Integrated Motion on EtherNet/IP PowerFlex 527 Overview Joseph A. Gutierrez Sr. Technical Support Engineer

Agenda Drive Capabilities Comparison Installation Module Properties Setup Axis Properties Setup Network Safety Settings

PowerFlex 527 Limitations Does not operate as a stand alone product Must be connected to a Logix controller for any type of operation AOP Only available on Logix firmware V24.xx and higher No internal parameters to monitor Induction Motor Control only Incremental Encoder Feedback Only Only one feedback port 22 kW / 30 HP maximum on 400V Class drives 4ms minimum Coarse Update Period No USB port for programming or flashing as with other 520 drives

PowerFlex 527 capabilities not in available in the PowerFlex 755 Four programmable digital inputs – Selections of: Enable Home Registration Positive Overtravel Negative Overtravel Network Safe Torque Off –With a GuardLogix ControlLogix Controller Only Analog Inputs Analog Outputs Digital Outputs Dual Port Ethernet built in for Linear and DLR configurations RSLogix V24.xx and later only

PowerFlex 755 capabilities not in available in the PowerFlex 527 Ability to run surface mount Permanent Magnet (PM) motors Multiple Feedback options Incremental Sine/Cosine Absolute position capability Hiperface, EnDat 2.1 SC, EnDat 2.2 SC /FD & SSI SC rotary SSI and Linear Stahl Linear feedback Dual Loop and Dual Integral Loop positioning control Load Observer and Acceleration Feedback SLAT control in Velocity mode Torque control mode Safe Limited Speed Monitoring 3ms coarse update rate vs 4ms min on PF527 RSLogix V19.xx and later

PowerFlex 527 Motor Selection Motor Data selection options Nameplate Datasheet Motor Type selection options

PowerFlex 755 Motor Selection Motor data selection options Nameplate Datasheet Catalog Number Drive NV

PowerFlex 755 Motor Selection Motor type selection options Rotary Permanent Magnet Rotary Induction

PowerFlex 527 One feedback type to select from Digital AqB

PowerFlex 755 Feedback Selection Several Feedback types available to select from Digital AqB With 20-750-UFB-1 Sine / Cosine Hiperface EnDat 2.1 EnDat 2.2 SSI Stahl SSI

Position Loop comparison 755 Position Feedback Configurations Motor Feedback Dual Feedback Dual Integral Feedback 527 Position Feedback Configurations

PowerFlex / Kinetix Integrated Motion Comparisons Feature PowerFlex 527 PowerFlex 755 Kinetix 5500 Digital I/O Yes 4 inputs / 4 Outputs Yes 1 Input for Enable Yes Analog I/O No Induction Motors Permanent Magnet Motors Absolute Feedback Devices Incremental Encoder Network Safe Torque Off Yes (ERS2) Safe Torque Off Wired Yes (20-750-S) Yes (ERS) Safe Limited Speed Monitor Yes (20-750-S1) Torque Mode SLAT Dual Loop Positioning Load Observer Coarse Update Minimum 4ms 3ms 2ms

Integrated Motion Portfolio Positioning LVD & KNX Product Differentiation and Target Applications PowerFlex 527 PowerFlex 755 Kinetix 5500 Kinetix 5700 Focus Control Type Speed Torque, Speed Position, Torque, Speed Motor Types Induction Open & Closed Loop sPM Open & Closed Loop iPM Open & Closed Loop Induction Open Loop sPM Closed Loop Focus Architecture Integrated Motion for Single Axis Control Multi Axis Count High Axis Count Focus Applications Medium Performance Feeder Conveyors, Pumps, Fans High Performance Web, ASRS, Roll Forming, Overland Conveyors, Chain Conveyors, Winders Highest Performance Packaging, Printing, Filler, Carton Forming Highest Performance Packaging, Printing, Filler, Carton Forming Safety Hardwired STO, Integrated Safety Hardwired STO & Safe Speed (Future Integrated Safety)

Technical Support - Knowledgebase PowerFlex® 527 technotes are available in our Knowledge. Search for PF527 related Technotes (*Disable Filters) as follows:

Summary PowerFlex® 527 focuses on applications that require only speed control, i.e. pumps, fans, conveyors PowerFlex® 755 targets applications that require speed and torque control, i.e. web, ASRS, winders, roll forming Kinetix® 5500 is best used on applications that require speed, torque and position control, i.e. filler, carton forming

Agenda Drive Capabilities Comparison Installation Drive Properties Setup Axis Properties Setup Network Safety Settings

PowerFlex 527 Installation Control Module can be used on existing PowerFlex 520 series power modules that meet the power ratings of the PowerFlex 527 table Install Encoder interface if being used (25-ENC-2) Remove existing Control Module and Replace with the PowerFlex 527 control module Connect EtherNet/IP, I/O and Hardwired safety if used Remove safety jumper as shipped if network safety is used (Inhibit M05 if not removed indicated on the drive) Publication 520-TD002 for Technical Data Publication 520-UM002 for Power Wiring Publication 520-IN002 for control module installation Follow guidelines in Publication Drives-IN001 Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives

PowerFlex 527 Installation Control Module Wiring Removable terminal blocks for ease of replacement

PowerFlex 527 Installation Encoder Connections Requires the 25-ENC-2 encoder card Quadrature (dual channel) 5V/12V DC supply, 10 mA min per channel Single Ended or Differential (A, B, and Z Channel) Duty Cycle of 50%, +10% Input Frequency up to 250 kHz No ability to select A channel only feedback in the axis properties

PowerFlex 527 Installation Power Module Same as any other 520-Series Use motor or motion polarity to change direction If the Hookup tests are done don’t change the motor leads

PowerFlex 527 Installation IP Address Default setting is Static IP with 192.168.001.180 as the address Use the LCD panel to configure for DHCP Press Sel button Select SETUP > NETWORK Select either STATIC IP or DHCP

Agenda Drive Capabilities Comparison Installation Module Properties Setup Axis Properties Setup Network Safety Settings

PowerFlex 527 Module Properties Studio 5000 V24.xx or greater Must be 1769-LxxERM or 1756-L7xx with 1756-ENxTx Right Click on the Network module and add a new Motion device PowerFlex 527-STO-CIP Safety

PowerFlex 527 Module Properties Studio 5000 V24.xx or greater Enter a Name and IP Address Click “Change” in the Module Definition Click to change Module Definition

PowerFlex 527 Module Properties Module Definition Select one of the three Connection types depending on what controller is used (New in V24.xx) Select the proper Power Structure:

PowerFlex 527 Module Properties Configuring the Power tab Bus Regulator Action PWM Frequency Regenerative Power Limits Click to select action Note: Adjustable Frequency selection will disable the axis position loop

PowerFlex 527 Module Properties Digital Input tab Select the digital inputs from the drop down list. Digital inputs can be read in the Axis tags if used for other functions No selection for Analog Inputs/Outputs Analog inputs and outputs are used by the customer program and are not used directly by the drive module Not all selections shown are available for every input

PowerFlex 527 Module Properties Digital Input tab Digital Input 2 – 4 selections showing different options available on each Input Input 2 available for registration Inputs 3 & 4 Enable or over-travel only

PowerFlex 527 Module Properties Associated Axis No motor feedback selections Add an axis or select an axis

Agenda Drive Capabilities Comparison Installation Module Properties Setup Axis Properties Setup Network Safety Settings

Motion Group Multiplexing Motion Group supports up to 3 multiplexed group update times

PowerFlex 527 Axis Properties Axis Properties General Category Position Loop (Default Axis configuration) Note: If Bus Regulator Action is set to Adjustable Frequency the axis position loop will be disabled

PowerFlex 527 Axis Properties Axis Properties General Category Velocity Loop – Motor feedback required

PowerFlex 527 Axis Properties Axis Properties General Category Frequency Control – No Motor Feedback allowed

PowerFlex 527 Axis Properties Axis Properties Scale Category Scale Units – Motion uses Units per Second

PowerFlex 527 Axis Properties Axis Properties General Category Frequency Control modes

PowerFlex 527 Axis Properties Motor Data selections Nameplate Datasheet only Rotary Induction only

PowerFlex 527 Axis Properties Motor Model and Motor Analyzer Induction motor model data

PowerFlex 527 Axis Properties Motor Feedback Only Digital AqB Incremental Startup method only

PowerFlex 527 Axis Properties Drive Parameters Ability to read/write Digital and Analog I/O every coarse update

PowerFlex 527 Axis Properties Drive Parameters Ability to read/write Digital and Analog I/O every coarse update Tag names from the Axis tag structure Must be selected in the Drive Parameters to be used by the program Analog Output is defaulted to 4-20ma and a message instruction is required to change it to voltage along with the jumper selection Analog I/O data is raw values of voltage or current

PowerFlex 527 Axis Properties Analog output message to change between Current and Voltage Jumper must be changed Message must be sent to configure output

PowerFlex 527 Axis Properties Drive I/O Addressing Digital Inputs Axis_Name:I.DigitalInputs.0 = Input 1 Axis_Name:I.DigitalInputs.1 = Input 2 Axis_Name:I.DigitalInputs.2 = Input 3 Axis_Name:I.DigitalInputs.3 = Input 4 Digital Outputs Axis_Name:O.DigitalOutputs.0 = OptoOutput1 Axis_Name:O.DigitalOutputs.1 = OptoOutput2 Axis_Name:O.DigitalOutputs.2 = RelayOutput1 Axis_Name:O.DigitalOutputs.3 = RelayOutput2

PowerFlex 527 Axis Properties Hookup tests Motor and Feedback Motor Feedback Marker

PowerFlex 527 Axis Properties Axis Actions Stop Action is for the MSF instruction only Disable & Coast Current Limit Decel & Disable

PowerFlex 527 Axis Properties Example Code MDS Instruction MAS Instruction MSF Instruction Use xxx.DirectCommandVelocity tag to change speed

Agenda Drive Capabilities Comparison Installation Module Properties Setup Axis Properties Setup Network Safety Settings

Safe Torque Off Certification TÜV Rheinland Approved Integrated safety with EtherNet/IP PLe, CAT3 per EN ISO 13849-1 SILCL3 per EN 62061 / EN 61800-5-2 and IEC 61508 Stop Category 0, EN 60204 Increased safety rating using PowerFlex 527 with Integrated Safety

Industry and Application Solutions Safe & Standard Connections

Integrated Safety on Ethernet/IP How it works Safety Message CRC-B Producer to Consumer Time_Stamp CRC Data B Data A CRC-A Mode Time Stamp Section Data Section normal data A B > Duality > Diagnostics > Diversity Inverted data Output B Output A Capable of SIL3 / PLe for Safe Torque Off STO Ethernet/IP CIP Safety Packet provides Duality, Diagnostics and Diversity!

Flexibility with safe and standard connection Integrated Safety on EtherNet/IP Flexibility with safe and standard connection

Integrated Safety on EtherNet/IP Kinetix® 5500 and PowerFlex® 527 with Integrated Safety GuardLogix® Integrated Safety System Controller PointGuard Safety I/O Stratix 5700™ Industrial Ethernet switch Integrated Safety Enhances Machine Performance and Flexibility

Use Safety reaction time tool to calculate system reaction time Safety Reaction Time Explanation Example of step taken in the system to initiate a STO Hardwired Safety vs Integrated Safety Light Curtain Light curtain Guard Point input Report to safety controller Safety task processing Report STO to Drive Drive STO Light Curtain Light Curtain MSR input MSR (delayed) output Drive STO 1 2 3 4 5 6 Integrated Safety Drive reaction time 10ms HW Drive reaction time 10ms 0 ms 1 2 3 4 1 2 3 4 5 6 Use Safety reaction time tool to calculate system reaction time

Safe Torque Off - reset K5500 Executed Manually PF 527 Auto reset Firmware develop planned to update K5500 to be consistent with auto-reset.

Logix configuration Add axis to the I/O tree Select Kinetix 5500 or PowerFlex 527 Integrated safety drive.

Logix configuration 3 selections Motion and Safety Motion Only Safety Only

Tag structure Motion only Drive Status Tags Only Safety only Safety Inputs and Output Status Tags Only Motion and Safety Both Safety and Drive Status Tags

Axis Tag Structure STO bits Drive_1:SO.SafeTorqueOff: bit that controls STO of drive.

Out of Box Operation – Configure Drive/Axis Properties Select Connection type Set IP address Associate axes Configure Power

Out of Box Operation – Motion Direct Motion direct commands are allowed in Program Mode. Motion Direct commands are allowed when Safety is not running

Out of Box Operation – Motion Direct Characteristics - Drive can operate without safety connection. Safety State: Not Configured (Torque Permitted) Motion Direct commands WARNING!! Safety Torque Off bypassed, Safety not configured

Out of Box Operation Characteristics - Drive can operate without safety connection. Why is this permitted Ensure drive is connected properly and ready for service Commission Machine before Safety System is configured Safety State Not Configured (Torque Permitted) Start Inhibited Not Inhibited

Safety State Display Safety State Not Configured: No safe connection to Guardlogix Running: Safe connection has been made to drive and safety task executing Not Running: configured but safety task is not running. Not Configured (Torque Permitted): Out of box allowing motion direct commands.

Integrated safety is easy to configure, program, modify and re-use. Logix Programming Inputs: scan safety devices Logic: Perform any necessary logic Outputs: Output safety request to the drive Integrated safety is easy to configure, program, modify and re-use.

Return to Out of Box Drive must be connected to GuardLogix controller From the I/O tree, right click and open up drive properties dialog box

Return to out of box Drive must be connected to GuardLogix controller Inhibit Module.

Return to out of box Drive must be connected to GuardLogix controller Inhibit Module Reset Ownership If active Safety connection is established to the drive, the request is rejected

Return to out of box

Cycle Power to the drive Return to out of box Drive must be connected to GuardLogix controller Inhibit Module Reset Ownership If active Safety connection is established to the drive, the request is rejected Cycle Power to the drive

PF527 Technical Support Contact Mequon Technical Support 440-646-3434 For PowerFlex 527 Support select the Component Class Queue If Support Engineer Requires further assistance the Customer can be connected to the PowerFlex Drives Motion Support Queue

Questions