3
Handheld IP 30 (NEMA Type 1)
Includes 1.0 meter cable
Panel mount with optional Bezel Kit
Panel mount for LCD Display, Remote Handheld unit, IP 30 (NEMA Type 1)
Bezel Kit 22-HIM-B1
Includes 2.0 m DSI cable
DSI HIM Cable 1.0 m (3.3 ft) 22-HIM-H10
(DSI HIM to RJ45 cable) 2.9 m (9.51 ft) 22-HIM-H30

IP 30/NEMA 1/UL Type 1 Kit

Frame
Item Description Catalog No.
Size
A 25-JBAA
Field installed kit. Converts drive to IP 30/NEMA 1/UL Type 1 B 25-JBAB
IP 30/NEMA 1/UL Type 1 Kit enclosure. Includes conduit box with mounting screws and C 25-JBAC
plastic top panel. D 25-JBAD
E 25-JBAE

Control Module Fan Kit

Frame
Item Description Catalog No.
Size
For use with drive in environments with ambient A...D 25-FAN1-70C
Control Module Fan Kit temperatures up to 70 °C or horizontal mounting. E 25-FAN2-70C

Incremental Encoder Input Option

Item Description Catalog No.
Incremental Encoder Incremental encoder input option board. 25-ENC-1

WARNING: Only the 25-ENC-1 Encoder works properly in the PowerFlex 525
drive. Installing an incorrect encoder card, such as the PowerFlex 527 25-ENC-
2 causes damage to the PowerFlex 525 drive.

PowerFlex 520-Series Drives Jumper Spare Kit

Item Description Catalog No.
• Wire Jumper
• MOV Jumper Replace the Protective Jumper from your Power
• Protective Jumper (Control I/O terminal module, drive Terminals Safety 1, Safety 2, and 25-ACCS-Drive
block) Safety +24V (S1, S2, S+) of the Control Module.
• Analog/Signal Configuration Jumper

PowerFlex 520 Series Communication Adapter Spare Kit

Item Description Catalog No.
• PowerFlex 525 Encoder card removable
terminal block
Communication adapter spare kits. 25-ACCS-COMM
• PowerFlex 523/525 Communication Adapter
interface connector

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 177

Appendix B Accessories and Dimensions

Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate

B160
Item Description Frame Catalog No.
Size
For use with drive when replacing Bulletin 160 drives in A 25-MAP-FA
existing installations to a PowerFlex 520-Series drive.
Mounting Adapter Plate Select the catalog number based on the frame size of your B 25-MAP-FB
Bulletin 160 drive.

Mounting Adapter Plate for PowerFlex 4 AC Drive to PowerFlex 520-Series

Drive Ratings PowerFlex 4 PowerFlex 520-series
Frame Catalog No. with
Input Voltage HP kW Catalog No. Catalog No.
Size external EMC Filter(1)
0.3 0.2 22A-V1P5N104 A
100 …120V, 25-AP0-FA 25-AP1-FA
0.5 0.4 22A-V2P3N104 A
Single-Phase,
50/60 Hz 1.0 0.8 22A-V4P5N104 B
25-AP0-FB 25-AP1-FB
1.5 1.1 22A-V6P0N104 B
0.3 0.2 22A-A1P5N104 A
0.5 0.4 22A-A2P3N104 A 25-AP0-FA 25-AP1-FA
1.0 0.8 22A-A4P5N104 A
2.0 1.5 22A-A8P0N104 B 25-AP0-FB 25-AP1-FB
200…240V, No Brake IGBT
Single-Phase,
50/60 Hz 0.3 0.2 22A-A1P4N103 A
0.5 0.4 22A-A2P1N103 A 25-AP0-FA 25-AP1-FA
1.0 0.8 22A-A3P6N103 A
2.0 1.5 22A-A6P8N103 B
25-AP0-FB 25-AP1-FB
3.0 2.2 22A-A9P6N103 B
0.3 0.2 22A-A1P5N114 A
0.5 0.4 22A-A2P3N114 A 25-AP0-FA 25-AP1-FA
1.0 0.8 22A-A4P5N114 A
200…240V, 2.0 1.5 22A-A8P0N114 B 25-AP0-FB 25-AP1-FB
Single-Phase, No Brake IGBT
50/60 Hz, with
integral EMC 0.3 0.2 22A-A1P4N113 A
Filter 0.5 0.4 22A-A2P1N113 A 25-AP0-FA 25-AP1-FA
1.0 0.8 22A-A3P6N113 A
2.0 1.5 22A-A6P8N113 B
25-AP0-FB 25-AP1-FB
3.0 2.2 22A-A9P6N113 B
0.3 0.2 22A-B1P5N104 A
0.5 0.4 22A-B2P3N104 A
200…240V, 25-AP0-FA 25-AP1-FA
1.0 0.8 22A-B4P5N104 A
Three-Phase,
50/60 Hz 2.0 1.5 22A-B8P0N104 A
3.0 2.2 22A-B012N104 B
25-AP0-FB 25-AP1-FB
5.0 3.7 22A-B017N104 B
0.5 0.4 22A-D1P4N104 A
380…480V, 1.0 0.8 22A-D2P3N104 A 25-AP0-FA 25-AP1-FA
Three-Phase 2.0 1.5 22A-D4P0N104 A
50/60 Hz 3.0 2.2 22A-D6P0N104 B
25-AP0-FB 25-AP1-FB
5.0 3.7 22A-D8P7N104 B
(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC
filter to PowerFlex 520-series drives with external EMC filter only.

178 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix B Accessories and Dimensions

Mounting Adapter Plate for PowerFlex 40 AC Drive to PowerFlex 520-Series

Drive Ratings PowerFlex 40 PowerFlex 520-series
Frame Catalog No. with
Input Voltage HP kW Catalog No. Catalog No.
Size external EMC Filter(1)
100 …120V, 0.5 0.4 22B-V2P3N104 B
Single-Phase, 1.0 0.8 22B-V5P0N104 B 25-AP0-FB 25-AP1-FB
50/60 Hz 1.5 1.1 22B-V6P0N104 B
0.5 0.4 22B-A2P3N104 B
200…240V, 1.0 0.8 22B-A5P0N104 B 25-AP0-FB 25-AP1-FB
Single-Phase,
50/60 Hz 2.0 1.5 22B-A8P0N104 B
3.0 2.2 22B-A012N104 C 25-AP0-FC 25-AP1-FC
200…240V, 0.5 0.4 22B-A2P3N114 B
Single-Phase, 1.0 0.8 22B-A5P0N114 B 25-AP0-FB 25-AP1-FB
50/60 Hz, with
integral EMC 2.0 1.5 22B-A8P0N114 B
Filter 3.0 2.2 22B-A012N114 C 25-AP0-FC 25-AP1-FC
0.5 0.4 22B-B2P3N104 B
1.0 0.8 22B-B5P0N104 B
2.0 1.5 22B-B8P0N104 B 25-AP0-FB 25-AP1-FB
200…240V,
Three-Phase, 3.0 2.2 22B-B012N104 B
50/60 Hz 5.0 3.7 22B-B017104 B
7.5 5.5 22B-B024N104 C 25-AP0-FC 25-AP1-FC
10.0 7.5 22B-B033N104 C 25-AP0-FD -(2)
0.5 0.4 22B-D1P4N104 B
1.0 0.8 22B-D2P3N104 B
2.0 1.5 22B-D4P0N104 B 25-AP0-FB 25-AP1-FB
380…480V, 3.0 2.2 22B-D6P0N104 B
Three-Phase
50/60 Hz 5.0 3.7 22B-D010N104 B
7.5 5.5 22B-D012N104 C
25-AP0-FC 25-AP1-FC
10.0 7.5 22B-D017N104 C
15.0 11.0 22B-D024N104 C 25-AP0-FD -(2)
1.0 0.8 22B-E1P7N104 B
2.0 1.5 22B-E3P0N104 B 25-AP0-FB 25-AP1-FB
3.0 2.2 22B-E4P2N104 B
525…600V,
Three-Phase 5.0 3.7 22B-E6P6N104 B
50/60 Hz 7.5 5.5 22B-E9P9N104 C
25-AP0-FC 25-AP1-FC
10.0 7.5 22B-E012N104 C
15.0 11.0 22B-E019N104 C 25-AP0-FD -(2)
(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC
filter to PowerFlex 520-series drives with external EMC filter only.
(2) Mounting Adapter Plate is not required for the following ratings, as it comes with matching footprint and mounting holes.
• Three-Phase 200…240V: 7.5 kW/10 HP
• Three-Phase 380…480V: 11 kW/15 HP
• Three-Phase 500…600V: 11 kW/15 HP

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Appendix B Accessories and Dimensions

Mounting Adapter Plate for PowerFlex 40P AC Drive to PowerFlex 520-Series

Drive Ratings PowerFlex 40P PowerFlex 520-series
Frame Catalog No. with
Input Voltage HP kW Catalog No. Catalog No.
Size external EMC Filter(1)
0.5 0.4 22D-B2P3N104 B
1.0 0.8 22D-B5P0N104 B
2.0 1.5 22D-B8P0N104 B 25-AP0-FB 25-AP1-FB
200…240V,
Three-Phase, 3.0 2.2 22D-B012N104 B
50/60 Hz 5.0 3.7 22D-B017N104 B
7.5 5.5 22D-B024N104 C 25-AP0-FC 25-AP1-FC
10.0 7.5 22D-B033N104 C 25-AP0-FD -(2)
0.5 0.4 22D-D1P4N104 B
1.0 0.8 22D-D2P3N104 B
2.0 1.5 22D-D4P0N104 B 25-AP0-FB 25-AP1-FB
380…480V, 3.0 2.2 22D-D6P0N104 B
Three-Phase50/
60 Hz 5.0 3.7 22D-D010N104 B
7.5 5.5 22D-D012N104 C
25-AP0-FC 25-AP1-FC
10.0 7.5 22D-D017N104 C
15.0 11.0 22D-D024N104 C 25-AP0-FD -(2)
1.0 0.8 22D-E1P7N104 B
2.0 1.5 22D-E3P0N104 B
25-AP0-FB 25-AP1-FB
3.0 2.2 22D-E4P2N104 B
525…600V,
Three-Phase50/ 5.0 3.7 22D-E6P6N104 B
60 Hz 7.5 5.5 22D-E9P9N104 C
25-AP0-FC 25-AP1-FC
10.0 7.5 22D-E012N104 C
15.0 11.0 22D-E019N104 C 25-AP0-FD -(2)
(1) The adapter plate catalogs starting with 25-AP1-Fx are used to replace PowerFlex 4/40/40P IP20 drives with external EMC
filter to PowerFlex 520-series drives with external EMC filter only.
(2) Mounting Adapter Plate is not required for the following ratings, as it comes with matching footprint and mounting holes.
• Three-Phase 200…240V: 7.5 kW/10 HP
• Three-Phase 380…480V: 11 kW/15 HP
• Three-Phase 500…600V: 11 kW/15 HP

Replacement Parts
PowerFlex 520-Series Power Module
Item Description
Replacement power module for use with PowerFlex 520-Series drives. Includes:
• Power Module
PowerFlex 520-Series • Power Module Front Cover
Power Module
• Power Terminal Guard
• Heatsink Fan

Output Ratings
Input Frame
Normal Duty Heavy Duty Output Catalog No.
Voltage Range Size
HP kW HP kW Current (A)
100...120V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 85...132 A 25-PM1-V1P6
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
1.5 1.1 1.5 1.1 6.0 85...132 B 25-PM1-V6P0
200...240V AC (-15%, +10%) – 1-Phase Input, 0...230V 3-Phase Output
0.25 0.2 0.25 0.2 1.6 170...264 A 25-PM1-A1P6
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

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 Appendix B Accessories and Dimensions

Output Ratings (Continued)

Input Frame
Normal Duty Heavy Duty Output Catalog No.
Voltage Range Size
HP kW HP kW Current (A)
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
0.25 0.2 0.25 0.2 1.6 170...264 A 25-PM2-A1P6
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
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
0.25 0.2 0.25 0.2 1.6 170...264 A 25-PM1-B1P6
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

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Appendix B Accessories and Dimensions

Output Ratings (Continued)

Input Frame
Normal Duty Heavy Duty Output Catalog No.
Voltage Range Size
HP kW HP kW Current (A)
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 520-Series Control Module

Frame
Item Description Catalog No.
Size
PowerFlex 523 Control Replacement control module for use with 25A-CTM1
Module PowerFlex 520-Series drives. Includes:
A...E
PowerFlex 525 Control • Control Module
• Control Module Front Cover 25B-CTM1
Module

Other Parts
Frame
Item Description Catalog No.
Size
PowerFlex 523 Control 25A-CTMFC1
Module Front Cover Replacement cover for the control module I/O terminals, A...E
PowerFlex 525 Control EtherNet/IP, and DSI ports.
25B-CTMFC1
Module Front Cover
B 25-PMFC-FB
PowerFlex 520-Series Replacement cover for the PowerFlex 520-Series power C 25-PMFC-FC
Power Module Front Cover module. D 25-PMFC-FD
E 25-PMFC-FE
A 25-PTG1-FA
B 25-PTG1-FB
PowerFlex 520-Series Replacement finger guard for power terminals. C 25-PTG1-FC
Power Terminal Guard
D 25-PTG1-FD
E 25-PTG1-FE
A 25-FAN1-FA
B 25-FAN1-FB
PowerFlex 520-Series Replacement fan for drive power module. C 25-FAN1-FC
Heatsink Fan Kit
D 25-FAN1-FD
E 25-FAN1-FE
25-CORE-A
A
25-CORE-RF-A
25-CORE-B
B
25-CORE-RF-B
PowerFlex 520-Series EMC Replacement EMC cores. 25-CORE-C
Cores C
25-CORE-RF-C
25-CORE-D
D
25-CORE-RF-D
25-CORE-E
E
25-CORE-RF-E

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 Appendix B Accessories and Dimensions

Communication Option Kits and Accessories

Item Description Catalog No.
Embedded communication options for use with the
PowerFlex 520-Series drives:
• DeviceNet® 25-COMM-D
Communication Adapters • Dual-port EtherNet/IP 25-COMM-E2P
25-COMM-P
• PROFIBUS DP-V1 25-COMM-PNET2P
• PROFINET 25-ACCS-COMM
Compact I/O™ Module Three channels 1769-SM2
Provides serial communication with DF1 protocol for use
with Connected Components Workbench software.
Universal Serial Bus (USB) Includes: 1203-USB
Converter Module • 2 m USB cable (1)
• 20-HIM-H10 cable (1)
• 22-HIM-H10 cable (1)
Provides serial communication with DF1 protocol for use
with Connected Components Workbench software.
Serial Converter Module Includes: 22-SCM-232
(RS-485 to RS-232) • DSI to RS-232 serial converter (1)
• 1203-SFC serial cable (1)
• 22-RJ45CBL-C20 cable (1)
DSI Cable 2.0 m RJ45 to RJ45 cable, male to male connectors. 22-RJ45CBL-C20
2.0 m serial cable with a locking low profile connector to
Serial Cable connect to the serial converter and a 9-pin subminiature D 1203-SFC
female connector to connect to a computer.
Splitter Cable RJ45 one to two port splitter cable (Modbus only) AK-U0-RJ45-SC1
Terminating Resistors RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1
Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P
Connected Components
Workbench Software Windows-based software packages for programming and
(Download via the configuring Allen-Bradley drives and other Rockwell
Software Subscription Automation products. rok.auto/ccw
Portal or DVD-ROM) Compatibility:
rok.auto/ccw Windows XP, Windows Vista, and Windows 7

Bulletin 1321-3R Series Line Reactors

Output Ratings(1) Input Line Reactor(2)(4) Output Line Reactor(2)(3)
IP00 IP11 IP00 IP11
Normal Duty Heavy Duty (Open Style) (NEMA/UL Type 1) (Open Style) (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
1321-3R55-A (ND) 1321-3RA55-A (ND) 1321-3R55-A (ND) 1321-3RA55-A (ND)
20.0 15.0 15.0 11.0 1321-3R45-A (HD) 1321-3RA45-A (HD) 1321-3R45-A (HD) 1321-3RA45-A (HD)

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Appendix B Accessories and Dimensions

Bulletin 1321-3R Series Line Reactors (Continued)

Output Ratings(1) Input Line Reactor(2)(4) Output Line Reactor(2)(3)
IP00 IP11 IP00 IP11
Normal Duty Heavy Duty (Open Style) (NEMA/UL Type 1) (Open Style) (NEMA/UL Type 1)
HP kW HP kW Catalog No. Catalog No. Catalog No. Catalog No.
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
1321-3R35-B (ND) 1321-3RA35-B (ND) 1321-3R35-B (ND) 1321-3RA35-B (ND)
20.0 15.0 15.0 11.0 1321-3R25-B (HD) 1321-3RA25-B (HD) 1321-3R25-B (HD) 1321-3RA25-B (HD)
25.0 18.5 20.0 15.0 1321-3R35-B 1321-3RA35-B 1321-3R35-B 1321-3RA35-B
1321-3R45-B (ND) 1321-3RA45-B (ND) 1321-3R45-B (ND) 1321-3RA45-B (ND)
30.0 22.0 25.0 18.5
1321-3R35-B (HD) 1321-3RA35-B (HD) 1321-3R35-B (HD) 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
1321-3R25-B (ND) 1321-3RA25-B (ND) 1321-3R25-B (ND) 1321-3RA25-B (ND)
20.0 15.0 15.0 11.0 1321-3R18-B (HD) 1321-3RA18-B (HD) 1321-3R18-B (HD) 1321-3RA18-B (HD)
1321-3R35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C (ND) 1321-3RA35-C (ND)
25.0 18.5 20.0 15.0 1321-3R25-C (HD) 1321-3RA25-C (HD) 1321-3R25-C (HD) 1321-3RA25-C (HD)
1321-3R35-C (ND) 1321-3RA35-C (ND) 1321-3R35-C (ND) 1321-3RA35-C (ND)
30.0 22.0 25.0 18.5 1321-3R25-B (HD) 1321-3RA25-B (HD) 1321-3R25-B (HD) 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.

Product Dimensions The PowerFlex 520-series drive is available in five frame sizes. See the
PowerFlex 520-Series Drive Ratings on page 173 for information on power
ratings.
PowerFlex 520-Series Drive Weight
Frame Size Weight (kg/lb)
A 1.1 / 2.4
B 1.6 / 3.5
C 2.3 / 5.0
D 3.9 / 8.6
E 12.9 / 28.4

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 Appendix B Accessories and Dimensions

IP 20/Open Type – Frame A

Dimensions are in millimeters and (inches)
72.0 (2.83) 172.0 (6.77)
57.5 (2.26)

152.0 (5.98)
Esc Sel

140.0 (5.51)

92.7 (3.65)
6.0 (0.24)

IP 20/Open Type – Frame B

Dimensions are in millimeters and (inches)
87.0 (3.43) 172.0 (6.77)
72.5 (2.85) 180.0 (7.09)

Esc Sel
168.0 (6.61)

6.0 (0.24) 92.7 (3.65)

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Appendix B Accessories and Dimensions

IP 20/Open Type – Frame C

Dimensions are in millimeters and (inches)

109.0 (4.29) 184.0 (7.24)
90.5 (3.56)

220.0 (8.66)
Esc Sel

207.0 (8.15)

92.7 (3.65)
6.0 (0.24)

IP 20/Open Type – Frame D

Dimensions are in millimeters and (inches)

130.0 (5.12) 212.0 (8.35)
116.0 (4.57)
260.0 (10.24)

Esc Sel
247.0 (9.72)

6.0 (0.24)

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 Appendix B Accessories and Dimensions

IP 20/Open Type – Frame E

Dimensions are in millimeters and (inches)

185.0 (7.28) 279.0 (10.98)
160.0 (6.30)

300.0 (11.81)
Esc Sel

280.0 (11.02)
7.6 (0.30)

Control Module Fan Kit

25-FAN1-70C 25-FAN2-70C

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
Airflow (At zero static pressure) max 0.575 m3/min 1.574 m3/min
Air Pressure (At zero airflow) min 7.70 mm H2O 9.598 mm H2O
Acoustical Noise 40.5 dB-A 46.0 dB-A
Insulation Type UL Class A
Frame Size Frame A...D Frame E
Wire Size 2 (22 AWG)
0.32 mm
Torque 0.29...0.39 N•m (2.6...3.47 lb•in)

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Appendix B Accessories and Dimensions

IP 20/Open Type with Control Module Fan Kit – Frame A...C

Dimensions are in millimeters and (inches)

Frame A Frame B Frame C

32.0 (1.26)

32.0 (1.26)

32.0 (1.26)
72.0 (2.83) 87.0 (3.43) 109.0 (4.29)
57.5 (2.26) 72.5 (2.85) 90.5 (3.56)

180.0 (7.09)
152.0 (5.98)

220.0 (8.66)
Esc Sel Esc Sel Esc Sel

168.0 (6.61)
140.0 (5.51)

207.0 (8.15)
IMPORTANT An external 24V DC power source is required when
using the Control Module Fan Kit with drive frames
A, B, and C.

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 Appendix B Accessories and Dimensions

IP 20/Open Type with Control Module Fan Kit – Frame D...E

Dimensions are in millimeters and (inches)

Frame D Frame E
196.0 (7.72)

32.0 (1.26)
130.0 (5.12) 185.0 (7.28)
116.0 (4.57) 160.0 (6.30)

52.0 (2.05)
260.0 (10.24)
Esc Sel

Esc Sel

300.0 (11.81)
247.0 (9.72)

280.0 (11.02)

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.

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame A

Dimensions are in millimeters and (inches)

15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
72.0 (2.83)
57.5 (2.26) 172.0 (6.77)

219.0 (8.62)
Esc Sel

152.0 (5.98)

92.7 (3.65)
140.0 (5.51)
6.0 (0.24)

IP 30/NEMA 1/ UL Type 1 conduit box

51.1 (2.01)
21.0 (0.82)

ø21.5 (ø0.85)
135.4 (5.33)
111.9 (4.41)
88.2 (3.47)
64.7 (2.55)

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 Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame B

Dimensions are in millimeters and (inches)

15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
87.0 (3.43)
72.5 (2.85) 172.0 (6.77)

218.0 (8.58)
Esc Sel

180.0 (7.09)
168.0 (6.61)

92.7 (3.65)
6.1 (0.24)

IP 30/NEMA 1/ UL Type 1 conduit box

66.1 (2.60)
63.1 (2.48)
33.5 (1.32)
23.9 (0.94)

ø21.5 (ø0.85)
ø27.5 (ø1.08)
128.5 (5.06)
108.5 (4.27)
88.3 (3.48)
67.3 (2.65)

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame C

Dimensions are in millimeters and (inches)

15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
109.0 (4.29)
90.5 (3.56) 184.0 (7.24)

255.0 (10.04)
Esc Sel

222.0 (8.66)
207.0 (8.15)

92.7 (3.65)
6.0 (0.24)

IP 30/NEMA 1/ UL Type 1 conduit box

80.5 (3.17)
66.5 (2.62)
34.5 (1.36)
26.5 (1.04)

ø21.5 (ø0.85)

ø27.5 (ø1.08)
123.3 (4.85)
82.2 (3.24)

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 Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame D

Dimensions are in millimeters and (inches)

15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
130.0 (5.12) 212.0 (8.35)
116.0 (4.57)

295.0 (11.61)
Esc Sel

260.0 (10.24)
247.0 (9.72)
6.0 (0.24)

96.0 (3.78) IP 30/NEMA 1/ UL Type 1 conduit box

70.0 (2.76)
44.0 (1.73)
30.0 (1.18)

ø21.5 (ø0.85)

ø33.5 (ø1.32)
153.3 (6.04)
109.8 (4.32)

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Appendix B Accessories and Dimensions

IP 30/NEMA 1/UL Type 1 – Frame E

Dimensions are in millimeters and (inches)

15.0 (0.59)
IP 30/NEMA 1/ UL Type 1 top panel
185.0 (7.28)
160.0 (6.30) 279.0 (10.98)

350.0 (13.78)
Esc Sel

300.0 (11.81)
280.0 (11.02)
7.6 (0.30)

IP 30/NEMA 1/ UL Type 1 conduit box

127.5 (5.02)
82.5 (3.25)
62.5 (2.46)
42.5 (1.67)

ø21.5 (ø0.85)
ø43.7 (ø1.72)
212.0 (8.35)
181.0 (7.13)
164.0 (6.46)

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 Appendix B Accessories and Dimensions

EMC Line Filter – Frame A

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.
55.0 (2.17) 72.0 (2.83)
30.0 (1.18) 54.0 (2.13) ø5.5 (ø0.22)

234.0
223.0 (9.21) 223.0
(8.78) (8.78)

20.0 (0.79) 23.0 (0.91) 5.5 (0.22)

54.0 (2.13)

EMC Line Filter – Frame B

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.
70.0 (2.76) 87.0 (3.43)
35.0 (1.38) 58.0 (2.28)
ø5.5 (ø0.22)

270.0
(10.63)
258.0 258.0
(10.16) (10.16)

25.0 (0.98) 24.0 (0.94) 5.5 (0.22)

58.0 (2.28)

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Appendix B Accessories and Dimensions

EMC Line Filter – Frame C

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.
70.0 (2.76) 109.0 (4.29)
37.0 (1.46) 76.0 (2.99)
ø5.5 (ø0.22)

275.0
(10.83)
263.0 263.0
(10.35) (10.35)

25.0 (0.98) 28.0 (1.10) 5.5 (0.22)

76.0 (2.99)

EMC Line Filter – Frame D

Dimensions are in millimeters and (inches) Filter can be mounted onto the back of the drive.
80.0 (3.15) 130.0 (5.12)
33.0 (1.30) 28.0 (1.10) 90.0 (3.54)
ø5.5 (ø0.22)

310.0
(12.20)
298.0 298.0
(11.73) (11.73)

33.0 (1.30) 28.0 (1.10) 5.5 (0.22)

90.0 (3.54)

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 Appendix B Accessories and Dimensions

EMC Line Filter – Frame E

Dimensions are in millimeters and (inches)
80.0 (3.15) 155.0 (6.10)
33.0 (1.30) 28.0 (1.10) 110.0 (4.33) ø5.5 (ø0.22)

390.0
(15.35)
375.0 375.0
(14.76) (14.76)

33.0 (1.30) 28.0 (1.10) 5.5 (0.22)

110.0 (4.33)

Adapter Plate Dimensions

Bulletin 160 to PowerFlex 520-Series Mounting Adapter Plate Dimensions

Dimensions are in millimeters and (inches)

Frame A Frame B
25-MAP-FA 25-MAP-FB

92.0 (3.62) 39.2 (1.54)

80.0 (3.15) 39.2 (1.54)
198.0 (7.80)

240.0 (9.45)

20.2 (0.80)
20.2 (0.80)

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Appendix B Accessories and Dimensions

PowerFlex 4/40/40P to PowerFlex 520-Series Mounting Adapter Plate Dimension

Adapter Plate - Frame A

Dimensions are in millimeters and (inches)

Frame A Frame A
25-AP0-FA 25-AP1-FA
80.0 (3.15) 80.0 (3.15)
67.0 (2.64) 12.0 (0.47) 60.0 (2.36) 10.6 (0.42)

248.0 (9.76)
164.0 (6.46)

207.5 (8.17)
139.5 (5.49)

Adapter Plate - Frame B

Dimensions are in millimeters and (inches)

Frame B Frame B
25-AP0-FB 25-AP1-FB
100.0 (3.94)
78.0 (3.07) 10.6 (0.42)

100.0 (3.94)
87.0 (3.43) 12.0 (0.47)

270.0 (10.63)
216.0 (8.50)
192.0 (7.56)
167.5 (6.59)

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 Appendix B Accessories and Dimensions

Adapter Plate - Frame C

Dimensions are in millimeters and (inches)

Frame C Frame C
25-AP0-FC 25-AP1-FC
130.0 (5.12)
90.0 (3.54) 10.6 (0.42)
130.0 (5.12)
116.0 (4.57) 9.4 (0.37)

309.0 (12.17)
296.5 (11.67)
260.0 (10.24)
245.5 (9.67)
Adapter Plate - Frame D

Dimensions are in millimeters and (inches)

Frame D
25-AP0-FD
130.0 (5.12)
116.0 (4.57) 11.0 (0.43)
272.0 (10.71)
245.5 (9.67)

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Appendix B Accessories and Dimensions

Optional Accessories and Installing a Communication Adapter

Kits 1. Insert the communication adapter interface connector into the Control
Module. Make sure that the indicator line on the connector is aligned
with the surface of the Control Module.
For PowerFlex 523

Communication
adapter interface
connector

For PowerFlex 525

Communication
adapter interface
connector

2. Align the connectors on the communication adapter to the

communication adapter interface connector, then push the back cover
down.

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 Appendix B Accessories and Dimensions

3. Press along the edges of the back cover until it snaps firmly into place.

Communication
adapter interface
connector

Removing a Communication Adapter

1. Insert a finger into the slot at the top of the back cover. Lift to separate
the back cover from the Control Module.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 201

Appendix B Accessories and Dimensions

Notes:

202 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix C

RS-485 (DSI) Protocol

PowerFlex 520-series drives support the RS-485 (DSI) protocol to allow

efficient operation with Rockwell Automation peripherals. In addition, some
Modbus functions are supported to allow simple networking. PowerFlex 520-
series drives can be multi-dropped on an RS-485 network using Modbus
protocol in RTU mode.

PowerFlex 520-Series Drive Network

Esc Sel Esc Sel Esc Sel Esc Sel

Controller

For information regarding EtherNet/IP or other communication protocols,

refer to the appropriate user manual.

Network Wiring Network wiring consists of a shielded 2-conductor cable that is daisy-chained
from node to node.

ATTENTION: Never attempt to connect a Power over Ethernet (PoE) cable to

the RS-485 port. Doing so may damage the circuitry.

Network Wiring Diagram Example

PowerFlex 525 PowerFlex 523 PowerFlex 525
Master Node 1 Node 2 Node “n”
TxRxD+ TxRxD+ TxRxD+ 120 ohm resistor FRONT
4 4 4
120 ohm resistor TxRxD- TxRxD-
TxRxD- 5 5 5
Shield Shield Shield
X X X PIN 1 PIN 8

C1 C2 C1 C2
RS485 RS485
(DSI) (DSI)
AK-U0-RJ45-TB2P
TxRxD+ TxRxD+
TxRxD- TxRxD-

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

DC- DC+ BR- DC- DC+ BR-

BR+ BR+

IMPORTANT The shield is connected at ONLY ONE end of each cable segment.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 203

Appendix C RS-485 (DSI) Protocol

Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the
PowerFlex 520-series drive’s RJ45 socket must not be connected because they
contain power, etc. for other Rockwell Automation peripheral devices.

Wiring terminations on the master controller will vary depending on the

master controller used and “TxRxD+” and “TxRxD-” are shown for illustration
purposes only. Refer to the master controller’s user manual for network
terminations. Note that there is no standard for the “+” and “-” wires, and
consequently Modbus device manufacturers interpret them differently. If you
have problems with initially establishing communications, try swapping the
two network wires at the master controller.

Standard RS-485 wiring practices apply.

• Termination resistors need to be applied at each end of the network
cable.
• RS-485 repeaters may need to be used for long cable runs, or if greater
than 32 nodes are needed on the network.
• Network wiring should be separated from power wires by at least
0.3 meters (1 foot).
• Network wiring should only cross power wires at a right angle.

I/O Terminal C1 (RJ45 Shield) for the Ethernet and DSI network cables on the
PowerFlex 520-series drive must also be connected to PE ground (there are two
PE terminals on the drive). The shield for the network cables should be
connected to PE ground at one end only.

I/O Terminal C2 (Comm Common) is internally tied to Network Common for

the network signals, and NOT to RJ45 Shield. Tying I/O Terminal C2 to PE
ground may improve noise immunity in some applications.

See I/O Control Terminal Designations on page 39 and page 42 for more
information.

Parameter Configuration The following PowerFlex 520-series drive parameters are used to configure the
drive to operate on a DSI network.

Configuring Parameters for DSI Network

Parameter Details Reference
P046 [Start Source 1] Set to 3 “Serial/DSI” if Start is controlled from the network. page 86
P047 [Speed Reference1] Set to 3 “Serial/DSI” if the Speed Reference is controlled from the page 86
network.
C123 [RS485 Data Rate] Sets the data rate for the RS-485 (DSI) Port. All nodes on the network page 100
must be set to the same data rate.
C124 [RS485 Node Addr] Sets the node address for the drive on the network. Each device on the page 100
network requires a unique node address.
C125 [Comm Loss Action] Selects the drive’s response to communication problems. page 100
C126 [Comm Loss Time] Sets the time that the drive will remain in communication loss before the page 100
drive implements C125 [Comm Loss Action].
Sets the transmission mode, data bits, parity, and stop bits for the RS-
C127 [Comm Format] page 101
485 (DSI) Port. All nodes on the network must be set to the same setting.
C121 [Comm Write Mode] Set to
Set 0 “Save” when programming drive. page 100
to 1 “RAM only” to only write to volatile memory.

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 Appendix C RS-485 (DSI) Protocol

Supported Modbus Function The Drive Serial Interface (DSI) used on PowerFlex 520-series drives supports
Codes some of the Modbus function codes.

Supported Modbus Function Codes

Modbus Function Code (Decimal) Command
03 Read Holding Registers
06 Preset (Write) Single Register
16 (10 Hexadecimal) Preset (Write) Multiple Registers

IMPORTANT Modbus devices can be 0-based (registers are numbered starting at 0)

or 1-based (registers are numbered starting at 1). Depending on the
Modbus Master used, the register addresses listed on the following
pages may need to be offset by +1. For example, Logic Command may
be register address 8192 for some master devices (for example, ProSoft
3150-MCM SLC™ Modbus scanner) and 8193 for others (for example,
PanelView™).

Writing (06) Logic The PowerFlex 520-series drive can be controlled through the network by
Command Data sending Function Code 06 writes to register address 2000H (Logic Command).
P046 [Start Source 1] must be set to 3 “Serial/DSI” in order to accept the
commands. PowerFlex 523 drives support only Velocity bit definitions.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 205

Appendix C RS-485 (DSI) Protocol

PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either
Velocity or Position bit definitions.

Powerup/Reset the drive after selecting an option for C122 [Cmd Stat
Select] for the change to take effect.

Velocity Bit Definitions

Comm Logic Command – C122 = 0 “Velocity”
Address (Decimal) Bit(s) Description
0 1 = Stop, 0 = Not Stop
1 1 = Start, 0 = Not Start
2 1 = Jog, 0 = No Jog
3 1 = Clear Faults, 0 = Not Clear Faults
00 = No Command
01 = Forward Command
5, 4
10 = Reverse Command
11 = No Command
6 1 = Force Keypad Control, 0 = Not Force Keypad Control
7 1 = MOP Increment, 0 = Not Increment
00 = No Command
01 = Accel Rate 1 Enable
9, 8
10 = Accel Rate 2 Enable
2000H (8192) 11 = Hold Accel Rate Selected
00 = No Command
01 = Decel Rate 1 Enable
11, 10
10 = Decel Rate 2 Enable
11 = Hold Decel Rate Selected
000 = No Command
001 = Freq. Source = P047 [Speed Reference1]
010 = Freq. Source = P049 [Speed Reference2]
011 = Freq. Source = P051 [Speed Reference3]
14, 13, 12
100 = A410 [Preset Freq 0]
101 = A411 [Preset Freq 1]
110 = A412 [Preset Freq 2]
111 = A413 [Preset Freq 3]
15 1 = MOP Decrement, 0 = Not Decrement

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 Appendix C RS-485 (DSI) Protocol

Position Bit Definitions

Comm Logic Command – C122 = 1 “Position”
Address (Decimal) Bit(s) Description
0 1 = Stop, 0 = Not Stop
1 1 = Start, 0 = Not Start
2 1 = Jog, 0 = No Jog
3 1 = Clear Faults, 0 = Not Clear Faults
00 = No Command
01 = Forward Command
5, 4
10 = Reverse Command
11 = No Command
6 1 = Logic In 1
7 1 = Logic In 2
000 = Freq. and Position Step 0
2000H (8192) 001 = Freq. and Position Step 1
010 = Freq. and Position Step 2
011 = Freq. and Position Step 3
10, 9, 8
100 = Freq. and Position Step 4
101 = Freq. and Position Step 5
110 = Freq. and Position Step 6
111 = Freq. and Position Step 7
11 1 = Find Home
12 1 = Hold Step
13 1 = Pos Redefine
14 1 = Sync Enable
15 1 = Traverse Disable

Writing (06) Comm The PowerFlex 520-series drive Comm Frequency Command can be controlled
Frequency Command through the network by sending Function Code 06 writes to register address
2001H (Comm Frequency Command).

Comm Frequency Command

Reference
Address (Decimal) Description
Used by internal comm modules to control the reference of the drive. In units of
2001H (8193) 0.01 Hz.

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Appendix C RS-485 (DSI) Protocol

Reading (03) Logic Status The PowerFlex 520-series drive Logic Status data can be read through the
Data network by sending Function Code 03 reads to register address 2100H (Logic
Status). PowerFlex 523 drives support only Velocity bit definitions.
PowerFlex 525 drives can use Parameter C122 [Cmd Stat Select] to select either
Velocity or Position bit definitions.

Velocity Bit Definitions

Comm Logic Status – C122 = 0 “Velocity”
Address (Decimal) Bit(s) Description
0 1 = Ready, 0 = Not Ready
1 1 = Active (Running), 0 = Not Active
2 1 = Cmd Forward, 0 = Cmd Reverse
3 1 = Rotating Forward, 0 = Rotating Reverse
4 1 = Accelerating, 0 = Not Accelerating
5 1 = Decelerating, 0 = Not Decelerating
6 Not Used
7 1 = Faulted, 0 = Not Faulted
2100H (8448)
8 1 = At Reference, 0 = Not At Reference
9 1 = Main Freq Controlled by Active Comm
10 1 = Operation Cmd Controlled by Active Comm
11 1 = Parameters have been locked
12 Digital Input 1 Status (DigIn TermBlk 05)
13 Digital Input 2 Status (DigIn TermBlk 06)
14 Digital Input 3 Status (DigIn TermBlk 07)
15 Digital Input 4 Status (DigIn TermBlk 08)

Position Bit Definitions

Comm Logic Status – C122 = 1 “Position”
Address (Decimal) Bit(s) Description
0 1 = Ready, 0 = Not Ready
1 1 = Active (Running), 0 = Not Active
2 1 = Cmd Forward, 0 = Cmd Reverse
3 1 = Rotating Forward, 0 = Rotating Reverse
4 1 = Accelerating, 0 = Not Accelerating
5 1 = Decelerating, 0 = Not Decelerating
6 1 = Forward Travel Position, 0 = Reverse Travel Position
7 1 = Faulted, 0 = Not Faulted
2100H (8448)
8 1 = At Reference, 0 = Not At Reference
9 1 = At Position, 0 = Not At Position
10 1 = At Home, 0 = Not At Home
11 1 = Drive Homed, 0 = Not Drive Homed
12 1 = Sync Hold, 0 = Not Sync Hold
13 1 = Sync Ramp, 0 = Not Sync Ramp
14 1 =Traverse On, 0 = Traverse Off
15 1 = Traverse Decel, 0 = Not Traverse Decel

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 Appendix C RS-485 (DSI) Protocol

Reading (03) Drive Error The PowerFlex 520-series Error Code data can be read through the network by
Codes sending Function Code 03 reads to register address 2101H (Drive Error Codes).
Drive Error Codes
Logic Status
Address (Decimal) Value (Decimal) Description
0 No Fault
2 Auxiliary Input
3 Power Loss
4 Undervoltage
5 Overvoltage
6 Motor Stalled
7 Motor Overload
8 Heatsink Overtemperature
9 Control Module Overtemperature
12 HW Overcurrent (300%)
13 Ground Fault
15 Load Loss
21 Output Phase Loss
29 Analog Input Loss
33 Auto Restart Tries
38 Phase U to Ground Short
39 Phase V to Ground Short
40 Phase W to Ground Short
41 Phase UV Short
42 Phase UW Short
43 Phase VW Short
48 Parameters Defaulted
2101H (8449) 59 Safety Open
63 Software Overcurrent
64 Drive Overload
70 Power Unit Fail
71 DSI Network Loss
72 Option Card Network Loss
73 Embedded EtherNet/IP Adapter Network Loss
80 AutoTune Fail
81 DSI Communication Loss
82 Option Card Communication Loss
83 Embedded EtherNet/IP Adapter Communication Loss
91 Encoder Loss
94 Function Loss
100 Parameter Checksum Error
101 External Storage
105 Control Module Connect Error
106 Incompatible Control-Power Module
107 Unrecognized Control-Power Module
109 Mismatched Control-Power Module
110 Keypad Membrane
111 Safety Hardware
114 Microprocessor Failure
122 I/O Board Fail
125 Flash Update Required
2101H (8449) 126 Non Recoverable Error
127 DSI Flash Update Required

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Appendix C RS-485 (DSI) Protocol

Reading (03) Drive The PowerFlex 520-series Drive Operational Values can be read through the
Operational Values network by sending Function Code 03 reads to register addresses
2102H...210AH.

Drive Operational Values

Reference
Address (Decimal) Description
2102H (8450) Frequency Command (xxx.xx Hz)
2103H (8451) Output Frequency (xxx.xx Hz)
2104H (8452) Output Current (xxx.xx A)
2105H (8453) DC-BUS Voltage (xxxV)
2106H (8454) Output Voltage (xxx.xV)

Reading (03) and Writing To access drive parameters, the Modbus register address equals the parameter
(06) Drive Parameters number. For example, a decimal “1” is used to address Parameter b001 [Output
Freq] and decimal “41” is used to address Parameter P041 [Accel Time 1].

Additional Information See https://www.ab.com/drives for additional information.

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 Appendix D

Velocity StepLogic, Basic Logic, and Timer/

Counter Functions

Four PowerFlex 520-series logic functions provide the capability to program

simple logic functions without a separate controller.
• Velocity StepLogic Function (specific to PowerFlex 525 drives only)

Steps through up to eight preset speeds based on programmed logic.

Programmed logic can include conditions that must be met from
digital inputs that are programmed as “Logic In 1” and “Logic In 2”
before stepping from one preset speed to the next. A timer is available
for each of the eight steps and is used to program a time delay before
stepping from one preset speed to the next. The status of a digital
output can also be controlled based on the step being executed.
• Basic Logic Function (specific to PowerFlex 525 drives only)

Up to two digital inputs can be programmed as “Logic In 1” and/or

“Logic In 2”. A digital output can be programmed to change state based
on the condition of one or both inputs based on basic logic functions
such as AND, OR, NOR. The basic logic functions can be used with or
without StepLogic.
• Timer Function

A digital input can be programmed for “Timer Start”. A digital output

can be programmed as a “Timer Out” with an output level that is
programmed to the desired time. When the timer reaches the time
that is programmed into the output level the output changes state. The
timer can be reset with a digital input programmed as “Reset Timer”.
• Counter Function

A digital input can be programmed for “Counter In”. A digital output

can be programmed as “Counter Out” with an output level that is
programmed to the desired number of counts. When the counter
reaches the count that is programmed into the output level the output
changes state. The counter can be reset with a digital input
programmed as “Reset Counter”.

Use the Wizard in Connected Components Workbench software to

simplify setup instead of manually configuring the parameters.

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Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

Velocity StepLogic Using

Timed Steps IMPORTANT This function is specific to PowerFlex 525 drives only.

To activate this function, set one of the three speed reference sources,
parameter P047, P049, or P051[Speed Referencex] to 13 “Step Logic” and
activate that speed reference source. Three parameters are used to configure
the logic, speed reference, and time for each step.
• Logic is defined using parameters L180...L187 [Stp Logic x].
• Preset Speeds are set with parameters A410...A417 [Preset Freq 0...7].
• Time of operation for each step is set with parameters L190...L197 [Stp
Logic Time x].

The direction of motor rotation can be forward or reverse.

Using Timed Steps

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Forward
0
Reverse

Time

Velocity StepLogic Sequence

• Sequence begins with a valid start command.
• A normal sequence begins with Step 0 and transition to the next step
when the corresponding StepLogic time has expired.
• Step 7 is followed by Step 0.
• Sequence repeats until a stop is issued or a fault condition occurs.

Velocity StepLogic Using

Basic Logic Functions IMPORTANT This function is specific to PowerFlex 525 drives only.

Digital input and digital output parameters can be configured to use logic to
transition to the next step. Logic In 1 and Logic In 2 are defined by
programming parameters t062...t063, t065...t068 [DigIn TermBlk xx] to 24
“Logic In 1” or 25 “Logic In 2”.

Example
• Run at Step 0.
• Transition to Step 1 when Logic In 1 is true.
Logic senses the edge of Logic In 1 when it transitions from off to on.
Logic In 1 is not required to remain “on”.
• Transition to Step 2 when both Logic In 1 and Logic In 2 are true.
The drive senses the level of both Logic In 1 and Logic In 2 and transitions
to Step 2 when both are on.

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 Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

• Transition to Step 3 when Logic In 2 returns to a false or off state.

Inputs are not required to remain in the “on” condition except under the
logic conditions that are used for the transition from Step 2 to Step 3.
Start Step 0 Step 1 Step 2 Step 3

Frequency

Logic In 1

Logic In 2

Time

The step time value and the basic logic may be used together to satisfy machine
conditions. For instance, the step may need to run for a minimum time period
and then use the basic logic to trigger a transition to the next step.

Start Step 0 Step 1

Frequency

Logic In 1

Logic In 2

Time

Timer Function Digital inputs and outputs control the timer function and are configured with
parameters t062...t063, t065...t068 [DigIn TermBlk xx] set to 19 “Timer Start”
and 21 “Reset Timer”.

Digital outputs (relay and opto type) define a preset level and indicate when
the level is reached. Level parameters t077 [Relay Out1 Level], t082[Relay Out2
Level], t070 [Opto Out1 Level] and t073 [Opto Out2 Level] are used to set the
desired time in seconds.

Parameters t076 [Relay Out1 Sel], t081 [Relay Out2 Sel], t069 [Opto Out1 Sel]
and t072 [Opto Out2 Sel] are set to 25 “Timer Out” and causes the output to
change state when the preset level is reached.

Example
• Drive starts up and accelerates to 30 Hz.
• After 30 Hz has been maintained for 20 seconds, a 4…20 mA analog input
becomes the reference signal for speed control.
• The timer function is used to select a preset speed with a 20 second
runtime that overrides the speed reference while the digital input is
active.
• Parameters are set to the following options:
- P047 [Speed Reference1] = 6 “4-20mA Input”
- P049 [Speed Reference2] = 7 “Preset Freq”
- t062 [DigIn TermBlk 02] = 1 “Speed Ref 2”

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Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

- t063 [DigIn TermBlk 03] = 19 “Timer Start”

- t076 [Relay Out1 Sel] = 25 “Timer Out”
- t077 [Relay Out1 Level] = 20.0 seconds
- A411 [Preset Freq 1] = 30.0 Hz
• The control terminal block is wired such that a start command also
triggers the timer start.
• The relay output is wired to I/O Terminal 02 (DigIn TermBlk 02) so that it
forces the input on when the timer starts.
• After the timer is complete, the output is turned off releasing the preset
speed command. The drive defaults to following the analog input
reference as programmed.

Note that a “Reset Timer” input is not required for this example since the
“Timer Start” input both clears and starts the timer.

Counter Function Digital inputs and outputs control the counter function and are configured
with parameters t062...t063, t065...t068 [DigIn TermBlk xx] set to 20 “Counter
In” and 22 “Reset Countr”.

Digital outputs (relay and opto type) define a preset level and indicate when
the level is reached. Level parameters t077 [Relay Out1 Level], t082[Relay Out2
Level], t070 [Opto Out1 Level] and t073 [Opto Out2 Level] are used to set the
desired count value.

Parameters t076 [Relay Out1 Sel], t081 [Relay Out2 Sel], t069 [Opto Out1 Sel]
and t072 [Opto Out2 Sel] are set to 26 “Counter Out” which causes the output to
change state when the level is reached.

Example
• A photo eye is used to count packages on a conveyor line.
• An accumulator holds the packages until 5 are collected.
• A diverter arm redirects the group of five packages to a bundling area.
• The diverter arm returns to its original position and triggers a limit
switch that resets the counter.
• Parameters are set to the following options:
- t065 [DigIn TermBlk 05] = 20 “Counter In”
- t066 [DigIn TermBlk 06] = 22 “Reset Countr”
- t076 [Relay Out1 Sel] = 26 “Counter Out”

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 Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

- t077 [Relay Out1 Level] = 5.0 Counts

Output
Frequency

Start

Relay Out

Photo Eye

DigIn TermBlk 05
Counter In
DigIn TermBlk 06
Reset Counter
Limit Switch

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Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

Velocity StepLogic
Parameters Code Descriptions for Parameters L180...L187
Digit 4 Digit 3 Digit 2 Digit 1
0 0 F 1

Digit 4 – Defines the action during the step currently executing

Setting Accel/Decel Parameter Used StepLogic Output State Commanded Direction
0 1 Off FWD
1 1 Off REV
2 1 Off No Output
3 1 On FWD
4 1 On REV
5 1 On No Output
6 2 Off FWD
7 2 Off REV
8 2 Off No Output
9 2 On FWD
A 2 On REV
b 2 On No Output

Digit 3 – Defines what step to jump to or how to end program when the logic conditions
specified in Digit 2 are met
Setting Logic
0 Jump to Step 0
1 Jump to Step 1
2 Jump to Step 2
3 Jump to Step 3
4 Jump to Step 4
5 Jump to Step 5
6 Jump to Step 6
7 Jump to Step 7
8 End Program (Normal Stop)
9 End Program (Coast to Stop)
A End Program and Fault (F002)

Digit 2 – Defines what logic must be met to jump to a step other than the
very next step
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] parameter. TIMED
2 Step if “Logic In 1” is active (logically true) TRUE
3 Step if “Logic In 2” is active (logically true) TRUE
4 Step if “Logic In 1” is not active (logically false) FALSE
5 Step if “Logic In 2” is not active (logically false) FALSE
6 Step if either “Logic In 1” or “Logic In 2” is active (logically true) OR
7 Step if both “Logic In 1” and “Logic In 2” is active (logically true) AND
8 Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR
9 Step if “Logic In 1” is active (logically true) and “Logic In 2” is not active (logically false) XOR
A Step if “Logic In2” is active (logically true) and “Logic In 1” is not active (logically false) XOR
b Step after [Stp Logic Time x] and “Logic In 1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) TIMED AND

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 Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

Digit 2 – Defines what logic must be met to jump to a step other than the
very next step (Continued)
Setting Description Logic
d Step after [Stp Logic Time x] and “Logic In 1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In 2” is not active (logically false) TIMED OR
F Do not step OR no “jump to”, so use Digit 0 logic IGNORE

Digit 1 – Defines what logic must be met to jump to the very next step
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] parameter. TIMED
2 Step if “Logic In 1” is active (logically true) TRUE
3 Step if “Logic In 2” is active (logically true) TRUE
4 Step if “Logic In 1” is not active (logically false) FALSE
5 Step if “Logic In 2” is not active (logically false) FALSE
6 Step if either “Logic In 1” or “Logic In 2” is active (logically true) OR
7 Step if both “Logic In 1” and “Logic In 2” is active (logically true) AND
8 Step if neither “Logic In 1” or “Logic In 2” is active (logically true) NOR
9 Step if “Logic In 1” is active (logically true) and “Logic In 2” is not active (logically false) XOR
A Step if “Logic In 2” is active (logically true) and “Logic In 1” is not active (logically false) XOR
b Step after [Stp Logic Time x] and “Logic In 1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In 2” is active (logically true) TIMED AND
d Step after [Stp Logic Time x] and “Logic In 1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In 2” is not active (logically false) TIMED OR
F Use logic programmed in Digit 1 IGNORE

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Appendix D Velocity StepLogic, Basic Logic, and Timer/Counter Functions

Notes:

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 Appendix E

Encoder/Pulse Train Usage and Position

StepLogic Application

Encoder and Pulse Train The PowerFlex 520-series drives include a pulse train input that is built into the
Usage terminal block. PowerFlex 525 drives also support an optional encoder card.
The pulse train and encoder can be used for many of the same functions, but
the pulse train supports up to 100 kHz at 24V, and uses the drive built-in
terminal block. The encoder supports up to 250 kHz dual channel at 5, 12V, or
24V and requires the optional encoder board to be installed. When A535 [Motor
Fdbk Type] is set to a value other than zero, the drive is set to use an encoder or
pulse train. The drive uses the encoder or pulse train in several ways
depending on the settings of other parameters. The drive uses the encoder or
pulse train as shown below (listed in order of priority):
1. If enabled by P047, P049, or P051 [Speed Referencex], the encoder or
pulse train is used directly as a commanded speed (normally used with a
pulse train) or as a position reference (normally used with a quadrature
encoder).
2. If not enabled by the Speed Reference parameters, the encoder or pulse
train can be used with the PID function if enabled by A459 or A471 [PID x
Ref Sel], or A460 or A472 [PID x Fdback Sel].
3. If not enabled by the Speed Reference or PID function parameters, the
encoder or pulse train can be used with A535 [Motor Fdbk Type] for direct
feedback and trim of the speed command. The normal slip compensation
is not used in this case. Instead the drive uses the encoder or pulse train
to determine actual output frequency and adjust the output frequency to
match the command. Parameters A538 [Ki Speed Loop] and A539 [Kp
Speed Loop] are used in this control loop. The primary benefit of this
mode is increased speed accuracy when compared to open-loop slip
compensation. It does not provide speed bandwidth improvement.

IMPORTANT The encoder usage, and position StepLogic application that is covered
in this chapter is specific to PowerFlex 525 drives only.

Encoder Interface

The incremental encoder option card can source 5 volt or 12 volt power and
accept 5, 12, or 24 volts single ended or differential inputs. See Appendix B for
ordering information.

IMPORTANT Only the 25-ENC-1 Encoder works properly in the PowerFlex 525 drive.
Installing an incorrect encoder card, such as the 25-ENC-2 for
PowerFlex 527 drives causes damage to the PowerFlex 525 drive.

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

A A- B B- Cm +V n
12V 5V HTL TTL (ON)

No. Signal Description

+V 5...12V Power(1)(2)
Internal power source 250 mA (isolated).
Cm Power Return
B- Encoder B (NOT)
Quadrature B input.
B Encoder B
A- Encoder A (NOT)
Single channel, pulse train, or quadrature A input.
A Encoder A

DIP switch selects 12 volt or 5 volt power that is supplied at terminals “+V” and
 Output “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.
(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.

Encoder Wiring Examples

I/O Connection Example I/O Connection Example
+12V DC
Encoder Power +V
(250 mA)
– Internal Drive

Common
Cm Encoder Power
Power B-
Common
to
– External

+
B SHLD
to SHLD
Power Source External
Internal (drive) A-
A
Power
Supply
12V DC, 250 mA

to Power Supply
Common
+V +V to SHLD
Encoder Signal – Cm
B NOT Encoder Signal – Cm
B NOT
Single-Ended, B-
B
B Differential, B-
B
Dual Channel A-
A NOT Dual Channel B
A- A NOT
A A
A A
to SHLD

HTL/TTL DIP Switches

This feature is available on 25-ENC-1 encoder. Set the two switches to HTL
(default) or TTL (On) based on the type of encoder signal that you are using in
your application. You must set all switches to the same position.

Compatible Encoder Output Voltage

Switch Position Low Level (UL) High Level (UH)
TTL <1.5V >2.5V
HTL <3.5V >5V

IMPORTANT Only the 25-ENC-1 Encoder works properly in the PowerFlex 525 drive.
Installing an incorrect encoder card, such as the 25-ENC-2 for
PowerFlex 527 drives causes damage to the PowerFlex 525 drive.

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 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

Wiring Notes The encoder option card can supply 5V or 12V power (250 mA maximum) for an
encoder. Be sure 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, but the pulse train can handle
only 24V inputs. The inputs automatically adjust to the voltage applied and no
additional drive adjustment is necessary. If a single-channel input is used, it
must be wired between the A (signal) and A- (signal common) channels.

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, then do one of the following:
• Swap the A and A (NOT) encoder channels.
• Swap the B and B (NOT) encoder channels.
• Swap any two motor leads.
Drives will fault when an encoder is incorrectly wired and A535 [Motor
Fdbk Type] is set to 5 “Quad Check”.

Determine Encoder Pulse Use the following formula to determine the encoder pulse per revolution (PPR)
Per Revolution (PPR) specification based on the speed resolution.
Specification Based on 1
x pole pairs
Speed Resolution Speed resolution (Hz) = encoder pulse number x 4

10-3 sec

The operating speed range depends on the motor control mode

selected (SVC or VVC). For more information, see Performance with
Encoder on page 168.

Example 1

To determine the PPR for quadrature encoder, to achieve 0.06 Hz of speed

resolution on a 4-pole motor (2-pole pair) with a base speed of 60 Hz:
1
x2
0.06 Hz = encoder pulse number x 4

10-3 sec
= ~8333 pulse

Therefore, select 8333 PPR or higher for the quadrature encoder to achieve the
desired speed resolution of 0.06 Hz.

Example 2

To determine the speed resolution, using a 1024 PPR quadrature incremental

encoder on a 4-pole (2-pole pair) motor:
1
x2
Speed resolution (Hz) = 1024 x 4

10-3 sec
= 0.49 Hz

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

Therefore, using a 1024 PPR quadrature encoder gives a speed resolution of

0.49 Hz.

Positioning Overview The PowerFlex 525 drive includes a simple position regulator, which can be
used without the need for multiple limit switches or photo-eyes. This can be
used as a standalone controller for simple applications (up to eight positions)
or in conjunction with a controller for more flexibility.

Note that this is not intended to replace high-end servo controllers or any
application that needs high bandwidth or very high torque at low speeds.

Common Guidelines for All The position regulator can be configured for operation appropriate for a
Applications variety of applications. Certain parameters need to be adjusted in all cases.

P047 [Speed Reference1] must be set to 16 “Positioning”.

A535 [Motor Fdbk Type] must be set to the match the feedback device.
Positioning mode must use A535 [Motor Fdbk Type] option 4.

A535 [Motor Fdbk Type] Options

0 “None” indicates that no encoder is used. This cannot be used for

positioning.

1 “Pulse Train” is a single channel input, no direction, speed feedback

only. This should not be used for positioning. The Single Channel
selection is similar to a Pulse Train, but uses the standard encoder
scaling parameters.

2 “Single Chan” is a single channel input, no direction, speed feedback

only. This should not be used for positioning. Single channel uses the
standard encoder scaling parameters.

3 “Single Check” is a single channel input with encoder signal loss

detection. The drive faults if it detects that the input pulses do not
match the expected motor speed. This should not be used for
positioning.

4 “Quadrature” is a dual channel encoder input with direction and

speed from the encoder. This may be used for positioning control.

5 “Quad Check” is a dual channel encoder with encoder signal loss

detection. The drive faults if it detects that the encoder speed does not
match the expected motor speed.

A544 [Reverse Disable] should be set to 0 “Rev Enabled” to allow bidirectional

movement necessary for position control.

P039 [Torque Perf Mode] default setting is 1 “SVC”. However, any mode can be
used to improve the low speed torque for positioning applications. For best

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 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

results, tune the application first. The autotune routine can be completed to
further improve the drive-motor performance.

A550 [Bus Reg Enable] default setting is 1 “Enabled”. If the deceleration time is
too short, the drive may overshoot the desired position. For best results, a
longer deceleration time may be necessary. A550 [Bus Reg Enable] can be
disabled to provide precise stopping movements, but the deceleration time
must be manually tuned so that it is long enough to avoid F005 “OverVoltage”
faults.

A437 [DB Resistor Sel] default setting is 0 “Disabled”. If improved deceleration

performance is required a Dynamic Brake resistor can be used. If used, this
parameter should be set to the appropriate setting for the resistor selected.

P035 [Motor NP Poles] must be set to match the number of motor poles on the
motor driven by the PowerFlex 520-series drive.

A536 [Encoder PPR] must be set to match the number of pulses per revolution
of the encoder used (that is, 1024 PPR Encoder).

A559 [Counts Per Unit] sets the number of encoder counts that will be used to
define one position unit. This allows the encoder positions to be defined in
terms of units important to the application. For example, if 1 cm of travel on a
conveyor belt requires 0.75 turns of the motor, the motor encoder is 1024 PPR,
and the Motor Feedback type is set to Quadrature, then this parameter would
need to be set to (4 x 1024 x 0.75) = 3072 counts for 1 cm of travel. Then all other
positions could be set up in units of “cm”.

A564 [Encoder Pos Tol] indicates the desired position tolerance for the system.
This determines how close the drive must be to the commanded position
before the drive indicates “At Home” or “At Position” in units of raw encoder
pulses. This has no effect on the actual positioning control of the motor.

Positioning Operation Parameter A558 [Positioning Mode] must be set to properly match the desired
operation of the positioning function.

A558 [Positioning Mode] Options

0 “Time Steps” uses StepLogic times. This mode ignores the StepLogic
settings and moves through the steps (Step 0 to Step 7 and back to Step
0) based on the times programmed into L190...L197 [Stp Logic Time x].
This can be used when the desired position is based only on time. In
addition, this mode only accepts absolute positions in a positive
direction from “home”. This option provides an easy way to implement
a simple positioning program or to test the basic positioning setup.
For additional flexibility one of the other settings should be used.

1 “Preset Input” directly commands movement to any step based on

the status of the digital inputs programmed for “Preset Freq”. This
setting ignores the StepLogic Commands settings and instead the
drive moves directly to whatever step is currently commanded by
A410...A425 [Preset Freq x] and L200...L214 [Step Units x]. This is useful

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

when an application needs direct access to any position step based on

discrete inputs. This mode moves in the forward direction from Home
and is an absolute move.

IMPORTANT Advanced StepLogic options such as incremental move are not

available in this mode.

2 “StepLogic” provides a highly flexible mode of operation. This can be

used to move through the steps (Step 0 to Step 7 and back to Step 0) or
can jump to a different step at any time based on time or the status of
digital inputs or communication commands. In this mode, the drive
always starts at Step 0 of the StepLogic profile.

3 “Preset StpL” is identical to 2 “StepLogic” except the drive uses the

current status of the Preset Inputs to determine which StepLogic step
to begin. This only affects the initial step. After start, the drive will
move through the steps in the same manner as if setting 2 was
selected.

4 “StpLogic-Lst” is identical to 2 “StepLogic” except the drive uses the

step prior to its last stop command to determine which StepLogic step
to begin. This only affects the initial step. After start, the drive will
move through the steps in the same manner as if setting 2 was
selected. This allows a process to be stopped and then restarted at the
position where it stopped.

In all position modes, the following parameters control the characteristics at

each step:

L200, L202, L204, L206, L208, L210, L212 and L214 [Step Units x] are the
number value to the left of the decimal (whole number) of the eight positions
desired for an application, beginning with Step 0 (L200) and continuing with
each step until Step 7 (L214). For example, enter 2 into this parameter if you
would like a commanded position of 2.77.

L201, L203, L205, L207, L209, L211, L213, and L215 [Step Units F x] are the
number value to the right of the decimal (the portion less than 1) of the eight
positions desired for an application, beginning with Step 0 (L201) and
continuing with each step until Step 7 (L215). For example, enter 0.77 into this
parameter if you would like a commanded position of 2.77.

A410...A417 [Preset Freq x] are the parameters that define the maximum
frequency that the drive runs at during the corresponding step. For example, if

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 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

[Preset Freq 2] is set to 40 Hz, the drive accelerates to 40 Hz maximum when

moving to Position 2.

Frequency Source Step Source Position Source

A410 [Preset Freq 0] L180 [Stp Logic 0] L200 [Step Units 0]
A411 [Preset Freq 1] L181 [Stp Logic 1] L202 [Step Units 1]
A412 [Preset Freq 2] L182 [Stp Logic 2] L204 [Step Units 2]
A413 [Preset Freq 3] L183 [Stp Logic 3] L206 [Step Units 3]
A414 [Preset Freq 4] L184 [Stp Logic 4] L208 [Step Units 4]
A415 [Preset Freq 5] L185 [Stp Logic 5] L210 [Step Units 5]
A416 [Preset Freq 6] L186 [Stp Logic 6] L212 [Step Units 6]
A417 [Preset Freq 7] L187 [Stp Logic 7] L214 [Step Units 7]

IMPORTANT The default value for A410 [Preset Freq 0] is 0.00 Hz. This value must be
changed or the drive will not be able to move during Step 0.

L190...L197 [Stp Logic Time x] are the parameters that define the time that the
drive remains in each corresponding step if that step is time-based. For
example, if L192 [Stp Logic Time 2] is set to 5.0 seconds and that step is time-
based, the drive remains in Step 2 for 5.0 seconds. Note that this is the total
time that is needed to accelerate, run, and decelerate to that position.

L180...L187 [Stp Logic x] are the parameters that allow additional flexibility and
control various aspects of each step when a positioning mode is selected that
utilizes the StepLogic functions. Note that in Positioning mode these
parameters have a different function than when used for normal velocity
StepLogic. Each of the four digits controls one aspect of the position step. The
following is a listing of the available settings for each digit:

Logic for next step Digit 1

Logic to jump to a different step Digit 2
Different step to jump Digit 3
Step settings Digit 4
Not Used

Velocity Control Settings (Digit 4) Settings (Digit 3)

Required Accel/Decel StepLogic Commanded Setting Description
Setting Param. Used Output State Direction 0 Jump to Step 0
0 Accel/Decel 1 Off FWD 1 Jump to Step 1
1 Accel/Decel 1 Off REV 2 Jump to Step 2
2 Accel/Decel 1 Off No Output 3 Jump to Step 3
3 Accel/Decel 1 On FWD 4 Jump to Step 4
4 Accel/Decel 1 On REV 5 Jump to Step 5
5 Accel/Decel 1 On No Output 6 Jump to Step 6
6 Accel/Decel 2 Off FWD 7 Jump to Step 7
7 Accel/Decel 2 Off REV 8 End Program (Normal Stop)
8 Accel/Decel 2 Off No Output 9 End Program (Coast to Stop)
9 Accel/Decel 2 On FWD A End Program and Fault (F2)
A Accel/Decel 2 On REV
b Accel/Decel 2 On No Output

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

Positioning Settings (Digit 4) Settings (Digit 2 and 1)

Required Accel/Decel StepLogic Direction Type of Setting Description
Setting Param. Used Output State From Home Command 0 Skip Step (Jump Immediately)
0 Accel/Decel 1 Off FWD Absolute 1 Step Based on [Stp Logic Time x]
1 Accel/Decel 1 Off FWD Incremental 2 Step if “Logic In 1” is Active
2 Accel/Decel 1 Off REV Absolute 3 Step if “Logic In 2” is Active
3 Accel/Decel 1 Off REV Incremental 4 Step if “Logic In 1” is Not Active
4 Accel/Decel 1 On FWD Absolute 5 Step if “Logic In 2” is Not Active
5 Accel/Decel 1 On FWD Incremental 6 Step if either “Logic In 1” or “Logic In 2” is Active
6 Accel/Decel 1 On REV Absolute 7 Step if both “Logic In 1” and “Logic In 2” are Active
7 Accel/Decel 1 On REV Incremental 8 Step if neither “Logic In 1” nor “Logic In 2” is Active
8 Accel/Decel 2 Off FWD Absolute Step if “Logic In 1” is Active and “Logic In 2” is Not
9 Accel/Decel 2 Off FWD Incremental 9 Active
A Accel/Decel 2 Off REV Absolute A Step if “Logic In 2” is Active and “Logic In 1” is Not
b Accel/Decel 2 Off REV Incremental Active
C Accel/Decel 2 On FWD Absolute b Step after [Stp Logic Time x] and “Logic In 1” is Active
d Accel/Decel 2 On FWD Incremental Step after [Stp Logic Time x] and “Logic In 2” is
C Active
E Accel/Decel 2 On REV Absolute
d Step after [Stp Logic Time x] and “Logic In 1” is Not
F Accel/Decel 2 On REV Incremental Active
Step after [Stp Logic Time x] and “Logic In 2” is Not
E
Active
F Do Not Step/Ignore Digit 2 Settings

Use the Wizard in Connected Components Workbench software to

simplify setup instead of manually configuring the parameters.

Note: Incremental move commands cause the drive to move the amount
specified based on the current position. Absolute commands are always with
reference to “Home”.

A565 [Pos Reg Filter] provides a low pass filter at the input of the position
regulator.

A566 [Pos Reg Gain] is a single adjustment for increasing or decreasing the
responsiveness of the position regulator. For faster response, the filter should
be reduced and/or the gain should be increased. For smoother response with
less overshoot, the filter should be increased and/or the gain should be
reduced. In general, the gain has a larger effect on most systems than the filter.

Homing Routine This drive supports incremental encoders only. Therefore, when the drive
powers up it resets the current position to zero. If this is known to be, correct
the position routine can be started without further adjustment. However, in
most applications the drive will need to be “homed” after each power-up and
prior to starting the position routine.

This can be accomplished in one of the following two ways:

1. Manual Homing–Program the following drive parameters:

t062, t063, t065...t068 [DigIn TermBlk xx] = 37 “Pos Redefine”

Program one of the digital inputs to 37 “Pos Redefine”. Then, move the
system into the home position with a run command, a jog command,
or by manually moving the system into the home position. Then,
toggle the “Pos Redefine” input. This sets the drive to “Home” at its
current position and d388 [Units Traveled H] and d389 [Units Traveled

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 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

L] are set to zero. Alternately, the “Pos Redefine” bit in A560 [Enh
Control Word] can be toggled instead of utilizing a digital input.

IMPORTANT The “Pos Redefine” input or bit must be returned to inactive before
starting the position routine. Otherwise the drive continuously
reads a position of “0” (home) and the position routine does not
function correctly.
2. Automatic Homing to Limit Switch–Program the following drive
parameters:

t062, t063, t065...t068 [DigIn TermBlk xx] = 35 “Find Home”

Program one of the digital inputs to 35 “Find Home”.

t062, t063, t065...t068 [DigIn TermBlk xx] = 34 “Home Limit”

Program one of the digital inputs to 34 “Home Limit”. Normally, the
“Home Limit” input would be wired to a proximity switch or photo-eye
and indicate that the system is in the home position.

A562 [Find Home Freq] sets the frequency that the drive uses while it is
moving to the home position during the automatic homing routine.

A563 [Find Home Dir] sets the direction that the drive uses while it is
moving to the home position during the automatic homing routine.

To begin the automatic homing routine, activate the “Find Home” input and
then initiate a valid start command. The drive then ramps to the speed set in
A562 [Find Home Freq] and in the direction set in A563 [Find Home Dir] until
the digital input defined as “Home Limit” is activated. If the drive passes this
point too quickly it then reverses direction at 1/10th A562 [Find Home Freq] to
the point where the Home Limit switch reactivates. Approximately 1 second
after the routine finds home the drive stops. Alternately, the “Find Home Freq”
and/or “Home Limit” bits in A560 [Enh Control Word] can be activated instead
of utilizing a digital input. The inputs or bits should be returned to inactive
after the routine is complete.

IMPORTANT After the position is reached the drive stops. If the Find Home is
removed before the homing is complete, the drive begins running the
position routine without the proper home. In this case Home is not reset
and the position is in relation to the power-up position.

Encoder and Position d376 [Speed Feedback] indicates the measured speed feedback or the
Feedback calculated speed feedback when no feedback device is selected. Parameter d376
[Speed Feedback] is the number value to the left of the decimal (whole number)
and d377 [Speed Feedback F] is the value to the right of the decimal (the portion
less than 1).

d378 [Encoder Speed] indicates the measured speed of the feedback device.
This is useful if the encoder is not used for motor speed control. However, the
encoder must be used for some purpose in order for d378 [Encoder Speed] to
indicate a value. Parameter d378 [Encoder Speed] is the number value to the
left of the decimal (whole number) and d379 [Encoder Speed F] is the number
to the right of the decimal (the portion less than 1).

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

d388, d389 [Units Traveled x] indicate the current position of the system in
terms of units away from Home. Parameter d388 [Units Traveled H] is the
number value to the left of the decimal (whole number) and d389 [Units
Traveled L] is the number to the right of the decimal (the portion less than 1).

d387 [Position Status] indicates the status of the positioning functions. The
indication bits are:

Bit 0 “Dir Positive” indicates the current direction that the drive has
moved from Home.

Bit 1 “At Position” indicates whether the drive is at its commanded

position. If the drive is within A564 [Encoder Pos Tol] of the
commanded position, this bit will be active.

Bit 2 “At Home” indicates whether the drive is at Home. If the drive is
within A564 [Encoder Pos Tol] of “Home”, this bit will be active.

Bit 3 “Drive Homed” indicates whether the drive has been homed
since power-up. This bit will be active once the drive has been homed
either manually or automatically. It will remain active until the next
power down.

Use Over Communications If eight steps are not adequate for the application or if dynamic program
changes are required, many of the positioning functions can be controlled
through an active communication network. The following parameters allow
this control.

C121 [Comm Write Mode]

Repeated writes to parameters over a communication network can cause
damage to the drive EEPROM. This parameter allows the drive to accept
parameter changes without writing to the EEPROM.

IMPORTANT Parameter values set prior to setting 1 “RAM only” are saved in RAM.

C122 [Cmd Stat Select]

Selects velocity-specific or position/fibers-specific Command and Status Word
bit definitions for use over a communication network.

A560 [Enh Control Word]

This parameter allows many of the positioning functions to be completed
through parameter control using an explicit message. This allows the
operation over communications instead of with hardware inputs. The bits
have the same functions as the digital input options of the same name. Options
relating to positioning are:

Bit 0 “Home Limit” indicates that the drive is at the home position.

Bit 1 “Find Home” causes the drive to find home at the next start
command. Deactivate this bit after completing the homing routine.

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 Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

Bit 2 “Hold Step” overrides other inputs and causes the drive to remain
at its current step (running at zero speed once it reaches its position)
until released.

Bit 3 “Pos Redefine” resets the home position to the current position
of the machine. Deactivate this bit after completing the homing
routine.

Bit 4 “Sync Enable” holds the existing frequency when A571 [Sync
Time] is set to enable speed synchronization. When this bit is
deactivated the drive accelerates to the new commanded frequency
based on A571 [Sync Time].

Bit 5 “Traverse Dis” disables the traverse function when this bit is
active.

Bit 6 “Logic In 1” provides an identical function and is logically ORed

with setting 24 “Logic In 1” for t062, t063, t065...t068 [DigIn TermBlk
xx]. It can be used to move through the StepLogic functions (speed or
position) using comms control without requiring actual digital input
transitions.

Bit 7 “Logic In 2” provides an identical function and is logically ORed

with setting 25 “Logic In 2” for t062, t063, t065...t068 [DigIn TermBlk
xx]. It can be used to move through the StepLogic functions (speed or
position) using comms control without requiring actual digital input
transitions.

L200...L214 [Step Units x]

All position steps can be written to while the drive is running. The changes
takes place at the next move. For example, if step 0 is overwritten while the
drive is moving to step 0, the drive moves to the previous command position at
step 0. The next time that the drive is commanded to return to step 0 it
proceeds to the new position. One possible use of this capability is when an
application requires full control of the movement by a controller external to
the drive. The StepLogic program might be written to jump from step 0 back to
step 0 when Input 1 is active. The controller could write any desired position to
step 0 and then toggle the input 1 bit of A560 [Enh Control Word] to cause the
drive to move to the new position. This allows almost unlimited flexibility and
can be used with absolute or incremental moves.

Setup Notes The RA computer tool (Connected Components Workbench software) can
make setup of the positioning functions much easier. See the latest versions
for additional tools or wizards, which can aid in the setup.

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Appendix E Encoder/Pulse Train Usage and Position StepLogic Application

Notes:

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 Appendix F

PID Set Up

PID Loop The PowerFlex 520-series drive features built-in PID (proportional, integral,
derivative) control loops. The PID loop is used to maintain a process feedback
(such as pressure, flow, or tension) at a desired setpoint. The PID loop works
by subtracting the PID feedback from a reference and generating an error
value. The PID loop reacts to the error, based on the PID Gains, and outputs a
frequency to try to reduce the error value to 0.

To enable the PID loop, P047, P049 or P051 [Speed Referencex] must be set to 11
“PID1 Output” or 12 “PID2 Output”, and the corresponding speed reference
activated.

IMPORTANT PowerFlex 523 has one PID control loop.

PowerFlex 525 has two PID control loops, of which only one can be in use at
any time.

Exclusive Control and Trim Control are two basic configurations where the
PID loop may be used.

Exclusive Control

In Exclusive Control, the Speed Reference becomes 0, and the PID Output
becomes the entire Freq Command. Exclusive Control is used when A458 or
A470 [PID x Trim Sel] is set to option 0. This configuration does not require a
master reference, only a desired setpoint, such as a flow rate for a pump.

PID Loop
PID Ref PID Prop Gain
+ PID + PID
– Error + Output Accel/Decel Freq
PID Fdbk PID Integ Time Ramp Command
+
PID Diff Rate
PID Selected

Example
• In a pumping application, the PID Reference equals the Desired System
Pressure setpoint.
• The Pressure Transducer signal provides PID Feedback to the drive.
Fluctuations in actual system pressure, due to changes in flow, result in a
PID Error value.
• The drive output frequency increases or decreases to vary motor shaft
speed to correct for the PID Error value.
• The Desired System Pressure setpoint is maintained as valves in the
system are opened and closed causing changes in flow.

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Appendix F PID Set Up

• When the PID Control Loop is disabled, the Commanded Speed is the
Ramped Speed Reference.

Esc Sel

PID Feedback =
Pressure Transducer Signal
Pump

PID Reference =
Desired System Pressure

Trim Control

In Trim Control, the PID Output is added to the Speed Reference. In Trim
mode, the output of the PID loop bypasses the accel/decel ramp as shown. Trim
Control is used when A458 or A470 [PID x Trim Sel] is set to any option other
than 0.

[Speed Referencex]
PID Loop Accel/Decel
PID Ref Ramp
PID Prop Gain
+ PID + PID +
– Error + Output + Output
PID Fdbk PID Integ Time Freq
+
PID Diff Rate
PID Selected

Example
• In a winder application, the PID Reference equals the Equilibrium
setpoint.
• The Dancer Pot signal provides PID Feedback to the drive. Fluctuations
in tension result in a PID Error value.
• The Master Speed Reference sets the wind/unwind speed.
• As tension increases or decreases during winding, the Speed Reference is
trimmed to compensate. Tension is maintained near the Equilibrium
setpoint.

0V

PID Reference = PID Feedback =

Equilibrium Set Point Dancer Pot Signal
Esc Sel

10V

[Speed Referencex]

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 Appendix F PID Set Up

PID Reference and PID mode is enabled by setting P047, P049 or P051 [Speed Referencex] to
Feedback 11 “PID1 Output” or 12 “PID2 Output”, and activating the corresponding speed
reference.

IMPORTANT PowerFlex 523 has one PID control loop.

PowerFlex 525 has two PID control loops, of which only one can be in use at
any time.

If A459 or A471 [PID x Ref Sel] is not set to 0 “PID Setpoint”, PID can still be
disabled by select programmable digital input options (parameters t062, t063,
t065...t068 [DigIn TermBlk xx]) such as “Purge”.

A459, A471 [PID x Ref Sel] Options

Options Description
0“PID Setpoint“ A464 or A476 [PID x Setpoint] is used to set the value of the PID Reference.
1“Drive Pot” The drive potentiometer is used to set the value of the PID Reference.
2“Keypad Freq” The drive keypad is used to set the value of the PID Reference.
2”Serial/DSI” The reference word from the Serial/DSI communication network becomes the PID Reference.
4“Network Opt” The reference word from a communication network option becomes the PID Reference.
Selects the 0…10V Input. The PID does not function with a bipolar analog input. It ignores any
5“0-10V Input” negative voltages and treats them like a zero.
6“4-20mA Input” Selects the 4…20 mA Input.
7“Preset Freq” A410...A425 [Preset Freq x] is used as an input for the PID Reference.
8“AnlgIn Multi”(1) The product of the 0…10V and 4…20mA Inputs is used as an input for the PID Reference.
9“MOP Freq” A427 [MOP Freq] is used as an input for the PID Reference.
10”Pulse Input” Pulse train is used as an input for the PID Reference.
11“Step Logic”(1) StepLogic is used as an input for the PID Reference.
12“Encoder”(1) Encoder is used as an input for the PID Reference.
The reference word from the EtherNet/IP communication network becomes the PID
13“EtherNet/IP”(1) Reference.
(1) Setting is specific to PowerFlex 525 drives only.

A460 and A472 [PID x Fdback Sel] are used to select the source of the PID
feedback.

A460, A472 [PID x Fdback Sel] Options

Options Description
Selects the 0…10V Input (default setting). The PID will not function with a bipolar analog
0“0-10V Input” input. It ignores any negative voltages and treat them like a zero.
1“4-20mA Input“ Selects the 4…20 mA Input.
2“Serial/DSI” Serial/DSI will be used as an input for the PID Feedback.
3“Network Opt” The reference word from a communication network option becomes the PID Reference.
4“Pulse Input” Pulse train will be used as an input for the PID Feedback.
5“Encoder”(1) Encoder will be used as an input for the PID Feedback.
6“EtherNet/IP”(1) EtherNet/IP will be used as an input for the PID Feedback.
(1) Setting is specific to PowerFlex 525 drives only.

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Appendix F PID Set Up

Analog PID Reference Parameters t091 [Anlg In 0-10V Lo] and t092 [Anlg In 0-10V Hi] are used to
Signals scale or invert an analog PID Reference or PID Feedback.

Scale Function

For a 0...5V signal, the following parameter settings are used so that a 0V
signal = 0% PID Reference and a 5V signal = 100% PID Reference.
• t091 [Anlg In 0-10V Lo] = 0.0%
• t092 [Anlg In 0-10V Hi] = 50.0%
• A459 [PID 1 Ref Sel] = 5 “0-10V Input”
12
10
8

Input Volts
6
4
2

0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)

Invert Function

For a 4…20 mA signal, the following parameter settings are used so that a 20
mA signal = 0% PID Reference and a 4 mA signal = 100% PID Reference.
• t095 [Anlg In4-20mA Lo] = 100.0%
• t096 [Anlg In4-20mA Hi] = 0.0%
• A459 [PID 1 Ref Sel] = 6 “4-20mA Input”
24
20
4-20 mA Input

16
12
8
4
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)

PID Deadband
Parameters A465 and A477 [PID x Deadband] are used to set a range, in
percent, of the PID Reference that the drive ignores.

Example
• A465 [PID 1 Deadband] = 5.0%
• The PID Reference is 25.0%
• The PID Regulator does not act on a PID Error that falls between 20.0%
and 30.0%

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 Appendix F PID Set Up

PID Preload

The value set in A466 or A478 [PID x Preload], in Hz, is pre-loaded into the
integral component of the PID at any start or enable. This causes the drive’s
frequency command to initially jump to that preload frequency, and the PID
loop starts regulating from there.

PID Enabled

PID Pre-load Value

PID Output

Freq Cmd
PID Pre-load Value > 0

PID Limits

A456 and A468 [PID x Trim Hi] and A457 and A469 [PID x Trim Lo] are used to
limit the PID output and are only used in trim mode. [PID x Trim Hi] sets the
maximum frequency for the PID output in trim mode. [PID x Trim Lo] sets the
reverse frequency limit for the PID output in trim mode. Note that when the
PID reaches the Hi or Lo limit, the PID regulator stops integrating so that
windup does not occur.

PID Gains

The proportional, integral, and differential gains make up the PID regulator.
• A461 and A473 [PID x Prop Gain]
The proportional gain (unitless) affects how the regulator reacts to the
magnitude of the error. The proportional component of the PID
regulator outputs a speed command proportional to the PID error. For
example, a proportional gain of 1 would output 100% of max frequency
when the PID error is 100% of the analog input range. A larger value for
[PID x Prop Gain] makes the proportional component more responsive,
and a smaller value makes it less responsive. Setting [PID x Prop Gain] to
0.00 disables the proportional component of the PID loop.
• A462 and A474 [PID x Integ Time]
The integral gain (units of seconds) affects how the regulator reacts to
error over time and is used to get rid of steady state error. For example,
with an integral gain of 2 seconds, the output of the integral gain
component would integrate up to 100% of max frequency when the PID
error is 100% for 2 seconds. A larger value for [PID x Integ Time] makes
the integral component less responsive, and a smaller value makes it
more responsive. Setting [PID x Integ Time] to 0.0 disables the integral
component of the PID loop.
• A463 and A475 [PID x Diff Rate]
The Differential gain (units of 1/seconds) affects the rate of change of the
PID output. The differential gain is multiplied by the difference between
the previous error and current error. Thus, with a large error the D has a
large effect and with a small error the D has less of an effect. This

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Appendix F PID Set Up

parameter is scaled so that when it is set to 1.00, the process response is

0.1% of P044 [Maximum Freq] when the process error is changing at 1% /
second. A larger value for [PID x Diff Rate] makes the differential term
have more of an effect and a small value makes it have less of an effect. In
many applications, the D gain is not needed. Setting [PID x Diff Rate] to
0.00 (factory default) disables the differential component of the PID
loop.

Guidelines for Adjusting the PID Gains

1. Adjust the proportional gain. During this step it may be desirable to
disable the integral gain and differential gain by setting them to 0. After
a step change in the PID Feedback:
- If the response is too slow increase A461 or A473 [PID x Prop Gain].
- If the response is too quick and/or unstable (see Unstable Response on
page 236), decrease A461 or A473 [PID x Prop Gain].
- Typically, A461 or A473 [PID x Prop Gain] is set to some value below the
point where the PID begins to go unstable.
2. Adjust the integral gain (leave the proportional gain set as in Step 1).
After a step change in the PID Feedback:
- If the response is too slow (see Slow Response – Over Damped on
page 236), or the PID Feedback does not become equal to the PID
Reference, decrease A462 or A474 [PID x Integ Time].
- If there is a lot of oscillation in the PID Feedback before settling out
(see Oscillation – Under Damped on page 237), increase A462 or A474
[PID x Integ Time].
3. At this point, the differential gain may not be needed. However, if after
determining the values for A461 or A473 [PID x Prop Gain] and A462 or
A474 [PID x Integ Time]:
- Response is still slow after a step change, increase A463 or A475 [PID x
Diff Rate].
- Response is still unstable, decrease A463 or A475 [PID x Diff Rate].

The following figures show some typical responses of the PID loop at different
points during adjustment of the PID Gains.

Unstable Response

PID Reference

PID Feedback

Time

Slow Response – Over Damped

PID Reference

PID Feedback

Time

236 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix F PID Set Up

Oscillation – Under Damped

PID Reference

PID Feedback

Time

Good Response – Critically Damped

PID Reference

PID Feedback

Time

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 237

Appendix F PID Set Up

Notes:

238 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix G

Safe Torque Off Function

The PowerFlex 525 Safe-Torque-Off function, when used with other safety
components, helps provide protection according to EN ISO 13849 and EN62061
for safe-off and protection against restart. The PowerFlex 525 Safe-Torque-Off
function is just one component in a safety control system. Components in the
system must be chosen and applied appropriately to achieve the desired level
of operator safeguarding.

Topic Page
PowerFlex 525 Safe-Torque-Off Overview 239
EC Type Examination Certification 240
UK Type Examination Certification 240
EMC Instructions 241
Using PowerFlex 525 Safe-Torque-Off 241
Enabling PowerFlex 525 Safe-Torque-Off 243
Wiring 243
Verify Operation 244
PowerFlex 525 Safe-Torque-Off Operation 244
Connection Examples 245
PowerFlex 525 Certification for Safe-Torque-Off 248

IMPORTANT The Safe-Torque-Off function covered in this chapter is specific to

PowerFlex 525 drives only.

PowerFlex 525 Safe- The PowerFlex 525 Safe-Torque-Off function:

Torque-Off Overview • Provides the Safe-Torque-Off (STO) function defined in
EN 61800-5-2.
• Blocks gate-firing signals from reaching the Insulated Gate Bipolar
Transistor (IGBT) output devices of the drive. This prevents the IGBTs
from switching in the sequence necessary to generate torque in the
motor.
• Can be used in combination with other safety devices to fulfill the
requirements of a system “safe torque off” function which satisfies

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 239

Appendix G Safe Torque Off Function

Category 3 / PL (d) according to EN ISO 13849-1 and SIL CL2 according to

EN 62061, IEC 61508, and EN 61800-5-2.

IMPORTANT The function is suitable for performing mechanical work on the drive
system or affected area of a machine only. It does not provide electrical
safety.

ATTENTION: Electric Shock Hazard. Verify that all sources of AC and DC

power are de-energized and locked out or tagged out in accordance with the
requirements of ANSI/NFPA 70E, Part II.
To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive.
Measure the DC bus voltage at the +DC and -DC terminals or test points
(refer to your drive’s User Manual for locations). The voltage must be zero.
In safe-off mode, hazardous voltages may still be present at the motor. To
avoid an electric shock hazard, disconnect power to the motor and verify
that the voltage is zero before performing any work on the motor.

EC Type Examination TÜV Rheinland has certified the PowerFlex 525 Safe-Torque-Off function
Certification compliant with the requirements for machines defined in Annex I of the
EC Directive 2006/42/EC, and that it complies with the requirements of the
relevant standards listed below:
• EN ISO 13849-1 Safety of machinery – Safety related parts of control
systems – Part 1: General principles for design.
(PowerFlex 525 STO achieves Category 3 / PL(d))
• EN 61800-5-2 Adjustable speed electrical power drive systems – Part 5-2
Safety requirements – Functional.
(PowerFlex 525 STO achieves SIL CL 2)
• EN 62061 Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control systems.
• IEC 61508 Part 1-7 Functional safety of electrical/electronic/
programmable electronic safety-related systems – Parts 1-7.

TÜV also certifies that the PowerFlex 525 STO may be used in applications up
to Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to
EN 62061 / EN 61800-5-2 / IEC 61508.

The TÜV Rheinland certificate may be found at rok.auto/certifications.

UK Type Examination TÜV Rheinland has certified the PowerFlex 525 Safe-Torque-Off function
Certification compliant with the requirements for machines defined in 2008 No. 1597
Supply of Machinery (Safety) Regulations (MD), and that it complies with the
requirements of the relevant standards listed below:
• EN ISO 13849-1 Safety of machinery – Safety related parts of control
systems – Part 1: General principles for design.
(PowerFlex 525 STO achieves Category 3 / PL(d))
• EN 61800-5-2 Adjustable speed electrical power drive systems – Part 5-2
Safety requirements – Functional.
(PowerFlex 525 STO achieves SIL CL 2)
• EN 62061 Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control systems.

240 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix G Safe Torque Off Function

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

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

TÜV also certifies that the PowerFlex 525 STO may be used in applications up
to Category 3/ PL(d) according to EN ISO 13849-1 and SIL 2 according to
EN 62061 / EN 61800-5-2 / IEC 61508.

The TÜV Rheinland certificate may be found at rok.auto/certifications.

EMC Instructions PowerFlex 525 Safe-Torque-Off function requires CE and UK Conformity as

described on page 51.

Using PowerFlex 525 Safe- The PowerFlex 525 Safe-Torque-Off function is intended to be part of the
Torque-Off safety related control system of a machine. Before use, a risk assessment
should be performed that compares the PowerFlex 525 Safe-Torque-Off
function specifications and all foreseeable operational and environmental
characteristics of the machine to which it is to be fitted.

A safety analysis of the machine section controlled by the drive is required to

determine how often the safety function should be tested for proper operation
during the life of the machine.

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 equipment. A hazard of personal injury
and/or equipment damage exists if codes are ignored during installation.
ATTENTION: In safe-off mode, hazardous voltages may still be present at
the motor. To avoid an electric shock hazard, disconnect power to the
motor and verify that the voltage is zero before performing any work on the
motor.
ATTENTION: In the event of the failure of two output IGBTs in the drive,
when the PowerFlex 525 Safe-Torque-Off has controlled the drive outputs
to the off state, the drive may provide energy for up to 180 ° of rotation in a
2-pole motor before torque production in the motor ceases.

Safety Concept The PowerFlex 525 Safe-Torque-Off function is suitable for use in safety
applications up to and including Category 3 / PL(d) according to EN ISO 13849-
1 and SIL 2 according to EN 62061 / EN 61800-5-2 / IEC 61508.

In addition, the PowerFlex 525 STO may be used together with other
components in a safety application to achieve an overall Category 3 / PL(e)
according to EN ISO 13849-1 and SIL 3 according to EN 62061 and IEC 61508.
This is illustrated in Example 3 in this appendix.

Safety requirements are based on the standards current at the time of

certification.

The PowerFlex 525 Safe-Torque-Off function is intended for use in safety-

related applications where the de-energized state is considered to be the safe
state. All of the examples in this manual are based on achieving de-

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 241

Appendix G Safe Torque Off Function

energization as the safe state for typical Machine Safety and Emergency
Shutdown (ESD) systems.

Important Safety Considerations

The system user is responsible for:

• the set-up, safety rating, and validation of any sensors or actuators
connected to the system.
• completing a system-level risk assessment and reassessing the system
any time a change is made.
• certification of the system to the desired safety performance level.
• project management and proof testing.
• programming the application software and the safety option
configurations in accordance with the information in this manual.
• access control to the system, including access code handling.
• analyzing all configuration settings and choosing the proper setting to
achieve the required safety rating.

IMPORTANT When applying Functional Safety, restrict access to qualified, authorized

personnel who are trained and experienced.

ATTENTION: When designing your system, consider how personnel will exit
the machine if the door locks while they are in the machine. Additional
safeguarding devices may be required for your specific application.

Functional Proof Test

The PFD and PFH values provided in the table below are contingent upon the
Proof Test Interval (PTI). Before the end of the PTI specified in the table below,
a proof test of the STO safety function must be performed in order for the
specified PFD and PFH values to remain valid.

PFD and PFH Data

PFD and PFH calculations are based on the equations from Part 6 of EN 61508.

This table provides data for a 20-year proof test interval and demonstrates the
worst-case effect of various configuration changes on the data.

PFD and PFH for 20-year Proof Test Interval

Attribute Value
PFD 6.62E-05 (MTTF = 3593 years)
PFHD 8.13E-10
SFF 83%
DC 62.5%
CAT 3

242 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix G Safe Torque Off Function

PFD and PFH for 20-year Proof Test Interval (Continued)

Attribute Value
HFT 1 (1oo2)
PTI 20 YEARS
Hardware Type A
Type

Safety Reaction Time

The safety reaction time is the amount of time from a safety-related event as
input to the system until the system is in the Safe State.

The safety reaction time from an input signal condition that triggers a safe
stop, to the initiation of safe-torque-off, is 100 ms (maximum).

Enabling PowerFlex 525 1. Remove all power to the drive.

Safe-Torque-Off ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing any
work on the drive. Measure the DC bus voltage at the +DC and -DC
terminals or test points (refer to your drive’s user manual for the
location of the terminals). The voltage must be zero.
2. Loosen the screw of terminals Safety 1, Safety 2 and Safety +24V
(S1, S2, S+) on the control I/O terminal block.
3. Remove the protective jumper.
R1 R2 R5 R6 01 02 03 04 05 06 07 08

S1 S2 S+ 11 12 13 14 15 16 17 18 19

4. Safe-Torque-Off function is now enabled and the terminals are ready to

function as safety inputs.

Wiring Important points to remember about wiring:

• Always use copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control wires should be separated from power wires by at least
0.3 m (1 ft).
Recommended Wire
Min Insulation
Type Wire Type(1) Description Rating

Shielded Multi-conductor shielded cable such as Belden 8770 (or 0.750 mm2 (18 AWG), 300V, 60 °C
equiv.) 3 conductor, shielded (140 °F)
(1) 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.

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Appendix G Safe Torque Off Function

See I/O Wiring on page 36 for wiring recommendations and Control I/O
Terminal Designations on page 42 for terminal descriptions.

If Safety Inputs S1 and S2 are powered by an external +24V source, apply it only
in SELV system, PELV system or low voltage Class 2 circuit.

PowerFlex 525 Safe- The PowerFlex 525 Safe-Torque-Off function disables the drive’s output IGBT’s
Torque-Off Operation by breaking the link with the drive microcontroller. When used in combination
with a safety input device, the system satisfies the requirements of EN ISO
13849 and EN62061 for safe-torque-off and helps protect against restart.

Under normal drive operation, both safety inputs (Safety 1 and Safety 2) are
energized, and the drive is able to run. If either input is de-energized, the gate
control circuit becomes disabled. To meet EN ISO 13849 operation, both safety
channels must be de-energized. See the following examples for more
information.

IMPORTANT By itself, the Safe-Torque-Off function initiates a coast to stop action.

Additional protective measures will need to be applied when an
application requires a change to the stop action.

Verify Operation Test the safety function for proper operation after the initial setup of the
PowerFlex 525 Safe-Torque-Off function. Retest the safety function at the
intervals determined by the safety analysis described on page 241.

Verify that both safety channels are functioning according to the table below.

Channel Operation and Verification

Safety Function Drive In Drive In Drive In Drive
Status Safe State Safe State Safe State Able To Run
Configured by t105 Fault F111 Fault F111
Drive Status Ready/Run
[Safety Open En] (Safety Hardware) (Safety Hardware)
Safety Channel Operation
Safety Input S1 No Power Applied Power Applied No Power Applied Power Applied
Safety Input S2 No Power Applied No Power Applied Power Applied Power Applied

IMPORTANT If an external fault is present on the wiring or circuitry controlling the

Safety 1 or Safety 2 inputs for a period of time, the Safe-Torque-Off
function may not detect this condition. When the external fault
condition is removed the Safe-Torque-Off function will allow an enable
condition. Fault in the external wiring shall either be detected by
external logic, or excluded (wiring must be protected by cable ducting or
armoring), according to EN ISO 13849-2.

Discrepancy Time of the Safety Inputs

For example, if S1 is disabled and S2 did not follow after the discrepancy time,
fault F111 “Safety Hardware” will occur. However, if S1 is disable and S2 follows
before the discrepancy time, fault F059 “Safety Open” will occur.

244 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix G Safe Torque Off Function

The discrepancy time is one second for PowerFlex 525 FRN 5.xxx and later. The
discrepancy time is 10 milliseconds for PowerFlex 525 FRN 4.xxx and earlier.

Connection Examples Example 1 – Safe-Torque-Off Connection with Coast-to-Stop Action,

SIL 2/PL d
Stop Category 0 – Coast

AC line
input power

+24V DC PF 525

+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
A1 S21 S11 S52 41 13 23 33 Start

E-Stop MSR Gate control

latching power supply
button
A2 S22 S14 S34 42 14 24 34

24V DC Gate control

common circuit

S1
S2
(1)

AC line
input power

PF 525

+24V DC
GuardMaster
Gate Trojan Stop
Stop
Start
Start

E-Stop Gate control

latching power supply
button

Gate control
circuit

S1
S2
(2)

(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure
or other measure to exclude these failure modes should be used.
(2) In some situations, a safety relay is not required if both the switch and PowerFlex 525 are installed in the same enclosure.

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Appendix G Safe Torque Off Function

Stop Category 0 – Coast with Two PowerFlex 525 Drives

(1)
24V DC Supply
Reset AC line
input power

PF 525
AC line
E-Stop +24V DC input power

A1 Stop PF 525
L12 Stop
S11 Start
S21 SI L11 Start
Dig. comm
+24V DC
Stop
Y32 Stop
S12
Gate control Start
Reset 0 S34 power supply Start
S22
AM Dig. comm
MM Gate control
Gate control power supply
circuit
13
(2)
14 S1
Gate control
23 S2 circuit

24 (2)
S1
A2
S2

24V DC COM

M M

(1) Enclosure Recommended. Note: External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure
or other measure to exclude these failure modes should be used.
(2) Each safety input draws 6 mA from the supply.

Circuit Status

Circuit shown with guard door closed and system ready for normal drive
operation.

Operating Principle

This is a dual channel system with monitoring of the Safe-Torque-Off circuit

and drive. Opening the guard door will switch the input circuits (S13-S14 & S21-
S22) to the Minotaur™ monitoring safety relay unit. The output circuits (13-14 &
23-24) will cause the Safe-Torque-Off Enable circuit to trip and the motor will
coast to stop. To restart the drive, the Minotaur safety relay must first be reset
followed by a valid start command to the drive.

Fault Detection

A single fault detected on the Minotaur safety input circuits will result in the
lock-out of the system at the next operation and will not cause loss of the safety
function.

A single fault detected on the PowerFlex 525 safety enable redundant inputs
will result in the lock-out of the drive and will not cause loss of the safety
function.

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 Appendix G Safe Torque Off Function

Example 2 – Safe-Torque-Off Connection with Controlled Stop Action,

SIL 2/PL d
Stop Category 1 – Controlled
(1) AC line
input power

GuardMaster PF 525
Trojan
Gate +24V DC
Stop
Stop
+24V DC Start
Start
A1 S21 S11 S52 S12 S22 37 47 57 13 23 S33 S34
Gate control
Minotaur power supply
MSR138DP
A2 X1 X2 X3 X4 Y39 Y40 38 48 58 14 24 Y2 Y1
24V DC
Common Gate control
circuit

S1
S2

(1) Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or
other measure to exclude these failure modes should be used.

Circuit Status

Circuit shown with guard door closed and system ready for normal drive
operation.

Operating Principle

This is a dual channel system with monitoring of the Safe-Torque-Off circuit

and drive. Opening the guard door will switch the input circuits (S11-S12 & S21-
S22) to the Minotaur monitoring safety relay unit. The output circuits (13-14)
will issue a Stop command to the drive and cause a controlled deceleration.
After the programmed delay, the timed output circuits (47-48 & 57-58) will
cause the Safe-Torque-Off Enable circuit to trip. If the motor is rotating when
the trip occurs, it will coast to stop. To restart the drive, the Minotaur safety
relay must first be reset followed by a valid start command to the drive.

Fault Detection

A single fault detected on the Minotaur safety input circuits will result in the
lock-out of the system at the next operation and will not cause loss of the safety
function.

A single fault detected on the PowerFlex 525 safety enable redundant inputs
will result in the lock-out of the drive and will not cause the loss of the safety
function.

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Appendix G Safe Torque Off Function

Example 3 – Safe-Torque-Off Connection with Coast-to-Stop Action

Using External +24V supply, SIL 3/PL e
Stop Category 0 – Coast
(1) AC line
input power

PF 525
External +24V DC
+24V DC
Stop
Reset Start
Open COM
A1 S11 S52 S12 13 23 33 41
Gate control
MSR127TP power supply

S21 S22 S34 A2 14 24 34 42

Closed
Gate control
circuit

S1
S2

X1 AUX
X2 13 23 33
A1 Coil 14 24 34
A2
24V DC COM External 100-C
contactor 100S-C

(1) Enclosure Recommended. External wiring failure modes must be considered as described in EN ISO 13849-2. Enclosure or
other measure to exclude these failure modes should be used.

Circuit Status

Circuit shown with guard door closed and system ready for normal drive
operation.

Operating Principle

This is a dual channel system with monitoring of the Safe-Torque-Off circuit

and drive. Opening the guard door will switch the input circuits (S11-S12 & S21-
S22) to the Minotaur monitoring safety relay unit. The output circuits (13-14 &
23-24 & 33-34) will cause the output contact and Safe-Torque-Off Enable circuit
to trip and the motor will coast to stop. To restart the drive, the Minotaur
safety relay must first be reset followed by a valid start command to the drive.

Fault Detection

A single fault detected on the Minotaur safety input circuits will result in the
lock-out of the system at the next operation and will not cause loss of the safety
function.

PowerFlex 525 Certification Certification information can be viewed at rok.auto/certifications.

for Safe-Torque-Off

248 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix H

EtherNet/IP

This section contains only basic information to setup an EtherNet/IP

connection with your PowerFlex 520-series drive. For comprehensive
information about EtherNet/IP (single and dual-port) and how to use it, see
the following publications:
• PowerFlex 525 Embedded EtherNet/IP Adapter User Manual, publication
520COM-UM001.
• PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter User Manual,
publication 520COM-UM003.

ATTENTION: PowerFlex 523 drives support only the 25-COMM-E2P dual-port

EtherNet/IP adapter. PowerFlex 525 drives support both the embedded
EtherNet/IP adapter and the 25-COMM-E2P dual-port EtherNet/IP adapter.

It is recommended to use Allen-Bradley Ethernet RJ45 cables, shielded or

unshielded (catalog number 1585J-M8xBJM-x), for connecting your
PowerFlex 520-series drive to an EtherNet/IP network.

Establishing A Connection There are three methods for configuring the Ethernet IP address:
With EtherNet/IP • BootP Server – Use BootP if you prefer to control the IP addresses of
devices using a server. The IP address, subnet mask, and gateway
addresses will then be provided by the BootP server.
• Adapter Parameters – Use adapter parameters when you want more
flexibility in setting up the IP address, or need to communicate outside
the control network using a gateway. The IP address, subnet mask, and
gateway addresses will then come from the adapter parameters you set.
• DHCP (Dynamic Host Configuration Protocol) (only with PowerFlex 25-
COMM-E2P adapter) – Use DHCP when you want additional flexibility
and ease-of-use compared to BOOTP in configuring the IP address,
subnet mask, and gateway address for the adapter using a DHCP server.

IMPORTANT If you are setting your network addresses manually using parameters,
you must set the appropriate drive or 25-COMM-E2P adapter parameter
value to 1 “Parameters”. See the respective EtherNet/IP adapter user
manual for more information.

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 remove and reapply
power to (or reset) the adapter.

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Appendix H EtherNet/IP

Ground Connections for Connect terminal C1 to a clean ground when using a network with a star
EtherNet/IP Networks topology. It is acceptable to ground both C1 and C2 terminals.

PowerFlex 525 Embedded Ethernet/IP Adapter

FWD

ENET LINK
EtherNet/IP

Esc Sel

Terminals C1/C2

Terminal Description
This terminal is tied to the RJ-45 port shield. Tie this
terminal to a clean ground in order to improve noise
C1 immunity when using external communication
peripherals.
This is the signal common for the communication
C2 signals.

Connect terminal CS1 or CS2 to a clean ground when using a network with a
ring topology.

PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter

Terminal Description
Provides a clean ground for the communication bus cable
shields.
CS1/CS2 CS1 or CS2 should be connected to a clean ground or PE
ground on the drive.

Terminals CS1/CS2

250 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix I

Control Diagrams

This chapter contains various diagrams on the PowerFlex 520-series drive

functions and behaviors.

Induction Motor Tuning [Speed Reg Sel] Diagrams For Motor Tuning
Diagrams Low Speed Mid Speed High Speed
Control Mode Control Mode Control Mode
Speed Controller
Gain
A509 [Speed Reg Sel] = 0

A515 [Freq 3 BW]

Gain set automatically

A513 [Freq 2 BW]

A511 [Freq 1 BW]

A510 Freq (Hz)
[Freq 1] A512
[Freq 2]
A514
[ Freq 3]

Low Speed Mid Speed High Speed

Control Mode Control Mode Control Mode
Speed Controller
Gain
A509 [Speed Reg Sel] = 1

A525 [Freq 3 Kp]

A526 [Freq 3 Ki]
Gain set manually

A523 [Freq 2 Kp]

A524 [Freq 2 Ki]

A521 [Freq 1 Kp]

A522 [Freq 1 Ki]
A510
[Freq 1] Freq (Hz)
A512
[Freq 2]
A514
[Freq 3]

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Appendix I Control Diagrams

Adjusting Speed Control These settings show how to adjust the speed control for motor tuning.
Parameters
Speed Loop Bandwidth:
Increase the bandwidth to obtain
A511 [Freq 1 BW] = 10 Hz
faster speed response. If oscillation
A513 [Freq 2 BW] = 10 Hz
occurs, decrease the bandwidth.
A515 [Freq 3 BW] = 10 Hz
For [Freq x Kp], gradually increase by 1%
For [Freq x Ki], gradually increase by 0.1 s

For general use, set A509 Set A509 A509 = 1 (Manual)

[Speed Reg Sel] to 0 (Automatic) [Speed Reg Sel]

A509 = 0 (Automatic)

Set Speed Controller Gain Set Speed Controller Gain

automatically manually:
A521 [Freq 1 Kp]
A522 [Freq 1 Ki]
A523 [Freq 2 Kp]
A524 [Freq 2 Ki]
A525 [Freq 3 Kp]
A526 [Freq 3 Ki]

Run

252 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J

PowerFlex 525 PM Motor Configuration

This chapter contains instructions and diagrams on configuring the

PowerFlex 525 drive for use with a PM motor. For more information, see the
PowerFlex 525 Configuration with Permanent Magnet Motors Application
Technique, publication 520-AT001

Topic Page
Manual Configuration Using Drive Keypad 258
Additional PM Motor Configuration 259
Optional Parameter Adjustments for Optimum Performance 263

ATTENTION: It is the responsibility of the startup engineer / end user to use

proper safety precautions with any equipment used during this startup.
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 document are included
solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell
Automation cannot assume responsibility or liability of actual use based on
the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
the information, circuits, equipment. Or software described in this
document. Rockwell Automation reserves the right to make changes to this
document without prior notice. When using examples in this document the
user recognizes that Rockwell Automation cannot be made liable for any
damage or claims. Because there are many application-specific variables,
users MUST ensure that products are correctly used and the appropriate
architecture is deployed. Reproduction of the contents of this document, in
whole or in part, without written permission of Rockwell Automation, Inc. is
prohibited.

To use PM motor control, you need to install the PowerFlex 525 drive firmware
revision 5.001 or later. If you wish to perform PM motor tuning by using the
PowerFlex 525 Startup Wizard in Connected Components Workbench
software, and update to the latest drive database.

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Appendix J PowerFlex 525 PM Motor Configuration

Motor Control

From the Torq Perf Mode drop-down list, select “PM Motor”.

This configuration can also be done by setting parameter P039 [Torq Perf
Mode] to 4 “PM Motor”.

Motor Data

Key in the details of your Motor Nameplate.

254 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J PowerFlex 525 PM Motor Configuration

Feedback

If you are configuring a closed loop PM motor control, key in the details of your
incremental encoder.

IMPORTANT Note the following:

• PowerFlex 525 drive only supports incremental AB encoder (25-ENC-1).
• Motor Feedback Type can be “Quadrature” or “Quad Check”.
• Only Interior Permanent magnet motor (iPM) is supported for closed loop
control.

Stop Mode/Brake Type

Key in the details of your configuration.

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Appendix J PowerFlex 525 PM Motor Configuration

Direction Test

IMPORTANT When configuring a PM motor or using an encoder, it is required to

perform a Direction Test before proceeding to the next step (Auto Tune).

Perform a Direction Test. The direction test can be performed with or without
the load attached. Consider your application requirements when deciding to
have the load attached or removed from the motor. This test runs in V/Hz
mode to verify the motor polarity relative to the feedback polarity. The test
confirms motor rotation and feedback polarity. After the test is completed, a
change can be made, if necessary.

IMPORTANT If the drive was never operated before (new installation), verify that
safeguards are in place to remove power safely from the drive during
an unstable situation where the drive can produce undesired motion.

Auto Tune

Ensure the load is uncoupled and perform a Rotate Tune test.

Run the drive with P040 [Autotune] = 2 “Rotate Tune” configured to

complete the auto tune process. This process measures and configures
the following:
• A501 [PM IR Voltage]
• A502 [PM IXd Voltage]
• A503 [PM IXq Voltage]
• A504 [PM BEMF Voltage]

The Auto Tune is used to identify the correct motor flux and stator electrical
properties, including the following:
• IR volt drop, which is voltage drop over resistance.
• IXd volt drop, which is voltage drop over inductance.

256 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J PowerFlex 525 PM Motor Configuration

• Flux current (estimated in Static Tune and measured in Rotate Tune

test).
• Slip RPM, which is calculated from motor nameplate data. If an encoder
is used, the Slip RPM becomes a measured value using the encoder.
Auto Tune Window

A properly tested motor and drive helps ensure higher starting torque and
better performance at low speeds. Conversely, an improperly performed Auto
Tune can cause the motor to exhibit instability at low speeds, uneven
performances when running through the motor speed range, and can generate
unnecessary faults such as overcurrent and overvoltage faults.

Static Tune

This test is used when the motor is connected to a high friction load and
cannot easily be uncoupled from the motor, or when the load cannot be rotated
due to mechanical constraints or a limited range of movement. The Static
Tune test does not generate any motor movement. The Static tune test results
may not be as accurate as the Rotate Tune test.

Rotate Tune (preferred for PM motor tuning)

This test is used when the motor is not coupled to the load or the load is low
friction. Rotate tune is generally used to better identify motor flux and stator
electrical properties, which are used to automatically tune the torque current
loop. The Rotate Tune test causes motor rotation at different speeds while it is
executing.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 257

Appendix J PowerFlex 525 PM Motor Configuration

ATTENTION: If the drive was never operated before (new installation),

verify that safeguards are in place to remove power safely from the drive
during an unstable situation where the drive can produce undesired motion.

After completing the configuration and running the Auto Tune test, you may
need to perform additional configuration depending on whether you have an
open loop or closed loop system.

For an open loop system (A535 [Motor Fdbk Type] = 0 “None”), you may need to
adjust two parameters if you encounter momentary reverse startup after a
Start command is issued.

For a closed loop system (A535 [Motor Fdbk Type] = 4 “Quadrature” or 5 “Quad
Check”, you must perform an angle alignment after the Auto Tune test before
running the motor normally.

See Additional PM Motor Configuration on page 259 for instructions.

Manual Configuration Using Besides using the PowerFlex 525 Startup Wizard in Connected Components
Drive Keypad Workbench software, you can also manually configure the parameters by
using the drive keypad. Make sure you have installed the PowerFlex 525 drive
firmware revision 5.001 or later.

To configure the parameters, do the following:

1. Reset all parameters to their default values.
Set P053 [Reset to Defalts] = 2 “Factory Rset”
2. Select the Control Mode.
Set P039 [Torque Perf Mode] = 4 “PM Control”
3. Enter Motor nameplate data:
• Set P031 [Motor NP Volts]
• Set P032 [Motor NP Hertz]
• Set P033 [Motor OL Current]
• Set P034 [Motor NP FLA]
• Set P035 [Motor NP Poles]
• Set P036 [Motor NP RMP]
• Set P037 [Motor NP Power]
• Set P043 [Minimum Freq]
• Set P044 [Maximum Freq]
4. Set A440 [PWM Frequency] = 4.0 kHz (default).
5. Set A535 [Motor Fdbk Type]:
• = 4 “Quadrature” or 5 “Quad Check” (for Closed Loop PM)
or
• = 0 “None” (for Open Loop PM)
• A536 [Encoder PPR]
6. Enter Stop mode and dynamic brake data, if any.
• P045 [Stop Mode]
• A437 [DB Resistor Sel]
7. Ensure the load is uncoupled and perform a Rotate Tune test.
Set P040 [Autotune] = 2 “Rotate Tune”

258 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J PowerFlex 525 PM Motor Configuration

Press the Start button (Take note of your Start Source settings P046,
P048, and P050. Default setting of P046 = 1 “Keypad”)

ATTENTION: If the drive was never operated before (new installation),

verify that safeguards are in place to remove power safely from the drive
during an unstable situation where the drive can produce undesired
motion.

After completing the configuration and running the Auto Tune test, you may
need to perform additional configuration depending on whether you have an
open loop or closed loop system.

For an open loop system (A535 [Motor Fdbk Type] = 0 “None”), you may need to
adjust two parameters if you encounter momentary reverse startup after a
Start command is issued.

For a closed loop system (A535 [Motor Fdbk Type] = 4 “Quadrature” or 5 “Quad
Check”, you must perform an angle alignment after the Auto Tune test before
running the motor normally.

See Additional PM Motor Configuration on page 259 for instructions.

Additional PM Motor After completing the initial configuration, there are additional steps that need
Configuration to be performed to complete the whole PM motor setup.

For an open loop PM motor (iPM and sPM) control, some parameters need to
be adjusted to prevent reverse startup. For a closed loop PM motor (iPM), an
angle alignment procedure needs to be performed before the motor is run
normally.

Additional Setup for Open Loop PM Motor

After performing an auto tune on an open loop PM motor, a momentary
“reverse startup” may occur. To prevent this from occurring, perform the
following steps:
1. Set A516 [PM Initial Sel] = 1 “HFI”.
2. Increase the value of A519 [PM HFI NS Cur] by 10%.
3. Perform a test run at a reference speed and check if the motor reverses.
4. If the motor reverses, repeat steps 2 and 3.
5. If A519 [PM HFI NS Cur] has reached its maximum value (200%):
• reset the value to the default (100%)
• set A516 [PM Initial Sel] = 2 “Six Pulse”
6. Perform a test run at a reference speed and check if the motor reverses.
7. If the motor reverses, repeat steps 2 and 3.
8. If A519 [PM HFI NS Cur] has reached its maximum value again and a
reverse motor startup still occurs, the motor setup has failed.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 259

Appendix J PowerFlex 525 PM Motor Configuration

Flowchart for Open Loop PM Motor (iPM and sPM) Setup

Basic Setting

P053 [Reset to Defalts]

Load Default = 2 (Factory Reset)

Control Mode P039 [Torque Perf Mode]

Selection = 4 (PM Control)

P031 [Motor NP Volts]

P032 [Motor NP Hertz]
P033 [Motor OL Current]
Set Motor P034 [Motor NP FLA]
Parameters P035 [Motor NP Poles]
P036 [Motor NP RPM]
P037 [Motor NP Power]
P043 [Minimum Freq]
P044 [Maximum Freq]

A440 [PWM Frequency]

A535 [Motor Fdbk Type]

Set PG = 0 (None)

P040 [Autotune]
Set Autotune = 2 (Rotate Tune)
Start Autotune

A501 [PM IR Voltage]

Obtain Parameters A502 [PM IXd Voltage]
from Autotune A503 [PM IXq Voltage]
A504 [PM BEMF Voltage]

P041 [Accel Time 1]

Set Accel and P042 [Decel Time 1]
Decel Time A439 [S Curve %]

Reverse Startup Perform a test run at

Check command frequency
Repeat steps 2 and 3 of
Additional Setup for
Open Loop PM Motor
Do you see
reverse startup?
Yes

No

Drive is aligned and

ready to run

260 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J PowerFlex 525 PM Motor Configuration

Additional Setup for Closed Loop PM Motor

After performing an auto tune on an closed loop PM motor, a PM angle

alignment needs to be performed to complete the setup.

Align the PM Angle

To align the PM angle, do the following:

1. Uncouple the load.
2. Set these parameters to the recommended value:
• A517 [PM DC Inject Cur] = 60% (default is 30%)
• A518 [PM Align Time] = 5.8 s (default is 0.7 s)
• A580 [Current Loop BW] = 300 Hz (default is 0 Hz)
3. Set the desired speed (10...40 Hz recommended).
Check the setting for P047 [Speed Reference 1]. Speed reference can be
from POT, control panel of Connected Components Workbench
software, and so on.
4. Set the Start Source.
Check the setting for P046 [Start Source 1]. Start source can be from POT,
control panel of Connected Components Workbench software, and so
on.
5. Start the drive to run at the desired speed.
6. Drive will begin to align itself (move forward and reverse) and run to the
desired speed.
7. Stop the drive. The drive is now aligned.
The PM angle alignment only needs to be performed once unless the
drive is power cycled or re-tuned.

IMPORTANT The PM angle alignment has failed when fault F012 (HW Overcurrent) or
F013 (Ground Fault) is observed during acceleration and deceleration.

Adjustments if PM Angle Alignment has Failed

If the PM angle alignment has failed, do the following:

1. Cycle drive power or set A535 [Motor Fdbk Type] = 0 “None”, then set back
to 4 “Quadrature” or 5 “Quad Check”.
2. Increase A517 [PM DC Inject Cur] by 50%.
3. Increase A518 [PM Align Time] by 0.2 s.
4. Repeat the Align the PM Angle instructions again, beginning from step 3.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 261

Appendix J PowerFlex 525 PM Motor Configuration

Flowchart for Closed Loop PM Motor (iPM) Setup

Basic Setting

P053 [Reset to Defalts]

Load Default = 2 (Factory Reset)

Control Mode P039 [Torque Perf Mode]

Selection = 4 (PM Control)

P031 [Motor NP Volts]

P032 [Motor NP Hertz]
P033 [Motor OL Current]
Set Motor P034 [Motor NP FLA]
Parameters P035 [Motor NP Poles]
P036 [Motor NP RPM]
P037 [Motor NP Power]
P043 [Minimum Freq]
P044 [Maximum Freq]

A440 [PWM Frequency]

A535 [Motor Fdbk Type]

= 4 (Quadrature)
or 5 (Quad Check)
Set PG
A536 [Encoder PPR]
A518 [Align Time]
A517 [PM DC Inject Cur]

P040 [Autotune]
Set Autotune = 2 (Rotate Tune)
Start Autotune

A501 [PM IR Voltage]

Obtain Parameters A502 [PM IXd Voltage]
from Autotune A503 [PM IXq Voltage]
A504 [PM BEMF Voltage]

P041 [Accel Time 1]

Set Accel and P042 [Decel Time 1]
Decel Time A439 [S Curve %]

Set alignment
Set Alignment See Align the PM Angle

See Adjustments if PM Angle

Alignment has Failed
Does drive
align successfully?
No (Fault F012 or F013 is observed
during acceleration and deceleration.)
Yes

Drive is aligned and

ready to run

262 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix J PowerFlex 525 PM Motor Configuration

Optional Parameter There are a few parameters that you can use to obtain optimum performance
Adjustments for Optimum during the test run. Usually, the default value of these parameters work well,
but you may need to adjust them under different conditions.
Performance
1. A517 [PM DC Inject Cur]

Maximum DC current in amps applied to the motor in order to reset the

rotor position of a PM motor.

Alignment has failed when fault F012 (HW Overcurrent) or F013 (Ground
Fault) is observed during acceleration and deceleration.

Default = 30%
Increase 50 of A517 [PM DC Inject Cur] for each trial when PM speed
response is slow after adding load.
2. A518 [PM Align Time]

Magnetic pole reorientation time.

Alignment failed when fault F012 (HW Overcurrent) or F013 (Ground

Fault) is observed during acceleration and deceleration.

Default = 0.7 s
Increase A518 [PM Align Time] to > 4.7 s.
3. A527 [PM FWKn 1 Kp]

The gain to ensure good performance in field weakening region.

Default = 450%
Increase 100 of A527 [PM FWKn 1Kp] for each trial when PM speed
response is slow after adding load.
Decrease 100 of A527 [PM FWKn 1Kp] for each trial when speed vibration
is observed after adding load.
4. A580 [Current loop BW]

Current loop bandwidth (0 = Auto calculate the control gain of current

loop)

Default = 0 Hz
Increase 50 of A580 [Current Loop BW] for each trial when PM speed
response is slow after adding load.
Decrease 50 of A580 [Current Loop BW] for each trial when speed
instability is observed after adding load.
5. A584 [PM Stable 2 Kp]

The gain for stabilization loop.

Default = 250%
Increase 100 of A584 [PM Stable 2 Kp] for each trial if fault F064 (Drive
overload) is experienced at high load.
Applicable to open loop tuning especially for sPM motor. In most cases,
the default value will work.

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 263

Appendix J PowerFlex 525 PM Motor Configuration

Notes:

264 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix K

PowerFlex 525 Synchronous Reluctance Motor

Configuration

This chapter contains instructions and diagrams on configuring the

PowerFlex 525 drive for use with a Synchronous Reluctance Motor (SynRM)
control.
Topic Page
SynRM Structure 265
SynRM Control Configuration 266

PowerFlex 525 drive is enhanced with SynRM control that allows an option to
pair with PF525 SynRM for energy efficiency and low effort in motor
maintenance.

SynRM Structure Control Diagram

With PowerFlex 525 drive firmware revision 7.001, SynRM control can only be
configured manually using the keypad.

Speed Loop Current Loop

Speed Speedcmd Current cmd Voltage out

Reference
P1 Regulator + P1 Regulator
(Keyboard, + dq/abc
-
2-wire, -
digital ...)

A510 [Freq 1]
A511 [Freq 1 BW] A580 [Current Loop BW]
A512 [Freq 2] Motor
A513 [Freq 2 BW]
A514 [Freq 3]
A515 [Freq 3 BW]

Current feedback
abc/dq

Theta
Speed / Theta
estimated
Speed
A590 [SYNRM SW Freq]

See Adjusting Speed Control Parameters on page 252 for more information on speed loop bandwidth A591 [SYNRM Flux Cur]
A592 [SYNRM Freq1 Volt]
adjustment. A593 [SYNRM Freq1 Kp]
A594 [SYNRM Freq1 Comp]
A595 [SYNRM Freq2 BW]
A596 [SYNRM Freq2 Kp]

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 265

Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration

SynRM Control To run the motor test, make sure you have installed the PowerFlex 525 drive
Configuration firmware revision 7.001 or later. For instructions, see Download Files on
page 10.

Start

Increase the bandwidth to obtain Select the Control Mode:

faster speed response. If oscillation Set P039 [Torque Perf Mode] = 5 “SynRm”
occurs, decrease the bandwidth.

Set the motor parameters setting:

Rated Voltage: P031 [Motor NP Volts]
Rated Frequency: P032 [Motor NP Hertz]
OL Current: P033 [Motor OL Current]
Rated Current: P034 [Motor NP FLA]
Pole Numbers: P034 [Motor NP Poles]
Rated RPM: P036 [Motor NP RMP]
Rated Power: P037 [Motor NP Power]
Minimum Frequency: P043 [Minimum Freq]
Maximum Frequency: P044 [Maximum Freq]
Set A484 [Current Limit 1]
recommended value: > 1.65 x Rated Motor Current

Motor Parameter Auto-Tuning:

Set P040 [Autotune] = 1 “Auto Tune” Make sure that the motor leaves
Press Run the load during auto-tuning

Check the following motor parameters:

Is the motor A501 [PM IR Voltage]
No SynRM parameters A502 [PM IXd Voltage]
auto-tuning
No A503 [PM IXq Voltage]
successful?
A504 [PM BEMF Voltage]
Yes

No-Load Run

266 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration

Startup with No-Load adjustment procedure

No-Load Test

Frequency command setting

higher than A590 [SYNRM SW Freq]

Motor starts running

• Increase A591 [SYNRM Flux Cur]

• Adjust A593 [SYNRM Freq1 Kp]

Is the
speed stable and
does not oscillate before
A590 [SYNRM SW Freq]? No

1. The start-up direction is wrong

and causes F013 fault
Yes 2. Motor stalls
3. Motor speed vibrates extremely

1. Increase A591 [SYNRM Flux Cur]

2. Adjust A595 [SYNRM Freq2 BW]
3. Adjust A596 [SYNRM Freq2 Kp]

When the
frequency operation exceeds No
A590 [SYNRM SW Freq],
is the speed stable and
Frequency speed vibration
does not oscillate?

Yes

Load operation test

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 267

Appendix K PowerFlex 525 Synchronous Reluctance Motor Configuration

Startup with Load adjustment procedure

Load operation test

Frequency command setting

higher than A590 [SYNRM SW Freq]

Motor starts running

1. Adjust the ASR Bandwidth
See Induction Motor Tuning Diagrams on page 251
2. Adjust the A593 [SYNRM Freq1 Kp]

Transient load: If the speed drops

drastically, increase the setting to
improve the response.
Steady-state load: If there is extreme
frequency vibration, decrease the setting.
Is the
speed stable and
No
does not oscillate before
A590 [SYNRM SW Freq]?
1. When the motor increases the load at low
frequency, the speed drop is too large
2. Output frequency low frequency flutters
Yes

High-frequency loading
performance test

1. Adjust A595 [SYNRM Freq2 BW]

2. Adjust A596 [SYNRM Freq2 Kp]
3. Adjust ASR Bandwidth
See Induction Motor Tuning Diagrams on page 251

Did the high-frequency No

loading performance
meet the request?
Insufficient high-frequency
loading performance

Yes

Finish

268 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Index

Numerics drive
auxiliary contact 34, 35
2-wire basic operation 58, 63, 162
inputs 49 common bus 35
3-wire mount 15
inputs 49 programming 59, 62
safety 244
drive damage
A preventing 19
accel ungrounded distribution systems 19
override priority 50
selecting 50
accessing E
control terminals 30 encoder
power terminals 31 programming 219
applications wiring 221
safety 241 environment
auxiliary contact storage 18
drive 34, 35 Ethernet
programming 249
B
basic operation 63 F
drive 58, 63, 162 fault monitoring
programming 63 ground 21
safety 244 fuses
rating 22
C
circuit breakers G
inputs 22 ground
ratings 23 fault monitoring 21
common bus motor 21
drive 35 RFI filter 22
communications safety 21
positioning 228 shielding 21
configuring
RS-485(DSI) 204
control terminals H
accessing 30 homing
counter automatic 227
programming 211, 214 manual 226
programming 226

D
decel
I
override priority 50 inputs
selecting 50 2-wire 49
derating 3-wire 49
factor 124 circuit breakers 22
temperature 17 power 20
digital inputs
selecting 49 L
start source 49
dimensions logic
mounting 16, 184 basic 211, 212
disconnect timed steps 211, 212
output 34

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 269

Index

M R
Modbus rating
reading 208, 209, 210 fuses 22
writing 205, 207, 210 ratings
motor circuit breakers 23
ground 21 reading
start 34 Modbus 208, 209, 210
stop 34 recommended
mount wiring 36, 243
drive 15 reflected
mounting wave protection 34
dimensions 16, 184 RFI filter
ground 22
RS-485(DSI)
N configuring 204
noise immunity
wiring 37, 204
S
safety
O applications 241
output basic operation 244
disconnect 34 drive 244
override priority ground 21
accel 50 testing 242
decel 50 wiring 243
speed reference 48 selecting
start source 48 accel 50
decel 50
digital inputs 49
P speed reference 48
parameters start source 48
separating
AppView 74, 150
CustomView 151 power and control module 28
programming 61, 65 shielded
PID wiring 33
programming 233 shielding
positioning ground 21
communications 228 speed reference
programming 222, 223 override priority 48
power selecting 48
inputs 20 start
power and control module motor 34
separating 28 start source
power terminals digital inputs 49
accessing 31 override priority 48
preventing selecting 48
stop
drive damage 19
programming 63 motor 34
storage
basic logic 211, 212
counter 211, 214 environment 18
drive 59, 62
encoder 219
Ethernet 249 T
homing 226 temperature
parameters 61, 65 derating 17
PID 233 wiring 32
positioning 222, 223 testing
pulse train 219 safety 242
timed steps 211, 212 timer
timer 211, 213
tools 62 programming 211, 213
pulse train tools
programming 219 programming 62

270 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 Index

U W
unshielded wave protection
wiring 33 reflected 34
wiring
encoder 221
V noise immunity 37, 204
voltage reflections recommended 36, 243
wiring 34 RS-485 (DSI) 203
safety 243
shielded 33
temperature 32
unshielded 33
voltage reflections 34
writing
Modbus 205, 207, 210

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 271

Index

Notes:

272 Rockwell Automation Publication 520-UM001M-EN-E - January 2023

 PowerFlex 520-series Adjustable Frequency AC Drive User Manual

Rockwell Automation Publication 520-UM001M-EN-E - January 2023 273

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