PowerFlex 527

Allen-Bradley PowerFlex 527 AC Drive Series

Allen-Bradley PowerFlex 527 Drives

Technical Specifications 

  • PowerFlex 527 Drives horsepower ratings range from 0.5-1.5HP, 0.5-20HP, or 0.5-30HP 
  • Input-voltage range from 100-120V, 200-240V, 380-480V, or 525-600V
  • Output voltage range from 0V to input voltage 
  • IP20/NEMA Open enclosure type
  • Maximum output frequency 500Hz
  • Digital control input bandwidth 10Rad/s

Overview

  • Safety features includes Safe Torque-off
  • Download configuration settings through built in EtherNet/IP dual port
  • Easy Installation and Programming
    • Side-by-side mounting permissible with 50 millimeter spacing at bottom and top of the drive
    • DIN rail mounting for frames A, B, and C

Allen-Bradley PowerFlex 527 Drives

Technical Specifications 

  • PowerFlex 527 Drives horsepower ratings range from 0.5-1.5HP, 0.5-20HP, or 0.5-30HP 
  • Input-voltage range from 100-120V, 200-240V, 380-480V, or 525-600V
  • Output voltage range from 0V to input voltage 
  • IP20/NEMA Open enclosure type
  • Maximum output frequency 500Hz
  • Digital control input bandwidth 10Rad/s

Overview

  • Safety features includes Safe Torque-off
  • Download configuration settings through built in EtherNet/IP dual port
  • Easy Installation and Programming
    • Side-by-side mounting permissible with 50 millimeter spacing at bottom and top of the drive
    • DIN rail mounting for frames A, B, and C

Troubleshooting Your PowerFlex 527 Drive

The following page provides you with information necessary to troubleshoot your PowerFlex 527 Drive. 

PowerFlex 527 Drive Fault Code Information

There are four status indicators located on the front of your PowerFlex 527 Drive in addition to a display which is used to view information. The fault indicator is located above the navigation keypad. If this indicator is on, this means the drive is faulted.

Fault code types are outlined below: 

INTI FLT Sxx and INTI FLT Mxx indicate there are exceptions that are preventing normal operation. These occur during the initialization process. 

FLT Sxx and FLT Mxx indicate there is a standard runtime axis exception.

INHIBIT Sxx and INHIBIT Mxx fault code types mean there are exceptions that prevent normal operation. These indicate whenever the drive is active. 

NODE ALARM xx is a fault code type that means there are exceptions that are preventing normal drive operation. However, these exceptions do not result in any action besides reporting the alarm to the controller. 

NODE FLTxx is a fault code type that means there are exceptions that are preventing normal drive operation. 

 

INIT FLT Fault Codes - PowerFlex 527

Exception Code Name - Description Action
INIT FLT S03 - NVMEM CHKSUM

Nonvolatile Memory Checksum Error-

Checksum error for the date in the nonvolatile memory

Cycle power and reset the drive. If the fault continues, click here for more information or to request a repair quote.
INIT FLT M14 - INVALID SAFETY FIRMWARE

Invalid Safety Firmware- 

Safety firmware incompatible with the drive firmware/ main safety firmware is missing

Cycle the power and reset the drive. If the fault continues, click here for more information or to request a repair quote.
INIT FLT M15 - POWER BOARD

Power Board Checksum Error- 

Checksum error in the power board

Cycle the power and reset the drive. If the fault continues, click here for more information or to request a repair quote.

 

FLT Sxx Fault Codes - PowerFlex 527

Exception Code Name - Description Action
FLT S03 - MTR OVERSPEED FL

Motor Overspeed Factory Limit Fault-

Motor speed in excess of 590 Hz

Review the control loop tuning.
FLT S04 - MTR OVERSPEED UL

Motor Overspeed User Limit Fault-

Motor speed exceeded the defined limit in Motor Overspeed User Limit parameter

Review the control loop tuning.
FLT S07 - MTR OVERLOAD FL

Motor Thermal Overload Factory Limit Fault-

The motor thermal model has exceeded the thermal capacity limit of 110%

Adjust the command profile. Reduce the speed or increase the time.
FLT S08 - MTR OVERLOAD UL

Motor Thermal Overload User Limit Fault-

The motor thermal model has exceeded the defined limit in the Motor Thermal Overload User Limit parameter

Adjust the command profile and increase the Motor Thermal Overload UL attribute value.
FLT S10 - INV OVERCURRENT

Inverter Overcurrent Fault-

The inverter current has surpassed the instantaneous current limit as determined by the hardware

First check for motor power cable shorts then ensure the motor windings are not shorted. Check the motor power wire gauge and ensure the operation is withing the continuous power rating. Finally, reduce the acceleration times. 
FLT S11 - INV OVERTEMP FL

Inverter Overtemperature Factory Limit Fault- 

The measured inverter temperature exceeds the factory-set temperature limit

Adjust the command profile and either reduce the speed or increase the time. Ensure nothing is obstructing the airflow through the drive and reduce the ambient temperature. 
FLT S13 - INV OVERLOAD FL

Inverter Thermal Overload Factory Limit Fault-

The power transistors indicate the thermal model temperature has exceeded the factory set capacity rating: 110%.

Adjust the command profile and either reduce the speed or increase the time. 
FLT S16 - GROUND CURRENT

Ground Current Factory Limit Fault- 

An excessive ground current ing the power stage has been detected by the sensing circuitry.

Review the motor power wiring and look for power cable shorts. If you are unable to resolve the fault, you must replace the motor. 
FLT S23 - AC PHASE LOSS

AC Single-Phase Loss Fault- 

The drive was enabled when a single AC input phase was lost

Check AC input voltage on every phase. 
FLT S25 - PRECHARGE FAILURE

Precharge Failure Fault- 

DC bus did not reach the factory set voltage level after charging for a certain period of time. Detected by the pre-charge circuit monitoring algorithm

Check AC input voltage on every phase and the input power wiring. If you are unable to resolve the fault, you must replace the drive.
FLT S29 - BUS OVERLOAD FL

Bus Regulator Thermal Overload Factory Limit Fault-

Shunt thermal model exceeded the factory thermal capacity limit

Adjust the duty cycle for the application. If necessary, add an external shunt to increase capacity and/or add a capacitor module. 
FLT S34 - BUS UNDERVOLT UL

Bus Undervoltage User Limit Fault- 

DC bus voltage level has fallen below the user set limit as defined in the Bus Undervoltage User Limit parameter

Adjust the incoming AC voltage level. Watch for glitches or line drops in the AC power source. You may need to install a UPS on the AC input. Decrease the attribute value in the Bus Undervoltage UL parameter. 
FLT S35 - BUS OVERVOLT FL

Bus Overvoltage Factory Limit Fault- 

DC Bus voltage level has risen above the factory set limit, which is determined by the configured input voltage

Adjust either the deceleration or motion profile for all of the drives connected to the DC bus. Detach the shunt connector then measure the shunt resistance. If the shunt resistor is open, you must replace the drive.
FLT S37 - BUS POWER LOSS

Bus Power Loss-

DC Bus voltage level has fallen below the Bus Power Loss Threshold for longer than the timeout period as specified in the Bus Power Loss Time parameter

Check incoming AC line's voltage level and watch the power source for glitches/line droop. You may need to install UPS on the AC input. 
FLT S41 - FDBK SIGNAL NOISE FL

Feedback Signal Noise Fault-

The number of noise events on the A/B channels has exceeded the Feedback Noise Factory Limit. The feedback channel number is encoded in the related Fault/Alarm Sub Code. 

Check the motor feedback cable, connector and the feedback shield connection. Cycle the power and reduce the shock and vibration to the motor. If the fault persists, you must replace the motor. 
FLT S45 - FDBK COMM FL

Motor Feedback Data Loss Factory Limit Fault-

The factory set limit of consecutively missed/corrupted serial data packets from the intelligent feedback device has been exceeded.

Check the motor feedback cable, connector, the motor power cable and feedback wire shields. The power cable and feedback wire shields should be correctly secured. Ensure the motor frame is correctly grounded. 
FLT S50 - HARDWARE OVERTRAVEL POSITIVE 

Hardware Overtravel Positive-

The axis exceeded the positive direction physical travel limits. This has activated the Positive Overtravel limit switch

Review the wiring and motion profile. Ensure the axis configuration is in the appropriate software.
FLT S51 - HARDWARE OVERTRAVEL NEGATIVE 

Hardware Overtravel Negative-

The axis exceeded the negative direction physical travel limits. This has activated the Negative Overtravel limit switch

Review the wiring and motion profile. Ensure the axis configuration is in the appropriate software.
FLT S54 - POSN ERROR

Excessive Position Error Fault-

The position error for the position control loop has surpassed the set value in the Position Error Tolerance parameter for longer than the time specified in the Position Error Tolerance Time parameter

Review the position loop tuning and increase the forward gain. Ensure the motor and drive sizing is correct and that the motor power wiring is correct. Increase either the Position Error Tolerance or the Position Error Tolerance time. You may adjust both parameters. 
FLT S55 - VEL ERROR

Excessive Velocity Error Fault-

The velocity error for the velocity control loop has surpassed the set value in the Velocity Error Tolerance parameter for longer than the time specified in the Velocity Error Tolerance Time parameter

Check the velocity loop tuning and reduce acceleration. Ensure the drive and motor sizing is correct. Verify the motor power wiring is correct
FLT S56 - OVERTORQUE LIMIT

Overtorque Limit Fault-

Motor torque has exceeded the maximum torque level as set in the Overtorque Limit for longer than the set time in the Overtorque Limit time parameter

Check/verify the Torque Trim value and the motion profile. Check the drive and motor sizing. Increase the Overtorque Limit and/or the Overtorque Limit Time values. 
FLT S57 - UNDERTORQUE LIMIT

Undertorque Limit Fault-

Motor torque has fallen below the minimum torque level as set in the Undertorque Limit for longer than the set time in the Undertorque Limit time parameter

Check/verify the Torque Trim value and the motion profile. Check the drive and motor sizing. Decrease the Undertorque Limit and/or the Undertorque Limit Time values.
FLT S61 - ENABLE INPUT DEACTIVATED

Enable Input Deactivated-

The Enable Input has been deactivated while the axis power structure was in Running state, enabled and while supplying a current to the DC motor or Bus. 

Check the Enable Input level and wiring. 

 

FLT Mxx Fault Codes - PowerFlex 527

Exception Code Name - Description  Action 
FLT M10 - CONTROL MODULE OVERTEMPERATURE FL

Control Module Overtemperature Fault-

Excessive heat detected by the Main Control Board's temperature sensor

Ensure the airflow through the drive is not obstructed and reduce the ambient temperature. Ensure the control module's internal fan is operational. If the error continues, replace the fan.
FLT M19 - DECEL OVERRIDE

Decel Override-

The drive is not following a deceleration command due to its attempt to limit the bus voltage

Adjust the Bus Regulator Action and eliminate any Adjustable Frequency selection. You can reprogram the Bus Regular Action to Shunt Regulator and add an external shunt. Ensure the AC input line is stable, if not, add an isolation transformer. Finally, reset the drive. 
FLT M21 - MOTOR TEST FAILURE

Motor Test Failure-

Failed Motor Test procedure

Chech the drive and motor sizing, the motor data and power wiring. 
FLT M26 - RUNTIME ERROR

Runtime Error-

Unrecoverable drive firmware runtime error.

Cycle the power and reset the drive. If the fault will not clear, contact us for repair information or to request a quote
FLT M28 - SAFETY MODULE COM ERROR

Safety Module Communication Error-

Issue when communicating to the Safety Module

Cycle the power. If the error is not resolved, replace the Safety Module.

All of the above-outlined NODE FLTxx Fault codes are major faults. 

INHIBIT Fault Codes - PowerFlex 527

Exception Code Name - Description Action
INHIBIT S01 - AXIS ENABLE INPUT

Axis Enable Input-

Deactivated Axis Enable Input

Check the Enable Input level and its wiring.
INHIBIT S02 - MOTOR NOT CONFIGURED

Motor Not Configured-

The motor is improperly configured for use

Check the motor configuration in the Logix Designer application
INHIBIT M05 - SAFE TORQUE OFF

Start Inhibit - Safe Torque Off-

Disabled power structure in the safety function 

Verify the safety input wiring and review the state of safety devices

 

NODE ALARM Fault Code - PowerFlex 527

Exception Code Name - Description Action 
NODE ALARM 01 - LATE CTRL UPDATE

Control Connection Update Alarm-

Late updates from the controller

Any unnecessary network devices must be removed from the motion network. Adjust the network topology, minimize the number of devices sharing common paths. Use both high-performance network equipment and shielded cables. You should have separate wiring from your power wiring. 
NODE ALARM 03 - CLOCK JITTER

Clock Jitter Alarm- 

Sync variance as surpassed the sync threshold while the drive was running in sync mode

Check the Ethernet connection and the controller and Ethernet switch operation.
NODE ALARM 04 - CLOCK SKEW ALARM

Clock Skew Alarm- 

The controller and drive system's times do not align 

Check the Ethernet connection and the controller and Ethernet switch operation.
NODE ALARM 05 - CLOCK SYNC ALARM 

Clock Sync Alarm-

Synchronization between the drive's local clock and the controller's clock lost for a time during synchronous operation 

Check the Ethernet connection and the controller and Ethernet switch operation.

 

NODE FLT Fault Codes - PowerFlex 527

Exception Code Name - Description Action 
NODE FLT 01 - LATE CTRL UPDATE

Control Connection Update Fault-

Multiple consecutive lost updates from the controller 

Any unnecessary network devices must be removed from the motion network. Adjust the network topology, minimize the number of devices sharing common paths. Use both high-performance network equipment and shielded cables. You should have separate wiring from your power wiring. 
NODE FLT 02 - PROC WATCHDOG nn

Processor Watchdog Fault-

Power board or control board processor updates have failed to update. The nn sub-codes 00-05 are internal, resulting in the same possible solution

Cycle the power and update the firmware. If the fault continues, contact us for repair information or to request a quote
NODE FLT 03 - HARDWARE 00

Hardware Fault -PwrlF-

Unable to establish communication with the power board

Cycle the power and update the firmware. If the fault continues, contact us for repair information or to request a quote.
NODE FLT 03 - HARDWARE 01

Hardware Fault - Piccolo HW- 

Failed DSP chip on the power board

Cycle the power. If the fault continues, contact us for repair information or to request a quote.
NODE FLT 03 - HARDWARE 02

Hardware Fault DSL-

Unable to establish communication with the encoder

DSL feedback wiring may be incorrect, shorted or opened. The DSL feedback cable and the bulletin VPL motor feedback device are defective. Cycle the power. If the fault continues, contact us for repair information or to request a quote.
NODE FLT 03 - HARDWARE 03

DSL External Memory Interface Fault- 

The DSL external memory interface has detected errors

Check the feedback device, cable, and wiring. Cycle the power.  If the fault continues, contact us for repair information or to request a quote.
NODE FLT 05 - CLOCK SKEW FLT

Clock Skew Fault- 

Controller time and drive's system time are out of sync

Cycle the power and check the controller and Ethernet switch operation.
NODE FLT 06 - LOST CTRL CONN

Lost Controller Connection Fault-

Lost communication with the controller

Check the Ethernet connection and the controller and Ethernet switch operation.
NODE FLT 07 - CLOCK SYNC

Clock Sync Fault-

Synchronization lost between the drive's local clock and the controller's clock. Unable to resynchronize withing specific time

Check the Ethernet connection and the controller and Ethernet switch operation.
NODE FLT 09 - DUPLICATE IP ADDRESS

Duplicate IP Address Fault-

Multiple consecutive updates lost from controller

Slect an IP address not used on the network

All of the above-outlined NODE FLTxx Fault codes are major faults. 

Repair Your PowerFlex 527 Drive

Here at DO Supply, we offer repair services for your Allen-Bradley products, such as the Allen-Bradley PowerFlex 527 Drive. Please click here for more information or to request a quote.


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PowerFlex 527DescriptionStock Level
PowerFlex 527DescriptionStock Level
25C-A011N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 11 Amperes output and 3 Horsepower
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25C-A011N114Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 11 Amperes output and 3 Horsepower
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25C-A2P5N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 2.5 Amperes output and 0.5 Horsepower
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25C-A2P5N114Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 2.5 Amperes output and 0.5 Horsepower
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25C-A4P8N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 4.8 Amperes output and 1 Horsepower
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25C-A4P8N114Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 4.8 Amperes output and 1 Horsepower
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25C-A8P0N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 8 Amperes output and 2 Horsepower
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25C-A8P0N114Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 8 Amperes output and 2 Horsepower
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25C-B011N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 11 Amperes output and 3 Horsepower
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25C-B017N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 17.5 Amperes output and 5 Horsepower
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25C-B024N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 24 Amperes output and 7.5 Horsepower
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25C-B032N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 32 Amperes output and 10 Horsepower
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25C-B048N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 48.3 Amperes output and 15 Horsepower
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25C-B062N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 62.1 Amperes output and 20 Horsepower
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25C-B2P5N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 2.5 Amperes output and 0.5 Horsepower
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25C-B5P0N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 5.0 Amperes output and 1 Horsepower
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25C-B8P0N104Allen-Bradley PowerFlex 527 Drive with 240 AC Volts power, 8.0 Amperes output and 2 Horsepower
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25C-D010N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 10.5 Amperes output and 5 Horsepower
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25C-D010N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 10.5 Amperes output and 5 Horsepower
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25C-D013N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 13 Amperes output and 7.5 Horsepower
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25C-D013N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 13 Amperes output and 7.5 Horsepower
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25C-D017N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 17 Amperes output and 10 Horsepower
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25C-D017N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 17 Amperes output and 10 Horsepower
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25C-D024N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 24 Amperes output and 15 Horsepower
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25C-D024N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 24 Amperes output and 15 Horsepower
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25C-D030N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 30 Amperes output and 20 Horsepower
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25C-D030N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 30 Amperes output and 20 Horsepower
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25C-D037N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 37 Amperes output and 25 Horsepower
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25C-D043N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 43 Amperes output and 30 Horsepower
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25C-D1P4N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 1.4 Amperes output and 0.5 Horsepower
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25C-D1P4N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 1.4 Amperes output and 0.5 Horsepower
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25C-D2P3N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 2.3 Amperes output and 1 Horsepower
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25C-D2P3N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 2.3 Amperes output and 1 Horsepower
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25C-D4P0N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 4 Amperes output and 2 Horsepower
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25C-D4P0N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 4 Amperes output and 2 Horsepower
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25C-D6P0N104Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 6 Amperes output and 3 Horsepower
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25C-D6P0N114Allen-Bradley PowerFlex 527 Drive with 480 AC Volts power, 6 Amperes output and 3 Horsepower
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25C-E012N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 12 Amperes output and 10 Horsepower
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25C-E019N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 19 Amperes output and 15 Horsepower
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25C-E022N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 22 Amperes output and 20 Horsepower
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25C-E027N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 27 Amperes output and 25 Horsepower
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25C-E032N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 32 Amperes output and 30 Horsepower
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25C-E0P9N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 0.9 Amperes output and 0.5 Horsepower
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25C-E1P7N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 1.7 Amperes output and 1 Horsepower
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25C-E3P0N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 3 Amperes output and 2 Horsepower
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25C-E4P2N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 4.2 Amperes output and 3 Horsepower
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25C-E6P6N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 6.6 Amperes output and 5 Horsepower
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25C-E9P9N104Allen-Bradley PowerFlex 527 Drive with 600 AC Volts power, 9.9 Amperes output and 7.5 Horsepower
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25C-V2P5N104Allen-Bradley PowerFlex 527 Drive with 120 AC Volts power, 2.5 Amperes output and 0.5 Horsepower
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25C-V4P8N104Allen-Bradley PowerFlex 527 Drive with 120 AC Volts power, 4.8 Amperes output and 1 Horsepower
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25C-V6P0N104Allen-Bradley PowerFlex 527 Drive with 120 AC Volts power, 6 Amperes output and 1.5 Horsepower
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