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

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

3. 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

4. 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

5. 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

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

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

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

9. PowerFlex 527
One feedback type to select from
Digital AqB

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

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

12. 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 ( S)
Yes (ERS)
Safe Limited Speed Monitor
Yes ( S1)
Torque Mode
SLAT
Dual Loop Positioning
Load Observer
Coarse Update Minimum
4ms
3ms
2ms

13. 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)

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

15. 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

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

17. 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

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

19. 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

20. 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

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

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

23. 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

24. 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

25. 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:

26. 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

27. 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

28. 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

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

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

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

32. 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

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

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

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

36. PowerFlex 527 Axis Properties
Axis Properties General Category
Frequency Control modes

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

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

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

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

41. 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

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

43. 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

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

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

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

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

48. Safe Torque Off Certification
TÜV Rheinland Approved
Integrated safety with EtherNet/IP
PLe, CAT3 per EN ISO
SILCL3 per EN / EN and IEC 61508
Stop Category 0, EN 60204
Increased safety rating using PowerFlex 527 with Integrated Safety

49. Industry and Application Solutions
Safe & Standard Connections

50. 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!

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

52. 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

53. 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

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

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

56. Logix configuration 3 selections Motion and Safety Motion Only
Safety Only

57. 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

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

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

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

61. 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

62. 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

63. 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.

64. 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.

65. 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

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

67. 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

68. Return to out of box

69. 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

70. 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

71. Questions